SEBU8734-09 (en-us)

January 2022

Operation and
Maintenance
Manual
C7.1 Marine Generator Set
JME 1-UP (C7.1 Generator
Set)

Language: Original Instrucitons

Scan to find and purchase genuine Cat® parts and related

service information.
 i07966018

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

NOTICE
When replacement parts are required for this product Caterpillar recommends using original Cater-
pillar® replacement parts.
Other parts may not meet certain original equipment specifications.
When replacement parts are installed, the machine owner/user should ensure that the machine re-
mains in compliance with all applicable requirements.

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.
SEBU8734-09 3
Table of Contents

Table of Contents Engine Stopping .............................................. 71

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

Refill Capacities............................................... 73
Safety Section
Maintenance Recommendations .................... 81
Safety Messages............................................... 6
Maintenance Interval Schedule....................... 87
General Hazard Information............................ 13

Burn Prevention............................................... 17 Warranty Section

Fire Prevention and Explosion Prevention...... 17 Warranty Information..................................... 141

Crushing Prevention and Cutting Prevention.. 19 Reference Information Section

Mounting and Dismounting ............................. 20 Engine Ratings .............................................. 142

High Pressure Fuel Lines ................................ 20 Customer Service.......................................... 144

Before Starting Engine .................................... 21 Reference Materials ...................................... 147

Engine Starting................................................ 21 Index Section

Engine Stopping .............................................. 22 Index.............................................................. 151

Electrical System............................................. 22

Engine Electronics........................................... 23

Generator Isolating for Maintenance............... 23

Product Information Section

General Information ........................................ 25

Product Identification Information ................... 30

Operation Section

Lifting and Storage .......................................... 36

Installation ....................................................... 41

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

Engine Starting................................................ 58

Engine Operation ............................................ 61

Generator Operation ....................................... 62

4 SEBU8734-09
Foreword
Foreword
California Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
WARNING – This product can
expose you to chemicals
including ethylene glycol, which
is known to the State of California to
cause birth defects or other reproductive
harm. For more information go to:
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands
after handling to avoid incidental
ingestion.
WARNING – This product can
expose you to chemicals
including lead and lead
compounds, which are known to the
State of California to cause cancer, birth
defects, or other reproductive harm. For
more information go to:
www.P65Warnings.ca.gov
Wash hands after handling components
that may contain lead.
Literature Information
This manual contains safety, operation instructions,
lubrication, and maintenance information. This
manual should be stored in or near the engine area in
a literature holder or literature storage area. Read,
study, and keep it with the literature and engine
information.
English is the primary language for all Cat
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual Whenever a question
arises regarding your engine, or this manual, please
consult with your Cat dealer for the latest available
information.
Safety
This safety section lists basic safety precautions. In
addition, this section identifies hazardous, warning
situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance,
and repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating,
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
follow.
Use fuel consumption or service hours to determine
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.
Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
freezing cold operating conditions, more frequent
lubrication, and maintenance than is specified in the
Maintenance Interval Schedule may be necessary.
SEBU8734-09 5
Foreword

The maintenance schedule items are organized for a

preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.

Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are accepted as proof of
maintenance or repair. Your authorized Cat dealer
can assist you in adjusting your maintenance
schedule to meet the needs of your operating
environment.

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available
from your Cat dealer. Consult with your dealer for
information regarding these options.
6 SEBU8734-09
Safety Section
Safety Messages

Safety Section
i06038019

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 Cat dealer
can provide new safety messages.

Illustration 1 g03784507
Radiator view right-hand side
(1) Universal Warning (5) Hot Fluid Under Pressure Warning (7) Crushing Hazard
(2) Shock/Electrocution Warning (6) Auto-Start Warning
SEBU8734-09 7
Safety Section
Safety Messages

Illustration 2 g03784526
Radiator view left-hand side
(1) Universal Warning (3) Do Not Use Ether Warning (6) Auto-Start Warning
(2) Shock/Electrocution Warning (4) Hand High Pressure (7) Crushing Hazard
8 SEBU8734-09
Safety Section
Safety Messages

Illustration 3 g03784654

(1) Universal Warning (4) Hand High Pressure (7) Crushing Hazard
(2) Shock/Electrocution Warning (6) Auto-Start Warning
SEBU8734-09 9
Safety Section
Safety Messages

Illustration 4 g03784651

(2) Shock/Electrocution Warning (3) Do Not Use Ether Warning (5) Hot Fluid Under Pressure

Universal Warning (1)

The universal warning label is located on the engine
and control consul. Refer to the illustrations for more
information.
10 SEBU8734-09
Safety Section
Safety Messages

Open and secure the main distribution switch, or

if the connection is permanent, install a double
throw switch to prevent electrical feedback.
Some generators are specifically approved by a
utility to run in parallel with the distribution
system and isolation may not be required.
Always check with your utility for the applicable
circumstances.

Do Not Use Ether (3)

The ether warning label is located on the rain cap for
the air cleaner.

Illustration 5 g01370904

Do not operate or work on this engine or genera-

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

Shock/Electrocution (2)
The safety message is located on the consul and the
generator. Refer to the illustrations for more
information.
Illustration 7 g01372254
If equipped with an air inlet heater (AIH) for cold
weather starting, do not use aerosal types of
starting aids such as ether. Such use could result
in an explosion and personal injury.

Hand High Pressure (4)

Hand high-pressure warning label is located on the
top cover of the engine.

Illustration 6 g01392482

Do not connect the generator to a utility electrical

distribution system unless it is isolated from the
system. Electrical feedback into the distribution
system can occur and could cause personal
injury or death.
SEBU8734-09
Illustration 8 g01381180
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
Hot Fluid Under Pressure (5)
The hot fluid under pressure label is located on top of
the expansion tank. Also, hot fluid under pressure
label is located on top of the radiator.
11
Safety Section
Safety Messages
Illustration 9 g01371640
Pressurized system! Hot coolant can cause seri-
ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order
to relieve the pressure. Read and understand the
Operation and Maintenance Manual before per-
forming any cooling system maintenance.
Automatic Starting (6)
The automatic starting warning label is located on the
control consul.
12 SEBU8734-09
Safety Section
Safety Messages

Illustration 10 g01392484

When the engine is in the AUTOMATIC mode, the

engine can start at any moment. To avoid person-
al injury, always remain clear of the the engine Illustration 11 g01378775
when the engine is in the AUTOMATIC mode.

Crushing Warning (7) Improper lifting of the engine during removal or

installation could cause a crushing hazard which
The crush warning label is located on each side of may result in injury or death. Read and under-
the base of the generator set. stand the Service Module before removing or in-
stalling the engine.
SEBU8734-09
i08340959
General Hazard Information
SMCS Code: 1000; 4450; 7405
Illustration 12 g00104545
Attach a “Do Not Operate” warning tag to the start
switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each
operator control station. When appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
• 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 at opposite ends of the cover
plate or the device. Before removing the last two
bolts or nuts, pry the cover loose to relieve any spring
pressure or other pressure.
13
Safety Section
General Hazard Information
Illustration 13 g00702020
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears to help
prevent damage to hearing.
• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers
are secured in place on the engine.
• Never put maintenance fluids into glass
containers. Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• The protective locks or the controls are in the
applied position.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks.
• When starting a new engine, make provisions to
stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
14
Safety Section
General Hazard Information
• Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.
Pressurized Air and Water
Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield. Always wear eye
protection for cleaning the cooling system.
SEBU8734-09
Avoid direct spraying of water on electrical
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when
redeposited on hot surfaces.
Fluid Penetration
Illustration 14 g00687600
Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
SEBU8734-09
Static Electricity Hazard when
Fueling with Ultra-low Sulfur Diesel
Fuel
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death
or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling
standards for proper grounding and bonding
practices.
Lines, Tubes, and Hoses
Do not bend or strike high-pressure lines. Do not
install lines, tubes, or hoses that are damaged.
Repair any fuel lines, oil lines, tubes, or hoses that
are loose or damaged. Leaks can cause fires.
Inspect all lines, tubes, and hoses carefully. Do not
use bare hands to check for leaks. Always use a
board or cardboard for checking engine components
for leaks. Tighten all connections to the
recommended torque.
Check for the following conditions:
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Wire that is exposed in reinforced hose
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
15
Safety Section
General Hazard Information
Ensure that all the clamps, the guards, and the heat
shields are installed correctly. Correct installation of
these components will help to prevent these effects:
vibration, rubbing against other parts and excessive
heat during operation.
Inhalation
Illustration 15 g02159053
Exhaust
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the equipment in an
enclosed area, adequate ventilation is necessary.
Ensure that the crankcase exhaust is routed outside
of the vessel.
Hexavalent Chromium
Cat equipment and replacement parts comply with
applicable regulations and requirements where
originally sold. Caterpillar recommends the use of
only genuine Cat replacement parts.
Hexavalent chromium has occasionally been
detected on exhaust and heat shield systems on Cat
engines. Although lab testing is the only accurate
way to know if hexavalent chromium is, in fact,
present, the presence of a yellow deposit in areas of
high heat (for example, exhaust system components
or exhaust insulation) may be an indication of the
presence of hexavalent chromium.
Use caution if you suspect the presence of
hexavalent chromium. Avoid skin contact when
handling items that you suspect may contain
hexavalent chromium, and avoid inhalation of any
dust in the suspect area. Inhalation of, or skin contact
with, hexavalent chromium dust may be hazardous to
your health.
16 SEBU8734-09
Safety Section
General Hazard Information

If such yellow deposits are found on the engine,
engine component parts, or associated equipment or
packages, Caterpillar recommends following local
health and safety regulations and guidelines, utilizing
good hygiene, and adhering to safe work practices
when handling the equipment or parts. Caterpillar
also recommends the following:
• Wear appropriate personal protective equipment
(PPE).
• Wash your hands and face with soap and water
prior to eating, drinking, or smoking, and also
during rest room breaks, to prevent ingestion of
any yellow powder.
• Never use compressed air for cleaning areas
suspected of containing hexavalent chromium.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.

• Avoid brushing, grinding, or cutting materials Softwrap

suspected of containing hexavalent chromium.
Keep the engine room ventilation operating at full
• Obey environmental regulations for the disposal of capacity. Wear a particulate respirator that has been
all materials that may contain or have come into approved by the National Institute of Occupational
contact with hexavalent chromium. Safety and Health (NIOSH). Wear appropriate
protective clothing to minimize direct contact. Use
• Stay away from areas that might have hexavalent good hygiene practices and wash hands thoroughly
chromium particles in the air. after handling Softwrap material. Do not smoke until
washing hands thoroughly after handling Softwrap
material. Clean up debris with a vacuum or by wet
Asbestos Information sweeping. Do not use pressurized air to clean up
debris.
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Reference: The applicable material safety data
Caterpillar recommends the use of only genuine Cat sheets can be found at the following web site by
replacement parts. Use the following guidelines when
searching using part number or the name:
you handle any replacement parts that contain
asbestos or when you handle asbestos debris. http://dsf2ws.cat.com/msds/servlet/
Use caution. Avoid inhaling dust that might be cat.cis.ecs.msdsSearch.controller.
generated when you handle components that contain UserIdentificationDisplayServlet
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain Dispose of Waste Properly
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method to clean up asbestos materials.

• A vacuum cleaner that is equipped with a high Illustration 16 g00706404

efficiency particulate air filter (HEPA) can also be
used. Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
SEBU8734-09
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i06039654
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
After the engine has stopped, wait for 10 minutes in
order to allow the fuel pressure to be purged from the
high-pressure fuel lines before any service or repair
is performed on the engine fuel lines.
Allow the pressure to be purged in the air system, in
the hydraulic system, in the lubrication system, or in
the cooling system before any lines, fittings, or
related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
17
Safety Section
Burn Prevention
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Skin may be irritated following repeated or prolonged
exposure to mineral and synthetic base oils. Refer to
your suppliers Material Safety Data Sheets for
detailed information. Hot oil and lubricating
components can cause personal injury. Do not allow
hot oil to contact the skin. Appropriate personal
protective equipment should be used.
Diesel Fuel
Diesel may be irritating to the eyes, respiratory
system, and skin. Prolonged exposure to diesel may
cause various skin conditions. Appropriate personal
protective equipment should be used. Refer to
supplier Material safety Data sheets for detailed
information.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for
servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is
recommended.
i06039680
Fire Prevention and Explosion
Prevention
SMCS Code: 1000; 4450; 7405
Illustration 17 g00704000
Use of personal protection equipment (PPE) may be
needed.
All fuels, most lubricants, and some coolant mixtures
are flammable.
18 SEBU8734-09
Safety Section
Fire Prevention and Explosion Prevention

Always perform a Walk-Around Inspection, which Arcing or sparking could cause a fire. Secure
may help you identify a fire hazard. Do not operate a connections, recommended wiring, and properly
product when a fire hazard exists. Contact your Cat maintained battery cables will help to prevent arcing
dealer for service. or sparking.
Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause a deterioration. Properly route all hoses. The lines and
fire. Fire may cause personal injury and property hoses must have adequate support and secure
damage. clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an Properly install all oil filters and fuel filters. The filter
emergency shutdown. housings must be tightened to the proper torque.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your Cat dealer for
additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
All fluids that are captured in the fluid spill
containment basin should be cleaned up
immediately. Failure to clean up spilled fluids can
cause a fire. Fire may cause personal injury and
property damage.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective Illustration 18 g00704059
containers. Do not smoke in areas that are used for
storing flammable materials. Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
Do not expose the engine to any flame. refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or Avoid static electricity risk when fueling. Ultra low
a seal failure. Exhaust shields must be installed sulfur diesel (ULSD) poses a greater static ignition
correctly. hazard that earlier diesel formulation with a higher
Do not weld on lines or tanks that contain flammable sulfur content. Avoid death or serious injury from the
fluids. Do not flame cut lines or tanks that contain fire or explosion. Consult with your fuel or fuel system
flammable fluid. Clean any such lines or tanks supplier to ensure that the delivery system is in
thoroughly with a nonflammable solvent prior to compliance with fueling standards for proper
welding or flame cutting. grounding and bonding practices.

Wiring must be kept in good condition. Properly route

and attach all electrical wires. Check all electrical
wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
SEBU8734-09
Illustration 19 g02298225
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. Charging a frozen
battery may result in an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Lines, Tubes, and Hoses
After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel
lines.
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
or damaged.
19
Safety Section
Crushing Prevention and Cutting Prevention
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or
for replacement parts.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible parts of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly in order to prevent vibration,
rubbing against other parts, and excessive heat.
i08162291
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 4450; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses to
avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
20 SEBU8734-09
Safety Section
Mounting and Dismounting

i08159517

Mounting and Dismounting

SMCS Code: 1000; 4450; 7405
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine to mount the engine or dismount the
engine. With your feet and hands, always maintain a
three-point contact with the steps and designated
handholds. Do not use any controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.

i06039689

High Pressure Fuel Lines Illustration 20 g03393372

SMCS Code: 1274 High-pressure fuel lines

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

Illustration 21 g03785176
MCS type of high-pressure fuel lines

These fuel lines are different from fuel lines on other

fuel systems because of the following items:

• The high-pressure fuel lines are constantly

charged with high pressure.
SEBU8734-09
• The internal pressures of the high-pressure fuel
lines are higher than other types of fuel system.
• The high-pressure fuel lines are formed to shape
and then strengthened by a special process.
Do not step on the high-pressure fuel lines. Do not
deflect the high-pressure fuel lines. Do not bend or
strike the high-pressure fuel lines. Deformation or
damage of the high-pressure fuel lines may cause a
point of weakness and potential failure.
Do not check the high-pressure fuel lines with the
engine or the starting motor in operation. After the
engine has stopped, allow 10 minutes to pass for the
pressure to be purged before any service or repair is
performed on the engine fuel lines.
Do not loosen the high-pressure fuel lines in order to
remove air from the fuel system. This procedure is
not required.
Visually inspect the high-pressure fuel lines before
the engine is started. This inspection should be each
day.
If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to this Operation and
Maintenance Manual, “General Hazard Information”.
• Inspect the high-pressure fuel lines for damage,
deformation, a nick, a cut, a crease, or a dent.
• Do not operate the engine with a fuel leak. If there
is a leak, do not tighten the connection in order to
stop the leak. The connection must only be
tightened to the recommended torque. Refer to
Disassembly and Assembly, “Fuel Injection Lines -
Remove and Install”.
• If the high-pressure fuel lines are torqued correctly
and the high-pressure fuel lines are leaking, the
high-pressure fuel lines must be replaced.
• Ensure that all clips on the high-pressure fuel lines
are in place. Do not operate the engine with clips
that are damaged, missing, or loose.
• Do not attach any other item to the high-pressure
fuel lines.
• Loosened high-pressure fuel lines must be
replaced. Also removed high-pressure fuel lines
must be replaced. Refer to Disassembly and
Assembly manual, “ Fuel Injection Lines - Remove
and Install”.
21
Safety Section
Before Starting Engine
i08614835
Before Starting Engine
SMCS Code: 1000
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
Engine exhaust contains products of combustion
which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust
to the outside.
Inspect the engine for potential hazards.
Do not start the engine if there is a “DO NOT
OPERATE” warning tag or similar warning tag
attached to the start switch. Do not move any of the
controls if there is a “DO NOT OPERATE” warning
tag or similar warning tag attached to the controls.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
All protective guards and all protective covers must
be installed if the engine must be started to perform
service procedures. To help prevent an accident that
is caused by parts in rotation, work around the parts
carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided to help prevent personal injury. The circuits
are also provided to help prevent engine damage.
See the Service Manual for repairs and for
adjustments.
i05348947
Engine Starting
SMCS Code: 1000
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
22
Safety Section
Engine Stopping
If a warning tag is attached to the engine start switch
or to the controls, do not start the engine or move the
controls. Consult with the person that attached the
warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operator compartment or
from the engine start switch.
Note: Do not overcrank the engine. Overcranking the
engine may cause water from the exhaust system to
enter into the cylinders.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Note: The engine is equipped with a device for cold
starting. If the engine will be operated in very cold
conditions, then an extra cold starting aid may be
required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
operation.
These engines are equipped with a glow plug starting
aid in each individual cylinder that heats the intake air
in order to improve starting.
i02328530
Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to this Operation and Maintenance
Manual, “Engine Stopping” topic (Operation Section).
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. DO NOT use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop the
engine if an overspeed condition occurs.
SEBU8734-09
To stop an electronic controlled engine, cut the power
to the engine and/or the air supply to the engine.
i08429368
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump-start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump-start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See the
Operation and Maintenance Manual for specific
starting instructions.
Grounding Practices
Properly ground the electrical system for the vessel
and the engine. Proper grounding is necessary for
optimum engine performance and reliability. Improper
grounding will result in uncontrolled or unreliable
electrical circuit paths.
Uncontrolled or unreliable electrical circuit paths may
result in damage to main bearings, crankshaft
bearing journal surfaces, and aluminum components.
Uncontrolled electrical circuit paths may also cause
electrical noise. Electrical noise may degrade the
performance of the vessel and of the radio.
Connect the starting motor directly to the negative “-”
battery terminal. Connect the alternator to the
negative “-” battery or negative “-” terminal for the
starting motor. The alternator and the starting motor
must meet marine isolation requirements.
Note: All electrical connections must meet or exceed
the American Boat and Yacht Council Standard E-11.
Use a bus bar with a direct path to the negative “-”
battery terminal for low current components that
require a negative “-” battery connection. Connect the
bus bar directly to the negative “-” battery terminal.
Note: All return paths to the negative “-” battery must
be able to carry fault currents.
The use of a bus bar ensures that the electronic
control module (ECM) and the components
connected to the ECM have a common reference
point.
SEBU8734-09
Note: If multiple bus bars are used to connect
components to the negative “-” battery, a common
reference should be provided. All bus bars must be
wired together for proper engine synchronization for
multiple engine operations.
i08429518
Engine Electronics
SMCS Code: 1000; 1900
Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.
Electrical Shock Hazard. The electronic unit injec-
tors use DC voltage. The ECM sends this voltage
to the electronic unit injectors. Do not come in
contact with the harness connector for the elec-
tronic unit injectors while the engine is operating.
Failure to follow this instruction could result in
personal injury or death.
This engine has a comprehensive, programmable
Engine Monitoring System. The Electronic Control
Module (ECM) monitors the engine operating
conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an
immediate action.
The following actions are available for engine
monitoring control:
• Warning
• Shutdown
• Shutdown Controller
The following monitored engine operating conditions
may limit engine speed:
• Engine Coolant Temperature
• Engine Oil Pressure
• Engine Speed
• Intake Manifold Air Temperature
• High exhaust Temperature
• High Fuel Rail Temperature
• Low Coolant Level
• Engine Sensors
23
Safety Section
Engine Electronics
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and
display modules that are available for Cat Engines
will work in unison with the Engine Monitoring
System. Together, the two controls will provide the
engine monitoring function for the specific engine
application. Refer to the Troubleshooting Guide for
more information on the Engine Monitoring System.
i05348959
Generator Isolating for
Maintenance
SMCS Code: 4450
When you service an electric power generation set or
when you repair an electric power generation set,
follow the procedure below:
1. Stop the engine.
Illustration 22 g00104545
2. Attach “DO NOT OPERATE” or similar warning tag
to the engine prime mover starting circuit.
Disconnect the engine starting circuit.
3. Disconnect the generator from the distribution
system.
4. Lock out the circuit breaker. Attach “DO NOT
OPERATE” or similar warning tag to the circuit
breaker. Refer to the electrical diagram. Verify that
all points of possible reverse power flow have
been locked out.
5. Engine that the engine control system is not in
“AUTO START” mode.
6. Attach “DO NOT OPERATE” or similar warning tag
to the generator excitation controls.
7. Remove the terminal box cover of the generator.
24 SEBU8734-09
Safety Section
Generator Isolating for Maintenance

8. Use an audio/visual proximity tester in order to

verify that the generator is de-energized. This
tester must be insulated for the proper voltage
rating. Follow all guidelines in order to verify that
the tester is operational.
9. Determine that the generator is in a de-energized
condition. Add ground straps to the conductors or
terminals. During the entire work period, these
ground straps must remain connected to the
conductors and to the terminals.
SEBU8734-09 25
Product Information Section
General Information

Product Information
Section

General Information
i06039698

Model View Illustrations

SMCS Code: 1000
The model views show are typical features of the
C7.1 marine generator set. Due to individual
applications your engine may appear different.

Sea Water Cooled with Marine

Classification Society (MCS) Control
Panel

Illustration 23 g03195460

(1) Expansion Tank (4) Aftercooler

(2) Filler for Engine Coolant (5) Isolator Key
(3) Heat Exchanger (6) Engine Electronic Control Module (ECM)
26 SEBU8734-09
Product Information Section
Model View Illustrations

(7) Duplex Primary Fuel Filters (10) Duplex Secondary Fuel Filters (13) Oil Filler Cap
(8) Cover for Fuel Transfer Pump (11) Water Inlet for Auxiliary Water Pump (14) Guard for Engine Alternator Belt
(9) Fuel Transfer Pump (12) Fresh Water Drain

Illustration 24 g03195461

(14) MCS Control Panel (18) Turbocharger (22) Starting Motor

(15) Emergency Stop (19) Engine Alternator (23) Oil Drain Valve
(16) Air Cleaner (20) Sampling Port for Engine Oil (24) Coolant Sampling Port
(17) Crankcase Breather (21) Duplex Oil Filters (25) Terminal Box
SEBU8734-09 27
Product Information Section
Model View Illustrations

Radiator Cooled

Illustration 25
Typical example
(1) Oil filler cap
(2) Air to air charge cooler
(3) Radiator cap
g03785202
(4) Radiator (7) Oil drain valve
(5) Auto drain valve (8) Oil gauge (Dipstick)
(6) Duplex oil filter lever (9) Air cleaner indicator
28 SEBU8734-09
Product Information Section
Product Description

Illustration 26 g03785257
Typical example
(10) Fuel cooler (12) Duplex secondary fuel lever
(11) Radiator drain (13) Duplex primary fuel lever

i06041257

Product Description
SMCS Code: 1000; 4450; 4491
The Cat C7.1 Marine Generator Set has the following
characteristics.
• An in-line 6 cylinder engine

• A four stroke cycle

• Direct fuel injection

• Turbocharged with water cooled or air to air

charge cooled Illustration 27 g01127295

• Heat exchanger cooled Keel cooled system or (A) Exhaust valve

(B) Inlet valve
Radiator cooling
Table 1
Engine Specifications C7.1 Marine Engine Specifications

The front end of the engine is opposite the flywheel Number of cylinders 6 In-Line
end of the engine. The left and the right sides of the
engine are determined from the flywheel end. The
number 1 cylinder is the front cylinder. (continued)
SEBU8734-09 29
Product Information Section
Product Description

(Table 1, contd) The ECM provides an electronic governor that

Bore 105 mm (4.13 inch)
controls the injector output in order to maintain the
desired engine rpm.
Stroke 135 mm (5.31495 inch)

Aspiration Turbocharged aftercooled Engine Speed Governing

Compression ratio 16.5:1 The ECM provides electronic governing that controls
characteristics of fuel injection in order to maintain
Displacement 7.01 L (428 in3)
the desired engine rpm.
Firing order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise

Electronic Engine Features
The engine operating conditions are monitored. The
Electronic Control Module (ECM) controls the
response of the engine to these conditions and to the
demands of the operator. These conditions and
operator demands determine the precise control of
fuel injection by the ECM. The electronic engine
control system provides the following features:
Engine Cooling and Lubrication
The cooling system consists of the following
components:
• Gear-driven centrifugal water pump
• Water temperature regulator which regulates the
engine coolant temperature
• Auxiliary gear-driven water pump
• Aftercooling

• Engine monitoring • Heat exchanger

• Engine speed governing • Gear-driven rotor type oil pump

• Control of the injection pressure • Oil cooler

• Cold start strategy
• Automatic air/fuel ratio control
• Torque rise shaping
• Injection timing control
• System diagnostics
Engine Diagnostics
The engine has built-in diagnostics in order to ensure
that the engine systems are functioning correctly. The
operator will be alerted to the condition by a “Stop or
Warning” lamp. The electronic service tool may be
used to display the diagnostic codes.
There are three types of diagnostic codes: active,
logged and event.
The engine lubricating oil is supplied by a rotor type
oil pump. The engine lubricating oil is cooled and the
engine lubricating oil is filtered. The bypass valve can
provide unrestricted flow of lubrication oil to the
engine if the oil filter element should become
plugged.
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants. Refer to this Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information on maintenance items.
30 SEBU8734-09
Product Information Section
Product Identification Information

Product Identification
Information
i08749199

Plate Locations and Film

Locations
SMCS Code: 1000; 4450
Cat products are identified with serial numbers and
with arrangement numbers. In some of the cases,
modification numbers are used. These numbers are
shown on the Serial Number plates and the Engine
Information Plates. The numbers are also shown on
the Generator Identification plates that are mounted
on the product.
Cat dealers need these numbers to determine the
components that were included with the product. This
numbering permits accurate identification of
replacement part numbers.

Illustration 28 g03785653
Typical example

Generator Identification Plate (1) Cat dealers need all of these numbers to determine
the components that were included with the engine.
The generator identification plate is on the front side This information permits accurate identification of
of the terminal box. replacement part numbers

Cat dealers need all of these numbers to determine Serial Number Plate (3)
the components that were included with the engine.
This information permits accurate identification of
replacement part numbers. The serial number plate is on the front of the frame.

Engine Information Plate (2)

Depending on the application, the engine information
plate can be installed on either side of the engine.
SEBU8734-09 31
Product Information Section
Plate Locations and Film Locations

Cat dealers need all of these numbers to determine

the components that were included with the engine.
This information permits accurate identification of
replacement part numbers.

Rating Plate

Illustration 29 g06696484

(1) Country of Origin (5) Month and Year of Manufacture (8) Mass
(2) Name/designation (6) Eurasian Economic Union Member
(3) Manufacturer name national language
(4) Model and serial number (7) Basic parameters/features
32 SEBU8734-09
Product Information Section
Plate Locations and Film Locations

Regional Product Marking (If • Year of Construction

Equipped) • Generator Set Type

Eurasian Economic Union

The rating plate is placed on generator sets certified
to the Eurasian Economic Union requirements
effective at the time of market entry.
The Month and Year of Manufacture are on the
identification plate.

Manufacturer Information
Manufacturer:

Caterpillar Inc.,
100 N.E. Adams Street
Illustration 30 g06650998
Peoria, Illinois 61629, USA
Regional marking plate Entity authorized by the manufacturer at the territory
of Eurasian Economic Union:
This plate is positioned on the bottom-left side of the
identification plate. Caterpillar Eurasia LLC
75, Sadovnicheskaya Emb.
Note: The regional marking plate is on generator Moscow 115035, Russia
sets that are certified to the applicable requirements
that were effective then.
Regional product marking may include one or more
of the following:
CE mark

UKCA mark

EAC mark

Gulf Standardization Organization

(GSO) mark

Ukraine mark

The following information may be stamped onto the

regional marking plate. For quick reference, record
this information in the spaces that are provided
below.

• Engine Power Primary Engine (kW)

• Engine Power for other Engine (If Equipped)

• Typical Generator Set Operating Weight

(kg)
SEBU8734-09 33
Product Information Section
Declaration of Conformity

Declaration of Conformity
(European Union)
SMCS Code: 1000

Table 2
An EU Declaration of Conformity document was provided with the machine if the machine was manufactured to comply with specific require-
ments for the European Union. To determine the details of the applicable Directives, review the complete EU Declaration of Conformity pro-
vided with the machine. The extract shown below from an EU Declaration of Conformity for machines that are declared compliant to “2006/42/
EC” applies only to those machines originally “CE” marked by the manufacturer listed and which have not since been modified.

ORIGINAL EU DECLARATION OF CONFORMITY

Manufacturer:CATERPILLAR INC. 100 N.E. ADAMS STREET PEORIA, IL 61629 USA

Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean Union Member States on request:

Standards & Regulations Manager,Caterpillar France S.A.S,

40 Avenue Leon-Blum 38000 Grenoble, France

I, the undersigned, _________, hereby certify that the construction equipment specified hereunder

Description: Generic Denomination: Power Generation Equipment

Function: Marine Auxiliary

Model/Type: C7.1

Serial Number:
Commercial Name: Caterpillar

Fulfills all the relevant provisions of the following Directives

Directives Notified Body Document No.

2006/42/EC N/A
2014/30/EU N/A

Engine Power per ____-____ kW Rated engine speed - _____ rpm

Technical Documentation accessible through person listed above authorized to compile the Technical File

Done at: Signature

Date: Name/Position

Note: The above information was correct as of August 2021, but may be subject to change. Refer to the individual declaration of conformity is-
sued with the product for exact details.
34 SEBU8734-09
Product Information Section
Declaration of Conformity

Declaration of Conformity
(Great Britain)
SMCS Code: 1000

Table 3
A Declaration of Conformity document was provided with the machine if the machine was manufactured to comply with specific requirements
for the Great Britain. To determine the details of the applicable legislation, review the complete Declaration of Conformity provided with the ma-
chine. The extract shown below from a Great Britain Declaration of Conformity for machines that are declared compliant to 2008 No. 1597 ap-
plies only to those machines originally “UKCA” marked by the manufacturer listed and which have not since been modified.

DECLARATION OF CONFORMITY

Manufacturer: Caterpillar Inc., 100 N.E. Adams Street, Peoria, Illinois 61629, USA

Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities on
request:

Standards & Regulations Manager Caterpillar France SAS

40 Avenue Leon-Blum 38000 Grenoble, France

I, the undersigned, _________, hereby certify that the construction equipment specified hereunder

Description: Generic Denomination: Power Generation Equipment

Function: Marine Auxiliary

Model/Type: C7.1

Serial Number:
Commercial Name: Caterpillar

Fulfills all the relevant provisions of these regulations and/or other enactments as listed below:

Legislation Approved Body Document No.

2008 No. 1597

2016 No. 1091
Engine Power per ____-____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File

Done at: Signature

Date: Name/Position

Note: The above information was correct as of August 2021, but may be subject to change. Refer to the individual declaration of conformity is-
sued with the machine for exact details.
SEBU8734-09 35
Product Information Section
Emissions Certification Film

i05381116 Generator Frame Size

Voltage Rating
Emissions Certification Film
SMCS Code: 1000; 7405 kW Rating

Note: This information is pertinent in the United Excitation System

States, in Canada and in Europe. AREP
Consult your Cat dealer for an Emission Control Self-Excited
Warranty Statement.
Permanent Magnet
The emissions label is located on the rocker cover on
the engine.

i04397923

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

Record for Reference

Engine Model
Engine Serial Number
Engine Arrangement Number
Modification Number
Engine Low Idle Speed
Engine Full Load Speed
Performance Specification Number
Primary Fuel Filter Element
Secondary Fuel Filter Element
Engine Oil Filter Element
Auxiliary Oil Filter Element
Supplemental Coolant Additive Maintenance
Element
Engine Oil Capacity
Total Cooling System Capacity
Air Cleaner Element
Fan Drive Belt
Alternator Belt
Generator Arrangement Number
Generator Set Serial Number
36 SEBU8734-09
Operation Section
Lifting and Storage

Operation Section

Lifting and Storage

i07452058

Product Lifting
SMCS Code: 7000; 7002

NOTICE
Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting.
Never bend the eyebolts and the brackets. Never
perform product lifting if components are damaged.
Only load the eyebolts and the brackets under ten-
sion. Remember that the capacity of an eyebolt is
less as the angle between the supporting members
and the object becomes less than 90 degrees.
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting fixtures to obtain
proper balance. Lifting fixtures also help to provide
safety.
Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Cat dealer for information regarding
fixtures for proper engine lifting.

Lifting the Entire Package

Do not use the engine lifting eyes or the
generator lifting eyes to lift the entire package.
Lifting points have been provided on the base rails of
the generator set for lifting the entire package.
However, lifting the engine and the generator
together requires special equipment and procedures.
Consult your Cat dealer for information regarding
fixtures for proper lifting of your complete package.
SEBU8734-09 37
Operation Section
Product Lifting

Illustration 31 g03392073
Typical example
(1) Two lift points for the generator set
38 SEBU8734-09
Operation Section
Product Lifting

To lift the application four lifting eyes are required.
Two lifting eyes are on the left-hand side on the
application and two are on the right-hand side.
Lifting the Engine Only
To remove the engine only, use lifting eyes that are
on the engine. The engine lifting eyes have covers
that must be removed before the engine lifting eyes
are used. Refer to 33 . These covers must be
installed after use.
Lifting the Generator Only
There are two lifting brackets designs that can be
installed on the generator set. The two lifting eye
design or the four lifting eye design.

Two lifting Eye Design

Illustration 32 g03393373
There are two lifting eyes on the engine.

Illustration 34 g03398665
Generator
(4) Lifting eyes for the generator

Illustration 33 g03402596
Lifting eye with cover installed
(3) Cover
SEBU8734-09
To remove the generator only, use both lifting eyes
that are on the generator. The generator lifting eyes
have covers that must be removed before the
generator lifting eyes are used. Refer to illustration
33 . These covers must be installed after use.
Four lifting Eye design
Illustration 35 g06106920
To remove the generator only, use all four lifting eyes
that are on the generator. The generator lifting eyes
have covers that must be removed before the
generator lifting eyes are used. Refer to illustration
33 . These covers must be installed after use.
i07026647
Product Storage
SMCS Code: 7002
If the generator is not installed immediately, store the
generator in a clean area. This area should also have
the following conditions: low humidity, stable
humidity, and stable temperature. Space heaters
must be energized to keep condensation from the
windings. All accessory equipment that is supplied
with the unit should be stored with the generator. The
combined unit should be covered with a durable
cover to protect against the following contaminants:
• Dust
• Dirt
• Moisture
• Other airborne abrasive substances
39
Operation Section
Product Storage
Storage - Greater than 7 Days and
less than 30 Days
Caterpillar recommends maintaining the temperature
of the engine to a temperature of at least 5° C (9° F)
above ambient temperature to prevent corrosion. The
usage of jacket water heaters is an appropriate
method.
Storage - Greater than 30 Days and
less than 1 Year
Engine Storage
Note: If long-term storage for time exceeding 1 year
is necessary, contact your local Caterpillar Dealer for
the preferred procedure to use in your specific case.
If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface, which will increase engine wear which
can reduce engine service life.
To help prevent excessive engine wear, use the
following guidelines:
• Complete all the lubrication recommendations that
are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).
• If freezing temperatures are expected, check the
cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
(Maintenance Section).
If an engine is out of operation and if use of the
engine is not planned, special precautions should be
made. If the engine will be stored for more than one
month, a complete protection procedure is
recommended.
For more detailed information on engine storage, see
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”.
Generator Storage
A storage period in excess of six months should be
preceded by the following preparation:
1. Install desiccant bags inside the exciter's cover
and install desiccant bags inside the screen of the
fan.
2. Seal the unit in a covering of plastic or other
material that has been designed for that purpose.
40 SEBU8734-09
Operation Section
Product Storage

3. Adequately tag the generator. This will ensure that

preservative greases and desiccant bags are
removed before the generator is placed in
operation.

Bearing Inspection
Ball bearing generators use grease. This grease is
subject to deterioration. If the generator is stored
more than one 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:
• Rapid changes in temperature
• Freezing

• Wet climate during storage

Note: These tests should be conducted prior to any
power connections that are being made. These tests
should be conducted prior to any control connections
that are made.
Refer to the Generator Maintenance section of this
manual to measure the following items:
• Exciter Field (Stator)

• Exciter Armature (Rotor)

• Generator Field (Rotor)

• Generator Armature (Stator)

For additional information on generator storage,
consult your Caterpillar dealer for assistance.
SEBU8734-09 41
Operation Section
Installation

Installation
i06258265

Product Installation
SMCS Code: 1000; 1404; 4450; 7002
For information about the correct installation
procedure for your product, refer to the Application
and Installation Guide (A&I Guide) for your product or
consult your Cat dealer.
42
Operation Section
Features and Controls
Features and Controls
i05336658
Alarms and Shutoffs
SMCS Code: 7400
This section contains some general information
about the function of typical engine protective
devices.
The alarms and shutoffs are set at critical operating
temperatures, pressures, fluid levels, or speeds in
order to protect the engine from damage.
An alarm warns the operator when an abnormal
operating condition occurs. The shutoffs shut down
the engine if a more critical operating condition
occurs. The shutoffs help to prevent damage to the
engine.
If an engine protective device shuts off the engine,
always determine the cause of the shutoff. Always
make the necessary repairs before attempting to start
the engine.
Become familiar with the following information:
• Types of the alarms and shutoffs
• Locations of the alarm and shutoff controls
• Conditions which cause each control to function
• The procedure that is required before starting the
engine
Shutoffs
The shutoffs are electrically operated. The alarms are
controlled by the control panel.
The particular shutoff may need to be reset before
the engine will start.
NOTICE
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart
the engine.
Alarms
The alarms are electrically operated. The operation
of the alarms is controlled by the ECM.
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 ECM. An event code is created by the
ECM. The ECM will send a signal in order to
illuminate the lamp.
Your engine may be equipped with the following
sensors or switches:
SEBU8734-09
Coolant level – The low coolant level switch
indicates when the coolant level is low.
Coolant temperature – The coolant temperature
sensor indicates high jacket water coolant
temperature.
Engine oil temperature – The engine oil
temperature sensor indicates when the temperature
is too high.
Exhaust gas temperature – The exhaust gas
sensor indicates when the temperature of the
exhaust gas is too high.
Filtered fuel delivery pressure – The filtered fuel
delivery pressure measures fuel pressure.
High-pressure fuel system leak detection – The
high-pressure fuel system leak detection sensor
detects fuel leaks.
Intake manifold air temperature – The intake
manifold air temperature sensor indicates high intake
air temperature.
Intake manifold pressure – The intake manifold
pressure sensor checks the rated pressure in the
engine manifold.
Fuel rail pressure – The fuel rail pressure sensor
checks for high pressure or low pressure in the fuel
rail.
Engine oil pressure – The engine oil pressure
sensor indicates when oil pressure drops below rated
system pressure, at a set engine speed.
Engine overspeed – The primary speed/timing
sensor checks the engine speed.
Primary fuel filter deferential pressure – The
primary fuel filter differential pressure sensor checks
for the proper differential pressure.
Sea water pressure – The sea water pressure
sensor checks for low sea water pressure.
Secondary fuel filter deferential pressure – The
secondary fuel filter differential pressure sensor
checks for the proper differential pressure.
User-defined switch – This switch can shut down
the engine remotely.
Water in fuel switch – This switch checks for water
in the primary fuel filter when the engine is operating.
Note: The sensing element of the coolant
temperature switch must be submerged in coolant in
order to operate.
Engines may be equipped with alarms in order to
alert the operator when undesirable operating
conditions occur.
SEBU8734-09
NOTICE
When an alarm is activated, corrective measures
must be taken before the situation becomes an emer-
gency in order to avoid possible engine damage.
If corrective measures are not taken within a
reasonable time, engine damage could result. The
alarm will continue until the condition is corrected.
The alarm may need to be reset.
Testing Alarms and Shutoffs
Alarms must function properly in order to provide
timely warning to the operator. Shutoffs help to
prevent damage to the engine. It is impossible to
determine if the engine protective devices are in
good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices. Refer to this Operation
and Maintenance Manual, “Engine Protective
Devices - Check” for more information.
Prevention of Start-up
The engine will not start if any of the conditions that
cause a shutoff are present. An overcrank will also
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:
• The condition that prevented starting is not
present.
43
Operation Section
Control Panel
• The condition that preventing starting has been
acknowledged on the control panel.
Setpoints for Alarms and Shutoffs
Some of the setpoints for the alarms and shutoffs can
be programmed with a Caterpillar Electronic
Technician (ET). Some of the parameters cannot be
programmed. For information on programming of
parameters, refer to the Systems Operation/Testing
and Adjusting. For the default setpoints, refer to the
Troubleshooting Guide.
i05371239
Control Panel
(Customer Connect)
SMCS Code: 7451
Illustration 36 g03398681
(1) Battery disconnect switch (Main switch)
(2) Customer connection receptacle
(3) Customer connection receptacle
(4) Customer power entry
(5) Starter connection
(6) Glow plug relay entry
(7) Service tool connector
(8) Circuit breaker for the glow plugs
(9) Circuit breaker for the controls
Battery Disconnect Switch – Rotate clockwise to
turn on the power. Rotate anti clockwise to turn off
the power.
44 SEBU8734-09
Operation Section
Control Panel

Circuit Breaker for the Glow Plugs – Press the

switch to reset the power.
Circuit Breaker for the Controls – Press the switch
to reset te power.

i06043598

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

MCS Control Panel

Illustration 37 g03393731
(1) MCS Panel
(2) “EMERGENCY STOP” switch
(3) “OVERSPEED SHUTDOWN” lamp
(4) “HIGH TEMPERATURE SHUTDOWN” lamp
(5) “LOW OIL PRESSURE SHUTDOWN” lamp
(6) “SHUTDOWN OVERRIDE” lamp
(7) “MAINTENANCE RESET” switch
SEBU8734-09 45
Operation Section
Marine Classification Society (MCS) Control Panel (If Equipped)

Illustration 38 g03787064
MCS Control Panel
(8) “ALARM” indicator (15) “ALARM” indicator (23) “MODE” key
(9) Display (16) Menu key for RIGHT (24) “INDICATOR LAMP” for the status of
(10) “LOG” (17) Menu key for SELECT the generator
(11) “VIEW” (18) “LAMP TEST” switch (25) “ENGINE OPERATING” indicator
(12) Menu key for UP (19) Menu key for DOWN (26) “STOP” key (reset)
(13) “INDICATOR LAMP” for the power (20) “BACK” key (27) “START” key
status of the controller (21) Menu key for LEFT (28) “JUMP” key
(14) “INDICATOR LAMP” for the status of (22) Indicator lamp for control in remote (29) “INFO” key
the controller mode

Controls for MCS Panel
“ ALARM”” indicator (8) – A flashing LED indicates
that alarms that have not been acknowledged are still
present. A fixed LED indicates that all alarms are
acknowledged. A red LED indicates shutdown. A
green LED is for an alarm.
Display Area (9) – The display area shows
information about the generator set.
“ LOG”” key (10) – This key shifts the display to the
three lower lines in order to show the event and a list
of alarms. The list holds 100 events. These events
are erased when the main unit is switched off. Press
the “LOG” key down for 5 seconds to display details
of the Engine Information Center (EIC) logged
events.
“ VIEW”” key (11) – Enter a menu number selection.
All settings have a specific number. The “VIEW” key
enables the user to select any setting. The “VIEW”
key enables the user to display any setting without
navigating through all of the menus.
Menu Key for “ UP”” (12) – This key increases the
value of the selected set point in the setting menus.
This key is also used for scrolling to the second line
that displays the values for the generator in the
display for daily use.
“ INDICATOR LAMP”” for the power status of the
controller (13) – This lamp indicates the power
status of the controller.
“ INDICATOR LAMP”” for the status of the
controller (14) – This lamp indicates that the unit is
running a self-check and the unit is functioning
properly.
“ INDICATOR LAMP”” for the alarm inhibit (15) –
This lamp indicates that the “inhibit input” is on.
Menu Key for “ RIGHT”” (16) – This key moves the
cursor to the right in order to maneuver in the menus.
“ SEL”” key (17) – This key is used to select the
function that has been chosen. The function that has
been chosen is the underlined selection in the lower
line of the display.
46 SEBU8734-09
Operation Section
Marine Classification Society (MCS) Control Panel (If Equipped)

“ LAMP TEST”” switch (18) – The lamp test switch is

used to test indicators on the control panel.
Menu Key for “ DOWN”” (19) – This key decreases
the value of the selected set point in the setting
menus. This key is also used for scrolling to the
second line that displays the values for the generator
in the display for daily use.
“ BACK”” key (20) – The “BACK” key jumps one step
backward in the menu to previous display or to the
entry screen.
Menu Key for “ LEFT”” (21) – This key moves the
cursor to the left for maneuvering in the menus.
“ INDICATOR LAMP”” for the control in remote
mode (22) – The indicator illuminated through
operation of Mode key. (12)
“ MODE”” key (23) – The “MODE” key switches the
system between “LOCAL START/STOP” and
“REMOTE START/STOP” . Lamp (13) is illuminated
for “REMOTE” control.
“ GENERATOR STATUS”” indicator (24) – This lamp
indicates that the voltage and frequency are present
and available.
“ ENGINE OPERATING”” indicator (25) – Lamp
indicates that the generator is running.
“ STOP”” key (reset) (26) – The “STOP” key shuts
down the engine when the engine is running.
Pressing the “ STOP”” key bypasses the cooldown
period.
“ START”” key (27) – The “START” key begins the
starting sequence. The PPU must be in manual
mode in order for the “START” key to function. The
remote indicator lamp (15) cannot be illuminated. To
switch off the remote indicator lamp, press “MODE”
key (14).
“ JUMP”” key (28) – The “JUMP” key is used to enter
a number in order to select a menu. Every setting has
a specific number. Use the “JUMP” key in order to
select any setting and display any setting without
navigating all the way through the menus.
“ INFO”” key (29) – This shifts the display in order to
show the list of alarms. The list has a maximum of 30
alarms. A history that displays the last 30 alarms can
be viewed.
SEBU8734-09 47
Operation Section
Control Panel

i08454345

Control Panel
(EMCP 4.2 (If Equipped))
SMCS Code: 7451

Electronic Control Module (Generator

Set)

Illustration 39 g02082653
EMCP 4 Control System Panel
(1) Display screen (7) Event log (13) Right key
(2) AC overview key (8) Run key (14) OK key
(3) Engine overview key (9) Auto key (15) Down key
(4) Main menu key (10) Stop key (16) Left key
(5) Alarms acknowledge key (11) Escape key
(6) Reset shut down Key (12) Up key

Navigation Keys information contains various engine parameters that

AC Overview (2) – The “AC OVERVIEW” key will
navigate the display to the first screen of AC
information. The “AC OVERVIEW” information
contains various AC parameters that summarize the
electrical operation of the generator set.
Engine Overview (3) – The “ENGINE OVERVIEW”
key will navigate the display to the first screen of
engine information. The “ENGINE OVERVIEW”
summarize the operation of the generator set.
Main Menu Key (4) – The “MAIN MENU” key will
navigate the display to the main menu directly
without having to navigate out of menus.
Acknowledge Key(5) – Pressing the
“ACKNOWLEDGE” key will cause the horn relay to
turn off. The horn relay being turned off will silence
the horn. Pressing the “ACKNOWLEDGE” key will
also cause any red or yellow flashing lights to either
48
Operation Section
Gauges and Indicators
turn off or to come on continuously. The
“ACKNOWLEDGE” key may also be configured to
send out a global alarm silence signal on the J1939
Data Link. Sending out a global alarm silence signal
on the J1939 Data Link will silence the horns on the
annunciators.
Reset Key (6) – Pressing the “RESET” key will reset
various events.
Event Log Key (7) – Pressing the “EVENT LOG” key
will navigate the display to the event log.
RUN Key (8) – Pressing the “RUN” key will start the
engine.
AUTO Key (9) – Pressing the “AUTO” key will cause
the engine to enter the “AUTO” mode. The engine will
start if the module receives a start command from a
remote source.
STOP Key (10) – Pressing the “STOP” key will stop
the engine.
Escape Key (11) – The “ESCAPE” key is used in
order to navigate through the menus. When the key
is pressed, the user moves backward or the user
moves upward through the menus. The “ESCAPE”
key is also used to exit out of entering data when the
user is programming the setpoints. If the “ESCAPE”
key is pressed while the user is programming the
setpoints, changes made on the screen will not be
saved to memory.
Up Key (12) – The “UP” key is used to navigate
through the various menus and monitoring screens.
The “UP” key is also used when a setpoint is entered.
When entering numeric data, the “UP” key is used in
order to increment the digits (0-9). If the setpoint
requires selection from a list, the “UP” key is used to
navigate UP through the list.
Right Key (13) – The “RIGHT” key is used during
setpoint adjustment. The “RIGHT” key is used to
select which digit is edited while entering numeric
data. The “RIGHT” key is also used during some
setpoint adjustments in order to select or to unselect
a check box. If a check box has a check mark, the
function has been enabled. Pressing the “RIGHT”
key will disable the function. Pressing the “RIGHT”
key will also cause the check mark to disappear. If
the check box does not have a check mark, the
function is disabled. Pressing the “RIGHT” key will
enable the function. Pressing the “RIGHT” key will
also cause a check mark to appear.
Enter Key (14) – The “ENTER” key is used in order
to navigate through the menus. When the key is
pressed, the user moves forward or the user moves
downward through the menus. The “ENTER” key is
also used to save any changes while the setpoints
are being programmed. Pressing the “OK” key during
programming the setpoints causes the changes to be
saved to memory.
Down Key (15) – The “DOWN” key is used to
navigate downward through the various menus or
screens. The “DOWN” key is also used to program
SEBU8734-09
the setpoints. The “DOWN” key is used to decrease
the digits when entering numeric data. If the setpoint
requires selection from a list, the “DOWN” key is
used to navigate DOWN through the list.
Left Key (16) – The “LEFT” key is used during
setpoint adjustment. The “LEFT” key is used to select
the digit that is edited during the entry of numeric
data. The “LEFT” key is also used during some of the
setpoint adjustments to select a check box. The key
is also used to unselect a check box. If a check box
has a check mark, pressing the “LEFT” key will
disable the function. Pressing the key will also
remove the check mark. Pressing the “LEFT” key will
also cause the check mark to disappear. If the check
box does not have a check mark, pressing the
“LEFT” key will enable the function. Pressing the
“LEFT” key will also cause a check mark to appear.
Alarm Indicators
Yellow Warning Lamp – A yellow warning lamp is
located above the “ACKNOWLEDGE” key. A flashing
yellow light indicates that there are active warnings
that have not been acknowledged. A continuous
yellow light indicates that there are acknowledged
warnings that are active. If there are any active
warnings, the yellow light will change from flashing
yellow to continuous yellow after the
“ACKNOWLEDGE” key is pressed. If there are no
longer any active warnings, the yellow light will turn
off after the “ACKNOWLEDGE” key is pressed.
Red Shutdown Lamp – A red shutdown lamp is
located above the “RESET” key. A flashing red light
indicates that there are active shutdowns that have
not been acknowledged. A continuous red light
indicates that there are active shutdowns that have
been acknowledged. If there are any active
shutdowns, the red light will change from flashing red
to continuous red after the “ACKNOWLEDGE” key is
pressed. Any condition that has caused a shutdown
must be manually reset. If there are no longer any
active shutdowns, the red light will turn off.
Digital Inputs
There are several digital inputs and outputs on
“EMCP 4.2” . For detailed information about the
inputs on this electronic control module, see Systems
Operation, Troubleshooting, Testing, and Adjusting,
UENR1209, “EMCP 4.2”.
i05027705
Gauges and Indicators
SMCS Code: 7450
Your engine may not have the same gauges or all of
the gauges that are described. For more information
about the gauge package, see the literature that is
from the OEM of the vessel.
SEBU8734-09 49
Operation Section
Overspeed

Most gauges and the indicator will be contained
within a control panel. Refer to this manual , “Control
Panel” for more information.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a time.
Noticeable changes in gauge readings indicate
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Cat dealer for
assistance.
Some engine applications are equipped with
Indicator Lamps. Indicator lamps can be used as a
diagnostic aid. There are two lamps. One lamp has
an orange lens and the other lamp has a red lens.
1. Reduce the load.
2. Determine if the engine must be shut down
immediately or if the engine can be cooled by
reducing the load.
3. Inspect the cooling system for leaks.
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.
i05336162
Overspeed
SMCS Code: 1900; 1907; 1912; 7427

These indicator lamps can be used in two ways: The engine overspeed depends on the operating
frequency for the generator.
• The indicator lamps can be used to identify the Table 4
current operational status of the engine. The
Marine C7.1 Generator Set
indicator lamps can also indicate that the engine
has a fault. This system is automatically operated Hertz (Hz) Alarm Shutdown
via the ignition switch.
50 Hz 1650 rpm 1725 rpm
• The indicator lamps can be used to identify active 60 Hz 1980 rpm 2070 rpm
diagnostic codes. This system is activated by
pressing the Flash Code button.
i06046755
Refer to the Troubleshooting Guide, “Indicator
Lamps” for further information. Sensors and Electrical
NOTICE Components
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP SMCS Code: 1900; 7400
the engine. Engine damage can result. The illustrations within the following sections are
typical location of the sensors or electrical
components.
Engine Oil Pressure – The oil pressure
should be greatest after a cold engine is
started. The typical engine oil pressure
with SAE15W40 is 500 ± 100 kPa
(72.52 ± 14.50 psi) at rated rpm.

Jacket Water Coolant Temperature –

Typical temperature range is 83° to 94°C
(181° to 169°F). The maximum allowable
temperature at sea level with the pressurized
cooling system at 48 kPa (7.0 psi) is 100° C
(212° F). Higher temperatures may occur under
certain conditions. The water temperature
reading may vary according to load. The
temperature reading should never exceed 7 °C
(44.6 °F) below the boiling point for the
pressurized system that is being used.
If the engine is operating above the normal range
and steam becomes apparent, perform the following
procedure:
50 SEBU8734-09
Operation Section
Sensors and Electrical Components

Standard Sensor View

Illustration 40 g03788580

(1) Coolant sensor (5) Inlet manifold pressure sensor (9) Electric priming/lift pump
(2) Glow plug (6) Electronic control module (10) Oil pressure sensor
(3) Fuel pressure sensor (rail) (7) Primary speed/timing sensor (11) Solenoid for high-pressure fuel pump
(4) Inlet manifold temperature sensor (8) Low-pressure fuel sensor (12) Fuel temperature sensor
SEBU8734-09 51
Operation Section
Sensors and Electrical Components

Illustration 41 g03789282

(1) Coolant sensor (2) Glow plug

52 SEBU8734-09
Operation Section
Sensors and Electrical Components

Illustration 42 g03789283

(3) Fuel pressure sensor (rail) (5) Inlet manifold pressure sensor (7) Primary speed/timing sensor
(4) Inlet manifold temperature sensor (6) Electronic control module
SEBU8734-09 53
Operation Section
Sensors and Electrical Components

Illustration 43 g03789284

(8) Low-pressure fuel sensor (10) Oil pressure sensor (12) Fuel temperature sensor
(9) Electric priming/lift pump (11) Solenoid for high-pressure fuel pump
54 SEBU8734-09
Operation Section
Sensors and Electrical Components

Illustration 44 g03788581

(13) Alternator (15) Starter solenoid

(14) Starting motor (16) Secondary speed/timing sensor
SEBU8734-09 55
Operation Section
Sensors and Electrical Components

Marine Classification Society (MCS)

Sensors

Illustration 45 g03788624

(1) Coolant level switch (4) Secondary fuel filter differential pressure (6) Primary fuel filter differential pressure
(2) Engine coolant temperature sensor sensor (Outlet) sensor (Inlet)
(3) Overspeed Sensor (5) Secondary fuel filter differential pressure (7) Primary fuel filter differential pressure
sensor (Inlet) sensor (Outlet)
56 SEBU8734-09
Operation Section
Sensors and Electrical Components

Illustration 46 g03788627

(8) Oil temperature sensor (9) Alarm tank switch for injector pipes
SEBU8734-09 57
Operation Section
Sensors and Electrical Components

Illustration 47 g03789237

(10) Engine oil pressure sensor (Differential) (11) Oil pressure switch (12) Oil filter pressure sensor (Differential)
58
Operation Section
Engine Starting
Engine Starting
i05326009
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Perform the required daily maintenance and other
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more
information.
• Ensure that the engine has an adequate fuel
supply.
• Open the fuel supply valve (if equipped).
• Open the fuel return valve (if equipped)
• Ensure that the sea cock is open if using a
seawater cooling system
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may
have entered the filter housing. Also, when fuel filters
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system. Also, check that the fuel
specification is correct and that the fuel condition is
correct. Refer to the Operation and Maintenance
Manual, “Fluid Recommendations”.
Engine exhaust contains products of combustion
which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust
to the outside.
• Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls.
• Reset all of the shutoffs or alarm components.
• Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.
SEBU8734-09
i03037760
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
Startability will be improved at temperatures below
−18 °C (0 °F) from the use of a jacket water heater or
extra battery capacity.
Disengage any driven equipment.
The control panel will automatically control the cold
starting of the engine.
i05355743
Starting the Engine
SMCS Code: 1000; 1450
Note: If the engine has not been used for 4 months
or more, the first start procedure must be used.
First Start Procedure
This procedure is intended to commence the oil
lubrication process, while rotating the engine at
cranking speed only, and not allowing the engine to
start.
Note: Failure to complete steps 1 through 5 prior to
starting the engine could cause the turbocharger
bearings to fail for lack of lubrication. If the engine
cranks and tries to start during these steps, activate
the E Stop immediately.
1. Turn the battery isolator key switch to the
CONNECTED position to power the ECM.
2. Use Cat Electronic Technician (ET) service tool to
disable all six injectors (this option is found in Cat
ET under the diagnostic test).
3. Start the unit. The unit should run through a full
starting sequence (three crank attempts) the
engine will crank but not start.
4. You will get a fail to start warning on the control
panel, which you must reset before moving to 5.
5. Start the unit. The unit will operate at rated speed.
Do not apply the electrical load to the generator.
Confirm the genset frequency on the control panel.
If the unit ramps beyond rated speed. shut down
the unit.
SEBU8734-09
6. Let the unit run at rated speed without load for 1
minute.
Normal Start Procedure
1. Disengage any equipment that is driven by the
engine power take-off (if equipped).
2. Turn the battery isolator switch to the
CONNECTED position.
3. Press the “RUN/START” switch on the control
panel.
4. Note: Do not overcrank if the engine is equipped
with a water-lock exhaust system.
5. Repeat step 2 through step 5 if the engine fails to
start.
i05379269
Starting with Jump Start
Cables
SMCS Code: 1000; 1401; 1402; 1900
Improper jump start cable connections can cause
an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
An external electrical source may be required to start
the engine if the installation is not equipped with a
backup battery system.
For information on troubleshooting the charging
system, refer to Special Instruction, REHS0354,
“Charging System Troubleshooting”.
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that are
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”.
59
Operation Section
Starting with Jump Start Cables
NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Do not reverse the battery cables. The alternator can
be damaged. Attach ground cable last and remove
first.
When using an external electrical source to start the
engine, turn the generator set control switch to the
“OFF” position. Turn all electrical accessories OFF
before attaching the jump start cables.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
gine being started.
1. Turn the start switch on the stalled engine to the
OFF position. Turn off all the engine accessories.
2. Connect one positive end of the jump-start cable to
the positive cable terminal of the discharged
battery. Connect the other positive end of the
jump-start cable to the negative terminal of the
engine starting motor.
3. Connect one negative end of the jump-start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump-start cable to the negative terminal of the
starting motor. This procedure helps to prevent
potential sparks from igniting the combustible
gases that are produced by some batteries.
4. Start the engine.
5. Immediately after the engine is started, disconnect
the jump-start cables in reverse order.
After jump starting, the alternator may not be able to
fully recharge batteries that are severely discharged.
The batteries must be replaced or charged to the
proper voltage with a battery charger after the engine
is stopped. Many batteries which are considered
unusable are still rechargeable. Refer to Operation
and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery Charger -
Check”.
Refer to the Electrical Schematic for your engine.
Consult your Cat dealer for more information.
60 SEBU8734-09
Operation Section
After Starting Engine

i03037960

After Starting Engine

SMCS Code: 1000

Note: In ambient temperatures from 0 to 60°C

(32 to 140°F), the warm-up time is approximately
three minutes. In temperatures below 0°C (32°F),
additional warm-up time may be required.
When the engine is in operation, observe the
following conditions:
Do not check the high pressure fuel lines with the
engine or the starting motor in operation. If you
inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
• Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.
Note: 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.
SEBU8734-09 61
Operation Section
Engine Operation

Engine Operation • Ensure that the turbocharger is operating correctly

i08483774
Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors in
obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.
The engine to reach normal operating temperature in
less time that is required for a walk-around inspection
of the generator set.
The engine can be operated at the rated load after
the engine is started and after the engine reaches
operating temperature. This procedure is more
effective than idling the engine at no load. The engine
should reach operating temperature in a few minutes.
Operating information displayed on the control panel
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.
so that the proper air/fuel ratio is maintained.
Clean exhaust indicates proper functioning.
• Maintain a good electrical system.
One faulty battery cell will overwork the alternator
and can consume excess power and excess fuel.
• Ensure that the belts are correctly adjusted. The
belts should be in good condition. Refer to the
Specifications manual for further information.
• Ensure that all the connections of the hoses are
tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.
• Cold engines consume excess fuel. Utilize heat
from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators. All
these items will help maintain operating
temperatures.

i07818141

Fuel Conservation Practices

SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. The design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Always ensure that genuine filters
are used. Follow the recommended procedures to
attain optimum performance for the life of the engine.
• Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.
Use only the recommended fuels. Refer to the
Operations and Maintenance Manual, “Fuel
Recommendations” for further information.

• Avoid unnecessary idling.

• Shut off the engine rather than idle for long
periods of time.

• Observe the service indicator frequently. Keep the

air cleaner elements clean.
62 SEBU8734-09
Operation Section
Generator Operation

Generator Operation
i05356044

Generator Operation
SMCS Code: 4450

Loading of the Generator

When a generator is installed or reconnected, be
sure that the total current in one phase does not
exceed the nameplate rating. Each phase should
carry the same load. This allows the engine to work
at the rated capacity. An electrical unbalance can
result in an electrical overload and overheating if one
phase current exceeds the nameplate amperage.
Allowable combinations of unbalanced loads are
shown in Illustration 48 . When you operate with
significant single-phase loads, the combinations of
single-phase load and three-phase load may be
used. Such combinations should be located below
the line on the graph.

Illustration 48 g00627416
Allowable Combinations of Unbalanced Loads

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

• Engine transient response

• Voltage regulator response

• Type of the voltage regulator

• Altitude of operation of the generator set

• Type of load
• The amount of load
SEBU8734-09
If derating is required in order to block load, refer to
ISO 3046 or SAE J1349 Standards. Also, reference
Engine Data Sheet, LEKX4066, “Loading Transient
Response” and Engine Data Sheet, LEKX4067,
“Block and Transient Response”.
Note: ISO stands for International Standards
Organization.
Power Factor
The power factor is the ratio of apparent power to
total power. The power factor is expressed as a
decimal. The power factor represents that portion of
the current which is doing useful work. The portion of
current which is not doing useful work is absorbed in
maintaining the magnetic field in motors or other
devices. This current is called the reactive load. This
current does not require engine power to be
maintained.
In most applications, electric motors and
transformers determine the power factor of the
system. Induction motors usually have a power factor
of 0.8 or less. Incandescent lighting is a resistive load
of about 1.0 power factor, or unity.
The power factor of a system may be determined by
a power factor meter or by calculations. Determine
the power requirement in kW by multiplying the
power factor by the kVA that is supplied to the
system. As the power factor goes up, the total current
that is supplied to a constant power demand will go
down. A 100 kW load that is at 0.8 power factor will
draw more current than a 100 kW load that is at 0.9
power factor. A high-power factor will result in a full
engine load at less than the generator rated
amperage. A lower power factor increases the
possibility of overloading the generator.
63
Operation Section
Single Unit Operation
Note: The Cat generators are rated at a power factor
of 0.8 unless the generator is specified otherwise.
Excitation System
The generator uses the AREP excitation system.
This system does not use a permanent magnet. The
voltage regulator is powered by two auxiliary
windings. These windings are independent of the
circuit for detecting voltage. The first winding is
labeled as “X1” and “X2” . This winding has a voltage
that is proportional to the output voltage of the
generator. The second winding is labeled as “Z1” and
“Z2” . This winding has a voltage that is proportional
to the current of the stator. The voltage from the
power supply is rectified and filtered before being
used by the regulator monitoring transistor. This
principle ensures that regulation is not affected by
interference that is generated by the load.
Standby (Emergency) Electric Sets
Most standby units are installed with controls for
automatic starting. Standby units start without an
operator in attendance.
Standby units cannot automatically change the
governor speed. Standby units cannot automatically
change the setting of the voltage level. The governor
speed and voltage level must be preset for the proper
operation of that unit. Whenever the generator is
operated manually, ensure that the settings for
governor speed and voltage level are correct for
automatic operation. Check all switches on the
electronic module control panel (EMCP Pane)l for the
proper setting. Check all push buttons on the Marine
Classification Society Panel (MCS Panel) for the
proper setting. On the Standard Control Panel, the
Start Select Switch should be in the AUTOMATIC
position. On the Premium Control Panel, the “AUTO”
push button is pressed.
Generator Options
Space Heaters
Most of the generators are provided with space
heaters. These space heaters are installed for
operation in all climates.
i03051927
Single Unit Operation
SMCS Code: 4450
Initial Start-Up
Measure the insulation resistance of each winding if
the generator was exposed to the following
conditions:
64
Operation Section
Parallel Operation
• Rapid changes in temperature
• Freezing
• Wet climate during shipment
• Wet climate during storage
Refer to this Operation and Maintenance Manual,
“Insulation - Test”.
Note: These tests should be conducted prior to any
power connections or control connections that are
being made.
Starting
1. Make all preliminary engine starting checks.
2. Be sure that the main circuit breaker or the line
circuit breaker is open.
3. Start the engine.
4. Close the main circuit breaker.
5. Apply the load. Do not try to apply the full load.
Apply the load in increments in order to maintain
system frequency at a constant level.
6. Readjust the governor for rated frequency.
Adjust the Voltage
Adjust the voltage regulator in order to obtain the
proper voltage. Refer to Operation and
Maintenance Manual, “Voltage Regulators” for
more information about the voltage regulator.
1. Turn the remote adjustment potentiometer to the
center position, if equipped.
2. Connect an analog voltmeter that is calibrated for
100 VDC on terminal E+ and terminal E-.
3. Connect a voltmeter that is calibrated for 300 VAC
to 500 VAC or 1000 VAC to the output terminals of
the generator.
4. Make sure that the ST3 wire is positioned on the
desired frequency. Also, the engine speed must be
changed from the factory setting in order to
change the frequency of the generator.
5. Turn voltage potentiometer (P2) to a full
counterclockwise position.
6. Turn frequency potentiometer (P4) to a full
clockwise position.
7. Turn stability potentiometer (P3) counterclockwise
to about 1/3 of the total rotation for the
potentiometer.
SEBU8734-09
8. Start the engine and set the engine speed to a
frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz.
9. Adjust the output voltage to the correct value with
potentiometer P2. This voltage should be the rated
voltage UN for single operation or UN plus 2% to
4% for parallel operation with a current
transformer. Use potentiometer P3 to make
adjustments if the voltage oscillates. Adjust
potentiometer P3 in both directions while you
observe the voltage between E+ and E-. The
voltage between E+ and E- should be
approximately 10 VDC. The best response times
are obtained at the limit of the instability. Try
cutting or replacing the wire ST2 if no stable
position can be obtained.
10. Check the LAM operation. ST5 must be closed.
11. Turn potentiometer (P4) slowly counterclockwise
until there is a significant voltage drop. The
voltage drop should be approximately 15 %.
12. Vary the frequency around 48 Hz or 58 Hz
according to the operating frequency. Check the
change in the voltage that was previously
observed.
Stopping
1. Remove the load in increments.
2. Open the circuit breaker.
3. Allow the engine to run for five minutes in order to
cool.
4. Stop the engine.
i03840814
Parallel Operation
SMCS Code: 4450
Initial Start-Up
Preparing a generator for parallel operation requires
special attention. Before you attempt to parallel units
for the first time, check all the units for the following
three conditions.
• Same phase rotation
• Same alternating current frequency
• Same voltage adjustment
1. Check the phase rotation.
SEBU8734-09
Units that operate in parallel must have the same
phase rotation. There are two methods that may
be used in order to determine if the incoming unit
and the unit that is on-line have the same phase
rotation. These methods are listed below:
2. Adjust the frequency.
• Using a phase rotation meter
• Using a set of three light bulbs
Use the procedure below to determine the proper
phase rotation by using three light bulbs.
Illustration 49 g00695380
3. Adjust the voltage.The potentiometers should be
When servicing or repairing electric power gen-
eration equipment:
Make sure the unit is off-line (disconnected
from utility and/or other generators power serv-
ice), and either locked out or tagged DO NOT
OPERATE. Remove all fuses.
a. Connect the light bulbs with rated voltage
between the generator leads and the
corresponding line phase. For example,
connect terminal 1 to line 1 across the open
circuit breaker.
b. Start the units that will be in operating in
parallel. Bring the units up to speed. As the
units approach the same speed, the lights will
start to blink.
• If the lights blink in sequence, one of the
units is connected backward. In order to
correct the problem, stop the units. Remove
generator leads 1 and 3 at the circuit
breaker. Exchange these generator leads.
This reverses the direction of phase
rotation. Terminal 2 should always be
connected to line 2. Go to 5.
65
Operation Section
Parallel Operation
• Both generators have the same phase
rotation when the lights blink in unison. The
first condition of “Initial Start-Up” has been
met.
The units that will be operating in parallel must
operate at the same speed. Speed is proportional
to the alternating current frequency.
a. Allow each electric set to run under load for
about 30 minutes.
b. Adjust the governor control in order to give the
rated frequency at full load.
c. Remove the load and check the high idle
speed. The high idle speed should be
approximately 2 to 5 percent above full load
speed for governors that are equipped with
droop. If these speeds cannot be obtained,
contact your Caterpillar dealer.
d. For the most consistent results, repeat 2b and
2c until the second condition of “Initial Start-Up”
has been met.
at the initial settings. Refer to Operation and
Maintenance Manual, “Voltage Regulators”.
Note: Make sure that the speed droop is identical
for all of the engines before adjustments are made
to the generator.
a. Preset the unit for parallel operation by
connecting the current transformer to S1 and
S2 of the connector J2. Set potentiometer P1
for quadrature droop in the center position.
Apply the rated load. The voltage should drop
for 2% to 3%. Switch the positions of the two
incoming secondary wires of the current
transformer if the voltage increases.
b. The no-load voltages should be identical for all
the generators that are operating in parallel.
Connect the generators in parallel. Try to obtain
a 0 kW power exchange by adjusting the speed
of the generator. Try to minimize the circulating
currents between generators by altering the
voltage setting with potentiometer P2 or Rhe on
one of the generators.
Note: Do not change the voltage settings after
this step.
c. Apply the available load. The setting is correct
only if a reactive load is available. Equalize the
Kilowatts or divide the rated power of the units
proportionally by altering the speed. Alter the
66
Operation Section
Parallel Operation
quadrature droop potentiometer (P1) in order to
equalize the currents or divide the currents.
Starting Multiple Units
Use the procedure for starting single units in order to
start multiple units. Refer to Operation Section,
“Single Unit Operation”.
Paralleling Multiple Units
Units may be paralleled at no load. Units may also be
paralleled with units under load. After the initial
conditions for start-up are satisfied, verify for the
following requirements:
• One of the governors can be an isochronous
governor. Electronic load sharing governors are
an exception.
• Generators must have voltage droop
compensation or cross current compensation.
1. Start the unit which will be paralleled.
2. Turn on the synchronizer lights.
3. After the engine has run a few minutes, bring the
engine up to synchronous speed. This means that
the frequency of the incoming unit will be the same
frequency as the unit that is on-line. The
synchronizing lights will begin to blink.
Note: The frequency of the incoming unit should be
slightly greater than the line frequency. This will allow
the incoming unit to assume some of the load instead
of adding to the system load.
4. By using the governor control, adjust the engine
speed until the lights blink very slowly.
5. The lights are off when the voltages of the two
units are in-phase. At this point, very quickly close
the breaker while the lights are out.
6. Use governor controls in order to share kW load
between engines.
SEBU8734-09
7. Generator temperature will be stabilized in
approximately one hour. After the generator
temperature has been stabilized, adjust the
voltage droop rheostat of each generator. This will
share the reactive load and this will limit the
circulating currents. Less droop increases the
reactive current that is carried by the generator.
Adjusting the voltage droop rheostat in a
counterclockwise direction will decrease the
droop. Adjusting the voltage droop rheostat in a
clockwise direction will increase droop.
Load Division and Speed Droop (If
Equipped)
Once two units have been paralleled, the unit's share
of the kW load is determined by the governor control
setting. If two units of the same capacity and the
same governor characteristics have the same
governor control settings, the units will share the load
equally. The total load must not exceed the capacity
of the one engine.
In order to transfer the load from one engine to
another engine, use the following procedure:
1. Increase the governor speed control of one unit in
order to increase the load.
2. Reduce the governor speed control of the other
unit in order to decrease the load on that unit.
3. Raise the governor speed control or lower the
governor speed control of both units in order to
change system frequency.
Parallel Operation Of Governors
Illustration 50 g00630841
Load Sharing Module (Typical Example)
SEBU8734-09
The generator set load sharing module provides
either the droop load sharing or the isochronous load
sharing for parallel applications. The load sharing
module has a synchronizing parallel module SPM-A
input. The module provides the proportional load
sharing. More information is available in the System
Operation, Testing and Adjusting, SENR6565,
“Generator Set Load Sensor and Generator Load
Sharing Module”.
Illustration 51 g00637397
(1) Droop potentiometer
The Speed brick converter changes the analog signal
of the speed potentiometer into a pulse width
modulated signal. The engine electronic control can
recognize this signal. The converter is mounted on
the subpanel which is located within the control
panel.
Function of The Engine Governor
This section describes the function of the engine
governor in relation to load division between parallel
electric sets.
It is very important to understand two basic facts
about load division between generator sets which are
operating in parallel.
1. The power which is supplied to the generator and
to the load is a function of the engine. The setting
of the engine governor and the position of the
engine governor control determine the amount of
power that is delivered by the engine. Therefore,
the governor setting and the position of the
governor control determine the kW load which is
carried by the generator. A change in the engine
power of any one of the units in a parallel
operation will result in the same change in engine
power for each of the other units in that parallel
operation. In other words, the units that are in
parallel operation will stay in parallel operation.
67
Operation Section
Parallel Operation
2. The division of power is not determined by
generator excitation or terminal voltage. The
excitation will determine the power factor for a
generator when the generator is operating in
parallel with other generators.
Governors that are used with Caterpillar powered
electric sets can be of two types:
• Governors with fixed speed droop
• Governors with adjustable speed droop
The values of speed droop which are commonly used
are 3 percent and 0 percent. Governors with
adjustable speed droop can be adjusted so the
characteristics match closely with the characteristics
of governors with fixed speed droop. If the governor
is adjusted for 0 percent speed droop or isochronous
operation, then the same speed from no load to full
load can be obtained.
Summary on Governor Operation
The preceding discussion of governor operation can
be summarized below:
• Each governor should have a three percent speed
droop in order to provide the simplest combination
of governors for electric sets that are connected in
parallel. If a constant frequency from no load to full
load is required, one governor can be adjusted for
isochronous operation. This isochronous unit will
be called a “lead unit” .
• In order for all paralleled units to accept the full
share of the load, the following governor
adjustments are required. The governors should
have the same full load speed. The governors
should have the same high idle speed in the case
of governors which are adjusted for speed droop
operation. Governor controls should be set to the
high idle position so that the full range of the
governor is available.
• Operating an isochronous governor in parallel with
a speed droop governor requires special
techniques.
• Any number of electric sets can be operated in
parallel. However, only one governor of the group
can be adjusted for isochronous operation. The
exception will be some special cases of electronic
governors with automatic load sharing.
Stopping
In order to remove a generator from the line, perform
the following procedure.
1. Check the load. The load must be less than the
rated capacity of the remaining units.
68
Operation Section
Voltage Regulators
2. Be sure that the neutral of one of the remaining
units is grounded.
3. Remove the load from the outgoing unit. See the
Parallel Operation, “Load Division - Speed Droop”.
The amperage may never go to zero due to
circulating currents.
4. Open the circuit breaker.
5. Allow the engine to cool for five minutes.
6. Stop the engine.
Circulating Currents
Understanding the circulating currents becomes very
important when you parallel the units. These
circulating currents are flowing between generators
in parallel operation. The circulating currents are
caused by voltage differences between the
generators. The circulating currents are not doing
useful work. The amount of the circulating current
can be determined by subtracting the amperage
which is going to the load from the total generator
amperage.
The circulating current may be as high as 25 percent
of rated amperes with cold generator sets. Such
current may not even be considered harmful. The
total generator current should not exceed the
amperage rating.
As the generators warm, the circulating currents will
decrease. The ammeter readings should decrease
slightly, but the voltage meter readings should remain
constant.
i08592496
Voltage Regulators
SMCS Code: 4467
DANGER: Shock/Electrocution Hazard-Do not
operate this equipment or work on this
equipment unless you have read and understand
the instructions and warnings in the Operation
and Maintenance Manual. Failure to follow the
instructions or heed the warnings will result in
serious injury or death.
SEBU8734-09
Personal injury or death can result from high
voltage.
When power generation equipment must be in
operation to make tests and/or adjustments, high
voltage and current are present.
Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
rent tests being made.
When servicing or repairing electric power gener-
ation equipment:
• Make sure the unit is off-line (disconnected
from utility and/or other generators power
service) , and either locked out or tagged DO
NOT OPERATE.
• Remove all fuses.
• Make sure the generator engine is stopped.
• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
Failure to do so could result in personal injury or
death. Make sure residual voltage in the rotor,
stator and the generator is discharged.
Accidental engine starting can cause injury or
death to personnel working on the equipment.
To avoid accidental engine starting and to bring
the equipment to a zero energy state, disconnect
all positive (+) and negative (−) battery cables. In-
stall an appropriate battery cable lockout device
and protect the battery posts to prevent acciden-
tal contact and shorting.
Place a Do Not Operate tag at the Start/Stop
switch location to inform personnel that the
equipment is being serviced.
Refer to Project Guide for more information
SEBU8734-09 69
Operation Section
Generator Lead Connections

i06756397

Generator Lead Connections

SMCS Code: 4450

Lead Numbering
The Wye Configurations and the Delta
Configurations are the most common generator lead
connections. The following three-phase connection
diagrams illustrate the proper connection and lead
identification.
The leads are numbered clockwise from the top and
from the outside inward. The diagrams that are
Illustration 53 g06107404
contained in the “Wye Configuration Diagrams, and
Wye Configuration” section show lead numbering for 12 Lead Wye Configuration - Low Voltage
the six lead generators and for the 12 lead Terminals L10, L11, and L12 become neutral
generators. The diagrams contained in the “Delta connection when the terminals are tied together.
Configuration Diagrams, and Delta Configuration”
section show lead numbering for the six lead Delta Configuration Diagrams
generators and for the 12 lead generators.
6 Lead
Wye Configuration Diagrams
12 Lead

Illustration 54 g06107407
6 Lead Delta Configuration
Illustration 52 g06107103
12 Lead Wye Configuration - High Voltage
Terminals L10, L11, and L12 become neutral
connection when the terminals are tied together.
70
Operation Section
Generator Lead Connections
12 Lead
Illustration 55 g06107411
12 Lead Delta Configuration
Terminals L6 and L9 become the neutral connection
when the terminals are tied together and grounded.
This configuration reflects the terminal L2 and L10
connection as the high phase.
Grounding the Frame
In any generator set installation, the frame of the
generator is positively connected to an earth ground.
This connection is the first connection that is made at
the installation. This connection is the last connection
that should be removed. If the generator set is on
flexible pads or on resilient pads, the ground
connection must be flexible. This configuration will
avoid possible breakage in later operation.
Ground connection cable or ground connection
straps should have at least the current carrying
capacity of the largest line lead to the connected
load. Joints in cables or in straps must be clean, free
of electrical resistance, and protected from possible
oxidation. Bolted ground connection joints eventually
oxidize. The joints are frequent sources of radio
frequency interference (RFI). Silver soldered joints
and bolted joints are electrically and mechanically
sound.
Neutral Connections
The generators with Wye Configuration usually have
the neutral grounded when the generator is installed.
However, there are some cases when definite
measures should be taken in order to prevent
grounds on the load side. The purpose of the
grounding of the neutral is to prevent load side
equipment damage.
SEBU8734-09
If the neutral wire is grounded and one of the phase
leads becomes grounded, the excessive current will
open a load circuit breaker. The excessive current
will also collapse the generator voltage. The result
depends on the following items: particular generator
electrical characteristics, type of fault and trip rating
of the circuit breaker. An undervoltage device may be
required in order to provide an adequate short circuit
protection.
There are some instances in which grounding the
neutral wire is undesirable. In other applications,
having an ungrounded neutral lead is acceptable.
Definite measures should be taken in such
applications in order to prevent grounds to the phase
leads. An example of such measures is ground fault
protective circuits. Ground fault protection requires
that the entire group of distribution circuits should be
studied. The entire group of distribution circuits
should be treated as a system. The owner should
engage a certified, registered consultant if a new
distribution system is being developed. The owner
should also engage a certified, registered consultant
if an existing system should be modified for the
ground fault protection.
Single Units
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
In applications in which definite measures are taken
in order to prevent grounds to the load leads, an
ungrounded neutral can be used. Be sure to check
your local wiring codes.
Multiple Units
Operation of multiple generators in parallel that have
all neutrals grounded, may result in the circulating
current through the neutral connections. In order to
eliminate the possibility of circulating currents,
ground the neutral of only one generator. If multiple
generators are alternated on line, a switch should be
installed in the neutral ground circuit of each
generator. In this case, all neutral ground circuits
except one circuit can be opened. Be sure that one of
the neutral ground circuits is closed.
Parallel to Utility
When a Wye connected generator is going to operate
in parallel with a utility system (infinite bus) and the
secondary of the step-down transformer in the utility
system is also a Wye connection, the following may
happen. The grounding of both Wye neutrals may
result in circulating currents through the neutrals.
Also, the coordination of ground fault protection
requires an entire system study. This study should be
done by a certified, registered consultant who is
familiar with generator systems. The study will
determine which grounding method should be used.
SEBU8734-09 71
Operation Section
Engine Stopping

Engine Stopping The emergency stop button is in the OUT position for
normal engine operation. Push the emergency stop
button. The engine will not start when the button is
i08488057 locked. Turn the button clockwise in order to reset.

Emergency Stopping i08257497

SMCS Code: 1000; 7418

NOTICE
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices
or controls for normal stopping procedure.
Ensure that any components for the external system
that support the engine operation are secured after
the engine is stopped.
NOTICE
Do not start the engine until the problem necessitat-
ing the emergency stop has been located and
corrected.
Manual Stop Procedure
SMCS Code: 1000; 7418
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
fore stopping the engine.
Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.

Emergency Stop Button Note: Individual applications have different control

systems. Ensure that the shutoff procedures are
understood. Use the following general guidelines to
stop the engine.

1. Remove the load from the engine so that the

engine has no more than 30% power.
2. Run the engine at the programmed low idle speed
for at least 3 minutes.
3. After the cool down period, turn the start switch to
the OFF position.

i08422542

After Stopping Engine

Illustration 56 g00104303
Typical emergency stop button SMCS Code: 1000

Note: After operation, allow 10 minutes for the

engine oil to return to the oil pan before checking the
engine oil level.
• Check the crankcase oil level. Maintain the oil
level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
Note: Only use oil that is recommended in this
Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.

• If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.
72 SEBU8734-09
Operation Section
After Stopping Engine

• Note the service hour meter reading. Perform the

maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
• Fill the fuel tank to prevent accumulation of
moisture in the fuel. Do not overfill the fuel tank.

• Allow the engine to cool. Check the coolant level.

Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.
Note: Only use coolant that is recommended in this
Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.
• If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
SEBU8734-09 73
Maintenance Section
Refill Capacities

Maintenance Section Diesel Engine Oil

Cat Diesel Engine Oil (Cat DEO)
Refill Capacities Cat oils have been developed and tested to provide
the full performance and service life that has been
i06043621 designed and built into Cat engines. Cat oils are
currently used to fill Cat Diesel Engines at the factory.
Refill Capacities These oils are offered by Cat dealers for continued
use when the engine oil is changed. Consult your Cat
SMCS Code: 1000; 1348; 1395; 7560 dealer for more information on these oils.
For information on the fluid recommendation refer Due to significant variations in the quality and in the
this Operation and Maintenance Manual, “Fluid performance of commercially available oils,
Recommendations”. Caterpillar makes the following recommendations:

Lubrication System Note: Cat DEO-ULS multigrade oils are the preferred
oils for use in this Cat Diesel Engine.
Table 5
Table 8
Engine oil
Commercial Viscosity Grade
Cat Lubricants
Liters 17.5 Lubricants

US gal 4.6 SAE 15W-40

Cat DEO - ULS
Diesel Engine Oil-Ul- SAE 10W-30
The engines that have duplex oil filters installed will tra Low Sulfur (API Cat DEO - ULS SYN SAE 5W-40
require additional oil. CJ-4)(1)
Cat DEO Cold
SAE 0W-40
Weather
Cooling System
Diesel Engine Oil SAE 15W-40
Table 6 (API CI-4/CI-4 PLUS Cat DEO
and API CH-4) SAE 10W-30
Sea Water Cooled Engine
(1) ACEA E9 oils are validated using some but not all API CJ-4
Liters 38 standard performance tests. ACEA E9 oils may be used if oil
meeting the API CJ-4 specifications is not available.
US gal 10
Caterpillar recommends the use of Cat DEO-ULS for
Table 7 engines that use ultra-low sulfur diesel fuel (ULSD
Radiator Cooled Engine fuel) or sulfur-free diesel fuel. Cat DEO-ULS has the
proper amount of lubricity for engines using ULSD.
Liters 40 The use of engine oil that meets Cat Engine
Crankcase Fluid specifications (Cat ECF-3)
US gal 10.5
specifications is acceptable. Refer to this article
“Commercial Oil” for more information.
i08592618
Engines which are Certified to US Marine
Environmental Protection Agency (EPA) Tier 3
Fluid Recommendations Regulations
SMCS Code: 1280; 1348; 1395; 7560
For further information about the correct fluids for the NOTICE
engine, refer to Special Publication, SEBU6251, “Cat An engine certified to US Environmental Protection
Commercial Diesel Engine Fluids Agency (US EPA) Marine Tier 3 regulations which is
Recommendations”. installed in a US flagged vessel must use ultra-low
sulfur diesel fuel (ULSD fuel) as defined by 40 CFR
part 80.510 (c). When an engine is not installed in a
US flagged vessel, refer to applicable local or Inter-
national Maritime Organization (IMO) regulations for
fuel requirements.
74 SEBU8734-09
Maintenance Section
Fluid Recommendations

Caterpillar recommends the use of Cat DEO-ULS for

engines that use ultra-low sulfur diesel fuel (ULSD
fuel) or sulfur-free diesel fuel. Cat DEO-ULS has the
proper amount of lubricity for engines using ULSD.
The use of engine oil that meets Cat Engine
Crankcase Fluid specifications (Cat ECF-3)
specifications is acceptable. Refer to this article
“Commercial Oil” for more information.

Engines which are Not Certified to US Marine EPA

Tier 3 Regulations

Cat DEO is recommended for engines using fuels of

sulfur levels that exceed 0.2 percent (> 2000 ppm
(mg/kg) ). Cat DEO-ULS may be used in these
applications if an oil analysis program is followed.
The oil change interval may be affected by the fuel
sulfur level. Refer to this Operation and Maintenance
Manual, “Engine Oil Sample - Obtain” for more
information about the Cat S·O·S Oil Sampling
program.

Commercial Oil
Note: Non-Cat commercial oils are, as a group,
second choice oils. Within this grouping of second
choice oils there are tiered levels of performance.

NOTICE
Caterpillar does not warrant the quality or perform-
ance of non-Cat fluids.
The three current Caterpillar ECF specifications are:
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each
higher Cat ECF specification provides increased
performance over lower Cat ECF specifications.
If a Cat oil is not used, an oil meeting the Cat ECF-3
performance requirement is preferred.
Table 9
Cat Engine Crankcase Fluids (ECF) Definitions

Cat Performance Requirement API Oil Category

Cat ECF-3 API CJ-4 Oil Category performance requirements

API CI-4/CI4 PLUS Oil Category and

Cat ECF-2 Passing standard Cat C13 engine test per API requirements and
Oils of sulfated ash > 1.50% are not allowed.

API CH-4 Oil Category performance requirements and

For oils that are between 1.3 % and 1.5 % sulfated ash, passing one additional Cat 1P SCOTE test
Cat ECF-1-a
(ASTM D6681) is required and
Oils of sulfated ash > 1.50 % are not allowed.

Lubricant Viscosity The proper SAE viscosity grade of oil is determined

In selecting oil for any engine application, both of the
following must be satisfied: the oil viscosity and the
category of oil performance or the specification for oil
performance . Using only one of these parameters
will not sufficiently define oil for an engine
application.
by the following temperatures: minimum ambient
temperature during cold engine start-up and
maximum ambient temperature during engine
operation.
Refer to Table 10 (minimum temperature) to
determine the required oil viscosity for starting a cold
engine.
SEBU8734-09 75
Maintenance Section
Fluid Recommendations

Refer to Table 10 (maximum temperature) to select Table 11

the oil viscosity for engine operation at the highest
TBN recommendations for applications in Cat engines
ambient temperature that is anticipated.
Fuel Sulfur Level per- TBN of Commercial
Note: Generally, use the highest oil viscosity that is Cat Engine Oils (1)
cent (ppm) Engine Oils
available to meet the requirement for the temperature
at start-up. 0.05 % (500ppm) or Cat DEO-ULS
Min 7
less Cat DEO
Table 10
0.05 - 0.2 % (>500 - Cat DEO
Min 10
Lubricant Viscosities for Ambient Temperatures for 2000 ppm(2) Cat DEO-ULS
Cat Diesel Engines (1) Cat DEO-ULS applies to Cat DEO-ULS SAE 15W-40,
°C °F SAE10W-30, Cat DEO-ULS SYN SAE 5W-40, and Cat DEO
Oil Type and Per- Cold-Weather SAE 0W-40.
Viscosity
formance (2) The use of an oil analysis program to determine oil drain inter-
Grade Min Max Min Max
Requirements vals is recommended.

Cat Cold-Weather
DEO-ULS
SAE 0W-40 −40 40 −40 104 S·O·S Services Oil Analysis
Cat DEO-ULS SYN SAE 5W-40 −30 50 −22 122 Caterpillar has developed a maintenance tool that
evaluates oil degradation. the maintenance
Cat DEO-ULS SAE 10W-30 −18 40 0 104
management also detects the early signs of wear on
Cat DEO SAE 15W-40 −10 50 14 122 internal components. The Cat tool for oil analysis is
called S·O·S oil analysis and the tool is part of the
SAE 0W-30 −40 30 −40 86 S·O·S Services program. S·O·S oil analysis divides
Cat ECF-1-a, Cat
SAE 5W-30 −30 30 −22 86 oil analysis into four categories:
ECF-2, Cat ECF-3
SAE 10W-40 −18 50 0 122 • Component wear rate

Note: A cold soaked start occurs when the engine
has not been operated recently, allowing the oil to
become more viscous due to cooler ambient
temperatures. Supplemental heat is recommended
for cold soaked starts below the minimum ambient
temperature. Supplemental heat may be necessary
for cold soaked starts that are above the minimum
temperature depending on factors such as parasitic
load.
Total Base Number (TBN) and Fuel Sulfur
Levels
The use of Cat S·O·S Services oil analysis is
recommended strongly for determining oil life.
The minimum required Total Base Number (TBN) for
oil depends on the fuel sulfur level. The TBN for new
oil is typically determined by the “ASTM D2896”
procedure. For direct injection engines that use
distillate fuel, the following guidelines apply:
• Oil condition
• Oil contamination
• Identification of oil
These four types of analysis are used to monitor the
condition of your equipment. The four types of
analysis will also help you identify potential problems.
A properly administered S·O·S oil analysis program
will reduce repair costs and the program will lessen
the impact of downtime.
The S·O·S Oil Analysis program uses a wide range
of tests to determine the condition of the oil and the
crankcase. Guidelines that are based on experience
and a correlation to failures have been established
for these tests. Exceeding one or more of these
guidelines could indicate serious fluid degradation or
a pending component failure. A trained person at
your Cat dealership should make the final analysis.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
76
Maintenance Section
Fluid Recommendations
Refer to Special Publication, SEBU6251, “Cat
Commercial Diesel Engine Fluids
Recommendations” to obtain additional information
about S·O·S Services oil analysis. You can also
contact your local Cat dealer.
Fuel
NOTICE
An engine certified to US Environmental Protection
Agency (US EPA) Marine Tier 3 regulations which is
installed in a US flagged vessel must use ultra-low
sulfur diesel fuel (ULSD fuel) as defined by 40 CFR
part 80.510 (c). When an engine is not installed in a
US flagged vessel, refer to applicable local or Inter-
national Maritime Organization (IMO) regulations for
fuel requirements.
NOTICE
An engine certified to EU 2017/654 which is installed
in a vessel operating within EU inland waterways
must use diesel fuel meeting standards EN590 or
EN16709.
NOTICE
In order to meet expected fuel system component life,
4 micron (c) absolute or less secondary fuel filtration
is required for all Cat Diesel Engines that are
equipped with unit injected fuel systems. All current
Cat Diesel Engines are factory equipped with Cat Ad-
vanced Efficiency 4 micron(c) absolute fuel filters.
Caterpillar does not warrant the quality or perform-
ance of non-Cat fluids and filters.
Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death
or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling
standards for proper grounding and bonding
practices.
SEBU8734-09
Specifications for Distillate Diesel Fuel
Diesel fuel must meet the standards required for the
engine emissions certification. Refer to table 13 for
the fuel specifications required for each certification.
Ensure the diesel fuel used when an applicable
emissions standard is in-force meets the
specifications detailed within this table. Table 12 lists
the key fuel specifications of each distillate diesel fuel
standard. Refer to this table to ensure that the correct
fuel standard is selected for compliant engine
operation. Failure to ensure that the engine is
operating on the correct fuel can render the exhaust
emissions to be non-compliant. Practically this table
means that engines operating in European Inland-
Waterways should use diesel fuel meeting either “EN
590” or “EN16709” standards. Engines installed in
US flagged vessels require ULSD diesel fuel meeting
the “ASTM D975” fuel to be used. In most other
cases the engine can use Marine Distillate Diesel
Fuels as listed in table 12 to the ISO 8217 standard if
so required. In all cases refer to applicable local or
International Maritime Organization (IMO) regulations
for fuel requirements. Lubricity (as tested to standard
ISO 12156-1) should not exceed 520am for any fuel
used. For additional information on diesel fuels. Refer
to Special Publication, SEBU6251, “Cat Commercial
Diesel Engine Fluids Recommendations.” This
manual can be found on the web at Safety.Cat.com.
Engines which are not Certified to US Marine EPA
Tier 3 Regulations
Note: Vessels that are traveling internationally and
that have on/off NOx controls must enable these
controls prior to entering a NECA. For US flagged
vessels, on/off controls are not allowed without an
exemption during international travel. The controls
must always be on. Foreign destinations should be
reviewed for supply of ULSD fuel and DEF prior to
departure. Exemptions for ULSD or DEF use by US
flagged vessels may be requested from the US
Environmental Protection Agency (EPA). The EPA
can be contacted at the following address:
complianceinfo@epa.gov
Physical address:
Designated Compliance Officer
Heavy-Duty and Nonroad Engine Group 6403-J
U.S. AVE. NW
Washington, DC 20460
Biodiesel
A blend of up to 20 percent may be used when it
meets the recommendations in table and meets the
recommendations in Special Publication, SEBU6251,
“Biodiesel”. A blend of greater than 20 percent
biodiesel may be acceptable sometimes. See your
Cat dealer for more information.
SEBU8734-09 77
Maintenance Section
Fluid Recommendations

Note: A complete Cat S·O·S Services oil analysis

program is recommended strongly when using
biodiesel blends above 5 percent.

Fuel Additives
Many types of fuel additives are available. Caterpillar
does not generally recommend the use of fuel
additives. For more information contact your Cat
dealer.
Table 12
Fuel Specifications by Fuel Standard

Fuel Specification Fuel Standard

ASTM D975 EN590 ISO 8217:2018 DMX ISO 8217:2018 DMA ISO 8217:2018 DFA
Cetane Number 40 51 45 40 40
Minimum
Sulphur 15 ppm 10 ppm 10,000 ppm (1%) The purchaser shall define the maximum sulphur
Maximum limit in accordance with relevant statutory regulations (Refer to ISO
8217:2018 for further information)

FAME 0% 7% 0% 7%
Maximum
Lubricity 520um 460um 520um 520um
Maximum Wear
Scar ISO 12156-1

Fuel Specification Requirements by

Emissions Certification
Table 13
Emissions Certification Cetane Number Sulphur FAME Maximum
Minimum Maximum
US EPA Tier 3 40 15 ppm 7%

EU Stage VEU 2017/654 45 10 ppm 7%

IMO II 40 1000 ppm 20%

Cooling System NOTICE

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

The cooling system operates under pressure

which is controlled by the pressure cap. Remov-
ing the cap while the system is hot may allow the
escape of hot coolant and steam, causing serious
burns.
Before you remove the pressure cap, allow the
system to cool. Use a thick cloth and turn the
pressure cap slowly to the first stop to allow
pressure to escape before fully removing the cap.
Avoid contact with coolant.
NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem-
perature or drained completely in order to prevent
damage caused by freezing coolant.
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system
problems can develop without water temperature
regulators.
78 SEBU8734-09
Maintenance Section
Fluid Recommendations

Coolant Recommendations
Note: Water alone or water mixed with supplemental
coolant additive (SCA) are not approved coolants.
Keel cooling or skin cooling is a closed circuit method
of cooling both the engine and charge air. To provide
engine protection an antifreeze mixture must be used
for both the engine and charge air cooling circuits.
• A 20 percent glycol mix will give protection to
−7° C (19.4° F)

• A 50 percent glycol mix will give protection to

−37° C (−34.6° F)
The glycol mixtures are recommended by Caterpillar,
not flowing these recommendations can damage
components internal.
Table 14
Coolant Recommendations for use in Cat Diesel Engines(1)
Service Hours(2)(3) Required
Recommendations Product (4) Maintenance

Add Cat ELC Extender

12000 hours or 6 at 6000 service hours
Preferred Cat ELC (Cat Extended Life Coolant)
years or one half of service
life
Cat EC-1 specification and “ASTM D6210” and
Organic Additive Technology (OAT) based on a combination of a
monocarboxylic acid and a dicarboxylic acid Add Extender at 3000
6000 hours or 6
Min requirements Phosphate, borate, and silicate free service hours or one
years
Tolyltriazole: minimum typical concentration of 900 ppm (mg/kg) half of service life
Nitrite: minimum typical concentration of 500 ppm (mg/kg) in new
coolants
SCA (Supplemental
3000 hours or 3
Acceptable Cat DEAC (Cat Diesel Engine Antifreeze/Coolant) coolant additive) at
years
maintenance intervals
“ASTM D6210” and
Min requirements for fully Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/
3000 hours or 2 SCA at maintenance
formulated Heavy-Duty US gal) and maximum of 2400 ppm (140 grains/US gal)
years intervals
Commercial coolants Silicon concentration: minimum of 100 ppm (mg/kg) and maximum
of 275 ppm (mg/kg)

“ASTM D4985” and(1)

Min requirements for Com- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/ SCA at initial fill and
3000 hours or 1
mercial coolants requiring US gal) and maximum of 2400 ppm (140 grains/US gal) SCA at maintenance
year
SCA precharge Silicon concentration: minimum of 100 ppm (mg/kg) and maximum intervals
of 275 ppm (mg/kg)
(1) The minimum acceptable coolant concentration is 20% glycol-based coolant by volume in clean water.
(2) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets
Reagent 4 “ASTM D1193” requirements.
(3) Maintain the in-service coolant at the given limits.
(4) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.
SEBU8734-09 79
Maintenance Section
Fluid Recommendations

(Table 16, contd)

NOTICE
Use Only Approved SCAs and Extenders Cat DEAC
Conventional Heavy- Every 250 hours Yearly(1)
Conventional coolants require the maintenance addi- Duty Coolants
tion of SCA throughout the expected life of the cool-
ants. Do NOT use an SCA with a coolant unless Cat ELC
approved specifically by the coolant supplier. The Commercial EC-1 Optional Yearly(1)
coolant manufacturer is responsible for ensuring Coolants
compatibility and acceptable performance. (1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- Note: Check the SCA (Supplemental Coolant
tender at coolant service mid-life. Do not use an ex- Additive) of the conventional coolant at every oil
tender with a coolant unless the extender has been
approved specifically for use by the coolant manufac- change or at every 250 hours. Perform this check at
turer. The coolant manufacturer is responsible for en- the interval that occurs first.
suring compatibility and acceptable performance.
S·O·S Services Coolant Analysis (Level 1)
Failure to follow these recommendations can result in
shortened cooling system component life. A coolant analysis (Level 1) is a test of the properties
of the coolant.
Cat ELC can be recycled into conventional coolants. The following properties of the coolant are tested:

Freeze Protection for Coolant • Glycol concentration for freeze protection and boil
protection
Concentrations
• Ability to protect from erosion and corrosion
Table 15
Freeze Protection for Antifreeze Concentrations(1) • pH
Protection to: Concentration • Conductivity
30% glycol
−15 °C (5 °F) • Visual analysis
70% water

−24 °C (−12 °F)

40% glycol • Odor analysis
60% water
The results are reported, and appropriate
50% glycol
−37 °C (−34 °F) recommendations are made.
50% water

60% glycol S·O·S Services Coolant Analysis (Level 2)

−52 °C (−62 °F)
40% water
(1) Ethylene glycol-based antifreeze.
A coolant analysis (Level 2) is a comprehensive
chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the cooling
S·O·S Services Coolant Analysis system.

Testing the engine coolant is important to ensure that The S·O·S coolant analysis (Level 2) has the
the engine is protected from internal cavitation and following features:
corrosion. The analysis also tests the ability of the
coolant to protect the engine from boiling and • Full coolant analysis (Level 1)
freezing. S·O·S coolant analysis can be done at your
Cat dealer. Cat S·O·S coolant analysis is the best • Identification of metal corrosion and of
way to monitor the condition of your coolant and your contaminants
cooling system. S·O·S coolant analysis is a program
that is based on periodic samples. • Identification of buildup of the impurities that
cause corrosion
Table 16

Recommended Interval • Identification of buildup of the impurities that

cause scaling
Type of Level 1 Level 2 • Determination of the possibility of electrolysis
Coolant within the cooling system of the engine
The results are reported, and appropriate
(continued) recommendations are made.
80 SEBU8734-09
Maintenance Section
Fluid Recommendations

For more information on S·O·S coolant analysis,

consult your Cat dealer.

Lubricating Grease
Before selecting a grease products for any
application, the performance requirements must be
determined. Consult the grease recommendations
that are made by the OEM for the equipment when
the equipment is operated in the expected
conditions. Then, consult with your Cat dealer for a
list of greases and the following related
characteristics.

• Performance specifications
• Available sizes of containers

• Part numbers
Some greases are not chemically compatible.
Consult your supplier to determine if two or more
greases are compatible.
Purge the grease from a joint at the following times:

• Switching from one grease to another grease

• Switching from one supplier to another supplier

Note: All Cat brand name greases are compatible

with each other.

Note: Refer to Special Publication, SEBU6251,

“Caterpillar Commercial Diesel Engine Fluids
Recommendations” for additional information that
relates to lubrication for your engine.
SEBU8734-09
Maintenance
Recommendations
i08259062
General Maintenance
Information
SMCS Code: 4450; 7000
Note: Read the warnings and read the instructions
that are contained in the Safety Section of this
manual. These warnings and instructions must be
understood before you perform any operation or any
maintenance procedures.
Rotating electric machines are complex structures
that are exposed to the following forms of stress:
• mechanical
• electrical
• thermal
• environmental
These stresses may be of varying magnitudes. The
electrical insulation systems are susceptible to
damage that is caused by the stresses that are listed
above. Exposure to these stresses may shorten the
effective life of the electrical insulation system.
Therefore, the service life of an electric machine will
largely depend on the serviceability of the electrical
insulation systems. An inspection program and a
testing procedure are recommended. An inspection
program and a testing procedure will ensure that the
equipment is maintained in satisfactory condition.
Maintaining the equipment will increase field
reliability.
A regular maintenance and inspection program can
provide an evaluation of the present condition of the
equipment. A regular maintenance program and a
regular inspection program can also reveal future
problems. The frequency of this maintenance
program will depend on the following factors:
• application
• environmental conditions
• experience level of the operator
• philosophy of the operator
A regular maintenance program is recommended.
This program would involve the following steps:
• periodic disassembly
• knowledgeable visual examination of the
equipment
81
Maintenance Section
Maintenance Recommendations
• the application of electrical tests
Never perform a test over the rated potential. These
tests can damage insulation that is contaminated or
insulation that is in marginal condition. For more
information, refer to “I.E.E.E. Standard 432-1992” or
consult a Cat dealer.
i06043719
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050
Coolant System
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
The engine is equipped with an auto start function.
Ensure that the power supply is isolated before any
service or repair is performed.
To relieve the pressure from the coolant system, turn
off the engine. Allow the cooling system pressure cap
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure.
Fuel System
To relieve the pressure from the fuel system, turn off
the engine.
High Pressure Fuel Lines
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
The high-pressure fuel lines are the fuel lines that are
between the high-pressure fuel pump and the high-
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
systems because.
• The high-pressure fuel lines are constantly
charged with high pressure.
• The internal pressures of the high-pressure fuel
lines are higher than other types of fuel system.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks:
82
Maintenance Section
Welding on Engines with Electronic Controls
1. Stop the engine.
2. Wait for 10 minutes.
Do not loosen the high-pressure fuel lines in order to
remove air from the fuel system. The pressure in the
high-pressure fuel lines will self purge to a level that
is safe without loosening the high-pressure fuel lines.
Engine Oil
To relieve pressure from the lubricating system, turn
off the engine.
i05356603
Welding on Engines with
Electronic Controls
SMCS Code: 1000
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Cat dealer regarding welding on a chas-
sis frame or rail.
Proper welding procedures are necessary in order to
avoid damage to the engine ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
possible, the following procedure must be followed
when you weld on a unit that is equipped with a Cat
Electronic Engine. The following procedure is
considered to be the safest procedure to weld on a
component. This procedure should provide a
minimum risk of damage to electronic components.
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
can cause damage to the drive train, the bearings,
hydraulic components, electrical components, and
other components.
Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
to the bearings, the crankshaft, the rotor shaft, and
other components.
Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.
Note: Perform the welding in areas that are free from
explosive hazards.
1. Stop the engine. Turn the switched power to the
OFF position.
SEBU8734-09
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
3. Disconnect the J1/P1 and J2/P2 connectors from
the ECM. Move the harness to a position that will
not allow the harness to move back accidentally,
and contact any of the ECM pins.
Illustration 57 g03392720
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
(2) Welding electrode
(3) Battery disconnect switch in the open position
(4) Disconnected battery cables
(5) Battery
(6) Electrical/Electronic component
(7) Minimum distance between the component that is being
welded and any electrical/electronic component
(8) The component that is being welded
(9) Current path of the welder
(10) Ground clamp for the welder
4. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.
Note: If electrical/electronic components are used as
a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
5. Protect the wiring harness from welding debris and
spatter.
SEBU8734-09 83
Maintenance Section
Generator Start-up Checklist

6. Use standard welding practices to weld the

materials.

i03860683

Generator Start-up Checklist

SMCS Code: 4450

Table 17
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________ Arrangement Number: ___________________

Generator Serial Number: _________________________________ Arrangement Number: ___________________

GENERATOR NAME PLATE INFORMATION

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

Amperage: _________________ Kilowatts: ________________________________________

Storage Location:

Main Stator Megohmmeter Reading: Before Storage: After Storage:

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

SPACE HEATERS Yes No Comments

Space heaters operating properly?

Space heater operated 48 hours before startup?

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

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

Table 18
GENERATOR START-UP CHECKLIST (CONT.)

Regulator Voltage Amps Comments

F1 to F2 DC
No Load All Frames
E1 to E2 AC

(continued)
84 SEBU8734-09
Maintenance Section
Generator Start-up Checklist

(Table 18, contd)

E1 to E3 AC
E2 to E3 AC
2400, 2500, PM1 to PM4 AC
2800, and 2900
Frames
PM1 to PM2 AC
2600 Frame PM1 to PM3 AC
PM2 to PM3 AC

Generator Excitation DC Compare with F1 to F2

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

Table 19
GENERATOR START-UP CHECKLIST (CONT.)

ELECTRICAL Yes No Comments

Unit properly grounded

Check diodes
Over current protection

Over voltage protection

Check for loose wiring

Adjust voltage

Adjust frequency

Table 20
GENERATOR START-UP CHECKLIST (CONT.)

MECHANICAL Data Comments

Bearing temperature readings at full load Front __________ Rear ___________

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

Air gap on main stator Top __________ Bottom __________

Air gap on exciter stator Top __________ Bottom __________

Air gap of PMG Top __________ Bottom __________

(continued)
SEBU8734-09 85
Maintenance Section
Severe Service Application

(Table 20, contd)

Ambient air to generator at full load Temperature ____________________

Supplier air opening to generator Size of Opening _________________

SWITCH GEAR/PARALLEL OPERATION

Manufacturer:
Setting 1 Setting 2 Setting 3 Comments

Type of Circuit breaker

Overload setting

Reverse power relay

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

Enclosure type - Size

Motor: Other loads:

- Total SKVA - Lighting

- Total HP - Computers

- Welding

- Non-linear
- Other

FULL LOAD DATA

Voltage Amps KW KVARS P.F.

i05070849 An application is a severe service application if any of

the following conditions apply:
Severe Service Application
SMCS Code: 1000 Severe Environmental Factors
An engine which operates outside of normal • Polluted water or water which is shallow or water
conditions is operating in a severe service that is dirty.
application.
• Frequent operation in dirty air
An engine that operates in a severe service
application may need more frequent maintenance • Frequent operation at an altitude which is above
intervals in order to maximize the following 1000 m (3280 ft)
conditions:
• Frequent operation in ambient temperatures which
• Reliability are above 50° C (122° F)
• Service life • Frequent operation in ambient temperatures which
are below 0° C (32° F)
The number of individual applications cause the
impossibility of identifying all of the factors which may
contribute to severe service operation. Consult your Severe Operating Conditions
Cat dealer for the unique maintenance that may be
necessary for your engine. • Frequent operation with inlet air which has a
corrosive content
86 SEBU8734-09
Maintenance Section
Severe Service Application

• Operation with inlet air which has a combustible

content

• Operation which is outside of the intended

application
• Operation with a plugged fuel filter

• Frequent dry starts (starting after more than 72

hours of shutdown)

• Frequent hot shutdowns (shutting down the

engine without the minimum of 2 minutes to 5
minutes of cool down time)

• Operating with fuel which does not meet the

standards for distillate diesel fuel as stated in
Special Publication, SEBU6251, “Cat Commercial
Diesel Engine Fluids Recommendations”
“Distillate Diesel Fuel”
• Operating with a blend of distillate fuel which
contains more than 20 percent biodiesel

Improper Maintenance Procedures

(Maintenance Procedures Which
May Contribute to a Severe Service
Application)
• Inadequate maintenance of fuel storage tanks
from causes such as excessive water, sediment,
and microorganism growth.
• Extending maintenance intervals beyond the
recommended intervals

• Using fluids which are not recommended in

Special Publication, SEBU6251, “Cat Commercial
Diesel Engine Fluids Recommendations”

• Extending maintenance intervals for changing the

engine oil and engine coolant without S·O·S
validation
• Extending maintenance intervals for changing air
filters, oil filters, and fuel filters

• Failure to use a water separator

• Failure to install a sea water strainer and failure to
perform frequent inspection.
• Using filters which are not recommended by
Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”
SEBU8734-09
i08749196
Maintenance Interval Schedule
SMCS Code: 1000; 4450; 7500
Ensure that all safety information, warnings, and
instructions are read and understood before any
operation or any maintenance procedures are
performed. The user is responsible for the
performance of maintenance, including all
adjustments, the use of proper lubricants, fluids, and
filters. The user is also responsible for the
replacement of components due to normal wear and
aging. Failure to adhere to proper maintenance
intervals and procedures may result in diminished
performance of the product and/or accelerated wear
of components. Use fuel consumption, service hours,
or calendar time, WHICH EVER OCCURS FIRST, to
determine the maintenance intervals. Products that
operate in severe operating conditions may require
more frequent maintenance. Before each
consecutive interval is performed, all maintenance
from the previous interval must be performed.
When Required
“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 93
“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 94
“ Coolant - Change“ . . . . . . . . . . . . . . . . . . . . . . . . . 96
“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . 103
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . 114
“ Generator - Dry“. . . . . . . . . . . . . . . . . . . . . . . . . . 122
“ Generator Load - Check“. . . . . . . . . . . . . . . . . . . 125
“ Generator Set - Test“ . . . . . . . . . . . . . . . . . . . . . . 126
“ Generator Winding Insulation - Test“ . . . . . . . . . 127
“ Rotating Rectifier - Check“ . . . . . . . . . . . . . . . . . 135
“ Rotating Rectifier - Inspect/Test“. . . . . . . . . . . . . 135
“ Sea Water Strainer - Clean/Inspect“. . . . . . . . . . 136
“ Standby Generator Set Maintenance
Recommendations“ . . . . . . . . . . . . . . . . . . . . . . . . 137
Daily
“ Coolant Level - Check“ . . . . . . . . . . . . . . . . . . . . . 99
“ Electrical Connections - Check“ . . . . . . . . . . . . . 103
“ Engine Air Cleaner Service Indicator -
Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . 106
“ Fuel System Primary Filter/Water Separator -
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
87
Maintenance Section
Maintenance Interval Schedule
“ Fuel Tank Water and Sediment - Drain“ . . . . . . . 121
“ Generator - Inspect“. . . . . . . . . . . . . . . . . . . . . . . 124
“ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . 138
Every Week
“ Automatic Start/Stop - Inspect“ . . . . . . . . . . . . . . . 93
“ Control Panel - Inspect/Test“. . . . . . . . . . . . . . . . . 96
“ Generator Bearing Temperature - Test/
Record“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
“ Hoses and Clamps - Inspect/Replace“. . . . . . . . 131
“ Jacket Water Heater - Check“. . . . . . . . . . . . . . . 132
Every 250 Service Hours
“ Coolant Sample (Level 1) - Obtain“ . . . . . . . . . . . 99
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . 107
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)
“ Coolant Sample (Level 2) - Obtain“ . . . . . . . . . . 100
Every 500 Service Hours
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . 107
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . 110
“ Fuel System Primary Filter (Water Separator)
Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . 114
“ Fuel System Secondary Filter - Replace“. . . . . . 118
Every 500 Service Hours or 1 Year
“ Auxiliary Water Pump (Rubber Impeller) - Inspect/
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
“ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 94
“ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . 101
“ Engine Air Cleaner Element (Single Element) -
Inspect/Clean/Replace“ . . . . . . . . . . . . . . . . . . . . . 103
“ Radiator - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . 134
“ Sea Water Strainer - Clean/Inspect“. . . . . . . . . . 136
Every 1000 Service Hours
“ Aftercooler Condensate Drain Valve - Inspect/
Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
88 SEBU8734-09
Maintenance Section
Maintenance Interval Schedule

“ Aftercooler Core - Inspect“ . . . . . . . . . . . . . . . . . . 91

“ Belt Tensioner - Check“ . . . . . . . . . . . . . . . . . . . . . 95
“ Belt - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
“ Speed Sensor - Clean/Inspect“. . . . . . . . . . . . . . 136
“ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . 140

Every 1000 Service Hours or 1 Year

“ Battery Charger - Check“ . . . . . . . . . . . . . . . . . . . 94

Every 1500 Service Hours

“ Engine Crankcase Breather - Replace“ . . . . . . . 104

Every 2000 Service Hours

“ Coolant Temperature Regulator - Replace“ . . . . 101
“ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . 106
“ Heat Exchanger - Inspect“. . . . . . . . . . . . . . . . . . 130
“ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . 138
“ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . 138

Every 2000 Service Hours or 1 Year

“ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 91
“ Coolant Sample (Level 2) - Obtain“ . . . . . . . . . . 100
“ Generator Set Vibration - Inspect“ . . . . . . . . . . . 126

Every 3000 Service Hours

“ Alternator and Fan Belts - Replace“ . . . . . . . . . . . 91

Every 3000 Service Hours or 3

Years
“ Engine Protective Devices - Check“ . . . . . . . . . . 113

Every 4000 Service Hours

“ Aftercooler Core - Clean/Test“ . . . . . . . . . . . . . . . 90

Every 6000 Service Hours or 3

Years
“ Coolant Extender (ELC) - Add“ . . . . . . . . . . . . . . . 98

Overhaul
“ Overhaul Considerations“ . . . . . . . . . . . . . . . . . . 132
SEBU8734-09 89
Maintenance Section
Aftercooler Condensate Drain Valve - Inspect/Clean

i06043720 Water cooled

Aftercooler Condensate Drain
Valve - Inspect/Clean
SMCS Code: 1063-042-DN

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
The boost pressure forces the plunger to move down
Illustration 58 g03787140
on the valve seat. The plunger must close against the
seat at a pressure of 27.5 kPa (4 psi). When the Aftercooler and heat exchanger
engine is stopped, the absence of boost pressure (1) Aftercooler
allows the plunger to rise to the open position. The (2) Valve assembly
absence of pressure allows the condensation from (3) Circlip
the aftercooler to drain out. (4) Spring
(5) Plunger
(6) O ring seal

Air Cooled

Illustration 59 g03787242
(1) Aftercooler
(2) valve
90
Maintenance Section
Aftercooler Core - Clean/Test
1. Remove valve assembly (2) from aftercooler (1), or
the tube assembly from the aftercooler.
2. Remove circlip (3) and remove plunger (4) and
spring (5) from valve assembly. Remove O ring
seal (6).
1. Ensure that all components are clean and free
from dirt.
2. Install new O ring seal (6) and spring (5).
3. Install plunger (5) and install circlip (3). Check the
operation of the plunger.
4. Install valve assembly (2) into aftercooler (1), or
into the tube assembly from the aftercooler. Refer
to the Specifications, SENR3130, “Torque
Specifications”.
i05371707
Aftercooler Core - Clean/Test
SMCS Code: 1064-081; 1064-070
1. Ensure that the sea cock is closed.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
2. Drain the sea water circuit by removing the sea
water pump inlet connection. Drain into a suitable
container.
3. Remove the sea water connection to the inlet of
the aftercooler assembly.
4. Remove the aftercooler core. Refer to the
Disassembly and Assembly Manual, “Aftercooler -
Remove and Install” for the procedure.
5. Turn the aftercooler core upside-down in order to
remove debris.
SEBU8734-09
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen-
tration of cleaner.
6. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 21 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
dealer.
Table 21
Hydrosolv Liquid Cleaners(1)
Part Number Description Size
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a 2%to a 5% concentration of the cleaner at temperatures
up to 93°C (200°F). Refer to Application Guide, NEHS0526 or
consult your Caterpillar dealer for more information.
7. Steam-clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
8. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
9. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
10. Inspect the core in order to ensure cleanliness.
Pressure-test the core. Many shops that service
radiators are equipped to perform pressure tests.
If necessary, repair the core.
11. Reinstall the aftercooler. Refer to the
Disassembly and Assembly Manual, “Aftercooler -
Remove and Install” for the procedure. Replace
the o'ring on the aftercooler inlet and secure the
flange connection.
12. Open the sea cock and check for water leaks.
SEBU8734-09 91
Maintenance Section
Aftercooler Core - Inspect

i05381019 When the engine is not run for long periods of time or
if the engine is run for short periods, the batteries
Aftercooler Core - Inspect may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
SMCS Code: 1064-040
i06044950
1. Ensure that the sea cock is closed.

NOTICE
Alternator and Fan Belts -
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Replace
nance, testing, adjusting, and repair of the product. SMCS Code: 1357-510
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- The engine may be able to auto start. Ensure that the
bling any component containing fluids. power supply is isolated before any service or repair
is performed.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication, There are two different configurations for the
PECJ0003, “Cat Shop Supplies and Tools Catalog” alternator and fan belts replace.
for tools and supplies suitable to collect and contain
fluids on Cat products. Keel Cooled and Heat Exchanged
Dispose of all fluids according to local regulations
and mandates.

2. Drain the sea water circuit by removing the sea

water pump inlet connection and draining the sea
water into a suitable container.
3. Remove the sea water connection to the inlet of
the aftercooler.
4. Inspect the aftercooler core for blockages or debris
that could restrict the flow of the sea water. If
debris or blockages are found, refer to this
Operation and Maintenance Manual, “Aftercooler
Core - Clean/Test” for the cleaning procedure.
5. Replace the o'ring on the aftercooler inlet and
secure the flange connection.
6. Open the sea cock and check for water leaks.

i05371774
Illustration 60 g03787777
Alternator - Inspect Typical example
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection of
the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required.
Check the alternator and the battery charger for
proper operation. Check the battery voltage on the
control panel. The voltage should be near 0. All
batteries should be kept charged. The batteries
should be kept warm because temperature affects
the cranking power of the battery. If the battery is too
cold, the battery will not crank the engine.
92 SEBU8734-09
Maintenance Section
Alternator and Fan Belts - Replace

4. Install the cover (2) and bolts (1), tighten bolts to a

torque of 28 N·m (247 lb in).

Engine that is Radiator Cooled

Illustration 61 g03787778
Typical example

1. Remove bolts (1) and remove cover (2).

2. Insert a ratchet with a square drive into the square
Illustration 62 g03787779
hole (5). Rotate the belt tensioner (4) clockwise in
Typical example
order to relieve tension on the fan drive belt (3).
Remove the belt.
3. Install the new belt correctly, as shown. Be sure
that the belt is fully seated on the pulleys. The
correct tension will automatically be applied when
the ratchet is removed.

Illustration 63 g03787780
Typical example

1. Remove bolts (1) and remove guard (2).

2. Insert a ratchet with a square drive into the square
hole (5). Rotate the belt tensioner (4) clockwise in
order to relieve tension on the fan drive belt (3).
Remove the belt.
SEBU8734-09
3. Install the new belt correctly, as shown. Be sure
that the belt is fully seated on the pulleys. The
correct tension will automatically be applied when
the ratchet is removed.
4. Install the guard (2) and bolts (1), tighten bolts to a
torque of 12 N·m (106 lb in).
i08259470
Automatic Start/Stop - Inspect
SMCS Code: 4462
The generator set must be ready to operate under a
load at any time. After performing maintenance on
the generator set, inspect the position of the control
switches. Ensure the following conditions:
• The starting system is enabled.
• The control switches are in the correct position for
automatic starting.
• The switchgear and the automatic transfer
switches that are associated with the generator
are enabled.
i05371783
Auxiliary Water Pump (Rubber
Impeller) - Inspect/Replace
SMCS Code: 1371-510
Note: Replace the impeller each time the
components of the pump are inspected. Refer to
the Disassembly and Assembly Manual for the
process.
Inspect the components of the pump more frequently
when the pump is exposed to debris, sand, or other
abrasive materials. Inspect the components if the
pump is operating at a differential pressure of more
than 103 kPa (15 psi).
Check the following components for wear and check
the following components for damage:
• Cam
• Impeller
• Seals
• Wear plate
• End cover
93
Maintenance Section
Automatic Start/Stop - Inspect
If wear is found or if damage is found, replace the
components which are worn or replace the
components which are damaged. Use the proper
repair kit for the pump. Refer to the Disassembly and
Assembly for more information on servicing the
auxiliary water pump.
i02322315
Battery - Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can
explode. A spark can cause the combustible
gases to ignite. This can result in severe personal
injury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Switch the engine to the OFF position. Remove all
electrical loads.
2. Turn off any battery chargers. Disconnect any
battery chargers.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “-” terminal
on the starting motor. Disconnect the cable from
the NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal.
Note: Always recycle a battery. Never discard a
battery. Dispose of used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
94
Maintenance Section
Battery Charger - Check
Note: Before the cables are connected, ensure that
the engine start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
8. Connect the NEGATIVE “-” cable to the
NEGATIVE “-” battery terminal.
i01942625
Battery Charger - Check
SMCS Code: 1401-535
Check the battery charger for proper operation. If the
batteries are properly charged, the needle of the
ammeter will register near “0” (zero).
The batteries should be kept warm, when possible.
The temperature of the battery will affect cranking
power. A battery that is too cold will not crank the
engine, even if the engine is warm.
The batteries may not fully recharge when the engine
is not run for long periods of time. The batteries may
not fully recharge if the engine only runs for short
periods. Ensure a full charge in order to help prevent
the battery from freezing.
i02724529
Battery Electrolyte Level -
Check
SMCS Code: 1401-535-FLV
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
very near zero,when the engine is in operation.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a
face shield and protective clothing when working
on or near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.
SEBU8734-09
Clean the battery case with one of the following
cleaning solutions:
• Use a solution of 0.1 kg (0.2 lb) baking soda
and 1 L (1 qt) of clean water.
• Use a solution of ammonium hydroxide.
Thoroughly rinse the battery case with clean
water.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with
5N-5561 Silicone Lubricant, petroleum jelly or
MPGM.
i05357573
Battery or Battery Cable -
Disconnect
SMCS Code: 1401; 1402-029
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the battery isolator switch to the OFF
position. Turn the ignition switch (if equipped) to
the OFF position and remove the key and all
electrical loads.
2. Disconnect the negative battery terminal. Ensure
that the cable cannot contact the terminal. When
four 12v batteries are involved, two negative
connections must be disconnected.
3. Remove the positive connection.
4. Clean all disconnected connection and battery
terminals.
5. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to fit incorrectly.
Coat the clamps and the terminals with a suitable
silicone lubricant or petroleum jelly.
SEBU8734-09
6. Tape the cable connections in order to help
prevent accidental starting.
7. Proceed with necessary system repairs.
8. In order to connect the battery, connect the
positive connection before the negative connector.
i06044965
Belt - Inspect
SMCS Code: 1357; 1357-040; 1397; 1397-040
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
The engine may be able to auto start. Ensure that the
power supply is isolated before any service or repair
is performed.
Illustration 64 g03201862
(1) Alternator belt
(2) Guard
Remove the guard, refer to this Operation and
Maintenance Manual, “Alternator and Fan Belts
Replace”.
To maximize the engine performance, inspect the
belt for wear and for cracking. Replace the belt if the
belt is worn or damaged.
• Inspect the belt for cracks, splits, glazing, grease,
displacement of the cord and evidence of fluid
contamination.
The belt must be replaced if the following conditions
are present.
• The belt has a crack in more than one rib.
95
Maintenance Section
Belt - Inspect
• More than one section of the belt is displaced in
one rib of a maximum length of 50.8 mm (2 inch).
If the belt is not worn or damaged, replace the belt.
Refer to this Operation and Maintenance Manual,
“Alternator and Fan Belts Replace” for more
information.
i06044949
Belt Tensioner - Check
SMCS Code: 1358-535
The engine may be able to auto start. Ensure that the
power supply is isolated before any service or repair
is performed.
Illustration 65 g03202436
(1) Belt tensioner
Remove the guard and remove the belt Refer to this
Operation and Maintenance Manual, “Alternator and
Fan Belt-Replace” for the procedures.
Inspect the belt. Refer to this Operation and
Maintenance Manual, “Belt - Inspect” for the
procedure.
Ensure that the belt tensioner is securely installed.
Visually inspect the belt tensioner (1) for damage.
Check that the pulley on the tensioner rotates freely
and that the bearing is not loose. If necessary,
replace damaged components.
Replace the tensioner if necessary. Refer to the
Disassembly and Assembly Manual, “Belt Tensioner -
Remove and Install” for the procedure.
Install the belt. Refer to this Operation and
Maintenance Manual, “Belt - Inspect” for the
procedure. Install the guard.
96 SEBU8734-09
Maintenance Section
Control Panel - Inspect/Test

i05074297
Control Panel - Inspect/Test
SMCS Code: 4490-040; 4490-081; 7451-081; 7451-
040
Inspect the control panel for good condition. Perform
the self test. All of the warning lamps should
illuminate. If a warning lamp does not illuminate,
replace the bulb immediately. If the alarm does not
sound, investigate the problem and correct the
problem.
Record the data in a log. Compare the new data to
the data that was previously recorded. Comparing
the new data to the recorded data will help to
establish the trends of engine performance. A gauge
reading that is abnormal may indicate a problem with
operation or a problem with the gauge.
i06045123
Coolant - Change
SMCS Code: 1350-044; 1352; 1395-044; 1395
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
Note: The engine may be able to auto start. Ensure
that the power supply is isolated before any service
or repair is performed.
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
cooling system is drained.

Refer to this Operation and Maintenance Manual, 2. Loosen the cooling system filler cap slowly in order
“Fluid Recommendations” for the correct intervals for to relieve any pressure. Remove the cooling
changing the coolant. system filler cap.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

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

• The fuel has entered the cooling system and the

coolant is contaminated.

Drain the Cooling System

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the Illustration 66 g03399113
pressure. (1) Drain valve for the cylinder block
SEBU8734-09
Illustration 67 g03787874
(2) Radiator drain
3. Open the cooling system drain valves
Note: If equipped, be sure to drain the heater and
any related supply and return lines.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Cat dealer or
consult Cat Dealer Service Tool Group:
Inside USA 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
International 1-309-578-7372
Flush
Systems Filled with Cat ELC or a
Conventional Coolant that Meets the Cat
EC-1 Requirements and the Standards of
ASTM D6210
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valves.
97
Maintenance Section
Coolant - Change
Note: Fill the system no faster than 5 L (5.3 qt) per
minute.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
4. Start and run the engine until the temperature
reaches 82 °C (180 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve. Allow the
water to drain. Flush the cooling system with clean
water. Close the drain valve. Refer to the
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
Systems Filled with Cat DEAC,
Conventional Coolant which does not
Meet the Cat EC-1 Requirements, or
Supplemental Coolant Additive (SCA)
and Water
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valves.
Note: Fill the system no faster than 5 L (5.3 qt) per
minute.
3. Fill the cooling system with a mixture of clean
water and Cat Fast Acting Cooling System
Cleaner.
4. Choose 1 of the following options.
• Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity.
• For cooling systems with heavy deposits or
plugging, add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling
system capacity.
5. Install the cooling system filler cap.
6. Start and run the engine for a minimum of 30
minutes. For cooling systems with heavy deposits
or plugging, run the engine for 90 minutes. The
coolant temperature should be at least 82 °C
(180 °F).
98
Maintenance Section
Coolant Extender (ELC) - Add
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal
components.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
cleaning agent are gone.
7. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve. Allow the
water to drain. Flush the cooling system with clean
water. If equipped, be sure to flush the heater and
any related supply and return lines. Close the
drain valve. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
information on the proper torques.
Fill the Cooling System
Note: Fill the system no faster than 5 L (5.3 qt) per
minute.
1. Fill the cooling system. Refer to this Operation and
Maintenance Manual, “Fluid Recommendations”
for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, “Refill Capacities” for
information about the capacity of the cooling
system. Do not install the cooling system filler cap.
2. Start and run the engine. Run the engine for 30
minutes in order to purge the air from the cavities
of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
within 25 mm (1.0 inch) below the filler neck on
the header tank or on the radiator.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. Only
install the used filler cap if the gasket is not
damaged. Use a 9S-8140 Pressurizing Pump to
pressure test a reinstalled cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
SEBU8734-09
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i03903772
Coolant Extender (ELC) - Add
SMCS Code: 1352-544-NL
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling
additives which are associated with the present
conventional coolants.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
with Cat ELC.
Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with con-
ventional coolants and/or conventional SCA reduces
the Cat ELC service life.
Check the cooling system only when the engine is
stopped and cool.
Personal injury can result from hot coolant,
steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations
and mandates.
SEBU8734-09
Note: The engine can auto start. Ensure that the
power supply is isolated before any service or repair
is performed.
1. Stop the engine and allow the engine to cool. Turn
isolator keyswitch to the OFF position.
2. Loosen the cooling system filler cap slowly in order
to relieve pressure. Remove the cooling system
filler cap.
3. It may be necessary to drain enough coolant from
the cooling system in order to add the Cat ELC
Extender.
4. Add Cat ELC Extender according to the
requirements for your engines cooling system
capacity. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
article for more information.
5. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
i05031748
Coolant Level - Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
Note: The engine has the ability to auto start. Ensure
that the power supply is isolated before any service
or repair is performed.
1. Stop the engine and allow the engine to cool. Turn
the isolator keyswitch to the OFF position.
2. Remove the cooling system filler cap slowly in
order to relieve pressure.
3. Ensure that the coolant level is 25 mm (1.0 inch)
below filler neck on the header tank or the radiator.
Note: Gasket is not installed on radiator filler caps.
99
Maintenance Section
Coolant Level - Check
4. Clean the cooling system filler cap and check the
condition of the filler cap gaskets . Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
5. Inspect the cooling system for leaks.
i05359020
Coolant Sample (Level 1) -
Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and
corrosion. The analysis also tests the ability of the
coolant to protect the engine from boiling and
freezing. S·O·S Systems Coolant Analysis can be
done at your Cat dealer. Cat S·O·S coolant analysis
is the best way to monitor the condition of your
coolant and your cooling system. S·O·S coolant
analysis is a program that is based on periodic
samples.
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with one of
the following coolants: Cat ELC (Extended Life
Coolant) and Conventional Heavy-Duty Coolant.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any of the following
coolants: Cat DEAC, Cat SCA and Commercial
EC-1 Coolant.
For additional information about coolant analysis and
about other coolants, see this Operation and
Maintenance Manual, “Fluid Recommendations” or
consult your Cat dealer.
Sampling Conditions
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained.
If the engine is not equipped with a sampling port, the
coolant should be warm.
Use the following guidelines for proper sampling of
the coolant:
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic
bags.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
100 SEBU8734-09
Maintenance Section
Coolant Sample (Level 2) - Obtain

• Keep the lids on empty sampling bottles until you Note: Level 1 results may indicate a need for Level 2
are ready to collect the sample. Analysis.

• Place the sample in the mailing tube immediately i08422574

after obtaining the sample in order to avoid
contamination.
Coolant Sample (Level 2) -
• Never collect samples from expansion bottles. Obtain
• Never collect samples from the drain for a system. SMCS Code: 1350-008; 1395-008; 1395-554; 7542
An S·O·S Coolant Analysis (Level 2) is a
Timing of the Sampling comprehensive chemical evaluation of the coolant.
This analysis is also a check of the overall condition
Table 22 of the cooling system. The S·O·S Coolant Analysis
(Level 2) has the following features:
Recommended Interval
• Full coolant analysis (Level 1)
Type of
Coolant(1) Level 1 Level 2 • Identification of metal corrosion and contaminants
Cat DEAC • Identification of buildup of the impurities that
Cat SCA cause corrosion and scaling
Every 250 hours Yearly(2)
Conventional Heavy-
Duty Coolants • Determination of the possibility of electrolysis
Cat ELC within the cooling system of the engine
Commercial EC-1 Optional(1) Yearly(1)
Coolants
The results are reported and appropriate
recommendations are made.
(1) Cat ELI is not an approved coolant for this engine.
(2) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified. Obtaining the Sample
Note: Check the SCA (Supplemental Coolant Refer to Operation and Maintenance Manual,
Additive) of the conventional coolant at every oil “Coolant Sample (Level 1) - Obtain” for the guidelines
change or at every 250 hours. Perform this check at for proper sampling of the coolant.
the interval that occurs first.
Submit the sample for Level 2 analysis.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, establish a
consistent trend of data. In order to establish a
pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your Cat
dealer.

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.

Submit the sample for Level 1 analysis.

SEBU8734-09
For further information, refer to this Operation and
Maintenance Manual, “Fluid Recommendations”.
i06920395
Coolant Temperature
Regulator - Replace
SMCS Code: 1355-510
Illustration 68 g06168244
Water Temperature Regulator (1)
Replace the water temperature regulator (1) before
the water temperature regulator fails. Replacing the
water temperature regulator reduces the chances for
unscheduled downtime.
A water temperature regulator that fails in a partially
opened position can cause overheating or over
cooling of the engine.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. Excessive carbon buildup could result in
accelerated wear of the piston rings and wear of the
cylinder liner.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
101
Maintenance Section
Coolant Temperature Regulator - Replace
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Cat engines incorporate a shunt bypass design cool-
ing system and require operating the engine with a
water temperature regulator installed.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera-
ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is
open.
Do not use liquid gasket material on the gasket or cyl-
inder head surface.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
Note: If replacing only the water temperature
regulator, only drain the coolant to a level that is
below the water temperature regulator housing.
Refer to two articles in the Disassembly and
Assembly Manual, “Water Temperature Regulator -
Remove and Water Temperature Regulator - Install”
for the replacement procedure or consult your Cat
dealer.
i08234814
Cooling System Supplemental
Coolant Additive (SCA) - Test/
Add
SMCS Code: 1352-045; 1395-081
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact
with the skin and eyes. Do not drink cooling sys-
tem coolant additive.
102 SEBU8734-09
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Note: Caterpillar recommends an S·O·S coolant Table 23

analysis (Level 1).
Concentration of Maintenance
Number of Drops SCA Required
Test the Concentration of the SCA
Less than 25 Less than the recom- Add SCA.
mended concentra- Retest the coolant.
Coolant/Antifreeze and SCA tion of SCA
25 to 30 The recommended None
NOTICE concentration of
Do not exceed the recommended six percent supple- SCA
mental coolant additive concentration.
More than 30 More than the rec- Remove the coolant.
Test the concentration of the SCA with the 4C-9301 ommended concen- Replace with water
Coolant Conditioner Test Kit. Follow the instructions tration of SCA only
that are provided in the kit. Retest the coolant.

Water and SCA

NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
Test the concentration of the SCA with the 4C-9301
Coolant Conditioner Test Kit. Use the instructions
that follow:
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.
3. Add tap water to the mixing bottle to bring the level
up to the “10 ml” mark. Place the cap on the bottle
and shake the bottle.
4. Add 2 to 3 drops of the “NITRITE INDICATOR
SOLUTION B” to the mixing bottle. Move the bottle
in a circular motion to mix the solution.
5. Add one drop of “NITRITE TEST SOLUTION A” to
the mixing bottle. Move the bottle in a circular
motion to mix the solution.
6. Repeat 5 until the solution changes color from red
to light gray, green, or blue. Record the number of
drops of “NITRITE TEST SOLUTION A” that were
required to cause the color change.
7. Use Table 23 to interpret the results.
Add the SCA, If Necessary
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
1. Remove the cooling system filler cap slowly.
Note: Always dispose of fluids according to local
regulations.
2. If necessary, drain some coolant to allow space for
the addition of the SCA.
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat ex-
changer, overheating, and/or accelerated wear of the
water pump seal.
Do not exceed the recommended amount of supple-
mental coolant additive concentration.

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
Operation and Maintenance Manual, “Refill
Capacities” topic. To determine the proper coolant,
see this Operation and Maintenance Manual,
“Fluid Recommendations” topic.
SEBU8734-09 103
Maintenance Section
Electrical Connections - Check

4. Clean the cooling system filler cap. Install the • Ease of maintenance
cooling system filler cap.
Note: For more information on cleaning and drying
electric generators, refer to Special Instruction,
i08230788
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
Electrical Connections - Check
SMCS Code: 4459-535 i05031813

Check all exposed electrical connections for

tightness.
Engine Air Cleaner Element
(Single Element) - Inspect/
Check the following devices for loose mounting or for
physical damage: Clean/Replace
• transformers SMCS Code: 1051; 1054-070; 1054-040; 1054-510

• fuses
• capacitors

• lightning arrestors
Check all lead wires and electrical connections for
proper clearance.

i08246334

Engine - Clean
SMCS Code: 1000-070

Personal injury or death can result from high

voltage.
Moisture could create paths of electrical
conductivity.
Make sure the unit is off line (disconnected from Illustration 69 g01560871
utility and/or other generators), locked out and Typical example
tagged "Do Not Operate".
Note: Some engines may be able to auto start.
Ensure that the power supply is isolated before any
NOTICE service or repair is performed.
Water or condensation can cause damage to genera-
tor components. Protect all electrical components 1. Release the clips (3) and remove the cover (2).
from exposure to water.
2. Remove the element (1) and discard the element.
3. Ensure that all parts are clean and free from dirt.
NOTICE
Accumulated grease and oil on an engine is a fire Install a new element.
hazard. Keep the engine clean. Remove debris and 4. Align the cover to the body of the air cleaner.
fluid spills whenever a significant quantity accumu-
lates on the engine. Ensure that the cover is oriented correctly and
install the cover.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics
104
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
i02335405
Engine Air Cleaner Service
Indicator - Inspect
SMCS Code: 7452-040
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner element or in a remote location.
Illustration 70 g00103777
Typical service indicator
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.
• The red piston locks in the visible position.
Test the Service Indicator
Service indicators are important instruments.
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
• Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
The yellow core should latch at the greatest
vacuum that is attained.
SEBU8734-09
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be restricted.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
i06045319
Engine Crankcase Breather -
Replace
SMCS Code: 1317-510
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Some engine may be able to auto start. Ensure that
the power has been isolated before any servicing or
repair is performed.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
The engine crankcase breather is important
component in the emissions system for the engine.
An engine crankcase breather which is not working
properly may cause the engine to be out of
compliance with the emissions compliance
certificate.
• The filter element within the crankcase breather
must be serviced at the prescribed service
interval.
• The correct filter element must be installed before
the engine is operated.
• The installation of the filter element is important.
• The quality of the filter element that is installed is
important.
SEBU8734-09 105
Maintenance Section
Engine Crankcase Breather - Replace

Illustration 72 g03090963

3. Remove the old seal (4) and install a new seal.

Note: The cut away from section (5) in the top cap
allows access to the seal.
Illustration 71 g03090965

1. Ensure that dirt cannot enter the breather

assembly. Ensure that the outside body of the
breather assembly is clean and free from damage.
Place a container under the breather assembly.
2. Rotate the top cap (1) counterclockwise into the
unlocked position. Remove the top cap from the
body of the breather (3) and remove the filter
element (2).

Illustration 73 g03090938
(A) Alignment position
(B) Alignment position
106 SEBU8734-09
Maintenance Section
Engine Mounts - Inspect

4. Install a new filter element into the breather body 7. Inspect the breather tube (1) for damage. Ensure
(3). Ensure the correct position of the element, that the outlet (2) is clean and free from any
refer to illustration 73 . Align position (A) on the top obstructions. Ice can cause obstructions in
cap to position (B) on the filter element. adverse weather conditions.

i02456872

Engine Mounts - Inspect

SMCS Code: 1152; 1152-040
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts
Any engine mount that shows deterioration should be
replaced. Refer to Special Publication, SENR3130,
“Torque Specifications” for the recommended
torques. Refer to the OEM recommendations for
more information.

i03353861

Illustration 74 g02346577
Engine Oil Level - Check
Typical example SMCS Code: 1348-535-FLV

5. Install the top cap (1). Rotate the top cap by hand
clockwise until the top cap locks into the locked
position (C) on the breather body.
6. Remove the container.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

Illustration 76 g01165836
(Y) “Min” mark. (X) “Max” mark.

NOTICE
Perform this maintenance with the engine stopped.

Illustration 75 g03787926
Typical example Note: Ensure that the engine is either level or that
the engine is in the normal operating position in order
to obtain a true level indication.
SEBU8734-09
Note: After the engine has been switched OFF, wait
for ten minutes in order to allow the engine oil to drain
to the oil pan before checking the oil level.
Note: The engine can have the ability to auto start.
Ensure that the power supply is isolated before any
service or repair is performed.
1. Maintain the oil level between the “ADD” mark (Y)
and the “FULL” mark (X) on the engine oil dipstick.
Do not fill the crankcase above the “FULL” mark
(X).
NOTICE
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
i08397634
Engine Oil Sample - Obtain
SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the
Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. To help
obtain the most accurate analysis, provide the
following information:
• Engine model
• Service hours on the engine
• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed oil sample.
107
Maintenance Section
Engine Oil Sample - Obtain
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve to
obtain oil samples. The quality and the consistency of
the samples are better when the sampling valve is
used. The location of the sampling valve allows oil
that is flowing under pressure to be obtained during
normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion into
the sump.
For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
i06045461
Engine Oil and Filter - Change
(Single Oil Filter)
SMCS Code: 1318-510
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
108
Maintenance Section
Single Oil Filter
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Ensure that all adjustments, maintenance, and
repairs are performed by authorized personnel that
have had the correct training.
Do not drain the engine lubricating oil when the
engine is cold. As the engine lubricating oil cools,
suspended waste particles settle on the bottom of the
oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
suspended in the oil to be drained properly.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Drain the Engine Lubricating Oil
Ensure that the vessel that will be used is large
enough to collect the waste oil.
Illustration 77 g01561243
Typical example
SEBU8734-09
1. The engine can have the ability to auto start.
Ensure that the power supply is isolated before
any service or repair is performed.
2. Remove drain plug (1). Install drain line to the
connection.
3. Open drain valve (2). Allow the engine oil to drain.
After the oil has drained, close the drain valve.
4. Remove drain line and install a new drain plug.
Tighten the drain plug securely.
Note: Some application may have a pump in order to
remove the engine oil. Connect a drain line to the
pump. Unlock the pump and operate the pump in
order to remove the engine oil. After the oil has been
removed, lock the pump and remove the drain line.
Single Oil Filter
Note: Change the oil filter with the engine stopped.
Caterpillar oil filters are manufactured to Caterpillar
specifications. Use of an oil filter that is not
recommended by Caterpillar could result in severe
damage to the engine bearings, and the crankshaft.
As a result of larger waste particles from unfiltered oil
that can enter the engine lubricating system. Only
use oil filters that are recommended by Caterpillar.
1. Clear the area around the oil filter.
2. Remove the oil filter with a 1U-8760 Chain
Wrench.
Note: The following actions can be carried out as
part of the preventive maintenance program.
Illustration 78 g01999595
Element with debris
SEBU8734-09
3. Cut the oil filter open with a 175-7546 Oil Filter
Cutter. Break apart the pleats and inspect the oil
filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early wear
or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts, or bronze parts of the
engine. Parts that may be affected include the
following items: main bearings, rod bearings,
turbocharger bearings and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order to
arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
Illustration 79 g01561654
4. Clean the sealing surface of the oil filter base (3).
5. Apply clean engine oil to the O ring seal (4) for the
new oil filter.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
to engine components.
109
Maintenance Section
Single Oil Filter
6. Install the engine oil filter. Spin on the oil filter until
the O ring seal contacts the oil filter base. Rotate
the oil filter ¾ of a full turn.
Fill the Oil Pan
1. Remove the oil filler cap. Refer to this Operation
and Maintenance Manual, “Fluid
Recommendations” for more information on
suitable oils. Fill the oil pan with the correct
amount of new engine lubricating oil. Refer to this
Operation and Maintenance Manual, “Refill
Capacities” for more information on refill
capacities.
2. Start the engine and operate the engine at “no
load” for 2 minutes. Perform this procedure in
order to ensure that the lubrication system has oil
and that the oil filters are filled. Inspect the oil filter
for oil leaks.
3. Stop the engine and allow the oil to drain back to
the oil pan for a minimum of 10 minutes.
Illustration 80 g01165836
Typical example
110 SEBU8734-09
Maintenance Section
Engine Oil and Filter - Change

4. Remove the engine oil level gauge in order to

check the oil level. Maintain the oil level between
the “MIN” and “MAX” marks on the engine oil level
gauge.

i06045669

Engine Oil and Filter - Change

(Duplex Oil filters)
SMCS Code: 1318-510

Replace Engine Oil

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Do not drain the engine lubricating oil when the
engine is cold. As the engine lubricating oil cools,
suspended waste particles settle on the bottom of the
oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
suspended in the oil to be drained properly.
Ensure that all adjustments, maintenance, and
repairs are performed by authorized personnel that
have the correct training.
Ensure that the vessel that will be used is large
enough to collect the waste oil.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Illustration 81 g03393368
(1) Engine oil filters
(2) Engine oil drain
(3) Fuel line lever
1. The engine can auto start. Ensure that the power
supply is isolated before any service or repair is
performed.
2. Open the drain valve. Install drain line to the
connection.
3. Allow the engine oil to drain. After the oil has
drained, close the drain valve.
4. Remove drain line and close the drain valve.
Fill the Lubrication System
1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual, “Fluid
Recommendations” for information on suitable
oils. Fill the lubrication system with the correct
amount of engine oil. Refer to this Operation and
Maintenance Manual, “Refill Capacities” for
information on refill capacities.
2. Refer to this article, “Commissioning Procedure for
Duplex Oil Filters”, before the engine is started.
3. Start the engine and operate the engine at “no
load” for 2 minutes. Perform this procedure in
order to ensure that the lubrication system has oil
and that the oil filters are filled. Inspect the oil filter
for oil leaks.
4. Stop the engine and allow the oil to drain back to
the oil pan for a minimum of 10 minutes.
SEBU8734-09 111
Maintenance Section
Duplex Oil filters

Illustration 82 g01165836
Typical example

5. Remove the engine oil level gauge in order to

check the oil level. Maintain the oil level between
the “MIN” and “MAX” marks on the engine oil level
gauge.

Commissioning Procedure for Duplex

Oil Filters

Illustration 83 g03399126

(4) Vent screw for the left filter (5) Vent screw for the right filter

• (A) The oil flow is to the left-hand oil filter.

• (B) The oil flow is to both oil filters.

• (C) The oil flow is to the right-hand oil filter.

1. The engine can auto start. Ensure that the power

supply is isolated before any service or repair is
performed.
112
Maintenance Section
Duplex Oil filters
Illustration 84 g03399163
(6) O' ring seals
2. Apply clean engine oil to both o' ring seals (6) for
the new oil filters.
3. Install the engine oil filters. Spin on the oil filter until
the o' ring seal contacts the oil filter base. Rotate
the oil filter 270°.
4. Ensure that the control lever is in position B. Refer
to illustration 83 .
5. Ensure that the engine has the correct amount of
engine oil. Refer to this Operation and
Maintenance Manual, “Refill Capacities” for the
correct quantity of oil.
6. Operate the engine with no load in order to fill both
oil filters.
7. Check the engine oil pressure. Stop the engine
and allow time for the engine oil to drain into the oil
pan. Check the engine oil, refer to the Operation
and Maintenance Manual, “Engine Oil Level -
Check”.
Replacement of Duplex Filter with the
Engine in Operation
NOTICE
The engine oil is hot and is under pressure. Only
properly trained personnel should perform this
procedure.
If duplex filters are installed, an engine can be
operated during the replacement of the filters.
SEBU8734-09
Note: With the control lever in position A, oil flows to
the left-hand oil filter. With the control lever in position
C, oil flows to the right-hand oil filter. Refer to
illustration 83 .
1. Clean the area around the oil filters.
Illustration 85 g03393369
(7) Control lever
(8) Oil filter base
(6) O' ring seal
2. Rotate the control lever slowly in the direction of
the oil filter that is not being replaced. For
instance, when the control lever is in the position
shown in Figure 85 , oil is flowing to the filter on
the left side and the filter on the right side may be
replaced. Allow time for the oil filter to fill and
check for leaks on the oil filter. Check that the
engine oil pressure is correct.
Note: Only open the vent screw for the filter that is
being changed.
3. Place a soft cloth over the vent screw and slightly
open the vent screw . Slightly opening the screw
will allow any pressure that is in the isolated oil
filter to be released.
4. Tighten the vent screw securely.
5. Remove the oil filter with a 1U-8760 Chain
Wrench.
6. Clean the sealing surface of the oil filter base .
7. Apply clean engine oil to the o' ring seal for the
new oil filter.
SEBU8734-09
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
to engine components.
8. Install the engine oil filter. Spin on the oil filter until
the o' ring seal contacts the oil filter base. Rotate
the oil filter 270°.
9. Place a soft cloth over the vent screw above the
new oil filter. Slightly open the vent screw.
10. Slowly rotate the control lever towards the new
filter allowing the filter to fill gradually with engine
oil. Once oil is present at the vent screw, securely
close the screw.
11. Rotate the control lever fully towards the second
filter. Repeat steps 3 through 10 for the second oil
filter.
12. Return the control lever to position B.
13. Drain the tray below the filter.
Preventative Maintenance
Note: The following actions can be carried out as
part of the preventive maintenance program.
Illustration 86 g01999595
Element with debris
Cut the oil filter open with a 175-7546 Oil Filter
Cutter. Break apart the pleats and inspect the oil filter
for metal debris. An excessive amount of metal
debris in the oil filter may indicate early wear or a
pending failure.
113
Maintenance Section
Engine Protective Devices - Check
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts, or bronze parts of the
engine. Parts that may be affected include the
following items: main bearings, rod bearings,
turbocharger bearings and cylinder heads.
Due to normal wear and friction, small amounts of
debris may be found in the oil filter. Consult your Cat
dealer in order to arrange for a further analysis if an
excessive amount of debris is found in the oil filter.
i08272025
Engine Protective Devices -
Check
SMCS Code: 7400-535
Visual Inspection
Visually check the condition of all gauges, sensors,
and wiring. Look for wiring and components that are
loose, broken, or damaged. Damaged wiring or
components should be repaired or replaced
immediately.
Calibration Check
NOTICE
During testing, abnormal operating conditions must
be simulated.
The tests must be performed correctly in order to pre-
vent possible damage to the engine.
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. Determining if the
engine protective devices are in good working order
during normal operation is impossible. Malfunctions
must be simulated to test the engine protective
devices. To prevent damage to the engine, only
authorized service personnel or your Cat dealer
should perform the tests.
114
Maintenance Section
Fuel System - Prime
Consult your Cat dealer or refer to the Service
Manual for more information.
i05032660
Fuel System - Prime
SMCS Code: 1250-548; 1258-548
Note: Refer to Systems Operation, Testing, and
Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
standards of cleanliness that must be observed
during all work on the fuel system.
Ensure that all adjustments and repairs are
performed by authorized personnel that have had the
correct training.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
• The fuel tank is empty or the fuel tank has been
partially drained.
• The low-pressure fuel lines are disconnected.
• A leak exists in the low-pressure fuel system.
• The fuel filter has been replaced.
Use the following procedures in order to remove air
from the fuel system:
1. Ensure that the fuel system and return valve are in
working order. Check that the fuel supply and
return valves are in the “ON” position.
2. Turn the keyswitch to the BATTERY CONNECTED
position.
3. The keyswitch will allow the electric priming pump
to operate. Operate the electric priming pump. The
ECM will stop the pump after 2 minutes.
4. Turn the keyswitch to the “OFF” position. The fuel
system should now be primed and the engine
should be able to start.
5. If possible, operate the engine starter and crank
the engine. After the engine has started, operate
the engine at low idle for a minimum of 5 minutes.
Ensure that the fuel system is free from leaks.
SEBU8734-09
Note: Operating the engine for this period will help
ensure that the fuel system is free of air. Do not
loosen the high-pressure fuel lines in order to
purge air from the fuel system. This procedure is
not required.
After the engine has stopped, wait for 10 minutes in
order to allow the fuel pressure to be purged from the
high-pressure fuel lines before any service or repair
is performed on the engine fuel lines. If necessary,
perform minor adjustments. Repair any leaks from
the low-pressure fuel system and from the cooling,
lubrication, or air systems. Replace any high-
pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection
Lines - Remove and Install”.
If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General Hazard Information”.
If the engine will not start, refer to Troubleshooting,
“Engine Cranks but will not Start”.
i05358116
Fuel System Primary Filter
(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Single Fuel Filter
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
Note: Refer to System Operation/Testing and
Adjusting Manual , “Cleanliness of Fuel System
Components” for detailed information on the
standards of cleanliness that must be observed
during ALL work on the fuel system.
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
SEBU8734-09
Fuel System Primary Filter (Water Separator) Element - Replace
After the engine has stopped, wait for 60 seconds in
order to allow the fuel pressure to be purged from the
high-pressure fuel lines before any service or repair
is performed on the engine fuel lines. If necessary,
perform minor adjustments. Repair any leaks from
the low-pressure fuel system and from the cooling,
lubrication, or air systems. Replace any high-
pressure fuel line that has leaked. Refer to
Disassembly and assembly Manual, “Fuel Injection
Lines - Install”.
Ensure that all adjustments, maintenance, and
repairs are performed by authorized personnel that
have the correct training.
Illustration 87 g03393240
(1) Fuel filter base (single filter)
(2) O' ring seal
(3) Primary fuel filter canister
(4) Drain valve
1. The engine can auto start. Ensure that the power
supply is isolated before any service or repair is
performed.
2. Turn the fuel supply valve to the OFF position
before performing this maintenance.
115
Maintenance Section
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
3. Place a suitable container under the water
separator to catch any fuel that might spill. Clean
up any spilled fuel. Clean the outside of the water
separator.
4. Place a soft cloth over the vent screw on the filter.
Open the vent screw in order to relieve the
pressure that may be within the fuel system.
5. Open the drain valve. Allow the fluid to drain into
the container. Tighten the drain valve by hand
pressure only. Then, tighten the vent screw
securely.
6. Use 1U-8760 Chain Wrench in order to remove
the fuel filter canister .
7. Lubricate O' ring seal with clean engine oil on the
new canister.
8. Spin on the canister until the O' ring seal contacts
the sealing surface. Then rotate the canister 270
degrees. Do not use a tool in order to install the
canister.
9. Open the fuel supply valve. Remove the container
and dispose of the fluid in a safe place.
10. The secondary filter must be replaced at the
same time as the primary filter. Perform the
priming procedure. Refer to this Operation and
Maintenance Manual , “Fuel System - Prime”.
Duplex Fuel Filters
Some engines are installed with duplex fuel filters.
116 SEBU8734-09
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

Filter Change with the Engine in

Operation

Illustration 88 g01627770

(A) The fuel flow is to the left-hand fuel filter. (C) The fuel flow is to the right-hand fuel
(B) The fuel flow is to both fuel filters. filter.

Note: The fuel selector lever will point in the direction

of the fuel filter that is active. With the fuel selector
lever in position A, the right-hand fuel filter can be
replaced. With the fuel selector lever in position C,
the left-hand fuel filter can be replaced.

1. Clean the outside of the filters. Isolate the

contaminated filter. Rotate the fuel selector lever
into position A or C.
2. Relieve the pressure in the filter. Place a soft cloth
over the vent screw and loosen the vent screw on
the filter that has been isolated. Do not remove the
vent screw.

Illustration 89 g03393305
(5) Filter selection lever
(6) Fuel filter base
(7) O' ring seals
(8) Fuel filter canisters
(9) Drain valve

3. Open the drain valve. Allow the fluid to drain into

the tray. Tighten the drain valve by hand pressure
only. Then, tighten the vent screw securely.
SEBU8734-09 117
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

4. Use 1U-8760 Chain Wrench in order to remove Single Fuel Filter

old canister (2).
Ensure that all adjustments, maintenance and repairs
5. Lubricate O' ring seal with clean engine oil on the are performed by authorized personnel that have had
new canister. Do not use a tool in order to install the correct training.
the canister. Install a new canister. Spin on the
canister until the O ring seal contacts the sealing
surface. Then rotate the canister 270 degrees.
6. The primary fuel filter and the secondary fuel filter
must be replaced at the same time. Purge the fuel
system after the new filters have been installed.
Do not remove the vent screws on the primary fuel
filter. The fuel system will be pressurized and
opening a vent screw will allow fuel that is under
pressure to escape.
a. Slowly rotate the control lever on the primary
fuel filter towards position B.
b. Cover the vent screw on the secondary filter
that is in operation with a soft cloth. Open the
vent screw on the secondary fuel filter that is in
operation.
c. Note: Opening the vent screw and rotating the
control lever must be performed simultaneously.
Removal of the air from the filter takes a short
Illustration 90 g01565193
time. Tighten the vent screw securely.
d. Note: Position B will allow the flow of fuel to 1. The engine can have the ability to auto start.
both filters. Rotate the control lever to the Ensure that the power supply is isolated before
required operating position. any service or repair is performed.
2. Place a suitable container under the water
i03084422
separator in order to catch any fuel that might spill.
Clean up any spilled fuel.
Fuel System Primary Filter/
3. Open drain (1). Allow the fluid to drain into the
Water Separator - Drain container.
SMCS Code: 1260-543; 1263-543
4. Tighten drain (1) by hand pressure only. Remove
the tube and dispose of the drained fluid in a safe
place.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent Duplex Fuel Filters
possible injury, turn the start switch off when
changing fuel filters or water separator elements. Note: Perform this maintenance with the engine
Clean up fuel spills immediately. stopped. The engine can have the ability to auto
start. Ensure that the power supply is isolated before
any service, maintenance or repair is performed.
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.

NOTICE
The water separator can be under suction during nor-
mal engine operation. Ensure that the drain valve is
tightened securely to help prevent air from entering
the fuel system.
118 SEBU8734-09
Maintenance Section
Fuel System Secondary Filter - Replace

Illustration 91 g01627770
Typical example

• (A) The fuel flow is to the left hand fuel filter. 3. Tighten the drain by hand pressure only.

• (B) The fuel flow is to both fuel filters. 4. Drain the tray below the filters.

• (C) The fuel flow is to the right hand fuel filter. i05372125

Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

Note: Refer to Testing and Adjusting Manual ,

“Cleanliness of Fuel System Components” for
detailed information on the standards of
cleanliness that must be observed during all
work on the fuel system.
Ensure that all adjustments, maintenance, and
repairs are performed by authorized personnel that
Illustration 92 g01565033 have had the correct training.
Typical example
Single Filter
1. Ensure that the control lever is in position B. Refer
to illustration 91 . Fuel flow is to both fuel filters.
NOTICE
2. Open the drains (1) and allow the fluid to drain into Ensure that the engine is stopped before any servic-
the tray. ing or repair is performed.
SEBU8734-09 119
Maintenance Section
Fuel System Secondary Filter - Replace

After the engine has stopped, wait for 60 seconds in 8. Prime the fuel system. Refer to the Operation and
order to allow the fuel pressure to be purged from the Maintenance Manual, “Fuel System - Prime” for
high-pressure fuel lines before any service or repair more information.
is performed. If necessary, perform minor
adjustments. Repair any leaks from the low-pressure
fuel system and from the cooling, lubrication, or air
systems. Replace any high-pressure fuel line that
has leaked. Refer to Disassembly and assembly
Manual, “Fuel Injection Lines - Install”.

Illustration 93 g01566557

1. The engine can auto start. Ensure that the power

supply is isolated before any service or repair is
performed.
2. Ensure that the fuel supply valve is in the OFF
position. Place a suitable container under the fuel
filter in order to catch any fuel that might spill.
Clean up any spilled fuel.
3. Clean the outside of the fuel filter. Use 1U-8760
Chain Wrench in order to remove canister (1)
from the engine and dispose of the canister in a
safe place.
4. Lubricate O' ring seal (2) with clean engine oil. Do
not fill the new canister with fuel before the
canister is installed.
5. Do not use a tool in order to install the canister.
Tighten the canister by hand.
6. Install the new canister. Spin on the canister until
the O' ring seal contacts the filter base. Then
rotate the canister 360 degree in order to tighten
the canister correctly.
7. Remove the container and dispose of the fluid in a
safe place. Open the fuel supply valve.
120 SEBU8734-09
Maintenance Section
Fuel System Secondary Filter - Replace

Replacing Duplex Filters While the

Engine is in Operation

Illustration 94 g01674473
Typical installation
(A) The fuel flow is to the left-hand fuel filter. (C) The fuel flow is to the right-hand fuel
(B) The fuel flow is to both fuel filters. filter.

1. The control lever will point in the direction of the

fuel filter that is active. With the control lever in
position A, the right-hand fuel filter can be
replaced. With the control lever in position C, the
left-hand fuel filter can be replaced. Refer to
illustration 94 .
2. Isolate the contaminated filter by rotating the
control lever into position A or position C.
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
procedure will relieve any pressure that is still in
the filter.
5. Clean the outside of the fuel filter. Use 1U-8760
Chain Wrench in order to remove canister (2)
from the engine and dispose of the canister in a
safe place.
Illustration 95 g01566558
Typical example 6. Lubricate O' ring seal (1) with clean engine oil. Do
not fill the new canister with fuel before the
canister is installed.
7. Do not use a tool in order to install the canister.
Tighten the canister by hand.
SEBU8734-09
8. Install the new canister. Spin on the canister until
the O' ring seal contacts the filter base. Then
rotate the canister 360 degree in order to tighten
the canister correctly.
9. Use the following procedure to prime the fuel
system:
a. Loosen the vent screw for the new secondary
filter.
b. Slowly rotate the control lever on the secondary
fuel filter towards position B. During this
process, the fuel will escape from the loosened
vent screw. Remove of the air from the filter will
take a short time.
c. Securely tighten the vent screw when fuel that
does not have air bubbled flows from the vent
screws.
i08397650
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
121
Maintenance Section
Fuel Tank Water and Sediment - Drain
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel. The
fuel tank utilizes a fuel tank vent to prevent an air lock
or vacuum. Ensure that the vent is free of debris and
not damaged.
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Prepare to catch water and sediment in an
appropriate container. Connect a hose (if necessary)
to the valve prior to opening the valve.
Open the drain valve on the bottom of the fuel tank to
drain the water and the sediment. Close the drain
valve.
Note: Failure to close the drain properly could result
in fuel leakage, which could have detrimental results
to performance.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure.
Fill the fuel tank after operating the engine to drive
out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use stand pipes that allow water and
sediment to settle below the end of the fuel stand
pipe. Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
Fuel Storage Tanks
Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly
• Refill of the tank
This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for
the breather vent on the fuel tank is also
recommended.
122
Maintenance Section
Generator - Dry
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
i07109997
Generator - Dry
SMCS Code: 4450-569
Personal injury or death can result from improper
troubleshooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
Refer to this Operation and Maintenance Manual,
“Generator Isolating for Maintenance” for information
regarding the procedure to isolate the generator in a
safe manner.
Refer to Special Instruction, SEHS9124, “Cleaning
and Drying of the Generator” for further necessary
information.
Of the following methods for drying the generator, the
use of external heat is preferred.
• External heat
• Internal heat
• Combination of external and internal heat
• Circulating current
External heat is the most preferable method.
Insulation drying time can vary from a few hours to
several days. The drying time depends on the
moisture content and the process for drying that is
used.
Note: Drying sometimes does not produce the
required results. The use of a qualified rebuild shop
may be necessary for dipping and drying the
generator.
SEBU8734-09
Illustration 96 g02175752
Typical curves of the resistance in the insulation that
is drying
(1) Curve of the temperature in the windings
(2) Heat turned off.
(3) Drying time in hours
(4) Temperature in degrees celsius
(5) Curve of insulation resistance during drying process
(6) Insulation resistance in megohms
Note: When new insulation or damp insulation is
being dried, the resistance will probably fall rapidly.
The rapid fall in resistance is the result of the
temperature being raised to a value for drying. After
reaching a minimum for a given temperature, the
resistance will again rise as moisture is driven out of
the insulation. The actual values will vary with each
situation. Refer to Illustration 97 .
If the windings or insulation is wet during the
resistance measurement, use a 5 megohm resistor
for protection in series with red positive lead. This
procedure limits the voltage across the circuit under
the test. Use this method until drying is well in
progress and the resistance has reached an
acceptable level.
Check the windings after every 4 hours when either
external or internal heat is used to dry the generator.
Check the windings every hour when circulating
current is used to dry the generator. Refer to Special
Instruction, SEHS9124, “Cleaning and Drying of the
Generator” for more information.
Drying is complete when the tests show no increase
in resistance and the resistance is above the
minimum. Record these readings and compare these
readings. Keep these records for future reference.
SEBU8734-09
Illustration 97 g01696934
Curve of insulation resistance for windings in good
condition
(1) Resistance after 30 seconds
(2) Resistance after 60 seconds
Illustration 97 indicates the curve of the resistance of
a normal high resistance in the windings over a
period of 60 seconds. The resistance after 60
seconds will be greater than the resistance or equal
to the resistance after 30 seconds .
Note: If the insulation resistance after 60 seconds is
not higher than the resistance after 30 seconds , the
insulation may be weak.
Illustration 98 g01697074
Curve of insulation resistance for windings that are
wet or dirty
(1) Resistance after 30 seconds
(2) Resistance after 60 seconds
Illustration 98 indicates the curve of the resistance
that is decaying over a period of 60 seconds. If the
insulation resistance after 60 seconds is not higher
than the resistance after 30 seconds , clean the
windings and thoroughly dry the windings. Refer to
Special Instruction, SEHS9124, “Cleaning and Drying
of the Generator” for more information.
123
Maintenance Section
Generator - Dry
Note: Caterpillar recommends a minimum
acceptable insulation resistance of 2 megohm for
generators which operate with less than 1000 V of
operating or rated voltage. Generators which operate
at 1000 V of operating or rated voltage should have a
minimum insulation resistance as determined by the
following equation:
R = (V/1000) + M
“R” is the minimum insulation resistance.
“V” is the rated voltage.
“M” is 1 megohm.
These values are approximate. Operating a
generator with less resistance may be possible.
External Heat
Ovens
The best oven is a forced air drying oven for drying
electrical equipment. Radiant ovens sometimes
cause localized overheating.
NOTICE
Do not heat the generator too quickly. Try to limit the
rise in temperature of the insulation and windings to
11.11° C (20° F) per hour. Failure to do so may cause
equipment damage.
Note: Many electrical shops are equipped with
baking ovens.
Heat the generator to approximately 75° C (167° F).
Never exceed 75° C (167° F) until the insulation
tester tests correctly for insulation resistance (at least
4 hours).
Alternate Method
A tent formed by a tarp or a canvas with heated
lamps or a portable space heater may be used as an
alternate method.
A hole should be left in the top of the tarp for ensuring
proper circulation through the generator and for
permitting the moisture to exhaust. Heat the
generator to approximately 75° C (167° F). Never
exceed 75° C (167° F) until the insulation tester tests
correctly for insulation resistance (at least 4 hours).
Internal Heating
If generators operate under one of the following
conditions, the electric space heaters should be
installed as part of the generator:
• Generators are in damp environments and go for
long periods of time without operation.
124
Maintenance Section
Generator - Inspect
• Generators operate regularly in an environment
with moisture laden air.
Circulating Current
Drying can be accomplished by circulating low
voltage current through the windings. Since the
voltage is low, the breakdown of the insulation will not
occur as the breakdown might have occurred with
normal operation and wet insulation. Refer to Special
Instruction, SEHS9124, “Cleaning and Drying of the
Generator” for this procedure.
i08273274
Generator - Inspect
SMCS Code: 4450-040
Personal injury or death can result from improper
troubleshooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “ OFF”” posi-
tion. Attach “ DO NOT OPERATE”” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the
procedure to isolate the generator safely.
Proper maintenance of electrical equipment requires
periodic visual examination of the generator and
periodic visual examination of the windings. Proper
maintenance of electrical equipment also requires
appropriate electrical checks and appropriate thermal
checks. Insulation material should be examined for
cracks. The insulation material should be examined
for accumulations of dirt and dust. If there is an
insulation resistance value that is below normal, a
conductive path may be present. This conductive
path may be made of one of the following materials:
• Carbon
• Salt
• Metal dust
SEBU8734-09
• Dirt that is saturated with moisture
These contaminants will develop a conductive path
which may produce shorts. Cleaning is advisable if
heavy accumulations of dirt can be seen or if heavy
accumulations of dust can be seen. If excess dirt is
the cause of a restriction in the ventilation, cleaning is
also advisable. Restricted ventilation will cause
excessive heating.
NOTICE
To avoid the possibility of deterioration to the genera-
tor windings, do not clean the generator unless there
is visual, electrical, or thermal evidence that dirt is
present.
If harmful dirt accumulations are present, various
cleaning techniques are available. The cleaning
procedure that is used may be determined by one of
the items on the following list:
• The extent of the cleaning procedure that is being
attempted
• The type of enclosure of the generator
• The voltage rating of the generator
• The type of dirt that is being removed
Cleaning (Assembled Generators)
Cleaning may be required at the point of installation.
At this point, complete disassembly of the generator
may not be necessary or feasible. In this case, a
vacuum cleaner should be used to pick up the
following items: dry dirt, dust, and carbon. This
cleaning will prevent the spreading of these
contaminants.
A small nonconductive tube may need to be
connected to the vacuum cleaner. This tube will allow
the vacuum cleaner to clean the surfaces that are not
exposed. After most of the dust has been removed, a
small brush may be attached to the vacuum hose.
This brush will help remove dirt that is more firmly
attached to the surface.
SEBU8734-09
After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure
should be a maximum of 210 kPa (30 psi) to prevent
mechanical damage to the insulation. If the above
cleaning procedures are not effective, consult a Cat
dealer.
Cleaning (Disassembled
Generators)
An initial insulation resistance check should be made
on the generator to confirm electrical integrity. A
minimum reading of 2 megohm would be expected
with severely contaminated generators. A zero
megohm reading may indicate an insulation
breakdown. An insulation breakdown requires more
than cleaning. An insulation breakdown requires
repair.
A high-pressure wash is normally an effective way to
clean windings. This cleaning includes windings that
have been exposed to flooding or windings that have
been contaminated by salt. A solution of hot water
and detergent is used for this method of cleaning.
A high-pressure wash sprays a high velocity fluid
stream of this solution over the generator that is
being cleaned. This detergent washing is followed by
multiple sprays of clean water. The clean water is
used to remove the detergent or the clean water is
used to dilute the detergent.
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation
resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. The
use of solvents can be used if the generator is
contaminated with oil or if the generator is
contaminated with grease.
Note: For more information on drying methods, refer
to Special Instructions, SEHS9124, “Cleaning and
Drying of Electric Set Generators”.
i04561397
Generator Bearing
Temperature - Test/Record
SMCS Code: 4471-081-TA
The monitoring of bearing temperature may prevent
premature bearing failure. A generator set should
never operate above the recommended set points.
Keep records in order to monitor the changes in the
temperature of the bearing.
Note: Measure the bearing temperature after the
generator reaches normal operating temperature.
125
Maintenance Section
Generator Bearing Temperature - Test/Record
Resistive Temperature Detectors
(RTDs)
Caterpillar Generators may be equipped with
resistance temperature detectors for generator
bearings. These detectors are 100 ohm resistance
temperature detectors. A resistance temperature
detector may be monitored by equipment that is
provided by the customer. Consult with your
Caterpillar dealer about other methods of measuring
the bearing temperature.
Infrared Thermometers
Bearing temperatures can also be recorded with the
use of an infrared thermometer. Refer to Special
Publication, NENG2500, “Caterpillar Dealer Service
Tools Catalog” for various infrared thermometers.
Follow the instructions that come with your infrared
thermometer.
i08286680
Generator Load - Check
SMCS Code: 4450-535-LA
Personal injury or death can result from high
voltage.
When power generation equipment must be in
operation to make tests and/or adjustments, high
voltage and current are present.
Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
rent tests being made.
During normal operation, monitor the power factor
and monitor generator loading.
When a three-phase generator is installed, ensure
that the total current in any one phase does not
exceed the nameplate rating. Or, when a three-phase
generator is reconnected, ensure that the total
current in any one phase does not exceed the
nameplate rating. Each phase should carry the same
load. Carrying the same load allows the three-phase
generator to work at the rated capacity. If one-phase
current exceeds the nameplate amperage, an
electrical imbalance will occur. An electrical
imbalance can result in an electrical overload and an
electrical imbalance can result in overheating on
three-phase generators. This imbalance is not
applicable to single-phase generators.
126
Maintenance Section
Generator Set - Test
The power factor can be referred to as the efficiency
of the load. This power factor can be expressed as
the ratio of kVA to actual kW. The power factor can
be calculated by dividing kW by kVA. Power factor is
expressed as a decimal. Power factor is used to
mean the portion of current that is supplied to a
system that is doing useful work. The portion of the
current that is not doing useful work is absorbed in
maintaining the magnetic field in motors. This current
(reactive load) can be maintained without engine
power.
i08286685
Generator Set - Test
SMCS Code: 4450-081
DANGER: Shock/Electrocution Hazard-Do not
operate this equipment or work on this
equipment unless you have read and understand
the instructions and warnings in the Operation
and Maintenance Manual. Failure to follow the
instructions or heed the warnings will result in
serious injury or death.
Personal injury or death can result from high
voltage.
When power generation equipment must be in
operation to make tests and/or adjustments, high
voltage and current are present.
Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
rent tests being made.
When servicing or repairing electric power gener-
ation equipment:
• Make sure the unit is off-line (disconnected
from utility and/or other generators power
service), and either locked out or tagged DO
NOT OPERATE.
• Make sure the generator engine is stopped.
• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
SEBU8734-09
Table 24
Tools Needed
Part Number Part Quantity
237-5130 Digital Multimeter 1
12 VDC battery 1
Potential
1
Transformer
The generator set functional test is a simplified test
that can be performed to determine if the generator is
functional. The generator set functional test should
be performed on a generator set that is under load.
The generator set functional test determines if the
following statements happen:
• A phase voltage is being generated.
• The phase voltages are balanced.
• The phase voltages change relative to engine
speed.
The generator set functional test consists of the
following steps:
1. Stop the generator. Connect the potential
transformer high voltage winding to the generator
terminals (T1) and (T2). Connect the voltmeter to
the low voltage winding. If two transformers are
available, connect the high voltage winding of the
second transformer to the generator terminals (T1)
and (T3). Connect the secondary terminals that
correspond to generator terminal (T2) of both
transformers together.
2. Disconnect wires “E+” and “E-” from the voltage
regulator. Disconnect the generator from the load.
3. Connect a 12 VDC automotive battery to wires “E
+” and “E-” .
4. Measure the AC voltage across the low voltage
terminals of the transformer that correspond to the
following generator terminals: “T1” and “T2” , “T2” ,
and “T3” and “T3” and “T1” . Record the voltages.
i08286683
Generator Set Vibration -
Inspect
SMCS Code: 4450-040-VI
Excessive vibration will indicate a problem with the
generator set. The vibration may be caused by the
following:
• Misalignment of the coupling between the engine
and the generator
SEBU8734-09 127
Maintenance Section
Generator Winding Insulation - Test

• Faulty mounting or play in the coupling i03904021

• Incorrect balancing of the generator shaft or Generator Winding Insulation -

engine crankshaft
Test
• A three-phase generator has too much load on a
SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
single phase.
081
• There is a short circuit in the stator.
Check for vibration damage. Vibration may cause the
Recommended Periodic Insulation
following problems: Tests
• loose fittings
• loose bolts
The high voltage that is produced by an operating
• excessive noise generator set can cause severe injury or death.
Before performing any maintenance or repairs,
• cracked insulation ensure that the generator will not start.
The following areas are susceptible to vibration Place the engine control switch in the “ OFF”” posi-
damage: tion. Attach “ DO NOT OPERATE”” tags to all start-
ing controls. Disconnect the batteries or disable
• stator output leads the starting system. Lock out all switchgear and
automatic transfer switches that are associated
• protective sleeving with the generator.

• insulation Table 25

• exposed electrical connections Tools Needed

142-5055 Insulation Testing Gp
• transformers
9U-6003 Insulation Testing Gp
• fuses
• capacitors Periodically, use an insulation tester to check the
insulation resistance of the generators main stator
Check the generator set vibration level by using a winding. The frequency of this test is determined by
broad spectrum analyzer. the generators environment. Previous insulation
tester readings will also determine the frequency of
this test.
Test the main stator windings with an insulation tester
in the following situations:
• The generator set is started for the first time.

• The generator set is removed from storage.

• The generator set is operating in a humid
environment. Test every 3 months.
• The generator set is not protected from the
elements in an enclosed area. Test every 3
months.
• The generator set is installed in an enclosed area.
This area needs to be low in humidity and this
area needs to have steady temperatures. Test
every 12 months (minimum).
128 SEBU8734-09
Maintenance Section
Generator Winding Insulation - Test

• The generator set has not been run under load for 9. Use the 30/60 Time Resistance Method:
3 months. Test the generator set weekly. Use
space heaters around the generator set if the a. Apply voltage.
generator is exposed to a sea water environment b. Observe the readings at 30 seconds. Observe
or if the humidity is above 75 percent. Also use the readings at 60 seconds.
space heaters if a test result was below 3
megohms. c. Record the 60 second reading. This reading
must be corrected for temperature.
Space heaters must be used whenever the generator
set is not under load. Space heaters must also be d. Record temperature.
used whenever salt is present or whenever high
humidity is present. Using a space heater in this e. Record humidity.
fashion is the only way to maintain insulation tester
readings above 1 megohm. Use space heaters only f. Remove voltage.
when the generator is not running. 10. Evaluate the readings. The actual value of the
For additional information, refer to Special resistance may vary greatly between generators.
Instruction, SEHS9124, “Cleaning and Drying of For this reason, the insulations condition must be
Electric Set Generators”. evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
Recommended Procedure for A the readings that were taken on previous dates.
These two readings must be taken under similar
Periodic Insulation Test conditions. If a 60 second resistance reading has
a 50 percent reduction from the previous reading,
the insulation may have absorbed too much
moisture.
Personal injury or death can result from
electrocution. Switch the insulation tester to the “OFF” position.
This will discharge the insulation testers leads.
The megohmmeter is applying a high voltage to Disconnect the insulation testers leads.
the circuit.
To avoid electrocution, do not touch the instru- Note: The results from the insulation resistance
ment leads without first discharging them. When checks indicate when cleaning and/or repairing is
finished testing also discharge the generator becoming critical. Generally, insulation resistance will
windings. vary greatly with temperature. Therefore, always test
at the same temperature and humidity. Refer to
Illustration 99 .
1. Take the generator out of service.
Serial Number (Engine)
2. Visually inspect the generator for moisture. If
moisture exists, do not perform this insulation test. Serial Number (Generator)
Dry the unit first. Refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
3. Inspect the installation. Determine the equipment
that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Isolate the stator windings of the generator by
disconnecting all other leads and cables from the
generator terminals. This includes connections to
the voltage regulator, the control panel, the
switchgear, or other devices.
6. Connect the insulation testers RED lead to ground.
7. Connect the insulation testers BLACK lead to the
wye point or star point of the generators windings.
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
voltage to 1000 V.
SEBU8734-09 129
Maintenance Section
Generator Winding Insulation - Test
130
Maintenance Section
Heat Exchanger - Inspect
Illustration 99
i05358465
Heat Exchanger - Inspect
SMCS Code: 1379-040
The interval for the maintenance of the tube type heat
exchanger depends on the operating environment of
the vessel and on the operating time. The sea water
that is circulated through the heat exchanger and the
amount of operating time of the vessel affects the
following items:
• Cleanliness of the tubes for the heat exchanger
• Effectiveness of the heat exchanger system
Operating in water that contains silt, sediment, salt,
algae, and so on, will adversely affect the heat
exchanger system. In addition, intermittent use of the
vessel will adversely affect the heat exchanger
system.
The following items indicate that the heat exchanger
may require cleaning:
• Increased coolant temperature
• Engine overheating
• Excessive pressure drop between the water inlet
and the water outlet
An operator that is familiar with the normal operating
temperature of the coolant can determine when the
coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger
are required if the engine is overheating.
Cleaning the Heat Exchanger
1. Drain the cooling system. Refer to this Operation
and Maintenance Manual, “Coolant - Change” for
the procedure.
2. After closing the sea cock, remove the sea water
pump inlet connection to drain the sea water
system.
3. Remove the heat exchanger. Refer toDisassembly
and Assembly Manual, “Aftercooler - Remove” for
the procedure.
4. Disassemble the heat exchanger. Refer to
Disassembly and Assembly Manual, “Aftercooler -
Disassemble” for the procedure.
5. Turn the heat exchanger cores upside-down in
order to remove debris.
SEBU8734-09
g00633226
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen-
tration of cleaner.
6. Back flush the cores with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 26 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
dealer.
Table 26
Hydrosolv Liquid Cleaners(1)
Part Number Description Size
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a 2 to 5 percent concentration of the cleaner at tempera-
tures up to 93°C (200°F). Refer to Application Guide,
NEHS0526 or consult your Caterpillar dealer for more
information.
7. Steam-clean the cores in order to remove any
residue. Flush the tubes of the heat exchanger
core. Remove any other trapped debris.
8. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
9. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
10. Inspect the core in order to ensure cleanliness.
Pressure-test the core. Many shops that service
radiators are equipped to perform pressure tests.
If necessary, repair the core.
11. Assemble the heat exchanger. Refer
toDisassembly and Assembly Manual, “Aftercooler
- Assemble” for the procedure.
12. Install the heat exchanger. Refer to Disassembly
and Assembly Manual, “Aftercooler - Install” for
the procedure.
SEBU8734-09
For more information on cleaning the core, consult
your Cat dealer.
i07819616
Hoses and Clamps - Inspect/
Replace
SMCS Code: 7554-510; 7554-040
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
If you inspect the engine in operation, always use the
proper inspection procedure to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”
and Operation and Maintenance Manual, “High
Pressure Fuel Lines” for the correct procedures.
Inspect all hoses for leaks that are caused by the
following conditions:
• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
Check for the following conditions:
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.
Due to extreme temperature changes, the hose will
harden. Hardening of the hoses will cause hose
clamps to loosen. This can result in leaks. A constant
torque hose clamp will help to prevent loose hose
clamps.
Each installation application can be different. The
differences depend on the following factors:
131
Maintenance Section
Hoses and Clamps - Inspect/Replace
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Replace the Hoses and the Clamps
Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).
The following text describes a typical method of
replacing coolant hoses. Refer to the OEM
information for further information on the coolant
system and the hoses for the coolant system.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly to
relieve any pressure. Remove the cooling system
filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
7. Install the hose clamps with a torque wrench.
Note: For the correct coolant, see this Operation and
Maintenance Manual, “Fluid Recommendations”.
8. Refill the cooling system. Refer to the OEM
information for further information on refilling the
cooling system.
9. Clean the cooling system filler cap. Inspect the
cooling system filler cap's seals. Replace the
cooling system filler cap if the seals are damaged.
Install the cooling system filler cap.
132
Maintenance Section
Jacket Water Heater - Check
10. Start the engine. Inspect the cooling system for
leaks.
i08257569
Jacket Water Heater - Check
SMCS Code: 1383-535
Jacket water heaters help to improve starting in
ambient temperatures that are below 21 °C (70 °F).
All installations that require automatic starting should
have jacket water heaters.
Check the operation of the jacket water heater.
Check the operation of the circulation pump, if
equipped. For an ambient temperature of 0 °C
(32 °F), the heater should maintain the jacket water
coolant temperature at approximately 32 °C (90 °F).
i01515272
Overhaul Considerations
SMCS Code: 7595-043
Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
The following factors are important when a decision
is being made on the proper time for an engine
overhaul:
• The need for preventive maintenance
• The quality of the fuel that is being used
• The operating conditions
• The results of the S·O·S analysis
Oil Consumption as an Overhaul
Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage of
the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
SEBU8734-09
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best
value for the following reasons:
• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the
standards for reusable parts.
• The engine's service life can be extended without
the risk of a major catastrophe due to engine
failure.
• The best cost/value relationship per hour of
extended life can be attained.
After Failure Overhaul
If a major engine failure occurs and the engine must
be removed, many options are available. An overhaul
should be performed if the engine block or the
crankshaft needs to be repaired.
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
with a similar exchange core.
This lower cost can be attributed to three aspects:
• Specially designed Caterpillar engine features
• Caterpillar dealer exchange components
• Caterpillar Inc. remanufactured exchange
components
Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you
with the best cost/value relationship.
SEBU8734-09 133
Maintenance Section
Overhaul Considerations

Note: Overhaul programs vary according to the • Rod bearings

engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
overhaul programs and about overhaul services for
extending the engine life.
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following
maintenance recommendations.
Rebuild or Exchange
Cylinder Head Assembly, Oil Pump, and Fuel
Transfer Pump
These components should be inspected according to
the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
If the parts comply with the established inspection
specifications that are expressed in the reusable
parts guideline, the parts should be reused.
Parts that are not within the established inspection
specifications should be dealt with in one of the
following manners:
• Salvaging
• Repairing
• Replacing
Using out-of-spec parts can result in the following
problems:
• Unscheduled downtime
• Costly repairs
• Damage to other engine parts
• Reduced engine efficiency
• Increased fuel consumption
Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing out-
of-spec parts or replacing out-of-spec parts.
Inspection and/or Replacement
Crankshaft Bearings and Crankshaft Seals
The following components may not last until the
second overhaul.
• Thrust bearings
• Main bearings
• Crankshaft seals
Caterpillar Inc. recommends the installation of new
parts at each overhaul period.
Inspect these parts while the engine is disassembled
for an overhaul.
Inspect the crankshaft for any of the following
conditions:
• Deflection
• Damage to the journals
• Bearing material that has seized to the journals
Check the journal taper and the profile of the
crankshaft journals. Check these components by
interpreting the wear patterns on the following
components:
• Rod bearing
• Main bearings
Inspect the camshaft for damage to the journals and
to the lobes.
Note: If the camshaft is removed for any reason, use
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:
• Camshaft bearings
• Lifters
Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
Oil Cooler Core
During an overhaul, Caterpillar Inc. recommends the
removal of the oil cooler core. Clean the oil cooler
core. Then, pressure test the oil cooler core.
NOTICE
Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the
core and cause leakage.
Note: Use this cleaning procedure to clean the oil
cooler core.
1. Remove the oil cooler core.
2. Remove any debris from the oil cooler core. To
remove debris from the oil cooler core, turn the oil
cooler core onto one end.
134
Maintenance Section
Radiator - Clean
3. Flush the oil cooler core internally with cleaner in
order to loosen foreign substances. This will also
help to remove oil from the oil cooler core.
Note: Caterpillar Inc. recommends the use of
Hydrosolv Liquid Cleaners. Table 27 lists the
Hydrosolv Liquid Cleaners that are available from
your Caterpillar dealer.
Table 27
Hydrosolv Liquid Cleaners
Part Number Description Size
1U-5490 Hydrosolv 4165 19 L (5 US gal)
1U-5492 Hydrosolv 100 19 L (5 US gallon)
4. Use steam to clean the oil cooler core. This
removes any remaining residue from the cleaner.
Flush the fins of the oil cooler core. Remove any
other trapped debris.
5. Wash the oil cooler core with hot, soapy water.
Rinse the oil cooler core thoroughly with clean
water.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
6. Dry the oil cooler core with compressed air. Direct
the air in the reverse direction of the normal flow.
7. Inspect the components in order to ensure
cleanliness. The oil cooler core should be
pressure tested. Repair the oil cooler core, if
necessary. Install the oil cooler core.
For more information about cleaning the cores,
consult your Caterpillar dealer.
Obtain Coolant Analysis
The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine is
overhauled.
For example, considerable deposits are found in the
water jacket areas on the external cooling system,
but the concentrations of coolant additives were
carefully maintained. The coolant water probably
contained minerals that were deposited on the
engine over time.
SEBU8734-09
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or an
agricultural agent. Private laboratories are also
available for water analysis.
Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2).
S·O·S Coolant Analysis (Level 2)
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2)
provides the following information:
• Complete S·O·S Coolant Analysis (Level 1)
• Visual inspection of properties
• Identification of metal corrosion
• Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see
your Caterpillar dealer.
i08254039
Radiator - Clean
SMCS Code: 1353-070
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
SEBU8734-09
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction of
the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between
the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water to soften mud. Clean the core from both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
After cleaning, start the engine and bring the engine
to high idle. This procedure will help in the removal of
debris and drying of the core. Stop the engine. Use a
light bulb behind the core to inspect the core for
cleanliness. Repeat the cleaning, if necessary.
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
i08361465
Rotating Rectifier - Check
SMCS Code: 4465-535
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “ OFF”” posi-
tion. Attach “ DO NOT OPERATE”” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
refer to Maintenance Procedure, “Rotating Rectifier -
Test”.
135
Maintenance Section
Rotating Rectifier - Check
i04327496
Rotating Rectifier - Inspect/
Test
SMCS Code: 4465-040; 4465-081
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “ OFF”” posi-
tion. Attach “ DO NOT OPERATE”” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Illustration 100 g00992269
(1) Positive DC terminal or Negative DC terminal
(2) AC terminal
(3) AC terminal
(4) AC terminal
The following procedure tests all three diodes within
a block. Check the positive rectifier block and the
negative rectifier block. If any meter reading does not
fall within the given ranges, replace the rectifier
block.
1. Set the digital multimeter on the diode range.
Remove all leads from the rectifier block.
2. To test the negative rectifier block, follow these
steps:
a. Place the red test lead on the negative “-”
terminal (1). Place the black test lead on the
following rectifier terminals: AC terminal (2), AC
terminal (3) and AC terminal (4). All readings on
the meter should be between 0.4 and 1.0.
b. Place the black test lead on the negative “-”
terminal (1). Place the red test lead on the
following rectifier terminals: AC terminal (2), AC
136 SEBU8734-09
Maintenance Section
Sea Water Strainer - Clean/Inspect

terminal (3) and AC terminal (4). In all cases, i05743227

the meter should read “OL” (overload).
3. To test the positive rectifier block, follow these
Speed Sensor - Clean/Inspect
steps: SMCS Code: 1907-040; 1907-070
a. Place the red test lead on the positive “+”
rectifier terminal (1). Place the black test lead
on the following rectifier terminals: AC terminal
(2), AC terminal (3) and AC terminal (4). In all
cases, the meter should read “OL” (overload).
b. Place the black test lead on the positive “+”
rectifier terminal (1). Place the red test lead on
the following rectifier terminals: AC terminal (2),
AC terminal (3) and AC terminal (4). All
readings on the meter should be between 0.4
and 1.0.

Note: A shorted diode can damage the exciter rotor.

If a diode is shorted, check the exciter rotor. Refer to
the Testing and Adjusting, “Winding - Test” and
Testing and Adjusting, “Insulation - Test”. Perform
these tests.

i06104394

Sea Water Strainer - Clean/ Illustration 101 g03648159

Inspect Typical example

SMCS Code: 1371-070; 1371-040
The sea water strainer must be clean in order to
allow proper engine cooling. Check the sea water
strainer for plugging. Inspect the sea water strainer
more frequently if the vessel is being operated in
water which is shallow or dirty. Refer to the OEM
recommendations for more information about
inspecting and cleaning the sea water strainer.
Ensure that the auxiliary water pump is primed and
that the suction line is open.
1. Shutoff sea water valve.
2. Remove the sea water strainer and clean the
screen. Remove any dirt and debris.
Note: An engine can be programmed to auto start.
Ensure that the power supply is isolated before any
service or repair is performed.
1. Remove the speed sensor (3) from the flywheel
housing. Check the condition of the end of the
speed sensor. Check for signs of wear and
contaminants.
2. Clean the metal shavings and other debris from
the face of the sensor.
3. Install the speed sensor until the end of the sensor
comes in contact with a tooth on the flywheel ring
gear (1).

3. Install the sea water strainer. Fill the sea water
strainer and the suction line for the auxiliary water
pump with water.
4. Open sea water valve.
4. Back out 180 degrees and tighten the locknut (2)
to 45 ± 7 N·m (33 ± 5 lb ft).
Note: Ensure that the speed sensor cannot rotate
when the locknut is tightened.
Refer to the Service Manual for more information on
the speed sensor in the flywheel housing.
SEBU8734-09
Standby Generator Set Maintenance Recommendations
i05371694
Standby Generator Set
Maintenance
Recommendations
(Emergency Standby Generator
Set)
SMCS Code: 4450-041
A standby generator set may be intermittently used.
However, the generator set is needed for operation in
an emergency situation. Maintenance of the standby
generator set is important for the following reasons:
• The generator set must always be in excellent
operating condition.
• The generator set must be ready to work under
load at any time.
Establishing a Preventive Maintenance Program will
provide these benefits:
• Maximum availability of the standby generator set
• Longer service life for the generator set
• Minimum of expensive repairs
Your Cat dealer can help you to establish an effective
Preventive Maintenance Program for your generator
set. Consult your Cat dealer for details.
Maintenance and Operation
Procedures
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “ OFF”” posi-
tion. Attach “ DO NOT OPERATE”” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
The recommended maintenance for the generator
set is listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).
137
Maintenance Section
Maintenance and Repair
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the
subsequent maintenance intervals must be
performed by an authorized service technician or by
your Cat dealer.
Unless other instructions are provided, perform
maintenance and repairs under the following
conditions:
• The engine is stopped.
• The starting system is disabled.
• The generator does not pose an electrical shock
hazard.
• The generator is disconnected from the load.
Operation
To ensure proper operation, the generator set must
be exercised regularly. For instructions on operating
the generator set, see the Operation and
Maintenance Manual for the generator set control
panel.
For these operation procedures, follow the
instructions that are provided in this Operation and
Maintenance Manual, “Operation Section”: starting
the engine, engine operation and stopping the
engine.
Record Keeping
Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems and repairs.
Space Heaters
Moisture can damage generators and other electrical
equipment. Make every effort to keep the generator
set as dry as possible.
Generators can operate without problems in humid
environments. However, problems can occur when
the generator is inactive. Moisture can condense on
the windings. This condition can result in poor
performance. Also, damage to the windings can
occur.
138
Maintenance Section
Starting Motor - Inspect
Use space heaters in order to help keep the windings
dry. When the generator is not active, ensure that the
space heaters are operating. When the generator is
operating, turn OFF the space heaters.
i02348493
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
Caterpillar recommends a scheduled inspection of
the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Check the starting motor for correct operation. Check
the electrical connections and clean the electrical
connections. Refer to the Systems Operation, Testing
and Adjusting Manual, “Electric Starting System -
Test” for more information on the checking procedure
and for specifications or consult your Caterpillar
dealer for assistance.
i03153545
Turbocharger - Inspect
SMCS Code: 1052-040
A regular visual inspection of the turbocharger is
recommended. If the turbocharger fails during engine
operation, damage to the turbocharger compressor
wheel and/or to the engine may occur. Damage to
the turbocharger compressor wheel can cause
additional damage to the pistons, the valves, and the
cylinder head.
NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air intake and exhaust sys-
tems. Loss of engine lubricant can result in serious
engine damage.
Minor leakage of oil into a turbocharger under ex-
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not
occured.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed.
A visual inspection of the turbocharger can minimize
unscheduled downtime. A visual inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
Removal and Installation
Note: The turbochargers that are supplied are
nonserviceable.
SEBU8734-09
For options regarding the removal, installation, and
replacement, consult your Carerpillar dealer. Refer to
the Disassembly and Assembly Manual,
“Turbocharger - Remove and Turbocharger - Install”
for further information.
Inspecting
NOTICE
The compressor housing for the turbocharger must
not be removed from the turbocharger for inspection
or removed for the cleaning of the compressor.
1. Remove the pipe from the turbocharger exhaust
outlet and remove the air intake pipe to the
turbocharger. Visually inspect the piping for the
presence of oil. Clean the interior of the pipes in
order to prevent dirt from entering during
reassembly.
2. Check for obvious heat discoloration of the
turbocharger. Check for any loose bolts or any
missing bolts. Check for damage to the oil supply
line and the oil drain line. Check for cracks in the
housing of the turbocharger. Ensure that the
compressor wheel can rotate freely.
3. Check for the presence of oil. If oil is leaking from
the back side of the compressor wheel, there is a
possibility of a failed turbocharger oil seal.
The presence of oil may be the result of a
restriction of the line for the intake air (clogged air
filters), which causes the turbocharger to slobber.
4. Inspect the bore of the housing of the turbine outlet
for corrosion.
5. Fasten the air intake pipe and the exhaust outlet
pipe to the turbocharger housing. Ensure that all
clamps are installed correctly and that all clamps
are tightened securely.
i06046713
Walk-Around Inspection
SMCS Code: 1000-040
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose
connections, and trash buildup. Make repairs, as
needed:
SEBU8734-09
Inspect the Tube for the Crankcase
Breather
Illustration 102 g03787926
Typical example
Inspect the breather tube (1) for damage. Ensure that
the outlet (2) is clean and free from any obstructions.
Ice can cause an obstruction in the tube in adverse
weather conditions.
Inspect the Engine for Leaks and
for Loose Connections
• The guards must be in the correct place. Repair
damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu-
id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.
NOTICE
Accumulated grease and/or oil on an engine is a fire
hazard. Remove the accumulated grease and oil. Re-
fer to this Operation and Maintenance Manual, “En-
gine - Clean” for more information.
139
Maintenance Section
Walk-Around Inspection
• Ensure that the cooling system hoses are correctly
clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all
pipes.
• Inspect the water pump for coolant leaks.
Note: The water pump seal is lubricated by the
coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and the parts contract.
Excessive coolant leakage may indicate the need to
replace the water pump. Remove the water pump.
Refer to Disassembly and Assembly , “Water Pump -
Remove and Install”. For more information, consult
your Cat dealer.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters, and the rocker cover.
• Inspect the piping for the air intake system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses.
• Ensure that the areas around the rotating parts are
clear.
• Inspect the alternator belts and any accessory
drive belts for cracks, breaks, or other damage.
• Inspect the wiring harness for damage.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
High Pressure Fuel Lines
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
After the engine has stopped, wait for 10 minutes in
order to allow the fuel pressure to be purged from the
high-pressure fuel lines before any service or repair
is performed on the engine fuel lines. If necessary,
perform minor adjustments. Repair any leaks from
the low-pressure fuel system and from the cooling,
lubrication, or air systems. Replace any high-
pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection
Lines - Install”.
140 SEBU8734-09
Maintenance Section
Water Pump - Inspect

If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General Hazard Information”.
Visually inspect the high-pressure fuel lines for
damage or signs of fuel leakage. Replace any
damaged high-pressure fuel lines or high-pressure
fuel lines that have leaked.
Ensure that all clips on the high-pressure fuel lines
are in place and that the clips are not loose.
• Inspect the rest of the fuel system for leaks. Look
for loose fuel line clamps.
Note: If engine coolant enters the engine lubricating
system the lubricating oil and the engine oil filter must
be replaced. This will remove any contamination that
is caused by the coolant and this will prevent any
irregular oil samples.
The water pump is not a serviceable item. In order to
install a new water pump, refer to the Disassembly
and Assembly Manual, “Water Pump - Remove and
Install” or contact your Caterpillar dealer.

• Drain the water and the sediment from the fuel

tank on a daily basis in order to ensure that only
clean fuel enters the fuel system.

• Drain the primary filter water separator.

• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires. Check for any loose tie-wraps or missing
tie-wraps.

• Inspect the ground strap for a good connection

and for good condition.

• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
cannot be calibrated.

i02794230

Water Pump - Inspect

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

• A piston seizure
• Other potential damage to the engine
Note: The water pump seal is lubricated by the
coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and parts contract.
Visually inspect the water pump for leaks.
SEBU8734-09 141
Warranty Section
Warranty Information

Warranty Section The aftertreatment system can be expected to

function properly for the lifetime of the engine
(emissions durability period) subject to prescribed
maintenance requirements being followed.
Warranty Information
A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and
i05549472 stationary diesel engines, including the components
covered and the warranty period, is found in a
Emissions Warranty supplemental Special Publication. Consult your
authorized Cat dealer to determine if your engine is
Information subject to an Emission Control Warranty and to
SMCS Code: 1000 obtain a copy of the applicable Special Publication.

The certifying engine manufacturer warrants to the

ultimate purchaser and each subsequent purchaser
that:
1. New non-road diesel engines and stationary diesel
engines less than 10 liters per cylinder (including
Tier 1 and Tier 2 marine engines < 37 kW, but
excluding locomotive and other marine engines)
operated and serviced in the United States and
Canada, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
standards prescribed by the United States
Environmental Protection Agency (EPA) by way
of regulation.
b. Free from defects in materials and
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and
workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
142
Reference Information Section
Engine Ratings
Reference Information
Section
Engine Ratings
i05379149
Engine Rating Conditions
SMCS Code: 1000
Ratings are based on SAE J1128/ISO 8665 standard
ambient conditions of 100 kPa (29.5 inch mercury)
and 25° C (77° F). Ratings also apply at AS1501,
BS5514, DIN 6271 and ISO 3046/1 standard
conditions of 100 kPa (29.5 inch mercury), 27° C (81°
F), and 60% relative humidity. Power is based on a
35° (16° C (61° F) fuel which has Low heat value
(LHV) of 42780 kJ/kg (18390 B/lb) used at 29° C (84°
F) with a density of 838.9 g/L (7.001 lb/US gal).
Engine ratings may be defined as gross output
ratings or as the total output capability of the engine
when equipped with lubrication oil, fuel and jacket
water pumps. The power to drive auxiliary
applications must be deducted from the gross output
to arrive at the net power available for the external
(flywheel) load. Typical auxiliary applications include
cooling fans, air compressors, charging alternators,
marine gears, and sea water pumps.
i08708606
Engine Rating Definitions
SMCS Code: 1000
The ratings must be reduced to accommodate
changes in the altitude. The ratings must be reduced
according to the data for derating that is obtained
from the test specification for the engine.
All ratings that are defined have a manufacturing
tolerance of ± 3 percent.
Use the following guidelines to determine the
applicable engine rating.
NOTICE
Operating an engine at a greater power output than
the engine is rated for will reduce the service life of
the engine before overhaul.
Ratings for Generator Set Engines
Load Factor – The sum of the loads divided by the
number of hours of operation. Idle time and down
time are not part of the calculation.
Power Interruption – Unexpected failure of the utility
power supply.
SEBU8734-09
Operating Cycle – Unless the operating cycle is
specified differently, the operating cycle for
calculating the load factors and the peak load limits is
not to exceed 24 hours. The operating cycle does not
include the time when the engine is not operating.
Continuous – This rating allows a constant load or a
load that varies for an unlimited number of hours per
year. The normal load factor is up to 100 percent for
an unlimited number of hours per year. The following
applications are suggested: base load, utility,
cogeneration, and parallel operation.
Prime – This rating allows a load that varies for an
unlimited number of hours per year. The normal load
factor is up to 80 percent for an unlimited number of
hours per year. A 100 percent load is only allowed for
5 percent of the operating cycle. The following
applications are suggested: industrial, pumping,
construction, and cogeneration.
Prime + 10% (Standby applications for a power
supply from a reliable utility) – This rating allows a
load that varies up to the Prime rating. An additional
10 percent is allowed during power interruption. The
normal load factor is up to 80 percent for 100 hours
per year. A 100 percent load is only allowed for 5
percent of the operating cycle. The suggested
application is Standby for a power supply from a
reliable utility.
Prime + 10% (Applications that are industrial,
pumping, construction, and cogeneration) – This
rating allows a load that varies up to the Prime rating.
The normal load factor is up to 80 percent for an
unlimited number of hours per year. A load of 100
percent is only allowed for 5 percent of the operating
cycle. The following applications are suggested:
industrial, pumping, construction, and cogeneration.
Standby – This rating allows a load that varies during
power interruption. The normal load factor is up to 80
percent for 100 hours per year. A 100 percent load is
only allowed for 5 percent of the operating cycle. The
suggested application is Standby for a power supply
from a reliable utility.
Mission Critical Standby Power Rating – Typical
usage of 200 hours per year and maximum usage of
500 hours per year with varying loads. Average
varying load factor is 85 percent of standby rating.
Typical peak demand of up to 100 percent of the
rating for 5 percent of the operating time. No overload
is available. Not for maintained utility paralleling
applications.
For Data Center Applications Only – Prime-DCP
power output available with varying load for unlimited
time. Average power output is not to exceed
100%. Typical peak demand is 100% of Prime-DCP
rated ekW with 10% overload capability for
emergency use for a maximum of 1 hour in
12. Overload operation cannot exceed 25 hours
per year.
SEBU8734-09 143
Reference Information Section
Engine Rating Definitions

Load Management Peak Shaving Rating

Guidelines
Interruptible (Isolated from the utility with a
Standby base rating for load factors) – This rating
allows a load that varies for less than 12 hours per
day. The typical peak load factor is up to 80 percent
for less than 500 hours per year. The peak operating
limit is a load factor up to 100 percent. A 100 percent
load is only allowed for 5 percent of the operating
cycle. The operating cycle for calculating the load
factors and the peak load limits is not to exceed 6
hours. The operating cycle does not include the time
when the engine is not operating.
Interruptible (Isolated from the utility with a Prime
base rating for load factors) – This rating allows a
load that varies for more than 12 hours per day. The
typical peak load factor is up to 80 percent for an
unlimited number of hours per year. The peak
operating limit is a load factor up to 100 percent. A
100 percent load is only allowed for 5 percent of the
operating cycle.
Curtailment (Connected to a utility with a special
base rating for load factors) – This rating allows a
constant load or a load that varies for less than 6
hours per day. The typical peak load factor is up to
100 percent for a maximum of 500 hours per year.
The peak operating limit is up to 100 percent load for
a maximum of 500 hours per year.
Curtailment (Connected to a utility with a
Continuous base rating for load factors) – This
rating allows a constant load or a load that varies for
more than 6 hours per day. The normal load factor is
up to 100 percent for an unlimited number of hours
per year. The peak load factor is up to 100 percent
for an unlimited number of hours per year.
144 SEBU8734-09
Reference Information Section
Customer Service

Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i08302979
P.O. Box 6000
CH-1211 Geneva 6
Customer Assistance Switzerland
SMCS Code: 1000; 4450 Phone: 22-849-4444
Fax: 22-849-4544
USA and Canada Far East
Caterpillar Asia Pte. Ltd.
When a problem arises concerning the operation or 7 Tractor Road
the service of an engine, the problem will normally be
managed by the dealer in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Cat dealers. If you have a problem that has Fax: 65-662-8302
not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level, use the phone number that is listed below to Hong Kong
talk with a Field Service Coordinator: Phone: 852-2848-0333
Fax: 852-2848-0440
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday Japan
Shin Caterpillar Mitsubishi Ltd.
through Friday Central Standard Time.
SBS Tower
3. If your needs have not been met still, submit the 10-1, Yoga 4-Chome
matter in writing to the following address: Setagaya-Ku, Tokyo 158-8530
Japan
Designated Compliance Officer Heavy-Duty and Phone: 81-3-5717-1150
Nonroad Engine Group 6403-J, Fax: 81-3-5717-1177
US Ave, NW, Washington,
DC 20460 Japan
Email address: complianceinfo@epa.gov. Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
Your problem may ultimately be solved at the 4-10-1, Yoga
dealership, using the dealership facilities, Setagaya-Ku, Tokyo 158-0097
equipment, and personnel. Therefore, follow the Phone: 81-3-5797-4300
steps in sequence when a problem is experienced. Fax: 81-3-5797-4359

Outside of the USA and of Canada

If a problem arises outside the USA and outside
Canada, and if the problem cannot be resolved at the
dealer level, consult the appropriate Cat office.

Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
SEBU8734-09 145
Reference Information Section
Ordering Replacement Parts

Australia and New Zealand i07517782

Caterpillar of Australia Ltd.
1 Caterpillar Drive On-Board Replacement Parts
Private Mail Bag 4
Tullamarine, Victoria 3043 SMCS Code: 7567
Australia The various Marine Classification Societies require a
Phone: 03-9953-9333 supply of replacement parts on vessels that are
Fax: 03-9335-3366 primarily powered by diesel engines. The
replacement parts may be needed for making repairs
i08292376 offshore or at remote ports. The types of replacement
parts and the numbers of parts depends on the range
Ordering Replacement Parts of the vessel. The following two categories of vessels
are considered:
SMCS Code: 4450; 7567
Category 1 – This category includes vessels that
make short trips between ports.
Category 2 – This category includes vessels in
When replacement parts are required for this ocean service that is unrestricted. The vessels may
product Caterpillar recommends using Caterpillar travel far from ports that provide service. The list of
replacement parts or parts with equivalent speci- replacement parts for this category is more
fications including, but not limited to, physical di- extensive.
mensions, type, strength and material.
Failure to heed this warning can lead to prema- Table 28 lists the parts that are recommended by
ture failures, product damage, personal injury or Caterpillar for vessels in both categories.
death.
The requirements of individual Marine Classification
Quality Cat replacement parts are available from Cat Societies may differ. Table 29 lists the requirements
dealers throughout the world. Cat dealer parts of all the Marine Classification Societies. Additionally,
inventories are up to date. The parts stocks include some items that are recommended by Caterpillar are
all the parts that are normally needed to protect your listed. All of the parts that are listed in Table 28 and
Cat engine investment. 29 are recommended for vessels in Category 2. To
customize this list for your specific engine
When you order parts, specify the following application, consult your Cat dealer.
information:
Note: Check with your local class society for any
• Part number questions regarding the onboard replacement parts.

• Part name Table 28

Recommended Replacement Parts for Vessels in Cat-
• Quantity egory 1 and Category 2
If there is a question concerning the part number, Quantity Item
provide your dealer with a complete description of the
needed item. 4 Air cleaner element

When a Cat engine requires maintenance and/or 1 Alternator belt

repair, provide the dealer with all the information that 1 Electronic control module (ECM)
is stamped on the Information Plate. This information
is described in this Operation and Maintenance 1 Electronic unit injector
Manual (Product Information Section).
- Engine oil
Discuss the problem with the dealer. Inform the - Extended Life Coolant (ELC) and Extender
dealer about the conditions of the problem and the or
nature of the problem. Inform the dealer about when Diesel Engine Antifreeze/Coolant (DEAC) and Sup-
the problem occurs. This information will help the plemental Coolant Additive (SCA)
dealer in troubleshooting the problem and solving the
problem faster. 4 Fuel filter elements
1 Fluid sampling bottles

- Liquid gasket material

(continued)
146 SEBU8734-09
Reference Information Section
On-Board Replacement Parts

(Table 28, contd) (Table 29, contd)

Recommended Replacement Parts for Vessels in Cat- Recommended Replacement Parts for Vessels in Cat-
egory 1 and Category 2 egory 2

Quantity Item System Quantity Item

4 Engine oil filters Miscellaneous 1 Gasket kit (engine)

1 Service kit (electronic connector) Piston 1 Connecting rod assembly

4 Water temperature regulator 1 Connecting rod bearing

4 Zinc rods 1 Cylinder liner

1 Filler band (cylinder liner)

Table 29
Recommended Replacement Parts for Vessels in Cat- 1 Main bearing
egory 2 2 Cap bolt and washer (main
bearing)
System Quantity Item
1 Piston assembly
Camshaft and 1 Bolt (crankshaft to flywheel)
crankshaft 1 Piston pin
1 Camshaft gear
2 Piston pin retainer
1 Crankshaft gear
1 Piston rings (complete set)
1 Idler gear and balance weight
gear assembly (water pump) 3 Seals (cylinder liner)
1 Shaft and thrust washer (idler Starting 1 Starting motor
gear and balance weight gear
assembly) Turbocharger 1 Complete turbocharger

Cooling 1 Aftercooler core and gasket - Gasket

1 Auxiliary water pump 4 Locknut

1 Jacket water pump 4 Stud (mounting)

1 SCAC Pump Valves 6 Exhaust valves

4 Inlet valves
4 Water temperature regulator
10 Valve guides
Cylinder head 6 Bolt and washer
24 Valve locks
1 Bolt and nut (exhaust manifold)
10 Valve rotators
1 Cylinder head assembly
10 Valve springs
4 Gasket (cylinder)

- Water seals for one cylinder

Fuel 3 Electronic unit injector

1 Fuel transfer pump

3 Seal (electronic unit injector)

Inlet air 2 Air cleaner element

Lubrication 1 Bypass valve (oil cooler)

1 Bypass valve (oil filter)

1 Gasket (oil pan)

1 Oil cooler core (engine)

1 Oil cooler core (marine gear)

(continued)
SEBU8734-09 147
Reference Information Section
Reference Materials

Reference Materials
i08530562

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

• Establish maintenance schedules for other

engines that are operated in the same
environment.

• Show compliance with the required maintenance

practices and maintenance intervals.
Maintenance records can be used for various other
business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is managed. Accurate
maintenance records can help your Cat dealer to
fine-tune the recommended maintenance intervals to
meet the specific operating situation. These
recommendations should result in a lower engine
operating cost.
Records should be kept for the following items:
Fuel Consumption – A record of fuel consumption is
essential to determine when the load sensitive
components should be inspected or repaired. Fuel
consumption assists in determining overhaul
intervals.
Service Hours – A record of service hours is
essential to determine when the speed sensitive
components should be inspected or repaired.
Documents – These items should be easy to obtain,
and these items should be kept in the engine history
file. All documents should show this information:
date, service hours, fuel consumption, unit number,
and engine serial number. The following types of
documents should be kept as proof of maintenance
or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
• Dealer work orders and itemized bills

• Owner repair costs

• Owner receipts

• Maintenance log
148 SEBU8734-09
Reference Information Section
Maintenance Log

i08254037

Maintenance Log
SMCS Code: 1000; 4450

Table 30
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU8734-09
i06046738
Reference Material
SMCS Code: 1000; 4450
The following literature can be obtained through any
Cat dealer.
Engine Oil
• Datasheet, PEHJ0159, “Cat DEO-ULS (SAE
15W-40)” (North America - Canada, Mexico, and
United States)
• Datasheet, PEHJ0059, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (North America - Canada,
Mexico, and United States)
• Datasheet, PEHJ0021, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Worldwide - except North
America, Egypt, Saudi Arabia, and Brazil)
• Datasheet, PEHJ0072, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Brazil)
• Datasheet, PEHJ0091, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Egypt and Saudi Arabia)
• Datasheet, PEHJ0008, “Cat Arctic DEO (SAE 0W-
30)” (Canada and United States)
Coolants
• Special Publication, PEHP4036, “Data Sheet -
Extended Life Coolant”
• Special Publication, SEBD0518, “Know Your
Cooling System”
• Special Publication, SEBD0970, “Coolant and
Your Engine”
Fuels
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine”
S·O·S Services
• Special Publication, PEHJ0191, “S·O·S Coolant
Analysis”
• Special Publication, PEGJ0047, “How To Take A
Good Oil Sample”
• Special Publications, PEDP7036, “S·O·S Fluids
Analysis Cornerstone”
• Special Publications, PEHP7076, “Understanding
S·O·S Services Tests”
149
Reference Information Section
Reference Material
• Special Publication, PEHP7052, “Making the Most
of S·O·S Services”
• Special Publication, PEGJ0045, “Reporting
Particle Count by ISO Code”
• Special Publication, PEGJ0046, “Understanding
Your S·O·S Services Results”
Miscellaneous
• Specifications, UENR0661, “C7.1 Marine
Generator Set Specifications”
• Systems Operation/Testing and Adjusting,
UENR0662, “C7.1 Marine Generator Set SOTA”
• Disassembly and Assembly, UENR0663, “C7.1
Marine Generator Engine D&A”
• Troubleshooting, UENR3438, “C7.1 Marine
Generator Set Engine Troubleshooting”
• Electrical Schematic, UENR3998, “C7.1 Marine
Generator Set Electrical System”
• Special Publication, PECP9067, “One Safe
Source” English language for use in NACD
• Special Publication, LEDM5615, “Caterpillar
Marine Parts and Service Locations Directory”
• Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
Operations”
• Special Publication, SEBF8062, “Procedure to
Inspect and Clean Air Filters”
• Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
• Special Publication, NEHS0526, “Service
Technician Application Guide”
• Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
Recommendations”
• Special Instruction, SEHS7633, “Battery Test
Procedure”
• Label, SEHS7332, “Danger Do Not Operate”
• Specifications, UENR0661, “C7.1 Marine
Generator Set Specifications”
• Systems Operation/Testing and Adjusting,
UENR0662, “C7.1 Marine Generator Set SOTA”
• Disassembly and Assembly, UENR0663, “C7.1
Marine Generator Set D&A”
150 SEBU8734-09
Reference Information Section
Decommissioning and Disposal

• Specifications, UENR3436, “C7.1 Marine

Generator Set Engines”

• Electrical Schematic, UENR3998, “C7.1 Marine

Generator Set Electrical System”

Emissions Warranty
This engine may be Certified and this engine may be
covered by an Emissions Warranty. A detailed
explanation of the Emissions Warranty that is
applicable to Certified engines is found in
Supplement, SMBU6981, “Emissions Control
Warranty Information”. The engine is Certified if the
engine has a special label that verifies the
certification. A Cat dealer can also inform you if the
engine is certified.

i08292382

Decommissioning and
Disposal
SMCS Code: 1000
When the product is removed from service, local
regulations for the product decommissioning will
vary. Disposal of the product will vary with local
regulations.
Improperly disposing of waste can threaten the
environment. Obey all local regulations for the
decommissioning and disposal of materials.
Utilize appropriate personal protective equipment
when decommissioning and disposing product.
Consult the nearest Cat dealer for additional
information. Including information for component
remanufacturing and recycling options.
SEBU8734-09 151
Index Section

Index
A MCS Control Panel ...................................... 44
Coolant - Change ............................................ 96
After Starting Engine ....................................... 60
Drain the Cooling System............................ 96
After Stopping Engine ..................................... 71
Fill the Cooling System ................................ 98
Aftercooler Condensate Drain Valve -
Flush ............................................................ 97
Inspect/Clean................................................. 89
Coolant Extender (ELC) - Add ........................ 98
Air Cooled .................................................... 89
Coolant Level - Check ..................................... 99
Water cooled................................................ 89
Coolant Sample (Level 1) - Obtain.................. 99
Aftercooler Core - Clean/Test.......................... 90
Sampling Conditions.................................... 99
Aftercooler Core - Inspect ............................... 91
Timing of the Sampling .............................. 100
Alarms and Shutoffs ........................................ 42
Coolant Sample (Level 2) - Obtain................ 100
Alarms.......................................................... 42
Obtaining the Sample ................................ 100
Prevention of Start-up.................................. 43
Coolant Temperature Regulator - Replace ... 101
Setpoints for Alarms and Shutoffs ............... 43
Cooling System Supplemental Coolant
Shutoffs........................................................ 42
Additive (SCA) - Test/Add............................ 101
Testing Alarms and Shutoffs........................ 43
Add the SCA, If Necessary ........................ 102
Alternator - Inspect .......................................... 91
Test the Concentration of the SCA ............ 102
Alternator and Fan Belts - Replace ................. 91
Crushing Prevention and Cutting Prevention.. 19
Engine that is Radiator Cooled.................... 92
Customer Assistance .................................... 144
Keel Cooled and Heat Exchanged .............. 91
Outside of the USA and of Canada ........... 144
Automatic Start/Stop - Inspect ........................ 93
USA and Canada....................................... 144
Auxiliary Water Pump (Rubber Impeller) -
Customer Service.......................................... 144
Inspect/Replace............................................. 93

D
B
Declaration of Conformity (European Union).. 33
Battery - Replace............................................. 93
Declaration of Conformity (Great Britain)........ 34
Battery Charger - Check.................................. 94
Decommissioning and Disposal.................... 150
Battery Electrolyte Level - Check .................... 94
Battery or Battery Cable - Disconnect............. 94
Before Starting Engine .............................. 21, 58 E
Belt - Inspect.................................................... 95 Electrical Connections - Check ..................... 103
Belt Tensioner - Check .................................... 95 Electrical System............................................. 22
Burn Prevention............................................... 17 Grounding Practices .................................... 22
Batteries....................................................... 17 Emergency Stopping....................................... 71
Coolant ........................................................ 17 Emergency Stop Button............................... 71
Diesel Fuel ................................................... 17 Emissions Certification Film ............................ 35
Oils............................................................... 17 Emissions Warranty Information ................... 141
Engine - Clean............................................... 103
C Engine Air Cleaner Element (Single
Element) - Inspect/Clean/Replace .............. 103
Cold Weather Starting ..................................... 58
Engine Air Cleaner Service Indicator -
Control Panel - Inspect/Test ............................ 96
Inspect ......................................................... 104
Control Panel (Customer Connect)................. 43
Test the Service Indicator .......................... 104
Control Panel (EMCP 4.2 (If Equipped)) ......... 47
Engine Crankcase Breather - Replace ......... 104
Electronic Control Module (Generator
Engine Electronics........................................... 23
Set)............................................................. 47
Engine Mounts - Inspect................................ 106
Control Panel (Marine Classification
Engine Oil and Filter - Change (Duplex Oil
Society (MCS) Control Panel (If Equipped)
filters) ............................................................110
)...................................................................... 44
152
Index Section
Commissioning Procedure for Duplex Oil
Filters ........................................................ 111
Replace Engine Oil .....................................110
Engine Oil and Filter - Change (Single Oil
Filter)............................................................ 107
Drain the Engine Lubricating Oil................ 108
Fill the Oil Pan............................................ 109
Single Oil Filter .......................................... 108
Engine Oil Level - Check............................... 106
Engine Oil Sample - Obtain........................... 107
Obtain the Sample and the Analysis ......... 107
Engine Operation ............................................ 61
Engine Protective Devices - Check................113
Calibration Check .......................................113
Visual Inspection.........................................113
Engine Rating Conditions.............................. 142
Engine Rating Definitions.............................. 142
Ratings for Generator Set Engines ........... 142
Engine Ratings .............................................. 142
Engine Starting.......................................... 21, 58
Engine Stopping ........................................ 22, 71
F
Features and Controls..................................... 42
Fire Prevention and Explosion Prevention...... 17
Fire Extinguisher.......................................... 19
Lines, Tubes, and Hoses ............................. 19
Fluid Recommendations ................................. 73
Cooling System............................................ 77
Diesel Engine Oil ......................................... 73
Fuel .............................................................. 76
Fuel Specification Requirements by
Emissions Certification .............................. 77
Lubricating Grease ...................................... 80
Foreword ........................................................... 4
California Proposition 65 Warning ................. 4
Literature Information .................................... 4
Maintenance .................................................. 4
Maintenance Intervals ................................... 5
Operation ....................................................... 4
Overhaul ........................................................ 5
Safety............................................................. 4
Fuel Conservation Practices ........................... 61
Fuel System - Prime .......................................114
Fuel System Primary Filter (Water
Separator) Element - Replace......................114
Duplex Fuel Filters......................................115
Single Fuel Filter.........................................114
Fuel System Primary Filter/Water
Separator - Drain ..........................................117
Duplex Fuel Filters......................................117
SEBU8734-09
Single Fuel Filter.........................................117
Fuel System Secondary Filter - Replace .......118
Replacing Duplex Filters While the Engine is
in Operation ............................................. 120
Single Filter.................................................118
Fuel Tank Water and Sediment - Drain ......... 121
Drain the Water and the Sediment ............ 121
Fuel Storage Tanks.................................... 121
Fuel Tank ................................................... 121
G
Gauges and Indicators .................................... 48
General Hazard Information............................ 13
Containing Fluid Spillage............................. 14
Dispose of Waste Properly .......................... 16
Fluid Penetration ......................................... 14
Inhalation ..................................................... 15
Lines, Tubes, and Hoses ............................. 15
Pressurized Air and Water........................... 14
Softwrap....................................................... 16
Static Electricity Hazard when Fueling with
Ultra-low Sulfur Diesel Fuel ....................... 15
General Information ........................................ 25
General Maintenance Information................... 81
Generator - Dry.............................................. 122
Circulating Current..................................... 124
External Heat ............................................. 123
Internal Heating ......................................... 123
Generator - Inspect ....................................... 124
Cleaning (Assembled Generators) ............ 124
Cleaning (Disassembled Generators) ....... 125
Generator Bearing Temperature - Test/
Record ......................................................... 125
Infrared Thermometers.............................. 125
Resistive Temperature Detectors
(RTDs) ..................................................... 125
Generator Isolating for Maintenance............... 23
Generator Lead Connections .......................... 69
Grounding the Frame .................................. 70
Lead Numbering .......................................... 69
Multiple Units ............................................... 70
Neutral Connections .................................... 70
Parallel to Utility ........................................... 70
Single Units.................................................. 70
Generator Load - Check................................ 125
Generator Operation ....................................... 62
Block Loading .............................................. 62
Excitation System ........................................ 63
Generator Options ....................................... 63
Loading of the Generator............................. 62
Power Factor ............................................... 63
SEBU8734-09
Standby (Emergency) Electric Sets............. 63
Generator Set - Test ...................................... 126
Generator Set Vibration - Inspect.................. 126
Generator Start-up Checklist........................... 83
Generator Winding Insulation - Test.............. 127
Recommended Periodic Insulation Tests .. 127
Recommended Procedure for A Periodic
Insulation Test .......................................... 128
H O
Heat Exchanger - Inspect.............................. 130
Cleaning the Heat Exchanger.................... 130
High Pressure Fuel Lines ................................ 20
Hoses and Clamps - Inspect/Replace........... 131
Replace the Hoses and the Clamps .......... 131
I Overhaul Recommendation....................... 132
Important Safety Information............................. 2
Installation ....................................................... 41
J Parallel Operation............................................ 64
Jacket Water Heater - Check ........................ 132
L Equipped)................................................... 66
Lifting and Storage .......................................... 36
M Stopping....................................................... 67
Maintenance Interval Schedule....................... 87
Daily ............................................................. 87
Every 1000 Service Hours........................... 87
Every 1000 Service Hours or 1 Year ........... 88
Every 1500 Service Hours........................... 88
Every 2000 Service Hours........................... 88
Every 2000 Service Hours or 1 Year ........... 88
Every 250 Service Hours ............................. 87
Every 3000 Service Hours........................... 88
Every 3000 Service Hours or 3 Years ......... 88
Every 4000 Service Hours........................... 88
Every 500 Service Hours ............................. 87
Every 500 Service Hours or 1 Year ............. 87
Every 6000 Service Hours or 3 Years ......... 88
Every Week ................................................. 87
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems) ........... 87
Overhaul ...................................................... 88
When Required............................................ 87
Maintenance Log........................................... 148
Maintenance Recommendations .................... 81
153
Index Section
Maintenance Records ................................... 147
Maintenance Section....................................... 73
Manual Stop Procedure .................................. 71
Model View Illustrations .................................. 25
Radiator Cooled........................................... 27
Sea Water Cooled with Marine Classification
Society (MCS) Control Panel..................... 25
Mounting and Dismounting ............................. 20
On-Board Replacement Parts ....................... 145
Operation Section............................................ 36
Ordering Replacement Parts......................... 145
Overhaul Considerations............................... 132
Oil Consumption as an Overhaul
Indicator ................................................... 132
Overspeed....................................................... 49
P
Circulating Currents..................................... 68
Initial Start-Up .............................................. 64
Load Division and Speed Droop (If
Parallel Operation Of Governors ................. 66
Paralleling Multiple Units ............................. 66
Starting Multiple Units.................................. 66
Plate Locations and Film Locations ................ 30
Engine Information Plate (2)........................ 30
Eurasian Economic Union ........................... 32
Generator Identification Plate (1) ................ 30
Rating Plate ................................................. 31
Regional Product Marking (If Equipped) ..... 32
Serial Number Plate (3) ............................... 30
Product Description......................................... 28
Electronic Engine Features ......................... 29
Engine Cooling and Lubrication .................. 29
Engine Diagnostics...................................... 29
Engine Specifications .................................. 28
Engine Speed Governing ............................ 29
Product Identification Information ................... 30
Product Information Section............................ 25
Product Installation.......................................... 41
Product Lifting ................................................. 36
Four lifting Eye design ................................. 39
Lifting the Engine Only................................. 38
Lifting the Entire Package............................ 36
Lifting the Generator Only ........................... 38
154
Index Section
Two lifting Eye Design ................................. 38
Product Storage .............................................. 39
Bearing Inspection....................................... 40
Electrical Measurements ............................. 40
Storage - Greater than 30 Days and less than
1 Year ......................................................... 39
Storage - Greater than 7 Days and less than
30 Days ...................................................... 39
R Starting Motor - Inspect ................................. 138
Radiator - Clean ............................................ 134
Reference Information..................................... 35
Record for Reference .................................. 35
Reference Information Section ..................... 142
Reference Material ........................................ 149
Coolants..................................................... 149
Emissions Warranty................................... 150
Engine Oil .................................................. 149
Fuels .......................................................... 149
Miscellaneous ............................................ 149
S·O·S Services .......................................... 149
Reference Materials ...................................... 147
Refill Capacities............................................... 73
Lubrication System ...................................... 73
Rotating Rectifier - Check ............................. 135
Rotating Rectifier - Inspect/Test .................... 135
S
Safety Messages............................................... 6
Automatic Starting (6)...................................11
Crushing Warning (7)................................... 12
Do Not Use Ether (3) ................................... 10
Hand High Pressure (4) ............................... 10
Hot Fluid Under Pressure (5)........................11
Shock/Electrocution (2) ............................... 10
Universal Warning (1) .................................... 9
Safety Section ................................................... 6
Sea Water Strainer - Clean/Inspect .............. 136
Sensors and Electrical Components............... 49
Marine Classification Society (MCS)
Sensors...................................................... 55
Standard Sensor View................................. 50
Severe Service Application ............................. 85
Improper Maintenance Procedures
(Maintenance Procedures Which May
Contribute to a Severe Service
Application) ................................................ 86
Severe Environmental Factors .................... 85
Severe Operating Conditions ...................... 85
Single Unit Operation ...................................... 63
SEBU8734-09
Adjust the Voltage........................................ 64
Initial Start-Up .............................................. 63
Starting ........................................................ 64
Stopping....................................................... 64
Speed Sensor - Clean/Inspect ...................... 136
Standby Generator Set Maintenance
Recommendations (Emergency Standby
Generator Set)............................................. 137
Maintenance and Operation Procedures .. 137
Starting the Engine.......................................... 58
First Start Procedure ................................... 58
Normal Start Procedure............................... 59
Starting with Jump Start Cables...................... 59
System Pressure Release............................... 81
Coolant System ........................................... 81
Engine Oil .................................................... 82
Fuel System................................................. 81
T
Table of Contents .............................................. 3
Turbocharger - Inspect .................................. 138
Inspecting .................................................. 138
Removal and Installation ........................... 138
V
Voltage Regulators .......................................... 68
W
Walk-Around Inspection ................................ 138
High Pressure Fuel Lines .......................... 139
Inspect the Engine for Leaks and for Loose
Connections ............................................. 139
Inspect the Tube for the Crankcase
Breather ................................................... 139
Warranty Information..................................... 141
Warranty Section ........................................... 141
Water Pump - Inspect.................................... 140
Welding on Engines with Electronic
Controls ......................................................... 82
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
SEBU8734 CAT, CATERPILLAR, LET’S DO THE WORK, their respective
©2022 Caterpillar logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat
All Rights Reserved “Modern Hex” trade dress as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used
without permission.

156 January 2022