Sebu9048 09 00 - Manuals Operation Maintenance

SEBU9048-09 (en-us)
September 2018
Operation and
Maintenance
Manual
C18 Marine Engine
DTP 1-UP (Generator Set)
PUBLICATIONS.CAT.COM
i06558969
Important Safety Information

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

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

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU9048-09 3
Table of Contents
Table of Contents Engine Stopping .............................................. 64
Foreword ........................................................... 4 Maintenance Section
Refill Capacities............................................... 66
Safety Section
Maintenance Recommendations .................... 74
Safety Messages............................................... 6
Maintenance Interval Schedule....................... 79
Additional Messages ........................................11
General Hazard Information............................ 13 Warranty Section
Burn Prevention............................................... 16 Warranty Information..................................... 143
Fire Prevention and Explosion Prevention...... 17 Reference Information Section
Crushing Prevention and Cutting Prevention.. 19 Engine Ratings .............................................. 144
Mounting and Dismounting ............................. 19 Engine Performance and Performance Analysis

Report (PAR) ............................................... 146
Before Starting Engine .................................... 19
Customer Service.......................................... 147
Engine Starting................................................ 20
Reference Materials ...................................... 150
Engine Stopping .............................................. 20
Index Section
Electrical System............................................. 20
Index.............................................................. 153
Engine Electronics........................................... 23
Generator Isolating for Maintenance............... 23
Product Information Section
General Information ........................................ 25
Product Identification Information ................... 31
Operation Section
Lifting and Storage .......................................... 33
Features and Controls..................................... 37
Engine Starting................................................ 44
Engine Operation ............................................ 48
Generator Operation ....................................... 49
Cold Weather Operation ................................. 60

4 SEBU9048-09
Foreword
Foreword Some photographs or illustrations in this manual

show details or attachments that may be different
from your engine. Guards and covers may have been
California Proposition 65 Warning removed for illustrative purposes. Continuing
improvement and advancement of product design
Diesel engine exhaust and some of its may have caused changes to your engine which are
not included in this manual Whenever a question
constituents are known to the State of arises regarding your engine, or this manual, please
California to cause cancer, birth defects, consult with your Cat dealer for the latest available
and other reproductive harm. information.
WARNING – This product can Safety

expose you to chemicals
including ethylene glycol, which This safety section lists basic safety precautions. In
is known to the State of California to addition, this section identifies hazardous, warning
cause birth defects or other reproductive situations. Read and understand the basic
harm. For more information go to: precautions listed in the safety section before
operating or performing lubrication, maintenance,
and repair on this product.
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands Operation
after handling to avoid incidental Operating techniques outlined in this manual are
ingestion. basic. They assist with developing the skills and
techniques required to operate the engine more
WARNING – This product can efficiently and economically. Skill and techniques
expose you to chemicals develop as the operator gains knowledge of the
including lead and lead engine and its capabilities.
compounds, which are known to the
The operation section is a reference for operators.
State of California to cause cancer, birth Photographs and illustrations guide the operator
defects, or other reproductive harm. For through procedures of inspecting, starting, operating,
more information go to: and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
www.P65Warnings.ca.gov
Maintenance
Wash hands after handling components
that may contain lead. The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
Literature Information by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
This manual contains safety, operation instructions, follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Use fuel consumption or service hours to determine
a literature holder or literature storage area. Read, intervals. Calendar intervals shown (daily, annually,
study, and keep it with the literature and engine etc.) may be used instead of service meter intervals if
information. they provide more convenient schedules and
approximate the indicated service meter reading.
English is the primary language for all Cat
publications. The English used facilitates translation Recommended service should be performed at the
and consistency in electronic media delivery. appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
freezing cold operating conditions, more frequent
lubrication, and maintenance than is specified in the
Maintenance Interval Schedule may be necessary.
SEBU9048-09 5
Foreword
The maintenance schedule items are organized for a

preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are accepted as proof of
maintenance or repair. Your authorized Cat dealer
can assist you in adjusting your maintenance
schedule to meet the needs of your operating
environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available
from your Cat dealer. Consult with your dealer for
information regarding these options.
6 SEBU9048-09
Safety Section
Safety Messages
Safety Section
i05608629
Safety Messages
SMCS Code: 1000; 7405
There may be several specific warning signs on an
engine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Become familiar with all warning signs.
Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if the
words cannot be read or if the pictures are not visible.
When the warning signs are cleaned, use a cloth,
water, and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the warning signs.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the warning signs. The
warning signs that are loosened could drop off the
engine.
Replace any damaged warning signs or missing
warning signs. If a warning sign is attached to a part
of the engine that is replaced, install a new warning
sign on the replacement part. Any Cat dealer can
provide new warning signs.
The warning labels that may be found on the engine
are illustrated and described below.
Illustration 1 g03185276
View of the right side of a Cat C18 Marine Generator Set
SEBU9048-09 7
Safety Section
Safety Messages
View of the left side of a Cat C18 Marine Generator Set
View of the rear of a Cat C18 Marine Generator Set
8 SEBU9048-09
Safety Section
Safety Messages
Universal Warning (1)

One safety message is located on each side of the
terminal box. One safety message is located on the
valve cover base on each side of the engine.
SEBU9048-09 9
Safety Section
Safety Messages
Do not operate or work on this product unless

you have read and understand the instructions
and warnings in the Operation and Maintenance Illustration 6 g01384734
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement man-
uals. Proper care is your responsibility.
Hot parts or hot components can cause burns or
personal injury. Do not allow hot parts or compo-
Hot Surface (2) nents to contact your skin. Use protective cloth-
ing or protective equipment to protect your skin.
One message is located on each side of the barrel of
the generator. This message is also located on the
left and right side of the radiator. Hot Fluid Under Pressure (3)
One message is located on each expansion tank.
The message is also located on top of the radiator
expansion tanks near the cap.
10 SEBU9048-09
Safety Section
Safety Messages
Pressurized system! Hot coolant can cause seri-

ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until Illustration 8 g01433231
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order
to relieve the pressure. Read and understand the
Operation and Maintenance Manual before per-
forming any cooling system maintenance. Crushing Hazard! Improper lifting could cause
serious injury or death. Follow the lifting instruc-
tions in the Operation and Maintenance Manual
Lifting the Genset (4) for safe lifting procedures.
This safety message for lifting the genset is located

on the side panels of the terminal box. Automatic Starting (5)
The safety message for automatic starting is located
on the sides of the terminal box.
SEBU9048-09 11
Safety Section
Additional Messages
Illustration 9 g01392484 Illustration 10 g01372247
When the engine is in the AUTOMATIC mode, the WARNING! Shock/Electrocution Hazard! Read
engine can start at any moment. To avoid person- and understand the instructions and warnings in
al injury, always remain clear of the the engine the Operation and Maintenance Manual. Failure
when the engine is in the AUTOMATIC mode. to follow the instructions or heed the warnings
could cause serious injury or death.
Electrical Shock (6) i06258221
The safety message for electrical shock is located on

the sides of the terminal box and the rear of the Additional Messages
terminal box.
SMCS Code: 1000; 7405
The exact location of the messages and the
description of the messages are reviewed in this
section. Become familiarized with all messages.
Make sure that all of the messages are legible. Clean
the messages or replace the messages if the words
or images are unreadable. When you clean the
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.
Replace any message that is damaged, or missing. If
a message is attached to a part that is replaced,
install a message on the replacement part. Any Cat
dealer can provide new messages.
12 SEBU9048-09
Safety Section
Additional Messages
(1) Coolant Fill (Film is located on the side of (2) Coolant Fill tag
both expansion tanks)
SEBU9048-09 13
Safety Section
General Hazard Information
i06300340

SMCS Code: 1000; 4450; 7405
• Wear a hard hat, protective glasses, and other

protective equipment, as required.
• When work is performed around an engine that is
Illustration 12 g03838041 operating, wear protective devices for ears in
order to help prevent damage to hearing.
Attach a “Do Not Operate” warning tag to the start
switch or controls before the engine is serviced or • Do not wear loose clothing or jewelry that can
repaired. These warning tags (Special Instruction, snag on controls or on other parts of the engine.
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each • Ensure that all protective guards and all covers
operator control station. When appropriate, are secured in place on the engine.
disconnect the starting controls.
• Never put maintenance fluids into glass
Do not allow unauthorized personnel on the engine, containers. Glass containers can break.
or around the engine when the engine is being
serviced. • Use all cleaning solutions with care.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids, • Report all necessary repairs.
hold a rag over the part that is being removed. Unless other instructions are provided, perform
• Filler caps the maintenance under the following conditions:
• Grease fittings • The engine is stopped. Ensure that the engine

cannot be started.
• Pressure taps
• The protective locks or the controls are in the
• Breathers applied position.
• Drain plugs • Disconnect the batteries when maintenance is

performed or when the electrical system is
Use caution when cover plates are removed. serviced. Disconnect the battery ground leads.
Gradually loosen, but do not remove the last two Tape the leads in order to help prevent sparks.
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last • When starting a new engine, make provisions to
two bolts or nuts, pry the cover loose in order to stop the engine if an overspeed occurs. If an
relieve any spring pressure or other pressure. engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
14 SEBU9048-09
Safety Section
• Start the engine with the operator controls. Never Avoid direct spraying of water on electrical
short across the starting motor terminals or the connectors, connections, and components. When
batteries. This method of starting the engine could using air for cleaning, allow the machine to cool to
bypass the engine neutral start system and/or the reduce the possibility of fine debris igniting when
electrical system could be damaged. redeposited on hot surfaces.
Pressurized Air and Water Fluid Penetration

Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield. Always wear eye
protection for cleaning the cooling system.
Always use a board or cardboard when you check for

a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
SEBU9048-09 15
Safety Section
Static Electricity Hazard when Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct
Fueling with Ultra-low Sulfur Diesel installation of these components will help to prevent
Fuel these effects: vibration, rubbing against other parts
and excessive heat during operation.
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the Inhalation
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater Exhaust
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death Use caution. Exhaust fumes can be hazardous to
or serious injury from fire or explosion. Consult your health. If you operate the equipment in an
with your fuel or fuel system supplier to ensure enclosed area, adequate ventilation is necessary.
the delivery system is in compliance with fueling
standards for proper grounding and bonding Asbestos Information
practices.
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Lines, Tubes, and Hoses Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
Do not bend or strike high-pressure lines. Do not you handle any replacement parts that contain
install lines, tubes, or hoses that are damaged. asbestos or when you handle asbestos debris.
Repair any fuel lines, oil lines, tubes, or hoses that Use caution. Avoid inhaling dust that might be
are loose or damaged. Leaks can cause fires. generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
Inspect all lines, tubes, and hoses carefully. Do not to your health. The components that may contain
use bare hands to check for leaks. Always use a asbestos fibers are brake pads, brake bands, lining
board or cardboard for checking engine components material, clutch plates, and some gaskets. The
for leaks. Tighten all connections to the asbestos that is used in these components is bound
recommended torque. in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
Check for the following conditions: asbestos is generated.
• End fittings that are damaged or leaking If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Outer covering that is chafed or cut
• Never use compressed air for cleaning.
• Wire that is exposed in reinforced hose
• Avoid brushing materials that contain asbestos.
• Outer covering that is ballooning locally
• Avoid grinding materials that contain asbestos.
• Flexible part of the hose that is kinked or crushed
• Use a wet method in order to clean up asbestos
• Armoring that is embedded in the outer covering materials.
16 SEBU9048-09
Safety Section
Burn Prevention
• A vacuum cleaner that is equipped with a high Reference: The applicable material safety data
efficiency particulate air filter (HEPA) can also be sheets can be found at the following web site by
used. searching using part number or the name:
• Use exhaust ventilation on permanent machining https://catmsds.cat.com/MSDSSearch/servlet/

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

particles in the air.
Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate Illustration 16 g00706404
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands Improperly disposing of waste can threaten the
thoroughly after handling Softwrap material. Do not environment. Potentially harmful fluids should be
smoke until washing hands thoroughly after handling disposed of according to local regulations.
Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean Always use leakproof containers when you drain
up debris. fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i02088921
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings or
related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
SEBU9048-09 17
Safety Section
Fire Prevention and Explosion Prevention
Check the coolant level after the engine has stopped All fuels, most lubricants, and some coolant mixtures
and the engine has been allowed to cool. Ensure that are flammable.
the filler cap is cool before removing the filler cap.
The filler cap must be cool enough to touch with a Always perform a Walk-Around Inspection, which
bare hand. Remove the filler cap slowly in order to may help you identify a fire hazard. Do not operate a
relieve pressure. product when a fire hazard exists. Contact your
Caterpillar dealer for service.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact Flammable fluids that are leaking or spilled onto hot
the skin, the eyes, or the mouth. surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
damage.
Oils
A flash fire may result if the covers for the engine
Hot oil and hot lubricating components can cause crankcase are removed within 15 minutes after an
personal injury. Do not allow hot oil or hot emergency shutdown.
components to contact the skin.
Determine whether the engine will be operated in an
If the application has a makeup tank, remove the cap environment that allows combustible gases to be
for the makeup tank after the engine has stopped. drawn into the air inlet system. These gases could
The filler cap must be cool to the touch. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Batteries If the application involves the presence of
The liquid in a battery is an electrolyte. Electrolyte is combustible gases, consult your Caterpillar dealer for
an acid that can cause personal injury. Do not allow additional information about suitable protection
electrolyte to contact the skin or the eyes. devices.
Remove all flammable materials such as fuel, oil, and
Do not smoke while checking the battery electrolyte debris from the engine. Do not allow any flammable
levels. Batteries give off flammable fumes which can materials to accumulate on the engine.
explode.
All fluids that are captured in the fluid spill
Always wear protective glasses when you work with containment basin should be cleaned up
batteries. Wash hands after touching batteries. The immediately. Failure to clean up spilled fluids can
use of gloves is recommended. cause a fire. Fire may cause personal injury and
property damage.
i05326156
Store fuels and lubricants in properly marked
Fire Prevention and Explosion containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Prevention containers. Do not smoke in areas that are used for
storing flammable materials.
SMCS Code: 1000; 4450; 7405
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray from a failed line,
tube, or seal. Exhaust shields must be installed
correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route
and securely attach all electrical wires. Check all
electrical wires daily. Repair any wires that are loose
or frayed before you operate the engine. Clean all
electrical connections and tighten all electrical
Illustration 17 g00704000 connections.
Use of personal protection equipment (PPE) may be Eliminate all wiring that is unattached or
needed. unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
18 SEBU9048-09
Safety Section
Fire Prevention and Explosion Prevention
Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Properly install all oil filters and all fuel filters. The
filter housings must be tightened to the proper
torque.
Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. Charging a frozen
Use caution when you are refueling an engine. Do battery may cause an explosion.
not smoke while you are refueling an engine. Do not
The batteries must be kept clean. The covers (if
refuel an engine near open flames or sparks. Always equipped) must be kept on the cells. Use the
stop the engine before refueling. recommended cables, connections, and battery box
Note: Avoid static electricity risk when fueling. Ultra- covers when the engine is operated.
low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formulations
with a higher sulfur content. Avoid death or serious
injury from fire or explosion. Consult your fuel or fuel
system supplier to ensure that the delivery system is
in compliance with fueling standards for proper
grounding and bonding practices.
SEBU9048-09 19
Safety Section
Crushing Prevention and Cutting Prevention
Fire Extinguisher Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
Make sure that a fire extinguisher is available. Be performed. After the maintenance is performed,
familiar with the operation of the fire extinguisher. reinstall the guards.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations Keep objects away from moving fan blades. The fan
on the instruction plate. blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
Ether order to avoid injury to the eyes.
Do not use ether as a starting aid. Refer to this Chips or other debris may fly off objects when objects
Operation and Maintenance Manual, “Starting the are struck. Before objects are struck, ensure that no
Engine” for information about starting the engine. one will be injured by flying debris.
Lines, Tubes, and Hoses i01372247
Do not bend high-pressure lines. Do not strike high- Mounting and Dismounting
pressure lines. Do not install any lines that are bent
or damaged. SMCS Code: 1000; 4450; 7405
Repair any lines that are loose or damaged. Leaks Inspect the steps, the handholds, and the work area
can cause fires. Consult your Caterpillar dealer for before mounting the engine. Keep these items clean
repair or for replacement parts. and keep these items in good repair.
Check lines, tubes, and hoses carefully. Do not use Mount the engine and dismount the engine only at
your bare hand to check for leaks. Use a board or locations that have steps and/or handholds. Do not
cardboard to check for leaks. Tighten all connections climb on the engine, and do not jump off the engine.
to the recommended torque.
Face the engine in order to mount the engine or
Replace the parts if any of the following conditions dismount the engine. Maintain a three-point contact
are present: with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• End fittings are damaged or leaking. controls as handholds.
• Outer coverings are chafed or cut. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Wires are exposed. platform. Secure the climbing equipment so that the
equipment will not move.
• Outer coverings are ballooning.
Do not carry tools or supplies when you mount the
• Portions of the hoses are kinked. engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
• Outer covers have embedded armoring.
i03560601
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
Before Starting Engine
are installed correctly in order to prevent vibration, SMCS Code: 1000
rubbing against other parts, and excessive heat.
NOTICE
i01359666 For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
Crushing Prevention and provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
Cutting Prevention air and/or fuel supply to the engine.
SMCS Code: 1000; 4450; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
20 SEBU9048-09
Safety Section
Engine Starting
To ensure that the jacket water heater (if equipped)

and/or the lube oil heater (if equipped) is working
Engine exhaust contains products of combustion properly, check the water temperature gauge and the
which may be harmful to your health. Always oil temperature gauge during the heater operation.
start and operate the engine in a well ventilated Engine exhaust contains products of combustion that
area and, if in an enclosed area, vent the exhaust can be harmful to your health. Always start the
to the outside.
engine and operate the engine in a ventilated area. If
Inspect the engine for potential hazards. the engine is started in an enclosed area, vent the
engine exhaust to the outside.
Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or similar i01462046
warning tag attached to the start switch or to the
controls. Engine Stopping
Before starting the engine, ensure that no one is on, SMCS Code: 1000
underneath, or close to the engine. Ensure that the
area is free of personnel. Stop the engine according to the procedure in the
Operation and Maintenance Manual, “Engine
If equipped, ensure that the lighting system for the Stopping (Operation Section)” in order to avoid
engine is suitable for the conditions. Ensure that all overheating of the engine and accelerated wear of
lights work properly, if equipped. the engine components.
All protective guards and all protective covers must Use the Emergency Stop Button (if equipped) ONLY
be installed if the engine must be started in order to in an emergency situation. Do not use the
perform service procedures. To help prevent an Emergency Stop Button for normal engine stopping.
accident that is caused by parts in rotation, work After an emergency stop, DO NOT start the engine
around the parts carefully. until the problem that caused the emergency stop
has been corrected.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are Stop the engine if an overspeed condition occurs
provided in order to help prevent personal injury. The during the initial start-up of a new engine or an
circuits are also provided in order to help prevent engine that has been overhauled. This may be
engine damage. accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the
See the Service Manual for repairs and for engine.
adjustments.
To stop an electronically controlled engine, cut the
i03941639 power to the engine.
Engine Starting i06948165
SMCS Code: 1000

Electrical System
If a warning tag is attached to the engine start switch SMCS Code: 1000; 1400
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached Never disconnect any charging unit circuit or battery
the warning tag before the engine is started. circuit cable from the battery when the charging unit
is operating. A spark may cause the combustible
All protective guards and all protective covers must gases that are produced by some batteries to ignite.
be installed if the engine must be started in order to
perform service procedures. To help prevent an Connect the negative jump-start cable last from the
accident that is caused by parts in rotation, work external power source to the negative terminal of the
around the parts carefully. starting motor. This connection sequence helps to
prevent sparks from igniting any combustible gasses
Start the engine with the engine start switch. which batteries may produce. If the starting motor is
not equipped with a negative terminal, connect the
Always start the engine according to the procedure jump-start cable to the engine block.
that is described in this Operation and Maintenance
Manual, “Starting the Engine” for information about Check the electrical wires daily for wires that are
starting the engine. Know the correct procedure to loose or frayed. Tighten all loose electrical wires
prevent major damage to the engine components. before the engine is operated. Repair all frayed
Know the correct procedure to prevent personal electrical wires before the engine is started. See this
injury. Operation and Maintenance Manual, “Engine
Starting” for specific starting instructions.
SEBU9048-09 21
Safety Section
Electrical System
Grounding Practices
Properly ground the electrical system for the vessel
and the engine. Proper grounding is necessary for
optimum engine performance and reliability. Improper
grounding will result in uncontrolled or unreliable
electrical circuit paths.
Uncontrolled or unreliable electrical circuit paths may
result in damage to main bearings, crankshaft
bearing journal surfaces, and aluminum components.
Uncontrolled electrical circuit paths may also cause
electrical noise. Electrical noise may degrade the
performance of the vessel and of the radio.
Connect the starting motor directly to the negative
battery terminal. Connect the alternator to the
negative battery or negative terminal for the starting
motor. The alternator and the starting motor must
meet marine isolation requirements.
Note: All electrical connections must meet or exceed

the American Boat and Yacht Council Standard E-11.
Use a bus bar with a direct path to the negative
battery terminal for low current components that
require a negative battery connection. Connect the
bus bar directly to the negative battery terminal.
Note: All return paths to the negative battery must be
able to carry fault currents.
The use of a bus bar ensures that the electronic
control module (ECM) and the components
connected to the ECM have a common reference
point.
Refer to Special Instruction, REHS1187, “Marine
Engine Electronic Installation Guide” for additional
information on grounding procedures.
22 SEBU9048-09
Safety Section
Electrical System
Refer to Application and Installation Guide,

LEBM0001-01, “Marine Engine Electronics C7 - C32”
for additional information on grounding procedures.
Negative Battery Connection for

Multiple Engines
(1) Engines (8) Direct current (DC) main negative bus (13) Immersed ground plate
(2) Parallel switch bar (14) Zinc bar
(3) Customer miscellaneous vessel loads (9) Alternating current (AC) grounding bus (15) Electronics ground plate
(4) Overcurrent protection bar (16) Chain plates
(5) Battery (10) Strainer (17) Grounding bus bar
(6) Battery disconnect switches (11) Cathodic protection bus bar (18) Engine negative terminal
(7) Battery (12) Lightening protection ground point (19) Battery
Install the battery disconnect switches as close as

possible to the battery positive (+) but outside of the
battery enclosure.
SEBU9048-09 23
Safety Section
Engine Electronics
Note: If multiple bus bars are used to connect i06795266

components to the negative battery, a common
reference should be provided. All bus bars must be Generator Isolating for
wired together for proper engine synchronization for
multiple engine operations. Maintenance
SMCS Code: 4450
i05391510
When you service an electric power generation set or
Engine Electronics when you repair an electric power generation set,
follow the procedure below:
SMCS Code: 1000; 1900
1. Stop the engine.
Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.
This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control
Module (ECM) may monitor the engine operating
conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an
immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes may Illustration 21 g00104545
limit engine speed and/or the engine power.
2. Attach a “DO NOT OPERATE” or similar warning
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring tag to the engine prime mover starting circuit.
functions. The following parameters can be Disconnect the engine starting circuit.
monitored as a part of the Engine Monitoring System:
3. Disconnect the generator from the distribution
• Operating Altitude system.
• Engine Coolant Level 4. Lock out the circuit breaker. Attach a “DO NOT
OPERATE” or similar warning tag to the circuit
• Engine Coolant Temperature breaker. Refer to the electrical diagram. Verify that
all points of possible reverse power flow have
• Engine Oil Pressure been locked out.
• Engine Speed 5. For the following circuitry, remove the
transformer's fuses:
• Fuel Temperature
• power
• Intake Manifold Air Temperature
• System Voltage • sensing
• Turbocharger Inlet Temperature • control
The engine monitoring package may vary for different 6. Attach a “DO NOT OPERATE” or similar warning
engine models and different engine applications. tag to the generator excitation controls.
However, the monitoring system and the engine
monitoring control will be similar for all engines. 7. Remove the cover of the generator's terminal box.
Note: In a derated condition, the amount of derate 8. Use an audio/visual proximity tester to verify that
can be determined by monitoring “Actual Maximum the generator is de-energized. This tester must be
Available Engine Torque %” . insulated for the proper voltage rating. Follow all
guidelines to verify that the tester is operational.
Refer to the Troubleshooting Manual for more
information.
24 SEBU9048-09
Safety Section
Generator Isolating for Maintenance
9. Determine that the generator is in a de-energized

condition. Add ground straps to the conductors or
terminals. During the entire work period, these
ground straps must remain connected to the
conductors and to the terminals.
SEBU9048-09 25
General Information
Product Information
Section
General Information
i05605203
Model View Illustrations

SMCS Code: 1000
View of the front of a C18 Marine Generator Set
(1) Expansion tank for the jacket water (6) Expansion tank for the separate circuit (11) Guard group for the belt and for the
cooling system aftercooled (SCAC) system alternator
(2) Engine oil filters (7) Housing for the temperature regulator (12) Engine oil level gauge
(3) Fuel filters (8) Fuel shutoff valve (13) Oil sampling port
(4) Fuel selector valve (9) Sampling port for the engine oil (14) Oil filter selector
(5) Fuel priming valve (10) Oil filler tube
26 SEBU9048-09
View of the right side of a C18 Marine Generator Set
(15) Turbocharger (20) Sight gauge for the jacket water system (25) Transmission oil cooler
(16) Lifting eye (21) Alternator (26) Drain for the engine oil pan
(17) Filler cap for engine oil (22) Sampling port for the separate cooling (27) Engine starting motor
(18) Heat exchanger aftercooler (SCAC) system (28) Generator arrangement
(19) Housing for deaerator (23) Engine oil cooler
(12) Engine oil level gauge (24) Engine oil pan
SEBU9048-09 27
View of the left side of a Cat Marine Generator Set
(29) Sight gauge for the SCAC system (33) Electronic control module (ECM) (37) Starting motor
(30) Aftercooler (34) Fumes disposal filter (38) Water pump for the jacket water system
(31) Drain for the aftercooler (35) Engine air cleaner (39) Water pump for the SCAC system
(32) Heat exchanger (36) Control panel for the generator set
View of the top of a Cat Marine Generator Set
(40) Service indicator for the air cleaner (16) Lifting eyes for the engine
28 SEBU9048-09
Radiator right side
(41) Jacket water inlet (44) Expansion tank cap (47) SCAC outlet
(42) Coolant level sight gauge (45) Lifting eye (48) Jacket water outlet
(43) Jacket water expansion tank (46) Radiator
SEBU9048-09 29
Product Description
Radiator Left Side
(42) Coolant level sight gauge (47) SCAC outlet (50) SCAC expansion tank
(45) Lifting eye (49) SCAC inlet
i05018390 • Separate circuit aftercooler (SCAC)
Product Description The electronic engine control system provides the

following features:
SMCS Code: 1000; 4450; 4491
• Engine monitoring
Engine • Electronic governing
The Cat C18 Marine Engine provides the following • Automatic air/fuel ratio control
features:
• Torque rise shaping
• Four-cycle
• Injection timing control
• Direct fuel injection
• System diagnostics
• Electronic unit injection
Electronic unit injectors combine the metering of fuel
• Turbocharged (duration and timing) and the injection of fuel.
Electronic unit injectors produce very high injection
• Keel cooling pressures.
30 SEBU9048-09
Product Description
The Electronic Control Module (ECM) controls the Engine Specifications

amount of fuel that is injected by varying the signals
to the electronic unit injectors. High injection
pressures help to reduce fuel consumption and
emissions. The use of this type of electronic unit
injector helps to provide precise control of injection
timing. The injection timing varies with engine
operating conditions thus optimizing performance for
starting, emissions, noise, and fuel consumption.
The timing advance is achieved through the precise
control of the firing of the electronic unit injector.
Engine rpm is controlled by adjusting the firing
duration. A speed/timing sensor provides information
to the ECM for detection of cylinder position and
engine rpm.
The engine has built-in diagnostics that are used in
order to ensure that all of the components function Illustration 28 g00904617
properly.
Cylinder and valve locations
The cooling system consists of the following (A) Exhaust valve
components: (B) Inlet valve
• Gear-driven centrifugal pump Table 1

C18 Marine Engine Specifications
• One water temperature regulator which regulates
the engine coolant temperature Cylinders and Arrangement 6 In-Line
• Oil cooler Bore 145 mm (5.7 inch)
Stroke 183 mm (7.2 inch)

• Separate circuit aftercooler (SCAC)
Compression Ratio 16.5:1
The engine lubricating oil, that is supplied by a gear
pump, is cooled. The engine lubricating oil is also Aspiration Turbocharged
filtered. Bypass valves provide unrestricted flow of Aftercooled
lubrication oil to the engine components during the
Displacement 18 L (1098 cubic inch)
following conditions:
Firing Order 1-5-3-6-2-4
• High oil viscosity
Rotation (viewed from flywheel) Counterclockwise
• Plugged oil cooler or plugged oil filter elements
(paper cartridge)
Description of the Generator
These brushless generators are used with the
following loads: mixed loads of motors and lights,
SCR-controlled equipment, computer centers,
installations of communications and petroleum
drilling applications. The elimination of the brushes in
the field circuit reduces maintenance. The elimination
of the brushes in the field circuit increases reliability.
The elimination of brushes provides a higher degree
of protection in potentially hazardous atmospheres.
The generator set packages can be utilized for prime
power generation or standby power generation. The
generator set packages can be used in land-based
applications or marine applications.
The generators have four poles. The generators have
12 lead configurations. The generators can produce
electrical power in either 50 Hz or 60 Hz applications.
SEBU9048-09 31
Product Identification Information
Product Identification
Information
i03596940
Plate Locations and Film

Locations
SMCS Code: 1000; 4450
Serial Number Plate for the • Engine serial number

Generator (1) • Engine model number
The generator identification is located on the side of • Arrangement number
the generator.
The generator identification film includes the Engine Information (3)
following information:
The Engine Information Plate is on the valve cover.
• Serial number for the generator
The Engine Information Plate contains the following
• Generator model number information:
• Engine serial number

Engine Serial Number (2)
• Arrangement number
The Engine Serial Number Plate is on the lower right
side of the cylinder block near the rear of the engine. • Compression ratio
The Engine Serial Number Plate contains the • Aftercooler temperature
32 SEBU9048-09
Emissions Certification Film
• Power Generator Arrangement Number

• Full load RPM Generator Set Serial Number
Generator Frame Size
i04019095
Voltage Rating
Emissions Certification Film
kW Rating
SMCS Code: 1000; 7405
Excitation System
Note: This information is pertinent in the United
States, in Canada and in Europe. AREP
Consult your Cat dealer for an Emission Control Self-Excited

Warranty Statement. Permanent Magnet
This label is located on the engine.
i04397923
Reference Information
SMCS Code: 1000; 4450
Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.
Record for Reference

Engine Model
Engine Serial Number
Engine Arrangement Number
Modification Number
Engine Low Idle Speed
Engine Full Load Speed
Performance Specification Number
Primary Fuel Filter Element
Secondary Fuel Filter Element
Engine Oil Filter Element
Auxiliary Oil Filter Element
Supplemental Coolant Additive Maintenance
Element
Engine Oil Capacity
Total Cooling System Capacity
Air Cleaner Element
Fan Drive Belt
Alternator Belt
SEBU9048-09 33
Operation Section
Lifting and Storage
Operation Section Lifting the Entire Package

Do NOT use the engine lifting eyes, generator
lifting eyes, or radiator lifting eyes to lift the
Lifting and Storage entire package. Lifting points have been provided on
the base rails of the generator set for lifting the entire
i05608751
package. However, lifting the engine and the
generator together requires special equipment and
procedures. Consult your Cat dealer for information
Product Lifting regarding fixtures for proper lifting of your complete
SMCS Code: 7000; 7002 package.
NOTICE
Lifting the Engine Only
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Re- To lift the engine ONLY, use the lifting eyes that are
member that the capacity of an eyebolt is less as the on the engine.
angle between the supporting members and the ob-
ject becomes less than 90 degrees. Lifting the Generator Only
When it is necessary to remove a component at an To lift the generator ONLY, use the lifting eyes that
angle, only use a link bracket that is properly rated for are on the generator.
the weight.
Use a hoist to remove heavy components. Use an Lifting the Radiator Only
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be To lift the radiator ONLY, use the lifting eyes that are
parallel to each other. The chains and cables should located on top of the radiator.
be perpendicular to the top of the object that is being
lifted. i07026634
Some removals require lifting fixtures in order to
obtain proper balance. Lifting fixtures also help to Product Storage
provide safety.
SMCS Code: 7002
Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting Engine
eyes and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided. Storage - Greater than 7 Days and less
Consult your Cat dealer for information regarding than 30 Days
fixtures for proper engine lifting.
Caterpillar recommends maintaining the temperature
of the engine to a temperature of at least 5° C (9° F)
above ambient temperature to prevent corrosion. The
usage of jacket water heaters is an appropriate
method.
Storage - Greater than 30 Days and less

than 1 Year
Note: If long-term storage for time exceeding 1 year
is necessary, contact your local Caterpillar Dealer for
the preferred procedure to use in your specific case.
If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft, and gears.
This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas
of high humidity.
34 SEBU9048-09
Operation Section
Product Storage
When the engine is started again, metal to metal Clean the primary fuel filter. Fill with calibration
contact will cause wear before the surfaces receive fluid or kerosene. Install the primary fuel filter and
oil. To minimize this wear, use the starter to turn the operate the priming pump. This procedure will
engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge, send clean oil to the secondary filter and the
start the engine. engine.
1. Clean the engine of any dirt, rust, grease, and oil. Open the fuel tank drain valve to drain any water
Inspect the exterior. Paint areas that contain paint and dirt from the fuel tank. Apply a spray of
damage with a good quality paint. calibration fluid or kerosene at the rate of
30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
2. Remove any dirt from any air cleaner. Check all
capacity to prevent rust in the fuel tank. Add
seals, gaskets, and the filter element for damage.
0.15 mL per L (.02 oz per 1 gal US) of commercial
3. Apply lubricant to all points in this Operation and biocide such as Biobor JF to the fuel.
Maintenance Manual, “Maintenance Interval
Apply a small amount of oil to the threads on the
Schedule”.
fuel tank filler neck and install the cap. Seal all
4. Drain the crankcase oil. Replace the crankcase oil openings to the tank to prevent evaporation of the
and change any oil filters. For the proper fuel and as a preservative.
procedure, refer to this Operation and
10. Remove the fuel nozzles or spark plugs. Apply
Maintenance Manual.
30 mL (1 oz) of the mixture of oils (50 percent VCI
5. If the engine is equipped with an air starting motor, oil and 50 percent engine oil) into each cylinder.
fill the reservoir with 50 percent volatile corrosion
Use a bar or a turning tool to turn over the engine
inhibitor oil (VCI) and 50 percent engine oil.
slowly. This procedure puts the oil on the cylinder
6. Add VCI oil to the crankcase oil. The volume of walls. Install all fuel nozzles or spark plugs and
VCI oil in the crankcase oil should be 3 to 4 tighten to the correct torque.
percent.
11. Spray a thin amount of the mixture of oil (50
Note: If the engine crankcase is full, drain enough percent VCI oil and 50 percent engine oil) onto the
engine oil so the mixture can be added. flywheel, ring gear teeth, and starter pinion. Install
the covers to prevent evaporation of the vapors
7. Remove any air filter elements. Turn the engine at from the VCI oil.
cranking speed with the throttle control in FUEL
OFF position. Use a sprayer to add a mixture of 50 12. Apply a heavy amount of Cat Multipurpose
percent VCI oil and 50 percent engine oil into the Grease (MPGM) to all outside parts that move,
air inlet or turbocharger inlet. such as rod threads, ball joints, linkage.
Note: VCI oil mixture is also to be added to the inlet Note: Install all covers. Ensure that tape has been
by removing a plug for checking boost pressure/ installed over the following components: openings,
temperature at the cylinder head air inlet area. The air inlets, exhaust openings, flywheel housing,
sprayer should produce a fog to ensure it is drawn crankcase breathers, dipstick tubes, and any other
into each cylinder. The minimum application rate is necessary components.
5.5 mL per L (3 oz per 1000 cu in) of engine
Ensure that all covers are airtight and
displacement.
weatherproof. Use a waterproof weather resistant
8. Use a sprayer to apply a mixture of 50 percent VCI tape such as Kendall No. 231 or an equivalent. Do
oil and 50 percent crankcase oil into the exhaust not use duct tape. Duct tape will only seal for a
openings. The minimum application rate for the oil short period.
mixture is 5.5 mL per L (3 oz per 1000 cu in) of 13. Remove the batteries. As an alternative, place
engine displacement. Seal the exhaust pipe and the batteries in storage. As needed, periodically
seal any drain holes in the muffler. charge the batteries while the batteries are in
9. Remove the fuel from the secondary fuel filter storage.
housing. Alternately, empty and reinstall the spin- If the batteries are not removed, wash the tops of
on fuel filter element to remove any dirt and water. the batteries until the tops are clean. Apply an
Drain any sleeve metering fuel pump. electrical charge to the batteries to obtain a
specific gravity of 1.225.
SEBU9048-09 35
Operation Section
Product Storage
Disconnect the battery terminals. Place a plastic 5. Remove the plastic covers from the air cleaner
cover over the batteries. elements.
Note: For additional information, refer to Special 6. Use a bar or a turning tool to turn the engine in the
Instruction, SEHS7633, “Battery Test Procedure”. normal direction of rotation. The procedure
ensures that no hydraulic locks or resistance exist.
14. Loosen all belts.
7. Before starting the engine, remove the valve cover
15. Place a waterproof cover over the engine. Ensure or covers. Put a large amount of engine oil on the
that the engine cover is secure. The cover should camshaft, cam followers, and valve mechanism to
be loose enough to allow air to circulate around prevent damage to the mechanism.
the engine to prevent damage from condensation.
8. Pressure- lubricate the engine before starting the
16. Attach a tag with the storage date to the engine. engine. Pressure lubricating the engine ensures
17. Remove the waterproof cover at 2 month or 3 immediate lubrication and prevents damage to the
month intervals to check the engine for corrosion. engine during the first few minutes of engine
If the engine has signs of corrosion, repeat the operation. If the engine is not equipped with a
protection procedure. prelube pump, contact your Cat dealer about
lubricating the engine before starting the engine.
Conventional Coolant System
9. Check the condition of all rubber hoses. Replace
Completely fill the cooling system before storage. any worn hoses. Replace any damaged hoses.
Water or water mixed with supplemental coolant 10. Before start-up, test the cooling system for a 3 to
additive (SCA) is not approved for use with Cat C7- 6 percent concentration of coolant conditioner.
C32 Marine Engines which are cooled with heat Add liquid coolant conditioner or a coolant
exchangers. Cat C7-C32 Marine Engines which are conditioner element, if equipped.
cooled with heat exchangers require a minimum of
30 percent glycol to prevent cavitation of cooling Test the coolant mixture for proper nitrite level. If
system components. A minimum of 50 percent glycol necessary, adjust the coolant mixture.
is verystronglyrecommended.
Prime the engine with clean diesel fuel before
Refer to this Operation and Maintenance Manual, starting.
“Fluid Recommendations” for more information about
coolants. 11. If the engine is equipped with a fresh water
system, ensure that the system is clean. Ensure
Raw Water System that the system is full. Ensure that the system has
the correct amount of supplemental cooling
Completely drain the raw water system by removing system conditioner.
all the drain plugs from the raw water pump, water
shielded manifolds, heat exchanger bonnets, and If the engine is equipped with a raw water system,
aftercooler. install all the drain plugs and zinc plugs. Fill the
After the system has been drained, inspect all zinc system. It may be necessary to prime the raw
plugs (normally painted red) for damage from water system pumps before operation.
corrosion.
12. On the first day of operation, check the entire
Note: To ensure complete drainage and evaporation engine several times for leaks and correct
during storage, DO NOT install the drain plugs and operation.
zinc plugs. Place all removed plugs in a cloth bag
and fasten the bag to the engine for storage.
Removal from Storage

1. Remove all outside protective covers.
2. Change the oil and filters.
3. Check the condition of the fan and alternator belts.
Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual, “Belts -
Inspect/Adjust/Replace” for the correct procedure.
4. Replace the fuel filter elements.
36 SEBU9048-09
Operation Section
Product Storage
13. If the engine was removed from storage in which 3. If the generator has not been run under load for 3
temperatures of less than -12°C (10°F) were months or more
encountered, refer to Service Manual, SEBU5898,
These intervals are only recommendations. Perform
“Cold Weather Recommendations Operation and a megohmmeter test more frequently if the
Maintenance”. environment is extremely humid, salty, or if the last
megohmmeter test was close to 1 megohm.
Generator
Additional Information
Storage (Less Than One Year)
For additional information about storage procedures,
When a generator is in storage, moisture condenses refer to Special Instruction, SEHS9031, “Storage
in the windings. To minimize condensation, always Procedure for Cat Products”.
place the generator in a dry storage area. Seal all
openings with tape.
If a brush-type generator (SRCR) is stored, lift the
brushes off the slip ring to prevent chemical action
damage to the slip ring. Attach a tag to the generator
which states that the brushes have been lifted.
Perform a resistance check of the windings. Record
this reading. This check is done to provide a base
line for determining whether moisture or winding
deterioration occurs during storage.
Removal From Storage

Remove all protective covers. Reseat the brushes on
the slip ring for SRCR generators.
Before start-up of a generator, use a megohmmeter
to check insulation resistance for moisture and/or
foreign material. Refer to this Operation and
Maintenance Manual, “Generator Start-up Check
List” for the procedure. A resistance reading of 1
megohm or less indicates that the winding has
absorbed too much moisture.
Use one of the following methods for drying the
generator to remove moisture which is caused by
high humidity or dampness:
1. Place the generator in an oven which is no hotter
than 85°C (185°F) for 4 hours.
2. Use a canvas enclosure around the generator and
heating lamps to increase the ambient
temperature. Provide an opening in the top of the
canvas to release the moisture.
3. Send a low voltage current through the windings to
increase the temperature of the windings to 85°C
(185°F).
Megohmmeter Checks
Test the main stator windings with a megohmmeter in
the following situations:
1. Before the initial start-up of the generator set
2. Every 3 months if the generator operates in a
humid environment
SEBU9048-09 37
Operation Section
Features and Controls
Features and Controls • Resetting procedure for engine restart
i04423643 Testing the Alarm System and the

Shutoff System
Alarms and Shutoffs
SMCS Code: 7400 NOTICE
During testing, abnormal operating conditions must
Alarms and shutoffs are one of the three following be simulated. Perform the tests correctly in order to
types: help prevent possible engine damage.
• Switches Refer to the System Operation, Testing and Adjusting
Manual for more information on testing procedures,
• Transducers or consult your Cat dealer.
• Differential pressure sensors
i03646563
Alarms Battery Disconnect Switch

Engines may be equipped with alarms that are used
to alert the operator when undesirable operating
(If Equipped)
conditions occur. SMCS Code: 1411
The battery disconnect switch and the engine start
NOTICE
When an alarm is activated, corrective measures switch perform different functions. Turn off the battery
must be taken before the situation becomes an emer- disconnect switch in order to disable the entire
gency in order to avoid possible engine damage. electrical system. The battery remains connected to
the electrical system when you turn off the engine
start switch.
The alarm will remain active until the condition is
corrected. Turn the battery disconnect switch to the OFF
position and remove the key when you service the
electrical system or any other components.
Shutoffs
Also turn the battery disconnect switch to the OFF
NOTICE position and remove the key when the engine will not
Always determine the cause of the engine shutdown. be used for an extended period of a month or more.
Make necessary repairs before attempting to restart This will prevent drainage of the battery.
the engine.
NOTICE
Shutoffs are set at critical levels for the following Never move the battery disconnect switch to the OFF
conditions: position while the engine is operating. Serious dam-
age to the electrical system could result.
• Coolant temperature
• Oil pressure To ensure that no damage to the engine occurs,
verify that the engine is fully operational before
• Overspeed cranking the engine. Do not crank an engine that is
not fully operational.
A particular shutoff may need to be acknowledged at
the control panel before the engine will start. Perform the following procedure in order to check the
battery disconnect switch for proper operation:
Make sure that you are familiar with the following
items: 1. With the battery disconnect switch in the ON
position, verify that electrical components are
• Types and locations of shutoff sensors functioning. Verify that the hour meter is displaying
information. Verify that the engine will crank.
• Conditions that cause each shutoff to function
2. Turn the battery disconnect switch to the OFF
position.
38 SEBU9048-09
Operation Section
Control Panel
3. Verify that the following items are not functioning:

electrical components, hour meter and engine
cranking. If any of the items continue to function
with the battery disconnect switch in the OFF
position, consult your Caterpillar dealer.
i05239848
Control Panel
(Cat Marine Engine Control
Panel III (MECP III )(If
Equipped))
SMCS Code: 7451
Refer to Special Instruction, REHS4817, “Overview
and Configuration of the Marine Classification
Society (MCS) Alarm and Protection (A&P), MCS
Controller and Remote Equipment Interface (REI) ”.
Cat Marine Engine Control Panel III (MECP III)
(1) Display control unit (DCU) (4) “ON/OFF” switch for the “LOCAL (6) “EMERGENCY STOP” switch
(2) “STOP” switch THROTTLE” (7) “OFF/MANUAL/REMOTE” switch
(3) “START” switch (5) “LOCAL THROTTLE” switch
SEBU9048-09 39
Operation Section
Derating Strategy
When the “OFF/MANUAL/REMOTE” switch is in the Note: In a derated condition, the amount of derate
OFF position, this control panel cannot be used to can be determined by monitoring the “Actual
start or to stop the engine. When the “OFF/MANUAL/ Maximum Available Engine Torque %” .
REMOTE” switch is in the REMOTE position, the
control panel can stop the engine but cannot be used Contact your Cat dealer for more information about
to start the engine. the derating procedure.
i02706567
Gauges and Indicators

SMCS Code: 7450
Your engine may not have the same gauges or all of
the gauges that are described.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time. Noticeable changes
in gauge readings indicate potential gauge or engine
problems. Problems may also be indicated by gauge
Illustration 31 g03342374 readings that change even if the readings are within
Inside of the control panel specifications. Determine and correct the cause of
(8) “CRANK OVERRIDE” switch
any significant change in the readings. Consult your
(9) “SHUTDOWN OVERRIDE” switch Caterpillar dealer for assistance.
i05391538 NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
Derating Strategy the engine. Engine damage can result.
SMCS Code: 1901
The engine electronic control module (ECM) may Engine Coolant Temperature – This
limit the amount of fuel flowing into the injectors in gauge indicates the engine coolant
order to protect the engine. Any of the following temperature. The temperature may vary
factors could initiate a derate: according to the load. Do not allow the
temperature to exceed the boiling temperature of
• The engine coolant level is high. the pressurized cooling system.
• The engine coolant temperature is high. The sensor for engine coolant temperature must be
fully submerged in order to detect the temperature
• The engine oil pressure is low. correctly. If the engine is operating above the normal
temperature range, perform the following procedure:
• The engine oil temperature is high.
1. Reduce the load and/or the engine rpm.
• The fuel pressure is high or the fuel pressure is
low. 2. Inspect the cooling system for leaks.
• The engine speed is high. 3. Determine if the engine must be shut down
immediately or if the engine can be cooled by
• The temperature of the air entering the air cleaner reducing the load and/or rpm.
is high.
Engine Load – This gauge indicates a
• The engine intake manifold temperature is high. percentage of the engine's full rated
torque. The calculation of the
Note: This fuel limiting strategy is in place to ensure percentage is based on these factors: flow of
the longevity and durability of the engine. fuel, engine rpm, fuel energy content and fuel
correction factor. This gauge flashes if the torque
The derate condition that may result will limit peak exceeds the maximum limit that is programmed
power. In no case will the power loss exceed a 50%
into the control strategy.
reduction in total engine power.
40 SEBU9048-09
Operation Section
Gauges and Indicators
Engine Oil Pressure – The oil pressure Fuel Usage – This gauge indicates the
should be greatest after a cold engine is rate of fuel usage.
started. The pressure will decrease as
the engine warms up. The pressure will increase
Inlet Manifold Air Pressure – This gauge
when the engine rpm is increased. The pressure
indicates the air pressure (turbocharger
will stabilize when the engine rpm is stable.
boost pressure) in the air inlet manifold
A lower oil pressure is normal at low idle. If the load is after the aftercooler. The inlet manifold air
stable and the gauge reading changes, perform the pressure depends on the engine rating, the load,
following procedure: and the operating conditions. To establish the
normal inlet manifold air pressure, compare the
1. Remove the load. data from the gauge to the data from the engine
commissioning and look for trends.
2. Reduce engine speed to low idle.
3. Check and maintain the oil level. Inlet Manifold Air Temperature – This
gauge indicates the inlet manifold air
Engine Oil Temperature – This gauge temperature after the aftercooler. As the
indicates the engine oil temperature inlet air increases in temperature the following
after the oil has passed through the oil conditions occur: expansion of the air, less
cooler. The oil cooler is thermostatically oxygen in the cylinders and less power. If the
controlled. temperature of the inlet air is too high during full
speed and load operation, the engine may
Exhaust Temperature – This gauge consume excessive fuel.
indicates the exhaust temperature at the
exhaust inlets to the turbochargers. The Service Hour Meter – This gauge
two exhaust temperatures may vary slightly. indicates the total number of clock
hours on the engine.
The exhaust temperatures at the exhaust inlets to the
turbochargers provide a good indication of engine System Voltage – This gauge indicates
performance. For engines with dry exhaust the voltage of the electrical system.
manifolds, the temperatures are representative of the
actual temperatures of the valves. Monitor this
parameter frequently. Tachometer – This gauge indicates
engine speed (rpm). When the throttle
NOTICE control lever is moved to the full throttle
Severe damage to the engine can result if the ex- position without load, the engine is running at
haust temperature at the inlet to the turbocharger ex- high idle. The engine is running at the full load
ceeds the extreme limit. rpm when the throttle control lever is at the full
throttle position with maximum rated load.
Fuel Level – This gauge indicates the NOTICE

fuel level in the fuel tank. Normally, the To help prevent engine damage, never exceed the
fuel level gauge will register the fuel high idle rpm. Overspeeding can result in serious
level only when the switch is in the ON position. damage to the engine. The engine can be operated
at high idle without damage, but should never be al-
Fuel Pressure – This gauge indicates lowed to exceed high idle rpm.
fuel pressure to the fuel injection pump
from the fuel filter. A decrease in fuel
pressure usually indicates a dirty fuel filter or a Note: The high idle rpm and the full load rpm are
plugged fuel filter. As the fuel filter becomes stamped on the Information Plate.
plugged, there will be a noticeable reduction in
the engine's performance. For more information, refer to Specifications,
Systems Operation, and Troubleshooting,
Fuel Temperature – This gauge indicates SENR5002, “Installation Guide for Marine Engine
the temperature of the fuel. A high fuel Electronic Displays”.
temperature can adversely affect
performance. If the temperature of the fuel is too
low, the fuel filter may begin to plug. See this
Operation and Maintenance Manual, “Fuel and
the Effect from Cold Weather” for more
information.
SEBU9048-09 41
Operation Section
Sensors and Electrical Components
i04981650 The ECM will detect the failure of the coolant

temperature sensor. The diagnostic lamp will warn
Sensors and Electrical the operator about the status of the coolant
temperature sensor. Strategies that are related to the
Components coolant temperature will be disabled if a failure
occurs. The failure of the coolant temperature sensor
SMCS Code: 1900; 7400 will not cause a shutdown of the engine or any
horsepower change.
Failure of Sensors
Coolant Level Sensor
All Sensors
The coolant level sensor monitors the engine coolant
A failure of any of the sensors may be caused by one level. The sensor will detect coolant level. The
of the following malfunctions: coolant level sensor provides information to the ECM.
The output from the ECM can indicate a low coolant
• Sensor output is open. level through a relay or a lamp. Coolant must be
added to the cooling system in order to correct the
• Sensor output is shorted to “- battery” or “+ condition. See the Operation and Maintenance
battery” . Manual for more information.
• Measured reading of the sensor is not within the The system can be programmed with one of the
following options:
specification.
Enabled – The system will monitor the input from the
Coolant Temperature Sensor coolant level sensor. The system is programmed with
this value when the engine is shipped by Caterpillar.
The coolant temperature sensor monitors engine
coolant temperature. The coolant temperature sensor Disabled – The system will monitor the input from
is used by the engine system diagnostics with an the coolant level sensor. All of the diagnostics that
output from the Electronic Control Module. The are associated with the coolant level sensor will be
disabled.
output of the ECM can indicate a high coolant
temperature through a relay or a lamp. In addition,
the sensor activates the cold start strategy which
improves the startability of the engine. Failure of the Coolant Level Sensor
The minimum coolant temperature that will activate A failure of the coolant level sensor may occur under
the alarm is 104° C (219° F). The switch opens as the following conditions:
the coolant cools. A procedure for resetting is not
required. • The coolant level sensor is open.
• The coolant level sensor is shorted to ground.

Failure of the Coolant Temperature
Sensor • The coolant level sensor is shorted to supply.
If one of the following conditions exist, a failure of the The failure of the coolant level sensor will not cause a
coolant temperature sensor may have occurred: shutdown of the engine or any horsepower change.
• Sensor output is open. Engine Oil Pressure Sensor

• Sensor output is shorted to ground or supply. The engine oil pressure sensor can detect engine oil
pressure for diagnostic purposes. The engine oil
• Measured reading of the coolant temperature is pressure sensor sends a signal to the Electronic
out of the specification. Control Module (ECM).
Low Oil Pressure Warning

The setpoint is dependent upon the engine rpm. The
fault will be active and logged only if the engine has
been running for more than 15 seconds.
42 SEBU9048-09
Operation Section
Very Low Oil Pressure Warning Table 3

Fuel Temperature Sensor
The very low oil pressure setpoint is dependent upon
the engine rpm. If Derate mode is selected, the ECM Operating range of the fuel temperature sen- 30 to 70°C
will derate the engine power. The engine horsepower sor for activation of the power correction by (86 to 158°F)
will be limited. the ECM
Failure of the Engine Oil Pressure Sensor

Air Temperature Sensor for the
If one of the following conditions exist, a failure of the Inlet Manifold
engine oil pressure sensor may have occurred:
The air temperature sensor for the inlet manifold
• The engine oil pressure sensor is open. measures the inlet manifold air temperature. The
Electronic Control Module (ECM) monitors the signal
• The engine oil pressure sensor is shorted to from the air temperature sensor for the inlet manifold.
ground or supply. The output of the ECM can indicate high inlet
manifold air temperature through a relay or a lamp.
• Measured reading of the oil pressure is out of the The air temperature sensor for the inlet manifold will
specification. not cause a shutdown of the engine or any
horsepower change.
The ECM will detect the failure of the engine oil
pressure sensor. The diagnostic lamp warns the user Note: The air temperature sensor for the inlet
about the status of the engine oil pressure sensor. manifold will be affected by the heat that is conducted
The strategies related to oil pressure will be disabled.
from the inlet manifold. This is true when the engine
The failure of the engine oil pressure sensor will not
cause a shutdown of the engine or any horsepower is idling and after the engine is shut off. This warm-up
change. is due to the lack of coolant circulation through the
engine. The reading from the air temperature sensor
for the inlet manifold may be significantly higher than
Fuel Pressure Sensor the actual temperature of the air inside the inlet
The fuel pressure sensor monitors the fuel filter manifold until the inlet manifold cools.
pressure. Low fuel pressure or high fuel pressure will
not cause a shutdown of the engine or any Air Pressure Sensor for the Inlet
horsepower change. Fuel pressure that is outside of
the normal range will affect the engine performance.
Manifold
If the fuel filter outlet pressure is low, the fuel filter The air/fuel ratio control utilizes actual engine speed
may need to be replaced. and actual boost pressure (inlet manifold air
Table 2 pressure) in order to control the transient smoke
Fuel Pressure Sensor level. When the throttle is increased and the engine
demands more fuel, the fuel limit is controlled in or to
Minimum allowable pressure of the fuel trans-
415 kPa (60 psi)
reduce overall smoke levels of the engine exhaust.
fer pump at full load speed
The Electronic Control Module (ECM) controls
Minimum allowable pressure in the fuel mani- injection timing and the amount of fuel that is
276 kPa (40 psi)
fold at full load speed injected.
Note: The air pressure sensor for the inlet manifold is
Fuel Temperature Sensor located on the top right side of the engine.
The fuel temperature sensor monitors the fuel The boost pressure is determined from the difference
temperature. Fuel temperature is monitored in order in pressure between the air pressure sensor for the
to adjust the fuel rate so that the engine will deliver inlet manifold and the atmospheric pressure sensor
consistent power. The fuel temperature sensor can (crankcase pressure).
also be used to warn the operator of excessive fuel
temperature. A high fuel temperature can adversely Failure of the Air Pressure Sensor for the
affect the engine performance. Inlet Manifold
A failure of the air pressure sensor for the inlet
manifold may have occurred if any of the following
conditions are present:
• The output of the air pressure sensor for the inlet
manifold is open.
SEBU9048-09 43
Operation Section
• The output of the air pressure sensor for the inlet

manifold is shorted to ground or to supply.
• The reading of the air pressure sensor for the inlet

manifold is out of the specification.
The ECM will detect the failure of the air pressure
sensor for the inlet manifold. The operator will be
warned of the problem through the diagnostic lamp.
The strategies that are related to the boost will be
disabled. The failure of the air pressure sensor for the
inlet manifold will not cause a shutdown of the engine
or any horsepower change.
Speed/Timing Sensor
If the ECM cannot receive a signal from the primary
speed/timing sensor, the “DIAGNOSTIC” lamp will
indicate a diagnostic fault code which will be logged
in the ECM memory.
The backup speed/timing sensor is used when the
ECM does not receive a signal from the primary
speed/timing sensor. The backup speed/timing
sensor will be used until the primary speed/timing
sensor is replaced.
Failure of the Speed/Timing Sensor

A failure of the speed/timing sensor may have
occurred if one of the following conditions occur:
• The output of the speed/timing sensor has
opened.
• The speed/timing sensor is shorted to ground.

• The speed/timing sensor is shorted to supply.
• The speed/timing sensor is missing pulses.

• The speed/timing sensor has extra pulses.
Intermittent failure causes erratic engine control. The
ECM will detect a failure of the primary speed/timing
sensor. The operator will be warned through the
diagnostic lamp.
44 SEBU9048-09
Operation Section
Engine Starting
Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i01486758 to the controls.
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
SMCS Code: 1000; 1400; 1450
• All of the guards must be put in place. Check for
Perform the required daily maintenance and other
damaged guards or for missing guards. Repair
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can any damaged guards. Replace damaged guards
help prevent major repairs at a later date. Refer to and/or missing guards.
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more • Disconnect any battery chargers that are not
information. protected against the high current drain that is
created when the electric starting motor (if
• For the maximum service life of the engine, make equipped) is engaged. Check electrical cables and
a thorough inspection before the engine is started. check the battery for poor connections and for
Look for the following items: oil leaks, coolant corrosion.
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed. • Reset all of the shutoffs or alarm components.
• Inspect the cooling system hoses for cracks and • Check the engine lubrication oil level. Maintain the
for loose clamps. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage. • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
• Inspect the wiring for loose connections and for the coolant level to the “FULL” mark on the coolant
worn wires or frayed wires. recovery tank.
• Check the fuel supply. Drain water from the water • If the engine is not equipped with a coolant
separator (if equipped). Open the fuel supply recovery tank maintain the coolant level within
valve. 13 mm (0.5 inch) of the bottom of the filler pipe. If
the engine is equipped with a sight glass, maintain
NOTICE the coolant level in the sight glass.
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel • Observe the air cleaner service indicator (if
pressure. High fuel pressure may cause filter housing equipped). Service the air cleaner when the yellow
failure or other damage. diaphragm enters the red zone, or when the red
piston locks in the visible position.
If the engine has not been started for several weeks, • Ensure that any driven equipment has been
fuel may have drained from the fuel system. Air may disengaged. Minimize electrical loads or remove
have entered the filter housing. Also, when fuel filters any electrical loads.
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel i04409253
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system. Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Engine exhaust contains products of combustion

which may be harmful to your health. Always When using starting fluid (ether), follow the man-
start and operate the engine in a well ventilated ufacturer's instructions carefully. Use the starting
area and, if in an enclosed area, vent the exhaust fluid sparingly and spray only while cranking the
to the outside. engine. Failure to do so could result in an explo-
sion and/or fire and personal injury.
SEBU9048-09 45
Operation Section
Starting the Engine
3. Increase the engine rpm to approximately 1/4 of

NOTICE
The optional ether starting aid is the only starting fluid the full load rpm.
system that is recommended on the engine. 4. Allow the engine to idle for 3 to 5 minutes, or allow
The engine is designed to start without starting aids the engine to idle until the water temperature
at temperatures greater than 13° C (55° F) indicator begins to rise. The engine should run at
low idle smoothly until speed is gradually
When No. 2 diesel fuel is used, the following items increased to high idle. Allow the white smoke to
provide a means of minimizing starting problems and disperse before proceeding with normal operation.
fuel problems in cold weather: starting aids, engine
oil pan heaters, jacket water heaters, fuel heaters 5. Operate the engine at low load until all systems
and fuel line insulation. reach operating temperature. Check the gauges
For temperatures below −18° C (0° F), consult your during the warm-up period.
Cat dealer.
i05237813
Use the procedure that follows for cold weather
starting.
Starting the Engine
Note: If the engine has not been run for several SMCS Code: 1000; 1450
weeks, fuel may have drained. Air may have moved
into the filter housing. Also, when fuel filters have
been changed, some air will be left in the filter Automatic Starting
housing. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.
When the engine is in the AUTOMATIC mode, the
NOTICE engine can start at any moment. To avoid person-
Do not engage the starting motor when flywheel is al injury, always remain clear of the the engine
turning. Do not start the engine under load. when the engine is in the AUTOMATIC mode.
If the engine fails to start within 30 seconds, release For automatic starting, the engine control switch must
the starter switch or button and wait two minutes to be in the AUTO position or in the REMOTE position.
allow the starting motor to cool before attempting to The engine will automatically start when the remote
start the engine again. start/stop initiate contact closes.
1. Turn the ignition switch to the RUN position. Manual Starting

Advance the throttle in order to supply fuel to the
engine. NOTICE
For initial start-up of a new or rebuilt engine, and for
NOTICE start-up of an engine that has been serviced, make
Excessive ether can cause piston and piston ring provision to shut the engine off should an overspeed
damage. Use ether for cold starting purposes only. occur. This may be accomplished by shutting off the
Do not use excessive starting fluid while starting the air and/or fuel supply to the engine.
engine. Do not use starting fluid after the engine is
running. Do not start the engine if a “DO NOT OPERATE”
warning tag or a similar warning tag is attached to
any of the controls.
2. If equipped, press the “STARTING AID” switch in
order to improve cold weather starting. Release Ensure that no one will be endangered before the
the “STARTING AID” switch when the engine engine is started and when the engine is started.
starts. Use the starting fluid sparingly. Carefully Perform all of the procedures that are described in
follow the instructions of the OEM. this Operation and Maintenance Manual, “Before
Starting Engine” topic.
NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine speed until the
oil pressure gauge indicates normal. If oil pressure is
not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investi-
gate and correct the cause.
46 SEBU9048-09
Operation Section
Starting the Engine
NOTICE
Starting the Engine with the Cat Marine
Do not engage the starting motor when flywheel is Engine Control Panel III (MECP III) (If
turning. Do not start the engine under load. Equipped)
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
Note: If the optional prelube is used, the prelube

pump will operate before cranking begins. The ECM
will allow the engine to be operated at rated rpm
when the oil pressure sensors indicate that the oil
pressure is sufficient.
Starting the Engine with the Cat Marine

Engine Control Panel I (MECP I) (If
Equipped)
(3) “START” switch
(4) “ON/OFF” switch for the “LOCAL THROTTLE”
(5) “LOCAL THROTTLE” switch
(6) “OFF/MANUAL/REMOTE” switch
(1) “OFF/MANUAL/REMOTE” switch
(2) “START” switch
Note: The engine key switch and the start circuits are
controlled by the “OFF/LOCAL/REMOTE” switch. Illustration 34 g03200996
The position of the “OFF/LOCAL/REMOTE” switch (7) “CRANK OVERRIDE” switch
does not affect the operation of the “STOP” switch. (8) “SHUTDOWN OVERRIDE” switch
(9) “TORQUE LIMIT” switch
1. Position the “OFF/LOCAL/REMOTE” switch to the
LOCAL position or to the REMOTE position. When the “OFF/LOCAL/REMOTE” switch is in
LOCAL mode, the engine cannot be started from the
2. Activate the “START” switch to start the engine. remote control unit. The LOCALl position does not
energize the key switch (J906 circuit) beyond the
engine harness.
1. Position the “OFF/LOCAL/REMOTE” switch to the
LOCAL position or to the REMOTE position.
2. Activate the “START” switch to start the engine.
SEBU9048-09 47
Operation Section
After Starting Engine
Note: If the “START” switch does not start the 5. Perform any necessary repairs before you operate
engine, start the engine with the “CRANK/ the engine.
OVERRIDE” switch on the inside of the control box.
6. After the inspections have been made, move the
i01042616 throttle control to the idle position and proceed
with operation.
After Starting Engine
SMCS Code: 1000
Note: In temperatures from 0 to 60 °C (32 to 140 °F),

the warm-up time is approximately five minutes. In
temperatures below 0 °C (32 °F), additional warm-up
time may be required.
Note: Ensure that the self-test for the monitoring

system is completed before you operate the engine
under load.
1. Operate the engine at low idle rpm for five minutes.

Perform these checks during the warm-up:
• Check for any fluid leaks and for any air leaks.
• Check all the gauges.
Observe the gauges and record the data

frequently while the engine is operating.
Comparing the data over time will help to
determine normal readings for each gauge. This
will also help detect abnormal operating
developments. Investigate any significant changes
in the readings.
2. After the engine has idled for five minutes and the
inspections have been made, increase the engine
speed to 1/2 rated rpm.
NOTICE
To avoid engine overheating and possible engine
damage, ensure that water discharge is visible at the
sea water outlet and/or the water flow is not
restricted.
If the water flow is restricted and/or water discharge
is not visible at the sea water outlet, follow the recom-
mended procedure.
3. Observe the water discharge at the sea water

outlet. If water discharge is not visible or the water
flow is restricted, perform the following procedure:
a. Stop the engine immediately.
b. Inspect the inlet screen and the sea water
strainer for debris. Remove any debris that is
found.
c. Inspect the cooling system and the auxiliary
water pumps for evidence of leaks.
4. Check for any fluid leaks and for any air leaks.
48 SEBU9048-09
Operation Section
Engine Operation
Engine Operation • Do not remove the cover for the air cleaner unless
the air filter service indicator indicates the need for
cleaning of the filter.
i05392621
• Maintain a good electrical system.
Engine Operation One bad battery cell will overwork the alternator. This
SMCS Code: 1000 will consume excess power and excess fuel.
Proper operation and maintenance are key factors in • Ensure that the belts are properly adjusted. The
obtaining the maximum life and economy of the belts should be in good condition.
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be • Ensure that all of the connections of the hoses are
minimized and engine service life can be maximized. tight. The connections should not leak.
The engine can reach normal operating temperature • Ensure that the driven equipment is in good
in less than the time for a walk-around inspection of
working order.
the engine.
The engine can be operated at the rated rpm after • Cold engines consume excess fuel. Keep cooling
the engine reaches operating temperature. The system components clean and keep cooling
engine will reach normal operating temperature system components in good repair. Never operate
sooner during a low engine speed (rpm) and during a the engine without water temperature regulators.
low-power demand. This procedure is more effective All of these items will help maintain operating
than idling the engine at no load. The engine should temperatures.
reach operating temperature in a few minutes.
• Settings for the fuel system and the limits for the
Gauge readings should be observed and the data operating altitude are stamped on the Engine
should be recorded frequently while the engine is Information Plate. If an engine is moved to a
operating. Comparing the data over time will help to higher altitude, the settings must be changed by a
determine normal readings for each gauge. Cat dealer. Changing the settings will help to
Comparing data over time will also help detect provide the maximum efficiency for the engine.
abnormal operating developments. Significant Engines can be operated safely at higher
changes in the readings should be investigated. altitudes, but the engines will deliver less
horsepower. The fuel settings should be changed
i04289968 by a Cat dealer in order to obtain the rated
horsepower.
Fuel Conservation Practices
SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. The design and technology used
byCaterpillar in manufacturing provides maximum
fuel efficiency in all applications. Follow the
recommended procedures in order to attain optimum
performance for the life of the engine.
• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.

Use only the recommended fuels.
• Avoid unnecessary operation at no load.

Shut off the engine instead of operating the engine at
no load for long periods of time.
• Observe the service indicator for the air cleaner
frequently, if equipped. Keep the air cleaner
elements clean.
SEBU9048-09 49
Operation Section
Generator Operation
Generator Operation
i04010770
Generator Operation
SMCS Code: 4450
Loading of the Generator

When a generator is installed or reconnected, be
sure that the total current in one phase does not
exceed the nameplate rating. Each phase should
carry the same load, allowing the engine to work at
the rated capacity. If one phase current exceeds the
nameplate amperage, an electrical unbalance can
result in an electrical overload and overheating.
Allowable combinations of unbalanced loads are
shown in Illustration 35 . When you operate with
significant single-phase loads, the combinations of
single-phase load and three-phase load may be
used. Such combinations should be located below
the line on the graph.
Allowable Combinations of Unbalanced Loads
Block Loading
Block loading is the instantaneous application of an
electrical load to a generator set. This load may be
anywhere from a moderate percentage of the rated
load up to the rated load.
The block loading capability of a generator set
depends on the following factors.
• Engine transient response

• Voltage regulator response
• Type of the voltage regulator

• Altitude of operation of the generator set
• Type of load
• Percent of load before the block load is applied
50 SEBU9048-09
Operation Section
Generator Operation
If derating for the block load is required, refer to ISO Note: Caterpillar generators are designed for a 0.8
3046 Standards or SAE J1349 Standards. Also, power factor unless otherwise specified.
reference Engine Data Sheet, LEKX4066, “Loading
Transient Response” and Engine Data Sheet,
LEKX4067, “Block and Transient Response”. Excitation System
Note: ISO stands for International Standards Permanent Magnet Pilot Excited
Organization. Generators
Power Factor Permanent Magnet Pilot Excited (PMPE) generators
receive power for the voltage regulator from a pilot
The power factor represents the efficiency of the exciter, rather than the main armature. The pilot
load. Power factor is the ratio of apparent power to exciter consists of a permanent magnet rotor and a
total power. The power factor is expressed as a permanent magnet stator. The pilot exciter operates
decimal. The power factor represents that portion of independently from the generator output voltage.
the current which is doing useful work. The portion of Constant excitation during a large load application is
current which is not doing useful work is absorbed in possible because the irregularities that occur in
maintaining the magnetic field in motors or other generator output voltage are not fed back into the
devices. exciter. Such irregularities can be caused by load
conditions. The independent operation also allows
In most applications, electric motors and the generator to better sustain an overload for a short
transformers determine the power factor of the duration. The pilot exciter also ensures that the
system. Induction motors usually have a 0.8 or generator will start properly even if the rotating field
smaller power factor. Incandescent lighting is a becomes completely demagnetized.
resistive load of about 1.0 power factor, or unity.
The power factor of a system may be determined by Low Idle Adjustment
a power factor meter or by calculations. Determine
the power requirement in kW by multiplying the Generator sets normally have a higher low idle
power factor by the kVA that is supplied to the setting than industrial engines. Low idle will be
system. As the power factor increases, the total approximately 66% of the full load speed of 60 Hz
current supplied to a constant power demand will units. Low idle will be approximately 80% of the full
decrease. For example, a 100 kW load at a 0.8 load speed of 50 Hz units.
power factor will draw more current than a 100 kW
load at 0.9 power factor. high-power factor will result Note: Operating the generator set at low idle speed
in full engine load at less than the rated amperage of for an extended time will cause some voltage
the generator. A lower power factor increases the regulators to shut off. The generator set must be
possibility of overloading the generator. completely shut down and restarted in order for the
voltage regulator to operate.
Standby Generator Sets

Most standby units are installed with controls that will
start the unit automatically. Standby units start, pick
up the load, run, and stop without an operator in
attendance.
SEBU9048-09 51
Operation Section
Single Unit Operation
Standby units cannot automatically change the Bearing Temperature Detectors

governor control. Standby units cannot automatically
change the voltage settings. The governor speed and Bearing temperature detectors are standard
voltage level must be preset for the proper operation equipment. If an MCS system is installed, the
of the standby unit. Whenever the set is operated detectors are connected to the RIO and are
manually, be sure that the governor speed and monitored by the MCS controller. Otherwise, the
voltage levels are correct for automatic operation. bearing temperature detectors are used with the
Check all switches for the proper setting. The start equipment that is provided by the customer. Thus,
select switch should be in the AUTOMATIC position. the temperature of the bearing can be measured or
Emergency Stop Switches should be in RUN monitored. Bearing temperature measurements may
position. help to prevent premature bearing failure. Contact
your Cat dealer for more information.
Generator Options
i04010972
Space Heaters
Single Unit Operation
All Cat Marine Generators are provided with space SMCS Code: 4450
heaters. These space heaters are installed for
operation in high humidity conditions. For more
information on space heaters, refer to this Operation Initial Start-Up
and Maintenance Manual, “Space Heater - Check”.
Before the initial start-up, perform the megohmmeter
Embedded Temperature Detectors test on the main stator winding. Refer to the Special
Instruction, SEHS9124, “Cleaning and Drying of
All Cat Marine Generators are available with Electric Set Generators” for the procedure.
embedded resistance type temperature detectors
(RTDs). The detectors are installed in the slots of the Starting
main armature. The main armature is also called a
stator. If the Marine Classification Society control
1. Make all of the preliminary checks listed in this
panel (MCS Control Panel) is installed, the detectors
are connected to the RIO and are monitored by the Operation and Maintenance Manual, “Before
MCS controller. Otherwise, the detectors are used Starting Engine” topic.
with the equipment that is provided by the customer.
2. Be sure that the main circuit breaker or the line
circuit breaker is open.
3. Start the engine according to this Operation and
Maintenance Manual, “Starting the Engine” topic.
Allow the engine to warm up.
4. Adjust to the full-load engine speed.
5. Close the main circuit breaker.
6. Apply the load. Apply the load in increments in
order to maintain system frequency and voltage at
a constant level.
52 SEBU9048-09
Operation Section
Parallel Operation
7. Readjust the governor for rated frequency.
Stopping
Refer to this Operation and Maintenance Manual,
“Manual Stop Procedure” for the required procedures
for stopping the generator set.
i04010991
Parallel Operation
SMCS Code: 4450
Initial Start-Up Illustration 36 g00695380
Preparing a generator for parallel operation requires

special attention. Before you attempt to parallel units
for the first time, check all the units for the following
three conditions. When servicing or repairing electric power gen-
eration equipment:
• Same phase rotation
Make sure the unit is off-line (disconnected
• Same alternating current frequency from utility and/or other generators power serv-
ice), and either locked out or tagged DO NOT
• Same winding pitch OPERATE. Remove all fuses.
• Same voltage adjustment a. Connect the light bulbs with rated voltage
between the generator leads and the
1. Check the phase rotation. corresponding line phase. For example,
Units that operate in parallel must have the same connect terminal 1 to line 1 across the open
phase rotation. Two methods may be used to circuit breaker.
determine if the incoming unit and the unit that is b. Start the units that will be in operating in
on-line have the same phase rotation. These parallel. Bring the units up to speed. As the
methods are listed below: units approach the same speed, the lights will
start to blink.
• Using a phase rotation meter
• If the lights blink in sequence, one of the
• Using a set of three light bulbs
units is connected backward. In order to
Use the procedure below to determine the proper correct the problem, stop the units. Remove
phase rotation by using three light bulbs. generator leads 1 and 3 at the circuit
breaker. Exchange generator leads 1 and
3, thus reversing the direction of phase
rotation. Terminal 2 should always be
connected to line 2.
• Both generators have the same phase

rotation when the lights blink in unison. The
first condition of “Initial Start-Up” has been
met.
2. Adjust the frequency.

The units that will be operating in parallel must
operate at the same speed. Speed is proportional
to the alternating current frequency. Verify that the
generator set is programmed to run at the correct
frequency.
3. Adjust the voltage.
SEBU9048-09 53
Operation Section
Parallel Operation
Refer to this Operation and Maintenance Manual, 5. The lights are off when the voltages of the two
“Voltage Regulators”. units are in-phase. Very quickly close the breaker
while the lights are out.
Note: Make sure that the speed droop is identical
for all of the engines before adjustments are made 6. Use governor controls in order to share kW load
to the generator. between engines.
a. 7. Generator temperature will be stabilized in

approximately 1 hour. After the generator
Note: Do not change the voltage settings after this temperature has been stabilized, adjust the
step. voltage droop rheostat of each generator. This
adjustment will share the reactive load and thus
b. will limit the circulating currents. Less droop
4. Check the winding pitch. increases the reactive current that is carried by the
generator. Adjusting the voltage droop rheostat in
The units that operate in parallel must have the
a counterclockwise direction will decrease the
same winding pitch to reduce the effect of
droop. Adjusting the voltage droop rheostat in a
circulating currents. It is possible to parallel units
clockwise direction will increase droop.
with different winding pitches after the amount of
circulating current flow between each of the units
has been determined. Contact your Cat dealer for
Load Division and Speed Droop (If
further information. Equipped)
Starting Multiple Units Once two units have been paralleled, the share of the
kW load for each unit is determined by the governor
control setting. If two units of the same capacity and
Use the procedure for starting single units in order to the same governor characteristics have the same
start multiple units. Refer to Operation Section, governor control settings, the units will share the load
“Single Unit Operation”. equally. The total load must not exceed the capacity
of the one engine.
Paralleling Multiple Units
In order to transfer the load from one engine to
Units may be paralleled at no load. Units may also be another engine, use the following procedure:
paralleled with units under load. After the initial 1. Increase the governor speed control of one unit in
conditions for start-up are satisfied, verify for the
following requirements: order to increase the load.
2. Reduce the governor speed control of the other
• One of the governors can be an isochronous
unit in order to decrease the load on that unit.
governor. Electronic load sharing governors are
an exception.
• Generators must have voltage droop
compensation or cross current compensation.
1. Start the unit which will be paralleled.

2. Turn on the synchronizer lights.
3. After the engine has run a few minutes, bring the
engine up to synchronous speed. This means that
the frequency of the incoming unit will be the same
frequency as the unit that is on-line. The
synchronizing lights will begin to blink.
Note: The frequency of the incoming unit should be
slightly greater than the line frequency. This will allow
the incoming unit to assume some of the load instead
of adding to the system load.
4. By using the governor control, adjust the engine

speed until the lights blink very slowly.
54 SEBU9048-09
Operation Section
Parallel Operation
3. Raise the governor speed control or lower the 2. The division of power is not determined by
governor speed control of both units in order to generator excitation or terminal voltage. The
change system frequency. excitation will determine the power factor for a
generator when the generator is operating in
Parallel Operation Of Governors parallel with other generators.
Governors that are used with Caterpillar powered
electric sets can be of two types:
• Governors with fixed speed droop

• Governors with adjustable speed droop
The values of speed droop which are commonly used
are 5 percent. Governors with adjustable speed
droop can be adjusted so the characteristics match
closely with the characteristics of governors with
fixed speed droop. If the governor is adjusted for 0
percent speed droop or isochronous operation, the
same speed from no load to full load can be
obtained.
Illustration 37 g00630841 Summary on Governor Operation

Load Sharing Module (Typical Example)
The preceding discussion of governor operation can
be summarized below:
The generator set load sharing module provides
either the droop load sharing or the isochronous load • Each governor should have a 5 percent speed
sharing for parallel applications. The load sharing droop to provide the simplest combination of
module has a synchronizing parallel module SPM-A
input. The module provides the proportional load governors for electric sets that are connected in
sharing. More information is available in the System parallel. If a constant frequency from no load to full
Operation, Testing and Adjusting, SENR6565, load is required, one governor can be adjusted for
“Generator Set Load Sensor and Generator Load isochronous operation. This isochronous unit will
Sharing Module”. be called a “lead unit” .
Function of The Engine Governor • In order for all paralleled units to accept the full
share of the load, the following governor
This section describes the function of the engine adjustments are required. The governors should
governor in relation to load division between parallel have the same full load speed. The governors
electric sets. should have the same high idle speed in the case
of governors which are adjusted for speed droop
It is very important to understand two basic facts operation. Governor controls should be set to the
about load division between generator sets which are high idle position so that the full range of the
operating in parallel. governor is available.
1. The power which is supplied to the generator and
• Operating an isochronous governor in parallel with
to the load is a function of the engine. The setting a speed droop governor requires special
of the engine governor and the position of the techniques.
engine governor control determine the amount of
power that is delivered by the engine. Therefore, • Any number of electric sets can be operated in
the governor setting and the position of the parallel. However, only one governor of the group
governor control determine the kW load which is can be adjusted for isochronous operation. The
carried by the generator. A change in the engine exception will be some special cases of electronic
power of any unit in a parallel operation will result governors with automatic load sharing.
in the same change in engine power for each unit
in that parallel operation. In other words, the units Stopping
that are in parallel operation will stay in parallel
In order to remove a generator from the line, perform
operation. the following procedure.
1. Check the load. The load must be less than the
rated capacity of the remaining units.
SEBU9048-09 55
Operation Section
Voltage Regulators
2. Be sure that the neutral of one of the remaining

units is grounded.
3. Remove the load from the outgoing unit. See the
Parallel Operation, “Load Division - Speed Droop”.
The amperage may never go to zero due to
circulating currents.
4. Open the circuit breaker.
5. Allow the engine to cool for 5 minutes.
6. Stop the engine.
Circulating Currents
Understanding the circulating currents becomes very
important when the units are paralleled. These
circulating currents are flowing between generators
in parallel operation. The circulating currents are
caused by voltage differences between the
generators. The circulating currents are not doing
useful work. The amount of the circulating current
can be determined by subtracting the amperage
which is going to the load from the total generator
amperage.
The circulating current may be as high as 25 percent
of rated amperes with cold generator sets. Such
current may not even be considered harmful. The
total generator current should not exceed the Illustration 38 g03844029
amperage rating.
The Cat DVR is a microprocessor-based voltage
As the generators warm, the circulating currents will regulator. Control power for the Cat DVR is supplied
decrease. The ammeter readings should decrease from an external source of 24 VDC. The power stage
slightly, but the voltage meter readings should remain of the Cat DVR is supplied from a multiple pole high
constant. frequency permanent magnet generator. The multiple
pole high frequency permanent magnet generator is
i06191154 mounted on the end of the generator shaft.
Connections to the Cat DVR are made through three
Voltage Regulators connectors. The communication between the Cat
DVR and the service tool is accomplished by using a
SMCS Code: 4467 CANBUS protocol.
The Cat DVR has the following features:
Cat Digital Voltage Regulator (Cat
DVR) • Three control modes:
1. Automatic voltage regulation (AVR)

2. Power factor (PF) regulation
The Cat Digital Voltage Regulator presents an 3. Reactive power (VAR) regulation
electrical shock/electrocution hazard. This
hazard will cause serious injury or death. • Programmable stability settings
Service by trained personnel only.
• Soft start control with an adjustable time setting in
The terminals and heat sinks are live at AVR mode
hazardous voltages when power is applied and
for up to 8 minutes after power is removed. • Dual slope voltage versus frequency (V/Hz)
characteristic
• Three-phase or single-phase voltage sensing

• Single-phase current sensing
56 SEBU9048-09
Operation Section
Voltage Regulators
• Field current sensing and field voltage sensing

• Ten protection functions
Adjusting the Cat DVR

In order to view and configure the parameters of the
Cat DVR, a PC with the Cat DVR software is
required.
Refer to Specifications, Systems Operation, Testing
and Adjusting, RENR7941, “Cat Digital Voltage
Regulator” for complete information.
Integrated Voltage Regulator (IVR)

The Integrated Voltage Regulator (IVR) provides
excitation current to the generator. The IVR is
controlled by the IVR function in the EMCP4. The IVR
function allows the EMCP4 to control the generator
voltage, optimize transient performance, and provide
feature specification.
The excitation module may interface with any of the
following excitation systems: Self Excitation (SE),
Internal Excitation (IE) and Permanent Magnet
(PMG) excitation systems.
For additional information about the IVR, see
Application and Installation, LEBE0006, and Special
Instruction, REHS9106.
SEBU9048-09 57
Operation Section
Voltage Regulators
Excitation Module 10 (EM10)
(1) Connector P3 (2) Connector P2 (3) Connector P4
EMCP IVR Connection (Table 4, contd)

Battery nega-
To regulate the generator terminal voltage, the EMCP tive splice
60 or 65 CS- P3-3
communicates the desired excitation command to the
excitation module through a pulse width modulation Battery nega-
(PWM) signal. A twisted pair of shielded cable must 60 or 65 Shield P3-1
tive splice
be used for the communication link. Table 4 details
the connections to be made between the EMCP and EMCP 4.3 and EMCP 4.4 Connections to Excitation Module
Excitation Module. (120-pin connector)
Table 4
EMCP 4.3 and EMCP 4.4 120- Excitation Module 3-Pin
EMCP 4.1 and EMCP 4.2 Connections to Excitation Module Pin Connector Connector
(70-pin connector)
PWM Output
28 CS+ P3-2
EMCP 4.1 and EMCP 4.2 70- Excitation Module 3-Pin #2 Positive
Pin Connector Connector
PWM Output
Digital Output 8 CS- P3-3
#2 Negative
68 CS+ P3-2
#2 / IVR CS+
Shield 19 Shield P3-1
(continued)
58 SEBU9048-09
Operation Section
Voltage Regulators
Table 5 provides information on the technical Note: The X2 and Z1 connections are internally
specification of the EM10 and EM15 modules. linked within the excitation module. The link provides
Selection of the appropriate module must be a point of common connection for the auxiliary
determined by the following: windings where an AREP or IE excitation supply is
available. Also, the X2 and Z1 connections may be
• Nominal and maximum generator excitation linked externally to the excitation module. Only three
current at full load (standby 0.8 PF). connections (X1, X2, and Z2) are needed for the EM.
• The maximum AC voltage input. Refer to Systems Operation/Test and Adjust/
Troubleshooting, UENR1209, “Integrated Voltage
Table 5 Regulator Connections” for excitation module wiring
connections. The wiring diagrams are for self-
EM10 and EM15 Technical Specifications
excitation (shunt), auxiliary windings (AREP/IE), and
EM10 EM15 permanent magnet (PM) configurations.
Compatible Genera- Permanent Magnet (PM) Self-Excitation The voltage regulator knee frequency must be
tor Excitation Types (SE) Internal Excitation (IE/AREP)(1) configured for your specific package requirements.
Nominal Field Cur- The knee frequency for 50 Hz operation will usually
rent Output
6A 7A be between 48.0 and 49.8 Hz. For 60 Hz operation,
the parameter must be set between 58.0 to 59.8 Hz.
Maximum (forcing)
10A 15A Refer to Illustration 38 for an example under-
Field Current Output
frequency roll-off (loading) profile.
Maximum AC Volt-
180Vms 240Vms
age Input
(1) Internal Excitation (IE is also referred to as “Auxiliary Regula-
tion Excitation Principle”(AREP)
IVR Excitation Module Connections

The EM10 and EM15 excitation modules have three
plug type multiple-pin connectors. The connectors
are labeled P2, P3, and P4 as shown in illustration 39
. Table 6 describes the signal and function of each
connector pin.
Table 6
Excitation Module Connections
Terminal Label Signal/Function
P2-1 F+ Exciter Field Positive
P2-2 F- Exciter Field Negative
P3-1 Shield Excitation Command Control

Signal Shield
P3-2 CS+ Excitation Command Control

Signal Positive
P3-3 CS- Excitation Command Control

Signal Negative
P4-1 X2 Excitation Power Supply In-

put X2
P4-2 Z1 Excitation Power Supply In-

put Z1
P4-3 X1 Excitation Power Supply In-

put X1
P4-4 Z2 Excitation Power Supply In-

put Z2
SEBU9048-09 59
Operation Section
Voltage Regulators
Under-frequency (loading) profile slope1 = 1.0 V/Hz, slope2 = 2.0 V/Hz
60 SEBU9048-09
Operation Section
Cold Weather Operation
Cold Weather Operation • Check all rubber parts (hoses, fan drive belts, and
so on) weekly.
i04557066 • Check all electrical wiring and connections for any
fraying or damaged insulation.
• Keep all batteries fully charged and warm.
SMCS Code: 1000; 1250
• Fill the fuel tank at the end of each shift.
Cat Diesel Engines can operate effectively in cold
weather. The starting and the operation of the diesel • Check the air cleaners and the air intake daily.
engine is dependent on the following items in cold Check the air intake more often when you operate
weather: in snow.
• The type of fuel that is used
• The viscosity of the oil
Personal injury or property damage can result
• Optional starting aids from alcohol or starting fluids.
• Optional warm-up aids Alcohol or starting fluids are highly flammable

and toxic and if improperly stored could result in
Refer to Special Publication, SEBU5898, “Cold injury or property damage.
Weather Recommendations for Cat Machines”.
The purpose of this section will cover the following
information:
• Explain potential problems that are caused by DO NOT USE ETHER (starting fluids) unless spe-
cold-weather operation. cifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
• Suggest steps which can be taken in order to fuel ignited manifold heater), DO NOT use ether
minimize starting problems and operating (starting fluids) at any time. The use could result
problems when the ambient air temperature is in engine damage and/or personal injury.
colder than 0 to −55 °C (32 to −67 °F).
The operation and maintenance of an engine in NOTICE
freezing temperatures is complex because of the The optional automatic ether injection system is the
following conditions: the unlimited differences in only starting fluid system that is recommended. Ex-
weather conditions, engine applications and the cessive starting fluid can cause piston and ring dam-
supplies that are available in your area. These age. Use starting fluid for cold starting purposes only.
factors, recommendations from your Cat dealer, past
proven practices, and the information that is
contained in this section should be combined to • Inject starting fluid only when the engine is
provide guidelines for cold-weather operation. cranking.
Hints for Cold Weather Operation • Dryers for the air system may be effective in
reducing moisture condensation and the formation
• If the engine is started, operate the engine until a of ice in air systems.
minimum operating temperature of 71 °C (160 °F)
• The injection of alcohol may prevent moisture from
is achieved. Achieving operating temperature will
freezing the air compressor governor and other
help prevent the intake valves and exhaust valves
components of the air system.
from sticking.
• The cooling system and the lubrication system for
the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
down for a few hours and the engine will start
readily. If the engine is shut down for at least
8hours, the engine should be considered cooled to
outside temperature.
• Install the correct lubricant in each compartment

before the beginning of cold weather.
SEBU9048-09 61
Operation Section
• For jump starting with cables in cold weather, refer Jacket Water Heater
to the Operation and Maintenance Manual for
jump starting instructions. A jacket water heater heats the coolant that
surrounds the combustion chamber providing the
following functions:
Viscosity of the Engine Lubrication
Oil • Startability is improved.
Proper engine oil viscosity is essential. Oil viscosity • Warm up time is reduced.
affects the amount of torque that is needed to crank
the engine. Refer to the Operation and Maintenance • The required temperature for ether is reduced.
Manual, “Fluid Recommendations” for the
recommended viscosity of oil. An electric jacket water heater can be activated once
the engine is stopped. An effective jacket water
heater is typically a 1500 W unit. Consult your marine
Lubricating Oil Heaters dealer for more information.
Note: Oil pan immersion heaters are not
recommended for heating the lube oil. To ensure the Idling the Engine
compatibility of the components, only use equipment
that is recommended by Caterpillar. While the engine is idling, the application of a light
load (parasitic load) will assist in maintaining the
minimum operating temperature. The minimum
NOTICE operating temperature is 71 °C (160 °F). Maintaining
Heating elements that are in direct contact with the an elevated low idle speed for extended periods will
lubricating oil can cause coking of the oil. be easier with the installation of a hand throttle. An
idle speed of 1200 rpm is preferred for all engines.
To aviod coking of the oil when the oil is heated, fol-
low these recommendations:
Recommendations for Coolant
The temperature of the heating surface must not ex-
ceed 150 °C (300 °F). The maximum heat density of Warm Up
the heating surface must not exceed 1.24 w/cm2
(8W/in2). Warm up any system that has cooled below normal
operating temperatures due to inactivity. The warm-
Engine oil pan heaters are useful devices that up should be performed before the engine is returned
provide the following functions: to full operation. During operation in very cold
temperature conditions, damage to engine valve
• Assist in reducing the cold cranking amperage mechanisms can result from engine operation for
that is needed to start the engine. short intervals. This damage can happen if the
engine is started and the engine is stopped many
• Improve the flow of oil at start-up. times without being operated in order to warm up
completely.
• The time that is needed to warm up the engine is
reduced. When the engine is operated below normal operating
temperatures, fuel and oil are not completely burned
• The service life of bearings is increased. in the combustion chamber. This fuel and oil causes
soft carbon deposits to form on the valve stems.
Engine oil pan heaters can reduce the minimum Generally, the deposits do not cause problems and
ambient temperatures that are normally the deposits are burned off during operation at
recommended for multigrade oil. Consult your dealer normal engine operating temperatures.
for more information.
When the engine is started and stopped without
operating long enough to warm up completely, the
Recommendations for the Coolant carbon deposits become thicker. The carbon
deposits will cause the following problems:
Provide cooling system protection for the lowest
expected outside temperature. Refer to the • Free operation of the valves is prevented.
Operation and Maintenance Manual, “Fluid
Recommendations” for the recommended coolant • Valves become stuck.
mixture.
• Pushrods are bent.
In cold weather, check the coolant often for the
proper glycol concentration in order to ensure • Other damage to valve train components can
adequate freeze protection.
result.
62 SEBU9048-09
Operation Section
Fuel and the Effect from Cold Weather
For this reason, when the engine is started, the Additional heat can be retained around the engine by
engine must be operated until the coolant insulating the engine compartment.
temperature is 71 °C (160 °F) minimum. Carbon
deposits on the valve stems are kept at a minimum i04408649
and the free operation of the valves and the valve
components are maintained.
Fuel and the Effect from Cold
Warm the engine thoroughly to keep other engine
parts in better condition. The service life of the engine
Weather
will be extended. Lubrication will be improved. There SMCS Code: 1000; 1250; 1280
will be less acid and less sludge in the oil. The better
condition of the oil will provide longer service life for The following fuels are the grades that are available
the engine bearings, the piston rings, and other parts. for Cat engines:
However, limit unnecessary idle time to 10 minutes.
Engine wear is greatest at low idle and unnecessary • No. 1
idling wastes fuel.
• No. 2
On/Off Fan Clutch • Blend of No. 1 and No. 2
Viscous fans continuously rotate in cold weather, No. 2 diesel fuel is the most commonly used fuel.
which creates unnecessary movement of the air. For Either No. 1 diesel fuel or a blend of No. 1 and No. 2
better control of the operation of the fan, an ON/OFF is best suited for cold-weather operation.
fan clutch may be used. ON/OFF fan clutches can
help prevent excessive cooling in cold weather. In the Quantities of No. 1 diesel fuel are limited. No. 1
“OFF” position, the fan is kept stationary by the ON/ diesel fuels are usually available during the months
OFF fan clutch. The unnecessary movement of the of the winter in the colder climates. During cold-
air is reduced in order to maintain adequate engine weather operation, if No. 1 diesel fuel is not available,
operating temperatures in cold weather. use No. 2 diesel fuel, if necessary.
Purge Valve and Insulated Heater Lines There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
During periods of operations with a light load, The
coolant must bypass the radiator in order to help • Lower cloud point
prevent excessive cooling of the engine. Coolant that
passes through the radiator must be minimized in • Lower pour point
order to maintain the engine operating temperature in
cold weather. • Lower rating of kJ (BTU) per unit volume of fuel
Excessive cooling of the engine is prevented by a When No. 1 diesel fuel is used, a decrease in power
“jiggle” valve that performs two functions. The valve and in fuel efficiency may be noticed. Other operating
allows the flow of air and the valve prevents the flow effects should not be experienced.
of coolant. These valves prevent the unnecessary
coolant flow, which may be diverted around the water The cloud point is the temperature when a cloud of
temperature regulator to the radiator. wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
Insulated cab heater lines for very cold weather are temperature when diesel fuel will thicken. The diesel
also beneficial. These lines provide more available fuel becomes more resistant to flow through fuel
heat from the coolant to the cab and less heat is lost pumps and through fuel lines.
to the outside air.
Be aware of these values when diesel fuel is
Insulating the Air Inlet and Engine purchased. Anticipate the average ambient
Compartment temperature of the area. Engines that are fueled in
one climate may not operate well if the engines are
When temperatures below −18 °C (−0 °F) will be moved to another climate. Problems can result due to
changes in temperature.
frequently encountered, an air cleaner inlet that is
located in the engine compartment may be specified. Before troubleshooting for low power or for poor
The special air cleaner inlet is sometimes referred to performance in the winter, check the type of fuel that
as a snow valve. An air cleaner that is located in the is being used.
engine compartment may also minimize the snow
that is packed in the air cleaner. Heat that is rejected When No. 2 diesel fuel is used, the following
by the engine warms the inlet air. components provide a means of minimizing problems
in cold weather:
• Starting aids
SEBU9048-09 63
Operation Section
Fuel Related Components in Cold Weather
• Engine oil pan heaters When the engine is equipped with a primary filter/
water separator, the primary filter/water separator
• Engine coolant heaters must use a 10 micron filter to a 15 micron filter. The
filters are becoming more critical as fuel injection
• Fuel line insulation pressures increase to 209 MPa (30000 psi) and
higher psi. For more information on priming the fuel
For more information on cold-weather operation, see system, see the Operation and Maintenance Manual,
Special Publication, SEBU5898, “Cold Weather “Fuel System - Prime” topic.
Recommendations”.
i04369188
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
Fuel Related Components in in cold weather due to waxing. A fuel heater should
Cold Weather be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
SMCS Code: 1000; 1250; 1280
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
Fuel Tanks also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
Condensation can form in partially filled fuel tanks. availability of engine power. Choose a fuel heater
Top off the fuel tanks after operating the engine. with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
Fuel tanks should contain some provision for draining to the limited surface area.
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water Disconnect the fuel heater in warm weather.
and sediment to settle below the end of the fuel
supply pipe. Note: Only use fuel heaters that are controlled by the
water temperature regulator or fuel heaters that are
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is self-regulating. Fuel heaters that are not controlled by
equipped with this system, regular maintenance of the water temperature regulator can heat the fuel in
the fuel system filter is important. excess of 65° C (149° F). A loss of engine power can
occur if the fuel supply temperature exceeds 37° C
Draining the fuel tank will help prevent water and/or (100° F).
sediment from being pumped from the fuel storage
tank and into the engine fuel tank. Drain the water Note: Heat exchanger type fuel heaters should have
and sediment from any fuel storage tank at the a bypass provision in order to prevent overheating of
following intervals: the fuel when the engine operates in warm weather.
• Weekly For further information on fuel heaters, consult your

Cat dealer.
• Oil changes
• Refueling of the fuel tank
Fuel Filters
NOTICE
Do not fill the fuel filters with fuel before installing
them. The fuel would not be filtered and could be con-
taminated. Contaminated fuel will cause accelerated
wear to fuel system parts.
NOTICE
Caterpillar requires the use of a 4 micron (c) secon-
dary fuel filter for the following reasons: to maximize
fuel system life and to prevent premature wear out
from abrasive particles in the fuel. Cat high efficiency
fuel filters meet these requirements. Consult your Cat
dealer for the proper part numbers.
64 SEBU9048-09
Operation Section
Engine Stopping
Engine Stopping i05237815
i03893229
Manual Stop Procedure
SMCS Code: 1000; 7418
Emergency Stopping
SMCS Code: 1000; 7418 NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
NOTICE celerated wear of the engine components.
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices If the engine has been operating at high rpm and/or
or controls for normal stopping procedure. high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
Ensure that any components for the external system fore stopping the engine.
that support the engine operation are secured after
the engine is stopped. Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.
1. Reduce the engine rpm to low idle.

2. Increase the engine rpm to no more than 50
percent of the rated rpm for 3 to 5 minutes in order
to cool the engine. Reduce the engine rpm to low
idle.
3. Push the “STOP” switch.
i04137729
After Stopping Engine

Illustration 41 g00104303 SMCS Code: 1000
Typical emergency stop button Note: After operation, allow 10 minutes for the
engine oil to return to the oil pan before checking the
The emergency stop button is in the OUT position for
normal engine operation. For an emergency stop, engine oil level.
push the emergency stop button. This shuts off the • Check the crankcase oil level. Maintain the oil
fuel to the engine. This also activates the air shutoff
level between the “ADD” mark and the “FULL”
(if equipped).
mark on the oil level gauge.
NOTICE Note: Only use oil that is recommended in this
Do not start the engine until the problem necessitat-
ing the emergency stop has been located and
corrected. Recommendations” article. Failure to do so may
result in engine damage.
The engine control switch and the emergency stop • If necessary, perform minor adjustments. Repair
button must be reset before the engine can be any leaks and tighten any loose bolts.
restarted. The air shutoff (if equipped) must be reset
before the engine can be restarted. Reset the engine • Note the service hour meter reading. Perform the
control switch before resetting the emergency stop maintenance that is in the Operation and
button. Maintenance Manual, “Maintenance Interval
Schedule”.
To reset the engine control switch, turn the switch to
the “OFF/RESET” position. • Fill the fuel tank to prevent accumulation of
moisture in the fuel. Do not overfill the fuel tank.
To reset the emergency stop button, turn the button
clockwise. The spring-loaded button will return to the • Allow the engine to cool. Check the coolant level.
OUT position. The button may also be pulled to the Maintain the cooling system at 13 mm (0.5 inch)
OUT position. from the bottom of the pipe for filling.
SEBU9048-09 65
Operation Section
After Stopping Engine
Note: Only use coolant that is recommended in this

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

driven equipment. This maintenance is outlined in
the instructions from the OEM.
66 SEBU9048-09
Maintenance Section
Refill Capacities
Maintenance Section (Table 10, contd)

Total Volume of the Jacket
118.1 L (31.2 US gal)
Water System(1)
Refill Capacities Make-up volume 5 L (1.3 US gal)
Total Volume of the SCAC Sys-

79.5 L (21 US gal)
i05612971 tem(2)
Refill Capacities Make-up volume 3 L (0.8 US gal)

(1) Total volume is to the “FULL” mark on the jacket water expan-
SMCS Code: 1000; 1348; 1395; 7560 sion tank sight gauge.
(2) Total volume is to the “FULL” mark on the SCAC expansion
tank sight gauge.
Lubrication System Capacity
i07277454
The capacity of the lubrication system includes the
capacity of the oil filters that are installed at the
factory. Fluid Recommendations
Auxiliary oil filter systems (if equipped) will require SMCS Code: 1280; 1348; 1395; 7560
additional oil. Refer to the specifications that are
provided by the OEM of the auxiliary oil filter system. Note: Refer to the emissions label on the engine to
determine to which emissions regulation the engine
For the recommended oil, see this Operation and is certified.
Maintenance Manual, “Fluid Recommendations”
topic. Note: The interval for changing the coolant varies
Table 7 depending on the type of coolant being replaced.
Refer to this article, “Coolant Recommendations”for
Lubricant Refill Quantity(1) the intervals.
68 L 72 qt
Note: For more information, refer to Special
(1) Refill quantities include oil for the filters installed at the factory. Publication, SEBU6251, “Cat Commercial Diesel
Engine Fluids Recommendations”.
Cooling System Capacity
Diesel Engine Oil
For the recommended coolant, refer to this Operation
and Maintenance Manual, “Fluid Recommendations” Cat Diesel Engine Oil (Cat DEO)
topic.
Table 8 Cat oils have been developed and tested to provide
C18 Hex Cooled Engines the full performance and service life that has been
designed and built into Cat engines. Cat oils are
System Coolant Refill Capacity currently used to fill Cat Diesel Engines at the factory.
These oils are offered by Cat dealers for continued
Jacket water system 43 L (11.3 US gal)
use when the engine oil is changed. Consult your Cat
SCAC system 24.7 L (6.5 US gal) dealer for more information on these oils.
Due to significant variations in the quality and in the
Table 9 performance of commercially available oils,
C18 Keel Cooled Engines Caterpillar makes the following recommendations:
System Coolant Refill Capacity Note: Cat DEO and Cat DEO-ULS multigrade oils
are the preferred oils for use in this Cat Diesel
Jacket water system 41 L (11 US gal) Engine.
SCAC system 17.2 L (4.5 US gal)
Table 11
Commercial Viscosity Grade
Table 10 Cat Lubricants
Lubricants
C18 Radiator Cooled Engines
Diesel Engine Oil-Ul- SAE 15W-40
System Coolant Refill Capacity tra Low Sulfur (API Cat DEO-ULS
CJ-4) SAE 10W-30
(continued)
(continued)
SEBU9048-09 67
Maintenance Section
Fluid Recommendations
(Table 11, contd) A commercial oil must meet the following standards
Commercial
to be considered an equivalent of a Cat diesel engine
Cat Lubricants Viscosity Grade oil:
Lubricants
Table 12
Cat DEO-ULS SYN SAE 5W-40
Cat Engine Crankcase Fluids (ECF) Definitions
Cat DEO Cold
SAE 0W-40 Cat Performance
Weather API Oil Category
Requirement
Diesel Engine Oil SAE 15W-40
(API CI-4/CI-4 PLUS Cat DEO API CJ-4 Oil Category performance
SAE 10W-30 Cat ECF-3
and API CH-4) requirements
API CI-4 / CI-4 PLUS Oil Category perform-

Engines which are Certified to US Marine ance requirements and
Environmental Protection Agency (EPA) Tier 3 Passing standard Cat C13 engine test per
Cat ECF-2
Regulations API requirements and
Oils of sulfated ash > 1.50 percent are not
allowed
NOTICE API CH-4 Oil Category performance require-
An engine certified to US Environmental Protection
ments and
Agency (US EPA) Marine Tier 3 regulations which is
For oils that are between 1.30 percent and
installed in a US flagged vessel must use ultra-low 1.50 percent sulfated ash, passing one more
sulfur diesel fuel (ULSD fuel) as defined by 40 CFR Cat ECF-1-a
Cat 1P SCOTE test (“ASTM D6681”) is re-
part 80.510 (c). When an engine is not installed in a quired and
US flagged vessel, refer to applicable local or Inter- Oils of sulfated ash > 1.50 percent are not
national Maritime Organization (IMO) regulations for allowed
fuel requirements.
Caterpillar recommends the use of Cat DEO-ULS for Engines which are Certified to US Marine
engines that use ultra-low sulfur diesel fuel (ULSD Environmental Protection Agency (EPA) Tier 3
fuel) or sulfur-free diesel fuel. Cat DEO-ULS has the Regulations
proper amount of lubricity for engines using ULSD.
The use of engine oil that meets Cat Engine Engines certified to US Marine EPA Tier 3
Crankcase Fluid specifications (Cat ECF-3) Regulations installed on a US flagged vessel and not
specifications is acceptable. Refer to this article using Cat DEO-ULS, Caterpillar recommends using
“Commercial Oil” for more information. an oil that meets the following standards: Cat ECF-3
specification and API CJ-4 oil category.
Engines which are Not Certified to US Marine EPA
Tier 3 Regulations Lubricant Viscosity
Cat DEO is recommended for engines using fuels of In selecting oil for any engine application, both of the
sulfur levels that exceed 0.2 percent (> 2000 ppm following must be satisfied: the oil viscosity and the
(mg/kg) ). Cat DEO-ULS may be used in these category of oil performance or the specification for oil
applications if an oil analysis program is followed. performance . Using only one of these parameters
The oil change interval may be affected by the fuel will not sufficiently define oil for an engine
sulfur level. Refer to this Operation and Maintenance application.
Manual, “Engine Oil Sample - Obtain” for more
information about the Cat S·O·S Oil Sampling The proper SAE viscosity grade of oil is determined
program. by the following temperatures: minimum ambient
temperature during cold engine start-up and
Commercial Oil maximum ambient temperature during engine
operation.
Note: Non-Cat commercial oils are, as a group,
second choice oils. Within this grouping of second Refer to Table 13 (minimum temperature) to
determine the required oil viscosity for starting a cold
choice oils there are tiered levels of performance. engine.
NOTICE Refer to Table 13 (maximum temperature) to select

Caterpillar does not warrant the quality or perform- the oil viscosity for engine operation at the highest
ance of non-Cat fluids. ambient temperature that is anticipated.
The three current Caterpillar ECF specifications are: Note: Generally, use the highest oil viscosity that is
Cat ECF-1-a, Cat ECF-2, and Cat ECF-3. Each available to meet the requirement for the temperature
higher Cat ECF specification provides increased at start-up.
performance over lower Cat ECF specifications.
68 SEBU9048-09
Maintenance Section
Table 13
Lubricant Viscosities for Ambient Temperatures for (Table 14, contd)
Cat Diesel Engines (2) Use of an oil analysis program to determine oil drain intervals is
recommended if fuel sulfur is between 0.05% (500 ppm) and
Oil Type and Per- °C °F 0.5% (5000 ppm).
Viscosity (3) Use of an oil analysis program to determine oil drain intervals is
formance
Grade Min Max Min Max required if fuel sulfur is above 0.5% (5000 ppm).
Requirements
(4) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
refer to TBN and engine oil guidelines given in this section.
Cat Cold-Weather (5) Cat DEO-ULS may be used if an oil analysis program is fol-
SAE 0W-40 −40 40 −40 104
DEO-ULS lowed. High fuel sulfur levels may reduce the oil drain intervals.
Cat DEO-ULS SYN SAE 5W-40 −30 50 −22 122
SAE 10W-30 −18 40 0 104
S·O·S Services Oil Analysis
Cat DEO-ULS
Cat DEO SAE 15W-40 −10 50 14 122 Caterpillar has developed a maintenance tool that
SAE 0W-30 −40 30 −40 86
evaluates oil degradation. the maintenance
Cat ECF-1-a, Cat management also detects the early signs of wear on
ECF-2, Cat ECF-3
SAE 5W-30 −30 30 −22 86 internal components. The Cat tool for oil analysis is
SAE 10W-40 −18 50 0 122
called S·O·S oil analysis and the tool is part of the
S·O·S Services program. S·O·S oil analysis divides
oil analysis into four categories:
Note: A cold soaked start occurs when the engine
has not been operated recently, allowing the oil to • Component wear rate
become more viscous due to cooler ambient
temperatures. Supplemental heat is recommended • Oil condition
for cold soaked starts below the minimum ambient • Oil contamination
temperature. Supplemental heat may be necessary
for cold soaked starts that are above the minimum • Identification of oil
temperature depending on factors such as parasitic
load. These four types of analysis are used to monitor the
condition of your equipment. The four types of
Total Base Number (TBN) and Fuel Sulfur analysis will also help you identify potential problems.
A properly administered S·O·S oil analysis program
Levels reduces repair costs and the program will lessen the
impact of downtime.
The use of Cat S·O·S Services oil analysis is
recommended strongly for determining oil life. The S·O·S Oil Analysis program uses a wide range
of tests to determine the condition of the oil and the
The minimum required Total Base Number (TBN) for crankcase. Guidelines that are based on experience
oil depends on the fuel sulfur level. The TBN for new and a correlation to failures have been established
oil is typically determined by the “ASTM D2896” for these tests. Exceeding one or more of these
procedure. For direct injection engines that use guidelines could indicate serious fluid degradation or
distillate fuel, the following guidelines apply: a pending component failure. A trained person at
Table 14 your Cat dealership should make the final analysis.
TBN recommendations for applications in Cat engines
NOTICE
Fuel Sulfur Level per- TBN of Commercial Always use a designated pump for oil sampling, and
Cat Engine Oils (1) use a separate designated pump for coolant sam-
cent (ppm) Engine Oils
pling. Using the same pump for both types of sam-
0.05 percent Cat DEO-ULS ples may contaminate the samples that are being
Min 7
(500ppm) Cat DEO drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
>0.05-0.2 percent Cat DEO cerns by both dealers and customers.
Min 10
(>500- 2000 ppm) (2) Cat DEO-ULS
Above 0.2 percent

Cat DEO (5) Min 10
(above 2000ppm) (3)(4)
(1) Cat DEO-ULS applies to Cat DEO-ULS SAE 15W-40,
SAE10W-30, Cat DEO-ULS SYN SAE 5W-40, and Cat DEO
Cold-Weather SAE 0W-40. Cat DEO applies to Cat DEO SAE
15W-40 and SAE 10W-30.
(continued)
SEBU9048-09 69
Maintenance Section
Refer to Special Publication, SEBU6251, “Cat

Commercial Diesel Engine Fluids
Recommendations” to obtain additional information
about S·O·S Services oil analysis. You can also
contact your local Cat dealer.
Fuel
Note: Caterpillar strongly recommends the filtration
of fuel through a fuel filter with a rating of four
microns(c) absolute or less. This filtration should be
on the device that dispenses the fuel to the fuel tank
for the engine. This filtration should also be on the
device that dispenses fuel from the bulk storage tank.
Series filtration is recommended.
NOTICE NACD Film

In order to meet expected fuel system component life,
4 micron (c) absolute or less secondary fuel filtration • Ultra-low Sulfur Diesel Fuel (ULSD fuel). ULSD
is required for all Cat Diesel Engines that are fuel contains ≤0.0015 percent (≤15 ppm (mg/kg) of
equipped with unit injected fuel systems. All current sulfur.
Cat Diesel Engines are factory equipped with Cat Ad-
vanced Efficiency 4 micron(c) absolute fuel filters. • Approved blends of biodiesel fuel. Refer to the
“Biodiesel” topic in this article for more
Caterpillar does not warrant the quality or perform- information.
ance of non-Cat fluids and filters.
The use of diesel fuel that contains >0.0050 percent
(>50 ppm (mg/kg)) of sulfur may cause the
Fuel for Cat Marine Diesel Engines aftercooler to foul. Fouling of the aftercooler may
which are certified to United States
Environmental Protection Agency Tier 3 Note: If the engine operates in an area outside of US
Standards (US EPA Tier 3 Standards) EPA jurisdiction and where fuel quality is unknown,
refer to EPA regulations for instructions on obtaining
a migratory exemption. To operate a Cat Marine
NOTICE Diesel Engine which is certified to US EPA Marine
An engine certified to US Environmental Protection Tier 3 Standards with fuel that contains >50 ppm (mg/
Agency (US EPA) Marine Tier 3 regulations which is kg) of sulfur, modifications to the crankcase
installed in a US flagged vessel must use ultra-low
ventilation system (CCV system) must be made to
sulfur diesel fuel (ULSD fuel) as defined by 40 CFR
part 80.510 (c). When an engine is not installed in a prevent fouling of the aftercooler. Crankcase fumes
US flagged vessel, refer to applicable local or Inter- cannot be routed back into the engine air intake
national Maritime Organization (IMO) regulations for when the engine is operating with fuel that contains
fuel requirements. >50 ppm (mg/kg) of sulfur. Contact your Cat dealer
for more information.
Cat Marine Diesel Engines which are certified to US
EPA Tier 3 Standards are designed to operate with Specifications for Distillate Diesel Fuel
the following types of fuel:
Note: Diesel fuel used to operate a Cat Marine
Diesel Engine which is certified to US EPA Tier 3
Standards must also meet the “Cat Specification for
Distillate Diesel Fuel for Off-Highway Diesel
Engines”. The acceptability of these fuels for use is
determined on a case by case basis. A complete fuel
analysis is required. Consult your Cat dealer for
further information.
NOTICE
The footnotes are a key part of the “Caterpillar Speci-
fication for Distillate Diesel Fuel for Off-Highway Die-
sel Engines” Table. Read ALL of the footnotes.
70 SEBU9048-09
Maintenance Section
Table 15
Caterpillar Specification for Distillate Fuel for Nonroad (Table 15, contd)
Diesel Engines
Caterpillar Specification for Distillate Fuel for Nonroad
ASTM Diesel Engines
Specifications Requirements Test ISO Test
ASTM
Aromatics 35% maximum “D1319” “ISO 3837” Specifications Requirements Test ISO Test
0.01% maximum “D1796”
Ash “D482” “ISO 6245” Water and
(weight) 0.05% maximum or “ISO 3734”
Sediment
“D2709”
Carbon Residue 0.35% maximum
“D524” “ISO 4262”
on 10% Bottoms (weight) No equiva-
Water 0.05% maximum “D6304”
lent test
40 minimum (DI
engines) “D613” 0.05% maximum
Sediment “D473” “ISO 3735”
Cetane Number (1) or “ISO 5165” (weight)
35 minimum (PC “D6890”
engines) Gums and Resins 10 mg per 100 mL
(4) “D381” “ISO 6246”
maximum
The cloud point
(1) Alternatively, to ensure a minimum cetane number of 35 (PC
must not exceed
engines), and 40 (DI engines), distillate diesel fuel should have
Cloud Point the lowest ex- “D2500” “ISO 3015” a minimum cetane index of 37.5 (PC engines), and 44.2 (DI en-
pected ambient gines) when the “ASTM D4737-96a” test method is used. A fuel
temperature. with a higher cetane number may be required for operation at a
higher altitude or in cold weather.
Copper Strip (2) Via standards tables, the equivalent kg/m3 (kilograms per cubic
No. 3 maximum “D130” “ISO 2160”
Corrosion meter) using the “ASTM D287” test method temperature of
15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/
10% at 282 °C
m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
(540 °F) (3) Certain Cat fuel systems and engine components can operate
maximum on fuel with a maximum sulfur content of 3%. Contact your Cat
Distillation “D86” “ISO 3405” dealer for guidance about appropriate maintenance intervals
90% at 360 °C
and fluids for engines operating on fuel with sulfur levels be-
(680 °F)
tween 0.1% and 3%.
maximum (4) Follow the test conditions and procedures for gasoline (motor).
Flash Point legal limit “D93” “ISO 2719”
Note: Vessels that are traveling internationally and
Minimum of 80% that have on/off NOx controls must enable these
reflectance after controls prior to entering a NECA. For US flagged
No equiva-
Thermal Stability aging for 180 mi- “D6468”
lent test vessels, on/off controls are not allowed without an
nutes at 150 °C
(302 °F)
exemption during international travel. The controls
must always be on. Foreign destinations should be
30 minimum No equiva- reviewed for supply of ULSD fuel and DEF prior to
API Gravity (2) “D287”
45 maximum lent test departure. Exemptions for ULSD or DEF use by US
flagged vessels may be requested from the US
6 °C (10 °F) mini- Environmental Protection Agency (EPA). The EPA
Pour Point mum below ambi- “D97” “ISO 3016” can be contacted at the following address:
ent temperature
“D5453” ISO 20846

[email protected]
Sulfur (3) or or
Physical address:
“D2622” ISO 20884
1.4 cSt minimum Designated Compliance Officer
and 20.0 cSt max- Heavy-Duty and Nonroad Engine Group 6403-J
imum as delivered U.S. AVE. NW
to the fuel injec- Washington, DC 20460
Kinematic tion pumps
- -
Viscosity 1.4 cSt minimum
and 4.5 cSt maxi-
mum as delivered
to the rotary fuel
injection pumps
(continued)
SEBU9048-09 71
Maintenance Section
Biodiesel
A biodiesel blend of up to 20 percent may be used in
the engine when the fuel blend meets the
recommendations in table 16 and meets the
recommendations in Special Publication, SEBU6251,
“Biodiesel”. A blend of greater than 20 percent
biodiesel may be acceptable sometimes. See your
Cat dealer for more information.
Note: A complete Cat S·O·S Services oil analysis

program is recommended strongly when using
biodiesel blends above 5 percent.
Table 16
Biodiesel Blends for Cat Commercial Diesel Engines
Distillate diesel fuel
Biodiesel blend stock Final blend
used for blend
Caterpillar distillate
Caterpillar biodiesel B20: “ASTM
diesel fuel specifica-
specification, “ASTM D7467” and “API”
tion, “ASTM D975” or
D6751” or “EN14214” gravity 30-45
“EN590”
Cooling System
The cooling system operates under pressure

which is controlled by the pressure cap. Remov-
ing the cap while the system is hot may allow the
escape of hot coolant and steam, causing serious
burns.
Before you remove the pressure cap, allow the
system to cool. Use a thick cloth and turn the
pressure cap slowly to the first stop to allow
pressure to escape before fully removing the cap.
Avoid contact with coolant.
NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.
NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem-
perature or drained completely in order to prevent
damage caused by freezing coolant.
Never operate an engine without water temperature

regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system
problems can develop without water temperature
regulators. Removing the regulators allows some
coolant to bypass the radiator, potentially causing
overheating.
72 SEBU9048-09
Maintenance Section
Coolant Recommendations
Table 17
Coolant Recommendations for use in Cat Diesel Engines
Service Required
Recommendations Product
Hours(1)(2)(3) Maintenance
Add Cat ELC Extender

12000 hours at 6000 service hours
Cat ELC (Cat Extended Life Coolant)
or 6 years or one half of service
life
Preferred
Add Cat ELC Extender
12000 hours at 6000 service hours
Cat ELI (Cat Extended Life Inhibitor)
or 6 years or one half of service
life
Cat EC-1 specification and “ASTM D6210” and
Organic Additive Technology (OAT) based on a combination of a mono-
carboxylic acid and a dicarboxylic acid Add Extender at 3000
6000 hours
Min requirements Phosphate, borate, and silicate free service hours or one
or 6 years
Tolyltriazole: minimum typical concentration of 900 ppm (mg/kg) half of service life
Nitrite: minimum typical concentration of 500 ppm (mg/kg) in new
coolants
SCA (Supplemental
3000 hours
Acceptable Cat DEAC (Cat Diesel Engine Antifreeze/Coolant) coolant additive) at
or 3 years
maintenance intervals
“ASTM D6210” and
Min requirements for fully for- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US gal)
3000 hours SCA at maintenance
mulated Heavy-Duty Com- and maximum of 2400 ppm (140 grains/US gal)
or 2 years intervals
mercial coolants Silicon concentration: minimum of 100 ppm (mg/kg) and maximum of
275 ppm (mg/kg)
“ASTM D4985” and(1)

Min requirements for Com- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US gal) SCA at initial fill and
3000 hours
mercial coolants requiring and maximum of 2400 ppm (140 grains/US gal) SCA at maintenance
or 1 year
SCA precharge Silicon concentration: minimum of 100 ppm (mg/kg) and maximum of intervals
275 ppm (mg/kg)
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets
Reagent 4 “ASTM D1193” requirements.
(2) Maintain the in-service coolant at the given limits.
(3) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.
Table 18
Special Requirements for Cat C7 through C32 Separate Circuit Aftercooled (SCAC) Marine Engines(1)(2)
Maximum of 20% glycol is allowed in the aftercooler circuit (not applicable to the jacket water circuit which is capable of 50% glycol).
Water mixed with ELI or water mixed with SCA are not recommended for use in applications that require freeze protection.(3)(4)(5)
(1) Heat exchanger cooled and keel cooled configurations
(2) For freezing protection of −5° C (23° F) temperatures and lower, consult your Cat dealer for guidance.
(3) For applications that allow the use of Cat ELI and water, a minimum of 7.5% of Cat ELI is recommended.
(4) For applications that allow the use of SCA and water, a minimum of 6% to a maximum of 8% concentration of Cat SCA is recommended.
(5) Refer to Operation and Maintenance Manual, “Cat Commercial Diesel Engine Fluids Recommendations” SEBU6251 for an example of the
amount of ELI to add when diluting ELC.
SEBU9048-09 73
Maintenance Section
• Glycol concentration for freeze protection and boil

NOTICE
Use Only Approved SCAs and Extenders protection
Conventional coolants require the maintenance addi- • Ability to protect from erosion and corrosion
tion of SCA throughout the expected life of the cool-
ants. Do NOT use an SCA with a coolant unless • pH
approved specifically by the coolant supplier. The
coolant manufacturer is responsible for ensuring • Conductivity
compatibility and acceptable performance.
• Visual analysis
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- • Odor analysis
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been The results are reported, and appropriate
approved specifically for use by the coolant manufac- recommendations are made.
turer. The coolant manufacturer is responsible for en-
suring compatibility and acceptable performance. S·O·S Services Coolant Analysis (Level 2)
Failure to follow these recommendations can result in A coolant analysis (Level 2) is a comprehensive
shortened cooling system component life. chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the cooling
Cat ELC can be recycled into conventional coolants. system.
S·O·S Services Coolant Analysis The S·O·S coolant analysis (Level 2) has the
following features:
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and • Full coolant analysis (Level 1)
corrosion. The analysis also tests the ability of the
• Identification of metal corrosion and of
coolant to protect the engine from boiling and
freezing. S·O·S coolant analysis can be done at your contaminants
Cat dealer. Cat S·O·S coolant analysis is the best
• Identification of buildup of the impurities that
way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program cause corrosion
that is based on periodic samples.
• Identification of buildup of the impurities that
Table 19 cause scaling
Recommended Interval • Determination of the possibility of electrolysis
within the cooling system of the engine
Type of Level 1 Level 2
Coolant The results are reported, and appropriate
recommendations are made.
Cat DEAC
Conventional Heavy- Every 250 hours Yearly(1) For more information on S·O·S coolant analysis,
Duty Coolants consult your Cat dealer.
Cat ELC
Cat ELI
Optional Yearly(1)
Greases
Commercial EC-1
Coolants If it is necessary to choose a single grease, always
(1) The Level 2 Coolant Analysis should be performed sooner if a
choose a grease that meets or exceeds the
problem is suspected or identified. requirements of the most demanding application.
Remember that the products which barely meet the
Note: Check the SCA (Supplemental Coolant minimum performance requirements can be
expected to barely produce the minimum lives of your
Additive) of the conventional coolant at every oil
parts. False economy is being used if a grease is
change or at every 250 hours. Perform this check at purchased with the lowest cost as the only
the interval that occurs first. consideration. Instead, use the grease that yields the
lowest total operating cost. The cost should be based
S·O·S Services Coolant Analysis (Level 1) on an analysis that includes the costs of parts, labor,
downtime. Cost analysis should also include the cost
A coolant analysis (Level 1) is a test of the properties of the amount of grease that is required.
of the coolant.
The following properties of the coolant are tested:
74 SEBU9048-09
Maintenance Section
Maintenance Recommendations
Maintenance • the application of electrical tests
Recommendations Never perform a test over the rated potential. These

tests can damage insulation that is contaminated or
insulation that is in marginal condition. For more
i05264090 information, refer to “I.E.E.E. Standard 432-1992” or
consult a Cat dealer.
General Maintenance
Information i02909163
SMCS Code: 4450; 7000 System Pressure Release

Note: Read the warnings and read the instructions SMCS Code: 1250; 1300; 1350; 5050
that are contained in the Safety Section of this
manual. These warnings and instructions must be Coolant System
understood before you perform any operation or any
maintenance procedures.
Rotating electric machines are complex structures
that are exposed to the following forms of stress: Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
• mechanical diator is cool. Then loosen cap slowly to relieve
the pressure.
• electrical
To relieve the pressure from the coolant system, turn
• thermal off the engine. Allow the cooling system pressure cap
to cool. Remove the cooling system pressure cap
• environmental slowly in order to relieve pressure.
These stresses may be of varying magnitudes. The
electrical insulation systems are susceptible to Fuel System
damage that is caused by the stresses that are listed
above. Exposure to these stresses may shorten the To relieve the pressure from the fuel system, turn off
effective life of the electrical insulation system. the engine.
Therefore, the service life of an electric machine will
largely depend on the serviceability of the electrical High Pressure Fuel Lines (If Equipped)
insulation systems. An inspection program and a
testing procedure are recommended. An inspection
program and a testing procedure will ensure that the
equipment is maintained in satisfactory condition.
This will increase field reliability. Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
A regular maintenance and inspection program can spray may cause a fire hazard. Failure to follow
provide an evaluation of the present condition of the these inspection, maintenance and service in-
equipment. A regular maintenance program and a structions may cause personal injury or death.
regular inspection program can also reveal future
problems. The frequency of this maintenance The high pressure fuel lines are the fuel lines that are
program will depend on the following factors: between the high pressure fuel pump and the high
pressure fuel manifold and the fuel lines that are
• application between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
• environmental conditions systems.
• experience level of the operator This is because of the following differences:
• philosophy of the operator • The high pressure fuel lines are constantly
charged with high pressure.
A regular maintenance program is strongly
recommended. This program would involve the • The internal pressures of the high pressure fuel
following steps: lines are higher than other types of fuel system.
• periodic disassembly Before any service or repair is performed on the
engine fuel lines, perform the following tasks:
• knowledgeable visual examination of the
equipment 1. Stop the engine.
SEBU9048-09 75
Maintenance Section
Welding on Engines with Electronic Controls
2. Wait for ten minutes. 3. Disconnect the J1/P1 and J2/P2 connectors from
the ECM. Move the harness to a position that will
Do not loosen the high pressure fuel lines in order to
remove air pressure from the fuel system. not allow the harness to move back accidentally,
and contact any of the ECM pins.
Engine Oil 4. Disconnect any component with a microprocessor
from the engine harness, such as:
To relieve pressure from the lubricating system, turn
off the engine. • Engine ECM
i05909227 • Product Link
Welding on Engines with • Cell/Sat Radio
Electronic Controls • DOC Identity Modules

SMCS Code: 1000
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Cat dealer regarding welding on a chas-
sis frame or rail.
Proper welding procedures are necessary in order to

avoid damage to the engine ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
possible, the correct procedure must be followed.
When welding on a unit that is equipped with a Cat
Electronic Engine, the following is considered to be
the safest procedure:
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
can cause damage to the drive train, the bearings,
hydraulic components, electrical components, and
other components.
Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
to the bearings, the crankshaft, the rotor shaft, and
other components.
Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close Use the example above. The current flow from the
as possible to the weld. This will help reduce the pos- welder to the ground clamp of the welder will not
sibility of damage. damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
Note: Perform the welding in areas that are free from (4) Battery disconnect switch in the open position
explosive hazards. (5) Disconnected battery cables
(6) Battery
1. Stop the engine. Turn the switched power to the (7) Electrical/Electronic component
OFF position. (8) Minimum distance between the component that is being
welded and any electrical/electronic component
2. Disconnect the negative battery cable from the (9) The component that is being welded
(10) Current path of the welder
battery. If a battery disconnect switch is provided, (11) Ground clamp for the welder
open the switch.
76 SEBU9048-09
Maintenance Section
Generator Start-up Checklist
5. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld. This location will
reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
components, and ground straps.
Note: If electrical/electronic components are used as

a ground for the welder, current flow from the welder
could severely damage the component. Current flow
from the welder could also severely damage
electrical/electronic components that are located
between the welder ground and the weld.
6. Protect the wiring harness from welding debris and

spatter.
7. Use standard welding practices to weld the
materials.
i03860683

SMCS Code: 4450
Table 20
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________ Arrangement Number: ___________________
Generator Serial Number: _________________________________ Arrangement Number: ___________________
GENERATOR NAME PLATE INFORMATION

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

Space heaters operating properly?
Space heater operated 48 hours before startup?
MEGOHMMETER TEST Special Instruction, 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments
SEHS9124 reading reading corrected corrected temp.
Main Stator
Main Rotor
Beginning of
Exciter Stator
Storage
Exciter Rotor
PMG Stator
Start-up Main Stator
(continued)
SEBU9048-09 77
Maintenance Section
(Table 20, contd)

GENERATOR START-UP CHECKLIST
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Table 21
GENERATOR START-UP CHECKLIST (CONT.)
Regulator Voltage Amps Comments
F1 to F2 DC
E1 to E2 AC
All Frames
E1 to E3 AC
E2 to E3 AC
No Load 2400, 2500, PM1 to PM4 AC

2800, and 2900
Frames
PM1 to PM2 AC
2600 Frame PM1 to PM3 AC
PM2 to PM3 AC
Generator Excitation DC Compare with F1 to F2
Name Plate Information:
F1 to F2 DC
All Frames
E1 to E2 AC
E1 to E3 AC
E2 to E3 AC
Full Load
2400, 2500, PM1 to PM4 AC
2800, and 2900
Frames
PM1 to PM2 AC
2600 Frame PM1 to PM3 AC
PM2 to PM3 AC
Table 22
ELECTRICAL Yes No Comments

Unit properly grounded
Check diodes
Over current protection
Over voltage protection
(continued)
78 SEBU9048-09
Maintenance Section
(Table 22, contd)

Check for loose wiring
Adjust voltage
Adjust frequency
Table 23
MECHANICAL Data Comments

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

Manufacturer:
Setting 1 Setting 2 Setting 3 Comments
Type of Circuit breaker
Overload setting
Reverse power relay
VAR/PF Controller
Load share
INSTALLATION & LOAD INFORMATION
Neutral grounding system UPS
Enclosure type - Size
Motor: Other loads:
- Total SKVA - Lighting
- Total HP - Computers
- Welding
- Non-linear
- Other
FULL LOAD DATA

Voltage Amps KW KVARS P.F.
SEBU9048-09 79
Maintenance Section
Maintenance Interval Schedule
i07195969 “ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 107
Maintenance Interval Schedule “ Generator - Dry”. . . . . . . . . . . . . . . . . . . . . . . . . . 116
SMCS Code: 1000; 4450; 7500 “ Generator Set - Test” . . . . . . . . . . . . . . . . . . . . . . 121
Ensure that all safety information, warnings, and “ Generator Set Alignment - Check” . . . . . . . . . . . . . . .
instructions are read and understood before any
operation or any maintenance procedures are “ Generator Winding - Test” . . . . . . . . . . . . . . . . . . 123
performed.
“ Heat Exchanger - Clean/Test”. . . . . . . . . . . . . . . 127
The user is responsible for the performance of all
maintenance which includes the following items: “ Heat Exchanger - Inspect”. . . . . . . . . . . . . . . . . . 128
performing all adjustments , using proper lubricants, “Maintenance Recommendations” . . . . . . . . . . . . . . . .
fluids, and filters and replacing old components with
new components due to normal wear and aging . “ Sea Water Strainer - Clean/Inspect”. . . . . . . . . . 138
Failure to adhere to proper maintenance intervals
and procedures may result in diminished Daily
performance of the product and/or accelerated wear
of components. “ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 91
Before each consecutive interval is performed, all “ Electrical Connections - Check” . . . . . . . . . . . . . . 96

maintenance from the previous intervals must be
performed. “ Engine Air Cleaner Service Indicator - Inspect” . . 97
Choose the interval that occurs first to determine the “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 100
correct maintenance interval: fuel consumption ,
service hours, and calendar time. Products that “ Fuel System Primary Filter/Water Separator -
operate in severe operating conditions may require Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
more frequent maintenance. “ Generator Load - Check”. . . . . . . . . . . . . . . . . . . 121
All the following will affect the oil change interval: “ Power Factor - Check”. . . . . . . . . . . . . . . . . . . . . 136
operating conditions , fuel type , oil type, and size of
the oil sump . Scheduled oil sampling analyzes used “Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . 141
oil to determine if the oil change interval is suitable
for your specific engine. Initial 20 to 40 Service Hours
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 86
“Engine Oil and Filter - Change” to determine the oil
change interval that is suitable for your specific
engine. Every Week
To determine the maintenance intervals for the “ Generator Bearing Temperature - Test/
overhauls, refer to this Operation and Maintenance Record” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Manual, “Maintenance Recommendations” .
“ Standby Generator Set Maintenance
When Required Recommendations” . . . . . . . . . . . . . . . . . . . . . . . . 138
“ Stator Winding Temperature - Test” . . . . . . . . . . 139
“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 82
“ Voltage and Frequency - Check” . . . . . . . . . . . . 141
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 83
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 84 Every 50 Service Hours or Weekly
“ Battery or Battery Cable - Disconnect” . . . . . . . . . 85 “ Aftercooler Condensate Drain Valve - Inspect/
Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“ Belt Tightener - Lubricate”. . . . . . . . . . . . . . . . . . . 85
“ Engine Cooling System Corrosion Protection
“ Coolant - Change” . . . . . . . . . . . . . . . . . . . . . . . . . 87 System - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . . 90 “ Sea Water Strainer - Clean/Inspect”. . . . . . . . . . 138
“ Engine Oil Level Gauge - Calibrate” . . . . . . . . . . 101
Every 250 Service Hours
“ Engine Storage Procedure - Check”. . . . . . . . . . 106
“ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 93
80 SEBU9048-09
Maintenance Section
“ Fan Drive Bearing - Lubricate” . . . . . . . . . . . . . . 107 “ Fuel Injector - Check” . . . . . . . . . . . . . . . . . . . . . 107
Initial 500 Hours (for New Systems, Every 14 400 L (3750 US gal) of
Refilled Systems, and Converted Fuel or 250 Service Hours or 1 Year
Systems) “ Battery Charger - Check” . . . . . . . . . . . . . . . . . . . 84
“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 94 “ Battery Electrolyte Level - Check” . . . . . . . . . . . . . . .
Initial 1000 Service Hours “ Cooling System Supplemental Coolant Additive

(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
“ Heat Exchanger - Inspect”. . . . . . . . . . . . . . . . . . 128
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Every 1000 Service Hours “ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 102
“ Engine Air Cleaner Element (Single Element) - “ Fuel Tank Water and Sediment - Drain” . . . . . . . 114
Inspect/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 “ Hoses and Clamps - Inspect/Replace”. . . . . . . . 128
Every 2000 Service Hours Every 28 500 L (7500 US gal) of

“ Fumes Disposal Filter Element - Replace”. . . . . 115 Fuel or 500 Service Hours or 1 Year
“ Generator - Inspect”. . . . . . . . . . . . . . . . . . . . . . . 118 “ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 102
“ Generator Bearing - Lubricate” . . . . . . . . . . . . . . 120 “ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 109
“ Generator Set Vibration - Inspect” . . . . . . . . . . . 122
“ Fuel System Secondary Filter - Replace”. . . . . . .111
“ Generator Winding Insulation - Test” . . . . . . . . . 124
“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . 136 Every 57 000 L (15 000 US gal) of
“ Stator Lead - Check” . . . . . . . . . . . . . . . . . . . . . . 139
Fuel or 1000 Service Hours
“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . 140
Every Year
Every 170 400 L (45 000 US gal) of
“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 94
“ Varistor - Check” . . . . . . . . . . . . . . . . . . . . . . . . . 141
“ Auxiliary Water Pump (Bronze Impeller) - Inspect/
“ Varistor - Inspect”. . . . . . . . . . . . . . . . . . . . . . . . . 141 Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 86
Every 2 Years
“ Coolant Temperature Regulator - Replace” . . . . . 94
“ Belt Tightener - Lubricate”. . . . . . . . . . . . . . . . . . . 85
“ Crankshaft Vibration Damper - Inspect” . . . . . . . . 95
Every 8000 Service Hours “ Engine Crankcase Breather - Clean” . . . . . . . . . . 99
“ Rotating Rectifier - Check” . . . . . . . . . . . . . . . . . 136 “ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . 100
First 14 400 L (3750 US gal) of Fuel “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 106
or 250 Service Hours “ Engine Valve Rotators - Inspect” . . . . . . . . . . . . 106
“ Engine Crankcase Breather - Clean” . . . . . . . . . . 99
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 106
“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . 106
SEBU9048-09 81
Maintenance Section
“ Fuel Injector - Check” . . . . . . . . . . . . . . . . . . . . . 107
Every 284 000 L (75 000 US gal) of

“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . 142
Overhaul
“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 82
“ Generator Bearing - Inspect/Replace” . . . . . . . . . . . .
“ Heat Exchanger - Clean/Test”. . . . . . . . . . . . . . . 127
“Maintenance Recommendations” . . . . . . . . . . . . . . . .
“ Oil Cooler Core - Check/Clean/Test” . . . . . . . . . 133
“Overhaul (Major)” . . . . . . . . . . . . . . . . . . . . . . . . . 133
82 SEBU9048-09
Maintenance Section
Aftercooler Condensate Drain Valve - Inspect/Clean
i07516291 1. Remove the valve from the adapter. Check the

valve in order to determine if the plunger moves
Aftercooler Condensate Drain freely. If the plunger does not move easily, clean
Valve - Inspect/Clean the valve with solvent.
SMCS Code: 1063-042-DN 2. Reassemble the aftercooler condensate drain

valve. See Specifications Manual, SENR3130,
“Torque Specifications” for more information on
NOTICE
Failure to keep the condensate drain valve functional the proper torques.
can cause severe damage to the engine.
i04363377
Aftercooler Core - Clean/Test

SMCS Code: 1064-081; 1064-070
Note: An aftercooler that circulates fresh water or

treated water may require cleaning less often than an
aftercooler which circulates salt water. The
maintenance interval for an aftercooler which
circulates fresh water or treated water should be
evaluated when the aftercooler is cleaned and tested
after the first 1000 hours of engine operation. The
interval will vary depending on operating conditions.
Clean the Aftercooler Core

Remove the core. Refer to the Disassembly and
Assembly Manual, “Aftercooler - Remove” for the
procedure.
1. Turn the aftercooler core on one side in order to
remove debris. Remove the debris that is
accessible.
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen-
tration of cleaner.
(1) Valve
(2) Plunger 2. Back flush the core with cleaner.
(3) Valve seat
Caterpillar recommends the use of Hydrosolv
The engine boost pressure forces the plunger to liquid cleaner. Table 24 lists Hydrosolv liquid
move down to the valve seat. The plunger must close cleaners that are available from your Cat dealer.
against the seat at a pressure of 2.8 kPa (0.4 psi). Table 24
The absence of boost pressure when the engine is
stopped allows the plunger to rise to the open Hydrosolv Liquid Cleaners(1)
position. The open position allows condensation from
Part Number Description Size
the aftercooler to drain out.
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
The plunger must be able to move freely in order to
close the system when the engine is running. The 174-6854 Hydrosolv 100 19 L (5 US gallon)
plunger must be able to move freely in order to allow
(1) Use a two to five percent concentration of the cleaner at tem-
condensation to drain from the aftercooler when the
engine is stopped. Residue from normal engine peratures up to 93°C (200°F). Consult your Cat dealer for more
information.
operation could cause the plunger to stick.
SEBU9048-09 83
Maintenance Section
Auxiliary Water Pump (Bronze Impeller) - Inspect/Replace
3. Steam clean the core in order to remove any For more information on cleaning the core, consult
residue. Flush the fins of the aftercooler core. your Cat dealer.
Remove any other trapped debris from the inside
and from the outside of the core. i03091745
Note: Do not use high pressure when the fins are Auxiliary Water Pump (Bronze
cleaned. High pressure can damage the fins.
Impeller) - Inspect/Replace
4. Wash the core with hot, soapy water. SMCS Code: 1371-510
5. Flush the core thoroughly in order to remove Impellers and seals require periodic inspection.
residue and remaining debris. Flush the core with Impellers have a service life that is limited. The
clean, fresh water until the water that is exiting the service life depends on the engine operating
core is clear and free of debris. conditions.
Inspect the components more frequently when the
pump is exposed to debris, sand, or other abrasive
materials. Inspect the components if the pump is
Personal injury can result from air pressure. operating at a differential pressure of more than
103 kPa (15 psi).
Personal injury can result without following prop-
er procedure. When using pressure air, wear a Refer to Disassembly and Assembly, “Auxiliary Water
protective face shield and protective clothing. Pump - Remove” in order to remove the auxiliary
water pump. Refer to Disassembly and Assembly ,
The maximum air pressure for cleaning purposes “Auxiliary Water Pump - Disassemble” in order to
must be reduced to 205 kPa (30 psi) when the air disassemble the auxiliary water pump.
nozzle is deadheaded.
Inspect the following components for wear or
6. Dry the core with compressed air. Direct the air in damage:
the reverse direction of the normal flow.
• Bearings
Test the Aftercooler Core • Impeller
1. Inspect the core for trapped debris and • Seals
cleanliness. If necessary, remove the debris and
repeat the cleaning procedure. • Wear plate
2. Inspect the core for damage and perform a If wear or damage is found, replace the components
pressure test in order to detect leaks. Many shops which are worn or damaged. Use the proper repair kit
for the pump.
that service radiators are equipped to perform
pressure tests. Refer to Disassembly and Assembly, “Auxiliary Water
Pump - Assemble” in order to assemble the auxiliary
3. Plug both ends of the aftercooler core and water pump. Refer to Disassembly and Assembly ,
pressurize the core to 205 kPa (30 psi). “Auxiliary Water Pump - Install” in order to install the
Submerge the core in water. Look for bubbles auxiliary water pump.
which are being emitted from the core. The
bubbles are evidence of leaks. i02039199
4. If any leaks are found, do not attempt to repair the

core.
Battery - Recycle
SMCS Code: 1401-510; 1401-561; 1401; 1401-005;
Install a core that is clean and a core that passes the 1401-535
pressure test in step 3. Refer to the Disassembly and
Assembly Manual, “Aftercooler - Install” for the Always recycle a battery. Never discard a battery.
procedure. Return used batteries to one of the following
locations:
• A battery supplier
• An authorized battery collection facility
• A recycling facility
84 SEBU9048-09
Maintenance Section
Battery - Replace
i06738473 8. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.
Battery - Replace 9. Connect the cable from the ground plane to the
SMCS Code: 1401-510 NEGATIVE “-” battery terminal.
i01942625
Batteries give off combustible gases which can

explode. A spark can cause the combustible
Battery Charger - Check
gases to ignite. This can result in severe personal SMCS Code: 1401-535
injury or death.
Check the battery charger for proper operation. If the
Ensure proper ventilation for batteries that are in batteries are properly charged, the needle of the
an enclosure. Follow the proper procedures in or- ammeter will register near “0” (zero).
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are The batteries should be kept warm, when possible.
serviced. The temperature of the battery will affect cranking
power. A battery that is too cold will not crank the
engine, even if the engine is warm.
The batteries may not fully recharge when the engine
is not run for long periods of time. The batteries may
The battery cables or the batteries should not be not fully recharge if the engine only runs for short
removed with the battery cover in place. The bat- periods. Ensure a full charge in order to help prevent
tery cover should be removed before any servic- the battery from freezing.
ing is attempted.
Removing the battery cables or the batteries with i07419560
the cover in place may cause a battery explosion
resulting in personal injury. Battery Electrolyte Level -
Check
Note: Always recycle a battery. Never discard a SMCS Code: 1401-535-FLV
battery. Return used batteries to an appropriate
recycling facility. When the engine has not run for long or short periods
of time, the batteries may not fully recharge. Ensure a
1. Turn the key start switch to the OFF position. full charge to help prevent the battery from freezing.
Remove the key and all electrical loads.
In warmer climates, check the electrolyte level more
2. Turn OFF the battery charger. Disconnect the frequently.
charger.
Ensure that the electrolyte level is 13 mm (0.5 inch)
3. Turn battery isolator switch to OFF position. above the top of the separators.
4. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane.
Disconnect the cable from the NEGATIVE “-”
All lead-acid batteries contain sulfuric acid which
battery terminal. can burn the skin and clothing. Always wear a
face shield and protective clothing when working
5. The POSITIVE “+” cable connects the POSITIVE
on or near batteries.
“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
battery terminal. 1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate If the addition of water is necessary, use distilled
recycling facility. water. If distilled water is not available, use clean
water that is low in minerals. Do not use artificially
6. Remove the used battery. softened water.
7. Install the new battery. 2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
Note: Before the cables are connected, ensure that
the key start switch is OFF. 3. Keep the batteries clean.
SEBU9048-09 85
Maintenance Section
Battery or Battery Cable - Disconnect
Clean the battery case with one of the following 2. Disconnect the negative battery terminal at the
cleaning solutions: battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
• A mixture of 0.1 kg (0.2 lb) of baking soda and 12 volt batteries are involved, the negative side of
1 L (1 qt) of clean water two batteries must be disconnected.
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L 3. Tape the leads in order to help prevent accidental
(1 qt) of clean water starting.
Thoroughly rinse the battery case with clean 4. Proceed with necessary system repairs. Reverse
water. the steps in order to reconnect all of the cables.
Use the 1U-9921 Battery Service Tool to clean i05609040

the battery terminals. Use a wire brush to clean
the cable clamps. Clean the items until the Belt Tightener - Lubricate
surfaces are bright or shiny. DO NOT remove
material excessively. Excessive removal of SMCS Code: 1358-086
material can cause the clamps to fit improperly.
Coat the clamps and the terminals with the Loctite
®
product listed below, petroleum jelly or MPGM.
• For Americas North - Loctite LB8632
• For Europe and Africa, Middle East, CIS

(AMEC) - Loctite LB8104
• For Asia Pacific - Loctite LB8801
• For Americas South - Loctite LB Superlube
For ordering the products listed above, go to the

following address.
http://www.loctite.com/en/meta/meta-nav/
location-selector.html
i06738663
Battery or Battery Cable -

Disconnect Illustration 45 g03561376
SMCS Code: 1401; 1402-029 1. Lubricate the threaded rod (1) at every belt tension
adjustment or every 2 years.
2. Remove pulley guards.
The battery cables or the batteries should not be 3. Clean the threaded rod tightener (1).
removed with the battery cover in place. The bat-
tery cover should be removed before any servic- 4. Apply grease to the threaded rod tightener.
ing is attempted.
5. Install pulley guards.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
86 SEBU9048-09
Maintenance Section
Belts - Inspect/Adjust/Replace
i05611623
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-510; 1357-040
Typical belt tensioner installation
(2) Square hole for ratchet
2. Insert a ratchet with a square drive into the square

hole that is located in the tensioner for the belt.
3. Rotate the tensioner counterclockwise in order to
relieve tension on the belt. Remove the belt.
4. Install the new belt correctly, as shown. Be sure
that the belt is fully seated on the pulleys. The
Illustration 46 g03120939 correct tension will automatically be applied when
(Belt guard removed for visibility) the ratchet is removed.
View of the belt and the belt tensioner on the front of 5. install the belt guard.
the engine
(1) Belt tensioner
Adjusting Fan Drive Belts
Engine Belt Inspection Note: Prior to tensioning, check the threaded rod for
lubricant. The threaded portion should be lubricated.
Inspect the belt for wear and for cracking. Replace
the belt if the belt is not in good condition. Note: For correct tension, follow the instructions on
the OEM drawing for the specific radiator. The
Check the belt tension according to the information in deflection distance and force will be listed. If the force
the SpecificationsManual, “Belt Tension Chart”. is given in Newtons (N), then convert to kgf by
Slippage of loose belts can reduce the efficiency of dividing by 9.81.
the driven components. Vibration of loose belts can
cause unnecessary wear on the following 1. Remove pulley guards.
components: 2. Loosen the four fasteners on the idler system.
• Belts 3. Using a belt tension tool, set the lower marker at
the deflection distance required on the lower
• Pulleys
scale. Set the upper marker ring against the edge
• Bearings of the top tube.
4. Place the belt tension tool against the top of the
Replacement belt at the center of the span. Apply a force at right
angles to the belt. Apply enough force to deflect
1. Remove the belt guard. the belt to the point where the marker ring is level
with the top of the adjacent belt.
5. Adjust the tension until the belt tension tool
indicates approximately 8.5 kgf.
SEBU9048-09 87
Maintenance Section
Coolant - Change
6. To adjust the tension, adjust the locknut of the

NOTICE
threaded adjusting rod. Care must be taken to ensure that fluids are con-
7. Turn the nut clockwise to shorten the rod and nance, testing, adjusting, and repair of the product.
increase belt tension. Turn the nut Be prepared to collect the fluid with suitable contain-
counterclockwise to lengthen the rod and ers before opening any compartment or disassem-
decrease belt tension. bling any component containing fluids.
Note: Do not over tension the belts. Refer to Special Publication, NENG2500, “Cat Dealer
8. Tighten the four fasteners on the idler system. PECJ0003, “Cat Shop Supplies and Tools Catalog”
Torque fasteners to 210 N·m (155 lb ft). for tools and supplies suitable to collect and contain
9. Install pulley guards.
10. Run engine for 20 minutes. Recheck belt tension. and mandates.
i06675653
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
Coolant - Change cooling system is drained.
SMCS Code: 1350-044; 1352; 1395; 1395-044
2. Loosen the cooling system filler caps slowly in
Note: The engine has two separate cooling systems, order to relieve any pressure. Remove the cooling
the jacket water system, and the separate circuit system filler caps.
aftercooler system (SCAC system). Change the
coolant in both systems whenever the coolant is 3. Open the cooling system drains.
changed. Note: If equipped, be sure to drain the heater and
Refer to this Operation and Maintenance Manual, any related supply and return lines.
“Fluid Recommendations” for the correct intervals for
changing the coolant. Allow the coolant to drain.
Clean the cooling system and flush the cooling NOTICE

system before the recommended maintenance Dispose of used engine coolant properly or recycle.
interval if the following conditions exist: Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems.
• The engine overheats frequently. The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant.
• Foaming is observed.
• The oil has entered the cooling system and the For information regarding the disposal and the
coolant is contaminated. recycling of used coolant, consult your Cat dealer or
consult Cat Dealer Service Tool Group:
• The fuel has entered the cooling system and the
coolant is contaminated. Inside USA 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL
Drain the coolant systems Canada 1-800-523-TOOL
International 1-309-578-7372
Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
88 SEBU9048-09
Maintenance Section
Coolant - Change
Jacket Water System SCAC System

Oil cooler outlet bonnet drain SCAC pump outlet bonnet drain

Jacket water heat exchanger drain (Some parts SCAC heat exchanger drain
removed for visibility)
SEBU9048-09 89
Maintenance Section
Coolant - Change
Radiator System 5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valves (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valves (if
equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
information on the proper torques.
Systems Filled with Cat DEAC,

Conventional Coolant which does not
Meet the Cat EC-1 Requirements, or
Supplemental Coolant Additive (SCA)
and Water
3. Flush the cooling system with clean water in order
to remove any debris.
4. Close the drain valves (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
(1) Jacket water outlet drain valve
(2) SCAC outlet drain valve
Specifications Manual, SENR3130, “Torque
(3) SCAC inlet drain valve Specifications” for more information on the proper
torques.
Flush NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Systems Filled with Cat ELC, Cat ELI, or per minute to avoid air locks.
a Conventional Coolant that Meets the
Cat EC-1 Requirements and the 5. Fill the cooling system with a mixture of clean
Standards of ASTM D6210 water and Cat Fast Acting Cooling System
Cleaner.
1. Flush the cooling system with clean water in order
6. Choose 1 of the following options.
to remove any debris.
2. Close the drain valves (if equipped). Clean the • Add 0.5 L (1 pt) of cleaner per 15 L (4 US gal)
drain plugs. Install the drain plugs. Refer to the of the cooling system capacity.
Specifications Manual, SENR3130, “Torque
• For cooling systems with heavy deposits or
Specifications” for more information on the proper
plugging, add 0.5 L (1 pt) of cleaner per
torques.
3.8 to 7.6 L (1 to 2 US gal) of the cooling
NOTICE system capacity.
per minute to avoid air locks. 7. Install the cooling system filler cap.
8. Start and run the engine at low idle for a minimum
3. Fill the cooling system with clean water. Install the of 30 minutes. For cooling systems with heavy
cooling system filler cap. deposits or plugging, run the engine for 90
minutes. The coolant temperature should be at
4. Start and run the engine at low idle until the least 82 °C (180 °F).
temperature reaches 49 to 66 °C (120 to 150 °F).
90 SEBU9048-09
Maintenance Section
Coolant Extender (ELC) - Add
1. Refer to this Operation and Maintenance Manual,

NOTICE
Improper or incomplete rinsing of the cooling system “Fluid Recommendations” for more information on
can result in damage to copper and other metal cooling system specifications Refer to this
components. Operation and Maintenance Manual, “Refill
Capacities” for information about the capacity of
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water. the cooling systems.
Continue to flush the system until all signs of the 2. Ensure coolant fill valve (1) is in the OPEN
cleaning agent are gone. position.
3. Fill the cooling system.
9. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in 4. Close the coolant fill valve. Do not install the
order to relieve any pressure. Remove the cooling coolant fill caps.
system filler cap. Open the drain valve (if
5. Start and run the engine at low idle. Increase the
equipped) or remove the cooling system drain
engine rpm to high idle. Run the engine at high
plugs. Allow the water to drain. Flush the cooling
idle for 1 minute in order to purge the air from the
system with clean water. If equipped, be sure to
cavities of the engine block. Stop the engine.
flush the heater and any related supply and return
lines. Close the drain valve (if equipped). Clean 6. Check the coolant level. Maintain the coolant level
the drain plugs. Install the drain plugs. Refer to the within 13 mm (0.5 inch) below the bottom of the
Specifications Manual, SENR3130, “Torque pipe for filling. Maintain the coolant level within
Specifications” for more information on the proper 13 mm (0.5 inch) to the proper level on the sight
torques. glass (if equipped).
7. Clean the cooling system filler caps. Inspect the
Fill the Cooling System gasket that is on the cooling system filler cap. Only
install the used filler cap if the gasket is not
damaged. Use a 9S-8140 Pressurizing Pump to
pressure test a reinstalled cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
8. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i04862631
Coolant Extender (ELC) - Add

SMCS Code: 1352-544-NL
Note: Refer to this Operation and Maintenance

Manual, “Fluid Recommendations” (Cooling System)
for the maintenance interval for the addition of the
coolant extender.
Cat ELC (Extended Life Coolant) and Cat ELI
(1) Coolant fill valve (Valve in the OPEN position)
(Extended Life Inhibitor) do not require the frequent
additions of any supplemental cooling additives. The
NOTICE Cat ELC Extender will only be added one time.
per minute to avoid air locks. Note: Do not use conventional supplemental coolant
additive (SCA) with Cat ELC or with Cat ELI.
Check the cooling system only when the engine is
stopped and cool.
SEBU9048-09 91
Maintenance Section
Coolant Level - Check
i06133465
Personal injury can result from hot coolant, Coolant Level - Check
steam and alkali. SMCS Code: 1395-082
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to There are two separate cooling systems for this C18
heaters or the engine contain hot coolant or Marine Engine. One is the jacket water system and
steam. Any contact can cause severe burns. one is the separate circuit aftercooler (SCAC)
system. Check the coolant level for each system
Remove cooling system pressure cap slowly to daily. Refer to this Operation and Maintenance
relieve pressure only when engine is stopped and Manual , “Model View Illustrations” for the positions
cooling system pressure cap is cool enough to of the expansion tank sight gauges.
touch with your bare hand.
Engines That Are Equipped with a
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing Coolant Recovery Tank
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
and mandates.
1. Loosen the cooling system filler cap slowly in order

to relieve pressure. Remove the cooling system
filler cap.
2. If necessary, drain enough coolant from the
cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the Illustration 54 g03729167
requirements for the cooling system capacity. (1) Filler cap

(2) “COLD FULL” mark
Refer to this Operation and Maintenance Manual, (3) “LOW ADD” mark
“Refill Capacities” for the coolant capacity.
4. Clean the cooling system filler cap. Inspect the 1. Observe the coolant level in the coolant recovery
gaskets on the cooling system filler cap. Replace tank. Maintain the coolant level to “COLD FULL”
the cooling system filler cap if the gaskets are mark (2) on the coolant recovery tank.
damaged. Install the cooling system filler cap. 2. Loosen filler cap (1) slowly in order to relieve any
For further information, refer to this Operation and pressure. Remove the filler cap.
Maintenance Manual, , “Fluid Recommendations”.
92 SEBU9048-09
Maintenance Section
Coolant Level - Check
3. Pour the proper coolant mixture into the tank. Note: The coolant will expand as the coolant heats
Refer to this Operation and Maintenance Manual, up during normal engine operation. The additional
“Refill Capacities” for information about coolants. volume will be forced into the coolant recovery tank
Do not fill the coolant recovery tank above “COLD during engine operation. When the engine is stopped
FULL” mark (2). and cool, the coolant will return to the engine.
4. Clean filler cap (1) and the receptacle. Reinstall Engines That Are Not Equipped
the filler cap and inspect the cooling system for
leaks.
with a Coolant Recovery Tank
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
volume will be forced into the coolant recovery tank Pressurized System: Hot coolant can cause seri-
during engine operation. When the engine is stopped ous burns. To open the cooling system filler cap,
and cool, the coolant will return to the engine. stop the engine and wait until the cooling system
Engines That Are Equipped with pressure cap slowly in order to relieve the
pressure.
Expansion Tanks and Sight
Gauges 1. Remove the cooling system filler cap slowly in
order to relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
(1) Filler caps
(2) Sight gauges
Check the position of the coolant in the sight gauge

(2) for each expansion tank. At normal operating
temperature, the proper coolant level is in the upper Illustration 56 g00103639
half of the sight gauge. If the coolant level is low, add
the correct amount of coolant. Typical filler cap gaskets
1. Loosen filler cap (1) slowly in order to relieve any 3. Clean the cooling system filler cap and inspect the
pressure. Remove the filler cap. condition of the filler cap gaskets. Replace the
2. Pour the proper coolant mixture into the tank. cooling system filler cap if the filler cap gaskets are
Refer to this Operation and Maintenance Manual, damaged. Reinstall the cooling system filler cap.
“Fluid Recommendations” for information about
coolants.
3. Clean filler cap (1) and the receptacle. Reinstall
the filler cap and inspect the cooling system for
leaks.
SEBU9048-09 93
Maintenance Section
Coolant Sample (Level 1) - Obtain
4. Inspect the cooling system for leaks. • Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
i04333559 contamination.
• Never collect samples from expansion bottles.

Coolant Sample (Level 1) -
Obtain • Never collect samples from the drain for a system.
SMCS Code: 1350-008; 1395-554; 1395-008; 7542
Timing of the Sampling
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and Table 25
corrosion. The analysis also tests the ability of the
coolant to protect the engine from boiling and Recommended Interval
freezing. S·O·S Systems Coolant Analysis can be
done at your Cat dealer. Cat S·O·S coolant analysis Type of Level 1 Level 2
is the best way to monitor the condition of your Coolant
coolant and your cooling system. S·O·S coolant
Cat DEAC
analysis is a program that is based on periodic Cat SCA
samples. Conventional Heavy-
Every 250 hours Yearly(1)
Duty Coolants
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with one of Cat ELC
the following coolants: Cat ELC (Extended Life Cat ELI
Optional(1) Yearly(1)
Coolant)., Cat ELI (Extended Life Inhibitor) and Commercial EC-1
Conventional Heavy-Duty Coolant. Coolants
(1) The Level 2 Coolant Analysis should be performed sooner if a
Note: Obtain a Coolant Sample (Level 1) if the problem is suspected or identified.
cooling system is filled with any of the following
coolants: Cat DEAC, Cat SCA and Conventional Note: Check the SCA (Supplemental Coolant
Heavy-Duty Coolants. Additive) of the conventional coolant at every oil
change or at every 250 hours. Perform this check at
For additional information about coolant analysis and the interval that occurs first.
about other coolants, see this Operation and
Maintenance Manual, “Fluid Recommendations” or Obtain the sample of the coolant as close as possible
consult your Cat dealer. to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, establish a
Sampling Conditions consistent trend of data. In order to establish a
pertinent history of data, perform consistent
If the engine is equipped with a sampling port, the samplings that are evenly spaced. Supplies for
engine should be running at operating temperature collecting samples can be obtained from your Cat
when the sample is obtained. dealer.
If the engine is not equipped with a sampling port, the NOTICE

coolant should be warm. Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
Use the following guidelines for proper sampling of pling. Using the same pump for both types of sam-
the coolant: ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
• Complete the information on the label for the and an incorrect interpretation that could lead to con-
sampling bottle before you begin to take the cerns by both dealers and customers.
samples.
• Keep the unused sampling bottles stored in plastic Submit the sample for Level 1 analysis.
bags.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
94 SEBU9048-09
Maintenance Section
Coolant Sample (Level 2) - Obtain
Note: Level 1 results may indicate a need for Level 2 A water temperature regulator that fails in the closed
Analysis. position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
i04638756
head or piston seizure problems.
Coolant Sample (Level 2) - NOTICE

Failure to replace your water temperature regulator
Obtain on a regularly scheduled basis could cause severe
engine damage.
SMCS Code: 1350-008; 1395-554; 1395-008; 7542
Caterpillar engines incorporate a shunt design cool-
An S·O·S Coolant Analysis (Level 2) is a ing system and require operating the engine with a
comprehensive chemical evaluation of the coolant. water temperature regulator installed.
This analysis is also a check of the overall condition
of the cooling system. The S·O·S Coolant Analysis If the water temperature regulator is installed incor-
(Level 2) has the following features: rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera-
• Full coolant analysis (Level 1) ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is
• Identification of metal corrosion and contaminants open.
• Identification of buildup of the impurities that Do not use liquid gasket material on the gasket or cyl-
cause corrosion and scaling inder head surface.
• Determination of the possibility of electrolysis

within the cooling system of the engine NOTICE
The results are reported and appropriate tained during performance of inspection, mainte-
recommendations are made. nance, testing, adjusting, and repair of the product.
Obtaining the Sample ers before opening any compartment or disassem-
Refer to Operation and Maintenance Manual, Refer to Special Publication, NENG2500, “Cat Dealer
“Coolant Sample (Level 1) - Obtain” for the guidelines Service Tool Catalog” or refer to Special Publication,
for proper sampling of the coolant. PECJ0003, “Cat Shop Supplies and Tools Catalog”
Submit the sample for Level 2 analysis.
For further information, refer to this Operation and
Maintenance Manual, “Fluid Recommendations”.
and mandates.
i04240223
Note: If replacing only the water temperature
Coolant Temperature regulator, only drain the coolant to a level that is
Regulator - Replace below the water temperature regulator housing.
SMCS Code: 1355-510 Refer to two articles in the Disassembly and

Assembly Manual, “Water Temperature Regulator -
Replace the water temperature regulator before the Remove and Water Temperature Regulator - Install”
water temperature regulator fails. Replacing the for the replacement procedure or consult your Cat
water temperature regulator reduces the chances for dealer.
unscheduled downtime.
i05053052
A water temperature regulator that fails in a partially
opened position can cause overheating or
overcooling of the engine. Cooling System Supplemental
A water temperature regulator that fails in the open
Coolant Additive (SCA) - Test/
position will cause the engine operating temperature Add
to be too low during partial load operation. Low
engine operating temperatures during partial loads SMCS Code: 1352-045; 1395-081
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result Note: This maintenance is NOT required for
in an accelerated wear of the piston rings and wear of cooling systems that are filled with Extended Life
the cylinder liner. Coolant.
SEBU9048-09 95
Maintenance Section
Crankshaft Vibration Damper - Inspect
Add the SCA, If Necessary
Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact
with the skin and eyes. Do not drink cooling sys- Pressurized System: Hot coolant can cause seri-
tem coolant additive. ous burns. To open the cooling system filler cap,
NOTICE pressure cap slowly in order to relieve the
Excessive supplemental coolant additive concentra- pressure.
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer 1. Remove the cooling system filler cap slowly.
could cause cracking of the cylinder head and other
high temperature components. 2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat ex- 3. Add the proper amount of SCA. For the proper
changer, overheating, and/or accelerated wear of the amount of SCA, refer to this Operation and
water pump seal. Maintenance Manual, “Refill Capacities and
Recommendations” or refer to this Operation and
Do not exceed the recommended amount of supple-
mental coolant additive concentration. Maintenance Manual, “Fluid Recommendations”.
The proper concentration of SCA depends on the
type of coolant that is used. For the proper
NOTICE concentration of SCA, refer to Special Publication,
Care must be taken to ensure that fluids are con- SEBU6251, “Caterpillar Commercial Diesel
tained during performance of inspection, mainte- Engine Fluids Recommendations”.
Be prepared to collect the fluid with suitable contain- 4. Clean the cooling system filler cap. Install the
ers before opening any compartment or disassem- cooling system filler cap.
Refer to Special Publication, NENG2500, “Caterpillar i05085918
Dealer Service Tool Catalog” and to Special Publica-
tion, GECJ0003, “Cat Shop Supplies and Tools” for Crankshaft Vibration Damper -
tools and supplies suitable to collect and contain flu-
ids on Caterpillar products. Inspect
SMCS Code: 1205-040
Dispose of all fluids according to applicable regula-
tions and mandates. Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to the
Note: Caterpillar recommends an S·O·S coolant crankshaft and to other engine components. A
analysis (Level 1). deteriorating damper can cause excessive gear train
noise at variable points in the speed range.
Cooling Systems that Use The damper is mounted to the crankshaft which is
Conventional Coolant located behind the belt guard on the front of the
engine. The damper on your engine may look like
Test the Concentration of the SCA one of the following dampers.
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Test the concentration of the SCA with the 4C-9301

Coolant Conditioner Test Kit.
96 SEBU9048-09
Maintenance Section
Electrical Connections - Check
• The bolt holes are worn or there is a loose fit for

the bolts.
• The engine has had a crankshaft failure due to

torsional forces.
Replace the damper if any of these conditions exist.
Removal and Installation

“Belts - Inspect/Adjust/Replace” for information on
removing and on installing the belt. Refer to the
Disassembly and Assembly Manual, “Vibration
Damper and Pulley - Remove and Install” for
information on removing and installing the damper.
i01595880
Electrical Connections - Check

SMCS Code: 4459-535
Check all exposed electrical connections for
Single viscous vibration damper tightness.
(1) Crankshaft pulley
(2) Weight Check the following devices for loose mounting or for
(3) Case physical damage:
• transformers
• fuses
• capacitors
• lightning arrestors
Check all lead wires and electrical connections for
proper clearance.
i06103535
Engine - Clean
SMCS Code: 1000-070
Dual viscous vibration damper
(1) Crankshaft pulley
(2) Weights Personal injury or death can result from high
(3) Cases voltage.
Moisture can create paths of electrical
Inspection conductivity.
Inspect the damper for the following conditions: Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO
• The damper is dented, cracked, or fluid is leaking NOT OPERATE”” .
from the damper.
• The paint on the damper is discolored from NOTICE
excessive heat. Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
• The damper is bent. fluid spills whenever a significant quantity accumu-
lates on the engine.
SEBU9048-09 97
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Periodic cleaning of the engine is recommended.

Steam cleaning the engine will remove accumulated NOTICE
Never service the air cleaner element with the engine
oil and grease. A clean engine provides the following running. Operating the engine without an air cleaner
benefits: allows dirt to enter the engine.
• Easy detection of fluid leaks
• Maximum heat transfer characteristics Replacing the Air Cleaner Element
• Ease of maintenance 1. Open the four latches on the air cleaner.
Note: Caution must be used in order to prevent 2. Remove the used air cleaner. Properly dispose of
electrical components from being damaged by the air cleaner according to local standards. Wipe
excessive water when you clean the engine. Avoid the inside of the air cleaner canister to remove any
electrical components such as the alternator, the accumulated dirt and debris.
starter, and the ECM.
3. Install a new air cleaner.
i06133551
4. Close the four latches.
Engine Air Cleaner Element 5. Reset the service indicator.
(Single Element) - Inspect/ i03612108
Replace
SMCS Code: 1051; 1054-040; 1054-510 Engine Air Cleaner Service
Indicator - Inspect
SMCS Code: 7452-040
A service indicator may be mounted on the air
cleaner element or in a remote location.
Typical air cleaner installation
(1) Cover for the air cleaner cannister
(2) Latches for the air cleaner
(3) Air cleaner cannister
Typical air cleaner service indicator
NOTICE
Never run the engine without an air cleaner element Some engines may be equipped with a different
installed. Never run the engine with a damaged air service indicator.
cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets, or seals. Dirt entering Observe the service indicator. Clean the air cleaner
the engine causes premature wear and damage to element or replace the air cleaner element when the
engine components. Air cleaner elements help to pre- following conditions occur:
vent airborne debris from entering the air inlet.
• The yellow diaphragm enters the red zone.
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element. • The red piston locks in the visible position.
Unfiltered air will drastically accelerate internal
engine wear. Your Cat dealer has the proper air • The air restriction reaches 6 kPa
cleaner elements for your application. Consult your (25 inches of H2O).
Cat dealer for the correct air cleaner element.
98 SEBU9048-09
Maintenance Section
Engine Cooling System Corrosion Protection System - Inspect
Test the Service Indicator Note: When a new service indicator is installed,
excessive force may crack the top of the service
Service indicators are important instruments. indicator. Tighten the service indicator to a torque of
2 N·m (18 lb in).
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
i05303334
• Check the movement of the yellow core when the

engine is accelerated to the engine rated rpm. The Engine Cooling System
yellow core should latch approximately at the
greatest vacuum that is attained.
Corrosion Protection System -
Inspect
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum, SMCS Code: 1388-040
the service indicator should be replaced. If the new
service indicator will not reset, the fitting for the Galvanic corrosion may harm components that cool
service indicator may be plugged. the engine. Corrosion is caused when dissimilar
metals are in contact and the dissimilar metals are
immersed in salt water. The voltage potential from
salt water to the engine must be tested on a regular
basis to protect the cooling components.
Location of the Corrosion

Protection Post
C18 SCAC Marine Engine
Porous filter
A porous filter is part of a fitting that is used for

mounting of the service indicator. Inspect the filter for
cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components are replaced.
(1) Bonding connector
(2) Bonding stud
(3) Vessel zinc
SEBU9048-09 99
Maintenance Section
Engine Crankcase Breather - Clean
C32 SCAC Marine Engine Measure the galvanic potential of the system and
apply zinc or other less noble metal to divert
corrosion. Contact your Cat dealer for more
information.
i02751871
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.
(4) Bonding connector
(5) Vessel zinc
(6) Bonding stud
Testing the Voltage Potential

Operate the engine for at least 30 minutes, then stop
the engine. Disconnect the engine from the shore
power connection. Use a 257-9140 Multimeter and
a 244-1536 Cable Group to test the voltage
potential from the salt water to the engine. A silver-
silver chloride half cell probe is widely available if the
Cat tools are not available.
1. Connect a #8 American Wire Gauge (AWG) cable
from the sacrificial anode to the bonding system of
the vessel.
2. Test the voltage at the bonding stud. Illustration 64 g01377732
3. Test the voltage at the bonding connector.

1. Loosen hose clamp (1) and remove breather hose
(2) from valve cover (3).
Results of the Test
2. Remove valve cover (3). Refer to the Disassembly
The voltage potential must be between -0.500 mV and Assembly Manual.
and -0.800 mV.
Note: A value near or greater than 0.0 mV is

extremely corrosive.
100 SEBU9048-09
Maintenance Section
Engine Mounts - Inspect
i04948069
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
Illustration 65 g01377736 (Y) “ADD” mark
(X) “FULL” mark
3. Wash breather (4) in solvent that is clean and
nonflammable. Allow the breather to dry before NOTICE
installation. Perform this maintenance with the engine stopped.
4. Install the valve cover. Refer to the Disassembly
and Assembly Manual. 1. Maintain the oil level between the “ADD” mark (Y)
and the “FULL” mark (X) on the oil level gauge .
5. Install the breather hose on the valve cover. Install Do not fill the crankcase above the “FULL” mark
the hose clamp. (X).
i02456872 NOTICE
Engine damage can occur if the crankcase is filled
Engine Mounts - Inspect above the “FULL” mark on the oil level gauge
(dipstick).
SMCS Code: 1152-040; 1152
An overfull crankcase can cause the crankshaft to dip
Inspect the engine mounts for deterioration and for into the oil. This will reduce the power that is devel-
proper bolt torque. Engine vibration can be caused oped and also force air bubbles into the oil. These
by the following conditions: bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
• Improper mounting of the engine pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption.
• Deterioration of the engine mounts
Excessive oil consumption will cause deposits to form
Any engine mount that shows deterioration should be on the pistons and in the combustion chamber. De-
replaced. Refer to Special Publication, SENR3130, posits in the combustion chamber lead to the follow-
“Torque Specifications” for the recommended ing problems: guttering of the valves, packing of
torques. Refer to the OEM recommendations for carbon under the piston rings and wear of the cylin-
more information. der liner.
If the oil level is above the “FULL” mark on the oil lev-
el gauge, drain some of the oil immediately.
2. Remove the oil filler cap and add oil, if necessary.

For the correct oil to use, see this Operation and
Maintenance Manual, “Fluid Recommendations”
topic. Do not fill the crankcase above the “FULL”
mark (X) on the oil level gauge. Clean the oil filler
cap. Install the oil filler cap.
3. Record the amount of oil that is added. For the
next oil sample and analysis, include the total
amount of oil that has been added since the
previous sample.
SEBU9048-09 101
Maintenance Section
Engine Oil Level Gauge - Calibrate
i02703804 4. Replace the engine oil filter by using the procedure

in this Operation and Maintenance Manual,
Engine Oil Level Gauge - “Engine Oil and Filter - Change ”.
Calibrate 5. Clean the engine oil level gauge and install the
SMCS Code: 1326-524; 1326 engine oil level gauge.
The engine is shipped with an engine oil level gauge 6. Use the information in Operation and Maintenance
that is not marked. The engine oil level gauge is not Manual, “Refill Capacities and Recommendations”
marked because the following features can be in order to select the correct oil for the engine.
different for each engine:
7. Add engine oil to the crankcase by using the
• Angle of the installation procedure in this Operation and Maintenance
Manual, “Engine Oil and Filter - Change ”. Choose
• Side for service the appropriate amount of oil from the following
The engine oil level gauge must be calibrated after two sumps:
the engine is installed in the vessel.
• Standard Oil Sump : Fill the crankcase with
Note: The engine may be equipped with auxiliary 45.4 L (48 qt) of the recommended oil.
engine oil filters. The extra filters require more engine
oil than the standard amounts. Refer to the OEM • Deep Oil Sump : Fill the crankcase with
specifications. 64.3 L (68 qt) of the recommended oil.
Use the following procedure in order to calibrate and 8. Start the engine. Ensure that the lubrication
mark the engine oil level gauge. system and the new engine oil filter are filled.
1. Ensure that the engine is properly aligned and that Inspect the lubrication system for leaks.
the engine is in the design trim. The engine must 9. Stop the engine and allow the engine oil to drain
be installed properly in the vessel. into the engine crankcase for approximately ten
Note: If the engine has oil in the crankcase, skip step minutes.
2 and proceed to step 3. 10. Check the engine oil level. Use a marking tool in
order to engrave the “ADD” mark (Y) to the correct
2. If there is no oil in the engine, use information in
location on the gauge assembly.
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” in order to 11. Add 3.8 L (4 qt) of the recommended oil grade
select the correct oil for the engine. Add engine oil and weight of engine oil to the crankcase. Add this
to the crankcase by using the procedure in this amount for both standard sumps and deep sumps.
Operation and Maintenance Manual, “Engine Oil
12. Check the engine oil level. Use a marking tool in
and Filter - Change ”. Choose the appropriate
order to engrave “FULL” mark (X) onto the correct
amount of oil from the following types of sumps:
location on the gauge assembly.
• Standard Oil Sump : Fill the crankcase with
45.4 L (48 qt) of the recommended oil.
• Deep Oil Sump : Fill the crankcase with

64.3 L (68 qt) of the recommended oil.
Clean the engine oil level gauge and install the

engine oil level gauge.
Note: If the engine contains oil, perform steps 3
through 7. Skip steps 3 through 7 if you are filling the Oil Level Gauge “ADD” mark (Y) and “FULL” mark (X)
engine with oil for the first time.
3. Operate the engine until normal operating

temperature is achieved. Stop the engine. Drain
the engine oil by using the procedure in this
and Filter - Change ”.
102 SEBU9048-09
Maintenance Section
Engine Oil Sample - Obtain
i04942291 To ensure that the sample is representative of the oil

in the crankcase, obtain a warm, mixed oil sample.
Engine Oil Sample - Obtain To avoid contamination of the oil samples, the tools
SMCS Code: 1348-554-SM and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve in
order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
For instructions, see Special Publication, PEGJ0047,
Oil sampling valve on the front of the engine “How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
In addition to a good preventive maintenance assistance in establishing an S·O·S program for your
program, Caterpillar recommends using S·O·S oil engine.
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
i05007775
for determining nitration and oxidation levels.
Obtain the Sample and the Engine Oil and Filter - Change
SMCS Code: 1318-510
Analysis
Drain the Oil
Hot oil and hot components can cause personal NOTICE

injury. Do not allow hot oil or hot components to Care must be taken to ensure that fluids are con-
contact the skin. tained during performance of inspection, mainte-
Before you take the oil sample, complete the Label, Be prepared to collect the fluid with suitable contain-
PEEP5031 for identification of the sample. In order to ers before opening any compartment or disassem-
help obtain the most accurate analysis, provide the bling any component containing fluids.
• Engine model Service Tool Catalog” or refer to Special Publication,
• Service hours on the engine for tools and supplies suitable to collect and contain
• The number of hours that have accumulated since
the last oil change and mandates.
• The amount of oil that has been added since the
last oil change
SEBU9048-09 103
Maintenance Section
Engine Oil and Filter - Change
Do not drain the oil when the engine is cold. As the oil 1. Remove used oil filters and properly discard the
cools, waste particles settle on the bottom of the oil used oil filters.
pan. The waste particles are not removed when the
cold oil is drained. Drain the crankcase when the oil
is warm. This method allows proper draining of the
waste particles that are suspended in the oil.
Failure to follow this recommended procedure will
allow the waste particles to be recirculated through
the engine lubrication system with the new oil.
1. After the engine has been operated at normal
operating temperature, STOP the engine.
Note: Drain the oil into a suitable container. DO NOT
drain the oil into the bilge sump. Dispose of the oil
according to local regulations.
Note: If a suction device is used in order to remove
the oil from the oil pan, ensure that the suction device Illustration 69 g00103713
is clean. Using a clean suction device prevents dirt
Typical filter mounting base and filter gasket
from entering into the oil pan. Be careful not to strike
the engine oil suction tubes or the piston cooling jets.
2. Clean the sealing surface of the filter mounting
2. Open the oil drain valve. After the oil has drained, base. Make sure that the former oil filter gaskets
close the valve are removed.
3. Drain the oil according to the equipment on the 3. Apply a thin film of clean engine oil to the seal of
engine. If the engine has a pump for removing each new filter gasket.
dirty oil, connect a hose to the outlet of the pump.
Place the hose in a suitable container. Open the NOTICE
Do not fill the oil filters with oil before installing them.
valve for the drain line. The two marks on the This oil would not be filtered and could be contami-
valve must be turned so that one mark points to nated. Contaminated oil can cause accelerated wear
the pump and the second mark points to the drain to engine components.
line. Operate the pump until the crankcase is
empty. Close the valve to the drain line. 4. Install the filters by hand. Tighten each filter
Disconnect the hose. according to the instructions that are printed on
4. Replace the engine oil filter elements before filling the filter.
the crankcase with new oil.
Note: You may need to use a Cat strap wrench, or
another suitable tool, in order to turn the filters to the
Replace the Oil Filter Elements amount that is required for final installation. Make
sure that the installation tool does not damage the
Replace the engine oil filters at every engine oil filters. Do not overtighten the oil filter.
change.
Note: Do not attempt to clean the used oil filters.
Replacing the Engine Oil Filters During
Used oil filters will retain waste particles. The used oil Engine Operation (Duplex Oil Filter
filters would not filter the oil properly. System Only)
Service tools are available to aid in the service of oil
filters. Consult your Cat dealer for the part names
and the part numbers. Follow the instructions that are
supplied with the service tools. If the service tools are This filter contains hot, pressurized oil that can
not used, perform the following appropriate cause burns and fire hazards, which may result in
procedure. bodily injury or death. Follow the instructions giv-
en in this Operation and Maintenance Manual and
Replacing the Engine Oil Filters With the stop the engine if rapid air movement exists to
Engine Stopped (Standard Oil Filters) blow the oil.
If the engine is equipped with duplex oil filters, the

Perform the following procedure after the oil has engine oil filter elements can be changed while the
been drained. engine is in operation.
104 SEBU9048-09
Maintenance Section
Instruction film for the engine oil selector valve
(9) “MAIN RUN” for Filter 1
(10) “AUXILIARY RUN” for the Filter 1
(11) “BOTH FLOW” for normal engine operation
(12) “AUXILIARY RUN” for Filter 2
(14) “MAIN RUN” for Filter 2
Duplex oil filters Main Run Filter 1 – The oil selector valve
(1) Filter 2 is in this position at the start of the oil
(2) Oil selector lever filter change procedure for Filter 2.
(3) Filter 1 100% of the oil flows to Filter 1.
(4) Air purge screw for Filter 1
(5) Pressure relief valve for Filter 1 Auxiliary Run for Filter 1 – A small
(6) Base for the oil selector lever
(7) Pressure relief valve for Filter 2
stream of oil fills Filter 2 with most oil
(8) Air purge screw for Filter 2 flowing through Filter 1.
Both Flow – Normal position for engine

operation. Oil is flowing equally to Filter
1 and to Filter 2.
Auxiliary Run Filter 2 – A small stream

of oil fills Filter 1 with most oil flowing
through Filter 2.
Main Run Filter 2 – The oil selector valve

is in this position at the start of the oil
filter change procedure for Filter 1. 100
% of the oil flows to Filter 2.
1. Position the oil selector lever on the MAIN RUN

FOR FILTER 1 position to start the filter change
procedure for Filter 2. When the selector lever is in
the MAIN RUN FOR FILTER 1 position, all of the
engine oil is flowing to Filter 1.
2. Place a container under the pressure relief valve
for Filter 2. Open the pressure relief valve for Filter
2 to relieve any oil pressure from Filter 2.
SEBU9048-09 105
Maintenance Section
3. Open the air purge screw for Filter 2 by 4 complete Aluminum debris may indicate problems with the
turns to purge the air out of the oil lines and to bearings of the front gears. If you find aluminum
drain the remaining oil out of Filter 2. The air purge debris, inspect the crankshaft vibration damper and
the idler gear bearings.
screw should remain open until the flow of oil
stops. Due to normal wear and friction, it is not uncommon
to find small amounts of debris in the oil filter
4. Close the air purge screw for Filter 2. element. If an excessive amount of debris is found in
the oil filter element, consult your Caterpillar dealer in
5. Replace Filter 2 with a new oil filter. order to arrange for further oil analysis.
a. Remove the used filter and properly discard.
Fill the Crankcase
b. Clean the sealing surface of the filter mounting
base. Make sure that the former oil filter gasket
is removed. NOTICE
If the engine is equipped with an auxiliary oil filter sys-
c. Apply a thin film of clean engine oil to the seal tem, extra oil must be added when filling the crank-
of the new filter gasket. case. If equipped with an auxiliary oil filter system
that is not supplied by Caterpillar, follow the recom-
d. Install the new filter by hand. Tighten the filter mendations of the OEM.
according to the instructions on the filter.
Note: You may need to use a Cat strap wrench to NOTICE
turn the filters to the amount that is required for Engine damage can occur if the crankcase is filled
final installation. Make sure that the installation tool above the “FULL” mark on the oil level gauge
does not damage the filters. Do not overtighten the (dipstick).
oil filter.
An overfull crankcase can cause the crankshaft to dip
6. Close the pressure relief valve for Filter 2 then into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
slightly open the pressure relief valve. bubbles (foam) can cause the following problems: re-
7. Position the oil selector lever to the AUXILIARY duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
RUN FOR FILTER 1 position. Oil will slowly fill
crankcase breathers and excessive oil consumption.
Filter 2. When oil flows out of the pressure relief
valve for Filter 1 for 5 seconds, close the filter relief Excessive oil consumption will cause deposits to form
valve. on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the follow-
8. Position the oil selector lever to the MAIN RUN ing problems: guttering of the valves, packing of
FOR FILTER 2 position to repeat the procedure for carbon under the piston rings and wear of the cylin-
Filter 2. der liner.
9. After both filters have been replaced and oil has If the oil level is above the “FULL” mark on the oil lev-
el gauge, drain some of the oil immediately.
filled both filters, position the oil selector valve to
the BOTH FLOW position.
1. Remove the oil filler cap. Fill the crankcase
Inspect the Used Oil Filter through the oil filler tube only. For the correct
amount of oil , refer to this Operation and
Elements Maintenance Manual, “Refill Capacities”. Refer to
Cut the oil filter open with a 175-7546 Oil Filter this Operation and Maintenance Manual, “Fluid
Cutter Gp. Break apart the pleats and inspect the oil Recommendations” for the correct type of oil.
filter for metal debris. An excessive amount of metal Clean the oil filler cap. Install the oil filler cap.
debris in the oil filter may indicate early wear or a
pending failure.
NOTICE
Use a magnet to differentiate between the ferrous To prevent crankshaft or bearing damage, crank en-
metals and the nonferrous metals that are found in gine with fuel off to fill all filters before starting.
the element. Ferrous metals may indicate wear on
the steel and the cast iron parts of the engine. Do Not crank engine for more than 30 seconds.
Nonferrous metals may indicate wear on the
aluminum parts, the brass parts, or the bronze parts
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings and cylinder heads.
106 SEBU9048-09
Maintenance Section
Engine Storage Procedure - Check
2. Close the fuel supply line and crank the engine The maintenance is recommended by Caterpillar as
until the oil pressure gauge indicates 70 kPa part of a lubrication and preventive maintenance
(10 psi). Open the fuel supply line. Allow the schedule to help provide maximum engine life.
starting motor to cool for 2 minutes before Note: Only qualified service personnel should
cranking again. perform this maintenance. For procedures on
3. Ensure that the oil level is to the “FULL” mark on adjusting the valve lash and adjusting the valve
the oil level gauge. Start the engine and operate bridge, see Systems Operation/Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
the engine at low idle for 2 minutes. This will
Consult your Cat dealer for assistance.
ensure that the lubrication system has oil and that
the oil filters are filled with oil. Inspect the engine Note: For information on adjusting the unit injector
and the oil filters for oil leaks. If any leaks exist, refer to Testing and Adjusting, RENR1232, Unit
stop the engine and make any necessary repairs. Injector Adjustment.
4. Stop the engine and allow the oil to drain back into
the sump for a minimum of 10 minutes.
5. Remove the oil level gauge and check the oil level. Ensure that the engine cannot be started while
Maintain the oil level between the “FULL” mark this maintenance is being performed. To help pre-
and the “ADD” mark on the oil level gauge. If vent possible injury, do not use the starting motor
to turn the flywheel.
necessary, add oil.
Hot engine components can cause burns. Allow
i02703023 additional time for the engine to cool before
measuring/adjusting valve lash clearance.
Engine Storage Procedure -
Check i01597115
SMCS Code: 1000-535
Engine Valve Rotators -
Caterpillar recommends storage procedures and
start-up procedures for all engines that are stored for Inspect
more than 1 month. These procedures provide SMCS Code: 1109-040
maximum protection to internal engine components.
Refer to Special Instruction, SEHS9031, “Storage
Procedure For Caterpillar Products” for information
on these procedures.
When inspecting the valve rotators, protective
An extension of the oil change interval to 12 months glasses or face shield and protective clothing
is permitted if you follow the required procedures for must be worn, to help prevent being burned by
storage and start-up. This extension is permitted if hot oil or spray.
the following intervals in the Operation and
Maintenance Manual, “Maintenance Interval Engine valve rotators rotate the valves when the
Schedule” have not been reached: engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
• Operating hours
Perform the following steps after the engine valve
• Fuel consumption lash is set, but before the valve covers are installed:
i07139300
1. Start the engine according to Operation and
Maintenance Manual, “Engine Starting” (Operation
Engine Valve Lash - Check Section) for the procedure.
SMCS Code: 1105-535 2. Operate the engine at low idle.
The initial valve lash adjustment on new engines, 3. Observe the top surface of each valve rotator. The
rebuilt engines, or remanufactured engines is valve rotators should turn slightly when the valves
recommended at the first scheduled oil change. The close.
adjustment is necessary due to the initial wear of the
valve train components and to the seating of the
valve train components.
SEBU9048-09 107
Maintenance Section
Fan Drive Bearing - Lubricate
i04841177
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and Fuel Injector - Check
shorten valve life. If a damaged rotator is not re-
placed, valve face guttering could result and cause SMCS Code: 1290-535
pieces of the valve to fall into the cylinder. This can
cause piston and cylinder head damage.
Be sure the engine cannot be started while this

If a valve fails to rotate, consult your Caterpillar maintenance is being performed. To prevent pos-
dealer. sible injury, do not use the starting motor to turn
the flywheel.
i05609157
Hot engine components can cause burns. Allow
Fan Drive Bearing - Lubricate additional time for the engine to cool before
measuring/adjusting the unit injectors.
SMCS Code: 1359-086-BD
The electronic unit injectors use high voltage.
Disconnect the unit injector enable circuit con-
nector in order to prevent personal injury. Do not
come in contact with the injector terminals while
the engine is running.
The operation of Cat engines with improper
adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
component life.
Only qualified service personnel should perform this
maintenance. Refer to the following topics for your
engine for the correct procedure: Refer to the
Systems Operation, Testing and Adjusting, “Fuel
System” for the maintenance procedure.
NOTICE
The camshafts must be correctly timed with the
crankshaft before an adjustment of the lash for the
fuel injector is made. The timing pins must be re-
moved from the camshafts before the crankshaft is
turned or damage to the cylinder block will be the
result.
i03570039
Fuel System - Prime

Illustration 72 g03561456 SMCS Code: 1250-548; 1258-548
The fan and pulley grease points are located on the

fan bearing cross beam. Refer to table26 for
capacities. A label that designates grease capacities
is located near the grease points. Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent
Table 26 possible injury, turn the start switch off when
Fan and Pulley Grease Capacities changing fuel filters or water separator elements.
Clean up fuel spills immediately.
Pulley Fan Idler (R) Idler (F)
11 gr (0.38 oz) 6 gr (0.21 oz) 3 gr (0.11 oz) 2 gr (0.07 oz)

108 SEBU9048-09
Maintenance Section
Fuel System - Prime
3. Start the engine. The engine should start and the

NOTICE
Care must be taken to ensure that fluids are con- engine should run smoothly. If the engine does not
tained during performance of inspection, mainte- start after 30 seconds, allow the starting motor to
nance, testing, adjusting, and repair of the product. cool for two minutes before attempting to start the
Be prepared to collect the fluid with suitable contain- engine again.
bling any component containing fluids. Note: You may use the hand priming pump for the
fuel filter (if equipped) instead of starting the engine
and running the engine.
for tools and supplies suitable to collect and contain 4. While the engine is running, observe the air purge
fluids on Cat products. screw. When a small drop of fuel appears at the
threads of the air purge screw, close and tighten
Dispose of all fluids according to local regulations air purge screw.
and mandates.
Note: There may be a noticeable change in the
sound of the running engine when the air purge
NOTICE screw is tightened. The change in the sound of the
Do not allow dirt to enter the fuel system. Thoroughly engine is normal.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- Note: Failure to tighten all fittings could result in
nected fuel system component. serious fuel leaks.
5. Clean any residual fuel from the engine

Note: Refer to this Operation and Maintenance components.
Manual, “Fuel System Secondary Filter - Replace” for
information on replacing the filter.
The Engine Has Been Run Out of
Fuel
1. Turn the ignition switch to the “OFF” position.
2. Fill the fuel tank(s) with clean diesel fuel.
3. Open the fuel pressure regulating valve by two
and one half turns. The regulating valve is located
in the integral fuel filter base.
Note: Do not remove the regulating valve completely.

Open the valve enough to allow the air that is trapped
in the cylinder head to be purged from the fuel
system.
Illustration 73 g01096972 NOTICE

Hand priming pump Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
(1) Air purge screw
(2) Fuel pressure regulating valve
minutes before cranking the engine again.
The Secondary Fuel Filter Has 4. Crank the engine for 30 seconds. Use a suitable
container to catch the fuel while you crank the
Been Replaced engine. Allow the starting motor to cool for two
minutes.
1. Turn the ignition switch to the “OFF” position.
2. Open the air purge screw for the fuel filter by three Note: You may use the hand priming pump for the
full turns. Do not remove the air purge screw. fuel filter (if equipped) instead of cranking the engine.
5. Crank the engine for 30 seconds. Allow the starting

NOTICE
Do not crank the engine continuously for more than motor to cool for two minutes.
30 seconds. Allow the starting motor to cool for two 6. Close and tighten the fuel pressure regulating
minutes before cranking the engine again.
valve.
SEBU9048-09 109
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
7. Crank the engine for 30 seconds. Allow the starting 12. Clean any residual fuel from the engine
motor to cool for two minutes. components.
8. Repeat Step 7 until the engine starts and the
i05264163
engine runs.
Note: Failure to tighten all fittings could result in Fuel System Primary Filter
serious fuel leaks. (Water Separator) Element -
9. Clean any residual fuel from the engine Replace
components. SMCS Code: 1260-510-FQ; 1263-510-FQ
The Engine Has Been Rebuilt Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
1. Turn the ignition switch to the “OFF” position. to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
2. Fill the fuel tank (s) with clean diesel fuel. scheduled interval.
3. Open the the air purge screw for the fuel filter by The primary filter/water separator also provides
three full turns. Do not remove the air purge screw. filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
4. Open the fuel pressure regulating valve by two and regularly. Install a vacuum gauge. Change the
one half turns. The regulating valve is located in element for the primary filter/water separator if the
pressure is at 50 to 70 kPa (15 to 20 inches Hg).
the integral fuel filter base.
Note: Do not remove the regulating valve completely. Replace the Element
Open the valve enough to allow the air that is trapped
in the cylinder head to be purged from the fuel
system.
Fuel leaked or spilled onto hot surfaces or electri-
NOTICE cal components can cause a fire. To help prevent
Do not crank the engine continuously for more than possible injury, turn the start switch off when
30 seconds. Allow the starting motor to cool for two changing fuel filters or water separator elements.
minutes before cranking the engine again. Clean up fuel spills immediately.
5. Crank the engine for 30 seconds. Use a suitable

container to catch the fuel while you crank the
engine. Allow the starting motor to cool for two
minutes.
Note: You may use the hand priming pump for the
fuel filter (if equipped) instead of cranking the engine.

motor to cool for two minutes.
7. Close and tighten the air purge screw.
motor to cool for two minutes.
9. Close and tighten the fuel pressure regulating Illustration 74 g03130076
valve. (1) Bowl
(2) Element
Note: Failure to tighten all fittings could result in (3) Drain
serious fuel leaks.
1. Stop the engine.
10. Crank the engine for 30 seconds. Allow the
starting motor to cool for two minutes. 2. Turn the start switch to the “OFF” position.
11. Repeat Step 10 until the engine starts and runs. 3. Shut off the fuel tank supply valve to the engine.
110 SEBU9048-09
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
4. If the primary fuel filter is equipped with a drain 12. Start the engine and check for leaks. Run the
valve, open the drain valve in order to drain any engine for 1 minute. Stop the engine and check
fuel from the filter case. Close the drain valve. the engine for leaks again.
Detection of leaks is very difficult especially if the
NOTICE
Care must be taken to ensure that fluids are con- engine is running. The primary filter/water
tained during performance of inspection, mainte- separator is under suction. A leak will allow air to
nance, testing, adjusting, and repair of the product. enter the fuel. The air in the fuel can cause low
Be prepared to collect the fluid with suitable contain- power due to aeration of the fuel. If air enters the
bling any component containing fluids. fuel, check the components for overtightening or
under tightening.
Service Tool Catalog” or refer to Special Publication, i02927285
Fuel System Primary Filter/
Water Separator - Drain
and mandates. SMCS Code: 1260-543; 1263-543
5. Remove the fuel filter bowl and wash the fuel filter
bowl with clean diesel fuel.
6. Remove the fuel filter. cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
7. Clean the gasket sealing surface of the fuel filter changing fuel filters or water separator elements.
base. Ensure that all of the old gasket is removed. Clean up fuel spills immediately.
8. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
NOTICE Care must be taken to ensure that fluids are con-
In order to maximize fuel system life and prevent pre- tained during performance of inspection, mainte-
mature wear out from abrasive particles in the fuel, nance, testing, adjusting and repair of the product.
use Cat fuel filters. Be prepared to collect the fluid with suitable contain-
Consult your Cat dealer for proper part numbers. bling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
9. Install the new fuel filter. Spin the fuel filter onto the Dealer Service Tool Catalog” for tools and supplies
fuel filter base until the gasket contacts the base. suitable to collect and contain fluids on Caterpillar
Use the rotation index marks on the filters as a products.
guide for proper tightening. Tighten the filter for an
additional 3/4 turn by hand. Do not overtighten the Dispose of all fluids according to local regulations
and mandates.
filter.
NOTICE
Do not fill the fuel filters with fuel before installing NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
them. The fuel would not be filtered and could be con-
taminated. Contaminated fuel will cause accelerated clean the area around a fuel system component that
wear to fuel system parts. will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
10. Install the clean fuel filter bowl 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
fuel system.
11. Open the fuel tank supply valve.

SEBU9048-09 111
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE
and mandates.
(1) Element
(2) Bowl
(3) Drain
NOTICE
Keep all parts clean from contaminants.
Bowl (2) should be monitored daily for signs of water. Contaminants may cause rapid wear and shortened
If water is present, drain the water from the bowl. component life.
1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container. Note: If the engine is equipped with duplex fuel
Dispose of the water properly. filters, the fuel filter elements can be replaced while
2. Close drain (3). the engine is in operation. Refer to “Replacing the
Fuel Filter Elements During Engine Operation For
NOTICE Engines That Are Equipped With Duplex Fuel
The water separator is under suction during normal Filters”.
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.
i05303381
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE

cal components can cause a fire. Clean up fuel
spills immediately.
112 SEBU9048-09
Maintenance Section
4. Unlock the fuel priming pump in order to relieve

residual pressure in the fuel system.
5. Remove the used fuel filter. Use a cloth or use a
container in order to catch excess fuel.
6. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
7. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
8. Install the new fuel filter. Tighten the fuel filter until
the gasket contacts the base. Tighten the fuel filter
by hand according to the instructions that are
shown on the fuel filter. Do not overtighten the fuel
filter.
Note: Do not remove the plug in the fuel filter base to
release the air from the fuel system during periodic
service of the fuel filter. Periodic removal of the plug
will result in increased wear of the threads in the fuel
filter base.
9. Operate the fuel priming pump plunger until a
Typical secondary fuel filter strong resistance is felt and until the check valve
(1) Priming pump clicks. This procedure will require considerable
(2) Fuel shutoff
(3) Drain valve strokes. Lock the fuel priming pump.
(4) Fuel indicators
(5) Auxiliary secondary fuel filter 10. Open the fuel tank supply valve.
(6) Main secondary fuel filter
(7) Fuel selector valve 11. Start the engine according to the normal
operating procedures. Immediately increase the
engine rpm between 1000 to 1200 rpm with no
Replacing the Fuel Filter Elements load. The engine will begin to misfire briefly until
with the Engine Stopped air from the fuel filter is purged. No damage to the
engine will occur.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly NOTICE
clean the area around a fuel system component that Do not crank the engine continuously for more than
will be disconnected. Fit a suitable cover over discon- 30 seconds. Allow the starting motor to cool for two
nected fuel system component. minutes before cranking the engine again.
1. Stop the engine. 12. If the engine stalls during the purging of the air,
refer to the Operation and Maintenance Manual,
2. Turn off the start switch or disconnect the battery
“Fuel System - Prime” for more information.
(starting motor) when maintenance is performed
on fuel filters.
Replacing the Fuel Filter Elements
3. Shut off the fuel tank supply valve to the engine.
During Engine Operation For
NOTICE Engines That Are Equipped With
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately. Duplex Fuel Filters
Note: The engine must be at IDLE in order to replace
the fuel filter elements during engine operation.
SEBU9048-09 113
Maintenance Section
This filter contains pressurized fuel that can

cause a fire hazard, which may result in bodily in-
jury or death. Follow the instructions given in this
Operation and Maintenance Manual and stop the
engine if rapid air movement exists to blow the
fuel.
NOTICE
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
Care must be taken to ensure that fluids are con- 2. Once the lever has been moved to the AUX RUN
tained during performance of inspection, mainte- position, the fuel gauge for the auxiliary filter
nance, testing, adjusting, and repair of the product. should indicate full pressure and the fuel gauge for
Be prepared to collect the fluid with suitable contain- the main filter should indicate no pressure.
bling any component containing fluids. 3. Slowly open the drain valve and purge any
remaining pressure from the main filter. Some fuel
may also drain from the fuel drain. The fuel
PECJ0003, “Cat Shop Supplies and Tools Catalog” indicator for the auxiliary filter should indicate full
for tools and supplies suitable to collect and contain pressure and the fuel indicator for the main filter
fluids on Cat products. should indicate no pressure.
Dispose of all fluids according to local regulations 4. Remove the used main fuel filter.
and mandates.
5. Clean the gasket sealing surface of the main fuel
filter base. Ensure that all of the old gasket is
Replacing the Main Fuel Filter removed.
6. Apply clean diesel fuel to the new main fuel filter
Use the following procedure to replace the main fuel gasket.
filter while the engine is in operation.
7. Install a new main fuel filter. Tighten the fuel filter
until the gasket contacts the base. Tighten the fuel
filter by hand according to the instructions that are
shown on the fuel filter. Do not overtighten the fuel
filter.
8. Move the lever to the RH FLOW - LH FILL position.
The indicator for the main filter should indicate
slight pressure. Purge the air from lines for the
main filter through the drain valve. Close the drain
valve when the fuel starts flowing through the
drain valve.
9. Move the fuel selection lever to the FLOW BOTH
position and monitor the main filter for leaks.
Uninstall and reinstall the main filter if necessary.
1. Move the fuel selector valve to the AUX RUN Replacing the Auxiliary Fuel Filter
position as marked on the indicator plate.
Use the following procedure to replace the auxiliary
fuel filter while the engine is in operation.
114 SEBU9048-09
Maintenance Section
Fuel Tank Water and Sediment - Drain
7. Install a new auxiliary fuel filter. Tighten the fuel

filter until the gasket contacts the base. Tighten
the fuel filter by hand according to the instructions
that are shown on the fuel filter. Do not overtighten
the fuel filter.
8. Move the fuel selection lever to the “LH FLOW -
RH FILL” position. The indicator for the auxiliary
filter should indicate slight pressure. Purge the air
from the lines for the auxiliary filter through the
drain valve. Close the drain valve when the fuel
starts to flow through the valve.
9. Move the fuel selection lever to the FLOW BOTH
position and monitor the auxiliary filter for leaks.
Illustration 79 g03409976 Uninstall and reinstall the auxiliary filter if
necessary.
1. Move the fuel selector valve to the MAIN RUN
position as marked on the indicator plate. i06104305
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
NOTICE
Illustration 80 g03410043 PECJ0003, “Cat Shop Supplies and Tools Catalog”
2. Once the lever has been moved to the MAIN RUN fluids on Cat products.
position, the fuel gauge for the main filter should
indicate full pressure and the fuel gauge for the and mandates.
auxiliary filter should indicate no pressure.
3. Slowly open the drain valve and purge any
remaining pressure from the auxiliary filter. Some
fuel may also drain from the fuel drain. The fuel
indicator for the main filter should indicate full
pressure and the fuel indicator for the auxiliary
filter should indicate no pressure.
4. Remove the used auxiliary filter.
5. Clean the gasket sealing surface of the auxiliary
fuel filter base. Ensure that all of the old gasket is
removed.
6. Apply clean diesel fuel to the new auxiliary fuel
filter gasket.
SEBU9048-09 115
Maintenance Section
Fumes Disposal Filter Element - Replace
Fuel Tank If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to
Fuel quality is critical to the performance and to the settle before filling the engine fuel tank. Internal
service life of the engine. Water in the fuel can cause baffles in the bulk storage tank will also help trap
excessive wear to the fuel system. Condensation sediment. Filtering fuel that is pumped from the
occurs during the heating and cooling of fuel. The storage tank helps to ensure the quality of the fuel.
condensation occurs as the fuel passes through the When possible, water separators should be used.
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining i05019230
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel. The
fuel tank utilizes a fuel tank vent to prevent an air lock Fumes Disposal Filter Element
or vacuum. Ensure that the vent is free of debris and
not damaged.
- Replace
SMCS Code: 1074
Drain the Water and the Sediment Replacement of the fumes disposal filter is affected
by the following items:
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the • Engine load
fuel tanks.
Prepare to catch water and sediment in an • Soot concentration
appropriate container. Connect a hose (if necessary)
to the valve prior to opening the valve. • Condition of the engine
Open the drain valve on the bottom of the fuel tank in Replacing the Fumes Disposal
order to drain the water and the sediment. Close the
drain valve. Filter
Note: Failure to close the drain properly could result
in fuel leakage, which could have detrimental results
to performance. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
Check the fuel daily. Drain the water and sediment contact the skin.
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure.
Fill the fuel tank after operating the engine in order to
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use stand pipes that allow water and
sediment to settle below the end of the fuel stand
pipe. Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
Fuel Storage Tanks

Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly
• Refill of the tank Illustration 81 g03123321
Typical installation
This procedure will help prevent water or sediment
from being pumped from the storage tank into the (1) Latches for the canister
(2) Service indicator
engine fuel tank. A four micron(c) absolute filter for (3) Cap for the canister
the breather vent on the fuel tank is also (4) Engine air cleaner
recommended. (5) Canister
116 SEBU9048-09
Maintenance Section
Generator - Dry
Note: When possible, perform the maintenance while 3. Replace the cover.
the engine is off.
i07109997
1. Release the latches that hold the canister to the
cap. Generator - Dry
Note: Removal of the canister may be difficult while SMCS Code: 4450-569
the engine is operating. The canister has negative air
pressure while the engine is operating which creates
a vacuum.
Personal injury or death can result from improper
2. Lower the canister in order to expose the element. troubleshooting and repair procedures.
There may be oil in the bottom of the canister.
Avoid spilling the oil. The following troubleshooting and repair proce-
dures should only be performed by qualified per-
3. Remove the filter element by pulling down. sonnel familiar with this equipment.
Dispose of the used element properly.
4. Replace the canister and align the canister with the “Generator Isolating for Maintenance” for information
boss on the filter base assembly. regarding the procedure to isolate the generator in a
safe manner.
5. Clamp the latches in the closed position.
Refer to Special Instruction, SEHS9124, “Cleaning
Resetting the Service Indicator (If and Drying of the Generator” for further necessary
information.
Equipped)
Of the following methods for drying the generator, the
use of external heat is preferred.
• External heat
• Internal heat
• Combination of external and internal heat
• Circulating current
External heat is the most preferable method.
Insulation drying time can vary from a few hours to
several days. The drying time depends on the
moisture content and the process for drying that is
used.
Note: Drying sometimes does not produce the
Illustration 82 g01292899 required results. The use of a qualified rebuild shop
(4) Plastic cover may be necessary for dipping and drying the
(5) Service indicator generator.
1. Remove the plastic cover.

2. Push down on the service indicator.
SEBU9048-09 117
Maintenance Section
Generator - Dry
Curve of insulation resistance for windings in good
condition
(1) Resistance after 30 seconds
Illustration 84 indicates the curve of the resistance of

Illustration 83 g02175752 a normal high resistance in the windings over a
Typical curves of the resistance in the insulation that period of 60 seconds. The resistance after 60
is drying seconds will be greater than the resistance or equal
(1) Curve of the temperature in the windings to the resistance after 30 seconds .
(2) Heat turned off.
(3) Drying time in hours Note: If the insulation resistance after 60 seconds is
(4) Temperature in degrees celsius not higher than the resistance after 30 seconds , the
(5) Curve of insulation resistance during drying process insulation may be weak.
(6) Insulation resistance in megohms
Note: When new insulation or damp insulation is

being dried, the resistance will probably fall rapidly.
The rapid fall in resistance is the result of the
temperature being raised to a value for drying. After
reaching a minimum for a given temperature, the
resistance will again rise as moisture is driven out of
the insulation. The actual values will vary with each
situation. Refer to Illustration 84 .
If the windings or insulation is wet during the
resistance measurement, use a 5 megohm resistor
for protection in series with red positive lead. This
procedure limits the voltage across the circuit under
the test. Use this method until drying is well in
progress and the resistance has reached an
acceptable level. Illustration 85 g01697074
Curve of insulation resistance for windings that are
Check the windings after every 4 hours when either wet or dirty
external or internal heat is used to dry the generator.
Check the windings every hour when circulating (2) Resistance after 60 seconds
current is used to dry the generator. Refer to Special
Instruction, SEHS9124, “Cleaning and Drying of the Illustration 85 indicates the curve of the resistance
Generator” for more information. that is decaying over a period of 60 seconds. If the
Drying is complete when the tests show no increase insulation resistance after 60 seconds is not higher
in resistance and the resistance is above the than the resistance after 30 seconds , clean the
minimum. Record these readings and compare these windings and thoroughly dry the windings. Refer to
readings. Keep these records for future reference. Special Instruction, SEHS9124, “Cleaning and Drying
of the Generator” for more information.
118 SEBU9048-09
Maintenance Section
Generator - Inspect
Note: Caterpillar recommends a minimum • Generators operate regularly in an environment

acceptable insulation resistance of 2 megohm for with moisture laden air.
generators which operate with less than 1000 V of
operating or rated voltage. Generators which operate Circulating Current
at 1000 V of operating or rated voltage should have a
minimum insulation resistance as determined by the Drying can be accomplished by circulating low
following equation: voltage current through the windings. Since the
voltage is low, the breakdown of the insulation will not
R = (V/1000) + M occur as the breakdown might have occurred with
normal operation and wet insulation. Refer to Special
“R” is the minimum insulation resistance.
Instruction, SEHS9124, “Cleaning and Drying of the
“V” is the rated voltage. Generator” for this procedure.
“M” is 1 megohm. i06021154
These values are approximate. Operating a

generator with less resistance may be possible. Generator - Inspect
SMCS Code: 4450-040
External Heat
Ovens
Personal injury or death can result from improper
The best oven is a forced air drying oven for drying troubleshooting and repair procedures.
electrical equipment. Radiant ovens sometimes
cause localized overheating. The following troubleshooting and repair proce-
dures should only be performed by qualified per-
NOTICE sonnel familiar with this equipment.
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.
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Note: Many electrical shops are equipped with Before performing any maintenance or repairs,
baking ovens. ensure that the generator will not start.
Heat the generator to approximately 75° C (167° F). Place the engine control switch in the “ OFF”” posi-
Never exceed 75° C (167° F) until the insulation tion. Attach “ DO NOT OPERATE”” tags to all start-
tester tests correctly for insulation resistance (at least ing controls. Disconnect the batteries or disable
4 hours). the starting system. Lock out all switchgear and
automatic transfer switches that are associated
Alternate Method with the generator.
A tent formed by a tarp or a canvas with heated Refer to Safety Section, “Generator Isolating for
lamps or a portable space heater may be used as an Maintenance” for information regarding the
alternate method. procedure to isolate the generator safely.
A hole should be left in the top of the tarp for ensuring Proper maintenance of electrical equipment requires
proper circulation through the generator and for periodic visual examination of the generator and
permitting the moisture to exhaust. Heat the periodic visual examination of the windings. Proper
generator to approximately 75° C (167° F). Never maintenance of electrical equipment also requires
exceed 75° C (167° F) until the insulation tester tests appropriate electrical checks and appropriate thermal
correctly for insulation resistance (at least 4 hours). checks. Insulation material should be examined for
cracks. The insulation material should be examined
for accumulations of dirt and dust. If there is an
Internal Heating insulation resistance value that is below normal, a
conductive path may be present. This conductive
If generators operate under one of the following path may be made of one of the following materials:
conditions, the electric space heaters should be
installed as part of the generator: • Carbon
• Generators are in damp environments and go for • Salt

long periods of time without operation.
• Metal dust
SEBU9048-09 119
Maintenance Section
Generator Bearing - Inspect/Replace
• Dirt that is saturated with moisture After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
These contaminants will develop a conductive path dirt. Compressed air that is used for cleaning should
which may produce shorts. Cleaning is advisable if be free of moisture and free of oil. Air pressure
heavy accumulations of dirt can be seen or if heavy should be a maximum of 210 kPa (30 psi) in order to
accumulations of dust can be seen. If excess dirt is prevent mechanical damage to the insulation. If the
the cause of a restriction in the ventilation, cleaning is above cleaning procedures are not effective, consult
also advisable. Restricted ventilation will cause a Cat dealer.
excessive heating.
NOTICE Cleaning (Disassembled

To avoid the possibility of deterioration to the genera- Generators)
tor windings, do not clean the generator unless there
is visual, electrical, or thermal evidence that dirt is
present. An initial insulation resistance check should be made
on the generator in order to confirm electrical
integrity. A minimum reading of two megohm would
If harmful dirt accumulations are present, various be expected with severely contaminated generators.
cleaning techniques are available. The cleaning A zero megohm reading may indicate an insulation
procedure that is used may be determined by one of breakdown. An insulation breakdown requires more
the items on the following list: than cleaning. An insulation breakdown requires
repair.
• The extent of the cleaning procedure that is being
attempted A high-pressure wash is normally an effective way to
clean windings. This includes windings that have
• The type of enclosure of the generator been exposed to flooding or windings that have been
contaminated by salt. A solution of hot water and
• The voltage rating of the generator detergent is used for this method of cleaning.
• The type of dirt that is being removed A high-pressure wash sprays a high velocity fluid
stream of this solution over the generator that is
being cleaned. This detergent washing is followed by
Cleaning (Assembled Generators) multiple sprays of clean water. The clean water is
used in order to remove the detergent or the clean
Cleaning may be required at the point of installation. water is used in order to dilute the detergent.
At this point, complete disassembly of the generator
may not be necessary or feasible. In this case, a Allow the generator to dry at room temperature.
vacuum cleaner should be used to pick up the Check the insulation resistance. The insulation
following items: dry dirt, dust and carbon. This will resistance should now be normal. If the insulation
prevent the spreading of these contaminants. resistance is not normal, repeat the procedure. It may
be necessary to use solvents if the generator is
A small nonconductive tube may need to be contaminated with oil or if the generator is
connected to the vacuum cleaner. This will allow the contaminated with grease.
vacuum cleaner to clean the surfaces that are not
exposed. After most of the dust has been removed, a Note: For more information on drying methods, refer
small brush may be attached to the vacuum hose in to Special Instructions, SEHS9124, “Cleaning and
order to loosen dirt that is more firmly attached to the Drying of Electric Set Generators”.
surface.
i07396531
Generator Bearing - Inspect/

Replace
(LC6/LC7Generator)
SMCS Code: 4471-510; 4471-040
The following maintenance procedure for generator
bearings should be followed at every major engine
overhaul:
120 SEBU9048-09
Maintenance Section
Generator Bearing - Lubricate
Inspect 6. For greasing intervals, follow the

recommendations on the lubrication plate (if
1. Remove the bearing bracket. Inspect the following equipped) or refer to Maintenance Schedule,
items: bracket bore, bearing outer race and rolling “Generator Bearing - Lubricate”. Whenever the
elements. On standby power units, the bearing bearings are greased, repeat Step 1. DO NOT
must be inspected and the grease must be MIX GREASES.
replaced at the specified intervals. intervals. The
sleeve in the bearing bracket should be inspected i04011489
for out of roundness, excessive wear, and a
bracket step that is less than 0.0762 mm Generator Bearing - Lubricate
(0.0030 inch). If there is no sleeve in the bearing SMCS Code: 4471-086
bracket, inspect the bore of the bearing bracket.
The bearing should be inspected for damage to
the outer race, severe fretting, and smoothness of
Lubricating Process (If Applicable)
operation. When possible, the bearing elements Note: If the generator already has a visible grease
should be inspected. Some double shielded ball point, go to Step 4.
bearings prevent visual inspection of the elements
of the bearing. Other double shielded ball bearings 1. Remove either the louver assembly or the rear
have a retaining ring. This retaining ring can be plate from the rear of the generator housing.
removed to allow access for a visual inspection of
2. Remove the top grease pipe plug and remove the
the elements of the bearing.
lower grease pipe plug.
On two-bearing generators, the front bearing can
3. Install a grease fitting in the grease pipe.
only be removed after the drive coupling is
removed. Refer to the Systems Operation Testing 4. Grease the bearings with 2S-3230 Bearing
and Adjusting Disassembly and Assembly, Lubricant.
“Coupling - Remove” for the generator for
5. Wipe off the excess grease. Remove the top
instructions for removing the drive coupling.
grease fitting. Install the plug.
Replace 6. Operate the generator for 1 hour. This process will
allow the grease to expand. The expanding grease
1. All ball bearings should be cleaned. The cavity in will force the excess grease from the cavity. When
the bracket should be repacked with 2S-3230 the excess grease is forced from the cavity, the
Grease. Pack the ball bearings (one-third to one- internal pressure will be reduced. The generator
half of the volume of the cavity). should continue to operate until the grease stops
purging.
2. Use an induction heater to heat the ball bearings to
107 °C (224.6 °F) for10 minutes to install either of 7. Stop the engine. Install the plug in the bottom
the following bearings: ball bearings that are new grease pipe. Wipe off the excess grease.
and ball bearings that have been inspected. Mount
the bearings on the shaft. To reinstall the hub, heat
the hub to 400 °C (752.0 °F) for 3 hours. Mount
the hub to the shaft.
3. Ensure that the tube of the grease gun is filled with
grease.
4. Remove the bracket drain plug and operate the
generator for 1 hour. This procedure 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.
5. Stop the engine. Install the bracket drain plug.
Wipe off the excess grease.
SEBU9048-09 121
Maintenance Section
Generator Bearing Temperature - Test/Record
8. Install the louver assembly or install the rear plate. The power factor can be referred to as the efficiency
of the load. This can be expressed as the ratio of kVA
Additional Information to actual kW. The power factor can be calculated by
dividing kW by kVA. Power factor is expressed as a
Refer to Special Instruction, REHS4892, “Generator decimal. Power factor is used to mean the portion of
Bearing Service” for further information. current that is supplied to a system that is doing
useful work. The portion of the current that is not
doing useful work is absorbed in maintaining the
i03677052 magnetic field in motors. This current (reactive load)
can be maintained without engine power.
Generator Bearing
Temperature - Test/Record i02377583
SMCS Code: 4471-081-TA Generator Set - Test

Bearing temperature detectors are optional on SMCS Code: 4450-081
generators. Bearing temperature detectors are used
with equipment that has been provided by the
customer in order to measure the bearing
temperature. Bearing temperature detectors may
DANGER: Shock/Electrocution Hazard-Do not
help to prevent premature bearing failure. operate this equipment or work on this
equipment unless you have read and understand
A bearing temperature that is 50 °C (122 °F) above
the instructions and warnings in the Operation
the ambient temperature may require a change in
and Maintenance Manual. Failure to follow the
operation. The unit should be shut down in order to instructions or heed the warnings will result in
prevent damage if the bearing temperature is 50 °C serious injury or death.
(122 °F) above the ambient temperature.
i01878834
Generator Load - Check Personal injury or death can result from high
SMCS Code: 4450-535-LA voltage.
When power generation equipment must be in
operation to make tests and/or adjustments, high
voltage and current are present.
Personal injury or death can result from high
voltage. Improper test equipment can fail and present a
high voltage shock hazard to its user.
When power generation equipment must be in
operation to make tests and/or adjustments, high Make sure the testing equipment is designed for
voltage and current are present. and correctly operated for high voltage and cur-
rent tests being made.
Improper test equipment can fail and present a
high voltage shock hazard to its user. When servicing or repairing electric power gener-
ation equipment:
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur- • Make sure the unit is off-line (disconnected
rent tests being made. from utility and/or other generators power
service), and either locked out or tagged DO
During normal operation, monitor the power factor NOT OPERATE.
and monitor generator loading.
• Make sure the generator engine is stopped.
When a three-phase generator is installed or when a
three-phase generator is reconnected, ensure that • Make sure all batteries are disconnected.
the total current in any one phase does not exceed
the nameplate rating. Each phase should carry the • Make sure all capacitors are discharged.
same load. This allows the three-phase generator to
work at the rated capacity. If one phase current
exceeds the nameplate amperage, an electrical
imbalance will occur. An electrical imbalance can
result in an electrical overload and an electrical
imbalance can result in overheating on three-phase
generators. This is not applicable to single-phase
generators.
122 SEBU9048-09
Maintenance Section
Generator Set Alignment - Check
Table 27
Tools Needed Properly maintain the alignment between the engine
Part Number Part Quantity and the driven equipment to minimize the following
problems:
237-5130 Digital Multimeter 1
• Bearing problems
12 VDC battery 1
Potential
• Vibration of the engine crankshaft
1
Transformer
• Vibration of the driven equipment
The generator set functional test is a simplified test Refer to the following information for more
that can be performed in order to determine if the information about the alignment of the generator set:
generator is functional. The generator set functional
test should be performed on a generator set that is • Special Instruction, SEHS7654, “Alignment -
under load. General Instructions”
The generator set functional test determines if the • Special Instruction, SEHS7259, “Alignment of
following statements happen: Single Bearing Generators”
• A phase voltage is being generated. • Special Instruction, REHS0177, “Alignment of the
Close Coupled Two Bearing Generators”
• The phase voltages are balanced.
Keep a record of the measurement of the alignment.
• The phase voltages change relative to engine The record may be used to check the trend of the
speed. alignment. The record may be used to analyze the
trend of the alignment.
The generator set functional test consists of the
following steps:
i05264206
1. Stop the generator. Connect the potential
transformer's high voltage winding to the Generator Set Vibration -
generator terminals (T1) and (T2). Connect the
voltmeter to the low voltage winding. If two
Inspect
transformers are available, connect the high SMCS Code: 4450-040-VI
voltage winding of the second transformer to the
Check for vibration damage. Vibration may cause the
generator terminals (T1) and (T3). Connect the following problems:
secondary terminals that correspond to generator
terminal (T2) of both transformers together. • Loose fittings
2. Disconnect wires “E+” and “E-” from the voltage • Loose belts
regulator. Disconnect the generator from the load.
• Excessive noise
3. Connect a 12 VDC automotive battery to wires “E
+” and “E-” . • Cracked insulation
4. Measure the AC voltage across the low voltage The following areas are susceptible to vibration
terminals of the transformer that correspond to the damage:
following generator terminals: “T1” and “T2” , “T2”
• Stator output leads
and “T3” and “T3” and “T1” . Record the voltages.
• Protective sleeving
i07376415
• Insulation
Generator Set Alignment - • Exposed electrical connections
Check
• Transformers
SMCS Code: 7002-024
• Fuses
Upon installation, or when moved, the generator set
must be checked for proper alignment. If the • Capacitors
generator set is run at the full continuous rating, the
alignment of the generator to the engine must be • Lightning arresters
checked annually.
SEBU9048-09 123
Maintenance Section
Generator Winding - Test
When a generator set is installed a vibration plot i04140299

should be recorded in order to assist in diagnosing
potential problems. This vibration plot should be
updated yearly. The vibration plot should also be
Generator Winding - Test
updated when the generator set is moved. Refer to SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
Data Sheet, LEKQ4023, “Linear Vibration” for the 081
allowable limits of vibration.
Contact the Cat Dealer Service Tools group for
information on ordering a vibration analyzer that will
meet your needs.
PMPE generator wiring diagram
(1) Voltage regulator and/or related components
(CR1) Diode
(CR2) Diode
(CR3) Diode
(CR4) Diode
(CR5) Diode
(CR6) Diode
(CR7) Varistor
(L1) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer
Table 28
Tools Needed
Part Number Part(1) Quantity
6V-7070 Digital Multimeter 1
Digital Multimeter
146-4080 1
(RS232)
(1) Only one multimeter is necessary for this test. Either of the mul-
timeters that are shown will work.
124 SEBU9048-09
Maintenance Section
Generator Winding Insulation - Test
i04437733
The high voltage that is produced by an operating Generator Winding Insulation -

generator set can cause severe injury or death.
Before performing any maintenance or repairs,
Test
ensure that the generator will not start. SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
081
Place the engine control switch in the “ OFF”” posi-
tion. Attach “ DO NOT OPERATE”” tags to all start-
ing controls. Disconnect the batteries or disable Recommended Periodic Insulation
the starting system. Lock out all switchgear and Tests
with the generator.
Measure the resistance of the following windings:
(L1), (L2), (L3), (L4) and (L5). The winding that is The high voltage that is produced by an operating
being tested must be disconnected from the other generator set can cause severe injury or death.
components before the resistance can be measured. Before performing any maintenance or repairs,
The following resistance measurements are ensure that the generator will not start.
approximations. If the measured value is not near the
listed approximation, the winding is probably Place the engine control switch in the “ OFF”” posi-
damaged. For a more precise resistance value, tion. Attach “ DO NOT OPERATE”” tags to all start-
consult the Technical Marketing Information (TMI). ing controls. Disconnect the batteries or disable
Refer to the generator arrangement that is in the starting system. Lock out all switchgear and
question. automatic transfer switches that are associated
with the generator.
Note: The winding temperature affects the
resistance. When the winding temperature increases, Periodically, use 300-8648 Insulation Testing Group
the winding resistance also increases. When the to check the insulation resistance of the main stator
winding temperature decreases, the winding winding. The frequency of this test is determined by
the generator environment. Previous insulation tester
resistance also decreases. Therefore, a correct readings will also determine the frequency of this
measurement can be performed only when the test.
winding is at room temperature.
Test the main stator windings with an insulation tester
The following armature windings have little in the following situations:
resistance: (L2), (L4) and (L5). The resistance of
these windings will measure near 0 ohms. Use a • The generator set is started for the first time.
milliohmmeter to measure the resistance of the
armature windings. • The generator set is removed from storage.
Exciter armature (rotor) – less than 0.1 ohm • The generator set is operating in a humid
Main armature (stator) – less than 0.1 ohm environment. Test every 3 months.
Pilot exciter armature (L5) – less than 0.1 ohm • The generator set is not protected from the
elements in an enclosed area. Test every 3
months.
Use a multimeter in order to measure the resistance
of field windings (L1) and (L3). • The generator set is installed in an enclosed area.
Exciter field (stator) (L1) – approximately 3.0 ohms This area needs to be low in humidity and this
to 6.0 ohms area needs to have steady temperatures. Test
every 12 months (minimum).
Main field (rotor) (L3) – approximately 1.25 ohms to
2.0 ohms • The generator set has not been run under load for
3 months. Test the generator set weekly. Use
space heaters around the generator set if the
Note: There should be no continuity between any generator is exposed to a sea water environment
winding and ground. There should be no continuity or if the humidity is above 75 percent. Also use
between any winding and another winding. space heaters if a test result was below 3
megohms.
SEBU9048-09 125
Maintenance Section
Space heaters must be used whenever the generator b. Observe the readings at 30 seconds. Observe
set is not under load. Space heaters must also be the readings at 60 seconds.
used whenever salt is present or whenever high
humidity is present. Using a space heater in this c. Record the 60 second reading. This reading
fashion is the only way to maintain insulation tester must be corrected for temperature.
readings above 1 megohm. Use space heaters only
when the generator is not running. d. Record temperature.
For additional information, refer to Special e. Record humidity.

Instruction, SEHS9124, “Cleaning and Drying of f. Remove voltage.
Electric Set Generators”.
10. Evaluate the readings. The actual value of the
Recommended Procedure for A resistance may vary greatly between generators.
Periodic Insulation Test For this reason, the condition of the insulation
must be evaluated. Base this evaluation on the
comparison between the 60 second resistance
readings and the readings that were taken on
Personal injury or death can result from previous dates. These two readings must be taken
electrocution. under similar conditions. If a 60 second resistance
reading has a 50 percent reduction from the
The megohmmeter is applying a high voltage to previous reading, the insulation may have
the circuit.
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 procedure will discharge the leads of the
windings. insulation tester. Disconnect the 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 will
2. Visually inspect the generator for moisture. If vary greatly with temperature. Therefore, always test
moisture exists, do not perform this insulation test. at the same temperature and humidity. Refer to
Dry the unit first. Refer to Special Instruction, Illustration 87 .
SEHS9124, “Cleaning and Drying of Electric Set
Serial Number (Engine)
Generators”.
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 RED of the insulation tester
lead to ground.
7. Connect the insulation BLACK lead of the tester to
the wye point or star point of the generator
windings.
8. For units that are 600 V or less, set the voltage to
500 V. For units that are more than 600 V, set the
voltage to 1000 V.
9. Use the 30/60 Time Resistance Method:
a. Apply voltage.
126 SEBU9048-09
Maintenance Section
SEBU9048-09 127
Maintenance Section
Heat Exchanger - Clean/Test
i05194829
Heat Exchanger - Clean/Test Personal injury can result from air pressure.
SMCS Code: 1379-070; 1379-081 Personal injury can result without following prop-
er procedure. When using pressure air, wear a
Clean the Heat Exchanger protective face shield and protective clothing.
1. Remove the heat exchanger from the engine. The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
Refer to the Disassembly and Assembly Manual, nozzle is deadheaded.
“Heat Exchanger - Remove” for the procedure.
2. Remove the heat exchanger core from the heat 8. Dry the heat exchanger core with compressed air.
exchanger. Refer to the Disassembly and Direct the air in the reverse direction of the normal
Assembly Manual, “Heat Exchanger - flow.
Disassemble” for the procedure.
Test the Heat Exchanger Core
3. Turn the heat exchanger core onto one side in
order to remove debris. Remove the debris that is 1. Inspect the heat exchanger core for trapped debris
accessible. and cleanliness. If necessary, remove the debris
and repeat the cleaning procedure.
NOTICE
Do not use a high concentration of caustic cleaner to 2. Inspect the heat exchanger core for damage and
clean the core. A high concentration of caustic perform a pressure test in order to detect leaks.
cleaner can attack the internal metals of the core and Many shops that service radiators are equipped to
cause leakage. Only use the recommended concen-
tration of cleaner. perform pressure tests.
3. Plug both ends of the heat exchanger core and
4. Back flush the heat exchanger core with cleaner. pressurize the core to 100 kPa (14.5 psi).
Submerge the core in water. Look for bubbles
Caterpillar recommends the use of Hydrosolv which are being emitted from the core. The
liquid cleaner. Table 29 lists Hydrosolv liquid bubbles are evidence of leaks.
cleaners that are available from your Cat dealer.
Table 29 4. If any leaks are found, do not attempt to repair the
core.
Hydrosolv Liquid Cleaners(1)
5. Install a core that is clean and that passes the
Part Number Description Size
pressure test in step 3. Refer to the Disassembly
1U-5490 Hydrosolv 4165 19 L (5 US gallon) and Assembly Manual, “Heat Exchanger -
174-6854 Hydrosolv 100 19 L (5 US gallon)
Assemble” for the procedure.
(1) Use a 2 to 5 percent concentration of the cleaner at tempera- 6. Install the heat exchanger onto the engine. Refer
tures up to 93°C (200°F). Consult your Cat dealer for more to the Disassembly and Assembly Manual, “Heat
information.
Exchanger - Install” for the procedure.
5. Clean the heat exchanger core with steam to
remove any residue. Flush the fins of the heat
exchanger. Remove any other trapped debris from
the inside and from the outside of the core.
6. Wash the heat exchanger core with hot, soapy
water.
7. Flush the heat exchanger core thoroughly in order
to remove residue and remaining debris. Flush the
heat exchanger core with clean, fresh water until
the water that is exiting the core is clear and free
of debris.
128 SEBU9048-09
Maintenance Section
Heat Exchanger - Inspect
For more information on cleaning the core, consult i06825542

your Cat dealer.
Hoses and Clamps - Inspect/
i06521408
Replace
Heat Exchanger - Inspect SMCS Code: 7554-040; 7554-510
(If Equipped) Hoses and clamps must be inspected periodically
and replaced at the recommended interval to ensure
SMCS Code: 1379-040 safe and continuous operation of the engine. Failure
The interval for the maintenance of the heat to replace a fuel hose at the recommended change
exchanger depends on the operating environment of interval may result in a hazardous situation. Take
the vessel and on the operating time. The sea water proper safety precautions before inspecting or
that is circulated through the heat exchanger and the replacing hoses and clamps.
amount of operating time of the vessel affects the
following items: Note: Always use a board or cardboard when the
engine components are checked for leaks. Leaking
• Cleanliness of the tubes of the heat exchanger fluid that is under pressure can cause serious injury
or possible death. Leaks that are the size of a pin
• Effectiveness of the heat exchanger system hole are included. Refer to Operation and
Maintenance Manual, “General Hazard Information”
Operating in water that contains silt, sediment, salt, for more information.
algae, and so on, will adversely affect the heat
exchanger system. In addition, intermittent use of the Note: Ensure that the hose is compatible with the
vessel will adversely affect the heat exchanger application.
system.
The following items indicate that the heat exchanger Inspect Tubes, Hoses, Bellows, and
may require cleaning: Clamps
• Increased coolant temperature
Inspect all tubes and hoses for leaks that are caused
• Engine overheating by the following conditions. Replace any tube or hose
which exhibits any of the following conditions. Failure
• Excessive pressure drop between the water inlet to replace a tube or hose which exhibits any of the
and the water outlet following conditions may result in a hazardous
situation.
An operator that is familiar with the normal operating
temperature of the coolant can determine when the • Hoses which are cracked
coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger • Hoses which are soft
are required if the engine is overheating.
• Outer covering that is chafed or cut
Your Cat dealer has the equipment and the trained
personnel that are needed to measure the pressure • Exposed wire that is used for reinforcement
drop across the heat exchanger.
• Outer covering that is ballooning locally
“Heat Exchanger - Clean/Test”. For more information • Flexible part of the hose that is kinked or crushed
on servicing the heat exchanger, consult your Cat
dealer. • Armoring that is embedded in the outer covering
• Exhaust bellows for leaks or damage

• Hoses which exhibit signs of leakage which are
not the result of loose couplings or clamps
Inspect all clamps for the following conditions.
Replace any clamp which exhibits signs of any of the
following conditions.
• Cracking
• Looseness
• Damage
SEBU9048-09 129
Maintenance Section
Hoses and Clamps - Inspect/Replace
Inspect all couplings for leaks. Replace any coupling

which exhibits signs of leaks.
Each installation application can be different. The Personal injury can result from removing hoses
differences depend on the following factors: or fittings in a pressure system.
• Type of hose Failure to relieve pressure can cause personal

injury.
• Type of fitting material Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the 1. Stop the engine.
fittings
2. Allow the engine to cool.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen 3. Before servicing a coolant hose, slowly loosen the
which can result in leaks. A constant torque hose filler cap for the cooling system to relieve any
clamp will help to prevent loose hose clamps. pressure.
Replace hoses that are cracked or soft. Replace 4. Remove the filler cap for the cooling system.
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps 5. Drain the coolant from the cooling system to a
that are cracked or damaged. Tighten or replace level that is below the hose that is being replaced.
hose clamps which are loose. Drain the coolant into a suitable clean container.
The coolant can be reused.
Replace the Hoses and the Clamps
6. Remove the hose clamps.
NOTICE 7. Disconnect the old hose.

tained during performance of inspection, mainte- 8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or
ers before opening any compartment or disassem- install new hose clamps. Refer to Specifications,
bling any component containing fluids. SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and
Refer to Special Publication, NENG2500, “Cat Dealer installing the proper hose clamps.
PECJ0003, “Cat Shop Supplies and Tools Catalog” 10. Refill the cooling system.
fluids on Cat products. 11. Clean the coolant filler cap. Inspect the gaskets
on the filler cap. Inspect the gasket seat. Inspect
Dispose of all fluids according to local regulations the vacuum valve and seat for debris or damage.
and mandates. Replace the filler cap if the gaskets are damaged.
Install the filler cap.
Cooling System 12. Start the engine. Inspect the cooling system for
leaks.
Fuel System
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
components are cool. Loosen the cooling system Personal injury can result from removing hoses
pressure cap slowly in order to relieve the or fittings in a pressure system.
pressure.
Failure to relieve pressure can cause personal
injury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
130 SEBU9048-09
Maintenance Section
Hoses and Clamps - Inspect/Replace
7. Refill the fuel system. Refer to this Operation and

Maintenance Manual, “Fuel System - Prime” for
Contact with high pressure fuel may cause fluid information about priming the engine with fuel.
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow 8. Start the engine. Inspect the fuel system for leaks.
these inspection, maintenance and service in-
structions may cause personal injury or death. Lubrication System
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
any loose or damaged fuel and oil lines, tubes and
contact the skin.
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
recommended torque. 1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.
NOTICE 2. Remove the hose clamps.
clean the area around a fuel system component that 3. Disconnect the old hose.
will be disconnected. Fit a suitable cover over any
disconnected fuel system components. 4. Replace the old hose with a new hose.
install new hose clamps. Refer to Specifications,
Note: High-pressure fuel lines may be installed
between the high-pressure fuel pump and the fuel SENR3130, “Torque Specifications” “Hose
injectors. High-pressure fuel lines are constantly Clamps” for information about selecting and
charged with high pressure. Do not check the high- installing the proper hose clamps.
pressure fuel lines with the engine or the starting 6. Refill the lubrication system. Refer to this
motor in operation. Wait for 10 minutes after the
engine stops before you perform any service or
repair on high-pressure fuel lines. Waiting for 10 Level - Check” to ensure that the lubrication
minutes will allow the pressure to be purged. system is filled with the proper amount of engine
oil.
1. Drain the fuel from the fuel system to a level that is
7. Start the engine. Inspect the lubrication system for
below the hose that is being replaced.
leaks.
2. Remove the hose clamps.
Air System
3. Disconnect the old hose.
Note: When servicing fuel system, use cap/s or 1. Remove the hose clamps.
cover/s as required to protect the system and 2. Disconnect the old hose.
maintain fuel system cleanliness.
3. Replace the old hose with a new hose.
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications,
install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose
SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and
Clamps” for information about selecting and installing the proper hose clamps.
installing the proper hose clamps.
Note: The bellows and the V-clamps that are used on
6. Carefully inspect the engine for any spilled fuel. the exhaust bellows should never be reused.
Make sure that no fuel remains on or close to the
engine.
Note: Fuel must be added to the fuel system ahead
of the fuel filter.
SEBU9048-09 131
Maintenance Section
5. Start the engine. Inspect the air lines for leaks. The following factors can contribute to severe
operation: environment, improper operating
i07196018
procedures, and improper maintenance practices.
Maintenance Environmental Factors

Recommendations Extreme Ambient Temperatures
SMCS Code: 1000
Extended operation in environments that are
extremely cold or hot can damage components.
Maintenance Information Valve components can be damaged by carbon
buildup if the engine is frequently started and
The operating conditions of an engine affect the stopped in very cold temperatures. Extremely hot
maintenance intervals and the time between inlet air reduces the performance capabilities of the
overhauls for the engine. The following conditions engine.
affect the maintenance intervals and the expected
overhaul interval for the engine. Note: See this Operation and Maintenance Manual,
“Cold-Weather Operation” topic (Operation Section),
Severe Operation or see Supplement, SEBU5898, “Cold-Weather
Recommendations”.
Severe operation is the use of an engine that
exceeds current published standards for the engine. Cleanliness
Caterpillar maintains standards for the following
engine parameters: Unless the equipment is cleaned regularly, extended
operation in a dirty environment and in a dusty
• Horsepower environment can damage components. Built up mud,
dirt, and dust can encase components. This
• Range of rpm operating environment can make maintenance
difficult. The buildup can contain corrosive chemicals.
• Fuel consumption Corrosive chemicals and salt can damage some
components.
• Fuel quality
Improper Operating Procedures
• Altitude
• Maintenance intervals • Extended operation at low idle
• Selection of oil • Minimum cool down periods after high load factor
operation
• Selection of coolant
• Operating the engine beyond the guidelines for
• Environmental qualities the engine rating
• Installation • Operating the engine at loads that are greater than

the rated load
Refer to the standards for your engine or consult your
Caterpillar dealer to determine if your engine is • Operating the engine at speeds that are greater
operating within the defined parameters. than the rated speed
Severe operation can accelerate component wear. • Use of the engine for an application that is not
Engines that are operating under severe conditions approved
may need more frequent maintenance intervals for
the following reasons: Improper Maintenance Practices
• Maximum reliability
• Extension of maintenance intervals
• Retention of full service life
Because of individual applications, identifying all the
factors which can contribute to severe operation is
not possible . Consult your Caterpillar dealer about
the maintenance that is needed for your specific
engine.
132 SEBU9048-09
Maintenance Section
• Not using recommended fuel, lubricants, and When the engine oil consumption has risen to three
antifreeze/coolant solutions times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
Overhaul Information and a slight increase in fuel consumption.
Caterpillar makes the following recommendations for
the timing of the overhaul procedures for your Overhaul Options
engine. The intervals may be extended based on
individual application and load factors. Contact your Before Failure Overhaul
Caterpillar dealer for further information about the
optimal maintenance interval for the overhaul To minimize downtime, Caterpillar Inc. recommends
procedures. a scheduled engine overhaul by your Caterpillar
Table 30
dealer before the engine fails. The scheduled
overhaul will provide you with the best cost/value
Overhaul Procedure Recommended Interval relationship.
Every 759997 L (200791 US gal) or 10000
Major Overhaul
SH
Note: Overhaul programs vary according to the
engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar
Note: Refer to this Operation and Maintenance dealer for specific information about the available
Manual, “Overhaul (Major)” for further information overhaul programs and about overhaul services for
about the major overhaul. extending the engine life.
Reduced hours of operation at full load will result in a A planned overhaul before failure may be the best
lower average power demand. A decreased average value for the following reasons:
power demand should increase both the engine
service life and the overhaul interval. • Costly unplanned downtime can be avoided.
The need for an overhaul is generally indicated by • Many original parts can be reused according to the
increased fuel consumption and by reduced power. standards for reusable parts.
The following factors are important when a decision • The service life of the engine can be extended
is being made on the proper time for an engine without the risk of a major catastrophe due to
overhaul:
engine failure.
• The need for preventive maintenance
• The best cost/value relationship per hour of
• The quality of the fuel that is being used extended life can be attained.
• The operating conditions After Failure Overhaul
• The results of the S·O·S analysis If a major engine failure occurs and the engine must
be removed from the hull, many options are
available. An overhaul should be performed if the
Oil Consumption as an Overhaul engine block or the crankshaft needs to be repaired.
Indicator If the engine block is repairable and/or the crankshaft
Oil consumption, fuel consumption, and maintenance is repairable, the overhaul cost should be between 40
information can be used to estimate the total percent and 50 percent of the cost of a new engine
operating cost for your Caterpillar engine. Oil with a similar exchange core.
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable This lower cost can be attributed to three aspects:
for the maintenance intervals.
• Specially designed Caterpillar engine features
Oil consumption is in proportion to the percentage of
the rated engine load. As the percentage of the • Caterpillar dealer exchange components
engine load is increased, the amount of oil that is
consumed per hour also increases.
The oil consumption rate (brake-specific oil
consumption) is measured in grams per kW/h (lb per
bhp). The brake-specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
SEBU9048-09 133
Maintenance Section
Oil Cooler Core - Check/Clean/Test
• Caterpillar Inc. remanufactured exchange

components
Personal injury can result from air pressure.
i07186224
Oil Cooler Core - Check/Clean/ er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Test
The maximum air pressure for cleaning purposes
SMCS Code: 1378-535; 1378-070; 1378-081 must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
This maintenance procedure shall be performed
when the major overhaul is performed. Refer to this
Operation and Maintenance Manual, “Maintenance 6. Dry the core with compressed air. Direct the air in
Recommendations” article for information about the the reverse direction of the normal flow.
maintenance interval for the major overhaul.
Test the Oil Cooler Core
Clean the Oil Cooler Core
1. Inspect the core for trapped debris and
Remove the core. Refer to the Disassembly and cleanliness. If necessary, remove the debris and
Assembly Manual, “Oil Cooler - Remove” for the
procedure. repeat the cleaning procedure.
1. Turn the oil cooler core on one side to remove 2. Inspect the core for damage and perform a
debris. Remove the debris that is accessible. pressure test to detect leaks. Many shops that
service radiators are equipped to perform
NOTICE pressure tests.
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic 3. Plug both ends of the oil cooler core and
cleaner can attack the internal metals of the core and pressurize the core to 205 kPa (30 psi).
cause leakage. Only use the recommended concen- Submerge the core in water. Look for bubbles
tration of cleaner. which are being emitted from the core. The
bubbles are evidence of leaks.
2. Back flush the core with cleaner. 4. If any leaks are found, do not attempt to repair the
Caterpillar recommends the use of Hydrosolv core.
liquid cleaner. Table 31 lists Hydrosolv liquid Install a core that is clean and a core that passes the
cleaners that are available from your Caterpillar pressure test in step 3. Refer to the Disassembly and
dealer. Assembly Manual, “Oil Cooler - Install” for the
Table 31 procedure.
Hydrosolv Liquid Cleaners(1) For more information on cleaning the core, consult
Description
your Caterpillar dealer.
Part Number Size
1U-5490 Hydrosolv 4165 19 L (5 US gal) i07186240
174-6854 Hydrosolv 100 19 L (5 US gal)

(1) Use a two to five percent concentration of the cleaner at tem-
Overhaul (Major)
peratures up to 93°C (200°F). Refer to Application Guide, SMCS Code: 7595-020-MJ
NEHS0526 or consult your Caterpillar dealer for more
information. Refer to this Operation and Maintenance Manual,
“Maintenance Recommendations” to determine the
3. Steam clean the core to remove any residue. Flush maintenance interval for a major overhaul.
the fins of the oil cooler core. Remove any other The need for a major overhaul is determined by
trapped debris from the inside and from the several factors.
outside of the core.
• An increase of oil consumption
4. Wash the core with hot, soapy water.
5. Flush the core thoroughly to remove residue and • An increase of crankcase blowby
remaining debris. Flush the core with clean, fresh • The total amount of fuel consumption
water until the water that is exiting the core is clear
and free of debris. • The service hours of the engine
134 SEBU9048-09
Maintenance Section
Overhaul (Major)
• The wear metal analysis of the lube oil International Convention for Safety of
• An increase in the levels of noise and vibration
Life at Sea (SOLAS)
An increase of wear metals in the lube oil indicates Caterpillar recommends replacing the following:
that the bearings and the surfaces that wear may
need service. An increase in the levels of noise and • All shields that have been installed to cover up fuel
vibration indicates that rotating parts require service. and oil line connections per (SOLAS) regulations
Note: An oil analysis may indicate a decrease of • All marine certification society approved tapes are
wear metals in the lube oil. The cylinder liners may installed to cover up fuel line connections and oil
be worn so that polishing of the bore occurs. Also, line connections according to the SOLAS
the increased use of lube oil will dilute the wear regulations.
metals.
Monitor the engine as the engine accumulates Inspection, Reconditioning, or
service hours. Consult your Cat dealer about Exchanging of Components
scheduling a major overhaul.
Inspect the following components according to the
Note: The driven equipment may also require service instructions that are in Caterpillar reusability
when the engine is overhauled. Refer to the literature publications. Refer to Guidelines for Reusable Parts
that is provided by the OEM of the driven equipment. and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used
A major overhaul includes more parts and labor. Parts”.
Additional parts and labor are required for a complete
engine rebuild. Recondition the worn components or exchange the
components, if necessary. Your Cat dealer can
For the major overhaul, all the bearings, seals, provide these services and components.
gaskets, and components that wear are
disassembled. The parts are cleaned and inspected. • Camshaft followers
If necessary, the parts are replaced. The crankshaft
is measured for wear. The crankshaft may require • Camshaft thrust washers
regrinding. Alternatively, the crankshaft may be
replaced with a Cat replacement part. • Connecting rods
Your Cat dealer can provide these services and • Crankshaft vibration damper
components. Your Cat dealer can ensure that the
components are operating within the appropriate • Cylinder head assembly
specifications.
• Cylinder liners
Replacement of Components • Engine mounts
Replace the following components during the major • Scavenge oil pump
overhaul:
• Engine wiring harness
• Camshaft bearings
• Exhaust manifold seals
• Connecting rod bearings
• Exhaust manifold bellows
• Crankshaft seals
• Fuel pressure regulating valve
• Crankshaft thrust washers
• Fuel priming pump
• Electronic unit injectors
• Fuel transfer pump
• Gear train bushings
• Inlet manifold gaskets
• Gear train bearings
• Inlet manifold seals
• Main bearings
• Oil cooler core
• Piston rings
• Oil pump
• Pistons
SEBU9048-09 135
Maintenance Section
Overhaul (Major)
• Piston pins Replace the crankshaft vibration damper if any of the

following conditions occur:
• Prelube pump
• Engine failure due to a broken crankshaft
• Pushrods
• Excessive wear of the front bearing for the
• Rocker arms crankshaft
• Spacer plate • Excessive wear of the gear train that is not caused
by a lack of lubrication
• Software update
Inspect the gears of the gear train and inspect the
• Turbocharger gear train bushings for the following conditions:
Inspection of Components • Worn gear teeth
Inspect the following components according to the • Unusual fit

instructions that are in Caterpillar reusability • Unusual wear
publications. Refer to Guidelines for Reusable Parts
and Salvage Operations, SEBF8029, “Index of In addition to the inspection of components, inspect
Publications on Reusability or Salvage of Used the alignment of the driven equipment. See the
Parts”. Application and Installation Guide for the engine or
see the literature that is provided by the OEM of the
• Camshaft driven equipment.
• Crankshaft
Cleaning of Components
• Driven equipment (alignment)
Clean the oil suction screen. Also, remove side
• Engine cylinder block covers to clean the oil sump. For instructions on
removal and installation of components, see the
• Engine control module Service Manual, “Disassembly and Assembly”
module.
• Flywheel
• Front gear train (gears)
Cleaning and Pressure Testing of
Components
• Oil suction screen
Clean and pressure test the aftercooler core. Refer to
• Rear gear train this Operation and Maintenance Manual, “Aftercooler
Core - Clean/Test” for the procedure.
Inspect the camshaft for damage to the journals and
the lobes. Clean and pressure test the heat exchanger. Refer to
Inspect the crankshaft for any of the following this Operation and Maintenance Manual, “Heat
conditions: Exchanger - Clean/Test” for the procedure.
• Deflection Obtain a Coolant Analysis

• Damage to the journals For conventional heavy-duty coolant or antifreeze,
check the concentration of supplemental coolant
• Bearing material that has seized to the journals additive (SCA) regularly. The concentration of SCA
can be checked with an S·O·S coolant analysis
Check the journal taper and the profile of the (Level I). A more detailed coolant analysis is
crankshaft journals. Check these components by recommended periodically.
interpreting the wear patterns on the following
components: For example, considerable deposits are found in the
water jacket areas on the external cooling system,
• Rod bearing but the concentrations of coolant additives were
carefully maintained. The coolant water probably
• Main bearings contained minerals which were deposited on the
engine over time.
Note: If the crankshaft or the camshaft are removed
for any reason, use the magnetic particle inspection
process to check for cracks.
136 SEBU9048-09
Maintenance Section
Power Factor - Check
A coolant analysis can be conducted to verify the

condition of the water that is being used in the
cooling system. A full water analysis may be obtained Personal injury can result from air pressure.
from the following sources:
• Cat dealer er procedure. When using pressure air, wear a
protective face shield and protective clothing.
• Local water utility company
Maximum air pressure at the nozzle must be less
• Agricultural agent than 205 kPa (30 psi) for cleaning purposes.
• Independent laboratory
Caterpillar recommends an S·O·S coolant analysis Note: To prevent damage to fins, ensure that the air
(Level II) which is a comprehensive chemical gun is maintained at right angles to the core face.
evaluation of the coolant. This analysis is also a
Pressurized air is the preferred method for removing
check of the overall condition inside the cooling
loose debris. Direct the air in the opposite direction of
system. The following services are provided: the fan air flow. Hold the nozzle approximately 6 mm
• Full Level I analysis (0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
• Identification of the source of metal corrosion and This procedure will remove debris that is between the
tubes.
of contaminants
Pressurized water may also be used for cleaning.
• Identification of buildup of the impurities that The maximum water pressure for cleaning purposes
cause corrosion must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
• Identification of buildup of the impurities that both sides.
cause scaling
Use a degreaser and steam for removal of oil and
• Determination of possible electrolysis within the grease. Clean both sides of the core. Wash the core
engine cooling system with detergent and hot water. Thoroughly rinse the
core with clean water.
A report of the results of the analysis is provided.
Maintenance recommendations are based on the After cleaning, start the engine. This procedure will
results. help in the removal of debris and drying of the core.
Stop the engine. Use a light bulb behind the core in
For more information about S·O·S coolant analysis, order to inspect the core for cleanliness. Repeat the
consult your Cat dealer. cleaning, if necessary.
i01216962 Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
Power Factor - Check clamps and seals. Make repairs, if necessary.
SMCS Code: 4450-535-PWR
For more detailed information on cleaning and
The power factor of a system can be determined by a inspection, refer to Special Publication, SEBD0518,
power factor meter or by calculations. The power “Know Your Cooling System”.
factor can be calculated by dividing kW by kVA.
Power factor is expressed as a decimal. i02331392
i05611689 Rotating Rectifier - Check

SMCS Code: 4465-535
Radiator - Clean
SMCS Code: 1353-070 Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
Note: Adjust the frequency of cleaning according to refer to “Testing A Brushless Exciter Rotating
the effects of the operating environment. Rectifier With An Ohmmeter”.
For additional information on cleaning the radiator,

refer to the OEM of the radiator.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.
SEBU9048-09 137
Maintenance Section
Rotating Rectifier - Check
Testing A Brushless Exciter Replace any faulty rectifiers with rectifiers that have
comparable operating characteristics. Include the
Rotating Rectifier With An following information when a rectifier is being ordered
Ohmmeter for replacement:
Table 32 • Part Number of the rectifier
Tools Needed
• Model number of the exciter
Part Number Part Name Quantity
• Type of the exciter
6V-7070 Digital Multimeter 1
• Serial number of the generator
9U-7330 Multimeter 1
146-4080 Digital Multimeter
(RS-232)
1
Rectifier Block Test
7X-1710 Multimeter Probe 1
Group
If the failure of a rectifier is suspected, use the

following procedure.
1. Remove the cover from the exciter.
2. Remove the nut that secures the rectifier to the
heat sink.
3. Remove the diode lead.
4. Lift the rectifier from the heat sink. Rectifier Block
5. Refer to Illustration 88 . Connect the ohmmeter's (1) “AC1” terminal
(2) “AC2” terminal
leads across the rectifier. Note the meter reading. (3) “AC3” terminal
(4) Negative terminal
6. Reverse the ohmmeter leads. Note the meter (5) Positive terminal
reading.
Perform the following steps in order to test the
The ohmmeter should indicate a low resistance when rectifier block. When possible, use the diode test
the ohmmeter leads are across the rectifier in one scale. If there is no diode test scale, use the
direction. The ohmmeter should indicate a high resistance scale.
resistance when the leads are reversed.
1. Touch the red ohmmeter lead to the rectifier
If the ohmmeter indicates a low resistance in both
directions, the rectifier is shorted. A high resistance in terminal that is marked “+” .
both directions indicates an open rectifier.
138 SEBU9048-09
Maintenance Section
Sea Water Strainer - Clean/Inspect
2. Touch the black ohmmeter lead to the rectifier • Serial number of the generator
terminals that have the following labels: “AC1” ,
“AC2” and “AC3” . The meter should indicate an i04277901
open circuit or high resistance for each rectifier
terminal. If the meter does not indicate an open Sea Water Strainer - Clean/
circuit or high resistance, the rectifier is bad.
Replace the rectifier.
Inspect
SMCS Code: 1371-040; 1371-070
3. Touch the black ohmmeter lead to the rectifier
terminal that is marked “+” . The sea water strainer must be clean in order to
allow proper engine cooling and component life. The
4. Touch the red ohmmeter lead to the rectifier sea water strainer is located before the sea water
terminals that have the following labels: “AC1” , pump impeller and filters out debris. Check the sea
water strainer for plugging. Inspect the sea water
“AC2” and “AC3” . The meter should indicate a
strainer more frequently if the vessel is being
good diode or low resistance. If the meter does not operated in water which is shallow or dirty. Refer to
indicate a good diode or low resistance, the the OEM recommendations for more information
rectifier is bad. Replace the rectifier. about inspecting and cleaning the sea water strainer.
5. Touch the black ohmmeter lead to the rectifier
i04524988
terminal that is marked “−” .
6. Touch the red ohmmeter lead to the rectifier Standby Generator Set
terminals that have the following labels: “AC1” , Maintenance
“AC2” and “AC3” . The meter should indicate an
open circuit or high resistance for each rectifier Recommendations
terminal. If the meter does not indicate an open SMCS Code: 4450-041
circuit or high resistance, the rectifier is bad.
Replace the rectifier. A standby generator set may be intermittently used.
However, the generator set is needed for operation in
7. Touch the red ohmmeter lead to the rectifier an emergency situation. Maintenance of the standby
terminal that is marked “−” . generator set is important for the following reasons:
8. Touch the black ohmmeter lead to the rectifier • The generator set must always be in excellent
terminals that have the following labels: “AC1” , operating condition.
“AC2” and “AC3” . The meter should indicate a
• The generator set must be ready to work under
good diode or low resistance. If the meter does not
load at any time.
indicate a good diode or low resistance, the
rectifier is bad. Replace the rectifier. Establishing a Preventive Maintenance Program will
provide these benefits:
Replace any faulty rectifiers with rectifiers that have
comparable operating characteristics. Include the • Maximum availability of the standby generator set
following information when a rectifier is being ordered
for replacement: • Longer service life for the generator set
• Part Number of the rectifier • Minimum of expensive repairs
• Model number of the exciter Your Cat dealer can help you to establish an effective
Preventive Maintenance Program for your generator
• Type of the exciter set. Consult your Cat dealer for details.
SEBU9048-09 139
Maintenance Section
Stator Lead - Check
Maintenance and Operation Space Heaters

Procedures Moisture can damage generators and other electrical
equipment. Make every effort to keep the generator
set as dry as possible.
The high voltage that is produced by an operating Generators can operate without problems in humid
generator set can cause severe injury or death. environments. However, problems can occur when
Before performing any maintenance or repairs, the generator is inactive. Moisture can condense on
ensure that the generator will not start. the windings. This condition can result in poor
performance. Also, damage to the windings can
Place the engine control switch in the “ OFF”” posi- occur.
tion. Attach “ DO NOT OPERATE”” tags to all start-
Use space heaters in order to help keep the windings
ing controls. Disconnect the batteries or disable
dry. When the generator is not active, ensure that the
the starting system. Lock out all switchgear and
space heaters are operating. When the generator is
with the generator. operating, turn OFF the space heaters.
The recommended maintenance for the generator i03230840

set is listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule (Standby
Generator Sets)” (Maintenance Section).
Stator Lead - Check
SMCS Code: 4459-535
Maintenance and Repair Ensure that the stator output leads are routed out of
the generator in a manner that prevents the leads
The maintenance that is recommended for Every from rubbing against metal objects.
Week can be performed by an authorized operator.
The maintenance that is recommended for the Visually inspect the following areas for cracking and
subsequent maintenance intervals must be physical damage:
performed by an authorized service technician or by
your Cat dealer. • stator output leads
Unless other instructions are provided, perform • protective sleeving
maintenance and repairs under the following
conditions: • insulation
• The engine is stopped.
i07059057
• The starting system is disabled.
Stator Winding Temperature -
• The generator does not pose an electrical shock
hazard. Test
SMCS Code: 4453-081-TA
• The generator is disconnected from the load.
Some generators are equipped with optional 100
Operation Ohm Resistance Temperature Detectors(RTD) that
are mounted in slots of the main stator. The
To ensure proper operation, the generator set must generator set is equipped with RTD modules that are
be exercised regularly. For instructions on operating interfaced to Electronic Modular Control Panels
the generator set, see the Operation and (EMCP). The modules can be interfaced to measure
Maintenance Manual for the generator set control the temperature of the stator. Alternately, there are
panel. measuring devices in the open market that can be
interfaced with the RTD. Caterpillar recommends the
For these operation procedures, follow the continuous monitoring of the RTD.
instructions that are provided in this Operation and
Maintenance Manual, “Operation Section”: starting Refer to the specifications in table 33 for the
the engine, engine operation and stopping the maximum temperatures of the setpoints.
engine.
Record Keeping
Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems and repairs.
140 SEBU9048-09
Maintenance Section
Turbocharger - Inspect
Table 33
Maximum Recommended Temperatures for the Set- Note: Turbocharger components require precision
point(1) clearances. The turbocharger cartridge must be
Generator set balanced due to high rpm. Severe Service
application Alarm Shutdown Applications can accelerate component wear. Severe
Service Applications require more frequent
Standby 180 °C inspections of the cartridge.
190 °C (374 °F)
(356 °F)
Continuous 155 °C
165 °C (329 °F)
Removal and Installation
(311 °F)
(1)
For options regarding the removal, installation, repair,
If the operating temperature is lower than the recommended
setpoints, adjust the alarm and shutdown setpoints to a lower
and replacement, consult your Cat dealer. Refer to
value to ensure that unusual temperature variances are the Service Manual for this engine for the procedure
recognized. and specifications.
i05965726 Cleaning and Inspecting

Turbocharger - Inspect 1. Remove the exhaust outlet piping and remove the
SMCS Code: 1052-040 air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean the
Periodic inspection and cleaning are recommended interior of the pipes in order to prevent dirt from
for the turbocharger compressor housing (inlet side). entering during reassembly.
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil 2. Turn the compressor wheel and the turbine wheel
and from combustion can collect in the turbocharger by hand. The assembly should turn freely. Inspect
compressor housing. Over time, this buildup can the compressor wheel and the turbine wheel for
contribute to loss of engine power, increased black contact with the turbocharger housing. There
smoke and overall loss of engine efficiency.
should not be any visible signs of contact between
If the turbocharger fails during engine operation, the turbine wheel or compressor wheel and the
damage to the turbocharger compressor wheel and/ turbocharger housing. If there is any indication of
or to the engine may occur. Damage to the contact between the rotating turbine wheel or the
turbocharger compressor wheel can cause additional compressor wheel and the turbocharger housing,
damage to the pistons, the valves, and the cylinder
head. the turbocharger must be reconditioned.
3. Check the compressor wheel for cleanliness. If
NOTICE only the blade side of the wheel is dirty, dirt and/or
Turbocharger bearing failures can cause large quan-
moisture is passing through the air filtering
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine system. If oil is found only on the back side of the
damage. wheel, there is a possibility of a failed turbocharger
oil seal.
Minor leakage of a turbocharger housing under ex-
tended low idle operation should not cause problems The presence of oil may be the result of extended
as long as a turbocharger bearing failure has not engine operation at low idle. The presence of oil
occurred. may also be the result of a restriction of the line for
When a turbocharger bearing failure is accompanied the inlet air (plugged air filters), which causes the
by a significant engine performance loss (exhaust turbocharger to slobber.
smoke or engine rpm up at no load), do not continue
4. Inspect the bore of the turbine housing for
engine operation until the turbocharger is repaired or
replaced. corrosion.
5. Clean the turbocharger housing with standard
An inspection of the turbocharger can minimize shop solvents and a soft bristle brush.
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
SEBU9048-09 141
Maintenance Section
Varistor - Check
6. Fasten the air inlet piping and the exhaust outlet

NOTICE
piping to the turbocharger housing. For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
i03291822 correct the leak. If leaking is suspected, check the flu-
id levels more often than recommended until the leak
Varistor - Check is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.
SMCS Code: 4466-535
The varistor must be checked at regular intervals. NOTICE
Refer to Systems Operation/Testing and Adjusting, Accumulated grease and/or oil on an engine or deck
KENR5284, “Varistor - Test” for instructions. is a fire hazard. Remove this debris with steam clean-
ing or high pressure water.
i04437749
Varistor - Inspect • Ensure that the cooling lines are tight and ensure
that the cooling lines are properly clamped. Check
SMCS Code: 4466-040 for leaks. Check the condition of all pipes.
The varistor must be checked at regular intervals. • Inspect the water pumps for coolant leaks.
Refer to Systems Operation/Testing and Adjusting,
KENR5284, “Varistor - Test” for instructions on Note: The water pump seal is lubricated by coolant in
checking the varistor. the cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and the
i01491868 parts contract.
Voltage and Frequency - Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
Check water pumps and the installation of water pumps and/
or seals, refer to the Service Manual for the engine or
SMCS Code: 4450-535-EL
consult your Caterpillar dealer.
Check for the proper voltage setting and check for
the proper frequency setting. Check for stability. • Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
For the correct voltage and frequency, refer to the pan, the oil filters and the valve cover.
generator set's Serial Plate.
• Inspect the fuel system for leaks. Look for loose
i02706582
fuel line clamps.
• Inspect the piping for the air inlet system and the
Walk-Around Inspection elbows for cracks and for loose clamps.
SMCS Code: 1000-040
• Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
Inspect the Engine for Leaks and
Belts for multiple groove pulleys must be replaced as
for Loose Connections matched sets. If only one belt is replaced, the belt will
A walk-around inspection should only require a few carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
minutes. When the time is taken to perform these the new belt could cause the belt to break.
checks, costly repairs and accidents can be avoided.
• Drain the water and the sediment from fuel tanks
For maximum engine service life, make a thorough
on a daily basis in order to ensure that only clean
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or fuel enters the fuel system.
coolant leaks, loose bolts, worn belts, loose
connections and trash buildup. Make repairs, as • Inspect the wiring and the wiring harnesses for
needed: loose connections and for worn wires or frayed
wires.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards. • Inspect the ground strap for a good connection
and for good condition.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system • Inspect the ECM to the cylinder head ground strap
contamination. for a good connection and for good condition.
142 SEBU9048-09
Maintenance Section
Water Pump - Inspect
• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges which are cracked and replace any
gauges that can not be calibrated.
i05264233
Water Pump - Inspect

SMCS Code: 1361-040
A failed water pump might cause severe engine
overheating problems that could result in the
following conditions:
• Cracks in the cylinder head
• A piston seizure
• Other potential damage to the engine
A failed water pump might cause severe engine
overheating problems. Overheating could result in
cracks in the cylinder head, a piston seizure, or other
potential damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Disassemble and Water Pump - Assemble” for the
disassembly and assembly procedure. If necessary
to remove the water pump, refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Remove and Water Pump - Install”.
Inspect the water pump for wear, cracks, pin holes,
and proper operation. Refer to the Parts Manual for
the correct part numbers for your engine or consult
your Cat dealer if repair is needed or replacement is
needed.
SEBU9048-09 143
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i04769870
Emissions Warranty
Information
SMCS Code: 1000
Caterpillar warrants to the ultimate purchaser and
each subsequent purchaser that new Marine Diesel
Engines up to 18.5 liters per cylinder (excluding Tier
1 and Tier 2 Marine Engines less than 50 kW)
operated and serviced in the United States, including
all parts of their emission control systems (emission-
related components), are:
• Designed, built, and equipped so as to conform, at
the time of sale, with applicable emission
standards prescribed by the United States
Enviromental Protection Agency (EPA) by way of
regulation.
• Free from defects in materials and workmanship in

emission-related components that can cause the
engine to fail to conform to applicable emission
standards for the warranty period.
A detailed explanation of the Emission Control
Warranty that is applicable to new nonroad and
stationary diesel engines, including the components
covered and the warranty period, is found in
Supplement, SELF9002, “Federal Emissions Control
Warranty”. Consult your Cat dealer to determine if
your engine is subject to an Emission Control
Warranty.
144 SEBU9048-09
Reference Information Section
Engine Ratings
Reference Information Prime Power

Section Output is available with varying load for an unlimited
time. The average power output is 70% of the prime
power rating. Typical peak demand of 100% of prime
rated ekW with 10% of overload capability is for
Engine Ratings emergency use for a maximum of one hour in 12.
The engine cannot be operated at overload for more
than 25 hours per year.
i05037610
Engine Rating Conditions Continuous Power

SMCS Code: 1000 Output is available with varying load for an unlimited
time. The average power output is between 70% and
Ratings are based on SAE J1128/ISO 8665 standard 100% of the continuous power rating. Typical peak
ambient conditions of 100 kPa (29.5 inch mercury) demand is 100% of continuous rated ekW for 100%
and 25° C (77° F). Ratings also apply at AS1501, of operating hours.
BS5514, DIN 6271 and ISO 3046/1 standard
conditions of 100 kPa (29.5 inch mercury), 27° C Standby Power
(81° F), and 60% relative humidity.
Power is based on a 35° (16° C (61° F) fuel which Output is available with varying load for the duration
has Low heat value (LHV) of 42780 kJ/kg of the interruption of the normal power source. The
(18390 B/lb) used at 29° C (84° F) with a density of average power output is 70% of the standby power
838.9 g/L (7.001 lb/US gal). rating. The typical operation is 200 hours per year.
The maximum expected usage is 500 hours per year.
Engine ratings may be defined as gross output
ratings or as the total output capability of the engine Emergency Standby Power
when equipped with lubrication oil, fuel, and jacket
water pumps. The power to drive auxiliary Output is available with varying load for the duration
applications must be deducted from the gross output of an emergency outage. The average power output
to arrive at the net power available for the external is 70% of the standby power rating. The typical
(flywheel) load. Typical auxiliary applications include operation is 50 hours per year. The maximum
cooling fans, air compressors, charging alternators, expected usage is 200 hours per year.
marine gears, and seawater pumps.
i05648181
i03570771
Engine Rating Definitions Marine Classification Society

SMCS Code: 1000
Certification Requirements
SMCS Code: 1000
Power rating definitions are in accordance with
ISO8528. The major seafaring nations have established
technical groups called marine classification
societies. Caterpillar has maintained standards and
quality under the guidelines that are set forth by the
14 major marine classification societies that are
listed. For more information, refer to Engine Data
Sheet, 103.1 and Engine Data Sheet, 103.1.1 in the
Caterpillar Technical Manual.
ABS – American Bureau of Shipping (USA)
BV – Bureau Veritas (France)
CCG – Canadian Coast Guard (Canada)
CCRS – China Corporation Register of Shipping
(Taiwan)
CCS – China Classification Society (China)
CR – Croatian Register of Shipping (Croatia)
DnV – Det norske Veritas (Norway)
SEBU9048-09 145
Marine Classification Society Certification Requirements
GL – Germanischer Lloyd (Germany)

IRS – Indian Register of Shipping (India)
KR – Korean Register of Shipping (Korea)
LR – Lloyd's Register of Shipping (Great Britain)
NK – Nippon Kaiji Kyokai (Japan)
PR – Polish Register (Poland)
RINa – Registro Italiano Navale (Italy)
RS – Maritime Register of Shipping (Russia)
146 SEBU9048-09
Engine Performance and Performance Analysis Report (PAR)
Engine Performance and If the engine is covered by a warranty, the Cat

warranty will cover the cost in order to solve a valid
Performance Analysis deficiency of the engine's performance. However, if
the engine is not at fault, all costs that are incurred
Report (PAR) will be the responsibility of the owner.
Note: Adjustment of the fuel system outside
i04537530 Caterpillar specified limits will not improve fuel
efficiency. Adjustment of the fuel system outside
Engine Performance Caterpillar specified limits could also result in
damage to the engine.
SMCS Code: 1000
Today's marine operator is concerned with Cat engines are manufactured with state-of-the-art
performance, cost of operation and satisfactory technology. Cat engines are designed to help provide
engine life. Traditionally, poor performance of the two characteristics in all applications:
vessel is believed to result from a lack of engine • Maximum performance
performance or from a loss of engine performance. In
fact, the engine is only one of numerous factors that • Fuel efficiency
influence the overall performance of a vessel.
To ensure optimum performance for the service life of
Several factors determine the power demand on an the engine, follow the recommended operation
engine. The engine does not have control over the procedures that are described in this manual. Also,
demand that is caused by the vessel design. The follow the preventive maintenance procedures that
vessel design includes the following features: are described in this manual.
• Hull
Performance Analysis Report
• Propeller (PAR)
• Drive train
To verify the condition of the propulsion system,
Those features also affect the amount of power that Caterpillar has developed the Performance Analysis
is available to perform additional work. For example, Report (PAR) for marine engines.
those features affect the power that is used to drive
an auxiliary pump. A PAR is an in-vessel test procedure that is
performed by a Caterpillar analyst under operating
If a problem with the performance of the vessel conditions. The test compares the performance of all
occurs, consider the following effects on power marine engine systems to the original testing
demand: specifications.
• Loads When a PAR is conducted at Sea Trial, an installation

of high quality can be ensured. The PAR will confirm
• Condition of the vessel the matching of the following components for
optimum performance and for fuel efficiency: hull,
• Vessel design rudders, propeller, marine transmission, ventilation
and cooling systems.
• Condition of the drive train
Caterpillar recommends scheduling a PAR in order to
• Condition of the propeller maintain optimum performance.
Deterioration of the engine systems decreases the A periodic PAR can define deterioration of the
ability of the engine to produce power and vessel propulsion system. A PAR can assist in repairs, in
speed. Engine systems include the cooling system, overhauls, and in maintenance schedules. This will
the lubrication system, the fuel system, etc. The help to provide the most economical, efficient cost of
engine is not likely to be the cause of poor fuel operation.
economy without excessive exhaust smoke and/or
the loss of power.
If you have a valid problem with the engine's
performance, consult an authorized Cat dealer for
assistance.
SEBU9048-09 147
Customer Service
Customer Service Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
i07240378
Miami, FL 33126-4670
USA
Customer Assistance Phone: 305-476-6800
SMCS Code: 1000; 4450 Fax: 305-476-6801
Europe, Africa, and Middle East
USA and Canada Caterpillar Overseas S.A.
76 Route de Frontenex
When a problem arises concerning the operation or P.O. Box 6000
the service of a Marine engine, the problem will
normally be managed by the dealer in your area. CH-1211 Geneva 6
Switzerland
Your satisfaction is a primary concern to Caterpillar Phone: 22-849-4444
and to Cat dealers. If you have a problem that has Fax: 22-849-4544
not been handled to your complete satisfaction,
follow these steps: Far East
Caterpillar Asia Pte. Ltd.
1. Discuss your problem with a manager from the 7 Tractor Road
dealership. Jurong, Singapore 627968
Republic of Singapore
2. If your problem cannot be resolved at the dealer Phone: 65-662-8333
level, use the phone number that is listed below to Fax: 65-662-8302
talk with a Field Service Coordinator:
China
877-228-9900 Caterpillar China Ltd.
The normal hours are from 7:00 AM to 6:00 PM 37/F., The Lee Gardens
33 Hysan Avenue
Monday through Friday Central Standard Time.
Causeway Bay
3. If your needs have not been met still, submit the G.P.O. Box 3069
matter in writing to the following address: Hong Kong
Phone: 852-2848-0333
Designated Compliance Officer Heavy-Duty and Fax: 852-2848-0440
Nonroad Engine Group 6403-J,
US Ave, NW, Washington, Japan
DC 20460 Shin Caterpillar Mitsubishi Ltd.
Email address: [email protected]. SBS Tower
10-1, Yoga 4-Chome
Keep in mind: probably, your problem will Setagaya-Ku, Tokyo 158-8530
ultimately be solved at the dealership, using the Japan
dealership facilities, equipment, and personnel. Phone: 81-3-5717-1150
Therefore, follow the steps in sequence when a Fax: 81-3-5717-1177
problem is experienced.
Japan
Caterpillar Power Systems, Inc.
Outside of the USA and of Canada SBS Tower (14th floor)
4-10-1, Yoga
If a problem arises outside the USA and outside
Canada, and if the problem cannot be resolved at the Setagaya-Ku, Tokyo 158-0097
dealer level, consult the appropriate Caterpillar office. Phone: 81-3-5797-4300
Fax: 81-3-5797-4359
Designated Compliance Officer Heavy-Duty and
Nonroad Engine Group 6403-J,
US Ave, NW, Washington,
DC 20460
Email address: [email protected].
148 SEBU9048-09
Ordering Replacement Parts
Australia and New Zealand i07510375

Caterpillar of Australia Ltd.
1 Caterpillar Drive On-Board Replacement Parts
Private Mail Bag 4
Tullamarine, Victoria 3043 SMCS Code: 7567
Australia The various Marine Classification Societies require a
Phone: 03-9953-9333 supply of replacement parts on vessels that are
Fax: 03-9335-3366 primarily powered by diesel engines. The
replacement parts may be needed for making repairs
i07500661 offshore or at remote ports. The types of replacement
parts and the numbers of parts depends on the range
Ordering Replacement Parts of the vessel. The following two categories of vessels
are considered:
SMCS Code: 4450; 7567
Category 1 – This category includes vessels that
make short trips between ports.
Category 2 – This category includes vessels in
When replacement parts are required for this ocean service that is unrestricted. The vessels may
product Caterpillar recommends using Caterpillar travel far from ports that provide service. The list of
replacement parts or parts with equivalent speci- replacement parts for this category is more
fications including, but not limited to, physical di- extensive.
mensions, type, strength and material.
Failure to heed this warning can lead to prema- Table 34 lists the parts that are recommended by
ture failures, product damage, personal injury or Caterpillar for vessels in both categories.
death.
The requirements of individual Marine Classification
Quality Cat replacement parts are available from Cat Societies may differ. Table 35 lists the requirements
dealers throughout the world. Cat dealer parts of all the Marine Classification Societies. Additionally,
inventories are up-to-date. The parts stocks include some items that are recommended by Caterpillar are
all the parts that are normally needed to protect your listed. All of the parts that are listed in Table 34 and
Cat engine investment. 35 are recommended for vessels in Category 2. To
customize this list for your specific engine
When you order parts, specify the following application, consult your Cat dealer.
information:
Note: Check with your local class society for any
• Part number questions regarding the onboard replacement parts.
• Part name Table 34

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

repair, provide the dealer with all the information that 1 Electronic control module (ECM)
is stamped on the Information Plate. This information
is described in this Operation and Maintenance 1 Electronic unit injector
Manual (Product Information Section).
- Engine oil
Discuss the problem with the dealer. Inform the - Extended Life Coolant (ELC) and Extender
dealer about the conditions of the problem and the or
nature of the problem. Inform the dealer about when Diesel Engine Antifreeze/Coolant (DEAC) and Sup-
the problem occurs. This information will help the plemental Coolant Additive (SCA)
dealer in troubleshooting the problem and solving the
problem faster. 4 Fuel filter elements
1 Fluid sampling bottles
- Liquid gasket material
(continued)
SEBU9048-09 149
On-Board Replacement Parts
(Table 34, contd) (Table 35, contd)

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

4 Engine oil filters Miscellaneous 1 Gasket kit (engine)
1 Service kit (electronic connector) Piston 1 Connecting rod assembly
4 Water temperature regulator 1 Connecting rod bearing
4 Zinc rods 1 Cylinder liner
1 Filler band (cylinder liner)

Table 35
Recommended Replacement Parts for Vessels in Cat- 1 Main bearing
egory 2 2 Cap bolt and washer (main
bearing)
System Quantity Item
1 Piston assembly
Camshaft and 1 Bolt (crankshaft to flywheel)
crankshaft 1 Piston pin
1 Camshaft gear
2 Piston pin retainer
1 Crankshaft gear
1 Piston rings (complete set)
1 Idler gear and balance weight
gear assembly (water pump) 3 Seals (cylinder liner)
1 Shaft and thrust washer (idler Starting 1 Starting motor
gear and balance weight gear
assembly) Turbocharger 1 Complete turbocharger
Cooling 1 Aftercooler core and gasket - Gasket
1 Auxiliary water pump 4 Locknut
1 Jacket water pump 4 Stud (mounting)
1 SCAC Pump Valves 6 Exhaust valves

4 Inlet valves
4 Water temperature regulator
10 Valve guides
Cylinder head 6 Bolt and washer
24 Valve locks
1 Bolt and nut (exhaust manifold)
10 Valve rotators
1 Cylinder head assembly
10 Valve springs
4 Gasket (cylinder)
- Water seals for one cylinder
Fuel 3 Electronic unit injector
1 Fuel transfer pump
3 Seal (electronic unit injector)
Inlet air 2 Air cleaner element

Lubrication 1 Bypass valve (oil cooler)
1 Bypass valve (oil filter)
1 Gasket (oil pan)
1 Oil cooler core (engine)
1 Oil cooler core (marine gear)
(continued)
150 SEBU9048-09
Reference Materials
Reference Materials
i05264255
Maintenance Records
SMCS Code: 1000; 4450
Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other

engines that are operated in the same
environment.
• Show compliance with the required maintenance

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

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
• Dealer work orders and itemized bills
• Owner repair costs
• Owner receipts
• Maintenance log
SEBU9048-09 151
Maintenance Log
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 36
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
152 SEBU9048-09
Reference Material
i07422648
Reference Material
SMCS Code: 1000; 4450
Additional literature regarding your product may be
purchased from your local Cat dealer or by visiting
publications.cat.com. Use the product name, sales
model, and serial number to obtain the correct
information for your product.
publications.cat.com
i04323034
Decommissioning and
Disposal
SMCS Code: 1000
When the generator set is removed from service,
local regulations for the generator set
decommissioning will vary. Disposal of the generator
set will vary with local regulations. Consult the
nearest Cat dealer for additional information.
SEBU9048-09 153
Index Section
Index
A Fill the Cooling System ................................ 90
Flush ............................................................ 89
Additional Messages ........................................11
Coolant Extender (ELC) - Add ........................ 90
After Starting Engine ....................................... 47
Coolant Level - Check ..................................... 91
After Stopping Engine ..................................... 64
Engines That Are Equipped with a Coolant
Aftercooler Condensate Drain Valve -
Recovery Tank ........................................... 91
Inspect/Clean................................................. 82
Engines That Are Equipped with Expansion
Aftercooler Core - Clean/Test.......................... 82
Tanks and Sight Gauges............................ 92
Clean the Aftercooler Core .......................... 82
Engines That Are Not Equipped with a
Test the Aftercooler Core............................. 83
Coolant Recovery Tank.............................. 92
Alarms and Shutoffs ........................................ 37
Coolant Sample (Level 1) - Obtain.................. 93
Alarms.......................................................... 37
Sampling Conditions.................................... 93
Shutoffs........................................................ 37
Timing of the Sampling ................................ 93
Testing the Alarm System and the Shutoff
Coolant Sample (Level 2) - Obtain.................. 94
System ....................................................... 37
Obtaining the Sample .................................. 94
Auxiliary Water Pump (Bronze Impeller) -
Coolant Temperature Regulator - Replace ..... 94
Inspect/Replace............................................. 83
Cooling System Supplemental Coolant
Additive (SCA) - Test/Add.............................. 94
B Cooling Systems that Use Conventional
Battery - Recycle ............................................. 83 Coolant....................................................... 95
Battery - Replace............................................. 84 Crankshaft Vibration Damper - Inspect........... 95
Battery Charger - Check.................................. 84 Inspection .................................................... 96
Battery Disconnect Switch (If Equipped)......... 37 Removal and Installation ............................. 96
Battery Electrolyte Level - Check .................... 84 Crushing Prevention and Cutting Prevention.. 19
Battery or Battery Cable - Disconnect............. 85 Customer Assistance .................................... 147
Before Starting Engine .............................. 19, 44 Outside of the USA and of Canada ........... 147
Belt Tightener - Lubricate ................................ 85 USA and Canada....................................... 147
Belts - Inspect/Adjust/Replace ........................ 86 Customer Service.......................................... 147
Adjusting Fan Drive Belts ............................ 86
Engine Belt Inspection................................. 86 D
Replacement................................................ 86
Decommissioning and Disposal.................... 152
Burn Prevention............................................... 16
Derating Strategy ............................................ 39
Batteries....................................................... 17
Coolant ........................................................ 16
Oils............................................................... 17 E
Electrical Connections - Check ....................... 96
C Electrical System............................................. 20
Grounding Practices .................................... 21
Cold Weather Operation ................................. 60
Negative Battery Connection for Multiple
Hints for Cold Weather Operation ............... 60
Engines ...................................................... 22
Idling the Engine .......................................... 61
Emergency Stopping....................................... 64
Recommendations for Coolant Warm Up.... 61
Emissions Certification Film ............................ 32
Recommendations for the Coolant.............. 61
Emissions Warranty Information ................... 143
Viscosity of the Engine Lubrication Oil ........ 61
Engine - Clean................................................. 96
Cold Weather Starting ..................................... 44
Engine Air Cleaner Element (Single
Control Panel (Cat Marine Engine Control
Element) - Inspect/Replace ........................... 97
Panel III (MECP III )(If Equipped))................. 38
Replacing the Air Cleaner Element ............. 97
Coolant - Change ............................................ 87
Drain the coolant systems ........................... 87
154 SEBU9048-09
Index Section
Engine Air Cleaner Service Indicator - California Proposition 65 Warning ................. 4

Inspect ........................................................... 97 Literature Information .................................... 4
Test the Service Indicator ............................ 98 Maintenance .................................................. 4
Engine Cooling System Corrosion Maintenance Intervals ................................... 5
Protection System - Inspect .......................... 98 Operation ....................................................... 4
Location of the Corrosion Protection Post... 98 Overhaul ........................................................ 5
Results of the Test ....................................... 99 Safety............................................................. 4
Testing the Voltage Potential ....................... 99 Fuel and the Effect from Cold Weather ........... 62
Engine Crankcase Breather - Clean ............... 99 Fuel Conservation Practices ........................... 48
Engine Electronics........................................... 23 Fuel Injector - Check ..................................... 107
Engine Mounts - Inspect................................ 100 Fuel Related Components in Cold Weather ... 63
Engine Oil and Filter - Change ...................... 102 Fuel Filters ................................................... 63
Drain the Oil ............................................... 102 Fuel Heaters ................................................ 63
Fill the Crankcase ...................................... 105 Fuel Tanks ................................................... 63
Inspect the Used Oil Filter Elements ......... 105 Fuel System - Prime...................................... 107
Replace the Oil Filter Elements ................. 103 The Engine Has Been Rebuilt ................... 109
Engine Oil Level - Check............................... 100 The Engine Has Been Run Out of Fuel ..... 108
Engine Oil Level Gauge - Calibrate............... 101 The Secondary Fuel Filter Has Been
Engine Oil Sample - Obtain........................... 102 Replaced.................................................. 108
Obtain the Sample and the Analysis ......... 102 Fuel System Primary Filter (Water
Engine Operation ............................................ 48 Separator) Element - Replace..................... 109
Engine Performance ..................................... 146 Replace the Element ................................. 109
Performance Analysis Report (PAR) ......... 146 Fuel System Primary Filter/Water
Engine Performance and Performance Separator - Drain ..........................................110
Analysis Report (PAR)................................. 146 Fuel System Secondary Filter - Replace ....... 111
Engine Rating Conditions.............................. 144 Replacing the Fuel Filter Elements During
Engine Rating Definitions.............................. 144 Engine Operation For Engines That Are
Continuous Power ..................................... 144 Equipped With Duplex Fuel Filters ...........112
Emergency Standby Power ....................... 144 Replacing the Fuel Filter Elements with the
Prime Power .............................................. 144 Engine Stopped ........................................112
Standby Power .......................................... 144 Fuel Tank Water and Sediment - Drain ..........114
Engine Ratings .............................................. 144 Drain the Water and the Sediment .............115
Engine Starting.......................................... 20, 44 Fuel Storage Tanks.....................................115
Engine Stopping ........................................ 20, 64 Fuel Tank ....................................................115
Engine Storage Procedure - Check .............. 106 Fumes Disposal Filter Element - Replace......115
Engine Valve Lash - Check ........................... 106 Replacing the Fumes Disposal Filter..........115
Engine Valve Rotators - Inspect .................... 106 Resetting the Service Indicator (If
Equipped)..................................................116
F
G
Fan Drive Bearing - Lubricate ....................... 107
Features and Controls..................................... 37 Gauges and Indicators .................................... 39
Fire Prevention and Explosion Prevention...... 17 General Hazard Information............................ 13
Ether ............................................................ 19 Containing Fluid Spillage............................. 14
Fire Extinguisher.......................................... 19 Dispose of Waste Properly .......................... 16
Lines, Tubes, and Hoses ............................. 19 Fluid Penetration ......................................... 14
Fluid Recommendations ................................. 66 Inhalation ..................................................... 15
Cooling System............................................ 71 Lines, Tubes, and Hoses ............................. 15
Diesel Engine Oil ......................................... 66 Pressurized Air and Water........................... 14
Fuel .............................................................. 69 Softwrap....................................................... 16
Greases ....................................................... 73 Static Electricity Hazard when Fueling with
Foreword ........................................................... 4 Ultra-low Sulfur Diesel Fuel ....................... 15
SEBU9048-09 155
Index Section
General Information ........................................ 25 L

General Maintenance Information................... 74
Lifting and Storage .......................................... 33
Generator - Dry...............................................116
Circulating Current......................................118
External Heat ..............................................118 M
Internal Heating ..........................................118 Maintenance Interval Schedule....................... 79
Generator - Inspect ........................................118 Daily ............................................................. 79
Cleaning (Assembled Generators) .............119 Every 1000 Service Hours........................... 80
Cleaning (Disassembled Generators) ........119 Every 14 400 L (3750 US gal) of Fuel or 250
Generator Bearing - Inspect/Replace (LC6/ Service Hours or 1 Year............................. 80
LC7Generator) .............................................119 Every 170 400 L (45 000 US gal) of Fuel or
Inspect ....................................................... 120 3000 Service Hours ................................... 80
Replace...................................................... 120 Every 2 Years............................................... 80
Generator Bearing - Lubricate....................... 120 Every 2000 Service Hours........................... 80
Additional Information................................ 121 Every 250 Service Hours ............................. 79
Lubricating Process (If Applicable)............ 120 Every 28 500 L (7500 US gal) of Fuel or 500
Generator Bearing Temperature - Test/ Service Hours or 1 Year............................. 80
Record ......................................................... 121 Every 284 000 L (75 000 US gal) of Fuel or
Generator Isolating for Maintenance............... 23 5000 Service Hours ................................... 81
Generator Load - Check................................ 121 Every 50 Service Hours or Weekly.............. 79
Generator Operation ....................................... 49 Every 57 000 L (15 000 US gal) of Fuel or
Block Loading .............................................. 49 1000 Service Hours ................................... 80
Excitation System ........................................ 50 Every 8000 Service Hours........................... 80
Generator Options ....................................... 51 Every Week ................................................. 79
Loading of the Generator............................. 49 Every Year ................................................... 80
Low Idle Adjustment .................................... 50 First 14 400 L (3750 US gal) of Fuel or 250
Power Factor ............................................... 50 Service Hours ............................................ 80
Standby Generator Sets .............................. 50 Initial 1000 Service Hours............................ 80
Generator Set - Test ...................................... 121 Initial 20 to 40 Service Hours....................... 79
Generator Set Alignment - Check ................. 122 Initial 500 Hours (for New Systems, Refilled
Generator Set Vibration - Inspect.................. 122 Systems, and Converted Systems) ........... 80
Generator Start-up Checklist........................... 76 Overhaul ...................................................... 81
Generator Winding - Test .............................. 123 When Required............................................ 79
Generator Winding Insulation - Test.............. 124 Maintenance Log........................................... 151
Recommended Periodic Insulation Tests .. 124 Maintenance Recommendations ............ 74, 131
Recommended Procedure for A Periodic Maintenance Information........................... 131
Insulation Test .......................................... 125 Oil Consumption as an Overhaul
Indicator ................................................... 132
H Overhaul Information ................................. 132
Maintenance Records ................................... 150
Heat Exchanger - Clean/Test ........................ 127
Maintenance Section....................................... 66
Clean the Heat Exchanger ........................ 127
Manual Stop Procedure .................................. 64
Test the Heat Exchanger Core .................. 127
Marine Classification Society Certification
Heat Exchanger - Inspect (If Equipped) ........ 128
Requirements .............................................. 144
Hoses and Clamps - Inspect/Replace........... 128
Model View Illustrations .................................. 25
Inspect Tubes, Hoses, Bellows, and
Mounting and Dismounting ............................. 19
Clamps..................................................... 128
Replace the Hoses and the Clamps .......... 129
O
I Oil Cooler Core - Check/Clean/Test .............. 133

Clean the Oil Cooler Core.......................... 133
Important Safety Information............................. 2
156 SEBU9048-09
Index Section
Test the Oil Cooler Core ............................ 133 Reference Materials ...................................... 150
On-Board Replacement Parts ....................... 148 Refill Capacities............................................... 66
Operation Section............................................ 33 Cooling System Capacity ............................ 66
Ordering Replacement Parts......................... 148 Lubrication System Capacity....................... 66
Overhaul (Major) ........................................... 133 Rotating Rectifier - Check ............................. 136
Cleaning and Pressure Testing of Rectifier Block Test .................................... 137
Components ............................................ 135 Testing A Brushless Exciter Rotating Rectifier
Cleaning of Components ........................... 135 With An Ohmmeter .................................. 137
Inspection of Components......................... 135
Inspection, Reconditioning, or Exchanging of S
Components ............................................ 134
Obtain a Coolant Analysis ......................... 135 Safety Messages............................................... 6
Replacement of Components.................... 134 Automatic Starting (5).................................. 10
Electrical Shock (6).......................................11
Hot Fluid Under Pressure (3)......................... 9
P
Hot Surface (2) .............................................. 9
Parallel Operation............................................ 52 Lifting the Genset (4) ................................... 10
Circulating Currents..................................... 55 Universal Warning (1) .................................... 8
Initial Start-Up .............................................. 52 Safety Section ................................................... 6
Load Division and Speed Droop (If Sea Water Strainer - Clean/Inspect .............. 138
Equipped)................................................... 53 Sensors and Electrical Components............... 41
Parallel Operation Of Governors ................. 54 Air Pressure Sensor for the Inlet Manifold... 42
Paralleling Multiple Units ............................. 53 Air Temperature Sensor for the Inlet
Starting Multiple Units.................................. 53 Manifold ..................................................... 42
Stopping....................................................... 54 Coolant Level Sensor .................................. 41
Plate Locations and Film Locations ................ 31 Coolant Temperature Sensor ...................... 41
Engine Information (3) ................................. 31 Engine Oil Pressure Sensor ........................ 41
Engine Serial Number (2) ............................ 31 Failure of Sensors........................................ 41
Serial Number Plate for the Generator (1) .. 31 Fuel Pressure Sensor.................................. 42
Power Factor - Check.................................... 136 Fuel Temperature Sensor ............................ 42
Product Description ......................................... 29 Speed/Timing Sensor .................................. 43
Description of the Generator ....................... 30 Single Unit Operation ...................................... 51
Engine.......................................................... 29 Initial Start-Up .............................................. 51
Product Identification Information ................... 31 Starting ........................................................ 51
Product Information Section............................ 25 Stopping....................................................... 52
Product Lifting ................................................. 33 Standby Generator Set Maintenance
Lifting the Engine Only................................. 33 Recommendations ...................................... 138
Lifting the Entire Package............................ 33 Maintenance and Operation Procedures .. 139
Lifting the Generator Only ........................... 33 Starting the Engine.......................................... 45
Lifting the Radiator Only .............................. 33 Automatic Starting ....................................... 45
Product Storage .............................................. 33 Manual Starting............................................ 45
Additional Information.................................. 36 Stator Lead - Check ...................................... 139
Engine.......................................................... 33 Stator Winding Temperature - Test ............... 139
Generator..................................................... 36 System Pressure Release............................... 74
Coolant System ........................................... 74
R Engine Oil .................................................... 75
Fuel System................................................. 74
Radiator - Clean ............................................ 136
Reference Information..................................... 32
T
Record for Reference .................................. 32
Reference Information Section ..................... 144 Table of Contents .............................................. 3
Reference Material ........................................ 152 Turbocharger - Inspect .................................. 140
SEBU9048-09 157
Index Section
Cleaning and Inspecting ............................ 140

Removal and Installation ........................... 140
V
Varistor - Check ............................................. 141
Varistor - Inspect............................................ 141
Voltage and Frequency - Check.................... 141
Voltage Regulators .......................................... 55
Cat Digital Voltage Regulator (Cat DVR).... 55
Integrated Voltage Regulator (IVR) ............. 56
W
Walk-Around Inspection ................................ 141
Inspect the Engine for Leaks and for Loose
Connections ............................................. 141
Warranty Information..................................... 143
Warranty Section........................................... 143
Water Pump - Inspect.................................... 142
Welding on Engines with Electronic
Controls ......................................................... 75
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
SEBU9048 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2018 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
160 September 2018

Sebu9048 09 00 - Manuals Operation Maintenance

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SEBU9048-09 (en-us)

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Engine Stopping .............................................. 64

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

General Hazard Information............................ 13 Warranty Section

Burn Prevention............................................... 16 Warranty Information..................................... 143

Fire Prevention and Explosion Prevention...... 17 Reference Information Section

Crushing Prevention and Cutting Prevention.. 19 Engine Ratings .............................................. 144

Mounting and Dismounting ............................. 19 Engine Performance and Performance Analysis

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

Product Information Section

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

Product Identification Information ................... 31

Lifting and Storage .......................................... 33

Features and Controls..................................... 37

Engine Operation ............................................ 48

Generator Operation ....................................... 49

Cold Weather Operation ................................. 60

Foreword Some photographs or illustrations in this manual

WARNING – This product can Safety

The maintenance schedule items are organized for a

Universal Warning (1)

Do not operate or work on this product unless

Pressurized system! Hot coolant can cause seri-

This safety message for lifting the genset is located

Illustration 9 g01392484 Illustration 10 g01372247

Electrical Shock (6) i06258221

The safety message for electrical shock is located on

General Hazard Information

• Wear a hard hat, protective glasses, and other

• Grease fittings • The engine is stopped. Ensure that the engine

• Drain plugs • Disconnect the batteries when maintenance is

Pressurized Air and Water Fluid Penetration

Always use a board or cardboard when you check for

Containing Fluid Spillage

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

• Stay away from areas that might have asbestos

Arcing or sparking could cause a fire. Secure

Gases from a battery can explode. Keep any open

Lines, Tubes, and Hoses i01372247

To ensure that the jacket water heater (if equipped)

Engine Starting i06948165

SMCS Code: 1000

Note: All electrical connections must meet or exceed

Refer to Application and Installation Guide,

Negative Battery Connection for

Install the battery disconnect switches as close as

Note: If multiple bus bars are used to connect i06795266

Tampering with the electronic system installation

This engine has a comprehensive, programmable

• System Voltage • sensing

• Turbocharger Inlet Temperature • control

9. Determine that the generator is in a de-energized

Model View Illustrations

i05018390 • Separate circuit aftercooler (SCAC)

Product Description The electronic engine control system provides the

The Electronic Control Module (ECM) controls the Engine Specifications