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C4.4 MSC3 GENERATOR SET Operation and Maintenance Manual Genset PDF
C4.4 MSC3 GENERATOR SET Operation and Maintenance Manual Genset PDF
March 2013
Operation and
Maintenance
Manual
C4.4 (Mech) Marine Generator Set MCS-
3
L1K 1-Up (Generator
Set)
S1M 1-Up (Generator
Set)
SAFETY.CAT.COM
i05086812
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.
SEBU8607 3
Table of Contents
Safety Section
i03904028
Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Please become familiar with all of the messages.
Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap for cleaning the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off the
engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
6 SEBU8607
Safety Section
Safety Messages
Illustration 1 g02162595
Typical example
SEBU8607 7
Safety Section
Safety Messages
Illustration 2 g02163184
Typical example
8 SEBU8607
Safety Section
Safety Messages
Illustration 4 g00930639
Illustration 3 g00934493
Pressurized system! Hot coolant can cause seri-
ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
Do not operate or work on this equipment unless the cooling system pressure cap slowly in order
you have read and understand the instructions to relieve the pressure. Read and understand the
and warnings in the Operation and Maintenance Operation and Maintenance Manual before per-
Manuals. Failure to follow the instructions or heed forming any cooling system maintenance.
the warnings could result in serious injury or
death.
Do Not Use Ether (3)
Hot Fluid Under Pressure (2) The safety message for no ether is located on the rain
cap for the air cleaner.
This safety message is located in the following
location. Top of the expansion tank
Illustration 5 g00930690
Electrocution (4)
This safety message is located on the following six
different locations. Top cover of the MCS panel, top of
the generator and on each of the four sides of
generator
Illustration 7 g01154070
i03901105
Illustration 9 g00104545
Illustration 8 g00928085
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
Crushing Hazard! Improper lifting could cause SEHS7332) are available from your Caterpillar
serious injury or death. Follow the lifting instruc- dealer. Attach the warning tags to the engine and to
tions in the Operation and Maintenance Manual each operator control station. When it is appropriate,
for safe lifting procedures. disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two bolts
or nuts that are located at opposite ends of the cover
plate or the device. Before removing the last two bolts
or nuts, pry the cover loose in order to relieve any
spring pressure or other pressure.
SEBU8607 11
Safety Section
General Hazard Information
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
Illustration 10 g00702020 or personal injury may occur. Refer to the OEM
information for any procedures that are required to
• Wear a hard hat, protective glasses, and other relieve the hydraulic pressure.
protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears in order
to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the engine.
Illustration 13 g00706404
i01480768 i04090689
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Illustration 14 g00704000
Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Use of personal protection equipment (PPE) may be
needed.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch All fuels, most lubricants, and some coolant mixtures
with a bare hand. Remove the filler cap slowly in are flammable.
order to relieve pressure.
Always perform a Walk-Around Inspection, which
Cooling system conditioner contains alkali. Alkali can may help you identify a fire hazard. Do not operate a
cause personal injury. Do not allow alkali to contact product when a fire hazard exists. Contact your Cat
the skin, the eyes, or the mouth. dealer for service.
Illustration 16 g02298225
Do not charge a frozen battery. Charging a frozen • End fittings are damaged or leaking.
battery may result in an explosion.
• Outer coverings are chafed or cut.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the • Wires are exposed.
recommended cables, connections, and battery box
covers when the engine is operated. • Outer coverings are ballooning.
Make sure that a fire extinguisher is available. Be • Outer covers have embedded armoring.
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire • End fittings are displaced.
extinguisher regularly. Obey the recommendations on
the instruction plate. Make sure that all clamps, guards, and heat shields
are installed correctly in order to prevent vibration,
rubbing against other parts, and excessive heat.
Ether
Ether is flammable and poisonous. i01359666
Lines, Tubes, and Hoses Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent or When objects are struck, wear protective glasses in
damaged. order to avoid injury to the eyes.
Repair any lines that are loose or damaged. Leaks Chips or other debris may fly off objects when objects
can cause fires. Consult your Cat dealer for repair or are struck. Before objects are struck, ensure that no
for replacement parts. one will be injured by flying debris.
Face the engine in order to mount the engine or See the Service Manual for repairs and for
dismount the engine. Maintain a three-point contact adjustments.
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
i03901111
controls as handholds.
Do not stand on components which cannot support Engine Starting
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the SMCS Code: 1000
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies. Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
i03901110
Before Starting Engine If a warning tag is attached to the engine start switch
or to the controls DO NOT start the engine or move
SMCS Code: 1000 the controls. Consult with the person that attached
the warning tag before the engine is started.
NOTICE All protective guards and all protective covers must
For initial start-up of a new or rebuilt engine, and for be installed if the engine must be started in order to
start-up of an engine that has been serviced, make perform service procedures. To help prevent an
provision to shut the engine off should an overspeed accident that is caused by parts in rotation, work
occur. This may be accomplished by shutting off the around the parts carefully.
air and/or fuel supply to the engine.
Start the engine from the operators compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Engine exhaust contains products of combustion Manual, “Engine Starting” topic in the Operation
which may be harmful to your health. Always start Section. Knowing that the correct procedure will help
and operate the engine in a well ventilated area to prevent major damage to the engine components.
and, if in an enclosed area, vent the exhaust to the Knowing that the procedure will also help to prevent
outside. personal injury.
To ensure that the jacket water heater (if equipped)
Inspect the engine for potential hazards. and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge and/or
Do not start the engine or move any of the controls if the oil temperature gauge during the heater
there is a “DO NOT OPERATE” warning tag or operation.
similar warning tag attached to the start switch or to
the controls. Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
Before starting the engine, ensure that no one is on, engine and operate the engine in a ventilated area. If
underneath, or close to the engine. Ensure that the the engine is started in an enclosed area, vent the
area is free of personnel. engine exhaust to the outside.
If equipped, ensure that the lighting system for the Note: The engine is equipped with a device for cold
engine is suitable for the conditions. Ensure that all starting. If the engine will be operated in cold
lights work properly, if equipped. conditions, then an extra cold starting aid may be
required. Normally, the engine will be equipped with
All protective guards and all protective covers must
the correct type of starting aid for your region of
be installed if the engine must be started in order to
perform service procedures. To help prevent an operation.
accident that is caused by parts in rotation, work These engines are equipped with a glow plug starting
around the parts carefully. aid in each individual cylinder that heats the intake air
Do not bypass the automatic shutoff circuits. Do not in order to improve starting.
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
SEBU8607 17
Safety Section
Engine Stopping
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit is
operating. A spark can cause the combustible gases
that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump-start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump-start cable to the engine block.
Illustration 17 g00104545
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires 2. Attach “DO NOT OPERATE” or similar warning
before the engine is started. Repair all frayed tag to the engine prime mover starting circuit.
electrical wires before the engine is started. See the Disconnect the engine starting circuit.
Operation and Maintenance Manual for specific
starting instructions. 3. Disconnect the generator from the distribution
system.
Grounding Practices
Correct grounding for the engine electrical system is 4. Lock out the circuit breaker. Attach “DO NOT
necessary for optimum engine performance and OPERATE” or similar warning tag to the circuit
reliability. Incorrect grounding will result in breaker. Refer to the electrical diagram. Verify that
uncontrolled electrical circuit paths and in unreliable all points of possible reverse power flow have been
electrical circuit paths. locked out.
Uncontrolled electrical circuit paths can result in 5. For the following circuitry, remove the fuses of the
damage to main bearings, to crankshaft bearing transformer:
journal surfaces, and to aluminum components.
Engines that are installed without engine-to-frame • power
ground straps can be damaged by electrical
discharge. • sensing
18 SEBU8607
Safety Section
Generator Isolating for Maintenance
• control
6. Attach “DO NOT OPERATE” or similar warning
tag to the generator excitation controls.
Product Information
Section
General Information
i03903864
Illustration 18 g02162614
Typical example
(1) Expansion tank (6) Rain cap for air cleaner (11) Fuel priming pump
(2) Filler for engine coolant (7) MCS control panel (12) Duplex oil filters
(3) Aftercooler (8) Generator terminal box (13) Water inlet for auxiliary water pump
(4) Air cleaner (9) Crankcase breather
(5) Indicator for the air cleaner (10) Duplex fuel filters
20 SEBU8607
General Information
Model View Illustrations
Illustration 19 g02163145
Typical example
(14) Engine alternator (15) Exhaust manifold (16) Intercooler
SEBU8607 21
General Information
Model View Illustrations
Illustration 20 g02162615
Typical example
(1) Cover for belts (6) Rain cap for air cleaner (11) Fuel priming pump
(2) Top oil filler cap (7) MCS control panel (12) Duplex oil filters
(3) Aftercooler (8) Generator terminal box (13) Water pump
(4) Air cleaner (9) Crankcase breather
(5) Indicator for the air cleaner (10) Duplex fuel filters
22 SEBU8607
General Information
Model View Illustrations
Illustration 21 g02163146
Typical example
(14) Engine alternator (16) Intercooler
(15) Exhaust manifold (17) Electric starting motor
SEBU8607 23
General Information
Model View Illustrations
Illustration 22 g02168837
Typical example
(1) Water temperature regulator (3) Filler cap for radiator (5) Tube from aftercooler to the inlet manifold
(2) Vent lines for cooling system (4) Air to air aftercooler
24 SEBU8607
General Information
Product Description
Illustration 23 g02168874
Typical example
(6) Cover on tube for the boost pressure
• Turbocharged
• Turbocharged aftercooled
SEBU8607 25
General Information
Product Description
Product Identification
Information
i05042129
Illustration 25 g02162619
Typical example
SEBU8607 27
Product Identification Information
Plate Locations and Film Locations
Illustration 26 g01332986
i03903992
Declaration of Conformity
SMCS Code: 1000
Table 2
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 provided
with the product. The extract shown below from an EC Declaration of Conformity for products 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.
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:
I, the undersigned, _________, hereby certify that the equipment specified hereunder
Serial Number:
Commercial Name: Caterpillar
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 the person listed above authorized to compile the Technical File
Date: Name/Position
Note: The above information was correct as of July, 2009, but may be subject to change, please refer to the individual declaration of conformity
issued with the product for exact details.
SEBU8607 29
Product Identification Information
Generator Set Intended for Stationary Use Only
i01297919
i03903859
Illustration 27 g02163676
Typical example
The IMO label is mounted on the engine. Supplemental Coolant Additive Maintenance Element
Number (Optional)
i03903750 Total Lubrication System Capacity
Reference Information Total Cooling System Capacity
SMCS Code: 1000; 4450 Air Cleaner Element Number
Information for the following items may be needed to Alternator Belt Number
order parts for your marine engine. Locate the
information for your engine. Record the information
on the appropriate space. Make a copy of this list for
a record. Keep this information for future reference.
Operation Section
Product Lifting
SMCS Code: 7000; 7002
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Engine Views
32 SEBU8607
Lifting and Storage
Product Lifting
MCS
Illustration 28 g02163637
Typical example
SEBU8607 33
Lifting and Storage
Product Storage
Bearing Inspection
Ball bearing generators use grease. This grease is
subject to deterioration. If the generator is stored
more than 1 year, new ball bearings may be required.
These bearings should be greased 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.
Electrical Measurements
Measure the insulation resistance of each winding if
the generator was exposed to the following
conditions:
Installation Location
The location of the generator must comply with all
i03903752 local regulations. The location of the generator must
also comply with all special industrial regulations.
Product Installation Locate the generator in an area that meets the
following requirements:
SMCS Code: 1000; 1404; 4450; 7002
• Clean
Receiving Inspection • Dry
If the generator is received during cold weather, allow
• Well ventilated
the unit to reach room temperature before you
remove the protective packing material. Warming the • Easily accessible for inspection and maintenance
generator to room temperature will prevent the
following problems: Do not obstruct air inlet openings. Do not obstruct
discharge openings. Coolant flow must reach these
• Water condensation on cold surfaces openings. If the generator is exposed to harsh
environmental conditions, the generator can be
• Early failures due to wet windings modified in the field in order to add filters and space
heaters. In addition, a more rigid periodic
• Early failures due to wet insulating materials maintenance schedule should be established.
Unpacking Electrical Measurements
Moving the Generator Measure the insulation resistance of each winding if
the generator was exposed to the following
Unpack the equipment with care in order to avoid conditions:
scratching painted surfaces.
• Rapid changes in temperature
• Freezing
Improper lift rigging can allow unit to tumble • Wet climate during shipment
causing injury and damage.
• Wet climate during storage
Note: These tests should be conducted prior to any
NOTICE power connections that are being made. These tests
Do not use the engine lifting eyes to remove the en- should be conducted prior to any control connections
gine and generator together. that are being made.
Refer to the Generator Maintenance section of this
Move the unit to the mounting location. The unit can manual in order to measure the following items:
be moved by either of the following methods:
• Exciter field (stator)
• Attach an overhead crane to the eyebolts that are
installed on the generator frame. • Exciter armature (rotor)
• Use a lift truck in order to lift the generator. • Generator field (rotor)
Refer to the Operation and Maintenance Manual, • Generator armature (stator)
“Product Lifting” section.
The hoist and the hoist cables should have a rating
Protective Devices
that is greater than the weight of the generator. When The output to the load of the generator should always
the unit is moved, ensure that the generator is be protected with an overload protection device such
supported by the lift truck's fork tines. Also ensure as a circuit breaker or fuses. Fuses should be sized
that the generator is balanced on the lift truck's fork by using the lowest possible current rating. However,
tines. Slide the fork tines beneath the attached skid in this rating must be above the current rating for full
order to lift the generator, if equipped. load. A common recommendation is 115 percent of
rated current. Determine the size of fuses or
determine the size of circuit breakers in accordance
with NEMA , IEC, and Local Electrical Codes.
36 SEBU8607
Features and Controls
Alarms and Shutoffs
Features and Controls Coolant level – The low coolant level switch
indicates when the coolant level is low.
i03905629 Coolant temperature – The coolant temperature
sensor indicates high jacket water coolant
Alarms and Shutoffs temperature.
SMCS Code: 7400 Engine oil pressure – The engine oil pressure
sensor indicates when oil pressure drops below rated
This section contains some general information about system pressure, at a set engine speed.
the function of typical engine protective devices.
Engine overspeed – The primary speed/timing
The alarms and shutoffs are set at critical operating sensor checks the engine speed.
temperatures, pressures, fluid levels, or speeds in
order to protect the engine from damage.
Note: The sensing element of the coolant
An alarm warns the operator when an abnormal temperature switch must be submerged in coolant in
operating condition occurs. The shutoffs shut down order to operate.
the engine if a more critical operating condition
occurs. The shutoffs help to prevent damage to the Engines may be equipped with alarms in order to
engine. alert the operator when undesirable operating
conditions occur.
If an engine protective device shuts off the engine,
always determine the cause of the shutoff. Always NOTICE
make the necessary repairs before attempting to start When an alarm is activated, corrective measures
the engine. must be taken before the situation becomes an emer-
gency in order to avoid possible engine damage.
Become familiar with the following information:
• Types of the alarms and shutoffs If corrective measures are not taken within a
reasonable time, engine damage could result. The
• Locations of the alarm and shutoff controls alarm will continue until the condition is corrected.
The alarm may need to be reset.
• Conditions which cause each control to function
Testing Alarms and Shutoffs
• The procedure that is required before starting the
engine Alarms must function properly in order to provide
timely warning to the operator. Shutoffs help to
Shutoffs prevent damage to the engine. It is impossible to
determine if the engine protective devices are in good
The shutoffs are electrically operated or mechanically working order during normal operation. Malfunctions
operated. The alarms for the MCS are controlled by must be simulated in order to test the engine
the control panel. protective devices. Refer to this Operation and
Maintenance Manual, “Engine Protective Devices -
The particular shutoff may need to be reset before the Check” for more information.
engine will start.
NOTICE
Prevention of Start-up
Always determine the cause of the engine shutdown. The engine will not start if any of the conditions that
Make necessary repairs before attempting to restart cause a shutoff are present. An overcrank will also
the engine. prevent starting of the engine. If any situation that
causes a shutoff occurs, the following conditions
must be met before the engine can be started:
Alarms
• The condition that prevented starting is not
The alarms are electrically operated. The operation of present.
the alarms are controlled by the control panel.
• The fault must be reset or cleared in the controller.
The alarm is operated by a sensor or by a switch.
When the sensor or the switch is activated a signal is
sent to the control panel. An event code is created by
the control panel. The control panel will send a signal
in order to illuminate the lamp.
Your engine may be equipped with the following
sensors or switches:
SEBU8607 37
Features and Controls
Control Panel
i03902899
Control Panel
SMCS Code: 7451
Illustration 30 g02160513
(1) Emergency stop push button (5) Low oil pressure shutdown indicator (10) Engine harness connector DC and
(2) Control panel (6) Isolator Keyswitch governor
(3) High coolant temperature shutdown (7) Glow plug circuit breaker (11) AC isolator jacket water heater (if
indicator (8) Engine harness connector DC and starter equipped)
(4) High oil temperature shutdown indicator (9) Generator harness connector
38 SEBU8607
Features and Controls
Control Panel
Illustration 31 g02160517
(1) Circuit breaker F1 Main controller (6) Relay K2 Primary power on (11) Starter relay
(2) Circuit breaker F2 Shutdown controls (7) Relay K3 Alternator charging (12) Engine shutdown override switch
(3) Circuit breaker F3 Sensor feeds (8) Relay K4 Generator running 2 (13) Backup start/stop switch
(4) Power dip capacitor (9) Glow plug relay
(5) Relay K1 Generator running 1 (10) Glow plug earth relay
SEBU8607 39
Features and Controls
Control Panel
Illustration 32 g02160519
The MCS control panel is operated by keys on the of alarms. The list holds 100 events. These events
control panel. The keys (4), (5), and (10) control the are erased when the main unit is switched off.
starting and the stopping of the generator set. The
keys (2), (3), (12), (13), (14), (15), (16), (20), (21), and “ VIEW”” Key (4) – Enter a menu number selection.
(22) allow the operator to access additional All settings have a specific number. The “VIEW” key
information about the generator set. enables the user to select any setting. The “VIEW”
key enables the user to display any setting without
Alarm Indicator (1) – A flashing LED indicates that navigating through all of the menus.
alarms that have not been acknowledged are still
Menu Key for UP(5) – This key increases the value
present. A fixed LED indicates that all alarms are
acknowledged. A red LED indicates shutdown. A of the selected set point in the setting menus. This
green LED is for an alarm. key is also used for scrolling to the second line that
displays the values for the generator in the display for
Display Area (2) – The display area shows daily use.
information about the generator set.
Indicator for Status of the Controller (7) – This light
“ LOG”” Key (3) – This key shifts the display to the indicates that the unit is running a self-check and the
three lower lines in order to show the event and a list unit is functioning properly.
40 SEBU8607
Features and Controls
Control Panel
Indicator Light for “ Alarm Inhibit”” (8) – This light Setting the Password
indicates that “inhibit input” is on.
Setting the password can only be accomplished by
Menu Key for RIGHT(9) – This key moves the cursor using the “JUMP” key.
to the right in order to maneuver in the menus.
“ SEL”” Key (10) – This key is used to select the Note: Keep a record of the password. If the password
function that has been chosen. The function that has is forgotten, it will not be possible to enter the menus.
been chosen is the underlined selection in the lower
line of the display. Use the following procedure to change the password.
Lamp Test Switch (11) – The lamp test switch is 1. Press the “JUMP” key.
used to test indicators on the control panel.
2. Use the Menu key for UP and the Menu key for
Menu Key for DOWN(12) – This key decreases the
value of the selected set point in the setting menus. DOWN In order to step to channel 4976.
This key is also used for scrolling to the second line
that displays the values for the generator in the 3. Press the “SEL” key.
display for daily use.
Note: The password must be re-entered when the
“ BACK”” Key (13) – The “BACK” key jumps one display has not been used for 3 minutes.
step backward in the menu to previous display or to
the entry screen. Service Menu
Menu Key for LEFT(14) – This key moves the cursor
Accessing the Service Menu can only be
to the left for maneuvering in the menus.
accomplished by using the “JUMP” key.
Indicator Light for Control in Remote Mode (15) –
The indicator illuminated through operation of the Use the following procedure to access the Service
Mode key. (12) Menu.
“ MODE”” Key (16) – The “MODE” key switches the 1. Press the “JUMP” key.
system between LOCAL START/STOP and
“REMOTE START/STOP” . Light (13) is illuminated 2. Use the Menu key for UP and the Menu key for
for “REMOTE” control. DOWN In order to step to channel 4980.
Generator Status Indicator (17) – This light 3. Press the “SEL” key.
indicates that the voltage and frequency is present
and OK. 4. Choose the desired functions, timers, inputs, or
Engine Operating Indicator (18) – Light indicates outputs by moving the cursor and pressing the
that the generator is running. “SEL” key.
“ STOP”” Key (reset) (19) – The “STOP” key shuts
down the engine when the engine is running. Alarms
Pressing the “ STOP”” key bypasses the cooldown
period. The following steps describe the function of the
alarm.
“ START”” Key (20) – The “START” key begins the
starting sequence. The PPU must be in manual mode 1. An alarm occurs. The alarm light starts flashing.
in order for the “START” key to function. The remote
indicator light (15) cannot be illuminated. To switch off 2. The display automatically shows the alarm
the remote indicator light, press “MODE” key (14). information.
“ JUMP”” Key (21) – The “JUMP” key is used to 3. Move the cursor to “ACK” and press the “SEL”
enter a number in order to select a menu. Every key in order to acknowledge the alarm. Take the
setting has a specific number. Use the “JUMP” key necessary action for the alarm.
in order to select any setting and display any setting
without navigating all the way through the menus. 4. The alarm will disappear when the condition that
“ INFO”” Key (22) – This shifts the display in order to caused the alarm is no longer present.
show the list of alarms. The list has a maximum of 30
alarms. A history that displays the last 30 alarms can 5. Alarms that have not been acknowledged are still
be viewed. present if the alarm light flashes.
If the engine is operating above the normal range and Sensors and Electrical
steam becomes apparent, perform the following
procedure: Components
1. Reduce the load and the engine rpm.
(MCS Switches and Alarms)
SMCS Code: 1900; 7400
2. Determine if the engine must be shut down
immediately or if the engine can be cooled by Locations of Electrical
reducing the load.
Components
3. Inspect the cooling system for leaks.
Coolant Level Switch 1
Tachometer – This gauge indicates
engine speed (rpm). When the throttle
control lever is moved to the full throttle
position without load, the engine is running at
high idle. The engine is running at the full load
rpm when the throttle control lever is at the full
throttle position with maximum rated load.
NOTICE
To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. Operation at speeds exceed-
ing high idle rpm should be kept to a minimum.
Illustration 34 g02161574
Typical example
Low Fuel Pressure Switch 6 The oil pressure transmitter is powered from the
panel. If an incorrect signal is received, an alarm will
be activated by the control panel when a signal is
received from the oil pressure transmitter .
Illustration 36 g02161577
Typical example
Illustration 38 g02161579
Typical example
Illustration 37 g02161578
Typical example
46 SEBU8607
Engine Diagnostics
Diagnostic Lamp
The control panel for the MCS has a diagnostic lamp. System configuration parameters are parameters that
affect the emissions and the power of the engine.
Default values for the parameters are programmed at
i03905681 the factory. Some parameters may be changed by the
customer in order to suit the needs of the specific
Engine Operation with Active application.
Diagnostic Codes Engine Rating Parameter
SMCS Code: 1000; 1900; 1901; 1902
“ Rating Number””
Control Panel for MCS The “Rating Number” corresponds to the selected
If a diagnostic lamp illuminates during normal engine set of performance maps for the application. Factory
operation, the system has identified a situation that is passwords are required in order to change the
not within the specification. Use the Caterpillar “Rating Number” .
electronic service tool (ET) in order to check the
active diagnostic codes. Contact your Caterpillar ECM Identification Parameter
dealer for more information.
The active diagnostic code should be investigated. Equipment ID
The cause of the problem should be corrected as
soon as possible. If the cause of the active diagnostic “Equipment ID” is the identification of the equipment
code is repaired and there is only one active that is assigned by the customer. This parameter
diagnostic code, the diagnostic lamp will turn off. allows the customer to enter a description into the
ECM in order to identify the engines application. A
Operation of the engine and performance of the maximum of 17 characters can be entered in the field.
engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates Miscellaneous
may be significantly slower and power outputs may
be automatically reduced. Monitoring Mode Shutdowns
i03905704 “Monitoring Mode Shutdowns” controls the
shutdown feature that is associated with the engine
Engine Operation with monitoring feature.
Intermittent Diagnostic Codes Configurable Inputs
SMCS Code: 1000; 1900; 1901; 1902
Overspeed Protection
Control Panel for MCS The “Overspeed Protection” speed is the engine rpm
If a diagnostic lamp illuminates during normal engine when a shutdown will occur. Overspeed protection is
operation and the diagnostic lamp shuts OFF, an used in order to protect the engine from damage.
intermittent fault may have occurred. Overspeed protection must be enabled in “Monitoring
Mode Shudowns” .
SEBU8607 47
Engine Diagnostics
Configuration Parameters
i03902841
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Perform the required daily maintenance and other Do not use aerosol types of starting aids such as
periodic maintenance before the engine is started. ether. Such use could result in an explosion and
Inspect the engine compartment. This inspection can personal injury.
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for more information. Startability will be improved at temperatures below
−18 °C (0 °F) from the use of a jacket water heater or
• Before you start the engine refer to this Operation extra battery capacity.
and Maintenance Manual, “Walk-Around
Inspection” . Disengage any driven equipment.
• Ensure that the engine has an adequate fuel The control panel will automatically control the cold
supply. starting of the engine.
If the engine has not been started for several weeks, Marine Certification Society (MCS)
fuel may have drained from the fuel system. Air may Control Panel
have entered the filter housing. Also, when fuel filters
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.
Starting Procedure
Illustration 39 g02162627
Typical example
(1) Isolator Keyswitch
50 SEBU8607
Engine Starting
Starting the Engine
Illustration 40 g02162628
Typical example
(2) Start Key (3) Stop Key (4) Mode Key
Use the following procedure for Marine Certification If “V3” is selected, the display will indicate the
Society control panels in order to start the engine. status in the start/run cycle. The display will show
“start prepare” and “start relay on” .
1. Turn the Isolator keyswitch (1) for the Generator
Set to the ON position. a. If the timer (preheat) is configured, then the
timer (preheat) will be initiated. After the timer
The “Power” LED will illuminate immediately. The (preheat) has expired, the engine will begin to
“Self Check OK” LED will illuminate after a few crank.
seconds. The Generator Set is now ready to start.
Line 4 on the display will read “SETUP V3 V2 V1” . Note: When the engine starts, the starting motor is
disengaged and the starting motor is locked out.
The view that is being displayed is underlined. Use
the left arrow button and the right arrow button to b. If the engine did not start, then the control
scroll between the four screens of the display. module will permit the starting motor to cool
down for a predetermined amount of time.
2. Make sure that the “Auto” LED is off. If the “Auto” Once the cooldown timer has expired, the
LED is on press the “Mode” key once in order to engine will crank.
extinguish the “Auto” LED and gain local control.
If the installation is not equipped with a backup After jump starting, the alternator may not be able to
battery system, it may be necessary to start the recharge batteries that are severely discharged. The
engine from an external electrical source. batteries must be replaced or charged to the proper
voltage with a battery charger after the engine is
For information on troubleshooting the charging stopped. Many batteries which are considered
system, refer to Special Instruction, REHS0354, unusable are still rechargeable. Refer to Operation
“Charging System Troubleshooting”. and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery - Test”.
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator Refer to the Electrical Schematic for your engine.
may not be able to recharge batteries that are Consult your Caterpillar dealer for more information.
severely discharged. The batteries must be charged
to the proper voltage with a battery charger. For
information on testing and charging, refer to the
Special Instruction, SEHS7633, “Battery Test
Procedure”.
52 SEBU8607
Engine Starting
After Starting Engine
i03902850
Engine Operation • Ensure that the belts are properly adjusted. The
belts should be in good condition. Refer to the
Specifications manual for further information.
i03902852
• Ensure that all of the connections of the hoses are
Engine Operation tight. The connections should not leak.
SMCS Code: 1000 • Ensure that the driven equipment is in good
working order.
Proper operation and maintenance are key factors in
obtaining the maximum life and economy of the • Keep cooling system components clean and keep
engine. If the directions in the Operation and cooling system components in good repair. Never
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. operate the engine without water temperature
regulators. All of these items will help maintain
The time that is needed for the engine to reach operating temperatures.
normal operating temperature can be less than the
time taken for a walk-around inspection of the engine.
Gauge readings should be observed and the data
should be recorded frequently while the engine is
operating. Comparing the data over time will help to
determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
i03902853
Power Factor
Power factor (PF) determines the relationship
between true power and apparent power. The true
power is also known as the active power. The
apparent power is also called kVA. The true power
(kW) is the work that is done on the load by the
engine. The true power determines the amount of
power that is available for the load to do work. The
apparent power (kVA) is the total power that is
produced by the generator. Power factor can be
calculated by using the following formula.
PF = kW / kVA,
• kilowatt (kW)
• kilovolt ampere (kVA)
Illustration 41 g00627416
Allowable Combinations of Unbalanced Loads
SEBU8607 55
Generator Operation
Single Unit Operation
Some generators are available with embedded 6. Readjust the governor for rated frequency.
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
Adjust the Voltage
equipment that is provided by the customer. Thus, the Adjust the voltage regulator in order to obtain the
temperature of the main armature winding can be proper voltage. Refer to Operation and
measured or monitored. RTD temperature detectors Maintenance Manual, “Voltage Regulators” for
are available. Contact your Caterpillar dealer for more information about the voltage regulator.
more information.
56 SEBU8607
Generator Operation
Parallel Operation
1. Turn the remote adjustment potentiometer to the 3. Allow the engine to run for 5 minutes in order to
center position, if equipped. cool.
8. Start the engine and set the engine speed to a Units that operate in parallel must have the same
phase rotation. There are two methods that may
frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz. be used in order to determine if the incoming unit
and the unit that is on-line have the same phase
9. Adjust the output voltage to the correct value with rotation. These methods are listed below:
potentiometer P2. This voltage should be the rated
voltage UN for single operation or UN plus 2% to • Using a phase rotation meter
4% for parallel operation with a current
transformer. Use potentiometer P3 to make • Using a set of three light bulbs
adjustments if the voltage oscillates. Adjust Use the procedure below to determine the proper
potentiometer P3 in both directions while you phase rotation by using three light bulbs.
observe the voltage between E+ and E-. The
voltage between E+ and E- should be
approximately 10 VDC. The best response times
are obtained at the limit of the instability. Try cutting
or replacing the wire ST2 if no stable position can
be obtained.
10. Check the LAM operation. ST5 must be closed.
Stopping
1. Remove the load in increments.
2. Open the circuit breaker.
SEBU8607 57
Generator Operation
Parallel Operation
Paralleling Multiple Units In order to transfer the load from one engine to
another engine, use the following procedure:
Units may be paralleled at no load. Units may also be
paralleled with units under load. After the initial 1. Increase the governor speed control of one unit in
conditions for start-up are satisfied, verify for the order to increase the load.
following requirements:
2. Reduce the governor speed control of the other
• One of the governors can be an isochronous unit in order to decrease the load on that unit.
governor. Electronic load sharing governors are an
exception. 3. Raise the governor speed control or lower the
governor speed control of both units in order to
• Generators must have voltage droop change system frequency.
compensation or cross current compensation.
The Speed brick converter changes the analog signal • Each governor should have a 3 percent speed
of the speed potentiometer into a pulse width droop in order to provide the simplest combination
modulated signal. The engine electronic control can of governors for electric sets that are connected in
recognize this signal. The converter is mounted on parallel. If a constant frequency from no load to full
the subpanel which is located within the control panel. load is required, one governor can be adjusted for
isochronous operation. This isochronous unit will
Function of The Engine Governor be called a “lead unit” .
This section describes the function of the engine • In order for all paralleled units to accept the full
governor in relation to load division between parallel share of the load, the following governor
electric sets. adjustments are required. The governors should
have the same full load speed. The governors
It is important to understand two basic facts about should have the same high idle speed in the case
load division between generator sets which are
operating in parallel. of governors which are adjusted for speed droop
operation. Governor controls should be set to the
1. The power which is supplied to the generator and high idle position so that the full range of the
to the load is a function of the engine. The setting governor is available.
of the engine governor and the position of the • Operating an isochronous governor in parallel with
engine governor control determine the amount of a speed droop governor requires special
power that is delivered by the engine. Therefore, techniques.
the governor setting and the position of the
governor control determine the kW load which is • Any number of electric sets can be operated in
carried by the generator. A change in the engine parallel. However, only one governor of the group
power of any one of the units in a parallel operation can be adjusted for isochronous operation. The
exception will be some special cases of electronic
will result in the same change in engine power for
governors with automatic load sharing.
each of the other units in that parallel operation. In
other words, the units that are in parallel operation Stopping
will stay in parallel operation.
In order to remove a generator from the line, perform
2. The division of power is not determined by the following procedure.
generator excitation or terminal voltage. The
excitation will determine the power factor for a 1. Check the load. The load must be less than the
generator when the generator is operating in rated capacity of the remaining units.
parallel with other generators.
2. Be sure that the neutral of one of the remaining
Governors that are used with Caterpillar powered units is grounded.
electric sets can be of two types:
3. Remove the load from the outgoing unit. See the
• Governors with fixed speed droop Parallel Operation, “Load Division - Speed Droop”.
The amperage may never go to zero due to
• Governors with adjustable speed droop
circulating currents.
The values of speed droop which are commonly used
are 3 percent and 0 percent. Governors with 4. Open the circuit breaker.
adjustable speed droop can be adjusted so the
characteristics match closely with the characteristics 5. Allow the engine to cool for 5 minutes.
of governors with fixed speed droop. If the governor is
adjusted for 0 percent speed droop or isochronous 6. Stop the engine.
operation, then the same speed from no load to full
load can be obtained. Circulating Currents
Summary on Governor Operation Understanding the circulating currents becomes
important when you parallel the units. These
circulating currents are flowing between generators in
The preceding discussion of governor operation can parallel operation. The circulating currents are
be summarized below: caused by voltage differences between the
generators. The circulating currents are not doing
useful work. The amount of the circulating current can
be determined by subtracting the amperage which is
going to the load from the total generator amperage.
60 SEBU8607
Generator Operation
Voltage Regulators
As the generators warm, the circulating currents will To avoid accidental engine starting, disconnect
decrease. The ammeter readings should decrease the battery cable from the negative (−) battery ter-
slightly, but the voltage meter readings should remain minal. Completely tape all metal surfaces of the
constant. disconnected battery cable end in order to pre-
vent contact with other metal surfaces which
could activate the engine electrical system.
i03902840
Place a Do Not Operate tag at the Start/Stop
Voltage Regulators switch location to inform personnel that the
equipment is being worked on.
SMCS Code: 4467
For generators with Auxiliary Winding Regulation
Excitation Principle (AREP), the voltage regulator is
powered by two auxiliary windings. These windings
Personal injury or death can result from high are independent from the voltage sensing circuit. The
voltage. first winding is Labeled as “X1” and “X2” . This
winding has a voltage that is proportional with the
When power generation equipment must be in op- output voltage of the generator. The second winding
eration to make tests and/or adjustments, high is Labeled as “Z1” and “Z2” . This winding has a
voltage and current are present. voltage that is proportional to the current of the stator.
The voltage from the power supply is rectified and
Improper test equipment can fail and present a filtered before being used by the AVR monitoring
high voltage shock hazard to its user.
transistor. The generator has a capacity of 3 IN for 10
Make sure the testing equipment is designed for seconds for a short circuit current. The generator also
and correctly operated for high voltage and cur- has good immunity to distortion from the generator
rent tests being made. load.
For generators with PMG excitation, a permanent
When servicing or repairing electric power gener-
magnet generator is added to the generator at the
ation equipment:
rear of the generator. The PMG supplies the voltage
• Make sure the unit is off-line (disconnected regulator with a voltage that is independent of the
main generator winding. The generator has a
from utility and/or other generators power serv- capacity of 3 IN for 10 seconds for a short circuit
ice) , and either locked out or tagged DO NOT current. The generator also has good immunity to
OPERATE. distortion from the generator load.
• Remove all fuses. The voltage regulator monitors the output voltage of
the generator. The voltage regulator corrects the
• Make sure the generator engine is stopped. output voltage by adjusting the excitation current.
• Make sure all batteries are disconnected. Table 4
Sustained short circuit capacity 3 IN for 10 seconds
• Make sure all capacitors are discharged. (AREP and PMG)
Failure to do so could result in personal injury or Standard power supply (AREP) Two auxiliary windings
death. Make sure residual voltage in the rotor, sta-
tor and the generator is discharged. Supply for shunt max 140 VAC at 50/60 Hz
(continued)
SEBU8607 61
Generator Operation
Voltage Regulators
(Table 4, contd)
Voltage sensing 5 VA that is isolated by the
transformer
0-110V terminals 95 to 140 V
0-220V terminals 170 to 260 V
0-380V terminals 340 to 520 V
Voltage regulation ±0.5%
R448 Adjustments
Illustration 45 g01015862
Illustration 46 g00995995
Connections for AREP excitation
SEBU8607 63
Generator Operation
Voltage Regulators
R448 Adjustment for Maximum 1. Open switch “D” . The excitation current should
Excitation increase up to the preset maximum value and the
excitation current should remain at the preset
maximum value for approximately 10 seconds.
The current will decrease to less than one Amp.
Special Use
Illustration 48 g01016266
(continued)
SEBU8607 65
Generator Operation
Generator Lead Connections
(Table 5, contd)
De-energized parallel
12 (1A) 1 - 2 seconds
operation Accidental engine starting can cause injury or
Standstill parallel operation 24 (2A) 5 - 10 seconds death to personnel working on the equipment.
There are some cases when the neutral wire is not Wiring Code A for Three-Phase
grounded. An ungrounded generator neutral lead is
acceptable when the possibility of grounds to the Configuration
phase leads has been eliminated. An example of
such measures are ground fault protective circuits.
Ground fault protection requires the entire group of
distribution circuits to be treated as a system. The
owner should contact a certified consultant if a new
distribution system is being developed. The owner
should also contact a certified consultant if an existing
system should be modified for the ground fault
protection.
Single Units
Each unit should be connected to a common ground.
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
Be sure to check your local wiring codes.
Connection Diagrams
Illustration 52 g00952030
Illustration 51 g02160959
Typical example
Change the position of the wire terminals in order to Factory connection for “A” wiring code
modify the connection. The code for the winding is
specified on the nameplate. Table 6
L-L Voltage for Wiring Code A
Winding 50 Hz 60 Hz
6 190-208 190-240
7 220-230 -
8 - 190-208
SEBU8607 67
Generator Operation
Generator Lead Connections
NOTICE
This configuration is not possible for LSA 44.2 gener-
ator models.
Illustration 54 g00952097
Illustration 55 g00952196
Factory connection for “B” wiring code
Table 7
L-L Voltage for Wiring Code B
Winding 50 Hz 60 Hz
6 110-120 120
7 120-130 -
8 - 110-120
Winding 50 Hz 60 Hz
Wiring Code D for Three-Phase 6 380-415 380-480
Configuration 7 440-460 -
8 - 380-416
Illustration 56 g00952201
Illustration 58 g00952381
Voltage LM equals one half of voltage LL.
Illustration 57 g00952365
Factory connection for “D” wiring code
SEBU8607 69
Generator Operation
Generator Lead Connections
Table 9 Table 10
L-L Voltage for Wiring Code F L-L Voltage for Wiring Code FF
Winding 50 Hz 60 Hz Winding 50 Hz 60 Hz
R 230 voltage sensing – 0 => (T8) / 110 V => (T11) R 230 voltage sensing – 0 => (T1) / 110 V => (T4)
R 438 LS voltage sensing – 0 => (T3) / 220 V => R 438 LS voltage sensing – 0 => (T10) / 220 V =>
(T2) (T1)
Illustration 60 g00952416
Voltage LM equals one half of voltage LL.
70 SEBU8607
Generator Operation
Generator Lead Connections
Illustration 64 g00953025
Connect the interference suppression, as shown. The
Illustration 62 g01153397
letters in the circles represent the wiring codes for the
generators.
(WHT) White
(BLU) Blue (BLK) Black
(BLK) Black (BLU) Blue
(RED) Red (WHT) White
(A) Wiring code “A”
(B) Wiring code “B”
Parallel Connection for Auxiliary Winding (D) Wiring code “D”
(F) Wiring code “F”
Regulation Excitation Principle (AREP) (FF) Wiring code “FF”
Illustration 63 g01147978
(WHT) White
(BLU) Blue
(BLK) Black
(RED) Red
SEBU8607 71
Cold Weather Operation
Fuel and the Effect from Cold Weather
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
four micron[c] absolute high efficiency fuel filter is re-
quired for all Caterpillar Hydraulic Electronic Unit In-
jectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer
for the proper part numbers.
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater with
a large heating surface. The fuel heater should be
practical in size. Small heaters can be too hot due to
the limited surface area.
Disconnect the fuel heater in warm weather.
Engine Stopping The emergency stop button (1) is in the OUT position
for normal engine operation. Push the emergency
stop button. The engine will not start when the button
i03902854 is locked. Turn the button clockwise in order to reset.
i03902856
Emergency Stopping
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices
or controls for normal stopping procedure.
Illustration 65 g02148927
Typical example
74 SEBU8607
Engine Stopping
Manual Stop Procedure
i03902885
Illustration 66 g02162627
Typical example
(1) Isolator Keyswitch
SEBU8607 75
Engine Stopping
Manual Stop Procedure
Illustration 67 g02162635
Typical example
(2) Stop key
76 SEBU8607
Engine Stopping
After Stopping Engine
i03902886
NOTICE
Only use antifreeze/coolant mixtures recommended
in the Refill Capacities and Recommendations topic
that is in this Operation and Maintenance Manual.
Failure to do so can cause engine damage.
SEBU8607 77
Maintenance Section
Refill Capacities and Recommendations
Refill Capacities and Note: When oil meets more than one API
classification, the applicable footnote is determined
Recommendations by the highest API classification that is met.
SMCS Code: 1348; 1395; 7560 Example – An oil meets both the API CH-4 and the
API CF oil classifications. In this case, the API CH-4
Engine Oil applies.
NOTICE
These recommendations are subject to change with- Cat DEO (Diesel Engine Oil)
out notice. Contact your local Caterpillar dealer for
the most up to date recommendations. Caterpillar Oils have been developed and tested in
order to provide the full performance and service life
that has been designed and built into Caterpillar
Engines . Caterpillar Oils are currently used to fill
API Oils diesel engines at the factory. These oils are offered
by Caterpillar dealers for continued use when the
The Engine Oil Licensing and Certification System engine oil is changed. Consult your Caterpillar dealer
by the American Petroleum Institute (API) is for more information on these oils.
recognized by Caterpillar . For detailed information
about this system, see the latest edition of the API Due to significant variations in the quality and in the
publication No. 1509. Engine oils that bear the API performance of commercially available oils,
symbol are authorized by API. Caterpillar makes the following recommendations:
• Cat DEO (Diesel Engine Oil) (10W-30)
Diesel engine oils CC, CD, CD-2, and CE have not Caterpillar multigrade DEO can be used in other
been API authorized classifications since January 1, diesel engines and in gasoline engines. See the
1996. engine manufacturers guide for the recommended
Table 11 specifications. Compare the specifications to the
specifications of Caterpillar multigrade DEO. The
API Classifications current industry standards for Caterpillar DEO are
Current Obsolete listed on the product label and on the data sheets for
the product.
CH-4(1)
CE, CC, CD
CI-4 Consult your Caterpillar dealer for part numbers and
CD-2 (2)
for available sizes of containers.
-
(continued)
78 SEBU8607
Refill Capacities
Refill Capacities and Recommendations
Note: Caterpillar SAE 15W-40 multigrade DEO requirements of Caterpillar's ECF-1 (Engine
exceeds the performance requirements for the Crankcase Fluid specification-1) are met.
following API classifications: CI-4, CH-4, CG-4, CF-4
and CF. The Caterpillar multigrade DEO exceeds API CH-4 – API CH-4 oils were developed in order to
the requirements of the Caterpillar specification that protect low emissions diesel engines that use a 0.05
is ECF-1(Engine Crankcase Fluid-1). The Caterpillar percent level of fuel sulfur. However, API CH-4 oils
SAE 15W-40 multigrade DEO passes the following may be used with higher sulfur fuels. API CH-4 oils
proprietary tests: sticking of the piston ring, oil control are acceptable if the requirements of Caterpillar's
tests, wear tests and soot tests. Proprietary tests help ECF-1 (Engine Crankcase Fluid specification-1) are
ensure that Caterpillar multigrade oil provides met.
superior performance in Caterpillar Diesel Engines. In
addition, Caterpillar multigrade oil exceeds many of
the performance requirements of other manufacturers Note: CH-4 oils and CI-4 oils that have not met the
of diesel engines. Therefore, this oil is an excellent requirements of Caterpillar's ECF-1 Specification
choice for many mixed fleets. True high may cause reduced engine life.
performance oil is produced with a combination
of the following factors: industry standard tests, NOTICE
proprietary tests, field tests and prior experience Failure to follow these oil recommendations can
with similar formulations. The design and the cause shortened engine service life due to deposits
development of Caterpillar lubricants that are and/or excessive wear.
both high performance and high quality are based
on these factors.
Note: Refer to Special Publication, SEBU6251,
Note: Non-Caterpillar commercial oils are second “Caterpillar Commercial Diesel Engine Fluids
choice oils. Recommendations ” for additional information that
relates to lubrication for your engine.
Commercial Oils
Lubricant Viscosity Recommendations
Note: If Caterpillar Multigrade DEO is not used, use
only commercial oils that meet the following The proper SAE viscosity grade of oil is determined
classifications. by the minimum ambient temperature during cold
engine start-up, and the maximum ambient
• API CH-4 multigrade oils and API CI-4 multigrade temperature during engine operation.
oils are acceptable if the requirements of Refer to Table 12 (minimum temperature) in order to
Caterpillar's ECF-1 (Engine Crankcase Fluid determine the required oil viscosity for starting a cold
specification-1) are met. CH-4 oils and CI-4 oils engine.
that have not met the requirements of Caterpillar's
ECF-1 Specification may cause reduced engine Refer to Table 12 (maximum temperature) in order to
life. select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
• API CF-4 multigrade oils are not recommended for
this series of diesel engines. For all other smaller Note: Generally, use the highest oil viscosity that is
commercial diesel engines, the oil drain interval available to meet the requirement for the temperature
should not exceed 50 percent of the standard oil at start-up.
drain interval for your engine.
If ambient temperature conditions at engine start-up
require the use of multigrade SAE 0W oil, SAE 0W-40
NOTICE viscosity grade is preferred over SAE 0W-20 or SAE
In selecting oil for any engine application, both the oil 0W-30 .
viscosity and oil performance classification/specifica- Table 12
tion as specified by the engine manufacturer must be
defined and satisfied. Using only one of these param- Engine Oil Viscosities for Ambient Temperatures
eters will not sufficiently define oil for an engine Ambient Temperature
application.
Viscosity Grade Minimum Maximum
In order to make the proper choice of a commercial SAE 0W-20 −40 °C (−40 °F) 10 °C (50 °F)
oil, refer to the following explanations: −40 °C (−40 °F) 30 °C (86 °F)
SAE 0W-30
API CI-4 – API CI-4 oils were developed in order to
meet the requirements of high performance diesel
engines that use cooled Exhaust Gas Recirculation (continued)
(EGR). API CI-4 oils are acceptable if the
SEBU8607 79
Refill Capacities
Refill Capacities and Recommendations
Additional tests are used to measure contamination Always choose a grease that satisfies the
levels from water, fuel, or coolant. Oil viscosity and recommendations that are specified by the equipment
corrosion protection can be evaluated, as needed. manufacturer for the application.
Refer to Special Publication, SEBU6251, Caterpillar Note: If it is necessary to choose a single grease
Commercial Diesel Engine Fluids Recommendations to use for all of the equipment at one site, always
or contact your local Caterpillar dealer for additional choose a grease that satisfies the requirements of
information concerning the S·O·S Oil Analysis the most demanding application.
program.
Do not use the cost per pound as the only factor
Refill Capacities for the Lubrication when you choose a grease. Use the grease that
yields the lowest total cost of operation. The cost
System analysis should include the following factors:
Water • Corrosion
• Formation of mineral deposits
NOTICE
Never use water alone without Supplemental Coolant • Rust
Additives (SCA) or without inhibited coolant. Water
alone is corrosive at engine operating temperatures. • Scale
Water alone does not provide adequate protection
against boiling or freezing. • Pitting and erosion from cavitation of the cylinder
liner
Total Hardness
170 mg/L
D1126 Glycol
(10 grains/US gal)
Total Solids 340 mg/L (20 grain/US gal) D1888 Glycol in the coolant helps to provide protection
against the following conditions:
Acidity pH of 5.5 to 9.0 D1293
• Boiling
For a water analysis, consult one of the following • Freezing
sources:
• Cavitation of the water pump and the cylinder liner
• Caterpillar dealer
For optimum performance, Caterpillar recommends a
• Local water utility company 1:1 mixture of a water/glycol solution.
• Agricultural agent Note: Use a mixture that will provide protection
against the lowest ambient temperature.
• Independent laboratory
Note: 100 percent pure glycol will freeze at a
Additives temperature of −23 °C (−9 °F).
Additives help to protect the metal surfaces of the Most conventional heavy-duty antifreezes use
cooling system. A lack of coolant additives or ethylene glycol. Propylene glycol may also be used.
insufficient amounts of additives enable the following In a 1:1 mixture with water, ethylene and propylene
conditions to occur: glycol provide similar protection against freezing and
boiling. See Tables 15 and 16 .
82 SEBU8607
Refill Capacities
Refill Capacities and Recommendations
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train, the bearings, hy-
draulic components, electrical components, and other
components.
Do not ground the welder across the centerline of the
package. Improper grounding could cause damage to
the bearings, the crankshaft, the rotor shaft, and other
components.
Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.
Note: Perform the welding in areas that are free from Illustration 69 g01075639
explosive hazards. Use the example above. The current flow from the
welder to the ground clamp of the welder will not
1. Stop the engine. Turn the switched power to the damage any associated components.
OFF position. (1) Engine
(2) Welding electrode
2. Disconnect the negative battery cable from the (3) Keyswitch in the OFF position
battery. If a battery disconnect switch is provided, (4) Battery disconnect switch in the open position
(5) Disconnected battery cables
open the switch. (6) Battery
(7) Electrical/Electronic component
3. Disconnect the J1/P1 and J2/P2 connectors from (8) Minimum distance between the component that is being welded
the ECM. Move the harness to a position that will and any electrical/electronic component
(9) The component that is being welded
not allow the harness to move back accidentally, (10) Current path of the welder
and contact any of the ECM pins. (11) Ground clamp for the welder
i03860683
Table 19
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________ Arrangement Number: ___________________
Storage Location:
MEGOHMMETER TEST Special Instruction, 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments
SEHS9124 reading reading corrected corrected temp.
Main Stator
Main Rotor
Beginning of
Exciter Stator
Storage
Exciter Rotor
PMG Stator
Main Stator
Main Rotor
Start-up Exciter Stator
Exciter Rotor
PMG Stator
Table 20
GENERATOR START-UP CHECKLIST (CONT.)
F1 to F2 DC
E1 to E2 AC
All Frames
E1 to E3 AC
No Load
E2 to E3 AC
2400, 2500, PM1 to PM4 AC
2800, and 2900
Frames
(continued)
88 SEBU8607
Maintenance Recommendations
Generator Start-up Checklist
Table 21
GENERATOR START-UP CHECKLIST (CONT.)
Check diodes
Over current protection
Adjust voltage
Adjust frequency
Table 22
GENERATOR START-UP CHECKLIST (CONT.)
(continued)
SEBU8607 89
Maintenance Recommendations
Severe Service Application
Overload setting
VAR/PF Controller
Load share
INSTALLATION & LOAD INFORMATION
Neutral grounding system UPS
- Total HP - Computers
- Welding
- Non-linear
- Other
Note: Before each consecutive interval is performed, Every 1000 Service Hours or 1 Year
all maintenance from the previous interval must be
performed. “Battery Charger - Check”........................................99
“Engine Air Cleaner Service Indicator - Inspect” ...112 Every 4150 L (1100 US gal) of Fuel
“Engine Oil Level - Check”.....................................115 or 500 Service Hours or 1 Year
“Generator Load - Check”..................................... 133 “Auxiliary Water Pump - Inspect”.............................97
“Battery Electrolyte Level - Check” ..........................99 Ensure that all safety information, warnings, and
instructions are read and understood before any
“Engine Air Cleaner Element (Dual Element) - operation or any maintenance procedures are
Inspect/Clean/Replace” ........................................ 109 performed.
“Engine Air Cleaner Element (Single Element) - The user is responsible for the performance of
Inspect/Clean/Replace” .........................................112 maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
“Engine Mounts - Inspect” .....................................114 of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
“Engine Oil Sample - Obtain”.................................115 procedures may result in diminished performance of
the product and/or accelerated wear of components.
“Engine Oil and Filter - Change”............................116
Use mileage, fuel consumption, service hours, or
“Engine Oil and Filter - Change”........................... 120 calendar time, WHICH EVER OCCURS FIRST, in
order to determine the maintenance intervals.
“Fuel System Primary Filter (Water Separator) Products that operate in severe operating conditions
Element - Replace”............................................... 126 may require more frequent maintenance.
“Fuel System Secondary Filter - Replace” ........... 127 Note: Before each consecutive interval is performed,
“Fuel Tank Water and Sediment - Drain” .............. 129 all maintenance from the previous interval must be
performed.
“Heat Exchanger - Inspect/Clean” ........................ 139
When Required
“Hoses and Clamps - Inspect/Replace”................ 139
“Battery - Replace”...................................................98
Every 8300 L (2190 US gal) of Fuel
“Battery or Battery Cable - Disconnect”................ 100
or 1000 Service Hours or 1 Year
“Engine - Clean”.................................................... 108
“Engine Valve Lash - Check” ................................ 123
“Fuel System - Prime”........................................... 123
Every 16 600 L (4390 US gal) of Fuel
“Generator - Dry”................................................... 129
or 2000 Service Hours or 2 Years
“Alternator - Inspect” ................................................97 “Generator Set - Test” ........................................... 133
“Generator Winding Insulation - Test”................... 134
“Coolant Temperature Regulator - Replace” ........ 106
“Rotating Rectifier - Inspect/Test” ......................... 143
“Generator - Inspect” ............................................ 131
“Generator Set Vibration - Inspect”....................... 134 Daily
“Rotating Rectifier - Check” .................................. 143 “Belts - Inspect/Adjust/Replace”........................... 100
“Coolant Sample (Level 1) - Obtain”..................... 105 “Engine Oil and Filter - Change”........................... 120
Initial 500 Hours (for New Systems, “Fuel System Primary Filter (Water Separator)
Element - Replace”............................................... 126
Refilled Systems, and Converted
“Fuel System Secondary Filter - Replace” ........... 127
Systems)
“Fuel Tank Water and Sediment - Drain” .............. 129
“Coolant Sample (Level 2) - Obtain”..................... 106
“Heat Exchanger - Inspect/Clean” ........................139
Every 500 Service Hours or 1 Year
“Hoses and Clamps - Inspect/Replace”................ 139
“Cooling System Supplemental Coolant Additive
(SCA) - Test/Add”.................................................. 107 “Sea Water Strainer - Clean/Inspect” ................... 144
“Sea Water Strainer - Clean/Inspect” ................... 144 Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, in
Every 20 700 L (5470 US gal) of Fuel order to determine the maintenance intervals.
Products that operate in severe operating conditions
or 1000 Service Hours or 1 Year may require more frequent maintenance.
“Engine Valve Lash - Check” ................................ 123 Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
Every 41 400 L (10 940 US gal) of performed.
Fuel or 2000 Service Hours or 2
When Required
Years
“Battery - Replace”...................................................98
“Alternator - Inspect” ................................................97
“Battery or Battery Cable - Disconnect”................ 100
“Coolant Temperature Regulator - Replace” ........ 106
“Engine - Clean”.................................................... 108
“Generator - Inspect” ............................................ 131
“Fuel System - Prime”........................................... 123
“Generator Set Vibration - Inspect”....................... 134
“Generator - Dry”................................................... 129
“Rotating Rectifier - Check” .................................. 143
“Generator Set - Test” ........................................... 133
“Starting Motor - Inspect” ...................................... 147
“Generator Winding Insulation - Test”................... 134
“Turbocharger - Inspect” ....................................... 147
“Rotating Rectifier - Inspect/Test” ......................... 143
“Water Pump - Inspect”......................................... 149
Daily
Every 110 400 L (29 160 US gal) of
Fuel or 8000 Service Hours “Belts - Inspect/Adjust/Replace”........................... 100
i03903115
i03903117
Illustration 70 g01740513
• Cam i03903118
• Wear plate
If wear is found or if damage is found, replace the
components which are worn or replace the Batteries give off combustible gases which can
components which are damaged. Use the proper explode. A spark can cause the combustible
repair kit for the pump. Refer to the Disassembly and gases to ignite. This can result in severe personal
Assembly for more information on servicing the injury or death.
auxiliary water pump.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
i03975610
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
Auxiliary Water Pump - Inspect serviced.
(Bronze Auxiliary Water Pump)
SMCS Code: 1371-040; 1371
The service life depends on the engine operating The battery cables or the batteries should not be
conditions of the bronze auxiliary water pump. removed with the battery cover in place. The bat-
Check the components for wear and check the tery cover should be removed before any servic-
components for damage. If wear is found or if ing is attempted.
damage is found, replace the components which are
worn or replace the components which are damaged. Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
Note: Before the cables are connected, ensure that 1. Remove the filler caps. Maintain the electrolyte
the engine start switch is OFF. level to the “FULL” mark on the battery.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal. If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
8. Connect the NEGATIVE “-” cable to the softened water.
NEGATIVE “-” battery terminal.
2. Check the condition of the electrolyte with the
i03903120 245-5829 Coolant Battery Tester Refractometer.
SMCS Code: 1401-535 Clean the battery case with one of the following
cleaning solutions:
Check the battery charger for proper operation. If the
batteries are properly charged, the needle of the • Use a solution of 0.1 kg (0.2 lb) baking soda
ammeter will register near “0” (zero). and 1 L (1 qt) of clean water.
The batteries should be kept warm, when possible. • Use a solution of ammonium hydroxide .
The temperature of the battery will affect cranking
power. A battery that is too cold will not crank the Thoroughly rinse the battery case with clean water.
engine, even if the engine is warm.
Use a fine grade of sandpaper to clean the
The batteries may not fully recharge when the engine terminals and the cable clamps. Clean the items
is not run for long periods of time. The batteries may until the surfaces are bright or shiny. DO NOT
not fully recharge if the engine only runs for short remove material excessively. Excessive removal of
periods. Ensure a full charge in order to help prevent material can cause the clamps to not fit properly.
the battery from freezing. Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
100 SEBU8607
Maintenance Recommendations
Battery or Battery Cable - Disconnect
i03903124 Inspection
Battery or Battery Cable - To maximize the engine performance, inspect the belt
for wear and for cracking. Replace a belt that is worn
Disconnect or damaged.
SMCS Code: 1401; 1402-029 If the belt is too loose, vibration causes unnecessary
wear on the belt and the pulley.
i03903126
Belts - Inspect/Adjust/Replace
(Single Belt)
SMCS Code: 1357-025; 1357-040; 1357-510
Adjustment
Illustration 74 g01626064
Replace
Refer to Disassembly and Assembly manual, “V belt
Remove and Install” for more information.
i03903771
Note: Inspect the water pump and the water 2. Close the drain valve. Clean the drain plugs. Install
temperature regulator after the cooling system has the drain plugs. Refer to Torque Specifications,
been drained. This is a good opportunity to replace SENR3130 for more information on the correct
the water pump, the water temperature regulator, and torques.
the hoses, if necessary.
Drain NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Pressurized System: Hot coolant can cause seri- Cooling system air locks may result in engine
damage.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
SEBU8607 103
Maintenance Recommendations
Coolant Extender (ELC) - Add
2. Fill the cooling system with Extended Life Coolant Check the cooling system only when the engine is
(ELC). Refer to this Operation and Maintenance stopped and cool.
Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
on cooling system specifications.
Personal injury can result from hot coolant, steam
3. Tighten the vent screw securely. Ensure that the and alkali.
coolant level is 25 mm (0.9843 inch) below filler
neck (2) on the header tank or the radiator. At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
4. Install the cooling system filler cap. Operate the steam. Any contact can cause severe burns.
engine without load for approximately 30 minutes,
in order to allow circulation. The coolant Remove cooling system pressure cap slowly to
temperature should be at least 82 °C (180 °F). relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
5. Stop the engine and allow the engine to cool. touch with your bare hand.
Loosen the cooling system filler cap slowly in order Do not attempt to tighten hose connections when
to relieve any pressure. Remove the cooling the coolant is hot, the hose can come off causing
system filler cap. Check the coolant level. If burns.
necessary, add coolant to the system.
Cooling System Coolant Additive contains alkali.
6. Clean the cooling system filler cap. Inspect the Avoid contact with skin and eyes.
gasket that is on the cooling system filler cap. If the
gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
gasket that is on the cooling system filler cap is not
damaged, perform a pressure test. A 9S-8140
Pressurizing Pump is used to perform the pressure
test. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
104 SEBU8607
Maintenance Recommendations
Coolant Level - Check
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
i03903773
Recommended Interval
Type of Level 1 Level 2
Coolant
Cat DEAC Every 250 Hours(1) Yearly(1) (2)
Illustration 77 g01618831
Typical filler cap gaskets NOTICE
Always use a designated pump for oil sampling, and
Note: Gasket (4) is not installed on radiator filler use a separate designated pump for coolant sam-
caps. pling. Using the same pump for both types of samples
4. Clean the cooling system filler cap and check the may contaminate the samples that are being drawn.
condition of the filler cap gaskets (3) and (4). This contaminate may cause a false analysis and an
Replace the cooling system filler cap if the filler cap incorrect interpretation that could lead to concerns by
both dealers and customers.
gaskets are damaged. Reinstall the cooling system
filler cap.
Note: Level 1 results may indicate a need for
5. Inspect the cooling system for leaks. Level 2 Analysis.
• Never collect samples from the drain for a system. A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
Submit the sample for Level 1 analysis. overheating could result in the cracking of the cylinder
head or piston seizure problems.
For additional information about coolant analysis, see
this Operation and Maintenance Manual, “Refill A water temperature regulator that fails in the open
Capacities and Recommendations” or consult your position will cause the engine operating temperature
Caterpillar dealer. to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
i03903779 cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of
Coolant Sample (Level 2) - the cylinder liner.
Obtain NOTICE
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
NOTICE
Always use a designated pump for oil sampling, and Caterpillar engines incorporate a shunt design cool-
use a separate designated pump for coolant sam- ing system and require operating the engine with a
pling. Using the same pump for both types of samples water temperature regulator installed.
may contaminate the samples that are being drawn.
This contaminate may cause a false analysis and an If the water temperature regulator is installed incor-
incorrect interpretation that could lead to concerns by rectly, the engine may overheat, causing cylinder
both dealers and customers. head damage. Ensure that the new water tempera-
ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is
Refer to Operation and Maintenance Manual, open.
“Cooling System Coolant Sample (Level 1) - Obtain” Do not use liquid gasket material on the gasket or cyl-
for the guidelines for a proper sampling of the coolant. inder head surface.
Submit the sample for Level 2 analysis.
For additional information about coolant analysis, see Refer to two articles in the Disassembly and
Special Publication, SEBU6251, “Caterpillar Assembly Manual, “Water Temperature Regulators -
Commercial Diesel Engines Fluids Remove and Water Temperature Regulators - Install”
Recommendations” or consult your Caterpillar for the replacement procedure of the water
dealer. temperature regulator, or consult your Caterpillar
dealer.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
SEBU8607 107
Maintenance Recommendations
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Test the Concentration of the SCA More than 30 More than the recom- Remove the coolant.
mended concentra- Replace with water
tion of SCA only
Coolant/Antifreeze and SCA Retest the coolant.
NOTICE
Do not exceed the recommended six percent supple-
Add the SCA, If Necessary
mental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296 Note: Always dispose of fluids according to local
Coolant Conditioner Test Kit. Use the instructions that regulations.
follow: 2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
1. Fill the syringe to the “1.0 ml” mark with the
coolant.
2. Dispense the 1.0 mL coolant sample from the
syringe into the empty mixing bottle.
i03903782
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
Engine - Clean
faces of the cooling system, reducing the engine's SMCS Code: 1000-070
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentra- Personal injury or death can result from high
tion could also result in blockage of the heat exchang- voltage.
er, overheating, and/or accelerated wear of the water
pump seal. Moisture could create paths of electrical
conductivity.
Do not exceed the recommended amount of supple-
mental coolant additive concentration. Make sure the unit is off line (disconnected from
utility and/or other generators), locked out and
tagged "Do Not Operate".
3. Add the proper amount of SCA. The concentration
of the SCA depends on the type of coolant that is
used. To determine the proper amount, see this NOTICE
Operation and Maintenance Manual, “Refill Water or condensation can cause damage to genera-
Capacities and Recommendations” topic. tor components. Protect all electrical components
from exposure to water.
4. Clean the cooling system filler cap. Install the
cooling system filler cap.
NOTICE
Accumulated grease and oil on an engine is a fire
i01595880
hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu-
Electrical Connections - Check lates on the engine.
SMCS Code: 4459-535
Check all exposed electrical connections for Steam cleaning the engine will remove accumulated
tightness. oil and grease. A clean engine provides the following
benefits:
Check the following devices for loose mounting or for
physical damage: • Easy detection of fluid leaks
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
NOTICE
Vacuum Cleaning
Do not clean the air cleaner elements by bumping or
Vacuum cleaning is a good method for cleaning
tapping. This could damage the seals. Do not use ele- primary air cleaner elements which require daily
ments with damaged pleats, gaskets or seals. Dam- cleaning because of a dry, dusty environment.
aged elements will allow dirt to pass through. Engine Cleaning with pressurized air is recommended prior
damage could result. to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Visually inspect the primary air cleaner elements Note: Refer to “Inspecting the Primary Air Cleaner
before cleaning. Inspect the air cleaner elements for Elements”.
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
There are two common methods that are used to
clean primary air cleaner elements:
• Pressurized air
• Vacuum cleaning
SEBU8607 111
Maintenance Recommendations
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Illustration 81 g00281694
Illustration 83 g00103777
Typical service indicator
Illustration 82 g01560871
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element
Typical example should be replaced when one of the following
conditions occur:
Note: The engine can auto start. Ensure that the • The yellow diaphragm enters the red zone.
power supply is isolated before any service or repair
• The red piston locks in the visible position.
is performed.
1. Release the clips (3) and remove the cover (2). Test the Service Indicator
2. Remove the element (1) and discard the element. Service indicators are important instruments.
3. Ensure that all parts are clean and free from dirt. • Check for ease of resetting. The service indicator
Install a new element. should reset in less than three pushes.
4. Align the cover to the body of the air cleaner. • Check the movement of the yellow core when the
Ensure that the cover is oriented correctly and engine is accelerated to the engine rated speed.
install the cover. The yellow core should latch at the greatest
vacuum that is attained.
i03903852 If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
Engine Air Cleaner Service the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
Indicator - Inspect indicator may be restricted.
SMCS Code: 7452-040 The service indicator may be replaced frequently in
Some engines may be equipped with a different environments that are severely dusty.
service indicator.
SEBU8607 113
Maintenance Recommendations
Engine Crankcase Breather - Replace
Illustration 85 g02160981
Typical example
Illustration 84 g02163655 1. Remove all dirt and oil from the outside of the
Typical example breather assembly (1).
3. Remove diaphragm (4) and spring (5). Discard 3. Install a new breather assembly. Refer to
diaphragm (4) and spring (5). Disassembly and Assembly, “Crankcase Breather -
Remove and Install”.
4. Install new diaphragm (4) and a new spring (5).
i05256770
5. Install cover (3) and screws (2). Tighten screws (2)
to a torque of 1.3 N·m (11.5 lb in). Engine Crankcase Breather
6. Install dust cover (1). Element - Replace
(Turbocharged Engines)
i05257281
SMCS Code: 1317-510-FQ
Engine Crankcase Breather - S/N: S1M1–Up
Replace
(Turbocharged Engines)
114 SEBU8607
Maintenance Recommendations
Engine Mounts - Inspect
NOTICE
Perform this maintenance with the engine stopped.
Illustration 87 g01157174
Typical example
Illustration 86 g02160981
Typical example 2. Turn lid (2) in a counterclockwise direction for
approximately 15 degrees. Remove the Lid.
1. Remove all dirt and oil from the outside of the
breather assembly (1). 3. Remove O-ring (3).
i03903843
Engine Oil Level - Check 2. Remove the oil filler cap and add oil, if necessary.
SMCS Code: 1348-535-FLV Clean the oil filler cap. Install the oil filler cap.
i03903839
Hot oil and hot components can cause personal Engine Oil Sample - Obtain
injury. Do not allow hot oil or hot components to SMCS Code: 1348-554-SM
contact the skin.
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order to
monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Note: Ensure that the engine is either level or that the • Service hours on the engine
engine is in the normal operating position in order to
obtain a true level indication. • The number of hours that have accumulated since
the last oil change
Note: After the engine has been switched OFF, wait
for 10 minutes in order to allow the engine oil to drain • The amount of oil that has been added since the
to the oil pan before checking the oil level. last oil change
Note: The engine can auto start. Ensure that the To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, well mixed oil
power supply is isolated before any service or repair sample.
is performed.
To avoid contamination of the oil samples, the tools
1. Maintain the oil level between the “ADD” mark (Y) and the supplies that are used for obtaining oil
and the “FULL” mark (X) on the engine oil samples must be clean.
dipstick. Do not fill the crankcase above the
Caterpillar recommends using the sampling valve in
“FULL” mark (X). order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
116 SEBU8607
Maintenance Recommendations
Engine Oil and Filter - Change
If the engine is not equipped with a sampling valve, Ensure that all adjustments, maintenance, and
use the 1U-5718 Vacuum Pump. The pump is repairs are performed by authorized personnel that
designed to accept sampling bottles. Disposable have the correct training.
tubing must be attached to the pump for insertion into Ensure that the vessel that will be used is large
the sump. enough to collect the waste oil.
For instructions, see Special Publication, PEgj0047, Failure to follow this recommended procedure will
“How To Take A Good S·O·S Oil Sample”. Consult cause the waste particles to be recirculated through
your Caterpillar dealer for complete information and the engine lubrication system with the new oil.
assistance in establishing an S·O·S program for your
engine.
1. The engine can auto start. Ensure that the power
supply is isolated before any service or repair is
i03906144 performed.
Engine Oil and Filter - Change
(Duplex Oil Filters)
SMCS Code: 1318-510
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 containers
before opening any compartment or disassembling
any component containing fluids.
Illustration 89 g02163658
Dispose of all fluids according to local regulations and Typical example
mandates.
2. Open the drain valve (1).
SEBU8607 117
Maintenance Recommendations
Engine Oil and Filter - Change
Illustration 91 g01165836
Typical example
Illustration 90 g02163659
Typical example
4. After the oil has drained, close the drain valve (1).
Illustration 92 g02163729
Typical example
• (A) The oil flow is to the left-hand oil filter. 2. Apply clean engine oil to both O ring seals (1) for
the new oil filters.
• (B) The oil flow is to both oil filters.
3. Install the engine oil filters. Spin on the oil filter until
• (C) The oil flow is to the right-hand oil filter. the O ring seal contacts the oil filter base. Rotate
the oil filter ¾ of a full turn.
1. The engine can auto start. Ensure that the power
supply is isolated before any service or repair is 4. Ensure that the control lever is in position B. Refer
performed. to illustration 92 .
5. Ensure that the engine has the correct amount of
clean engine lubricating oil. Refer to “Replace
Engine Oil” for more information.
Illustration 95 g00588944
Element with debris
Illustration 94 g02163739
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
Typical example oil filter. Consult your Caterpillar dealer in order to
arrange for a further analysis if an excessive
Note: The control lever is in position A. The right- amount of debris is found in the oil filter.
hand oil filter has been isolated from the oil flow.
2. Rotate the control lever (1) slowly in the direction of 7. Clean the sealing surface of the oil filter base (2).
the oil filter that is intended to be used. Allow time
8. Apply clean engine oil to the O ring seal (3) for the
for the oil filter to fill and check for leaks on the oil
new oil filter.
filter. Check that the engine oil pressure is correct.
3. Place a soft cloth over the vent screw (4) and open NOTICE
the vent screw. This will allow any pressure that is Do not fill the oil filters with oil before installing them.
in the isolated oil filter to be released. This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
4. Tighten the vent screw securely. to engine components.
5. Remove the oil filter with a 1U-8760 Chain
Wrench. 9. Install the engine oil filter. Spin on the oil filter until
the O ring seal contacts the oil filter base. Rotate
Note: The following actions can be carried out as part the oil filter ¾ of a full turn.
of the preventive maintenance program.
10. Drain the tray below the filter.
120 SEBU8607
Maintenance Recommendations
Engine Oil and Filter - Change
i03906141
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 containers
before opening any compartment or disassembling
any component containing fluids.
Illustration 96 g02163658
Dispose of all fluids according to local regulations and Typical example
mandates.
1. The engine can auto start. Ensure that the power
NOTICE supply is isolated before any service or repair is
Keep all parts clean from contaminants. performed.
Contaminants may cause rapid wear and shortened 2. Open the drain valve (1).
component life.
Illustration 98 g00588944
Element with debris
4. Clean the sealing surface of the oil filter base (3). i03903838
5. Apply clean engine oil to the O ring seal for the new Engine Protective Devices -
oil filter.
Check
NOTICE SMCS Code: 7400-535
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami- Visual Inspection
nated. Contaminated oil can cause accelerated wear
to engine components. Visually check the condition of all gauges, sensors,
and wiring. Look for wiring and components that are
loose, broken, or damaged. Damaged wiring or
6. Install the engine oil filter. Spin on the oil filter until components should be repaired or replaced
the O ring seal contacts the oil filter base. Rotate immediately.
the oil filter ¾ of a full turn.
Calibration Check
Fill the Oil Pan
NOTICE
1. Remove the oil filler cap. Refer to Operation and During testing, abnormal operating conditions must
Maintenance Manual, “Refill Capacities and be simulated.
Recommendations” for more information on
The tests must be performed correctly in order to pre-
suitable oils. Fill the oil pan with the correct amount vent possible damage to the engine.
of new engine lubricating oil. Refer to Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” for more information on refill Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
capacities. to prevent damage to the engine. It is impossible to
determine if the engine protective devices are in good
2. Start the engine and operate the engine at “no working order during normal operation. Malfunctions
load” for 2 minutes. Perform this procedure in must be simulated in order to test the engine
order to ensure that the lubrication system has oil protective devices. To prevent damage to the engine,
and that the oil filters are filled. Inspect the oil filter only authorized service personnel or your Caterpillar
for oil leaks. dealer should perform the tests.
3. Stop the engine and allow the oil to drain back to Consult your Caterpillar dealer or refer to the Service
the oil pan for a minimum of 10 minutes. Manual for more information.
SEBU8607 123
Maintenance Recommendations
Engine Speed/Timing Sensor - Clean/Inspect
i03906205 i03903837
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, “Valve Lash and Valve Bridge
Adjustment” article or consult your Caterpillar dealer
for the complete valve lash adjustment procedure.
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.
Note: The engine can auto start. Ensure that the Ensure that the engine is stopped before measuring
power supply is isolated before any service or repair the valve lash. To obtain an accurate measurement,
is performed. allow the valves to cool before this maintenance is
1. Remove the sensor (3) from the flywheel housing. performed.
Check the condition of the end of the sensor.
Refer to the Service Manual for more information.
Check for signs of wear and contaminants.
2. Clean the metal shavings and other debris from the i03906146
face of the magnet.
Fuel System - Prime
3. Install the sensor until the magnet comes in contact
with a tooth on the flywheel ring gear (1).
(Duplex Fuel Filter if Equipped)
SMCS Code: 1250-548; 1258-548
4. Back out 180 degrees and tighten the locknut (2) to
45 ± 7 N·m (33 ± 5 lb ft). Ensure that all adjustments, maintenance, and
repairs are performed by authorized personnel that
Note: Ensure that the sensor cannot rotate when the have had the correct training.
locknut is tightened.
NOTICE
Refer to the Service Manual for more information on Do not crank the engine continuously for more than
the sensor. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
124 SEBU8607
Maintenance Recommendations
Fuel System - Prime
Commissioning procedure
Use the following procedure in order to remove air
from both fuel filters.
Fuel System Primary Filter Note: The fuel level in element (3) should be reduced
before removal of the element. Remove cap (1) if the
(Water Separator) Element - element is not equipped with a drain on the bottom.
Replace Remove the nylon insert in order to reduce the level
of fuel in the element. A reduction in the level of fuel in
(if Equipped) the element will help prevent fuel from being spilled
SMCS Code: 1260-510-FQ; 1263-510-FQ when the element is removed.
NOTICE
Do not use a tool in order to remove the fuel filter. At-
Fuel leaked or spilled onto hot surfaces or electri- tempting to remove the fuel filter with a filter wrench
cal components can cause a fire. To help prevent or a filter strap could damage the locking ring.
possible injury, turn the start switch off when
changing fuel filters or water separator elements. 3. Hold element (3) and rotate locking ring (2)
Clean up fuel spills immediately.
counterclockwise. Remove locking ring (2). The
used element should be removed and discarded.
NOTICE Note: If the element is equipped with a sediment
Do not allow dirt to enter the fuel system. Thoroughly bowl, remove the sediment bowl from the element.
clean the area around a fuel system component that Thoroughly clean the sediment bowl. Inspect the O-
will be disconnected. Fit a suitable cover over discon- ring seals for wear or damage. Install new O-ring
nected fuel system component. seals, if necessary. Install the sediment bowl onto the
new element. Hand tighten the sediment bowl. Hand
Turn the fuel supply valve to the OFF position before tightening is the only method that should be used.
performing this maintenance. Place a tray under the
fuel filter in order to catch any fuel that might spill.
Clean up any spilled fuel immediately.
SEBU8607 127
Maintenance Recommendations
Fuel System Secondary Filter - Replace
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
i03906236
Duplex Filters
(A) The fuel flow is to the left-hand fuel filter. (B) The fuel flow is to both fuel filters. (C) The fuel flow is to the right-hand fuel filter.
3. Place a soft cloth over the vent of the filter that has
been isolated, before opening the vent screw.
4. Open the vent screw and then close the vent screw
on the filter that has been isolated. This will relieve
any pressure that is still in the filter.
i03903833 Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If the
- Drain engine is equipped with this system, regular
maintenance of the fuel system filter is important.
SMCS Code: 1273-543-M&S
Fuel Storage Tanks
NOTICE
Care must be taken to ensure that fluids are con- Drain the water and the sediment from the fuel
tained during performance of inspection, mainte- storage tank during the following conditions:
nance, testing, adjusting and repair of the product. Be • Weekly
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling • Oil change
any component containing fluids.
• Refill of the tank
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publi- This will help prevent water or sediment from being
cation, PECJ0003, “Caterpillar Shop Supplies and pumped from the storage tank into the engine fuel
Tools Catalog” for tools and supplies suitable to col- tank. A four micron(c) absolute filter for the breather
lect and contain fluids on Caterpillar products. vent on the fuel tank is also recommended. Refer to
Special Publication, SENR9620, “Improving Fuel
Dispose of all fluids according to local regulations and System Durability”.
mandates.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
Fuel Tank settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
Fuel quality is critical to the performance and to the sediment. Filtering fuel that is pumped from the
service life of the engine. Water in the fuel can cause storage tank helps to ensure the quality of the fuel.
excessive wear to the fuel system. Condensation When possible, water separators should be used.
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the i03997990
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable Generator - Dry
sources can help to eliminate water in the fuel. SMCS Code: 4450-569
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the Personal injury or death can result from improper
fuel tanks. troubleshooting and repair procedures.
Open the drain valve on the bottom of the fuel tank in The following troubleshooting and repair proce-
order to drain the water and the sediment. Close the dures should only be performed by qualified per-
drain valve. sonnel familiar with this equipment.
Note: Failure to close the drain can allow air into the
system, which could have detrimental results to Refer to this Operation and Maintenance Manual,
performance. “Generator Isolating for Maintenance” for information
regarding the procedure to isolate the generator in a
Check the fuel daily. Drain the water and sediment safe manner.
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the Refer to Special Instruction, REHS9124, Cleaning
fuel tank has been filled. Allow 5 to 10 minutes before and Drying of the Generator for further necessary
performing this procedure. information.
Fill the fuel tank after operating the engine in order to Of the following methods for drying the generator, the
drive out moist air. This will help prevent use of external heat is preferred.
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
130 SEBU8607
Maintenance Recommendations
Generator - Dry
Illustration 108 g02175752 Illustration 109 indicates the curve of the resistance
of a normal high resistance in the windings over a
Typical curves of the resistance in the insulation that period of 60 seconds. The resistance after 60
is drying seconds will be greater than the resistance or equal
(1) Curve of the temperature in the windings to the resistance after 30 seconds .
(2) Heat turned off.
(3) Drying time in hours
(4) Temperature in degrees celsius
Note: If the insulation resistance after 60 seconds is
(5) Curve of insulation resistance during drying process not higher than the resistance after 30 seconds , the
(6) Insulation resistance in megohms insulation may be weak.
Alternate Method
A tent formed by a tarp or a canvas with heated
lamps or a portable space heater may be used as an
alternate method.
A hole should be left in the top of the tarp for ensuring
proper circulation through the generator and for
Illustration 110 g01697074 permitting the moisture to exhaust. Heat the
Curve of insulation resistance for windings that are generator to approximately 75° C (167° F). Never
wet or dirty exceed 75° C (167° F) until the insulation tester tests
(1) Resistance after 30 seconds
correctly for insulation resistance (at least 4 hours).
(2) Resistance after 60 seconds
Internal Heating
Illustration 110 indicates the curve of the resistance
that is decaying over a period of 60 seconds. If the If generators operate under one of the following
insulation resistance after 60 seconds is not higher conditions, the electric space heaters should be
than the resistance after 30 seconds , clean the installed as part of the generator:
windings and thoroughly dry the windings. Refer to
Special Instruction, REHS9124, Cleaning and Drying • Generators are in damp environments and go for
of the Generator for more information. long periods of time without operation.
Note: Caterpillar recommends a minimum • Generators operate regularly in an environment
acceptable insulation resistance of 1 megohm for with moisture laden air.
generators which operate with less than 1000 V of
operating or rated voltage. Generators which operate Circulating Current
at 1000 V of operating or rated voltage should have a
minimum insulation resistance as determined by the Drying can be accomplished by circulating low
following equation: voltage current through the windings. Since the
voltage is low, the breakdown of the insulation will not
R = (V/1000) + M occur as the breakdown might have occurred with
normal operation and wet insulation. Refer to Special
“R” is the minimum insulation resistance. Instruction, REHS9124, Cleaning and Drying of the
Generator for this procedure.
“V” is the rated voltage.
“M” is 1 megohm. i01880220
Personal injury or death can result from high Personal injury or death can result from high
voltage. voltage.
When power generation equipment must be in op- When power generation equipment must be in op-
eration to make tests and/or adjustments, high eration to make tests and/or adjustments, high
voltage and current are present. voltage and current are present.
Improper test equipment can fail and present a Improper test equipment can fail and present a
high voltage shock hazard to its user. high voltage shock hazard to its user.
Make sure the testing equipment is designed for Make sure the testing equipment is designed for
and correctly operated for high voltage and cur- and correctly operated for high voltage and cur-
rent tests being made. rent tests being made.
When servicing or repairing electric power gener-
During normal operation, monitor the power factor ation equipment:
and monitor generator loading.
• Make sure the unit is off-line (disconnected
When a three-phase generator is installed or when a from utility and/or other generators power serv-
three-phase generator is reconnected, ensure that ice), and either locked out or tagged DO NOT
the total current in any one phase does not exceed OPERATE.
the nameplate rating. Each phase should carry the
same load. This allows the three-phase generator to • Make sure the generator engine is stopped.
work at the rated capacity. If one phase current
exceeds the nameplate amperage, an electrical • Make sure all batteries are disconnected.
imbalance will occur. An electrical imbalance can
result in an electrical overload and an electrical • Make sure all capacitors are discharged.
imbalance can result in overheating on three-phase
generators. This is not applicable to single-phase Table 25
generators.
Tools Needed
The power factor can be referred to as the efficiency Part Number Part Quantity
of the load. This can be expressed as the ratio of kVA
to actual kW. The power factor can be calculated by 237-5130 Digital Multimeter 1
dividing kW by kVA. Power factor is expressed as a
decimal. Power factor is used to mean the portion of 12 VDC battery 1
current that is supplied to a system that is doing Potential
useful work. The portion of the current that is not Transformer
1
doing useful work is absorbed in maintaining the
magnetic field in motors. This current (reactive load)
can be maintained without engine power. The generator set functional test is a simplified test
that can be performed in order to determine if the
generator is functional. The generator set functional
test should be performed on a generator set that is
under load.
134 SEBU8607
Maintenance Recommendations
Generator Set Vibration - Inspect
2. Disconnect wires “E+” and “E-” from the voltage Check the generator set's vibration level by using a
regulator. Disconnect the generator from the load. broad spectrum analyzer.
Periodically, use an insulation tester to check the 2. Visually inspect the generator for moisture. If
insulation resistance of the generators main stator moisture exists, do not perform this insulation test.
winding. The frequency of this test is determined by Dry the unit first. Refer to Special Instruction,
the generators environment. Previous insulation
SEHS9124, “Cleaning and Drying of Electric Set
tester readings will also determine the frequency of
this test. Generators”.
Test the main stator windings with an insulation tester 3. Inspect the installation. Determine the equipment
in the following situations: that will be tested by the insulation tester.
• The generator set is started for the first time. 4. Discharge the capacitance of the windings.
• The generator set is removed from storage. 5. Isolate the stator windings of the generator by
disconnecting all other leads and cables from the
• The generator set is operating in a humid
generator terminals. This includes connections to
environment. Test every 3 months.
the voltage regulator, the control panel, the
• The generator set is not protected from the switchgear, or other devices.
elements in an enclosed area. Test every 3
months. 6. Connect the insulation testers RED lead to ground.
• The generator set is installed in an enclosed area. 7. Connect the insulation testers BLACK lead to the
This area needs to be low in humidity and this area wye point or star point of the generators windings.
needs to have steady temperatures. Test every 12
months (minimum). 8. For units that are 600 V or less, set the voltage to
500 V. For units that are more than 600 V, set the
• The generator set has not been run under load for voltage to 1000 V.
3 months. Test the generator set weekly. Use
space heaters around the generator set if the 9. Use the 30/60 Time Resistance Method:
generator is exposed to a sea water environment
or if the humidity is above 75 percent. Also use a. Apply voltage.
space heaters if a test result was below 3
megohms. b. Observe the readings at 30 seconds. Observe
the readings at 60 seconds.
Space heaters must be used whenever the generator
set is not under load. Space heaters must also be c. Record the 60 second reading. This reading
used whenever salt is present or whenever high must be corrected for temperature.
humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester d. Record temperature.
readings above 1 megohm. Use space heaters only
when the generator is not running.
e. Record humidity.
For additional information, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set f. Remove voltage.
Generators”.
10. Evaluate the readings. The actual value of the
Recommended Procedure for A resistance may vary greatly between generators.
For this reason, the insulations condition must be
Periodic Insulation Test evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
the readings that were taken on previous dates.
These two readings must be taken under similar
Personal injury or death can result from
conditions. If a 60 second resistance reading has a
electrocution.
50 percent reduction from the previous reading,
The megohmmeter is applying a high voltage to the insulation may have absorbed too much
the circuit. moisture.
To avoid electrocution, do not touch the instru- Switch the insulation tester to the “OFF” position.
ment leads without first discharging them. When This will discharge the insulation testers leads.
finished testing also discharge the generator Disconnect the insulation testers leads.
windings.
i03903805 Table 27
Hydrosolv Liquid Cleaners(1)
Heat Exchanger - Inspect/
Part Number Description Size
Clean
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
SMCS Code: 1379-040; 1379-070
174-6854 Hydrosolv 100 19 L (5 US gallon)
The interval for the maintenance of the tube type heat (1)
exchanger depends on the operating environment of Use a 2 to 5 percent concentration of the cleaner at tempera-
tures up to 93°C (200°F). Refer to Application Guide,
the vessel and on the operating time. The sea water NEHS0526 or consult your Caterpillar dealer for more
that is circulated through the heat exchanger and the information.
amount of operating time of the vessel affects the
following items:
4. Steam clean the core in order to remove any
• Cleanliness of the tubes for the heat exchanger residue. Flush the tubes of the heat exchanger
core. Remove any other trapped debris.
• Effectiveness of the heat exchanger system
5. Wash the core with hot, soapy water. Rinse the
Operating in water that contains silt, sediment, salt, core thoroughly with clean water.
algae, and so on, will adversely affect the heat
exchanger system. In addition, intermittent use of the
vessel will adversely affect the heat exchanger
system.
The following items indicate that the heat exchanger Personal injury can result from air pressure.
may require cleaning:
Personal injury can result without following prop-
• Increased coolant temperature er procedure. When using pressure air, wear a
protective face shield and protective clothing.
• Engine overheating
Maximum air pressure at the nozzle must be less
• Excessive pressure drop between the water inlet than 205 kPa (30 psi) for cleaning purposes.
and the water outlet
6. Dry the core with compressed air. Direct the air in
An operator that is familiar with the normal operating
temperature of the coolant can determine when the the reverse direction of the normal flow.
coolant temperature is out of the normal range. 7. Inspect the core in order to ensure cleanliness.
Inspection and maintenance of the heat exchanger
are required if the engine is overheating. Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests. If
Cleaning the Heat Exchanger necessary, repair the core.
1. Remove the heat exchanger. Refer to the Service 8. Install the heat exchanger. Refer to the Service
Manual for the procedure. Manual for the procedure.
For more information on cleaning the core, consult
2. Turn the heat exchanger core upside-down in order
your Caterpillar dealer.
to remove debris.
i03903802
NOTICE
Do not use a high concentration of caustic cleaner to Hoses and Clamps - Inspect/
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and Replace
cause leakage. Only use the recommended concen- SMCS Code: 7554-040; 7554-510
tration of cleaner.
Inspect all hoses for leaks that are caused by the
following conditions:
3. Back flush the core with cleaner.
• Cracking
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 27 lists Hydrosolv liquid • Softness
cleaners that are available from your Caterpillar
dealer. • Loose clamps
140 SEBU8607
Maintenance Recommendations
Overhaul Considerations
Replace hoses that are cracked or soft. Tighten any 2. Loosen the cooling system filler cap slowly in order
loose clamps. to relieve any pressure. Remove the cooling
system filler cap.
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair Note: Drain the coolant into a suitable, clean
any loose or damaged fuel and oil lines, tubes and container. The coolant can be reused.
hoses. Leaks can cause fires. Inspect all lines, tubes 3. Drain the coolant from the cooling system to a level
and hoses carefully. Tighten all connections to the that is below the hose that is being replaced.
recommended torque.
4. Remove the hose clamps.
Check for the following conditions: 5. Disconnect the old hose.
• End fittings that are damaged or leaking 6. Replace the old hose with a new hose.
• Outer covering that is chafed or cut 7. Install the hose clamps with a torque wrench.
• Exposed wire that is used for reinforcement
Note: Refer to the Specifications, SENR3130,
• Outer covering that is ballooning locally “Torque Specifications” in order to locate the proper
torques.
• Flexible part of the hose that is kinked or crushed
8. Refill the cooling system.
• Armoring that is embedded in the outer covering
9. Clean the cooling system filler cap. Inspect the
A constant torque hose clamp can be used in place of gaskets of the cooling system filler cap. Replace
any standard hose clamp. Ensure that the constant the cooling system filler cap if the gaskets are
torque hose clamp is the same size as the standard damaged. Install the cooling system filler cap.
clamp.
10. Start the engine. Inspect the cooling system for
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen. leaks.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. i03903800
Replace the Hoses and the Clamps The following factors are important when a decision is
being made on the proper time for an engine
overhaul:
• The need for preventive maintenance
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, • The quality of the fuel that is being used
stop the engine and wait until the cooling system • The operating conditions
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the • The results of the S·O·S analysis
pressure.
• Repairing
After Failure Overhaul
• Replacing
If a major engine failure occurs and the engine must
be removed, many options are available. An overhaul Using out-of-spec parts can result in the following
should be performed if the engine block or the problems:
crankshaft needs to be repaired.
• Unscheduled downtime
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40 • Costly repairs
percent and 50 percent of the cost of a new engine
with a similar exchange core. • Damage to other engine parts
This lower cost can be attributed to three aspects: • Reduced engine efficiency
Caterpillar Inc. recommends the installation of new 3. Flush the oil cooler core internally with cleaner in
parts at each overhaul period. order to loosen foreign substances. This will also
help to remove oil from the oil cooler core.
Inspect these parts while the engine is disassembled
for an overhaul. Note: Caterpillar Inc. recommends the use of
Hydrosolv Liquid Cleaners. Table 28 lists the
Inspect the crankshaft for any of the following
conditions: Hydrosolv Liquid Cleaners that are available from
your Caterpillar dealer.
• Deflection Table 28
Hydrosolv Liquid Cleaners
• Damage to the journals
Part Number Description Size
• Bearing material that has seized to the journals
1U-5490 Hydrosolv 4165 19 L (5 US gal)
Check the journal taper and the profile of the
crankshaft journals. Check these components by 1U-5492 Hydrosolv 100 19 L (5 US gallon)
interpreting the wear patterns on the following
components:
4. Use steam to clean the oil cooler core. This
• Rod bearing removes any remaining residue from the cleaner.
Flush the fins of the oil cooler core. Remove any
• Main bearings other trapped debris.
Inspect the camshaft for damage to the journals and 5. Wash the oil cooler core with hot, soapy water.
to the lobes.
Rinse the oil cooler core thoroughly with clean
Note: If the camshaft is removed for any reason, use water.
the magnetic particle inspection process to check for
cracks in the camshaft.
Inspect the following components for signs of wear or
for signs of scuffing: Personal injury can result from air pressure.
• Camshaft bearings Personal injury can result without following prop-
er procedure. When using pressure air, wear a
• Lifters protective face shield and protective clothing.
Caterpillar Inc. recommends replacing the crankshaft Maximum air pressure at the nozzle must be less
vibration damper. than 205 kPa (30 psi) for cleaning purposes.
S·O·S Coolant Analysis (Level 2) Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
An S·O·S Coolant Analysis (Level 2) is a refer to Operation and Maintenance Manual,
comprehensive coolant analysis which completely “Rotating Rectifier - Inspect/Test”.
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2) i03903798
provides the following information:
• Identification of built up impurities (corrosion and The high voltage that is produced by an operating
scale) generator set can cause severe injury or death.
Before performing any maintenance or repairs,
S·O·S Coolant Analysis (Level 2) provides a report of ensure that the generator will not start.
the results of both the analysis and the maintenance
recommendations. Place the engine control switch in the “ OFF”” po-
For more information about coolant analysis, see your sition. Attach “ DO NOT OPERATE”” tags to all
starting controls. Disconnect the batteries or dis-
Caterpillar dealer.
able the starting system. Lock out all switchgear
and automatic transfer switches that are associ-
ated with the generator.
1. Stop the generator set. Disconnect the wires for the 5. The assembly should have characteristics that are
AVR and isolate the wires for the AVR. compatible with the power for the field excitation of
the generator.
2. Make an assembly for separate excitation. The
assembly can use a 12 V battery or a variable DC 6. Operate the generator set at rated speed.
power supply as a power source. Refer to Step 3
for an assembly that uses a 12 V battery. Refer to 7. Gradually increase the current of the exciter field
Step 4 for an assembly that uses a variable DC by adjusting the rheostat or the variable power
power supply. supply. Measure the output voltage and the current
at no load. Measure the output voltage and
measure the current at no load.
8. The generator is operating properly when the
output voltage is at the rated value and the output
voltage is balanced within 1 percent for the rated
level of excitation.
i03903797
S/N: S1M1–Up
Illustration 112 g01015807
(A) Exciter Field The sea water strainer must be clean in order to allow
(B) Diode (one Amp) proper engine cooling. Check the sea water strainer
(C) Rheostat (50 Ohms 300 W) for plugging. Inspect the sea water strainer more
frequently if the vessel is being operated in water
3. Connect a 12 V battery in series with a rheostat (C) which is shallow or dirty. The sea water strainer
of “50 Ohms 300 Watts” and a diode (B) on both protects the aftercooler from debris. The sea water
strainer will catch pieces of the rubber impeller from
wires for the exciter field (5+ and 6-). Go to step 5. the raw water pump due to a failure from debris. The
sea water strainer is installed on turbocharged
engines only.
3. Open the valve for the sea water. Illustration 116 g00752040
Typical example
i03903795
NOTICE
1. Remove the pipe from the turbocharger exhaust For any type of leak (coolant, lube, or fuel) clean up
outlet and remove the air intake pipe to the the fluid. If leaking is observed, find the source and
turbocharger. Visually inspect the piping for the correct the leak. If leaking is suspected, check the flu-
presence of oil. Clean the interior of the pipes in id levels more often than recommended until the leak
order to prevent dirt from entering during is found or fixed, or until the suspicion of a leak is
reassembly. proved to be unwarranted.
3. Check for the presence of oil. If oil is leaking from • Ensure that the cooling system hoses are correctly
the back side of the compressor wheel, there is a clamped and that the cooling system hoses are
possibility of a failed turbocharger oil seal. tight. Check for leaks. Check the condition of all
pipes.
The presence of oil may be the result of a
restriction of the line for the intake air (clogged air • Inspect the water pump for coolant leaks.
filters), which causes the turbocharger to slobber.
Note: The water pump seal is lubricated by the
4. Inspect the bore of the housing of the turbine outlet coolant in the cooling system. It is normal for a small
for corrosion. amount of leakage to occur as the engine cools down
and the parts contract.
5. Fasten the air intake pipe and the exhaust outlet
pipe to the turbocharger housing. Ensure that all Excessive coolant leakage may indicate the need to
clamps are installed correctly and that all clamps replace the water pump seal. For the removal of the
are tightened securely. water pump and the installation of water pump and/or
seal, refer to the Disassembly and Assembly Manual,
“Water Pump - Remove and Install” for more
i03903792 information or consult your Caterpillar dealer.
Walk-Around Inspection • Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
SMCS Code: 1000-040 pan, the oil filters, and the rocker cover.
Inspect the Engine for Leaks and • Inspect the fuel system for leaks. Look for loose
fuel line clamps and/or tie-wraps.
for Loose Connections
• Inspect the piping for the air intake system and the
A walk-around inspection should only take a few
minutes. When the time is taken to perform these elbows for cracks and for loose clamps. Ensure
checks, costly repairs and accidents can be avoided. that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, and so on.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting • Inspect the alternator belts and any accessory
the engine. Look for items such as oil leaks or coolant drive belts for cracks, breaks, or other damage.
leaks, loose bolts, worn belts, loose connections, and
trash buildup. Make repairs, as needed: Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
SEBU8607 149
Maintenance Recommendations
Water Pump - Inspect
i03903791
Warranty Section
Warranty Information
i05264237
Emissions Warranty
Information
SMCS Code: 1000
This engine may be certified to comply with exhaust
emission standards and gaseous emission
standards. Standards are prescribed by law at the
time of manufacture, and this engine may be covered
by an Emissions Warranty. A detailed explanation of
the Emissions Warranty that is applicable to
emissions certified engines is found in Supplement,
SEBU6981, Federal Emissions Control Warranty
Information. Consult your authorized Cat dealer to
determine if your engine is emissions certified and if
your engine is subject to an Emissions Warranty.
SEBU8607 151
Reference Information Section
Engine Rating Conditions
• 100 kPa (29.3 Inches Hg) • 100 typical operating hours per year
• industrial
Standard accessories include the following
components: • pumping
• Oil pumps • construction
• Fuel pumps • peak shaving
• Water pumps • cogeneration
Subtract the power that is required to drive auxiliary
components from the gross output. This will produce NOTICE
the net power that is available for the external load Operating a generator set engine above the rating
(flywheel). definitions will result in a shorter engine service life
before overhaul.
152 SEBU8607
Customer Service
Customer Assistance
i01028392
• 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.
154 SEBU8607
Reference Materials
Maintenance Records
Reference Materials
i05264255
Maintenance Records
SMCS Code: 1000; 4450
Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:
• Maintenance log
SEBU8607 155
Reference Materials
Maintenance Log
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 29
Engine Model Customer Identifier
Service Quantity Of
Service Item Date Authorization
Hours Fuel
156 SEBU8607
Reference Materials
Reference Material
i03901129 Miscellaneous
Reference Material • Service Manual, REG1139F, “Service Manual
Contents Microfiche”
SMCS Code: 1000; 4450
• Specifications, SENR3130, “Torque
The following literature can be obtained through any Specifications”
Caterpillar dealer.
• Special Publication, PECP9067, “One Safe
Lubricants Source” English language for use in NACD
• Special Publication, PEHP8038, “Data Sheet - • Special Publication, LEDM5615, “Caterpillar
Caterpillar Diesel Engine Oils (DEO) (CH-4) (North Marine Parts and Service Locations Directory”
America)”
• Special Publication, SEBF8029, “Index to
• Special Publication, PEHP9536, “Data Sheet - Guidelines for Reusable Parts and Salvage
Caterpillar Diesel Engine Oil (DEO) (CF-4) Operations”
(International only)”
• Special Publication, SEBF8062, “Procedure to
• Special Publication, NEDG6022, “Cat Lubricating Inspect and Clean Air Filters”
Grease”
• Special Instruction, SEHS9031, “Storage
• Special Publication, PEHP0002, “Data Sheet - Procedure for Caterpillar Products”
Molybdenum (MPGM) Grease”
• Special Publication, NEHS0526, “Service
• Special Publication, NEHP6015, “Data Sheet - Technician Application Guide”
Caterpillar Special Purpose Grease (SPG)”
• Special Publication, SEBU6251, “Caterpillar
• Special Publication, SEBD0640, “Oil and Your Commercial Diesel Engine Fluids
Engine” Recommendations”
• Operation and Maintenance Manual, SEBU5898, • Special Instruction, SEHS7633, “Battery Test
“Cold Weather Recommendations” Procedure”
• Operation and Maintenance Manual, SEBU6251, • Label, SEHS7332, “Danger Do Not Operate”
“Caterpillar Commercial Diesel Engine Fluids
Recommendations” Emissions Warranty
• Special Publication, PEHP6001, “How To Take A This engine may be Certified and this engine may be
Good Oil Sample” covered by an Emissions Warranty. A detailed
explanation of the Emissions Warranty that is
Fuels applicable to Certified engines is found in
Supplement, SMBU6981, “Emissions Control
• Special Publication, SEBD0717, “Diesel Fuels and Warranty Information”. The engine is Certified if the
Your Engine” engine has a special label that verifies the
certification. A Caterpillar dealer can also inform you
Coolants if the engine is certified.
Index
A Coolant Extender (ELC) - Add ....................... 103
Coolant Level - Check ................................... 104
After Starting Engine........................................ 52
Coolant Sample (Level 1) - Obtain ................ 105
After Stopping Engine...................................... 76
Coolant Sample (Level 2) - Obtain ................ 106
Alarms and Shutoffs ........................................ 36
Coolant Temperature Regulator - Replace .... 106
Alarms.......................................................... 36
Cooling System Supplemental Coolant
Prevention of Start-up .................................. 36
Additive (SCA) - Test/Add ............................ 107
Shutoffs........................................................ 36
Add the SCA, If Necessary ........................ 107
Testing Alarms and Shutoffs ........................ 36
Test the Concentration of the SCA............. 107
Alternator - Inspect .......................................... 97
Crushing Prevention and Cutting Prevention .. 15
Automatic Start/Stop - Inspect......................... 97
Customer Assistance..................................... 152
Auxiliary Water Pump - Inspect ....................... 97
Outside of the USA and of Canada ........... 152
Auxiliary Water Pump - Inspect (Bronze
USA and Canada ...................................... 152
Auxiliary Water Pump) ................................... 98
Customer Service .......................................... 152
B
D
Battery - Replace............................................. 98
Declaration of Conformity ................................ 28
Battery Charger - Check .................................. 99
Diagnostic Lamp.............................................. 46
Battery Electrolyte Level - Check .................... 99
Battery or Battery Cable - Disconnect ........... 100
Before Starting Engine ...............................16, 48 E
Belts - Inspect/Adjust/Replace (Single Belt) .. 100
Adjustment................................................. 101 Electrical Connections - Check...................... 108
Inspection................................................... 100 Electrical System ............................................. 17
Replace...................................................... 101 Grounding Practices .................................... 17
Burn Prevention............................................... 13 Emergency Stopping ....................................... 73
Batteries....................................................... 13 Emergency Stop Button............................... 73
Coolant......................................................... 13 Emissions Certification Film ............................ 29
Oils............................................................... 13 Emissions Warranty Information.................... 150
Engine - Clean ............................................... 108
Engine Air Cleaner Element (Dual Element)
C - Inspect/Clean/Replace .............................. 109
Cleaning the Primary Air Cleaner Elements
Cold Weather Operation.................................. 71
..................................................................110
Cold Weather Starting ..................................... 48
Servicing the Air Cleaner Elements ........... 109
Configuration Parameters (Customer
Engine Air Cleaner Element (Single
Specified Parameters) ................................... 46
Element) - Inspect/Clean/Replace................112
Configurable Inputs...................................... 46
Engine Air Cleaner Service Indicator -
ECM Identification Parameter...................... 46
Inspect ..........................................................112
Engine Rating Parameter............................. 46
Test the Service Indicator............................112
Miscellaneous .............................................. 46
Engine Crankcase Breather - Replace
Control Panel................................................... 37
(Turbocharged Engines and Naturally
Marine Classification Society (MCS) Control
Aspirated Engines) .......................................113
Panel .......................................................... 37
Engine Crankcase Breather - Replace
Coolant (ELC) - Change ................................ 101
(Turbocharged Engines) ...............................113
Drain .......................................................... 102
Engine Crankcase Breather Element -
Fill............................................................... 103
Replace (Turbocharged Engines).................113
Flush .......................................................... 102
Engine Diagnostics.......................................... 46
158 SEBU8607
Index Section
Standby Generator Sets .............................. 55 Initial 500 Hours (for New Systems, Refilled
Generator Set - Test ...................................... 133 Systems, and Converted Systems)............ 91
Generator Set Intended for Stationary Use When Required............................................ 91
Only ............................................................... 29 Maintenance Interval Schedule
Generator Set Vibration - Inspect .................. 134 (Turbocharged Aftercooled Marine
Generator Start-up Checklist ........................... 87 Generator Set Rated at 50 Hz 69 ekW and
Generator Winding Insulation - Test .............. 134 60 Hz 76 ekW) ............................................... 95
Recommended Periodic Insulation Tests... 134 Daily ............................................................. 95
Recommended Procedure for A Periodic Every 1000 Service Hours ........................... 96
Insulation Test .......................................... 135 Every 1000 Service Hours or 1 Year............ 96
Every 110 400 L (29 160 US gal) of Fuel or
8000 Service Hours.................................... 96
H Every 12 000 Service Hours or 6 Years ....... 96
Heat Exchanger - Inspect/Clean.................... 139 Every 13 800 L (3650 US gal) of Fuel or 1000
Cleaning the Heat Exchanger.................... 139 Service Hours or 1 Year ............................. 96
Hoses and Clamps - Inspect/Replace ........... 139 Every 165 600 L (43 750 US gal) of Fuel or 12
Replace the Hoses and the Clamps .......... 140 000 Service Hours...................................... 96
Every 250 Service Hours ............................. 96
Every 27 600 L (7290 US gal) of Fuel or 2000
I Service Hours or 2 Years ........................... 96
Important Safety Information ............................. 2 Every 3000 Service Hours or 3 Years .......... 96
Installation ....................................................... 35 Every 500 Service Hours or 1 Year.............. 96
Every 6000 Service Hours or 3 Years .......... 96
Every 6900 L (1820 US gal) of Fuel or 500
L Service Hours or 1 Year ............................. 96
Lifting and Storage........................................... 31 Every Week.................................................. 96
Every Year.................................................... 96
Initial 500 Hours (for New Systems, Refilled
M Systems, and Converted Systems)............ 96
Maintenance Interval Schedule (Naturally When Required............................................ 95
Aspirated Marine Generator Sets) ................. 91 Maintenance Interval Schedule
Daily ............................................................. 91 (Turbocharged Aftercooled Marine
Every 1000 Service Hours ........................... 91 Generator Sets Rated at 50 Hz 86 ekW
Every 1000 Service Hours or 1 Year............ 91 and 60 Hz 93 ekW) ........................................ 94
Every 12 000 Service Hours or 6 Years ....... 91 Daily ............................................................. 94
Every 16 600 L (4390 US gal) of Fuel or 2000 Every 10 350 L (2730 US gal) of Fuel or 500
Service Hours or 2 Years ........................... 92 Service Hours or 1 Year ............................. 94
Every 250 Service Hours ............................. 91 Every 1000 Service Hours ........................... 94
Every 3000 Service Hours or 3 Years .......... 91 Every 1000 Service Hours or 1 Year............ 94
Every 4150 L (1100 US gal) of Fuel or 500 Every 110 400 L (29 160 US gal) of Fuel or
Service Hours or 1 Year ............................. 91 8000 Service Hours.................................... 95
Every 500 Service Hours or 1 Year.............. 91 Every 12 000 Service Hours or 6 Years ....... 94
Every 6000 Service Hours or 3 Years .......... 91 Every 165 600 L (43 750 US gal) of Fuel or 12
Every 8000 Service Hours ........................... 91 000 Service Hours...................................... 95
Every 8300 L (2190 US gal) of Fuel or 1000 Every 20 700 L (5470 US gal) of Fuel or 1000
Service Hours or 1 Year ............................. 92 Service Hours or 1 Year ............................. 95
Every 99 600 L (26 310 US gal) of Fuel or 12 Every 250 Service Hours ............................. 94
000 Service Hours...................................... 92 Every 3000 Service Hours or 3 Years .......... 94
Every Week.................................................. 91 Every 41 400 L (10 940 US gal) of Fuel or
Every Year.................................................... 91 2000 Service Hours or 2 Years .................. 95
Every 500 Service Hours or 1 Year.............. 94
160 SEBU8607
Index Section
Every 6000 Service Hours or 3 Years .......... 94 Overhaul Considerations ............................... 140
Every Week.................................................. 94 Oil Consumption as an Overhaul Indicator
Every Year.................................................... 94 ................................................................. 141
Initial 500 Hours (for New Systems, Refilled Overhaul Recommendation ....................... 141
Systems, and Converted Systems)............ 94 Overspeed ....................................................... 43
When Required............................................ 94
Maintenance Interval Schedule
(Turbocharged Marine Generator Set P
Without Aftercooler)....................................... 92 Parallel Operation............................................ 56
Daily ............................................................. 92 Circulating Currents ..................................... 59
Every 1000 Service Hours ........................... 93 Initial Start-Up .............................................. 56
Every 1000 Service Hours or 1 Year............ 93 Load Division and Speed Droop (If Equipped)
Every 11 100 L (2930 US gal) of Fuel or 1000 ................................................................... 58
Service Hours or 1 Year ............................. 93 Parallel Operation Of Governors.................. 58
Every 12 000 Service Hours or 6 Years ....... 93 Paralleling Multiple Units.............................. 58
Every 133 200 L (35 190 US gal) of Fuel or 12 Starting Multiple Units .................................. 57
000 Service Hours...................................... 93 Stopping....................................................... 59
Every 22 200 L (5860 US gal) of Fuel or 2000 Plate Locations and Film Locations................. 26
Service Hours or 2 Years ........................... 93 Engine Information Plate 1........................... 27
Every 250 Service Hours ............................. 93 Generator Identification Plate 3 ................... 27
Every 3000 Service Hours or 3 Years .......... 93 Serial Number Plate 2 .................................. 27
Every 500 Service Hours or 1 Year.............. 93 Power Factor - Check .................................... 143
Every 5550 L (1470 US gal) of Fuel or 500 Product Description ......................................... 24
Service Hours or 1 Year ............................. 93 Engine Cooling and Lubrication................... 25
Every 6000 Service Hours or 3 Years .......... 93 Engine Service Life ...................................... 25
Every 8300 L (2190 US gal) of Fuel or 1000 Engine Specifications .................................. 24
Service Hours or 1 Year ............................. 93 Product Identification Information.................... 26
Every 88 800 L (23 460 US gal) of Fuel or Product Information Section ............................ 19
8000 Service Hours.................................... 93 Product Installation.......................................... 35
Every Week.................................................. 92 Electrical Measurements ............................. 35
Every Year.................................................... 93 Location ....................................................... 35
Initial 500 Hours (for New Systems, Refilled Protective Devices ....................................... 35
Systems, and Converted Systems)............ 93 Receiving Inspection.................................... 35
When Required............................................ 92 Unpacking.................................................... 35
Maintenance Log ........................................... 155 Product Lifting.................................................. 31
Maintenance Recommendations..................... 84 Engine Views ............................................... 31
Maintenance Records.................................... 154 Lifting the Engine Only................................. 33
Maintenance Section....................................... 77 Lifting the Entire Package ............................ 33
Manual Stop Procedure................................... 74 Lifting the Generator Only ............................ 33
Stopping Procedure for the MCS Control Product Storage............................................... 33
Panel .......................................................... 74 Bearing Inspection ....................................... 34
Model View Illustrations................................... 19 Electrical Measurements ............................. 34
A Keel Cooled System ................................. 21 Long Time Storage....................................... 33
Radiator Cooled System.............................. 23 Short Time Storage...................................... 33
Sea Water Cooled........................................ 19
Mounting and Dismounting.............................. 15
R
Reference Information..................................... 30
O
Record for Reference................................... 30
Operation Section............................................ 31 Reference Information Section ...................... 151
Ordering Replacement Parts ......................... 153 Reference Material ........................................ 156
SEBU8607 161
Index Section
Delivery Date:
Product Information
Model:
Transmission
Serial Number:
Attachment Information:
Dealer Equipment
Number:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
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All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.