Cat C9 Engine

MAINTENANCE INTERVALS
Operation and Maintenance
Manual Excerpt

© 2010 Caterpillar
All Rights Reserved

®

®

SEBU7878-03
October 2009

Operation and
Maintenance
Manual
C9 Generator Set
C9E1-Up (Generator Set)

SAFETY.CAT.COM

SEBU7878-03

87
Maintenance Section
Maintenance Interval Schedule

Maintenance Interval Schedule

Instrument Panel - Inspect .................................. 130
Stator Winding Temperature - Measure/Record .. 141
Voltage and Frequency - Check ......................... 142

SMCS Code: 1000; 7500

Every 250 Service Hours

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, ﬂuids, ﬁlters, and the installation of new components due to normal wear and aging. The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed.

Cooling System Coolant Sample (Level 1) Obtain ............................................................... 101

i03638078

Every 250 Service Hours or 6 Months
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ............................................... 102
Engine Oil and Filter - Change ............................ 111
Fuel System Secondary Filter - Replace ............. 118
Fuel Tank Water and Sediment - Drain ................ 119
Hoses and Clamps - Inspect/Replace ................ 129

Initial 500 Service Hours

Note: Use whichever of the following that occurs ﬁrst in order to determine the maintenance intervals: fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all maintenance from the previous intervals must be performed. Engine Valve Lash - Inspect/Adjust ..................... 115

Products that operate in severe operating conditions may require more frequent maintenance.

Engine Oil Sample - Obtain ................................. 111
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................. 117

When Required

Every 500 Service Hours or 6 Months
Battery Electrolyte Level - Check .......................... 92

Every 500 Service Hours or 1 Year

Battery - Replace .................................................. 91
Battery or Battery Cable - Disconnect .................. 93
Engine - Clean .................................................... 106
Engine Air Cleaner Element (Dual Element) Clean/Replace .................................................. 106
Engine Air Cleaner Element - Clean/Replace ..... 107
Ether Starting Aid Cylinder - Replace .................. 115
Fuel System - Prime ............................................ 116
Generator - Dry ................................................... 120
Generator Bearing - Inspect ............................... 122
Generator Bearing - Lubricate ............................ 122
Generator Set - Test ........................................... 127
Generator Set Alignment - Check ....................... 128
Winding - Test ..................................................... 144

Every 1000 Service Hours

Daily

Every 2000 Service Hours or 1 Year

Cooling System Coolant Level - Check .............. 100
Electrical Connections - Check ........................... 105
Engine Air Cleaner Service Indicator - Inspect ... 109
Engine Oil Level - Check ..................................... 110
Fuel System Primary Filter/Water Separator Drain .................................................................. 117
Generator Bearing Temperature - Test/Record ... 126
Generator Load - Check ..................................... 127
Power Factor - Check ......................................... 138

Alternator - Inspect ............................................... 91
Belts - Inspect/Adjust/Replace .............................. 94
Engine Valve Lash - Inspect/Adjust ..................... 115
Radiator - Clean .................................................. 138

Every Week
Generator Lead - Check ..................................... 126

Engine Protective Devices - Check ..................... 114

Every 2000 Service Hours
Bearing (Ball) - Lubricate ...................................... 93
Generator - Inspect ............................................. 121

Every 2000 Service Hours or 6 Months
Generator Set Vibration - Inspect .......................
Generator Set Vibration - Test/Record ................
Insulation - Test ...................................................
Stator Lead - Check ............................................

128
129
131
141

Every Year
Cooling System Coolant Sample (Level 2) Obtain ...............................................................
Generator Bearing - Inspect ...............................
Rotating Rectiﬁer - Check ...................................
Varistor - Check ..................................................
Varistor - Inspect .................................................

101
122
138
142
142

88
Maintenance Section
Maintenance Interval Schedule

Every 4000 Service Hours or 2 Years
Cooling System Coolant (DEAC) - Change .......... 95
Cooling System Water Temperature Regulator Replace ............................................................. 103
Crankshaft Vibration Damper - Inspect ............... 104
Cylinder Head Grounding Stud - Inspect/Clean/
Tighten .............................................................. 105
Engine Crankcase Breather - Clean .................... 110
Engine Mounts - Inspect ...................................... 110
Engine Speed/Timing Sensors - Check/Clean/
Calibrate ............................................................. 115
Starting Motor - Inspect ...................................... 141
Turbocharger - Inspect ........................................ 141
Water Pump - Inspect ......................................... 143

Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add .... 99

Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ............. 97

Overhaul
Generator Bearing - Replace .............................. 125
Overhaul Considerations .................................... 135

SEBU7878-03

SEBU7878-03

89
Maintenance Section
Maintenance Interval Schedule

i02673166

Maintenance Interval Schedule
(Standby)
SMCS Code: 1000; 7500
Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, ﬂuids, ﬁlters, and the installation of new components due to normal wear and aging. The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed.
Note: Use whichever of the following that occurs ﬁrst in order to determine the maintenance intervals: fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all maintenance from the previous intervals must be performed. Products that operate in severe operating conditions may require more frequent maintenance.

When Required
Battery - Replace .................................................. 91
Battery or Battery Cable - Disconnect .................. 93
Fuel System - Prime ............................................ 116
Generator Bearing - Lubricate ............................ 122
Generator Load - Check ..................................... 127
Generator Set - Test ........................................... 127
Rotating Rectiﬁer - Test ...................................... 138
Winding - Test ..................................................... 144

Every Week
Automatic Start/Stop - Inspect .............................. 91
Battery Charger - Check ....................................... 92
Battery Electrolyte Level - Check .......................... 92
Bearing Temperature - Measure/Record .............. 94
Cooling System Coolant Level - Check .............. 100
Electrical Connections - Check ........................... 105
Engine Air Cleaner Service Indicator - Inspect ... 109
Engine Oil Level - Check ..................................... 110
Fuel System Primary Filter/Water Separator Drain .................................................................. 117
Fuel Tank Water and Sediment - Drain ................ 119
Generator - Inspect ............................................. 121
Generator Bearing Temperature - Test/Record ... 126
Generator Lead - Check ..................................... 126
Instrument Panel - Inspect .................................. 130
Jacket Water Heater - Check .............................. 135
Power Factor - Check ......................................... 138
Space Heater - Check ........................................ 139

Standby Generator Set Maintenance
Recommendations ............................................
Stator Winding Temperature - Measure/Record ..
Voltage and Frequency - Check .........................
Walk-Around Inspection ......................................

140
141
142
142

Every 250 Service Hours
Engine Oil and Filter - Change ............................ 111

Every 6 Months
Cooling System Coolant Sample (Level 1) Obtain ............................................................... 101

Every Year
Alternator - Inspect ............................................... 91
Bearing (Ball) - Lubricate ...................................... 93
Belts - Inspect/Adjust/Replace .............................. 94
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 101
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ............................................... 102
Crankshaft Vibration Damper - Inspect ............... 104
Cylinder Head Grounding Stud - Inspect/Clean/
Tighten .............................................................. 105
Engine - Clean .................................................... 106
Engine Air Cleaner Element (Dual Element) Clean/Replace .................................................. 106
Engine Air Cleaner Element - Clean/Replace ..... 107
Engine Crankcase Breather - Clean .................... 110
Engine Mounts - Inspect ...................................... 110
Engine Oil Sample - Obtain ................................. 111
Engine Performance - Test .................................. 113
Engine Protective Devices - Check ..................... 114
Engine Valve Lash - Inspect/Adjust ..................... 115
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................. 117
Fuel System Secondary Filter - Replace ............. 118
Generator - Dry ................................................... 120
Generator Set Vibration - Inspect ....................... 128
Generator Set Vibration - Test/Record ................ 129
Hoses and Clamps - Inspect/Replace ................ 129
Insulation - Test ................................................... 131
Radiator - Clean .................................................. 138
Rotating Rectiﬁer - Check ................................... 138
Starting Motor - Inspect ...................................... 141
Stator Lead - Check ............................................ 141
Varistor - Check .................................................. 142
Varistor - Inspect ................................................. 142
Water Pump - Inspect ......................................... 143

Every 3 Years
Cooling System Coolant (DEAC) - Change .......... 95
Cooling System Coolant (ELC) - Change ............. 97
Cooling System Coolant Extender (ELC) - Add .... 99
Cooling System Water Temperature Regulator Replace ............................................................. 103
Engine Speed/Timing Sensors - Check/Clean/
Calibrate ............................................................. 115

90
Maintenance Section
Maintenance Interval Schedule

Ether Starting Aid Cylinder - Replace .................. 115
Turbocharger - Inspect ........................................ 141

Overhaul
Generator Bearing - Replace .............................. 125
Overhaul Considerations .................................... 135

Commissioning
Generator Set Alignment - Check ....................... 128

SEBU7878-03

SEBU7878-03

91
Maintenance Section
Alternator - Inspect

i02676048

i02153996

Alternator - Inspect

Battery - Replace

SMCS Code: 1405-040

SMCS Code: 1401-510

Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required.
Check the alternator and the battery charger for proper operation. If the batteries are properly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. The battery will not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge. i01942284 Automatic Start/Stop - Inspect
SMCS Code: 4462
The generator set must be ready to operate under a load at any time. After performing maintenance on the generator set, inspect the position of the control switches. Ensure the following conditions:

• The starting system is enabled.
• The control switches are in the correct position for automatic starting.

• The switchgear and the automatic transfer switches

that are associated with the generator are enabled.

Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.
Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced. The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.
1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the charger. 3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane. Disconnect the cable from the NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+” battery terminal.
Note: Always recycle a battery. Never discard a battery. Return used batteries to an appropriate recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that the key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.

92
Maintenance Section
Battery Charger - Check

SEBU7878-03

8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal. i01917570 Battery Charger - Check
SMCS Code: 1401-535

Checking Before Start-Up
Check the battery charger for proper operation. If the batteries are properly charged, the needle of the ammeter will register near “0” (zero).
The battery charger must not produce excessive current during start-up. Alternatively, the charger must be automatically disconnected for start-up.
If the engine has an alternator, the charger must be automatically disconnected during start-up and during engine operation.

Charging the Battery

• A strong odor of acid is present.
• The battery emits smoke or a dense vapor (gas).
Perform one of the following procedures if the battery shows symptoms of overcharging:

• Reduce the rate of charging by a signiﬁcant

amount. Complete the charging at the reduced rate. • Turn OFF the charger.
Table 16 describes the effects of overcharging on different types of batteries.
Table 16

Effects of Overcharging Batteries
Type of Battery

Effect

Caterpillar General Service
Batteries
Caterpillar Premium High
Output Batteries

All of the battery cells have a low level of electrolyte.

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the ﬂammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.
Perform the following procedure to charge the battery: When the plates of the battery are inspected through the ﬁller holes, the plates may appear to be warped. This is caused by an excessive temperature.
The battery may not pass a load test.
Caterpillar Maintenance
Free Batteries

The battery may not pass a load test.

1. Ensure that the charger is turned OFF.
2. Adjust the voltage of the charger in order to match the voltage of the battery.
3. Connect the POSITIVE “+” lead of the charger to the POSITIVE “+” battery terminal. Connect the NEGATIVE “-” lead of the charger to the
NEGATIVE “-” battery terminal.

The battery may not accept a charging current.

Checking After Stopping
Ensure that the battery charger is connected properly. Observe the meter of the charger. Record the amperage.

4. Turn ON the battery charger.
Overcharging of Batteries
Overcharging reduces the service life of batteries.
Use a battery charger that will not overcharge the battery. DO NOT charge the battery if the meter of the battery charger is in the RED zone.
Overcharging is indicated by the following symptoms:

• The battery is very warm to the touch.

i02601752

Battery Electrolyte Level Check
SMCS Code: 1401-535
When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing.

SEBU7878-03

93
Maintenance Section
Battery or Battery Cable - Disconnect

All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.
1. Remove the ﬁller caps. Maintain the electrolyte level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artiﬁcially softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.
Clean the battery case with one of the following cleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water

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

Thoroughly rinse the battery case with clean water.
Use a ﬁne grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not ﬁt properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM. i01492654 Battery or Battery Cable Disconnect
SMCS Code: 1402-029

The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the battery that goes to the start switch. Ensure that the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental starting. 4. Proceed with necessary system repairs. Reverse the steps in order to reconnect all of the cables. i02023749 Bearing (Ball) - Lubricate
(Generator)
SMCS Code: 4471-086
The following ball bearings must be lubricated: no shield and single shield. Double shielded ball bearings may not require lubrication. Refer to the instructions that are located on the machine.
For ball bearings, use Caterpillar 2S-3230 Bearing
Lubricant. This grease is an NLGI No. 2 Grade.
There is Polyurea (a thickener) in this grease. The temperature range of Caterpillar 2S-3230 Bearing
Lubricant is −29 °C (−20.2 °F) to 177 °C (350.6 °F).
For extremely low temperatures, use either NLGI No.
1 Grade or NLGI No. 0 Grade.

Lubricating Process
1. Remove either the louver assembly or the rear plate from the rear of the generator housing.
2. Remove the top grease pipe plug and remove the lower grease pipe plug.
3. Install a grease ﬁtting in the grease pipe.
4. Grease the shielded ball bearings with 2S-3230
Bearing Lubricant (53.28 mL (1.8 ounces) to
59.20 mL (2.0 ounces)). Lubricate shielded ball bearings at 2000 hour intervals. Do not mix greases. Note: Some two-bearing generators have spherical roller bearings in the front bracket and ball bearings in the rear bracket. These units should use a common
108-8611 Grease Cartridge. This grease should be used for the front bearing and the rear bearing.
5. Wipe off the excess grease. Remove the top grease ﬁtting. Install the plug.

94
Maintenance Section
Bearing Temperature - Measure/Record

SEBU7878-03

6. Operate the generator for one hour. This will allow the grease to expand. The expanding grease will force the excess grease from the cavity. When the excess grease is forced from the cavity, the internal pressure will be reduced. The generator should continue to operate until the grease stops purging. 7. Stop the engine. Install the plug in the bottom grease pipe. Wipe off the excess grease.
8. Install the louver assembly or install the rear plate. i03212480 Bearing Temperature Measure/Record

If the belts are too tight, unnecessary stress is placed on the components. This reduces the service life of the components.

Replacement
For applications that require multiple drive belts, replace the drive belts in matched sets. Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched. The additional load on the new drive belt could cause the new drive belt to fail.

Alternator Belt Adjustment

SMCS Code: 4471-082-TA
Bearing temperature detectors are optional on all
Caterpillar generators. These detectors are 100 ohm resistance temperature detectors. The optional monitoring for the generator bearing temperature may be available in the EMCP 3 control panel.
Bearing temperature detectors may be used with equipment that has been provided by the customer in order to measure the bearing temperature. Bearing temperature detectors may help to prevent premature bearing failure.
A sudden increase in bearing temperature may indicate impending bearing failure. i02229322 Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510

Inspection
Inspect the alternator belt and any accessory belts for wear and for cracking. Replace the belts if the belts are not in good condition.
Check the belt tension according to the information in the Service Manual, “Speciﬁcations”.
Slippage of loose belts can reduce the efﬁciency of the driven components. Vibration of loose belts can cause unnecessary wear on the following components: • Belts
• Pulleys
• Bearings

Illustration 59
(1)
(2)
(3)
(4)

Adjusting
Mounting
Mounting
Mounting

g00960176

nuts bolt bolt bolt 1. Remove the drive belt guard.
2. Loosen mounting bolts (2), (3), and (4). Loosen adjusting nuts (1).
3. Turn adjusting nuts (1) in order to increase or decrease the drive belt tension.
4. Tighten adjusting nuts (1). Tighten mounting bolts
(2), (3), and (4).
5. Reinstall the drive belt guard.
If new drive belts are installed, check the drive belt tension again after 30 minutes of engine operation at the rated rpm.

SEBU7878-03

95
Maintenance Section
Cooling System Coolant (DEAC) - Change

i02367023

Cooling System Coolant
(DEAC) - Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and ﬂush the cooling system before the recommended maintenance interval if the following conditions exist:

• The engine overheats frequently.
• Foaming of the coolant
• The oil has entered the cooling system and the coolant is contaminated.

• The fuel has entered the cooling system and the coolant is contaminated.

NOTICE
Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines.
Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause serious 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.

NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Flush
1. Flush the cooling system with clean water in order to remove any debris.
2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the
Speciﬁcations Manual for your particular engine for more speciﬁc information on the proper torques.
Refer to the Speciﬁcations, SENR3130, “Torque
Speciﬁcations” for more general information on the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install the cooling system ﬁller cap.
4. Start the engine and run the engine at low idle for a minimum of 30 minutes. The coolant temperature should be at least 82 °C (180 °F).

1. 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.

NOTICE
Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components.

2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain valve, remove the drain plugs.

To avoid damage to the cooling system, make sure to completely ﬂush the cooling system with clear water. Continue to ﬂush the system until all signs of the cleaning agent are gone.

Allow the coolant to drain.

96
Maintenance Section
Cooling System Coolant (DEAC) - Change

SEBU7878-03

5. Stop the engine and allow the engine to cool.
Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller cap. Open the drain valve
(if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Speciﬁcations Manual for your particular engine for more speciﬁc information on the proper torques. Refer to the Speciﬁcations,
SENR3130, “Torque Speciﬁcations” for more general information on the proper torques.

5. Stop the engine and allow the engine to cool.
Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller cap. Open the drain valve
(if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Speciﬁcations Manual for your particular engine for more speciﬁc information on the proper torques. Refer to the Speciﬁcations,
SENR3130, “Torque Speciﬁcations” for more general information on the proper torques.

Cooling Systems with Heavy
Deposits or Plugging

Fill

Note: For the following procedure to be effective, there must be some active ﬂow through the cooling system components.
1. Flush the cooling system with clean water in order to remove any debris.
2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the
Speciﬁcations Manual for your particular engine for more speciﬁc information on the proper torques.
Refer to the Speciﬁcations, SENR3130, “Torque
Speciﬁcations” for more general information on the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(1 to 2 US gal) of the cooling system capacity.
Install the cooling system ﬁller cap.
4. Start the engine and run the engine at low idle for a minimum of 90 minutes. The coolant temperature should be at least 82 °C (180 °F).
NOTICE
Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure to completely ﬂush the cooling system with clear water. Continue to ﬂush the system until all signs of the cleaning agent are gone.

Refer to the Operation and Maintenance Manual,
“Reﬁll Capacities and Recommendations” topic for information regarding acceptable water, coolant/antifreeze, and supplemental coolant additive requirements. Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and
Recommendations” topic for the capacity of the engine's system.

Engines that are Equipped with a Coolant
Recovery Tank
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
1. Fill the cooling system with coolant/antifreeze.
Refer to the Operation and Maintenance Manual,
“Reﬁll Capacities and Recommendations” topic
(Maintenance Section) for more information on cooling system speciﬁcations. Do not install the cooling system ﬁller cap.
2. Start the engine and run the engine at low idle.
Increase the engine rpm to 1500 rpm. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. Stop the engine.
3. Add coolant to the cooling system until the cooling system is full.

SEBU7878-03

97
Maintenance Section
Cooling System Coolant (ELC) - Change

4. Clean the cooling system ﬁller cap. Inspect the gasket that is on the cooling system ﬁller cap. If the gasket that is on the cooling system ﬁller cap is damaged, discard the old cooling system ﬁller cap and install a new cooling system ﬁller cap.
If the gasket that is on the cooling system ﬁller cap is not damaged, perform a pressure test. A
9S-8140 Pressurizing Pump is used to perform the pressure test. The correct pressure for the cooling system ﬁller cap is stamped on the face of the cooling system ﬁller cap. If the cooling system ﬁller cap does not retain the correct pressure, install a new cooling system ﬁller cap.

Illustration 60

g00103638

(1) Recovery tank ﬁller cap
(2) “COLD FULL” mark
(3) “LOW ADD” mark

5. Loosen the cap for the coolant recovery tank slowly in order to relieve any pressure. Remove the cap for the coolant recovery tank.
6. Pour coolant into the coolant recovery tank until the coolant reaches the “COLD FULL” mark.
DO NOT ﬁll the coolant recovery tank above the
“COLD FULL” mark.

1. Fill the cooling system with coolant/antifreeze.
Refer to the Operation and Maintenance Manual,
“Reﬁll Capacities and Recommendations” topic
(Maintenance Section) for more information on cooling system speciﬁcations. Do not install the cooling system ﬁller cap.
2. Start the engine and run the engine at low idle.
Increase the engine rpm to 1500 rpm. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level within 13 mm (.5 inch) below the bottom of the pipe for ﬁlling. Maintain the coolant level within
13 mm (.5 inch) to the proper level on the sight glass (if equipped).
4. Clean the cooling system ﬁller cap. Inspect the gasket that is on the cooling system ﬁller cap. If the gasket that is on the cooling system ﬁller cap is damaged, discard the old cooling system ﬁller cap and install a new cooling system ﬁller cap.
If the gasket that is on the cooling system ﬁller cap is not damaged, perform a pressure test. A
9S-8140 Pressurizing Pump is used to perform the pressure test. The correct pressure for the cooling system ﬁller cap is stamped on the face of the cooling system ﬁller cap. If the cooling system ﬁller cap does not retain the correct pressure, install a new cooling system ﬁller cap.
5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature. i02367032 Cooling System Coolant (ELC)
- Change

7. Clean the cap for the coolant recovery tank. Install the cap for the coolant recovery tank.

SMCS Code: 1350-070; 1395-044

8. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

Clean the cooling system and ﬂush the cooling system before the recommended maintenance interval if the following conditions exist:

Engines that are Not Equipped with a
Coolant Recovery Tank

• The engine overheats frequently.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.

• The oil has entered the cooling system and the

• Foaming of the coolant coolant is contaminated.

• The fuel has entered the cooling system and the coolant is contaminated.

Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced. 98
Maintenance Section
Cooling System Coolant (ELC) - Change

SEBU7878-03

Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.

Drain

3. Fill the cooling system with clean water. Install the cooling system ﬁller cap.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
1. Stop the engine 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.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain valve, remove the cooling system drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Flush
1. Flush the cooling system with clean water in order to remove any debris.
2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the
Speciﬁcations Manual for your particular engine for more speciﬁc information on the proper torques.
Refer to the Speciﬁcations, SENR3130, “Torque
Speciﬁcations” for more general information on the proper torques.

4. Start the engine and run the engine at low idle until the temperature reaches 49 to 66 °C
(120 to 150 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller cap. Open the drain valve
(if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Speciﬁcations Manual for your particular engine for more speciﬁc information on the proper torques. Refer to the Speciﬁcations,
SENR3130, “Torque Speciﬁcations” for more general information on the proper torques.

Fill
Engines that are Equipped with a Coolant
Recovery Tank
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to the Operation and Maintenance
Manual, “Reﬁll Capacities and Recommendations” topic (Maintenance Section) for more information on cooling system speciﬁcations. Do not install the cooling system ﬁller cap.
2. Start the engine and operate the engine at low idle. Increase the engine rpm to 1500 rpm.
Operate the engine at 1500 rpm for one minute in order to purge air from the cavities of the engine block. Stop the engine.
3. Pour more ELC into the cooling system until the cooling system is full.

SEBU7878-03

99
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

4. Clean the cooling system ﬁller cap. Inspect the gasket that is on the cooling system ﬁller cap. If the gasket that is on the cooling system ﬁller cap is damaged, discard the old cooling system ﬁller cap and install a new cooling system ﬁller cap. If the gasket that is on the cooling system ﬁller cap is not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system ﬁller cap. The correct pressure for the cooling system ﬁller cap is stamped on the face of the cooling system ﬁller cap. If the cooling system ﬁller cap does not retain the correct pressure, install a new cooling system ﬁller cap.

Illustration 61

g00103638

(1) Recovery tank ﬁller cap
(2) “COLD FULL” mark
(3) “LOW ADD” mark

5. Loosen the cap for the coolant recovery tank slowly in order to relieve any pressure. Remove the cap for the coolant recovery tank.
6. Pour Extended Life Coolant (ELC) into the coolant recovery tank until the coolant reaches the “COLD
FULL” mark. DO NOT ﬁll the coolant recovery tank above the “COLD FULL” mark.
7. Clean the cap for the coolant recovery tank. Install the cap for the coolant recovery tank.
8. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

Engines that are NOT Equipped with a
Coolant Recovery Tank
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.

1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to the Operation and Maintenance
Manual, “Reﬁll Capacities and Recommendations” topic (Maintenance Section) for more information on cooling system speciﬁcations. Do not install the cooling system ﬁller cap.
2. Start the engine and operate the engine at low idle. Increase the engine rpm to 1500 rpm.
Operate the engine at 1500 rpm for one minute in order to purge air from the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level within 13 mm (.5 inch) below the bottom of the pipe for ﬁlling. Maintain the coolant level within
13 mm (.5 inch) to the proper level on the sight glass (if equipped).
4. Clean the cooling system ﬁller cap. Inspect the gasket that is on the cooling system ﬁller cap. If the gasket that is on the cooling system ﬁller cap is damaged, discard the old cooling system ﬁller cap and install a new cooling system ﬁller cap. If the gasket that is on the cooling system ﬁller cap is not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system ﬁller cap. The correct pressure for the cooling system ﬁller cap is stamped on the face of the cooling system ﬁller cap. If the cooling system ﬁller cap does not retain the correct pressure, install a new cooling system ﬁller cap.
5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature. i02482066 Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants. The Cat ELC Extender only needs to be added once.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender with Cat ELC.
Do NOT use conventional supplemental coolant additive (SCA) with Cat ELC. Mixing Cat ELC with conventional coolants and/or conventional SCA reduces the
Cat ELC service life.
Check the cooling system only when the engine is stopped and cool.

100
Maintenance Section
Cooling System Coolant Level - Check

SEBU7878-03

i02372255

Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.
Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containing ﬂuids.

Cooling System Coolant Level
- Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped and cool.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
1. Remove the cooling system ﬁller cap slowly 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.

Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain ﬂuids on Caterpillar products. Dispose of all ﬂuids according to local regulations and mandates. 1. Loosen the cooling system ﬁller cap slowly in order to relieve pressure. Remove the cooling system ﬁller cap.
2. It may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the requirements for your engine's cooling system capacity. Refer to the Operation and Maintenance
Manual, “Reﬁll Capacities and Recommendations” article for more information.
4. Clean the cooling system ﬁller cap. Inspect the gaskets on the cooling system ﬁller cap. Replace the cooling system ﬁller cap if the gaskets are damaged. Install the cooling system ﬁller cap.

Illustration 62

g00103639

Typical ﬁller cap gaskets

3. Clean the cooling system ﬁller cap and inspect the condition of the ﬁller cap gaskets. Replace the cooling system ﬁller cap if the ﬁller cap gaskets are damaged. Reinstall the cooling system ﬁller cap.
4. Inspect the cooling system for leaks.

SEBU7878-03

101
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

i02837191

Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling system is ﬁlled with Cat
ELC (Extended Life Coolant). Cooling systems that are ﬁlled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule.

Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from your Caterpillar dealer.
Use the following guidelines for proper sampling of the coolant:

• Complete the information on the label for the sampling bottle before you begin to take the samples. Note: Obtain a Coolant Sample (Level 1) if the cooling system is ﬁlled with any other coolant instead of Cat ELC. This includes the following types of coolants:

• Keep the unused sampling bottles stored in plastic

• Commercial long life coolants that meet the

• Obtain coolant samples directly from the coolant

Caterpillar Engine Coolant Speciﬁcation -1
(Caterpillar EC-1)

sample port. You should not obtain the samples from any other location.

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Keep the lids on empty sampling bottles until you

• Commercial heavy-duty coolant/antifreeze

bags.

are ready to collect the sample.

• Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination. Table 17

Recommended Interval
Type of Coolant

Level 1

Level 2

• Never collect samples from expansion bottles.

Cat DEAC

Every 250
Hours(1)

Yearly(1)(2)

• Never collect samples from the drain for a system.

Cat ELC

Optional(2)

Yearly(2)

(1)

This is the recommended interval for coolant samples for all conventional heavy-duty coolant/antifreeze. This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC-1 speciﬁcation for engine coolant. (2) The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identiﬁed.

Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see this Operation and Maintenance Manual, “Reﬁll
Capacities and Recommendations” or consult your
Caterpillar dealer. i01987714 NOTICE
Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.

Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain” for the guidelines for proper sampling of the coolant.

102
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Submit the sample for Level 2 analysis.
For additional information about coolant analysis, see Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engines Fluids
Recommendations” or consult your Caterpillar dealer. i02839449 Cooling System Supplemental
Coolant Additive (SCA) Test/Add
SMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with the skin and eyes. Do not drink cooling system coolant additive.
NOTICE
Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components.
Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water pump seal.
Do not exceed the recommended amount of supplemental coolant additive concentration.
NOTICE
Care must be taken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containing ﬂuids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” and to Special Publication, GECJ0003, “Cat Shop Supplies and Tools” for tools and supplies suitable to collect and contain ﬂuids on Caterpillar products.
Dispose of all ﬂuids according to applicable regulations and mandates.
Note: Caterpillar recommends an S·O·S coolant analysis (Level 1).

SEBU7878-03

Cooling Systems that Use
Conventional Coolant
This maintenance procedure is required for conventional coolants such as DEAC.This maintenance is NOT required for cooling systems that are ﬁlled with Extended Life Coolant.

Test the Concentration of the SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit.

Add the SCA, If Necessary

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
1. Remove the cooling system ﬁller cap slowly.
2. If necessary, drain some coolant in order to allow space for the addition of the SCA.
3. Add the proper amount of SCA. For the proper amount of SCA, refer to this Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” topic. The proper concentration of SCA depends on the type of coolant that is used. For the proper concentration of SCA, refer to Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engine Fluids
Recommendations”.
4. Clean the cooling system ﬁller cap. Install the cooling system ﬁller cap.

SEBU7878-03

Cooling Systems that Use Water and SCA
Test the Concentration of the SCA
Test the concentration of the SCA with a 298-5311
Coolant Nitrite Test Kit for SCA or perform an S·O·S
Coolant Analysis. The test kit includes the following items: a tool for the testing, 30 ampoules for testing nitrite, instructions, and a case. 294-7420 Test
Kit contains the reﬁll ampoules for the 298-5311
Coolant Nitrite Test Kit. Use the instructions that are included with the test kit in order to properly conduct the testing.

103
Maintenance Section
Cooling System Water Temperature Regulator - Replace

i01852885

Cooling System Water
Temperature Regulator Replace
SMCS Code: 1355-510

Refer to this Operation and Maintenance Manual,
“Maintenance Interval Schedule” for the times at which the procedures should be conducted. Test the concentration of the SCA more frequently if more frequent testing is indicated by the results of the
S·O·S Coolant Analysis.
NOTICE
Do not exceed the recommended eight percent supplemental coolant additive concentration.

Add the SCA, If Necessary

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
1. Remove the cooling system ﬁller cap slowly.
2. If necessary, drain some coolant in order to allow space for the addition of the SCA.
3. Add the proper amount of SCA. For the proper amount of SCA, refer to this Operation and
Maintenance Manual, “Reﬁll Capacities and
Recommendations” topic. For the proper concentration of SCA, refer to Special Publication,
SEBU6251, “Caterpillar Commercial Diesel
Engine Fluids Recommendations”.
4. Clean the cooling system ﬁller cap. Install the cooling system ﬁller cap.

Illustration 63

g00944247

Top view of the expansion tank

Replace the water temperature regulator before the water temperature regulator fails. This is a recommended preventive maintenance practice.
Replacing the water temperature regulator reduces the chances for unscheduled downtime.
A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine.
A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive overheating could result in cracking of the cylinder head or piston seizure problems.
A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner.

104
Maintenance Section
Crankshaft Vibration Damper - Inspect

SEBU7878-03

NOTICE
Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage.
Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed.
If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or cylinder head surface.
Refer to the Service Manual for the replacement procedure of the water temperature regulator, or consult your Caterpillar dealer.
Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing. i03175962

Crankshaft Vibration Damper
- Inspect
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations. This can result in damage to the crankshaft and to other engine components. A deteriorating damper can cause excessive gear train noise at variable points in the speed range.
The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine. Illustration 64

g01134779

Viscous vibration damper
Typical example
(1) Crankshaft pulley
(2) Weight
(3) Case

Inspection
Inspect the damper for the following conditions:

• The damper is dented, cracked, or ﬂuid is leaking from the damper.

• The paint on the damper is discolored from excessive heat.

• The damper is bent.
• 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
Refer to this Operation and Maintenance Manual,
“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.

SEBU7878-03

105
Maintenance Section
Cylinder Head Grounding Stud - Inspect/Clean/Tighten

i02674924

i02398768

Cylinder Head Grounding Stud
- Inspect/Clean/Tighten

Electrical Connections - Check
SMCS Code: 4459-535

SMCS Code: 7423-040; 7423-070; 7423-079
DANGER: Shock/Electrocution Hazard-Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death. Checking the electrical connections is an important part of the maintenance for the generator set.
Improper connections may cause the generator set to malfunction.
Check all exposed electrical connections for tightness. Check the following devices for loose mounting or for physical damage:
Illustration 65

g01344048

(1) Primary ground location

Caterpillar recommends grounding to the cylinder head. Speciﬁc applications may place the location of the grounding at other points on the engine. Refer to the information that is supplied by the OEM for ground locations that are not standard.
Inspect the OEM harness for good connections and condition. • Transformers
• Fuses
• Capacitors
• Lightning arresters
Check the connections for the following components:

• Load cables

The cylinder head grounding stud must have a wire ground to the battery. Tighten the cylinder head grounding stud at every oil change. Ground wires and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.

• Cables for the generator

• Clean the cylinder head grounding stud and the

Check all lead wires and electrical connections for proper clearance. Inspect all cables for chaﬁng, abrasion and corrosion.

terminals for the cylinder head ground strap with a clean cloth.

• If the connections are corroded, clean the

connections with a solution of baking soda and water. • Keep the cylinder head grounding stud and the strap clean and coated with MPGM grease or petroleum jelly.

• Potential transformers
• Current transformers

106
Maintenance Section
Engine - Clean

SEBU7878-03

i01664717

Engine - Clean
SMCS Code: 1000-070

Personal injury or death can result from high voltage.
Moisture could create paths of electrical conductivity.
Make sure the unit is off line (disconnected from utility and/or other generators), locked out and tagged "Do Not Operate".
NOTICE
Water or condensation can cause damage to generator components. Protect all electrical components from exposure to water.
NOTICE
Accumulated grease and oil on an engine is a ﬁre hazard. Keep the engine clean. Remove debris and ﬂuid spills whenever a signiﬁcant quantity accumulates on the engine.
Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following beneﬁts: Inspecting and Replacing the
Secondary Air Cleaner Element (If
Equipped)
NOTICE
Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.
Operating conditions (dust, dirt, and debris) may require more frequent service of the air cleaner element. If the air cleaner element becomes plugged, the air can split the material of the air cleaner element. Unﬁltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has the proper air cleaner elements for your application.
Consult your Caterpillar dealer for the correct air cleaner element.
The secondary air cleaner element is not serviceable or washable. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element.

• Easy detection of ﬂuid leaks
• Maximum heat transfer characteristics
• Ease of maintenance
Note: For more information on cleaning and drying electric generators, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
i02353651

Engine Air Cleaner Element
(Dual Element) - Clean/Replace
(If Equipped)
SMCS Code: 1054-037; 1054-510
See this Operation and Maintenance Manual,
“Engine Air Cleaner Element - Clean/Replace” for information on servicing the primary air ﬁlter.

Illustration 66
(1)
(2)
(3)
(4)

g00736431

Cover
Primary air cleaner element
Secondary air cleaner element
Air inlet for the turbocharger

1. Remove the cover. Remove the primary air cleaner element.
2. Cover the air inlet for the turbocharger with adhesive material in order to keep dirt out of the turbocharger. SEBU7878-03

107
Maintenance Section
Engine Air Cleaner Element - Clean/Replace

3. Clean the inside of the air cleaner cover and body with a clean, dry cloth.
4. Remove the adhesive covering that covers the air inlet for the turbocharger. Install the secondary air cleaner element. Install a primary air cleaner element that is new or clean.
5. Install the air cleaner cover.
6. Reset the air cleaner service indicator.

• The air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

Replace the dirty paper elements with clean elements. Before installation, thoroughly inspect the element for tears and/or holes in the ﬁlter material.
Inspect the gasket or the seal of the element for damage. Maintain a supply of suitable elements for replacement purposes.

i01943356

Engine Air Cleaner Element Clean/Replace
SMCS Code: 1054-070; 1054-510
NOTICE
Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.

Illustration 67

g00317608

Fasteners for the air cleaner cover

NOTICE
Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements
If the air cleaner element becomes plugged, the air pressure can split the ﬁlter material of the element.
Unﬁltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has the proper air cleaner elements for your application.
The air cleaner may be mounted high above the engine. If necessary, use a ladder or a platform to reach the air cleaner.

• Check the precleaner (if equipped) daily for

accumulation of dirt and debris. Remove any dirt and debris, as needed.

• Operating conditions (dust, dirt and debris) may require more frequent service of the air cleaner element. • The air cleaner element may be cleaned up to

six times if the element is properly cleaned and inspected. Illustration 68

g00781084

(1) Cover
(2) Element
(3) Air inlet

1. Release the fasteners for cover (1).
2. Remove the cover and element (2).
3. Cover air inlet (3) with tape in order to keep dirt out. 4. Clean the inside of the cover and the body with a clean, dry cloth.
5. Remove the tape for the air inlet. Install a new element or a clean element.
6. Install the cover.

108
Maintenance Section
Engine Air Cleaner Element - Clean/Replace

SEBU7878-03

7. If necessary, reset the air cleaner service indicator.

Cleaning the Primary Air Cleaner
Elements
The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. When the element is cleaned, check the ﬁlter material for rips or tears. Replace the element at least one time per year regardless of the number of cleanings.
Use clean elements while dirty elements are being cleaned. NOTICE
Do not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result.

Aim the hose so that the air ﬂows inside the element along the length of the ﬁlter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the primary air cleaner element. Dirt could be forced into the pleats.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.

Vacuum Cleaning
Vacuum cleaning is a good method for cleaning elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.

Inspecting the Primary Air Cleaner
Elements

Visually inspect the elements before cleaning. Inspect the elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged elements.
Air cleaner elements can be cleaned with pressurized air and with a vacuum.

Pressurized Air
Pressurized air can be used to clean elements that have not been cleaned more than two times.
Pressurized air will not remove deposits of carbon and oil. Use ﬁltered, dry air with a maximum pressure of 207 kPa (30 psi).

Illustration 70

g00281693

Inspect the clean, dry element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the element. Rotate the element.
Inspect the element for tears and/or holes. Inspect the element for light that may show through the ﬁlter material. If it is necessary in order to conﬁrm the result, compare the element to a new element that has the same part number.
Do not use an element that has any tears and/or holes in the ﬁlter material. Do not use an element with damaged pleats, gaskets or seals. Discard damaged elements. Illustration 69

g00281692

Note: When the elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside).

Storing Primary Air Cleaner Elements
If an element that passes inspection will not be used immediately, store the element for future use.

SEBU7878-03

Illustration 71

109
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

g00281694

Do not use paint, a waterproof cover, or plastic as a protective covering for storage. Restricted air ﬂow may result. To protect against dirt and damage, wrap the elements in Volatile Corrosion Inhibited (VCI) paper. Place the element into a cardboard box for storage.
For identiﬁcation, mark the outside of the container and mark the element. Include the following information: Illustration 72

g01174131

(1) Service Indicator Screen

Inspect and Clean the Indicator
Inspect the service indicator. Clean the air cleaner element or replace the element when the following conditions occur:

• The screen on the service indicator becomes totally red.

• Restriction of the air ﬂowing through the2 air ﬁlter

• Date of cleaning

reaches 762 ± 6 mm (30 ± 2.3 inches)H O.

• Number of cleanings

• The service indicator has one or more of the following: Store the container in a dry location.
For more detailed information on cleaning the primary air cleaner element, refer to Special Publication,
SEBF8062, “Procedure to Inspect and Clean Air
Filters”.
i02349277

Engine Air Cleaner Service
Indicator - Inspect
SMCS Code: 7452-040
The service indicator is mounted on the tube that leads from the engine air cleaner to the turbocharger inlet. • Cracks
• Holes
• Loose ﬁttings

Test the Service Indicator
Service indicators are important instruments. Test the service indicator by using one of the following methods. • Push the plunger into the element in order to reset.
If the service indicator does not reset in three pushes or less, replace the service indicator.

• The following method can only be used when

the air cleaner has been used. This test will not work when the air cleaner has just been cleaned. Push the plunger into the element. Start the engine. If the plunger does not move, replace the service indicator.

110
Maintenance Section
Engine Crankcase Breather - Clean

SEBU7878-03

The service indicator may need to be replaced frequently in environments that are severely dusty.
Replace the service indicator at the end of each year if the service indicator has not been replaced during the year. Replace the service indicator when the engine is overhauled. Replace the service indicator whenever major engine components are replaced.

i02456872

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

i02369771

Engine Crankcase Breather Clean

• Improper mounting of the engine

SMCS Code: 1317-070

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

NOTICE
Perform this maintenance with the engine stopped.
NOTICE
If the crankcase breather is not maintained on a regular basis, it can become plugged. A plugged breather will cause excessive crankcase pressure that may cause crankshaft seal leakage.

• Deterioration of the engine mounts

i01007363

Engine Oil Level - Check
SMCS Code: 1348-535-FLV
Check the oil level after the engine has stopped.
This maintenance procedure must be performed on a level surface.

Illustration 74

Illustration 73

g01182276

(1) Bolt and Washer

g00110310

(Y) “ADD” mark
(X) “FULL” mark

1. Maintain the oil level between the “ADD” mark (Y) and the “FULL” mark (X) on the oil level gauge.
Do not ﬁll the crankcase above “FULL” mark (X).

(2) Breather Assembly
(3) Engine Block
1. Remove the bolt and the washer. Remove the breather assembly and the seal.
2. Wash the breather element in solvent that is clean and nonﬂammable. Allow the breather element to dry before installation.
3. Install a breather element that is clean and dry.
Install breather assembly and the seal.
4. Install the bolt and the washer. Refer to Speciﬁcations, SENR3130, “Torque
Speciﬁcations” for the correct torque.

NOTICE
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil's lubricating characteristics and could result in the loss of power.
2. Remove oil ﬁller cap and add oil, if necessary.
Clean the oil ﬁller cap. Reinstall the oil ﬁller cap.

SEBU7878-03

111
Maintenance Section
Engine Oil Sample - Obtain

i02368863

Engine Oil Sample - Obtain
SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM
In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. S·O·S oil analysis provides infrared analysis, which is required for determining nitration and oxidation levels.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
See this Operation and Maintenance Manual, “Model
Views” in order to locate the oil sampling valve.

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 sampling.
Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion into the sump.
For instructions, see Special Publication, PEHP6001,
“How To Take A Good Oil Sample”. Consult your
Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your engine. Before you take the oil sample, complete the Label,
PEEP5031 for identiﬁcation of the sample. In order to help obtain the most accurate analysis, provide the following information:

Engine Oil and Filter - Change

• Engine model

SMCS Code: 1318-510; 1348-044

i02354905

• Service hours on the engine
• The number of hours that have accumulated since the last oil change

• The amount of oil that has been added since the last oil change

To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean.
Caterpillar recommends using the sampling valve 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.

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with the draining cold oil. Drain the crankcase with the engine stopped. Drain the engine oil from the crankcase while the engine oil is warm.
This draining method allows the waste particles that are suspended in the oil to be drained properly.
Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil.

Drain the Engine Oil
After the engine has been run at the normal operating temperature, stop the engine. Use one of the following methods to drain the engine crankcase oil:

112
Maintenance Section
Engine Oil and Filter - Change

SEBU7878-03

• If the engine is equipped with a drain valve, turn the drain valve knob counterclockwise in order to drain the oil. After the oil has drained, turn the drain valve knob clockwise in order to close the drain valve.

• If the engine is not equipped with a drain valve,

remove the oil drain plug in order to allow the oil to drain. If the engine is equipped with a shallow sump, remove the bottom oil drain plugs from both ends of the oil pan.

After the oil has drained, the oil drain plugs should be cleaned and installed.

Replace the Oil Filter

Illustration 75

g00103713

Typical ﬁlter mounting base and ﬁlter gasket

NOTICE
Caterpillar oil ﬁlters are built to Caterpillar speciﬁcations. Use of an oil ﬁlter not recommended by
Caterpillar could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unﬁltered oil entering the engine lubricating system. Only use oil ﬁlters recommended by Caterpillar.
1. Remove the oil ﬁlter with a 1U-8760 Chain
Wrench.
2. Cut the oil ﬁlter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the oil ﬁlter for metal debris. An excessive amount of metal debris in the oil ﬁlter may indicate early wear or a pending failure.
Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil ﬁlter element. Ferrous metals may indicate wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the aluminum parts, brass parts or bronze parts of the engine. Parts that may be affected include the following items: main bearings, rod bearings, turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not uncommon to ﬁnd small amounts of debris in the oil ﬁlter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil ﬁlter.

3. Clean the sealing surface of the ﬁlter mounting base. Ensure that all of the old oil ﬁlter gasket is removed. 4. Apply clean engine oil to the new oil ﬁlter gasket.
NOTICE
Do not ﬁll the oil ﬁlters with oil before installing them.
This oil would not be ﬁltered and could be contaminated. Contaminated oil can cause accelerated wear to engine components.
5. Install the oil ﬁlter. Tighten the oil ﬁlter until the oil ﬁlter gasket contacts the base. Tighten the oil ﬁlter by hand according to the instructions that are shown on the oil ﬁlter. Do not overtighten the oil ﬁlter. Fill the Engine Crankcase
1. Remove the oil ﬁller cap. Fill the crankcase with the proper amount of oil. Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and
Recommendations” for more information on lubricant speciﬁcations and reﬁll capacities.
NOTICE
If equipped with an auxiliary oil ﬁlter system or a remote oil ﬁlter system, follow the OEM or ﬁlter manufacturer's recommendations. Under ﬁlling or overﬁlling the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will ﬁll the oil ﬁlters before starting the engine. Do not crank the engine for more than 30 seconds.

SEBU7878-03

113
Maintenance Section
Engine Performance - Test

2. Start the engine and run the engine at “LOW
IDLE” for two minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil ﬁlters are ﬁlled. Inspect the oil ﬁlter for oil leaks.
3. Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the oil level. Maintain the oil level between the “ADD” and “FULL” marks on the oil level gauge. i02366807 Engine Performance - Test
(Standby Generator Sets)
SMCS Code: 1000-081
Operate the engine for a minimum of two hours at a minimum load of 60 percent.
Frequently monitor the following parameters duringengine operation:

• Engine Oil Pressure
• Engine Coolant Temperature
• Inlet Air Restriction
Record the data in a log. Compare the new data to the data that was previously recorded. Comparing the new data to the recorded data will establish the normal indicator readings for the engine. An indicator reading that is abnormal may indicate a problem with engine operation. Abnormal indicator readings may also indicate a possible problem with the indicator.
Table 18 is offered as an example of an engine log.
Record the engine performance regularly. Retain the recorded information for reference. Compare the recorded data in order to provide an indication of engine condition.
Records of engine performance are an important element of a maintenance program. Record information about the engine operation on a regular basis. This will help to reveal the trends of the engine performance. Records of engine performance will also provide a baseline for evaluating the mechanical condition of the engine.
The data on engine performance can help to predict problems with operation. This data can provide your Caterpillar dealer with information that is useful for recommending maintenance management information. A maintenance program that is properly managed will provide your engine with an optimum service life.

114
Maintenance Section
Engine Protective Devices - Check

SEBU7878-03

Table 18

Engine Log
Date
Authorization
Engine Serial Number
Engine Hours
Engine Speed
Percent Load
Ambient Temperature
Engine Coolant Temperature
Engine Oil Temperature
Engine Oil Pressure
System Battery Voltage
Generator Voltage
Generator Amperage
Comments

i00626013

Engine Protective Devices Check
SMCS Code: 7400-535
Alarms and shutoffs must function properly. Alarms provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation.
Malfunctions must be simulated in order to test the engine protective devices.

A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints. Ensure that the engine protective devices are functioning properly.
NOTICE
During testing, abnormal operating conditions must be simulated. The tests must be performed correctly in order to prevent possible damage to the engine.
To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer should perform the tests.

SEBU7878-03

115
Maintenance Section
Engine Speed/Timing Sensors - Check/Clean/Calibrate

Visual Inspection
Visually check the condition of all gauges, sensors and wiring. Look for wiring and components that are loose, broken, or damaged. Damaged wiring or components should be repaired or replaced immediately. i02372750

Engine Speed/Timing Sensors
- Check/Clean/Calibrate
SMCS Code: 1912-040; 1912-070; 1912-524

This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life. NOTICE
Only qualiﬁed service personnel should perform this maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve adjustments can reduce engine efﬁciency. This reduced efﬁciency could result in excessive fuel usage and/or shortened engine component life.

Ensure that the engine can not be started while this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn the ﬂywheel.
Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance.

Illustration 76

g01183578

1. Remove the speed/timing sensors from the front housing. Check the condition of the plastic end of the speed/timing sensors for wear and/or contaminants. 2. Clean the metal shavings and other debris from the face of the speed/timing sensors. Use the procedure in the Service Manual in order to calibrate the speed/timing sensors.
Refer to the Service Manual for more information on the speed/timing sensors. i00869628 Engine Valve Lash Inspect/Adjust
SMCS Code: 1102-025
The initial valve lash adjustment on new engines, rebuilt engines, or remanufactured engines is recommended at the ﬁrst scheduled oil change. The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components.

Ensure that the engine is stopped before measuring the valve lash. To obtain an accurate measurement, allow the valves to cool before this maintenance is performed. Refer to the Service Manual for more information. i02325386 Ether Starting Aid Cylinder Replace
(If Equipped)
SMCS Code: 1456-510-CD
The ether canister is mounted inside the compartment on the side of the engine.

116
Maintenance Section
Fuel System - Prime

SEBU7878-03

Illustration 78

g01182169

(1) Priming Pump

Illustration 77

g01044394

1. Loosen the retaining clamp. Remove the old canister by turning the canister counterclockwise.
2. Remove the old gasket. Install the new gasket.
3. Install the new canister. Turn the canister clockwise. Hand tighten the canister. Tighten the clamp around the canister. i02369407 Fuel System - Prime
SMCS Code: 1258-548

Priming the fuel system ﬁlls the fuel ﬁlters. Priming the fuel system also removes air from the fuel system. This procedure is used primarily when the engine runs out of fuel.
1. Unlock the fuel priming pump by turning the handle counterclockwise. Move the plunger for the fuel priming pump in and out until a strong pressure is felt on the fuel priming pump and until the check valve clicks. This procedure will require considerable strokes. Lock the fuel priming pump.
2. Crank the engine after the system is pressurized.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
3. If the engine does not start, repeat Steps 1 and 2 in order to start the engine.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a ﬁre. To help prevent possible injury, turn the start switch off when changing fuel ﬁlters or water separator elements.
Clean up fuel spills immediately.

SEBU7878-03

117
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

i02370475

Fuel System Primary
Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543

i02349031

Fuel System Primary Filter
(Water Separator) Element Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ

Personal injury or death may result from failure to adhere to the following procedures.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a ﬁre.
Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.
Illustration 79

g00668636

(1) Bowl
(2) Element
(3) Drain

Bowl (1) should be monitored weekly for signs of water. If water is present, drain the water from the bowl. 1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container.
Dispose of the water properly.
2. Close drain (3).
NOTICE
The water separator is under suction during normal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel ﬁlters.
NOTICE
Do not ﬁll the fuel ﬁlters with fuel before installing the fuel ﬁlters. The fuel will not be ﬁltered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
NOTICE
Care must be taken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containing ﬂuids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” guide for tools and supplies suitable to collect and contain ﬂuids on
Caterpillar products.
Dispose of all ﬂuids according to local regulations and mandates. 1. Turn the start switch to the OFF position or disconnect the battery (starting motor) when maintenance is performed on a fuel ﬁlter.
2. Shut off the fuel supply.

118
Maintenance Section
Fuel System Secondary Filter - Replace

SEBU7878-03

13. Install the new ﬁlter onto the base. Tighten the ﬁlter by hand until the seal contacts the ﬁlter base.
Additionally tighten the ﬁlter by 1/3 to 1/2 rotation.
14. Open the fuel shutoff valve.
15. Reconnect the battery, if necessary.
16. Purge the air from the fuel system. See this
Operation and Maintenance Manual, “Fuel System
- Prime” for further instructions.
17. Stop the engine and check for leaks.
Illustration 80

g00104012

(1) ﬁlter body
(2) bowl
(3) drain valve

Note: Refer to this Operation and Maintenance
Manual, “General Hazard Information” that pertains to containing ﬂuid spillage.
3. Turn drain valve (3) counterclockwise in order to open. The drain valve is located on the bottom of the water separator.
4. Drain the water and sediment into a suitable container. Dispose of the drained ﬂuids and used ﬁlters according to local regulations.
5. Close the drain valve.
6. Hold the bottom of the ﬁlter while you loosen the bowl. Remove the bowl.

Note: The secondary fuel ﬁlter should also be replaced at this time. See this Operation and
Maintenance Manual, “Fuel System Secondary Filter
- Replace” for further information. i02326422 Fuel System Secondary Filter Replace
SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or electrical components can cause a ﬁre. To help prevent possible injury, turn the start switch off when changing fuel ﬁlters or water separator elements.
Clean up fuel spills immediately.

7. Turn the ﬁlter counterclockwise in order to loosen the ﬁlter. If the ﬁlter will not turn, use a strap wrench to loosen the ﬁlter.
8. Remove the ﬁlter and discard the ﬁlter. Clean the bottom of the ﬁlter mounting base. Make sure that all of the old ﬁlter seal is removed from the bottom groove of the opening in the base.
9. Clean the water separator bowl and clean the groove for the seal. Inspect the seal. If the seal is worn or damaged, replace the seal.
10. Lubricate the seal with clean diesel fuel or lubricate the seal with clean motor oil. Place the seal in the groove on the water separator bowl.
11. Install the water separator bowl onto the new fuel ﬁlter by hand. Tighten the bowl assembly to 15
15 N·m (11 lb ft).
12. Apply clean diesel fuel to the seal of the new ﬁlter.

Illustration 81

g01162207

(1) Fuel supply connections
(2) Fuel ﬁlter

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components.

SEBU7878-03

119
Maintenance Section
Fuel Tank Water and Sediment - Drain

i03645042

NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
1. It may be necessary to relieve residual fuel pressure from the fuel system before removing the fuel ﬁlter.
Loosen one of the fuel supply connections (1) in order to purge any residual pressure.
NOTICE
Do not loosen fuel lines or ﬁttings at the fuel manifold or ECM. The engine components may be damaged.
2. Remove the used fuel ﬁlter.
3. Clean the gasket sealing surface of the fuel ﬁlter base. Ensure that all of the old gasket is removed.
4. Apply clean diesel fuel to the new fuel ﬁlter gasket.
NOTICE
Do not ﬁll the secondary fuel ﬁlter with fuel before installing. The fuel would not be ﬁltered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
5. Install the new fuel ﬁlter. Spin the fuel ﬁlter onto the fuel ﬁlter base until the gasket contacts the base. Use the rotation index marks on the ﬁlters as a guide for proper tightening. Tighten the ﬁlter for an additional 3/4 turn by hand. Do not overtighten the ﬁlter.

Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containing ﬂuids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain ﬂuids on Caterpillar products.
Dispose of all ﬂuids according to local regulations and mandates. Fuel Tank
Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.

Drain the Water and the Sediment
Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks.
Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve.
Note: Failure to properly close the drain can allow air into the system, which could have detrimental results to performance.
Check the fuel daily. Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been ﬁlled. Allow ﬁve to ten minutes before performing this procedure.

120
Maintenance Section
Generator - Dry

SEBU7878-03

Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not ﬁll the tank to the top. The fuel expands as the fuel gets warm. The tank may overﬂow. Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the procedure to safely isolate the generator.
If the insulation resistance values are less than 1 megohm for the stator or the insulation resistance values are less than 100,000 ohms for the other windings, one of the following drying procedures must be selected. This decision should be based on the following factors:

Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply 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.

• the size of the unit

Fuel Storage Tanks

• the location of the unit

Drain the water and the sediment from the fuel storage tank during the following conditions:

• Weekly
• Oil change
• Reﬁll of the tank
This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. A four micron(c) absolute ﬁlter for the breather vent on the fuel tank is also recommended. Refer to Special Publication, SENR9620, “Improving Fuel
System Durablity”.
If a bulk storage tank has been reﬁlled or moved recently, allow adequate time for the sediment to settle before ﬁlling the engine fuel tank. Internal bafﬂes in the bulk storage tank will also help trap sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. i01936148 Generator - Dry
SMCS Code: 4450-569

• the equipment that is available
• the experience of personnel
Measure insulation resistance at one hour intervals.
Typically, the insulation resistance will slowly drop while the temperature is rising. The insulation resistance will then start to increase at a slow rate until the insulation resistance reaches a constant level. The following methods can be used for drying a generator: • Self-circulating air method
• Oven method
• Controlled current method

Self-Circulating Air Method
Blow hot air into the air intake for the generator.
Disconnect the exciter ﬁeld and run the engine. This will help circulate air. Operate the generator space heaters. Oven Method
Disconnect the AVR. Place the entire generator inside a forced air drying oven for 24 hours at 110 °C
(230 °F).

Personal injury or death can result from improper troubleshooting and repair procedures.
The following troubleshooting and repair procedures should only be performed by qualiﬁed personnel familiar with this equipment.
Note: The use of space heaters and occasional cranking of the engine will help to avoid drying the generator. Space heaters should be used continuously while the machine is stopped in order for the space heaters to be effective.

NOTICE
Use a forced air type oven rather than a radiant type oven. Radiant type ovens can cause localized overheating.

SEBU7878-03

121
Maintenance Section
Generator - Inspect

Controlled Current Method
Table 19

Tools Needed
Part
Number

Description

Qty

8T-0900

Clamp on ammeter (0 1200 amperes)

1

External 24 Volt DC Power
Source

1

Rheostat

1

Heat can be used in order to dry the generator windings. This heat can be created by allowing a controlled current to ﬂow through the generator. No high voltages are generated during the following procedure. Therefore, insulation breakdown will not occur. 1. Disconnect the AVR.
2. Short circuit the three output power terminals with connectors that are capable of supporting the rated current. Try not to exceed 6 Amp per square millimeter. 3. Use a clamp-on ammeter in order to monitor the current through the short circuit connections.
4. Connect a 24 volt DC power source in series with a rheostat of 100 ohms or 50 Watts to the ﬁeld terminals of the exciter. Make the connections with the correct polarity.
5. Open all the openings on the generator in order to allow air ﬂow.
6. Operate the generator at the rated speed. Adjust the current in the exciter ﬁeld with the rheostat.
Obtain the rated output current in the short circuit connections. i01880220

Generator - Inspect
SMCS Code: 4450-040

Personal injury or death can result from improper troubleshooting and repair procedures.
The following troubleshooting and repair procedures should only be performed by qualiﬁed personnel familiar with this equipment.

The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the procedure to safely isolate the generator.
Proper maintenance of electrical equipment requires periodic visual examination of the generator and periodic visual examination of the windings. Proper maintenance of electrical equipment also requires appropriate electrical checks and appropriate thermal checks. Insulation material should be examined for cracks. The insulation material should be examined for accumulations of dirt and dust. If there is an insulation resistance value that is below normal, a conductive path may be present. This conductive path may be made of one of the following materials:

• Carbon
• Salt
• Metal dust
• Dirt that is saturated with moisture
These contaminants will develop a conductive path which may produce shorts. Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be seen. If excess dirt is the cause of a restriction in the ventilation, cleaning is also advisable. Restricted ventilation will cause excessive heating.
NOTICE
To avoid the possibility of deterioration to the generator windings, do not clean the generator unless there is visual, electrical, or thermal evidence that dirt is present. If harmful dirt accumulations are present, a variety of cleaning techniques are available. The cleaning procedure that is used may be determined by one of the items on the following list:

• The extent of the cleaning procedure that is being attempted 122
Maintenance Section
Generator Bearing - Inspect

• The type of enclosure of the generator
• The voltage rating of the generator
• The type of dirt that is being removed

Cleaning (Assembled Generators)
Cleaning may be required at the point of installation.
At this point, complete disassembly of the generator may not be necessary or feasible. In this case, a vacuum cleaner should be used to pick up the following items: dry dirt, dust, and carbon. This will prevent the spreading of these contaminants.
A small nonconductive tube may need to be connected to the vacuum cleaner. This will allow the vacuum cleaner to clean the surfaces that are not exposed. After most of the dust has been removed, a small brush may be attached to the vacuum hose in order to loosen dirt that is more ﬁrmly attached to the surface.
After the initial cleaning with a vacuum, compressed air may be used to remove the remaining dust and dirt. Compressed air that is used for cleaning should be free of moisture and free of oil. Air pressure should be a maximum of 210 kPa (30 psi) in order to prevent mechanical damage to the insulation. If the above cleaning procedures are not effective, consult a Caterpillar dealer.

Cleaning (Disassembled
Generators)
An initial insulation resistance check should be made on the generator in order to conﬁrm electrical integrity. A minimum reading of one megohm would be expected with severely contaminated generators.
A zero megohm reading may indicate an insulation breakdown. An insulation breakdown requires more than cleaning. An insulation breakdown requires repair. SEBU7878-03

Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation resistance should now be normal. If the insulation resistance is not normal, repeat the procedure. It may be necessary to use solvents if the generator is contaminated with oil or if the generator is contaminated with grease.
Note: For more information on drying methods, refer to Special Instructions, SEHS9124, “Cleaning and
Drying of Electric Set Generators”. i03132339 Generator Bearing - Inspect
SMCS Code: 4471-040
The ball bearings that are used in LC5, LC6, and SR5 generators contain grease. This grease is subject to deterioration. If the generator is stored more than one year, without rotating the rotor, new ball bearings may be required. These bearings are greased at the factory. These bearings do not require any additional greasing in the ﬁeld. Remove any necessary covers in order to inspect the rear bearings of the generators.
Front bearings may be inspected through the fan screen. Perform a visual inspection for obvious damage, for corrosion, or for an excessive amount of purged grease around the bearing sleeves. Small amounts of purged grease are expected. Grease that covers the brackets or the windings is excessive.
Bearing inspection should include the collection of vibration data. Refer to this Operation and
Maintenance Manual, “Generator Set Vibration Test/Record” for further information concerning checking the vibration levels.
Bearing temperature should also be measured and recorded as a part of this inspection. Refer to this
Operation and Maintenance Manual, “Generator
Bearing Temperature - Test/Record” for further information concerning checking the vibration levels.

A high pressure wash is normally an effective way to clean windings. This includes windings that have been exposed to ﬂooding or windings that have been contaminated by salt. A solution of hot water and detergent is used for this method of cleaning.

If inspection indicates that bearings are free of rust or corrosion, and no noise or excessive vibration occur on start-up, replacement is not necessary.

A high pressure wash sprays a high velocity ﬂuid stream of this solution over the generator that is being cleaned. This detergent washing is followed by multiple sprays of clean water. The clean water is used in order to remove the detergent or the clean water is used in order to dilute the detergent.

Generator Bearing - Lubricate

i03547528

SMCS Code: 4471-086

Lubricating Process (If Applicable)
Note: If the generator already has a visible grease point, go to Step 4.

SEBU7878-03

123
Maintenance Section
Generator Bearing - Lubricate

1. Remove either the louver assembly or the rear plate from the rear of the generator housing.
2. Remove the top grease pipe plug and remove the lower grease pipe plug.
3. Install a grease ﬁtting in the grease pipe.
4. Grease the bearings with the appropriate grease from Table 20. Do not mix greases.
Table 20

Bearing
Part
Number

Bearing
Type

Frame
Size

Temperature
Min/Max(1)

Grease
Part
Number

Interval

Weight

Volume

Shaft
Diameter

108-1760
Ball Bearing

321 BC
225.0 mm
(8.9 inch)
OD

680

−29 °C
(−20.2 °F) minimum /
80 °C
(176 °F) maximum 2S-3230
Bearing
Lubricant

Every 2000 service hours or 12 months 51.2 g
(1.8 oz)

59 mL (2 oz)

105.0 mm
(4.1 inch)

690 /
800

−29 °C
(−20.2 °F)
/
80 °C
(176 °F)

2S-3230
Bearing
Lubricant

Every 2000 service hours or 12 months 51.2 g
(1.8 oz)

59 mL (2 oz)

110.0 mm
(4.3 inch)

105.0 mm
(4.1 inch) ID
108-1761
Ball Bearing

322 BC
240.0 mm
(9.4 inch)
OD
110.0 mm
(4.3 inch) ID

139-0349
Roller
Bearing

Roller

2900 /
2800

−40 °C
(−40 °F)
/
80 °C
(176 °F)

Mobilith
SHC220

Every 250 service hours

2.8 g
(0.1 oz)

NA

127.0 mm
(5.0 inch)

139-0350
Roller
Bearing

Roller

2900 /
2800

−40 °C
(−40 °F)
/
80 °C
(176 °F)

Mobilith
SHC220

Every 250 service hours

2.8 g
(0.1 oz)

NA

127.0 mm
(5.0 inch)

154-3032
Ball Bearing

326 BC
280.0 mm
(11.0 inch)
OD

820 /
2600 /
2700

−29 °C
(−20.2 °F)
/
80 °C
(176 °F)

2S-3230
Bearing
Lubricant

Every 2000 service hours or 12 months 51.2 g
(1.8 oz)

59 mL (2 oz)

130.0 mm
(5.1 inch)

LC7

−29 °C
(−20.2 °F)
/
60 °C
(140 °F)(2)

UNIREX
N3

Every 4500 service hours or 12 months 60 g (2.1 oz)

NA

100.0 mm
(3.9 inch)

130.0 mm
(5.1 inch) ID
241-4644
Bearing

320 BC
215.0 mm
(8.5 inch)
OD
100.0 mm
(3.9 inch) ID

(continued)

124
Maintenance Section
Generator Bearing - Lubricate

SEBU7878-03

(Table 20, contd)

Bearing
Part
Number

Bearing
Type

Frame
Size

Temperature
Min/Max(1)

Grease
Part
Number

Interval

Weight

Volume

Shaft
Diameter

243-5220
Bearing

315 BB
160.0 mm
(6.3 inch)
OD

LC6100
/
LC5000

−29 °C
(−20.2 °F)
/
60 °C
(140 °F)(2)

UNIREX
N3

Nonregreasable bearing(3) Nonregreasable bearing Nonregreasable bearing 75.0 mm
(3.0 inch)

LC2000

−29 °C
(−20.2 °F)
/
50 °C
(122 °F)(2)

UNIREX
N3

Nonregreasable bearing(3) Nonregreasable bearing Nonregreasable bearing 35.0 mm
(1.4 inch)

LC2000

−29 °C
(−20.2 °F)
/
60 °C
(140 °F)(2)

UNIREX
N3

Nonregreasable bearing(3) Nonregreasable bearing Nonregreasable bearing 35.0 mm
(1.4 inch)

LC3000

−29 °C
(−20.2 °F)
/
60 °C
(140 °F)(2)

UNIREX
N3

Nonregreasable bearing(3) Nonregreasable bearing Nonregreasable bearing 45.0 mm
(1.8 inch)

580 /
590

−29 °C
(−20.2 °F)
/
80 °C
(176 °F)

2S-3230
Bearing
Lubricant

Every 2000 service hours or 12 months 51.2 g
(1.8 oz)

59 mL (2 oz)

75.0 mm
(3.0 inch)

450

−29 °C
(−20.2 °F)
/
80 °C
(176 °F)

2S-3230
Bearing
Lubricant

Every 2000 service hours or 12 months 51.2 g
(1.8 oz)

59 mL (2 oz)

100.0 mm
(3.9 inch)

597

−29 °C
(−20.2 °F)
/
80 °C
(176 °F)

2S-3230
Bearing
Lubricant

Every 2000 service hours or 12 months 51.2 g
(1.8 oz)

59 mL (2 oz)

90.0 mm
(3.5 inch)

75.0 mm
(3.0 inch)
ID
261-3545
Bearing

307 BB
80.0 mm
(3.1 inch)
OD
35.0 mm
(1.4 inch)
ID

262-5921
Bearing

307 BC
80.0 mm
(3.1 inch)
OD
35.0 mm
(1.4 inch)
ID

263-0161
Bearing

309 BC
100.0 mm
(3.9 inch)
OD
45.0 mm
(1.8 inch)

5P-2448
Ball Bearing

315 BC
160.0 mm
(6.3 inch)
OD
75.0 mm
(3.0 inch)
ID

6Y-3955
Ball Bearing

220 BC
180.0 mm
(7.1 inch)
OD
100.0 mm
(3.9 inch) ID

6Y-6488
Ball Bearing

318 BC
190.0 mm
(7.5 inch)
OD
90.0 mm
(3.5 inch)

(continued)

SEBU7878-03

125
Maintenance Section
Generator Bearing - Replace

(Table 20, contd)

Bearing
Part
Number

Bearing
Type

Frame
Size

Temperature
Min/Max(1)

Grease
Part
Number

Interval

Weight

Volume

Shaft
Diameter

311-0843
Ball Bearing

326 BC
280.0 mm
(11.0 inch)
OD

1800
FR

−40 °C
(−40 °F)
/
80 °C
(176 °F)

EA6

Nonregreasable bearing(1) Nonregreasable bearing Nonregreasable bearing 130.0 mm
(5.1 inch)

1600
FR

−40 °C
(−40 °F)
/
80 °C
(176 °F)

EA6

Nonregreasable bearing(1) Nonregreasable bearing Nonregreasable bearing 110.0 mm
(4.3 inch)

1400
FR

−29 °C
(−20.2 °F)
/
80 °C
(176 °F)

UNIREX
N3

Nonregreasable bearing(1) Nonregreasable bearing Nonregreasable bearing 100.0 mm
(3.9 inch)

498/499

−29 °C
(−20.2 °F)
/
80 °C
(176 °F)

2S-3230
Bearing
Lubricant

Every 2000 service hours or 12 months 51.2 g
(1.8 oz)

59 mL (2 oz)

90.0 mm
(3.5 inch)

130.0 mm
(5.1 inch) ID
311-0844
Ball Bearing

322 BC
240.0 mm
(9.4 inch)
OD
110.0 mm
(4.3 inch) ID

253-9789
Bearing

320 BC
215.0 mm
(8.5 inch)
OD
100.0 mm
(3.9 inch) ID

193-4070
Ball Bearing

018 BC
140.0 mm
(5.5 inch)
OD
90.0 mm
(3.5 inch)
ID

(1)

This temperature is for a generator set that is equipped with a resistive temperature detector (RTD).
Do not exceed 60 °C (140 °F) above the ambient temperature.
(3) This bearing can not be greased. Refer to this Operation and Maintenance Manual, “Generator Bearing - Replace” article for information concerning the replacement of these bearings.
(2) Do not exceed 50 °C (122 °F) above the ambient temperature.
(2)

5. Wipe off the excess grease. Remove the top grease ﬁtting. Install the plug.
6. Operate the generator for one hour. This 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. i03098183

Generator Bearing - Replace
(SR5 Generator Bearings)
SMCS Code: 4471-510

Standard Usage

7. Stop the engine. Install the plug in the bottom grease pipe. Wipe off the excess grease.

Caterpillar recommends replacement of the generator bearing at the major overhaul unless the generator is installed in any of the following conditions:

8. Install the louver assembly or install the rear plate.

• High temperature environment (refer to the temperature chart in this Operation and
Maintenance Manual, “Generator Bearing Lubricate” article.

• Condensing humidity
• Coastal environment

126
Maintenance Section
Generator Bearing Temperature - Test/Record

SEBU7878-03

• Chemical environment
• Abrasive environment
If any of these conditions exist, consult your
Caterpillar dealer for the appropriate checks:

• alignment
• environmental
• environmental
• exercising the generator
• temperature
• vibration

Standby Usage
The generator bearings are shielded and greased for the life of the bearing. Some purging of the grease occurs normally with the bearings. Carefully adhere to the recommendations for the following conditions: temperature, vibration, contamination, and alignment.
Over time, the bearing grease may deteriorate.
This deterioration may cause the grease to loose lubricating properties.
Caterpillar recommends the replacement of the bearing after ten years of service in a standby application in normal conditions. If the bearing is installed in the following conditions, Caterpillar recommends replacement of the bearing in 5 years.

• High temperature environment (Refer to

the temperature chart in this Operation and
Maintenance Manual, “Generator Bearing Lubricate” article.

• Condensing humidity
• Coastal environment
• Chemical environment

i03642839

Generator Bearing
Temperature - Test/Record
SMCS Code: 4471-081-TA
The monitoring of bearing temperature may prevent premature bearing failure. A generator set should never operate above the recommended set points.
Keep records in order to monitor the changes in the temperature of the bearing.
Note: Measure the bearing temperature after the generator reaches normal operating temperature.

Resistive Temperature Detectors
(RTDs)
Caterpillar Generators may be equipped with resistance temperature detectors for generator bearings. These detectors are 100 ohm resistance temperature detectors. A resistance temperature detector may be monitored by the optional monitor for the EMCP 3.2/3.3 resistance temperature detector. A resistance temperature detector may be monitored by equipment that is provided by the customer. Consult with your Caterpillar dealer about other methods of measuring the bearing temperature.
The EMCP 3.2/3.3 may be conﬁgured to “ALARM” or the EMCP 3.2/3.3 may be conﬁgured to
“SHUTDOWN”. An alarm is activated if the temperature of the bearing reaches 85 °C (185 °F).
A shutdown occurs if the temperature of the bearing reaches 95 °C (203 °F).

Infrared Thermometers
Bearing temperatures can also be recorded with the use of an infrared thermometer. Refer to Special
Publication, NENG2500, “Caterpillar Dealer Service
Tools Catalog” for a variety of infrared thermometers.
Follow the instructions that come with your infrared thermometer. • Abrasive environment

i02517207

Generator Lead - Check
SMCS Code: 4450-535
The generator set may have braided cables between the generator and the breaker instead of wire cables.
Check for signs of wear along the braided cables.
Pay particular attention to the cables at the housing for the breaker and the generator terminal box.

SEBU7878-03

127
Maintenance Section
Generator Load - Check

If the rubber mats or the insulation on the braided cables show signs of wear at points of contact with other surfaces, replace the mats or the cable immediately. If your generator set does not have rubber mats in place, contact your Caterpillar dealer.

i02377583

Generator Set - Test
SMCS Code: 4450-081

i01878834

Generator Load - Check
SMCS Code: 4450-535-LA

Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
During normal operation, monitor the power factor and monitor generator loading.
When a three-phase generator is installed or when a three-phase generator is reconnected, ensure that the total current in any one phase does not exceed the nameplate rating. Each phase should carry the same load. 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. The power factor can be referred to as the efﬁciency of the load. This can be expressed as the ratio of kVA to actual kW. The power factor can be calculated by dividing kW by kVA. Power factor is expressed as a decimal. Power factor is used to mean the portion of current that is supplied to a system that is doing useful work. The portion of the current that is not doing useful work is absorbed in maintaining the magnetic ﬁeld in motors. This current (reactive load) can be maintained without engine power.

DANGER: Shock/Electrocution Hazard-Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death. Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
When servicing or repairing electric power generation equipment:

• Make sure the unit is off-line (disconnected

from utility and/or other generators power service), and either locked out or tagged DO
NOT OPERATE.

• Make sure the generator engine is stopped.
• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
Table 21

Tools Needed
Part Number

Part

Quantity

237-5130

Digital
Multimeter

1

12 VDC battery

1

Potential
Transformer

1

128
Maintenance Section
Generator Set Alignment - Check

SEBU7878-03

The generator set functional test is a simpliﬁed test that can be performed in order to determine if the generator is functional. The generator set functional test should be performed on a generator set that is under load.

• Special Instruction, SEHS7654, “Alignment -

The generator set functional test determines if the following statements happen:

• Special Instruction, REHS0177, “Alignment of the

• A phase voltage is being generated.

Keep a record of the measurement of the alignment.
The record may be used to check the trend of the alignment. The record may be used to analyze the trend of the alignment.

• The phase voltages are balanced.
• The phase voltages change relative to engine speed. The generator set functional test consists of the following steps:
1. Stop the generator. Connect the potential transformer's high voltage winding to the generator terminals (T1) and (T2). Connect the voltmeter to the low voltage winding. If two transformers are available, connect the high voltage winding of the second transformer to the generator terminals (T1) and (T3). Connect the secondary terminals that correspond to generator terminal (T2) of both transformers together.

General Instructions”

• Special Instruction, SEHS7259, “Alignment of
Single Bearing Generators”

Close Coupled Two Bearing Generators”

The genset must be aligned when the genset is moved into a ﬁnal position. The genset must be aligned if the genset is moved into a different position. i02291365 Generator Set Vibration Inspect
SMCS Code: 4450-040-VI
Excessive vibration will indicate a problem with the generator set. The vibration may be caused by the following: 2. Disconnect wires “E+” and “E-” from the voltage regulator. Disconnect the generator from the load.

• Misalignment of the coupling between the engine

3. Connect a 12 VDC automotive battery to wires
“E+” and “E-”.

• Faulty mounting or play in the coupling

4. Measure the AC voltage across the low voltage terminals of the transformer that correspond to the following generator terminals: “T1” and “T2”, “T2” and “T3”, and “T3” and “T1”. Record the voltages. i03100396 Generator Set Alignment Check
(Generator Sets)

and the generator

• Incorrect balancing of the generator shaft or engine crankshaft • A three-phase generator has too much load on a single phase.

• There is a short circuit in the stator.
Check for vibration damage. Vibration may cause the following problems:

• loose ﬁttings

SMCS Code: 7002-024

• loose bolts

The alignment between the engine and the driven equipment must be properly maintained in order to minimize the following problems:

• excessive noise

• Bearing problems
• Vibration of the engine crankshaft
• Vibration of the driven equipment
Refer to the following information for more information about the alignment of the generator set:

• cracked insulation
The following areas are susceptible to vibration damage: • stator output leads
• protective sleeving
• insulation

SEBU7878-03

129
Maintenance Section
Generator Set Vibration - Test/Record

• exposed electrical connections
• transformers
• fuses
• capacitors
Check the generator set's vibration level by using a broad spectrum analyzer. i03643886 Generator Set Vibration Test/Record
SMCS Code: 4450-081-VI
Check for vibration damage.
Vibration may cause the following problems:

• Coupling wear
• Loose ﬁttings
• Fatigue of the metal components of the engine

When a generator set is installed, a vibration plot should be recorded in order to assist in diagnosing potential problems. This vibration plot should be updated yearly. The vibration plot should also be updated when the generator set is moved and when the engine is overhauled. This will allow the trend of the vibration to be monitored and analyzed. A potential problem may be prevented by monitoring the trend of the vibration. If the vibration is approaching the limit of the speciﬁcation of the component, the problem may be more imminent.
Refer to Data Sheet, LEKQ4023, “Linear Vibration” for the allowable limits of vibration.
Caterpillar also recommends recording the vibration of the bearing at the generator bearing bracket.
If the vibration exceeds the EDS limits for vibration, check the alignment. Refer to this Operation and
Maintenance Manual, “Generator Set Alignment Check” for the alignment procedure.
Contact the Caterpillar Dealer Service Tools group for information on ordering a vibration analyzer that will meet your needs. i02121526 • Cracks in the cabinet which surrounds the

Hoses and Clamps Inspect/Replace

• Cracks in welds

SMCS Code: 7554-040; 7554-510

• Excessive noise

Inspect all hoses for leaks that are caused by the following conditions:

generator

• Cracked insulation
The following areas are susceptible to vibration damage: • Cracking
• Softness

• Coupling for the generator set

• Loose clamps

• Generator bearings

Replace hoses that are cracked or soft. Tighten any loose clamps.

• Stator output leads
• Protective sleeving
• Insulation
• Exposed electrical connections
• Transformers

NOTICE
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause ﬁres. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.

• Fuses

Check for the following conditions:

• Capacitors

• End ﬁttings that are damaged or leaking

• Lightning arresters

• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement

130
Maintenance Section
Instrument Panel - Inspect

• Outer covering that is ballooning locally

SEBU7878-03

• Flexible part of the hose that is kinked or crushed

Note: Refer to the Speciﬁcations, SENR3130,
“Torque Speciﬁcations” in order to locate the proper torques. • Armoring that is embedded in the outer covering

8. Reﬁll the cooling system.

A constant torque hose clamp can be used in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp. 9. Clean the cooling system ﬁller cap. Inspect the cooling system ﬁller cap's gaskets. Replace the cooling system ﬁller cap if the gaskets are damaged. Install the cooling system ﬁller cap.

Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.

10. Start the engine. Inspect the cooling system for leaks. Each installation application can be different. The differences depend on the following factors:

Instrument Panel - Inspect

• Type of hose

i02365179

SMCS Code: 7451-040

• Type of ﬁtting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the ﬁttings Replace the Hoses and the Clamps

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller cap.
Note: Drain the coolant into a suitable, clean container. The coolant can be reused.

Illustration 82

3. Drain the coolant from the cooling system to a level that is below the hose that is being replaced.

(1) Electronic Control Module

4. Remove the hose clamps.

(2) Control Panel

5. Disconnect the old hose.

(3) Annunciator Panel

6. Replace the old hose with a new hose.
7. Install the hose clamps with a torque wrench.

Rear View of the Genset

g01186363

SEBU7878-03

131
Maintenance Section
Insulation - Test

Inspect each component of the panel in order to ensure that the components are in good condition before testing each individual component. For more complete testing information, see Systems
Operation, Troubleshooting, Testing and Adjusting,
RENR7902, “EMCP 3”.

Annunciator Panel

Electronic Control Module

Illustration 83

g01184041

The Lamp Test button is located on the top right side of the electronic control module. Press and hold the Lamp Test button in order to test all of the LED lights and the display screen. The LED lights and the display screen should remain on until the button is released. If any of the components do not pass this test, replace the faulty components before starting the engine.

Illustration 85

g01101388

It is possible to test the LED indicators and the horn when the data link is connected and when the data link is not connected. The Lamp Test button is located near the top of the annunciator panel. Test both the horn and the indicators by pressing and holding the
Lamp Test button. Replace any faulty components before starting the engine. i01951994 Insulation - Test

Control Panel

SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081

Recommended Periodic Insulation
Tests

The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Illustration 84

g01185966

Toggle the panel light switch in order to test the panel lights. Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.

132
Maintenance Section
Insulation - Test

Table 22

Tools Needed

SEBU7878-03

Recommended Procedure for A
Periodic Insulation Test

142-5055 Insulation Testing Gp
9U-6003 Insulation Testing Gp

Periodically, use an insulation tester to check the insulation resistance of the generator's main stator winding. The frequency of this test is determined by the generator's environment. Previous insulation tester readings will also determine the frequency of this test.

Personal injury or death can result from electrocution.
The megohmmeter is applying a high voltage to the circuit.

Test the main stator windings with an insulation tester in the following situations:

To avoid electrocution, do not touch the instrument leads without ﬁrst discharging them. When ﬁnished testing also discharge the generator windings. • The generator set is started for the ﬁrst time.

1. Take the generator out of service.

• The generator set is removed from storage.
• The generator set is operating in a humid environment. Test every three months.

• The generator set is not protected from the

elements in an enclosed area. Test every three months. • The generator set is installed in an enclosed area.

This area needs to be low in humidity and this area needs to have steady temperatures. Test every twelve months (minimum).

• The generator set has not been run under load

for three months. Test the generator set weekly.
Use space heaters around the generator set if the generator is exposed to a sea water environment or if the humidity is above 75 percent. Also use space heaters if a test result was below 3 megohms.

Space heaters must be used whenever the generator set is not under load. Space heaters must also be used whenever salt is present or whenever high humidity is present. Using a space heater in this fashion is the only way to maintain insulation tester readings above one megohm. Use space heaters only when the generator is not running.
For additional information, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.

2. Visually inspect the generator for moisture. If moisture exists, do not perform this insulation test. Dry the unit ﬁrst. Refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
3. Inspect the installation. Determine the equipment that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Isolate the stator windings of the generator by disconnecting all other leads and cables from the generator terminals. This includes connections to the voltage regulator, the control panel, the switchgear or other devices.
6. Connect the insulation tester's RED lead to ground. 7. Connect the insulation tester's BLACK lead to the wye point or star point of the generator's windings.
8. For units that are 600 volts or less, set the voltage to 500 Volts. For units that are more than 600 volts, set the voltage to 1000 Volts.
9. Use the 30/60 Time Resistance Method:
a. Apply voltage.
b. Observe the readings at 30 seconds. Observe the readings at 60 seconds.
c. Record the 60 second reading. This reading must be corrected for temperature.
d. Record temperature.
e. Record humidity.
f. Remove voltage.

SEBU7878-03

10. Evaluate the readings. The actual value of the resistance may vary greatly between generators.
For this reason, the insulation's condition must be evaluated. Base this evaluation on the comparison between the 60 second resistance readings and the readings that were taken on previous dates.
These two readings must be taken under similar conditions. If a 60 second resistance reading has a 50 percent reduction from the previous reading, the insulation may have absorbed too much moisture.
Switch the insulation tester to the “OFF” position.
This will discharge the insulation tester's leads.
Disconnect the insulation tester's leads.
Note: The results from the insulation resistance checks indicate when cleaning and/or repairing is becoming critical. Generally, insulation resistance will vary greatly with temperature. Therefore, always test at the same temperature and humidity. Refer to
Illustration 86.
Serial Number (Engine)_________
__________________________
Serial Number (Generator)_________
______________________

133
Maintenance Section
Insulation - Test

134
Maintenance Section
Insulation - Test

Illustration 86

SEBU7878-03

g00633226

SEBU7878-03

135
Maintenance Section
Jacket Water Heater - Check

i03230758

Jacket Water Heater - Check
SMCS Code: 1383-535
Jacket water heaters help to improve startability in ambient temperatures that are below 21 °C (70 °F).
All installations that require automatic starting should have jacket water heaters.
Check the operation of the jacket water heater. Check the operation of the circulation pump, if equipped. For an ambient temperature of 0 °C (32 °F), the heater should maintain the jacket water coolant temperature at approximately 32 °C (90 °F). i02378613 Overhaul Considerations
SMCS Code: 7595-043
Reduced hours of operation at full load will result in a lower average power demand. A decreased average power demand should increase both the engine service life and the overhaul interval.
The need for an overhaul is generally indicated by increased fuel consumption and by reduced power.
The following factors are important when a decision is being made on the proper time for an engine overhaul: • The need for preventive maintenance
• The quality of the fuel that is being used
• The operating conditions
• The results of the S·O·S analysis

Oil Consumption as an Overhaul
Indicator
Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals.
Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases.

The oil consumption rate (brake speciﬁc oil consumption) is measured in grams per kW/h (lb per bhp). The brake speciﬁc oil consumption (BSOC) depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine.
When an engine's oil consumption has risen to three times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby and a slight increase in fuel consumption.

Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best value for the following reasons:

• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the standards for reusable parts.

• The engine's service life can be extended without the risk of a major catastrophe due to engine failure. • The best cost/value relationship per hour of extended life can be attained.

After Failure Overhaul
If a major engine failure occurs and the engine must be removed from the hull, many options are available.
An overhaul should be performed if the engine block or the crankshaft needs to be repaired.
If the engine block is repairable and/or the crankshaft is repairable, the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core.
This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features
• Caterpillar dealer exchange components
• Caterpillar Inc. remanufactured exchange components Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. This will provide you with the best cost/value relationship.

136
Maintenance Section
Overhaul Considerations

Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for speciﬁc information about the available overhaul programs and about overhaul services for extending the engine life.
If an overhaul is performed without overhaul service from your Caterpillar dealer, be aware of the following maintenance recommendations.

SEBU7878-03

• Thrust bearings
• Main bearings
• Rod bearings
• Valve rotators
• Crankshaft seals

Rebuild or Exchange

Caterpillar Inc. recommends the installation of new parts at each overhaul period.

Cylinder Head Assembly, Cylinder Packs, Oil
Pump, and Fuel Transfer Pump

Inspect these parts while the engine is disassembled for an overhaul.

These components should be inspected according to the instructions that are found in various Caterpillar reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are needed for inspecting the engine parts.

Inspect the crankshaft for any of the following conditions: If the parts comply with the established inspection speciﬁcations that are expressed in the reusable parts guideline, the parts should be reused.

• Deﬂection
• Damage to the journals
• Bearing material that has seized to the journals

Parts that are not within the established inspection speciﬁcations should be dealt with in one of the following manners:

Check the journal taper and the proﬁle of the crankshaft journals. Check these components by interpreting the wear patterns on the following components: • Salvaging

• Rod bearing

• Repairing

• Main bearings

• Replacing

Note: If the crankshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the crankshaft.

Using out-of-spec parts can result in the following problems: • Unscheduled downtime
• Costly repairs
• Damage to other engine parts
• Reduced engine efﬁciency
• Increased fuel consumption
Reduced engine efﬁciency and increased fuel consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing out-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement
Crankshaft Bearings, Valve Rotators, and
Crankshaft Seals
The following components may not last until the second overhaul.

Inspect the camshaft for damage to the journals and to the lobes.
Note: If the camshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the camshaft.
Inspect the following components for signs of wear or for signs of scufﬁng:

• Camshaft bearings
• Camshaft followers
Caterpillar Inc. recommends replacing the crankshaft vibration damper.
Oil Cooler Core and Aftercooler Core
During an overhaul, Caterpillar Inc. recommends the removal of both the oil cooler core and the aftercooler core. Clean the oil cooler core and the aftercooler core. Then, pressure test both of these cores.

SEBU7878-03

137
Maintenance Section
Overhaul Considerations

NOTICE
Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the core and cause leakage.
Note: Use this cleaning procedure to clean the oil cooler core and the aftercooler core.
1. Remove the oil cooler core and the aftercooler core. 2. Remove any debris from the oil cooler core and the aftercooler core. To remove debris from the oil cooler core, turn the oil cooler core onto one end.
To remove debris from the aftercooler core, turn the aftercooler core upside-down.
3. Flush the oil cooler core and the aftercooler core internally with cleaner in order to loosen foreign substances. This will also help to remove oil from the oil cooler core and the aftercooler core.
Note: Caterpillar Inc. recommends the use of
Hydrosolv Liquid Cleaners. Table 23 lists the
Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer.
Table 23

Hydrosolv Liquid Cleaners(1)
Part
Number

Description

1U-5490

Hydrosolv 4165

19 L (5 US gallon)

174-6854

Hydrosolv 100

19 L (5 US gallon)

(1)

Size

Use a two to ﬁve percent concentration of the cleaner at temperatures up to 93°C (200°F).

4. Use steam to clean the oil cooler core and the aftercooler core. This removes any remaining residue from the cleaner. Flush the ﬁns of the oil cooler core and the aftercooler core. Remove any other trapped debris.
5. Wash the oil cooler core and the aftercooler core with hot, soapy water. Rinse the oil cooler core and the aftercooler core thoroughly with clean water.

6. Dry the oil cooler core and the aftercooler core with compressed air. Direct the air in the reverse direction of the normal ﬂow.
7. Inspect the components in order to ensure cleanliness. The oil cooler core and the aftercooler core should be pressure tested. Repair the oil cooler core and the aftercooler core, if necessary.
Install the oil cooler core and the aftercooler core.
For more information about cleaning the cores, consult your Caterpillar dealer.

Obtain Coolant Analysis
The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or with S·O·S Coolant Analysis (Level 1). Further coolant analysis is recommended when the engine is overhauled.
For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals that were deposited on the engine over time.
A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. Private laboratories are also available for water analysis.
Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2).
S·O·S Coolant Analysis (Level 2)
An S·O·S Coolant Analysis (Level 2) is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system. An S·O·S Coolant Analysis (Level 2) provides the following information:

• Complete S·O·S Coolant Analysis (Level 1)
• Visual inspection of properties
• Identiﬁcation of metal corrosion
• Identiﬁcation of contaminants

Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

• Identiﬁcation of built up impurities (corrosion and scale) S·O·S Coolant Analysis (Level II) provides a report of the results of both the analysis and the maintenance recommendations. 138
Maintenance Section
Power Factor - Check

SEBU7878-03

For more information about coolant analysis, see your Caterpillar dealer. i01216962 Power Factor - Check
SMCS Code: 4450-535-PWR
The power factor of a system can be determined by a power factor meter or by calculations. The power factor can be calculated by dividing kW by kVA.
Power factor is expressed as a decimal.

After cleaning, start the engine. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.
Inspect the ﬁns for damage. Bent ﬁns may be opened with a “comb”. Inspect these items for good condition: welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.
For more detailed information on cleaning and inspection, refer to Special Publication, SEBD0518,
“Know Your Cooling System”.

i02372787

Radiator - Clean
SMCS Code: 1353-070

i01880286

Rotating Rectiﬁer - Check
SMCS Code: 4465-535

Note: Adjust the frequency of cleaning according to the effects of the operating environment.
Inspect the radiator for these items: damaged ﬁns, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.

Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the fan's air ﬂow. Hold the nozzle approximately
6 mm (0.25 inch) away from the ﬁns. Slowly move the air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides.
Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
Check the exciter armature. Ensure that the rotating rectiﬁer is tight. If a failure of a rectiﬁer is suspected, refer to Maintenance Procedure, “Rotating Rectiﬁer Test”. i01936391 Rotating Rectiﬁer - Test
SMCS Code: 4465-081

The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.

SEBU7878-03

139
Maintenance Section
Space Heater - Check

Use the following procedure in order to test the rotating rectiﬁer.
1. Stop the generator set. Disconnect the wires for the AVR and isolate the wires for the AVR.
2. Make an assembly for separate excitation. The assembly can use a 12 volt battery or a variable
DC power supply as a power source. Refer to
Step 3 for an assembly that uses a 12 Volt battery.
Refer to Step 4 for an assembly that uses a variable DC power supply.

5. The assembly should have characteristics that are compatible with the power for the ﬁeld excitation of the generator.
6. Operate the generator set at rated speed.
7. Gradually increase the current of the exciter ﬁeld by adjusting the rheostat or the variable power supply. Measure the output voltage and the current at no load. Measure the output voltage and measure the current at no load.
8. The generator is operating properly when the output voltage is at the rated value and the output voltage is balanced within one percent for the rated level of excitation. i02985289 Space Heater - Check
SMCS Code: 4450-535-HTR
The space heater is attached to the rear bearing bracket. The space heater is located in the generator's exciter end.
Illustration 87

g01015807

(A) Exciter Field
(B) Diode (1 Amp)
(C) Rheostat (50 Ohms 300 Watts)

3. Connect a 12 volt battery in series with a rheostat
(C) of “50 Ohms 300 Watts” and a diode (B) on both wires for the exciter ﬁeld (5+ and 6-). Go to step 5.

Illustration 89

g00610396

Space Heater Connection Diagram

Illustration 88

g01015808

(D) AC supply
(E) Variable power supply
(F) Exciter ﬁeld
(G) Diode bridge

4. Connect a variable power supply and a diode bridge to both of the wires for the exciter ﬁeld (5+) and (6-).

An SR5 generator can operate in high humidity conditions without problems. The humidity can be as high as 100% non-condensing humidity. However, problems can occur when the generator is idle and the surrounding air is warmer than the generator.
Moisture can form on the windings. Moisture will result in poor performance or even damage to the windings. Whenever the generator is not active, the optional space heaters should be operated.
An external source is required to operate the space heaters. Both of the sources must be a single phase.
This source can be either 115 vac or 230 vac. When the external source is 50 hertz, 200 vac must be used. Refer to Illustration 89.

140
Maintenance Section
Standby Generator Set Maintenance Recommendations

See your Caterpillar dealer for information on checking your Caterpillar generator. i03108463 Standby Generator
Set Maintenance
Recommendations
SMCS Code: 4450-041
A standby generator set may not need to be used very often. However, the generator set is usually needed for operation in an emergency situation.
Maintenance of the standby generator set is very important for the following reasons:

• The generator set must always be in excellent operating condition.

• The generator set must be ready to work under load at any time.

Establishing a Preventive Maintenance Program will provide these beneﬁts:

• Maximum availability of the standby generator set
• Longer service life for the generator set
• Minimum of expensive repairs
Your Caterpillar dealer can help you to establish an effective Preventive Maintenance Program for your generator set. Consult your Caterpillar dealer for details. Maintenance and Operation
Procedures

SEBU7878-03

Maintenance and Repair
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the subsequent maintenance intervals must be performed by an authorized service technician or by your Caterpillar dealer.
Unless other instructions are provided, perform maintenance and repairs under the following conditions: • The engine is stopped.
• The starting system is disabled.
• The generator does not pose an electrical shock hazard. • The generator is disconnected from the load.
Operation
To ensure proper operation, the generator set must be exercised regularly. For instructions on operating the generator set, see the Operation and Maintenance
Manual for the generator set control panel.
For these operation procedures, follow the instructions that are provided in this Operation and
Maintenance Manual, “Operation Section”: starting the engine, engine operation, and stopping the engine. Record Keeping
Maintain a record in order to document these items: gauge readings, maintenance that is performed, problems, and repairs.

Space Heaters
The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
The recommended maintenance for the generator set is listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule (Standby Generator
Sets)” (Maintenance Section).

Moisture causes damage to generators and other electrical equipment. Make every effort to keep the generator set as dry as possible.
Generators can operate without problems in humid environments. However, problems can occur when the generator is inactive. Moisture can condense on the windings. This can result in poor performance.
Also, damage to the windings can occur.
Use space heaters in order to help keep the windings dry. When the generator is not active, ensure that the space heaters are operating. When the generator is operating, turn OFF the space heaters.

SEBU7878-03

141
Maintenance Section
Starting Motor - Inspect

i00651416

i01539769

Starting Motor - Inspect

Turbocharger - Inspect

SMCS Code: 1451-040; 1453-040

SMCS Code: 1052-040; 1052

Caterpillar Inc. recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine may not start in an emergency situation.

Periodic inspection and cleaning is recommended for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are ﬁltered through the air inlet system. Therefore, by-products from oil and from combustion can collect in the turbocharger compressor housing. Over time, this buildup can contribute to loss of engine power, increased black smoke and overall loss of engine efﬁciency.

Check the starting motor for proper operation. Check the electrical connections and clean the electrical connections. Refer to the Service Manual for more information on the checking procedure and for speciﬁcations or consult your Caterpillar dealer for assistance. i03230840

Stator Lead - Check
SMCS Code: 4459-535
Ensure that the stator output leads are routed out of the generator in a manner that prevents the leads from rubbing against metal objects.
Visually inspect the following areas for cracking and physical damage:

• stator output leads
• protective sleeving
• insulation i02514961 Stator Winding Temperature Measure/Record
SMCS Code: 4453-082-TA
Some generators are provided with optional 100 Ohm
Resistance Temperature Detectors (RTD). When the temperature of the stator winding is suspected to be high, measure the temperature. If the generator is furnished with Resistance Temperature Detectors, the detectors are installed in the slots of the main armature (stator). The detectors are used with equipment that is available from the factory. This equipment is used in order to measure the main armature's winding temperature.

If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder head. NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine damage. Minor leakage of a turbocharger housing under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occurred.
When a turbocharger bearing failure is accompanied by a signiﬁcant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is repaired or replaced. An inspection of the turbocharger can minimize unscheduled downtime. An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts.
Note: Turbocharger components require precision clearances. The turbocharger cartridge must be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent inspections of the cartridge.

Removal and Installation
For options regarding the removal, installation, repair and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the procedure and speciﬁcations.

142
Maintenance Section
Varistor - Check

SEBU7878-03

Cleaning and Inspecting

i03291802

1. Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger. Visually inspect the piping for the presence of oil. Clean the interior of the pipes in order to prevent dirt from entering during reassembly.
2. Turn the compressor wheel and the turbine wheel by hand. The assembly should turn freely. Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing. If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing, the turbocharger must be reconditioned.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt and/or moisture is passing through the air ﬁltering system. If oil is found only on the back side of the wheel, there is a possibility of a failed turbocharger oil seal.
The presence of oil may be the result of extended engine operation at low idle. The presence of oil may also be the result of a restriction of the line for the inlet air (plugged air ﬁlters), which causes the turbocharger to slobber.
4. Use a dial indicator to check the end clearance on the shaft. If the measured end play is greater than the Service Manual speciﬁcations, the turbocharger should be repaired or replaced.
An end play measurement that is less than the minimum Service Manual speciﬁcations could indicate carbon buildup on the turbine wheel. The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual speciﬁcations.
5. Inspect the bore of the turbine housing for corrosion. Varistor - Inspect
SMCS Code: 4466-040
The varistor must be visually inspected at regular intervals. For generator sets with 1400 or with
1600 frames, discoloration of the varistor indicates that replacement of the varistor is necessary. For generator sets with 1800 frames, physical signs of failure indicate that replacement of the varistor is necessary. i01189996

Voltage and Frequency - Check
SMCS Code: 4450-535-EL
Check for proper voltage and frequency setting.
Check for stability.
Refer to the generator set Serial Plate for correct voltage and frequency. i02378188 Walk-Around Inspection
SMCS Code: 1000-040

Inspect the Engine for Leaks and for Loose Connections
A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:

6. Clean the turbocharger housing with standard shop solvents and a soft bristle brush.

• The guards must be in the proper place. Repair

7. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.

• Wipe all caps and plugs before the engine is

i03291822

Varistor - Check
SMCS Code: 4466-535
The varistor must be checked at regular intervals.
Refer to Systems Operation/Testing and Adjusting,
KENR5284, “Varistor - Test” for instructions.

damaged guards or replace missing guards.

serviced in order to reduce the chance of system contamination. NOTICE
For any type of leak (coolant, lube, or fuel) clean up the ﬂuid. If leaking is observed, ﬁnd the source and correct the leak. If leaking is suspected, check the ﬂuid levels more often than recommended until the leak is found or ﬁxed, or until the suspicion of a leak is proved to be unwarranted. SEBU7878-03

143
Maintenance Section
Water Pump - Inspect

• Check the condition of the led indicators. Replace
NOTICE
Accumulated grease and/or oil on an engine or deck is a ﬁre hazard. Remove this debris with steam cleaning or high pressure water.

• Ensure that cooling lines are properly clamped.

Check for leaks. Check the condition of all pipes.

• Inspect the water pump for coolant leaks.
Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract.
Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of water pump and the installation of water pump and/or seals, refer to the Service Manual for the engine or consult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil ﬁlters and the valve cover.

• Inspect the fuel system for leaks. Look for loose fuel line clamps.

• Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps.

• Inspect the alternator belt and the accessory drive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on the new belt could cause the belt to break.

• Drain the water and the sediment from fuel tanks

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

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed wires. any led indicators which are cracked.

Inspect the Insulation
A visual inspection should be initially directed at the areas that are most prone to damage and deterioration. The most prone areas to damage and deterioration are listed below:

• Ground Insulation. Ground insulation is insulation that is intended to isolate components that are carrying current from components that are not carrying current.

• Support Insulation. Support insulation is

usually made from one of the following items: a compressed lamination of ﬁbrous materials, polyester, or felt pads that have been impregnated with various types of bonding agents.

There are many different types of damage that can occur in these areas. Several of the different types of damage are listed below:
Thermal Aging – Thermal aging can cause the degradation of insulation or the deterioration of insulation. An examination of the coils may reveal that the insulation has expanded into the ventilation ducts. This is the result of a loss of bond which will cause the insulation material to separate. The insulation material could also separate from the conductors on the windings.
Abrasion – The surfaces of coils and the surfaces of connectors may be damaged by abrasion. These surfaces may also be damaged by contamination from other sources. An example of these sources would be chemicals or abrasive substances.
Cracking – Cracking of insulation may result from mechanical stress. The structure that is used to brace the stator winding will become loose if the problem is not corrected. Further mechanical damage or electrical damage may also result.
Erosion – Erosion can be caused when foreign substances rub against the surfaces of the insulation.

• Inspect the ground strap for a good connection and for good condition.

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

• Disconnect any battery chargers that are not

protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery.

i03543200

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

144
Maintenance Section
Winding - Test

SEBU7878-03

• A piston seizure
• Other potential damage to the engine
A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head, a piston seizure or other potential damage to the engine.

i03233061

Winding - Test
SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081

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 it is 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 Caterpillar dealer if repair is needed or replacement is needed.

g01388839

Illustration 90

PMPE Generator wiring diagram for the family of 1800 frames
(CR1-C6) Diodes
(CR7) Varistor
(L1) Exciter stator
(L2) Exciter rotor
(L3) Main rotor
(L4) Main stator
(L5) Permanent magnet generator (PMG) stator
(PM) Permanent magnet
(RFA) Rotating ﬁeld assembly
(CT1) Optional voltage droop transformer
(T0, T1, T2, T3, T7, T8, T9) Generator terminals
Table 24

Quantity

Needed Tool

1

Low ohmmeter

SEBU7878-03

145
Maintenance Section
Winding - Test

Measure the resistance of the following windings:
(L1), (L2), (L3), (L4), and (L5). The winding that is being tested must be disconnected from the other components before the resistance can be measured.
Note: The winding temperature affects the resistance. When the winding temperature increases, the winding resistance increases. When the winding temperature decreases, the winding resistance decreases. Therefore, a correct measurement can be performed only when the winding is at room temperature. The following resistance measurements are approximations. If the measured value is not near the listed approximation, the winding is probably damaged. For a more precise resistance value, consult the Technical Marketing Information (TMI).
Refer to the generator arrangement that is in question. The following windings have very little resistance:
(L2), (L4), and (L5). The resistance of these windings will measure near 0 ohms. Use a milliohmmeter to measure the resistance of the windings.
Exciter rotor (L2) – Refer to Table 25.
Main stator (L4) – less than 0.1 ohm
Pilot exciter stator (L5) – less than 0.1 ohm
Use a multimeter in order to measure the resistance of ﬁeld windings (L1) and (L3).
Exciter ﬁeld (stator) (L1) – Refer to table 25.
Main ﬁeld (rotor) (L3) – approximately 0.35 ohms to 1.2 ohms
Note: There should be no continuity between any winding and ground. There should be no continuity between any winding and another winding.
Table 25

L1 Exciter
Field

L2 Exciter
Rotor

Main Field for the Rotor

1800 Frame

10.9 ohms

0.05 ohms

.9 ohms

1600 Frame

10 ohms

0.06 ohms

.5 ohms

1400 Frame

11 ohms

0.06 ohms

.35 ohms

Similar Documents

Ceh Test Questions

Structure

Snort

Lokjmhnbvc

Rute Linux Tutorial

A Hands on Intro to Hacking

Mass Media

Pyplot

Introduction to Statistical Thought

Srs Template

Study Vba

Work, Culture and Identity in Mozambique and Southafrica 1860-1910

Supply Chain

Lulzking

International Finance

Popular Essays