OMM SEBU9236-5 DE Series Generator Set With Cat C1.1, C1.5, and C2.2 Engine Caterpillar

SEBU9236-05 (en-us)
August 2017
Operation and
Maintenance
Manual
DE Series Generator Set with Cat C1.1,
C1.5, and C2.2 Engine
TYB 1-UP (Generator Set)
GB8 1-UP (Generator Set)
TY2 1-UP (Generator Set)
SMF 1-UP (Generator Set)
GBY 1-UP (Generator Set)
TYC 1-UP (Generator Set)
WRT 1-UP (Generator Set)
GB9 1-UP (Generator Set)
SAFETY.CAT.COM
i06558969
Important Safety Information

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

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

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU9236-05 3
Table of Contents
Table of Contents Refill Capacities............................................... 60
Maintenance Recommendations .................... 62

Foreword ........................................................... 4
Maintenance Interval Schedule (Standby)...... 64
Safety Section
Maintenance Interval Schedule (Prime
Safety Messages............................................... 5
Power) ........................................................... 65
Additional Messages ....................................... 13
Reference Information Section
General Hazard Information............................ 15
Customer Service............................................ 97
Burn Prevention............................................... 18
Reference Materials ........................................ 99
Fire Prevention and Explosion Prevention...... 19
Index Section
Crushing Prevention and Cutting Prevention.. 21
Index.............................................................. 101
Before Starting Engine .................................... 21
Engine Starting................................................ 21
Engine Stopping .............................................. 22
Electrical System............................................. 22
Generator Isolating for Maintenance............... 22
Product Information Section
Model Views .................................................... 24
Product Identification Information ................... 28
Operation Section
Lifting and Storage .......................................... 35
Installation ....................................................... 37
Features and Controls..................................... 38
Engine Starting................................................ 54
Engine Operation ............................................ 56
Engine Stopping .............................................. 58
Cold Weather Operation ................................. 59
Maintenance Section
4 SEBU9236-05
Foreword
Foreword Recommended service should be performed at the

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

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped Diesel engine exhaust and some of its constituents
by fuel consumption, service hours and/or calendar are known to the State of California to cause cancer,
time maintenance intervals. Items in the maintenance birth defects, and other reproductive harm.
schedule are referenced to detailed instructions that
follow. Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
Use fuel consumption or service hours to determine after handling.
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.
SEBU9236-05 5
Safety Section
Safety Messages
Safety Section
i06739710
Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your generator set. The exact location and a
description of the safety messages are reviewed in
this section. Become familiar with all safety
messages.
Ensure that all the safety messages are legible.
Clean the safety signs or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off the
engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
Do not operate or work on this engine unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
6 SEBU9236-05
Safety Section
Safety Messages
Illustration 1 g06100118
Side view of an enclosed generator set (access door removed)
SEBU9236-05 7
Safety Section
Safety Messages
Top view of an enclosed generator set
8 SEBU9236-05
Safety Section
Safety Messages
Side view of an enclosed generator set
SEBU9236-05 9
Safety Section
Safety Messages
Side view of an open generator set
10 SEBU9236-05
Safety Section
Safety Messages
View of the control panel
Universal Warning (1)

This safety message is on the enclosure for the
control panel on open generator sets and enclosed
generator sets.
SEBU9236-05 11
Safety Section
Safety Messages
Illustration 6 g01370904 Illustration 7 g01392484
Do not operate or work on this equipment unless When the engine is in the AUTOMATIC mode, the
you have read and understand the instructions engine can start at any moment. To avoid person-
and warnings in the Operation and Maintenance al injury, always remain clear of the the engine
Manuals. Failure to follow the instructions or when the engine is in the AUTOMATIC mode.
heed the warnings could result in serious injury
or death.
Hot Surface (3)
Automatic Starting (2) This safety message is on the top of the enclosure
and the sides of the enclosure on enclosed generator
This safety message is on the sides of the enclosure sets. This safety message is on the top of the
on enclosed generator sets. This safety message is generator and the sides of the radiator on enclosed
on the top of the generator for open generator sets. generator sets.
This safety message is also on the enclosure for the
generator sets.
12 SEBU9236-05
Safety Section
Safety Messages
Do not connect 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 in-
jury or death.
Open and secure main distribution system
switch, or if the connection is permanent, install
a double throw transfer switch to prevent electri-
cal feedback. Some generators are specifically
approved by a utility to run in parallel with the
distribution system and isolation may not be re-
quired. Always check with your utility as to the
applicable circumstances.
Crush (5)
Hot parts or hot components can cause burns or This safety message is on the base of enclosed and
personal injury. Do not allow hot parts or compo- open generator sets.
nents to contact your skin. Use protective cloth-
ing or protective equipment to protect your skin.
Electrocution (4)
This safety message is on the side of the enclosure
for enclosed generator sets. This safety message is
on the top of the generator for open generator sets.
This safety message is also on the enclosure for the
generator sets.
Crushing hazard! Read and understand the in-

structions and warnings in the Operation and
Maintenance manual. Failure to follow the in-
structions or heed the warnings could cause seri-
ous injury or death.
DANGER: Shock/Electrocution Hazard-Do not
operate this equipment or work on this
equipment unless you have read and understand Hot Fluid Under Pressure (6)
the instructions and warnings in the Operation
and Maintenance Manual. Failure to follow the
instructions or heed the warnings will result in This safety message is located by the cooling system
serious injury or death. filler cap on open generator sets and enclosed
generator sets.
SEBU9236-05 13
Safety Section
Additional Messages
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.
i06749219
Additional Messages
SMCS Code: 1000; 7405
There are several specific messages on these
machines. The exact location of the messages and
the description of the messages are reviewed in this
section. Become familiarized with all messages.
Make sure that all the messages are legible. Clean
the messages or replace the messages if the words
or images are unreadable. When you clean the
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.
Replace any message that is damaged, or missing. If
a message is attached to a part that is replaced,
install a message on the replacement part. Any
Caterpillar dealer can provide new messages.
14 SEBU9236-05
Safety Section
Additional Messages
Engine Oil Drain (1) Engine Coolant Drain (2)

This message is on the side of the generator set This message is on the side of the generator set
toward the bottom of the generator set. toward the bottom of the generator set.
Illustration 13 g01151083 Illustration 14 g01151053
This is the location of the engine oil drain. Refer to This is the location of the engine coolant drain. Refer
this Operation and Maintenance Manual, “Engine Oil to this Operation and Maintenance Manual, “Cooling
and Filter - Change”. System Coolant (ELC) - Change”.
Hot oil and components can cause personal in-

jury. Do not allow hot oil or components to con-
tact skin.
SEBU9236-05 15
Safety Section
General Hazard Information
Personal injury can result from 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.
i06300340

SMCS Code: 1000; 7405
• Wear a hard hat, protective glasses, and other

protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears in
order to help prevent damage to hearing.
• 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
Attach a “Do Not Operate” warning tag to the start containers. Glass containers can break.
switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction, • Use all cleaning solutions with care.
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each • Report all necessary repairs.
operator control station. When appropriate, Unless other instructions are provided, perform
disconnect the starting controls. the maintenance under the following conditions:
Do not allow unauthorized personnel on the engine,
• The engine is stopped. Ensure that the engine
or around the engine when the engine is being
serviced. cannot be started.
Cautiously remove the following parts. To help • The protective locks or the controls are in the
prevent spraying or splashing of pressurized fluids, applied position.
hold a rag over the part that is being removed.
• Disconnect the batteries when maintenance is
• Filler caps performed or when the electrical system is
serviced. Disconnect the battery ground leads.
• Grease fittings Tape the leads in order to help prevent sparks.
• Pressure taps • When starting a new engine, make provisions to
stop the engine if an overspeed occurs. If an
• Breathers engine has not been started since service has
been performed, make provisions to stop the
• Drain plugs engine if an overspeed occurs. Shutting down the
Use caution when cover plates are removed. engine may be accomplished by shutting off the
Gradually loosen, but do not remove the last two fuel supply and/or the air supply to the engine.
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last • Do not attempt any repairs that are not
two bolts or nuts, pry the cover loose in order to understood. Use the proper tools. Replace any
relieve any spring pressure or other pressure. equipment that is damaged or repair the
equipment.
16 SEBU9236-05
Safety Section
• Start the engine with the operator controls. Never Avoid direct spraying of water on electrical
short across the starting motor terminals or the connectors, connections, and components. When
batteries. This method of starting the engine could using air for cleaning, allow the machine to cool to
bypass the engine neutral start system and/or the reduce the possibility of fine debris igniting when
electrical system could be damaged. redeposited on hot surfaces.
Pressurized Air and Water Fluid Penetration

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.
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.
SEBU9236-05 17
Safety Section
Static Electricity Hazard when Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct
Fueling with Ultra-low Sulfur Diesel installation of these components will help to prevent
Fuel these effects: vibration, rubbing against other parts
and excessive heat during operation.
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the Inhalation
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 Exhaust
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death Use caution. Exhaust fumes can be hazardous to
or serious injury from fire or explosion. Consult your health. If you operate the equipment in an
with your fuel or fuel system supplier to ensure enclosed area, adequate ventilation is necessary.
the delivery system is in compliance with fueling
standards for proper grounding and bonding Asbestos Information
practices.
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Lines, Tubes, and Hoses Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
Do not bend or strike high-pressure lines. Do not you handle any replacement parts that contain
install lines, tubes, or hoses that are damaged. asbestos or when you handle asbestos debris.
Repair any fuel lines, oil lines, tubes, or hoses that Use caution. Avoid inhaling dust that might be
are loose or damaged. Leaks can cause fires. generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
Inspect all lines, tubes, and hoses carefully. Do not to your health. The components that may contain
use bare hands to check for leaks. Always use a asbestos fibers are brake pads, brake bands, lining
board or cardboard for checking engine components material, clutch plates, and some gaskets. The
for leaks. Tighten all connections to the asbestos that is used in these components is bound
recommended torque. in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
Check for the following conditions: asbestos is generated.
• End fittings that are damaged or leaking If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Outer covering that is chafed or cut
• Never use compressed air for cleaning.
• Wire that is exposed in reinforced hose
• Avoid brushing materials that contain asbestos.
• Outer covering that is ballooning locally
• Avoid grinding materials that contain asbestos.
• Flexible part of the hose that is kinked or crushed
• Use a wet method in order to clean up asbestos
• Armoring that is embedded in the outer covering materials.
18 SEBU9236-05
Safety Section
Burn Prevention
• A vacuum cleaner that is equipped with a high Reference: The applicable material safety data
efficiency particulate air filter (HEPA) can also be sheets can be found at the following web site by
used. searching using part number or the name:
• Use exhaust ventilation on permanent machining https://catmsds.cat.com/MSDSSearch/servlet/

jobs. cat.cis.ecs.
msdsSearch.controller.
• Wear an approved respirator if there is no other UserIdentificationDisplayServlet
way to control the dust.
• Comply with applicable rules and regulations for Dispose of Waste Properly
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos

particles in the air.
Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate Illustration 19 g00706404
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands Improperly disposing of waste can threaten the
thoroughly after handling Softwrap material. Do not environment. Potentially harmful fluids should be
smoke until washing hands thoroughly after handling disposed of according to local regulations.
Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean Always use leakproof containers when you drain
up debris. fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01480768
Burn Prevention
SMCS Code: 1000; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the hydraulic system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings or related items are
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 the coolant level after the engine has stopped
and the engine has been allowed to cool.
SEBU9236-05 19
Safety Section
Fire Prevention and Explosion Prevention
Ensure that the filler cap is cool before removing the Determine whether the engine will be operated in an
filler cap. The filler cap must be cool enough to touch environment that allows combustible gases to be
with a bare hand. Remove the filler cap slowly in drawn into the air inlet system. These gases could
order to relieve pressure. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact If the application involves the presence of
the skin, the eyes, or the mouth. combustible gases, consult your Cat dealer for
additional information about suitable protection
Oils devices.
Remove all flammable materials such as fuel, oil, and
Hot oil and hot lubricating components can cause debris from the engine. Do not allow any flammable
personal injury. Do not allow hot oil to contact the materials to accumulate on the engine.
skin. Also, do not allow hot components to contact
the skin. Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
Batteries oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
Electrolyte is an acid. Electrolyte can cause personal storing flammable materials.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for Do not expose the engine to any flame.
servicing batteries. Wash hands after touching the Exhaust shields (if equipped) protect hot exhaust
batteries and connectors. Use of gloves is components from oil or fuel spray in a line, a tube, or
recommended. a seal failure. Exhaust shields must be installed
correctly.
i04823639
Do not weld on lines or tanks that contain flammable
Fire Prevention and Explosion fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
Prevention thoroughly with a nonflammable solvent prior to
welding or flame cutting.
SMCS Code: 1000; 7405
Wiring must be kept in good condition. Check all
electrical wires daily. Ensure that all electrical wires
are properly routed and securely attached. Repair
any wires that are loose or frayed before you operate
the engine. Clean all electrical connections and
tighten all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Illustration 20 g00704000 Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
All fuels, most lubricants, and some coolant mixtures hoses must have adequate support and secure
are flammable. clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a Properly install all oil filters and fuel filters. The filter
fire. Fire may cause personal injury and property housings must be tightened to the proper torque.
damage.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
20 SEBU9236-05
Safety Section
Fire Prevention and Explosion Prevention
Improper jumper cable connections can cause an

explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. Charging a frozen
battery may cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Use caution when you are refueling an engine. Do

not smoke while you are refueling an engine. Do not Do not use ether. This machine is equipped with
refuel an engine near open flames or sparks. Always glow plugs. Using ether can create explosions or
stop the engine before refueling. fires that can cause personal injury or death.
Read and follow the engine starting procedure in
the Operation and Maintenance Manual.
Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or
for replacement parts.
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.

Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do • Wires are exposed.
not smoke in battery charging areas.
• Outer coverings are ballooning.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a • Flexible parts of the hoses are kinked.
hydrometer.
• Outer covers have embedded armoring.
• End fittings are displaced.

SEBU9236-05 21
Safety Section
Crushing Prevention and Cutting Prevention
Make sure that all clamps, guards, and heat shields Before starting the engine, ensure that no one is on,
are installed correctly in order to revent vibration, underneath, or close to the engine. Ensure that the
rubbing against other parts, and excessive heat. area is free of personnel.
i01359666
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
Crushing Prevention and
Cutting Prevention All protective guards and all protective covers must
be installed if the engine must be started in order to
SMCS Code: 1000; 7405 perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
Support the component properly when work beneath around the parts carefully.
the component is performed.
Do not bypass the automatic shutoff circuits. Do not
Unless other maintenance instructions are provided, disable the automatic shutoff circuits. The circuits are
never attempt adjustments while the engine is provided in order to help prevent personal injury. The
running. circuits are also provided in order to help prevent
engine damage.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is See the Service Manual for repairs and for
performed. After the maintenance is performed, adjustments.
reinstall the guards.
i01185283
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Engine Starting
When objects are struck, wear protective glasses in SMCS Code: 1000
order 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. Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
i03560601 personal injury.
If a warning tag is attached to the engine start switch

Before Starting Engine or to the controls, DO NOT start the engine or move
SMCS Code: 1000 the controls. Consult with the person that attached
the warning tag before the engine is started.
NOTICE All protective guards and all protective covers must
For initial start-up of a new or rebuilt engine, and for be installed if the engine must be started in order to
start-up of an engine that has been serviced, make perform service procedures. To help prevent an
provision to shut the engine off should an overspeed accident that is caused by parts in rotation, work
occur. This may be accomplished by shutting off the around the parts carefully.
air and/or fuel supply to the engine.
Start the engine from the operator's compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Engine exhaust contains products of combustion Manual, “Engine Starting” topic in the Operation
which may be harmful to your health. Always Section. Knowing the correct procedure will help to
start and operate the engine in a well ventilated prevent major damage to the engine components.
area and, if in an enclosed area, vent the exhaust Knowing the procedure will also help to prevent
to the outside.
personal injury.
Inspect the engine for potential hazards. To ensure that the jacket water heater (if equipped)
Do not start the engine or move any of the controls if and/or the lube oil heater (if equipped) is working
there is a “DO NOT OPERATE” warning tag or similar properly, check the water temperature gauge and the
warning tag attached to the start switch or to the oil temperature gauge during the heater operation.
controls.
22 SEBU9236-05
Safety Section
Engine Stopping
Engine exhaust contains products of combustion Uncontrolled electrical circuit paths can result in
which can be harmful to your health. Always start the damage to main bearings, to crankshaft bearing
engine and operate the engine in a well ventilated journal surfaces, and to aluminum components.
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside. Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
i01928905
discharge.
To ensure that the engine and the engine electrical
Engine Stopping systems function correctly, an engine-to-frame
SMCS Code: 1000 ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
Stop the engine according to the procedure in the engine ground to the frame.
Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid All grounds should be tight and free of corrosion. The
overheating of the engine and accelerated wear of engine alternator must be grounded to the negative
the engine components. “-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the i03491163
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
Generator Isolating for
has been corrected. Maintenance
Stop the engine if an overspeed condition occurs SMCS Code: 4450
during the initial start-up of a new engine or an
engine that has been overhauled. This may be Note: If the rated output voltage of the generator
accomplished by shutting off the fuel supply to the is greater than 600 volts, the generator and
engine and/or shutting off the air supply to the connected load cable capacitances must be
engine. discharged prior to servicing the generator.
i02176668
When you service an electric power generation set or
when you repair an electric power generation set,
follow the procedure below:
Electrical System
1. Stop the engine.
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 Illustration 23 g00104545
Operation and Maintenance Manual for specific
starting instructions. 2. Attach a “DO NOT OPERATE” or similar warning
tag to the engine prime mover starting circuit.
Grounding Practices Disconnect the engine starting circuit.
3. Disconnect the generator from the distribution
Correct grounding for the engine electrical system is
necessary for optimum engine performance and system.
reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
SEBU9236-05 23
Safety Section
Generator Isolating for Maintenance
4. Lock out the circuit breaker. Attach a “DO NOT

OPERATE” or similar warning tag to the circuit
breaker. Refer to the electrical diagram. Verify that
all points of possible reverse power flow have
been locked out.
5. For the following circuitry, remove the
transformer's fuses:
• Power
• Sensing
• Control
6. Attach a “DO NOT OPERATE” or similar warning

tag to the generator excitation controls.
7. Remove the cover of the generator's terminal box.
8. Use an audio/visual proximity tester in order to
verify that the generator is de-energized. This
tester must be insulated for the proper voltage
rating. Follow all guidelines in order to verify that
the tester is operational.
9. Determine that the generator is in a de-energized
condition. Ensure that any power source is in this
condition: removed, disabled, locked state, tagged
out and tested out. Add ground straps to the
conductors or terminals. Connect the ground
straps to the electrical distribution system's
common grounding location or to the ground
system. During the entire work period, these
ground straps must remain connected to the
conductors and generator terminals.
24 SEBU9236-05
Model Views
Product Information
Section
Model Views
i06749249
Model View Illustrations

SMCS Code: 1000
The following model views display typical features of
the generator sets that are described in this manual.
The operator should become familiar with the
locations of these items. Due to individual
applications, your generator set may appear different
from the illustrations.
SEBU9236-05 25
Side view of an enclosed generator set
(1) Rain Cap for the Exhaust System (4) Control Panel (7) Frame
(2) Fuel Filler (5) Generator (8) Alternator
(3) Engine Air Cleaner (6) Starting Motor
26 SEBU9236-05
(9) Engine Crankcase Breather
SEBU9236-05 27
(10) Cooling System Filler Cap (11) Radiator
28 SEBU9236-05
Product Identification Information
Product Identification
Information
i05674511
Plate Locations and Film

Locations Illustration 28 g01131696
SMCS Code: 1000 Serial number plate
Emission Certification Film

Note: This information is pertinent in the United
States and in Canada.
A typical example is shown.
Typical example
Caterpillar engines are identified by serial numbers

and by arrangement numbers. These numbers are
shown on the engine serial number plate. Caterpillar
dealers need these numbers in order to determine Illustration 29 g01527177
the components that were included with the engine.
This information permits accurate identification of
i01484579
replacement part numbers.
Serial Number Plate (1) Engine Identification

SMCS Code: 1000
The engine serial number plate is located on the
upper right side of the engine block above the fuel Caterpillar engines are identified with model
injection pump. numbers, and serial numbers, with performance
specification numbers, and with arrangement
numbers. These numbers are shown on the serial
number plate that is mounted on the engine.
The numbers for fuel setting information for electronic
engines are stored within the personality module.
These numbers can be read by using Caterpillar
electronic service tools.
Caterpillar dealers need these numbers in order to
determine the components that were included with
the engine. This permits accurate identification of
replacement part numbers.
SEBU9236-05 29
Generator Lead Connections
i02279700
Generator Lead Connections Accidental engine starting can cause injury or

SMCS Code: 4450 death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the
DANGER: Shock/Electrocution Hazard-Do not disconnected battery cable end in order to pre-
operate this equipment or work on this vent contact with other metal surfaces which
equipment unless you have read and understand could activate the engine electrical system.
the instructions and warnings in the Operation
and Maintenance Manual. Failure to follow the Place a Do Not Operate tag at the Start/Stop
instructions or heed the warnings will result in switch location to inform personnel that the
serious injury or death. equipment is being worked on.
Grounding the Frame

Personal injury or death can result from high In any generator set installation, the frame of the
voltage. generator must be positively connected to an earth
ground. This connection is the first connection that is
When power generation equipment must be in made at the installation. This connection is the last
operation to make tests and/or adjustments, high connection that should be removed. If the generator
voltage and current are present. set is on flexible mounting pads, the ground
connection must be flexible in order to avoid possible
Improper test equipment can fail and present a breakage in later operation.
high voltage shock hazard to its user.
Ground connection cable or straps should have at
Make sure the testing equipment is designed for least the current carrying capacity of the largest line
and correctly operated for high voltage and cur- lead to the connected load. Joints in cables or straps
rent tests being made. must be clean, free of electrical resistance, and
protected from possible oxidation. Bolted ground
When servicing or repairing electric power gener- connection joints eventually oxidize. The joints are
ation equipment: frequent sources of radio frequency interference
(RFI). Joints that are silver soldered and bolted are
• Make sure the unit is off-line (disconnected
preferred.
from utility and/or other generators power
service) , and either locked out or tagged DO
NOT OPERATE. Neutral Connections
• Remove all fuses. The generators with a Wye Configuration usually
have the neutral ground when the generator is
• Make sure the generator engine is stopped. installed. Grounding the neutral is for preventing
damage to equipment.
• Make sure all batteries are disconnected.
If the neutral wire is grounded and one of the phase
• Make sure all capacitors are discharged. leads becomes grounded, the excessive current will
open a load circuit breaker. Also, the excessive
Failure to do so could result in personal injury or current will cause the generator voltage to collapse.
death. Make sure residual voltage in the rotor, The result depends on the following items: electrical
stator and the generator is discharged. characteristics of the generator , 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.
30 SEBU9236-05
There are some cases when the neutral wire is not Wiring Code A for Three-Phase
grounded. An ungrounded generator neutral lead is
acceptable when the possibility of grounds to the
Configuration
phase leads has been eliminated. An example of
such measures are ground fault protective circuits.
Ground fault protection requires the entire group of
distribution circuits to be treated as a system. The
owner should contact a certified consultant if a new
distribution system is being developed. The owner
should also contact a certified consultant if an
existing system should be modified for the ground
fault protection.
Single Units
Each unit should be connected to a common ground.
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
Be sure to check your local wiring codes.
Connection Diagrams
The connections are located in the enclosure for the
control panel.
Change the position of the wire terminals in order to
modify the connection. The code for the winding is
specified on the nameplate.
Factory connection for “A” wiring code
Table 1
L-L Voltage for Wiring Code A
Winding 50 Hz 60 Hz
6 190-208 190-240
7 220-230 -
8 - 190-208
SEBU9236-05 31
R 230 voltage sensing – 0 => (T8) / 110 V => (T11) Table 2
R 438 LS voltage sensing – 0 => (T3) / 220 V => L-L Voltage for Wiring Code B
(T2) Winding 50 Hz 60 Hz
6 110-120 120
Wiring Code B for Single-Phase 7 120-130 -
Configuration or Three-Phase
8 - 110-120
Configuration
R 230 voltage sensing – 0 => (T8) / 110 V => (T11)
R 438 LS voltage sensing – 0 => (T3) / 110 V =>
(T2)
Factory connection for “B” wiring code
32 SEBU9236-05
Wiring Code D for Three-Phase R 230 voltage sensing – 0 => (T8) / 110 V => (T11)
Configuration R 438 LS voltage sensing – 0 => (T3) / 380 V =>
(T2)
Wiring Code F for Single-Phase

Configuration or Three-Phase
Configuration
Voltage LM equals one half of voltage LL.
Factory connection for “D” wiring code
Table 3
L-L Voltage for Wiring Code D
Winding 50 Hz 60 Hz
6 380-415 380-480
7 440-460 - Factory connection for “F” wiring code
8 - 380-416
SEBU9236-05 33
Table 4
L-L Voltage for Wiring Code F Table 5
Winding 50 Hz 60 Hz L-L Voltage for Wiring Code FF
6 220-240 220-240 Winding 50 Hz 60 Hz

7 250-260 - 6 220-240 220-240
8 200 220-240 7 250-260 -
8 200 220-240
R 438 LS voltage sensing – 0 => (T3) / 220 V => R 230 voltage sensing – 0 => (T1) / 110 V => (T4)
(T2)
R 438 LS voltage sensing – 0 => (T10) / 220 V =>
(T1)
Wiring Code FF for Single-Phase
Configuration Single Phase with 4 Leads, Winding
Dedicated Type M or Type M1
Voltage LM equals one half of voltage LL.
Wiring diagram for a connection in series
Table 6
Voltage at 50/
Connect. Output
60 Hz
L-L L-M L L M
220 110
T2 - T3
230 115 T1 T4 T2 - T3
240 120
Factory connection for “FF” wiring code
34 SEBU9236-05
Wiring diagram for a parallel connection
Table 7
Voltage at 50/60
Connect. Output
Hz
L-L L-M L L M
110 - T1 - T3
115 - T2 - T4 T1 - T3 T2 - T4 -
120 -
R 791 T Interference Suppression
Connect the interference suppression, as shown.
The letters in the circles represent the wiring codes
for the generators.
(BLK) Black
(BLU) Blue
(WHT) White
(A) Wiring code “A”
(B) Wiring code “B”
(D) Wiring code “D”
(F) Wiring code “F”
(FF) Wiring code “FF”
SEBU9236-05 35
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage

i02354265
Product Lifting
SMCS Code: 1000; 1404; 7002
NOTICE
Improper lifting or tiedowns can allow load to shift
and can cause injury and damage.
Use a hoist to remove heavy components. Use an

adjustable lifting beam, if necessary. Some removals
require lifting fixtures in order to obtain proper
balance and safety.
Lifting eyes are designed and installed for the
specific arrangement. Alterations to the lifting eyes Illustration 44 g01166103
and/or the engine make the lifting eyes and the lifting Label for lifting at four points
fixtures obsolete. If alterations are made, ensure that
proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
Label for lifting eye
The lifting labels are located on the lifting eyes.

These labels designate the proper lifting locations for
the gensets. Some gensets may be lifted at the base
of the genset. Use the configuration that is on the
lifting label in order to lift the generator set. Use lifting
devices that are properly rated for the weight of the
generator set.
Label for lifting at a single point
On some enclosed generator sets, it may be

necessary to remove a top panel of the enclosure in
order to access the lifting eye.
Note: Lifting a generator set with a fuel tank requires

special equipment and procedures. Do not lift the unit
with fuel in the fuel tank.
36 SEBU9236-05
Operation Section
Product Storage
i06595394
Product Storage
SMCS Code: 1000; 1404; 7002
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 1
month, a complete protection procedure is
recommended.
Your Caterpillar dealer will have instructions for
preparing the engine for extended storage periods.
For more detailed information on engine storage, see
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”.
Generator Storage
Store the generator set in a dry area to minimize
condensation on the windings. Use space heaters to
keep the windings dry, when possible. Wrap the
genset in plastic with bags of desiccant for extended
storage. Test the insulation of the generator when the
generator is removed from storage. Refer to this
Special Instruction, SEHS9124, “Winding Insulation
Maintenance and Cleaning and Drying of the
Generators - "Insulation Resistance Tests"”. Dry the
generator if the insulation is not acceptable. Refer to
this Special Instruction, SEHS9124, “Winding
Insulation Maintenance and Cleaning and Drying of
the Generators - "Drying"”.
SEBU9236-05 37
Operation Section
Installation
Installation • Clean
• Dry
i02290564
• Well ventilated
Generator Set Installation
• Easily accessible for inspection and maintenance
SMCS Code: 7002
Do not obstruct air inlet openings. Do not obstruct
Receiving Inspection discharge openings. Coolant flow must reach these
openings. If the generator is exposed to harsh
environmental conditions, the generator can be
If the generator is received during cold weather, allow modified in the field in order to add filters and space
the unit to reach room temperature before you heaters. In addition, a more rigid periodic
remove the protective packing material. Warming the maintenance schedule should be established.
generator to room temperature will prevent the
following problems:
Remote Fuel Tanks and Auxiliary
• Water condensation on cold surfaces Fuel Tanks
• Early failures due to wet windings Connect the generator to a remote fuel tank or an
• Early failures due to wet insulating materials auxiliary fuel tank, if necessary. The tank should have
good clean fuel and there should be provisions for
draining water and sediment from the fuel tank. Refer
Unpacking to this Operation and Maintenance Manual, “Fuel
Tank Water and Sediment - Drain”.
Moving the Generator Connect the tank to the fuel supply fitting and the fuel
return fitting on the generator set.
Electrical Measurements
Improper lift rigging can allow unit to tumble
causing injury and damage. Measure the insulation resistance of each winding if
the generator was exposed to the following
conditions:
NOTICE
Do not use the engine lifting eyes to remove the en- • Rapid changes in temperature
gine and generator together.
• Freezing
Unpack the equipment with care in order to avoid
scratching painted surfaces. Move the unit to the • Wet climate during shipment
mounting location. The unit can be moved by either
of the following methods: • Wet climate during storage
• Attach an overhead crane to the lifting eye that is Refer to this Operation and Maintenance Manual,
“Insulation - Test”.
installed on the generator package.
Note: These tests should be conducted prior to any
• Use a lift truck in order to lift the generator.
power connections or control connections that are
The hoist and the hoist cables should have a rating being made.
that is greater than the weight of the generator. When
the unit is moved, ensure that the generator is
completely supported by the lift truck's fork tines.
Also ensure that the generator is balanced on the lift
truck's fork tines. Slide the fork tines beneath the
attached skid in order to lift the generator.
Location
The location of the generator must comply with all
local regulations. The location of the generator must
also comply with all special industrial regulations.
Locate the generator in an area that meets the
following requirements:
38 SEBU9236-05
Operation Section
Features and Controls
Features and Controls

i07111498
Control Panel
SMCS Code: 7451
EMCP 4.1/4.2 (if equipped)
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 Main Menu Key (4) – The “MAIN MENU” key will
navigate the display to the main menu directly
AC Overview (2) – The “AC OVERVIEW” key will without having to navigate out of menus.
navigate the display to the first screen of AC
information. The “AC OVERVIEW” information Acknowledge Key(5) – Pressing the
contains various AC parameters that summarize the “ACKNOWLEDGE” key will cause the horn relay to
electrical operation of the generator set. turn off. The horn relay being turned off will silence
the horn. Pressing the “ACKNOWLEDGE” key will
Engine Overview (3) – The “ENGINE OVERVIEW” also cause any red or yellow flashing lights to either
key will navigate the display to the first screen of turn off or to come on continuously. The
engine information. The “ENGINE OVERVIEW” “ACKNOWLEDGE” key may also be configured to
information contains various engine parameters that send out a global alarm silence signal on the J1939
summarize the operation of the generator set. Data Link. Sending out a global alarm silence signal
SEBU9236-05 39
Operation Section
Control Panel
on the J1939 Data Link will silence the horns on the

annunciators. Left Key (16) – The “LEFT” key is used during
setpoint adjustment. The “LEFT” key is used to select
Reset Key (6) – Pressing the “RESET” key will reset the digit that is edited during the entry of numeric
various events. data. The “LEFT” key is also used during some of the
Event Log Key (7) – Pressing the “EVENT LOG” key setpoint adjustments to select a check box. The key
will navigate the display to the event log. is also used to unselect a check box. If a check box
has a check mark, pressing the “LEFT” key will
RUN Key (8) – Pressing the “RUN” key will start the disable the function. Pressing the key will also
engine. remove the check mark. Pressing the “LEFT” key will
also cause the check mark to disappear. If the check
AUTO Key (9) – Pressing the “AUTO” key will cause box does not have a check mark, pressing the
the engine to enter the “AUTO” mode. The engine will “LEFT” key will enable the function. Pressing the
start if the module receives a start command from a “LEFT” key will also cause a check mark to appear.
remote source.
STOP Key (10) – Pressing the “STOP” key will stop Alarm Indicators
the engine.
Escape Key (11) – The “ESCAPE” key is used to Yellow Warning Lamp – A yellow warning lamp is
navigate through the menus. When the key is located above the “ACKNOWLEDGE” key. A flashing
pressed, the user moves backward or the user yellow light indicates that there are active warnings
moves upward through the menus. The “ESCAPE” that have not been acknowledged. A continuous
key is also used to exit out of entering data when the yellow light indicates that there are acknowledged
user is programming the setpoints. If the “ESCAPE” warnings that are active. If there are any active
key is pressed while the user is programming the warnings, the yellow light will change from flashing
setpoints, changes made on the screen will not be yellow to continuous yellow after the
saved to memory. “ACKNOWLEDGE” key is pressed. If there are no
longer any active warnings, the yellow light will turn
Up Key (12) – The “UP” key is used to navigate off after the “ACKNOWLEDGE” key is pressed.
through the various menus and monitoring screens.
The “UP” key is also used when a setpoint is entered. Red Shutdown Lamp – A red shutdown lamp is
When entering numeric data, the “UP” key is used to located above the “RESET” key. A flashing red light
increment the digits (0-9). If the setpoint requires indicates that there are active shutdowns that have
not been acknowledged. A continuous red light
selection from a list, the “UP” key is used to navigate
indicates that there are active shutdowns that have
UP through the list. been acknowledged. If there are any active
Right Key (13) – The “RIGHT” key is used during shutdowns, the red light will change from flashing red
setpoint adjustment. The “RIGHT” key is used to to continuous red after the “ACKNOWLEDGE” key is
select which digit is edited while entering numeric pressed. Any condition that has caused a shutdown
data. The “RIGHT” key is also used during some must be manually reset. If there are no longer any
setpoint adjustments to select or to unselect a check active shutdowns, the red light will turn off.
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 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
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.
40 SEBU9236-05
Operation Section
Control Panel
Digital Inputs
There are several digital inputs and outputs on
“EMCP 4.1” and “EMCP 4.2” . For detailed
information about the inputs on this electronic control
module, see Systems Operation, Troubleshooting,
Testing, and Adjusting, UENR1209, “EMCP4.1/4.2”
or Application and Installation, LEBE0006.
TCP 1000 (if equipped)
(1) Up key (3) Display screen (5) Auto key

(2) Down key (4) Stop/Reset key (6) Start key
This section provides an overview of key functions for

this control. Detailed information on operating the (2) Up Key – The “Up” key is used to navigate up
TCP 1000 can be found in Special Instruction, through the various menus or monitoring screens.
M0085765, “TCP 1000 Control Panel”. The key is also used during set point entry. During
numeric data entry, the key is used to increment the
(1) Down Key – The “Down” key is used to navigate digits (0-9). If the set point requires selection from a
down through the various menus or monitoring list, then the key is used to navigate up through the
screens. The key is also used during set point entry. list.
During numeric data entry, the key is used to
decrement the digits (0-9). If the set point requires (3) Main Status and Instrumentation Display –
selection from a list, then the key is used to navigate Information from the TCP 1000 is displayed on the
down through the list. main status and instrumentation display. Keys (1)
SEBU9236-05 41
Operation Section
Control Panel
and (2) are used to navigate through different menu

screens. For further details, see Special Instruction,
M0085765, “TCP 1000 Control Panel”Description of
the Controls.
(4) Stop/Reset – Pressing the “Stop/Reset” key
causes the module to enter the stop/reset mode.
Entering the stop/reset mode will clear any alarm
conditions for which the triggering criteria have been
removed. If the engine is running, and the module is
in stop mode, the module will automatically instruct
the generator to unload (Close Generator and
Delayed Load Output 1, 2, 3, & 4 become inactive if
used). The fuel supply de-energizes, and the engine
comes to a standstill. Should a remote start signal be
present while operating in stop/reset mode, a remote
start will not occur.
(5) AUTO – Pressing the “AUTO” key causes the
module to enter the auto mode. Auto mode allows the
module to control the function of the generator
automatically. The module will monitor the remote
start input and battery charge status and once a start
request is made, the set will be automatically started,
and placed on load (Close Generator, and Delayed
Load Output 1, 2, 3, & 4 become active in order from
lowest to highest if used). Upon removal of the
starting signal, the module will remove the load from
the generator and shut down the set observing the
stop delay timer and cooling timer as necessary
(Close Generator, and Delayed Load Output 1, 2, 3,
& 4 become active in order from lowest to highest if
used). The module will then await the next start
event. For further details, see Special Instruction,
M0085765, “TCP 1000 Control Panel”Auto
Operation.
(6) Manual/Start – Pressing the “Manual” key will
start the engine, and run off load. To place the
generator on load, digital inputs are required to be
assigned to perform this function. If the engine is
running off load in manual mode and a remote start
signal becomes present, the module will
automatically instruct the changeover device to place
the generator on load (Close Generator, and Delayed
Load Output 1, 2, 3, & 4 become active in order from
lowest to highest if used). Upon removal of the
remote start signal, the generator remains on load
until either selection of the stop/reset, or auto modes.
For further details, see Special Instruction,
M0085765, “TCP 1000 Control Panel”Manual
Operation.
42 SEBU9236-05
Operation Section
Control Panel
(1) OK key (6) Display screen (11) Manual key

(2) Up key (7) Transfer to Generator key (12) Close Generator Indicator lamp
(3) Right key (8) Start key (13) Auto key
(4) Left key (9) Open Generator key (14) Mute key and Lamp Test key
(5) Down key (10) Stop/Reset key
Function Keys The key is also used during set point entry. During
numeric data entry, the key is used to increment the
This section provides an overview of key functions for digits (0-9). If the set point requires selection from a
this control. Detailed information on operating the list, then the key is used to navigate up through the
TCP 2000 can be found in Special Instruction, list.
M0085763, “TCP 2000 & TCP 3000 Control Panel”.
(3) Right Key – The “Right” key is used during set
(1) OK Key – The “OK” key is used during menu point adjustment. During numeric data entry, the key
navigation to move forward (downward) through the is used to choose which digit is being edited. The key
menu/submenu structure. The key is also used is also used during certain set point adjustments to
during set point programming to save set points select a check box or to deselect a check box. If a
changes. Pressing the OK key during set point box has a check mark inside, then pressing the key
programming causes set point changes to be saved will cause the check mark to disappear. If the box
to memory. does not have a check mark inside, then pressing the
key will cause a check mark to appear inside.
(2) Up Key – The “Up” key is used to navigate up
through the various menus or monitoring screens.
SEBU9236-05 43
Operation Section
Control Panel
(4) Left Key – The “Left” key is used during set point signal becomes present, the module will
adjustment. During numeric data entry, the key is automatically instruct the changeover device to place
used to choose which digit is being edited. The key is the generator on load ( “Close Generator” becomes
also used during certain set point adjustments to active (if used)). Upon removal of the remote start
select a check box or to deselect a check box. If a signal, the generator remains on load until either
box has a check mark inside, then pressing the key selection of the stop/reset or auto modes. For further
will cause the check mark to disappear. If the box details, see Special Instruction, M0085763, “TCP
does not have a check mark inside, then pressing the 2000 & TCP 3000 Control Panel”Manual Operation.
key will cause a check mark to appear inside.
(12) Close Generator – the Close Generator
(5) Down Key – The “Down” key is used to navigate Indicator lamp is ON when the generator is on load.
down through the various menus or monitoring
screens. The key is also used during set point entry. (13) AUTO – Pressing the “AUTO” key causes the
During numeric data entry, the key is used to module to enter the auto mode. Auto mode allows the
decrement the digits (0-9). If the set point requires module to control the function of the generator
selection from a list, then the key is used to navigate automatically. The module will monitor the Remote
down through the list. Start input and mains supply status and once a start
request is made, the set will be automatically started,
(6) Main Status and Instrumentation Display – and placed on load. Upon removal of the starting
Information from the TCP 2000 is displayed on the signal, the module will automatically transfer the load
main status and instrumentation display. Keys (1) - from the generator and shut down the set observing
(5) are used to navigate through different menu the stop delay timer and cooling timer as necessary.
screens. For further details, see Special Instruction, The module will then await the next start event. For
M0085763, “TCP 2000 & TCP 3000 Control further details, see Special Instruction, M0085763,
Panel”Description of the Controls. “TCP 2000 & TCP 3000 Control Panel”Auto
Operation.
(7) Transfer to Generator – Operative in manual
mode only. Normal breaker key control allows the (14) Mute/Lamp Test – Pressing the “Mute/Lamp”
operator to transfer the load to the generator. test key will silence the audible alarm if it is sounding,
Alternative breaker key control. If mains is on load, and illuminate all the indicator lamps as a test
pressing the “Transfer to Generator” key transfers the feature. Pressing the mute/lamp test key while in
load to the generator. If generator is on load, stop/reset mode after pressing the START key will
pressing the “Transfer to Generator” key opens the also cancel any passive alarms on the engine ECU.
generator breaker. If generator and mains are off
load, pressing the “Transfer to Generator” key closes
the generator breaker.
(8) Start – The “Start” key is only active in Stop/
Reset mode. Pressing the “Start” key in manual or
test mode will cause the engine and run off load
(manual) or on load (test). Pressing the “Start” key
while in Stop/Reset mode will turn on the CAN engine
ECU (when correctly configured, and fitted to a
compatible engine ECU).
(9) Open Generator – Pressing “Open Generator”
allows the operator to open the generator (when in
Manual mode only).
(10) Stop/Reset – Pressing the “Stop/Reset” key
causes the module to enter the stop/reset mode.
Entering the stop/reset mode will clear any alarm
conditions for which the triggering criteria have been
removed. If the engine is running, and the module is
in Stop mode, the module will automatically instruct
the changeover device to unload the generator
(Close Generator becomes inactive if used). The fuel
supply de-energizes, and the engine comes to a
standstill. Should a Remote Start Signal be present
while operating in Stop/Reset mode, a remote start
will not occur.
(11) Manual – Pressing the “Manual” key allows
manual control of the generator functions. Once in
manual mode, the module will respond to the “Start”
key, start the engine, and run off load. If the engine is
running off-load in manual mode and a remote start
44 SEBU9236-05
Operation Section
Control Panel
(1) OK key (7) Transfer to Generator key (13) Test key (TP3000 only)
(2) Up key (8) Start key (14) Auto key
(3) Right key (9) Transfer to Mains key (15) Close Bus indicator lamp
(4) Left key (10) Stop/Reset key (16) Mute key and Lamp Test key
(5) Down key (11) Manual key
(6) Display screen (12) Close Mains indicator lamp
Function Keys (2) Up Key – The “Up” key is used to navigate up

through the various menus or monitoring screens.
This section provides an overview of key functions for The key is also used during set point entry. During
this control. Detailed information on operating the numeric data entry, the key is used to increment the
TCP 3000 can be found in Special Instruction, digits (0-9). If the set point requires selection from a
M0085763, “TCP 2000 & TCP 3000 Control Panel”. list, then the key is used to navigate up through the
list.
(1) OK Key – The “OK” key is used during menu
navigation to move forward (downward) through the (3) Right Key – The “Right” key is used during set
menu/submenu structure. The key is also used point adjustment. During numeric data entry, the key
during set point programming to save set points is used to choose which digit is being edited. The key
changes. Pressing the OK key during set point is also used during certain set point adjustments to
programming causes set point changes to be saved select a check box or to deselect a check box. If a
to memory. box has a check mark inside, then pressing the key
will cause the check mark to disappear. If the box
SEBU9236-05 45
Operation Section
Voltage Regulators
does not have a check mark inside, then pressing the

key will cause a check mark to appear inside. (11) Manual – Pressing the “Manual” key allows
manual control of the generator functions. Once in
(4) Left Key – The “Left” key is used during set point manual mode, the module will respond to the “Start”
adjustment. During numeric data entry, the key is key, start the engine, and run off load. If the engine is
used to choose which digit is being edited. The key is running off-load in manual mode and a remote start
also used during certain set point adjustments to signal becomes present, the module will
select a check box or to deselect a check box. If a automatically instruct the changeover device to place
box has a check mark inside, then pressing the key the generator on load (Close Generator becomes
will cause the check mark to disappear. If the box active (if used)). Upon removal of the remote start
does not have a check mark inside, then pressing the signal, the generator remains on load until either
key will cause a check mark to appear inside. selection of the stop/reset or auto modes. For further
(5) Down Key – The “Down” key is used to navigate details, see Special Instruction, M0085763, “TCP
down through the various menus or monitoring 2000 & TCP 3000 Control Panel”Manual Operation.
screens. The key is also used during set point entry. (12) Close Mains – the close mains indicator lamp is
During numeric data entry, the key is used to ON when the generator is on load.
decrement the digits (0-9). If the set point requires
selection from a list, then the key is used to navigate (13) Test – Pressing the “Test” key causes the
down through the list. module to enter the test mode. In test mode, an on
load test of the generator can be performed. Once in
(6) Main Status and Instrumentation Display – test mode, the module will respond to the start
Information from the TCP 3000 is displayed on the button, start the engine, and run on load. For further
main status and instrumentation display. Keys (1) - details, see Special Instruction, M0085763, “TCP
(5) are used to navigate through different menu 2000 & TCP 3000 Control Panel”Test Operation.
screens. For further details, see Special Instruction,
M0085763, “TCP 2000 & TCP 3000 Control (14) AUTO – Pressing the “AUTO” key causes the
Panel”Description of the Controls. module to enter the auto mode. Auto mode allows the
module to control the function of the generator
(7) Transfer to Generator – Operative in manual automatically. The module will monitor the Remote
mode only. Normal breaker key control allows the Start input and mains supply status and once a start
operator to transfer the load to the generator. request is made, the set will be automatically started,
Alternative breaker key control. If mains is on load, and placed on load. Upon removal of the starting
pressing the “Transfer to Generator” key transfers the signal, the module will automatically transfer the load
load to the generator. If generator is on load, from the generator and shut down the set observing
pressing the “Transfer to Generator” key opens the the stop delay timer and cooling timer as necessary.
generator breaker. If generator and mains are off The module will then await the next start event. For
load, pressing the “Transfer to Generator” key closes further details, see Special Instruction, M0085763,
the generator breaker. “TCP 2000 & TCP 3000 Control Panel”Auto
Operation.
(8) Start – The “Start” key is only active in Stop/
Reset mode. Pressing the “Start” key in manual or (15) Close Bus – the close generator indicator lamp
test mode will cause the engine and run off load is ON when the generator is on load.
(manual) or on load (test). Pressing the “Start” key
while in Stop/Reset mode will turn on the CAN engine (16) Mute/Lamp Test – Pressing the “Mute/Lamp”
ECU (when correctly configured, and fitted to a test key will silence the audible alarm if it is sounding,
compatible engine ECU). and illuminate all the indicator lamps as a test
feature. Pressing the mute/lamp test key while in
(9) Transfer to Mains – Operative in Manual mode stop/reset mode after pressing the “Start” key will
only. Normal breaker key control allows the operator also cancel any passive alarms on the engine ECU.
to transfer the load to the mains. Alternative breaker
key control, if generator is on load, transfers the load
to the mains. If mains is on load, opens the mains i02955141
breaker. If generator and mains are off load, closes
the mains breaker. Voltage Regulators
(10) Stop/Reset – Pressing the “Stop/Reset” key SMCS Code: 4467
causes the module to enter the Stop/Reset mode.
This will clear any alarm conditions for which the
triggering criteria have been removed. If the engine is
running, and the module is in Stop mode, the module
will automatically instruct the changeover device to DANGER: Shock/Electrocution Hazard-Do not
operate this equipment or work on this
unload the generator (Close Generator becomes equipment unless you have read and understand
inactive if used). The fuel supply de-energizes, and the instructions and warnings in the Operation
the engine comes to a standstill. Should a Remote and Maintenance Manual. Failure to follow the
Start Signal be present while operating in Stop/Reset instructions or heed the warnings will result in
mode, a remote start will not occur. serious injury or death.
46 SEBU9236-05
Operation Section
Voltage Regulators
The voltage regulator is powered by two auxiliary

windings. These windings are independent from the
circuit for detection of voltage. The first winding is
labelled as “X1” and “X2” . This winding has a voltage
Personal injury or death can result from high that is proportional with the output voltage of the
voltage. generator. The second winding is labelled as “Z1”
and “Z2” . This winding has a voltage that is
When power generation equipment must be in proportional to the current of the stator. The voltage
operation to make tests and/or adjustments, high from the power supply is rectified and filtered before
voltage and current are present. being used by the regulator monitoring transistor.
This principle ensures that regulation is not affected
Improper test equipment can fail and present a by interference that is generated by the load.
These voltage regulators may have an optional
Make sure the testing equipment is designed for remote potentiometer for voltage adjustment. This
and correctly operated for high voltage and cur- potentiometer is 450 ohms 0.5 W minimum. The
rent tests being made. adjustment range is 5%. The voltage range is limited
by the internal potentiometer “P2” . Remove “ST4” in
When servicing or repairing electric power gener- order to connect the potentiometer. A 1000 ohm
ation equipment: potentiometer can also be used to extend the
adjustment range.
• Make sure the unit is off-line (disconnected
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, disconnect
the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the
disconnected battery cable end in order to pre-
vent contact with other metal surfaces which
could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop
switch location to inform personnel that the
equipment is being worked on.
The voltage regulator is located in the enclosure for

the control panel.
SEBU9236-05 47
Operation Section
Voltage Regulators
Illustration of the control panel for open gensets
R230 Adjustments
Table 8
R230 Regulator
Voltage regulation ±0.5%
Voltage detection range 85 to 139 V (50/60 Hz)
Rapid response time for a tran- 500 ms

sient voltage variation amplitude
of ±20%
Voltage setting “P1”
Stability setting “P2”
8 Amp Fuse for protection of the 10 amperes for 10 seconds

power supply
50 or 60 Hz selection with jumper “ST3” (1).
Underspeed protection and adjustment of frequency threshold via

potentiometer “P3”
(1) The engine speed setting must be changed in order to change
the frequency of the generator set.
Illustration of a control panel for enclosed gensets
1. Remove bolts (2) from the side of control panel (1).

2. Remove panel (3) in order to access the voltage
regulator.
48 SEBU9236-05
Operation Section
Voltage Regulators
R230 Voltage Regulator with components
SEBU9236-05 49
Operation Section
Voltage Regulators
(Table 9, contd)
Supply for shunt max 48 VAC at 50/60 Hz (1)
Rated overload current 8 amperes for 10 seconds
Electronic protection for over- Excitation ceiling current for 10

load and short circuit opening seconds and return to approxi-
on voltage sensing mately 1 ampere
THE GENERATOR MUST BE
STOPPED IN ORDER TO RE-
SET THE PROTECTION.
Fuse “F1” on input side “X1” and “X2”
Voltage sensing 5 VA isolated via the

transformer
Terminals for 0 to 110 VAC 95 to 140 ACV
R230 connections Terminals for 0 to 220 VAC 170 to 260 ACV
Use the following procedure to adjust the R230 Terminals for 0 to 380 VAC 340 to 520 VAC
voltage regulator. Voltage regulation (R438) ±1%
1. Make sure that the “ST3” wire is connected for 50 Voltage regulation (R448) ±.5%
Hz applications. Remove the “ST3” wire for 60 Hz
applications. Also, the engine speed must be Rapid response time or normal response time from the location of
jumper “ST2”
changed from the factory setting in order to
change the frequency of the generator. Refer to Voltage adjustment via potentiometer “P2” (A DC voltage of ±1 V
the Operation and Maintenance Manual, “Change on the terminals of the external potentiometer “ST4” can be used
the Engine Speed for Desired Frequency” in this instead)
section. Maximum excitation current adjustment via potentiometer “P5”
(4.5 to 10 amperes)
2. Turn potentiometer “P1” to the full
counterclockwise position. 50 or 60 Hz selection with jumper “ST3” (2)
(1) This information only applies to the R438 AVR. This does not
3. Turn the potentiometer “ST4” to the middle of the
apply to the R448 AVR. The R448 AVR is only used with AREP
total rotation for the potentiometer ,if equipped. or PMG excitation systems.
Run the generator at the rated speed. If the (2) The engine speed setting must be changed in order to change
voltage does not increase, the field may need to the frequency of the generator set.
be energized. Refer to the “Special Use” section.
4. Turn potentiometer “P1” until the rated output
voltage is obtained.
5. Adjust the stability with potentiometer “P2” .
6. The sealed potentiometer “P3” is set at the factory
for 50 Hz or 60 Hz.
R438 and R448 Adjustments

NOTICE
“ST9” must be closed for AREP excitation.
Table 9
R438 and R448 Automatic Voltage Regulators
Maximum current for short 3 x In for 10 seconds

circuit
Standard power supply Two auxiliary windings
(continued)
50 SEBU9236-05
Operation Section
Voltage Regulators
SEBU9236-05 51
Operation Section
Voltage Regulators
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 of both parts between 48 Hz
or 58 Hz according to the operating frequency.
Check the change in the voltage that was
previously observed.
Use the following procedure in order to run the
generator set in parallel operation.
1. Preset the unit for parallel operation by connecting
the current transformer to “S1” and “S2” of the
connector “J2” . Set potentiometer “P1” for
R438 connections quadrature droop in the center position. Apply the
Use the following procedure to adjust the R438 rated load. The voltage should drop for 2% to 3%.
voltage regulator. Switch the positions of the two incoming
secondary wires of the current transformer if the
1. Remove wire “ST4” . voltage increases.
2. Connect an analog voltmeter that is calibrated for 2. The no-load voltages should be identical for all the
50 VDC on terminal E+ and terminal E-. generators that are operating in parallel. Connect
3. Connect a voltmeter that is calibrated for 300 VAC the generators in parallel. Try to obtain a 0 kW
to 500 VAC or 1000 VAC. power exchange by adjusting the speed of the
generator. Try to minimize the circulating currents
4. Make sure that the “ST3” wire is positioned on the between generators by altering the voltage setting
desired frequency. Also, the engine speed must be with potentiometer “P2” on one of the generators.
changed from the factory setting in order to
change the frequency of the generator. Refer to Note: Do not change the voltage settings after
the Operation and Maintenance Manual, “Change this step.
the Engine Speed for the Desired Frequency” in
this section.
5. Turn potentiometer “P2” to a full counterclockwise
position.
6. Turn potentiometer “P4” to a full clockwise
position.
7. Turn potentiometer “P3” counterclockwise to about
1/3 of the total rotation for the potentiometer.
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. 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.
52 SEBU9236-05
Operation Section
Voltage Regulators
3. Apply the available load. The setting is correct only 1. Open switch “D” . The excitation current should
if a reactive load is available. Equalize the increase up to the preset maximum value and the
Kilowatts or divide the rated power of the units excitation current should remain at the preset
proportionally by altering the speed. Equalize or maximum value for approximately 10 seconds.
divide the currents by altering the quadrature The current will decrease to less than 1 Amp.
droop potentiometer.
2. Open switch “A” in order to reset the internal
protection.
R438 and R448 Adjustment for
Maximum Excitation Note: The voltage must be adjusted after the
maximum excitation current has been set.
Change the Engine Speed for the

Desired Frequency
Note: The “ST3” connection on the voltage regulator
must also be changed in order to change the
frequency of the generator. Refer to Step 1 of “R230
Adjustments” and Step 4 of “R438 and R448
Adjustments” in Operation and Maintenance Manual,
“Voltage Regulators”.
The engine speed must be set at 1500 rpm for 50 Hz
applications. The engine speed must be set at 1800
rpm for 60 Hz applications. Use the following
procedure in order to change the engine speed.
The factory setting corresponds to an excitation

current that is required to obtain a three-phase short
circuit current of 3 X IN at 50 Hz for industrial power,
unless this is specified otherwise.
The maximum level of excitation may be reduced by
a static method. The static method is safer for the
generator and the network. Use the following steps to
reduce the maximum excitation level.
1. Disconnect the power supply wires “X1” , “X2” ,
“Z1” and “Z2” .
2. Disconnect sensing leads “0V” , 110V, 220V and
380V on the generator.
3. Connect the main power supply 200V-240V, as Illustration 58 g00956648
shown. X1,X2:120V (1) Bolt

(2) Cover
4. Install a 10 Amp DC ammeter in series with the (3) Circuit breaker
exciter field.
1. Switch circuit breaker (3) to the OFF position.
5. Turn potentiometer “P5” to a full counterclockwise Remove bolts (1) and cover (2) from the right side
position and activate the power supply. If there is of the generator.
no output current from the voltage regulator, turn
potentiometer “P2” clockwise until the ammeter
indicates a stable current.
6. Switch off the power supply. Switch on the power
supply. Turn potentiometer “P5” until the required
maximum current is obtained. The maximum
current must not be greater than 10 Amperes.
Use the following steps in order to check the internal
protection.
SEBU9236-05 53
Operation Section
Voltage Regulators
4. Install cover (2). Fasten cover (2) with bolts (1).

Switch circuit breaker (3) to the ON position.
Special Use
The exciter is switched off by disconnecting the

power supply to the voltage regulator. The
connection is identical for resetting the internal
protection for the voltage regulator.
(A) Terminal for the engine speed
(50) Connection for 50 Hz applications
(60) Connection for 60 Hz applications
2. Disconnect terminal (A) from the circuit board.

3. Connect terminal (A) to the connection for 50 Hz
(50) or connect terminal (A) to the connection for Use a 12 VDC power source in order to energize the
60 Hz (60). The engine speed will change to 1500 field, if necessary. Refer to the following table.
rpm for 50 Hz applications. The engine speed will Table 10
change to 1800 rpm for 60 Hz applications.
Applications B Volts Time
Voltage build up 12 (1A) 1 - 2 seconds
De-energized parallel
12 (1A) 1 - 2 seconds
operation
Standby parallel operation 24 (2A) 5 - 10 seconds
Battery starting 48 (4A) 5 - 10 seconds
Voltage that is sustained at

48 (4A) 5 - 10 seconds
overload
54 SEBU9236-05
Operation Section
Engine Starting
Engine Starting 2. The EMCP checks the system prior to start of the
crank cycle. The EMCP checks that no system
faults are present. The EMCP checks that all
i03907410
previous shutdown faults have been reset. The
EMCP also checks that the engine is not already
Starting the Engine running. If the engine is equipped with prelube, the
SMCS Code: 1000; 1450 EMCP checks the status of the prelube. If the
prelube is not complete, the EMCP will not crank
the engine.
Engine exhaust contains products of combustion 3. The EMCP begins the crank cycle.
which may be harmful to your health. Always 4. The EMCP cranks the engine until the crank cycle
start and operate the engine in a well ventilated time reaches the setpoint for total crank time or
area and, if in an enclosed area, vent the exhaust
to the outside. until the engine starts.
5. The EMCP deactivates the starting motor relay
(SMR) when the engine speed reaches the
setpoint for crank terminate speed.
When the engine is in the AUTOMATIC mode, the
i02242604
engine can start at any moment. To avoid person-
al injury, always remain clear of the the engine
when the engine is in the AUTOMATIC mode. Starting with Jump Start
Before manually starting the engine, perform all of Cables
the procedures that are described in this Operation SMCS Code: 1000; 1401; 1402; 1900
and Maintenance Manual, “Before Starting Engine”.
Ensure that no one will be endangered before the
engine is started and when the engine is started.
NOTICE Improper jump start cable connections can cause

Do not engage the starting motor when flywheel is an explosion resulting in personal injury.
turning. Do not start the engine under load.
Prevent sparks near the batteries. Sparks could
If the engine fails to start within 30 seconds, release cause vapors to explode. Do not allow jump start
the starter switch or button and wait two minutes to cable ends to contact each other or the engine.
allow the starting motor to cool before attempting to
start the engine again. If the installation is not equipped with a backup
battery system, it may be necessary to start the
engine from an external electrical source.
NOTICE First, determine the reason that it is necessary to
For initial start-up of a new or rebuilt engine, and for
start with power from an external source.
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed Many batteries which are considered unusable are
occur. This may be accomplished by shutting off the still rechargeable. After jump starting, the alternator
air and/or fuel supply to the engine. may not be able to fully recharge batteries that are
severely discharged. The batteries must be charged
1. Start the engine by one of these three methods. to the proper voltage with a battery charger. For
information on testing and charging, refer to the
Special Instruction, SEHS7633, “Battery Test
• The operator presses the “RUN” Key.
Procedure”.
• The control is in “AUTO” and the remote initiate
contact (IC) becomes active.
• The operator presses the “AUTO” Key and a

start command is sent via the RS-485 SCADA
Data Link.
SEBU9236-05 55
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 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 positive cable terminal of the
electrical source.
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 engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Charge the batteries. The engine will not continue
to run after starting if the batteries have not been
charged.
5. Start the engine.
6. Immediately after the stalled engine is started,
disconnect the jump start cables in reverse order.
56 SEBU9236-05
Operation Section
Engine Operation
Engine Operation 3. Perform another walk-around inspection. Check

the engine for fluid leaks and air leaks.
i06545704 4. Increase the rpm to the rated rpm. Check for fluid
leaks and air leaks. The engine may be operated
Engine Operation at full rated rpm and at full load when the jacket
SMCS Code: 1000 water temperature reaches 60°C (140°F).
Proper operation and maintenance are key factors in i02309560

obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
Fuel Conservation Practices
minimized and engine service life can be maximized. SMCS Code: 1000; 1250
The time that is needed for the engine to reach The efficiency of the engine can affect the fuel
normal operating temperature can be less than the economy. Caterpillar's design and technology in
time needed for a walk-around inspection of the manufacturing provides maximum fuel efficiency in
engine. all applications. Follow the recommended procedures
in order to attain optimum performance for the life of
After the engine is started and after the engine the engine.
reaches normal operating temperature, the engine
can be operated at the rated rpm. The engine will • Avoid spilling fuel.
reach normal operating temperature faster when the
engine is at rated speed. The engine will reach Fuel expands when the fuel is warmed up. The fuel
normal operating temperature faster when the engine may overflow from the fuel tank. Inspect fuel lines for
is at low-power demand. This procedure is more leaks. Repair the fuel lines, as needed.
effective than idling the engine at no load. The engine
should reach operating temperature in a few minutes. • Be aware of the properties of the different fuels.
Use only the recommended fuels.
Gauge readings should be observed and the data
should be recorded frequently while the engine is • Avoid unnecessary idling.
operating. Comparing the data over time will help to
determine normal readings for each gauge. Shut off the engine rather than idle for long periods of
Comparing data over time will also help detect time.
abnormal operating developments. Significant
changes in the readings should be investigated. • Observe the service indicator frequently. Keep the
air cleaner elements clean.
Engines rated for constant speed use are allowed to
complete a starting sequence, an operation at a • Maintain a good electrical system.
single constant speed, and a shutdown sequence.
Every time the engine is run, each of these One bad battery cell will overwork the alternator. This
operations should occur only once. The starting will consume excess power and excess fuel.
sequence and shutdown sequence can include a
short period of operation at the low idle speed for • Ensure that the belts are properly adjusted. The
purposes of warming up and cooling down the engine belts should be in good condition.
or driven equipment. The emissions type approval is
not valid for operation of a constant speed engine in • Ensure that all of the connections of the hoses are
a manner different from that described above. tight. The connections should not leak.
• Ensure that the driven equipment is in good
i00613522
working order.
Engine Warm-up • Cold engines consume excess fuel. Utilize heat
SMCS Code: 1000 from the jacket water system and the exhaust
system, when possible. Keep cooling system
1. Run the engine at low idle for three to five minutes, components clean and keep cooling system
or run the engine at low idle until the jacket water components in good repair. Never operate the
engine without water temperature regulators. All of
temperature starts to rise.
these items will help maintain operating
More time may be necessary when the temperatures.
temperature is below −18°C (0°F).
2. Check all of the gauges during the warm-up
period.
SEBU9236-05 57
Operation Section
Fuel Conservation Practices
• Settings for the fuel system and the limits for the
operating altitude are stamped on the Engine
Information Plate. If an engine is moved to a
higher altitude, the settings must be changed by a
Caterpillar dealer. Changing the settings will help
to provide the maximum efficiency for the engine.
Engines can be operated safely at higher
altitudes, but the engines will deliver less
horsepower. The fuel settings should be changed
by a Caterpillar dealer in order to obtain the rated
horsepower.
58 SEBU9236-05
Operation Section
Engine Stopping
Engine Stopping
i02358286
Stopping the Engine

SMCS Code: 1000; 7000
Note: The emergency stop push button should be

pushed immediately without disconnecting the load if
an emergency requires an immediate shutdown.
Use the following procedures in order to stop the
generator set.
Manual Stopping
1. Turn off the load by switching the generator output
circuit breaker to the OFF position.
2. Allow the generator set to operate without a load
for a few minutes in order to cool.
3. Turn the control switch to STOP. The generator set
will shut down.
Automatic Stopping
1. Open the remote switch and remove the remote
start signal.
2. When the start signal is removed a cool down
timer will allow the generator set to run for a short
time in order to cool prior to stopping
automatically.
SEBU9236-05 59
Operation Section
Cold Weather Operation
Cold Weather Operation • Engine oil pan heaters

• Engine coolant heaters
i05264084
• Fuel heaters
Fuel and the Effect from Cold • Fuel line insulation
Weather For more information on cold-weather operation, see
SMCS Code: 1000; 1250 Special Publication, SEBU5898, “Cold Weather
Recommendations”.
The following fuels are the grades that are available
for Cat engines:
• No. 1
• No. 2
• Blend of No. 1 and No. 2
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold-weather operation.
Quantities of No. 1 diesel fuel are limited. No. 1
diesel fuels are usually available during the months
of the winter in the colder climates. During cold-
weather operation, if No. 1 diesel fuel is not available,
use No. 2 diesel fuel, if necessary.
There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
• Lower cloud point

• Lower pour point
• Lower rating of kJ (BTU) per unit volume of fuel
When No. 1 diesel fuel is used, a decrease in power
and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
The cloud point is the temperature when a cloud of
wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
pumps and through fuel lines.
Be aware of these values when diesel fuel is
purchased. Anticipate the average ambient
temperature of the area. Engines that are fueled in
one climate may not operate well if the engines are
moved to another climate. Problems can result due to
changes in temperature.
Before troubleshooting for low power or for poor
performance in the winter, check the type of fuel that
is being used.
When No. 2 diesel fuel is used the following
components provide a means of minimizing problems
in cold weather:
• Starting aids
60 SEBU9236-05
Maintenance Section
Refill Capacities
Maintenance Section Table 12

Engine Oil Viscosity
Caterpillar DEO Ambient Temperature

Refill Capacities Multigrade
API CH-4
API CG-4 Minimum Maximum
i06094172
Viscosity Grade
Refill Capacities and SAE 0W-20 −40 °C (−40 °F) 10 °C (50 °F)
Recommendations SAE 0W-30 −40 °C (−40 °F) 30 °C (86 °F)
SMCS Code: 1348; 1395; 7560 SAE 0W-40 −40 °C (−40 °F) 40 °C (104 °F)
SAE 5W-30 −30 °C (−22 °F) 30 °C (86 °F)

Lubrication System
SAE 5W-40 −30 °C (−22 °F) 50 °C (104 °F)
Lubrication Capacities SAE 10W-30 −18 °C (0 °F) 40 °C (104 °F)
The refill capacities for the engine crankcase reflect SAE 15W-40 −9.5 °C (15 °F) 50 °C (122 °F)
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will For additional information on selecting an oil, refer to
require additional oil. Refer to the OEM specifications Special Publication, SEBU6251, “Caterpillar
for the capacity of the auxiliary oil filter. Commercial Diesel Engine Fluids
Table 11 Recommendations”.
Approximate Refill Capacity of the Lubrication
System Fuel
DE Series Generator Sets with C1.1 and C1.5 Engines
Compartment or System Liters Quarts

Fuel Recommendations
Crankcase(1) 6.0 6.3 Diesel engines can burn a wide variety of fuels.
These fuels are divided into two general groups. The
(1) These values are the approximate capacities for the crankcase two groups are called the preferred fuels and the
oil sump which include the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
permissible fuels.
to the OEM specifications for the capacity of the auxiliary oil
filter. The preferred fuels provide maximum engine service
life and performance. The preferred fuels are
distillate fuels. These fuels are commonly called
Lubricant Viscosity Recommendations diesel fuel, furnace fuel, gas oil, or kerosene.
for Direct Injection (DI) Diesel Engines
The permissible fuels are crude oils or blended fuels.
The proper SAE viscosity grade of oil is determined Use of these fuels can result in higher maintenance
by the minimum ambient temperature during cold costs and in reduced engine service life.
engine start-up, and the maximum ambient
temperature during engine operation. In North America, diesel fuel that is identified as No.
1-D or No. 2-D in “ASTM D975” generally meet the
Refer to Table 12 (minimum temperature) in order to specifications. Diesel fuels from other sources could
determine the required oil viscosity for starting a cold exhibit detrimental properties that are not defined or
engine. controlled by this specification.
Refer to Table 12 (maximum temperature) in order to

select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
Generally, use the highest oil viscosity that is
available to meet the requirement for the temperature
at start-up.
SEBU9236-05 61
Maintenance Section
Refill Capacities and Recommendations
Refer to Special Publication, SEBU6251, “Caterpillar Table 14

Commercial Diesel Engine Fluids
Caterpillar Minimum Acceptable Water Requirements
Recommendations” for additional information that
relates to diesel fuel. Property Maximum Limit ASTM Test
Cooling System Chloride (Cl)

40 mg/L
(2.4 grains/US gal)
“D512”,
“D4327”
Coolant Capacities Sulfate (SO4)

100 mg/L
“D516”
(5.9 grains/US gal)
To maintain the cooling system, the Total Cooling 170 mg/L
System capacity must be known. The approximate Total Hardness (10 grains/US gal) “D1126”
capacity for the engine cooling system is listed.
External System capacities will vary among 340 mg/L
Total Solids “D1888”
applications. Refer to the OEM specifications for the (20 grain/US gal)
External System capacity. This capacity information
Acidity pH of 5.5 to 9.0 “D1293”
will be needed in order to determine the amount of
coolant/antifreeze that is required for the Total
Cooling System. In stationary engine applications that do not require
Table 13 protection from boiling or freezing, a mixture of SCA
and water is acceptable. Caterpillar recommends a
Approximate Refill Capacity of the Cooling System
minimum of six percent to a maximum of eight
DE Series Generator Sets with C1.1 and C1.5 Engines
percent SCA concentration in those cooling
Compartment or System Liters Quarts systems. Distilled water or deionized water is
preferred. Water which has the required properties
Total Cooling System 6 6.3 may be used. For the water properties, refer to
Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
Coolant Recommendations Recommendations” for additional information that
relates coolant.
NOTICE Note: The service life of coolant is limited by use of
Do not use a commercial coolant/antifreeze that only service hours. Refer to the specific engine's
meets the ASTM “D3306” or equivalent specification. Operation and Maintenance Manual, “Maintenance
This type of coolant/antifreeze is made for light duty Interval Schedule” (Maintenance Section). To
automotive applications. achieve this service life, the coolants must be
Use only the coolant/antifreeze that is recommended. properly maintained. The maintenance program
includes S·O·S coolant analysis.
The following coolants are the primary types of
Table 15
coolants that are used in Caterpillar Engines:
Coolant Service Life
Preferred – Caterpillar Extended Life Coolant (ELC)
or a commercial extended life coolant that meets the Coolant Type Service Life (1)
Caterpillar EC-1 specification Caterpillar ELC Six Years
Caterpillar DEAC Three Years

Acceptable – Caterpillar Diesel Engine Antifreeze/
Coolant (DEAC) or a commercial heavy-duty coolant/ Commercial Heavy-Duty Cool-
antifreeze that meets “ASTM D4985” or “ASTM ant/Antifreeze that meets Two Years
D5345” specifications “ASTM D5345”
Commercial Heavy-Duty Cool-
Caterpillar recommends a 1:1 mixture of water and ant/Antifreeze that meets One Year
glycol. This mixture will provide optimum heavy-duty “ASTM D4985”
performance as a coolant/antifreeze.
Caterpillar SCA and Water Two Years
Note: Caterpillar DEAC DOES NOT require a Commercial SCA and Water One Year
treatment with an SCA at the initial fill. Commercial
(1) The service life of coolant is also limited by use (service hours).
heavy-duty antifreeze/coolant that meets “ASTM
Refer to the specific engine's Operation and Maintenance Man-
D4985” or “ASTM D5345” specifications MAY require ual, “Maintenance Interval Schedule” (Maintenance Section).
a treatment with an SCA at the initial fill. Read the
label or the instructions that are provided by the OEM
of the product.
62 SEBU9236-05
Maintenance Section
Maintenance Recommendations
Maintenance Do not loosen the high pressure fuel lines in order to

remove air pressure from the fuel system.
Recommendations
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
System Pressure Release off the engine.
SMCS Code: 1250; 1300; 1350; 5050 i05909227
Coolant System Welding on Engines with

Electronic Controls
SMCS Code: 1000
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Cat dealer regarding welding on a chas-
off the engine. Allow the cooling system pressure cap sis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure. Proper welding procedures are necessary in order to
avoid damage to the engine ECM, sensors, and
Fuel System associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off
possible, the correct procedure must be followed.
the engine.
When welding on a unit that is equipped with a Cat
Electronic Engine, the following is considered to be
High Pressure Fuel Lines (If Equipped) the safest procedure:
NOTICE
Do not ground the welder to electrical components
Contact with high pressure fuel may cause fluid such as the ECM or sensors. Improper grounding
penetration and burn hazards. High pressure fuel can cause damage to the drive train, the bearings,
hydraulic components, electrical components, and
spray may cause a fire hazard. Failure to follow
other components.
these inspection, maintenance and service in-
structions may cause personal injury or death. Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
The high pressure fuel lines are the fuel lines that are to the bearings, the crankshaft, the rotor shaft, and
between the high pressure fuel pump and the high other components.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These Clamp the ground cable from the welder to the com-
fuel lines are different from fuel lines on other fuel ponent that will be welded. Place the clamp as close
systems. as possible to the weld. This will help reduce the pos-
This is because of the following differences: sibility of damage.
• The high pressure fuel lines are constantly

charged with high pressure. Note: Perform the welding in areas that are free from
explosive hazards.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. 1. Stop the engine. Turn the switched power to the
OFF position.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks: 2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
1. Stop the engine. open the switch.
2. Wait for ten minutes.
SEBU9236-05 63
Maintenance Section
Welding on Engines with Electronic Controls
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the
the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as
not allow the harness to move back accidentally, close as possible to the weld. This location will
and contact any of the ECM pins. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
4. Disconnect any component with a microprocessor
components, and ground straps.
from the engine harness, such as:
Note: If electrical/electronic components are used as
• Engine ECM a ground for the welder, current flow from the welder
could severely damage the component. Current flow
• Product Link
from the welder could also severely damage
electrical/electronic components that are located
• Cell/Sat Radio
between the welder ground and the weld.
• DOC Identity Modules
6. Protect the wiring harness from welding debris and
spatter.
7. Use standard welding practices to weld the
materials.
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
64 SEBU9236-05
Maintenance Section
Maintenance Interval Schedule
i07111408 “ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Maintenance Interval Schedule “ Engine Air Cleaner Element (Single Element) -

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
(Standby)
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 76
SMCS Code: 1000; 7500
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 76
Ensure that all safety information, warnings, and
instructions are read and understood before any “ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 77
operation or any maintenance procedures are
performed. “ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 82
The user is responsible for the performance of
maintenance, including all adjustments, the use of “ Fuel System Secondary Filter - Replace”. . . . . . . 83
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure “ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 89
to adhere to proper maintenance intervals and
procedures may result in diminished performance of “ Insulation - Test”. . . . . . . . . . . . . . . . . . . . . . . . . . . 90
the product and/or accelerated wear of components. “ Rotating Rectifier - Check” . . . . . . . . . . . . . . . . . . 94
Use mileage, fuel consumption, service hours, or “ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 95
calendar time, WHICH EVER OCCURS FIRST, to
determine the maintenance intervals. Products that “ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . . 96
operate in severe operating conditions may require
more frequent maintenance.
Every 3 Years
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be “ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 68
performed.
“ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
When Required
“ Cooling System Water Temperature Regulator -
“ Battery or Battery Cable - Disconnect” . . . . . . . . . 69 Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Every 6 Years
“ Cooling System Coolant (ELC) - Change” . . . . . . 69
Every Week
“ Alternator - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 67
“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 69
“ Cooling System Coolant Level - Check”. . . . . . . . 71
“ Electrical Connections - Check” . . . . . . . . . . . . . . 74
“ Engine Air Cleaner Service Indicator - Inspect” . . 75
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 76
“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 85
“ Instrument Panel - Inspect” . . . . . . . . . . . . . . . . . . 90
“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 95
Every Year
“ Alternator and Fan Belts - Replace” . . . . . . . . . . . 68
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SEBU9236-05 65
Maintenance Section
Maintenance Interval Schedule
i07111409 “Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 95
Maintenance Interval Schedule Every Week

(Prime Power) “ Alternator - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 67
SMCS Code: 1000; 7500
Ensure that all safety information, warnings, and
instructions are read and understood before any “ Generator - Inspect”. . . . . . . . . . . . . . . . . . . . . . . . 86
operation or any maintenance procedures are
performed. “ Instrument Panel - Inspect” . . . . . . . . . . . . . . . . . . 90
The user is responsible for the performance of Every 6000 Service Hours or 3
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Years
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and “ Cooling System Coolant Extender (ELC) -
procedures may result in diminished performance of Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
Every 12 000 Service Hours or 6
calendar time, WHICH EVER OCCURS FIRST, in Years
order to determine the maintenance intervals.
Products that operate in severe operating conditions “ Cooling System Coolant (ELC) - Change” . . . . . . 69
may require more frequent maintenance.
Note: Before each consecutive interval is performed, Every 50 Service Hours or Weekly
all maintenance from the previous interval must be
performed. “ Fuel Tank Water and Sediment - Drain” . . . . . . . . 85
When Required Overhaul

“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . . 91
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 68
“ Battery or Battery Cable - Disconnect” . . . . . . . . . 69 Every 250 Service Hours
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 “ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 76
“ Engine Air Cleaner Element (Single Element) -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Every 250 Service Hours or 6
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . . 80
Months
“ Alternator and Fan Belts - Inspect/Adjust” . . . . . . 67
“ Generator - Dry”. . . . . . . . . . . . . . . . . . . . . . . . . . . 86
“ Generator Set - Test” . . . . . . . . . . . . . . . . . . . . . . . 88
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
“ Rotating Rectifier - Test” . . . . . . . . . . . . . . . . . . . . 94
Initial 500 Hours (for New Systems,
Daily Refilled Systems, and Converted
“ Cooling System Coolant Level - Check”. . . . . . . . 71 Systems)
“ Electrical Connections - Check” . . . . . . . . . . . . . . 74 “Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 76 Every 500 Service Hours
“ Fuel System Primary Filter/Water Separator - “ Glow Plugs - Inspect”. . . . . . . . . . . . . . . . . . . . . . . 89
Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
“ Generator Load - Check”. . . . . . . . . . . . . . . . . . . . 88 Every 500 Service Hours or 1 Year
“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 69
66 SEBU9236-05
Maintenance Section
Prime Power

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 77
“ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 82
“ Fuel System Secondary Filter - Replace”. . . . . . . 83
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 89
Every 1000 Service Hours

“ Engine Valve Lash - Inspect/Adjust” . . . . . . . . . . . 78
Every 1000 Service Hours or 1 Year

“ Rotating Rectifier - Check” . . . . . . . . . . . . . . . . . . 94

“ Alternator - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 67
“ Engine Crankcase Breather - Clean/Replace”. . . 75
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 76
“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 95
Every 2000 Service Hours or 6

Months
“ Insulation - Test”. . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Every Year
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
“ Insulation - Test”. . . . . . . . . . . . . . . . . . . . . . . . . . . 90

“ Fuel Injection Nozzles - Test/Exchange” . . . . . . . 79
“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . . 96
Every 3000 Service Hours or 2

Years
“ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SEBU9236-05 67
Maintenance Section
Alternator - Inspect
i05668153
Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection of
the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
charged, the ammeter reading should be very near Illustration 63 g01003936
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature Typical example
affects the cranking power. If the battery is too cold, (1) 144-0235 Belt Tension Gauge
the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm. Install the gauge (1) at the center of the belt between
When the engine is not run for long periods of time or the alternator and the crankshaft pulley and check
if the engine is run for short periods, the batteries the belt tension. The correct tension for a new belt is
may not fully charge. A battery with a low charge will 400 N (90 lb) to 489 N (110 lb). The correct tension
freeze more easily than a battery with a full charge. for a used belt that has been in operation for 30
minutes or more at the rated speed is 267 N (60 lb)
to 356 N (80 lb).
i05693471
If twin belts are installed, check and adjust the
Alternator and Fan Belts - tension on both belts.
Inspect/Adjust Adjustment
SMCS Code: 1357-040; 1357-025
Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry
more load because the older belt is stretched. The
additional load on the new belt could cause the new
belt to break.
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
To accurately check the belt tension, Gauge
144-0235 Belt Tension Gauge should be used.
Typical example
(1) Adjusting bolt
(2) Mounting bolts
1. Loosen the mounting bolts (2) and the adjusting

bolt (1).
68 SEBU9236-05
Maintenance Section
Alternator and Fan Belts - Replace
2. Move the alternator in order to increase or i05674633

decrease the belt tension.
3. Tighten the adjusting bolt (1). Tighten the mounting
Battery - Replace
bolts (2). Refer to the Specifications Manual for SMCS Code: 1401-510
the correct torque settings.
i05693529
Batteries give off combustible gases which can
Alternator and Fan Belts - explode. A spark can cause the combustible
gases to ignite. This can result in severe personal
Replace injury or death.
SMCS Code: 1357-510 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. Turn the key start switch to the OFF position.

Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
charger.
Illustration 65 g01091158 3. The NEGATIVE “-” cable connects the NEGATIVE
Typical example “-” battery terminal to the ground plane.
(1) Adjusting bolt Disconnect the cable from the NEGATIVE “-”
(2) Mounting bolts battery terminal.
When new belts are installed, check the belt tension 4. The POSITIVE “+” cable connects the POSITIVE
again after 20 hours of engine operation. For the “+” battery terminal to the starting motor.
correct belt tension, refer to this Operation and Disconnect the cable from the POSITIVE “+”
Maintenance Manual, “Alternator and Fan Belts - battery terminal.
Inspect Adjust”.
Refer to the Disassembly and Assembly Manual for Note: Always recycle a battery. Never discard a
the installation procedure and the removal procedure battery. Return used batteries to an appropriate
for the belt. recycling facility.
5. Remove the used battery.

6. Install the new battery.
Note: Before the cables are connected, ensure that

the key start switch is OFF.
7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
SEBU9236-05 69
Maintenance Section
Battery Electrolyte Level - Check
i05674636 i05674649
Battery Electrolyte Level - Battery or Battery Cable -

Check Disconnect
SMCS Code: 1401-535 SMCS Code: 1402-029
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. 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.
All lead-acid batteries contain sulfuric acid which Removing the battery cables or the batteries with
can burn the skin and clothing. Always wear a the cover in place may cause a battery explosion
face shield and protective clothing when working resulting in personal injury.
on or near batteries.
1. Turn the start switch to the OFF position. Turn the
1. Remove the filler caps. Maintain the electrolyte ignition switch (if equipped) to the OFF position
level to the “FULL” mark on the battery. and remove the key and all electrical loads.
If the addition of water is necessary, use distilled 2. Disconnect the negative battery terminal at the
water. If distilled water is not available use clean battery that goes to the start switch. Ensure that
water that is low in minerals. Do not use artificially
the cable cannot contact the terminal. When four
softened water.
12 V batteries are involved, the negative side of
2. Check the condition of the electrolyte with the two batteries must be disconnected.
245-5829 Coolant Battery Tester Refractometer.
3. Tape the leads in order to help prevent accidental
3. Keep the batteries clean. starting.
Clean the battery case with one of the following 4. Proceed with necessary system repairs. Reverse
cleaning solutions: the steps in order to reconnect all of the cables.
• A mixture of 0.1 kg (0.2 lb) of baking soda and i05674653
1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

Cooling System Coolant (ELC)
(1 qt) of clean water - Change
Thoroughly rinse the battery case with clean SMCS Code: 1350-070; 1395-044
water.
Clean the cooling system and flush the cooling
Use a fine grade of sandpaper to clean the system before the recommended maintenance
terminals and the cable clamps. Clean the items interval if the following conditions exist:
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal • The engine overheats frequently.
of material can cause the clamps fit incorrectly.
Coat the clamps and the terminals with 5N-5561 • Foaming is observed.
Silicone Lubricant, petroleum jelly or MPGM.
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
replaced.
70 SEBU9236-05
Maintenance Section
Cooling System Coolant (ELC) - Change
Note: Inspect the water pump and the water 4. Start and run the engine at low idle until the
temperature regulator after the cooling system has temperature reaches 49 to 66 °C (120 to 150 °F).
been drained. This inspection is a good opportunity
to replace the water pump, the water temperature 5. Stop the engine and allow the engine to cool.
regulator, and the hoses, if necessary. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
Drain system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
Pressurized System: Hot coolant can cause seri- equipped). Clean the drain plugs. Install the drain
ous burns. To open the cooling system filler cap, plugs. Refer to Torque Specifications, SENR3130
stop the engine and wait until the cooling system for more information on the correct torques.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure. Fill
1. Stop the engine and allow the engine to cool. NOTICE

Do not fill the cooling system faster than 5 L
Loosen the cooling system filler cap slowly in (1.3 US gal) per minute to avoid air locks.
order to relieve any pressure. Remove the cooling
system filler cap. Cooling system air locks may result in engine
damage.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove the cooling system drain plugs. 1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to this Operation and Maintenance
Allow the coolant to drain. Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
NOTICE on cooling system specifications. Do not install the
Dispose of used engine coolant properly or recycle. cooling system filler cap.
Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems. 2. Start and run the engine at low idle. Increase the
The full distillation procedure is the only method ac- engine rpm to high idle. Run the engine at high
ceptable by Caterpillar to reclaim the used coolant. idle for 1 minute in order to purge the air from the
For information regarding the disposal and the cavities of the engine block. Stop the engine.
recycling of used coolant, consult your Caterpillar 3. Check the coolant level. Maintain the coolant level
dealer or consult Dealer Service Tools.
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
Flush 13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
1. Flush the cooling system with clean water in order
to remove any debris. 4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
2. Close the drain valve (if equipped). Clean the drain
the gasket that is on the cooling system filler cap is
plugs. Install the drain plugs. Refer to Torque
damaged, discard the old cooling system filler cap
Specifications, SENR3130 for more information on
and install a new cooling system filler cap. If the
the correct torques.
gasket that is on the cooling system filler cap is not
damaged, use a 9S-8140 Pressurizing Pump in
NOTICE
Do not fill the cooling system faster than 5 L order to pressure test the cooling system filler cap.
(1.3 US gal) per minute to avoid air locks. The correct pressure for the cooling system filler
cap is stamped on the face of the cooling system
Cooling system air locks may result in engine filler cap. If the cooling system filler cap does not
damage.
retain the correct pressure, install a new cooling
system filler cap.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
SEBU9236-05 71
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
5. Start the engine. Inspect the cooling system for

NOTICE
leaks and for proper operating temperature. Care must be taken to ensure that fluids are con-
i05674673 nance, testing, adjusting, and repair of the product.
Cooling System Coolant ers before opening any compartment or disassem-
Extender (ELC) - Add
Refer to Special Publication, NENG2500, “Dealer
SMCS Code: 1352-045; 1395-081 Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling Dispose of all fluids according to local regulations
additives which are associated with the present and mandates.
conventional coolants. The Cat ELC Extender only
needs adding once.
1. Loosen the cooling system filler cap slowly in order
NOTICE to relieve pressure. Remove the cooling system
Use only Cat Extended Life Coolant (ELC) Extender filler cap.
with Cat ELC.
2. It may be necessary to drain enough coolant from
Do NOT use conventional supplemental coolant addi- the cooling system in order to add the Cat ELC
tive (SCA) with Cat ELC. Mixing Cat ELC with con-
ventional coolants and/or conventional SCA reduces Extender.
the Cat ELC service life. 3. Add Cat ELC Extender according to the
requirements for your engines cooling system
Check the cooling system only when the engine is capacity. Refer to the Operation and Maintenance
stopped and cool. Manual, “Refill Capacities and Recommendations”
article for more information.
4. Clean the cooling system filler cap. Inspect the
Personal injury can result from hot coolant, gaskets on the cooling system filler cap. Replace
steam and alkali. the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
i05674691
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Cooling System Coolant Level
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and - Check
cooling system pressure cap is cool enough to SMCS Code: 1395-082
touch with your bare hand.
Check the coolant level when the engine is stopped
Do not attempt to tighten hose connections when and cool.
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
Cooling system filler cap
72 SEBU9236-05
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant
Pressurized System: Hot coolant can cause seri- instead of Cat ELC including the following
ous burns. To open the cooling system filler cap, coolants:
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system • Commercial long life coolants that meet the
pressure cap slowly in order to relieve the Caterpillar Engine Coolant Specification -1
pressure. (Caterpillar EC-1)
• Cat DEAC (Diesel Engine Antifreeze/Coolant)
1. Remove the cooling system filler cap slowly in
order to relieve pressure. • Commercial heavy-duty coolant/antifreeze
2. Maintain the coolant level within 13 mm (0.5 inch) Table 16
of the bottom of the filler pipe. If the engine is Recommended Interval
equipped with a sight glass, maintain the coolant
Type of Coolant Level 1 Level 2
level to the proper level in the sight glass.
Cat DEAC
Conventional heavy
duty-coolant
Every 250 service
Commercial coolant Every year(1)
hours
that meets the re-
quirements of the
Caterpillar EC-1
standard
Cat ELC or conven-
Optional Every year(1)
tional EC-1 coolant
(1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
Typical filler cap gaskets pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
3. Clean the cooling system filler cap and check the drawn. This contaminate may cause a false analysis
condition of the filler cap gaskets. Replace the and an incorrect interpretation that could lead to con-
cooling system filler cap if the filler cap gaskets are cerns by both dealers and customers.
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks. Note: Level 1 results may indicate a need for
Level 2 Analysis.
i04035949
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to
Cooling System Coolant receive the full effect of S·O·S analysis, establish a
Sample (Level 1) - Obtain consistent trend of data. In order to establish a
pertinent history of data, perform consistent
SMCS Code: 1350-008; 1395-554; 1395-008; 7542 samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your
Note: Obtaining a Coolant Sample (Level 1) is Caterpillar dealer.
optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems Use the following guidelines for proper sampling of
the coolant:
filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended • Complete the information on the label for the
interval as stated in the maintenance interval sampling bottle before you begin to take the
schedule. samples.
• Keep the unused sampling bottles stored in plastic

bags.
SEBU9236-05 73
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Obtain coolant samples directly from the coolant i05677509

sample port. You should not obtain the samples
from any other location. Cooling System Water
• Keep the lids on empty sampling bottles until you Temperature Regulator -
are ready to collect the sample. Replace
• Place the sample in the mailing tube immediately SMCS Code: 1355-510
after obtaining the sample in order to avoid
contamination. Replace the water temperature regulator before the
water temperature regulator fails. This is a
• Never collect samples from expansion bottles. recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
• Never collect samples from the drain for a system. the chances for unscheduled downtime. Refer to this
Operation and Maintenance Manual, “Maintenance
Submit the sample for Level 1 analysis. Interval Schedule” for the proper maintenance
interval.
For additional information about coolant analysis, see
this Operation and Maintenance Manual, “Refill A water temperature regulator that fails in a partially
Capacities and Recommendations” or consult your opened position can cause overheating or
Caterpillar dealer. overcooling of the engine.
A water temperature regulator that fails in the closed
i02785234 position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
Cooling System Coolant head or piston seizure problems.
Sample (Level 2) - Obtain A water temperature regulator that fails in the open
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
NOTICE could cause an excessive carbon buildup inside the
Always use a designated pump for oil sampling, and cylinders. This excessive carbon buildup could result
use a separate designated pump for coolant sam- in an accelerated wear of the piston rings and wear of
pling. Using the same pump for both types of sam- the cylinder liner.
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis NOTICE
and an incorrect interpretation that could lead to con- Failure to replace your water temperature regulator
cerns by both dealers and customers. on a regularly scheduled basis could cause severe
engine damage.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain” Caterpillar engines incorporate a shunt design cool-
for the guidelines for proper sampling of the coolant. ing system and require operating the engine with a
water temperature regulator installed.
Submit the sample for Level 2 analysis.
If the water temperature regulator is installed incor-
For additional information about coolant analysis, rectly, the engine may overheat, causing cylinder
refer to the Operation and Maintenance Manual, head damage. Ensure that the new water tempera-
“Refill Capacities and Recommendations” topic or ture regulator is installed in the original position. En-
consult your Caterpillar dealer. sure that the water temperature regulator vent hole is
open.
Do not use liquid gasket material on the gasket or cyl-
inder head surface.
Refer to two articles in the Disassembly and

Assembly Manual, “Water Temperature Regulators -
Remove and Water Temperature Regulators - Install”
for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
dealer.
74 SEBU9236-05
Maintenance Section
Electrical Connections - Check
Note: If only the water temperature regulators are • Easy detection of fluid leaks
replaced, drain the coolant from the cooling system
to a level that is below the water temperature • Maximum heat transfer characteristics
regulator housing.
• Ease of maintenance
i01595880 Note: Caution must be used in order to prevent
electrical components from being damaged by
Electrical Connections - Check excessive water when you clean the engine. Avoid
SMCS Code: 4459-535 electrical components such as the alternator, the
starter, and the ECM.
Check all exposed electrical connections for
tightness. Note: For more information on cleaning and drying
electric generators, refer to Special Instruction,
Check the following devices for loose mounting or for SEHS9124, “Cleaning and Drying of Electric Set
physical damage: Generators”.
• transformers i02309550
• fuses
Engine Air Cleaner Element
• capacitors (Single Element) - Replace
• lightning arrestors SMCS Code: 1051; 1054-510
Check all lead wires and electrical connections for
proper clearance. NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
i02305808
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
utility and/or other generators), locked out and
tagged "Do Not Operate".
NOTICE (1) Air cleaner element. (2) Clamp.
Water or condensation can cause damage to genera-
tor components. Protect all electrical components 1. Loosen clamp (2) which fastens air cleaner
from exposure to water.
element (1) to the air inlet. Remove the dirty air
cleaner element and clamp.
NOTICE 2. Install clamp (2) on new air cleaner element (1).
Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and 3. Install new air cleaner element (1) to the air inlet
fluid spills whenever a significant quantity accumu- and tighten clamp (2). Refer to Torque
lates on the engine. Specifications, SENR3130 for the correct torque.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
SEBU9236-05 75
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
i05677672 If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
Engine Air Cleaner Service the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
Indicator - Inspect indicator may be plugged.
(If Equipped) The service indicator may need replacing frequently
in environments that are severely dusty, if necessary.
SMCS Code: 7452-040
Replace the service indicator annually regardless of
Some engines may be equipped with a different the operating conditions. Replace the service
service indicator. indicator when the engine is overhauled, and
whenever major engine components are replaced.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet Note: When a new service indicator is installed,
air pressure displays the difference in the pressure excessive force may crack the top of the service
that is measured before the air cleaner element and indicator. Tighten the service indicator to a torque of
the pressure that is measured after the air cleaner 2 N·m (18 lb in).
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
i05693590
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator. Engine Crankcase Breather -
The service indicator may be mounted on the air Clean/Replace
cleaner housing or in a remote location. SMCS Code: 1317-510; 1317-070
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 (1) Screw
should reset in less than three pushes. (2) Breather cover
(3) Spring
• Check the movement of the yellow core when the (4) Diaphragm and plate
engine is accelerated to the engine rated speed. (5) Breather body
(6) Gauze
The yellow core should latch approximately at the (7) Valve mechanism Cover
greatest vacuum that is attained. (8) Screw
(9) Cover plate
76 SEBU9236-05
Maintenance Section
Engine Mounts - Inspect
Refer to the Disassembly and Assembly, “Crankcase 2. Remove the oil filler cap and add oil, if necessary.
Breather - Remove and Install” for more information. Clean the oil filler cap. Install the oil filler cap.
i02456872 i04237495
Engine Mounts - Inspect Engine Oil Sample - Obtain

SMCS Code: 1152-040 SMCS Code: 1000-008; 1348-554-SM; 7542-554-
OC; 7542-554-SM
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused In addition to a good preventive maintenance
by the following conditions: program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
• Improper mounting of the engine analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
• Deterioration of the engine mounts
Any engine mount that shows deterioration should be Obtain the Sample and the
replaced. Refer to Special Publication, SENR3130,
“Torque Specifications” for the recommended Analysis
torques. Refer to the OEM recommendations for
more information.
i05677736 Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
Engine Oil Level - Check contact the skin.
SMCS Code: 1348-535-FLV Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order to
help obtain the most accurate analysis, provide the
following information:
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to • Engine model
contact the skin.
• 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.
Illustration 71 g00110310 To avoid contamination of the oil samples, the tools
(Y) “ADD” mark. (X) “FULL” mark. and the supplies that are used for obtaining oil
samples must be clean.
NOTICE Caterpillar recommends using the sampling valve in
Perform this maintenance with the engine stopped. order to obtain oil samples. The quality and the
consistency of the samples are better when the
1. Maintain the oil level between “ADD” mark (Y) and sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
“FULL” mark (X) on oil level gauge (1). Do not fill obtained during normal engine operation.
the crankcase above “FULL” mark (X).
The 169-8373 Fluid Sampling Bottle is
NOTICE recommended for use with the sampling valve. The
Operating your engine when the oil level is above the fluid sampling bottle includes the parts that are
“FULL” mark could cause your crankshaft to dip into needed for obtaining oil samples. Instructions are
the oil. The air bubbles created from the crankshaft also provided.
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.
SEBU9236-05 77
Maintenance Section
Engine Oil and Filter - Change
Failure to follow this recommended procedure will

NOTICE cause the waste particles to be recirculated through
Always use a designated pump for oil sampling, and
the engine lubrication system with the new oil.
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 Drain the Engine Oil
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con- After the engine has been run at the normal
cerns by both dealers and customers. operating temperature, stop the engine. Use one of
the following methods to drain the engine crankcase
oil:
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is • If the engine is equipped with a drain valve, turn
designed to accept sampling bottles. Disposable the drain valve knob counterclockwise in order to
tubing must be attached to the pump for insertion into drain the oil. After the oil has drained, turn the
the sump. drain valve knob clockwise in order to close the
For instructions, see Special Publication, PEGJ0047, drain valve.
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and • If the engine is not equipped with a drain valve,
assistance in establishing an S·O·S program for your remove the oil drain plug in order to allow the oil to
engine. drain. After the oil has drained, the oil drain plug
should be cleaned and installed.
i05680489
Replace the Oil Filter
Engine Oil and Filter - Change
SMCS Code: 1318-510; 1348-044 NOTICE
Caterpillar oil filters are built to Caterpillar specifica-
tions. Use of an oil filter not recommended by Cater-
pillar could result in severe engine damage to the
engine bearings, crankshaft, etc., as a result of the
Hot oil and hot components can cause personal larger waste particles from unfiltered oil entering the
injury. Do not allow hot oil or hot components to engine lubricating system. Only use oil filters recom-
contact the skin. mended by Caterpillar.
NOTICE 1. Remove the oil filter with a 1U-8760 Chain

Care must be taken to ensure that fluids are con- Wrench.
nance, testing, adjusting and repair of the product. Note: The following actions can be carried out as
Be prepared to collect the fluid with suitable contain- part of the preventive maintenance program.
bling any component containing fluids. 2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
Dispose of all fluids according to local regulations oil filter for metal debris. An excessive amount of
and mandates.
metal debris in the oil filter may indicate early wear
or a pending failure.
NOTICE Use a magnet to differentiate between the ferrous
Keep all parts clean from contaminants. metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
Contaminants may cause rapid wear and shortened wear on the steel and cast iron parts of the engine.
component life.
Nonferrous metals may indicate wear on the
Do not drain the oil when the engine is cold. As the oil aluminum parts, brass parts, or bronze parts of the
cools, suspended waste particles settle on the engine. Parts that may be affected include the
bottom of the oil pan. The waste particles are not following items: main bearings, rod bearings,
removed with the draining cold oil. Drain the turbocharger bearings and cylinder heads.
crankcase with the engine stopped. Drain the
crankcase with the oil warm. This draining method Due to normal wear and friction, it is not
allows the waste particles that are suspended in the uncommon to find small amounts of debris in the
oil to be drained correctly. 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.
78 SEBU9236-05
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer's recommendations. Under filling or
overfilling the crankcase with oil can cause engine
damage.
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at “LOW IDLE”

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
Illustration 72 g01091799 the sump for a minimum of 10 minutes.
(1) Oil cooler
(2) Adapter
(3) Oil filter
Note: The oil cooler (1) and the adapter (2) are
installed to the C2.2/3024CT engine only.
3. Clean the sealing surface of the cylinder block or

the oil cooler (1).
4. Apply clean engine oil to the new oil filter seal (3).
NOTICE 4. Remove the oil level gauge in order to check the oil
Do not fill the oil filters with oil before installing them. level. Maintain the oil level between the “ADD” and
This oil would not be filtered and could be contami- “FULL” marks on the oil level gauge.
nated. Contaminated oil can cause accelerated wear
to engine components.
i05680529
5. Install the oil filter. Tighten the oil filter until the oil Engine Valve Lash - Inspect/
filter seal contacts the cylinder block or the oil
cooler. Tighten the oil filter by hand according to
Adjust
the instructions that are shown on the oil filter. Do SMCS Code: 1102-025
not overtighten the oil filter.
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
Fill the Engine Crankcase recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of the
1. Remove the oil filler cap. Refer to this Operation valve train components and to the seating of the
and Maintenance Manual , “Refill Capacities and valve train components.
Recommendations” for more information on This maintenance is recommended by Caterpillar as
lubricant specifications. Fill the crankcase with the part of a lubrication and preventive maintenance
correct amount of oil. Refer to this Operation and schedule in order to help provide maximum engine
Maintenance Manual , “Refill Capacities” for more life.
information on refill capacities.
SEBU9236-05 79
Maintenance Section
Fuel Injection Nozzles - Test/Exchange
Fuel Injection nozzles should be cleaned, inspected,

NOTICE tested, and replaced, if necessary. Refer to Special
Only qualified service personnel should perform this
maintenance. Refer to the Systems Operation/Test- Instruction, SEHS7292 for using the 8S-2245
ing and Adjusting Manual, “Valve Lash and Valve Injection Cleaning Tool Group. Consult your
Bridge Adjustment” article or consult your Caterpillar Caterpillar dealer about cleaning the fuel injection
dealer for the complete valve lash adjustment nozzle and testing the fuel injection nozzle.
procedure.
NOTICE
Operation of Caterpillar engines with improper valve Never wire brush or scrape a fuel injection nozzle.
adjustments can reduce engine efficiency. This re- Wire brushing or scraping a fuel injection nozzle will
duced efficiency could result in excessive fuel usage damage the finely machine orifice. Proper tools for
and/or shortened engine component life. cleaning and testing the fuel injection nozzles can be
obtained from Caterpillar dealers.
The following items are symptoms of a malfunction of

the fuel injection nozzle:
Ensure that the engine cannot be started while
this maintenance is being performed. To help pre- • Abnormal engine operation
vent possible injury, do not use the starting motor
to turn the flywheel. • Smoke emission
Hot engine components can cause burns. Allow • Engine knock
additional time for the engine to cool before
measuring/adjusting valve lash clearance. Each fuel injection nozzle must be isolated one at a
time in order to determine the malfunctioning fuel
injection nozzle.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement, 1. Start the engine.
allow the valves to cool before this maintenance is
performed. 2. Loosen each fuel line nut one at a time at the fuel
injection pump. A cloth or similar material must be
Refer to the Service Manual for more information. used in order to prevent fuel from spraying on the
hot exhaust components. Tighten each nut before
i05680682
loosening the next nut.
Fuel Injection Nozzles - Test/ 3. A defective fuel injection nozzle may be identified
when a fuel line nut is loosened and the following
Exchange conditions are present:
SMCS Code: 1254-081; 1254-013
• The exhaust smoke is partially eliminated or
the exhaust smoke is completely eliminated.
Fuel leaked or spilled onto hot surfaces or electri- • Engine performance is not affected.
cal components can cause a fire. A fuel injection nozzle that is suspected of being
defective should be removed. A new fuel injection
nozzle should be installed in the cylinder in order
NOTICE to determine if the removed fuel injection nozzle is
Do not allow dirt to enter the fuel system. Thoroughly defective.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Fuel injection nozzles are subject to tip wear. Tip

wear is a result of fuel contamination. Tip wear can
cause the following problems:
• Increased fuel consumption

• Black smoke
• Misfire
• Rough running
80 SEBU9236-05
Maintenance Section
Fuel System - Prime
Removal and Installation of the

Fuel Injection Nozzles
For the removal and the installation of fuel injection
nozzles, special tooling is required. Refer to the
Service Manual for more information. Consult your
Caterpillar dealer for assistance.
i05680715
Fuel System - Prime

SMCS Code: 1258-548
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
• The fuel tank is empty or the fuel tank has been
partially drained.
• The low-pressure fuel lines are disconnected. Illustration 74 g03612976
• A leak exists in the low-pressure fuel system. (1) Vent

(2) Vent
(3) Filter
• The fuel filter is replaced. (4) Body
(5) Drain valve
NOTICE
Care must be taken to ensure that fluids are con- 1. Open vents (1) and (2). Operate the priming pump.
nance, testing, adjusting and repair of the product. 2. When fuel free from air comes from the vents,
Be prepared to collect the fluid with suitable contain- close the vents.
bling any component containing fluids. There are two types of secondary fuel filter that may
be installed on these engines. The procedure to
Dispose of all fluids according to local regulations prime the fuel system will depend on the type of filter
and mandates. that is installed on the engine and the type of
connector that is installed on the fuel injection pump.
Both types of filter and connections are shown.
Primary fuel filter will need to be primed. Ensure that
the fuel supply valve is open. Use the following procedure in order to prime the fuel
system:
SEBU9236-05 81
Maintenance Section
Fuel System - Prime
3. Operate the hand primer. When fuel free from air

flows from the vent screw tighten the vent screw.
Fuel filter with element
(1) Fuel valve
(2) Vent screw Illustration 77 g01122126
Connector that is installed three cylinder engines
(4) Connector bolt
(5) Fuel return hose for the injector
Fuel filter with canister
(3) Vent screw
1. Ensure that the fuel valve (1) for the fuel filter that Connector that is installed on four cylinder engines
has an element is in the ON position. The fuel (6) Connector bolt
valve for the fuel filter that has a canister may be
located away from the engine. Refer to the OEM 4. Loosen the connector (4) or (6) at the fuel injection
information for further details. pump.
2. Loosen the vent screw (2) or (3). Note: For illustration 77 , the fuel return hose (5) may
need to be removed at the fuel injection pump.
82 SEBU9236-05
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
5. Operate the hand primer. When fuel free from air 3. Close vents and close drain valve. Remove filter
flows from the connector tighten the connector body (4) and replace the filter element (3).
bolt.
4. Install filter body (4).
6. Try to start the engine.
5. The secondary filter must be replaced. Refer to
Note: Do not operate the starting motor for more than this Operation and Maintenance Manual, “Fuel
15 seconds. If the engine does not start after 15 System Secondary Filter - Replace” for more
seconds, stop and wait for 30 seconds before trying information.
again.
i05690234
i05690241
Fuel System Primary Filter/
Fuel System Primary Filter Water Separator - Drain
(Water Separator) Element - SMCS Code: 1260-543; 1263-543
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
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
Fuel leaked or spilled onto hot surfaces or electri- changing fuel filters or water separator elements.
cal components can cause a fire. To help prevent Clean up fuel spills immediately.
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately. NOTICE
The water separator is not a filter. The water separa-
tor separates the water from the fuel. The engine
should never be run when the water separator is
more than half full of water. Engine damage may
result.
(1) Vent
(2) Vent
(3) Filter
(4) Body
(5) Drain valve
(1) Vent
1. Clean the outside of the filter assemble and close (2) Vent
the fuel supply valve. (3) Nylon Gauze Filter
(4) Drain valve
2. Open vents (1) and (2). open drain valve (5). Drain (5) Transparent body
the filter assemble.
SEBU9236-05 83
Maintenance Section
Fuel System Secondary Filter - Replace
1. Open vents (1) and vent (2).

2. Open the drain valve (5). Drain the water into a
suitable container. When fuel free from water
flows, close the drain valve, and dispose of the
water properly.
3. Close vents (1) and vent (2).
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.
i05690289
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE
2. Clean the outside of the fuel filter assembly.

Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent 3. Open the fuel drain (2) in the bottom of the filter
possible injury, turn the start switch off when assembly, if equipped. Drain the fuel into a
changing fuel filters or water separator elements. suitable container.
Clean up fuel spills immediately.
4. Loosen the setscrew (1).
5. Remove the canister (3).
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
nance, testing, adjusting and repair of the product.
and mandates.
Fuel Filter With Canister

1. Close the fuel supply valve.
84 SEBU9236-05
Maintenance Section
Fuel System Secondary Filter - Replace
2. Clean the outside of the fuel filter assembly.

3. Loosen the locking ring (3).
4. Remove the casing for the filter (2) and the
element.
6. Assemble the following items: seals (8), seal (7),

canister (9) and base (10). Place washer (5) and
seal (6) on setscrew (4).
7. Fasten the assembly to the fuel filter base with
setscrew (4).
The fuel system will need to be primed after the new
filter is installed. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime”.
Fuel Filter With Element

1. Close the fuel supply valve (1).
SEBU9236-05 85
Maintenance Section
Fuel Tank Water and Sediment - Drain
The fuel system will need to be primed after the new

filter is installed. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime”.
i05683629
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
NOTICE
nance, testing, adjusting, and repair of the product.
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.
and mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
5. Assemble the following items: seal (5), filter the fuel tank regularly and obtaining fuel from reliable
element (6) and casing (7). sources can help to eliminate water in the fuel.
6. Install the assembled items to the filter head (4).
Drain the Water and the Sediment
7. Install the locking ring (8) to the filter head. Rotate
the locking ring in order to lock the assembly. Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank in
order to drain the water and the sediment. Close the
drain valve.
Note: Failure to close the drain can allow air into the
system, which could have detrimental results to
performance.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine. 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.
86 SEBU9236-05
Maintenance Section
Generator - Dry
Fill the fuel tank after operating the engine in order to • Self-circulating air method
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel • Oven method
expands as the fuel gets warm. The tank may
overflow. NOTICE
Some fuel tanks use supply pipes that allow water Do not allow the winding temperature to exceed
and sediment to settle below the end of the fuel 85 °C (185.0 °F). Temperatures that are greater than
supply pipe. Some fuel tanks use supply lines that 85 °C (185.0 °F) will damage the winding insulation.
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. Self-Circulating Air Method
Fuel Storage Tanks Note: Disable the excitation before using this
method.
Drain the water and the sediment from the fuel Run the engine and disconnect the generator load.
storage tank during the following conditions:
This will help circulate air. Operate the generator
• Weekly space heaters.
• Oil change Oven Method

• Refill of the tank Place the entire generator inside a forced air drying
oven for four hours at 65 °C (149 °F).
This procedure will help prevent water or sediment
from being pumped from the storage tank into the NOTICE
engine fuel tank. A four micron(c) absolute filter for Use a forced air type oven rather than a radiant type
the breather vent on the fuel tank is also oven.
recommended.
Radiant type ovens can cause localized overheating.
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
i06639212
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. Generator - Inspect
When possible, water separators should be used. SMCS Code: 4450-040
i03642821
Generator - Dry Personal injury or death can result from improper

SMCS Code: 4450-569 troubleshooting and repair procedures.
The following troubleshooting and repair proce-
NOTICE dures should only be performed by qualified per-
Do not operate the generator if the windings are wet. sonnel familiar with this equipment.
If the generator is operated when the windings are
wet, damage can occur due to insulation breakdown.
When moisture is present or when moisture is
suspected in a generator, the generator must be
dried before being energized. The high voltage that is produced by an operating
generator set can cause severe injury or death.
If the drying procedure does not restore the insulation Before performing any maintenance or repairs,
resistance to an acceptable value, the winding should ensure that the generator will not start.
be reconditioned.
Place the engine control switch in the “ OFF”” posi-
Note: For additional information, refer to Special tion. Attach “ DO NOT OPERATE”” tags to all start-
Instruction, SEHS9124 . ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
Drying Methods with the generator.
The following methods can be used for drying a

generator:
SEBU9236-05 87
Maintenance Section
Generator - Inspect
Refer to Safety Section, “Generator Isolating for Cleaning may be required at the point of installation.
Maintenance” for information regarding the Complete disassembly of the generator may not be
procedure to isolate the generator safely. necessary or feasible. In this case, a vacuum cleaner
should be used to pick up the following items: dry dirt,
Proper maintenance of electrical equipment requires dust, and carbon. Cleaning the generator will prevent
periodic visual examination of the generator and the spreading of these contaminants.
periodic visual examination of the windings. Proper
maintenance of electrical equipment also requires A small nonconductive tube may need to be
appropriate electrical checks and appropriate thermal connected to the vacuum cleaner. The small
checks. Insulation material should be examined for nonconductive tube will allow the vacuum cleaner to
cracks. The insulation material should be examined clean the surfaces that are not exposed. After dust is
for accumulations of dirt and dust. If there is an removed, use a small brush attached to the vacuum
insulation resistance value that is below normal, a hose to remove dirt that is firmly attached to the
conductive path may be present. This conductive surface.
path may be made of one of the following materials:
After the initial cleaning with a vacuum, compressed
• Carbon air may be used to remove the remaining dust and
dirt. Compressed air that is used for cleaning should
• Salt be free of moisture and free of oil. Air pressure
should be a maximum of 210 kPa (30 psi) to prevent
• Metal dust mechanical damage to the insulation. If the above
cleaning procedures are not effective, consult a
• Dirt that is saturated with moisture Caterpillar dealer.
These contaminants will develop a conductive path
which may produce shorts. Cleaning is advisable if Cleaning (Disassembled
heavy accumulations of dirt can be seen or if heavy Generators)
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 NOTICE
excessive heating. Do not use water to clean the generator.
NOTICE
To avoid the possibility of deterioration to the genera- NOTICE
tor windings, do not clean the generator unless there Do not use trichloroethane, perchloroethylene, tri-
is visual, electrical, or thermal evidence that dirt is chloroethane, or any alkaline products to clean the
present. generator.
An initial insulation resistance check should be made
If harmful dirt accumulations are present, various on the generator to confirm electrical integrity. A
cleaning techniques are available. The cleaning minimum reading of 1megohm would be expected
procedure that is used may be determined by one of with severely contaminated generators. A zero
the items on the following list: megohm reading may indicate an insulation
breakdown. An insulation breakdown requires more
• The extent of the cleaning procedure that is being than cleaning. An insulation breakdown requires
attempted repair.
• The type of enclosure of the generator Use the following for cleaning the stator, the rotor, the
exciter, and the diode bridge:
• The voltage rating of the generator
• Unleaded Gasoline
• The type of dirt that is being removed
• Toluene
Cleaning (Assembled Generators)
• Benzene
NOTICE • Cyclohexane
Do not use water to clean the generator.
Avoid permitting the solvent to run into the slots.
Apply the solvent with a brush. Use a sponge on the
NOTICE windings frequently to remove the debris. Dry the
Do not use trichloroethane, perchloroethylene, tri- winding with a dry cloth. Allow the solvent to
chloroethane, or any alkaline products to clean the evaporate before reassembling the generator.
generator.
88 SEBU9236-05
Maintenance Section
Generator Load - Check
Allow the generator to dry at room temperature. i05731121

Check the insulation resistance. The insulation
resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure.
Generator Set - Test
SMCS Code: 4450-081
Note: For more information on drying methods, refer
to Special Instructions, SEHS9124, “Cleaning and
Drying of Electric Set Generators”.
Personal injury or death can result from high
i01878834 voltage.
Generator Load - Check When power generation equipment must be in

operation to make tests and/or adjustments, high
SMCS Code: 4450-535-LA voltage and current are present.
Improper test equipment can fail and present a
Personal injury or death can result from high Make sure the testing equipment is designed for
voltage. and correctly operated for high voltage and cur-
When power generation equipment must be in rent tests being made.
operation to make tests and/or adjustments, high When servicing or repairing electric power gener-
voltage and current are present. ation equipment:
Improper test equipment can fail and present a
high voltage shock hazard to its user. • Make sure the unit is off-line (disconnected
Make sure the testing equipment is designed for service), and either locked out or tagged DO
and correctly operated for high voltage and cur- NOT OPERATE.
rent tests being made.
• Make sure the generator engine is stopped.
During normal operation, monitor the power factor
and monitor generator loading. • Make sure all batteries are disconnected.
When a three-phase generator is installed or when a • Make sure all capacitors are discharged.
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 Table 17
same load. This allows the three-phase generator to Required Tools
work at the rated capacity. If one phase current
exceeds the nameplate amperage, an electrical Part Number Part Description Qty
imbalance will occur. An electrical imbalance can
result in an electrical overload and an electrical 6V-7070 Digital Multimeter 1
imbalance can result in overheating on three-phase
generators. This is not applicable to single-phase - 12 VDC Battery 1
generators. - Potential Transformer 1
The power factor can be referred to as the efficiency
of the load. This can be expressed as the ratio of kVA The generator set functional test is a simplified test
to actual kW. The power factor can be calculated by that can be performed in order to determine if the
dividing kW by kVA. Power factor is expressed as a generator is functional. The generator set functional
decimal. Power factor is used to mean the portion of test should be performed on a generator set that is
current that is supplied to a system that is doing under load.
useful work. The portion of the current that is not
doing useful work is absorbed in maintaining the The generator set functional test determines if the
magnetic field in motors. This current (reactive load) following statements happen:
can be maintained without engine power.
• 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:
SEBU9236-05 89
Maintenance Section
Glow Plugs - Inspect
1. Stop the generator. Connect the potential • End fittings that are damaged or leaking
transformer high voltage winding to the generator
terminals (T1) and (T2). Connect the voltmeter to • Outer covering that is chafed or cut
the low voltage winding. If two transformers are • Exposed wire that is used for reinforcement
available, connect the high voltage winding of the
second transformer to the generator terminals (T1) • Outer covering that is ballooning locally
and (T3). Connect the secondary terminals that
correspond to generator terminal (T2) of both • Flexible part of the hose that is kinked or crushed
transformers together. • Armoring that is embedded in the outer covering
2. Disconnect wires “E+” and “E-” from the voltage
A constant torque hose clamp can be used in place
regulator. Disconnect the generator from the load. of any standard hose clamp. Ensure that the constant
3. Connect a 12 VDC automotive battery to wires “E torque hose clamp is the same size as the standard
clamp.
+” and “E-” .
4. Measure the AC voltage across the low voltage Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
terminals of the transformer that correspond to the This can result in leaks. A constant torque hose
following generator terminals: “T1” and “T2” , “T2” clamp will help to prevent loose hose clamps.
and “T3” and “T3” and “T1” . Record the voltages.
Each installation application can be different. The
i05697889
differences depend on the following factors:
• Type of hose
Glow Plugs - Inspect
SMCS Code: 1412-040 • Type of fitting material
Visually inspect the glow plugs for damage and • Anticipated expansion and contraction of the hose
check all connection.
• Anticipated expansion and contraction of the
For more information refer to Systems Operation fittings
Testing and Adjusting, “Glow Plugs - Test”.
Replace the Hoses and the Clamps
i05683670
Hoses and Clamps - Inspect/

Replace Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
SMCS Code: 7554-040; 7554-510 stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Inspect all hoses for leaks that are caused by the pressure cap slowly in order to relieve the
following conditions: pressure.
• Cracking
1. Stop the engine. Allow the engine to cool.
• Softness
2. Loosen the cooling system filler cap slowly in order
• Loose clamps to relieve any pressure. Remove the cooling
Replace hoses that are cracked or soft. Tighten any system filler cap.
loose clamps. Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
NOTICE
Do not bend or strike high-pressure lines. Do not in- 3. Drain the coolant from the cooling system to a
stall bent or damaged lines, tubes, or hoses. Repair
any loose or damaged fuel and oil lines, tubes, and level that is below the hose that is being replaced.
hoses. Leaks can cause fires. Inspect all lines, tubes, 4. Remove the hose clamps.
and hoses carefully. Tighten all connections to the
recommended torque. Do not attach any item to the 5. Disconnect the old hose.
high-pressure fuel lines.
6. Replace the old hose with a new hose.
Check for the following conditions: 7. Install the hose clamps with a torque wrench.
90 SEBU9236-05
Maintenance Section
Instrument Panel - Inspect
Note: Refer to the Specifications, SENR3130, Table 18

“Torque Specifications” in order to locate the proper TOOLS NEEDED
torques.
Part Number Tool Quantity
8. Refill the cooling system.
142-5055 Insulation Tester 1
9. Clean the cooling system filler cap. Inspect the Megohmmeter
cooling system filler caps gaskets. Replace the
cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
10. Start the engine. Inspect the cooling system for Personal injury or death can result from
leaks. electrocution.
The megohmmeter is applying a high voltage to
i01917577 the circuit.
Instrument Panel - Inspect To avoid electrocution, do not touch the instru-

ment leads without first discharging them. When
SMCS Code: 7451-040 finished testing also discharge the generator
windings.
Inspect the instrument panel for good condition.
Perform the self test. All of the warning lamps should The following materials will cause the winding
illuminate. If a warning lamp does not illuminate, insulation to deteriorate:
replace the bulb immediately. If the alarm does not
sound, investigate the problem and correct the • moisture (water)
problem.
• dust
Check the condition of all of the gauges. If a gauge is
broken, repair the gauge or replace the gauge • grease
immediately.
• other foreign matter within the generator
Frequently monitor the gauges during normal
operation. This deterioration reduces the resistance of the
insulation. This test will measure the resistance of the
Record the data in a log. Compare the new data to winding insulation.
the data that was previously recorded. Comparing
the new data to the recorded data will help to The insulation tester (megohmmeter) produces a
establish the trends of engine performance. A gauge high potential voltage between the test leads. During
reading that is abnormal may indicate a problem with the test, a small current flows. The tester converts
this current to a resistance reading.
operation or a problem with the gauge.
The insulation test is performed as part of periodic
i03878716 maintenance in order to detect the deterioration of
the winding insulation. When there is a rapid
Insulation - Test decrease in the insulation resistance in a short
amount of time, the generator needs to be cleaned.
SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
081 Note: For information on generator cleaning, refer to
Special Instruction, SEHS9124.
When generators have not been used for a period of
time, moisture can accumulate. Therefore, the
The high voltage that is produced by an operating insulation test should be performed on generators
generator set can cause severe injury or death. that have been idle. If moisture is known to exist, the
Before performing any maintenance or repairs, windings must be dried prior to testing. Refer to
ensure that the generator will not start. Testing And Adjusting, “Generator - Dry”.
Place the engine control switch in the “ OFF”” posi- The insulation test should be performed on
tion. Attach “ DO NOT OPERATE”” tags to all start- generators that are being used for the first time. The
ing controls. Disconnect the batteries or disable insulation test should be performed more frequently
the starting system. Lock out all switchgear and in the following cases:
with the generator. • The generator set is operating in a humid
environment.
SEBU9236-05 91
Maintenance Section
Overhaul Considerations
• The generator set is not protected from the Prevent these wires from coming into contact with
elements in an enclosed area. each other and prevent these wires from
contacting ground.
• The generator set has not been run under load for
three months. 2. Isolate the main armature (L4) from the voltage
regulator by disconnecting the wires for voltage
Note: Space heaters may need to be used around sensing. If generator lead (T0) is connected to the
the generator set in the following cases: generator frame or ground, open the connection.
• The generator set has not been run under load for 3. Connect one test lead of the insulation tester
three months. (megohmmeter) to the generator enclosure
(ground).
• The generator set is exposed to a sea water
environment. 4. Connect the other test lead of the insulation tester
(megohmmeter) to generator lead (T0).
• The humidity is above 75 percent.
5. The insulation resistance must be one megohm or
• A test result was below 3 megohms. more.
The winding needs to be reconditioned or the winding
needs to be replaced in the following cases: Exciter Field (Stator L1)
• The measured insulation resistance falls below the 1. Isolate exciter field (L1) from the voltage regulator
specified amount. The cleanup procedure does by disconnecting wires 5+ and 6-. Prevent these
not correct the discrepancy. wires from coming into contact with each other
and prevent these wires from contacting ground.
• The measured insulation resistance falls below the
specified amount. The drying procedure does not 2. Connect one test lead of the insulation tester
correct the discrepancy. (megohmmeter) to the generator enclosure
(ground).
The specified insulation resistance is an approximate
value. It can be possible to operate the generator 3. Connect one test lead of the insulation tester
with less than the specified value. However, a (megohmmeter) to exciter field lead (5+ or 6-).
generator that has a low winding insulation
resistance will be more likely to have a failure. 4. Measure the resistance of the exciter field winding
insulation to ground. The insulation resistance
must be a minimum of 0.25 megohm (250000
ohms).
Personal injury or death can result from improper
troubleshooting and repair procedures. Exciter Armature (Rotor L2)
The following troubleshooting and repair proce-
dures should only be performed by qualified per- 1. Isolate exciter armature (L2) from the rectifier
sonnel familiar with this equipment. circuit. Disconnect the three wires of the exciter
armature from the rectifier blocks.
The insulation test gives accurate results only when 2. Connect one test lead of the insulation tester
the generator windings are free of moisture and the (megohmmeter) to the rotor shaft.
generator windings are at room temperature.
3. Connect one test lead of the insulation tester
Each winding must have a minimum insulation (megohmmeter) to any one exciter field lead.
resistance of one megohm.
4. The insulation resistance must be a minimum of
Main Armature (Stator L4) 0.25 megohm (250000 ohms).
1. Remove the load from the generator by either of i01437994

the following:
• Open the line circuit breaker.
SMCS Code: 7595-043
• Open the following load connections: T1, T2, Reduced hours of operation at full load will result in a
T3 and T0. lower average power demand. A decreased average
power demand should increase both the engine
service life and the overhaul interval.
92 SEBU9236-05
Maintenance Section
The need for an overhaul is generally indicated by After Failure Overhaul

increased fuel consumption and by reduced power.
Many options are available if a major engine failure
The following factors are important when a decision occurs. An overhaul should be performed if the
is being made on the proper time for an engine engine block or the crankshaft can be repaired.
overhaul:
If the engine block is repairable and/or the crankshaft
• The need for preventive maintenance is repairable, the overhaul cost should be less than
the cost of a new engine with a similar exchange
• The quality of the fuel that is being used core.
• The operating conditions This lower cost can be attributed to these aspects:
• The results of the S·O·S analysis • Caterpillar dealer exchange components
• Caterpillar Inc. remanufactured exchange

Oil Consumption as an Overhaul components
Indicator
Overhaul Recommendation
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total To minimize downtime, Caterpillar Inc. recommends
operating cost for your Caterpillar engine. Oil a scheduled engine overhaul by your Caterpillar
consumption can also be used to estimate the dealer before the engine fails. This will provide you
required capacity of a makeup oil tank that is suitable with the best cost/value relationship.
for the maintenance intervals.
Note: Overhaul programs vary according to the
Oil consumption is in proportion to the percentage of
the rated engine load. As the percentage of the engine application and according to the dealer that
engine load is increased, the amount of oil that is performs the overhaul. Consult your Caterpillar
consumed per hour also increases. dealer for specific information about the available
overhaul programs and about overhaul services for
The oil consumption rate (brake specific oil extending the engine life.
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) If an overhaul is performed without overhaul service
depends on the engine load. Consult your Caterpillar from your Caterpillar dealer, be aware of the following
dealer for assistance in determining the typical oil maintenance recommendations.
consumption rate for your engine.
Rebuild or Exchange
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal These components should be inspected according to
wear, an engine overhaul should be scheduled. the instructions that are found in various Caterpillar
There may be a corresponding increase in blowby reusability publications. The Special Publication,
and a slight increase in fuel consumption. SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
Overhaul Options
If the parts comply with the established inspection
Before Failure Overhaul specifications that are expressed in the reusable
parts guideline, the parts should be reused.
A planned overhaul before failure may be the best
value for the following reasons: Parts that are not within the established inspection
specifications should be dealt with in one of the
• Costly unplanned downtime can be avoided. following manners:
• Many original parts can be reused according to the • Salvaging

standards for reusable parts.
• Repairing
• The engine's service life can be extended without
the risk of a major catastrophe due to engine • Replacing
failure. Using out-of-spec parts can result in the following
problems:
• The best cost/value relationship per hour of
extended life can be attained. • Unscheduled downtime
• Costly repairs
SEBU9236-05 93
Maintenance Section
• Damage to other engine parts • Camshaft bearings

• Reduced engine efficiency • Valve lifters
• Increased fuel consumption Testing

Reduced engine efficiency and increased fuel
consumption translates into higher operating costs. Test the following components during the overhaul.
Therefore, Caterpillar Inc. recommends repairing out- • Fuel injection nozzles
of-spec parts or replacing out-of-spec parts.
• Fuel injection pump
Inspection and/or Replacement
Testing the fuel system during the overhaul will
The following components may not last until the ensure that your engine operates at peak efficiency.
second overhaul. Your Caterpillar dealer can provide these services
and components in order to ensure that your fuel
• Piston rings system is operating within the appropriate
specifications.
• Thrust bearings
Cleaning
• Main bearings
• Connecting rod bearings Caterpillar Inc. recommends the use of Hydrosolv
Liquid Cleaners. Table 19 lists the Hydrosolv Liquid
• Crankshaft seals Cleaners that are available from your Caterpillar
dealer.
• Engine mounts Table 19
HydrosolvLiquid Cleaners
• Hoses
Part Number Description Size
Caterpillar Inc. recommends the installation of new
parts at each overhaul period.
Inspect these parts while the engine is disassembled 1U-8812 4 L (1 US gallon)
for an overhaul. Hydrosolv4165
Inspect the crankshaft for any of the following 1U-5490 19 L (5 US gallon)
conditions:
8T-7570 208 L (55 US gallon)
• Deflection
1U-8804 4 L (1 US gallon)
• Damage to the journals
Hydrosolv100
1U-5492 19 L (5 US gallon)
• Bearing material that has seized to the journals
8T-5571 208 L (55 US gallon)
Check the journal taper and the profile of the
crankshaft journals. Check these components by
interpreting the wear patterns on the following Obtain Coolant Analysis
components:
• Rod bearing The concentration of supplemental coolant additive

(SCA) should be checked regularly with test kits or
• Main bearings with S·O·S Coolant Analysis (Level I). Further
coolant analysis is recommended when the engine is
Note: If the crankshaft is removed for any reason, overhauled.
use the magnetic particle inspection process to check For example, considerable deposits are found in the
for cracks in the crankshaft. water jacket areas on the external cooling system,
Inspect the camshaft for damage to the journals and but the concentrations of coolant additives were
carefully maintained. The coolant water probably
to the lobes.
contained minerals that were deposited on the
Note: If the camshaft is removed for any reason, use engine over time.
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:
94 SEBU9236-05
Maintenance Section
Rotating Rectifier - Check
A coolant analysis can be conducted in order to verify i02290281

the condition of the water that is being used in the
cooling system. A full water analysis can be obtained Rotating Rectifier - Test
by consulting your local water utility company or an
agricultural agent. Private laboratories are also SMCS Code: 4465-081
available for water analysis.
Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level II).
The high voltage that is produced by an operating
S·O·S Coolant Analysis (Level II) generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
An S·O·S Coolant Analysis (Level II) is a
comprehensive coolant analysis which completely Place the engine control switch in the “ OFF”” posi-
analyzes the coolant and the effects on the cooling tion. Attach “ DO NOT OPERATE”” tags to all start-
system. An S·O·S Coolant Analysis (Level II) ing controls. Disconnect the batteries or disable
provides the following information: the starting system. Lock out all switchgear and
• Complete S·O·S Coolant Analysis (Level I) with the generator.
• 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 II) provides a report of
the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see
your Caterpillar dealer.
i01880286
Rotating Rectifier - Check (1) Positive DC terminal or Negative DC terminal

(2) AC terminal
SMCS Code: 4465-535 (3) AC terminal
(4) AC terminal
The following procedure tests all three diodes within

a block. Check the positive rectifier block and the
The high voltage that is produced by an operating negative rectifier block. If any meter reading does not
generator set can cause severe injury or death. fall within the given ranges, replace the rectifier
Before performing any maintenance or repairs, block.
ensure that the generator will not start.
1. Set the digital multimeter on the diode range.
Place the engine control switch in the “ OFF”” posi- Remove all leads from the rectifier block.
tion. Attach “ DO NOT OPERATE”” tags to all start-
ing controls. Disconnect the batteries or disable 2. To test the negative rectifier block, follow these
the starting system. Lock out all switchgear and steps:
with the generator. a. Place the red test lead on the negative “-”
terminal (1). Place the black test lead on the
Check the exciter armature. Ensure that the rotating
following rectifier terminals: AC terminal (2), AC
rectifier is tight. If a failure of a rectifier is suspected,
refer to Maintenance Procedure, “Rotating Rectifier - terminal (3) and AC terminal (4). All readings on
Test”. 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
SEBU9236-05 95
Maintenance Section
Starting Motor - Inspect
terminal (3) and AC terminal (4). In all cases, the • The guards must be in the proper place. Repair
meter should read “OL” (overload). damaged guards or replace missing guards.
3. To test the positive rectifier block, follow these • Wipe all caps and plugs before the engine is
steps: serviced in order to reduce the chance of system
contamination.
a. Place the red test lead on the positive “+”
rectifier terminal (1). Place the black test lead on NOTICE
the following rectifier terminals: AC terminal (2), For any type of leak (coolant, lube, or fuel) clean up
AC terminal (3) and AC terminal (4). In all cases, the fluid. If leaking is observed, find the source and
the meter should read “OL” (overload). correct the leak. If leaking is suspected, check the flu-
id levels more often than recommended until the leak
b. Place the black test lead on the positive “+” is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.
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 NOTICE
on the meter should be between 0.4 and 1.0. Accumulated grease and/or oil on an engine or deck
is a fire hazard. Remove this debris with steam clean-
Note: A shorted diode can cause damage to the ing or high pressure water.
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”. • Ensure that cooling lines are properly clamped
Perform these tests. and tight. Check for leaks. Check the condition of
all pipes.
i00651416
• Inspect the water pump for coolant leaks.
Starting Motor - Inspect Note: The water pump seal is lubricated by coolant in
SMCS Code: 1451-040; 1453-040 the cooling system. A small amount of leakage to
occur as the engine cools down and the parts
Caterpillar Inc. recommends a scheduled inspection contract is normal.
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation. Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
Check the starting motor for proper operation. Check water pump and the installation of water pump and/or
the electrical connections and clean the electrical seals, refer to the Service Manual for the engine or
connections. Refer to the Service Manual for more consult your Cat dealer.
information on the checking procedure and for
specifications or consult your Caterpillar dealer for • Inspect the lubrication system for leaks at the front
assistance. crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters, and the valve cover.
i05701589
• Inspect the fuel system for leaks. Look for loose
Walk-Around Inspection fuel line clamps.
SMCS Code: 1000-040 • Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
Inspect the Engine and Generator • Inspect the alternator belt and the accessory drive
Set for Leaks and for Loose belts for cracks, breaks, or other damage.
Connections Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
A walk-around inspection should only take a few
carry more load than the belts that are not replaced.
minutes. When the time is taken to perform these
The older belts are stretched. The additional load on
checks, costly repairs and accidents can be avoided. the new belt could cause the belt to break.
For maximum service life, make a thorough • Drain the water and the sediment from fuel tanks
inspection of the engine generator set before starting
on a daily basis in order to ensure that only clean
the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose fuel enters the fuel system.
connections, and trash buildup. Make repairs, as
needed:
96 SEBU9236-05
Maintenance Section
Water Pump - Inspect
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection

and for good condition.
• Inspect the engine-to-frame ground strap for a

good connection and for good condition.
• Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges which are cracked or cannot be calibrated.
i05701632
Water Pump - Inspect

SMCS Code: 1361; 1361-040
A failed water pump may 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. A small amount of
leakage to occur as the engine cools down and parts
contract is normal.
Visually inspect the water pump for leaks. Renew the
water pump seal or the water pump if there is an
excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, “Water Pump -
Remove and Install” for the disassembly and
assembly procedure.
SEBU9236-05 97
Customer Service
Reference Information Latin America, Mexico, Carribean

Caterpillar Americas Co.
Section 701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Customer Service Phone: 305-476-6800
Fax: 305-476-6801
i03910306 Europe, Africa, and Middle East
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000 CH-1211 Geneva 6
Switzerland
USA and Canada Phone: 22-849-4444
Fax: 22-849-4544
When a problem arises concerning the operation or
the service of an engine, the problem will normally be Far East
managed by the dealer in your area. Caterpillar Asia Pte. Ltd.
7 Tractor Road
Your satisfaction is a primary concern to Caterpillar Jurong, Singapore 627968
and to Caterpillar dealers. If you have a problem that Republic of Singapore
has not been handled to your complete satisfaction,
follow these steps: Phone: 65-662-8333
Fax: 65-662-8302
1. Discuss your problem with a manager from the
dealership. China
Caterpillar China Ltd.
2. If your problem cannot be resolved at the dealer 37/F., The Lee Gardens
level, use the phone number that is listed below to 33 Hysan Avenue
talk with a Field Service Coordinator: Causeway Bay
G.P.O. Box 3069
1-800-447-4986 Hong Kong
Phone: 852-2848-0333
The normal hours are from 8:00 to 4:30 Monday Fax: 852-2848-0440
through Friday Central Standard Time.
3. If your needs have not been met still, submit the Japan
Shin Caterpillar Mitsubishi Ltd.
matter in writing to the following address:
SBS Tower
Caterpillar Inc. 10-1, Yoga 4-Chome
Manager, Customer Service, Engine Division Setagaya-Ku, Tokyo 158-8530
Mossville Bldg AC Japan
P.O. Box 610 Phone: 81-3-5717-1150
Mossville, Illinois 61552-0610 Fax: 81-3-5717-1177
Please keep in mind: probably, your problem will Japan

ultimately be solved at the dealership, using the Caterpillar Power Systems, Inc.
dealership facilities, equipment, and personnel. SBS Tower (14th floor)
Therefore, follow the steps in sequence when a 4-10-1, Yoga
problem is experienced. Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Outside of the USA and of Canada Fax: 81-3-5797-4359
If a problem arises outside the USA and outside

Canada, and if the problem cannot be resolved at the
dealer level, consult the appropriate Caterpillar office.
98 SEBU9236-05
Ordering Replacement Parts
Australia and New Zealand

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

SMCS Code: 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent speci-
fications including, but not limited to, physical di-
mensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
SEBU9236-05 99
Reference Materials
Reference Materials
i05975063
Reference Material
SMCS Code: 1000
Additional literature regarding your product may be
purchased from your local Cat dealer or by visiting
www.cat.com. Use the product name, sales model,
and serial number in order to obtain the correct
information for your product.
i01176304
Maintenance Log
SMCS Code: 1000
Table 20
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
(continued)
100 SEBU9236-05
Maintenance Log
(Table 20, contd)

SEBU9236-05 101
Index Section
Index
A Electrical System............................................. 22
Grounding Practices .................................... 22
Additional Messages ....................................... 13
Engine - Clean................................................. 74
Alternator - Inspect .......................................... 67
Engine Air Cleaner Element (Single
Alternator and Fan Belts - Inspect/Adjust ....... 67
Element) - Replace........................................ 74
Adjustment................................................... 67
Engine Air Cleaner Service Indicator -
Inspection .................................................... 67
Inspect (If Equipped) ..................................... 75
Alternator and Fan Belts - Replace ................. 68
Test the Service Indicator ............................ 75
Engine Crankcase Breather - Clean/
B Replace ......................................................... 75
Battery - Replace............................................. 68 Engine Identification........................................ 28
Battery Electrolyte Level - Check .................... 69 Engine Mounts - Inspect.................................. 76
Battery or Battery Cable - Disconnect............. 69 Engine Oil and Filter - Change ........................ 77
Before Starting Engine .................................... 21 Drain the Engine Oil..................................... 77
Burn Prevention............................................... 18 Fill the Engine Crankcase............................ 78
Batteries....................................................... 19 Replace the Oil Filter ................................... 77
Coolant ........................................................ 18 Engine Oil Level - Check................................. 76
Oils............................................................... 19 Engine Oil Sample - Obtain............................. 76
Obtain the Sample and the Analysis ........... 76
Engine Operation ............................................ 56
C
Engine Starting.......................................... 21, 54
Cold Weather Operation ................................. 59 Engine Stopping ........................................ 22, 58
Control Panel................................................... 38 Engine Valve Lash - Inspect/Adjust................. 78
EMCP 4.1/4.2 (if equipped) ......................... 38 Engine Warm-up ............................................. 56
TCP 1000 (if equipped)................................ 40
TCP 2000 (if equipped)................................ 42 F
TCP 3000 (if equipped)................................ 44
Cooling System Coolant (ELC) - Change ....... 69 Features and Controls..................................... 38
Drain ............................................................ 70 Fire Prevention and Explosion Prevention...... 19
Fill ................................................................ 70 Ether ............................................................ 20
Flush ............................................................ 70 Fire Extinguisher.......................................... 20
Cooling System Coolant Extender (ELC) - Lines, Tubes, and Hoses ............................. 20
Add ................................................................ 71 Foreword ........................................................... 4
Cooling System Coolant Level - Check........... 71 California Proposition 65 Warning ................. 4
Cooling System Coolant Sample (Level 1) - Literature Information .................................... 4
Obtain ............................................................ 72 Maintenance .................................................. 4
Cooling System Coolant Sample (Level 2) - Maintenance Intervals ................................... 4
Obtain ............................................................ 73 Operation ....................................................... 4
Cooling System Water Temperature Overhaul ........................................................ 4
Regulator - Replace....................................... 73 Safety............................................................. 4
Crushing Prevention and Cutting Prevention.. 21 Fuel and the Effect from Cold Weather ........... 59
Customer Assistance ...................................... 97 Fuel Conservation Practices ........................... 56
Outside of the USA and of Canada ............. 97 Fuel Injection Nozzles - Test/Exchange .......... 79
USA and Canada......................................... 97 Removal and Installation of the Fuel Injection
Customer Service............................................ 97 Nozzles ...................................................... 80
Fuel System - Prime........................................ 80
Fuel System Primary Filter (Water
E
Separator) Element - Replace....................... 82
Electrical Connections - Check ....................... 74
102 SEBU9236-05
Index Section
Fuel System Primary Filter/Water Installation ....................................................... 37

Separator - Drain ........................................... 82 Instrument Panel - Inspect .............................. 90
Fuel System Secondary Filter - Replace ........ 83 Insulation - Test ............................................... 90
Fuel Filter With Canister .............................. 83 Exciter Armature (Rotor L2)......................... 91
Fuel Filter With Element .............................. 84 Exciter Field (Stator L1) ............................... 91
Fuel Tank Water and Sediment - Drain ........... 85 Main Armature (Stator L4) ........................... 91
Drain the Water and the Sediment .............. 85
Fuel Storage Tanks...................................... 86 L
Fuel Tank ..................................................... 85
Lifting and Storage .......................................... 35
G
M
General Hazard Information............................ 15
Containing Fluid Spillage............................. 16 Maintenance Interval Schedule................. 64–65
Dispose of Waste Properly .......................... 18 Maintenance Interval Schedule (Prime Power)
Fluid Penetration ......................................... 16 Daily ............................................................. 65
Inhalation ..................................................... 17 Every 1000 Service Hours........................... 66
Lines, Tubes, and Hoses ............................. 17 Every 1000 Service Hours or 1 Year ........... 66
Pressurized Air and Water........................... 16 Every 12 000 Service Hours or 6 Years....... 65
Softwrap....................................................... 18 Every 2000 Service Hours........................... 66
Static Electricity Hazard when Fueling with Every 2000 Service Hours or 6 Months....... 66
Ultra-low Sulfur Diesel Fuel ....................... 17 Every 250 Service Hours ............................. 65
Generator - Dry................................................ 86 Every 250 Service Hours or 6 Months......... 65
Drying Methods............................................ 86 Every 3000 Service Hours........................... 66
Generator - Inspect ......................................... 86 Every 3000 Service Hours or 2 Years ......... 66
Cleaning (Assembled Generators) .............. 87 Every 50 Service Hours or Weekly.............. 65
Cleaning (Disassembled Generators) ......... 87 Every 500 Service Hours ............................. 65
Generator Isolating for Maintenance............... 22 Every 500 Service Hours or 1 Year ............. 65
Generator Lead Connections .......................... 29 Every 6000 Service Hours or 3 Years ......... 65
Connection Diagrams .................................. 30 Every Week ................................................. 65
Grounding the Frame .................................. 29 Every Year ................................................... 66
Neutral Connections .................................... 29 Initial 500 Hours (for New Systems, Refilled
Single Units.................................................. 30 Systems, and Converted Systems) ........... 65
Generator Load - Check.................................. 88 Overhaul ...................................................... 65
Generator Set - Test ........................................ 88 When Required............................................ 65
Generator Set Installation ............................... 37 Maintenance Interval Schedule (Standby)
Electrical Measurements ............................. 37 Every 3 Years............................................... 64
Location ....................................................... 37 Every 6 Years............................................... 64
Receiving Inspection ................................... 37 Every Week ................................................. 64
Remote Fuel Tanks and Auxiliary Fuel Every Year ................................................... 64
Tanks.......................................................... 37 When Required............................................ 64
Unpacking.................................................... 37 Maintenance Log............................................. 99
Glow Plugs - Inspect ....................................... 89 Maintenance Recommendations .................... 62
Maintenance Section....................................... 60
Model View Illustrations .................................. 24
H
Model Views .................................................... 24
Hoses and Clamps - Inspect/Replace............. 89
Replace the Hoses and the Clamps ............ 89 O
Operation Section............................................ 35
I
Ordering Replacement Parts........................... 98
Important Safety Information............................. 2 Overhaul Considerations................................. 91
SEBU9236-05 103
Index Section
Oil Consumption as an Overhaul Indicator.. 92 V

Overhaul Recommendation......................... 92
Voltage Regulators .......................................... 45
Change the Engine Speed for the Desired
P Frequency .................................................. 52
Plate Locations and Film Locations ................ 28 R230 Adjustments ....................................... 47
Emission Certification Film .......................... 28 R438 and R448 Adjustment for Maximum
Serial Number Plate (1) ............................... 28 Excitation ................................................... 52
Product Identification Information ................... 28 R438 and R448 Adjustments....................... 49
Product Information Section............................ 24 Special Use.................................................. 53
Product Lifting ................................................. 35
Product Storage .............................................. 36 W
Generator Storage....................................... 36
Walk-Around Inspection .................................. 95
Inspect the Engine and Generator Set for
R Leaks and for Loose Connections ............. 95
Reference Information Section ....................... 97 Water Pump - Inspect...................................... 96
Reference Material .......................................... 99 Welding on Engines with Electronic
Reference Materials ........................................ 99 Controls ......................................................... 62
Refill Capacities............................................... 60
Refill Capacities and Recommendations ........ 60
Cooling System............................................ 61
Fuel .............................................................. 60
Lubrication System ...................................... 60
Rotating Rectifier - Check ............................... 94
Rotating Rectifier - Test ................................... 94
S
Safety Messages............................................... 5
Automatic Starting (2)...................................11
Crush (5) ...................................................... 12
Electrocution (4)........................................... 12
Hot Fluid Under Pressure (6)....................... 12
Hot Surface (3) .............................................11
Universal Warning (1) .................................. 10
Safety Section ................................................... 5
Starting Motor - Inspect ................................... 95
Starting the Engine.......................................... 54
Starting with Jump Start Cables...................... 54
Stopping the Engine ........................................ 58
Automatic Stopping ..................................... 58
Manual Stopping.......................................... 58
System Pressure Release............................... 62
Coolant System ........................................... 62
Engine Oil .................................................... 62
Fuel System................................................. 62
T
Table of Contents .............................................. 3
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:
SEBU9236 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2017 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
106 August 2017

OMM SEBU9236-5 DE Series Generator Set With Cat C1.1, C1.5, and C2.2 Engine Caterpillar

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SEBU9236-05 (en-us)

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Refill Capacities............................................... 60

Maintenance Recommendations .................... 62

Engine Stopping .............................................. 22

Generator Isolating for Maintenance............... 22

Product Information Section

Model Views .................................................... 24

Product Identification Information ................... 28

Lifting and Storage .......................................... 35

Features and Controls..................................... 38

Engine Operation ............................................ 56

Engine Stopping .............................................. 58

Cold Weather Operation ................................. 59

Foreword Recommended service should be performed at the

Maintenance California Proposition 65 Warning

Do not operate or work on this engine unless you

Universal Warning (1)

Illustration 6 g01370904 Illustration 7 g01392484

Do not connect generator to a utility electrical

Crushing hazard! Read and understand the in-

Pressurized system! Hot coolant can cause seri-

Engine Oil Drain (1) Engine Coolant Drain (2)

Illustration 13 g01151083 Illustration 14 g01151053

Hot oil and components can cause personal in-

Personal injury can result from hot coolant. Any

General Hazard Information

• Wear a hard hat, protective glasses, and other

• Ensure that all protective guards and all covers

Pressurized Air and Water Fluid Penetration

Always use a board or cardboard when you check for

Containing Fluid Spillage

• Use exhaust ventilation on permanent machining https://catmsds.cat.com/MSDSSearch/servlet/

• Stay away from areas that might have asbestos

Improper jumper cable connections can cause an

Use caution when you are refueling an engine. Do

Lines, Tubes, and Hoses

• Outer coverings are chafed or cut.

• End fittings are displaced.

If a warning tag is attached to the engine start switch

4. Lock out the circuit breaker. Attach a “DO NOT

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

Model View Illustrations

Plate Locations and Film

Emission Certification Film

Caterpillar engines are identified by serial numbers

Serial Number Plate (1) Engine Identification

Generator Lead Connections Accidental engine starting can cause injury or

Grounding the Frame

R 230 voltage sensing – 0 => (T8) / 110 V => (T11) Table 2

Wiring Code F for Single-Phase

6 220-240 220-240 Winding 50 Hz 60 Hz

R 230 voltage sensing – 0 => (T1) / 110 V => (T2)

R 230 voltage sensing – 0 => (T1) / 110 V => (T2)

R 791 T Interference Suppression

Lifting and Storage

Use a hoist to remove heavy components. Use an

The lifting labels are located on the lifting eyes.

On some enclosed generator sets, it may be

Note: Lifting a generator set with a fuel tank requires

Features and Controls