Cat 3406 Intervalos Mantenimientos PDF

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
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© 2010 Caterpillar
All Rights Reserved
SEBU7828-10
August 2010
Operation and
Maintenance
Manual
3406C Generator Set
ZKC1-Up (Generator Set)
C2G1-Up (Generator Set)
NKM1-Up (Generator Set)
C2Y1-Up (Generator Set)
SAFETY.CAT.COM
SEBU7828-10 119
Maintenance Section
Maintenance Interval Schedule
i04002881 Walk-Around Inspection ...................................... 176

Maintenance Interval Schedule Every Week
(Prime) Electrical Connections - Check ........................... 137
Generator - Inspect ............................................. 153
SMCS Code: 1000; 7500
Generator Lead (Flat Braided Cable) - Check .... 158
Ensure that all safety information, warnings, Instrument Panel - Inspect .................................. 164
Space Heater - Check ........................................ 173
and instructions are read and understood before
Stator Winding Temperature - Measure/Record .. 174
any operation or any maintenance procedures
are performed. The user is responsible for the Voltage and Frequency - Check ......................... 176
performance of all maintenance including the
following procedures: all adjustments, the use of Every 2000 Service Hours
proper lubricants, fluids, filters, and the installation Generator Lead (Round Cable) - Check ............. 158
of new components due to normal wear and aging .
The performance of this product may be diminished if Every 2000 Service Hours or 6 Months
proper maintenance intervals and procedures are not
followed. Components may experience accelerated Generator Set Vibration - Test/Record ................ 161
wear if proper maintenance intervals and procedures Insulation - Test ................................................... 164
are not followed. Stator Lead - Check ............................................ 174
Note: Use whichever of the following that occurs Every Year

first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time Alternator - Inspect ............................................. 123
. Before each consecutive interval is performed, all Fan Drive Bearing - Lubricate ............................. 146
maintenance from the previous intervals must be Generator Set Vibration - Inspect ....................... 160
performed. Varistor - Check .................................................. 176
Varistor - Inspect ................................................. 176
Products that operate in severe operating conditions
may require more frequent maintenance. Every 3 Years
When Required Turbocharger - Inspect ........................................ 175
Battery - Recycle ................................................ 126 First 9500 L (2500 US gal) of Fuel or 250
Battery - Replace ................................................ 126 Service Hours
Battery or Battery Cable - Disconnect ................ 128
Circuit Breakers - Reset ...................................... 129 Engine Valve Lash - Inspect/Adjust .................... 145
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 135 Every 9500 L (2500 US gal) of Fuel or 250
Engine - Clean .................................................... 138 Service Hours or Yearly
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................. 138 Aftercooler Core - Clean/Test ............................. 123
Ether Starting Aid Cylinder - Replace ................. 146 Battery Electrolyte Level - Check ........................ 127
Fuel System - Prime ........................................... 146 Belts - Inspect/Adjust/Replace ............................ 128
Generator - Dry ................................................... 151 Cooling System Coolant Sample (Level 1) -
Generator Bearing - Lubricate ............................ 155 Obtain ............................................................... 134
Generator Set - Test ........................................... 159 Cooling System Supplemental Coolant Additive
Generator Set Alignment - Check ....................... 160 (SCA) - Test/Add ............................................... 135
Rotating Rectifier - Test ...................................... 171 Engine Crankcase Breather - Clean ................... 141
Severe Service Application - Check ................... 172 Engine Oil Sample - Obtain ................................ 142
Engine Oil and Filter - Change ........................... 143
Daily Fuel System Secondary Filter - Replace ............ 149
Fuel Tank Water and Sediment - Drain ............... 150
Annunciator Panel - Inspect ................................ 123 Hoses and Clamps - Inspect/Replace ................ 161
Cooling System Coolant Level - Check .............. 133 Magnetic Pickups - Clean/Inspect ...................... 167
Engine Air Cleaner Service Indicator - Inspect ... 141 Radiator - Clean .................................................. 170
Engine Oil Level - Check .................................... 142 Rotating Rectifier - Check ................................... 171
Fuel System Primary Filter/Water Separator -
Drain ................................................................. 149 Every 19 000 L (5000 US gal) of Fuel or 250
Generator Bearing Temperature - Test/Record ... 158 Service Hours
Generator Load - Check ..................................... 159
Power Factor - Check ......................................... 170 Fan Drive Bearing - Lubricate ............................. 146
120 SEBU7828-10
Maintenance Section
Every 19 000 L (5000 US gal) of Fuel or 500

Service Hours
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 148
Every 28 400 L (7500 US gal) of Fuel or 1000

Service Hours
Engine Protective Devices - Check .................... 145
Every 114 000 L (30 000 US gal) of Fuel or

3000 Service Hours or 2 Years
Cooling System Coolant (DEAC) - Change ........ 129
Cooling System Coolant Extender (ELC) - Add .. 132
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 135
Cooling System Water Temperature Regulator -
Replace ............................................................. 136
Crankshaft Vibration Damper - Inspect ............... 137
Engine Mounts - Inspect ..................................... 142
Engine Valve Lash - Inspect/Adjust .................... 145
Engine Valve Rotators - Inspect ......................... 145

Crankshaft Vibration Damper - Inspect ............... 137

5000 Service Hours
Alternator - Inspect ............................................. 123
Magnetic Pickups - Clean/Inspect ...................... 167
Starting Motor - Inspect ...................................... 174
Turbocharger - Inspect ........................................ 175
Water Pump - Inspect ......................................... 177
Every 228 000 L (60 000 US gal) of Fuel or 12

Cooling System Coolant (ELC) - Change ........... 131
Overhaul
Generator Bearing - Inspect/Replace ................. 154
Overhaul Considerations .................................... 167
SEBU7828-10 121
Maintenance Section
i04002886 Standby Generator Set Maintenance

Recommendations ............................................ 173
Maintenance Interval Schedule Stator Winding Temperature - Measure/Record .. 174
(Standby) Voltage and Frequency - Check ......................... 176
SMCS Code: 1000; 7500 Every 6 Months
Ensure that all safety information, warnings, Cooling System Coolant Sample (Level 1) -
Obtain ............................................................... 134
and instructions are read and understood before
Generator Lead (Round Cable) - Check ............. 158
any operation or any maintenance procedures
are performed. The user is responsible for the Stator Lead - Check ............................................ 174
performance of all maintenance including the
following procedures: all adjustments, the use of Every Year
proper lubricants, fluids, filters, and the installation Alternator - Inspect ............................................. 123
of new components due to normal wear and aging . Belts - Inspect/Adjust/Replace ............................ 128
The performance of this product may be diminished if Cooling System Coolant Sample (Level 2) -
proper maintenance intervals and procedures are not Obtain ............................................................... 135
followed. Components may experience accelerated Cooling System Supplemental Coolant Additive
wear if proper maintenance intervals and procedures (SCA) - Test/Add ............................................... 135
are not followed. Crankshaft Vibration Damper - Inspect ............... 137
Engine - Clean .................................................... 138
Note: Use whichever of the following that occurs Engine Air Cleaner Element (Dual Element) -
first in order to determine the maintenance intervals: Clean/Replace .................................................. 138
fuel consumption, service hours, and calendar time Engine Crankcase Breather - Clean ................... 141
. Before each consecutive interval is performed, all Engine Mounts - Inspect ..................................... 142
maintenance from the previous intervals must be Engine Oil Sample - Obtain ................................ 142
performed. Engine Oil and Filter - Change ........................... 143
Engine Performance - Test ................................. 144
Products that operate in severe operating conditions Engine Protective Devices - Check .................... 145
may require more frequent maintenance. Engine Valve Lash - Inspect/Adjust .................... 145
Fan Drive Bearing - Lubricate ............................. 146
When Required Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 148
Battery - Recycle ................................................ 126
Fuel System Secondary Filter - Replace ............ 149
Circuit Breakers - Reset ...................................... 129
Cooling System Coolant Sample (Level 2) - Generator - Dry ................................................... 151
Generator Set Vibration - Inspect ....................... 160
Obtain ............................................................... 135
Generator Set Vibration - Test/Record ................ 161
Ether Starting Aid Cylinder - Replace ................. 146
Fuel System - Prime ........................................... 146 Hoses and Clamps - Inspect/Replace ................ 161
Insulation - Test ................................................... 164
Fuel System Primary Filter/Water Separator -
Magnetic Pickups - Clean/Inspect ...................... 167
Drain ................................................................. 149
Generator Bearing - Lubricate ............................ 155 Radiator - Clean .................................................. 170
Starting Motor - Inspect ...................................... 174
Generator Load - Check ..................................... 159
Varistor - Check .................................................. 176
Generator Set - Test ........................................... 159
Rotating Rectifier - Test ...................................... 171 Varistor - Inspect ................................................. 176
Water Pump - Inspect ......................................... 177
Every Week
Every 3 Years
Automatic Start/Stop - Inspect ............................ 125
Battery Charger - Check ..................................... 126
Cooling System Coolant Extender (ELC) - Add .. 132
Battery Electrolyte Level - Check ........................ 127
Cooling System Coolant Level - Check .............. 133 Cooling System Water Temperature Regulator -
Replace ............................................................. 136
Electrical Connections - Check ........................... 137
Rotating Rectifier - Check ................................... 171
Engine Air Cleaner Service Indicator - Inspect ... 141
Engine Oil Level - Check .................................... 142 Turbocharger - Inspect ........................................ 175
Fuel Tank Water and Sediment - Drain ............... 150
Generator - Inspect ............................................. 153 Every 6 Years
Generator Bearing Temperature - Test/Record ... 158 Cooling System Coolant (ELC) - Change ........... 131
Generator Lead (Flat Braided Cable) - Check .... 158
Jacket Water Heater - Check .............................. 167
Power Factor - Check ......................................... 170
Space Heater - Check ........................................ 173
122 SEBU7828-10
Maintenance Section

5000 Service Hours
Alternator - Inspect ............................................. 123
Commissioning
Generator Set Alignment - Check ....................... 160
SEBU7828-10 123
Maintenance Section
Aftercooler Core - Clean/Test
i01546702 7. Inspect the core in order to ensure cleanliness.

Pressure test the core. Many shops that service
Aftercooler Core - Clean/Test radiators are equipped to perform pressure tests.
If necessary, repair the core.
SMCS Code: 1064-070; 1064-081
8. Install the core. Refer to the Service Manual for
1. Remove the core. Refer to the Service Manual the procedure.
for the procedure.
For more information on cleaning the core, consult
2. Turn the aftercooler core upside-down in order to your Caterpillar dealer.
remove debris.
i02676048
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
Alternator - Inspect
can attack the internal metals of the core and cause SMCS Code: 1405-040
leakage. Only use the recommended concentration of
cleaner. Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
3. Back flush the core with cleaner. connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
Caterpillar recommends the use of Hydrosolv order to ensure proper battery performance and/or
liquid cleaner. Table 24 lists Hydrosolv liquid proper performance of the electrical system. Make
cleaners that are available from your Caterpillar repairs, as required.
dealer.
Check the alternator and the battery charger for
Table 24 proper operation. If the batteries are properly
Hydrosolv Liquid Cleaners(1) charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
Part batteries should be kept warm because temperature
Description Size
Number affects the cranking power. If the battery is too cold,
1U-5490 Hydrosolv 4165 19 L (5 US gallon) the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
174-6854 Hydrosolv 100 19 L (5 US gallon) When the engine is not run for long periods of time
(1) Use a two to five percent concentration of the cleaner or if the engine is run for short periods, the batteries
at temperatures up to 93°C (200°F). Refer to Application may not fully charge. A battery with a low charge will
Guide, NEHS0526 or consult your Caterpillar dealer for more freeze more easily than a battery with a full charge.
information.
4. Steam clean the core in order to remove any i01148030

residue. Flush the fins of the aftercooler core.
Remove any other trapped debris. Annunciator Panel - Inspect
5. Wash the core with hot, soapy water. Rinse the SMCS Code: 4490-040
core thoroughly with clean water.
Inspect the annunciator panel for good condition.
Perform a lamp test. All of the warning lamps should
illuminate. If a warning lamp does not illuminate,
replace the bulb immediately. If the alarm does
Personal injury can result from air pressure. not sound, investigate the problem and correct the
problem.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro- Check the condition of all of the gauges. If a gauge
tective face shield and protective clothing. is broken, repair the gauge or replace the gauge
immediately.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. Frequently monitor the following parameters during
normal engine operation:
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow. • Engine Oil Pressure
• Engine Coolant Temperature
124 SEBU7828-10
Maintenance Section
Annunciator Panel - Inspect
• Inlet Air Restriction

• Exhaust Temperature
Record the data in a log. Compare the new data to
the data that was previously recorded. Comparing
the new data to the recorded data will establish the
normal gauge readings for the engine. A gauge
reading that is abnormal may indicate a problem with
engine operation. Abnormal gauge readings may
also indicate a possible problem with the gauge.
Record the Performance of the

Engine
Table 25 is offered as an example for use as a daily
engine log. Record the engine performance regularly.
Retain the recorded information for reference.
Compare the recorded data in order to provide an
indication of engine condition.
Records of engine performance are an important

element of a maintenance program. Record
information about the engine operation on a daily
basis. This will help to reveal the trends of the engine
performance. Records of engine performance will
also provide a baseline for evaluating the mechanical
condition of the engine.
The data on engine performance can help to predict

problems with operation. This data can provide
your Caterpillar dealer with information that is
useful for recommending maintenance management
information. A maintenance program that is properly
managed will provide your engine with an optimum
service life.
SEBU7828-10 125
Maintenance Section
Automatic Start/Stop - Inspect
Table 25
Daily Engine Log
Date
Authorization
Engine Serial Number
Engine Hours
Engine Speed
Percent Load
Ambient Temperature
Inlet Air Restriction
Engine Coolant Temperature
Engine Oil Temperature
Engine Oil Pressure
System Battery Voltage
Exhaust Manifold Temperature
Generator Voltage
Generator Amperage
Comments
i01942284 • The control switches are in the correct position for

automatic starting.
Automatic Start/Stop - Inspect
• The switchgear and the automatic transfer switches
SMCS Code: 4462 that are associated with the generator are enabled.
The generator set must be ready to operate under a
load at any time. After performing maintenance on
the generator set, inspect the position of the control
switches. Ensure the following conditions:
• The starting system is enabled.

126 SEBU7828-10
Maintenance Section
Battery - Recycle
i02039199 4. The POSITIVE “+” cable connects the POSITIVE

“+” battery terminal to the starting motor.
Battery - Recycle Disconnect the cable from the POSITIVE “+”
battery terminal.
SMCS Code: 1401-561
Note: Always recycle a battery. Never discard a
Always recycle a battery. Never discard a battery. battery. Return used batteries to an appropriate
Return used batteries to one of the following recycling facility.
locations:
5. Remove the used battery.
• A battery supplier
6. Install the new battery.
• An authorized battery collection facility
Note: Before the cables are connected, ensure that
• A recycling facility the key start switch is OFF.
i02153996
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
Battery - Replace
8. Connect the cable from the ground plane to the
SMCS Code: 1401-510 NEGATIVE “-” battery terminal.
i01917570
Batteries give off combustible gases which can Battery Charger - Check
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in- SMCS Code: 1401-535
jury or death.
Checking Before Start-Up
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or- Check the battery charger for proper operation. If
der to help prevent electrical arcs and/or sparks the batteries are properly charged, the needle of the
near batteries. Do not smoke when batteries are ammeter will register near “0” (zero).
serviced.
The battery charger must not produce excessive
current during start-up. Alternatively, the charger
must be automatically disconnected for start-up.
If the engine has an alternator, the charger must
The battery cables or the batteries should not be be automatically disconnected during start-up and
removed with the battery cover in place. The bat- during engine operation.
tery cover should be removed before any servic-
ing is attempted.
Charging the Battery
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
Never disconnect any charging unit circuit or bat-
1. Turn the key start switch to the OFF position. tery circuit cable from the battery when the charg-
Remove the key and all electrical loads. ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro-
2. Turn OFF the battery charger. Disconnect the gen and oxygen that is released from the elec-
charger. trolyte through the battery outlets. Injury to per-
sonnel can be the result.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane. Disconnect Perform the following procedure to charge the
the cable from the NEGATIVE “-” battery terminal. battery:
1. Ensure that the charger is turned OFF.

SEBU7828-10 127
Maintenance Section
Battery Electrolyte Level - Check
2. Adjust the voltage of the charger in order to match Table 26

the voltage of the battery. Effects of Overcharging Batteries
3. Connect the POSITIVE “+” lead of the charger Type of Battery Effect
to the POSITIVE “+” battery terminal. Connect
the NEGATIVE “-” lead of the charger to the
NEGATIVE “-” battery terminal. Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte.
Caterpillar Premium High
4. Turn ON the battery charger. Output Batteries
Overcharging of Batteries
Overcharging reduces the service life of batteries. When the plates of the
Use a battery charger that will not overcharge the battery are inspected
battery. DO NOT charge the battery if the meter of through the filler holes, the
the battery charger is in the RED zone. plates may appear to be
warped. This is caused by
Overcharging is indicated by the following symptoms: an excessive temperature.
The battery may not pass
• The battery is very warm to the touch. a load test.
• A strong odor of acid is present. Caterpillar Maintenance The battery may not accept
Free Batteries a charging current.
• The battery emits smoke or a dense vapor (gas). The battery may not pass
a load test.
Perform one of the following procedures if the battery
shows symptoms of overcharging:
Checking After Stopping
• Reduce the rate of charging by a significant
amount. Complete the charging at the reduced Ensure that the battery charger is connected
rate. properly. Observe the meter of the charger. Record
the amperage.
• Turn OFF the charger.
Table 26 describes the effects of overcharging on i02601752
different types of batteries. Battery Electrolyte Level -

Check
SMCS Code: 1401-535
When the engine is not run for long periods of time or

when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled

water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
128 SEBU7828-10
Maintenance Section
Battery or Battery Cable - Disconnect
2. Check the condition of the electrolyte with the i02200198

245-5829 Coolant Battery Tester Refractometer.
Belts - Inspect/Adjust/Replace
3. Keep the batteries clean.
SMCS Code: 1357-025; 1357-040; 1357-510
Clean the battery case with one of the following
cleaning solutions: Inspection
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
i01492654
Battery or Battery Cable -

Disconnect g00750216
Illustration 82
SMCS Code: 1402-029 The belt cover must be removed for inspection, adjustment and
replacement.
(1) Mounting bolts
(2) Adjustment bolt
(3) Typical belt tension gauge
The battery cables or the batteries should not be
removed with the battery cover in place. The bat- To maximize the engine performance, inspect the
tery cover should be removed before any servic- belt for wear and for cracking. Check the belt tension.
ing is attempted. Adjust the belt tension in order to minimize belt
slippage. Belt slippage will decrease the life of the
Removing the battery cables or the batteries with belt.
the cover in place may cause a battery explosion
resulting in personal injury. For the correct tension on the belt, refer to
Specifications, “Belt Tension Chart”.
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position Adjustment
and remove the key and all electrical loads.
1. Remove the belt cover.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that 2. Loosen mounting bolts (1) and adjusting bolt (2).
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of 3. Slide the alternator in the direction that will give
two batteries must be disconnected. the correct tension.
3. Tape the leads in order to help prevent accidental 4. Tighten adjusting bolt (2). Tighten mounting
starting. bolts (1). For the proper torque, refer to the
Specifications Manual, SENR3130, “Torque
4. Proceed with necessary system repairs. Reverse Specifications”.
the steps in order to reconnect all of the cables.
5. Reinstall the belt cover.
SEBU7828-10 129
Maintenance Section
Circuit Breakers - Reset
If new belts are installed, check the belt adjustment • Foaming is observed.
again after 30 minutes of engine operation at the
rated rpm. • The oil has entered the cooling system and the
coolant is contaminated.
Replacement of Multiple Drive Belts
• The fuel has entered the cooling system and the
For applications that require multiple drive belts, coolant is contaminated.
replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry NOTICE
more load because the older belts are stretched. The Use of commercially available cooling system clean-
additional load on the new belt could cause the new ers may cause damage to cooling system compo-
belt to break. nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
i02456186
Note: Inspect the water pump and the water
Circuit Breakers - Reset temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
SMCS Code: 1417-529; 1420-529 the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
Illustration 83
g01225779 1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
Push in on the circuit breaker in order to reset the order to relieve any pressure. Remove the cooling
circuit breaker. system filler cap.
(A) 60 Amp Circuit Breaker – This circuit breaker 2. Open the cooling system drain valve (if equipped).
is for the battery charger and the circuit for the If the cooling system is not equipped with a drain
alternator. valve, remove one of the drain plugs.
(B) 15 Amp Circuit Breaker – This circuit breaker is Note: If equipped, be sure to drain the heater and
for the Electronic Control Module (ECM). any related supply and return lines.
(C) 20 Amp Circuit Breaker – This circuit breaker is Allow the coolant to drain.
for the control panel.
NOTICE
Dispose of used engine coolant properly or recycle.
i02139869 Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
Cooling System Coolant distillation procedure is the only method acceptable by
(DEAC) - Change Caterpillar to reclaim the used coolant.
SMCS Code: 1350-070; 1395-044

For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
Clean the cooling system and flush the cooling
dealer or consult Caterpillar Dealer Service Tool
system before the recommended maintenance
Group:
interval if the following conditions exist:
• The engine overheats frequently.

130 SEBU7828-10
Maintenance Section
Cooling System Coolant (DEAC) - Change
Outside Illinois: 1-800-542-TOOL Cooling Systems with Heavy

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Deposits or Plugging
Note: For the following procedure to be effective,
Flush there must be some active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris. 1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to Note: If equipped, be sure to flush the heater and
the Specifications Manual, SENR3130, “Torque any related supply and return lines.
Specifications” for more information on the proper
torques. 2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to
NOTICE the Specifications Manual, SENR3130, “Torque
Fill the cooling system no faster than 19 L (5 US gal) Specifications” for more information on the proper
per minute to avoid air locks. torques.
NOTICE
3. Fill the cooling system with a mixture of clean Fill the cooling system no faster than 19 L (5 US gal)
water and Caterpillar Fast Acting Cooling System per minute to avoid air locks.
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap. 3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
4. Start and run the engine at low idle for a minimum Cleaner. Add 0.5 L (1 pint) of cleaner per
of 30 minutes. The coolant temperature should be 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
at least 82 °C (180 °F). capacity. Install the cooling system filler cap.
NOTICE 4. Start and run the engine at low idle for a minimum
Improper or incomplete rinsing of the cooling system of 90 minutes. The coolant temperature should be
can result in damage to copper and other metal com- at least 82 °C (180 °F).
ponents.
NOTICE
To avoid damage to the cooling system, make sure Improper or incomplete rinsing of the cooling system
to completely flush the cooling system with clear wa- can result in damage to copper and other metal com-
ter. Continue to flush the system until all signs of the ponents.
cleaning agent are gone.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
5. Stop the engine and allow the engine to cool. ter. Continue to flush the system until all signs of the
Loosen the cooling system filler cap slowly cleaning agent are gone.
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain 5. Stop the engine and allow the engine to cool.
plugs. Allow the water to drain. Flush the cooling Loosen the cooling system filler cap slowly
system with clean water. If equipped, be sure to in order to relieve any pressure. Remove the
flush the heater and any related supply and return cooling system filler cap. Open the drain valve
lines. Close the drain valve (if equipped). Clean (if equipped) or remove the cooling system drain
the drain plugs. Install the drain plugs. Refer to plugs. Allow the water to drain. Flush the cooling
the Specifications Manual, SENR3130, “Torque system with clean water. Close the drain valve
Specifications” for more information on the proper (if equipped). Clean the drain plugs. Install the
torques. drain plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
information on the proper torques.
SEBU7828-10 131
Maintenance Section
Cooling System Coolant (ELC) - Change
Fill • The fuel has entered the cooling system and the
coolant is contaminated.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) Note: When the cooling system is cleaned, only
per minute to avoid air locks. clean water is needed when the ELC is drained and
replaced.
1. Fill the cooling system with coolant/antifreeze. Note: Inspect the water pump and the water
Refer to the Operation and Maintenance Manual, temperature regulator after the cooling system has
“Refill Capacitites and Recommendations” topic been drained. This is a good opportunity to replace
(Maintenance Section) for more information on the water pump, the water temperature regulator and
cooling system specifications. Do not install the the hoses, if necessary.
cooling system filler cap.
2. Start and run the engine at low idle. Increase the Drain
engine rpm to 1500 rpm. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level ous burns. To open the cooling system filler cap,
within 13 mm (0.5 inch) below the bottom of the stop the engine and wait until the cooling system
pipe for filling. Maintain the coolant level within components are cool. Loosen the cooling system
13 mm (0.5 inch) to the proper level on the sight pressure cap slowly in order to relieve the pres-
glass (if equipped). sure.
4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If 1. Stop the engine and allow the engine to cool.
the gasket that is on the cooling system filler cap Loosen the cooling system filler cap slowly in
is damaged, discard the old cooling system filler order to relieve any pressure. Remove the cooling
cap and install a new cooling system filler cap. system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A 2. Open the cooling system drain valve (if equipped).
9S-8140 Pressurizing Pump is used to perform If the cooling system is not equipped with a drain
the pressure test. The correct pressure for the valve, remove the cooling system drain plugs.
cooling system filler cap is stamped on the face of
the cooling system filler cap. If the cooling system Allow the coolant to drain.
filler cap does not retain the correct pressure,
install a new cooling system filler cap. NOTICE
Dispose of used engine coolant properly or recycle.
5. Start the engine. Inspect the cooling system for Various methods have been proposed to reclaim used
leaks and for proper operating temperature. coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
i02215595
Cooling System Coolant (ELC) For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
- Change dealer or consult Caterpillar Dealer Service Tool
Group:
SMCS Code: 1350-070; 1395-044
Outside Illinois: 1-800-542-TOOL
Clean the cooling system and flush the cooling
Inside Illinois: 1-800-541-TOOL
system before the recommended maintenance
Canada: 1-800-523-TOOL
interval if the following conditions exist:
• The engine overheats frequently. Flush

• Foaming is observed. 1. Flush the cooling system with clean water in order
to remove any debris.
• The oil has entered the cooling system and the
coolant is contaminated. Note: If equipped, be sure to flush the heater and
any related supply and return lines.
132 SEBU7828-10
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
2. Close the drain valve (if equipped). Clean the 4. Clean the cooling system filler cap. Inspect the
drain plugs. Install the drain plugs. For the gasket that is on the cooling system filler cap. If
proper torque, refer to the Specifications Manual, the gasket that is on the cooling system filler cap
SENR3130, “Torque Specifications”. is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
NOTICE the gasket that is on the cooling system filler cap is
Fill the cooling system no faster than 19 L (5 US gal) not damaged, use a 9S-8140 Pressurizing Pump
per minute to avoid air locks. in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
3. Fill the cooling system with clean water. Install the system filler cap. If the cooling system filler cap
cooling system filler cap. does not retain the correct pressure, install a new
cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F). 5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
i02482066
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
Cooling System Coolant
drain plugs. Allow the water to drain. Flush the Extender (ELC) - Add
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install SMCS Code: 1352-045; 1395-081
the drain plugs. For the proper torque, refer to
the Specifications Manual, SENR3130, “Torque Cat ELC (Extended Life Coolant) does not require
Specifications”. the frequent additions of any supplemental cooling
additives which are associated with the present
conventional coolants. The Cat ELC Extender only
Fill needs to be added once.
NOTICE
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Use only Cat Extended Life Coolant (ELC) Extender
per minute to avoid air locks.
with Cat ELC.
1. Fill the cooling system with Extended Life Coolant Do NOT use conventional supplemental coolant addi-
(ELC). See Special Publication, SEBU6251, tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
“Caterpillar Commercial Diesel Engine Fluids tional coolants and/or conventional SCA reduces the
Recommendations” for more information on Cat ELC service life.
cooling system specifications. Do not install the
cooling system filler cap. Check the cooling system only when the engine is
stopped and cool.
2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level

within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
SEBU7828-10 133
Maintenance Section
Cooling System Coolant Level - Check
i01197583
Cooling System Coolant Level

Personal injury can result from hot coolant, steam
and alkali. - Check
At operating temperature, engine coolant is hot SMCS Code: 1395-082
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or Check the coolant level when the engine is stopped
steam. Any contact can cause severe burns. and cool.
Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
NOTICE g00285520
Care must be taken to ensure that fluids are contained Illustration 84
during performance of inspection, maintenance, test- Cooling system filler cap
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
ous burns. To open the cooling system filler cap,
Refer to Special Publication, NENG2500, “Caterpillar
stop the engine and wait until the cooling system
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
pressure cap slowly in order to relieve the pres-
products.
sure.
Dispose of all fluids according to local regulations and
mandates. 1. Remove the cooling system filler cap slowly in
order to relieve pressure.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling 2. Maintain the coolant level within 13 mm (0.5 inch)
system filler cap. of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
2. It may be necessary to drain enough coolant from level to the proper level in the sight glass.
the cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the

requirements for your engine's cooling system
capacity. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
article for more information.
4. Clean the cooling system filler cap. Inspect the

gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
g00103639
Illustration 85
Typical filler cap gaskets
134 SEBU7828-10
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the NOTICE
cooling system filler cap if the filler cap gaskets are Always use a designated pump for oil sampling, and
damaged. Reinstall the cooling system filler cap. use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
4. Inspect the cooling system for leaks. contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
i04035949
dealers and customers.
Cooling System Coolant
Sample (Level 1) - Obtain Note: Level 1 results may indicate a need for
Level 2 Analysis.
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Obtain the sample of the coolant as close as possible
Note: Obtaining a Coolant Sample (Level 1) is to the recommended sampling interval. In order to
optional if the cooling system is filled with Cat receive the full effect of S·O·S analysis, establish
ELC (Extended Life Coolant). Cooling systems filled a consistent trend of data. In order to establish
with Cat ELC should have a Coolant Sample (Level a pertinent history of data, perform consistent
2) that is obtained at the recommended interval as samplings that are evenly spaced. Supplies for
stated in the maintenance interval schedule. collecting samples can be obtained from your
Caterpillar dealer.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant Use the following guidelines for proper sampling of
instead of Cat ELC including the following the coolant:
coolants:
• Complete the information on the label for the
• Commercial long life coolants that meet the sampling bottle before you begin to take the
Caterpillar Engine Coolant Specification -1 samples.
(Caterpillar EC-1)
• Keep the unused sampling bottles stored in plastic
• Cat DEAC (Diesel Engine Antifreeze/Coolant) bags.
• Commercial heavy-duty coolant/antifreeze • Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
Table 27 from any other location.
Recommended Interval
• Keep the lids on empty sampling bottles until you
Type of Coolant Level 1 Level 2 are ready to collect the sample.
Cat DEAC
• Place the sample in the mailing tube immediately
Conventional after obtaining the sample in order to avoid
heavy duty- contamination.
coolant
Every 250 • Never collect samples from expansion bottles.
Commercial Every year(1)
service hours
coolant that
meets the • Never collect samples from the drain for a system.
requirements
of the Caterpillar Submit the sample for Level 1 analysis.
EC-1 standard
Cat ELC or
For additional information about coolant analysis,
conventional Optional Every year(1) see this Operation and Maintenance Manual, “Refill
EC-1 coolant Capacities and Recommendations” or consult your
(1)
Caterpillar dealer.
The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
SEBU7828-10 135
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
i01987714 Use the 8T-5296 Coolant Conditioner Test Kit

or use the 4C-9301 Coolant Conditioner Test Kit
Cooling System Coolant in order to check the concentration of the SCA.
Sample (Level 2) - Obtain Refer to this Operation and Maintenance Manual,
“Refill Capacities and Recommendations” for more
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 information.
NOTICE Water and SCA

Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. NOTICE
Using the same pump for both types of samples may Do not exceed the recommended eight percent sup-
contaminate the samples that are being drawn. This plemental coolant additive concentration.
contaminate may cause a false analysis and an incor-
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Refer to the Special
Publication, SEBU6251, “Caterpillar Commercial
Refer to Operation and Maintenance Manual, Diesel Engine Fluids Recommendations” for more
“Cooling System Coolant Sample (Level 1) - Obtain” information.
for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.

S·O·S Coolant Analysis
S·O·S coolant samples can be analyzed at your
For additional information about coolant
Caterpillar dealer. S·O·S Coolant Analysis is a
analysis, see Special Publication, SEBU6251,
program that is based on periodic samples.
“Caterpillar Commercial Diesel Engines Fluids
Recommendations” or consult your Caterpillar dealer.
Level 1
i02456600 Level 1 is a basic analysis of the coolant. The
following items are tested:
Cooling System Supplemental
Coolant Additive (SCA) - • Glycol Concentration
Test/Add • Concentration of SCA
SMCS Code: 1352-045; 1395-081 • pH
• Conductivity
Cooling system coolant additive contains alkali. The results are reported, and recommendations
To help prevent personal injury, avoid contact with are made according to the results. Consult your
the skin and the eyes. Do not drink cooling system Caterpillar dealer for information on the benefits of
coolant additive. managing your equipment with an S·O·S Coolant
Analysis.
Note: Test the concentration of the Supplemental
Coolant Additive (SCA) or test the SCA concentration
Level 2
as part of an S·O·S Coolant Analysis.
This level coolant analysis is recommended when the
engine is overhauled. Refer to this Operations and
Test for SCA Concentration Maintenance Manual, “Overhaul Considerations” for
further information.
Coolant and SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
136 SEBU7828-10
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Add the SCA, If Necessary i03645060
Cooling System Water

NOTICE
Do not exceed the recommended amount of sup- Temperature Regulator -
plemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
Replace
deposits on the higher temperature surfaces of the SMCS Code: 1355-510
cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause Replace the water temperature regulator before
cracking of the cylinder head and other high temper- the water temperature regulator fails. This is a
ature components. Excessive supplemental coolant recommended preventive maintenance practice.
additive concentration could also result in radiator Replacing the water temperature regulator reduces
tube blockage, overheating, and/or accelerated water the chances for unscheduled downtime. Refer to this
pump seal wear. Never use both liquid supplemental Operation and Maintenance Manual, “Maintenance
coolant additive and the spin-on element (if equipped) Interval Schedule” for the proper maintenance
at the same time. The use of those additives together interval.
could result in supplemental coolant additive concen-
tration exceeding the recommended maximum. A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed

Pressurized System: Hot coolant can cause seri- position can cause excessive overheating. Excessive
ous burns. To open the cooling system filler cap, overheating could result in cracking of the cylinder
stop the engine and wait until the cooling system head or piston seizure problems.
pressure cap slowly in order to relieve the pres- A water temperature regulator that fails in the open
sure. position will cause the engine operating temperature
to be too low during partial load operation. Low
1. Slowly loosen the cooling system filler cap in engine operating temperatures during partial loads
order to relieve the pressure. Remove the cooling could cause an excessive carbon buildup inside the
system filler cap. cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
Note: Always discard drained fluids according to of the cylinder liner.
local regulations.
NOTICE
2. If necessary, drain some coolant from the cooling Failure to replace your water temperature regulator
system into a suitable container in order to allow on a regularly scheduled basis could cause severe
space for the extra SCA. engine damage.
3. Add the proper amount of SCA. Refer Caterpillar engines incorporate a shunt design cooling
to the Special Publication, SEBU6251, system and require operating the engine with a water
“Caterpillar Commercial Diesel Engines Fluids temperature regulator installed.
Recommendations” for more information on SCA
requirements. If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head
4. Clean the cooling system filler cap. Inspect the damage. Ensure that the new water temperature reg-
gaskets of the cooling system filler cap. If the ulator is installed in the original position. Ensure that
gaskets are damaged, replace the old cooling the water temperature regulator vent hole is open.
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap. Do not use liquid gasket material on the gasket or
cylinder 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.
SEBU7828-10 137
Maintenance Section
Crankshaft Vibration Damper - Inspect
Note: If only the water temperature regulators are Inspect the damper for evidence of fluid leaks. If
replaced, drain the coolant from the cooling system to a fluid leak is found, determine the type of fluid.
a level that is below the water temperature regulator The fluid in the damper is silicone. Silicone has
housing. the following characteristics: transparent, viscous,
smooth, and difficult to remove from surfaces.
i00894991
If the fluid leak is oil, inspect the crankshaft seals for
Crankshaft Vibration Damper leaks. If a leak is observed, replace the crankshaft
seals.
- Inspect
Inspect the damper and repair or replace the damper
SMCS Code: 1205-040 for any of the following reasons:
Damage to the crankshaft vibration damper or failure • The damper is dented, cracked, or leaking.
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to • The paint on the damper is discolored from heat.
the crankshaft and to other engine components. A
deteriorating damper can cause excessive gear train • The engine has had a failure because of a broken
noise at variable points in the speed range. crankshaft.
The damper is mounted to the crankshaft which is • Analysis of the oil has revealed that the front main
located behind the belt guard on the front of the bearing is badly worn.
engine.
• There is a large amount of gear train wear that is
Rubber Damper not caused by a lack of oil.
Your engine may be equipped with a rubber damper. Refer to the Service Manual or consult your
The rubber damper uses a ring which is mounted in Caterpillar dealer for information about damper
rubber in order to reduce vibrations in the crankshaft. replacement.
Inspect the damper and repair or replace the damper i01228274

for any of the following reasons:
Electrical Connections - Check
• There is deterioration and cracking of the rubber.
SMCS Code: 4459-535
• There is slippage of the outer ring from the original
position. Check all exposed electrical connections for
tightness.
• The engine has had a failure because of a broken
crankshaft. Check the following devices for loose mounting or
for physical damage:
• Analysis of the oil has revealed that the front main
bearing is badly worn. • transformers
• There is a large amount of gear train wear that is • fuses
not caused by lack of oil.
• capacitors
Refer to the Service Manual or consult your
Caterpillar dealer for information about damper • lightning arrestors
replacement.
Check all lead wires and electrical connections for
proper clearance.
Visconic Damper
Your engine may be equipped with a visconic
damper. The visconic damper has a weight that is
located inside a fluid filled case. The weight moves in
the case in order to limit torsional vibration.
138 SEBU7828-10
Maintenance Section
Engine - Clean
i01866598
NOTICE
Engine - Clean Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
SMCS Code: 1000-070
Servicing the Air Cleaner Elements

Personal injury or death can result from high volt- If the air cleaner element becomes plugged, the air
age. can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
Moisture could create paths of electrical conduc- wear. Your Caterpillar dealer has the proper air
tivity. cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
Make sure the unit is off line (disconnected from
utility and/or other generators), locked out and • Check the precleaner (if equipped) daily for
tagged "Do Not Operate". accumulation of dirt and debris. Remove any dirt
and debris, as needed.
NOTICE • Operating conditions (dust, dirt and debris) may
Water or condensation can cause damage to gen- require more frequent service of the air cleaner
erator components. Protect all electrical components element.
from exposure to water.
• The air cleaner element may be cleaned up to
six times if the element is properly cleaned and
NOTICE
inspected.
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on • The air cleaner element should be replaced at least
one time per year. This replacement should be
the engine.
performed regardless of the number of cleanings.
Do not steam clean the generator. Water may Replace the dirty paper air cleaner elements with
damage the generator. clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked
Steam cleaning the engine will remove accumulated for tears and/or holes in the filter material. Inspect
oil and grease. A clean engine provides the following the gasket or the seal of the air cleaner element for
benefits: damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.
• Easy detection of fluid leaks
Dual Element Air Cleaners
• Maximum heat transfer characteristics
The dual element air cleaner contains a primary
• Ease of maintenance air cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
i01553486
and inspected. The primary air cleaner element
Engine Air Cleaner Element should be replaced at least one time per year. This
replacement should be performed regardless of the
(Dual Element) - Clean/Replace number of cleanings.
SMCS Code: 1054-037; 1054-510 The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
NOTICE should be removed and discarded for every three
Never run the engine without an air cleaner element cleanings of the primary air cleaner element. When
installed. Never run the engine with a damaged air the engine is operating in environments that are
cleaner element. Do not use air cleaner elements with dusty or dirty, air cleaner elements may require more
damaged pleats, gaskets or seals. Dirt entering the frequent replacement.
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
SEBU7828-10 139
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Cleaning the Primary Air Cleaner

Elements
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to

clean the filter element:
Do not tap or strike the filter element in order to re-

move dust.
g00736431
Illustration 86
(1) Cover Do not wash the filter element.
(2) Primary air cleaner element
(3) Secondary air cleaner element Use low pressure compressed air in order to remove
(4) Turbocharger air inlet
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
1. Remove the cover. Remove the primary air pleats and down the pleats from the inside of the filter
cleaner element. element. Take extreme care in order to avoid damage
to the pleats.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings Do not use air filters with damaged pleats, gaskets, or
of the primary air cleaner element. seals. Dirt entering the engine will cause damage to
engine components.
Note: Refer to “Cleaning the Primary Air Cleaner
Elements”.
The primary air cleaner element can be used up
3. Cover the turbocharger air inlet with tape in order to six times if the element is properly cleaned and
to keep dirt out. inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
4. Clean the inside of the air cleaner cover and body The primary air cleaner element should be replaced
with a clean, dry cloth. at least one time per year. This replacement should
be performed regardless of the number of cleanings.
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a Use clean primary air cleaner elements while dirty
primary air cleaner element that is new or cleaned. elements are being cleaned.
6. Install the air cleaner cover. NOTICE

Do not clean the air cleaner elements by bumping or
7. Reset the air cleaner service indicator. tapping. This could damage the seals. Do not use el-
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air cleaner elements

before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
There are two common methods that are used to

clean primary air cleaner elements:
• Pressurized air
• Vacuum cleaning
140 SEBU7828-10
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Pressurized Air Inspecting the Primary Air Cleaner

Elements
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
g00281693
Illustration 88
Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
g00281692
Illustration 87 element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
Note: When the primary air cleaner elements are and/or holes. Inspect the primary air cleaner element
cleaned, always begin with the clean side (inside) for light that may show through the filter material. If it
in order to force dirt particles toward the dirty side is necessary in order to confirm the result, compare
(outside). the primary air cleaner element to a new primary air
cleaner element that has the same part number.
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent Do not use a primary air cleaner element that has
damage to the paper pleats. Do not aim the stream any tears and/or holes in the filter material. Do not
of air directly at the primary air cleaner element. Dirt use a primary air cleaner element with damaged
could be forced further into the pleats. pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”. Storing Primary Air Cleaner Elements
Vacuum Cleaning If a primary air cleaner element that passes inspection
will not be used, the primary air cleaner element can
Vacuum cleaning is a good method for cleaning be stored for future use.
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
g00281694
Illustration 89
SEBU7828-10 141
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Do not use paint, a waterproof cover, or plastic as a Observe the service indicator. The air cleaner
protective covering for storage. An airflow restriction element should be cleaned or the air cleaner element
may result. To protect against dirt and damage, wrap should be replaced when one of the following
the primary air cleaner elements in Volatile Corrosion conditions occur:
Inhibited (VCI) paper.
• The yellow diaphragm enters the red zone.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of • The red piston locks in the visible position.
the box and mark the primary air cleaner element.
Include the following information: Test the Service Indicator
• Date of cleaning Service indicators are important instruments.
• Number of cleanings • Check for ease of resetting. The service indicator
should reset in less than three pushes.
Store the box in a dry location.
• Check the movement of the yellow core when the
i01900118 engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
Engine Air Cleaner Service greatest vacuum that is attained.
Indicator - Inspect If the service indicator does not reset easily, or if the
(If Equipped) yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
SMCS Code: 7452-040 service indicator will not reset, the hole for the service
indicator may be plugged.
Some engines may be equipped with a different
service indicator. The service indicator may need to be replaced
frequently in environments that are severely dusty, if
Some engines are equipped with a differential gauge necessary. Replace the service indicator annually
for inlet air pressure. The differential gauge for inlet regardless of the operating conditions. Replace the
air pressure displays the difference in the pressure service indicator when the engine is overhauled, and
that is measured before the air cleaner element and whenever major engine components are replaced.
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty, Note: When a new service indicator is installed,
the pressure differential rises. If your engine is excessive force may crack the top of the service
equipped with a different type of service indicator, indicator. Tighten the service indicator to a torque
follow the OEM recommendations in order to service of 2 N·m (18 lb in).
the air cleaner service indicator.
i01564253
The service indicator may be mounted on the air
cleaner housing or in a remote location. Engine Crankcase Breather -
Clean
SMCS Code: 1317-070
NOTICE
Perform this maintenance with the engine stopped.
If the crankcase breather is not maintained on a

regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
g00103777
Illustration 90
Typical service indicator
142 SEBU7828-10
Maintenance Section
Engine Mounts - Inspect
i00623423
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
g00812591
Illustration 91
Typical example
(1) Hose clamp
(2) Cover clamp
(3) Crankcase breather cover
g00110310
Illustration 92
1. Loosen hose clamp (1) and remove the hose from (Y) “ADD” mark. (X) “FULL” mark.
crankcase breather (2).
2. Remove the crankcase breather (2). NOTICE

Perform this maintenance with the engine stopped.
3. Wash the breather element in solvent that is clean
and nonflammable. Allow the breather element to 1. Maintain the oil level between “ADD” mark (Y) and
dry before installation. “FULL” mark (X) on oil level gauge (1). Do not fill
the crankcase above “FULL” mark (X).
4. Install a breather element that is clean and dry.
Install the crankcase breather (2). Refer to the
Operation and Maintenance Manual for the proper NOTICE
torque. Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into
5. Install the hose. Install hose clamp (1). Refer to the oil. The air bubbles created from the crankshaft
the Operation and Maintenance Manual for the dipping into the oil reduces the oil's lubricating char-
proper torques. acteristics and could result in the loss of power.
i02139969 2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
Engine Mounts - Inspect
i03542996
SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for

Engine Oil Sample - Obtain
proper bolt torque. Engine vibration can be caused SMCS Code: 1000-008; 1348-554-SM;
by the following conditions: 7542-554-OC, SM
• Improper mounting of the engine In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
• Deterioration of the engine mounts analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
Any engine mount that shows deterioration should maintenance requirements of the engine. S·O·S oil
be replaced. Refer to the Specifications Manual, analysis provides infrared analysis, which is required
SENR3130, “Torque Specifications”. Refer to your for determining nitration and oxidation levels.
Caterpillar dealer for more information.
SEBU7828-10 143
Maintenance Section
Engine Oil and Filter - Change
Obtain the Sample and the Analysis For instructions, see Special Publication, PEgj0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
injury. Do not allow hot oil or hot components to
contact the skin. i02107152
Engine Oil and Filter - Change

Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order SMCS Code: 1318-510; 1348-044
to help obtain the most accurate analysis, provide
the following information:
• Engine model
• Service hours on the engine injury. Do not allow hot oil or hot components to
contact the skin.
• The number of hours that have accumulated since
the last oil change Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
• The amount of oil that has been added since the of the oil pan. The waste particles are not removed
last oil change with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the
To ensure that the sample is representative of the oil warm. This draining method allows the waste
oil in the crankcase, obtain a warm, well mixed oil particles that are suspended in the oil to be drained
sample. properly.
To avoid contamination of the oil samples, the tools Failure to follow this recommended procedure will
and the supplies that are used for obtaining oil cause the waste particles to be recirculated through
samples must be clean. the engine lubrication system with the new oil.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the Drain the Engine Oil
consistency of the samples are better when the
sampling valve is used. The location of the sampling After the engine has been run at the normal operating
valve allows oil that is flowing under pressure to be temperature, stop the engine. Use one of the
obtained during normal engine operation. following methods to drain the engine crankcase oil:
The 169-8373 Fluid Sampling Bottle is • If the engine is equipped with a drain valve, turn the
recommended for use with the sampling valve. The drain valve knob counterclockwise in order to drain
fluid sampling bottle includes the parts that are the oil. After the oil has drained, turn the drain valve
needed for obtaining oil samples. Instructions are knob clockwise in order to close the drain valve.
also provided.
• If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil
NOTICE to drain. If the engine is equipped with a shallow
Always use a designated pump for oil sampling, and sump, remove the bottom oil drain plugs from both
use a separate designated pump for coolant sampling. ends of the oil pan.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This After the oil has drained, the oil drain plugs should
contaminate may cause a false analysis and an incor- be cleaned and installed.
If the engine is not equipped with a sampling valve,

use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
144 SEBU7828-10
Maintenance Section
Engine Performance - Test
Replace the Oil Filter

NOTICE
NOTICE Do not fill the oil filters with oil before installing them.
Caterpillar oil filters are built to Caterpillar speci- This oil would not be filtered and could be contaminat-
fications. Use of an oil filter not recommended by ed. Contaminated oil can cause accelerated wear to
Caterpillar could result in severe engine damage to engine components.
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering 5. Install the oil filter. Tighten the oil filter until the
the engine lubricating system. Only use oil filters oil filter gasket contacts the base. Tighten the oil
recommended by Caterpillar. filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
1. Remove the oil filter with a 1U-8760 Chain filter.
Wrench.
Fill the Engine Crankcase
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the 1. Remove the oil filler cap. Refer to the Operation
oil filter for metal debris. An excessive amount and Maintenance Manual, “Refill Capacities and
of metal debris in the oil filter may indicate early Recommendations” for more information.
wear or a pending failure.
NOTICE
Use a magnet to differentiate between the ferrous If equipped with an auxiliary oil filter system or a re-
metals and the nonferrous metals that are found in mote oil filter system, follow the OEM or filter manu-
the oil filter element. Ferrous metals may indicate facturer's recommendations. Under filling or overfilling
wear on the steel and cast iron parts of the engine. the crankcase with oil can cause engine damage.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of NOTICE
the engine. Parts that may be affected include To prevent crankshaft bearing damage, crank the en-
the following items: main bearings, rod bearings, gine with the fuel OFF. This will fill the oil filters before
turbocharger bearings, and cylinder heads. starting the engine. Do not crank the engine for more
than 30 seconds.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order 2. Start the engine and run the engine at “LOW
to arrange for a further analysis if an excessive IDLE” for two minutes. Perform this procedure in
amount of debris is found in the oil filter. order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back to

the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the oil level gauge.
i01042067
Engine Performance - Test

g00103713
SMCS Code: 1000-081
Illustration 93
Typical filter mounting base and filter gasket Operate the engine for a minimum of two hours at a
minimum load of 60 percent.
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is • Monitor the operation of the generator set.
removed.
• Observe the gauges. Ensure that the gauges are
4. Apply clean engine oil to the new oil filter gasket. in the normal ranges.
SEBU7828-10 145
Maintenance Section
Engine Protective Devices - Check
• Record the data. Maintain a record of the data for This maintenance is recommended by Caterpillar
the engine performance. as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
i00626013
Engine Protective Devices - NOTICE

Only qualified service personnel should perform this
Check maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, “Valve Lash and Valve Bridge
SMCS Code: 7400-535 Adjustment” article or consult your Caterpillar dealer
for the complete valve lash adjustment procedure.
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help Operation of Caterpillar engines with improper valve
to prevent damage to the engine. It is impossible adjustments can reduce engine efficiency. This re-
to determine if the engine protective devices are duced efficiency could result in excessive fuel usage
in good working order during normal operation. and/or shortened engine component life.
Malfunctions must be simulated in order to test the
engine protective devices.
A calibration check of the engine protective devices

will ensure that the alarms and shutoffs activate Ensure that the engine cannot be started while this
at the setpoints. Ensure that the engine protective maintenance is being performed. To help prevent
devices are functioning properly. possible injury, do not use the starting motor to
turn the flywheel.
NOTICE
During testing, abnormal operating conditions must be Hot engine components can cause burns. Allow
simulated. additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
The tests must be performed correctly in order to pre-
vent possible damage to the engine. Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
To prevent damage to the engine, only authorized allow the valves to cool before this maintenance is
service personnel or your Caterpillar dealer should performed.
perform the tests.
Refer to the Service Manual for more information.
Visual Inspection
i01597115
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that Engine Valve Rotators - Inspect
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced SMCS Code: 1109-040
immediately.
i03840829
When inspecting the valve rotators, protective
Engine Valve Lash - glasses or face shield and protective clothing
must be worn, to help prevent being burned by
Inspect/Adjust hot oil or spray.
SMCS Code: 1102-025
Engine valve rotators rotate the valves when the
The initial valve lash adjustment on new engines, engine runs. This helps to prevent deposits from
rebuilt engines, or remanufactured engines is building up on the valves and the valve seats.
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of Perform the following steps after the engine valve
the valve train components and to the seating of the lash is set, but before the valve covers are installed:
valve train components.
1. Start the engine according to Operation and
Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
146 SEBU7828-10
Maintenance Section
Ether Starting Aid Cylinder - Replace
2. Operate the engine at low idle. i02784507
3. Observe the top surface of each valve rotator. The Fan Drive Bearing - Lubricate
valve rotators should turn slightly when the valves
close. SMCS Code: 1359-086-BD
Some of the fan drives have grease fittings and some

NOTICE
of the fan drives do not have grease fittings. If there is
A valve rotator which does not operate properly will
no grease fitting, periodic lubrication is not required.
accelerate valve face wear and valve seat wear and
The fan drive requires grease only if the fan drive
shorten valve life. If a damaged rotator is not replaced,
is equipped with a zerk.
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
If a valve fails to rotate, consult your Caterpillar

dealer.
i00805059
Ether Starting Aid Cylinder -

Replace
(If Equipped)
SMCS Code: 1456-510-CD Illustration 95
g00746166
Typical location of the grease fitting (if equipped) that is for the fan
drive bearing
The pulley is shown with the belt guards that have been removed.
Lubricate the grease fitting that is on the fan drive

bearing with High Speed Ball Bearing Grease or the
equivalent.
Inspect the fan drive pulley assembly for wear or for

damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to
the Systems Operation Testing and Adjusting Manual
for additional information.
g00104888
Illustration 94
i00891826
Typical example
Fuel System - Prime
1. Loosen the ether cylinder clamp. Unscrew and
remove the empty ether cylinder. SMCS Code: 1258-548
2. Remove the used gasket. Install the new gasket

that is provided with each new ether cylinder.
Personal injury or death can result from a fire.
3. Install the new ether cylinder. Hand tighten the
ether cylinder. Tighten the ether cylinder clamp Fuel leaked or spilled onto hot surfaces or electri-
securely. cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.
Turn the disconnect switch OFF or disconnect the

battery when changing fuel filters.
SEBU7828-10 147
Maintenance Section
Fuel System - Prime
Prime the fuel system in order to fill dry fuel filters. 7. Crank the engine. If the engine starts and if the
You must also prime the fuel system after any one of engine runs rough, run the engine at low idle.
the following conditions exist: Continue running the engine until the engine runs
smoothly.
• The fuel system has run dry.
Note: If the engine will not start, more priming is
• The engine has been in prolonged storage. necessary. If the engine continues to run rough, more
priming is necessary as well.
• The fuel filter has been cleaned.
NOTICE
• The fuel filter has been replaced. Do not let the tops of fuel nozzles turn when the fuel
line nuts are loosened or tightened.
Note: If the engine does not have a fuel priming
pump, refer to Step 4. The nozzles will be damaged if the top of the nozzle
turns in the body.
1. Unlock the priming pump, and operate the priming
pump until a resistance is felt. This procedure The engine will be damaged if a defective fuel injec-
will probably require a considerable amount of tion nozzle is used because the shape of fuel (spray
priming. pattern) that comes out of the nozzles will not be cor-
rect.
2. Push in the plunger, and hand tighten the plunger.
NOTICE
Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies
that the oil pressure is sufficient.
3. Crank the engine.
If the engine starts and the engine runs rough,

run the engine at low idle. Continue running the
engine until the engine runs smoothly.
g00290109
Illustration 96
NOTICE
During periodic service, DO NOT remove the fuel filter 8. Loosen the fuel line nuts at the valve cover base.
plug that is in the fuel filter base in order to purge air Loosen these line nuts one at a time.
from the fuel system. The periodic removal of the fuel
filter plug will result in increased wear on the threads 9. Operate the priming pump until the flow of fuel
in the fuel filter base. This wear leads to fuel leakage. from the fuel line is continuous and the flow of fuel
is free of air bubbles.
4. Open the vent valve (if equipped) on the fuel
10. Push in the plunger, and hand tighten the plunger.
injection pump's housing.
If the engine does not have a fuel priming pump,
crank the engine.
5. Operate the priming pump until the flow of fuel
from the vent valve is continuous and the flow of
11. Tighten each fuel line nut before you loosen the
fuel is free of air bubbles.
next fuel line nut. Tighten the fuel line nuts to a
torque of 40 ± 7 N·m (30 ± 5 lb ft).
If the engine does not have a fuel priming pump,
crank the engine. Crank the engine until the fuel
Continue this procedure until all of the fuel lines
flows freely and until the fuel is free of air bubbles.
have been cleared of any air. Before you start
the engine, make sure that the fuel line nuts
6. Close the vent valve. Then, push in the plunger.
are properly tightened. Also make sure that the
Hand tighten the plunger.
priming is locked.
148 SEBU7828-10
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i02049797
NOTICE
Fuel System Primary Filter Use a suitable container to catch any fuel that might
(Water Separator) Element - spill. Clean up any spilled fuel immediately.
Replace
5. Remove the fuel filter bowl (1) and wash the fuel
SMCS Code: 1260-510-FQ; 1263-510-FQ filter bowl with clean diesel fuel.
Water in the fuel can cause the engine to run rough. 6. Remove the fuel filter (2).
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water, 7. Clean the gasket sealing surface of the fuel filter
the element should be changed before the regularly base. Ensure that all of the old gasket is removed.
scheduled interval.
8. Apply clean diesel fuel to the new fuel filter gasket.
The primary filter/water separator also provides
filtration in order to help extend the life of the NOTICE
secondary fuel filter. The element should be changed In order to maximize fuel system life and prevent pre-
regularly. Install a vacuum gauge. Change the mature wear out from abrasive particles in the fuel,
element for the primary filter/water separator if the use Caterpillar fuel filters.
pressure is at 50 to 70 kPa (15 to 20 inches Hg).
Consult your Caterpillar dealer for proper part num-
Replace the Element bers.
9. Install the new fuel filter (2). Spin the fuel filter
onto the fuel filter base until the gasket contacts
Fuel leaked or spilled onto hot surfaces or elec- the base. Use the rotation index marks on the
trical components can cause a fire. To help pre- filters as a guide for proper tightening. Tighten the
vent possible injury, turn the start switch off when filter for an additional 3/4 turn by hand. Do not
changing fuel filters or water separator elements. overtighten the filter.
Clean up fuel spills immediately.
NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contami-
nated. Contaminated fuel will cause accelerated wear
to fuel system parts.
10. Install the clean fuel filter bowl (1) on the new fuel
filter.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the fu-
el system.
g00668636
Illustration 97
(1) Bowl 11. Open the fuel tank supply valve.
(2) Element
(3) Drain
12. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and check
1. Stop the engine. the engine for leaks again.
2. Turn the start switch to the “OFF” position. Detection of leaks is very difficult especially if
the engine is running. The primary filter/water
3. Shut off the fuel tank supply valve to the engine. separator is under suction. A leak will allow air to
enter the fuel. The air in the fuel can cause low
4. If the primary fuel filter is equipped with a drain power due to aeration of the fuel. If air enters the
valve (3), open the drain valve in order to drain any fuel, check the components for overtightening or
fuel from the filter case. Close the drain valve (3). undertightening.
SEBU7828-10 149
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
i01254694
Fuel System Primary

Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543
g00410343
Illustration 99
(1) Fuel priming pump
(2) Fuel filter
(3) Fuel block
(4) Fuel filter air purge plug
Illustration 98
g00668636 NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
(1) Bowl
(2) Element
clean the area around a fuel system component that
(3) Drain will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
Bowl (1) should be monitored daily for signs of water.
If water is present, drain the water from the bowl.
NOTICE
1. Open drain (3). The drain is a self-ventilated drain. Use a suitable container to catch any fuel that might
Catch the draining water in a suitable container. spill. Clean up any spilled fuel immediately.
Dispose of the water properly.
1. It may be necessary to relieve residual fuel
2. Close drain (3). pressure from the fuel system before removing
the fuel filter.
NOTICE
The water separator is under suction during normal Loosen the fuel filter air purge plug (4) in order to
engine operation. Ensure that the drain valve is tight- purge any residual pressure.
ened securely to help prevent air from entering the fuel
system. NOTICE
Do not loosen fuel lines or fittings at the fuel manifold
or ECM. The engine components may be damaged.
i01250684
Fuel System Secondary Filter - 2. Remove the used fuel filter.

Replace 3. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
SMCS Code: 1261-510-SE
4. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
Fuel leaked or spilled onto hot surfaces or elec- In order to maximize fuel system life and prevent
trical components can cause a fire. To help pre- premature wear out from abrasive particles in the
vent possible injury, turn the start switch off when fuel, a two micron absolute high efficiency fuel filter
changing fuel filters or water separator elements. is required for all Caterpillar Electronic Unit Injectors.
Clean up fuel spills immediately. Caterpillar High Efficiency Fuel Filters meet these
requirements. Consult your Caterpillar dealer for the
proper part numbers.
150 SEBU7828-10
Maintenance Section
Fuel Tank Water and Sediment - Drain
Open the drain valve on the bottom of the fuel tank

NOTICE in order to drain the water and the sediment. Close
Do not fill the secondary fuel filter with fuel before in- the drain valve.
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler- Note: Failure to properly close the drain can allow air
ated wear to fuel system parts. into the system, which could have detrimental results
to performance.
5. Install the new fuel filter. Spin the fuel filter onto Check the fuel daily. Drain the water and sediment
the fuel filter base until the gasket contacts the from the fuel tank after operating the engine or drain
base. Use the rotation index marks on the filters the water and sediment from the fuel tank after the
as a guide for proper tightening. Tighten the fuel tank has been filled. Allow five to ten minutes
filter for an additional 3/4 turn by hand. Do not before performing this procedure.
overtighten the filter.
Fill the fuel tank after operating the engine in
6. Open the fuel tank supply valve and prime the fuel order to drive out moist air. This will help prevent
system. condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
i03645042
overflow.
Fuel Tank Water and Sediment Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
- Drain supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
SMCS Code: 1273-543-M&S the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Fuel Storage Tanks
Drain the water and the sediment from the fuel
storage tank during the following conditions:
nent containing fluids.
• Weekly
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub- • Oil change
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col- • Refill of the tank
lect and contain fluids on Caterpillar products.
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
Dispose of all fluids according to local regulations and
tank. A four micron(c) absolute filter for the breather
mandates.
vent on the fuel tank is also recommended. Refer
to Special Publication, SENR9620, “Improving Fuel
Fuel Tank System Durablity”.
Fuel quality is critical to the performance and to the If a bulk storage tank has been refilled or moved
service life of the engine. Water in the fuel can cause recently, allow adequate time for the sediment to
excessive wear to the fuel system. Condensation settle before filling the engine fuel tank. Internal
occurs during the heating and cooling of fuel. The baffles in the bulk storage tank will also help trap
condensation occurs as the fuel passes through the sediment. Filtering fuel that is pumped from the
fuel system and the fuel returns to the fuel tank. This storage tank helps to ensure the quality of the fuel.
causes water to accumulate in fuel tanks. Draining When possible, water separators should be used.
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment

Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
SEBU7828-10 151
Maintenance Section
Generator - Dry
i03997990
Generator - Dry
SMCS Code: 4450-569
Personal injury or death can result from improper

troubleshooting and repair procedures.
The following troubleshooting and repair proce-

dures should only be performed by qualified per-
sonnel familiar with this equipment.
Refer to this Operation and Maintenance Manual,

“Generator Isolating for Maintenance” for information
regarding the procedure to isolate the generator in
a safe manner.
Refer to Special Instruction, REHS9124, “Cleaning g02175752

Illustration 100
and Drying of the Generator” for further necessary
information. Typical curves of the resistance in the insulation that is drying
(1) Curve of the temperature in the windings
Of the following methods for drying the generator, the (2) Heat turned off.
(3) Drying time in hours
use of external heat is preferred. (4) Temperature in degrees celsius
(5) Curve of insulation resistance during drying process
• External heat (6) Insulation resistance in megohms
• Internal heat Note: When new insulation or very damp insulation

is being dried, the resistance will probably fall
• Combination of external and internal heat rapidly. The rapid fall in resistance is the result of the
temperature being raised to a value for drying. After
• Circulating current reaching a minimum for a given temperature, the
resistance will again rise as moisture is driven out of
External heat is the most preferable method. the insulation. The actual values will vary with each
Insulation drying time can vary from a few hours situation. Refer to Illustration 101.
to several days. The drying time depends on the
moisture content and the process for drying that is If the windings or insulation are wet during the
used. resistance measurement, use a 5 megohm resistor
for protection in series with red positive lead. This
Note: Drying sometimes does not produce the procedure limits the voltage across the circuit
required results. The use of a qualified rebuild under the test. Use this method until drying is well
shop may be necessary for dipping and drying the in progress and the resistance has reached an
generator. acceptable level.
Check the windings after every 4 hours when either

external or internal heat is used to dry the generator.
Check the windings very hour when circulating
current is used to dry the generator. Refer to Special
Instruction, REHS9124, “Cleaning and Drying of the
Generator” for more information.
Drying is complete when the tests show no increase

in resistance and the resistance is above the
minimum. Record these readings and compare these
readings. Keep these records for future reference.
152 SEBU7828-10
Maintenance Section
Generator - Dry
Note: Caterpillar recommends a minimum acceptable

insulation resistance of 1 megohm for generators
which operate with less than 1000 V of operating or
rated voltage. Generators which operate at 1000 V
of operating or rated voltage should have a minimum
insulation resistance as determined by the following
equation:
R = (V/1000) + M
“R” is the minimum insulation resistance.
“V” is the rated voltage.
g01696934
“M” is 1 megohm.
Illustration 101
Curve of insulation resistance for windings in good condition These values are approximate. It may be possible to
(1) Resistance after 30 seconds operate a generator with less resistance.
(2) Resistance after 60 seconds
Illustration 101 indicates the curve of the resistance External Heat

of a normal high resistance in the windings over
a period of 60 seconds. The resistance after 60 Ovens
seconds will be greater than the resistance or equal
to the resistance after 30 seconds . The best oven is a forced air drying oven for drying
electrical equipment. Radiant ovens sometimes
Note: If the insulation resistance after 60 seconds is cause localized overheating.
not higher than the resistance after 30 seconds , the
insulation may be weak. NOTICE
Do not heat the generator too quickly. Try to limit the
rise in temperature of the insulation and windings to
11.11° C (20° F) per hour. Failure to do so may cause
equipment damage.
Note: Many electrical shops are equipped with

baking ovens.
Heat the generator to approximately 75° C (167° F).

Never exceed 75° C (167° F) until the insulation
tester tests correctly for insulation resistance (at least
4 hours).
g01697074
Alternate Method
Illustration 102
Curve of insulation resistance for windings that are wet or dirty A tent formed by a tarp or a canvas with heated
(1) Resistance after 30 seconds lamps or a portable space heater may be used as
(2) Resistance after 60 seconds an alternate method.
Illustration 102 indicates the curve of the resistance A hole should be left in the top of the tarp for
that is decaying over a period of 60 seconds. If the ensuring proper circulation through the generator
insulation resistance after 60 seconds is not higher and for permitting the moisture to exhaust. Heat the
than the resistance after 30 seconds , clean the generator to approximately 75° C (167° F). Never
windings and thoroughly dry the windings. Refer exceed 75° C (167° F) until the insulation tester tests
to Special Instruction, REHS9124, “Cleaning and correctly for insulation resistance (at least 4 hours).
Drying of the Generator” for more information.
Internal Heating
If generators operate under one of the following
conditions, the electric space heaters should be
installed as part of the generator:
SEBU7828-10 153
Maintenance Section
Generator - Inspect
• Generators are in damp environments and go for These contaminants will develop a conductive path
long periods of time without operation. which may produce shorts. Cleaning is advisable if
heavy accumulations of dirt can be seen or if heavy
• Generators operate regularly in an environment accumulations of dust can be seen. If excess dirt is
with moisture laden air. the cause of a restriction in the ventilation, cleaning
is also advisable. Restricted ventilation will cause
Circulating Current excessive heating.
Drying can be accomplished by circulating low NOTICE

voltage current through the windings. Since the To avoid the possibility of deterioration to the genera-
voltage is low, the breakdown of the insulation will not tor windings, do not clean the generator unless there
occur as the breakdown might have occurred with is visual, electrical, or thermal evidence that dirt is
normal operation and wet insulation. Refer to Special present.
Instruction, REHS9124, “Cleaning and Drying of the
Generator” for this procedure.
If harmful dirt accumulations are present, a variety
of cleaning techniques are available. The cleaning
i01461264 procedure that is used may be determined by one of
the items on the following list:
Generator - Inspect
• The extent of the cleaning procedure that is being
SMCS Code: 4450-040 attempted
• The type of enclosure of the generator

Personal injury or death can result from improper • The voltage rating of the generator
troubleshooting and repair procedures.
• The type of dirt that is being removed
The following troubleshooting and repair proce-
dures should only be performed by qualified per- Cleaning (Assembled Generators)
sonnel familiar with this equipment.
Cleaning may be required at the point of installation.
Refer to Safety Section, “Generator Isolating for At this point, complete disassembly of the generator
Maintenance” for information regarding the procedure may not be necessary or feasible. In this case,
to safely isolate the generator. a vacuum cleaner should be used to pick up the
following items: dry dirt, dust, and carbon. This will
Proper maintenance of electrical equipment requires prevent the spreading of these contaminants.
periodic visual examination of the generator and
periodic visual examination of the windings. Proper A small nonconductive tube may need to be
maintenance of electrical equipment also requires connected to the vacuum cleaner. This will allow the
appropriate electrical checks and appropriate thermal vacuum cleaner to clean the surfaces that are not
checks. Insulation material should be examined for exposed. After most of the dust has been removed,
cracks. The insulation material should be examined a small brush may be attached to the vacuum hose
for accumulations of dirt and dust. If there is an in order to loosen dirt that is more firmly attached to
insulation resistance value that is below normal, a the surface.
conductive path may be present. This conductive
path may be made of one of the following materials: After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
• Carbon dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure
• Salt should be a maximum of 210 kPa (30 psi) in order to
prevent mechanical damage to the insulation. If the
• Metal dust above cleaning procedures are not effective, consult
a Caterpillar dealer.
• Dirt that is saturated with moisture
154 SEBU7828-10
Maintenance Section
Generator Bearing - Inspect/Replace
Cleaning (Disassembled Inspect

Generators) 1. Remove the bearing bracket. Inspect the following
items: bracket bore, bearing outer race, and
An initial insulation resistance check should be
rolling elements. On standby power units, the
made on the generator in order to confirm electrical
bearing must be inspected and the grease must
integrity. A minimum reading of one megohm would
be replaced at three year intervals. The sleeve
be expected with severely contaminated generators.
in the bearing bracket should be inspected for
A zero megohm reading may indicate an insulation
out of roundness, excessive wear, and a bracket
breakdown. An insulation breakdown requires more
step that is less than 0.0762 mm (0.0030 inch). If
than cleaning. An insulation breakdown requires
there is no sleeve in the bearing bracket, inspect
repair.
the bore of the bearing bracket. The bearing
should be inspected for damage to the outer race,
A high pressure wash is normally an effective way
severe fretting, and smoothness of operation.
to clean windings. This includes windings that have
When possible, the bearing elements should be
been exposed to flooding or windings that have been
inspected. Some double shielded ball bearings
contaminated by salt. A solution of hot water and
prevent visual inspection of the elements of the
detergent is used for this method of cleaning.
bearing. Other double shielded ball bearings
have a retaining ring. This retaining ring can be
A high pressure wash sprays a high velocity fluid
removed in order to allow access for a visual
stream of this solution over the generator that is
inspection of the elements of the bearing.
being cleaned. This detergent washing is followed by
multiple sprays of clean water. The clean water is
On two-bearing generators, the front bearing
used in order to remove the detergent or the clean
can only be removed after the drive coupling
water is used in order to dilute the detergent.
is removed. Refer to the Systems Operation
Testing and Adjusting Disassembly and Assembly,
Allow the generator to dry at room temperature.
“Coupling - Remove” for the generator for
Check the insulation resistance. The insulation
instructions for removing the drive coupling.
resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. It
may be necessary to use solvents if the generator Replace
is contaminated with oil or if the generator is
contaminated with grease. 1. All ball bearings should be cleaned. The cavity
in the bracket should be repacked with 2S-3230
Note: For more information on drying methods, refer Grease. Pack the ball bearings (one-third to
to Special Instructions, SEHS9124, “Cleaning and one-half of the volume of the cavity).
Drying of Electric Set Generators”.
2. Use an induction heater to heat the ball bearings to
107 °C (224.6 °F) for ten minutes in order to install
i03099722
either of the following bearings: ball bearings
Generator Bearing - that are new and ball bearings that have been
inspected. Mount the bearings on the shaft. To
Inspect/Replace reinstall the hub, heat the hub to 400 °C (752.0 °F)
(SR4 Generator) for three hours. Mount the hub to the shaft.
3. Ensure that the tube of the grease gun is filled

SMCS Code: 4471-040; 4471-510
with grease.
The following maintenance procedure for generator
4. Remove the bracket drain plug and operate the
bearings should be followed at every major engine
generator for one hour. This will allow the grease
overhaul:
to expand. The expanding grease will force the
excess grease from the cavity. When the excess
grease is forced from the cavity, the internal
pressure will be reduced. The generator should
continue to operate until the grease stops purging.
5. Stop the engine. Install the bracket drain plug.

Wipe off the excess grease.
SEBU7828-10 155
Maintenance Section
Generator Bearing - Lubricate
6. For greasing intervals, follow the recommendations

on the lubrication plate (if equipped) or refer to
Maintenance Schedule, “Generator Bearing -
Lubricate”. Whenever the bearings are greased,
repeat Step 1. DO NOT MIX GREASES.
i03997526

SMCS Code: 4471-086
Lubricating Process (If Applicable)

Note: If the generator already has a visible grease
point, go to Step 4.
1. Remove either the louver assembly or the rear

plate from the rear of the generator housing.
2. Remove the top grease pipe plug and remove the

lower grease pipe plug.
3. Install a grease fitting in the grease pipe.
4. Grease the bearings with the appropriate grease

from Table 28. Do not mix greases.
Table 28
Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
108-1760 321 BC 680 −29 °C 2S-3230 Every 2000 51.2 g 59 mL 105.0 mm
Ball Bearing 225.0 mm (−20.2 °F) Bearing service (1.8 oz) (2 oz) (4.1 inch)
(8.9 inch) minimum Lubricant hours or 12
OD / months
80 °C
105.0 mm (176 °F)
(4.1 inch) ID maximum
108-1761 322 BC 690 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL 110.0 mm
Ball Bearing 240.0 mm 800 (−20.2 °F) Bearing service (1.8 oz) (2 oz) (4.3 inch)
(9.4 inch) / Lubricant hours or 12
OD 80 °C months
(176 °F)
110.0 mm
(4.3 inch) ID
139-0349 Roller 2900 / −40 °C Mobilith Every 250 2.8 g NA 127.0 mm
Roller 2800 (−40 °F) SHC220 service (0.1 oz) (5.0 inch)
Bearing / hours
80 °C
(176 °F)
139-0350 Roller 2900 / −40 °C Mobilith Every 250 2.8 g NA 127.0 mm
Roller 2800 (−40 °F) SHC220 service (0.1 oz) (5.0 inch)
Bearing / hours
80 °C
(176 °F)
(continued)
156 SEBU7828-10
Maintenance Section
(Table 28, contd)

Number Number
154-3032 326 BC 820 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL 130.0 mm
Ball Bearing 280.0 mm 2600 / (−20.2 °F) Bearing service (1.8 oz) (2 oz) (5.1 inch)
(11.0 inch) 2700 / Lubricant hours or 12
OD 80 °C months
(176 °F)
130.0 mm
(5.1 inch) ID
241-4644 320 BC LC7 −29 °C UNIREX Every 4500 60 g NA 100.0 mm
Bearing 215.0 mm (−20.2 °F) N3 service (2.1 oz) (3.9 inch)
(8.5 inch) / hours or 12
OD 60 °C months
(140 °F)(2)
100.0 mm
(3.9 inch) ID
243-5220 315 BB LC6100 −29 °C UNIREX Non- Non- Non- 75.0 mm
Bearing 160.0 mm / (−20.2 °F) N3 regreasable regreasable regreasable (3.0 inch)
(6.3 inch) LC5000 / bearing(3) bearing bearing
OD 60 °C
(140 °F)(2)
75.0 mm
(3.0 inch) ID
261-3545 307 BB LC2000 −29 °C UNIREX Non- Non- Non- 35.0 mm
Bearing 80.0 mm (−20.2 °F) N3 regreasable regreasable regreasable (1.4 inch)
(3.1 inch) / bearing(3) bearing bearing
OD 50 °C
(122 °F)(2)
35.0 mm
(1.4 inch) ID
262-5921 307 BC LC2000 −29 °C UNIREX Non- Non- Non- 35.0 mm
OD 60 °C
(140 °F)(2)
35.0 mm
(1.4 inch) ID
263-0161 309 BC LC3000 −29 °C UNIREX Non- Non- Non- 45.0 mm
OD 60 °C
(140 °F)(2)
45.0 mm
(1.8 inch)
5P-2448 315 BC 580 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL 75.0 mm
OD 80 °C months
(176 °F)
75.0 mm
(3.0 inch) ID
6Y-3955 220 BC 450 −29 °C 2S-3230 Every 2000 51.2 g 59 mL 100.0 mm
OD 80 °C months
(176 °F)
100.0 mm
(3.9 inch) ID
(continued)
SEBU7828-10 157
Maintenance Section
(Table 28, contd)

Number Number
6Y-6488 318 BC 597 −29 °C 2S-3230 Every 2000 51.2 g 59 mL 90.0 mm
OD 80 °C months
(176 °F)
90.0 mm
(3.5 inch)
311-0843 326 BC 1800 −40 °C EA6 Non- Non- Non- 130.0 mm
Ball Bearing 280.0 mm FR (−40 °F) regreasable regreasable regreasable (5.1 inch)
OD 80 °C
(176 °F)
130.0 mm
(5.1 inch) ID
311-0844 322 BC 1600 −40 °C EA6 Non- Non- Non- 110.0 mm
Ball Bearing 240.0 mm FR (−40 °F) regreasable regreasable regreasable (4.3 inch)
OD 80 °C
(176 °F)
110.0 mm
(4.3 inch) ID
253-9789 320 BC 1400 −29 °C UNIREX Non- Non- Non- 100.0 mm
Bearing 215.0 mm FR (−20.2 °F) N3 regreasable regreasable regreasable (3.9 inch)
OD 80 °C
(176 °F)
100.0 mm
(3.9 inch) ID
193-4070 018 BC 498/ −29 °C 2S-3230 Every 2000 51.2 g 59 mL 90.0 mm
OD 80 °C months
(176 °F)
90.0 mm
(3.5 inch) ID
(1) This temperature is for a generator set that is equipped with a resistive temperature detector (RTD).
(2) Do not exceed 60 °C (140 °F) above the ambient temperature.
(3) This bearing cannot be greased. Refer to this Operation and Maintenance Manual, “Generator Bearing - Replace” article for information
concerning the replacement of these bearings.
(2) Do not exceed 50 °C (122 °F) above the ambient temperature.
5. Wipe off the excess grease. Remove the top Additional Information
grease fitting. Install the plug.
Refer to Special Instruction, REHS4892, “Generator
6. Operate the generator for 1 hour. This process Bearing Service” for further information.
will allow the grease to expand. The expanding
grease will force the excess grease from the
cavity. When the excess grease is forced from
the cavity, the internal pressure will be reduced.
The generator should continue to operate until the
grease stops purging.
7. Stop the engine. Install the plug in the bottom

grease pipe. Wipe off the excess grease.
8. Install the louver assembly or install the rear plate.

158 SEBU7828-10
Maintenance Section
Generator Bearing Temperature - Test/Record
i03642839 i04032220
Generator Bearing Generator Lead (Flat Braided

Temperature - Test/Record Cable) - Check
SMCS Code: 4471-081-TA SMCS Code: 4450-535
The monitoring of bearing temperature may prevent

premature bearing failure. A generator set should
never operate above the recommended set points.
Keep records in order to monitor the changes in the
temperature of the bearing.
Note: Measure the bearing temperature after the

generator reaches normal operating temperature.
Resistive Temperature Detectors

(RTDs)
Caterpillar Generators may be equipped with
resistance temperature detectors for generator
bearings. These detectors are 100 ohm resistance
temperature detectors. A resistance temperature
detector may be monitored by the optional monitor for
the EMCP 3.2/3.3 resistance temperature detector. A
resistance temperature detector may be monitored by
equipment that is provided by the customer. Consult Illustration 103
g02146533
with your Caterpillar dealer about other methods of
Typical flat braided conductor
measuring the bearing temperature.
The EMCP 3.2/3.3 may be configured to “ALARM” The generator set may have braided square
or the EMCP 3.2/3.3 may be configured to conductors or multiple round cables between the
“SHUTDOWN”. An alarm is activated if the generator and the breaker.
temperature of the bearing reaches 85 °C (185 °F).
A shutdown occurs if the temperature of the bearing Check braided conductors for signs of wear. Pay
reaches 95 °C (203 °F). particular attention to the conductor protective sleeve
insulation at the housing for the breaker and in the
generator terminal box. Replace the mats or the
Infrared Thermometers cable immediately if the rubber mats or the insulation
on the braided cables show signs of wear at points of
Bearing temperatures can also be recorded with the contact. If your generator set does not have rubber
use of an infrared thermometer. Refer to Special mats in place, contact your Cat dealer.
Publication, NENG2500, “Caterpillar Dealer Service
Tools Catalog” for a variety of infrared thermometers.
Follow the instructions that come with your infrared i04032349
thermometer.
Generator Lead (Round Cable)
- Check
SMCS Code: 4450-535
The generator set may have braided square

conductors or multiple round cables between the
generator and the breaker.
SEBU7828-10 159
Maintenance Section
Generator Load - Check
Electric sets normally have a low idle setting that

is higher than industrial engines. Low idle will be
approximately 66% of the full speed that is achieved
by 60 Hz units. This would be equal to 80% of the full
speed that is achieved by 50 Hz units.
Some electric sets are equipped with Woodward

governors and some electric sets are equipped
with Caterpillar electronic governors. These electric
sets have no low idle stop. On electric sets with
mechanical governors and natural gas electric sets,
the low idle is set at the factory. Adjustment of the
low idle on these machines should only be done by
a Caterpillar dealer.
g02223453
Illustration 104 Note: Operating the electric set at low idle speed for
Round generator lead cables an extended time will cause some voltage regulators
to shut off. The electric set must be completely shut
Ensure that the generator output leads are routed out down and the electric set must be restarted. This
of the generator in a manner that prevents the leads will allow the voltage regulator to again produce an
from rubbing against metal objects. Visually inspect output.
the following areas for cracking and physical damage:
• Stator output leads i01593517
• Protective sleeving
Generator Set - Test
SMCS Code: 4450-081
• Insulation
i01228480
Generator Load - Check Personal injury or death can result from high volt-
age.
SMCS Code: 4450-535-LA
When power generation equipment must be in op-
During normal operation, monitor the power factor eration to make tests and/or adjustments, high
and monitor generator loading. voltage and current are present.
When a generator is installed or when a generator Improper test equipment can fail and present a
is reconnected, ensure that the total current in any high voltage shock hazard to its user.
one phase does not exceed the nameplate rating.
Each phase should carry the same load. This allows Make sure the testing equipment is designed for
the generator to work at the rated capacity. If one and correctly operated for high voltage and cur-
phase current exceeds the nameplate amperage, rent tests being made.
an electrical imbalance will occur. An electrical
imbalance can result in an electrical overload and an When servicing or repairing electric power gener-
electrical imbalance can result in overheating . ation equipment:
The power factor can be referred to as the efficiency • Make sure the unit is off-line (disconnected
of the load. This can be expressed as the ratio of kVA from utility and/or other generators power
to actual kW. The power factor can be calculated by service), and either locked out or tagged DO
dividing kW by kVA. Power factor is expressed as a NOT OPERATE.
decimal. Power factor is used to mean the portion
of current that is supplied to a system that is doing • Make sure the generator engine is stopped.
useful work. The portion of the current that is not
doing useful work is absorbed in maintaining the • Make sure all batteries are disconnected.
magnetic field in motors. This current (reactive load)
can be maintained without engine power. • Make sure all capacitors are discharged.
160 SEBU7828-10
Maintenance Section
Generator Set Alignment - Check
Table 29 i03956450
Tools Needed Generator Set Alignment -

Part Number Part Quantity Check
6V-7070
Digital
Multimeter
1 (Generator Sets)
12 VDC battery 1 SMCS Code: 7002-024
Potential
Transformer
1 The genset must be aligned when the genset is
installed or moved into a different position. If the
generator set is run at the full continuous rating, the
The generator set functional test is a simplified test alignment of the generator to the engine must be
that can be performed in order to determine if the checked annually.
generator is functional. The generator set functional
test should be performed on a generator set that is Properly maintain the alignment between the engine
under load. and the driven equipment in order to minimize the
following problems:
The generator set functional test determines if the
following statements happen: • Bearing problems
• A phase voltage is being generated. • Vibration of the engine crankshaft
• The phase voltages are balanced. • Vibration of the driven equipment
• The phase voltages change relative to engine Refer to the following information for more information
speed. about the alignment of the generator set:
The generator set functional test consists of the • Special Instruction, SEHS7654, “Alignment -
following steps: General Instructions”
1. Stop the generator. Connect the potential • Special Instruction, SEHS7259, “Alignment of
transformer's high voltage winding to the Single Bearing Generators”
generator terminals (T1) and (T2). Connect
the voltmeter to the low voltage winding. If two • Special Instruction, REHS0177, “Alignment of the
transformers are available, connect the high Close Coupled Two Bearing Generators”
voltage winding of the second transformer to the
generator terminals (T1) and (T3). Connect the Keep a record of the measurement of the alignment.
secondary terminals that correspond to generator The record may be used to check the trend of the
terminal (T2) of both transformers together. alignment. The record may be used to analyze the
trend of the alignment.
2. Disconnect wires “E+” and “E-” from the voltage
regulator. Disconnect the generator from the load.
i01228545
3. Connect a 12 VDC automotive battery to wires
“E+” and “E-”.
Generator Set Vibration -
Inspect
4. Measure the AC voltage across the low voltage
terminals of the transformer that correspond to the SMCS Code: 4450-040-VI
following generator terminals: “T1” and “T2”, “T2”
and “T3”, and “T3” and “T1”. Record the voltages. Check for vibration damage. Vibration may cause the
following problems:
• loose fittings
• loose bolts
• excessive noise
• cracked insulation
SEBU7828-10 161
Maintenance Section
Generator Set Vibration - Test/Record
The following areas are susceptible to vibration • Exposed electrical connections

damage:
• Transformers
• stator output leads
• Fuses
• protective sleeving
• Capacitors
• insulation
• Lightning arresters
• exposed electrical connections
When a generator set is installed, a vibration plot
• transformers should be recorded in order to assist in diagnosing
potential problems. This vibration plot should be
• fuses updated yearly. The vibration plot should also be
updated when the generator set is moved and
• capacitors when the engine is overhauled. This will allow
the trend of the vibration to be monitored and
• lightning arrestors analyzed. A potential problem may be prevented by
monitoring the trend of the vibration. If the vibration
Check the generator set's vibration level by using a is approaching the limit of the specification of the
broad spectrum analyzer. component, the problem may be more imminent.
Refer to Data Sheet, LEKQ4023, “Linear Vibration”
for the allowable limits of vibration.
i03643886
Generator Set Vibration - Caterpillar also recommends recording the vibration

of the bearing at the generator bearing bracket.
Test/Record
If the vibration exceeds the EDS limits for vibration,
SMCS Code: 4450-081-VI check the alignment. Refer to this Operation and
Maintenance Manual, “Generator Set Alignment -
Check for vibration damage. Check” for the alignment procedure.
Vibration may cause the following problems: Contact the Caterpillar Dealer Service Tools group
for information on ordering a vibration analyzer that
• Coupling wear will meet your needs.
• Loose fittings
i03847809
• Fatigue of the metal components of the engine Hoses and Clamps -

• Cracks in the cabinet which surrounds the Inspect/Replace
generator
SMCS Code: 7554-040; 7554-510
• Cracks in welds
Hoses and clamps must be inspected periodically
• Excessive noise in order to ensure safe operation and continuous
operation of the engine. Take proper safety
• Cracked insulation precautions before inspecting or replacing hoses and
clamps.
The following areas are susceptible to vibration
damage: Note: Always use a board or cardboard when the
engine components are checked for leaks. Leaking
• Coupling for the generator set fluid that is under pressure can cause serious
injury or possible death. This includes leaks that
• Generator bearings are the size of a pin hole. Refer to Operation and
Maintenance Manual, “General Hazard Information”
• Stator output leads for more information.
• Protective sleeving
• Insulation
162 SEBU7828-10
Maintenance Section
Hoses and Clamps - Inspect/Replace
Inspect the Hoses and the Clamps Replace the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the
NOTICE
following conditions. Replace any hose which exhibits
Care must be taken to ensure that fluids are contained
any of the following conditions. Failure to replace a
during performance of inspection, maintenance, test-
hose which exhibits any of the following conditions
may result in a hazardous situation.
• Hoses which are cracked nent containing fluids.
• Hoses which are soft Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
• Outer covering that is chafed or cut lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-
• Exposed wire that is used for reinforcement lect and contain fluids on Caterpillar products.
• Outer covering that is ballooning locally Dispose of all fluids according to local regulations and
mandates.
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering Cooling System
• Hoses which exhibit signs of leakage which are not
the result of loose couplings or clamps
Inspect all clamps for the following conditions. Pressurized System: Hot coolant can cause seri-
Replace any clamp which exhibits signs of any of the ous burns. To open the cooling system filler cap,
following conditions. stop the engine and wait until the cooling system
• Cracking pressure cap slowly in order to relieve the pres-
sure.
• Looseness
• Damage
Inspect all couplings for leaks. Replace any coupling Personal injury can result from removing hoses or
which exhibits signs of leaks. fittings in a pressure system.
Each installation application can be different. The Failure to relieve pressure can cause personal in-
differences depend on the following factors: jury.
• Type of hose Do not disconnect or remove hoses or fittings un-

til all pressure in the system has been relieved.
• Type of fitting material
1. Stop the engine.
• Anticipated expansion and contraction of the hose
2. Allow the engine to cool.
• Anticipated expansion and contraction of the
fittings 3. Before servicing a coolant hose, slowly loosen the
filler cap for the cooling system in order to relieve
Due to extreme temperature changes, the hose will any pressure.
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose 4. Remove the filler cap for the cooling system.
clamp will help to prevent loose hose clamps.
5. Drain the coolant from the cooling system to a
Replace hoses that are cracked or soft. Replace level that is below the hose that is being replaced.
hoses that show signs of leakage. Replace hoses Drain the coolant into a suitable clean container.
that show signs of damage. Replace hose clamps The coolant can be reused.
that are cracked or damaged. Tighten or replace
hose clamps which are loose. 6. Remove the hose clamps.
SEBU7828-10 163
Maintenance Section
Hoses and Clamps - Inspect/Replace
7. Disconnect the old hose. Note: High pressure fuel lines may be installed
between the high pressure fuel pump and the fuel
8. Replace the old hose with a new hose. injectors. High pressure fuel lines are constantly
charged with high pressure. Do not check the high
9. Install hose clamps which have been inspected or pressure fuel lines with the engine or the starting
install new hose clamps. Refer to Specifications, motor in operation. Wait for 10 minutes after the
SENR3130, “Torque Specifications”, “Hose engine stops before you perform any service or repair
Clamps” for information about selecting and on high pressure fuel lines in order to allow pressure
installing the proper hose clamps. to be purged.
10. Refill the cooling system. 1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap 2. Remove the hose clamps.
if the gaskets are damaged. Install the filler cap.
3. Disconnect the old hose.
12. Start the engine. Inspect the cooling system for
leaks. 4. Replace the old hose with a new hose.
Fuel System 5. Install hose clamps which have been inspected or

install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
Personal injury can result from removing hoses or
fittings in a pressure system. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Failure to relieve pressure can cause personal in- engine.
jury.
Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved.
7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime” for
information about priming the engine with fuel.
Contact with high pressure fuel may cause fluid 8. Start the engine. Inspect the fuel system for leaks.
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol- Lubrication System
low these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE Hot oil and hot components can cause personal

Do not bend or strike high pressure lines. Do not in- injury. Do not allow hot oil or hot components to
stall bent or damaged lines, tubes or hoses. Repair contact the skin.
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec- 1. Drain the oil from the lubrication system to a level
ommended torque. that is below the hose that is being replaced.
2. Remove the hose clamps.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly 3. Disconnect the old hose.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis- 4. Replace the old hose with a new hose.
connected fuel system components.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
164 SEBU7828-10
Maintenance Section
Instrument Panel - Inspect
6. Refill the lubrication system. Refer to this i01951994

Operation and Maintenance Manual, “Engine
Oil Level - Check” in order to ensure that the Insulation - Test
lubrication system is filled with the proper amount
of engine oil. SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081
7. Start the engine. Inspect the lubrication system
for leaks. Recommended Periodic Insulation
Tests
Air System
1. Remove the hose clamps.
2. Disconnect the old hose. The high voltage that is produced by an operating
generator set can cause severe injury or death.
3. Replace the old hose with a new hose. Before performing any maintenance or repairs,
ensure that the generator will not start.
4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications, Place the engine control switch in the “OFF” posi-
SENR3130, “Torque Specifications”, “Hose tion. Attach “DO NOT OPERATE” tags to all start-
Clamps” for information about selecting and ing controls. Disconnect the batteries or disable
installing the proper hose clamps. the starting system. Lock out all switchgear and
automatic transfer switches that are associated
5. Start the engine. Inspect the air lines for leaks. with the generator.
Table 30
i01917577
Tools Needed
Instrument Panel - Inspect 142-5055 Insulation Testing Gp
SMCS Code: 7451-040 9U-6003 Insulation Testing Gp
Inspect the instrument panel for good condition.

Perform the self test. All of the warning lamps should Periodically, use an insulation tester to check the
illuminate. If a warning lamp does not illuminate, insulation resistance of the generator's main stator
replace the bulb immediately. If the alarm does winding. The frequency of this test is determined by
not sound, investigate the problem and correct the the generator's environment. Previous insulation
problem. tester readings will also determine the frequency of
this test.
Check the condition of all of the gauges. If a gauge
is broken, repair the gauge or replace the gauge Test the main stator windings with an insulation tester
immediately. in the following situations:
Frequently monitor the gauges during normal • The generator set is started for the first time.
operation.
• The generator set is removed from storage.
Record the data in a log. Compare the new data to
the data that was previously recorded. Comparing • The generator set is operating in a humid
the new data to the recorded data will help to environment. Test every three months.
establish the trends of engine performance. A gauge
reading that is abnormal may indicate a problem with • The generator set is not protected from the
operation or a problem with the gauge. elements in an enclosed area. Test every three
months.
• The generator set is installed in an enclosed area.

This area needs to be low in humidity and this area
needs to have steady temperatures. Test every
twelve months (minimum).
SEBU7828-10 165
Maintenance Section
Insulation - Test
• The generator set has not been run under load 8. For units that are 600 volts or less, set the voltage
for three months. Test the generator set weekly. to 500 Volts. For units that are more than 600
Use space heaters around the generator set if the volts, set the voltage to 1000 Volts.
generator is exposed to a sea water environment or
if the humidity is above 75 percent. Also use space 9. Use the 30/60 Time Resistance Method:
heaters if a test result was below 3 megohms.
a. Apply voltage.
Space heaters must be used whenever the generator
set is not under load. Space heaters must also be b. Observe the readings at 30 seconds. Observe
used whenever salt is present or whenever high the readings at 60 seconds.
humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester c. Record the 60 second reading. This reading
readings above one megohm. Use space heaters must be corrected for temperature.
only when the generator is not running.
d. Record temperature.
For additional information, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set e. Record humidity.
Generators”.
f. Remove voltage.
Recommended Procedure for A 10. Evaluate the readings. The actual value of the
Periodic Insulation Test resistance may vary greatly between generators.
For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
Personal injury or death can result from electro- the readings that were taken on previous dates.
cution. These two readings must be taken under similar
conditions. If a 60 second resistance reading
The megohmmeter is applying a high voltage to has a 50 percent reduction from the previous
the circuit. reading, the insulation may have absorbed too
much moisture.
To avoid electrocution, do not touch the instru-
ment leads without first discharging them. When Switch the insulation tester to the “OFF” position.
finished testing also discharge the generator This will discharge the insulation tester's leads.
windings. Disconnect the insulation tester's leads.
Note: The results from the insulation resistance

1. Take the generator out of service. checks indicate when cleaning and/or repairing is
becoming critical. Generally, insulation resistance
2. Visually inspect the generator for moisture. If will vary greatly with temperature. Therefore, always
moisture exists, do not perform this insulation test at the same temperature and humidity. Refer to
test. Dry the unit first. Refer to Special Instruction, Illustration 105.
SEHS9124, “Cleaning and Drying of Electric Set
Generators”. Serial Number (Engine)___________________________________
3. Inspect the installation. Determine the equipment Serial Number (Generator)_______________________________

that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Isolate the stator windings of the generator by

disconnecting all other leads and cables from the
generator terminals. This includes connections
to the voltage regulator, the control panel, the
switchgear or other devices.
6. Connect the insulation tester's RED lead to

ground.
7. Connect the insulation tester's BLACK lead to the

wye point or star point of the generator's windings.
166 SEBU7828-10
Maintenance Section
Insulation - Test
g00633226
Illustration 105
SEBU7828-10 167
Maintenance Section
Jacket Water Heater - Check
i01917546 1. Remove the magnetic pickup (1) from the flywheel

housing. Check the condition of the end of the
Jacket Water Heater - Check magnetic pickup. Check for signs of wear and
(Standby Generator Sets (If contaminants.
Equipped)) 2. Clean the metal shavings and other debris from

the face of the magnet.
SMCS Code: 1383-535
3. Install the magnetic pickup and adjust the
Jacket water heaters help to improve startability in magnetic pickup. Refer to the Service Manual for
ambient temperatures that are below 21 °C (70 °F). the installation procedure.
All installations that require automatic starting should
have jacket water heaters.
i02436705
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 °F), the heater Overhaul Considerations
should maintain the jacket water coolant temperature
at approximately 32 °C (90 °F). SMCS Code: 7595-043
Reduced hours of operation at full load will result in

i00850920 a lower average power demand and reduced fuel
consumption. A decreased average power demand
Magnetic Pickups - should increase both the engine service life and the
Clean/Inspect overhaul interval.
SMCS Code: 1907-040; 7400-040; 7400-070 The need for an overhaul is generally indicated
by increased fuel consumption, increased oil
consumption, excessive engine blowby, and
reduced power. Arctic temperatures, extremely high
temperatures, corrosive environments, or extremely
dusty conditions contribute to premature wear and
the need for an overhaul.
The following factors are important when a decision

is being made on the proper time for an engine
overhaul:
• The need for preventive maintenance

• The quality of the fuel that is being used
Illustration 106
g00422322 • The operating conditions
(1) Magnetic pickup. (2) Flywheel housing.
• The results of the S·O·S analysis
Oil Consumption as an Overhaul

Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage

of the rated engine load. As the percentage of the
Illustration 107
g00293337 engine load is increased, the amount of oil that is
consumed per hour also increases.
Typical magnetic pickup
168 SEBU7828-10
Maintenance Section
Overhaul Considerations
The oil consumption rate (brake specific oil Note: Overhaul programs vary according to the
consumption) is measured in grams per kW/h (lb per engine application and according to the dealer that
bhp). The brake specific oil consumption (BSOC) performs the overhaul. Consult your Caterpillar
depends on the engine load. Consult your Caterpillar dealer for specific information about the available
dealer for assistance in determining the typical oil overhaul programs and about overhaul services for
consumption rate for your engine. extending the engine life.
When an engine's oil consumption has risen to three If an overhaul is performed without overhaul service
times the original oil consumption rate due to normal from your Caterpillar dealer, be aware of the following
wear, an engine overhaul should be scheduled. maintenance recommendations.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption. Rebuild or Exchange
Overhaul Options Cylinder Head Assembly, Cylinder Packs, Oil
Pump, and Fuel Transfer Pump
Before Failure Overhaul
These components should be inspected according to
A planned overhaul before failure may be the best the instructions that are found in various Caterpillar
value for the following reasons: reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
• Costly unplanned downtime can be avoided. needed for inspecting the engine parts.
• Many original parts can be reused according to the If the parts comply with the established inspection
standards for reusable parts. specifications that are expressed in the reusable
parts guideline, the parts should be reused.
• The engine's service life can be extended without
the risk of a major catastrophe due to engine Parts that are not within the established inspection
failure. specifications should be dealt with in one of the
following manners:
• The best cost/value relationship per hour of
extended life can be attained. • Salvaging
After Failure Overhaul • Repairing
If a major engine failure occurs and the engine • Replacing
must be removed, many options are available. An
overhaul should be performed if the engine block or Using out-of-spec parts can result in the following
the crankshaft needs to be repaired. problems:
If the engine block is repairable and/or the crankshaft • Unscheduled downtime

is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine • Costly repairs
with a similar exchange core.
• Damage to other engine parts
This lower cost can be attributed to three aspects:
• Reduced engine efficiency
• Specially designed Caterpillar engine features
• Increased fuel consumption
• Caterpillar dealer exchange components
Reduced engine efficiency and increased fuel
• Caterpillar Inc. remanufactured exchange consumption translates into higher operating costs.
components Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
Overhaul Recommendation
Inspection and/or Replacement
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar Crankshaft Bearings, Valve Rotators, and
dealer before the engine fails. This will provide you Crankshaft Seals
with the best cost/value relationship.
The following components may not last until the
second overhaul.
SEBU7828-10 169
Maintenance Section
Overhaul Considerations
• Thrust bearings
NOTICE
• Main bearings Do not use caustic cleaners to clean the core.
• Rod bearings Caustic cleaners can attack the internal metals of the
core and cause leakage.
• Valve rotators
• Crankshaft seals Note: Use this cleaning procedure to clean the oil
cooler core.
Caterpillar Inc. recommends the installation of new
parts at each overhaul period. 1. Remove the oil cooler core.
Inspect these parts while the engine is disassembled 2. Remove any debris from the oil cooler core. To
for an overhaul. remove debris from the oil cooler core, turn the oil
cooler core onto one end.
Inspect the crankshaft for any of the following
conditions: 3. Flush the oil cooler core internally with cleaner in
order to loosen foreign substances. This will also
• Deflection help to remove oil from the oil cooler core.
• Damage to the journals Note: Caterpillar Inc. recommends the use of

Hydrosolv Liquid Cleaners. Table 31 lists the
• Bearing material that has seized to the journals Hydrosolv Liquid Cleaners that are available from
your Caterpillar dealer.
Check the journal taper and the profile of the
Table 31
crankshaft journals. Check these components by
interpreting the wear patterns on the following HydrosolvLiquid Cleaners
components:
Part
Description Size
Number
• Rod bearing
1U-8812 4 L (1 US gallon)
• Main bearings 1U-5490 Hydrosolv4165 19 L (5 US gallon)
Inspect the camshaft for damage to the journals and 8T-7570 208 L (55 US gallon)
to the lobes. 1U-8804 4 L (1 US gallon)
Note: If the camshaft is removed for any reason, use 1U-5492 Hydrosolv100 19 L (5 US gallon)
the magnetic particle inspection process to check for 8T-5571 208 L (55 US gallon)
cracks in the camshaft.
Inspect the following components for signs of wear or 4. Use steam to clean the oil cooler core. This
for signs of scuffing: removes any remaining residue from the cleaner.
Flush the fins of the oil cooler core. Remove any
• Camshaft bearings other trapped debris.
• Camshaft followers 5. Wash the oil cooler core with hot, soapy water.
Rinse the oil cooler core thoroughly with clean
Caterpillar Inc. recommends replacing the crankshaft water.
vibration damper.
Oil Cooler Core

Personal injury can result from air pressure.
During an overhaul, Caterpillar Inc. recommends the
removal of the oil cooler core. Clean the oil cooler Personal injury can result without following prop-
core. Then, pressure test the oil cooler core. er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
170 SEBU7828-10
Maintenance Section
Power Factor - Check
6. Dry the oil cooler core with compressed air. Direct i01191656
the air in the reverse direction of the normal flow.
Power Factor - Check
7. Inspect the components in order to ensure
cleanliness. The oil cooler core should be SMCS Code: 4450-535-PWR
pressure tested. Repair the oil cooler core, if
necessary. Install the oil cooler core. The power factor of a system can be determined by
a power factor meter or by calculations. The power
For more information about cleaning the cores, factor can be calculated by dividing kW by kVA.
consult your Caterpillar dealer. Power factor is expressed as a decimal.
Obtain Coolant Analysis i04020194
The concentration of supplemental coolant additive Radiator - Clean

(SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level 1). Further SMCS Code: 1353-070
coolant analysis is recommended when the engine
is overhauled. Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
For example, considerable deposits are found in the
water jacket areas on the external cooling system, but Inspect the radiator for these items: damaged fins,
the concentrations of coolant additives were carefully corrosion, dirt, grease, insects, leaves, oil, and other
maintained. The coolant water probably contained debris. Clean the radiator, if necessary.
minerals that were deposited on the engine over time.
A coolant analysis can be conducted in order to verify

the condition of the water that is being used in the Personal injury can result from air pressure.
cooling system. A full water analysis can be obtained
by consulting your local water utility company or Personal injury can result without following prop-
an agricultural agent. Private laboratories are also er procedure. When using pressure air, wear a pro-
available for water analysis. tective face shield and protective clothing.
Caterpillar Inc. recommends an S·O·S Coolant The maximum air pressure for cleaning purposes
Analysis (Level 2). must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
S·O·S Coolant Analysis (Level 2)
An S·O·S Coolant Analysis (Level 2) is a Pressurized air is the preferred method for removing
comprehensive coolant analysis which completely loose debris. Direct the air in the opposite direction
analyzes the coolant and the effects on the cooling of the air flow. Hold the nozzle approximately 6 mm
system. An S·O·S Coolant Analysis (Level 2) provides (0.25 inch) away from the fins. Slowly move the air
the following information: nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between
• Complete S·O·S Coolant Analysis (Level 1) the tubes.
• Visual inspection of properties Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
• Identification of metal corrosion must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
• Identification of contaminants both sides.
• Identification of built up impurities (corrosion and Use a degreaser and steam for removal of oil and
scale) grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
S·O·S Coolant Analysis (Level 2) provides a report of core with clean water.
the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see

your Caterpillar dealer.
SEBU7828-10 171
Maintenance Section
Rotating Rectifier - Check
After cleaning, start the engine and accelerate the 1. Stop the generator set. Disconnect the wires for
engine to high idle rpm. This procedure will help in the AVR and isolate the wires for the AVR.
the removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order to 2. Make an assembly for separate excitation. The
inspect the core for cleanliness. Repeat the cleaning, assembly can use a 12 volt battery or a variable
if necessary. DC power supply as a power source. Refer to
Step 3 for an assembly that uses a 12 Volt battery.
Inspect the fins for damage. Bent fins may be opened Refer to Step 4 for an assembly that uses a
with a “comb”. Inspect these items for good condition: variable DC power supply.
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
i01880286
Rotating Rectifier - Check

SMCS Code: 4465-535
The high voltage that is produced by an operating

Before performing any maintenance or repairs,
ensure that the generator will not start. Illustration 108
g01015807
(A) Exciter Field

Place the engine control switch in the “OFF” posi- (B) Diode (1 Amp)
tion. Attach “DO NOT OPERATE” tags to all start- (C) Rheostat (50 Ohms 300 Watts)
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and 3. Connect a 12 volt battery in series with a rheostat
automatic transfer switches that are associated (C) of “50 Ohms 300 Watts” and a diode (B) on
with the generator. both wires for the exciter field (5+ and 6-). Go to
step 5.
Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
refer to Maintenance Procedure, “Rotating Rectifier -
Test”.
i01936391
Rotating Rectifier - Test

SMCS Code: 4465-081
The high voltage that is produced by an operating g01015808

Illustration 109
Before performing any maintenance or repairs, (D) AC supply
(E) Variable power supply
ensure that the generator will not start. (F) Exciter field
(G) Diode bridge
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start- 4. Connect a variable power supply and a diode
ing controls. Disconnect the batteries or disable bridge to both of the wires for the exciter field (5+)
the starting system. Lock out all switchgear and and (6-).
automatic transfer switches that are associated
with the generator. 5. The assembly should have characteristics that are
compatible with the power for the field excitation
Use the following procedure in order to test the of the generator.
rotating rectifier.
172 SEBU7828-10
Maintenance Section
Severe Service Application - Check
6. Operate the generator set at rated speed. • Operation with inlet air which has a combustible
content
7. Gradually increase the current of the exciter field
by adjusting the rheostat or the variable power • Operation which is outside of the intended
supply. Measure the output voltage and the application
current at no load. Measure the output voltage
and measure the current at no load. • Operation with a plugged fuel filter
8. The generator is operating properly when the • Extended operation at low idle (more than 20% of
output voltage is at the rated value and the output hours)
voltage is balanced within one percent for the
rated level of excitation. • Frequent cold starts at temperatures below 0° C
(32° F)
i03937573
• Frequent dry starts (starting after more than 72
Severe Service Application - hours of shutdown)
Check • Frequent hot shutdowns (shutting down the engine

without the minimum of 2 minutes to 5 minutes of
SMCS Code: 1000-535 cool down time)
An engine which operates outside of normal • Operation above the engine rated speed
conditions is operating in a severe service
application. • Operation below the peak torque speed
An engine that operates in a severe service • Operating with fuel which does not meet
application may need more frequent maintenance the standards for distillate diesel fuel as
intervals in order to maximize the following conditions: stated in Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engine Fluids
• Reliability Recommendations”, “Distillate Diesel Fuel”
• Service life • Operating with fuel which contains greater than

1000 ppm (0.1%) sulfur
The number of individual applications cause the
impossibility of identifying all of the factors which may • Operating with a blend of distillate fuel which
contribute to severe service operation. Consult your contains more than 5 percent biodiesel
Caterpillar dealer for the unique maintenance that
may be necessary for your engine.
Improper Maintenance Procedures
An application is a severe service application if any (Maintenance Procedures Which
of the following conditions apply:
May Contribute to a Severe Service
Severe Environmental Factors Application)
• Inadequate maintenance of fuel storage tanks from
• Frequent operation in dirty air causes such as excessive water, sediment, and
microorganism growth.
• Frequent operation at an altitude which is above
1525 m (5000 ft)
• Extending maintenance intervals beyond the
recommended intervals
• Frequent operation in ambient temperatures which
are above 32° C (90° F)
• Using fluids which are not recommended in Special
Publication, SEBU6251, “Caterpillar Commercial
• Frequent operation in ambient temperatures which Diesel Engine Fluids Recommendations”
are below 0° C (32° F)
• Extending maintenance intervals for changing
Severe Operating Conditions the engine oil and engine coolant without S·O·S
validation
• Frequent operation with inlet air which has a
corrosive content • Extending maintenance intervals for changing air
filters, oil filters, and fuel filters
SEBU7828-10 173
Maintenance Section
Space Heater - Check
• Failure to use a water separator i03108463
• Using filters which are not recommended by Standby Generator

Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”
Set Maintenance
Recommendations
• Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage, SMCS Code: 4450-041
refer to Special Publication, SEHS9031, “Storage
Procedure for Caterpillar Products”) A standby generator set may not need to be used
very often. However, the generator set is usually
• Storing the engine for 1 yr to 2 years (For needed for operation in an emergency situation.
information about engine storage, refer to Special Maintenance of the standby generator set is very
Instruction, SEHS5001, “The Long Term Storage important for the following reasons:
and Recovery of Certain Commercial Engines”)
• The generator set must always be in excellent
operating condition.
i02501318
Space Heater - Check • The generator set must be ready to work under
load at any time.
SMCS Code: 4450-535-HTR Establishing a Preventive Maintenance Program will
provide these benefits:
A Caterpillar generator is capable of operating in
high humidity conditions without problems. However,
problems can occur when the generator is idle and • Maximum availability of the standby generator set
the surrounding air is warmer than the generator.
Moisture can form on the windings that will result in • Longer service life for the generator set
poor performance from the windings. Moisture can
also result in damage to the windings. Whenever the
• Minimum of expensive repairs
generator is not active, ensure that the space heaters Your Caterpillar dealer can help you to establish an
are in operation. effective Preventive Maintenance Program for your
Table 32
generator set. Consult your Caterpillar dealer for
details.
Tools Needed
Part Number Part Quantity Maintenance and Operation
237-5130
Digital
1 Procedures
Multimeter
1. Stop the generator set.

The high voltage that is produced by an operating
2. Remove the panels in order to allow access to generator set can cause severe injury or death.
the regulator and control terminal strips. Locate Before performing any maintenance or repairs,
terminal strip “TS1”. ensure that the generator will not start.
3. For 240 V systems, use the multimeter to measure Place the engine control switch in the “OFF” posi-
the voltage between terminal “H1” and terminal tion. Attach “DO NOT OPERATE” tags to all start-
“H4”. If voltage is not present, disconnect the ing controls. Disconnect the batteries or disable
power source to terminal “H1” and terminal “H4”, the starting system. Lock out all switchgear and
and check for 3 to 12 ohms resistance. If there is automatic transfer switches that are associated
no resistance, check the generator service manual with the generator.
for further information. For 120 V systems, use
the multimeter to measure the voltage between
terminal “H1” and terminal “H2”. If voltage is not The recommended maintenance for the generator set
present, disconnect the power source to terminal is listed in this Operation and Maintenance Manual,
“H1”, terminal “H2”, terminal “H3”, and terminal “Maintenance Interval Schedule (Standby Generator
“H4”, and check for 3 to 12 ohms resistance. If Sets)” (Maintenance Section).
there is no resistance, check the generator service
manual for further information.
174 SEBU7828-10
Maintenance Section
Starting Motor - Inspect
Maintenance and Repair i00651416
The maintenance that is recommended for Every Starting Motor - Inspect

Week can be performed by an authorized operator.
The maintenance that is recommended for the SMCS Code: 1451-040; 1453-040
subsequent maintenance intervals must be
performed by an authorized service technician or by Caterpillar Inc. recommends a scheduled inspection
your Caterpillar dealer. of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Unless other instructions are provided, perform
maintenance and repairs under the following Check the starting motor for proper operation. Check
conditions: the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
• The engine is stopped. information on the checking procedure and for
specifications or consult your Caterpillar dealer for
• The starting system is disabled. assistance.
• The generator does not pose an electrical shock i03230840

hazard.
Stator Lead - Check
• The generator is disconnected from the load.
SMCS Code: 4459-535
Operation
Ensure that the stator output leads are routed out of
To ensure proper operation, the generator set must be the generator in a manner that prevents the leads
exercised regularly. For instructions on operating the from rubbing against metal objects.
generator set, see the Operation and Maintenance
Manual for the generator set control panel. Visually inspect the following areas for cracking and
physical damage:
For these operation procedures, follow the
instructions that are provided in this Operation and • stator output leads
Maintenance Manual, “Operation Section”: starting
the engine, engine operation, and stopping the • protective sleeving
engine.
• insulation
Record Keeping
i03086301
Maintain a record in order to document these items:
gauge readings, maintenance that is performed, Stator Winding Temperature -
problems, and repairs. Measure/Record
Space Heaters SMCS Code: 4453-082-TA
Moisture causes damage to generators and other Some generators are equipped with optional 100
electrical equipment. Make every effort to keep the Ohm Resistance Temperature Detectors(RTD) that
generator set as dry as possible. are mounted in slots of the main stator. When the
generator set is equipped with RTD modules that
Generators can operate without problems in humid are interfaced to an EMCP 3.2 or EMCP 3.3, the
environments. However, problems can occur when RTD modules can be interfaced in order to measure
the generator is inactive. Moisture can condense on the temperature of the stator. Alternately, there are
the windings. This can result in poor performance. measuring devices in the open market that can be
Also, damage to the windings can occur. interfaced with the RTD. Caterpillar recommends the
continuous monitoring of the RTD.
Use space heaters in order to help keep the windings
dry. When the generator is not active, ensure that the Refer to the specifications in table 33 for the
space heaters are operating. When the generator is maximum temperatures of the setpoints.
operating, turn OFF the space heaters.
SEBU7828-10 175
Maintenance Section
Turbocharger - Inspect
Table 33 Note: Turbocharger components require precision

Maximum Recommended Temperatures
clearances. The turbocharger cartridge must
for the Setpoint(1) be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Generator set Severe Service Applications require more frequent
Alarm Shutdown
application inspections of the cartridge.
Standby 180 °C 190 °C
(356 °F) (374 °F) Removal and Installation
Continuous 155 °C 165 °C
(311 °F) (329 °F) For options regarding the removal, installation, repair
(1)
and replacement, consult your Caterpillar dealer.
If the trend of the operating temperature of the main stator
is measured and the temperature is much lower than the Refer to the Service Manual for this engine for the
recommended setpoints, adjust the alarm setpoint and the procedure and specifications.
shutdown setpoint to a lower value in order to ensure that
unusual temperature variances are recognized promptly.
Cleaning and Inspecting
i01539769 1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
Turbocharger - Inspect inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt
SMCS Code: 1052-040; 1052 from entering during reassembly.
Periodic inspection and cleaning is recommended 2. Turn the compressor wheel and the turbine wheel
for the turbocharger compressor housing (inlet side). by hand. The assembly should turn freely. Inspect
Any fumes from the crankcase are filtered through the compressor wheel and the turbine wheel for
the air inlet system. Therefore, by-products from oil contact with the turbocharger housing. There
and from combustion can collect in the turbocharger should not be any visible signs of contact between
compressor housing. Over time, this buildup can the turbine wheel or compressor wheel and the
contribute to loss of engine power, increased black turbocharger housing. If there is any indication of
smoke and overall loss of engine efficiency. contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
If the turbocharger fails during engine operation, the turbocharger must be reconditioned.
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the 3. Check the compressor wheel for cleanliness.
turbocharger compressor wheel can cause additional If only the blade side of the wheel is dirty, dirt
damage to the pistons, the valves, and the cylinder and/or moisture is passing through the air filtering
head. system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
NOTICE oil seal.
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems. The presence of oil may be the result of extended
Loss of engine lubricant can result in serious engine engine operation at low idle. The presence of oil
damage. may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
Minor leakage of a turbocharger housing under ex- turbocharger to slobber.
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc- 4. Use a dial indicator to check the end clearance
curred. on the shaft. If the measured end play is greater
than the Service Manual specifications, the
When a turbocharger bearing failure is accompanied turbocharger should be repaired or replaced.
by a significant engine performance loss (exhaust An end play measurement that is less than the
smoke or engine rpm up at no load), do not continue minimum Service Manual specifications could
engine operation until the turbocharger is repaired or indicate carbon buildup on the turbine wheel. The
replaced. turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
5. Inspect the bore of the turbine housing for
turbocharger can also reduce the chance for potential
corrosion.
damage to other engine parts.
176 SEBU7828-10
Maintenance Section
Varistor - Check
6. Clean the turbocharger housing with standard For maximum engine service life, make a thorough
shop solvents and a soft bristle brush. inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
7. Fasten the air inlet piping and the exhaust outlet leaks, loose bolts, worn belts, loose connections and
piping to the turbocharger housing. trash buildup. Make repairs, as needed:
• The guards must be in the proper place. Repair

i03291822
damaged guards or replace missing guards.
Varistor - Check
• Wipe all caps and plugs before the engine is
SMCS Code: 4466-535 serviced in order to reduce the chance of system
contamination.
The varistor must be checked at regular intervals.
Refer to Systems Operation/Testing and Adjusting, NOTICE
KENR5284, “Varistor - Test” for instructions. For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
i03291802 more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
Varistor - Inspect unwarranted.
SMCS Code: 4466-040
NOTICE
The varistor must be visually inspected at regular Accumulated grease and/or oil on an engine or deck is
intervals. For generator sets with 1400 or with a fire hazard. Remove this debris with steam cleaning
1600 frames, discoloration of the varistor indicates or high pressure water.
that replacement of the varistor is necessary. For
generator sets with 1800 frames, physical signs of
failure indicate that replacement of the varistor is • Ensure that cooling lines are properly clamped.
necessary. Check for leaks. Check the condition of all pipes.
• Inspect the water pump for coolant leaks.

i01491868
Note: The water pump seal is lubricated by coolant
Voltage and Frequency - Check in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
SMCS Code: 4450-535-EL the parts contract.
Check for the proper voltage setting and check for Excessive coolant leakage may indicate the need
the proper frequency setting. Check for stability. to replace the water pump seal. For the removal of
water pump and the installation of water pump and/or
For the correct voltage and frequency, refer to the seals, refer to the Service Manual for the engine or
generator set's Serial Plate. consult your Caterpillar dealer.
i01908686 • Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil
Walk-Around Inspection pan, the oil filters and the valve cover.
SMCS Code: 1000-040 • Inspect the fuel system for leaks. Look for loose
fuel line clamps.
Inspect the Engine for Leaks and
• Inspect the piping for the air inlet system and the
for Loose Connections elbows for cracks and for loose clamps.
A walk-around inspection should only take a few • Inspect the alternator belt and the accessory drive
minutes. When the time is taken to perform these belts for cracks, breaks or other damage.
checks, costly repairs and accidents can be avoided.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
SEBU7828-10 177
Maintenance Section
Water Pump - Inspect
• Drain the water and the sediment from fuel tanks Cracking – Cracking of insulation may result from
on a daily basis in order to ensure that only clean mechanical stress. The structure that is used to brace
fuel enters the fuel system. the stator winding will become loose if the problem
is not corrected. Further mechanical damage or
• Inspect the wiring and the wiring harnesses for electrical damage may also result.
loose connections and for worn wires or frayed
wires. Erosion – Erosion can be caused when foreign
substances rub against the surfaces of the insulation.
• Inspect the ground strap for a good connection and
for good condition.
i03543200
• Inspect the engine-to-frame ground strap for a

good connection and for good condition.
Water Pump - Inspect
SMCS Code: 1361-040; 1361
• Disconnect any battery chargers that are not
protected against the current drain of the starting A failed water pump might cause severe engine
motor. Check the condition and the electrolyte level overheating problems that could result in the following
of the batteries, unless the engine is equipped with conditions:
a maintenance free battery.
• Cracks in the cylinder head
• Check the condition of the gauges. Replace any
gauges which are cracked or replace any gauges
that can not be calibrated.
• A piston seizure
• Other potential damage to the engine
Inspect the Insulation
A failed water pump might cause severe engine
A visual inspection should be initially directed at overheating problems that could result in cracks in
the areas that are most prone to damage and the cylinder head, a piston seizure or other potential
deterioration. The most prone areas to damage and damage to the engine.
deterioration are listed below:
Visually inspect the water pump for leaks. If leaking
• Ground Insulation. Ground insulation is insulation of the water pump seals is observed, replace all of
that is intended to isolate components that are the water pump seals. Refer to two articles in the
carrying current from components that are not Disassembly and Assembly Manual, “Water Pump
carrying current. - Disassemble and Water Pump - Assemble” for
the disassembly and assembly procedure. If it is
• Support Insulation. Support insulation is necessary to remove the water pump, refer to two
usually made from one of the following items: articles in the Disassembly and Assembly Manual,
a compressed lamination of fibrous materials, “Water Pump - Remove and Water Pump - Install”.
polyester, or felt pads that have been impregnated
with various types of bonding agents. Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Parts Manual
There are many different types of damage that can for the correct part numbers for your engine or
occur in these areas. Several of the different types of consult your Caterpillar dealer if repair is needed or
damage are listed below: replacement is needed.
Thermal Aging – Thermal aging can cause the

degradation of insulation or the deterioration of
insulation. An examination of the coils may reveal
that the insulation has expanded into the ventilation
ducts. This is the result of a loss of bond which
will cause the insulation material to separate. The
insulation material could also separate from the
conductors on the windings.
Abrasion – The surfaces of coils and the surfaces

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

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What maintenance is required daily?

What maintenance is required daily?

What should be inspected weekly?

What should be inspected weekly?

MAINTENANCE INTERVALS

Operation and Maintenance

i04002881 Walk-Around Inspection ...................................... 176

Note: Use whichever of the following that occurs Every Year

When Required Turbocharger - Inspect ........................................ 175

Every 19 000 L (5000 US gal) of Fuel or 500

Every 28 400 L (7500 US gal) of Fuel or 1000

Every 114 000 L (30 000 US gal) of Fuel or

Every 114 000 L (30 000 US gal) of Fuel or

Every 190 000 L (50 000 US gal) of Fuel or

Every 228 000 L (60 000 US gal) of Fuel or 12

i04002886 Standby Generator Set Maintenance

SMCS Code: 1000; 7500 Every 6 Months

Every 190 000 L (50 000 US gal) of Fuel or

i01546702 7. Inspect the core in order to ensure cleanliness.

4. Steam clean the core in order to remove any i01148030

• Inlet Air Restriction

Record the Performance of the

Records of engine performance are an important

The data on engine performance can help to predict

Engine Serial Number

Inlet Air Restriction

Engine Coolant Temperature

Engine Oil Temperature

Engine Oil Pressure

System Battery Voltage

Exhaust Manifold Temperature

i01942284 • The control switches are in the correct position for

• The starting system is enabled.

i02039199 4. The POSITIVE “+” cable connects the POSITIVE

1. Ensure that the charger is turned OFF.

2. Adjust the voltage of the charger in order to match Table 26

different types of batteries. Battery Electrolyte Level -

When the engine is not run for long periods of time or

All lead-acid batteries contain sulfuric acid which

1. Remove the filler caps. Maintain the electrolyte

If the addition of water is necessary, use distilled

2. Check the condition of the electrolyte with the i02200198

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the

Battery or Battery Cable -

Pressurized System: Hot coolant can cause seri-

SMCS Code: 1350-070; 1395-044

• The engine overheats frequently.

Outside Illinois: 1-800-542-TOOL Cooling Systems with Heavy

4. Clean the cooling system filler cap. Inspect the

• The engine overheats frequently. Flush

3. Check the coolant level. Maintain the coolant level

Cooling System Coolant Level

Remove cooling system pressure cap slowly to

Do not attempt to tighten hose connections when

Cooling System Coolant Additive contains alkali.

3. Add Cat ELC Extender according to the

4. Clean the cooling system filler cap. Inspect the