SEBU7843-3408C&3412C Aux OMM

CATERPILLAR
t o andl
Ma\ntenanee
TAMI-Up (Generator Set)

RLR1-Up (Generator Set)
- -- - -
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
C
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or ,
pictorially presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannobanticipateevery possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time .that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
3
Table of Contents
s Table of Contents
Foreword ................................................................. 4
Refill Capacities ....................................................
Maintenance Recommendations .......................... 84

83
Maintenance Interval Schedule (34080 Engine) .. 88

Safety Section Maintenance Interval Schedule (3412C Engine) .. 89
Safety Messages ....................................................6 Reference lnformation Section
General Hazard Information ................................... 8
Engine Ratings ................................................... 128
Burn Prevention ..............................................
10
Customer Service ........................................ 130
Fire Prevention and Explosion Prevention ............10
Reference Materials ........................................ 132
Crushing Prevention and Cutting Prevention ........ 12
lndex Section
Mounting and Dismounting ................................... 12
Index .............................................................. 135
Before Starting Engine .......................................... 12
Engine Starting ..................................................... 13
Engine Stopping ................................................... 13
Generator Isolating for Maintenance ..................... 14
Product lnformation Section

D Model Views ......................................................... 15
Product Identification Information ........................20.

Operation Section
Lifting and Storage ................................................ 28
Installation............................................................. 30
Gauges and Indicators ........................................ 32
Features and Controls .......................................... 33
Engine Starting ..................................................... 42
Engine Operation .................................................. 47
Engine Stopping ............................................... 48

Cold Weather Operation ....................................... 50
Generator Operation ............................................55
Maintenance Section
Lubricant Specifications ........................................ 63
b ..
............................................
Fuel Spec~f~cations 69
Cooling System Specifications .............................71

4
Foreword
Foreword Use fuel consumption or service hours to determine

intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals
Literature Information if they provide more convenient schedules and
approximate the indicated service meter reading.
This manual contains safety, operation instructions,
lubrication and maintenance information. This Recommended service should be performed
manual should be stored in or near the engine area at the appropriate intervals as indicated in
in a literature holder or literature storage area. Read, the Maintenance lnterval Schedule. The actual
study and keep it with the literature and engine operating environment of the engine also governs
information. the Maintenance lnterval Schedule. Therefore,
under extremely severe, dusty, wet or freezing cold
English is the primary language for all Caterpillar operating conditions, more frequent lubrication and
publications. The English used facilitates translation maintenance than is specified in the Maintenance
and consistency in electronic media delivery. lnterval Schedule may be necessary.
Some photographs or illustrations in this manual The maintenance schedule items are organized
show details or attachments that may be different for a preventive maintenance management
from your engine. Guards and covers may have program. If the preventive maintenance program
been removed for illustrative purposes. Continuing is followed, a periodic tune-up is not required.
improvement and advancement of product design The implementation of a preventive maintenance
may have caused changes to your engine which are management program should minimize operating
not included in this manual. Whenever a question costs through cost avoidances resulting from
arises regarding your engine, or this manual, please reductions in unscheduled downtime and failures.
consult with your Caterpillar dealer for the latest
available information.
Maintenance Intervals
Safety Perform maintenance on items at multiples
of the original requirement. Each level and/or
This safety section lists basic safety precautions. individual items in each level should be shifted
In addition, this section identifies hazardous, ahead or back depending upon your specific
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance
maintenance practices, operation-and application.
We recommend that the maintenance schedules
be reproduced and displayed near the engine as
1I
and repair on this product. a convenient reminder. We also recommend that a
maintenance record be maintained as part of the
Operation engine's permanent record.
Operating techniques outlined in this manual are See the section in the Operation and Maintenance
basic. They assist with developing the skills and Manual, "Maintenance Records" for information
techniques required to operate the engine more regarding documents that are generally accepted
efficiently and economically. Skill and techniques as proof of maintenance or repair. Your authorized
develop as the operator gains knowledge of the Caterpillar dealer can assist you in adjusting your
engine and its capabilities. maintenance schedule to meet the needs of your
operating environment.
The operation section is a reference for operators.
Photographs and illustrations guide the operator Overhaul
through procedures of inspecting, starting,
operating and stopping the engine. This section
also includes a discussion of electronic diagnostic
information.
Major engine overhaul details are not covered in the
O~erationand Maintenance Manual except for the
inierval and the maintenance items in thai interval.
11
Major repairs are best left to trained personnel or
Maintenance an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
The maintenance section is a guide to engine programs. If you experience a major engine failure,
care. The illustrated, step-by-step instructions are there are also numerous after failure overhaul
grouped'by fuel consumption, service hours and/or options available from your Caterpillar dealer.
calendar time maintenance intervals. Items in the Consult with your dealer for information regarding
maintenance schedule are referenced to detailed these options.
instructions that follow.
5
Foreword
California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.
I"
Safety Section
Safety Messages
Safety Section
i01943602
Safety Messages
SMCS Code: 1000; 7405
Illustration 1 g01012141
There may be several specific safety signs on your Replace any sign that is damaged or missing. If
engine. The exact location and a description of the a sign is attached to a part of the engine that is
signs are reviewed in this section. Please become replaced, install a new sign on the replacement
familiar with all of the signs. part. Your Caterpillar dealer can provide new signs.
Ensure that all of the signs are legible. Clean the
signs or replace the signs if the words cannot be
read or if the illustrations are not visible. Use a
cloth, water, and soap for cleaning the signs. Do not Do not operate or work on this engine unless you
use solvents, gasoline, or other harsh chemicals. have read and understand the instructions and
Solvents, gasoline, or harsh chemicals could loosen warnings in the Operation and Maintenance Man-
the adhesive that secures the signs. The signs that ual. Failure to follow the instructions or heed the
are loosened could drop off of the engine. warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
7
Safety Section
Safety Messages
The safety signs that may be attached on the (2) Read the Manual
1 engine are illustrated and described below.
The warning label for reading the manual is located
(1) Pressurized System on the cover of the junction box.
This safety message is located near the front of the

expansion tank.
Do not operate or work on this engine unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Man-
Pressurized System: Hot coolant can cause seri- ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
' ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
any Caterpillar dealer for replacement manuals.
P r o ~ ecare
r is vour res~onsibilit~.
8
Safety Section
General Hazard lnformation
(3)Electrical Distribution
The safety message for an improper jumper cable
connection is located near the batteries.
Illustration 2 000104545
Do not allow unauthorized personnel on the engine

or around the engine when the engine is serviced.
Engine exhaust contains products of con;lbustion

which may be harmful to your health. Always
start the engine and operate the engine in a well
IMPROPER JUMPER CABLE CONNECTIONS CAN ventilated area. If the engine is in an enclosed area,
CAUSE EXPLOSION RESULTING IN PERSONAL vent the engine exhaust to the outside.
INJURY.
Cautiously remove the following parts:
BAlTERlES MAY BE LOCATED IN SEPARATE
COMPARTMENTS. WHEN USING JUMPER CA- Filler caps
BLES, ALWAYS CONNECT POSITIVE (+) CABLE
TO POSITIVE (+) TERMINAL OF BAlTERY CON- Grease fittings
NECTED TO STARTER SOLENOID AND NEGA-
TIVE (-) CABLE FROM EXTERNAL SOURCE TO Pressure taps
STARTER NEGATIVE (-) TERMINAL (IF MACHINE
NOT EQUIPPED WITH
~~-~ ~~ ...... STARTER NEGATIVE TER- Breathers
MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
PROCEDURE IN THE OPERATION MANUAL. Drain plugs
To help prevent spraying or splashing of pressurized

101159865 fluids, hold a rag over the part that is being
removed.
General Hazard lnformation
Use caution when cover plates are removed.
SMCS Code: 1000; 7405 Gradually loosen but do not remove the last two
bolts or nuts that are located at opposite ends of
Attach a "Do Not Operate" warning tag or a similar the cover plate or the device. Before removing the
warning tag to the start switch or to the controls last two bolts or nuts, pry the cover loose in order
before the engine is serviced or before the engine to relieve any spring pressure or other pressure.
is repaired. These warning tags (Tag, SEHS7332)
are available from your Caterpillar dealer. Attach the Wear a hard hat, protective glasses, and other
warning tags to the engine and to each operator protective equipment, as required.
control station. When it is appropriate, disconnect
the starting controls. When work is performed around an engine that
is operating, wear protective devices for ears in
order to help prevent damage to hearing.
Do not wear loose clothing or jewelry that can

snag on controls or on other parts of the engine
Ensure that all protective guards and all covers

are secured in place on the engine.
-
9
Safety Section
General Hazard Information
Never put maintenance fluids into glass Fluid Spillage

I containers. Glass containers can break.
Care must be used in order to ensure that the
Use all cleaning solutions with care. fluids are contained during the inspection, the
maintenance, the testing, the adjusting, and the
Report all necessary repairs. repair of the engine. Make provision to collect
the fluid with a suitable container before any
Unless other instructions are provided, perform compartment is opened or before any component
the maintenance under the following cond~t~ons: is disassembled. Refer to the Special Publication,
NENG2500. This publication explains the items that
The engine is stopped. Ensure that the engine are needed for collecting and for containing fluids
cannot be started. that are used in Caterpillar engines. Dispose of
fluids according to local regulations.
Disconnect the batteries when maintenance
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Asbestos Information
Tape the leads in order to help prevent sparks.
Cater~illareaui~mentand re~lacementoarts that
are shipped irom Caterpillar 'are asbestos free.
Do not attempt any repairs that are not Caterpillar recommends the use of only genuine
understood. Use the proper tools. Replace
Caterpillar replacement parts. Use the following
any equipment that is damaged or repair the
--, li..mrrn+ guidelines when any replacement parts that contain
tzqU'p1II~I
,I.
asbestos or debris that contains asbestos are
handled.
Pressurized Air and Water
The asbestos in these components is usually sealed
Pressurized air andlor water can cause debris or bonded in a resin. Handling these materials
and/or hot water to be blown out. This could result normally is not hazardous unless airborne dust that
in personal injury. contains asbestos is generated.
I When pressurized air is used for cleaning, wear Do not inhale dust that might be generated when
a protective face shield, protective clothing, and components that contain asbestos fibers are
protective shoes. handled. Inhaling this dust can be hazardous to
your health.
The maximum air pressure for' cleaning purposes
must be below 205 kPa (30 psi). The maximum If dust which may contain asbestos is present,
water pressure for cleaning purposes must be follow these guidelines:
below 275 kPa (40 psi).
Never use compressed air for cleaning
Always wear eye protection for cleaning the cooling
system. Avoid abrasion of materials that contain asbestos.
Fluid Penetration Use a wet method to clean up asbestos debris.

A vacuum cleaner that is equipped with a high
Always use a board or cardboard when the engine efficiency particulate air filter can also be used.
components are checked for leaks. Leaking fluid
that is under pressure can cause serious injury or Use exhaust ventilation when parts that contain
possible death. This includes leaks that are the size asbestos are machined.
of a pin hole.
Wear an approved respirator if there is no other
If fluid is injected into the skin, seek treatment way to control the dust.
immediately. Seek treatment from a doctor that is
familiar with this type of injury. Comply with applicable rules and regulations for
the work place. In the USA, use the Occupational
Safetv and Health Administration reauirements.
~ h e s eOSHA requirements can be found in "29
CFR 1910.1001".
Obey environmental regulations for disposal of

asbestos.
10
Safety Section
Burn Prevention
I
Stay away from areas that might have asbestos Any contact with hot coolant or with steam
particles in the air. can cause severe burns. Allow cooling system
components to cool before the cooling system is
Lines, Tubes, and Hoses drained.
I
Do not bend or strike high pressure lines. Do not Check the coolant level after the engine has
stopped and the engine has been allowed to cool. I
install lines, tubes, or hoses that are damaged.
Ensure that the filler cap is cool before removing
Repair any fuel lines, oil lines, tubes, or hoses that
the filler cap. The filler cap must be cool enough I
are loose or damaged. Leaks can cause fires.
to touch with a bare hand. Remove the filler cap
slowly in order to relieve pressure. 1
Inspect all lines, tubes and hoses carefully. Do I
not use bare hands to check for leaks. Always I
Cooling system conditioner contains alkali. Alkali
use a board or cardboard for checking engine
can cause personal injury. Do not allow alkali to
components for leaks. Tighten all connections to
contact the skin, the eyes, or the mouth.
the recommended torque.
Check for the following conditions: Oils

End fittings that are damaged or leaking Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to cohtact the
Outer covering that is chafed or cut skin. Also, do not allow hot components to contact
the skin.
Wire that is exposed in reinforced hose 1
I
I
Outer covering that is ballooning locally

Batteries
Electrolyte is an acid. Electrolyte can cause
II I
Flexible part of the hose that is kinked or crushed
Armoring that is embedded in the outer covering

personal injury. Do not allow electrolyte to contact
the skin or the eyes Always wear protective glasses
for servicing batteries. Wash hands after touching
04
the batteries and connectors. Use of gloves is
Ensure that all of the clamps, the guards, and the recommended.
heat shields are installed correctly. This will help
to prevent these effects: vibration, rubbing against
other parts, and excessive heat during operation. i01372262
Fire Prevention and Explosion

i01460768
Prevention
Burn Prevention
SMCS Code: 1000; 7405
SMCS Code: 1000; 7405
II
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or Illustration 3
to the engine contain hot coolant.
g007M"
All fuels, most lubricants, and some coolant mlxtures
are flammable.
04
11
Safety Section
Fire Prevention and Explosion Prevention
Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause deterioration. The hoses must be properly routed.
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after Oil filters and fuel filters must be properly installed.
an emergency shutdown. The filter housings must be tightened to the proper
torque.
Determine whether the engine will be operated in
an environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of

combustible gases, consult your Caterpillar dealer
for additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil,

and debris from the engine. Do not allow any
flammable materials to accumulate on the engine.
Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame. Illustration 4

Exhaust shields (if equipped) protect hot exhaust
Gases from a battery can explode. Keep any open
components from oil or fuel spray in case of a line, flames or sparks away from the top of a battery. Do
a hose, or a seal failure. Exhaust shields must be not smoke in battery charging areas.
installed correctly.
hever check [he bakery charge by pacing a meral
Do not weld on lines or tanks that contain flammable ooiecr across rhe terminal oosts. Use a votmerer or
fluids. Do not flame cut lines that contain flammable
fluid. Clean any such lines thoroughly with a
nonflammable solvent prior to welding or flame Improper jumper cable connections can cause
cutting.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
Wiring must be kept in good condition. All electrical instructions.
wires must be properly routed and securely
attached. Check all electrical wires daily. Repair any
Do not charge a frozen battery. This may cause
wires that are loose or frayed before you operate an explosion.
the engine. Clean all electrical connections and
tighten all electrical connections. The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
Eliminate all wiring that is unattached or recommended cables, connections, and battery
unnecessary. Do not use any wires or cables that box covers when the engine is operated.
are smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Fire Extinguisher
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly Make sure that a fire extinguisher is available. Be
maintained battery cables will help to prevent arcing familiar with the operation of the fire extinguisher.
or sparking. lnspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
12
Safety Section
Crushing Prevention and Cutting Prevention
Lines, Tubes and Hoses Chips or other debris may fly off objects when
objects are struck. Before objects are struck, ensure
Do not bend high pressure lines. Do not strike high that no one will be injured by flying debris.
pressure lines. Do not install any lines that are bent
or damaged.
101372247
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
Mounting and Dismounting
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not

SMCS Code: 1000; 7405
I
use your bare hand to check for leaks. Use a
board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Inspect the steps, the handholds, and the work
area before mounting the engine. Keep these items
clean and keep these items in good repair.
1
I
Mount the engine and dismount the engine only at

Replace the parts if any of the following conditions locations that have steps and/or handholds. Do not
are present: climb on the engine, and do not jump off the engine.
End fittings are damaged or leaking. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
Outer coverings are chafed or cut. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use
Wires are exposed. any controls as handholds.
Outer coverings are ballooning. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
Flexible part of the hoses are kinked. platform. Secure the climbing equipment so that the
equipment will not move.
Outer covers have embedded armoring.
Do not carry tools or supplies when you mount the
End fittings are displaced. engine or when you dismount the engine. Use a
hand line to raise and lower tools or supplies.
Make sure that all clamps, guards, and heat shields
are installed correctly. Duringengine operation, this
will help to prevent vibration, rubbing against other 101805780
parts, and excessive heat.
Before Starting Engine
i01359666 SMCS Code: 1000
Crushing Prevention and NOTICE
Cutting Prevention For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
SMCS Code: 1000; 7405 provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
Support the component properly when work air and/or fuel supply to the engine.
beneath the component is performed.
Unless other maintenance instructions are provided, Overspeed shutdown should occur automatically.
never attempt adjustments while the engine is If automatic shutdown does not occur, press the
running. emergency stop button in order to cut the fuel
and/or air to the engine.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
Inspect the engine for potential hazards.
I I
reinstall the guards. Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
Keep objects away from moving fan blades. The area is free of personnel.
fan blades will throw objects or cut objects.
If equipped, ensure that the lighting system for the
When objects are struck, wear protective glasses in engine is suitable for the conditions. Ensure that all
order to avoid injury to the eyes. lights work properly, if equipped.
13
Safety Section
Engine Starting
All protective guards and all protective covers must Do not inhale ether, and do not allow ether to
be installed if the engine must be started in order contact the skin. Personal injury could result.
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work Do not smoke while ether cylinders are changed.
around the parts carefully.
Use ether in well ventilated areas.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits Use ether with care in order to avoid fires
are provided in order to help prevent personal
injury. The circuits are also provided in order to help Keep ether cylinders out of the reach of
prevent engine damage. unauthorized persons.
See the Service Manual for repairs and for Store ether cylinders in authorized storage areas
adjustments. only.
Do not store ether cylinders in direct sunlight or at

iO1103904
temperatures above 49 'C (120 OF).
Engine Starting Discard the ether cylinders in a safe place. Do not
SMCS Code: 1000 puncture the ether cylinders. Do not burn the ether
cylinders.
If a warning tag is attached to the engine start
switch or to the controls, DO NOT start the engine i01462046
or move the controls. Consult with the person that
attached the warning tag before the engine is Engine Stopping
started.
SMCS Code: 1000
All protective guards and all protective covers must
be installed if the engine must be started in order Stop the engine according to the procedure in
to perform service procedures. To help prevent an the Operation and Maintenance Manual, "Engine
accident that is caused by parts in rotation, work . Stopping (Operation Section)" in order to avoid
around the parts carefully. overheating of the engine and accelerated wear of
the engine components.
Start the engine from the operator's compartment or
from the engine start switch. Use the Emergency Stop Button (if equipped)
ONLY in an emergency situation. Do not use the
Always start the engine according to the procedure Emergency Stop Button for normal engine stopping.
that is described in this Operation and Maintenance After an emergency stop, DO NOT start the engine
Manual, "Engine Starting" topic (Operation Section). until the problem that caused the emergency stop
Knowing the correct proced~rewill help to prevent has been corrected.
maior damaae to rhe enaine comoonents. Anowina
the' procedce will also 6elp to prevent personal
- Stop the engine if an overspeed condition occurs
injury. during the initial start-up of a new engine or an
engine that has been overhauled. This may be
To ensure that the ;acket water neater (if equ:pped) accomplished by shutting off the fuel supply to
anolor the lube oil heater (if eauiooea) is workina
properly, check the water 'tempeiature gauge
- the engine and/or shutting off the air supply to the
engine.
and the oil temperature gauge during the heater
operation. To stop an electronically controlled engine, cut the
power to the engine.
Engine exhaust contains products of combustion
that can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Ether,
Ether is poisonous and flammable.
14
Safety Section
Generator Isolating for Maintenance
i0122M91 8. Use an audiolvisual proximity tester in order to

verify that the generator is de-energized. This
Generator Isolating for tester must be insulated for the proper voltage
Maintenance rating. Follow all guidelines in order to verify that
the tester is operational.
SMCS Code: 4450
9. Determine that the generator is in a de-energized
When you service an electric power generation set condition. Add ground straps to the conductors
or when you repair an electric power generation or terminals. During the entire work period, these
set, follow the procedure below: ground straps must remain connected to the
conductors and to the terminals.
1. Stop the engine.
Illustration 5
2. Attach a "DO NOT OPERATE" or similar warning

tag to the engine prime mover starting circuit.
Disconnect the engine starting circuit.
3. Disconnect the generator from the distribution
system.
4. Lock out the circuit breaker. Attach a "DO NOT
OPERATE or similar warning tag to the circuit
breaker. Refer to the electrical diagram. Verify
that all points of possible reverse power flow
have been locked out.
5. Remove the fuses for the transformers for the
following circuitry:
power
8 sensing
8 control
6. Attach a "DO NOT OPERATE or similar warning
tag to the generator excitation controls.
7. Remove the cover of the generator's terminal
box.
Product Information
Section
Model Views
101972863
Model View Illustrations

SMCS Code: 1000
The following engine model views show typical

Generator Set features. The operator should
become familiar with the locations of these items.
Due to individual applications, your package may
appear different from the illustrations.
product Information Section
Model Views
~
II
Illustration 6 go1024205
3408C
(1) Generator (7) Governor control lever (13) Fuei filter
(2) Fuel priming pump (8) Manual shut off lever (14) Engine oil drains
(3) Exhaust (9)Lifting eye (15) Oil filters
(4) Crankcase breathers (10) Water inlets (16) Service meter
(5)Oil level gauge (1 1) Water outiets (17) Air filter
(6) Instrument panel (12) Fuel inlet
17
Product Information Section
Model Views
Illustration 7
3412C
(1) Generator (11) Water inlets
(2) Fuel filter (12) Water outlets
(3) Exhaust (13) Engine oil drain
(4) Fuel priming pump (14) Oil filters
(5) Crankcase breathers (15) Sewice meter
(6) Oil level gauge (16) Oil filler
(7) instrument panel (17) Air inlet
(8) Governor control lever (18) Air filter
(19j Sea water inlet
(20) Sea water outlet
18
Model Views
i01926181
Engine Description
SMCS Code: 1000
Engine lnformation
The 3408C Marine Auxiliary Generator Set is
powered by a V-8 engine. The 3412C Marine
Auxiliary Generator Set is powered by a V-12
engine. Both engines have direct fuel injection.
Engine Specifications
Illustration 9
Cylinder and valve locations
(A) lnlet valves
(B) Exhaust valves
Table 2
1 3412C Marine Auxiliarv Enaine S~ecifications I
Cylinders and
Arranaement
I Bore 1 137 mm (5.4 inch) I
I Stroke 1 165 mm (6.5 inch) I
Compression Ratio 16:25:1
@-- Asdiration
. .
I T and JWACIl)
go0299698
Illustration 8
Cylinder and valve locations
(A) lnlet valves I Firing Order 1 1-4-9-8-5-2-11-10-3-6-7-12 1
(B) Exhaust valves Rotation (flywheel end) I Counterclockwise
Table 1 (1) Turbocharged with a jacket water aftercooler
3408C Marine Auxiliary Engine Specifications

Cylinders and
Engine Service Life
Arrangement V8
Engine efficiency and maximum engine performance
Bore 137 mm (5.4 inch) depend on the adherence to proper application
Stroke 165 mm (6.5 inch) guidelines and the operation and maintenance
recommendations. In addition, use recommended
I Com~ressionRatio I 16:25:1 I fuels, coolants, and lubricants. Use this Operation
and Maintenance Manual as a guide for required
engine maintenance.
Expected engine life is generally dependent on the

average power that is demanded. The average
power that is demanded is based on the fuel
(1) Turbochargedwith a jacket water aftercooler consumption of the engine over a period of time.
For more information, refer to this Operation and
Maintenance Manual, "Overhaul Considerations"
topic.
19
Model Views
i01972407
I
Generator Description
SMCS Code: 4450
These brushless generators are used with the

following loads: mixed loads of motors and lights,
SCR-controlled equipment, computer centers,
installations of communications, and petroleum
drilling applications. The elimination of the brushes
in the field circuit reduces maintenance. The
elimination of the brushes in the field circuit
increases reliability. The elimination of brushes
provides a higher degree of protection in potentially
hazardous atmospheres.
The generator set packages can be utilized

for prime power generation or standby power
generation. The generator set packages can
be used in land based applications or marine
applications.
The generators have four poles. The generators

have six or twelve lead configurations. The
configuration depends on the frame size. The
generators are capable of producing electrical
power in either 50 Hz or 60 Hz applications.
20
Product ldentification lnformation
Product ldentification
lnformation
i01943614
Plate Locations and Film

Locations
SMCS Code: 1000
Engine ldentification
Caterpillar engines are identified with serial lilusiration 11
numbers, with performance specification numbers, (2) Engine information plate
and with arrangement numbers. In some of the
cases, modification numbers are used. These The following information is stamped on the
numbers are shown on the Serial Number Plate lnformation Plate: compression ratio, aftercooler
and the lnformation Plate that are mounted on the temperature, power (kilowatts and horsepower), full
engine. load rpm, and other information.
Caterpillar dealers need these numbers in order to
determine the components that were included with Generator ldentification
the engine. This permits accurate identification of
replacement part numbers. The generator identification and information plate is
located on the barrel of the generator.
Serial Number Plate
The Serial Number Plate is on the left side of the
cylinder block near the rear of the engine.
(3) Generator identification plate

(4) Generator serial number plate
go1003863 When service is required, the information that is

lllustration 10
given on this plate should be used. The generator
(1) Engine serial number plate identification and information plate includes the
following information: serial number, model number,
The following information is stamped on the Serial and the rating of the generator set. The generator
Number Plate: engine serial number, model, and set consists of the engine and a generator. All
arrangement number. pertinent generator data is also included on the
plate in order to provide the information that is
lnformation Plate necessary to order parts.
The Information Plate is on the right side rear valve

cover.
-
21
Product Identification Information
@b Emissions Certification Film

iO1830750
SMCS Code: 1000; 7405
1 Note: This information is pertinent in the United

States, in Canada and in Europe.
A typical example is shown.
WlERPILURIIC. IMfflRTMEWGIUElUWRMATIOU 2000 JDMOOOOI

u' ENGIHEMOOEL: a116 - OISPULCEMEHT:6,6L - VNYEUSH: 0.38mm WAKE O.64mm EXMUST
MU
m
l WWW WRmRLTt. OWWPT
RLTm LOW W MI
W
SPrm v*) m(IYIRPIS(SIM
MIS 3118 M P W C ( W P A I I S l O O ~ W E ¶ ~ K C H I R U L I I . R 0 1MOM%

0 CCTIPEBQMVNIII. I(ALAL¶6M.mMnDD
TMS 3118 M ~ C O F O R I S T O ~ W ~ U ~ . T P I U ~ U U ~ R Y U R T O U U ~ ~ Y S ~ ~ ~ ~ X I L D C ~ ~ R T S S I ~ Y I P M D Y ~ ~ ~ .
lWOmYIISEWnRDlDOPWI~OUCO~MUYAVIIUN01LOaRR.
OI~OF~YURLMREMPUM: 08 lrnm n
@ The EPA/EU Emissions Certification Film

(if applicable) i s Iocaled eilher on the side.
the top, or the front of the engine.
I Gar MOD~LE
CATFRP(LURINC.
MOMA :3 1 ~ O -
: 8.6
~ I IJWSOUPMS:
I
WF~~lMnOUINMAlANlESUA
.
OLB mm
LEMOlEUR
MMISSIOM: 0.64 mm ~HIPPEMEW
L'ou~ocollont d'hornologotion du dispositif

ontipollution EPA/EU (selon 6quipemenl) est silu6
soil. sur le ~ 6 t hdu moteur. soit sur le dessus du
moteur, soit sur le devont du moteur.
go0776690
Illustration 13
22
Product Identification lnformation
i01551639 S.E.
Reference Numbers P.M.
SMCS Code: 1000
101553111
lnformation for the following items may be needed
to order parts. Locate the information for your Generator Lead Connections
engine. Record the information in the appropriate
space. Make a copy of this list for a record. Retain SMCS Code: 4450 I
the information for future reference.
Record for Reference

Lead Numbering
The Wye Configurations and the Delta
I
Engine Model Configurations are the most common generator lead
connections. The following three-phase connection
Engine Serial Number diagrams illustrate the proper connection and lead
identification.
Engine Arrangement Number
The leads are numbered clockwise from the top
Modification Number and from the outside inward. The diagrams that
are contained in the "Wye Configuration Diagrams"
Engine Low Idle Speed section show lead numbering for the six lead
generators and for the twelve lead generators. The
diagrams contained in the "Delta Configuration
,
Engine Full Load Speed
Diagrams" section show lead numbering for the SIX
Performance Specification Number lead generators and for the twelve lead generators.
Primary Fuel Filter Element Wye Configuration Diagrams

Secondary Fuel Filter Element 6 Lead
Engine Oil Filter Element
Auxiliary Oil Filter Element
Supplemental Coolant Additive Maintenance

Element
Engine Oil Capacity
Total Cooling System Capacity
Air Cleaner Element
Fan Drive Belt
Alternator Belt
Generator Arrangement Number
Generators Serial Number

illustration 14 go0611486
Generator Frame Size 6 Lead Wye Configuration
Voltage Rating Terminals T4, T5 and T6 become a neutral connection when the
terminals are tied together.
kW Rating
Excitation System
23
12 Lead Delta Configuration Diagrams

I
6 Lead
-
12 Lead Wye Configuration High Voltage
Terminals T10, T I 1 and T I 2 become neutral connection when Illustration 17
the terminals are tied together. 6 Lead Delta Configuration
12 Lead
lllustmtion 16 go0611606
12 Lead Wye Configuration - Low Voltage
Terminals T10, T I 1 and T I 2 become neutral connection when
the terminals are tied together. 12 Lead Delta Configuration
Terminals T6 and T9 become the neutral connection when the
terminals are tied together and grounded. This reflectsthe terminal
T2 and TI0 connection as the high phase.
24
I
Grounding the Frame Single Units
In any generator set installation, the frame of the In a three-phase, four-wire system, the neutral
generator must be positively connected to an earth wire should be grounded according to local wiring
ground or to the hull of a vessel. This connection is codes.
the first connection that is made at the installation.
This connection is the last connection that should In applications in which definite measures are taken
be removed. If the generator set is on flexible pads in order to prevent grounds to the load leads, an
or on resilient pads, the ground connection must ungrounded neutral can be used. Be sure to check
be flexible in order to avoid possible breakage in your local wiring codes.
later operation.
Ground connection cable or around connection

Multiple Units
straps should have at least ttie current carrying Operation of multiple generators in parallel that have
capacity of the largest line lead to the connected
all neutrals grounded, may result in the circulating
load. Joints in cables or in straps must be clean, current through the neutral connections. In order
free of electrical resistance, and protected from to eliminate the possibility of circulating currents,
possible oxidation. Bolted ground connection ground the neutral of only one generator. If multiple
joints eventually oxidize. The joints are frequent
generators are alternated on line, a switch should
sources of radio frequency interference (RFI). Silver be installed in the neutral ground circuit of each
soldered joints and bolted joints are electrically and generator. In this case, all neutral ground circuits
mechanically sound. exceot one circuit can be o ~ e n e dBe. sure that one 1
of the neutral ground circuit's is closed.
Neutral Connections
The generators with Wye Configuration usually
Parallel to Utility
have the neutral ground when the generator is When a Wye connected generator is going to
installed. However, there are some cases when operate in parallel with a utility system (infinite
definite measures should be taken in order to bus) and when the secondary of the step-down
prevent grounds on the load side. The purpose of transformer in the utility system is also a Wye
the grounding of the neutral is to prevent load side connection, the following may happen. The
equipment damage. grounding of both Wye neutrals may result in
circulating currents through the neutrals. Also, the
If the neutral wire is grounded and one of the phase coordination of ground fault protection requires an
leads becomes grounded, the excessive current will entire system study. This study should be done by
open a load circuit breaker. The excessive current a certified, registered consultant who is familiar with
will also collapse the generator voltage. The result generator systems. The study will determine which
depends on the following items: particular generator grounding method should be used.
electrical characteristics, type of fault, and trio
rating of the circuit breakei.'~nundervoltage device.
may be required in order to provide an adequate
short circuit protection.
Voltage
- Connections
There are some instances in which it is undesirable i
to ground the neutral wire. In other applications, SMCS Code: 4450
it is acceptable to have an ungrounded generator
neutral lead. Definite measures should be taken in
such aoolications in order to orevent arounds to
the phase leads. An example'of such-measures
Three-Phase Voltage Connections ,
i
I
The Wye Configuration for a 480 V generator and
are ground fault protective circuits. Ground
fault protection requires that the entire group of
the Delta Configuration for a 240 V generator are
given in the following diagrams. i
distribution circuits should be studied. The entire i
group of distribution circuits should be treated as
a system. The owner should engage a certified,
registered consultant if a new distribution system is
The rerminals must be connecred sec~rely.The
- . .
terminals musr a so oe ins~latedwith a aood aualitv
electrical taoe.
I
being developed. The owner should also engage a
certified, registered consultant if an existing system
should be modified for the ground fault protection.
25
Product InformationSection
If a Delta Configuration with grounded neutral

is being used, a two-thirds winding pitch is
recommended. If the generator winding pitch is not
two-thirds, third harmonics will cause a high neutral
current. This current can damage the wiring, which
may cause a fire hazard. A floating neutral does not
require a two-thirds pitch winding.
Wye Configuration Diagrams

6 Lead Generators
lllustration 21 go0637320
Typical Parallel Wye Configuration (60 Hz, 12 Lead)
This is a typical high voltage connection.
Delta Configuration Diagrams

6 Lead Generators
Typical Wye Configuration (60 Hz, 6 Lead)
12 Lead Generators
~p
Illustration 22 ~00626129
Typical Delta Configuration (60 Hz, 6 Lead)
lllustration 20 go0637319
Typical Series Wye Configuration (60 Hz, 12 Lead)
This is a typical high voltage connection.
26
12 Lead Generators Do not exceed the nameplate current rating for any
one phase.
Wye Configuration Diagrams 1i

I
6 Lead Generators I
Illustration 23 go0626130 ~ A NVOLTAGE

,:E~P,H,~:\NAN~~~~
Typical Delta Configuration (60 Hz, 12 Lead) THREE THREE
PHASE PHASE
LINE LINE
Single-Phase Current From a

Three-Phase Generator lliustration 24 900626132
Single-PhaseVoltage Diagmm with 6 Lead Wye Configuration
Three-phase current and single-phase current
can be taken simultaneously from a generator 12 Lead Generators
that is connected for three-phase service. In
the Wye Configuration, connect the load to the
three-phase leads (any two of the three leads). In
the Delta Configuration, connect the load to the
three-phase leads (any two of the three leads). In TI THREE-PHASE LINE
both configurations, this connection will provide I
single-phase voltage at the same voltage as
three-phase voltage. GENERATOR
AT 58% OF
CONNECTED
T7 GENERATOR CONNECTED
Connect the load to any phase lead and neutral VOLTAGE
lead of the Wye Configuration. This will produce
SINGLE-PHASE AT
voltage at 58% of three-phase voltage. GENERATOR CONNECTED ~ 1 2
YO TAGE
In the Delta Configuration that produces 240 Volts
60 Hz three-phase power, the voltages will be the
following: SINGLE-PHASE AT
GENERATOR CONNECTE
208 Volts between the high phase and neutral PHASE

THREE
PHASE
LINE LINE
240 Volts between either one of the low phases 1
and neutral 1
Illustration 25 gW637321
Refer to Operation Section, "Generator Operation"
for allowable single-phase loading unbalance. Single-PhaseVoltage Diagram with 12 Lead Wye Configuration
Single-phase power that is taken from a three-phase

source can be a problem. Ensure that the
single-phase loading is equally distributed.
27
Delta Configuration Diagrams

P 6 Lead Generators
THREE-PHASE LINE
SINGLE-PHASE AT
GENERATOR CONNECTEO SINGLE-PHASE AT
VOLTAGE GENERATOR CONNECTEO
VOLTAGE
12
THREE
PHASE
LINE
C SINGLE-PHASE AT
GENERATOR CONNECTE
VOLTAGE 4 THREE
PHASE
LINE
Illustration 26 gW626135
Single-Phase Voltage Diagram with 6 Lead Delta Configuration
12 Lead Generators
Singie-PhaseVoltage Diagram with 12 Lead Delta Configuration
Operation Section
Lifting and Storage
Operation Section Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes andlor the engine make the lifting eyes and
fi
the lifting fixtures obsolete. If alterations are made. i
Lifting and Storage ensure that proper lifting devices are provided.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.
i01934462
Generator Set Lifting Generator Set

SMCS Code: 7002 NOTICE i
Do not use the engine lifting eyes to remove the engine ;
and generator together.
Engine Only
A lifting plate is provided with the package
generator set. Instructions for lifting the package
generator set are stamped on the lifting plate.
Consult your Caterpillar dealer for information

regarding proper fixtures and lifting devices.
Generator sets will not be level if you lift the unit i

from a single lifting point. A counterweight can be I
added between the package frame rails whenever
the application requires frequent relocation of the
unit. For complete information about adding the
counterweight, consult your Caterpillar dealer. A‘
I
The single point lifting eye is secured from
the factory before being shipped. The correct
61.'
NOTICE orientation of the single point lifting eye will allow
Never bend the eyebolts and the brackets. Only load you to look through the eye when you stand at the
the eyebolts and the brackets under tension. Remem- side of the enclosure. The lifting eye may stretch i
1
ber that the capacity of an eyebolt is less as the angle when the package is lifted. This may cause the !
between the supporting members and the object be- locking nuts to loosen. This could cause the lifting I
comes less than 90 degrees. eye to swivel. Ensure that the lifting eye is correctly i
oriented on the packaged generator set. Ensure
When it is necessary to remove a component at an that the lifting eye is tightened to the correct torque
angle, only use a link bracket that is properly rated for before you lift the packaged generator set.
the weight.
Use a hoist to remove heavy components. Use

an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should
be parallel to each other. The chains and cables
should be perpendicular to the top of the object
that is being lifted.
Some removals require lifting fixtures in order to

obtain proper balance and safety.
To remove the engine ONLY,use the lifting eyes that

are on the engine.
Note: The lifting eyes must be removed before

the engine is operated.
29
Operation Section
Lifting and Storage
@ Generator Set Storage 101972430
I
I
SMCS Code: 7002
( Engine Storage
If the engine will not be started for several weeks,
the lubricating oil will drain from the cylinder walls
and from the piston rings. Rust can form on the
cylinder liner surface, which will increase engine
wear which can reduce engine service life.
To help prevent excessive engine wear, use the

following guidelines:
Complere a of the ~ b r i ~ a trecommendarions

i~n
that are lisred in rnis Ooerarion and Maintenance
Manual, "Maintenance'lnterval Schedule"
(Maintenance Section).
If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual. "General Coolant Information"
If an engine is out of operation and if use of the

I engine is not planned, special precautions should
be made. If the engine will be stored for more than
one month, a complete protection procedure is
recommended.
Your Caterpillar dealer will have instructions for

preparing the engine for extended storage periods.
For more detailed information on engine storage,

see Special Instruction, SEHS9031, "Storage
Procedure for Caterpillar Products".
Generator Storage
For information on generator storage, refer to this
Operation and Maintenance Manual, "Generator
Installation" (Operation Section).
30
Operation Section
lnstallation
Installation Storage
Short Time Storage
i01856938
Generator Set Installation If the generator is not installed immediately, store

the generator in a clean area. This area should also
SMCS Code: 7002 have the following conditions: low humidity, stable
humidity, and stable temperature. Space heaters
must be energized in order to keep condensation
Receiving lnspection from the windings. All accessory equipment that
is supplied with the unit should be stored with the
If the generator is received during cold weather, generator. The combined unit should be covered
allow the unit to reach room temperature before you with a durable cover in order to protect against the
remove the protective packing material. Warming following contaminants:
the generator to room temperature will prevent the
following problems: Dust
Water condensation on cold surfaces Dirt
Early failures due to wet windings Moisture
Early failures due to wet insulating materials Long Time Storage
Unpacking and Storage A storage period in excess of six months should be
preceded by the following preparation:
Moving the Generator
1. Install desiccant bags inside the exciter's cover
and install desiccant bags inside the screen of
the fan.
Improper lift rigging can allow unit to tumble caus- 2. Seal the'unit in a covering of plastic or other
ina iniurv and damaae. material that has been designed for that purpose.
~p
3. Adequately tag the generator. This will ensure

NOTICE that preservative greases and desiccant bags are
Do not use the engine lifting eyes to remove the engine removed before the unit is placed in operation.
and generator together.
Bearing lnspection
Unpack the equipment with care in order to avoid
scratching painted surfaces. Move the unit to the Ball bearing generators use grease. This grease is
mounting location. The unit can be moved by either subject to deterioration. If the generator is stored
of the following methods: longer than one year, new ball bearings should be
installed. These bearings should be greased to the
Attach an overhead crane to the lifting eyes that proper level prior to being put into operation. If
are installed on the generator package. inspection indicates that bearings are free of rust
or corrosion, and no noise or excessive vibration
Use a lift truck in order to lift the generator. appear on start-up, replacement is not necessary.
The hoist and the hoist cables should have a rating
that is greater than the weight of the generator. Location
When the unit is moved, ensure that the generator
is completely supported by the lift truck's fork tines. The location of the generator must comply with all
Also ensure that the generator is balanced on the local regulations. The location of the generator must
lift truck's fork tines. Slide the fork tines beneath the also comply with all special industrial regulations.
attached skid in order to lift the generator. Locate the generator in an area that meets the
following requirements:
Clean
Dry
31
Operation Section
Installation
Well ventilated Protective Devices

Easily accessible for inspection and maintenance The output to the load of the generator should
always be protected with an overload protection
Do not obstruct air inlet openings. Do not obstruct device such as a circuit breaker or fuses. Fuses
discharge openings. Coolant flow must reach these should be sized by using the lowest possible
openings. If the generator is exposed to harsh current rating. However, this rating must be
environmental conditions, the generator can be above the current rating for full load. A common
modified in the field in order to add filters and recommendation is 115 percent of rated current.
space heaters. In addition, a more rigid periodic Determine the size of fuses or determine the size of
maintenance schedule should be established. circuit breakers in accordance with NEMA, IEC, and
Local Electrical Codes.
Electrical Measurements
Measure the insulation resistance of each winding
if the generator was exposed to the following
conditions:
Rapid changes in temperature
Freezing
Wet climate during shipment
Wet climate during storage
Note: These tests should be conducted prior to any

power connections that are being made. These
tests should be conducted prior to any control
connections that are being made.
Refer to the Generator Maintenance section of this

manual in order to measure the following items:
Exciter field (stator)
Exciter armature (rotor)
Generator field (rotor)
Generator armature (stator)
Alignment
After the generator set has been placed in the final
position, the generator must be aligned. Refer to
these publications:
Special Instruction, SEHS7654, "Alignment -

General Instructions"
Special Instruction, SEHS7259, "Alignment of

Single-Bearing Generators"
Special Instruction, REHS0177, "Alignment of the

Close Coupled Two-Bearing Generators"
32
Operation Section
Gauges and lndicators
Gauges and lndicators 2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down

i01936622 immediately or if the engine can be cooled by
reducing the load.
Gauges and lndicators
Tachometer -This gauge indicates engine
SMCS Code: 1900; 7450 @
"" speed (rprn) When the throttle control
lever is moved to the full throttle position
Your engine may not have the same gauges or all of without load, the engine is running at high idle. The
the gauges that are described. For more information engine is running at the full load rpm when the
about the gauge package, see the OEM information. throttle control lever is at the full throttle position
with maximum rated load.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing NOTICE
the gauges over a period of time. To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
Noticeable changes in gauge readings indicate damage to the engine. The engine can be operated
potential gauge or engine problems. Problems may at high idle without damage, but should never be
also be indicated by gauge readings that change allowed to exceed hiah idle rDm.
even if the readings are within specifications.
Determine and correct the cause of any significant Note: The high idle rprn and the full load rpm are
change in the readings. Consult your Caterpillar stamped on the Information Plate.
dealer for assistance.
Ammeter - This gauge indicates the
NOTICE amount of charge or discharge in the
If no oil pressure is indicated, STOP the engine. If battery charging circuit. Operation of the
maximum coolant temperature is exceeded, STOP the indicator should be to the right side of "O"(zero).
enaine. Enaine damaae can result.
Fuel Level -This gauge indicates the fuel
-
Engine Oil Pressure The oil pressure level in the fuel tank. Normally, the fuel
@ should be greatest after a cold engine is
started.
level gauge will register the fuel level only
when the switch is in the ON position.
A lower oil pressure is normal at low idle. If the load Fuel Pressure -This gauge indicates fuel
is stable and the gauge reading changes, perform pressure to the electronic unit injectors
the following procedure: from the fuel filter. The indicator should
indicate the "NORMAL" range. Typical fuel pressure
1. Remove the load. at low idle is 410 kPa (60 psi). Typical operating fuel
pressure is 500 kPa (73 psi). Minimum fuel pressure
2. Reduce engine speed to low idle. at rated speed is 400 kPa (58 psi). Minimum fuel
pressure is 160 kPa (23 psi) when the engine is
3. Check and maintain the oil level. under load. A decrease in fuel pressure usually .
indicates a plugged fuel filter.
Jacket Water Coolant Temperature -The
maximum allowable temperature with the Service Hour Meter -This gauge indicates
pressurized cooling system at 103 kPa
(15 psi) is 110 "C (230 OF). Higher temperatures
@ the total number of clock hours on the
engine.
may occur under certain conditions. The water
temperature reading may vary according to load.
The reading should never exceed the boiling point
for the pressurized system that is being used.
If the engine is operating above the normal range

and steam becomes apparent, perform the following
procedure:
1. Reduce the load and the engine rpm

Features and Controls A switch may be installed in the alarm circuit for
silencing the alarm while the engine is stopped for
repairs. Before starting, be sure that the switch is
i01927889 moved to the closed ON. Be sure that the warning
lamps will operate. The engine will not be protected
Engine Shutoffs and Engine if the switch is left in the open OFF position.
Alarms
NOTICE
I SMCS Code: 1900; 7400; 7418 Always determine the cause of the engine shutdown.
/ Shutoff and Alarm Systems

Make necessary repairs before attempting to restart
the engine.
Shutoffs and alarms are electrically operated or

mechanically operated. The operation of all electric Air Shutoff Solenoid (If Equipped)
shutoffs and alarms utilize components which
actuate switches in a sensing unit. This optional solenoid is located on top of the
engine. The air shutoff is part of the air inlet system.
Shutoffs are set at more critical levels for the When the solenoid is activated, the solenoid
operating temperature, operating pressure, mechanically shuts off the inlet air to the engine. The
operating coolant level, and operating speed (rpm) solenoid can be activated only by the overspeed
than the alarms. The particular shutoff may need to switch or by the emergency stop push button
be reset before the engine will start. (ESPB). The air shutoff must be reset before the
engine is restarted.
NOTICE Fuel Shutoff Solenoid
Always determine the cause of the engine shutdown.
Make necessaly repairs before attempting to restart
The fuel shutoff solenoid is located on the governor
the engine.
or the fuel shutoff solenoid is located on the fuel
injection pump. When the fuel shutoff solenoid is
Be fam~liarwith the following items: activated, the solenoid moves the fuel rack "OFF.
The fuel shutoff solenoid moves the fuel rack
I Types and locations of shutoff directly or the fuel shutoff solenoid moves the fuel
rack through the governor.
1 Conditions which cause each shutoff to function

Mechanical Oil Pressure and Water
I The resetting procedure that is required to restart

the engine
Alarm switches consist of a sensor and a contactor. '

Temperature Shutoff
Examples of sensors are the magnetic pickup for

detecting speed, and the pressure and temperature
sensors. Sensors are wired to contactors. The
contactors activate alarm circuits in the annunciator
panel.
Alarm switches are set at less critical levels than

the shutoffs. The alarms warn the operator that an
unsafe operating condition is occurring. The engine
will continue to run when an alarm sounds.
g01009004
When an alarm is activated, corrective measures Illustration 29
must be taken before the situation becomes an (1) Water temperature sensing valve
'
emergency in order to avoid possible engine (2) Oil pressure sensing valve
damage. If corrective measures are not taken within (3) Shutdown cylinder
(4) Shutdown cylinder knob
a reasonable time, engine damage could result.
Alternatively, a corresponding shutdown device
~f equipped) will stop the engine. The alarm will
Lontinue until the condition is corrected or the alarm
is reset by the operator.
34
O~erationSection
~eaturesand Controls
Overspeed Shutoffs
I I
A mechanical shutoff system (if equipped) provides
protection for low oil pressure and for high water
temperature. The main components are a water
temperature sensing valve (I), a oil pressure
sensing valve ( Z ) , and a shutdown cylinder (3).
Pull out the shutdown cylinder knob (4) while you
start the engine. Hold the knob out until the engine
develops enough oil pressure. When the engine
has developed enough pressure, the knob will
stay in place. If low oil pressure or if high water
temperature is sensed, the knob will be released
and the plunger in the governor housing will hold
the fuel rack in the "FUEL OFF position.
Oil Pressure Switches

Illustration 31
(1) Magnetic pickup
(2) Flywheel housing
The magnetic pickup senses the passage of

the teeth that are on the flywheel ring gear.
The Electronic Overspeed Switch is set at 118
percent of the rated engine speed. If the engine
speed increases above the overspeed setting, the
magnetic pickup will sense the overspeed. A signal
is sent to the Electronic Overspeed Switch. The
Electronic Overspeed Switch activates both the air
shutoff solenoid (if equipped) and the fuel shutoff
solenoid.
Illustration 30
Typical example The shutoffs must be reset before the engine will
restart. The air shutoff lever that is located at the
An oil pressure switch has wires that are connected top of the air inlet housing must be manually reset.
to the electrical system for the alarm and/or for the The cause of 'the overspeed must be determined
shutoff. The oil pressure switch senses oil pressure before the engine is restarted.
at the bearing oil gallery. If sufficient oil pressure is
not achieved after engine starting, or if the engine Water Temperature Contactor Switch
is running and then loses oil pressure, the fuel
shutoff solenoid is energized to shut the engine off. The water temperature contactor switch is located
No resetting procedure is required. in the cylinder head. High water temperature closes
the switch which activates an alarm or fuel shutoff.
Engine Step Oil Pressure No resetting is required. The switch will open as
the coolant cools.
This is an adjustable engine speed setting that
protects the engine from a failure that is caused NOTICE
by too little oil pressure for a specified speed Coolant level must be maintained in order for the shut-
range. This option requires two different oil pressure off to function, because the sensing element must be
switches. One switch has a high pressure rating. submerged in the coolant to operate.
When the engine is running above the speed
setting, the engine must maintain oil pressure higher
than the rating of the switch. The other switch has Coolant Loss Sensor (If Equipped)
a low pressure rating. When the engine is running
below the speed setting, the engine must maintain The optional coolant loss sensor is usually mounted
oil pressure above the rating of the switch. In an near the top of the expansion tank or radiator. The
automatic startlstop system, an automatic reset sensor monitors the coolant level.
switch is used.
~-
35
Operation Section
Features and Controls
Testing of the Overspeed Switch
!
I,
i
Illustration 32
Electronic Overspeed Switch
If the coolant drops below the minimum level, the The overspeed shutoff switch is located in the
sensor may sound an alarm, or the sensor may junction box. The overspeed shutoff switch must be
cause a shutoff to avoid engine overheating or reset before you can restart the engine. To reset
possible engine damage. Coolant must be added the switch, push the "RESET" button. The button
to the radiator or the expansion tank in order to will remain in this position unless an overspeed
reset the condition. condition occurs.
Testing the Shutoff and Alarm The Electronic Overspeed Switch with Cranking
Termination has a 75 percent "VERIW button, a
"RESET" button, and an "OVERSPEED" indicator
lamp.
Most control panels are equipped with a lamp test
switch. Turn the switch to the ON position in order
to check the indicator lights for proper operation. The Electronic Overspeed Shutoff Switch with
Replace worn bulbs immediately. Cranking Termination has a sensing circuit which I
prevents the starter pinion from remaining engaged II
The shutoffs and alarms should be tested every in the flywheel at excessive rpm. Crank Termination !
has an adjustable engine speed setting. This

1000 service hours or twice a year for proper I
operation by authorized, experienced service signals the starter motor when the engine is firing
personnel. and cranking must be terminated. Once the speed
setting is reached, a switch opens. This will start the 1
engine hour meter. i
NOTICE
During testing, abnormal operating conditions must be Once the starting motor cranks the engine, the I
simulated. Perform the tests correctly in order to help pinion gear can remain engaged with the flywheel
prevent possible engine damage. as the engine speed increases. The magnetic
1
1
pickup opens the circuit to the starting motor at 400 I
rpm. This will allow the pinion gear to disengage.
Refer to the Service Manual for more information on
testing procedures or consult your Caterpillar dealer.
The circuit will remain open until the flywheel stops.
I
This prevents energizing the starting motor circuit !
again while the flywheel is turning. 1
The engine may be equipped with either an
Overspeed Shutoff Switch or an Electronic
Overspeed Switch with Cranking Termination. Both
switches can be checked for proper operation at 75
percent of overspeed condition. Use the following
procedure: I
I
1. Determine full load speed (rpm) from the Engine
Information Plate.
-
36
Operation Section
2. Operate the engine at the corresponding speed iO1972436

(rprn) that is shown for the engine. Refer to table
3. Voltage Regulators
3. Maintain the test speed (rprn). Press the SMCS Code: 4467
"VERIFY button and hold the "VERIW button.
The engine should stop. If the engine does not
stop at the specified test speed (rprn), contact
your Caterpillar dealer. Personal injury or death can result from high volt-
age.
Table 3
GENERATOR SET When power generation equipment must be in op-
OVERSPEED TEST RPM eration to make tests andlor adjustments, high
INU I
RPM
Test RPM For
Overspeedm
/ Actual RPM Of
Overspeedm
/ voltage and current are present.
Improper test equipment can fail and present a

high voltage shock hazard to its user.
1800 1593 2124
Make sure the testing equipment is designed for
(1) The Test RPM for Overspeed is slower than the Full Load and correctly operated for high voltage and cur-
RPM. Multiply the Full Load RPM by 0.885. The product is rent tests being made.
the Test RPM.
(2) Multiply the Full Load RPM by 1.18. The product is the Actual
RPM of Overspeed. When servicing or repairing electric power gener-
ation equipment:
Note: The "OVERSPEED" lamp will illuminate as the
engine stops. Push the "RESET" button before you Make sure the unit is off-line (disconnected
restart the engine. from utility andlor other generators power
service) , and either locked out or tagged DO
NOT OPERATE.
Remove all fuses.
Make sure the generator engine is stopped.
Make sure all batteries are disconnected.
Make sure all capacitors are discharged.
Failure to do so could result in personal injury or

death. Make sure residual voltage in the rotor, sta-
tor and the generator is discharged.
Accidental engine starting can cause injury or

death to personnel working on the equipment.
To avoid accidental engine starting, disconnect

the battery cable from the negative (-) battery ter-
minal. Completely tape all metal surfaces of the
disconnectedbattery cable end in order to prevent
contact with other metal surfaces which could ac-
tivate the engine electrical system.
Place a Do Not Operate tag at the StartlStop switch

location to inform personnelthat the equipment is
being worked on.
37
Operation Section
The generator with shunt field excitation is Table 4

1 self-excited with a voltage regulator. The voltage
regulator monitors the excitation current as a
Sustained short circuit
ca~acrtv(AREP and PMG)
1
3 x In for 10 seconds
I
function of the output voltage of the generator.
The generator with shunt field excitation has no
sustained short circuit capacity.
Standard power supply
(AREPI
Two auxiliary windings
I
For generators with Auxiliary Winding Regulation
I SUDD~V for shunt I max 140 VAC at 50160 Hz I
Excitation Principle (AREP), the voltage regulator is I Rated overload current 1 10 amperes for 10 seconds I
powered by two auxiliary windings. These windings
are independent from the circuit for detection of
voltage. The first winding is labelled as "XI" and
Electronic protection for
overload and loss of
voltage sensing
I Excitation ceiling current
for 10 seconds and return
to approximately 1 ampere
I
"X2". This winding has a voltage that is proportional THE GENERATOR
with the output voltage of the generator. The MUST BE STOPPED
second winding is labelled as "Z1" and "22". IN ORDER TO RESET
This winding has a voltage that is proportional
to the current of the stator. The voltage from the
power supply is rectified and filtered before being
I Fuse "Fl" on inout s i d e I "1" and "X2" I
used by the regulator monitoring transistor. This Voltage sensing 5 VAC that is isolated by
principle ensures that regulation is not affected by the transformer
interference that is generated by the load. Terminals for 0 and 110 95 to 140 VAC
VAC
For generators with PMG excitation, a permanent
magnet generator is added to the generator at the Terminals for 0 and 220 170 to 260 VAC
VAC
rear of the generator. The PMG supplies the voltage
regulator with a voltage that is independent of the
main generator winding. The generator has a short
circuit capability of 3 X In for 10 seconds. The
I Termlnals for 0 and 380
VAC '
340 to 520 VAC
I
generator also has good immunity to distortion from
I Voltage regulation 1 +0.5% I
1 the generator load.
The voltage regulator monitors and corrects the

I Rap~dresponse tlme or normal response time from the
location of iurnoe; "ST2"
output voltage of the generator by adjusting the

I Voltage adjustment via potentiometer "P2" I
excitation current. Quadrature droop adjustment via potentiometer 'PI"
Underspeed protection and adjustment of frequency
threshold via potentiometer "P4" (Factory setting) I
Maximum adjustment for excitation via potentiometer
'P5" (4 to 10 amperes)
1 50 or 60 Hz selection with jumper "ST3"Il). I
(1) The engine speed setting must be changed in order to change
the frequency of the generator set.
These voltage regulators may have an optional

remote potentiometer for voltage adjustment. This
potentiometer is 420 ohms 3 W minimum. The
adjustment range is 5%. The voltage range is
limited by the internal potentiometer "P2". Remove
"ST4 in order to connect the potentiometer. A 1000
ohm potentiometer can also be used to extend the
adjustment range.
38
Operation Section
R448 Adjustments
I
I
I
140 V Maximum supply 1!
50/60 Hz !
1/2 phase TI. T4
E+ i!
I
Exciter field
I
Illustration 35 Illustration 36 ~00995949 1

Connections for shunt excitation Connections for shunt excitation
6 wires 12 wires
I
-
( ~ 4 4 8 X2
(
...
- 22
Illustration 37
I
Yellow
Red
7 . Turn stability potentiometer (P3) counterclockwise
Connections for AREP excitation
PMG excitation
Illustration38
Connections for PMG excitation
creen AUX
Black
windings]
Exciter field
Exciter field
1
~W996011
to about 113 of the total rotation for the
potentiometer.
8. Start the engine and set the engine speed to a
to make adjustments if the voltage oscillates.

Adjust potentiometer P3 in both directions while
you observe the voltage between E+ and E-.
The voltage between E+ and E- should be
approximately 10 VDC. The best response times
39
Operation Section
6. Turn the potentiometer (P4) for frequency to a

full clockwise position.
frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz.
9. Adjust the output voltage to the correct value

with potentiometer P2. This voltage should be
the rated voltage UN for single operation or
UN plus 2% to 4% for parallel operation with
a current transformer. Use potentiometer P3
are obtained at the limit of the instability. Try

cutting or replacing the wire ST2 if no stable
position can be obtained.
10.Check the operation of the Load Adjustment

Module (LAM). ST5 must be closed. The LAM
can be adjusted to 15% or 25% voltage dip by
. moving the ST10 jumper wire.
11.Turn potentiometer (P4) slowly counterclockwise

until there is a significant voltage drop. The
voltage drop should be approximately 15 %.
l2.Vary the frequency around 48 Hz or 58 Hz

according to the operating frequency. Check
.
Use the following procedure to adjust the R448 the change in the voltage that was previously
voltage regulator. observed.
Use the following procedure in order to run the
generator set in parallel operation.
Adjustments for Generators in Parallel
Operation
Adjustments for Stand-alone Generators Note: Make sure that the speed droop is identical
for all of the engines before adjustments are made
1. Turn the remote adjustment potentiometer to the
to the generator.
center position, if equipped.
1. Preset the unit for parallel operation by
2. Connect an analog voltmeter that is calibrated
connecting the current transformer to S1 and S2
for 100 VDC on terminal E+ and terminal E-.
of the connector J2. Set potentiometer P I for
quadrature droop in the center position. Apply
3. Connect a voltmeter that is calibrated for 300
the rated load. The voltage should drop for 2%
VAC to 500 VAC or 1000 VAC to the output
to 3%. Switch the positions of the two incoming
terminals of the generator.
secondary wires of the current transformer if the
voltage increases.
4. Make sure that the ST3 wire is positioned on the
desired frequency. Also, the engine speed must
be changed from the factory setting in order to
change the frequency of the generator.
)
5. Turn potentiometer (P2) to a full counterclockwise
position.
40
Operation Section
2. The no-load voltages should be identical for all 5. Turn potentiometer P5 to a full counterclockwise
the generators that are operating in parallel. position and activate the power supply. If there is
Connect the generators in parallel. Try to obtain no output current from the voltage regulator, turn
a 0 kW power exchange by adjusting the speed potentiometer P2 clockwise until the ammeter
of the generator. Try to minimize the circulating indicates a stable current.
currents between generators by altering the
voltage setting with potentiometer P2 or Rhe on 6. Switch off the power supply. Switch on the power
one of the generators. supply. Turn potentiometer P5 until the required
maximum current is obtained. The maximum
Note: Do not change the voltage settings after current must not be greater than 1 0 Amperes.
this step.
Use the following steps in order to check the
3. Apply the available load. The setting is correct internal protection.
only if a reactive load is available. Equalize the
Kilowatts or divide the rated power of the units 1. Open switch D. The excitation current should
proportionally by altering the speed. Alter the increase up to the preset maximum value and
quadrature droop potentiometer (PI) in order to the excitation current should remain at the preset
equalize the currents or divide the currents. maximum value for approximately 1 0 seconds.
The current will decrease to less than 1 Amp.
R448 Adjustment for Maximum 2. Open switch A in order to reset the internal
Excitation protection.
Note: The voltage must be adjusted after the
maximum excitation current has been set.
Special Use
go1016266
Illustration 39
The maximum factory setting corresponds to an

excitation current that is required to obtain a
three-phase short circuit current of 3 X IN at 5 0
Hz for industrial power, unless this is specified go0952821
otherwise. Illustration 40
The maximum level of excitation may be reduced The exciter is switched off by disconnecting
by a static method. The static method is safer for the power supply to the voltage regulator. The
the generator and the installation. Use the following connection is identical for resetting the internal
steps to reduce the maximum excitation level. protection for the voltage regulator.
1. Disconnect the power supply wires X I , X2, Z 1

and 22.
2. Disconnect sensing leads OV, 1 IOV, 220V and
380V on the generator.
3. Connect the main power supply 200V-240V to

X I and X2, as shown.
4. Install a 10 Amp DC ammeter in series with the

exciter field.
41
Operation Section
. '
B Volts
Exciter field
g00952830
Illustration 41
I Use a 12 VDC power source in order to energize

the field, if necessary. Refer to the following table.
Table 5
A~~lications I B Volts I Time
I Voltage build up I 12 (1A) I 1 - 2 seconds I
I De-energized parallel
ooeration'
I 12 (1A) 1 1 - 2 seconds I
Standby parallel 24 (2A) 5 - 10 seconds
operation
I Freauencv startina 1 48 14A) 1 5 - 10 seconds I
Voltage that is sustained
at overload
48 (4A, - seconds
42
Operation Section
Engine Starting
Engine Starting Do not start the engine or move any of the

controls if there is a 'DO NOT OPERATE" warning
taa or similar warnina taa attached to the start
(3
Before Starting Engine
i01233590 s h c h or to the confols-
I
SMCS Code: 1000; 1400; 1450
Ensure that the areas around the rotating parts
are clear.
All of the guards must be put in place. Check for

I
Perform the required daily maintenance and other damaged guards or for missing guards. Repair
periodic maintenance before the engine is started. any damaged guards. Replace damaged guards
lnspect the engine compartment. This inspection and/or missing guards.
can help prevent major repairs at a later date. Refer
to the Operation and Maintenance Manual for more Disconnect any battery chargers that are not
information. protected against the high current drain that
is created when the electric starting motor (if
For the maximum service life of the engine, make equipped) is engaged. Check electrical cables
a thorough inspection before starting the engine. and check the battery for poor connections and
Look for the following items: oil leaks, coolant for corrosion.
leaks, loose bolts, and trash buildup. Remove
trash buildup and arrange for repairs, as needed.
lnspect the cooling system hoses for cracks and

Reset all of the shutoffs or alarm components.
Check the engine lubrication oil level. Maintain

I
for loose clamps. the oil level between the "ADD" mark and the
"FULL" mark on the oil level gauge.
lnspect the alternator and accessory drive belts
for cracks, breaks, and other damage. Check the coolant level. Observe the coolant
. level in the coolant recovery tank (if equipped).
lnspect the wiring for loose connections and for Maintain the coolant level to the "FULL" mark on
worn wires or frayed wires. the coolant recovery tank.
!
Check the fuel supply. Drain water from the water If the engine is not equipped with a coolant I
separator (if equipped). Open the fuel supply recovery tank maintain the coolant level within i
valve. 13 mm (0.5 inch) of the bottom of the filler pipe. i
I
If the engine is equipped with a sight glass,
NOTICE maintain the coolant level in the sight glass. !
All valves in the fuel return line must be open before I
and during engine operation to help prevent high fuel Observe the air cleaner service indicator (if
pressure. High fuel pressure may cause filter housing equipped). Service the air cleaner when the
failure or other damaae. yellow diaphragm enters the red zone, or when
the red piston locks in the visible pos~tion.
If the engine has not been started for several weeks, Ensure that any driven equipment has been
fuel may have drained from the fuel system. Air disengaged. Remove any electrical loads.
may have entered the filter housing. Also, when fuel
filters have been changed, some air space will be
left in the housing. In these instances, prime the fuel Starting the Engines, Operating the
system. Refer to the Operation and Maintenance Engines, and Stopping the Engines
Manual, "Fuel System-Prime" for more information
on priming - the fuel system.
that are Equipped with Control
Panels !!
For information regarding the generator control II

Engine exhaust contains products of combustion panel that is used, refer to the Operation and
which may be harmfulto your health. Always start Maintenance Manual that is for the generator and i
and operate the ennine in a well ventilated area the control panel. :
and, if inan enclosea area, vent the exhaust to the
outside.
43
Operation Section
Engine Starting
i01972462 Manual Starting

Starting the Engine
NOTICE
SMCS Code: 1000; 1450 For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area Do not start the engine or move any of the controls
and, if in an enclosed area, vent the exhaust to the if there is a "DO NOT OPERATE" warning tag or a
outside. similar warning tag attached to the start switch or
to the controls.
Note: The crank cycle and the number of crank Ensure that no one will be endangered before the
cycles are programmable. The crank cycle is the engine is started and when the engine is started.
amount of time for engagement of the starting
motor. This also includes the amount of time for 1. Perform all of the procedures that are described
cooling of the starting motor between crank cycles. in this Operation and Maintenance Manual
If the engine does not start within the number (Operation Section), "Before Starting Engine".
of crank cycles that are programmed, the fuel
system is disabled. The "OVERCRANK" indicator
will illuminate in order to warn the operator of an NOTICE
overcrank. Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
Operation of the Generator Set If the engine fails to start within 30 seconds, release
Control Panel the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
For information onoperation of the generator set start the engine again.
control panel, see Operation and Maintenance
Manual. SEBU7050, "SR4B Generators and Control
Panels". OFF
@ T E @
: @
I Automatic Starting
COOLDOWN .,.-a
AU l U
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode. €3
The position for the engine control switch depends g00319402
Illustration 42
on the type of control panel. The engine control
switch must be in the "AUTO" position for the Engine conlrol switch in the "MAN. START" position
EMCP II and the EMCP 11+ control panel. For the This engine control switch is used for the EMCP II and for the
Switchgear Conversion control panel, the engine EMCP II+ control panel.
control switch must be in the "REMOTE position.
2. To start an engine with the EMCP I1 or the EMCP
The engine will automatically start when the remote 11+ control panel, turn the engine control switch
startlstop initiate contact closes. to the "MAN. START" position.
44
Operation Section
Engine Starting
101400713 A jacket water heater is available as an option for

starting in temperatures as low as 0 C (32 OF).
Air Starting The jacket water heater can maintain the water
temperature at approximately 32 OC (90 OF). The
SMCS Code: 1451 heated water will help to keep the oil in the engine
block warm enough to flow when the engine is
For good life of the air starting motor, the air supply started.
must be free from dirt and water.
Maintain the proper level of electrolyte in the
1. Open the drain valve and close the drain valve batteries. Keep the batteries fully charged.
in order to drain condensation and ,oil carryover.
This drain valve is located .on the bottom of the To maximize the battery power, heat the battery
air tank. compartment or store the batteries in a warm
location. Typically, batteries only have 50 percent of
2. Check the air supply pressure. The air starting the capability at -10 "C (14 O F ) versus 27 'C (80 OF).
motor requires a minimum of 690 kPa (100 psi)
air pressure to operate properly. The maximum Extra battery capacity may be necessary for very
air pressure must not exceed 1550 kPa (225 psi). cold temperatures.
The normal operating air pressure will be
758 to 965 kPa (110 to 140 psi). When No. 2 diesel fuel is used, a fuel heater will
maintain the temperature of the fuel above the cloud
point. Fuel line insulation will help to maintain the
fuel temperature.
Consult your Caterpillar dealer for more information

on the starting aids that are available for cold
weather starting.
Starting With the Starting Aid

Switch . .
Illustration 43
(1) Air valve
Personal injury or property damage can result
from alcohol or starting fluids.
I!
I I
3. Press the air valve or press the start button for
the engine in order to crank the engine. After
Alcohol or starting fluids are highly flammableand
. . .
toxic and if i m ~ r o ~ e rstored
lv - -
could result in iniurv I
the engine starts, release the air valve or release
the start button.
or property damage.
I
iO1108737
NOTICE
Excessive starting fluid can cause piston and ring
damage.
, II
,
Cold Weather Starting
SMCS Code: 1000; 1250; 1450 1453; 1456; 1900
Use starting fluid for cold starting purposes only.
I
Do not use excessive starting fluid during starting or
after the engine is running.
1
Note: Oil pan immersion heaters are not
recommended for heating the engine oil. To ensure I I
the compatibility of the components, only use

equipment that is recommended by Caterpillar.
The optional ether starting aid which is located
on the control panel i s the only system that is
1 I
Startability will be improved at temperatures below

recommended for the injection of starting fluid. I
16 OC (60 O F ) with a starting aid. A jacket water Perform the procedures that are described in this
heater may be needed and/or the crankcase oil Operation and Maintenance Manual (Operation
may need to be warmed. Section), "Before Starting Engine".
1. Turn the Engine Control Switch to the "MAN.

START" position. The engine will crank.
45
Operation Section
Engine Starting
2. Ether will automatically be injected if the following

conditions are met: NOTICE
Using a battery source with the same voltage as the
I a. The "STARTING AID" switch is in the

AUTOMATIC position.
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
I b. The jacket water coolant temperature is less

than 0 "C (32 OF).
Note: Additional injections may be necessary in

Do not reverse the battery cables. The alternator can
be damaged. Attach ground cable last and remove
first.
order to start the engine. Additional injections may
also be necessary in order to achieve low idle. When using an external electrical source to start the
engine, turn the engine control switch to the "OFF po-
3. If additional injection is necessary, toggle the sition. Turn all electrical accessories OFF before at-
"STARTING AID" switch to the MANUAL position. taching the jump start cables.
For additional injection, the jacket water coolant
temperature must be less than 10 "C (50 OF). Ensure that the main power switch is in the OFF posi-
tion before attaching
- the jump start cables to the en-
4. The "STARTING AID" switch is a momentary gine being started.
switch. To stop the injection, release the
"STARTING AID" switch.
1. Turn the start switch on the stalled engine to the
OFF position. Turn off all accessories.
101037941
2. Connect one positive end of the jump start cable
Starting with Jump Start to the positive cable terminal of the discharged
Cables battery. Connect the other positive end of the
jump start cable to the positive cable terminal
f % SMCS Code: 1000; 1401; 1402; 1900 of the electrical source.
3. Connect one negative end of the jump start cable

to the negative cable terminal of the electrical
source. Connect the other negative end of the
Improper jump start cable connections can cause jump start cable to the engine block or to the
an explosion resulting in personal injury. chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
Prevent sparks near the batteries. Sparks could that are produced by some batteries.
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine. 4. Charge the batteries. The engine will not
continue to run after starting if the batteries have
If the installation is not equipped with a backup not been charged.
battery system, it may be necessary to start the
engine from an external electrical source. 5. Start the engine.
First, determine the reason that it is necessary to 6. Immediately after the stalled engine is started,
start with power from an external source. Refer to disconnect the jump start cables in reverse order.
Special Instruction, SEHS7768, "Use of the 6V-2150
StartingICharging Analyzer". Refer to the Electrical Schematic for your engine.
Consult your Caterpillar dealer for more information.
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that
are severely discharged. The batteries must be
charged to the proper voltage with a battery
charger. For information on testing and charging,
0 refer to the Special Instruction, SEHS7633, "Battery

Test Procedure'.
46
Operation Section
Engine Starting
101646248
After Starting Engine

SMCS Code: 1000
Note: In temperatures from 0 to 60% (32 to 14O0F),
the warm-up time is approximately three minutes. In
temperatures below O°C (32"F), additional warm-up
time may be required.
Note: Ensure that the self test for the monitoring

system (if equipped) is completed before operating
the engine under load.
When the engine idles during warm-up, observe

the following conditions:
Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is
not possible in some applications.
Operate the engine at low idle until all systems

achieve operating temperatures. Check all
gauges during the warm-up period.
Note: Gauge readings should be observed and the

data should be recorded frequently while the engine
is operating. Comparing the data over time will
help to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
47
Operation Section
Engine Operation
Engine Operation Avoid unnecessary idling.
Shut off the engine rather than idle for long periods
of time.
I Engine Operation Observe the service indicator frequently. Keep
I SMCS Code: 1000
the air cleaner elements clean.
Ensure that the turbochargers are operating

Proper operation and maintenance are key factors correctly so that the proper airlfuel ratio is
in obtaining the maximum life and economy of maintained. Clean exhaust indicates proper
the engine. If the directions in the Operation and functioning.
Maintenance Manual are followed, costs can
be minimized and engine service life can be Maintain a good electrical system.
maximized.
One defective battery cell will overwork the
The time that is needed for the engine to reach alternator. This will consume excess power and
normal operating temperature can be less than the excess fuel.
time needed for a walk-around inspection of the
engine. Ensure that the belts are properly adjusted. The
belts should be in good condition.
After the engine is started and after the engine
reaches normal operating temperature, the engine Ensure that all of the connections of the hoses
can be operated at the rated rpm. The engine will are tight. The connections should not leak.
reach normal operating temperature faster when
the engine is at rated speed. The engine will reach Ensure that the driven equipment is in good
normal operating temperature faster when the working order.
engine is at low power demand. This procedure is
more effective than idling the engine at no load. Cold engines consume excess fuel. Utilize heat
The engine should reach operating temperature in from the jacket water system and the exhaust
a few minutes. system, when possible. Keep cooling system
components clean and keep cooling system
Gauge readings should be observed and the data components in good repair. Never operate the
should be recorded frequently while the engine is engine without water temperature regulators.
operating. Comparing the data over time will help All of these items will help maintain operating
to determine normal readings for each gauge. temperatures.
Comparing data over time will also help detect
abnormal operating developments. Significant Settings for the fuel system and the limits for the
changes in the readings should be investigated. operating altitude are stamped on the Engine
Information Plate. If an engine is moved to a
higher altitude, the settings must be changed
i00165110
by a Caterpillar dealer. Changing the settings
Fuel Conservation Practices will help prevent damage to the turbocharger.
I SMCS Code: IOOQ 1250

Changing the settings will help to provide the
maximum efficiency for the engine. Engines can
be operated safely at higher altitudes, but the
The efficiency of the engine can affect the fuel engines will deliver less horsepower. The fuel
economy. Caterpillar's design and technology in settings should be changed by a Caterpillar
manufacturing provides maximum fuel efficiency dealer in order to obtain the rated horsepower.
in all applications. Follow the recommended
procedures in order to attain optimum performance
for the life of the engine.
I Avoid spilling fuel,
Fuel expands when the fuel is warmed up. The fuel

may overflow from the fuel tank. Inspect fuel lines
for leaks. Repair the fuel lines, as needed.
Be aware of the properties of the different fuels.

Use only the recommended fuels.
48
Operation Section
Engine Stopping
Engine Stopping 1. Open the main circuit breaker in order to

disengage the driven equipment.
i01057253 2. Use one of the following methods in order to

stop the engine:
Emergency Stopping
Note: If the cooldown feature is not utilized,
SMCS Code: 1000; 7418 operate the engine for a cooldown period before
stopping the engine. After the driven equipment is
NOTICE disengaged, allow the engine to operate at rated
Emergency shutoff controls are for EMERGENCY use rpm for five minutes. Then stop the engine.
ONLY DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
Ensure that any components for the external system

that support the engine operation are secured after
the engine is stopped.
Emergency Stop Button 1-1 AUTO
START
8
lllustmtion 45 go0320124
Engine control switch in the "OFFIRESET position
a. For all control panels, turn the engine control

switch to the "OFFIRESET" position. The
engine will immediately shut off.
b. For engines with the EMCP II+ or the EMCP

- - - II control panel, the engine control switch
Illustration 44 g00104303 may be turned to the "COOLDOWNISTOP"
Typical emergency stop button position. If the cooldown feature is utilized, the
engine will operate for a programmed period
The emergency stop button is in the OUT position of time before the engine stops. Otherwise,
for normal engine operation. Push the emergency the engine will immediately shut off.
stop button. The engine will not start when the
button is locked. Turn the button clockwise in order c. For engines with the Switchgear Conversion
to reset. control panel, the engine will stop if the engine
control switch is turned to the "Service"
position. The Caterpillar Monitoring System
will remain energized. This position of the
engine control switch is used in order to
Manual Stop Procedure program the Caterpillar Monitoring System.
SMCS Code: 1000 The engine will coast to a stop. Ensure that any
system that provides external support to the engine
NOTICE is secured after the engine is stopped.
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components. Automatic Stopping
Excessive temperatures in the turbocharger center- Automatic stopping will occur when the engine'is
housing will cause oil coking problems. operating in the automatic mode and the remote
startlstop initiate contact opens. If the cooldown
Allow the engine to gradually cool before stopping the feature is utilized, the engine will operate for a
engine programmed per'od of time before rhe engine stops.
Otherwise, the engine will immediarely shut off.
49
Operation Section
Engine Stopping
fa ~r Stopping Engine
101233977
I
I
SMCS Code: 1000
Check the crankcase oil level. Maintain the oil

level between the "ADD" mark and the "FULL"
mark on the oil level gauge.
I If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.
Note the service hour meter reading. Perform

the maintenance that is in the Operation and
Maintenance Manual, "Maintenance Interval
Schedule".
Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not
overfill the fuel tank.
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.
Allow the engine to cool. Check the coolant level.

Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.
If freezing temperatures are expected, check

the coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolantlwater mixture, if necessary.
Perform all required periodic maintenance on the

generator. The generator maintenance is outlined
in the Operation and Maintenance Manual that is
supplied with the generator.
50
Operation Section
Cold Weather Operation
Cold Weather Operation 8 The cooling system and the lubrication system for
the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
i01781235 down for a few hours and the engine can still have I
the ability to start readily. If the engine is shut
Cold Weather Operation down for at least eight hours, the engine should
be considered cooled to outside temperature.
SMCS Code: 1000; 1250
8 Install the correct lubricant in each compartment
Caterpillar Diesel Engines can operate effectively in before the beginning of cold weather.
cold weather. The starting and the operation of the
diesel engine is dependent on the following items in Check all rubber parts (hoses, fan drive belts,
cold weather: etc) weekly.
8 The type of fuel that is used 8 Check all electrical wiring and connections for
any fraying or damaged insulation.
8 The viscosity of the oil
Optional starting aids

8 Keep all batteries fully charged and warm. 1 I
I I
8
8 Fill the fuel tank at the end of each shift.
8 Optional warm up aids
8 Check the air cleaners and the air intake daily.
Refer to Operation and Maintenance Manual, Check the air intake more often when you operate
SEBU5898, "Cold Weather Recommendations for in snow.
Caterpillar Machines".
The purpose of this section will cover the following

information:
Personal injury or property damage can result
Explain potential problems that are caused by from alcohol or starting fluids.
cold weather operation.
8 Suggest steps which can be taken in order

Alcohol or startingfluidsarehighly flammable and
toxicand if improperly stored could result in injury 1-
1
or property damage.
to minimize starting problems and operating
problems when the ambient air temperature is I
colder than 0 to -55 "C (32 to -67 OF).
The operation and maintenance of an engine in

freezing temperatures is complex. This is because DO NOT USE ETHER (starting fluids) unless
of the following conditions: the unlimited differences specifically instructed to do so. If the engine is
in weather conditions, engine applications, and equipped with an Air Inlet Heater (electrically or
the supplies that are available in your area. These fuel ignited manifold heater), DO NOT use ether
factors, recommendations from your Caterpillar (starting fluids) at any time. The use could result
dealer, past proven practices, and the information in engine damage andlor ~ersonaliniuw.
that is contained in this section should be combined
in order to provide guidelines for cold weather i
NOTICE
operations. The optional automatic ether injection system is the
only starting fluid system that is recommended. Ex-
!:
Hints for Cold Weather Operation cessive starting fluid can cause piston and ring dam-
age. Use starling fluid for cold starting purposes only.
8 If the engine is started, operate the engine until a
minimum operating temperature of 71 "C (160 O F ) 8 Inject starting fluid only when the engine is
is achieved. Achieving operating temperature will
cranking.
help prevent the intake valves and exhaust valves
from sticking.
Dryers for the air system may be effective
in reducing moisture condensation and the
formation of ice in air systems.
Alcohol injection may prevent moisture from

freezing the air compressor governor and other
components of the air system.
51
Operation Section
For jump starting with cables in cold weather, In cold weather, check the coolant often for the
refer to the Operation and Maintenance Manual proper glycol concentration in order to ensure
for jump starting instructions. adequate freeze protection.
Viscosity of the Engine Lubrication Jacket Water Heater

Oil A jacket water heater heats the coolant that
surrounds the combustion chamber. This provides
Proper engine oil viscosity is essential. Oil viscosity the following functions:
affects the amount of torque that is needed to
crank the engine. Refer to the Operation and Startability is improved.
Maintenance Manual, "Lubricant Specifications" for
the recommended viscosity of oil. Warm up time is reduced,
I Lubricating Oil Heaters The required temperature for ether is reduced,
Note: Oil pan immersion heaters are not An electric jacket water heater can be activated
recommended for heating the lube oil. To ensure once the engine is stopped. An effective jacket
the compatibility of the components, only use water heater is typically a 125011500 W unit. Consult
equipment that is recommended by Caterpillar. your truck dealer for more information.
NOTICE Idling the Engine

Heating elements that are in direct contact with the
lubricating oil can cause coking of the oil. When idling after the engine is started in cold
weather, increase the engine rpm to 1000 to 1200
1 To aviod coking of the oil when the oil is heated, follow

these recommendations:
The temperature of the heating surface must not ex-

rpm. This will warm up the engine more quickly. The
engine should not be "raced" in order to speed up
ihe warm up process.
ceed 150 "C (300 O F ) . The maximum heat density While the engine is idling, the application of a light
of the heating surface must not exceed 1.24 w/cm2 load (parasitic load) will assist in maintaining the
(8W/ln2). minimum operating temperature. The minimum
operating temperature is 71 "C (160 OF). Maintaining
I Engine oil pan heaters are useful devices that an elevated low idle speed for extended periods will
be easier with the installation of a hand throttle. An
provide the following functions:
idle speed of 1000 rpm is preferred for all engines.
I Assist in reducing the cranking amperage that is

needed to start the engine. Recommendations for Coolant
Warm Up
I Improve the flow of oil at start-up.
Warm up any system that has cooled below normal
II The time that is needed to warm up the engine

is reduced.
The service life of bearings is increased.

operating temperatures due to inactivity. This should
be performed before the engine is returned to full
operation. During operation in very cold temperature
conditions, damage to engine valve mechanisms
can result from engine operation for short intervals.
Engine oil pan heaters can reduce the minimum This can happen if the engine is started and
ambient temperatures that are normally the engine is stopped many times without being
recommended for multigrade oil. Consult your operated in order to warm up completely.
dealer for more information.
I Recommendations for the Coolant

When the engine is operated below normal
operating temperatures, fuel and oil are not
completely burned in the combustion chamber.
Provide cooling system protection for the lowest This fuel and oil causes soft carbon deposits to
expected outside temperature. Refer to the form on the valve stems. Generally, the deposits do
Operation and Maintenance Manual, "Lubricant not cause problems and the deposits are burned
Specifications" for the recommended coolant off during operation at normal engine operating
mixture. temperatures.
52
Operation Section
When the engine is started and the engine is Insulated cab heater lines for very cold weather are
stopped many times without being operated in also beneficial. These lines provide more available
order to warm up completely, the carbon deposits heat from the coolant to the cab and less heat is
become thicker. This will cause the following lost to the outside air.
problems:
Insulating the Air Inlet and Engine
8 Free operation of the valves is prevented.
Compartment
Valves become stuck. When temperatures below -18 "C (-0 OF) will be
8 Pushrods are bent. frequently encountered, an air cleaner inlet that
is located in the engine compartment may be
8 Other damage to valve train components can specified. This is sometimes referred to as a "Snow
Valve". An air cleaner that is located in the engine
result. compartment may also minimize the snow that is
For this reason, when the engine is started, packed in the air cleaner. Heat that is rejected by
the engine must be operated until the coolant the engine warms the inlet air.
temperature is 71 OC (160 OF) minimum. Carbon
deposits on the valve stems will be kept at a Additional heat can be retained around the engine
minimum and the free operation of the valves and by insulating the engine compartment.
the valve components will be maintained.
i01646447
In addition, the engine must be thoroughly warmed
in order to keep other engine parts in better Radiator Restrictions
condition and the service life of the engine will be
generally extended. Lubrication will be improved. SMCS Code: 1353; 1396
There will be less acid and less sludge in the
oil. This will provide longer service life for the Caterpillar disco~ragesthe Lse of airf.ow restriction
engine bearings, the piston rings, and other parts. devices that are momtea in fronr of radiators. Airf ow
However, limit unnecessary idle time to ten minutes. restriction can cause the following conditions:
Engine wear is greatest at low idle and unnecessary
idling wastes fuel. a High exhaust temperatures
OnlOff Fan Clutch 8 Power loss
Viscous fans continuously rotate in cold weather, Excessive fan usage

which creates unnecessary movement of the air. For
better control of the operation of the fan, an ONIOFF 8 Reduction in fuel economy
fan clutch may be used. ONIOFF fan clutches can
help prevent excessive cooling in cold weather. In If an airflow restriction device must be used, the
the "OFF" position, the fan is kept stationary by the device should have a permanent opening directly
ONIOFF fan clutch. The unnecessary movement of in line with the fan hub. A centered opening that is
the air is reduced in order to maintain adequate directly in line with the fan hub is specified in order
engine operating temperatures in cold weather. to prevent an interrupted airflow on the fan blades.
Interrupted airflow on the fan blades could cause a
fan failure.
Purge Valve and Insulated Heater Lines
Caterpillar recommends a warning device for the
During periods of operations with a light load, inlet manifold temperature and/or the installation of
The coolant must bypass the radiator in order an inlet air temperature gauge. The warning device
to help prevent excessive cooling of the engine. for the inlet manifold temperature should be set at
Coolant that passes through the radiator must be 75 "C (167 O F ) . The inlet manifold air temperature
minimized in order to maintain the engine operating should not exceed 75 OC (167 OF). Temperatures
temperature in cold weather. that exceed this limit can cause power loss and
potential engine damage.
Excessive cooling of the engine is prevented by a
"jiggle" valve that performs two functions. The valve
allows the flow of air and the valve prevents the flow
of coolant. These valves prevent the unnecessary
coolant flow, which may be diverted around the
water temperature regulator to the radiator.
53
Operation Section
~01190421 When No. 2 diesel fuel is used the following

(3 Fuel and the Eftect from Cold components provide a means of minimizing
I Weather problems in cold weather:
/ SMCS Code: 1000; 1250

Starting aids
Engine oil pan heaters
II The following fuels are the grades that are available

for Caterpillar engines:
No. 1
Engine coolant heaters
Fuel heaters
I
. No. 2 Fuel line insulation
I Blend of No. 1 and No. 2 For more information on cold weather operation, see
Operation and Maintenance Manual, SEBU5898,
No. 2 diesel fuel is the most commonly used fuel. "Cold Weather Recommendations".
Either No. 1 diesel fuel or a blend of No. 1 and No,
2 is best suited for cold weather operation. 101821501
Quantities of No. 1 diesel fuel are limited. No. Fuel Related Components in
1 diesel fuels are usually available during the
months of the winter in the colder climates. During Cold Weather
cold weather operation, if No. 1 diesel fuel is not
available, use No. 2 diesel fuel, if necessary. SMCS Code: 1000; 1250
I There are three major differences between No. 1

and No. 2 diesel fuel. No. 1 diesel fuel has the
Fuel Tanks
14I following properties:
Lower cloud point

Lower pour point
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.
. .
Fuel tanks should contain some provision for
draining water and sediment from the bottom of the
tanks. Some fuel tanks use supply pipes that allow
I Lower rating of kJ (BTU) per unit volume of fuel
When No. 1 diesel fuel is used, a decrease in

water and sediment to settle below the end of the
fuel supply pipe.
power and in fuel efficiency may be noticed. Other Some fuel tanks use supply lines that take fuel
operating effects should not be experienced. directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
The cloud point is the temperature when a cloud the fuel system filter is important.
of wax crystals begins to form in the fuel. These
crystals can cause the fuel filters to plug. The Drain the water and sediment from any fuel storage
pour point is the temperature when diesel fuel will tank at the following intervals: weekly, oil changes,
thicken. The diesel fuel becomes more resistant to and refueling of the fuel tank. This will help prevent
flow through fuel pumps and through fuel lines. water andlor sediment from being pumped from the
fuel storage tank and into the engine fuel tank.
Be aware of these values when diesel fuel is
purchased. Anticipate the average ambient
temperature within the area that the engine will be Fuel Filters
operated. Engines that are fueled in one climate
may not operate well if the engines are moved It is possible that a primary fuel filter is installed
to another climate. Problems can result due to between the fuel tank and the engine fuel inlet. After
changes in temperature. you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
Before troubleshooting for low power or for poor system. Refer to the Operation and Maintenance
performance in the winter, check the type of fuel Manual in the Maintenance Section for more
that is being used. information on priming the fuel system.
54
Operation Section
The micron rating and the location of a primary

fuel filter is important in cold weather operation.
The primary fuel filter and the fuel supply line are
the most common components that are affected by
cold fuel.
Fuel Heaters
Fuel heaters help to prevent fuel filters from
plugging in cold weather due to waxing. A fuel
heater should be installed in the fuel system before
the primary fuel filter.
The following fuel heaters are recommended for

Caterpillar engines:
7C-3557 Fuel Heater Group
7C-3558 Heater Kit
For further information on fuel heaters, consult your

Caterpillar dealer.
Disconnect the fuel heater in warm weather.
Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters
that are not controlled by the water temperature
regulator can heat the fuel in excess of 65°C
(149°F). A loss of engine power can occur if the fuel
supply temperature exceeds 37°C (100°F).
Note: Heat exchanger type fuel heaters should have

a bypass provision in order to prevent overheating
of the fuel in warm weather operation.
55
Operation Section
Generator Operation
Generator Operation
43 i01972467
Generator Operation
I SMCS Code: 4450
I Loading of the Generator

When a generator is installed or reconnected, be
sure that the total current in one phase does not
exceed the nameplate rating. Each phase should
carry the same load. This allows the engine to work
at the rated capacity. An electrical unbalance can
result in an electrical overload and overheating
if one phase current exceeds the nameplate
amperage.
Allowable combinations of unbalanced loads are

shown in Illustration 46. When you operate with
significant single-phase loads, the combinations of
single-phase load and three-phase load may be
used. Such combinations should be located below
the line.on the graph.
SINGLE-PHASE LOAD A S A PERCENT OF

THREE-PHASE KV-A .RATING
Allowable Combinations of Unbalanced Loads
Block Loading
When an electrical load is applied to a generator
set, block loading occurs. This load may be
anywhere from a moderate percentage of the rated
load up to the rated load.
The block loading capability of a generator set

depends on the following factors.
engine transient response
voltage regulator response
type of the voltage regulator
altitude of operation of the generator set
type of load
the amount of load that is already present

56
Operation Section
Generator Operation
If a block load derating is required, refer to IS0 Excitation Systems

8268 Standards or SAE J1349 Standards. Also,
reference Engine Data Sheet, LEKX4066, "Loading Refer to the Operation and Maintenance Manual.
Transient Response" and Engine Data Sheet, "Voltage Regulators" for information on excitation
LEKX4067, "Block and Transient Response". systems.
Power Factor Low Idle Adjustment

Power factor (PF) determines the relationship The low idle is typically 1200 rpm. On 60 Hz units,
between true power and apparent power. The true low idle will be approximately 66 percent of the
power is also known as the active power. The full load speed. On 50 Hz units, low idle will be
apparent power is also called kVA. The true power approximately 80 percent of full load speed.
(kW) is the work that is done on the load by the
engine. The true power determines the amount of The low idle is set at the factory on generator sets
power that is available for the load to do work. with mechanical governors. The low idle should only
The apparent power (kVA) is the total power that is be adjusted by your Caterpillar dealer if adjustment
produced by the generator. Power factor can be is required.
calculated by using the following formula.
Note: Operating the electric set at low idle speed
for an extended time will cause some voltage
regulators to shut off. The electric set must be
kW - kilowatts completely shut down. Then, the electric set must
be restarted. This will allow the voltage regulator to
kVA - Kilo-Volt-Ampere again produce an output.
KVAR stands for Kilo-Volt-Ampere-Reactive,which

is the unit of measurement for reactive power.
Standby Generator Sets
Most standby units are automatic. Without an
Note: The generator does NOT control power factor. operator in attendance, standby units will perform
Power factor is determined by the load. the following functions: start, pick up the load, run,
and stop.
In most applications, electric motors, solid-state '
controls, and transformers determine the power Standby units will not change the governor speed
factor of the system. Induction motors usually control or voltage level settings automatically. The
have a power factor that is no larger than 0.8. governor speed and voltage level must be preset
Incandescent lighting is a resistive load of about 1.0 for the proper operation of that unit. Whenever the
power factor, or unity. Solid-state controls, variable set is operated manually, ensure that the governor
frequency drivers (VFD), variable speed drivers speed and the voltage level settings are set
(VSD), and systems for the UPS can operate at any correctly for automatic operation. Check all switches
power factor, leading or lagging. In this case, the for the proper setting. The Start Selector Switch
power factor can be between 0.4 and 1.O. should be in the AUTOMATIC position. Emergency
Stop Switches should be in RUN position.
The power factor of a system may be determined by
a power factor meter or by calculations. Determine
the power requirement in kW by multiplying the Generator Options
power factor by the kVA that is supplied to the
system. As the power factor increases, the total Space Heaters
current that is supplied to a constant power
demand will decrease. With equal loads, a lower Most of the generators are provided with space
power factor will draw more current. A high power heaters. These space heaters are installed for
factor will result in full engine load that is less than operation in all climates. For more information
the generator's rated amperage. A lower power on space heaters, refer to Maintenance Section,
factor increases the possibility of overloading the "Space Heater - Check".
generator.
Note: Normally, Caterpillar generators are designed

for a power factor of 0.8 lagging. Please consult
your Caterpillar dealer in order to check the
generator rating if the operation at less than 0.7
lagging power factor or operation at a leading
power factor of 0.8 is desired.
57
Operation Section
Generator Operation
a Embedded Temperature Detectors i01490164
3 Some generators are available with embedded Single Unit Operation

temperature detectors. The detectors are installed
in the slots of the main armature. The main armature SMCS Code: 4450
is also called a stator. The detectors are used with
the equipment that is provided by the customer. Initial Start-Up
Thus, the temperature of the main armature winding
can be measured or monitored. RTDtemperature Before the initial start-up, perform the megohmmeter
detectors are available. Contact your Caterpillar test on the main stator winding. Refer to the Special
dealer for more information. Instruction, SEHS9124, "Cleaning and Drying of
Electric Set Generators" for the procedure.
Bearing Temperature Detectors
Starting
Bearing temperature detectors are available on
large-frame generators. Bearing temperature 1. Make all preliminary engine starting checks.
detectors measure the main bearing temperature.
Thus, the temperature of the bearing can be 2. Be sure that the main circuit breaker or the line
measured or monitored. Bearing temperature circuit breaker is open.
measurements may help to prevent premature
bearing failure. Bearing temperature detectors are 3. Start the engine. Allow the engine to warm up.
used with customer provided equipment. Contact
your Caterpillar dealer for more information. 4. Adjust to the full load engine speed,
5. Close the main circuit breaker.
6. Apply the load. Do not try to apply the full load.

Apply the load in increments in order to maintain
system frequency at a constant level.
7. Readjust the governor for rated frequency.
Stopping
1. Remove the load in increments.
2. Open the circuit breaker.
3. Allow the engine to run for five minutes in order

to cool.
4. Stop the engine.
Parallel Operation
SMCS Code: 4450; 4480
Initial Start-Up
Preparing a generator for parallel operation requires
special attention. Before you attempt to parallel
units for the first time, check all the units for the
following three conditions.
8 same phase rotation
8 same alternating current frequency

58
Operation Section
Generator Operation
same voltage adjustment If the lights blink in sequence, one of the

units is connected backward. In order to
1. Check the phase rotation. correct the problem, stop the units. Remove
generator leads 1 and 3 at the circuit
The phase rotation of the paralleled units must breaker. Exchange these generator leads.
be the same. There are two methods that are This reverses the direction of phase rotation.
used to determine whether the phase rotation of Terminal 2 should always be connected to
the incoming unit and the phase rotation of the line 2. Go to 5.
on line unit(s) are the same. These methods are
listed below: If the lights blink in unison, the phase
rotation of both generators is the same.
using a phase rotation meter The first condition of "Initial Start-Up" has
been met.
using a set of three light bulbs
2. Adjust the frequency.
Use the procedure below to determine the
proper phase rotation by using three light bulbs. The speed of the units that will be paralleled
must be the same. Speed is proportional to the
alternating current frequency.
a. Allow each electric set to run under load for

3 about 30 minutes.
SYNCHRONIZING
b. Adjust the governor control in order to give
the rated frequency at full load.
c. Remove the load and check the high idle

GENERATOR speed. The high idle speed should be
GENERATOR approximately 2 to 5 percent above full load
speed for governors that are equipped with
droop. If these speeds can not be obtained,
contact your Caterpillar dealer.
d. For the most consistent results, repeat 2.b
and 2.c until the second condition of "Initial
Start-Up" has been met.
When servicing or repairing electric power gener-
ation equipment: 3. Adjust the voltage.
Make sure the unit is off-line (disconnected from There are two integrally different methods for
utility andlor other generators power service), and reactive power equalization.
either locked out or tagged DO NOT OPERATE. Re-
move all fuses. reactive droop compensation (individual
compensation)
a. Connect the light bulbs with rated voltage cross current compensation (differential
between the generator leads and the compensation)
corresponding line phase. For example,
connect terminal 1 to line 1 across the open
circuit breaker.
b. Start the units that are going to be paralleled.

Bring the units up to speed. As the units
approach the same speed, the lights will start
to blink.
59
Operation Section
Generator Operation
In the reactive droop compensation the voltage If the driven load has the unity power factor,
3 regulator causes an output voltage of an
individual generator to change in proportion
to the reactive current. The reactive current is
set the voltage droop potentiometer on all
generators at half of full range. Proceed to
3.9.
measured with a current transformer (CT). The
reactive current can be either lagging or leading. If the driven load is to be normal
As the lagging reactive current increases, the (approximately 0.8 power factor), proceed
voltage regulator will cause the generator output to 3.c.
voltage to lower (to droop) proportionally. As the
leading reactive current increases, the voltage c. Readjust the voltage level rheostat until the
regulator will cause the generator output voltage voltage is approximately 5 percent above
to rise proportionally. This method will tend to desired voltage.
reduce the reactive current for better KVAR
sharing with other units. The reactive droop d. Apply full load.
compensation is a standard method on the
Caterpillar generator sets. The following voltage e. Readjust the voltage droop rheostat in order
adjustment procedure is for the reactive droop to obtain desired voltage with full load at
compensation. 0.8 power factor. The voltage droop of each
generator must be the same in order to
In the cross current compensation the voltage satisfactorily divide the reactive load.
regulator is biased by the difference in reactive
current outputs of the paralleled generators. f. Repeat 3.c, 3.d and 3.e for each generator
Cross current compensation is very similar to the until the following two conditions are met:
reactive droop compensation. The difference
is that the secondary circuits of the current The line voltage is equal to the desired level
transformers are interconnected in a series at full load.
string. When one of the generators carries
more reactive current than other generators, No load voltage is approximately 5 percent
a net difference voltage signal will offset the above Jhe rated voltage.
generated voltage. When the current that the
generator carries is either lagging or leading, g. Parallel the generators and apply the driven
a net difference voltage signal will offset the load. Check the output current of the
generated voltage. This will also reduce the generator. If the sum of the amperes of the
reactive current. Refer to the Engine Data Sheet, individual generator amperes exceeds the
LEKX8142, "Caterpillar Zero Droop Voltage for total amperes that are going to the load by
Parallel Operation" for the adjustment procedure. 10 percent at full load, adjust voltage droop
rheostats. This will lead to proportional current
Note: The voltage level adjustment and the sharing between generators. Some circulating
voltage droop adjustment determine the amount current is permitted at light load. Some
of circulating currents between the generators. circulating current can be expected when
The circulating currents between the generators generators are cold.
will be reduced when the voltage adjustments are
carefully matched. Use the same voltmeter to make NOTICE
adjustments on each unit which will be paralleled. Damage to the generator is possible. Do NOT exceed
the rated ampere load on any single generator.
Note: Voltage droop is expressed as the percentage
of voltage change from no load to full load. Loads
of 0.8 power factor (primarily motors) require a h. Make final adjustments after paralleled
generator voltage droop of about 5 percent. A generators have been running at full load for
voltage droop adjustment that causes 3 percent to one hour or more. Tighten the locknuts on all
8 percent droop in voltage is usually required for controls. Install the access cover. The last
satisfactory division of ampere loading. condition of "Initial Start-Up" has been met.
a. Adjust the voltage. Refer to the "lnitial
Start-Up" in the Operation Section, "Single
Starting Multiple Units
p Unit Operation".
b. While the engine is running at rated speed,

Multiple unitsare started the same as single units.
Refer to Operation Section, "Single Unit Operation"
turn the voltage droop potentiometer
clockwise about 112 of full range.
60
Operation Section
Generator Operation
Paralleling Multiple Units -

Load Division Speed Droop (If
Units may be paralleled at no load. Units may
Equipped)
also be paralleled with units under load. After the Once two units have been paralleled, the unit's
initial start-up conditions are satisfied, verify for the share of the kW load is determined by the governor
following requirements: control setting. If two units of the same capacity
and the same governor characteristics have the
One of the governors can be an isochronous same governor control settings, the units will share
governor. Electronic load sharing governors are
the load equally. The total load must not exceed the
an exception. capacity of the one engine.
Generators must have voltage droop In order to transfer the load from one engine to
compensation or cross current compensation.
another, use the following procedure:
1. Start the unit which will be paralleled. Refer
1. Increase the governor speed control of one unit
to the appropriate engine service manual for in order to increase the load.
start-up procedures.
2. Reduce the governor speed control of the other
2. Turn the synchronizer lights on.
unit in order to decrease the load on that unit.
3. After the engine has run a few minutes, bring the
3. Raise the governor speed control or lower the
engine up to synchronous speed. This means
governor speed control of both units in order to
that the frequency of the incoming unit will be change system frequency.
the same as the frequency of the unit on line.
The synchronizing lights will begin to blink.
Parallel Operation Of Governors
Note: The frequency of the incoming unit should
be slightly greater than the line frequency. This will
allow the incoming unit to assume some of the load
rather than add to the system load.
4. Using the governor control, adjust the engine

speed until the lights blink very slowly.
5. The lights are off when the voltages of the two

units are in phase. At this point, very quickly
close the breaker while the lights are out.
6. Use governor controls in order to share kW load

between engines.
go0630841
7. Generator temperature will be stabilized in Illustration 48
approximately one hour. After the generator -
Load Sharing Module Typical Example
temperature has been stabilized, adjust the
voltage droop rheostat of each generator. This The generator set load sharing module provides
will share the reactive load and will limit the either droop load sharing or isochronous load
circulating currents. Less droop increases the sharing for paralleled generator applications. The
reactive current that is carried by the generator. load sharing module has a synchronizing parallel
Adjusting the voltage droop rheostat in a module (SPM-A) input. The module provides
counterclockwise direction (CCW) will decrease proportional load sharing. More information is
droop. Adjusting the voltage droop rheostat in a available in the System Operation, Testing and
clockwise direction (CW) will increase droop. Adjusting, SENR6565, "Generator Set Load Sensor
and Generator Load Sharing Module".
61
Operation Section
Generator Operation
Governors that are used with Caterpillar powered

electric sets can be of two types:
Governors with fixed speed droop
Governors with adjustable speed droop
The values of speed droop which are commonly

used are 3 percent and 0 percent. Governors
with adjustable speed droop can be adjusted
so their characteristics match quite closely the
characteristics of governors with fixed speed droop.
If the governor is adjusted for 0 percent speed
droop (isochronous) operation, then the same
speed from no load to full load can be obtained.
(1) Drwp potentiometer
Summary on Governor Operation
The Speed brick converter changes the analog The preceding discussion of governor operation
signal of the speed potentiometer (SP) into a pulse can be summarized below:
width modulated (PWM) signal that the engine
electronic control can recognize. The converter is The simplest governor combination for parallel
mounted on the subpanel which is located within electric sets is to have approximately 3 percent
the control panel. speed droop characteristics for each governor.
If a constant frequency from no load to full load
I Function of The Engine Governor
This section describes the function of the engine
is required, one governor can be adjusted for
isochronous operation. This isochronous unit will
be called a "lead unit".
CP governor in relation to load division between parallel

eiectric sets. For detailed information on governor
controls and adjustments, see the Operation &
In order for all paralleled units to accept their
full share of the load, the following governor
Maintenance Manual and the Service Manual for adjustments are required. The governors should
the appropriate engine. have the same full load speed. The governors
should have the same high idle (no load) speed
It is very important to understand two basic facts in the case of governors which are adjusted for
about load division between generator sets which speed droop operation. Governor controls should
are operating in parallel. be set to the high idle position so that the full
governor range is available.
1. The power which is supplied to the generator
and, thus, to the load is a function of the engine. Operation of an isochronous governor in parallel
The engine governor settings and the positions with speed droop governors requires special
of the governor controls determine the amount of techniques.
power that is delivered by the engine. Therefore,
the engine governor settings and the positions a Any number of electric sets can be operated in
of the governor controls determine the kW load parallel. However, only one governor of the group
which is carried by the generator. If the governor can be adjusted for isochronous operation. The
control setting is advanced, the engine and exception will be some special cases of electronic
generator will assume more kW load. Likewise, governors with automatic load sharing.
decreasing the governor control setting will result
in a reduction of load on the unit. Any other units
on the line will, conversely, either reduce load or Stopping
the units will gain load at the same time. These
other units will assume that no change in total In order to remove a generator from the line,
load or no change in the governor settings of the perform the following procedure.
other units has taken place.
1. Check the load. The load must be less than the
('
b
) 2. The division of power is not determined by
generator excitation or terminal voltage. The
rated capacity of the remaining units.
power factor at which a generator will operate 2. Be sure that the neutral of one of the remaining
when the generator is paralleled with other units is grounded.
generators is determined by the excitation.
3. Remove the load from the outgoing unit. See
the Parallel Operation, "Load Division - Speed
Droop". The amperage may never go to zero due
to circulating currents.
4. Open the circuit breaker.
5. Allow the engine to cool for five minutes.
6. Stop the engine.
Circulating Currents
Understanding the circulating currents becomes
very important when you parallel the units. These
circulating currents are flowing between paralleled
generators. The circulating currents are caused by
voltage differences between the generators. The
circulating currents are not doing useful work. The
amount of the circulating current can be determined
by subtracting the amperage which is going to the
load from the total generator amperage.
The circulating current may be as high as 25

percent of rated amperes with cold generator sets.
Such current may not even be considered harmful.
The total generator current should not exceed the
amperage rating.
As the generators warm, the circulating currents will

decrease. The ammeter readings should decrease
slightly, but the voltage meter readings should
remain constant.
Maintenance Section
--
Lubricant Specifications
Maintenance Section Table 6
3 I
I Current
API Classifications
I Obsolete
I
1.
Lubricant Specifications CF-4, CG-4, CH-4 CE
CF CC. CD
i01111306
I I
Lubricant lnformation I
('1 CD-2 and API CF-2 are ciassificafions for two-cycle diesel
engines. Caterpillar does not sell engines that utilize CD-2 and
SMCS Code: 1000; 1300; 7581 API CF-2 oils.
Note: API CF is not the same classification as

General lnformation API CF-4. API CF oils are only recommended
for Caterpillar 3600 Series Diesel Engines and
Because of government regulations regarding Caterpillar engines with precombustion chamber
the certification of engine exhaust emissions, the (PC) fuel systems.
lubricant recommendations must be followed.
Grease
Engine Manufacturers Association
(EMA) Oils The classifications of grease are based on the
"ASTM D217" worked penetration characteristics.
The "Engine Manufacturers Association These characteristics for grease are given a defined
Recommended Guideline on Diesel Engine Oil" is consistency number.
recognized by Caterpillar. For detailed information
about this guideline, see the latest edition of EMA. Terminology
publication, "EMA LRG-I".
Certain abbreviations follow the nomenclature of
3 APl Oils .
"SAE J754". Some classifications follow "SAE J183"
abbreviations, and some classifications follow the
The Engine Oil Licensing and Certification System "€MA Recommended Guideline on Diesel Engine
by the American Petroleum Institute (API) is Oil". In addition to Caterpillar definitions, there
recognized by Caterpillar. For detailed information are other definitions that will be of assistance in
about this system, see the latest edition of the "API purchasing lubricants. Recommended oil viscosities
publication No. 1509". Engine oils that bear the API can be found in this publication, "Engine Oil" topic
symbol are authorized by API. (Maintenance Section).
i01539915
Engine Oil
SMCS Code: 1300; 1348; 7581
Caterpillar Diesel Engine Oil

Caterpillar Oils have been developed and tested in
order to provide the full performance and service
life that has been designed and built into Caterpillar
Engines. Caterpillar Oils are currently used to fill
diesel engines at the factory. These oils are offered
by Caterpillar dealers for continued use when the
engine oil is changed. Consult your Caterpillar
Typical API symbol dealer for more information on these oils.
Diesel engine oils CC, CD, CD-2, and CE have Due to significant variations in the quality and in
not been API authorized classifications since 1 the performance of commercially available oils,
January 1996. Table 6 summarizes the status of the Caterpillar makes the following recommendations:
classifications.
Caterpillar Diesel Engine Oil (10W30)
64
Maintenance Section
Caterpillar Diesel Engine Oil (15W40) EMA LRG-1 - The Engine Manufacturers
Association (EMA) has developed lubricant
Caterpillar multigrade Diesel Engine Oil is recommendations as an alternative to the API oil
formulated with the correct amounts of detergents. classification system. LRG-1 is a Recommended
dispersants, and alkalinity in order to provide Guideline that defines a level of oil performance
superior performance in Caterpillar Diesel Engines. for these types of diesel engines: high speed, four
stroke cycle, heavy-duty, and light duty. LRG-I
Caterpillar multigrade Diesel Engine Oil is available oils may be used in Caterpillar engines when the
in two viscosity grades (10W30 and 15W40). following oils are recommended: API CH-4, API
For direct injection engines, see Table 7 in order CG-4, and API CF-4. LRG-1 oils are intended to
to choose the correct viscosity grade for the provide superior performance in comparison to API
ambient temperature. Multigrade oils provide the CG-4 and API CF-4.
correct viscosity for a broad range of operating
temperatures. LRG-I oils will meet the needs of high performance
Caterpillar diesel engines that are operating in
Multigrade oils are effective in maintaining low oil many applications. The tests and the test limits that
consumption and low levels of piston deposits. are used to define LRG-1 are similar to the new
API CH-4 classification. Therefore, these oils will
Caterpillar multigrade Diesel Engine Oil can be also meet the requirements of the low emissions
used in other diesel engines and in gasoline diesel engines. LRG-I oils are designed to control
engines. See the engine manufacturer's guide for the harmful effects of soot with improved wear
tne recommended specifications. Compare the resistance and improved resistance to plugging of
s~ecificationsto the s~ecificationsof Cater~ilar the oil filter. These oils will also provide superior
multigrade Diesel ~ n ~ / Oil.
n eThe current in'dustry piston deposit control for engines with either
standards for Caterpillar Diesel Engine Oil are listed two-piece steel pistons or aluminum pistons.
on the product label and on the data sheets for the
product. All LRG-1 oils must complete a full test program
with the base stock and with the viscosity grade of
Consult your Caterpillar dealer for part numbers the finished commercial oil. The use of "API Base
and for available sizes of containers. Oil Interchange Guidelines" are not appropriate for
LRG-1 oils. This feature reduces the variation in
Commercial Oils performance that can occur when base stocks are
changed in commercial oil formulations.
The performance of commercial diesel engine
oils is based on American Petroleum Institute LRG-I oils are recommended for use in extended
(API) classifications. These API classifications are oil change interval programs that optimize oil life.
developed in order to provide commercial lubricants These oil change interval programs are based
for a broad range of diesel engines that operate at on oil analysis. LRG-I oils are recommended
various conditions. for conditions that demand a premium oil. Your
Caterpillar dealer has the specific guidelines for
If Caterpillar multigrade Diesel Engine Oil is not optimizing oil change intervals.
used, only use commercial oils that meet the
following classifications: API CH-4 - API CH-4 oils were developed in
order to meet the requirements of the new high
EMA LRG-I multigrade oil (preferred oil) performance diesel engines. Also, the oil was
designed to meet the requirements of the low
API CH-4 multigrade oil (preferred oil) emissions diesel engines. API CH-4 oils are also
acceptable for use in older diesel engines and in
API CG-4 multigrade oil (preferred oil) diesel engines that use high sulfur diesel fuel. API
CH-4 oils may be used in Caterpillar engines that
API CF-4 multigrade oil (acceptable oil) use API CG-4 and API CF-4 oils. API CH-4 oils will
generally exceed the performance of API CG-4 oils
In order to make the proper choice of a commercial in the following criteria: deposits on pistons, control
oil, refer to the following explanations: of oil consumption, wear of piston rings, valve train
wear, viscosity control, and corrosion.
65
Maintenance Section
Three new engine tests were developed for the Some commercial oils that meet the API
3 API CH-4 oil. The first test specifically evaluates
deposits on pistons for engines with the two-piece
steel piston. This test (piston deposit) also measures
classifications may require reduced oil change
intervals. To determine the oil change interval,
closely monitor the condition of the oil and perform a
the control of oil consumption. A second test is wear metal analysis. Caterpillar's S.0.S oil analysis
conducted with moderate oil soot. The second program is the preferred method.
test measures the following criteria: wear of piston
rings, wear of cylinder liners, and resistance to NOTICE
corrosion. A third new test measures the following Failure to follow these oil recommendations can cause
characteristics with high levels of soot in the oil: shortened engine service life due to deposits andlor
wear of the valve train, resistance of the oil in excessive wear.
plugging the oil filter, and control of sludge.
In addition to the new tests, API CH-4 oils have Total Base Number (TBN) and Fuel
tougher limits for viscosity control in applications
that generate high soot. The oils also have improved Sulfur Levels for Direct Injection
oxidation resistance. API CH-4 oils must pass an (Dl) Diesel Engines
additional test (piston deposit) for engines that use
aluminum pistons (single piece). Oil performance is The Total Base Number (TEN) for an oil depends on
also established for engines that operate in areas the fuel sulfur level. For direct injection engines that
with high sulfur diesel fuel. use distillate fuel, the minimum TEN of the new oil
must be 10 times the fuel sulfur level. The TEN is
All of these improvements allow the API CH-4 oil defined by "ASTM D2896". The minimum TEN of
to achieve optimum oil change intervals. API CH-4 the oil is 5 regardless of fuel sulfur level. Illustration
oils are recommended for use in extended oil 51 demonstrates the TEN.
change intervals. API CH-4 oils are recommended
for conditions that demand a premium oil. Your
Caterpillar dealer has specific guidelines for
optimizing oil change intervals.
-
API CG-4 API CG-4 oils were developed primarily
for diesel engines that use a 0.05 percent level of
fuel sulfur. However, API CG-4 oils can be used
with higher sulfur fuels. The TEN of the new oil
determines the maximum fuel sulfur level for API
CG-4 and API CF-4 oils. See Illustration 51.
API CG-4 oils are the first oils that are required to
pass industry standard tests for foam control and
viscosity shear loss. API CG-4 oils must also pass
go0799818
tests that were developed for corrosion, wear and Illustration 51
oxidation. (Y) TEN by "ASTM D2896"
(X) Percentage of fuel sulfur by weight
API CF-4 -These oils service a wide variety of (1) TEN of new oil
(2) Change the oil when the TEN deteriorates to 50 percent of
modern diesel engines. API CF-4 oils provide more the original TBN.
stable oil control and reduced piston deposits in
comparison to API CF and the obsolete CE and CD Use the following guidelines for fuel sulfur levels
classifications of oil. API CF-4 oils provide improved that exceed 1.5 percent:
soot dispersancy in comparison to API CF and
obsolete CD oils. The API CF-4 classification was Choose an oil with the highest TEN that meets
developed with a 0.40 percent sulfur diesel fuel. one of these classifications: EMA LRG-1, API
This represents the type of diesel fuels that are CH-4, API CG-4, and API CF-4.
commonly available worldwide.
Reduce the oil change interval. Base the oil
Note: Do not use single grade API CF oils or change interval on the oil analysis. Ensure that
multigrade API CF oils in Caterpillar Direct lnjection the oil analysis includes the condition of the oil
(Dl) Commercial Diesel Engines. and a wear metal analysis.
66
Maintenance Section
Excessive piston deposits can be produced by an i01906082

oil with a high TBN. These deposits can lead to a
loss of control of the oil consumption and to the Synthetic Base Stock Oils
polishing of the cylinder bore.
SMCS Code: 1300; 1348; 7581
NOTICE Synthetic base oils are acceptable for use
Operating Direct Injection (Dl) diesel engines with fuel in Caterpillar engines if these oils meet the
sulfur levels over 1.0 percent may require shortened performance requirements that are specified for the
oil change intervals in orderto help maintain adequate engine compartment.
wear ~rotection.
Synthetic base oils generally perform better than
conventional oils in the following two areas:
Lubricant Viscosity Recommendations
for Direct Injection (Dl) Diesel Engines Synthetic base oils have improved flow at low
temperatures especially in arctic conditions.
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during Synthetic base oils have improved oxidation
cold engine start-up, and the maximum ambient stability especially at high operating temperatures.
temperature during engine operation.
Some synthetic base oils have performance
Refer to Table 7 (minimum temperature) in order characteristics that enhance the service life of the
to determine the required oil viscosity for starting oil. However, Caterpillar does not recommend the
a cold engine. automatic extension of oil change intervals for
any type of oil. Oil change intervals for Caterpillar
Refer to Table 7 (maximum temperature) in order to engines can only be adjusted after an oil analysis
select the oil viscosity for engine operation at the program that contains the following data: oil
highest ambient temperature that is anticipated. . condition and wear metal analysis (Caterpillar's
S.0.S oil analysis), trend analysis, fuel consumption,
Generally, use the highest oil viscosity that and oil consumption.
is available to meet the requirement for the
temperature at start-up.
i01946671
I Enaine Oil Viscositv I Re-refined Base Stock Oils

Caterpillar DEO Ambient TeIn~erature SMCS Code: 1300; 7581
Multigrade
EMA LRG-1 Re-refined base stock oils are acceptable for
API CH-4 use in Caterpillar engines if these oils meet the
API CG-4 and Minimum Maximum performance requirements that are specified by
API CF-4 Caterpillar. Re-refined base stock oils can be used
Viscosity Grade exclusively in finished oil or in a combination with
SAE OW20 1 -40 "C (-40 "F) 1 10 "C (50 OF) new base stock oils. The US military specifications
and the specifications of other heavy equipment
SAE OW30 -40 "C (-40 "F) 30 "C (86 "F) manufacturers also allow the use of re-refined base
SAE OW40 I -40 "C (-40 "FI 1 40 "C H04 "FI I stock oils that meet the same criteria.
SAE 5W30 1 -30 "C (-22 "FI 1 30 "C (86 "FI I The process that is used to make re-refined base
I SAE 5W40 I -30 "C (-22°F) 1 40 ' C (104 "F) I stock oil should adequately remove all wear metals
that are in the used oil and all additives that are
I SAE 10W30 I -20 "C (-4°F) I 40 "C (104'F) I in the used oil. The process that is used to make
SAE 15W40 1 -15 "C (5 "F) I 50 "C (122 OF) 1 re-refined base stock oil generally involves the
processes of vacuum distillation and hydrotreating
the used oil. Filtering is inadequate for the
production of high quality re-refined base stock oils
from used oil.
67
Maintenance Section
101113213
C .d Cold Weather Lubricants Aftermarket Oil Additives

i01Q08162
I SMCS Code: 1300; 1348; 7581
When an engine is started and an engine is

SMCS Code: 1300; 1348; 7581
Caterpillar does not recommend the use of

operated in ambient temperatures below -20 "C aftermarket additives in oil. It is not necessary to
(-4 OF), use multigrade oils that are capable of use aftermarket additives in order to achieve the
flowing in low temperatures. engine's maximum service life or rated performance.
Fully formulated, finished oils consist of base oils
I These oils have lubricant viscosity grades of SAE

OW or SAE 5W.
When an engine is started and operated in ambient

and of commercial additive packages. These
additive packages are blended into the base oils
at precise percentages in order to help provide
finished oils with performance characteristics that
temperatures below -30 "C (-22 OF), use a synthetic meet industry standards.
base stock multigrade oil with a OW viscosity grade
or with a 5W viscosity grade. Use an oil with a pour There are no industry standard tests that evaluate
point that is lower than -50 C (-58 O F ) . the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
The number of acceptable lubricants is limited in not be compatible with the finished oil's additive
, cold weather conditions. Caterpillar recommends package, which could lower the performance of the
the following lubricants for use in cold weather finished oil. The aftermarket additive could fail to
conditions: mix with the finished oil. This could produce sludge
in the crankcase. Caterpillar discourages the use of
P
I
I
First Choice -use an oil with an EMA LRG-I
Recommended Guideline or use a CH-4 oil that is
API licensed with an SAE OW2O. SAE OW30. SAE
-, OW40, SAE 5W30, or SAE 5 ~ 4 lubricant
0 viscositv
grade. A CG-4 oil that is API licensed with an SAE
aftermarket additives in finished oils.
To achieve the best performance from a Caterpillar

engine, conform to the following guidelines:
OW20, SAE OW30, SAE OW40, SAE 5W30, or SAE Select the proper Caterpillar oil or a commercial
I 5W40 lubricant viscosity grade may also be used.

A CF-4 oil that is API licensed with an SAE OW20.
oil that meets the Caterpillar recommendations.
I SAE OW30, SAE OW40, SAE 5W30, or SAE 5 ~ 4 0 '

lubricant viscosity grade may also be used.
See the appropriate "Lubricant Viscosities" table
in order to find the correct oil viscosity grade for
your engine.
1I Second Choice -use an oil that contains the CH-4,

CG-4, or CF-4 additive uackaae althouah the oil
has not been tested for'the r&uireme& of the
At the specified interval, service the engine
compartment. Use new oil and install a new oil
II API license. The oil must have'an SAE OW20,

SAE OW30. SAE OW40, SAE 5W30, or SAE 5W40
lubricant viscosity grade.
filter.
perform maintenance at the intervals that are

specified in the Operation and Maintenance
II NOTICE
Shortened engine service life could result if second
choice oils are used.
Manual. "Maintenance Interval Schedule".
i01065849
S.0.S Oil Analysis

SMCS Code: 1348; 7542; 7581
Caterpillar recommends the use of the S.0.S

oil analysis program in order to monitor the
condition and the maintenance requirements of
the equipment. The S.0.S oil analysis program will
complement the preventive maintenance program.
68
Maintenance Section
The S.0.S oil analysis is a diagnostic tool that is

used to determine oil performance and component
wear rates. Contamination can be identified and
measured through the use of the S.0.S oil analysis.
The S.0.S oil analysis includes the following tests:
The Wear Rate Analysis monitors the wear of the

engine's metals. The amount of wear metal and
type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in
the oil is as important as the quantity of engine
wear metal in the oil. For thls reason, regular
sampling at specified intervals is necessary
in order to establish wear rates. Intermittent
sampling does not allow wear rate trend lines
to be established. Engine wear metals in the oil
sample are compared to established Caterpillar
norms in order to determine acceptability.
Tests are conducted in order to detect

contamination of the oil by water, glycol or fuel.
The Oil Condition Analysis determines the loss

of the oil's lubricating properties. An infrared
analysis is used to compare the properties of
uew oil to the properties of the used oil sample.
This analysis allows technicians to determine
the amount of deterioration of the oil during use.
This analysis also allows technicians to verify
the performance of the oil according to the
specification during the entire oil change interval.
The test results of the oil samples will then be used

as a basis for determining the oil change interval
for the engine. The results of the S.0.S oil analysis
may allow the engine to operate longer between oil
changes without the risk of engine damage.
Table 8
I S.06 Oil Analysis Interval I

Compartment Interval
Engine crankcase Every 250 Service Hours
For more information, see Special Publication,

PEDP7036, "S.0.S Fluid Analysis". Consult your
Caterpillar dealer for complete information and
assistance about the program. .
69
Maintenance Section
Fuel Specifications
Fuel Specifications
C3 I Caterpillar Specifications for Distillate Diesel Fuel
Specifications Requirements ASTM
I
101878876
Test
Fuel Recommendations 10% at 282 "C (540 OF) "D86"
I SMCS Code: 1250; 1280 Distillation
maximum
90% at 360 "C (680 OF)
Diesel engines have the ability to burn a wide maximum
variety of fuels. These fuels are divided into two Flash Point legal limit "D93"
general groups. The two groups are called the
preferred fuels and the permissible fuels. 30 minimum 'D287"
API Gravity
45 maximum
The preferred fuels provide maximum engine
service life and performance. The preferred fuels
are distillate fuels. These fuels are commonly called I pour point I 6 "C (10 OF) minimum
below ambient
I "D97" I
diesel fuel, furnace fuel, gas oil, or kerosene.
3% maximum '03605"
The permissible fuels are crude oils or blended Sulfur (1)
fuels. Use of these fuels can result in higher "D1552"
maintenance costs and in reduced engine service
life. 1.4 cSt minimum and 20.0
Kinematic
cSt maximum at 40 'C
I
Viscosity R (104
Diesel fuels that meet the specifications in Table 9
will h e l to
~ Drovide maximum enaine service life I Water and I 0.1% maximum 1 'D1796" 1
and performance. In North ~ m e r h a diesel
, fuel that Sediment
is identified as No. I - D or No. 2-D in "ASTM D975" Water 0.1% maximum 'Dl 744"
generally meet the specifications. Table 9 is for
%3 diesel fuels that are distilled from crude oil. Diesel ~~~
Sediment 0.05% maximum (weight)
. . . "D473"
fuels from other sources could exhibit detrimental Gums and 10 mg per 100 mL "D381"
properties
... .
that are not defined or controlled by this Resins P, maximum
I specitication.
1 3100 g minimum 1 "D6078"
0.45 mm (0.018 inch)
I Cater~illarS~ecificationsfor Distillate Diesel Fuel I Lubricity (4)
maximum at 60 "C
(140 OF) "D6079"
Specifications Requirements ASTM
Test 0.38 mm (0.015 inch)
I Aromatics 1 35% maximum I 'D1319" I I maximumat 25 'C (7? OF) I
(1) Caterpillar fuel systems and engine components can
I Ash I 0.02% maximum (weight) 1 "D482" 1 operate on high sulfur fuels. Fuel sulfur levels affectexhaust
t
emissions. High sulfur fuels also increase the potential for
Carbon 0.35% maximum (weight) 'D524" corrosion of internal components. Fuel sulfur levels above 1.0
Residue on percent may significantly shorten the oil change interval. For
10% Bottoms additional information,see this publication, 'Engine Oil" topic
(2) The values of the fuel viscosity are the values as the fuei
Cetane Number is delivered to the fuei iniection oumos. if a fuel with a low
viscositv is used. coolinaof the fuel niav be reouired to maintain
1 I
The cloud point must a 1.4 c ~viscosiiy
t at thi fuel injection pump. ~"elswith high
viscosity might require fuel heaters in order to bring down the
not exceed the lowest viscosity to a 20 cSt viscosity. For addilional information, see
CloudPoint expected ambient - Special Publication, SEBD0717, *Diesel Fuel and Your Engine".
(3) Follow the test conditions and orocedures for aasoline (motor). '
(4) The lubricity of a fuel is a concern with low sifur fuel.'~o
Copper Strip No. 3 maximum "D130"
determine the lubricity of the fuel, use either the "ASTM D6078
Corrosion Scuffing Load Wear Test (SBOCLE)"or the "ASTM 136079 High
- (continued) Freaueicy ReciprocatingRig (HFRR)"test. If the lubricitv of
fuel doesnot meet the minimum requirements, consult your
fuel suoolier. Do not treat the fuei without consultina the fuel
supplier: Some additives are not compatible. ~hese-additives
can cause problems in the fuel system.
70
Maintenance Section
Fuel Specifications
There are many other diesel fuel specifications that

NOTICE are published by governments and by technological
Operating with fuels that do not meet Caterpillar's rec- societies. Usually, those specifications do not
ommendations can cause the following effects: start- review all the requirements that are addressed
ing difficulty, poor combustion, deposits in the fuel in- in this specification. To ensure optimum engine
jectors, reduced service life of the fuel system, de- performance, a complete fuel analysis should be
posits in the combustion chamber, and reduced ser- obtained before engine operation. The fuel analysis
vice life of the engine. should include all of the properties that are listed
in Table 9.
In the USA, 0.05 percent sulfur diesel fuels
have been used in all on-highway truck engines
since 1 January 1994. This low sulfur diesel fuel
was mandated as a means of directly reducing
particulate emissions from diesel truck engines.
This low sulfur fuel will also be used in Caterpillar
commercial diesel engines when low emissions are
required or when the source of your fuel supply
provide this type of fuel. Caterpillar has not seen
any detrimental effects with 0.05 percent sulfur fuel
in Caterpillar diesel engines.
NOTICE
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
must NOT be used in Caterpillar diesel engines (ex-
cept in 3600 Series HFO engines). Severe component
wear and component failures will result if HFO type fu-
els are used in engines that are configured to use dis-
tillate fuel.
In extreme cold ambient conditions, you may

use the distillate fuels that are specified in Table
10. However, the fuel that is selected must meet
the requirements that are specified in Table 9.
These fuels are intended to be used in operating
temperatures that are down to -54 ' C (-65 OF).
Table 10
Distillate Fuels (1)
I Soecification I ~ r a i e l
I "ASTM D1655" 1 Jet-A-1 I

"MIL-T-83133D" JP-8
(1) The fuels that are listed in this Table may not meet the
requirements that are specified in the "CaterpillarSpecifications
for Distillate Diesel Fuel"Table. Consult the suDdier for the
recommendedadditives in order to maintain t h e proper fuel
lubricity.
These fuels are lighter than the No. 2 grades of fuel.

The cetane number of the fuels in Table 10 must be
at least 40. If the viscosity is below 1.4 cSt at 38 "C
(100 O F ) , use the fuel only in temperatures below
0 "C (32 O F ) . Do not use any fuels with a viscosity
of less than 1.2 cSt at 38 O C (100 OF). Fuel cooling
may be required in order to maintain the minimum
viscosity of 1.4 cSt at the fuel injection pump.
71
Maintenance Section
Cooling System Specifications
Cooling System Many engine failures are related to the cooling
3 Specifications
system. The following problems are related to
cooling system failures: overheating, leakage of the
water pump, plugged radiators or heat exchangers,
and pitting of the cylinder liners.
i01646523
These failures can be avoided with proper cooling
General Coolant Information system maintenance. Cooling system maintenance
is as important as maintenance of the fuel system
SMCS Code: 1350; 1395 and the lubrication system. Quality of the coolant
is as important as the quality of the fuel and the
NOTICE lubricating oil.
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first. Coolant is normally composed of three elements:
water, additives, and glycol.
NOTICE
If the engine is to be stored in, or shipped to an area Water
with below freezing temperatures, the cooling system
must be either protectedto the lowest outside temper- NOTICE
ature or drained completely to prevent damage. All Caterpillar diesel engines equipped with air-to-air
aftercooling (ATAAC) require a minimum of 30 percent
glycol to prevent water pump cavitation.
NOTICE
Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection. NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
Clean the cooling system for the following reasons: alone is corrosive at engine operating temperatures.
C3 Contamination of the cooling system
Water alone does not provide adequate protection
against boiling or freezing.
Overheating of the engine
Water is used in the cooling system in order to
Foaming of the coolant transfer heat.
Note: Air pockets can form in the cooling system if Distilled water or deionized water is
the cooling system is filled at a rate that is greater recommended for use in engine cooling systems.
than 20 L (5 US gal) per minute.
DO NOT use the following types of water in cooling
After you drain the cooling system and after you systems: hard water, softened water that has been
refill the cooling system, operate the engine. conditioned with salt, and sea water.
Operate the engine without the filler cap until the
coolant reaches normal operating temperature and If distilled water or deionized water is not available,
the coolant level stabilizes. Ensure that the coolant use water with the properties that are listed in Table
is maintained to the proper level. 11.
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
;ii
3 Refer to Special Instruction, SEBD0518, "Know
Your Cooling System" and Special Instruction,
SEBD0970, "Coolant and Your Engine" for more
detailed information.
A
72
Maintenance Section
Table 11 Formation of gel compounds

I Cateroillar MinimumAcceotable Water Reauirements I Reduction of heat transfer
I Pro~ertv I Maximum Limit I ASTM Test I
Leakage of the water pump seal
I Il
Plugging of radiators, coolers, and small
passages
Glycol
I Acidii I pH of 5.5 to 9.0 1 'D1293" 1

Glycol in the coolant helps to provide protection
against the following conditions:
Boiling
II
For a water analysis, consult one of the following Freezing
sources:
Caterpillar dealer
For optimum performance, Caterpillar recommends
a 1:l mixture of a waterlglycol solution.
II
Local water utility company
Agricultural agent
Note: Use a mixture that will provide protection
against the lowest ambient temperature.
Note: 100 percent pure glycol will freeze at a

.
II
Independent laboratory temperature of -23 "C (-9 OF).
Most conventional heavy-duty coolantlant~freezes

Additives use ethylene glycol. Propylene glycol may also be
used. In a 1:l mixture with water, ethylene and
Additives help to protect the metal surfaces of propylene glycol provide similar protection against
the cooling system. A lack of coolant additives freezing and boiling. See Tables 12 and 13.
or insufficient amounts of additives enable the
following conditions to occur: Tabla 1 1
Corrosion I Ethylene Glycol I

Formation of mineral deposits I Concentration I Freeze
Protection I protection
=Oil I
Rust
50 Percent I -36 "C(-33 "F) I 106 "C(223 OF)
60 Percent -51 "C(-60 "F) 11 1 "C (232O F )

a Scale
Pitting and erosion from cavitation of the cylinder NOTICE

liner Do not use propylene glycol in concentrations that ex-
ceed 50 percent glycol because of propylene glycol's
Foaming of the coolant reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
Many additives are depleted during engine boiling or freezing.
operation. These additives must be replaced
periodically. This can be done by adding
Supplemental Coolant Additives (SCA) to Diesel
Engine AntifreezeICoolant (DEAC) or by adding
ELC Extender to Extended Life Coolant (ELC).
Additives must be added at the proper

concentration. Overconcentration of additives can
cause the inhibitors to drop out-of-solution. The
deposits can enable the following problems to
occur:
73
Maintenance Section
3 Table I3
Propylene Glycol NOTICE
-J All Caterpillar diesel engines equipped with air-to-air
Concentration Freeze Boil aftercooling (ATAAC) require a minimum of 30 percent
Protection Protection glycol to prevent water pump cavitation.
1 50 Percent 1 -29 "C (-20 OF) 1 106 "C (223 OF) 1
Table 14
To check the concentration of glycol, use the Coolant Service Life
111-7298 CoolantIBattery Tester (Degree Celsius)
or use the 111-7297 CoolantIBattery Tester (Degree 1 Coolant Type I Service Life I
Fahrenheit). The testers give readings that are
immediate and accurate. The testers can be used
with ethylene or propylene glycol.
I Caterpillar ELC 1 6000 Service Hours or
Six Years
I
Caterpillar DEAC 3000 Service Hours or
i01096597
Coolant Recommendations CoolanVAntifreeze that

meets "ASTM D5345" Two Years
SMCS Code: 1350; 1395 Commercial Heavy-~uty 3000 Hours or
CoolantIAntifreeze that
meets "ASTM D4985" One Year
The following two coolants are used in Caterpillar
diesel engines: I Caterpillar SCA and
Water
1 3000 Service Hours or
Two Years
-
Preferred Caterpillar Extended Life Coolant (ELC)
or a commercial extended life coolant that meets
the Caterpillar EC-1 specification
I Commercial SCA and
Water
1 3000 Service Hours or
One Year
I
Acceptable - A Caterpillar Diesel Engine
3 AntifreezelCoolant (DEAC) or a commercial
heavy-duty coolanrlantifreeze rhat meets "ASTM
i01624614
D4985" or "ASTM D5345" specificarions S.0.S Coolant Analysis

SMCS Code: 1352; 1395; 7542
NOTICE
Do not use a commercial coolanVantifreeze that only Testing the engine coolant is important to ensure
meets the ASTM D3306 or D4656 specification. This that the engine is protected from internal cavitation
type of coolanVantifreeze is made for light duty auto- and corrosion. The analysis also tests the ability of
motive applications. the coolant to protect the engine from boiling and
freezing. S.0.S Coolant Analysis can be done at
Caterpillar recommends a 1 : l mixture of water your Caterpillar dealer. Caterpillar S.0.S Coolant
and glycol. This mixture of water and glycol will Analysis is the best way to monitor the condition
provide optimum heavy-duty performance as a of your coolant and your cooling system. S.0.S
coolantIantifreeze. Coolant Analysis is a program that is based on
periodic samples.
Note: Caterpillar DEAC DOES NOT require a
treatment with an SCA at the initial fill. Commercial NOTICE
heavy-duty coolantIantifreeze that meets "ASTM Do not use the same vacuum sampling pump for ex-
D4985" or "ASTM D5345" specifications MAY tracting oil samples that is used for extracting coolant
require a treatment with an SCA at the initial fill. samples.
Read the label or the instructions that are provided
by the OEM of the product. A small residue of either type sample may remain in
the pump and may cause a false positive analysis for
In stationary engine applications and marine engine the sample being taken.
applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water is Always use a designated pump for oil sampling and a
) acceptable. Caterpillar recommends a six percent
to eight percent concentration of SCA in those
designated pump for coolant sampling.
cooling systems. Distilled water or deionized water Failure to do so may cause a false analysis which
is preferred. Water which has the recommended could lead to customer and dealer concerns.
properties may be used.
74
Maintenance Section
New Systems, Refilled Systems, 8 ldentification of the source of metal corrosion and
and Converted Systems of contaminants
Perform a coolant analysis (Level 2) at 500 service 8 Water hardness

hours for new systems, for refilled systems, or
for converted systems that use Cat Extended ldentification of buildup of the impurities that
Life Coolant (ELC) or use Cat Diesel Engine cause corrosion
Antifreeze/Coolant (DEAC). This 500 hour check will
also check for any residual cleaner that may have 8 ldentification of buildup of the impurities that
contaminated the system. cause scaling
The results are reported, and appropriate

Recommended Interval for S.0.S recommendations are made.
Coolant Sample For more information on S.0.S Coolant Analysis,
Perform a coolant analysis (Level 1) at every 500 consult your Caterpillar dealer.
service hour interval. Perform a coolant analysis
(Level 2) annually, or perform a coolant analysis iO1857987
(Level 2) when a problem is identified by a coolant
analysis (Level 1). Extended Life Coolant (ELC)
Note: Check the standard coolant's Supplemental SMCS Code: 1350; 1395
Coolant Additive (SCA) at every oil change.
Caterpillar provides Extended Life Coolant (ELC) for
S.0.S Coolant Analysis (Level 1) use in the following applications:
8 Heavy-duty spark ignited gas engines

A coolant analysis (Level 1) is a test of the
properties of the coolant.
8 Heavy-duty diesel engines
The following properties of the coolant are tested:
8 Automotive applications
Glycol concentration for freeze protection and
boil protection The anti-corrosion package for Caterpillar ELC is
different from the anti-corrosion package for other
Ability to protect from erosion and corrosion coolants. Caterpillar ELC is an ethylene glycol
base coolant. However, Caterpillar ELC contains
organic corrosion inhibitors and antifoam agents
with low amounts of nitrite. Caterpillar ELC has
8 Conductivity been formulated with the correct amount of these
additives in order to provide superior corrosion
8 Visual analysis protection for all metals in engine cooling systems.
Odor analysis ELC extends the service life of the coolant to 12000
service hours or six years. ELC does not require
The results are reported, and appropriate a frequent addition of a Supplemental Coolant
recommendations are made. Additive (SCA). An Extender is the only additional
maintenance that is needed at 6000 service hours
or one half of the ELC service life.
S.0.S Coolant Analysis (Level 2)
ELC is available in a 1:l premixed cooling solution
A coolant analysis (Level 2) is a comprehensive with distilled water. The Premixed ELC provides
chemical evaluation of the coolant. This analysis is freeze protection to 3 6 "C (-33 OF). The Premixed
also a check of the overall condition of the inside of ELC is recommended for the initial fill of the cooling
the cooling system. system. The Premixed ELC is also recommended
for topping off the cooling system.
The S.0.S Coolant Analysis has the following
features: ELC Concentrate is also available. ELC Concentrate
can be used to lower the freezing point to -51 "C
8 Full coolant analysis (Level 1) (-60 OF) for arctic conditions.
Maintenance ~ e c t i b i
9 Containers of several sizes are available. Consult

your Caterpillar dealer for the part numbers.
Caterpillar ELC Extender
Caterpillar ELC Extender is added to the cooling
Note: Caterpillar developed the EC-1 specification. system halfway through the ELC service life. Treat
The EC-I specification is an industry standard. The the cooling system with ELC Extender at 6000 hours
EC-1 specification defines all of the performance or one half of the coolant service life. Use Table 15
requirements that are needed for an engine coolant in order to determine the proper amount of ELC
to be sold as an extended life coolant for Caterpillar Extender that is required.
engines. ELC can be used in most OEM engines of
the following types: diesel, gasoline, and natural Containers of several sizes are available. Consult
gas. ELC meets the performance requirements of your Caterpillar dealer for the part numbers.
"ASTM D4985" and "ASTM D5345" for heavy-duty
low silicate antifreeze/coolants. ELC also meets the Use the formula in Table 15 to determine the proper
performance requirements of "ASTM D3306" and amount of ELC Extender for your cooling system.
"ASTM D4656" for automotive applications. Refer to Operation and Maintenance Manual. "Refill
Capacities" in order to determine the capacity of
the cooling system.
i01857992
Extended Life Coolant (ELC) Table 15
Cooling System Maintenance I Formula For Adding ELC Extender To ELC I

V x 0.02 = X
SMCS Code: 1350; 1352; 1395 V is the total capacity of the cooling system.
X is the amount of ELC Extender that is reauired.
Proper additions to the Extended
Life Coolant Table 16 is an example for using the formula that
is in Table 15.
1 NOTICE
Useonly Caterpillar products or commercial products
that have passed Caterpillar's EC-1 specification for
Table 16
pre-mixed or concentrated coolants. I Example Of The Equation For Adding ELC

Extender To ELC(1) I
Use only Caterpillar Extender with Extended Life Total Volume Multiplication Amount of ELC
Coolant. of the Cooling Factor Extender that is
System 01) Required (X)
Mixing Extended Life Coolant with other products re- 9 L (2.4 US gal) x 0.02 0.18 L
duces the Extended Life Coolant service life. Failure to (0.05 US gal)
follow the recommendations can reduce cooling sys- or (6 fl oz)
tem components life unless appropriate corrective ac- (7) This example is based on the capacity of a C2.2 Generator Set
tion is performed. with a cooling system capacity of 9 L (2.4 US gal).
In order to maintain the correct balance between NOTICE

the antifreeze and the additives, you must maintain When using Cat ELC, do not use standard SCA's or
the recommended concentration of Extended Life SCA filters. To avoid SCA contamination of an ELC
Coolant (ELC). Lowering the proportion of antifreeze system, remove the SCA filter base and plug off or
lowers the proportion of additive. This will lower by-pass the coolant lines.
the ability of the coolant to protect the system from
pitting, from cavitation, from erosion, and from
deposits. ELC Cooling System Cleaning
NOTICE Note: If the cooling system is already using ELC,
Do not use a conventional coolant to top-off a cooling cleaning agents are not required to be used at
system that is filled with Extended Life Coolant (ELC). the specified coolant change interval. Cleaning
agents are only required if the system has been
Do not use standard supplemental coolant additive contaminated by the addition of some other type of
(SCA). Only use ELC Extender in cooling systems that coolant or by cooling system damage.
are filled with ELC.
Clean water is the only cleaning agent that is
required when ELC is drained from the cooling
system.
76
Maintenance Section
ELC can be recycled. The drained coolant mixture 6. Drain the cleaner into a suitable container. Flush
can be distilled in order to remove the ethylene the cooling system with clean water.
glycol and the water. The ethylene glycol and the
water can be reused. Consult your Caterpillar dealer 7 . Fill the cooling system with clean water and
for more information. operate the engine until the engine is warmed to
49' to 66% (120' to 150°F).
After the cooling system is drained and after the
cooling system is refilled, operate the engine while NOTICE
the cooling system filler cap is removed. Operate Improper or incomplete rinsing of the cooling system
the engine until the coolant level reaches the normal can result in damage to copper and other metal com-
operating temperature and until the coolant level ponents.
stabilizes. As needed, add the coolant mixture in
order to fill the system to the proper level. To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
Changing to Caterpillar ELC ter. Continue to flush the system until all signs of the
cleaning agent are gone.
To change from heavy-duty coolant/antifreeze to the
Caterpillar ELC, perform the following steps: 8. Drain the cooling system into a suitable container
and flush the cooling system with clean water.
. .- . .- -
NOTICE
Care must be taken to ensure that fluids are contained Note: The cooling system cleaner must be
durino oerformance of insoection. maintenance. test- thoroughly flushed from the cooling system. Cooling
ing, a'lj'usting and repair of'the product. Be to system cleaner that is left in the system will
collect the fluid with suitable containers before open- contaminate the coolant. The cleaner may also
ing any compartment or disassembling any compo- corrode the cooling system.
nent containing fluids.
9. Repeat Steps 7 and 8 until the system is
Refer to Special Publication, NENG2500, "Caterpillar completely clean.
Tools and Shop ProductsGuidel'for tools and supplies
suitable to collect and contain fluids on Caterpillar 10. Fill the cooling system with the Caterpillar
products. premixed ELC.
Dispose of all fluids according to local regulations and 11.Attach the Special Publication, PEEP5027,
mandates. "Label" to the cooling system filler for the engine
in order to indicate the use of Caterpillar ELC.
1. Drain the coolant into a suitable container.
ELC Cooling System
2. Dispose of the coolant according to local
regulations.
Contamination
NOTICE
NOTICE Mixing ELC with other products reduces the effective-
Do not leave an empty SCA filter on an ELC system. ness of the ELC and shortens the ELC service life.
Use only Caterpillar products or commercial products
The filter housing may corrode and leak causing an that have passed the Caterpillar EC-1 specificationfor
engine failure. premixed or concentrate coolants. Use only Caterpillar
ELC Extender with Caterpillar ELC. Failure to follow
Remove the SCA filter base and plug off or by-pass these recommendations can result in shortened cool-
the coolant lines. ing system component life.
3. Remove the empty SCA filter and remove the

filter base. Plug the coolant lines or bypass the ELC cooling systems can withstand contamination
coolant lines. to a maximum of ten percent of conventional
heavy-duty coolant/antifreeze or SCA. If the
4. Flush the system with clean water in order to contamination exceeds ten percent of the total
remove any debris. system capacity, perform ONE of the following
procedures:
5. Use Caterpillar cleaner to clean the system.
Follow the instruction on the label.
77
Maintenance Section
Drain the cooling system into a suitable container. 101946663
1 Dispose of the coolant according to local

regulations. Flush the system with clean water Fill
the system with the Caterpillar ELC.
Supplemental Coolant Additive
Drain a portion of the cooling system into a SMCS Code: 1350; 1352; 1395
suitable container according to local regulations.
Then, fill the cooling system with premixed ELC. The use of SCA helps to prevent the following
This should lower the contamination to less than conditions from occurring:
10 percent.
Corrosion
Maintain the system as a conventional Diesel
Engine AntifreezeICoolant (DEAC). Treat the Formation of mineral deposits
system with an SCA. Change the coolant at the
interval that is recommended for the conventional Cavitation erosion of the cylinder liners
Diesel Engine AntifreezeICoolant (DEAC).
I Commercial ELC
Foaming of the coolant
Caterpillar Diesel Engine AntifreezeICoolant (DEAC)

If Caterpillar ELC is not used, then select a is formulated with the correct level of Caterpillar
commercial ELC that meets the Caterpillar SCA. When the cooling system is initially filled with
specification of EC-I and either the "ASTM D5345 DEAC, adding more SCA is not necessary until the
specification or the "ASTM D4985" specification. Do concentration of SCA has been depleted. To ensure
not use an extended life coolant that does not meet that the correct amount of SCA is in the cooling
the EC-I specification. Follow the maintenance system, the concentration of SCA must be tested
guide for the coolant from the supplier of the on a sched~.edbasis. Refer to the specific engine's
commercial ELC. Follow the Caterpillar guidelines Operaton and Maintenance Manua , "Mantenance
3 for the quality of water and the specified coolant

change interval.
Interval Schedule",
Containers of Cat SCA are available in several sizes.

Consult yotr Caterpillar dealer for the part numbers.
iO1908729
Diesel Engine Antifreeze1 iO1161094
Coolant (DEAC) Commercial Heavy-Duty

I SMCS Code: 1350; 1395 CoolantIAntifreeze and SCA
Caterpillar recommends using Caterpillar SMCS Code: 1350; 1395
Diesel Engine AntifreezeICoolant (DEAC) for
cooling systems that require a heavy-duty If Caterpillar DEAC is not used, select a
coolantlantifreeze. Caterpillar DEAC is an alkaline coolantlantifreeze with low silicate content for
I s ngle-pnase ethylene giyco type antifreeze that heavy-duty applications that meets "TMC RP329",
contains corrosion inhioitors and anrifoam agents. "ASTM D5345" or "ASTM D4985" specifications.
Caterpillar DEAC is formulated with the correct Note: When you are not using Caterpillar DEAC the
amount of Caterpillar Supplemental Coolant Additive cooling system must be drained one time during
(SCA). Do not use SCA at the initial fill when DEAC every year. The cooling system must be flushed at
is used. this time as well.
Containers of several sizes are available. Consult When a heavy-duty coolantlantifreeze is used, the
your Caterpillar dealer for the part numbers. cooling system should be treated with three to
six percent Cater~illarSCA bv volume. Refer to
If concentrated DEAC is used, Caterpillar this'publication, "conventiond CoolantlAntifreeze
recommends mixing the concentrate with distilled Cooling System Maintenance" topic (Maintenance
3
,
water or with deionized water. If distilled water
or deionized water is not available, use water
which has the required properties. For the water
Section).
If Caterpillar SCA is not used, select a commercial

properties, see this publication, "General Coolant SCA. The commercial SCA must provide a minimum
Information" topic (Maintenance Section). of 1200 mg/L or 1200 ppm (70 grains per gallon) of
nitrites in the final coolant mixture.
78
Maintenance Section
Coolantlantifreezes for heavy-duty applications if Caterpillar SCA is not used, select a commercial
that meet "ASTM D5345 or "ASTM D4985" SCA. The commercial SCA must provide a minimum
specifications MAY require treatment with SCA at of 2400 mg/L or 2400 ppm (140 grainslUS gal) of
the initial fill. These coolants WILL require treatment nitrites in the final coolant mixture.
with SCA on a maintenance basis.
The quality of the water is a very important factor
Coolantlantifreezes for heavy-duty applications that in this type of cooling system. Distilled water
meet "TMC RP329 specifications do not require or deionized water is recommended for use in
treatment with SCA at the initial fill, but the SCA cooling systems. If distilled water or deionized
should be treated at the regular maintenance water is not available, use water that meets the
intervals. minimum requirements that are listed in the table for
recommended water properties in this publication,
When concentrated coolants are mixed, Caterpillar "General Coolant Information" topic (Maintenance
recommends mixing the concentrate with distilled Section).
water or with deionized water. If distilled water or
deionized water is not available, refer to the table in A cooling system that uses a mixture of SCA
this publication, "General Coolant Information" topic and water only needs more SCA than a cooling
(Maintenance Section). system that uses a mixture of glycol and water. The
SCA concentration in a cooling system that uses
SCA and water should be six to eight percent by
volume. Refer to Table 17 for the amount of SCA .
WaterISupplemental Coolant that is required for various capacities of the cooling
system.
Additive (SCA)
Table 17
SMCS Code: 1350; 1352; 1395
NOTICE
All Caterpillar diesel engines equipped with air-to-air
aftercooling (ATAAC) require a minimum of 30 percent
glycol to prevent water pump cavitation.
NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
alone is corrosive at engine operating temperatures.
Water alone does not provide adequate protection
against boiling or freezing.
Note: Premix the coolant solution in order to provide

protection to the lowest ambient temperature that
is expected.
Note: Pure undiluted antifreeze freezes at

(-9 OF).
In engine cooling systems that use water alone,

Caterpillar recommends the use of SCA. SCA helps
to prevent the following conditions from occurring:
Corrosion
Refer to Table 18 for part numbers and for quantities
Formation of mineral deposits of SCA.
Cavitation erosion of the cylinder liner
Foaming of the coolant

."
Maintenance Section
Use the 8T-5296 Coolant Conditioner Test Kit to

( 3 TI8 Caterpillar Liquid SCA
test the concentration of SCA. Make the following
modifications to Steps 3 and 5 of the 8T-5296
I Part Number Quantity Coolant Conditioner Test Kit instructions:
STEP 3 -Add tap water to the vial up to the "20

ml" mark.
STEP 5 -When the defined procedure is used,

a concentration of six to eight percent will yield
between 20 drops and 27 drops. If the number of
8C-3680 19 L (5 US gal)
drops is below 20 drops, the concentration of SCA
5P-2907 208 L (55 US gal) is low. If the number of drops is above 27 drops, the
concentration of SCA is high. Make the appropriate
adjustments to the concentration of SCA.
Maintain the SCA in the same way as you would
maintain a cooling system that uses heavy-duty
Test the concentration of SCA or submit a
coolantlantifreeze. Adjust the maintenance for the
coolant sample to your Caterpillar dealer. See
amount of SCA additions. See Table 17 for the
amount of SCA that is required. this publication, "S.0.S Coolant Analysis" topic
. Cooling Systems with Larger Additions of SCA are based on the results of the
Capacities test or based on the results of the coolant analysis.
The size of the cooling system determines the
amount of SCA that is required.
I Adding the SCA to Water at the Initial Fill
Use the equation that is in Table 19 to determine
1 Use the equation that is in Table 19 to determine
the amount of Caterpillar SCA that is required at
the amount of Caterpillar SCA that is required for
maintenance, if necessary:
the initial fill. This equation is for a mixture of only
SCA and water. Table 21
SCA To Water Addition Equation For Maintenance
Equation For Adding The SCA To Water V x 0.023 = X
At The Initial Fill V is the total volume of the cooling system.
V x 0.07 = X X is the amount of SCA that is required.
I V is the total volume of the cooling system.
II
I X is the amount of SCA that is required. Table 22 is an example for using the equation that
is in Table 19.
Table 20 is an example for using the equation that Table 22
is in Table 19.
SCA To Water Addition Equation Example
Table 20 For Maintenance
Example Of The Equation For Adding The SCA Total Volume Multiplication Amount of SCA
To Water At The Initial Fill of the Cooling Factor that is Required
Total Volume
of the Cooling
Svstem I V I
Multiplication
Factor I Amount of SCA
that isEquired I 1
System (V)
946 L
(250 US gal) I
x 0.023
1
(X)
22 L
(6 US gal) I
(250 US gal) I 1 (18 US gal) I Note: Specific engine applications may require
maintenance practices to be periodically evaluated
in order to properly maintain the engine's cooling
Adding the SCA to Water for Maintenance system.
) Operation
For the recommended service interval, refer to the
and Maintenance Manual, "Maintenance
Table 18 lists part numbers and quantities of SCA
that is available from your Caterpillar dealer.
Interval Schedule" for your engine.
80
Maintenance Section
101570193
Conventional Coolant1
Antifreeze Cooling System
Maintenance
SMCS Code: 1350; 1352; 1395
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
Check the coolanVantifreeze (glycol concentration)

in order to ensure adequate protection against
boiling or freezing. Caterpillar recommends the
use of a refractometer for checking the glycol
concentration. Use the 1U-7298 CoolanVBatLery
Tester (Degree Celsius) or use the 111-7297
CoolanffBattery Tester (Degree Fahrenheit). The
testers give readings that are immediate and
accurate. The testers can be used with ethylene
or with propylene glycol.
Caterpillar engine cooling systems should be

tested at 250 hour intervals for the concentration of
Supplemental Coolant Additive (SCA). SCA test kits
are available from your Caterpillar dealer. Test the
concentration of SCA or submit a coolant sample to
your Caterpillar dealer at 250 hour intervals. Refer
to S.0.S Coolant Analysis for more information on
this topic.
Additions of SCA are based on the results of the

test or based on the results of the coolant analysis.
An SCA that is liquid or a maintenance element for
an SCA (if equipped) may be needed at 250 hour
intervals.
Table 23 lists the amount of Caterpillar SCA

that is needed at the initial fill in order to treat
coolant/antifreeze. These amounts of SCA are for
systems that use heavy-duty coolanVantifreeze.
Table 23 also lists additions of SCA for liquid

and for maintenance elements at 250 hours. The
additions are required for Caterpillar DEAC and for
commercial coolant/antifreezes.
81
Maintenance Section
Table 23
I Caterpillar SCA Requirements for Heavy-Duty CoolantlAntifreeze I

Spin-on
250 Service Element at 250
Cooling System
Initial Fillil) Hour Service Hour
Capacity Maintenance@ Maintenance
(If Equipped)@
22 to 30 L 0.95 L (32 fl oz) 0.24 L (8 fl 02) 111-2370 (1)
(6 to 8 US gal)
31 to 38 L 0.36L(12floz) 111-2369(1)
l.l8L(40floz)
(9 to 10 US gal)
39 to 49 L
1 1.42 L (48fl oz) I 0.36 L (12fl oz) 1 111-2369 (1) I
50 to 64 L 0.47 L (16fl oz) 9N-3368 (1)
1.90 L (64fl oz)
(14 to 17 US gal)
65 to 83 L 2.37 L (80 fl oz) 0.60 L (20 fl 02) 111 -2371 (1)
(18 to 22 US gal)
84 to 'I4
3.32 L (112 fl oz) 0.95 L (32floz) 9N-3718 (1)
(23 to 30 US gal)
16' 242
(44 to 64 US gal)
7.60 L (256102) 1.90 L ( 60 ) 1 9N-3718 (2)
(1) When the coolant system is first filled, the SCA is not required to be used with
Caterpillar DEAC.
(2) DOnit exceed the six percent maximum concentration. Check the concentration
of SCA with a SCA test kit.
(3) Do not use the maintenance element for the SCA and the liquid for the SCA at the
same time.
Note: Specific engine applications may require Cooling Systems with Larger
maintenance practices to be periodically evaluated Capacities
system.
Adding the SCA to Conventional
Refer to Table 24 for part numbers and for quantities CoolanVAntifreeze at the Initial Fill
of SCA.
Note: Caterpillar DEAC DOES NOT require an
Table 24 addition of SCA when the cooling system is initially
I Caterpillar Liquid SCA
filled.
Commercial heavy-duty cooiant/antifreeze

6V-3542 0.24 L (8 oz) that meets "ASTM D4985" or "ASTM D5345"
specifications MAY require an addition of SCA at
the initial fill. Read the label or the instructions that
are provided by the OEM of the product.
19 L (5 US gal) the amount of Caterpillar SCA that is required when
8C-3880
the cooling system is initially filled with the following
fluids:
"ASTM D4985
"ASTM D5345"
82
Maintenance Section
Table 25 Table 28
Equation For Adding The SCA To Conventional
CoolanVAntifreeze At The Initial Fill
V x 0.045 = X
of the Cooling Factor that is Required
V is the total volume of the cooling system. Svstem fV)
X is the amount of SCA that is required. 946 L x 0.014 9 L
(250 US gal) (4 US gal)
Table 26 is an example for using the equation that
is in Table 25. Note: Specific engine applications may require
maintenance practices to be periodically evaluated
Table 26
Example Of The Equation For Adding The SCA To system.
Table 24 lists part numbers and quantities of SCA

of the Cooling Factor that is Required that is available from your Caterpillar dealer.
Svstem N)
946 L x 0.045 43 L Cleaning the System of Heavy-Duty
(250 US gal) (11 US gal) CoolantlAntifreeze
Adding the SCA to Conventional Caterpillar cooling system cleaners are designed
to clean the cooling system of harmful scale and
CoolantIAntifreeze For Maintenance corrosion. Caterpillar cooling system cleaners
dissolve mineral scale, corrosion products, light oil
Heavy duty coolantlantifreeze of all types REQUIRE contamination and sludge.
periodic additions of an SCA.
Clean the cooling system after used coolant is
Test the coolant/antifreeze periodically for the drained or before the cooling system is filled with
concentration of SCA. For the interval, see the
Operation and Maintenance Manual, "Maintenance
- --
.new -. -. ...
. .. rnnlant
Interval Schedule" (Maintenance Section). SCA Clean the cooling system whenever the coolant is
test kits are available from your Caterpillar contaminated or whenever the coolant is foaming. I
dealer. Test the concentration of SCA or submit
a coolant sample to your Caterpillar dealer. See For the recommended service interval, refer
this publication, "S.0.S Coolant Analysis" topic to the Operation and Maintenance Manual,
(Maintenance Section). "Maintenance Interval Schedule" for your engine.
Additions of SCA are based on the results of the
test or based on the results of the coolant analysis.
The size of the cooling system determines the
amount of SCA that is needed.

the amount of Caterpillar SCA that is required, if
necessary:
Tahla 37
Equation For Adding The SCA To Conventional

CoolanVAntifreeze For Maintenance
V x 0.014 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
Table 28 is an example for using the equation that

is in Table 27.
83
Maintenance Section
Refill Capacities
Refill Capacities
3
Refill Capacities
SMCS Code: 1348; 1395; 7560
Lubrication System
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems
will require additional oil. Refer to the specifications
for the capacity of the auxiliary oil filter. Refer to
the Operation and Maintenance Manual, "Lubricant
Specifications" for more information.
Table 29
I Approximate Refill Capacities I
Compartment or System 3408C 3412C
Engine crankcase 45 L 68 L
(48 qt) (72 qt)
-9 Cooling System
To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate
capacity for the Engine Cooling System is listed.
External System capacities will vary among
applications. Refer to the specifications for the
External System capacity. This capacity information
will be needed in order to determine the amount
of coolant/antifreeze that is required for the Total
Cooling System.
Table 30
Approximate Refill Capacities
Compartment or System 3408C 3412C
Engine only
Engine and radiator
External system(')
Total coolina svstemm
(11 The external system includes a radiator or an expansion tank
with the fol.owing components: heat exchanger, attercooler.
and piping. Refer to the Caterpillar specification, or refer to
the specification for the cwl:ng system capacily Information.
~ n t ethe
r information in this row.
(21 The total coolng system includes the capacity for the engine
plus the capacity for the external system. Enter the toral in this
row.
Maintenance Section
Maintenance Recommendations
Maintenance knowledgeable visual examination of the

equipment
Recommendations
the application of electrical tests
iO1179728 Never perform a test over the rated potential. These
tests can damage insulation that is contaminated
General Maintenance or insulation that is in marginal condition. For more
Information information, refer to "I.E.E.E. Standard 432-1992" or
consult a Caterpillar dealer.
SMCS Code: 4450; 7000
Note: Read the warnings and read the instructions

that are contained in the Safety Section of this
manual. These warnings and instructions must be
understood before you perform any operation or
any maintenance procedures.
Rotating electric machines are complex structures

that are exposed to the following forms of stress:
mechanical
electrical
thermal
environmental
These stresses may be of varying magnitudes. The

electrical insulation systems are very susceptible to
damage that is caused by the stresses that are listed
above. Exposure to these stresses may shorten
the effective life of the electrical insulation system.
Therefore, the service life of an electric machine will
largely depend on the serviceability of the electrical
insulation systems. An inspection program and a
testing procedure are recommended. An inspection
program and a testing procedure will ensure that the
equipment is maintained in satisfactory condition.
This will increase field reliability.
A regular maintenance and inspection program can

provide an evaluation of the present condition of
the equipment. A regular maintenance program
and a regular inspection program can also reveal
future problems. The frequency of this maintenance
program will depend on the following factors:
application
environmental conditions
operator's experience
operator's philosophy
A regular maintenance program is strongly

recommended. This program would involve the
following steps:
periodic disassembly
85
Maintenance Section
(01227545
C Generator Start-up Checklist

SMCS Code: 4450
Table 31
I GENERATOR START-UP CHECKLIST I
I RATING INFORMATION I
I I Engine Serial Number: Arrangement Number:

Generator Serial Number: Arrangement Number:
IGENERATOR
NAMEPLATE INFORMATION I
Voltage: Package (prime, continuous, standby):
Amperage: Kilowatts:
Storage Location:
Main Stator Meoohmmeter Readino: I Before Storaoe: I After Storaoe:
Generator dried for 24 hours prior to startup? I C//N) Drying method:
I SPACE HEATERS I yes I NO I Comments I
Space heaters operating properly?
Space heater operated 48 hrs. before
startup?
MEGOHMMETER TEST (SEHS9124)
I 30 sec.
reading I 60 sec.
reading
30 sec.
corrected
I ,",?6,"zd I Apibint
I I
of Storage
Main Rotor
l PMG stator I I
Start-up Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Regulator Voltage Amps Comments
No Load F1 to F2 DC
20 to 22 AC
26 to 28 (PM only) AC
26 to 30 (PM only) AC
L 28 to 30 (PM only) AC I (continued)

86
Maintenance Section
GENERATOR START-UP CHECKLIST
I Full I Generator Excitation

Name Plate Information: DC I I Compare with F1 to F2
F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
24 to 30 (SE only) AC
26 to 28 (PM only) AC I
26 to 30 IPM onlv) AC I
87
Maintenance Section
53
"
9 3
I
88
Maintenance Section
Maintenance Interval Schedule
i01943637 Every 13 000 L (3400 US gal) of Fuel or 250

Service Hours
(3408C Engine) Battery Charger .Check ....................................... 92
Battery Electrolyte Level .Check .......................... 92
SMCS Code: 1000; 7500 Belts .InspecVAdjust/Replace.............................. 93
Cooling System Coolant Sample (Level 1) .
Obtain ................................................................. 98
Cooling System Supplemental Coolant Additive
Use fuel consumption. service hours. or calendar (SCA) .TesVAdd ................................................. 99
time. whichever occurs first. to determine Engine Crankcase Breather .Clean ................... 105
maintenance intervals. Experience has shown Engine Oil Sample .Obtain ................................ 106
that maintenance intervals are most accurately Engine Oil and Filter .Change ........................... 107
scheduled on the basis of fuel consumed rather Fan Drive Bearing .Lubricate ............................. 109
than service hours. Fuel System Primary Filter .CleanlReplace ...... 112
Fuel System Secondary Filter .Replace ............ 112
When Required Hoses and Clamps .InspectlReplace ................ 118
Radiator .Clean .................................................. 122
Battery or Battery Cable .Disconnect .................. 92
Cooling System Coolant Sample (Level 2) . Every 51 000 L (13 500 US gal) of Fuel or
Obtain ................................................................. 98 1000 Service Hours
Engine Air Cleaner Element .CleanIReplace ..... 102
Fuel System .Prime ........................................... 111 Engine Protection Devices .Calibrate ................ 108
Generator .Dry .............................................. 114 Fuel Control Linkage .ChecklLubricate ............. 109
Generator Set .Test ........................................... 117
Overhaul Considerations .................................... 120 Every 114 000 L (30 000 US gal) of Fuel or
3000 Service Hours or 2 Years
Daily
Air Starting Motor Lubricator Oil Level .Check .... 90 Obtain ................................................................. 98
Air Tank Moisture and Sediment .Drain ............... 91
Cooling System Coolant Level .Check ................ 97 Every 153 500 L (40 500 US gal) of Fuel or
Engine Air Cleaner Service Indicator .Inspect ... 104 3000 Service Hours
Engine Oil Level .Check .................................... 106
Fuel Tank Water and Sediment .Drain ............... 113 Air Starting Motor Lubricator Bowl .Clean ........... 90
Generator .Inspect ........................................... 115 Cooling System Coolant (DEAC) .Change .......... 94
Generator Load .Check ..................................... 117 Cooling System Coolant Extender (ELC) -Add ....97
Walk-Around Inspection ...................................... 125 Cooling System Water Temperature Regulator .
Replace ............................................................. 100
Every Week Crankshaft Vibration Damper .Inspect ............... 101
Engine Mounts .Inspect ..................................... 105
Standby Generator Set Maintenance Engine Valve Lash .InspecVAdjust .................... 108
Recommendations ............................................ 123 Engine Valve Rotators .Inspect .......................... 109
Fuel Ratio Control .InspecVAdjust ..................... 110
Every Year Turbocharger .Inspect ........................................ 124
Generator Set Vibration .Inspect ....................... 118 Every 256 000 L (67 500 US gal) of Fuel or
5000 Service Hours
Every 3800 L (1000 US gal) of Fuel or 50
Service Hours Alternator .Inspect ............................................... 91
Fuel Injection Nozzles .TesVExchange .............. 110
Engine Air Precleaner .Clean ............................ 105 Magnetic Pickups .Cleanllnspect ...................... 119
Starting Motor .Inspect ...................................... 124
First 13 000 L (3400 US gal) of Fuel or 250 Water Pump .Inspect ......................................... 126
Service Hours
Engine Valve Lash .InspectlAdjust .................... 108 Every 306 000 L (81 000 US gal) of Fuel or
Magnetic Pickups .Cleanllnspect ...................... 119 6000 Service Hours or 6 Years /
Cooling System Coolant (ELC) .Change .............96 L
89
Maintenance Section
101943638 Every 19 000 L (5000 US gal) of Fuel or 250

Service Hours
(3412C Engine) Battery Charger .Check ....................................... 92
Battery Electrolyte Level .Check .......................... 92
SMCS Code: 1000; 7500 Belts .InspectlAdjustlReplace.............................. 93
SIN: RLRI-Up Obtain ................................................................. 98
Cooling System Supplemental Coolant Additive
Use fuel consumption. service hours. or calendar (SCA) .TestlAdd ................................................. 99
time. whichever occurs first. to determine Engine Crankcase Breather .Clean ...................
105
maintenance intervals. Experience has shown Engine Oil Sample .Obtain ................................ 106
that maintenance intervals are most accurately Engine Oil and Filter .Change ........................... 107
scheduled on the basis of fuel consumed rather Fan Drive Bearing .Lubricate ............................. 109
than service hours. Fuel System Primary Filter .CleanIReplace ...... 112
Fuel System Secondary Filter .Replace ............ 112
When Required Hoses and Clamps .InspectlReplace ................ 118
Radiator .Clean ........................................... 122
-
Battery or Battery Cable Disconnect .................. 92
Cooling System Coolant Sample (Level 2) - Every 76 000 L (20 000 US gal) of Fuel or
Obtain ............................................................ 98 1000 Service Hours
Engine Air Cleaner Element .CIeanlReplace ..... 102
Fuel System .Prime ........................................... 111 Engine Protection Devices .Calibrate ................ 108
Generator .Dry ................................................... 114 Fuel Control Linkage .CheckILubricate ............. 109
Generator Set .Test ........................................... 117
Overhaul Considerations .................................... 120 Every 114 000 L (30 000 US gal) of Fuel or
3000 Service Hours or 2 Years
Daily
Air Starting Motor Lubricator Oil Level .Check .... 90 Obtain ................................................................ 98
Air Tank Moisture and Sediment .Drain ............... 91
Cooling System Coolant Level .Check ................
97 '
Every 228 000 L (60 000 US gal) of Fuel or
Engine Air Cleaner Service Indicator .Inspect ... 104 3000 Service Hours
Engine Oil Level .Check .................................... 106
Fuel Tank Water and Sediment .Drain ............... 113 Air Starting Motor Lubricator Bowl .Clean ........... 90
Generator .Inspect ............................................. 115 Cooling System Coolant (DEAC) .Change .......... 94
Generator Load .Check ..................................... 117 Cooling System Coolant Extender (ELC) -Add .... 97
Walk-Around Inspection ...................................... 125 Cooling System Water Temperature Regulator .
Replace .............................................................100
Every Week Crankshaft Vibration Damper .Inspect ............... 101
Engine Mounts .Inspect ..................................... 105
Standby Generator Set Maintenance Engine Valve Lash .InspectlAdjust .................... 108
Recommendations ............................................ 123 Engine Valve Rotators .Inspect .......................... 109
Fuel Ratio Control .InspectlAdjust .....................
110
Every Year Turbocharger .Inspect ........................................ 124
Generator Set Vibration .Inspect ....................... 118 Every 379 000 L (100 000 US gal) of Fuel or
5000 Service Hours
Every 3800 L (1000 US gal) of Fuel or 50
Service Hours Alternator .Inspect ..............................................
91
Fuel Injection Nozzles .TestlExchange .............. 110
Engine Air Precleaner .Clean ............................ 105 Magnetic Pickups .Cleanllnspect ...................... 119
Starting Motor .Inspect ...................................... 124
First 19 000 L (5000 US gal) of Fuel or 250 Water Pump .Inspect ......................................... 126
Service Hours
Engine Valve Lash .InspectlAdjust .................... 108
Every 456 000 L (120 000 US gal) of Fuel or
Magnetic Pickups .Clean/lnspect ...................... 119 6000 Service Hours or 6 Years
Cooling System Coolant (ELC) .Change ............. 96
90
Maintenance Section
Air Starting Motor Lubricator Bowl - Clean
i01924136 3. Place a suitable container under bowl (2) and i

Air Starting Motor Lubricator
Bowl - Clean
open drain valve (3) in order to drain the oil from
the bowl. C. 1
4. Remove bowl (2). Clean the bowl with warm
SMCS Code: 1451-070 water.
If the engine is equipped with an air starting motor, 5. Dry the bowl. Inspect the bowl for cracks. If the
use the following procedure: bowl is cracked, replace the damaged bowl with
a new bowl.
6. Install the bowl.
Personal injury can result from removing hoses or 7. Make sure that drain valve (3) is closed.
fittings in a pressure system.
8. For instructions on filling the lubricator, see this
Failure t o relieve pressure can cause personal in- Operation and Maintenance Manual, "Air Starting
jury. Motor Lubricator Oil Level - Check" topic.
Do not disconnect or remove hoses or fittings un-
til all Dressure in the svstem has been relieved. i01924142
Air Starting Motor Lubricator

1. Ensure that the air supply to the lubricator is OFF.
Oil Level Check -
SMCS Code: 1451-535
NOTICE
Never allow the lubricator bowl to become empty. The
air starting motor will be damaged by a lack of lubrica-
tion. Ensure that sufficient oil is in the lubricator bowl.
illustration 52 go0745554
(1) Flller plug
(2) Bowl
(3) Drain valve
2. Slowly loosen filler plug (1) in order to release

the pressure from the lubricator.
NOTICE
Care must be taken to ensure that fluids are contained
during pelformance of inspection, maintenance, test-
1. Observe the oil level in sight gauge (3). If the oil

II
ing, adjusting and repair of the product. Be preparedto level 1s less than 112, add oil to the lubricator
collect the fluid with suitable containers before open- bowl.
ing any compartment or disassembling any compo-
Refer to Special Publication, NENG2500, "Caterpillar

Tools and Shop Products Guide" fortools and supplies
suitable to collect and contain fluids on Caterpillar
products. C1
Dispose of all fluids according to local regulations and
mandates. I
I
91
Maintenance Section
-
Air Tank Moisture and Sediment Drain
Freezing
Corrosion of internal parts

Personal injury can result from removing hoses or
fittings in a pressure system.
Malfunction of the air starting system
I Failure to relieve pressure can cause personal in-

jury.
I Do not disconnect or remove hoses or fittings un-

til all pressure in the system has been relieved.
When opening the drain valve, wear protective
gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could
2. Ensure that the air supply to the lubricator is OFF.
cause debris to be blown and result in personal
Slowly loosen filler plug (4) in order to release injury.
pressure from the lubricator bowl.
1. Open the drain valve that is on the bottom of
3. Remove filler plug (4). Pour oil into the the air tank. Allow the moisture and sediment
lubricator bowl. Use nondetergent "10W oil for to drain.
temperatures that are greater than 0 "C (32 O F ) .
Use air tool oil for temperatures that are below 2. Close the drain valve.
0 "C (32 OF).
3. Check the air supply pressure. The air starting
4. Install filler plug (4). motor requires a minimum of 620 kPa (90 psi) of
air pressure to operate properly. The maximum
Adjust the Lubricator air pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa
Note: Adjust the lubrcator w:th a constant rate of air (110 to 140 psi).
. flow. After tne adiustment, the lubr;cator will release
oil in proportion tb variations of the air flow.
/
1. Ensure that the fuel supply to the engine is OFF. Alternator Inspect -
NOTICE SMCS Code: 1405-040
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two Caterpillar recommends a scheduled inspection
minutes before cranking the engine again. of the alternator. inspect the alternator for loose
connections and proper battery charging. Inspect
the ammeter (if equipped) during engine operation
2. Operate the air starting motor. Observe the drops in order to ensure proper battery performance
of oil that are released in dome (1). and/or proper performance of the electrical system.
Make repairs, as required. Refer to the Service
Note: Some lubricators have an adjustment screw Manual.
rather than a knob.
Check the alternator and the battery charger for
3. if necessary, adjust the lubricator in order proper operation. If the batteries are properly
to release from one to three drops of oil per charged, the ammeter reading should be very near
second. To increase the rate, turn knob (2) zero. All batteries should be kept charged. The
counterclockwise. To decrease the rate, turn the batteries should be kept warm because temperature
knob clockwise. 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
Air Tank Moisture and or if the engine is run for short periods, the batteries
Sediment Drain - may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
V
SMCS Code: 1466-543-M&S
Moisture and sediment in the air starting system

can cause the following conditions:
92
Maintenance Section
-
Battery Charger Check
i01942625 A mixture of 0.1 kg (0.2 lb) of baking soda and

Battery Charger Check - 1 L (1 qt) of clean water
SMCS Code: 1401-535

A mixture of 0.1 L (0.11 qt) of ammonia and
1 L (1 qt) of clean water
I
I
Check the battery charger for proper operation. If Thoroughly rinse the battery case with clean
the batteries are properly charged, the needle of water.
the ammeter will register near "0" (zero).
Use a fine grade of sandpaper to clean the
The batteries should be kept warm, when possible. terminals and the cable clamps. Clean the items
The temperature of the battery will affect cranking until the surfaces are bright or shiny. DO NOT
power. A battery that is too cold will not crank the remove material excessively. Excessive removal
engine, even if the engine is warm. of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with
The batteries may not fully recharge when the 5N-5561 Silicone Lubricant, petroleum jelly or
engine is not run for long periods of time. The MPGM grease.
batteries may not fully recharge if the engine only
runs for short periods. Ensure a full charge in order
to help prevent the battery from freezing. i01492654
Battery or Battery Cable -

i01639002
Disconnect
Battery Electrolyte Level -
SMCS Code: 1402-029
Check
SMCS Code: 1401-535
When the engine is not run for long periods of The battery cables or the batteries should not be
time or when the engine is run for short periods, removed with the battery cover in place. The bat-
the batteries may not fully recharge. Ensure a full . tery cover should be removed before any servic-
charge in order to help prevent the battery from ing is attempted.
freezing. If batteries are properly charged, ammeter
reading should be very near zero. Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
All leadacid batteries contain sulfuric acid which 1. Turn the start switch to the OFF position. Turn the
can burn theskin and clothing. Always wear a face ignition switch (if equipped) to the OFF position
shield and protective clothing when working on or and remove the key and all electrical loads.
near batteries.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
1. Remove the filler caps. Maintain the electrolyte the cable cannot contact the terminal. When four
level to the "FULL" mark on the battery. 12 volt batteries are involved, the negative side
of two batteries must be disconnected.
If the addition of water is necessary, use distilled
water. If distilled water is not available use 3. Tape the leads in order to help prevent accidental
clean water that is low in minerals. Do not use starting.
artificially softened water.
4. Proceed with necessary system repairs. Reverse
2. Check the condition of the electrolyte with the the steps in order to reconnect all of the cables.
111-7298 CoolantIBattery Tester (C) or the
111-7297 Coolant/Battery Tester ("F).
3. Keep the batteries clean.
Clean the battery case with one of the following

cleaning solutions:
93
Maintenance Section
-
Belts lnspecVAdjusVReplace
i01920141 Adjusting the Alternator Belt

_) -
Belts lnspectlAdjustlReplace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspection
Inspect the alternator belt and the fan drive 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 Illustration 54
(1) Adjusting nuts
Bearings (2) Mounting bolt
If the belts are too tight, unnecessary stress is 1. Remove the drive belt guard.
placed on the components. This reduces the
service life of the components. 2. Loosen mounting bolt (2) and adjusting nuts (1).
-
Replacement 3. Turn adjusting nuts (1) in order to increase or
decrease the drive belt tension.
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing 4. Tighten adjusting nuts (1). Tighten mounting bolt
one drive belt of a matched set will cause the new (2).
drive belt to carry more load because the older
drive belts are stretched. The additional load on the 5. Reinstall the drive belt guard.
new drive belt could cause the new drive belt to fail.
If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation
at the rated rpm.
Adjusting the Fan Drive Belt

1. Loosen the mounting bolt for the pulley.
2. Loosen the adjusting nut for the pulley.
3. Move the pulley in order to adjust the belt

tension.
4. Tighten the adjusting nut.
5. ighten the mounting bolt.

94
Maintenance Section
-
Cooling System Coolant (DEAC) Change
i01892737
NOTICE
Cooling System Coolant
(DEAC) Change - Dispose of used engine coolant properly or recycle.
Various methods have been proposedto reclaim used
coolant for reuse in engine cooling systems. The full
SMCS Code: 1350-070; 1395-044 distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
Clean the cooling system and flush the cooling
system before the recommended maintenance For information regarding the disposal and the
interval if the following conditions exist: recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
The engine overheats frequently. Group:
b Foaming is observed. Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
The oil has entered the cooling system and the Canada: 1-800-523-TOOL
coolant is contaminated.
The fuel has entered the cooling system and the Flush
1. Flush the cooling system with clean water in
NOTICE order to remove any debris.
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo- 2. Close the drain valve (if equipped). Clean the
nents. Use only cooling system cleaners that are ap- drain plugs. Install the drain plugs. Refer to
proved for Caterpillar engines. the Specifications Manual, SENR3130, "Torque
Specifications" for more information on the
proper torques.
Note: inspect the water pump and the water
temperature regulator after the cooling system has NOTICE
been drained. This is a good opportunity to replace
Fill the cooling system no faster than 19 L (5 US gal)
the water pump, the water temperature regulator per minute to avoid air locks.
and the hoses, if necessary.
Drain 3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
Pressurized System: Hot coolant can cause seri-
ous burns. To ooen the coolina svstem filler cao. 4:Start and run the engine at low idle for a
stop the enginesandwait until ;hecooling system minimum of 30 minutes. The coolant temperature
components are cool. Loosen the cooling system should be at least 82 OC (180 OF).
pressure cap slowly in order to relieve the pres-
sure.
NOTICE
Improper or incomplete rinsing of the cooling system
1. Stop the engine and allow the engine to cool, can result in damage to copper and other metal com-
Loosen the cooling system filler cap slowly ponents.
in order to relieve any pressure. Remove the
cooling system filler cap. To avoid damage to the cooling system, make sure
2. Open the cooling system drain valve (if ter. Continue to flush the system until all signs of the
equipped). If the cooling system is not equipped cleaning agent are gone.
with a drain valve, remove one of the drain plugs.
Note: If equipped, be sure to drain the heater and

any related supply and return lines.
Allow the coolant to drain

~~
95
Maintenance Section
-
Cooling System Coolant (DEAC) Change
5. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool.
1 Loosen the cooling system filler cap slowly
in order to relieve any pressure Remove the
cooling system filler cap. Open the drain valve (if
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 equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure system with clean water. Close the drain valve
to flush the heater and any related supply and (if equipped). Clean the drain plugs. Install the
return lines. Close the drain valve (if equipped). drain plugs. Refer to the Specifications Manual,
Clean the drain plugs. Install the drain plugs. SENR3130, "Torque Specifications" for more
Refer to the Specifications Manual. SENR3130, information on the proper torques.
"Torque Specifications" for more information on
the proper torques. Fill
Cooling Systems with Heavy NOTICE
Deposits Or Plugging Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Note: For the following procedure to be effective,
there must be some active flow through the cooling 1. Fill the cooling system with coolantlantifreeze.
system components. Refer to the Operation and Maintenance
Manual, "Cooling System Specifications" topic
1. Flush the cooling system with clean water in (Maintenance Section) for more information on
order to remove any debris. cooling system specifications. Do not install the
cooling system filler cap.
Note: If equipped, be sure to flush the heater and
any related supply and return lines. 2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at high
2. Close the drain valve (if equipped). Clean the
8 drain plugs. lnstall the drain plugs. Refer to
the Specifications Manual, SENR3130, "Torque
Specifications" for more information on the
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

proper torques. level within 13 mm (0.5 inch) below the bottom
of the pipe for filling. Maintain the coolant level
NOTICE within 13 mm (0.5 inch) to the proper level on the
Fill the cooling system no faster than 19 L (5 US gal) sight glass (if equipped).
per minute to avoid air locks.
4. Clean the cooling system filler cap. lnspect the
gasket that is on the cooling system filler cap. If
3. Fill the cooling system with a mixture of clean the gasket that is on the cooling system filler cap
water and Caterpillar Fast Acting Cooling System is damaged, discard the old cooling system filler
Cleaner. Add 0.5 L (1 pint) of cleaner per cap and install a new cooling system filler cap.
3.8 to 7.6 L (1 to 2 US gal) of the cooling system If the gasket that is on the cooling system filler
capacity. Install the cooling system filler cap. cap is not damaged, perform a pressure test. A
95-8140 Pressurizing Pump is used to perform
4. Start and run the engine at low idle for a the pressure test. The correct pressure for the
minimum of 90 minutes. The coolant temperature cooling system filler cap is stamped on the face
should be at least 82 OC (180 OF). of the cooling system filler cap. If the cooling
system filler cap does not retain the correct
NOTICE pressure, install a new cooling system filler cap.
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com- 5. Start the engine. Inspect the cooling system for
ponents. leaks and for proper operating temperature.
To avoid damage to the cooling system, make sure

!->, 3 ter. Continue to flush the system until all signs of the
cleaning agent are gone.
I
Maintenance Section
-
Cooling System Coolant (ELC) Change
NOTICE
Cooling System Coolant (ELC)
-Change
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
SMCS Code: 1350-070; 1395-044 distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
Clean the cooling system and flush the cooling
system before the recommended maintenance For information regarding the disposal and the
interval if the following conditions exist: recycling of used coolant, consult your Caterpillar
8 The engine overheats frequently. dealer or consult Caterpillar Service Technology
Group:
8 Foaming is observed. Outside Illinois: 1-800-542-TOOL
8 The oil has entered the cooling system and the Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
8 The fuel has entered the cooling system and the Flush
1. Flush the cooling system with clean water in
Note: When the cooling system is cleaned, only order to remove any debris.
clean water is needed when the ELC is drained
and replaced. Note: If equipped, be sure to flush the heater and
any related supply and return lines.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has 2. Close the drain valve (if equipped). Clean the
been drained. This is a good opportunity to replace drain plugs. Install the drain plugs. Refer to
the water pump, the water temperature regulator the Specifications Manual, SENR3130. "Torque
and the hoses, if necessary. Specifications" for more information on the
proper torques.
Drain

ous burns. To open the cooling system filler cap, 3. Fill the cooling system with clean water. Install
stop the engine and wait until the cooling system the cooling system filler cap.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- 4. Start and run the engine at low idle until the
sure. temperature reaches 49 to 66 "C (120 to 150 OF).
5. Stop the engine and allow the engine to cool.

1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the in order to relieve any pressure. Remove the
cooling system filler cap. cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
2. Open the cooling system drain valve (if plugs. Allow the water to drain. Flush the cooling
equipped). If the cooling system is not equipped system with clean water. Close the drain valve
with a drain valve, remove the cooling system (if equipped). Clean the drain plugs. Install the
drain plugs. drain plugs. Refer to the Specifications Manual,
SENR3130, "Torque Specifications" for more
Allow the coolant to drain. information on the proper torques. I I
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
clI
I
~ e minute
r to avoid air locks. I
97
Maintenance Section
-
Cooling System Coolant Extender (ELC) Add
1. Fill the cooling system with Extended Life Coolant 3. Add Extender according to the requirements for
) (ELC). Refer to the Operation and Maintenance
Manual, "Cooling System Specifications" topic
your engine's cooling system capacity. Refer to
the Operation and Maintenance Manual, "Refill
(Maintenance Section) for more information on Capacities" in the Maintenance Section for the
cooling system specifications. Do not install the capacity of the cooling system for your engine.
cooling system filler cap. Refer to the Operation and Maintenance Manual,
"Cooling System Specifications" information for
2. Start and run the engine at low idle. Increase the the Caterpillar ELC Extender additions.
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from 4. Clean the cooling system filler cap. lnspect the
the cavities of the engine block. Stop the engine. cooling system filler cap gaskets. Replace the
cooling system filler cap if the cooling system
3. Check the coolant level. Maintain the coolant filler cap gaskets are damaged. Install the
level within 13 mm (0.5 inch) below the bottom cooling system filler cap.
of the pipe for filling. Maintain the coolant level
within 13 mm (0.5 inch) to the proper level on the
sight glass (if equipped).
Cooling System Coolant Level
4. Clean the cooling system filler cap. lnspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
-Check
is damaged, discard the old cooling system filler SMCS Code: 1395-082
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap Check the coolant level when the engine is stopped
is not damaged, use a 95-8140 Pressurizing and cool.
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
9 system filler cap does not retain the correct
pressure, install a new cooling system filler cap.
5. Start the engine. lnspect the cooling system for

leaks and for proper operating temperature.

Extender (ELC) Add -
1 SMCS Code: 1352-045; 1395-081
Illustration 55
Cooling system filler cap
Caterpillar Extended Life Coolant (ELC) does not

require the frequent Supplemental Coolant Additive
(SCA) additions associated with the present Pressurized System: Hot coolant can cause seri-
conventional coolants. The Extender only needs to
ous burns. To open the cooling system filler cap,
be added once. stop the engine and wait until the cooling system
Check the cooling system only when the engine is pressure cap slowly in order to relieve the pres-
stopped and cool.
sure.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling 1. Remove the cooling system filler cap slowly in
system filler cap. order to relieve pressure.
2. It may be necessary to drain enough coolant 2. Maintain the coolant level within 13 mm (0.5 inch)
from the cooling system in order to add the of the bottom of the filler pipe. If the engine is
Extender. equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
98
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Never collect samples from expansion bottles.
Never collect samples from the drain for a system.
Keep the unused sampling bottles stored in

plastic bags.
Keep the lids on empty sampling bottles until you

are ready to collect the sample.
Complete the information on the label for the

sampling bottle before you begin to take the
samples.
Obtain coolant samples directly from the coolant

Illustration 56
sample port. You should not obtain the samples
Typical filler cap gaskets from any other location.
3. Clean the cooling system filler cap and check the In order to avoid contamination, immediately
condition of the filler cap gaskets. Replace the place the sample in the tube that is provided for
cooling system filler cap if the filler cap gaskets mailing.
are damaged. Reinstall the cooling system filler
cap. Submit the sample for Level 1 analysis.
4. Inspect the cooling system for leaks. Note: Level 1 results may indicate a need for
Level 2 Analysis.
i01949691
For additional information about coolant analysis,
Cooling System Coolant see this Operation and Maintenance Manual, "S.0.S
Sample (Level I ) Obtain - Coolant Analysis" or consult your Caterpillar dealer.
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.
Sample (Level 2) Obtain -
Using the same pump for both types of samples may SMCS Code: 1350-008; 1395-008; 1395-554 7542
contaminate the samples that are being drawn. This
contaminate may cause a false analysi6and an incor- NOTICE
rect interpretation that could lead to concerns by both Always use a designated pump for oil sampling, and
dealers and customers. use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
For conventional heavy-duty coolant/antifreeze, contaminate the samples that are being drawn. This
check the concentration of supplemental coolant contaminate may cause a false analysis and an incor-
additive (SCA) regularly. The concentration of SCA rect interpretation that could lead to concerns by both
can be checked with an S.0.S coolant analysis dealers and customers.
(Level 1).
Obtain the sample of the coolant as close as
Obtain the sample of the coolant as close as possible to the recommended sampling intewal.
possible to the recommended sampling interval. In Supplies for collecting samples can be obtained
order to receive the full effect of S.0.S analysis, you from your Caterpillar dealer.
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform Refer to Operation and Maintenance Manual,
consistent samplings that are evenly spaced. "Cooling System Coolant Sample (Level 1) - Obtain"
Supplies for collecting samples can be obtained for the guidelines for proper sampling of the coolant.
from your Caterpillar dealer.
Submit the sample for Level 2 analysis.
Use the following guidelines for proper sampling
of the coolant:
99
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - TesWAdd
For additional information about coolant analysis,

see this Operation and Maintenance Manual, "S.0.S NOTICE
Coolant Analysisn or consult your Caterpillar dealer. Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
Cooling System Supplemental could cause cracking of the cylinder head and other
Coolant Additive (SCA) - high temperature components.
TesVAdd Excessive supplemental coolant additive concentra-

tion could also result in blockage of the heat exchang-
SMCS Code: 1352-045; 1395-081 er, overheating, andlor accelerated wear of the water
pump seal.
NOTICE Do not exceed the recommended amount of supple-
Do not change the coolant until you read and under- mental coolant additive concentration.
stand the material in the Cooling System Specifica-
tions section.
Use the 8T-5296 Coolant Conditioner Test Kit
or use the 4C-9301 Coolant Conditioner Test
Kit in order to check the concentration of the
SCA. Add SCA if the concentration is too low.
Pressurized System: Hot coolant can cause seri- If the concentration is excessive, drain half the
ous burns. To open the cooling system filler cap, coolant and replace the coolant with the proper
stop the engine and wait until the cooling system waterlantifreeze mixture.
pressure cap slowly in order to relieve the pres- S.0.S Coolant Analysis
sure.
a Check the cooling system only after the engine is

stopped and cool. Remove the filler cap slowly
in order to relieve pressure. To prevent engine
Coolant samples can be analyzed at your Caterpillar
dealer. S.0.S Coolant Analysis is a program that is
based on periodic samples. For more information
on S.0.S Coolant Analysis, see this Operation and
damage, never add coolant to an overheated Maintenance Manual, "S.0.S Coolant Analysis"
engine. Allow the engine to cool first. topic. For guidelines on taking a sample, see this
Operation and Maintenance Manual, "Coolant
Test the concentration of the Supplemental Coolant -
System Coolant Sample (Level 1) Obtain".
Additive (SCA) or test the SCA concentration as
part of an S.0.S Coolant Analysis. Add the SCA, If Necessary
1 Test the Concentration of SCA

The use of Caterpillar SCA will help prevent internal
NOTICE
Do not exceed the recommended amount of sup-
plemental coolant additive concentration. Excessive
damage to the engine. If the concentration is too supplemental coolant additive concentration can form
low, pitting of the cylinder wall may occur. deposits on the higher temperature surfaces of the
cooling system, reducing the engine's heat transfer
If the concentration is too high, sludge and mud-like characteristics. Reduced heat transfer could cause
deposits may form in the cooling system. This cracking of the cylinder head and other high temper-
adversely affects engine performance and lead to ature components. Excessive supplemental coolant
costly repairs of the engine and cooling system. additive concentration could also result in radiator
tube blockage, overheating, andlor accelerated water
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
could result in supplemental coolant additive concen-
tration exceeding the recommended maximum.
1. Slowly loosen the cooling system filler cap in

order to relieve the pressure. Remove the cooling
system filler cap.
100
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Note: Always discard drained fluids according to 3. Refer to this Operation and Maintenance Manual,
local regulations. "Cooling System Specifications" for the proper
SCA element for your system. Coat the gasket of
2. If necessary, drain some coolant from the cooling the new SCA element with a thin film of coolant.
system into a suitable container in order to allow Install the element. Tighten the element until the
space for the extra SCA. gasket contacts the base. Hand tighten another
270'. DO NOT overtighten the element.
3. Add the proper amount of SCA. Refer to
this Operation and Maintenance Manual, 4. Open the inlet and outlet valves,
"Commercial Heavy-Duty Antifreeze and SCA"
for more information on SCA requirements. 5. Remove the radiator filler cap. Start the engine
and check for leaks. Allow the coolant level to
4. Clean the cooling system filler cap. lnspect the stabilize.
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling 6. Check the coolant level. Maintain the coolant
system filler cap with a new cooling system filler level within 13 mm (0.5 inch)below the bottom of
cap. Install the cooling system filler cap. the filler pipe. Maintain the coolant level within
13 mm (0.5 inch)of the proper level on the sight
Replace the SCA Element (If glass (if equipped).
Equipped) 7 . Inspect the filler cap. Replace the cap if the
gasket is damaged. Install the filler cap.
NOTICE
Do not exceed the recommended amount of sup- 100912898
plemental coolant additive concentration. Excessive
Cooling System Water
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
Temperature Regulator
Replace
-
cracking of the cylinder head and other high temper-
ature components. Excessive supplemental coolant SMCS Code: 1355-510
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water Replace the water temperature regulator before
pump seal wear. Never use both liquid supplemental the water temperature regulator fails. This is a
coolant additive and the spin-on element (if equipped) recommended preventive maintenance practice.
at the same time. The use of those additives together Replacing the water temperature regulator reduces
could result in supplemental coolant additive concen- the chances for unscheduled downtime.
tration exceedina the recommended maximum.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the

closed 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
Illustration 57 g01010641 result in an accelerated wear of the piston rings and
wear of the cylinder liner.
1. Close inlet valve (1) and outlet valve (2). Remove
coolant additive element (3). Discard the used
element according to local regulations.
2. Clean the element mounting base. Make sure

that all of the old gasket is removed.
101
Maintenance Section
-
Crankshaft Vibration Damper lnspect
There is slippage of the outer ring from the

NOTICE original position.
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe The engine has had a failure because of a broken
engine damage. crankshaft.
Caterpillar engines incorporate a shunt design cooling Analysis of the oil has revealed that the front main
system and require operating the engine with a water bearing is badly worn.
temperature regulator installed.
There is a large amount of gear train wear that is
If the water temperature regulator is installed incor- not caused by lack of oil.
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg- Refer to the Service Manual or consult your
ulator is installed in the original position. Ensure that Caterpillar dealer for information about damper
the water temperature regulator vent hole is open. replacement.
Do not use liquid gasket material on the gasket or Visconic Damper

cylinder head surface.
Your engine may be equipped with a visconic
Refer to the Service Manual for the replacement damper. The visconic damper has a weight that is
procedure of the water temperature regulator, or located inside a fluid filled case. The weight moves
consult your Caterpillar dealer. in the case in order to limit torsional vibration.
Note: If only the water temperature regulators are lnspect the damper for evidence of fluid leaks. If
replaced, drain the coolant from the cooling system a fluid leak is found, determine the type of fluid.
to a level that is below the water temperature The fluid in the damper is silicone. Silicone has
regulator housing. the following characteristics: transparent, viscous,
smooth, and difficult to remove from surfaces.
If the fluid leak is oil, inspect the crankshaft seals for

leaks. If a leak is observed, replace the crankshaft
Crankshaft Vibration Damper
-lnspect
seals.
lnspect the damper and repair or replace the

SMCS Code: 1205-040 damper for any of the following reasons:
Damage to the crankshaft vibration damper or The damper is dented, cracked, or leaking.
failure of the crankshaft vibration damper can
increase torsional vibrations. This can result in The paint on the damper is discolored from heat.
damage to the crankshaft and to other engine
components. A deteriorating damper can cause The engine has had a failure because of a broken
excessive gear train noise at variable points in the crankshaft.
speed range.
Analysis of the oil has revealed that the front main
The damper is mounted to the crankshaft which is bearing is badly worn.
located behind the belt guard on the front of the
engine. There is a large amount of gear train wear that is
not caused by a lack of oil.
Rubber Damper Refer to the Service Manual or consult your
Caterpillar dealer for information about damper
Your engine may be equipped with a rubber replacement.
damper. The rubber damper uses a ring which is
mounted in rubber in order to reduce vibrations in
the crankshaft.
lnspect the damper and repair or replace the

damper for any of the following reasons:
There is deterioration and cracking of the rubber.

102
Maintenance Section
Engine Air Cleaner Element - CleanIReplace
iO1943356
Engine Air Cleaner Element -

CleanIReplace
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 prematurewear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet. Illustration 58 goo317608
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. 1 2, 3,
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 Illustration 59 go0781084
reach the air cleaner. (1) Cover
(2) Element
Check the precleaner (if equipped) daily for (3) Air inlet
accumulation of dirt and debris. Remove any dirt
and debris, as needed. 1. Release the fasteners for cover (1).
Operating conditions (dust, dirt and debris) may 2. Remove the cover and element (2).
require more frequent service of the air cleaner
element. 3. Cover air inlet (3) with tape in order to keep dirt
out.
The air cleaner element may be cleaned up to
six times if the element is properly cleaned and 4. Clean the inside of the cover and the body with
inspected. a clean, dry cloth.
The air cleaner element should be replaced 5. Remove the tape for the air inlet. Install a new
at least one time per year. This replacement element or a clean element.
should be performed regardless of the number
of cleanings. 6. Install the cover.
Replace the dirty paper elements with clean 7. If necessary, reset the air cleaner service
elements. Before installation, thoroughly inspect the indicator.
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.
103
Maintenance Section
Engine Air Cleaner Element - CleanIReplace
Cleaning the Primary Air Cleaner Aim the hose so that the air flows inside the element
I) Elements 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.
The primary air cleaner element can be used up
Dirt could be forced into the pleats.
to six times if the element is properly cleaned and
inspected. When the element is cleaned, check the
Note: Refer to "lnspecting the Primary Air Cleaner
filter material for rips or tears. Replace the element
Elements".
at least one time per year regardless of the number
of cleanings.
Vacuum Cleaning
I Use clean elements while dirty elements are being

cleaned.
-
NOTICE
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.
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use el- Vacuum cleaning will not remove deposits of carbon
ements with damaged pleats, gaskets or seals. Dam- and oil.
aged elements will allow dirt to pass through. Engine
damage could result. Note: Refer to "lnspecting the Primary Air Cleaner
Elements".
Visually inspect the elements before cleaning. Inspecting the Primary Air Cleaner
lnspect the elements for damage to the seal, the Elements
gaskets, and the outer cover. Discard any damaged
elements.
Air cleaner elements can be cleaned with

pressurized air and with a vacuum.
A
. 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).
lnspect 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.
lnspect the element for tears and/or holes. lnspect
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
go0281692
Illustration 60 with damaged pleats, gaskets or seals. Discard
damaged elements.
Note: When the elements are cleaned, always begin
with the clean side (inside) in order to force dirt Storing Primary Air Cleaner Elements
particles toward the dirty side (outside).
I If an element that passes inspection will not be
used immediately, store the element for future use.
104
Maintenance Section
-
Engine Air Cleaner Service lndicator lnspect
The service indicator may be mounted on the air

cleaner housing or in a remote location.
Do not use paint, a waterproof cover, or plastic as a Illustration 63 000103777

protective covering for storage. Restricted air flow Typical service indicator
may result. To protect against dirt and damage,
wrap the elements in Volatile Corrosion Inhibited Observe the service indicator. The air cleaner
(VCI) paper. element should be cleaned or the air cleaner
element should be replaced when one of the
Place the element into a cardboard box for storage. following conditions occur:
For identification, mark the outside of the container
and mark the element. include the following The yellow diaphragm enters the red zone
information:
Date of cleaning
.* The red piston locks in the visible position.
Number of cleanings Test the Service lndicator
Store the container in a dry location. Service indicators are important instruments.
For more detailed information on cleaning the Check for ease of resetting. The service indicator
primary air cleaner element, refer to Special should reset in less than three pushes.
Publication, SEBF8062, "Procedure to lnspect and
Clean Air Filters". Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
i01900118 greatest vacuum that is attained.
Engine Air Cleaner Service
Indicator lnspect - If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the
(If Equipped) new service indicator will not reset, the hole for the
service indicator may be plugged.
SMCS Code: 7452-040
The service indicator may need to be replaced
Some engines may be equipped with a different frequently in environments that are severely dusty, if
service indicator. necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
Some engines are equipped with a differential service indicator when the engine is overhauled,
gauge for inlet air pressure. The differential gauge and whenever major engine components are
for inlet air pressure displays the difference in the replaced.
pressure that is measured before the air cleaner
element and the pressure that is measured after Note: When a new service indicator is installed,
the air cleaner element. As the air cleaner element excessive force may crack the top of the service
becomes dirty, the pressure differential rises. If your indicator. Tighten the service indicator to a torque
engine is equipped with a different type of service of 2 N.m (18 lb in).
indicator, follow the OEM recommendations in order
to service the air cleaner service indicator.
105
Maintenance Section
Engine Air Precleaner - Clean
i01397717
9 Engine Air Precleaner - Clean

SMCS Code: 1055-070
Illustration 65
(1) Hose clamp
(2) Breather assembly
(3) Seal
go0736588
Illustration 64 1. Loosen hose clamp (1) and remove the hose
Typical precleaner from breather assembly (2).
(1) Wing nut
(2) Cover 2. Remove breather assembly (2)and seal (3).
(3)Body
3. Wash the breather element in solvent that is
Remove wing nut (I)and cover (2).Check for an clean and nonflammable. Allow the breather
accumulation of dirt and debris in body (3).Clean element to dry before installation.
the body, if necessary.
4. Install a breather element that is clean and dry.
After cleaning the precleaner, install cover (2)and Install seal (3)and breather assembly (2).
wing nut (1).
5. Install the hose. Install hose clamp (1).Refer to
Note: When the engine is operated in dusty the Operation and Maintenance Manual, "Torque
applications, more frequent cleaning is required. Specifications" topic (Maintenance Section) for
the proper torque.
i01007514
Engine Crankcase Breather - Engine Mounts lnspect -

i00687861
Clean
SMCS Code: 1 152-040
SMCS Code: 1317-070
lnspect the engine mounts for deterioration and for
NOTICE proper bolt torque. Engine vibration can be caused
Perform this maintenance with the engine stopped. by the following conditions:
If the crankcase breather is not maintained on a 8 Improper mounting of the engine

regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause 8 Deterioration of the engine mounts
excessive crankcase pressure that may cause
crankshaft seal leakage. Any engine mount that shows deterioration should
be replaced. Refer to the Service Manual for the
recommended torques. Refer to your Caterpillar
dealer for more information.
106
Maintenance Section
-
Engine Oil Level Check
i00623423 Obtain the Sample and the Analysis

Engine Oil Level Check -
SMCS Code: 1348-535-FLV
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to Before you take the oil sample, complete the Label,
contact the skin. PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
Engine model
ADD 1 1 FULL i Service hours on the engine
The number of hours that have accumulated

since the last oil change
Illustration 66
(Y) "ADD" mark. (X) 'FULL" mark. The amount of oil that has been added since the
last oil change
NOTICE
Perform this maintenance with the engine stopped. To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
1. Maintain the oil level between "ADD" mark (Y)
and "FULL" mark (X) on oil level gauge (1). Do To avoid contamination of the oil samples, the tools
not fill the crankcase above "FULL" mark (X). and the supplies that are used for obtaining oil
samples must be clean.
NOTlCE
Operating your engine when the oil level is above the Caterpillar recommends using the sampling valve
"FULL" mark could cause your crankshaft to dip into in order to obtain oil samples. The quality and the
the oil. The air bubbles created from the crankshaft consistency of the samples are better when the
dipping into the oil reduces the oil's lubricating char- sampling valve is used. The location of the sampling
acteristics and could result in the loss of power. valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
2. Remove the oil filler cap and add oil, if necessary. The 169-8373 Fluid Sampling Bottle is
Clean the oil filler cap. Install the oil filler cap. recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
i01935337
needed for obtaining oil samples. Instructions are
Engine Oil Sample Obtain - also provided.
NOTICE
SMCS Code: 1000-008; 1348-554-SM; Always use a designated pump for oil sampling, and
7542-554-OC, SM use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
In addition to a good preventive maintenance contaminate the samples that are being drawn. This
program. Caterpillar recommends using S.0.S oil contaminate may cause a false analysis-and an incor-
analysis at regularly scheduled intervals in order rect interpretation that could lead to concerns by both
to monitor the condition of the engine and the dealers and customers.
maintenance requirements of the engine. S.0.S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels. If the engine is not equipped with a sampling valve,
use the IU-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
Maintenance Section
-
Engine Oil and Filter Change
For instructions, see Special Publication, PEHP6001, Replace the Oil Filter
"How To Take A Good Oil Sample". Consult your
Caterpillar dealer for complete information and
assistance in establishing an S.0.S program for NOTICE
your engine. Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
101591548 the engine bearings, crankshaft, etc., as a result of
Engine Oil and Filter Change - the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
SMCS Code: 1318-510; 1348-044
1. Remove the oil filter with a IU-8760 Chain
Wrench.
Hot oil and hot components can cause personal 2. Cut the oil filter open with a 175-7546 Oil Filter
injury. Do not allow hot oil or hot components to Cutter Gp. Break apart the pleats and inspect the
contact the skin. oil filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early
Do not drain the oil when the engine is cold. As wear or a pending failure.
the oil cools, suspended waste particles settle
on the bottom of the oil pan. The waste particles Use a magnet to differentiate between the
are not removed with the draining cold oil. Drain ferrous metals and the nonferrous metals that
the crankcase with the engine stopped. Drain the are found in the oil filter element. Ferrous metals
crankcase with the oil warm. This draining method may indicate wear on the steel and cast iron
allows the waste particles that are suspended in the parts of the engine.
oil to be drained properly.
Nonferrous metals may indicate wear on the
P Failure to follow this recommended procedure will

cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
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.
Drain the Engine Oil Due to normal wear and friction, it is not
uncommonto find small amounts of debris in the
After the engine has been run at the normal oil filter. Consult your Caterpillar dealer in order
operating temperature, stop the engine. Use one of to arrange for a further analysis if an excessive
the following methods to drain the engine crankcase amount of debris is found in the oil filter.
/ .
oil:
If the engine is eq~ippedwith a orain vave, [urn

tne dra:n valve knob counterclockwise in oroer 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
g00103713
be cleaned and installed. Illustration 67
Typical filter mounting base and filter gasket
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.

108
Maintenance Section
-
Engine Protection Devices Calibrate
NOTICE
Do not fill the oil filters with oil before installing them.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.
C)
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to For the calibration of temperature contactors, see
engine components. Special Instruction, SEHS9827, "Calibration of
Temperature Contactors".
5. Install the oil filter. Tighten the oil filter until the For the calibration of pressure contactors, see
oil filter gasket contacts the base. Tighten the oil Special Instruction, SEHS9828, "Calibration of
filter by hand according to the instructions that Pressure Contactors".
are shown on the oil filter. Do not overtighten the
oil filter. For engines with the Caterpillar Marine Monitoring
System, see Owner's Manual, SEBU7134, "3600
Fill the Engine Crankcase Diesel Marine Monitoring System".
1. Remove the oil filler cap. Refer to the Operation Consult your Caterpillar dealer or refer to the
and Maintenance Manual for more information on Service Manual for more information.
lubricant specifications. Fill the crankcase with
the proper amount of oil. Refer to the Operation 100869626
and Maintenance Manual for more information
on refill capacities. Engine Valve Lash -
NOTICE
-
Inspect/Adjust
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer's recommendations. Under filling or overfilling
SMCS Code: 1102-025
The initial valve lash adjustment on new engines,

II
the crankcase with oil can cause engine damage. rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change.
The adjustment is necessary due to the initial wear
(
NOTICE of the valve train components and'to the seating of
To prevent crankshaft bearing damage, crank the en- the valve train components.
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more This maintenance is recommended by Caterpillar
than 30 seconds. as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
2. Start the engine and run the engine at "LOW life.
IDLE for two minutes. Perform this procedure in
order to ensure that the lubrication system has NOTICE
oil and that the oil filters are filled. Inspect the oil Only qualified service personnel should perform this
filter for oil leaks. maintenance. Refer to the Service Manual or your
Cater~illardealer for the com~letevalve lash adiust-
3. Stop the engine and allow the oil to drain back
to the sump for a minimum of ten minutes.
ment procedure.
Operation of Caterpillar engines with improper valve

II
4. Remove the oil level gauge in order to check the adjustments can reduce engine efficiency. This re-
oil level. Maintain the oil level between the "ADD" duced efficiency could result in excessive fuel usage
and "FULL" marks on the oil level gauge. andlor shortened engine component life.
iO1046330
Engine Protection Devices - Ensure that the engine can not be started while
Calibrate this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
SMCS Code: 7400-524
A calibration check of the engine protective devices

t o turn the flywheel.
Hot engine components can cause burns. Allow

C1
will ensure that the alarms and shutoffs activate at additional time for the engine t o cool before mea-
the setpoints. suringladjusting valve lash clearance. I
I
I
109
Maintenance Section
Engine Valve Rotators - lnspect
Ensure that the engine is stopped before measuring

) the valve lash To obtain an accurate measurement.
- allow the valves to cool before this maintenance Fan Drive Bearing Lubricate -
i00175571
is performed.
SMCS Code: 1359-086-BD
Refer to the Service Manual for more information. 8 2
i01597115
Engine Valve Rotators lnspect -

SMCS Code: 1109-040
When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, t o help prevent being burned by
hot oil or surav. go0123252
Illustration 68
Typical Fan Drive Bearing Grease Fitting
Engine vaive rotators rotate the valves when the
engine runs. This helps to prevent deposits from Lubricate the fan drive bearing grease fitting with
building up on the valves and the valve seats. Bearing Lubricant Special Purpose Grease or the
equivalent.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed: lnspect the fan drive pulley assembly. If the shaft
is loose, an inspection of the internal components
1. Start the engine according to Operation
9 and Maintenance Manual, "Engine Starting"
(Operation Section) for the procedure.
should be performed. Refer to the Service Manual.
i01432350
2. Operate the engine at low idle.
Fuel Control Linkage -
3. Observe the top surface of each vaive rotator. CheckILubricate
The valve rotators should turn slightly when the
valves close. SMCS Code: 1257-086; 1257-535
NOTICE Check the fuel control linkage for proper operation.

A valve rotator which does not operate properly will If necessary, adjust the fuel control linkage. A
accelerate valve face wear and valve seat wear and variety of linkages can be used. The type of linkage
shorten valve life. If a damaged rotator is not replaced, depends on the type of installation. Therefore, refer
valve face guttering could result and cause pieces of to the OEM of the vessel for the specific type of
thevalve to fall into the cylinder. This can cause piston fuel control linkage.
and cylinder head damage.
Some fuel control linkages require lubrication.
Lubricate the grease fittings with 1P-0808
If a valve fails to rotate, consult your Caterpillar Multipurpose Grease or the equivalent.
dealer.
110
Maintenance Section
Fuel lnjection Nozzles - TestIExchange
100626014 2. Loosen each fuel line nut one at a time at the fuel
Fuel lnjection Nozzles - injection pump. A cloth or similar material must
be used in order to prevent fuel from spraying on
the hot exhaust components. Tighten each nut
TesVExchange before loosening the next nut.
SMCS Code: 1254-013; 1254-081
3. A defective fuel injection nozzle may be identified
when a fuel line nut is loosened and the following
conditions are present:
The exhaust smoke is partially eliminated or

cal components can cause a fire. the exhaust smoke is completely eliminated.
Engine performance is not affected.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly A fuel injection nozzle that is suspected of
clean the area around a fuel system component that being defective should be removed. A new
will be disconnected. Fit a suitable cover over discon- fuel injection nozzle should be installed in the
nected fuel system component. cylinder in order to determine if the removed fuel
injection nozzle is defective.
Fuel injection nozzles are subject to tip wear. Tip
wear is a result of fuel contamination. Tip wear can Removal and Installation of the
cause the following problems:
Fuel lnjection Nozzles
Increased fuel consumption
For the removal and the installation of fuel injection
Black smoke nozzles, special tooling is required. Refer to the
Service Manual for more information. Consult your
Misfire Caterpillar dealer for assistance.
Rough running
Fuel lnjection nozzles should be cleaned, inspected,

tested, and replaced, if necessary. Refer to Special
Fuel Ratio Control -
Instruction, SEHS7292 for using the 8s-2245 InspecVAdjust
lnjection Cleaning Tool Group. Consult your
Caterpillar dealer about cleaning the fuel injection SMCS Code: 1278-025; 1278-040
nozzle and testing the fuel injection nozzle.
Slow engine response and low power may indicate
a need for adjustment or repair of the fuel ratio
NOTICE control. Refer to the Service Manual or your
Never wire brush or scrape a fuel injection nozzle. Caterpillar dealer for the complete adjustment
Wire brushing or scraping a fuel injection nozzle will procedure on the fuel ratio control.
damage the finely machine orifice. Proper tools for
cleaning and testing the fuel injection nozzles can be
obtained from Caterpillar dealers.
The following items are symptoms of a malfunction

of the fuel injection nozzle:
Abnormal engine operation
Smoke emission
Engine knock
Each fuel injection nozzle must be isolated one at a

time in order to determine the malfunctioning fuel
injection nozzle.
1. Start the engine.

111
Maintenance Section
Fuel System - Prime
9 Fuel System Prime - NOTICE

During periodic service, DO NOT remove the fuel filter
plug that is in the fuel filter base in order to purge air
SMCS Code: 1258-548 from the fuel
- -~ svstem. The Deriodic removal of the fuel
~ ~
-,
~ ~~
filter plug will result in increased wear on the threads

in the fuel filter base. This wear leads to fuel leakage.
Personal injury or death can result from a fire.

4. Open the vent valve (if equipped) on the fuel
Fuel leaked or spilled onto hot surfaces or electri- injection pump's housing.
cal components can cause a fire.
5. Operate the priming pump until the flow of fuel
Clean up all leaked or spilled fuel. Do not smoke from the vent valve is continuous and the flow of
while working on the fuel system. fuel is free of air bubbles.
Turn the disconnect switch OFF or disconnect the If the engine does not have a fuel priming pump,
b a t t e when
~ chanaina fuel filters. crank the engine. Crank the engine until the
fuel flows freely and until the fuel is free of air
bubbles.
Prime the fuel system in order to fill dry fuel filters.
You must also prime the fuel system after any one 6. Close the vent valve. Then, push in the plunger.
of the following conditions exist: Hand tighten the plunger.
The fuel system has run dry. 7. Crank the engine. If the engine starts and if the
engine runs rough, run the engine at low idle.
The engine has been in prolonged storage. Continue running the engine until the engine
runs smoothly.
- The fuel filter has been cleaned.
8 The fuel filter has been replaced.

Note: If the engine will not start, more priming is
necessary. If the engine continues to run rough,
more priming is necessary as well.
Note: If the engine does not have a fuel priming
pump, refer to Step 4. NOTICE
Do not let the tops of fuel nozzles turn when the fuel
1. Unlock the priming pump, and operate the line nuts are loosened or tightened.
priming pump until a resistance is felt. This
procedure will probably require a considerable The nozzles will be damaged if the top of the nozzle
amount of priming. turns in the body.
2. Push in the plunger, and hand tighten the The engine will be damaged if a defective fuel injec-
plunger. tion nozzle is used because the shape of fuel (spray
oattern) that comes out of the nozzles will not be cor-
NOTICE Iect. '
Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies
that the oil pressure is sufficient.
3. Crank the engine.
If the engine starts and the engine runs rough,

run the engine at low idle. Continue running the
engine until the engine runs smoothly.
Illustration 69
g00290109
112
Maintenance Section
-
Fuel System Primary Filter CleanlReplace
8. Loosen the fuel line nuts at the valve cover base.

Loosen these line nuts one at a time. 1
9. Operate the priming pump until the flow of fuel
from the fuel line is continuous and the flow of
fuel is free of air bubbles.
2
l0.Push in the plunger, and hand tighten the
plunger. If the engine does not have a fuel
priming pump, crank the engine.
11.Tighten each fuel line nut before you loosen the

next fuel line nut. Tighten the fuel line nuts to a 3
torque of 40 + 7 N.m (30 + 5 lb ft).
go0485293
Continue this procedure until all of the fuel lines Illustration 70
have been cleared of any air. Before you start (I) Bolt
the engine, make sure that the fuel line nuts (2) Element
(3) Case
are properly tightened. Also make sure that the
priming is locked. 5. Loosen the bolt (1) that is on the filter housing.
Remove the filter case (3).
i00951418
Fuel System Primary Filter - 6. Remove the element (2) and wash the element
in clean, nonflammable solvent.
CleanIReplace
NOTICE
SMCS Code: 1260-070; 1260-510 Do not fill thefuel filters with fuel before installingthem. .
The fuel would not be filtered and could be contami-
nated. Contaminated fuel will cause accelerated wear
to fuel system parts.
( 3
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre- 7. Install the element (2) and the filter case (3).
vent possible injury, turn the start switch off when Tighten the bolt (1) to a torque of 24 4 N.m*
changing fuel filters or water separator elements. *
(18 3 lb ft).
Clean up fuel spills immediately.
i01776046
1. Stop the engine.
Fuel System Secondary Filter -
2. Turn the start switch to the "OFF" position.
Disconnect the battery.
Replace
SMCS Code: 1261-510-SE
3. Shut off the fuel tank supply valve to the engine.
4. If the primary fuel filter is equipped with a drain

valve, open the drain valve in order to drain any
fuel from the filter case. Close the drain valve. Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
NOTICE
Use a suitable container to catch any fuel that might changing fuel filters or water separator elements.
Clean up fuel spills immediately.
spill. Clean up any spilled fuel immediately.
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 dis-
connected fuel system components.
( #
A
113
Maintenance Section
-
Fuel Tank Water and Sediment Drain
101877350
NOTICE
Use a suitable container to catch any fuel that might Fuel Tank Water and Sediment
spill. Clean up any spilled fuel immediately. - Drain
1. Stop the engine. Turn the ignition switch to the SMCS Code: 1273-543-M&S
OFF position or disconnect the battery. Refer
to the Operation and Maintenance Manual, NOTICE
"Battery or Battery Cable - Disconnect" topic Care must be taken to ensure that fluids are contained
(Maintenance Section) for more information. Shut during performance of inspection, maintenance, test-
off the fuel supply valve (if equipped). ing, adjusting and repair ofthe product. Be preparedto
collect the fluid with suitable containers before open-
2. It may be necessary to relieve residual fuel ina
-
- anv. comDattment or disassemblina anv* comDo-
pressure from the fuel system before the fuel
filter is removed. Wait for one to five minutes until
the fuel pressure has lowered. Use a suitable Refer to Special Publication, NENG2500, "Caterpillar
container in order to catch any fuel that may spill. Tools and Shop Products Guide"fortools and supplies
suitable to collect and contain fluids on Caterpillar
3. Remove the used fuel filter and discard the used products.
fuel filter.
Dispose of all fluidsaccording to local regulations and
4. Clean the gasket sealing surface of the fuel mandates.
filter base. Ensure that all of the old gasket is
removed.
Fuel Tank
5. Apply clean diesel fuel to the new fuel filter
gasket. Fuel quality is critical to the performance and to
.the service life of the engine. Water in the fuel
b NOTICE
Do not fill the secondary fuel filter with fuel before in-
can cause excessive wear to the fuel system.
Condensation occurs during the heating and
cooling of fuel. The condensation occurs as the fuel
stalling. The fuel would not be filtered and could be passes through the fuel system and the fuel returns
contaminated. Contaminated fuel will cause acceler- to the fuel tank. This causes water to accumulate
ated wear to fuel system parts. in fuel tanks. Draining the fuel tank regularly and
obtaining fuel from reliable sources can help to
eliminate water in the fuel.
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a Drain the Water and the Sediment
two micron high efficiency fuel filter is required for all
Caterpillar Electronic Unit Injectors. Caterpillar High Fuel tanks should contain some provision for
Efficiency Fuel Filters meet these requirements. Con- draining water and draining sediment from the
sult your Caterpillar dealer for the proper part num- bottom of the fuel tanks.
bers.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
6. Install the new fuel filter. Spin the fuel filter onto the drain valve.
the fuel filter base until the oasket contacts the
base. Use the rotation indexmarks on the filters Check the fuel daily. Drain the water and sediment
as a guide for proper tightening. Tighten the filter from the fuel tank after operating the engine or drain
according to the instructions that are on the fuel the water and sediment from the fuel tank after the
filter. Do not overtighten the filter. fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
7. Open the fuel supply valve. The engine will need
to be purged of air. Refer to the Operation and Fill the fuel tank after operating the engine in
Maintenance Manual, "Fuel System - Prime" topic order to drive out moist air. This will help prevent
(Maintenance Section) for more information.
Ib condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
114
Maintenance Section
Generator - Dry
Some fuel tanks use supply pipes that allow water the experience of personnel
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that Note: For more information on drvina methods. refer
take fuel directly from the bottom of the tank. If lo Special Instrucrion, ~ ~ ~ ~ 9%leaning
1 2 4 , 'no
the engine is equipped with this system, regular Drying of Electric Set Generators".
maintenance of the fuel system filter is important.
Remove the voltage regulator. Cover all of the inlet
Fuel Storage Tanks openings. Cover all of the discharge holes. Provide
an opening at the top of the machine. This opening
Drain the water and the sediment from the fuel will allow moisture to evaporate. Preferably, this
storage tank during the following conditions: opening will be located at the fan end. Monitor the
winding temperatures. DO NOT APPLY HEAT TOO
Weekly RAPIDLY. Winding temperature should be raised
gradually at a rate of 10 "C (50 OF) per hour up to
Oil change 85 'C (185 OF). Measure insulation resistance at one
hour intervals. Typically, the insulation resistance
Refill of the tank will slowly drop while the temperature is rising. The
insulation resistance will then start to increase at a
This will help prevent water or sediment from being slow rate until the insulation resistance reaches a
pumped from the storage tank into the engine fuel constant level .
tank.
The following methods can be used for drying a
If a bulk storage tank has been refilled or moved generator:
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal Self-circulating air method
baffles in the bulk storage tank will also help trap
sediment. Filterina fuel that is D u I ~ from
D the
~ ~
Oven method
storage tank helps to ensure the q;ality of the fuel.
When possible, water separators should be used. Controlled current method
i01831525
Self-circulating Air Method
Generator Dry - Run the engine and disconnect the generator load:
This will help circulate air. Operate the generator
SMCS Code: 4450-569 space heaters.
Oven Method
Personal injury or death can result from improper Place the entire generator inside a forced air drying
troubleshooting and repair procedures. oven for four hours at 65 "C (149 OF).
The following troubleshooting and repair proce- NOTICE

dures should only be performed by qualified per- Use a forced air type oven rather than a radiant type
sonnel familiar with this equipment. oven.
Refer to Safety Section, "Generator Isolating Radiant type ovens can cause localized overheating.
for Maintenance" for information regarding the
procedure to safely isolate the generator.
If the insulation resistance values are less than the

recommended values, one of the following drying
procedures must be selected. This decision should
be based on the following factors:
the size of the unit
the location of the unit
a the equipment that is available

115
Maintenance Section
-
Generator lnspect
Controlled Current Method 1. Obtain an external 12 Volt DC power source.

. Tahla X' 2. Refer to the above diagram. Disconnect "Fl+"
1 Tools Needed 1 from the voltage regulator. Disconnect "F2-" from
the voltage regulator.
I Number
Description
I Qw I 3. Disconnect the generator load. Connect the
I 8T-0900 I clam^ on ammeter (0 - I 1 I generator output leads "TO", "TI", "T2, and
1'200 amperes) ' "T3" together. Install the clamp-on ammeter to
generator output lead "TI".
I External 12 Volt DC Power I 1
I I Source I I Note: When the line current is measured on
Rheostat 1 1 multiple-lead units, measure the current in each
conductor for each phase. Add the currents
Switch 1
together.
Heat can be used in order to dry the generator 4. Refer to the above diagram. Connect rheostat
windings. This heat can be created by allowing a (C). Adjust rheostat (C) to the maximum
controlled current to flow through the generator. No resistance value. Connect the external power
high voltages are generated during the following source to wires"F1c" and "F2-"with switch (E) in
procedure. Therefore, insulation breakdown will not the open position.
occur.
5. Start the generator set. Run the generator set
TI at idle speed.
6. Monitor the phase current. Gradually increase
the engine RPM. Increase the engine RPM until
one of the following conditions are met:
, The rated phase current is obtained.

. .
0 The full generator set speed is obtained.
7. If more phase current is still necessary, run the

generator at idle speed and close switch (E).
Slowly turn rheostat (C) until the rated phase
current is reached.
.-------------, /-- 8. On I D
an hourly basis, stop the drying procedure.
Check the insulation resistance. R e ~ e athe
t
above steps until the insulation resistance is
acceptable.
i01461264
Generator lnspect -
SMCS Code: 4450-040
Illustration71 900935477
Generator Wiring Diagram

(A) Clamp-onammeter
Personal injury or death can result from improper
(B) Rotating field assembly troubleshooting and repair procedures.
(C) Rheostat
(D) External 12 Volt DC Power Source The following troubleshooting and repair proce-
(E) Switch dures should only be performed by qualified per-
(CRI-CR6) Diodes
(CR7) Varistor sonnel familiar with this equipment.
(LI) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
116
Maintenance Section
-
Generator inspect
Refer to Safety Section, "Generator Isolating Cleaning (Assembled Generators)

for Maintenance" for information regarding the
procedure to safely isolate the generator. Cleaning may be req~iredat the point of insta lation.
At ths ooint, como ete disassemblv of rhe aeneraror
Proper maintenance of electrical equipment requires may not benecessary or feasible.'ln this &se, a
periodic visual examination of the generator and vacuum cleaner should be used to pick up the
periodic visual examination of the windings. Proper following items: dry dirt, dust, and carbon. This will
maintenance of electrical equipment also requires prevent the spreading of these contaminants.
appropriate electrical checks and appropriate
thermal checks. Insulation material should be A small nonconductive tube may need to be
examined for cracks. The insulation material should connected to the vacuum cleaner. This will allow the
be examined for accumulations of dirt and dust. vacuum cleaner to clean the surfaces that are not
If there is an insulation resistance value that is exposed. After most of the dust has been removed,
below normal, a conductive path may be present. a small brush may be attached to the vacuum hose
This conductive path may be made of one of the in order to loosen dirt that is more firmly attached
following materials: to the surface.
Carbon After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
Salt dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure
Metal dust should be a maximum of 210 kPa (30 psi) in order
to prevent mechanical damage to the insulation. If
Dirt that is saturated with moisture the above cleaning procedures are not effective,
consult a Caterpillar dealer.
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
Cleaning i is assembled
accumulations of dust can be seen. If excess dirt is Generators)
the cause of a restriction in the ventilation, cleaning
is also advisable. Restricted ventilation will cause An initial insulation resistance check should be
excessive heating. made on the generator in order to confirm electrical
rntegriry. A minimum reading of one megohm would
NOTICE be exoected witn severe v conraminareo aenerators.
To avoid the possibility of deterioration to the genera- A zero megohm reading ;nay indicate acinsulation
tor windings, do not clean the generator unless there breakdown. An insulation breakdown requires more
is visual, electrical, or thermal evidence that dirt is than cleaning. An insulation breakdown requires
present. repair.
A high pressure wash is normally an effective way

If harmful dirt accumulations are present, a variety to clean windings. This includes windings that have
of cleaning techniques are available. The cleaning been exposed to flooding or windings that have
procedure that is used may be determined by one been contaminated by salt. A solution of hot water
of the items on the following list: and detergent is used for this method of cleaning.
The extent of the cleaning procedure that is A high pressure wash sprays a high velocity fluid
being attempted stream of this solution over the generator that is
being cleaned. This detergent washing is followed
The type of enclosure of the generator by multiple sprays of clean water. The clean water is
used in order to remove the detergent or the clean
The voltage rating of the generator water is used in order to dilute the detergent.
The type of dirt that is being removed 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.
117
Maintenance Section
Generator Load - Check
Note: For more information on drying methods, refer i01593517

to Special Instructions, SEHS9124, "Cleaning and
Drying of Electric Set Generators". Generator Set Test -
SMCS Code: 4450-081
i01228480
Generator Load Check -

SMCS Code: 4450-535-LA Personal injury or death can result from high volt-
age.
During normal operation, monitor the power factor
and monitor generator loading. When power generation equipment must be in op-
eration to make tests and/or adjustments, high
When a generator is installed or when a generator voltage and current are present.
is reconnected, ensure that the total current in any
one phase does not exceed the nameplate rating. improper test equipment can fail and present a
Each phase should carry the same load. This allows high voltage shock hazard to its user.
the generator to work at the rated capacity. If one
phase current exceeds the nameplate amperage, Make sure the testing equipment is designed for
an electrical imbalance will occur. An electrical and correctly operated for high voltage and cur-
imbalance can result in an electrical overload and rent tests being made.
an electrical imbalance can result in overheating .
When servicing or repairing electric power gener-
The power factor can be referred to as the efficiency ation equipment:
of the load. This can be expressed as the ratio
of kVAto actual kW. The power factor can be Make sure the unit is off-line (disconnected
calculated by dividing kW by kVA. Power factor is from utility and/or other generators power
expressed as a decimal. Power factor is used to service), and either locked out or tagged DO
mean the portion of current that is supplied to a NOT OPERATE.
system that is doing useful work. The portion of the
current that is not doing useful work is absorbed Make sure the generator engine is stopped.
in maintaining the magnetic field in motors. This
current (reactive load) can be maintained without Make sure all batteries are disconnected.
engine power.
Make sure all ca~acitorsare discharaed.
Electric sets normally have a low idle setting that
is higher than industrial engines. Low idle will be Table 34
approximately 66% of the full speed that is achieved
by 60 Hz units. This would be equal to 80% of the Tools Needed
full speed that is achieved by 50 Hz units. Part Number I Part Quantitv
Some electric sets are equipped with Woodward 6\1-7070 Digital 1
governors and some electric sets are equipped Multimeter
with Caterpillar electronic governors. These electric 12 VDC b a t t e ~ 1
sets have no low idle stop. On electric sets with
mechanical governors and natural gas electric sets, Potential 1
the low idle is set at the factory. Adjustment of the Transformer
low idle on these machines should only be done
by a Caterpillar dealer. The generator set functional test is a simplified test
that can be performed in order to determine if the
Note: Operating the electric set at low idle speed generator is functional. The generator set functional
for an extended time will cause some voltage test should be performed on a generator set that
regulators to shut off. The electric set must be is under load.
completely shut down and the electric set must be
restarted. This will allow the voltage regulator to The generator set functional test determines if the
again produce an output. following statements happen:
A phase voltage is being generated
The phase voltages are balanced.

118
Maintenance Section
-
Generator Set Vibration lnspect
The phase voltages change relative to engine capacitors

speed.
lightning arrestors
The generator set functional test consists of the
following steps: Check the generator set's vibration level by using a
broad spectrum analyzer.
1. Stop the generator. Connect the potential
transformer's high voltage winding to the 101849025
generator terminals (TI) and (T2). Connect the
voltmeter to the low voltage winding. If two
transformers are available, connect the high
Hoses and Clamps -
voltage winding of the second transformer to the InspectIReplace
generator terminals (TI) and (T3). Connect the
secondary terminals that correspond to generator SMCS Code: 7554-040; 7554-510
terminal (T2) of both transformers together.
lnspect all hoses for leaks that are caused by the
2. Disconnect wires "E+" and "E-" from the voltage following conditions:
regulator. Disconnect the generator from the
load. Cracking
3. Connect a 12 VDC automotive battery to wires Softness

"E+" and "E-",
Loose clamps
4. Measure the AC voltage across the low voltage
terminals of the transformer that correspond to Replace hoses that are cracked or soft. Tighten any
.the following generator terminals: "TI" and "T2", loose clamps.
"T2" and "T3", and "T3" and "TI". Record the --
voltages. NOTICE
Do not bend or strike high pressure lines. Do not in-
101228545
stall bent or damaged lines, tubes or hoses. Repair
Generator Set Vibration - anyGlooseor damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. lnspect all lines, tubes
and hoses carefully. Tighten all connectionsto the rec-
lnspect ommended torque.
SMCS Code: 4450-040-Vl
Check for the following conditions:
Check for vibration damage. Vibration may cause
the following problems: End fittings that are damaged or leaking
loose fittings Outer covering that is chafed or cut
loose bolts Exposed wire that is used for reinforcement
excessive noise Outer covering that is ballooning locally
cracked insulation Flexible part of the hose that is kinked or crushed
The following areas are susceptible to vibration Armoring that is embedded in the outer covering
damage:
A constant torque hose clamp can be used in
stator output leads place of any standard hose clamp. Ensure that the
constant torque hose clamp is the same size as
protective sleeving the standard clamp.
insulation Due to extreme temperature changes, the hose

will heat set. Heat setting causes hose clamps to
exposed electrical connections loosen. This can result in leaks. A constant torque
hose clamp will help to prevent loose hose clamps.
transformers
Each installation application can be different. The
fuses differences depend on the following factors:
119
Maintenance Section
-
Magnetic Pickups Cleanllnspect
8 Type of hose i00906366
0 Type of fitting material Magnetic Pickups -

Clean/lnspect
8 Anticipated expansion and contraction of the
I a
hose
Anticipated expansion and contraction of the
SMCS Code: 1907-040; 7400-040; 7400-070
fittings
Replace the Hoses and the Clamps

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
pressure cap slowly in order to relieve the pres-
sure.
Illustration72
Typical example
1. Stop the engine. Allow the engine to cool.
(1) Magnetic pickup
(2) Flywheel housing
2. Loosen the cooling system filler cap slowly
in order to relieve anv Dressure. Remove the
cooling system filler cap.
Note: Drain the cooiant into a suitable, clean

container. The coolant can be reused.
3. Drain the coolant from the cooling system to

a level that is below the hose that is being
replaced.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose. Illustration 73

goo293337
Typical magnetic pickup

Note: Refer to the Specifications, SENR3130 in
order to locate the proper torques.
1. Remove magnetic pickup (1) from flywheel
7. Install the hose clamps with a torque wrench. housing (2). Check the condition of the end of
the magnetic pickup. Check for signs of wear
Note: For the proper coolant to use, see this and contaminants.
Operation and Maintenance Manual, "Coolant
Recommendations" (Maintenance Section). 2. Clean the metal shavings and other debris from
the face of the magnet.
8. Refill the cooling system.
3. install the magnetic pickup and adjust the
magnetic pickup. Refer to the Service Manual for
'
9. Clean the cooling system filler cap. Inspect the
cooling system filler cap's gaskets. Replace the installation procedure.
the cooling system filler cap if the gaskets are
damaged. install the cooling system filler cap.
10.Start the engine inspect the cooling system for

leaks.
.--
Maintenance Section
Overhaul Considerations
i01452713 Costly unplanned downtime can be avoided.

Overhaul Considerations Many original parts can be reused according to
the standards for reusable parts.
SMCS Code: 7595-043
The engine's service life can be extended without
Reduced hours of operation at full load will result the risk of a major catastrophe due to engine
in a lower average power demand. A decreased failure.
average power demand should increase both the
engine service life and the overhaul interval. The best cost/value relationship per hour of
extended life can be attained.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power. After Failure Overhaul
The following factors are important when a decision If a major engine failure occurs and the engine
is being made on the proper time for an engine must be removed, many options are available. An
overhaul: overhaul should be performed if the engine block
or the crankshaft needs to be repaired.
The need for preventive maintenance
If the engine block is repairable and/or the
The quality of the fuel that is being used crankshaft is repairable, the overhaul cost should
be between 40 percent and 50 percent of the cost
The operating conditions of a new engine with a similar exchange core.
The results of the S.0.S analysis This lower cost can be attributed to three aspects:
Oil Consumption as an Overhaul Specially designed Caterpillar engine features

Indicator Caterpillar dealer exchange components
Oil consumption, fuel consumption, and Caterpillar Inc. remanufactured exchange
maintenance information can be used to estimate components
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 Overhaul Recommendation
suitable for the maintenance intervals.
To minimize downtime, Caterpillar Inc. recommends
Oil consumption is in proportion to the percentage a scheduled engine overhaul by your Caterpillar
of the rated engine load. As the percentage of the dealer before the engine fails. This will provide you
engine load is increased, the amount of oil that is with the best cost/value relationship.
consumed per hour also increases.
Note: Overhaul programs vary according to the
The oil consumption rate (brake specific oil engine application and according to the dealer
consumption) is measured in grams per kW/h that performs the overhaul. Consult your Caterpillar
(Ib per bhp). The brake specific oil consumption dealer for specific information about the available
(BSOC) depends on the engine load. Consult your overhaul programs and about overhaul services for
Caterpillar dealer for assistance in determining the extending the engine life.
typical oil consumption rate for your engine.
If an overhaul is performed without overhaul service
When an engine's oil consumption has risen to from your Caterpillar dealer, be aware of the
three times the original oil consumption rate due following maintenance recommendations.
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:
.-.
Maintenance Section
Overhaul Considerations
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 lnspect these parts while the engine is disassembled
for an overhaul.
These components should be inspected according
to the instructions that are found in various lnspect the crankshaft for any of the following
Caterpillar reusability publications. The Special conditions:
Publication, SEBF8029 lists the reusability
publications that are needed for inspecting the Deflection
engine parts.
Damage to the journals
If the parts comply with the established inspection
specifications that are expressed in the reusable Bearing material that has seized to the journals
parts guideline, the parts should be reused.
Check the journal taper and the profile of the
Parts that are not within the established inspection crankshaft journals. Check these components by
specifications should be dealt with in one of the interpreting the wear patterns on the following
following manners: components:
Salvaging Rod bearing
Repairing Main bearings
Replacing lnspect the camshaft for damage to the journals

and to the lobes.
Using out-of-spec parts can result in the following
problems: Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check
Unscheduled downtime for cracks in the camshaft.
Costly repairs lnspect the following components for signs of wear

or for signs of scuffing:
Damage to other engine parts
Camshaft bearings
Reduced engine efficiency
Camshaft followers
Increased fuel consumption
Caterpillar Inc. recommends replacing the
Reduced engine efficiency and increased fuel . crankshaft vibration damper.
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing Oil Cooler Core
out-of-spec parts or replacing out-of-spec parts.
During an overhaul, Caterpillar Inc. recommends
Inspection andlor Replacement the removal of the oil cooler core. Clean the oil
cooler core. Then, pressure test the oil cooler core.
Crankshaft Bearings, Valve Rotators, and
Crankshaft Seals NOTICE
Do not use caustic cleaners to clean the core.
The following components may not last until the
second overhaul. Caustic cleaners can attack the internal metals of the
core and cause leakaae.
Thrust bearings
Main bearings Note: Use this cleaning procedure to clean the oil
cooler core. '
Rod bearings
1. Remove the oil cooler core.
Valve rotators
Crankshaft seals
122
Maintenance Section
-
Radiator Clean
2. Remove any debris from the oil cooler core. To Obtain Coolant Analysis
remove debris from the oil cooler core, turn the
oil cooler core onto one end. The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits
3. Flush the oil cooler core internally with cleaner in or with S.0.S Coolant Analysis (Level 1). Further
order to loosen foreign substances. This will also coolant analysis is recommended when the engine
help to remove oil from the oil cooler core. is overhauled.
Note: Caterpillar Inc. recommends the use of For example, considerable deposits are found in the
Hydrosolv Liquid Cleaners. Table 35 lists the water jacket areas on the external cooling system,
Hydrosolv Liquid Cleaners that are available from but the concentrations of coolant additives were
your Caterpillar dealer. carefully maintained. The coolant water probably
contained minerals that were deposited on the
Table 35 engine over time.
HydrosolvLiquid Cleaners
A coolant analysis can be conducted in order
Part to verify the condition of the water that is being
Number Description Size
used in the cooling system. A full water analysis
1U-8812 4 L (1 US gallon) can be obtained by consulting your local water
utility company or an agricultural agent. Private
1U-5490 Hydrosolv4165 19 L (5 US gallon) laboratories are also available for water analysis.
8T-7570 208 L (55 US gallon)
Caterpillar Inc. recommends an S.0.S Coolant
1U-8804 4 L (1 US gallon) Analysis (Level 2).
1U-5492 Hydrosolv100 19 L (5 US gallon)
S . 0 6 Coolant Analysis (Level 2)
8T-5571 208 L (55 US gallon)
4. Use steam to clean the oil cooler core. This

removes any remaining residue from the cleaner.
An S.0.S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
(,i
Flush the fins of the oil cooler core. Remove any system. An S.0.S Coolant Analysis (Level 2)
other trapped debris. provides the following information:
5. Wash the oil cooler core with hot, soapy water. Complete S.0.S Coolant Analysis (Level 1)
Rinse the oil cooler core thoroughly with clean
water. Visual inspection of properties
ldentification of metal corrosion
ldentification of contaminants
Personal injury can result from air pressure.
ldentification of built up impurities (corrosion and
Personal injury can result without following prop- scale)
er procedure. When using pressureair, wear a pro-
tective face shield and protective clothing. S.0.S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
Maximum air pressure at the nozzle must be less recommendations.
than 205 kPa (30 psi) for cleaning purposes.
For more information about coolant analysis, see
6. Dry the oil cooler core with compressed air. your Caterpillar dealer.
Direct the air in the reverse direction of the
normal flow. i01604510
7. Inspect the components in order to ensure

cleanliness. The oil cooler core should be
Radiator Clean -
pressure tested. Repair the oil cooler core, if SMCS Code: 1353-070
necessary. Install the oil cooler core.
For more information about cleaning the cores,

Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
C !I
consult your Caterpillar dealer.
A
123
Maintenance Section
Standby Generator Set Maintenance Recommendations
Inspect the radiator for these items: damaged fins, 101038735

corrosion, dirt, grease, insects, leaves, oil, and
other debris. Clean the radiator, if necessary. Standby Generator
Set Maintenance
Recommendations
Personal injury can result from air pressure. SMCS Code: 4450-041
Personal injury can result without following prop- A standby generator set may not need to be used
er procedure. When using pressureair, wear a pro- very often. However, the generator set is usually
tective face shield and protective clothing. needed for operation in an emergency situation.
Maintenance of the standby generator set is very
Maximum air pressure at the nozzle must be less important for the following reasons:
than 205 kPa (30 ~ s ifor
) cleaning DurDoses.
8 The generator set must always be in excellent
Pressurized air is the preferred method for removing operating condition.
loose debris. Direct the air in the opposite direction
of the fan's air flow. Hold the nozzle approximately 8 The generator set must be ready to work under
6 mm (0.25 inch) away from the fins. Slowly move load at any time.
the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the Establishing a Preventive Maintenance Program will
tubes. provide these benefits:
Pressurized water mav also be used for cleanina. Maximum availability of the standby generator set
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized 8 Longer service life for the generator set
water in order to soften mud. Clean the core from
both sides. 8 Minimum of expensive repairs
Use a degreaser and steam for removal of oil and Your Caterpillar dealer can help you to establish
grease. Clean both sides of the core. Wash the core an effective Preventive Maintenance Program for
with detergent and hot water. Thoroughly rinse the your generator set. Consult your Caterpillar dealer
core with clean water. for details.
After cleaning, start the engine and accelerate the Maintenance and Operation
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine. Procedures
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
The high voltage that is produced by an operat-
lnspect the fins for damage. Bent fins may be ing generator set can causesevere injury or death.
opened with a "comb". lnspect these items for Before performing any maintenanceor repairs, en-
good condition: welds, mounting brackets, air lines, sure that the generator will not start.
connections, clamps, and seals. Make repairs, if
necessary. Place the engine control switch in the "OFF" posi-
tion. Attach "DO NOT OPERATE" tags to all start-
For more detailed information on cleaning and ing controls. Disconnect the batteries or disable
inspection, refer to Special Publication, SEBD0518. the starting system. Lock out all switchgear and
"Know Your Cooling System". automatic transfer switches that are associated
with the generator.
The recommended maintenance for the engine is

listed in this Operation and Maintenance Manual,
"Maintenance Interval Schedule (Standby Generator
Set Engines)" (Maintenance Section).
For the recommended generator maintenance, see

the Operation and Maintenance Manual for the
generator and the control panel.
124
Maintenance Section
-
Starting Motor lnspect
Maintenance and Repair i00651416
The maintenance that is recommended for Every

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

i01539769
hazard.
Operation
Turbocharger lnspect -
SMCS Code: 1052-040
To ensure proper operation, the generator set
must be exercised regularly. For instructions on Periodic inspection and cleaning is recommended
operating the generator set, see the Operation and for the turbocharger compressor housing (inlet
Maintenance Manual for the generator set control side). Any fumes from the crankcase are filtered
panel. through the air inlet system. Therefore, by-products
from oil and from combustion can collect in the
For these operation procedures, follow the turbocharger compressor housing. Over time, this
instr~crionsthat are provioed in th s Operation and buildup can contribute to loss of engine power,
Maintenance Manua , "Operat'on Secrion": srarting increased black smoke and overall loss of engine
the engine, engine operation, and stopping the efficiency.
engine.
If the turbocharger fails during engine operation.
Record Keeping damage to the turbocharger compressor wheel
andlor to the engine may occur. Damage to
Maintain a record in order to document these items: the turbocharger compressor wheel can cause
gauge readings, maintenance that is performed, additional damage to the pistons, the valves, and
problems, and repairs. the cylinder head.
Space Heaters NOTICE

Turbocharger bearing failures can cause large quan-
Moisture causes damage to generators and other tities of oil to enter the air inlet and exhaust systems.
electrical equipment. Make every effort to keep the Loss of engine lubricant can result in serious engine
generator set as dry as possible. damage.
Generators can operate without problems in humid Minor leakage of a turbocharger housing under ex-
environments. However, problems can occur when tended low idle operation should not cause problems
the generator is inactive. Moisture can condense on as long as a turbocharger bearing failure has not oc-
the windings. This can result in poor performance. curred.
Also, damage to the windings can occur.
When a turbocharger bearing failure is accompanied
Use space heaters in order to help keep the by a significant engine performance loss (exhaust
windings dry. When the generator is not active, smoke or engine rpm up at no load), do not continue
ensure that the space heaters are operating. When engine operation until the turbocharger is repaired or
the generator is operating, turn OFF the space replaced.
heaters.
125
Maintenance Section
Walk-Around Inspection
An inspection of the turbocharger can minimize 4. Use a dial indicator to check the end clearance
unscheduled downtime. An inspection of the on the shaft. If the measured end play is greater
turbocharger can also reduce the chance for than the Service Manual specifications, the
potential damage to other engine parts. turbocharger should be repaired or replaced.
An end play measurement that is less than the
Note: Turbocharger components require precision minimum Service Manual specifications could
clearances. The turbocharger cartridge must indicate carbon buildup on the turbine wheel.
be balanced due to high rpm. Severe Service The turbocharger should be disassembled for
Applications can accelerate component wear. cleaning and for inspection if the measured end
Severe Service Applications require more frequent play is less than the minimum Service Manual
inspections of the cartridge. specifications.
5. lnspect the bore of the turbine housing for

Removal and Installation corrosion.
For options regarding the removal, installation,
6. Clean the turbocharger housing with standard
repair and replacement, consult your Caterpillar
shop solvents and a soft bristle brush.
dealer. Refer to the Service Manual for this engine
for the procedure and specifications.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
Cleaning and Inspecting
1. Remove the exhaust outlet piping and remove i01972472
the air inlet piping from the turbocharger. Visually Walk-Around Inspection
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt SMCS Code: 1000-040
from entering during reassembly.
2. Turn the compressor wheel and the turbine Inspect the Engine for Leaks and
\3 wheel by hand. The assembly should turn freely.
Inspect the compressor wheel and the turbine
for Loose Connections
wheel for contact with the turbocharger housing. A walk-around inspection should only take a few
There should not be any visible signs of contact minutes. When the time is taken to perform these
between the turbine wheel or compressor checks, costly repairs and accidents can be
wheel and the turbocharger housing. If there is avoided.
any indication of contact between the rotating
turbine wheel or the compressor wheel and the For maximum engine service life, make a thorough
turbocharger housing, the turbocharger must be inspection of the engine compartment before
reconditioned. startina the enaine. Look for items such as oil leaks
or coiant leak, loose bolts, worn belts, loose
3. Check the compressor wheel for cleanliness. connections and trash buildup. Make repairs, as
If only the blade side of the wheel is dirty, needed:
dirt and/or moisture is ~assinathrouah the air
I 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

The guards must be in the proper place. Repair
damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system
engine operation at low idle. The presence of oil contamination.
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber. NOTICE
Forany typeof leak(coolant, lube, orfuel) 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.
126
Maintenance Section
-
Water Pump lnspect
Check the conditron of the gauges. Replace any

NOTICE
Accumulated grease andlor oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
gauges which are cracked or replace any gauges
that can not be calibrated. 60
or high pressure water. lnspect the Insulation
8 Ensure that cooling lines are properly clamped. A visual inspection should be initially directed at
Check for leaks. Check the condition of all pipes. the areas that are most prone to damage and
deterioration. The most prone areas to damage and
8 lnspect the water pump for coolant leaks. deterioration are listed below:
Note: The water pump seal is lubricated by coolant Ground Insulation. Ground insulation is insulation
in the cooling system. It is normal for a small amount that is intended to isolate components that are
of leakage to occur as the engine cools down and carrying current from components that are not
the parts contract. carrying current.
Excessive coolant leakage may indicate the need Support Insulation. Support insulation is
to replace the water pump seal. For the removal usually made from one of the following items:
of water pump and the installation of water pump a compressed lamination of fibrous materials,
and/or seals, refer to the Service Manual for the polyester, or felt pads that have been impregnated
engine or consult your Caterpillar dealer. with various types of bonding agents.
8 lnspect the lubrication system for leaks at the There are many different types of damage that can
front crankshaft seal, the rear crankshaft seal, the occur in these areas. Several of the different types
oil pan, the oil filters and the valve cover. of damage are listed below:
8 lnspect the fuel system for leaks. Look for loose Thermal Aging -Thermal aging can cause the
fuel line clamps. degradation of insulation or the deterioration of
insulation. An examination of the coils may reveal
lnspect the piping for the air inlet system and the that the insulation has expanded into the ventilation
elbows for cracks and for loose clamps. ducts. This is the result of a loss of bond which
will cause the insulation material to separate. The
lnspect the alternator belt and the accessory insulation material could also separate from the
drive belts for cracks, breaks or other damage. conductors on the windings.
Belts for multiple groove pulleys must be replaced Abrasion -The surfaces of coils and the surfaces
as matched sets. If only one belt is replaced, the of connectors may be damaged by abrasion. These
belt will carry more load than the belts that are surfaces may also be damaged by contamination
not replaced. The older belts are stretched. The from other sources. An example of these sources
additional load on the new belt could cause the would be chemicals or abrasive substances.
belt to break.
Cracking -Cracking of insulation may result from
Drain the water and the sediment from fuel tanks mechanical stress. The structure that is used to
on a daily basis in order to ensure that only clean brace the stator winding will become loose if the
fuel enters the fuel system. problem is not corrected. Further mechanical
damage or electrical damage may also result.
8 lnspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed Erosion - Erosion can be caused when foreign
wires. substances rub against the surfaces of the
insulation.
lnspect the ground strap for a good connection
and for good condition.
8 lnspect the engine-to-frame ground strap for a

good connection and for good condition.
Water Pump lnspect -
SMCS Code: 1361-040; 1361
Disconnect any battery chargers that are not
protected against the current drain of the starting
t-
YI
A failed water pump might cause severe engine
motor. Check the condition and the electrolyte overheating problems that could result in the
level of the batteries, unless the engine is following conditions:
equipped with a maintenance free battery.
127
Maintenance Section
-
Water Pump Inspect
' Cracks in the cylinder head
A piston seizure
Other potential damage to the engine
Visually inspect the water pump for leaks. If any

leaking is observed, replace the water pump
seal or the water pump assembly. Refer to the
Service Manual for the disassembly and assembly
procedure.
Note: Refer to the Service Manual or consult your

Caterpillar dealer if any repair is needed or any
replacement is needed.
Reference lnformation Section
Engine Ratings
Reference lnformation 100715039
Section Engine Rating Definitions f

SMCS Code: 1000
Engine Ratings The ratings must be reduced in order to

accommodate changes in the altitude. The ratings
must be reduced according to the data for derating
that is obtained from the test specification for the
engine.
Engine Rating Conditions
All of the ratings that are defined have a
SMCS Code: 1000 manufacturing tolerance of + three percent.
All engine ratings are in compliance with the Load Factor -The sum of the loads divided by the
following standard ambient air conditions of "SAE number of hours of operation. Idle time and down
J1349": time are not part of the calculation.
99 kPa (29.3 inches of Hg) Power Interruption -Unexpected failure of the utility
power supply.
30 percent relative humidity
A temperature of 25 "C (77 OF)

- < -
O~eratinaCvcle ExceDt when the o~eratina
c i c e is specified differenrly, an operaing cyce for
calcu ating load factors and peak load limirs is not
Ratings relate to the standard conditions of to exceed-24 hours. The operating cycle does not
"lS08665", of "lS03046/1", of "DIN6271", and of include the time when the engine is not operating.
"BS5514".
Use the following guidelines in order to determine
The engine ratings are based on the following fuel the applicable engine rating.
specifications:
Low heat value (LHV) of the fuel of 42 780 kJ/kg NOTICE

(18,390 Btullb) at 29 OC (84 OF) Operating an engine at a greater power output than
the engine is rated for will reduce the service life of
Gravity (API) of 35 degrees at 15 O C (60 OF) the engine before overhaul.
Specific gravity of ,849 at 15 O C (60 OF) Continuous -This rating allows a constant load
or a load that varies for an unlimited number of
Density of 850 kg/m3(7.085 lb/US gal) hours per year. The normal load factor is up to 100
percent for an unlimited number of hours per year.
The engine ratings are gross output ratings. The following applications are suggested: base
load, utility, cogeneration, and parallel operation.
Gross Output Ratings -The total output capability
of the engine that is equipped with standard Prime -This rating allows a load that varies for an
accessories. unlimited number of hours per year. The normal
load factor is up to 80 percent for an unlimited
Standard accessories include the following number of hours per year. A 100 percent load is
components: only allowed for 5 percent of the operating cycle.
The following applications are suggested: industrial,
Oil pumps pumping, construction, and cogeneration.
Fuel pumps Prime + 10% (Standby applications for a power
supply from a reliable utility) -This rating allows a
Water pumps load that varies up to the Prime rating. An additional
ten percent is allowed for the duration of the power
Subtract the power that is required to drive auxiliary
components from the gross output. This will produce
the net power that is available for the external load
interruption. The normal load factor is up to 80
percent for 100 hours per year A 100 percent load
is only allowed for 5 percent of the operating cycle.
C
(flywheel). The suggested application is Standby for a power
supply from a reliable utility.
129
Reference Information Section
Engine Ratings
Prime + 10% (Applications that are industrial, i00899220

pumping, construction, and cogeneration) - This
rating allows a load that varies up to the Prime Marine Classification Society
rating. The normal load factor is up to 80 percent Certification Requirements
for an unlimited number of hours per year. A 100
percent load is only allowed for 5 percent of the SMCS Code: 1000
operating cycle. The following applications are
suggested: industrial, pumping, construction, and The major seafaring nations have established
cogeneration. technical groups called marine classification
societies. Caterpillar Inc. has maintained standards
Standby -This rating allows a load that varies for and quality under the guidelines that are set forth
the duration of the power interruption. The normal by the 14 major marine classification societies that
load factor is up to 80 percent for 100 hours per are listed. For more information, refer to Engine
year. A 100 percent load is only allowed for 5 Data Sheet, 103.1 and Engine Data Sheet, 103.1.1
percent of the operating cycle. The suggested in the Caterpillar Technical Manual.
application is Standby for a power supply from a
reliable utility. ABS -American Bureau of Shipping (USA)
Load Management Peak Shaving BV - Bureau Veritas (France)

Rating Guidelines CCG - Canadian Coast Guard (Canada)
Interruptable (Isolated from the utility with a Standby CCRS - China Corporation Register of Shipping
base rating for load factors) -This rating allows a (Taiwan)
load that varies for less than 12 hours per day. The
typical peak load factor is up to 80 percent for less
than 500 hours per year. The peak operating limit is
CCS - China Classification Society (China)
a load factor up to 100 percent. A 100 percent load CR -Croatian Register of Shipping (Croatia)
is only allowed for 5 percent of the operating cycle.
The operating cycle for calculating the load factors DnV - Det norske Veritas (Norway)
and the peak load limits is not to exceed six hours.
The operating cycle does not include the time when GL - Germanischer Lloyd (Germany)
the engine is not operating.
KR - Korean Register of Shipping (Korea)
Lnterruptable (Isolated from the utility with a Prime
base rating for load factors) -This rating allows a LR -Lloyd's Register of Shipping (Great Britain)
load that varies for more than 12 hours per day.
The typical peak load factor is up to 80 percent for
an unlimited number of hours per year. The peak
NK - Nippon Kaiji Kyokai (Japan)
operating limit is a load factor up to 100 percent. A PR - Polish Register (Poland)
100 percent load is only allowed for 5 percent of
the operating cycle. RlNa - Registro italiano Navale (Italy)
Curtailable (Connected to a utility with a special RS -Maritime Register of Shipping (Russia)
base rating for load factors) - This rating allows a
constant load or a load that varies for less than six
hours per day. The typical peak load factor is up to
100 percent for a maximum of 500 hours per year.
The peak operating limit is up to 100 percent load
for a maximum of 500 hours per year.
Curtailable (Connected to a utility with a Continuous

base rating for load factors) -This rating allows a
constant load or a load that varies for more than six
hours per day. The normal load factor is up to 100
percent for an unlimited number of hours per year.
The peak load factor is up to 100 percent for an
unlimited number of hours per year.
130
Customer Service
Customer Service Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
i01706971 Miami, FL 33126-4670
I ISA.
Customer Assistance Phone: 305-476-6800
Fax: 305-476-6801
SMCS Code: 1000
Europe, Africa, and Middle East
USA and Canada Caterpillar Overseas S.A.
76 Route de Frontenex
When a problem arises concerning the operation of P.O. Box 6000
an engine or concerning the service of an engine, CH-1211 Geneva 6
the problem will normally be managed by the dealer Switzerland
in your area. Phone: 22-849-4444
Fax: 22-849-4544
Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem Far East
that has not been handled to your complete Caterpillar Asia Pte. Ltd.
satisfaction, follow these steps: 7 Tractor Road
Jurong, Singapore 627968
1. Discuss your problem with a manager from the Republic of Singapore
dealership. Phone: 65-662-8333
Fax: 65-662-8302
2. If your problem cannot be resolved at the dealer
.level without additional assistance, use the China
phone number that is listed belowto talk with a Caterpillar China Ltd.
Field Service Coordinator: 37/F., The Lee Gardens
33 Hvsan Avenue
Causeway Bay
.G.P.O. .Box 3069
The normal hours are from 8:00 to 4:30 Monday Hong Kong
through Friday Central Standard Time. Phone: 852-2848-0333
Fax: 852-2848-0440
3. If your needs have not been met still, submit the
matter in writing to the following address: Japan
Shin Caterpillar Mitsubishi Ltd.
Caterpillar Inc. SBS Tower
Manager, Customer Service, Engine Division 10-1, Yoga 4-Chome
Mossville Bldg AC Setaaava-Ku. Tokvo 158-8530
P.O. Box 610 ~ a *~ $
Mossville, Illinois 61552-0610 Phone: 81-3-5717-1 150
Fax: 81-3-5717-1177
Please keep in mind: probably, your problem will
ultimately be solved at the dealership, using the Japan
dealership's facilities, equipment, and personnel. Caterpillar Power Systems, Inc.
Therefore, follow the steps in sequence when a 8F, AIG Aoyama Bldg.
problem is experienced. 2-1 1-16, Minami-Aoyama
Minato-ku, Tokyo 107-0062
Phone: 81-3-5786-3803
Outside of the USA and of Canada Fax: 81-3-5786-3809
If a problem arises outside the USA and outside Australia and New Zealand
Canada, and if the problem cannot be resolved at
Caterpillar of Australia Ltd.
the dealer level, consult the appropriate Caterpillar
1 Caterpillar Drive
office.
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
131
Reference lnformation Section
Customer Service
101028392
) Ordering Replacement Parts

SMCS Code: 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
D.
information:
Part number
Part name
Quantity
If there is a question concerning the part number,

please provide your deaier with a complete
description of the needed item.
When a Caterpiliar engine requires maintenance

and/or repair, provide the dealer with all the
information that is stamped on the lnformation Plate.
This information is described in this Operation and
Maintenance Manual (Product lnformation Section).
Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and
the nature of the problem. Inform the deaier about
when the problem occurs. This will help the dealer
in troubleshooting the problem and solving the
problem faster.
132
Reference InformationSection
Reference Materials
7 i
i
Reference Materials Special Publication, SEBDO~IE, "Knowing Your
Cooling Systemn Cd
.,
i01944083 Special Publication, SEBD0970, "Coolant and
Your Engine" I
Reference Material I
1
o Special Publication, SEBU6251, "Caterpillar
SMCS Code: 1000 Commercial Diesel Engine Fluids
Recommendations"
The following literature can be obtained through any
!
Caterpillar dealer.
Miscellaneous
1
I
Lubricants Disassembly and Assembly, SENR1133, "3408C

and 3412C Marine Auxiliary and Generator Set
Special Publication, PEDP7036, "S.0.S Fluid Engines"
Analysis" I
I
Parts Manual. SEBP3958, "3408C Marine Auxiliary
Special Publication, PEHP0002. "Data Sheet
- Multipurpose Lithium Complex Grease with
Molybdenum (MPGM)"
and Generator Set Engines"
Parts Manual, SEBP3959, "3412C Marine Auxiliary

I1
. Special Publication, PEHP0017, "Data Sheet -
Special Purpose Grease (SPG) Bearing Lubricant" Special Instruction, SEHS7332, "Do Not Operate i
Tag" i
Special Publication, PEHP6001, "How To Take A I
Good Oil Sample" Special Instruction, SEHS8622, "Using the
FT-1984 Air-To-Air Aftercooler Leak Test Group"
!
Special Publication, PEHP7041, "Product Data
Sheet for Caterpillar Diesel Engine Oils (DEO),
CG-4 engine oils (International only)"
Special Instruction, SEHS8742, "Using the
8T-8697 Electronic Control Analyzer Programmer
(ECAP)"
(I
Special Publication, PEHP8038, "Product Data !
Sheet for Caterpillar Diesel Engine Oils (DEO), Special Instruction, SEHS9031, "Storage
CH-4 engine oils (North America, Australia)" Procedure for Caterpillar Products"
Special Publication, PEWP9733, "Caterpillar Special Publication, PECP9067, "One Safe
Fluids Selector" Source"
Special Publication, SEBD0640, "Oil and Your Special Publication. SEBF8029, "Index to
Engine" Guidelines for Reusable Parts and Salvage i
1
Operations" i
Special Publication, SEBU6251, "Caterpillar I
I
Commercial Diesel Engine Fluids Special Publication, SEBF8062, "Guideline for
Recommendations" Reusable Parts - Cleaning and Inspection of Air
Filters"
i1
Fuels !!
Specifications, SENR1131, "3408C and 3412C
Special Publication, SEBD0717, "Diesel Fuels and Marine Auxiliary and Generator Set Engines" !I
Your Engine" I
Specifications, SENR3130, "Torque Specifications" I
Special Publication, SEBU6251, "Caterpillar
Commercial Diesel Engine Fluids Systems Operationnesting and Adjusting,
Recommendations" SENR1132, "3408C and 34120 Marine Auxiliary
Coolants Troubleshooting, RENR7941. "Voltage Regulator"
Special Publication, PEHP4036, "Data Sheet-
Caterpillar Coolant"
&!I
Special Publication, PEHP7057, "S.0.S Coolant
Analysis"
133
Reference Materials
Additional Reference Material Establish maintenance schedules for other

I engines that are operated in the same
The "Engine Fluids Data Book" can be obtained environment.
from the following locations: local technological
society, local library, and local college. If necessary, Show compliance with the required maintenance
consult EMA at the following address: practices and maintenance intervals.
Engine Manufacturers Associaton Maintenance records can be used for a variety of

Two North LaSalle Street, Suite 2200 other business decisions that are related to engine
Chicago, IL. USA 60602 maintenance.
E-mail! ema@enginemanufacturers.org
(312) 827-8737 Maintenance records are a key element of a
maintenance program that is well managed.
The "Society of Automotive Engineers (SAE) Accurate maintenance records can help your
Specifications" can be found in your SAE handbook. Caterpillar dealer to fine tune the recommended
This publication can also be obtained from the maintenance intervals in order to meet the specific
following locations: local technological society, local operating situation. This should result in a lower
library, and local college. If necessary, consult SAE engine operating cost.
at the following address:
Records should be kept for the following items:
SAE International
400 Commonwealth Drive Fuel Consumption - A record of fuel consumption
Warrendale, PA, USA 15096-0001 is essential in order to determine when the load
E-mail: www.sae.org sensitive components should be inspected or
(724) 776-4841 repaired. Fuel consumption also determines
overhaul intervals.
The "American Petroleum lnsttute P~olicationNo.
1509 can oe ootained from the follow;na locarions: Service Hours - A record of service hours is
local technological society, local library, and local essential to determine when the speed sensitive
college. If necessary, consult API at the following components should be inspected or repaired.
address:
Documents -These items should be easy to obtain,
American Petroleum institute and these items should be kept in the engine
1220 L St. N.W. history file. All of the documents should show this
Washington, DC, USA 20005 information: date, service hours, fuel consumption,
E-mail: -www.api.org 'unit number, and engine serial number. The
(202) 682-8000 following types of documents should be kept as
proof of maintenance or repair for warranty:
For information regarding "Technology and
Maintenance Council (TMC) Specifications", refer Keep the following types of documents as proof of
to the following address: maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
Technology and Maintenance Council
American Trucking Association Dealer work orders and itemized bills
2200 Mill Road
Alexandria, VA, USA 22314 Owner's repair costs
E-mail: www.trucking.org/cc/councils/tmc
(703) 838-1763 Owner's receipts
Maintenance log
iOW12149
Maintenance Records
SMCS Code: 1000
' Caterpillar Inc. recommends the retention

of accurate maintenance records. Accurate
maintenance records can be used for the following
purposes:
Determine operating costs.

134
7
@
Reference Materials
i
Maintenance Log
i01176304
C ,g
2
SMCS Code: 1000

Table 36
68
iI
4
!
I
135
Index Section
Cooling System Coolant (DEAC) .Change ........... 94

Cooling Systems with Heavy Deposits or
After Starting Engine ........................................... 46 Plugging ........................................................... 95
After Stopping Engine............................................ 49 Drain .................................................................. 94
I
I
Aftermarket Oil Additives ....................................... 67
Air Starting............................................................. 44
Air Starting Motor Lubricator Bowl .Clean ............90
Fill ...................... :...............................................
Flush ..................................................................94
Cooling System Coolant (ELC) .Change.............. 96
95
Air Starting Motor Lubricator Oil Level .Check ..... 90 Drain .................................................................. 96
Adjust the Lubricator.......................................... 91 Fill ...................................................................... 96
I
1! Air Tank Moisture and Sediment .Drain (If Flush ............................................................ 96
Equipped) ............................................................ 91 Cooling System Coolant Extender (ELC) .Add ..... 97
!
Alternator .Inspect ................................................ 91 Cooling System Coolant Level .Check ................. 97
Obtain ..................................................................98
Obtain .....;............................................................ 98
! Battery Charger .Check....................................... 92 Cooling System Specifications .............................. 71
Battery Electrolyte Level .Check .......................... 92 Cooling System Supplemental Coolant Additive
Battery or Battery Cable .Disconnect ................... 92 (SCA) .TesffAdd........................................... 99
Before Starting Engine .................................... 12. 42 Add the SCA, If Necessary ................................ 99
Starting the Engines. Operating the Engines. and Replace the SCA Element (If Equipped).......... 100
Stopping the Engines that are Equipped with S.0.S Coolant Analysis ...................................... 99
Control Panels.................................................. 42 Test the Concentration of SCA........................... 99
i Belts .InspectlAdjusffReplace.............................. 93 Cooling System Water Temperature Regulator .
Adjusting the Alternator Belt .............................. 93 Replace.......................................................... 100
Adjusting the Fan Drive Belt............................... 93 Crankshaft Vibration Damper .Inspect ............... 101
Inspection...................................................... 93 Rubber Damper ............................................ 101
Replacement...................................................... 93 Visconic Damper.............................................. 101
! Burn Prevention..................................................... 10 Crushing Prevention and Cutting Prevention ......... 12
I
Batteries............................................................. 10 Customer Assistance........................................... 130
i Coolant............................................................... 10 Outside of the USA and of Canada.................. 130
I
Oils ..................................................................... 10 USA and Canada ............................................. 130
Customer Service................................................ 130
1 Cold Weather Lubricants....................................... 67

I Cold Weather Operation........................................ 50 Diesel Engine AntifreezeICoolant (DEAC) ............ 77
Hints for Cold Weather Operation ...................... 50
Idling the Engine................................................ 51
Recommendationsfor Coolant Warm Up .......... 51
Recommendationsfor the Coolant .................... 51
i! Viscosity of the Engine Lubrication Oil ..............
Cold Weather Starting ...........................................
51
44
Emergency Stopping ............................................. 48
Emergency Stop Button..................................... 48
Starting With the Starting Aid Switch................. 44 Emissions Certification Film .................................. 21
Commercial Heavy-Duty CoolanffAntifreeze and Engine Air Cleaner Element .CleanlReplace ..... 102
SCA ..................................................................... 77 Cleaning the Primary Air Cleaner Elements .... 103
I Conventional CoolanffAntifreeze Cooling System Servicing the Air Cleaner Elements ................. 102
i Maintenance ........................................................ 80 Engine Air Cleaner Service lndicator .lnspect (If
Cleaning the System of Heavy-Duty Equipped) ....................................................... 104
CoolanVAntifreeze ........................................... 82 Test the Service Indicator ................................ 104
Cooling . Svstems
. with Larger . Ca~acities ........... 81 Engine Air Precleaner .Clean ............................. 105
I
Coolant Recommendations................................... Engine Crankcase
. . Breather .Clean.................... 105
Engine Descr~pt~on .............................................. 18
Engine Information............................................. 18
Engine Service Life ........................................... 18
Engine Specifications......................................... 18
Engine Mounts .Inspect..................................... 105
136
Index Section
Engine Oil .............................................................. 63 Fuel Related Components in Cold Weather .......... 53

Caterpillar Diesel Engine Oil .............................. 63 Fuel Filters .........................................................
Commercial Oils................................................. 64 Fuel Heaters ...................................................... 54
Total Base Number (TBN) and Fuel Sulfur Levels
for Direct Injection (Dl) Diesel Engines ............ 65
. . .......................................................... 53
Fuel Tanks
Fuel Speclflcations ................................................ 69
Engine Oil and Filter .Change ............................107 Fuel System .Prime............................................ 111
Drain the Engine Oil ......................................... 107 Fuel System Primary Filter .CleanlReplace ....... 112
Fill the Engine Crankcase................................ 108 Fuel System Secondary Filter .Replace............. 112
Replace the Oil Filter ....................................... 107 Fuel Tank Water and Sediment .Drain................ 113
Engine Oil Level .Check ..................................... 106 Drain the Water and the Sediment ................... 113
Engine Oil Sample .Obtain ................................. 106 Fuel Storage Tanks .......................................... 114
Obtain the Sample and the Analysis ................ 106 Fuel Tank ......................................................... 113
Engine Operation................................................... 47
Engine Protection Devices .Calibrate................. 108
Engine Rating Conditions .................................... 128
Engine Rating Definitions .................................... 128
Load Management Peak Shaving Rating Gauges and Indicators .......................................... 32
Guidelines ...................................................... 129 General Coolant Information ................................. 71
Engine Ratings .................................................... 128 Additives ............................................................ 72
Engine Shutoffs and Engine Alarms ...................... 33 Glycol................................................................. 72
Shutoff and Alarm Systems ............................... 33 Water ................................................................. 71
Testing the Shutoff and Alarm System............... 35 General Hazard Information .................................... 8
Engine Starting ................................................ 13, 42 Asbestos Information........................................... 9
Ether ................................................................. 13 Fluid Penetration.................................................. 9
Engine Stopping .............................................. 13, 48 Fluid Spillage ....................................................... 9
Engine Valve Lash - InspecVAdjust..................... 108 Lines. Tubes. and Hoses.................................... 10
Engine Valve Rotators .Inspect .......................... 109 Pressurized Air and Water ................................... 9
Extended Life Coolant (ELC) ................................. 74 General Maintenance Information......................... 84
Extended Life Coolant (ELC) Cooling System Generator .Dry ................................................... 114
Maintenance........................................................ 75 Controlled Current Method............................... 115
Caterpillar ELC Extender .................................. 75 Oven Method ................................................... 114
Changing to Caterpillar ELC .............................. 76 Self-circulatingAir Method .............................. 114
Commercial ELC................................................ 77 Generator .Inspect......................................... 115
ELC Cooling System Cleaning........................... 75 Cleaning (Assembled Generators)................... 116
ELC Cooling System Contamination.................. 76 Cleaning (Disassembled Generators).............. 116
Proper additions to the Extended Life Coolant 75 .. Generator Description ........................................... 19
Generator Isolatingfor Maintenance ..................... 14
Generator Lead Connections ................................ 22
Grounding the Frame ......................................... 24
Lead Numbering ................................................ 22
Fan Drive Bearing .Lubricate.............................. 109 Multiple Units ..................................................... 24
Features and Controls ........................................... 33 Neutral Connections
.. .......................................... 24
Fire Prevention and Explosion Prevention............. 10 Parallel to Utlllty ................................................. 24
Fire Extinguisher................................................ 11 Single Units........................................................ 24
Lines. Tubes and Hoses.................................... 12 Generator Load .Check ...................................... 117
Foreword.................................................................. 5 Generator Operation.............................................. 55
California Proposition 65 Warning ....................... 5 Block Loading .................................................... 55
Literature Information........................................... 4 Excitation Systems............................................. 56
Maintenance ........................................................4 Generator Options ............................................. 56
Maintenance Intervals......................................... 4 Loading of the Generator................................... 55
Operation ............................................................. 4 Low Idle Adjustment ...................................... 56
Overhaul .............................................................. 4 Power Factor...................................................... 56
Safely.............................................................. 4 Standby Generator Sets .................................... 56
Fuel and the Effect from Cold Weather ................. 53 Generator Set .Test ............................................ 117
Fuel Conservation Practices.................................. 47
Fuel Control Linkage .ChecklLubricate .............. 109
Fuel Injection Nozzles .TesVExchange............... 110
Removal and Installation of the Fuel lnjection
Nozzles ..................................................... 110
Fuel Ratio Control .InspecVAdjust...................... 110
Fuel Recommendations.........................................69
137
Index Section
Generator Set Installation...................................... 30

Alignment ...........................................................31
I/
Bearing Inspection ............................................. 30 Operation Section.................................................. 28
Electrical Measurements ................................... 31 Ordering Replacement Parts............................... 131
Location ............................................................. 30 Overhaul Considerations ..................................... 120
Protective Devices ............................................. 31 Oil Consumption as an Overhaul Indicator ...... 120
Receiving Inspection.......................................... 30 Overhaul Recommendation ............................. 120
Storage .............................................................. 30
Unpacking and Storage ..................................... 30
Generator Set Lifting .............................................28
Engine Only ..................................................... 28
1 Generator Set .................................................... 28

Generator Set Storage .......................................... 29
Engine Storage ................................................. 29
Generator Storage .............................................
Generator Set Vibration .Inspect........................ 118
29
Parallel Operation.................................................. 57
Circulating Currents ........................................... 62
Initial Start-up .................................................... 57
Load Division .Speed Droop (If Equipped) ....... 60
Parallel Operation Of Governors........................ 60
1 Generator Start-up Checklist ................................. 85 Paralleling Multiple Units................................... 60
Starting Multiple Units ........................................
59
Stopping........................................................ 61
Plate Locations and Film Locations....................... 20
Engine Identification.......................................... 20
Hoses and Clamps .InspecffReplace ................. 118 Generator Identification...................................... 20
Replace the Hoses and the Clamps ................ 119 Information Plate............................................... 20
Serial Number Plate........................................ 20
Product Identification Information.......................... 20
Product InformationSection .................................. 15
lm~ortantSafetv Information................................... 2
:Q Installation.............................................................
Radiator .Clean ..................................................122

Radiator Restrictions........................................ 52
Re-refined Base Stock Oils ................................... 66
I Lifting and Storage ................................................ 28 Reference InformationSection ............................ 128
Lubricant Information............................................. 63 Reference Material ..............................................132
I API Oils .............................................................. 63 Additional Reference Material.......................... 133
Engine Manufacturers Association (EMA) Oils .. 63 Coolants........................................................... 132
General Information........................................... 63 Fuels .......................................................... 132
Lubricant Specifications ........................................63
1
1 Lubricants ...................................................... 132
Miscellaneous .................................................. 132
Reference Materials .......................................... 132
Reference Numbers .............................................. 22
Magnetic Picku~s.Cleanllns~ect....................... 119

. ~ e s ................................... 22
Record for. Reference
Refill C a ~ a c ~ t.............................................. 83
~ahtenancelniewal ~cheduie(34080 Engine) 88 ... Cooling ..................................................
. . System ............................................ 83
System
Maintenance Interval Schedule (3412C Engine)... 89 Lubr~cat~on 83
Maintenance Log ................................................. 134
Maintenance Recommendations ...........................
84
Maintenance Records.......................................... 133
Maintenance Section ............................................. 63
Manual Stop Procedure......................................... 48 S.0.S Coolant Analysis .........................................73
Automatic Stopping .......................................... 48 New Systems. Refilled Systems. and Converted
Marine Classification Society Certification Systems .......................................................... 74
Requirements ............................................... 129 Recommended Interval for S.0.S Coolant
Model View Illustrations......................................... 15 Sample ............................................................. 74
Model Views .......................................................... 15 S.0.S Coolant Analysis (Level 1)....................... 74
Mounting and Dismounting.................................... 12 S . 0 6 Coolant Analysis (Level 2) ....................... 74
S.0.S Oil Analysis ................................................. 67
Safety Messages ............................................... 6
Safety Section .........................................................
6
Single Unit Operation ............................................ 57
Initial Start-up .................................................... 57
Starting .............................................................. 57
Stopping ............................................................. 57
Standby Generator Set Maintenance
Recommendations.............................................123
Maintenance and Operation Procedures......... 123
Starting Motor .Inspect ....................................... 124
Starting the Engine................................................ 43
Automatic Starting ............................................. 43
Manual Starting.................................................. 43
Operation of the Generator Set Contml Panel 43 ...
Starting with Jump Start Cables ............................ 45
Supplemental Coolant Additive (SCA)................... 77
Synthetic Base Stock Oils ..................................... 66
Table of Contents..................................................... 3
Turbocharger .Inspect......................................... 124
Cleaning and Inspecting ..................................125
Removal and Installation.................................. 125
Voltage Connections.......................................... 24
Single-Phase Current From a Three-Phase
Generator ......................................................... 26
Three-Phase Voltage Connections .................... 24
Voltage Regulators ............................................. 36
R448 Adjustment for Maximum Excitation......... 40
R448 Adjustments............................................ 38
Special Use........................................................ 40
Walk-Around Inspection ...................................... 125

lnspect the Engine for Leaks and for Loose
Connections ................................................... 125
Inspect the Insulation....................................... 126
Water Pump .Inspect.......................................... 126
WaterISupplementalCoolant Additive (SCA) ........
78
Cooling Systems with Larger Capacities ........... 79
Product and Dealer lnformation
Note: For product identification plate locations, see the section "Product ldentification lnformation" in the
Operation and Maintenance Manual.
Delivery Date:
Product lnformation
Model:
Product ldentification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer lnformation
Name: Branch,
Address:
Dealer Contact Phone Number Hours

Sales:
Parts:
Service:
02003 Caterpillar
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CATERPILLAR

TAMI-Up (Generator Set)

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Maintenance Recommendations .......................... 84

Maintenance Interval Schedule (34080 Engine) .. 88

Engine Starting ..................................................... 13

Engine Stopping ................................................... 13

Generator Isolating for Maintenance ..................... 14

Product lnformation Section

Product Identification Information ........................20.

Gauges and Indicators ........................................ 32

Features and Controls .......................................... 33

Engine Starting ..................................................... 42

Engine Operation .................................................. 47

Engine Stopping ............................................... 48

Generator Operation ............................................55

Cooling System Specifications .............................71

Foreword Use fuel consumption or service hours to determine

California Proposition 65 Warning

Battery posts, terminals and related accessories

This safety message is located near the front of the

Do not operate or work on this engine unless you

Do not allow unauthorized personnel on the engine

Engine exhaust contains products of con;lbustion

To help prevent spraying or splashing of pressurized

Do not wear loose clothing or jewelry that can

Ensure that all protective guards and all covers

Never put maintenance fluids into glass Fluid Spillage

Fluid Penetration Use a wet method to clean up asbestos debris.

Obey environmental regulations for disposal of

Check for the following conditions: Oils

Outer covering that is ballooning locally

Armoring that is embedded in the outer covering

Fire Prevention and Explosion

If the application involves the presence of

Remove all flammable materials such as fuel, oil,

Store fuels and lubricants in properly marked

Do not expose the engine to any flame. Illustration 4

Check lines, tubes and hoses carefully. Do not

Mount the engine and dismount the engine only at

Do not store ether cylinders in direct sunlight or at

i0122M91 8. Use an audiolvisual proximity tester in order to

2. Attach a "DO NOT OPERATE" or similar warning

Model View Illustrations

The following engine model views show typical

3408C Marine Auxiliary Engine Specifications

Expected engine life is generally dependent on the

These brushless generators are used with the

The generator set packages can be utilized

The generators have four poles. The generators

Plate Locations and Film

(3) Generator identification plate

go1003863 When service is required, the information that is

The Information Plate is on the right side rear valve

@b Emissions Certification Film

SMCS Code: 1000; 7405

1 Note: This information is pertinent in the United

A typical example is shown.