SAFETY.CAT.

COM™

C27 and C32

GENERATOR SETS
Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU8088-07-01)

® ®
© 2009 Caterpillar
All Rights Reserved
SEBU8088-07 73
Maintenance Section
Maintenance Interval Schedule

i03450220 Space Heater - Check ......................................... 119

Standby Generator Set Maintenance
Maintenance Interval Schedule Recommendations ............................................ 121
(Standby) Stator Winding Temperature - Measure/Record .. 123
Voltage and Frequency - Check ......................... 125
SMCS Code: 1000; 4450; 7500
Every 6 Months
Ensure that all safety information, warnings and
Belts - Inspect/Adjust/Replace .............................. 79
instructions are read and understood before any
Cooling System Coolant Sample (Level 1) -
operation or any maintenance procedures are
performed. Obtain ................................................................. 85
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 86
The user is responsible for the performance of
maintenance, including all adjustments, the use of Heat Shield - Inspect/Replace ............................ 109
Stator Lead - Check ............................................ 122
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and Every Year
procedures may result in diminished performance of Alternator - Inspect ............................................... 77
the product and/or accelerated wear of components. Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 86
Use mileage, fuel consumption, service hours, or Crankshaft Vibration Damper - Inspect ................. 88
calendar time, WHICH EVER OCCURS FIRST, Engine - Clean ...................................................... 89
in order to determine the maintenance intervals. Engine Air Cleaner Element (Dual Element) -
Products that operate in severe operating conditions Clean/Replace .................................................... 89
may require more frequent maintenance. Engine Crankcase Breather - Clean ..................... 91
Engine Mounts - Check ........................................ 91
Note: Before each consecutive interval is performed, Engine Oil Sample - Obtain .................................. 92
all maintenance from the previous interval must be Engine Oil and Filter - Change ............................. 93
performed. Engine Protective Devices - Check ...................... 94
Engine Valve Lash - Inspect/Adjust ...................... 95
When Required Fan Drive Bearing - Lubricate ............................... 95
Battery - Recycle .................................................. 77 Fuel Injector - Inspect/Adjust ................................ 95
Fuel System Primary Filter (Water Separator)
Battery Charger - Check ....................................... 78
Element - Replace .............................................. 97
Battery or Battery Cable - Disconnect .................. 79
Fuel System - Prime ............................................. 96 Fuel System Secondary Filter - Replace .............. 98
Generator Bearing - Lubricate ............................ 102
Generator - Dry ................................................... 100
Generator Set Vibration - Test/Record ................ 109
Generator Set - Test ........................................... 107
Varistor - Test ...................................................... 124 Hoses and Clamps - Inspect/Replace ................. 110
Insulation - Test .................................................... 111
Winding - Test ..................................................... 127
Prelube Pump - Inspect ....................................... 117
Radiator - Clean ................................................... 117
Daily Speed Sensor - Clean/Inspect ............................. 119
Cooling System Coolant Level - Check ................ 85 Starting Motor - Inspect ...................................... 122
Engine Oil Level - Check ...................................... 92 Water Pump - Inspect ......................................... 126
Generator Load - Check ..................................... 107
Power Factor - Check .......................................... 117 Every 3 Years
Walk-Around Inspection ...................................... 125
Batteries - Replace ............................................... 77
Cooling System Water Temperature Regulator -
Every Week Replace ............................................................... 88
Air Inlet Filter - Check ........................................... 77 Rotating Rectifier - Check .................................... 118
Battery Electrolyte Level - Check .......................... 78 Turbocharger - Inspect ........................................ 123
Control Panel - Inspect ......................................... 80
Electrical Connections - Check ............................. 89 Every 3000 Service Hours or 3 Years
Engine Air Cleaner Service Indicator - Inspect ..... 90
Cooling System Coolant (DEAC) - Change .......... 81
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 98
Fuel Tank Water and Sediment - Drain ................. 99 Every 6000 Service Hours or 3 Years
Generator - Inspect ............................................. 100 Cooling System Coolant Extender (ELC) - Add .... 84
Generator Bearing Temperature - Test/Record ... 106
Jacket Water Heater - Check ............................... 114
74 SEBU8088-07
Maintenance Section
Maintenance Interval Schedule

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 83
SEBU8088-07 75
Maintenance Section
Maintenance Interval Schedule

i03450208 Electrical Connections - Check ............................. 89

Generator - Inspect ............................................. 100
Maintenance Interval Schedule Space Heater - Check ......................................... 119
(Standard) Stator Winding Temperature - Measure/Record .. 123
Voltage and Frequency - Check ......................... 125
SMCS Code: 1000; 4450; 7500
Initial 250 Service Hours
Ensure that all safety information, warnings and
Engine Valve Lash - Inspect/Adjust ...................... 95
instructions are read and understood before any
Fuel Injector - Inspect/Adjust ................................ 95
operation or any maintenance procedures are
performed.
Every 250 Service Hours
The user is responsible for the performance of Battery Electrolyte Level - Check .......................... 78
maintenance, including all adjustments, the use of Belts - Inspect/Adjust/Replace .............................. 79
proper lubricants, fluids, filters, and the replacement Cooling System Coolant Sample (Level 1) -
of components due to normal wear and aging. Failure Obtain ................................................................. 85
to adhere to proper maintenance intervals and Cooling System Supplemental Coolant Additive
procedures may result in diminished performance of (SCA) - Test/Add ................................................. 86
the product and/or accelerated wear of components. Fan Drive Bearing - Lubricate ............................... 95
Radiator - Clean ................................................... 117
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, Initial 500 Hours (for New Systems, Refilled
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
Systems, and Converted Systems)
may require more frequent maintenance. Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 86
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Every 2000 Service Hours
performed.
Engine Mounts - Check ........................................ 91
When Required Fuel Injector - Inspect/Adjust ................................ 95
Generator Set Vibration - Test/Record ................ 109
Batteries - Replace ............................................... 77 Insulation - Test .................................................... 111
Battery - Recycle .................................................. 77 Stator Lead - Check ............................................ 122
Battery or Battery Cable - Disconnect .................. 79
Engine - Clean ...................................................... 89 Every Year
Fuel System - Prime ............................................. 96
Generator - Dry ................................................... 100 Cooling System Coolant Sample (Level 2) -
Generator Set - Test ........................................... 107 Obtain ................................................................. 86
Generator Set Alignment - Check ....................... 108 Generator Bearing - Lubricate ............................ 102
Varistor - Test ...................................................... 124
Winding - Test ..................................................... 127 Every 3000 Service Hours or 3 Years
Daily Cooling System Coolant (DEAC) - Change .......... 81

Control Panel - Inspect ......................................... 80 Every 6000 Service Hours or 3 Years

Cooling System Coolant Level - Check ................ 85
Engine Air Cleaner Service Indicator - Inspect ..... 90 Cooling System Coolant Extender (ELC) - Add .... 84
Engine Oil Level - Check ...................................... 92
Fuel System Primary Filter/Water Separator - Every 6000 Service Hours or 6 Years
Drain ................................................................... 98
Fuel Tank Water and Sediment - Drain ................. 99 Alternator - Inspect ............................................... 77
Generator Bearing Temperature - Test/Record ... 106 Prelube Pump - Inspect ....................................... 117
Generator Load - Check ..................................... 107 Speed Sensor - Clean/Inspect ............................. 119
Jacket Water Heater - Check ............................... 114
Power Factor - Check .......................................... 117 Every 8000 Service Hours
Walk-Around Inspection ...................................... 125
Rotating Rectifier - Check .................................... 118
Every Week
Every 12 000 Service Hours or 6 Years
Air Inlet Filter - Check ........................................... 77
Battery Charger - Check ....................................... 78 Cooling System Coolant (ELC) - Change ............. 83
76 SEBU8088-07
Maintenance Section
Maintenance Interval Schedule

Every 19 000 L (5000 US gal) of Fuel or 250

Service Hours
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 89
Engine Oil Sample - Obtain .................................. 92
Engine Oil and Filter - Change ............................. 93
Engine Protective Devices - Check ...................... 94
Fuel System Secondary Filter - Replace .............. 98
Heat Shield - Inspect/Replace ............................ 109
Hoses and Clamps - Inspect/Replace ................. 110

Every 38 000 L (10 000 US gal) of Fuel or 500

Service Hours
Engine Crankcase Breather - Clean ..................... 91
Fuel System Primary Filter (Water Separator)
Element - Replace .............................................. 97

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

3000 Service Hours
Cooling System Water Temperature Regulator -
Replace ............................................................... 88
Crankshaft Vibration Damper - Inspect ................. 88
Engine Valve Lash - Inspect/Adjust ...................... 95

Every 379 000 L (100 000 US gal) of Fuel or

5000 Service Hours
Starting Motor - Inspect ...................................... 122
Turbocharger - Inspect ........................................ 123
Water Pump - Inspect ......................................... 126

Overhaul
Generator Bearing - Inspect/Replace ................. 102
Overhaul Considerations ..................................... 114
SEBU8088-07 77
Maintenance Section
Air Inlet Filter - Check

i02574676 1. Turn the key start switch to the OFF position.

Remove the key and all electrical loads.
Air Inlet Filter - Check
2. Turn OFF the battery charger. Disconnect the
SMCS Code: 1051-535 charger.
Monitor the connector contacts of the differential 3. The NEGATIVE “-” cable connects the NEGATIVE
pressure switch for the air inlet filter. If the differential “-” battery terminal to the ground plane. Disconnect
pressure rises above 0.15 kPa (0.6 inch of H2O) of the cable from the NEGATIVE “-” battery terminal.
water, clean the filter with a solution of soap and
water. Be sure that the filter is thoroughly dry before 4. The POSITIVE “+” cable connects the POSITIVE
the start-up. Replace the filter, if necessary. “+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
i02676048
battery terminal.

Alternator - Inspect Note: Always recycle a battery. Never discard a

battery. Return used batteries to an appropriate
SMCS Code: 1405-040 recycling facility.

Caterpillar recommends a scheduled inspection 5. Remove the used battery.

of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the 6. Install the new battery.
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or Note: Before connecting the cables, ensure that the
proper performance of the electrical system. Make key start switch is OFF.
repairs, as required.
7. Connect the cable from the starting motor to the
Check the alternator and the battery charger for POSITIVE “+” battery terminal.
proper operation. If the batteries are properly
charged, the ammeter reading should be very near 8. Connect the cable from the ground plane to the
zero. All batteries should be kept charged. The NEGATIVE “-” battery terminal.
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
i00993589
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
Battery - Recycle
or if the engine is run for short periods, the batteries SMCS Code: 1401-005; 1401-510; 1401-535;
may not fully charge. A battery with a low charge will 1401-561; 1401
freeze more easily than a battery with a full charge.
Always recycle a battery. Never discard a battery.
i01041029
Always return used batteries to one of the following
Batteries - Replace locations:

SMCS Code: 1401-510 • A battery supplier

• An authorized battery collection facility

Batteries give off combustible gases which can • Recycling facility

explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.

Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
78 SEBU8088-07
Maintenance Section
Battery Charger - Check

i01039758 Perform one of the following procedures if the battery

shows symptoms of overcharging:
Battery Charger - Check
• Reduce the rate of charging by a significant
SMCS Code: 1401-535 amount. Complete the charging at the reduced
rate.
Checking Before Start-Up
• Turn OFF the charger.
Check the battery charger for proper operation. If
the batteries are properly charged, the needle of the Table 8 describes the effects of overcharging on
ammeter will register near “0” (zero). different types of batteries.

Table 8
The battery charger must not produce excessive
current during start-up. Alternatively, the charger Effects of Overcharging Batteries
must be automatically disconnected for start-up.
Type of Battery Effect
If the engine has an alternator, the charger must
be automatically disconnected during start-up and
during engine operation. Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte.
Charging the Battery Caterpillar Premium High
Output Batteries

Never disconnect any charging unit circuit or bat- When the plates of the
tery circuit cable from the battery when the charg- battery are inspected
ing unit is operated. A spark can cause an explo- through the filler holes, the
sion from the flammable vapor mixture of hydro- plates may appear to be
gen and oxygen that is released from the elec- warped. This is caused by
trolyte through the battery outlets. Injury to per- an excessive temperature.
sonnel can be the result. The battery may not pass
a load test.
Perform the following procedure to charge the Caterpillar Maintenance The battery may not accept
battery: Free Batteries a charging current.
The battery may not pass
1. Ensure that the charger is turned OFF. a load test.

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

the voltage of the battery. Checking After Stopping
3. Connect the POSITIVE “+” lead of the charger Ensure that the battery charger is connected
to the POSITIVE “+” battery terminal. Connect properly. Observe the meter of the charger. Record
the NEGATIVE “-” lead of the charger to the the amperage.
NEGATIVE “-” battery terminal.

4. Turn ON the battery charger. i02601752

Overcharging of Batteries Battery Electrolyte Level -

Check
Overcharging reduces the service life of batteries.
Use a battery charger that will not overcharge the SMCS Code: 1401-535-FLV
battery. DO NOT charge the battery if the meter of
the battery charger is in the RED zone. When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
Overcharging is indicated by the following symptoms: may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
• The battery is very warm to the touch.
• A strong odor of acid is present.
• The battery emits smoke or a dense vapor (gas).
SEBU8088-07 79
Maintenance Section
Battery or Battery Cable - Disconnect

1. Switch the engine to the OFF position. Turn the

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
2. Disconnect the negative battery terminal at the
shield and protective clothing when working on or
battery that goes to the start switch. Ensure that
near batteries.
the cable cannot contact the terminal.

1. Remove the filler caps. Maintain the electrolyte 3. Tape the leads in order to help prevent accidental
level to the “FULL” mark on the battery. starting.

If the addition of water is necessary, use distilled 4. Proceed with necessary system repairs. Reverse
water. If distilled water is not available use clean the steps in order to reconnect all of the cables.
water that is low in minerals. Do not use artificially
softened water.
i03450184

2. Check the condition of the electrolyte with the

245-5829 Coolant Battery Tester Refractometer.
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
3. Keep the batteries clean.

Clean the battery case with one of the following Inspection

cleaning solutions:
Inspect the alternator belt and the fan drive belts for
• A mixture of 0.1 kg (0.2 lb) of baking soda and wear and for cracking. Replace the belts if the belts
1 L (1 qt) of clean water are not in good condition.

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L Check the belt tension according to the information in
(1 qt) of clean water the Service Manual, “Specifications”.

Thoroughly rinse the battery case with clean water. Slippage of loose belts can reduce the efficiency
of the driven components. Vibration of loose belts
Use a fine grade of sandpaper to clean the can cause unnecessary wear on the following
terminals and the cable clamps. Clean the items components:
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal • Belts
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561 • Pulleys
Silicone Lubricant, petroleum jelly or MPGM.
• Bearings
i01857537 If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
Battery or Battery Cable - the components.
Disconnect
Replacement
SMCS Code: 1401; 1402-029
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
The battery cables or the batteries should not be drive belt to carry more load because the older drive
removed with the battery cover in place. The bat- belts are stretched. The additional load on the new
tery cover should be removed before any servic- drive belt could cause the new drive belt to fail.
ing is attempted.
Adjustment of the Fan Drive Belt
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion 1. Remove the belt guard.
resulting in personal injury.
2. Loosen the mounting bolt for the pulley.

3. Loosen the adjusting nut for the pulley.

80 SEBU8088-07
Maintenance Section
Control Panel - Inspect

4. Move the pulley in order to adjust the belt tension. i02373355

5. Tighten the adjusting nut. Control Panel - Inspect

6. Tighten the mounting bolt. SMCS Code: 4490-040; 7451-040

7. Reinstall the belt guard. Inspect the condition of the panel. If a component is
damaged, ensure that the component is repaired or
If new drive belts are installed, check the drive belt that the component is replaced. If equipped, ensure
tension again after 30 minutes of engine operation that the electronic displays are operating properly.
at the rated rpm. Inspect the wiring for good condition. Ensure that the
wiring connections are secure.
Adjustment of the Alternator Belt
Electronic Modular Control Panel 3
(EMCP 3)

g01184041
Illustration 54

The Lamp Test button is located on the top right side

of the electronic control module. Press and hold
Illustration 53
g00960176 the Lamp Test button in order to test all of the LED
lights and the display screen. The LED lights and the
(1) Adjusting nuts
(2) Mounting bolt
display screen should remain on until the button is
(3) Mounting bolt released. If any of the components do not pass this
(4) Mounting bolt test, replace the faulty components before starting
the engine.
1. Remove the drive belt guard.

2. Loosen mounting bolts (2), (3), and (4). Loosen

Switch Panel
adjusting nuts (1). The Panel Lights switch should turn on the panel
lights. Toggle the switch in order to ensure that the
3. Turn adjusting nuts (1) in order to increase or panel lights are working.
decrease the drive belt tension.

4. Tighten adjusting nuts (1). Tighten mounting bolts

(2), (3), and (4).

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belt

tension again after 30 minutes of engine operation at
the rated rpm.
SEBU8088-07 81
Maintenance Section
Cooling System Coolant (DEAC) - Change

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

Drain

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.

1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
g01101388
Illustration 55
2. Open the cooling system drain valve (if equipped).
It is possible to test the LED indicators and the horn If the cooling system is not equipped with a drain
when the data link is connected and when the data valve, remove one of the drain plugs.
link is not connected. The Lamp Test button is located
near the top of the annunciator panel. Test both the Allow the coolant to drain.
horn and the indicators by pressing and holding the
Lamp Test button. Replace any faulty components NOTICE
before starting the engine. Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
i02056137
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Cooling System Coolant Caterpillar to reclaim the used coolant.
(DEAC) - Change
For information regarding the disposal and the
SMCS Code: 1350-044 recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools
Clean the cooling system and flush the cooling Group:
system before the recommended maintenance
interval if the following conditions exist: Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
• The engine overheats frequently. Canada: 1-800-523-TOOL

• Foaming is observed. Flush

• The oil has entered the cooling system and the 1. Flush the cooling system with clean water in order
coolant is contaminated.
to remove any debris.
• The fuel has entered the cooling system and the 2. Close the drain valve (if equipped). Clean the
coolant is contaminated.
drain plugs. Install the drain plugs. Refer to
the Specifications Manual, SENR3130, “Torque
NOTICE Specifications” for more information on the proper
Use of commercially available cooling system clean- torques.
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
82 SEBU8088-07
Maintenance Section
Cooling System Coolant (DEAC) - Change

3. Fill the cooling system with a mixture of clean 4. Start and run the engine at low idle for a minimum
water and Caterpillar Fast Acting Cooling System of 90 minutes. The coolant temperature should be
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L at least 82 °C (180 °F).
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap. NOTICE
Improper or incomplete rinsing of the cooling system
4. Start and run the engine at low idle for a minimum can result in damage to copper and other metal com-
of 30 minutes. The coolant temperature should be ponents.
at least 82 °C (180 °F).
To avoid damage to the cooling system, make sure
NOTICE to completely flush the cooling system with clear wa-
Improper or incomplete rinsing of the cooling system ter. Continue to flush the system until all signs of the
can result in damage to copper and other metal com- cleaning agent are gone.
ponents.

To avoid damage to the cooling system, make sure 5. Stop the engine and allow the engine to cool.
to completely flush the cooling system with clear wa- Loosen the cooling system filler cap slowly
ter. Continue to flush the system until all signs of the in order to relieve any pressure. Remove the
cleaning agent are gone. cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
5. Stop the engine and allow the engine to cool. system with clean water. Close the drain valve
Loosen the cooling system filler cap slowly (if equipped). Clean the drain plugs. Install the
in order to relieve any pressure. Remove the drain plugs. Refer to the Specifications Manual,
cooling system filler cap. Open the drain valve SENR3130, “Torque Specifications” for more
(if equipped) or remove the cooling system drain information on the proper torques.
plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to
flush the heater and any related supply and return
Fill
lines. Close the drain valve (if equipped). Clean
the drain plugs. Install the drain plugs. Refer to NOTICE
the Specifications Manual, SENR3130, “Torque Fill the cooling system no faster than 19 L (5 US gal)
Specifications” for more information on the proper per minute to avoid air locks.
torques.
1. Fill the cooling system with coolant/antifreeze.
Cooling Systems with Heavy Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic
Deposits or Plugging (Maintenance Section) for more information on
cooling system specifications. Do not install the
Note: For the following procedure to be effective, cooling system filler cap.
there must be some active flow through the cooling
system components. 2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at high
1. Flush the cooling system with clean water in order idle for one minute in order to purge the air from
to remove any debris. the cavities of the engine block. Stop the engine.
2. Close the drain valve (if equipped). Clean the 3. Check the coolant level. Maintain the coolant level
drain plugs. Install the drain plugs. Refer to within 13 mm (0.5 inch) below the bottom of the
the Specifications Manual, SENR3130, “Torque pipe for filling. Maintain the coolant level within
Specifications” for more information on the proper 13 mm (0.5 inch) to the proper level on the sight
torques. glass (if equipped).

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

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
SEBU8088-07 83
Maintenance Section
Cooling System Coolant (ELC) - Change

4. Clean the cooling system filler cap. Inspect the 1. Stop the engine and allow the engine to cool.
gasket that is on the cooling system filler cap. If Loosen the cooling system filler cap slowly in
the gasket that is on the cooling system filler cap order to relieve any pressure. Remove the cooling
is damaged, discard the old cooling system filler system filler cap.
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler 2. Open the cooling system drain valve (if equipped).
cap is not damaged, perform a pressure test. A If the cooling system is not equipped with a drain
9S-8140 Pressurizing Pump is used to perform valve, remove the cooling system drain plugs.
the pressure test. The correct pressure for the
cooling system filler cap is stamped on the face of Allow the coolant to drain.
the cooling system filler cap. If the cooling system
filler cap does not retain the correct pressure, NOTICE
install a new cooling system filler cap. Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
5. Start the engine. Inspect the cooling system for coolant for reuse in engine cooling systems. The full
leaks and for proper operating temperature. distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
i02056152
For information regarding the disposal and the
Cooling System Coolant (ELC) recycling of used coolant, consult your Caterpillar
- Change dealer or consult Caterpillar Dealer Service Tool
Group:
SMCS Code: 1350-044-NL
Outside Illinois: 1-800-542-TOOL
Clean the cooling system and flush the cooling Inside Illinois: 1-800-541-TOOL
system before the recommended maintenance Canada: 1-800-523-TOOL
interval if the following conditions exist:
Flush
• The engine overheats frequently.
1. Flush the cooling system with clean water in order
• Foaming is observed. to remove any debris.
• The oil has entered the cooling system and the 2. Close the drain valve (if equipped). Clean the
coolant is contaminated. drain plugs. Install the drain plugs. Refer to
the Specifications Manual, SENR3130, “Torque
• The fuel has entered the cooling system and the Specifications” for more information on the proper
coolant is contaminated. torques.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and NOTICE
replaced. Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has 3. Fill the cooling system with clean water. Install the
been drained. This is a good opportunity to replace cooling system filler cap.
the water pump, the water temperature regulator and
the hoses, if necessary. 4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
Drain
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
Pressurized System: Hot coolant can cause seri-
(if equipped) or remove the cooling system drain
ous burns. To open the cooling system filler cap,
plugs. Allow the water to drain. Flush the cooling
stop the engine and wait until the cooling system
system with clean water. Close the drain valve
components are cool. Loosen the cooling system
(if equipped). Clean the drain plugs. Install the
pressure cap slowly in order to relieve the pres-
drain plugs. Refer to the Specifications Manual,
sure.
SENR3130, “Torque Specifications” for more
information on the proper torques.
84 SEBU8088-07
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

Fill
NOTICE
NOTICE Use only Cat Extended Life Coolant (ELC) Extender
Fill the cooling system no faster than 19 L (5 US gal) with Cat ELC.
per minute to avoid air locks.
Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
1. Fill the cooling system with Extended Life Coolant tional coolants and/or conventional SCA reduces the
(ELC). Refer to the Operation and Maintenance Cat ELC service life.
Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
on cooling system specifications. Do not install the Check the cooling system only when the engine is
cooling system filler cap. stopped and cool.

2. Start and run the engine at low idle. Increase the

engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from Personal injury can result from hot coolant, steam
the cavities of the engine block. Stop the engine. and alkali.
3. Check the coolant level. Maintain the coolant level At operating temperature, engine coolant is hot
within 13 mm (0.5 inch) below the bottom of the and under pressure. The radiator and all lines
pipe for filling. Maintain the coolant level within to heaters or the engine contain hot coolant or
13 mm (0.5 inch) to the proper level on the sight steam. Any contact can cause severe burns.
glass (if equipped).
Remove cooling system pressure cap slowly to
4. Clean the cooling system filler cap. Inspect the relieve pressure only when engine is stopped and
gasket that is on the cooling system filler cap. If cooling system pressure cap is cool enough to
the gasket that is on the cooling system filler cap touch with your bare hand.
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If Do not attempt to tighten hose connections when
the gasket that is on the cooling system filler cap is the coolant is hot, the hose can come off causing
not damaged, use a 9S-8140 Pressurizing Pump burns.
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system Cooling System Coolant Additive contains alkali.
filler cap is stamped on the face of the cooling Avoid contact with skin and eyes.
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap. NOTICE
Care must be taken to ensure that fluids are contained
5. Start the engine. Inspect the cooling system for during performance of inspection, maintenance, test-
leaks and for proper operating temperature. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
i02482066
nent containing fluids.
Cooling System Coolant
Refer to Special Publication, NENG2500, “Caterpillar
Extender (ELC) - Add Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
SMCS Code: 1352-544-NL products.
Cat ELC (Extended Life Coolant) does not require Dispose of all fluids according to local regulations and
the frequent additions of any supplemental cooling mandates.
additives which are associated with the present
conventional coolants. The Cat ELC Extender only
needs to be added once. 1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
system filler cap.

2. It may be necessary to drain enough coolant from

the cooling system in order to add the Cat ELC
Extender.
SEBU8088-07 85
Maintenance Section
Cooling System Coolant Level - Check

3. Add Cat ELC Extender according to the

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

4. Clean the cooling system filler cap. Inspect the

gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.

i01197583

Cooling System Coolant Level

- Check Illustration 57
g00103639

Typical filler cap gaskets

SMCS Code: 1350-535-FLV
3. Clean the cooling system filler cap and check the
Check the coolant level when the engine is stopped condition of the filler cap gaskets. Replace the
and cool. cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i02837191

Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) is

optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems that
g00285520
Illustration 56 are filled with Cat ELC should have a Coolant Sample
Cooling system filler cap (Level 2) that is obtained at the recommended interval
that is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant
Pressurized System: Hot coolant can cause seri- instead of Cat ELC. This includes the following
ous burns. To open the cooling system filler cap, types of coolants:
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
sure. (Caterpillar EC-1)

1. Remove the cooling system filler cap slowly in • Cat DEAC (Diesel Engine Antifreeze/Coolant)
order to relieve pressure.
• Commercial heavy-duty coolant/antifreeze
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
86 SEBU8088-07
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

Table 9 Submit the sample for Level 1 analysis.

Recommended Interval
For additional information about coolant analysis,
Type of Coolant Level 1 Level 2 see this Operation and Maintenance Manual, “Refill
Every 250
Capacities and Recommendations” or consult your
Cat DEAC Yearly(1)(2) Caterpillar dealer.
Hours(1)
Cat ELC Optional(2) Yearly(2)
i01987714
(1) This is the recommended interval for coolant samples for all
conventional heavy-duty coolant/antifreeze. This is also the
recommended interval for coolant samples of commercial
Cooling System Coolant
coolants that meet the Cat EC-1 specification for engine
coolant.
Sample (Level 2) - Obtain
(2) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified. SMCS Code: 1350-008; 1395-008; 1395-554; 7542

NOTICE NOTICE
Always use a designated pump for oil sampling, and Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may Using the same pump for both types of samples may
contaminate the samples that are being drawn. This contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor- contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both rect interpretation that could lead to concerns by both
dealers and customers. dealers and customers.

Note: Level 1 results may indicate a need for Refer to Operation and Maintenance Manual,
Level 2 Analysis. “Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order Submit the sample for Level 2 analysis.
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order For additional information about coolant
to establish a pertinent history of data, perform analysis, see Special Publication, SEBU6251,
consistent samplings that are evenly spaced. “Caterpillar Commercial Diesel Engines Fluids
Supplies for collecting samples can be obtained from Recommendations” or consult your Caterpillar dealer.
your Caterpillar dealer.
i02839449
Use the following guidelines for proper sampling of
the coolant: Cooling System Supplemental
• Complete the information on the label for the Coolant Additive (SCA) -
sampling bottle before you begin to take the Test/Add
samples.
SMCS Code: 1352-045; 1395-081
• Keep the unused sampling bottles stored in plastic
bags.

• Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples Cooling system coolant additive contains alkali.
from any other location. To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
• Keep the lids on empty sampling bottles until you coolant additive.
are ready to collect the sample.

• Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.
SEBU8088-07 87
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Add the SCA, If Necessary

NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
Pressurized System: Hot coolant can cause seri-
heat transfer characteristics. Reduced heat transfer ous burns. To open the cooling system filler cap,
could cause cracking of the cylinder head and other
stop the engine and wait until the cooling system
high temperature components.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
Excessive supplemental coolant additive concentra-
sure.
tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water
pump seal. 1. Remove the cooling system filler cap slowly.

Do not exceed the recommended amount of supple- 2. If necessary, drain some coolant in order to allow
mental coolant additive concentration. space for the addition of the SCA.

3. Add the proper amount of SCA. For the

NOTICE proper amount of SCA, refer to this Operation
Care must be taken to ensure that fluids are contained and Maintenance Manual, “Refill Capacities
during performance of inspection, maintenance, test- and Recommendations” topic. The proper
ing, adjusting and repair of the product. Be prepared to concentration of SCA depends on the type of
collect the fluid with suitable containers before open- coolant that is used. For the proper concentration
ing any compartment or disassembling any compo- of SCA, refer to Special Publication, SEBU6251,
nent containing fluids. “Caterpillar Commercial Diesel Engine Fluids
Recommendations”.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” and to Special Publica- 4. Clean the cooling system filler cap. Install the
tion, GECJ0003, “Cat Shop Supplies and Tools” for cooling system filler cap.
tools and supplies suitable to collect and contain flu-
ids on Caterpillar products.
Cooling Systems that Use Water
Dispose of all fluids according to applicable regula- and SCA
tions and mandates.
Test the Concentration of the SCA
Note: Caterpillar recommends an S·O·S coolant
analysis (Level 1). Test the concentration of the SCA with a 298-5311
Coolant Nitrite Test Kit for SCA or perform an S·O·S
Cooling Systems that Use Coolant Analysis. The test kit includes the following
items: a tool for the testing, 30 ampoules for testing
Conventional Coolant nitrite, instructions, and a case. 294-7420 Test
Kit contains the refill ampoules for the 298-5311
This maintenance procedure is required for Coolant Nitrite Test Kit. Use the instructions that are
conventional coolants such as DEAC.This included with the test kit in order to properly conduct
maintenance is NOT required for cooling systems the testing.
that are filled with Extended Life Coolant.
Refer to this Operation and Maintenance Manual,
Test the Concentration of the SCA “Maintenance Interval Schedule” for the times at
which the procedures should be conducted. Test the
NOTICE concentration of the SCA more frequently if more
Do not exceed the recommended six percent supple- frequent testing is indicated by the results of the
mental coolant additive concentration. S·O·S Coolant Analysis.

Test the concentration of the SCA with the 8T-5296 NOTICE

Coolant Conditioner Test Kit. Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
88 SEBU8088-07
Maintenance Section
Cooling System Water Temperature Regulator - Replace

Add the SCA, If Necessary

NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Caterpillar engines incorporate a shunt design cooling
stop the engine and wait until the cooling system
system and require operating the engine with a water
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- temperature regulator installed.
sure.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head
1. Remove the cooling system filler cap slowly. damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
2. If necessary, drain some coolant in order to allow the water temperature regulator vent hole is open.
space for the addition of the SCA.
Do not use liquid gasket material on the gasket or
3. Add the proper amount of SCA. For the proper cylinder head surface.
amount of SCA, refer to this Operation and
Maintenance Manual, “Refill Capacities and
Recommendations” topic. For the proper Refer to two articles in the Disassembly and
concentration of SCA, refer to Special Publication, Assembly Manual, “Water Temperature Regulators
SEBU6251, “Caterpillar Commercial Diesel - Remove and Water Temperature Regulators -
Engine Fluids Recommendations”. Install” for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
4. Clean the cooling system filler cap. Install the dealer.
cooling system filler cap.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
i02623972 a level that is below the water temperature regulator
housing.
Cooling System Water
Temperature Regulator - i02933380
Replace Crankshaft Vibration Damper
SMCS Code: 1355-510 - Inspect
Replace the water temperature regulator before SMCS Code: 1205-040
the water temperature regulator fails. This is a
recommended preventive maintenance practice. Damage to the crankshaft vibration damper or failure
Replacing the water temperature regulator reduces of the crankshaft vibration damper can increase
the chances for unscheduled downtime. torsional vibrations. This can result in damage to
the crankshaft and to other engine components. A
A water temperature regulator that fails in a damper that is damaged can cause excessive gear
partially opened position can cause overheating or train noise at variable points in the speed range.
overcooling of the engine.
The damper is mounted to the crankshaft which is
A water temperature regulator that fails in the closed located behind the belt guard on the front of the
position can cause excessive overheating. Excessive engine.
overheating could result in cracking of the cylinder
head or piston seizure problems.
Visconic Damper
A water temperature regulator that fails in the open
The visconic damper has a weight that is located
position will cause the engine operating temperature
inside a fluid filled case. The weight moves in the
to be too low during partial load operation. Low
case in order to limit torsional vibration.
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
SEBU8088-07 89
Maintenance Section
Electrical Connections - Check

Inspect the damper for evidence of fluid leaks. If i01664717

a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has Engine - Clean
the following characteristics: transparent, viscous,
smooth, and adhering. SMCS Code: 1000-070

If the fluid leak is oil, inspect the crankshaft seals for

leaks. If a leak is observed, replace the crankshaft
seals. Personal injury or death can result from high volt-
age.
Inspect the damper and repair or replace the damper
for any of the following reasons: Moisture could create paths of electrical conduc-
tivity.
• The damper is dented, cracked, or leaking.
Make sure the unit is off line (disconnected from
• The paint on the damper is discolored from heat. utility and/or other generators), locked out and
tagged "Do Not Operate".
• The engine has had a failure because of a broken
crankshaft.
NOTICE
• Analysis of the oil has revealed that the front main Water or condensation can cause damage to gen-
bearing is badly worn. erator components. Protect all electrical components
from exposure to water.
• There is a large amount of gear train wear that is
not caused by a lack of oil.
NOTICE
Refer to the Disassembly and Assembly Manual, Accumulated grease and oil on an engine is a fire haz-
“Vibration Damper and Pulley - Remove and Install” ard. Keep the engine clean. Remove debris and fluid
or consult your Caterpillar dealer for information spills whenever a significant quantity accumulates on
about damper replacement. the engine.

i01217164 Steam cleaning the engine will remove accumulated

oil and grease. A clean engine provides the following
Electrical Connections - Check benefits:

SMCS Code: 4459-535 • Easy detection of fluid leaks

Check all exposed electrical connections for • Maximum heat transfer characteristics
tightness.
• Ease of maintenance
Check the following devices for loose mounting or
physical damage: Note: For more information on cleaning and drying
electric generators, refer to Special Instruction,
• transformers SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
• fuses
i02353651
• capacitors
Engine Air Cleaner Element
• lightning arrestors
(Dual Element) - Clean/Replace
Check all lead wires and electrical connections for
proper clearance.
(If Equipped)
SMCS Code: 1051; 1054-037

See this Operation and Maintenance Manual,

“Engine Air Cleaner Element - Clean/Replace” for
information on servicing the primary air filter.
90 SEBU8088-07
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Inspecting and Replacing the 3. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
Secondary Air Cleaner Element (If
Equipped) 4. Remove the adhesive covering that covers the air
inlet for the turbocharger. Install the secondary
NOTICE air cleaner element. Install a primary air cleaner
Never run the engine without an air cleaner element element that is new or clean.
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with 5. Install the air cleaner cover.
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine 6. Reset the air cleaner service indicator.
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet. i01900118

Engine Air Cleaner Service

NOTICE
Never service the air cleaner element with the engine Indicator - Inspect
running since this will allow dirt to enter the engine. (If Equipped)
Operating conditions (dust, dirt, and debris) may SMCS Code: 7452-040
require more frequent service of the air cleaner
element. If the air cleaner element becomes plugged, Some engines may be equipped with a different
the air can split the material of the air cleaner service indicator.
element. Unfiltered air will drastically accelerate
internal engine wear. Your Caterpillar dealer has Some engines are equipped with a differential gauge
the proper air cleaner elements for your application. for inlet air pressure. The differential gauge for inlet
Consult your Caterpillar dealer for the correct air air pressure displays the difference in the pressure
cleaner element. that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
The secondary air cleaner element is not serviceable element. As the air cleaner element becomes dirty,
or washable. The secondary air cleaner element the pressure differential rises. If your engine is
should be removed and discarded for every three equipped with a different type of service indicator,
cleanings of the primary air cleaner element. follow the OEM recommendations in order to service
the air cleaner service indicator.

The service indicator may be mounted on the air

cleaner housing or in a remote location.

g00736431
Illustration 58
(1) Cover
(2) Primary air cleaner element
(3) Secondary air cleaner element
g00103777
(4) Air inlet for the turbocharger Illustration 59
Typical service indicator
1. Remove the cover. Remove the primary air
cleaner element. Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element
2. Cover the air inlet for the turbocharger with should be replaced when one of the following
adhesive material in order to keep dirt out of the conditions occur:
turbocharger.
• The yellow diaphragm enters the red zone.
SEBU8088-07 91
Maintenance Section
Engine Crankcase Breather - Clean

• The red piston locks in the visible position. 2. Remove the bolts (1) and remove the breather
from the engine.
Test the Service Indicator 3. Check the condition of the seal. Replace the seal
if the seal is damaged.
Service indicators are important instruments.
4. Remove the breather element. Wash the breather
• Check for ease of resetting. The service indicator element and wash the breather in a clean
should reset in less than three pushes.
nonflammable solvent.
• Check the movement of the yellow core when the 5. Shake the breather element until the breather
engine is accelerated to the engine rated speed.
element is dry. You may also use pressurized air
The yellow core should latch approximately at the
greatest vacuum that is attained. in order to dry the breather element.

6. Check the condition of the tube. Replace the tube

If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum, if the tube is damaged.
the service indicator should be replaced. If the new
7. Install the element into the breather and install the
service indicator will not reset, the hole for the service
indicator may be plugged. breather.

8. Install the tube onto the outlet of the breather

The service indicator may need to be replaced
frequently in environments that are severely dusty, if cover and tighten the clamp.
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the i01786814
service indicator when the engine is overhauled, and
whenever major engine components are replaced. Engine Mounts - Check
Note: When a new service indicator is installed, SMCS Code: 1152-535
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque Misalignment of the engine and the driven equipment
of 2 N·m (18 lb in). will cause extensive damage. Excessive vibration
can lead to misalignment. Excessive vibration of the
engine and the driven equipment can be caused by
i02327200 the following conditions:
Engine Crankcase Breather - • Improper mounting
Clean
• Loose bolts
SMCS Code: 1317-070
• Deterioration of the isolators
Ensure that the mounting bolts are tightened
to the proper torque. For standard torques, see
Specifications, SENR3130, “Torque Specifications”.

Ensure that the isolators are free of oil and

contamination. Inspect the isolators for deterioration.
Ensure that the bolts for the isolators are tightened to
the proper torque.

Replace any isolator that shows deterioration. For

more information, see the literature that is provided
by the OEM of the isolators. Also see the Application
g01162493
and Installation Guide for the engine. Consult your
Illustration 60 Caterpillar dealer for assistance.
The crankcase breather is located on the back of
the engine.

1. Remove the tube (2) from the outlet of the breather

and loosen the clamp.
92 SEBU8088-07
Maintenance Section
Engine Oil Level - Check

i02108396 2. Remove the oil filler cap and add oil, if necessary.
For the correct oil to use, see this Operation
Engine Oil Level - Check and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
SMCS Code: 1348-535-FLV Do not fill the crankcase above “FULL” mark (X)
on the oil level gauge. Clean the oil filler cap.
Install the oil filler cap.

Hot oil and hot components can cause personal 3. Record the amount of oil that is added. For the
injury. Do not allow hot oil or hot components to next oil sample and analysis, include the total
contact the skin. amount of oil that has been added since the
previous sample. This will help to provide the most
accurate oil analysis.

i01935337

Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM
g00110310
Illustration 61
In addition to a good preventive maintenance
(Y) “ADD” mark program, Caterpillar recommends using S·O·S oil
(X) “FULL” mark
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
NOTICE maintenance requirements of the engine. S·O·S oil
Perform this maintenance with the engine stopped. analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
1. Maintain the oil level between “ADD” mark (Y) and
“FULL” mark (X) on the oil level gauge. Do not fill Obtain the Sample and the Analysis
the crankcase above “FULL” mark (X).

NOTICE
Engine damage can occur if the crankcase is filled Hot oil and hot components can cause personal
above the “FULL” mark on the oil level gauge (dip- injury. Do not allow hot oil or hot components to
stick). contact the skin.
An overfull crankcase can enable the crankshaft to
dip into the oil. This will reduce the power that is de- Before you take the oil sample, complete the Label,
veloped and also force air bubbles into the oil. These PEEP5031 for identification of the sample. In order
bubbles (foam) can cause the following problems: re- to help obtain the most accurate analysis, provide
duction of the oil's ability to lubricate, reduction of oil the following information:
pressure, inadequate cooling of the pistons, oil blow-
ing out of the crankcase breathers, and excessive oil • Engine model
consumption.
• Service hours on the engine
Excessive oil consumption will enable deposits to form
on the pistons and in the combustion chamber. De- • The number of hours that have accumulated since
posits in the combustion chamber lead to the following the last oil change
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner. • The amount of oil that has been added since the
last oil change
If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately. To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.

To avoid contamination of the oil samples, the tools

and the supplies that are used for obtaining oil
samples must be clean.
SEBU8088-07 93
Maintenance Section
Engine Oil and Filter - Change

Caterpillar recommends using the sampling valve Drain the Engine Oil
in order to obtain oil samples. The quality and the
consistency of the samples are better when the After the engine has been run at the normal operating
sampling valve is used. The location of the sampling temperature, stop the engine. Use one of the
valve allows oil that is flowing under pressure to be following methods to drain the engine crankcase oil:
obtained during normal engine operation.
• If the engine is equipped with a drain valve, turn the
The 169-8373 Fluid Sampling Bottle is drain valve knob counterclockwise in order to drain
recommended for use with the sampling valve. The the oil. After the oil has drained, turn the drain valve
fluid sampling bottle includes the parts that are knob clockwise in order to close the drain valve.
needed for obtaining oil samples. Instructions are
also provided. • If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil
NOTICE to drain. If the engine is equipped with a shallow
Always use a designated pump for oil sampling, and sump, remove the bottom oil drain plugs from both
use a separate designated pump for coolant sampling. ends of the oil pan.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This After the oil has drained, the oil drain plugs should
contaminate may cause a false analysis and an incor- be cleaned and installed.
rect interpretation that could lead to concerns by both
dealers and customers. Replace the Oil Filter
If the engine is not equipped with a sampling valve, NOTICE
use the 1U-5718 Vacuum Pump. The pump is Caterpillar oil filters are built to Caterpillar speci-
designed to accept sampling bottles. Disposable fications. Use of an oil filter not recommended by
tubing must be attached to the pump for insertion Caterpillar could result in severe engine damage to
into the sump. the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
For instructions, see Special Publication, PEHP6001, the engine lubricating system. Only use oil filters
“How To Take A Good Oil Sample”. Consult your recommended by Caterpillar.
Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine. 1. Remove the oil filter with a 1U-8760 Chain
Wrench.

i02107152 2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
Engine Oil and Filter - Change oil filter for metal debris. An excessive amount
of metal debris in the oil filter may indicate early
SMCS Code: 1318-510 wear or a pending failure.

Use a magnet to differentiate between the ferrous

metals and the nonferrous metals that are found in
Hot oil and hot components can cause personal the oil filter element. Ferrous metals may indicate
injury. Do not allow hot oil or hot components to wear on the steel and cast iron parts of the engine.
contact the skin.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
Do not drain the oil when the engine is cold. As the oil the engine. Parts that may be affected include
cools, suspended waste particles settle on the bottom the following items: main bearings, rod bearings,
of the oil pan. The waste particles are not removed turbocharger bearings, and cylinder heads.
with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the Due to normal wear and friction, it is not
oil warm. This draining method allows the waste uncommon to find small amounts of debris in the
particles that are suspended in the oil to be drained oil filter. Consult your Caterpillar dealer in order
properly. to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
94 SEBU8088-07
Maintenance Section
Engine Protective Devices - Check

3. Stop the engine and allow the oil to drain back to

the sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the oil level gauge.

i00626013

Engine Protective Devices -

Check
SMCS Code: 7400-535
g00103713
Illustration 62 Alarms and shutoffs must function properly. Alarms
Typical filter mounting base and filter gasket provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
3. Clean the sealing surface of the filter mounting to determine if the engine protective devices are
base. Ensure that all of the old oil filter gasket is in good working order during normal operation.
removed. Malfunctions must be simulated in order to test the
engine protective devices.
4. Apply clean engine oil to the new oil filter gasket.
A calibration check of the engine protective devices
NOTICE will ensure that the alarms and shutoffs activate
Do not fill the oil filters with oil before installing them. at the setpoints. Ensure that the engine protective
This oil would not be filtered and could be contaminat- devices are functioning properly.
ed. Contaminated oil can cause accelerated wear to
engine components. NOTICE
During testing, abnormal operating conditions must be
simulated.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
The tests must be performed correctly in order to pre-
filter by hand according to the instructions that are
vent possible damage to the engine.
shown on the oil filter. Do not overtighten the oil
filter.
To prevent damage to the engine, only authorized
Fill the Engine Crankcase service personnel or your Caterpillar dealer should
perform the tests.
1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual, “Refill Capacities and Visual Inspection
Recommendations” for more information.
Visually check the condition of all gauges, sensors
NOTICE and wiring. Look for wiring and components that
If equipped with an auxiliary oil filter system or a re- are loose, broken, or damaged. Damaged wiring
mote oil filter system, follow the OEM or filter manu- or components should be repaired or replaced
facturer's recommendations. Under filling or overfilling immediately.
the crankcase with oil can cause engine damage.

NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.

2. Start the engine and run the engine at “LOW

IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
SEBU8088-07 95
Maintenance Section
Engine Valve Lash - Inspect/Adjust

i02562758 i02784507

Engine Valve Lash - Fan Drive Bearing - Lubricate

Inspect/Adjust SMCS Code: 1359-086-BD
SMCS Code: 1102-025
Some of the fan drives have grease fittings and some
of the fan drives do not have grease fittings. If there is
NOTICE no grease fitting, periodic lubrication is not required.
Only qualified service personnel should perform this The fan drive requires grease only if the fan drive
maintenance. Refer to the Service Manual or your is equipped with a zerk.
Caterpillar dealer for the complete valve lash adjust-
ment procedure.

Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.

The initial valve lash adjustment on new engines,

rebuilt engines, or remanufactured engines should
be performed at the first oil change. The initial valve
lash adjustment on new engines, rebuilt engines, or
remanufactured engines must be performed before
the fourth oil change, or at the fourth oil change. The
adjustment is necessary due to the initial wear of g00746166
Illustration 63
the valve train components and to the seating of the
valve train components. Typical location of the grease fitting (if equipped) that is for the fan
drive bearing

This maintenance is part of a lubrication and The pulley is shown with the belt guards that have been removed.
preventive maintenance schedule in order to help
provide maximum engine life. Lubricate the grease fitting that is on the fan drive
bearing with High Speed Ball Bearing Grease or the
equivalent.

Inspect the fan drive pulley assembly for wear or for

Ensure that the engine can not be started while damage. If the shaft is loose, an inspection of the
this maintenance is being performed. To help pre- internal components should be performed. Refer to
vent possible injury, do not use the starting motor the Systems Operation Testing and Adjusting Manual
to turn the flywheel. for additional information.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea- i01565926

suring/adjusting valve lash clearance.

Fuel Injector - Inspect/Adjust
To obtain an accurate measurement, allow the valves SMCS Code: 1290-025
to cool before this maintenance is performed.
Note: Perform this procedure when the engine valve
The following components should be inspected and lash is inspected.
adjusted when the valves are inspected and adjusted.
NOTICE
• Valve actuators The camshafts must be correctly timed with the crank-
shaft before an adjustment of the lash for the fuel in-
• Injectors jector is made. The timing pins must be removed from
the camshafts before the crankshaft is turned or dam-
• Compression brakes age to the cylinder block will be the result.
Refer to Systems Operation, Testing and Adjusting,
“Engine Valve Lash - Inspect/Adjust” in your service
manual for more information.
96 SEBU8088-07
Maintenance Section
Fuel System - Prime

Inspect the adjustment of the lash for the fuel injector

according to the Testing And Adjusting, “Fuel Injector
Adjustment”. Adjust the lash for the fuel injector, if
necessary.

i02879917

Fuel System - Prime

SMCS Code: 1250-548; 1258-548

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
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

The fuel system should be primed after a unit injector

is changed or when the fuel system is totally dry.

Note: The fuel system does not typically need to be

primed when the primary fuel filters or secondary fuel
filters are changed or when an Electronic Control
Module (ECM) is replaced. When the engine is
started under these circumstances, the engine may Illustration 64
g01275925
momentarily run rough until the air is purged from
The right side view of a typical C27 or C32 Engine that is
the system. configured for a genset
(1) Fuel priming pump
NOTICE (2) Fuel filter base
Do not allow dirt to enter the fuel system. Thoroughly (3) Secondary fuel filter
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.

g01275944
Illustration 65
The secondary fuel filter and the fuel priming pump is shown.
(1) Fuel priming pump
(2) Fuel filter base
(3) Secondary fuel filter
(4) Priming pump plunger
SEBU8088-07 97
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

Follow the procedure below in order to prime the Replace the Element
engine with fuel.

1. Turn the priming pump plunger (4)

counterclockwise in order to unlock the
plunger. Manually pump the plunger in order to fill Fuel leaked or spilled onto hot surfaces or elec-
the fuel lines and the fuel filters with fuel. trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
2. As the air is purged from the fuel system, fuel changing fuel filters or water separator elements.
pressure will increase. This will create resistance Clean up fuel spills immediately.
in the plunger. Continue to pump the plunger until
a strong resistance is felt. The number of strokes
will vary with the amount of air in the fuel lines.

3. After resistance is felt in the plunger, push in the

plunger. Lock the plunger by turning the plunger
clockwise.

4. Start the engine at low idle.

5. If the engine runs rough, continue to run the

engine at low idle until the engine runs smoothly.

NOTICE
Do not crank the engine continuously for more than g00668636
Illustration 66
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. (1) Bowl
(2) Element
(3) Drain

i02049797 1. Stop the engine.

Fuel System Primary Filter 2. Turn the start switch to the “OFF” position.
(Water Separator) Element -
3. Shut off the fuel tank supply valve to the engine.
Replace
4. If the primary fuel filter is equipped with a drain
SMCS Code: 1260-510-FQ; 1263-510-FQ valve (3), open the drain valve in order to drain any
fuel from the filter case. Close the drain valve (3).
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water, NOTICE
the element should be changed before the regularly Use a suitable container to catch any fuel that might
scheduled interval. spill. Clean up any spilled fuel immediately.

The primary filter/water separator also provides 5. Remove the fuel filter bowl (1) and wash the fuel
filtration in order to help extend the life of the filter bowl with clean diesel fuel.
secondary fuel filter. The element should be changed
regularly. Install a vacuum gauge. Change the 6. Remove the fuel filter (2).
element for the primary filter/water separator if the
pressure is at 50 to 70 kPa (15 to 20 inches Hg). 7. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.

8. Apply clean diesel fuel to the new fuel filter gasket.

98 SEBU8088-07
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

i01463757
NOTICE
In order to maximize fuel system life and prevent pre-
Fuel System Primary
mature wear out from abrasive particles in the fuel, Filter/Water Separator - Drain
use Caterpillar fuel filters.
SMCS Code: 1260-543; 1263-543
Consult your Caterpillar dealer for proper part num-
bers.

9. Install the new fuel filter (2). Spin the fuel filter
onto the fuel filter base until the gasket contacts
the base. Use the rotation index marks on the
filters as a guide for proper tightening. Tighten the
filter for an additional 3/4 turn by hand. Do not
overtighten the filter.

NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contami-
nated. Contaminated fuel will cause accelerated wear
to fuel system parts. Illustration 67
g00668636

(1) Bowl
(2) Element
10. Install the clean fuel filter bowl (1) on the new fuel (3) Drain
filter.
Bowl (1) should be monitored daily for signs of water.
NOTICE If water is present, drain the water from the bowl.
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight- 1. Open drain (3). The drain is a self-ventilated drain.
ened securely to help prevent air from entering the fu- Catch the draining water in a suitable container.
el system. Dispose of the water properly.

2. Close drain (3).

11. Open the fuel tank supply valve.

12. Start the engine and check for leaks. Run the NOTICE
engine for one minute. Stop the engine and check The water separator is under suction during normal
the engine for leaks again. engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
Detection of leaks is very difficult especially if system.
the engine is running. The primary filter/water
separator is under suction. A leak will allow air to
enter the fuel. The air in the fuel can cause low i02326422
power due to aeration of the fuel. If air enters the
fuel, check the components for overtightening or Fuel System Secondary Filter -
undertightening. Replace
SMCS Code: 1261-510-SE

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
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
SEBU8088-07 99
Maintenance Section
Fuel Tank Water and Sediment - Drain

5. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters
as a guide for proper tightening. Tighten the
filter for an additional 3/4 turn by hand. Do not
overtighten the filter.

i03071053

Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
g01162207
Illustration 68
NOTICE
(1) Fuel supply connections Care must be taken to ensure that fluids are contained
(2) Fuel filter
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
NOTICE collect the fluid with suitable containers before open-
Do not allow dirt to enter the fuel system. Thoroughly ing any compartment or disassembling any compo-
clean the area around a fuel system component that nent containing fluids.
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
NOTICE Tools Catalog” for tools and supplies suitable to col-
Use a suitable container to catch any fuel that might lect and contain fluids on Caterpillar products.
spill. Clean up any spilled fuel immediately.
Dispose of all fluids according to local regulations and
1. It may be necessary to relieve residual fuel mandates.
pressure from the fuel system before removing
the fuel filter.
Fuel Tank
Loosen one of the fuel supply connections (1) in
order to purge any residual pressure. Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
NOTICE occurs during the heating and cooling of fuel. The
Do not loosen fuel lines or fittings at the fuel manifold condensation occurs as the fuel passes through the
or ECM. The engine components may be damaged. fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
2. Remove the used fuel filter.
sources can help to eliminate water in the fuel.
3. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed. Drain the Water and the Sediment
4. Apply clean diesel fuel to the new fuel filter gasket. Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
NOTICE fuel tanks.
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be Open the drain valve on the bottom of the fuel tank
contaminated. Contaminated fuel will cause acceler- in order to drain the water and the sediment. Close
ated wear to fuel system parts. the drain valve.

Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
100 SEBU8088-07
Maintenance Section
Generator - Dry

Fill the fuel tank after operating the engine in Drying Methods
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The The following methods can be used for drying a
fuel expands as the fuel gets warm. The tank may generator:
overflow.
• Self-circulating air method
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel • Oven method
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If NOTICE
the engine is equipped with this system, regular Do not allow the winding temperature to exceed 85 °C
maintenance of the fuel system filter is important. (185.0 °F). Temperatures that are greater than 85 °C
(185.0 °F) will damage the winding insulation.
Fuel Storage Tanks
Drain the water and the sediment from the fuel Self-Circulating Air Method
storage tank during the following conditions:
Run the engine and disconnect the generator load.
• Weekly This will help circulate air. Operate the generator
space heaters.
• Oil change
Oven Method
• Refill of the tank
Place the entire generator inside a forced air drying
This will help prevent water or sediment from being oven for four hours at 65 °C (149 °F).
pumped from the storage tank into the engine fuel
tank. A four micron(c) absolute filter for the breather NOTICE
vent on the fuel tank is also recommended. Refer Use a forced air type oven rather than a radiant type
to Special Publication, SENR9620, “Improving Fuel oven.
System Durablity”.
Radiant type ovens can cause localized overheating.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
i01461264
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
Generator - Inspect
When possible, water separators should be used. SMCS Code: 4450-040

i02290310

Generator - Dry Personal injury or death can result from improper

troubleshooting and repair procedures.
SMCS Code: 4450-569
The following troubleshooting and repair proce-
NOTICE dures should only be performed by qualified per-
Do not operate the generator if the windings are wet. If sonnel familiar with this equipment.
the generator is operated when the windings are wet,
damage can occur due to insulation breakdown.
Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the procedure
When moisture is present or when moisture is to safely isolate the generator.
suspected in a generator, the generator must be
dried before being energized.

If the drying procedure does not restore the insulation

resistance to an acceptable value, the winding should
be reconditioned.

Note: For additional information, refer to Special

Instruction, SEHS9124 .
SEBU8088-07 101
Maintenance Section
Generator - Inspect

Proper maintenance of electrical equipment requires A small nonconductive tube may need to be
periodic visual examination of the generator and connected to the vacuum cleaner. This will allow the
periodic visual examination of the windings. Proper vacuum cleaner to clean the surfaces that are not
maintenance of electrical equipment also requires exposed. After most of the dust has been removed,
appropriate electrical checks and appropriate thermal a small brush may be attached to the vacuum hose
checks. Insulation material should be examined for in order to loosen dirt that is more firmly attached to
cracks. The insulation material should be examined the surface.
for accumulations of dirt and dust. If there is an
insulation resistance value that is below normal, a After the initial cleaning with a vacuum, compressed
conductive path may be present. This conductive air may be used to remove the remaining dust and
path may be made of one of the following materials: dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure
• Carbon should be a maximum of 210 kPa (30 psi) in order to
prevent mechanical damage to the insulation. If the
• Salt above cleaning procedures are not effective, consult
a Caterpillar dealer.
• Metal dust
Cleaning (Disassembled
• Dirt that is saturated with moisture
Generators)
These contaminants will develop a conductive path
which may produce shorts. Cleaning is advisable if An initial insulation resistance check should be
heavy accumulations of dirt can be seen or if heavy made on the generator in order to confirm electrical
accumulations of dust can be seen. If excess dirt is integrity. A minimum reading of one megohm would
the cause of a restriction in the ventilation, cleaning be expected with severely contaminated generators.
is also advisable. Restricted ventilation will cause A zero megohm reading may indicate an insulation
excessive heating. breakdown. An insulation breakdown requires more
than cleaning. An insulation breakdown requires
repair.
NOTICE
To avoid the possibility of deterioration to the genera-
A high pressure wash is normally an effective way
tor windings, do not clean the generator unless there
to clean windings. This includes windings that have
is visual, electrical, or thermal evidence that dirt is
been exposed to flooding or windings that have been
present.
contaminated by salt. A solution of hot water and
detergent is used for this method of cleaning.
If harmful dirt accumulations are present, a variety
of cleaning techniques are available. The cleaning A high pressure wash sprays a high velocity fluid
procedure that is used may be determined by one of stream of this solution over the generator that is
the items on the following list: being cleaned. This detergent washing is followed by
multiple sprays of clean water. The clean water is
• The extent of the cleaning procedure that is being used in order to remove the detergent or the clean
attempted water is used in order to dilute the detergent.

• The type of enclosure of the generator Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation
• The voltage rating of the generator resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. It
• The type of dirt that is being removed may be necessary to use solvents if the generator
is contaminated with oil or if the generator is
contaminated with grease.
Cleaning (Assembled Generators)
Note: For more information on drying methods, refer
Cleaning may be required at the point of installation. to Special Instructions, SEHS9124, “Cleaning and
At this point, complete disassembly of the generator Drying of Electric Set Generators”.
may not be necessary or feasible. In this case,
a vacuum cleaner should be used to pick up the
following items: dry dirt, dust, and carbon. This will
prevent the spreading of these contaminants.
102 SEBU8088-07
Maintenance Section
Generator Bearing - Inspect/Replace

i03099722 4. Remove the bracket drain plug and operate the

generator for one hour. This will allow the grease
Generator Bearing - to expand. The expanding grease will force the
Inspect/Replace excess grease from the cavity. When the excess
grease is forced from the cavity, the internal
(SR4 Generator) pressure will be reduced. The generator should
continue to operate until the grease stops purging.
SMCS Code: 4471-040; 4471-510
5. Stop the engine. Install the bracket drain plug.
The following maintenance procedure for generator Wipe off the excess grease.
bearings should be followed at every major engine
overhaul: 6. For greasing intervals, follow the recommendations
on the lubrication plate (if equipped) or refer to
Inspect Maintenance Schedule, “Generator Bearing -
Lubricate”. Whenever the bearings are greased,
1. Remove the bearing bracket. Inspect the following repeat Step 1. DO NOT MIX GREASES.
items: bracket bore, bearing outer race, and
rolling elements. On standby power units, the i03072525
bearing must be inspected and the grease must
be replaced at three year intervals. The sleeve Generator Bearing - Lubricate
in the bearing bracket should be inspected for
out of roundness, excessive wear, and a bracket SMCS Code: 4471-086
step that is less than 0.0762 mm (0.0030 inch). If
there is no sleeve in the bearing bracket, inspect
the bore of the bearing bracket. The bearing
Lubricating Process (If Applicable)
should be inspected for damage to the outer race,
severe fretting, and smoothness of operation. Note: If the generator already has a visible grease
point, go to Step 4.
When possible, the bearing elements should be
inspected. Some double shielded ball bearings
prevent visual inspection of the elements of the 1. Remove either the louver assembly or the rear
plate from the rear of the generator housing.
bearing. Other double shielded ball bearings
have a retaining ring. This retaining ring can be
removed in order to allow access for a visual 2. Remove the top grease pipe plug and remove the
lower grease pipe plug.
inspection of the elements of the bearing.

On two-bearing generators, the front bearing 3. Install a grease fitting in the grease pipe.
can only be removed after the drive coupling
is removed. Refer to the Systems Operation 4. Grease the bearings with the appropriate grease
Testing and Adjusting Disassembly and Assembly, from Table 10. Do not mix greases.
“Coupling - Remove” for the generator for
instructions for removing the drive coupling.

Replace
1. All ball bearings should be cleaned. The cavity
in the bracket should be repacked with 2S-3230
Grease. Pack the ball bearings (one-third to
one-half of the volume of the cavity).

2. Use an induction heater to heat the ball bearings to

107 °C (224.6 °F) for ten minutes in order to install
either of the following bearings: ball bearings
that are new and ball bearings that have been
inspected. Mount the bearings on the shaft. To
reinstall the hub, heat the hub to 400 °C (752.0 °F)
for three hours. Mount the hub to the shaft.

3. Ensure that the tube of the grease gun is filled

with grease.
SEBU8088-07 103
Maintenance Section
Generator Bearing - Lubricate

Table 10
Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
108-1760 321 BC 680 −29 °C 2S-3230 Every 2000 51.2 g 59 mL (2 oz) 105.0214
Ball 224.9856 ± (−20.2 °F) Bearing service (1.8 oz) ± 0.0076
Bearing 0.0152 mm minimum Lubricant hours or 12 mm
(8.8577 ± / months (4.1347
.0006 inch) 80 °C ± .0003
OD (176 °F) inch)
maximum
104.9909 ±
0.0102 mm
(4.1335 ±
.0004 inch)
ID
108-1761 322 BC 690 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL (2 oz) 110.0201
Ball 239.9843 ± 800 (−20.2 °F) Bearing service (1.8 oz) ± 0.0076
Bearing 0.0152 mm / Lubricant hours or 12 mm
(9.4482 ± 80 °C months (4.3315
.0006 inch) (176 °F) ± .0003
OD inch)

109.9896 ±
0.0102 mm
(4.3303 ±
.0004 inch)
ID
139-0349 Roller 2900 / −40 °C Mobilith Every 250 2.8 g NA 126.9873
Roller 2800 (−40 °F) SHC220 service (0.1 oz) ± 0.0127
Bearing / hours mm
80 °C (4.9995
(176 °F) ± .0005
inch)
139-0350 Roller 2900 / −40 °C Mobilith Every 250 2.8 g NA 126.9873
Roller 2800 (−40 °F) SHC220 service (0.1 oz) ± 0.0127
Bearing / hours mm
80 °C (4.9995
(176 °F) ± .0005
inch)
154-3032 326 BC 820 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL (2 oz) 130.0391
Ball 279.9817 ± 2600 / (−20.2 °F) Bearing service (1.8 oz) ± 0.0114
Bearing 0.0178 mm 2700 / Lubricant hours or 12 mm
(11.0229 ± 80 °C months (5.11965
.0007 inch) (176 °F) ± .00045
OD inch)

129.9870 ±
0.0127 mm
(5.1176 ±
.0005 inch)
ID
(continued)
104 SEBU8088-07
Maintenance Section
Generator Bearing - Lubricate

(Table 10, contd)

Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
241-4644 320 BC LC7 −29 °C UNIREX Every 4500 60 g NA 100.0100
Bearing 214.9856 ± (−20.2 °F) N3 service (2.1 oz) ± 0.0076
0.0152 mm / hours or 12 mm
(8.4640 ± 60 °C months (3.9374
.0006 inch) (140 °F)(2) ± .0003
OD inch)

99.9896 ±
0.0102 mm
(3.9366 ±
.0004 inch)
ID
243-5220 315 BB LC6100 −29 °C UNIREX Non- Non- Non- 75.0087
Bearing 159.9870 ± / (−20.2 °F) N3 regreasable regreasable regreasable ± 0.0076
0.0127 mm LC5000 / bearing(3) bearing bearing mm
(6.2987 ± 60 °C (2.9531
.0005 inch) (140 °F)(2) ± .0003
OD inch)

74.9935 ±
0.0076 mm
(2.9525 ±
.0003 inch)
ID
261-3545 307 BB LC2000 −29 °C UNIREX Non- Non- Non- 35.0075
Bearing 79.9935 ± (−20.2 °F) N3 regreasable regreasable regreasable ± 0.0063
0.0063 mm / bearing(3) bearing bearing mm
(3.14935 50 °C (1.37825
± .00025 (122 °F)(2) ± .00025
inch) OD inch)

34.9923 ±
0.0063 mm
(1.37765
± .00025
inch) ID
262-5921 307 BC LC2000 −29 °C UNIREX Non- Non- Non- 35.0075
Bearing 79.9935 ± (−20.2 °F) N3 regreasable regreasable regreasable ± 0.0063
0.0063 mm / bearing(3) bearing bearing mm
(3.14935 60 °C (1.37825
± .00025 (140 °F)(2) ± .00025
inch) OD inch)

34.9923 ±
0.0063 mm
(1.37765
± .00025
inch) ID
(continued)
SEBU8088-07 105
Maintenance Section
Generator Bearing - Lubricate

(Table 10, contd)

Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
263-0161 309 BC LC3000 −29 °C UNIREX Non- Non- Non- 45.0075
Bearing 99.9896 ± (−20.2 °F) N3 regreasable regreasable regreasable ± 0.0063
0.0102 mm / bearing(3) bearing bearing mm
(3.9366 ± 60 °C (1.77195
.0004 inch) (140 °F)(2) ± .00025
OD inch)

44.9948 ±
0.0063 mm
(1.77145
± .00025
inch)
5P-2448 315 BC 580 / −29 °C 2S-3230 Every 2000 51.2 g 59 mL (2 oz) 75.0126
Ball 159.9870 ± 590 (−20.2 °F) Bearing service (1.8 oz) ± 0.0089
Bearing 0.0127 mm / Lubricant hours or 12 mm
(6.2987 ± 80 °C months (2.95325
.0005 inch) (176 °F) ± .00035
OD inch)

74.9935 ±
0.0076 mm
(2.9525 ±
.0003 inch)
ID
6Y-3955 220 BC 450 −29 °C 2S-3230 Every 2000 51.2 g 59 mL (2 oz) 100.0201
Ball 179.9869 ± (−20.2 °F) Bearing service (1.8 oz) ± 0.0076
Bearing 0.0127 mm / Lubricant hours or 12 mm
(7.0861 ± 80 °C months (3.9378
.0005 inch) (176 °F) ± .0003
OD inch)

99.9896 ±
0.0102 mm
(3.9366 ±
.0004 inch)
ID
6Y-6488 318 BC 597 −29 °C 2S-3230 Every 2000 51.2 g 59 mL (2 oz) 90.0201
Ball 189.9844 ± (−20.2 °F) Bearing service (1.8 oz) ± 0.0076
Bearing 0.0152 mm / Lubricant hours or 12 mm
(7.4797 ± 80 °C months (3.5441
.0006 inch) (176 °F) ± .0003
OD inch)

89.9897 ±
0.0102 mm
(3.5429 ±
.0004 inch)
(continued)
106 SEBU8088-07
Maintenance Section
Generator Bearing Temperature - Test/Record

(Table 10, contd)

Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
311-0843 326 BC 1800 FR −40 °C EA6 Non- Non- Non- 130.0391
Ball 279.9817 ± (−40 °F) regreasable regreasable regreasable ± 0.0114
Bearing 0.0178 mm / bearing(1) bearing bearing mm
(11.0229 ± 80 °C (5.11965
.0007 inch) (176 °F) ± .00045
OD inch)

129.9870 ±
0.0127 mm
(5.1176 ±
.0005 inch)
ID
311-0844 322 BC 1600 FR −40 °C EA6 Non- Non- Non- 110.0239
Ball 239.9843 ± (−40 °F) regreasable regreasable regreasable ± 0.0089
Bearing 0.0152 mm / bearing(1) bearing bearing mm
(9.4482 ± 80 °C (4.33165
.0006 inch) (176 °F) ± .00035
OD inch)

109.9896 ±
0.0102 mm
(4.3303 ±
.0004 inch)
ID
253-9789 320 BC 1400 FR −29 °C UNIREX Non- Non- Non- 100.0100
Bearing 214.9856 ± (−20.2 °F) N3 regreasable regreasable regreasable ± 0.0076
0.0152 mm / bearing(1) bearing bearing mm
(8.4640 ± 80 °C (3.9374
.0006 inch) (176 °F) ± .0003
OD inch)

99.9896 ±
0.0102 mm
(3.9366 ±
.0004 inch)
ID
(1) This temperature is for a generator set that is equipped with a resistive temperature detector (RTD).
(2) Do not exceed 60 °C (140 °F) above the ambient temperature.
(3) This bearing can not be greased. Refer to this Operation and Maintenance Manual, “Generator Bearing - Replace” article for information
concerning the replacement of these bearings.
(2) Do not exceed 50 °C (122 °F) above the ambient temperature.

5. Wipe off the excess grease. Remove the top i03098750

grease fitting. Install the plug.
Generator Bearing
6. Operate the generator for one hour. This will allow Temperature - Test/Record
the grease to expand. The expanding grease will
force the excess grease from the cavity. When SMCS Code: 4471-081-TA
the excess grease is forced from the cavity, the
internal pressure will be reduced. The generator The monitoring of bearing temperature may prevent
should continue to operate until the grease stops premature bearing failure. A generator set should
purging. never operate above the recommended set points.
Keep records in order to monitor the changes in the
7. Stop the engine. Install the plug in the bottom temperature of the bearing.
grease pipe. Wipe off the excess grease.
Note: Measure the bearing temperature after the
8. Install the louver assembly or install the rear plate. generator reaches normal operating temperature.
SEBU8088-07 107
Maintenance Section
Generator Load - Check

Resistive Temperature Detectors Electric sets normally have a low idle setting that
is higher than industrial engines. Low idle will be
(RTDs) approximately 66 percent of the full speed that is
achieved by 60 Hz units. This would be equal to 80
Resistance temperature detectors for generator
percent of the full speed that is achieved by 50 Hz
bearings are optional on all Caterpillar Generators.
units.
These detectors are 100 ohm resistance temperature
detectors. A resistance temperature detector
Some electric sets are equipped with Woodward
may be monitored by the optional monitor for the
governors and some electric sets are equipped
EMCP 3.2/3.3 resistance temperature detector. A
with Caterpillar electronic governors. These electric
resistance temperature detector may be monitored by
sets have no low idle stop. On electric sets with
equipment that is provided by the customer. Consult
mechanical governors and natural gas electric sets,
with your Caterpillar dealer about other methods of
the low idle is set at the factory. Adjustment of the
measuring the bearing temperature.
low idle on these machines should only be done by
a Caterpillar dealer.
The EMCP 3.2/3.3 may be configured to “ALARM”
or the EMCP 3.2/3.3 may be configured to
Note: Operating the electric set at low idle speed for
“SHUTDOWN”. An alarm is activated if the
an extended time will cause some voltage regulators
temperature of the bearing reaches 85 °C (185 °F).
to shut off. The electric set must be completely shut
A shutdown occurs if the temperature of the bearing
down and the electric set must be restarted. This
reaches 95 °C (203 °F).
will allow the voltage regulator to again produce an
output.
Infrared Thermometers
Bearing temperatures can also be recorded with the i03292462

use of an infrared thermometer. Refer to Special

Publication, NENG2500, “Caterpillar Dealer Service
Generator Set - Test
Tools Catalog” for a variety of infrared thermometers. SMCS Code: 4450-081
Follow the instructions that come with your infrared
thermometer.

i01473721 Personal injury or death can result from high volt-

age.
Generator Load - Check
When power generation equipment must be in op-
SMCS Code: 4450-535-LA
eration to make tests and/or adjustments, high
voltage and current are present.
During normal operation, monitor the power factor
and monitor generator loading.
Improper test equipment can fail and present a
high voltage shock hazard to its user.
When a generator is installed or when a generator
is reconnected, ensure that the total current in any
Make sure the testing equipment is designed for
one phase does not exceed the nameplate rating.
and correctly operated for high voltage and cur-
Each phase should carry the same load. This allows
rent tests being made.
the generator to work at the rated capacity. If one
phase current exceeds the nameplate amperage,
When servicing or repairing electric power gener-
an electrical imbalance will occur. An electrical
ation equipment:
imbalance can result in an electrical overload and an
electrical imbalance can result in overheating.
• Make sure the unit is off-line (disconnected
from utility and/or other generators power
The power factor can be referred to as the efficiency
service), and either locked out or tagged DO
of the load. This can be expressed as the ratio of kVA
NOT OPERATE.
to actual kW. The power factor can be calculated by
dividing kW by kVA. Power factor is expressed as a
decimal. Power factor is used to mean the portion • Make sure the generator engine is stopped.
of current that is supplied to a system that is doing
useful work. The portion of the current that is not • Make sure all batteries are disconnected.
doing useful work is absorbed in maintaining the
magnetic field in motors. This current (reactive load) • Make sure all capacitors are discharged.
can be maintained without engine power.
108 SEBU8088-07
Maintenance Section
Generator Set Alignment - Check

NOTICE
DANGER: Shock/Electrocution Hazard-Do not op- Do not operate the generator set at a speed that is
erate this equipment or work on this equipment higher than one-half of the rated speed.
unless you have read and understand the instruc-
tions and warnings in the Operation and Mainte- Higher speeds under these test conditions can cause
nance Manual. Failure to follow the instructions or damage to the system.
heed the warnings will result in serious injury or
death.
4. Operate the generator set at half the rated speed.

Table 11 5. Measure the AC voltage across the low voltage

Tools Needed terminals of the transformer that correspond to the
following generator terminals: “T1” and “T2”, “T2”
Part Number Part Quantity and “T3”, and “T3” and “T1”. Record the voltages.
Digital
237-5130 1 6. Monitor the voltage between any two of the
Multimeter
locations in step 5. Decrease the generator set
12 VDC Battery 1 speed by 10 percent. Increase the generator set
Potential speed by 10 percent.
1
Transformer
7. The voltages that were measured in Step 5 should
be nearly equal. These voltages should measure
The generator set functional test is a simplified test a minimum of 85 VAC.
that can be performed in order to determine if the
generator is functional. The generator set functional 8. When the generator set speed is decreased by
test should be performed on a generator set that is 10 percent, the voltages that were measured in
under load. Step 6 should decrease by 10 percent. When the
generator set speed is increased by 10 percent,
The generator set functional test determines if the the voltages that were measured in Step 6 should
following statements happen: increase by 10 percent.
• A phase voltage is being generated.
i03100396
• The phase voltages are balanced.
Generator Set Alignment -
• The phase voltages change relative to engine
speed.
Check
(Generator Sets)
The generator set functional test consists of the
following steps: SMCS Code: 7002-024

1. Stop the generator. Connect the potential The alignment between the engine and the driven
transformer's high voltage winding to the equipment must be properly maintained in order to
generator terminals (T1) and (T2). Connect minimize the following problems:
the voltmeter to the low voltage winding. If two
transformers are available, connect the high • Bearing problems
voltage winding of the second transformer to the
generator terminals (T1) and (T3). Connect the • Vibration of the engine crankshaft
secondary terminals that correspond to generator
terminal (T2) of both transformers together. • Vibration of the driven equipment
2. Disconnect wires “F1+” and “F2-” from the voltage Refer to the following information for more information
regulator. Disconnect the generator from the load. about the alignment of the generator set:

3. Connect a 12 VDC automotive battery to wires • Special Instruction, SEHS7654, “Alignment -

“F1+” and “F2-”. General Instructions”

• Special Instruction, SEHS7259, “Alignment of

Single Bearing Generators”
SEBU8088-07 109
Maintenance Section
Generator Set Vibration - Test/Record

• Special Instruction, REHS0177, “Alignment of the When a generator set is installed, a vibration plot
Close Coupled Two Bearing Generators” should be recorded in order to assist in diagnosing
potential problems. This vibration plot should be
Keep a record of the measurement of the alignment. updated yearly. The vibration plot should also be
The record may be used to check the trend of the updated when the generator set is moved and
alignment. The record may be used to analyze the when the engine is overhauled. This will allow
trend of the alignment. the trend of the vibration to be monitored and
analyzed. A potential problem may be prevented by
The genset must be aligned when the genset is monitoring the trend of the vibration. If the vibration
moved into a final position. The genset must be is approaching the limit of the specification of the
aligned if the genset is moved into a different position. component, the problem may be more imminent.
Refer to Data Sheet, LEKQ4023, “Linear Vibration”
for the allowable limits of vibration.
i03100151

Generator Set Vibration - Caterpillar also recommends recording the vibration

of the bearing at the generator bearing bracket.
Test/Record
If the vibration exceeds the EDS limits for vibration,
SMCS Code: 4450-081-VI check the alignment. Refer to this Operation and
Maintenance Manual, “Product Alignment - Check”
Check for vibration damage. for the alignment procedure.

Vibration may cause the following problems: Contact the Caterpillar Dealer Service Tools group
for information on ordering a vibration analyzer that
• Coupling wear will meet your needs.

• Loose fittings
i02574347

• Fatigue of the metal components of the engine Heat Shield - Inspect/Replace

• Cracks in the cabinet which surrounds the SMCS Code: 1067-040; 1067-510
generator

• Cracks in welds NOTICE

Use caution when you inspect heat shields. Ensure
• Excessive noise that the engine is not running and ensure that the
engine components are cool before you touch heat
• Cracked insulation shields.

The following areas are susceptible to vibration Visually inspect all heat shields for signs of wear.
damage: Some unacceptable signs of wear are listed below.

• Coupling for the generator set • Outer covering that is chafed or cracked
• Generator bearings • Outer covering that is cut
• Stator output leads • Outer covering that shows signs of abrasion
• Protective sleeving • Fasteners that are loose or missing
• Insulation • Insulation material that is exposed
• Exposed electrical connections Replace all heat shields that show any signs of wear.

• Transformers
• Fuses
• Capacitors
• Lightning arresters
110 SEBU8088-07
Maintenance Section
Hoses and Clamps - Inspect/Replace

i02121526 • Anticipated expansion and contraction of the

fittings
Hoses and Clamps -
Inspect/Replace Replace the Hoses and the Clamps
SMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by the

following conditions: Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
• Cracking stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• Softness pressure cap slowly in order to relieve the pres-
sure.
• Loose clamps
1. Stop the engine. Allow the engine to cool.
Replace hoses that are cracked or soft. Tighten any
loose clamps. 2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
NOTICE system filler cap.
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair Note: Drain the coolant into a suitable, clean
any loose or damaged fuel and oil lines, tubes and container. The coolant can be reused.
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec- 3. Drain the coolant from the cooling system to a
ommended torque. level that is below the hose that is being replaced.

4. Remove the hose clamps.

Check for the following conditions:
5. Disconnect the old hose.
• End fittings that are damaged or leaking
6. Replace the old hose with a new hose.
• Outer covering that is chafed or cut
7. Install the hose clamps with a torque wrench.
• Exposed wire that is used for reinforcement
Note: Refer to the Specifications, SENR3130,
• Outer covering that is ballooning locally “Torque Specifications” in order to locate the proper
torques.
• Flexible part of the hose that is kinked or crushed
8. Refill the cooling system.
• Armoring that is embedded in the outer covering
9. Clean the cooling system filler cap. Inspect the
A constant torque hose clamp can be used in place cooling system filler cap's gaskets. Replace
of any standard hose clamp. Ensure that the constant the cooling system filler cap if the gaskets are
torque hose clamp is the same size as the standard damaged. Install the cooling system filler cap.
clamp.
10. Start the engine. Inspect the cooling system for
Due to extreme temperature changes, the hose will leaks.
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.

Each installation application can be different. The

differences depend on the following factors:

• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
SEBU8088-07 111
Maintenance Section
Insulation - Test

i03230486 • The generator set has not been run under load
for three months. Test the generator set weekly.
Insulation - Test Use space heaters around the generator set if the
generator is exposed to a sea water environment or
SMCS Code: 4453-081; 4454-081; 4457-081; if the humidity is above 75 percent. Also use space
4470-081 heaters if a test result was below 3 megohms.

Recommended Periodic Insulation Space heaters must be used whenever the generator
set is not under load. Space heaters must also be
Tests used whenever salt is present or whenever high
humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester
readings above one megohm. Use space heaters
The high voltage that is produced by an operating only when the generator is not running.
generator set can cause severe injury or death.
Before performing any maintenance or repairs, For additional information, refer to Special Instruction,
ensure that the generator will not start. SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start- Recommended Procedure for the
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and Insulation Test
automatic transfer switches that are associated
with the generator.

Table 12 Personal injury or death can result from electro-

cution.
Tools Needed
Part Number Part Name Quantity The megohmmeter is applying a high voltage to
the circuit.
300-8648 Insulation 1
Testing Gp
To avoid electrocution, do not touch the instru-
ment leads without first discharging them. When
Periodically, use an insulation tester to check the finished testing also discharge the generator
insulation resistance of the generator's main stator windings.
winding. The frequency of this test is determined by
the generator's environment. Previous insulation
tester readings will also determine the frequency of 1. Take the generator out of service.
this test.
2. Visually inspect the generator for moisture. If
Test the main stator windings with an insulation tester moisture exists, do not perform this insulation
in the following situations: test. Dry the unit first. Refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
• The generator set is started for the first time. Generators”.

• The generator set is removed from storage. 3. Inspect the installation. Determine the equipment
that will be tested by the insulation tester.
• The generator set is operating in a humid
environment. Test every three months. 4. Discharge the capacitance of the windings.

• The generator set is not protected from the 5. Disconnect “T0” from ground.
elements in an enclosed area. Test every three
months. 6. Disconnect the sensing lead wires for the
regulator. This may be accomplished by
• The generator set is installed in an enclosed area. unplugging the harness connectors.
This area needs to be low in humidity and this area
needs to have steady temperatures. Test every 7. Connect the insulation tester's RED lead to
twelve months (minimum). ground.

8. Connect the insulation tester's BLACK lead to

“T0”.
112 SEBU8088-07
Maintenance Section
Insulation - Test

9. For units that are 600 volts or less, set the voltage
to 500 Volts. For units that are more than 600
volts, set the voltage to 1000 Volts.

10. Use the 30/60 Time Resistance Method:

a. Apply voltage.

b. Observe the readings at 30 seconds. Observe

the readings at 60 seconds.

c. Record the 60 second reading. This reading

must be corrected for temperature.

d. Record temperature.

e. Record humidity.

f. Remove voltage.

11. Evaluate the readings. The actual value of the

resistance may vary greatly between generators.
For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
the readings that were taken on previous dates.
These two readings must be taken under similar
conditions. If a 60 second resistance reading
has a 50 percent reduction from the previous
reading, the insulation may have absorbed too
much moisture.

Switch the insulation tester to the “OFF” position.

This will discharge the insulation tester's leads.
Disconnect the insulation tester's leads.

Note: The results from the insulation resistance

checks indicate when cleaning and/or repairing is
becoming critical. Generally, insulation resistance
will vary greatly with temperature. Therefore, always
test at the same temperature and humidity. Refer to
Illustration 69.

Engine Serial Number_____________________________________

Serial Number for the Generator________________________

SEBU8088-07 113
Maintenance Section
Insulation - Test

g00633226
Illustration 69
114 SEBU8088-07
Maintenance Section
Jacket Water Heater - Check

i01917546 The oil consumption rate (brake specific oil

consumption) is measured in grams per kW/h (lb per
Jacket Water Heater - Check bhp). The brake specific oil consumption (BSOC)
(Standby Generator Sets (If depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
Equipped)) consumption rate for your engine.

SMCS Code: 1383-535 When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
Jacket water heaters help to improve startability in wear, an engine overhaul should be scheduled.
ambient temperatures that are below 21 °C (70 °F). There may be a corresponding increase in blowby
All installations that require automatic starting should and a slight increase in fuel consumption.
have jacket water heaters.
Overhaul Options
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 °F), the heater
Using Fuel Consumption For Calculating the
should maintain the jacket water coolant temperature Overhaul Intervals
at approximately 32 °C (90 °F).
Experience has shown that maintenance intervals
i03257588 are most accurately based on fuel consumption. Fuel
consumption corresponds more accurately to the
Overhaul Considerations engine load. Table 13 and 14 lists average ranges of
fuel consumption for a load factor of approximately
SMCS Code: 7595-043 60 percent.

Reduced hours of operation at full load will result in a Table 13

lower average power demand. A decreased average Service Hours and Fuel Consumption for
power demand should increase both the engine C27 Generator Set(1)
service life and the overhaul interval.
Top End 7500 Service Hours
The need for an overhaul is generally indicated by Overhaul
804399 L (212500 US gal)
increased fuel consumption and by reduced power.
Major 15000 Service Hours
The following factors are important when a decision Overhaul
1608799 L (425000 US gal)
is being made on the proper time for an engine (1) Fuel consumption is based on a load factor of approximately
overhaul: 60 percent.

• The need for preventive maintenance Table 14

Service Hours and Fuel Consumption for
• The quality of the fuel that is being used C32 Generator set(1)
• The operating conditions Top End 7500 Service Hours
Overhaul
946360 L (250000 US gal)
• The results of the S·O·S analysis
Major 15000 Service Hours
Overhaul
Oil Consumption as an Overhaul 1892700 L (500000 US gal)
Indicator (1) Fuel consumption is based on a load factor of approximately
60 percent.
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total Table 15
operating cost for your Caterpillar engine. Oil Equation For Calculating Overhaul Intervals
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable F/R = H
for the maintenance intervals. “F” is the estimated total amount of fuel consumption of
the engine.
Oil consumption is in proportion to the percentage
“R” is the rate of fuel consumption in liters per hour or
of the rated engine load. As the percentage of the gallons per hour.
engine load is increased, the amount of oil that is
consumed per hour also increases. “H” is the number of estimated hours until the overhaul
interval.
SEBU8088-07 115
Maintenance Section
Overhaul Considerations

Use the actual records of fuel consumption, when Note: Overhaul programs vary according to the
possible. If the actual records are not available, use engine application and according to the dealer that
the following procedure in order to estimate the fuel performs the overhaul. Consult your Caterpillar
consumption. dealer for specific information about the available
overhaul programs and about overhaul services for
1. Estimate the average percent of the load for the extending the engine life.
operation of the engine.
If an overhaul is performed without overhaul service
2. Refer to the data for fuel consumption in the from your Caterpillar dealer, be aware of the following
Technical Marketing Information (TMI) for your maintenance recommendations.
engine. This will determine the fuel consumption
for the percent of the load that was estimated Unit Fuel Injector
in Step 1. Use this figure as variable “F” for the
equation in Table 15. For more information about Clean the fuel injector body and replace the O-rings.
the Technical Marketing Information (TMI) for your Replace the O-rings and the gasket on the injector
engine, consult your Caterpillar dealer. sleeve. Clean the area around the injector seating
in the injector sleeve. Refer to the Service Manual
Before Failure Overhaul for the complete procedure, or consult with your
Caterpillar dealer for assistance.
A planned overhaul before failure may be the best
value for the following reasons:
Rebuild or Exchange
• Costly unplanned downtime can be avoided. Cylinder Head Assembly, Connecting Rods,
Pistons, Cylinder Liners, Turbocharger, Cylinder
• Many original parts can be reused according to the Packs, Oil Pump, and Fuel Transfer Pump
standards for reusable parts.
These components should be inspected according to
• The engine service life can be extended without the the instructions that are found in various Caterpillar
risk of a major catastrophe due to engine failure.
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
• The best cost/value relationship per hour of needed for inspecting the engine parts.
extended life can be attained.
If the parts comply with the established inspection
After Failure Overhaul
specifications that are expressed in the reusable
parts guideline, the parts should be reused.
If a major engine failure occurs and the engine
must be removed, many options are available. An
overhaul should be performed if the engine block or Parts that are not within the established inspection
specifications should be dealt with in one of the
the crankshaft needs to be repaired.
following manners:
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40 • Salvaging
percent and 50 percent of the cost of a new engine
with a similar exchange core. • Repairing

This lower cost can be attributed to three aspects: • Replacing

Using out-of-spec parts can result in the following
• Specially designed Caterpillar engine features problems:
• Caterpillar dealer exchange components
• Unscheduled downtime
• Caterpillar Inc. remanufactured exchange
components • Costly repairs
• Damage to other engine parts
Overhaul Recommendation
• Reduced engine efficiency
To minimize downtime, a scheduled engine overhaul
by your Caterpillar dealer is recommended. This will • Increased fuel consumption
provide you with the best cost/value relationship.
116 SEBU8088-07
Maintenance Section
Overhaul Considerations

Reduced engine efficiency and increased fuel • Camshaft bearings

consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing • Camshaft followers
out-of-spec parts or replacing out-of-spec parts.
Caterpillar Inc. recommends replacing the crankshaft
Inspection and/or Replacement vibration damper.

Piston Rings, Crankshaft Bearings, Valve Oil Cooler Core and Aftercooler Core
Rotators, and Crankshaft Seals
During an overhaul, the removal of the oil cooler
The following components may not last until the core and the aftercooler core is recommended. The
second overhaul. oil cooler core and the aftercooler core should be
cleaned and pressure tested.
• Thrust bearings
NOTICE
• Main bearings Do not use caustic cleaners to clean the core.

• Rod bearings Caustic cleaners can attack the internal metals of the
core and cause leakage.
• Valve rotators
• Crankshaft seals Note: Use this cleaning procedure to clean the oil
cooler core and the aftercooler core.
Caterpillar Inc. recommends the installation of new
parts at each overhaul period. 1. Remove the oil cooler core and the aftercooler
core.
Inspect these parts while the engine is disassembled
for an overhaul. 2. Remove any debris from the oil cooler core and
the aftercooler core. To remove debris from the oil
Inspect the crankshaft for any of the following cooler core, turn the oil cooler core onto one end.
conditions: To remove debris from the aftercooler core, turn
the aftercooler core upside-down.
• Deflection
3. Flush the oil cooler core and the aftercooler core
• Damage to the journals internally with cleaner in order to loosen foreign
substances. This will also help to remove oil from
• Bearing material that has seized to the journals the oil cooler core and the aftercooler core.

Check the journal taper and the profile of the Note: The use of Hydrosolv Liquid Cleaners is
crankshaft journals. Check these components by recommended. Table 16 lists the Hydrosolv Liquid
interpreting the wear patterns on the following Cleaners that are available from your Caterpillar
components: dealer.

Table 16
• Rod bearing
Hydrosolv Liquid Cleaners(1)
• Main bearings Part
Description Size
Number
Note: If the crankshaft is removed for any reason,
use the magnetic particle inspection process to check 1U-5490 Hydrosolv 4165 19 L (5 US gallon)
for cracks in the crankshaft. 174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner
Inspect the camshaft for damage to the journals and
at temperatures up to 93°C (200°F). Refer to Application
to the lobes. Guide, NEHS0526 or consult your Caterpillar dealer for more
information.
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for 4. Use steam to clean the oil cooler core and the
cracks in the camshaft. aftercooler core. This removes any remaining
residue from the cleaner. Flush the fins of the oil
Inspect the following components for signs of wear or cooler core and the aftercooler core. Remove any
for signs of scuffing: other trapped debris.
SEBU8088-07 117
Maintenance Section
Power Factor - Check

5. Wash the oil cooler core and the aftercooler core • Identification of contaminants
with hot, soapy water. Rinse the oil cooler core and
the aftercooler core thoroughly with clean water. • Identification of built up impurities (corrosion and
scale)

S·O·S Coolant Analysis (Level 2) provides a report of

the results of both the analysis and the maintenance
Personal injury can result from air pressure. recommendations.
Personal injury can result without following prop- For more information about coolant analysis, consult
er procedure. When using pressure air, wear a pro- your Caterpillar dealer.
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less i01216962

than 205 kPa (30 psi) for cleaning purposes.
Power Factor - Check
6. Dry the oil cooler core and the aftercooler core SMCS Code: 4450-535-PWR
with compressed air. Direct the air in the reverse
direction of the normal flow. The power factor of a system can be determined by
a power factor meter or by calculations. The power
7. Inspect the components in order to ensure factor can be calculated by dividing kW by kVA.
cleanliness. The oil cooler core and the aftercooler Power factor is expressed as a decimal.
core should be pressure tested. Repair the oil
cooler core and the aftercooler core, if necessary.
Install the oil cooler core and the aftercooler core. i02569617

For more information about cleaning the cores, Prelube Pump - Inspect
consult your Caterpillar dealer.
SMCS Code: 1319-040
Obtain Coolant Analysis Inspect the prelube pump for the following conditions:
The concentration of supplemental coolant additive • Cracks
(SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level 1). Further • Pin holes
coolant analysis is recommended when the engine
is overhauled. • Proper operation
A coolant analysis can be conducted in order to verify • Wear
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained If repair or replacement is necessary, see the
by consulting your local water utility company or literature that is provided by the OEM of the pump.
an agricultural agent. Private laboratories are also Consult your Caterpillar dealer for assistance.
available for water analysis.

Caterpillar Inc. recommends an S·O·S Coolant i02559063

Analysis (Level 2).
Radiator - Clean
S·O·S Coolant Analysis (Level 2)
SMCS Code: 1353-070
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely Note: Adjust the frequency of cleaning according to
analyzes the coolant and the effects on the cooling the effects of the operating environment.
system. An S·O·S Coolant Analysis (Level 2) provides
the following information: Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
• Complete S·O·S Coolant Analysis (Level 2) debris. Clean the radiator, if necessary.

• Visual inspection of properties

• Identification of metal corrosion
118 SEBU8088-07
Maintenance Section
Rotating Rectifier - Check

Testing a Three-Diode Rectifier

Block
Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction
of the fan's air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.

Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from g00610240
both sides. Illustration 70

Use a degreaser and steam for removal of oil and

grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.

After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.

Inspect the fins for damage. Bent fins may be opened

with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning and

inspection, refer to Special Publication, SEBD0518,
“Know Your Cooling System”.
g00613971
Illustration 71
Three-Diode Rectifier Block (two pieces)
i02246950

Rotating Rectifier - Check The following procedure tests all three diodes within
a block. Check the positive rectifier block and the
SMCS Code: 4465-535 negative rectifier block. If any meter reading does not
fall within the given ranges, replace the rectifier block.
Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected, 1. Set the digital multimeter on the diode range.
proceed to the “Testing a Three-Diode Rectifier Remove all leads from the rectifier block.
Block” section.
2. To test the negative rectifier block, follow these
steps:
SEBU8088-07 119
Maintenance Section
Space Heater - Check

a. Place the red test lead on the negative “-”

terminal. Place the black test lead on the
following rectifier terminals: “AC1”(3), “AC2”(4),
and “AC3”(5). All readings on the meter should
be between 0.4 and 1.0.

b. Place the black test lead on the negative

“-” terminal. Place the red test lead on the
following rectifier terminals: “AC1”(3), “AC2”(4),
and “AC3”(5). In all cases, the meter should
read “OL” (overload).

3. To test the positive rectifier block, follow these

steps:
g00610396
a. Place the red test lead on the positive “+” Illustration 72
rectifier terminal. Place the black test lead Space Heater Connection Diagram
on the following rectifier terminals: “AC1”(3),
“AC2”(4), and “AC3”(5). In all cases, the meter An SR5 generator can operate in high humidity
should read “OL” (overload). conditions without problems. The humidity can be as
high as 100% non-condensing humidity. However,
b. Place the black test lead on the positive “+” problems can occur when the generator is idle and
rectifier terminal. Place the red test lead on the the surrounding air is warmer than the generator.
following rectifier terminals: “AC1”(3), “AC2”(4), Moisture can form on the windings. Moisture will
and “AC3”(5). All readings on the meter should result in poor performance or even damage to the
be between 0.4 and 1.0. windings. Whenever the generator is not active, the
optional space heaters should be operated.
Note: A shorted diode can cause damage to the
exciter rotor. If a diode is shorted, check the exciter An external source is required to operate the space
rotor. Refer to the Testing and Adjusting, “Winding - heaters. Both of the sources must be a single phase.
Test” and Testing and Adjusting, “Insulation - Test”. This source can be either 115 vac or 230 vac. When
Perform these tests. the external source is 50 hertz, 200 vac must be
used. Refer to Illustration 72.
Note: This rectifier block also contains varistor “CR7”.
“CR7” can be checked by measuring the resistance See your Caterpillar dealer for information on
between the positive “+” rectifier terminal and the checking your Caterpillar generator.
negative “-” rectifier terminal. The resistance should
be a minimum of 15000.
i02627547

i02985289
Speed Sensor - Clean/Inspect
Space Heater - Check SMCS Code: 1907-040; 1907-070

SMCS Code: 4450-535-HTR The C32 Generator Set has three different speed
sensors.
The space heater is attached to the rear bearing
bracket. The space heater is located in the
generator's exciter end.
120 SEBU8088-07
Maintenance Section
Speed Sensor - Clean/Inspect

g01184155
Illustration 75

1. Remove the sensor. Inspect the condition of the

end of the magnet. Look for signs of wear and
contaminants.

2. Clean any debris from the face of the magnet.

3. Check the tension of the sliphead. Gently extend

sliphead (4) for a minimum of 4 mm (0.16 inch).
Then push back the sliphead.

When the sliphead has the correct tension, at

Illustration 73
g01184074 least 22 N (5 lb) of force is required to push in the
sliphead from the extended position.
One speed/timing sensor (1) is mounted in the
camshaft cover. A second speed/timing sensor (2) is NOTICE
mounted in the front housing. Both of these sensors The sliphead must be fully extended when the speed/
are pulled into position by a bolt. timing sensor is installed so that the sensor maintains
the correct clearance with the speed-timing wheel.
1. Remove the speed/timing sensors from the front If the correct clearance is not maintained, the signal
housing. Check the condition of the plastic end from the sensor will not be generated.
of the speed/timing sensors for wear and/or
contaminants. Do not install the sensor between the teeth of the
speed-timing wheel. Damage to the sensor would re-
2. Clean the metal shavings and other debris from sult. Before installing the sensor, ensure that a tooth
the face of the speed/timing sensors. Use the of the wheel is visible in the mounting hole for the sen-
procedure in the Service Manual in order to sor.
calibrate the speed/timing sensors.
4. Install the engine speed/timing sensor.

a. Ensure that a tooth on the speed-timing wheel

is visible in the mounting hole for the sensor.

b. Extend sliphead (2) by a minimum of 4 mm

(0.16 inch).

c. Coat the threads of the sensor with 4C-5597

Anti-Seize Compound.

Note: The sliphead is designed to contact a tooth

during the first revolution of the speed-timing wheel.
For the maximum allowable clearance between
Illustration 74
g01184093 the sliphead and the tooth, refer to the engine's
Specifications manual.
The third speed/timing sensor has a threaded end,
and screws directly into the flywheel housing. d. Install the sensor. Tighten the sensor to
40 ± 5 N·m (30 ± 4 lb ft).
SEBU8088-07 121
Maintenance Section
Standby Generator Set Maintenance Recommendations

i03108463 Maintenance and Repair

Standby Generator The maintenance that is recommended for Every
Set Maintenance Week can be performed by an authorized operator.
The maintenance that is recommended for the
Recommendations subsequent maintenance intervals must be
performed by an authorized service technician or by
SMCS Code: 4450-041 your Caterpillar dealer.

A standby generator set may not need to be used Unless other instructions are provided, perform
very often. However, the generator set is usually maintenance and repairs under the following
needed for operation in an emergency situation. conditions:
Maintenance of the standby generator set is very
important for the following reasons: • The engine is stopped.
• The generator set must always be in excellent • The starting system is disabled.
operating condition.
• The generator does not pose an electrical shock
• The generator set must be ready to work under hazard.
load at any time.
• The generator is disconnected from the load.
Establishing a Preventive Maintenance Program will
provide these benefits: Operation
• Maximum availability of the standby generator set To ensure proper operation, the generator set must be
exercised regularly. For instructions on operating the
• Longer service life for the generator set generator set, see the Operation and Maintenance
Manual for the generator set control panel.
• Minimum of expensive repairs
For these operation procedures, follow the
Your Caterpillar dealer can help you to establish an
instructions that are provided in this Operation and
effective Preventive Maintenance Program for your Maintenance Manual, “Operation Section”: starting
generator set. Consult your Caterpillar dealer for
the engine, engine operation, and stopping the
details.
engine.

Maintenance and Operation Record Keeping

Procedures
Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems, and repairs.
The high voltage that is produced by an operating
generator set can cause severe injury or death. Space Heaters
Before performing any maintenance or repairs,
ensure that the generator will not start. Moisture causes damage to generators and other
electrical equipment. Make every effort to keep the
Place the engine control switch in the “OFF” posi- generator set as dry as possible.
tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable Generators can operate without problems in humid
the starting system. Lock out all switchgear and environments. However, problems can occur when
automatic transfer switches that are associated the generator is inactive. Moisture can condense on
with the generator. the windings. This can result in poor performance.
Also, damage to the windings can occur.

The recommended maintenance for the generator set Use space heaters in order to help keep the windings
is listed in this Operation and Maintenance Manual, dry. When the generator is not active, ensure that the
“Maintenance Interval Schedule (Standby Generator space heaters are operating. When the generator is
Sets)” (Maintenance Section). operating, turn OFF the space heaters.
122 SEBU8088-07
Maintenance Section
Starting Motor - Inspect

i02618737 The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine
Starting Motor - Inspect to start properly. The engine will not start if the
(If equipped) starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
SMCS Code: 1451-040; 1453-040 the flywheel ring gear can be damaged because of
irregular engagement.
Air Starting Motor Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
If the starting motor fails, the engine may not start in teeth of the starting motor pinion and the flywheel
an emergency situation. A scheduled inspection of ring gear. Look for patterns of wear on the teeth. Look
the starting motor is recommended. for teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
The starting motor pinion and the flywheel ring gear ring gear must be replaced.
must be in good condition in order for the engine
to start properly. The engine will not start if the Problems with the electric starting motor can be
starting motor pinion does not engage the flywheel caused by the following conditions: malfunction of
ring gear. The teeth of the starting motor pinion and the solenoid and malfunction of the electric starting
the flywheel ring gear can be damaged because of system.
irregular engagement.
Inspect the electrical system for the following
Inspect the starting motor for proper operation. Listen conditions:
for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel • Loose connections
ring gear. Look for patterns of wear on the teeth. Look
for teeth that are broken or chipped. If damaged teeth • Corrosion
are found, the starting motor pinion and the flywheel
ring gear must be replaced. • Wires that are worn or frayed
• Cleanliness

Personal injury or death can result from improp- Removal and Installation of the
erly checking for a leak.
Starting Motor
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure, Refer to the Service Manual, “Disassembly and
even a pin-hole size leak, can penetrate body tis- Assembly” module for information on removing the
sue causing serious injury, and possible death. starting motor and installing the starting motor.

If fluid is injected into your skin, it must be treated Consult your Caterpillar dealer for assistance and/or
immediately by a doctor familiar with this type of for options on replacement of the starting motor.
injury.
i03230840

Inspect all of the components in the air circuit for

the starting motor. Inspect all of the air lines and
Stator Lead - Check
connections for leaks. SMCS Code: 4459-535
If damaged teeth are found, the air circuit for Ensure that the stator output leads are routed out of
the starting motor must be examined in order to the generator in a manner that prevents the leads
determine the cause of the problem. from rubbing against metal objects.

Electric Starting Motor Visually inspect the following areas for cracking and
physical damage:
If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of • stator output leads
the starting motor is recommended.
• protective sleeving
• insulation
SEBU8088-07 123
Maintenance Section
Stator Winding Temperature - Measure/Record

i03086301
NOTICE
Stator Winding Temperature - Turbocharger bearing failures can cause large quan-
Measure/Record tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
SMCS Code: 4453-082-TA damage.

Some generators are equipped with optional 100 Minor leakage of a turbocharger housing under ex-
Ohm Resistance Temperature Detectors(RTD) that tended low idle operation should not cause problems
are mounted in slots of the main stator. When the as long as a turbocharger bearing failure has not oc-
generator set is equipped with RTD modules that curred.
are interfaced to an EMCP 3.2 or EMCP 3.3, the
RTD modules can be interfaced in order to measure When a turbocharger bearing failure is accompanied
the temperature of the stator. Alternately, there are by a significant engine performance loss (exhaust
measuring devices in the open market that can be smoke or engine rpm up at no load), do not continue
interfaced with the RTD. Caterpillar recommends the engine operation until the turbocharger is repaired or
continuous monitoring of the RTD. replaced.

Refer to the specifications in table 17 for the

An inspection of the turbocharger can minimize
maximum temperatures of the setpoints.
unscheduled downtime. An inspection of the
Table 17 turbocharger can also reduce the chance for potential
damage to other engine parts.
Maximum Recommended Temperatures
for the Setpoint(1) Note: Turbocharger components require precision
Generator set clearances. The turbocharger cartridge must
Alarm Shutdown be balanced due to high rpm. Severe Service
application
Applications can accelerate component wear.
Standby 180 °C 190 °C
Severe Service Applications require more frequent
(356 °F) (374 °F)
inspections of the cartridge.
Continuous 155 °C 165 °C
(311 °F) (329 °F)
(1)
Removal and Installation
If the trend of the operating temperature of the main stator
is measured and the temperature is much lower than the
recommended setpoints, adjust the alarm setpoint and the
For options regarding the removal, installation, repair
shutdown setpoint to a lower value in order to ensure that and replacement, consult your Caterpillar dealer.
unusual temperature variances are recognized promptly. Refer to the Service Manual for this engine for the
procedure and specifications.
i01539769
Cleaning and Inspecting
Turbocharger - Inspect
1. Remove the exhaust outlet piping and remove
SMCS Code: 1052-040 the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean
Periodic inspection and cleaning is recommended the interior of the pipes in order to prevent dirt
for the turbocharger compressor housing (inlet side). from entering during reassembly.
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil 2. Turn the compressor wheel and the turbine wheel
and from combustion can collect in the turbocharger by hand. The assembly should turn freely. Inspect
compressor housing. Over time, this buildup can the compressor wheel and the turbine wheel for
contribute to loss of engine power, increased black contact with the turbocharger housing. There
smoke and overall loss of engine efficiency. should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
If the turbocharger fails during engine operation, turbocharger housing. If there is any indication of
damage to the turbocharger compressor wheel contact between the rotating turbine wheel or the
and/or to the engine may occur. Damage to the compressor wheel and the turbocharger housing,
turbocharger compressor wheel can cause additional the turbocharger must be reconditioned.
damage to the pistons, the valves, and the cylinder
head.
124 SEBU8088-07
Maintenance Section
Varistor - Test

3. Check the compressor wheel for cleanliness. i01494879

If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering Varistor - Test
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger SMCS Code: 4466-081
oil seal.

The presence of oil may be the result of extended

engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
turbocharger to slobber.

4. Use a dial indicator to check the end clearance

on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.

5. Inspect the bore of the turbine housing for

corrosion.

6. Clean the turbocharger housing with standard

shop solvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outlet

piping to the turbocharger housing.
g00677004
Illustration 76
PMPE Generator Wiring Diagram
(CR1-CR6) Diodes
(CR7) Varistor
(L1) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer

Ohmmeter
An ohmmeter can be used to check a varistor
(CR7). Place an ohmmeter across the varistor. The
resistance should be a minimum of 15000 ohms. If
the resistance is less than 15000 ohms, the varistor
is faulty.
SEBU8088-07 125
Maintenance Section
Voltage and Frequency - Check

Test Light i02591373

Walk-Around Inspection
SMCS Code: 1000-040

Personal injury or death can result from improper

troubleshooting and repair procedures.

The following troubleshooting and repair proce-

dures should only be performed by qualified per-
sonnel familiar with this equipment.

Illustration 77
g00555113
Inspect the Engine for Leaks and
Test Light
for Loose Connections
Refer to the test light that is shown in Illustration 77. A walk-around inspection should only take a few
Follow these steps in order to test the varistor: minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
1. Disconnect either lead of the varistor (CR7).
For maximum engine service life, make a thorough
2. Place the test light across the varistor. inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
3. Observe the results. The lamp should not light. leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
4. Reverse the test light.

5. Observe the results. The lamp should not light.

• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
If the test light illuminates in either direction, there is
a short in the varistor. Replace any faulty varistors
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
with varistors that have comparable operating contamination.
characteristics. Include the following information
when a varistor is being ordered for replacement:
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
• Part number of the varistor
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
• Serial number of the generator
more often than recommended until the leak is found
After the varistor has been replaced, verify that the or fixed, or until the suspicion of a leak is proved to be
strapping of the field winding lead is securely wound unwarranted.
on the shaft. Also, verify that the strapping of the field
winding lead is securely tied. NOTICE
Accumulated grease and/or oil on an engine or deck is
i01491868
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
Voltage and Frequency - Check
SMCS Code: 4450-535-EL • Ensure that cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
Check for the proper voltage setting and check for
the proper frequency setting. Check for stability. • Inspect the water pump for coolant leaks.
Note: The water pump seal is lubricated by coolant
For the correct voltage and frequency, refer to the
in the cooling system. It is normal for a small amount
generator set's Serial Plate.
of leakage to occur as the engine cools down and
the parts contract.
126 SEBU8088-07
Maintenance Section
Water Pump - Inspect

Excessive coolant leakage may indicate the need A visual inspection should be initially directed at
to replace the water pump seal. For the removal of the areas that are most prone to damage and
water pump and the installation of water pump and/or deterioration. The most prone areas to damage and
seals, refer to the Service Manual for the engine or deterioration are listed below:
consult your Caterpillar dealer.
Ground insulation – Ground insulation is insulation
• Inspect the lubrication system for leaks at the front that is intended to isolate components that are
crankshaft seal, the rear crankshaft seal, the oil carrying current from components that are not
pan, the oil filters and the valve cover. carrying current.

• Inspect the Closed Crankcase Ventilation (CCV) Support insulation – Support insulation is usually
filter, if equipped. If the restriction indicator is made from one of the following items: a compressed
visible, service the CCV. lamination of fibrous materials, polyester, or felt pads
that have been impregnated with various types of
• Inspect the fuel system for leaks. Look for loose bonding agents.
fuel line clamps.
There are many different types of damage that can
• Inspect the piping for the air inlet system and the occur in these areas. Several of the different types of
elbows for cracks and for loose clamps. damage are listed below:

• Inspect the alternator belt and the accessory drive Thermal aging – Thermal aging can cause the
belts for cracks, breaks or other damage. degradation of insulation or the deterioration of
insulation. An examination of the coils may reveal
Belts for multiple groove pulleys must be replaced as that the insulation has expanded into the ventilation
matched sets. If only one belt is replaced, the belt will ducts. This is the result of a loss of bond which
carry more load than the belts that are not replaced. will cause the insulation material to separate. The
The older belts are stretched. The additional load on insulation material could also separate from the
the new belt could cause the belt to break. conductors on the windings.

• Drain the water and the sediment from fuel tanks Abrasion – The surfaces of coils and the surfaces
on a daily basis in order to ensure that only clean of connectors may be damaged by abrasion. These
fuel enters the fuel system. surfaces may also be damaged by contamination
from other sources. An example of these sources
• Inspect the wiring and the wiring harnesses for would be chemicals or abrasive substances.
loose connections and for worn wires or frayed
wires. Cracking – Cracking of insulation may result from
mechanical stress. The structure that is used to brace
• Inspect the ground strap for a good connection and the stator winding will become loose if the problem
for good condition. is not corrected. Further mechanical damage or
electrical damage may also result.
• Inspect the engine-to-frame ground strap for a
good connection and for good condition. Erosion – Erosion can be caused when foreign
substances rub against the insulation that is on the
• Disconnect any battery chargers that are not surface of the coil .
protected against the current drain of the starting
motor. Check the condition and the electrolyte level
i01057943
of the batteries, unless the engine is equipped with
a maintenance free battery. Water Pump - Inspect
• Check the condition of the gauges. Replace any SMCS Code: 1361-040
gauges that are cracked. Replace any gauges that
can not be calibrated. A failed water pump might cause severe engine
overheating problems that could result in the following
Inspect the Generator conditions:

Refer to Safety Section, “Generator Isolating for • Cracks in the cylinder head
Maintenance” for information regarding the procedure
to safely isolate the generator. • A piston seizure
• Other potential damage to the engine
SEBU8088-07 127
Maintenance Section
Winding - Test

Visually inspect the water pump for leaks. If any Table 18

leaking is observed, replace the water pump seal Tools Needed
or the water pump assembly. Refer to the Service
Manual for the disassembly and assembly procedure. Part Number Part(1) Quantity
Digital
Note: Refer to the Service Manual or consult your 6V-7070 1
Multimeter
Caterpillar dealer if any repair is needed or any
replacement is needed. Digital
146-4080 Multimeter 1
(RS232)
i02903565 (1) Only one multimeter is necessary for this test. Either of the
Winding - Test multimeters that are shown will work.

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

4470-081
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.

Place the engine control switch in the “OFF” posi-

tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.

Measure the resistance of the following windings:

(L1), (L2), (L3), (L4), and (L5). The winding that
is being tested must be disconnected from the
other components before the resistance can be
measured. The following resistance measurements
are approximations. If the measured value is
not near the listed approximation, the winding is
probably damaged. For a more precise resistance
value, consult the Technical Marketing Information
(TMI). Refer to the generator arrangement that is in
question.

Note: The winding temperature affects the

resistance. When the winding temperature increases,
the winding resistance also increases. When
g01445763 the winding temperature decreases, the winding
Illustration 78
resistance also decreases. Therefore, a correct
PMPE generator wiring diagram measurement can be performed only when the
(1) Voltage regulator and/or related components winding is at room temperature.
(CR1) Diode
(CR2) Diode
(CR3) Diode The following armature windings have very little
(CR4) Diode resistance: (L2), (L4), and (L5). The resistance of
(CR5) Diode these windings will measure near 0 ohms. Use a
(CR6) Diode milliohmmeter to measure the resistance of the
(CR7) Varistor
(L1) Exciter field (stator)
armature windings.
(L2) Exciter armature (rotor)
(L3) Main field (rotor) Exciter armature (rotor) – less than 0.1 ohm
(L4) Main armature (stator)
(L5) Pilot exciter armature Main armature (stator) – less than 0.1 ohm
(PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer Pilot exciter armature (L5) – less than 0.1 ohm

Use a multimeter in order to measure the resistance

of field windings (L1) and (L3).
128 SEBU8088-07
Maintenance Section
Winding - Test

Exciter field (stator) (L1) – approximately 3.0 ohms

to 6.0 ohms

Main field (rotor) (L3) – approximately 1.25 ohms

to 2.0 ohms

Note: There should be no continuity between any

winding and ground. There should be no continuity
between any winding and another winding.