Escolar Documentos
Profissional Documentos
Cultura Documentos
November 2016
Operation and
Maintenance
Manual
G3500 Generator Sets
CWW 1-UP (Generator Set) F6F 1-UP (Generator Set)
CWY 1-UP (Generator Set) F6G 1-UP (Generator Set)
TJB 1-UP (Generator Set) FZA 1-UP (Generator Set)
TJC 1-UP (Generator Set) FZB 1-UP (Generator Set)
B9P 1-UP (Generator Set) FZC 1-UP (Generator Set)
MAD 1-UP (Generator Set) FZD 1-UP (Generator Set)
HAT 1-UP (Generator Set) FZE 1-UP (Generator Set)
HAL 1-UP (Generator Set) FZF 1-UP (Generator Set)
SLY 1-UP (Generator Set) FZG 1-UP (Generator Set)
SXY 1-UP (Generator Set) SB3 1-UP (Generator Set)
GZN 1-UP (Generator Set) F6M 1-UP (Generator Set)
GZM 1-UP (Generator Set) NWD 1-UP (Engine)
GZL 1-UP (Generator Set)
GZZ 1-UP (Generator Set)
GSB 1-UP (Generator Set)
GAS 1-UP (Generator Set)
GZK 1-UP (Generator Set)
GZJ 1-UP (Generator Set)
GZH 1-UP (Generator Set)
GZG 1-UP (Generator Set)
RLP 1-UP (Generator Set)
LGS 1-UP (Generator Set)
GZA 1-UP (Generator Set)
GZB 1-UP (Generator Set)
GZC 1-UP (Generator Set)
GYM 1-UP (Engine)
NGS 1-UP (Generator Set)
F6D 1-UP (Generator Set)
F6E 1-UP (Generator Set)
SAFETY.CAT.COM
i06558969
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7681-22 3
Table of Contents
Refill Capacities............................................... 59
Safety Section
Maintenance Recommendations .................... 62
Safety Messages............................................... 5
Maintenance Interval Schedule (Prime).......... 68
General Hazard Information.............................. 8
Maintenance Interval Schedule (Standby)...... 70
Burn Prevention................................................11
Maintenance Interval Schedule....................... 72
Fire Prevention and Explosion Prevention...... 12
Maintenance Interval Schedule....................... 74
Crushing Prevention and Cutting Prevention.. 13
Maintenance Interval Schedule....................... 76
Mounting and Dismounting ............................. 14
Operation Section
Installation ....................................................... 25
Engine Starting................................................ 42
Safety Section
i03624588
Safety Messages
SMCS Code: 1000; 7405
Illustration 1 g01944213
Illustration 2 g01944352
Illustration 3 g01370904
Illustration 7 g01392482
Illustration 6 g01372256
Illustration 8 g01392484
Lifting the Genset (7) Crushing Hazard! Improper lifting could cause
serious injury or death. Follow the lifting instruc-
This safety message for lifting the genset is located tions in the Operation and Maintenance Manual
on the side panels of the generator. for safe lifting procedures.
i04076154
Illustration 10 g00104545
Do not allow unauthorized personnel on the engine, Report all necessary repairs.
or around the engine when the engine is being
serviced. Unless other instructions are provided, perform
the maintenance under the following conditions:
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the The engine is stopped. Ensure that the engine
engine and operate the engine in a well ventilated cannot be started.
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside. The protective locks or the controls are in the
applied position.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids, Disconnect the batteries when maintenance is
hold a rag over the part that is being removed. performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Filler caps Tape the leads in order to help prevent sparks.
Grease fittings When starting a new engine or an engine which
Pressure taps has not been started since service has been
performed, make provisions to stop the engine if
Breathers an overspeed occurs. Shutting down the engine
may be accomplished by shutting off the fuel
Drain plugs supply and/or the air supply to the engine.
Use caution when cover plates are removed. Do not attempt any repairs that are not
Gradually loosen, but do not remove the last two understood. Use the proper tools. Replace any
bolts or nuts that are located at opposite ends of the equipment that is damaged or repair the
cover plate or the device. Before removing the last equipment.
two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure. Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.
California Proposition 65 Warning
Some engine exhaust constituents are known to the
State of California to cause cancer, birth defects, and
other reproductive harm.
The maximum air pressure for cleaning purposes Repair any fuel lines, oil lines, tubes, or hoses that
must be reduced to 205 kPa (30 psi) when the air are loose or damaged. Leaks can cause fires.
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective Inspect all lines, tubes, and hoses carefully. Do not
equipment. The maximum water pressure for use bare hands to check for leaks. Always use a
cleaning purposes must be below 275 kPa (40 psi). board or cardboard for checking engine components
Always wear eye protection for cleaning the cooling for leaks. Tighten all connections to the
system. recommended torque.
Check for the following conditions:
Fluid Penetration
End fittings that are damaged or leaking
Outer covering that is chafed or cut
Use caution. Avoid inhaling dust that might be Reference: The applicable material safety data
generated when you handle components that contain sheets can be found at the following web site by
asbestos fibers. Inhaling this dust can be hazardous searching by the part number or the name of the
to your health. The components that may contain product:
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The http://dsf2ws.cat.com/msds/servlet/
asbestos that is used in these components is usually cat.cis.ecs.msdsSearch.controller.
bound in a resin or sealed in some way. Normal UserIdentificationDisplayServlet
handling is not hazardous unless airborne dust that
contains asbestos is generated.
Dispose of Waste Properly
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
Wear an approved respirator if there is no other Improperly disposing of waste can threaten the
way to control the dust. environment. Potentially harmful fluids should be
disposed of according to local regulations.
Comply with applicable rules and regulations for
the work place. In the United States, use Always use leakproof containers when you drain
Occupational Safety and Health Administration fluids. Do not pour waste onto the ground, down a
(OSHA) requirements. These OSHA requirements drain, or into any source of water.
can be found in 29 CFR 1910.1001.
i01480768
Obey environmental regulations for the disposal of
asbestos. Burn Prevention
Stay away from areas that might have asbestos SMCS Code: 1000; 4450; 7405
particles in the air.
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
Softwrap performed on the engine. Relieve all pressure in the
air system, in the hydraulic system, in the lubrication
Keep the engine room ventilation operating at full system, in the fuel system, or in the cooling system
capacity. Wear a National Institute of Occupational before any lines, fittings or related items are
Safety and Health (NIOSH) approved particulate disconnected.
respirator. Wear appropriate protective clothing in
order to minimize direct contact. Use good hygiene
practices and wash hands thoroughly after handling Coolant
Softwrap. Do not smoke until washing hands
When the engine is at operating temperature, the
thoroughly after handling Softwrap. Clean up debris
engine coolant is hot. The coolant is also under
with a vacuum or by wet sweeping. Do not use
pressure. The radiator and all lines to the heaters or
pressurized air to clean up debris. to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
12 SEBU7681-22
Safety Section
Fire Prevention and Explosion Prevention
Ensure that the filler cap is cool before removing the Determine whether the engine will be operated in an
filler cap. The filler cap must be cool enough to touch environment that allows combustible gases to be
with a bare hand. Remove the filler cap slowly in drawn into the air inlet system. These gases could
order to relieve pressure. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact If the application involves the presence of
the skin, the eyes, or the mouth. combustible gases, consult your Cat dealer for
additional information about suitable protection
Oils devices.
Remove all flammable materials such as fuel, oil, and
Hot oil and hot lubricating components can cause debris from the engine. Do not allow any flammable
personal injury. Do not allow hot oil to contact the materials to accumulate on the engine.
skin. Also, do not allow hot components to contact
the skin. Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
Batteries oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
Electrolyte is an acid. Electrolyte can cause personal storing flammable materials.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for Do not expose the engine to any flame.
servicing batteries. Wash hands after touching the Exhaust shields (if equipped) protect hot exhaust
batteries and connectors. Use of gloves is components from oil or fuel spray in a line, a hose, or
recommended. a seal failure. Exhaust shields must be installed
correctly.
i04823690
Do not weld on lines or tanks that contain flammable
Fire Prevention and Explosion fluids. Do not flame cut lines that contain flammable
fluid. Clean any such lines thoroughly with a
Prevention nonflammable solvent prior to welding or flame
cutting.
SMCS Code: 1000; 4450; 7405
Wiring must be kept in good condition. Ensure that all
electrical wires are properly routed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Illustration 15 g00704000
Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
All fuels, most lubricants, and some coolant mixtures hoses must have adequate support and secure
are flammable. clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a Properly install all oil filters and fuel filters. The filter
fire. Fire may cause personal injury and property housings must be tightened to the proper torque.
damage.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
SEBU7681-22 13
Safety Section
Crushing Prevention and Cutting Prevention
The batteries must be kept clean. The covers (if Stay clear of all rotating parts and of all moving parts.
equipped) must be kept on the cells. Use the Leave the guards in place until maintenance is
recommended cables, connections, and battery box performed. After the maintenance is performed,
covers when the engine is operated. reinstall the guards.
Keep objects away from moving fan blades. The fan
Fire Extinguisher blades will throw objects or cut objects.
Make sure that a fire extinguisher is available. Be When objects are struck, wear protective glasses in
familiar with the operation of the fire extinguisher. order to avoid injury to the eyes.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations Chips or other debris may fly off objects when objects
on the instruction plate. are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or
for replacement parts.
14 SEBU7681-22
Safety Section
Mounting and Dismounting
Do not carry tools or supplies when you mount the If a warning tag is attached to the engine start switch
generator set or when you dismount the generator or to the controls, DO NOT start the engine or move
set. Use a hand line to raise and lower tools or the controls. Consult with the person that attached
supplies. the warning tag before the engine is started.
All protective guards and all protective covers must
i00702251
be installed if the engine must be started in order to
perform service procedures. To help prevent an
Ignition Systems accident that is caused by parts in rotation, work
SMCS Code: 1550 around the parts carefully.
Ignition systems can cause electrical shocks. Avoid If there is a possibility that unburned gas remains in
contacting the ignition system components and the exhaust system, refer to the purge procedure in
wiring. this Operation and Maintenance Manual, Engine
Starting topic in the Operation Section.
Do not attempt to remove the valve covers when the
engine is operating. The transformers are grounded Start the engine from the operator's compartment or
to the valve covers. Personal injury or death may from the engine start switch.
result and the ignition system will be damaged if the
valve covers are removed during engine operation. Always start the engine according to the procedure
The engine will not operate without the valve covers. that is described in the Operation and Maintenance
Manual, Engine Starting topic in the Operation
Section. Knowing the correct procedure will help to
i00659904 prevent major damage to the engine components.
Knowing the procedure will also help to prevent
Before Starting Engine personal injury.
SMCS Code: 1000 To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Inspect the engine for potential hazards. properly, check the water temperature and the oil
temperature during heater operation.
SEBU7681-22 15
Safety Section
Engine Stopping
Engine exhaust contains products of combustion Ground the engine block with a ground strap that is
which can be harmful to your health. Always start the furnished by the customer. Connect this ground strap
engine and operate the engine in a well ventilated to the ground plane.
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside. Use a separate ground strap to ground the battery
negative terminal for the control system to the ground
i00659907
plane.
Rubber couplings may connect the steel piping of the
Engine Stopping cooling system and the radiator. This causes the
piping and the radiator to be electrically isolated.
SMCS Code: 1000
Ensure that the piping and the radiator is
To avoid overheating of the engine and accelerated continuously grounded to the engine. Use ground
wear of the engine components, stop the engine straps that bypass the rubber couplings.
according to the instructions in this Operation and
Ensure that all grounds are secure and free of
Maintenance Manual, Engine Stopping topic
corrosion.
(Operation Section).
Use the Emergency Stop Button (if equipped) ONLY i06795266
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping. Generator Isolating for
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop Maintenance
has been corrected. SMCS Code: 4450
On the initial start-up of a new engine or an engine When you service an electric power generation set or
that has been serviced, make provisions to stop the when you repair an electric power generation set,
engine if an overspeed occurs. This may be
follow the procedure below:
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system. 1. Stop the engine.
i02896515
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started.
Proper grounding is necessary for optimum engine 2. Attach a DO NOT OPERATE or similar warning
performance and reliability. Improper grounding will tag to the engine prime mover starting circuit.
result in uncontrolled electrical circuit paths and in Disconnect the engine starting circuit.
unreliable electrical circuit paths.
3. Disconnect the generator from the distribution
Uncontrolled electrical circuit paths can result in system.
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components. 4. Lock out the circuit breaker. Attach a DO NOT
Uncontrolled electrical circuit paths can also cause OPERATE or similar warning tag to the circuit
electrical activity that may degrade the engine breaker. Refer to the electrical diagram. Verify that
electronics and communications. all points of possible reverse power flow have
Use a ground strap to ground the case of all control been locked out.
panels to the engine block.
5. For the following circuitry, remove the
transformer's fuses:
16 SEBU7681-22
Safety Section
Generator Isolating for Maintenance
power
sensing
control
Product Information
Section
General Information
i03676402
Typical Example
Illustration 18 g01944933
i03676743
Product Description
SMCS Code: 1000; 4450; 4491
The Generator Set consists of an engine, a
generator, and a control system.
SEBU7681-22 19
Product Information Section
Product Description
Inlet Manifold Pressure Sensor The turbocharged engine has a Separate Circuit
Aftercooler (SCAC). The temperature depends on
Load Signal the engine rating and the application.
Inlet manifold temperature sensor The circuit for the aftercooler may be combined or the
circuit for the aftercooler may be separate circuits. In
The fuel metering valve controls the flow of fuel to the the combined system, a pump circulates water
engine. The ECM determines the requirement for the through both the aftercooler and oil cooler cores. The
mixture of air and fuel. The ECM sends a signal to combined system uses a thermostatic control to
the fuel metering valve. The fuel metering valve regulate the oil temperature. This prevents
controls the volume of the gas flow to the engine. overcooling.
The fuel flows through the fuel metering valve into the For a more detailed description, refer to the Systems
air inlet elbow. The mixture of air and fuel flows Operation/Testing and Adjusting manual.
through the turbocharger compressor. The air/fuel
mixture is cooled in the aftercooler. The mixture Description of the Generator
enters the manifold through a throttle which is
electronically controlled.
The SR4B brushless generator can be used with the
The ECM sends an electronic throttle signal to the following loads: mixed loads of motors and lights,
electronic actuator. The throttle is controlled by the SCR-controlled equipment, computer centers and
actuator. petroleum drilling applications.
The generator set packages can be utilized for prime
Ignition System power generation or standby power generation.
The engine is equipped with an electronic ignition SR4B generators are utilized in three-phase full-
system. The system provides dependable firing and wave excitation and regulation. The generators are
low maintenance. The system provides precise either four pole or six pole design. The generators
control of the spark and the ignition timing for each have six lead configuration or twelve lead
cylinder. configuration. The generators are capable of
producing electrical power in either 50 Hz or 60 Hz
The system also provides diagnostic capability that applications.
enhances troubleshooting.
The engines are equipped with protection from Island Mode and Coal Mine
detonation. A detonation sensor is located between Methane (CMM) application
every two cylinders. The ignition timing is retarded for
a cylinder when excessive detonation is sensed in
that cylinder. If the maximum retarded position is Island Mode refers to an application for Generator
attained and detonation continues to occur, the ECM Sets that is not paralleled to a public utility. In this
shuts down the engine. operational state, the gas engine must maintain
torque and crankshaft speed during steady state
The engines are equipped with flame arresters. The operations.
flame arresters are located at the entrance of each
inlet port. If the engine backfires, the flame arresters The Coal Mine Methane (CMM) application is a
prevent the fire from entering the air/fuel mixture. generator package that makes use of methane gas
that is embedded in coal mines. The methane gas is
used as fuel for the Generator Sets.
20 SEBU7681-22
Product Information Section
Product Identification Information
Arrangement number
i05819574
Illustration 19 g01044252
Arrangement number
Compression ratio
Aftercooler temperature
Power
Declaration of Conformity
SEBU7681-22 21
Product Information Section
Declaration of Conformity
Table 1
An EC Declaration of Conformity document was provided with the product if the product was manufactured to comply with specific requirements
for the European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity pro-
vided with the product. The extract shown below from an EC Declaration of Conformity for product that are declared compliant to 2006/42/EC
applies only to those products originally CE marked by the manufacturer listed and which have not since been modified.
Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean Union Member States on request:
I, the undersigned, _________, hereby certify that the construction equipment specified hereunder
Model/Type: G3500C
Serial Number:
Commercial Name: Caterpillar
2006/42/EC N/A
2006/95/EC N/A
2004/108/EC N/A
2000/14/EC amended by 2005/88/EC, Note (1) Note (2)
Note (1) Annex -_____ Guaranteed Sound Power Level -_____dB (A)
Representative Equipment Type Sound Power Level - _____dB (A)
Engine Power per ____-____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File
Date: Name/Position
Note: The above information was correct as of October, 2009, but may be subject to change. Refer to the individual declaration of conformity is-
sued with the machine for exact details.
22 SEBU7681-22
Product Information Section
Reference Information
i01934436
Reference Information
SMCS Code: 1000; 4450
Identification of the items in Table 2 may be needed
in order to obtain parts and service. Some of the
numbers are on the engine Serial Number Plate and/
or Information Plate. Locate the information for your
engine. Record the information on the appropriate
space in Table 2 . Make a copy of this list for a
record. Retain the information for future reference.
The top level part numbers in the Parts Manual for
the engine are listed with the engine arrangement
number.
The packaging arrangement may also be called a
pricing arrangement or a customer arrangement.
This is the total package with attachments and
options that are not included in the engine
arrangement.
The performance specification can be used by your
Caterpillar dealer with the Technical Marketing
Information system. Before the engine leaves the
factory, the engine performance is tested. Detailed
performance data is recorded. The performance
specification number can be used for obtaining the
data.
Table 2
Reference Numbers
Engine Model
Packaging Arrangement
Turbocharger
Performance Specification
Number
Low Idle rpm
Power Rating
SEBU7681-22 23
Operation Section
Lifting and Storage
i05324948
Illustration 20 g01955415
Product Storage
SMCS Code: 7002
NOTICE
Never bend the eyebolts and the brackets. Only load If the engine will not be started for several weeks, the
the eyebolts and the brackets under tension. Re- lubricating oil will drain from the cylinder walls and
member that the capacity of an eyebolt is less as the from the piston rings. Rust can form on the cylinder
angle between the supporting members and the ob- liner surface, which will increase engine wear which
ject becomes less than 90 degrees. can reduce engine service life.
When it is necessary to remove a component at an To help prevent excessive engine wear, use the
angle, only use a link bracket that is properly rated for following guidelines:
the weight.
Complete all of the lubrication recommendations
Use a hoist to remove heavy components. Use an that are listed in this Operation and Maintenance
adjustable lifting beam to lift the entire package. Use Manual, Maintenance Interval Schedule
an adjustable lifting beam to lift the engine. All
(Maintenance Section).
supporting members (chains and cables) should be
parallel to each other. The chains and cables should If freezing temperatures are expected, check the
be perpendicular to the top of the object that is being
lifted. cooling system for adequate protection against
freezing. Refer to this Operation and Maintenance
Some removals require lifting fixtures in order to Manual, Fluid Recommendations (Maintenance
obtain proper balance. Lifting fixtures also help to Section).
provide safety.
If an engine is out of operation and if use of the
Lifting eyes are designed and installed for each engine is not planned, special precautions should be
package. Alterations to the lifting eyes and/or the made. If the engine will be stored for more than 1
package make the lifting eyes and the lifting fixtures month, a complete protection procedure is
obsolete. If alterations are made, ensure that proper recommended.
lifting devices are provided. Consult your Caterpillar
dealer for information regarding fixtures for proper Your Cat dealer will have instructions for preparing
lifting. the engine for extended storage periods.
For more detailed information on engine storage,
refer to Special Instruction, SEHS9031, Storage
Procedure for Caterpillar Products.
24 SEBU7681-22
Operation Section
Product Storage
Generator Storage
For information on generator storage, refer to this
Operation and Maintenance Manual, Generator Set
Installation (Operation Section).
SEBU7681-22 25
Operation Section
Installation
Installation The hoist and the hoist cables should have a rating
that is greater than the weight of the generator. When
the unit is moved, ensure that the generator is
i03676783 completely supported by the lift truck's fork tines.
Also ensure that the generator is balanced on the lift
Product Installation truck's fork tines. Slide the fork tines beneath the
attached skid in order to lift the generator.
SMCS Code: 1000; 1404; 4450; 7002
Storage
Receiving Inspection
If the generator is received during cold weather, allow
Short Time Storage
the unit to reach room temperature before you
remove the protective packing material. Warming the If the generator is not installed immediately, store the
generator to room temperature will prevent the generator in a clean area. This area should also have
following problems: the following conditions: low humidity, stable humidity
and stable temperature. Space heaters must be
Water condensation on cold surfaces energized in order to keep condensation from the
windings. All accessory equipment that is supplied
Early failures due to wet windings with the unit should be stored with the generator. The
combined unit should be covered with a durable
Early failures due to wet insulating materials cover in order to protect against the following
contaminants:
Unpacking and Storage Dust
Moisture
Location
The location of the generator must comply with all
local regulations. The location of the generator must
also comply with all special industrial regulations.
Locate the generator in an area that meets the
following requirements:
26 SEBU7681-22
Operation Section
Product Installation
Electrical Measurements
Measure the insulation resistance of each winding if
the generator was exposed to the following
conditions:
Rapid changes in temperature
Freezing
Wet climate during shipment
Alignment
After the generator set has been placed in the final
position, the generator must be aligned. Refer to
these publications:
Alarms and shutoffs are electronically controlled. The The tests must be performed correctly in order to pre-
operation of all alarms and shutoffs utilize vent possible damage to the engine.
components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating Periodic testing of engine protective devices for
temperatures, pressures, or speeds in order to proper operation is recommended maintenance. To
protect the engine from damage. prevent damage to the engine, only authorized
The alarms function in order to warn the operator service personnel or your Caterpillar dealer
when an abnormal operating condition occurs. The should perform the tests.
shutoffs function in order to shut down the engine
when a more critical abnormal operating condition Setpoints for Alarms and Shutoffs
occurs. The shutoffs help to prevent damage to the
engine. Inlet Manifold Air Temperature
Shutoffs may cause unburned gas to remain in the air
inlet and in the exhaust manifold. Table 3 lists information on the operating
temperatures and the shutdown temperatures for
inlet manifold air temperature. The temperatures are
associated with different water temperature
regulators for separate circuit aftercoolers. The
Unburned gas in the air inlet and exhaust system temperatures are also associated with different types
may ignite when the engine is started. Personal of gas engines.
injury and/or property damage may result.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the Starting the Engine
section.
Table 3
Approximate Operating Temperatures and Shutdown Temperatures for G3500 Inlet Manifold Air Temperature
Illustration 21 g01147692
Electronic Modular Control Panel II+ (EMCP II+)
(1) Generator set control + (GSC+) (5) Synchronizing lights module or Custom (7) Voltage adjust rheostat (VAR)
(2) Engine control switch (ECS) alarm module (CAM) (8) Emergency stop push button (ESPB)
(3) Panel lights (PL) (6) Speed potentiometer (SP) or Governor (9) Panel light switch (PLS)
(4) Alarm module (ALM) switch
The Electronic Modular Control Panel II+ (EMCP II+) Engine Control Switch (2) The engine control
is located above the generator distribution housing. switch (ECS) determines the status of the control
The control panel consists of the following panel. In the AUTOMATIC position, the engine will
components: a main panel with indicators, meters start automatically when a remote initiated contact is
and control switches. This control panel may be closed. The engine will be shutdown after the contact
equipped with optional modules in order to match the opens. The engine will be shutdown after a cooldown
customers' needs and requirements. period that is programmable has elapsed. The
cooldown period can be programmed to give a 0 to
The left side of the control panel contains the 30 minute cooldown period before the engine shuts
Generator Set Control + (GSC+). This is the main down.
component of the system. The GSC+ displays the
following information: generator output, fault
conditions and key engine parameters. The center In the MANUAL START position, the engine will start.
section of the control panel contains switches and an In the MANUAL START position, the engine will run
optional alarm module. The right side of the control when ECS remains in the MANUAL START position.
panel may be blank, or the right side of the control
panel may contain the Synchronizing Lights Module In the STOP position, the engine is shutdown by the
or the Custom Alarm Module. fuel solenoid after a programmable cool down time
period has elapsed.
Some components are optional. The optional
components may not be required for your particular In the OFF/RESET position (12 o'clock), the fault
application. lights are reset and the engine shuts down
immediately.
Generator Set Control + (1) The generator set
control + (GSC+) is the main component of the
EMCP II+. See the topic Generator Set Control +
(GSC+) in this section.
30 SEBU7681-22
Operation Section
Electronic Modular Control Panel II+ (EMCP II+)
NOTICE
Generator Set Control + (GSC+)
The engine must be cranking before using the start
aid switch. Damage to the engine is possible if ether Functions and features of the GSC+
is released to the engine but not exhausted or burned
by the engine when cranking.
The red fault shutdown indicator (21) FLASHES occurs, the engine overspeed indicator flashes. The
when the GSC+ detects a shutdown fault. The engine engine is shutdown and the engine is not allowed to
will be shut down if the engine is running. The engine start until the fault is corrected.
will not be allowed to start. Fault shutdown indicator
(21) is accompanied by a fault code that is Overcrank The engine does not start within the
immediately shown on the upper display (25). setpoint for total cycle crank time that is programmed
into the GSC+. When the overcrank fault occurs, the
The yellow spare fault indicators (24) FLASH when overcrank indicator FLASHES. The engine is not
the conditions that are associated with that spare allowed to start until the fault is corrected.
fault are active. The three spare faults can be
programmed to show coolant loss, engine oil
temperature, spare fault condition or no assignment. Note: The GSC+ can be programmed to override the
The spare fault condition may be a customer shutdown for low oil pressure and high water
generated switch input. The yellow fault alarm temperature faults. When the operator overrides the
indicator (22) or the red fault shutdown indicator (21) shutdown faults, the GSC+ responds to the faults as
will accompany the spare fault indicators (24). The though the faults are alarm faults. The dedicated
spare fault indicators will tell whether the spare fault shutdown indicator is on continuously, and the
input is programmed to be an alarm condition or a indicator will not be flashing. The engine continues to
shutdown condition. run and the engine can be restarted. When the
dedicated shutdown indicator is ON continuously, the
The red dedicated shutdown indicators (23)
represent the following shutdown faults: low engine setpoint for shutdown has been exceeded, but the
oil pressure, emergency stop, high water GSC+ is programmed to override the shutdown fault.
temperature, engine overspeed and engine The GSC+ does not treat the shutdown fault as a
overcrank. When the GSC+ detects a fault in one of shutdown fault. The GSC+ treats the shutdown fault
these areas, the dedicated shutdown indicator as an alarm fault. At the factory, the GSC+ is
flashes. The engine is shutdown if the engine is programmed to treat a low oil pressure fault and a
running, and the engine is not allowed to start. No high water temperature fault as shutdown faults. The
fault codes are associated with the dedicated operator or the service technician must decide to
shutdown indicators because each indicator has a override these shutdown faults. The operator or the
descriptive label.
service technician must program the GSC+ to treat
Many of the dedicated shutdown faults depend on the shutdown faults as alarm faults.
certain setpoints in the GSC+.
Display
The conditions that are required to activate the
dedicated fault shutdowns and the results of each
dedicated fault are in the following list.
Low Oil Pressure The engine oil pressure drops
below the setpoints for low oil pressure shutdown
that are programmed into the GSC+. There are two
low oil pressure setpoints. One setpoint is used when
the engine is at idle speed. The other setpoint is used
when the engine is at rated speed. When a low oil
pressure fault occurs, the low oil pressure indicator
FLASHES, and the engine is shut down. The engine
is not allowed to start until the fault is corrected.
Emergency Stop The operator presses the
emergency stop push button (ESPB) on the front
panel. When an emergency stop condition occurs,
the emergency stop indicator FLASHES and the
engine is shut down. The engine is not allowed to
start until the condition is corrected.
High Water Temperature The engine coolant
temperature rises above the setpoint for high water
temperature shutdown that is programmed into the
GSC+. When the high water temperature fault
occurs, the high water temperature indicator Illustration 24 g00786776
FLASHES. The engine is shutdown and the engine is Display area of the GSC+
not allowed to start until the fault is corrected.
(25) Upper display
Engine Overspeed The engine speed exceeds the (27) Lower display
(28) The power meter key
setpoint for engine overspeed that is programmed (29) The AC meter key
into the GSC+. When the fault for engine overspeed (30) The engine meter key
SEBU7681-22 33
Operation Section
Electronic Modular Control Panel II+ (EMCP II+)
The display consists of the upper display and the Real power phase C (kW)
lower display. Both displays are used for
programming functions when the display is in the Total apparent power (kVA)
service mode.
Total reactive power (KVAR)
Upper display
Percentage of rated power (%kW)
The upper display (25) shows: AC voltage, current
and frequency. Several options are available on the Power factor (average)
upper display for AC metering. These options can be
viewed one at a time by pressing the AC meter key Power factor phase A
(29) on the keypad. The options are listed below:
Power factor phase B
Average voltage, generator frequency and total
current Power factor phase C
Total energy output (kW/h)
Line to line voltage, generator frequency and line
current for any one phase Total reactive energy output (kVAR/Hr)
Line to line voltage for all three phases Note: All real power values are signed with a + or a
Line current for all three phases . A negative value indicates reverse power.
Note: When total current increases above 9999A , Note: The Real power phase and the power factor
the GSC+ will show current in kA units. phase are not shown when setpoint P032 is set to 1
for delta generator sets.
Line to neutral voltage for all three phases
Note: Total energy output that is greater than
Upper display (25) is also used to show the various 999,999 kW/h will be shown as MW/h in two steps in
fault codes for system faults. order to maintain a resolution of 1 kW/h. The first
step will show MW/h as a whole number up to six
Note: Line to neutral voltages are not shown when places. The second step will show MW/h as a
the setpoint P032 is set to 1 for delta generator sets. decimal to three places.
Lower display The right side of lower display (27) shows the value
of certain engine parameters. The parameters are
The lower display (27) shows values for power listed below:
metering, engine parameters and the relay status.
Engine oil temperature (if equipped)
The left side of the lower display (27) serves as a
power meter for the generator set. The following System battery voltage
functions will scroll automatically:
Engine hours
Total real power (kW)
Engine speed
Total reactive power (KVAR)
Engine oil pressure
Percentage of rated power (%kW)
Engine coolant temperature
Power factor (average)
The value for one of these conditions is shown on
Total energy output (kW/h) display (27) for two seconds. The display then scrolls
to the value for the next condition. A small pointer
The display will stop scrolling when the operator identifies the engine condition that corresponds to
presses the power meter key for less than five the value that is showing. When the engine meter key
seconds. The display will show a particular (30) is pressed, the lower display (27) stops scrolling.
parameter continuously. Additional power meter The lower display continuously shows one particular
functions will scroll, if the power meter key (28) is value. The pointer flashes above the value that is
held for more than five seconds and then released. showing on the display. When the engine meter key
The additional functions are shown below: (30) is pressed for the second time, the lower display
will return to scrolling.
Total real power (kW)
Real power phase A (kW)
The relay status indicators are on the bottom of the Engine Meter Key (30) This key controls the
lower display (27). When a relay for the GSC+ is viewing of engine parameters on the lower display.
activated, the corresponding indicator is shown on Pressing the key stops the scrolling of engine
the lower display (27). When a relay is not activated, conditions. The value for one particular engine
the corresponding indicator is not shown. condition will show continuously. The pointer flashes
indicating that the scrolling is stopped. The scrolling
Keypad of the engine conditions will resume when the engine
meter key is pressed again.
Lamp Test Key (31) Pressing this key performs a
lamp test on the GSC+ and the optional alarm
module. On the GSC+, the ten fault indicators are ON
CONTINUOUSLY. Every segment of upper display
(5) and lower display (6) is ON. On the optional alarm
module, all of the indicators are ON and the horn
sounds. The function for the lamp test automatically
turns off if the operator presses the key and the
operator holds the key for ten seconds.
The Alarm Codes Key (26) If fault alarm indicator
(22) is FLASHING, pressing this key causes the
upper display (25) to show the corresponding alarm
fault code. If this key is pressed again, the generator
AC output information will be shown on the upper
display (25). If fault alarm indicator (22) is OFF, this
key has no function.
Exit Key (32) This key only functions when the
GSC+ is in Service Mode.
Service Mode Key (33) Pressing this key causes
the GSC+ to enter Service Mode.
Illustration 25 g00786777
Keypad area of the GSC+
Alarm Module
(21) Fault shutdown indicator
(22) Fault alarm indicator
(25) Upper display
(26) Key for the alarm codes
(27) Lower display
(28) Power meter key
(29) AC meter key
(30) Engine meter key
(31) Lamp test key
(32) Exit key
(33) Service mode key
(34) Keypad
One basic alarm module is used to satisfy the Four red indicators, which are used to display
requirements for the following modules: standby shutdown conditions
NFPA 99 alarm module, standby NFPA 110 alarm
module, NFPA 99 remote annunciator panel and
prime power alarm.
Synchronizing Lights Module
The front of the alarm module consists of the
following indicators:
Four amber indicators, which can indicate High
Coolant Temperature, Low Coolant Temperature
or Low Coolant Level, Low Oil Pressure,
Generator On Load, Charger Malfunction, Low
Engine Oil Level and Low Fuel Level
Four red indicators, which can indicate a Low DC
Voltage, Air Damper Closed, Low Oil Pressure
Shutdown, Overcrank Shutdown, High Coolant
Temperature Shutdown, and Overspeed
Shutdown
A reverse power fault is indicated by the Fault Governing of the engine rpm
Shutdown Indicator on the front of the GSC+.
Control of ignition
The reverse power relay is a single phase protective
relay. This relay is energized by power in only one Control of the air/fuel ratio
direction. In a reverse power fault, the relay contacts
close and the engine shuts down. This will take the Start/stop control
generator off the line. The reverse power relay is
equipped with a test switch and adjustments. Monitoring and protection of the engine
Sensors and Electrical The ECM receives a signal from the speed/timing
sensor. The ECM maintains the desired engine rpm
Components through electrical control of the engine's throttle.
SMCS Code: 1900; 7400
Control of Ignition
Note: This section contains some general
information about the engine electronic system and Each cylinder has an ignition transformer that is
sensors. For more information, refer to Systems located on top of the valve cover. In order to initiate
Operation/Testing and Adjusting. combustion in each cylinder, the ECM sends a pulse
to the primary coil of the ignition transformer at the
correct time. The time is based on firing order and
Electronic System engine speed. The transformer increases the voltage
which creates a spark across the spark plug
The Caterpillar Electronic System is a complete electrode.
electronic control system for gas engines. The
following benefits are the most significant The transformers are grounded through the valve
advantages of the electronic system: cover. Use caution when a valve cover is removed.
Always disconnect the ignition harness from the
Air/Fuel ratio control
transformer when a valve cover is removed.
Extensive system diagnostics An ignition harness connects each transformer to the
ECM.
Precise control of engine operation
Protection from detonation Control of Air/Fuel Ratio
Timing control of individual cylinders The ECM determines the desired volumetric flow rate
for fuel. The determination is based on the
components: actual engine speed, actual load, MAP,
MAT and internal maps. Next, the ECM sends
information on the desired fuel flow to the fuel
metering valve via the CAN data link. The ECM
adjusts the signal to the fuel metering valve in order
to maintain emissions. The process is repeated
continuously during engine operation.
Start/Stop Control
The ECM contains the logic and the inputs for
controlling the starting and stopping of the engine.
The logic for starting and stopping can be
programmed by the customer. The ECM supplies
positive + battery voltage to the starting motor relay
and the gas shutoff valve.
Illustration 29 g00882978
The engine uses an energize-to-run system. The gas
Junction box shutoff valve must remain energized in order to
supply fuel to the engine. If power is removed from
Most of the functions of the electronic system are the gas shutoff valve, the fuel is shut off. The gas
provided by the Engine Control Module (ECM). The shutoff valve may be controlled by the customer.
ECM is a sealed unit that is located inside a junction
box at the rear of the engine.
Five primary functions are supported by the ECM:
SEBU7681-22 37
Operation Section
Sensors and Electrical Components
Sensors
Sensors provide information to the ECM. The
information enables the ECM to control the engine as
efficiently as possible over a wide range of operating
conditions. The information is used for monitoring
engine operation and for protecting the engine.
Illustration 30 shows the locations of the sensors.
38 SEBU7681-22
Operation Section
Sensors and Electrical Components
Illustration 30 g01974561
(1) Engine oil temperature sensor (5) Pressure sensor for filtered oil (9) Manifold air pressure sensor
(2) Jacket water pressure switch (inlet) (6) Manifold air temperature sensor (10) Temperature sensor (Jacket Water
(3) Speed/timing sensor (7) Jacket water pressure sensor (outlet) Coolant)
(4) Pressure sensor for unfiltered oil (8) Flywheel speed sensor (11) Detonation sensor
Engine oil temperature sensor (1) An oil Speed/timing sensor (11) The engine speed/
temperature sensor monitors the engine oil timing sensor is located on the rear end of the left
temperature. A high oil temperature will activate an camshaft. The engine speed/timing sensor provides
alarm or a shutdown. The ECM compares the oil accurate information to the ECM about the position of
temperature to the engine coolant temperature. A the crankshaft and the engine rpm. The ECM uses
high difference between the two temperatures will the position of the crankshaft in order to determine
activate an alarm or a shutdown. ignition timing.
Jacket water pressure switch (2) A pressure
switch is located at the outlet of the oil cooler. The Integrated Temperature Sensing Module
jacket water pressure switch is a limit switch for the
coolant that is entering the block. (ITSM)
Engine speed sensor (3) This sensor only applies The ITSM monitors thermocouples that are located at
to engines that are configured for Island Mode. The the exhaust port of each cylinder. Thermocouples are
Auxiliary Sensing Module uses the signal from this also mounted at the inlets and outlets to the
sensor to accurately determine engine speed. In turbochargers. The temperatures are broadcast over
addition, the Auxiliary Sensing Module determines the Caterpillar data link for use with other modules.
the rate of change of the engine speed. The Auxiliary
Sensing Module uses this information to rapidly The ITSM calculates the average temperature for
respond to changes in engine load. The Auxiliary each bank. Event codes are generated if the
Sensing Module sends information on engine speed following conditions occur:
to the master ECM via the Cat Data Link.
The temperature is higher than the limit that is
Oil pressure sensors (4) and (5) The engine oil programmed.
pressure is measured before the oil filters and after
the oil filters. An alarm or a shutdown can be The temperature of a cylinder deviates
activated by any of the following occurrences: low significantly from the average temperature for all
filtered oil pressure, low oil filter differential pressure of the cylinders.
and high oil filter differential pressure.
Manifold air temperature sensor (6) A sensor for
monitoring the air inlet temperature is located in the
elbow after the number twenty cylinder head.
Excessive inlet air temperature can activate an alarm
or a shutdown.
Jacket water pressure sensor (7) A pressure
sensor is located at the outlet for the engine jacket
water. If the outlet pressure is too low, the ECM will
activate a shutdown.
Manifold air pressure sensor (8) A sensor for
monitoring the air inlet pressure is located in the front
end of the manifold. Excessive inlet air temperature
can activate an alarm or a shutdown.
Engine coolant temperature sensor (9) The
temperature sensor is located in the water
temperature regulator housing. To monitor the
coolant temperature, the element must be in contact
with the coolant. If overheating occurs due to low
coolant level, the sensor will not function properly. A
high coolant temperature will activate an alarm or a
shutdown. A low coolant temperature will only
activate an alarm. The setpoints for the activation can
be programmed with the Cat ET. The engine can be
restarted after a shutdown due to high engine coolant
temperature. However, another shutdown will occur
after one minute if the temperature remains high.
Detonation sensors (10) The detonation sensors
monitor the engine for detonation in each cylinder. To
eliminate detonation, the ECM retards the timing of
the cylinder. If excessive detonation continues, the
ECM will shut down the engine.
40 SEBU7681-22
Operation Section
Engine Diagnostics
Ensure that the areas around the rotating parts are Loose connections
clear.
Wiring that is worn or frayed
Air Inlet System Inspect the gauge panel and the control panel for
good condition. Reset any shutoff or alarm
components.
Unburned gas in the air inlet and exhaust system Fuel System
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air NEVER use a flame to check for gas leaks. Use a
inlet and exhaust system. Refer to the topic on gas detector.
purging unburned gas in the Starting the Engine
section. An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.
Ensure that the air inlet piping and the air filters
are in place and clean.
Check the fuel lines for leaks with a gas detector.
Ensure that all clamps and connections are
secure.
SEBU7681-22 43
Operation Section
Cold Weather Starting
Inspect the fuel lines for loose fittings and leaks. Air Starting Motor
Ensure that the fuel lines are properly clamped.
Drain moisture and sediment from the air tank and
Ensure that the fuel is supplied to the engine at the from any other air piping.
correct pressure for the engine.
Check the oil level in the lubricator. Keep the
Lubrication System lubricator at least half full. Add oil, if necessary.
Loose connections
Illustration 31 g00760044 Wires that are worn or frayed
Oil level gauge (dipstick)
Corrosion
(1) ADD mark
(2) FULL mark
i01934528
NOTICE
Excessive engine oil will increase oil consumption
Cold Weather Starting
and result in excessive deposits in the combustion SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
chamber. Do not overfill the engine with oil.
NOTICE
Check the engine crankcase oil level. Maintain the Oil pan immersion heaters are not recommended for
heating the lube oil. To ensure the compatibility of the
oil level between the ADD and FULL marks on
components, only use equipment that is recom-
the ENGINE STOPPED WITH OIL COLD side of mended by Caterpillar.
the oil level gauge. For information on the proper
oil to use, see this Operation and Maintenance A jacket water heater is required to maintain a
Manual, Refill Capacities and Recommendations minimum starting temperature of 45 C (113 F). The
(Maintenance Section). engine may be difficult to start if the jacket water
coolant temperature is below 43 C (110 F). The
Check for leaks at the following components: spark plugs may become fouled with moisture
crankshaft seals, crankcase, oil filters, oil gallery condensation if the engine is cranked and the jacket
plugs, sensors and valve covers. water coolant temperature is below 43 C (110 F).
Inspect the tubes, tee pieces, and clamps on the For air starting motors, a larger volume of starting air
crankcase breathers. and/or a higher air pressure may be necessary in
order to start the engine at colder temperatures.
Starting System For electric starting, extra battery capacity may be
necessary.
Note: If the engine is equipped with a system for
external support, prepare the system before starting Consult your Caterpillar dealer for more information
the engine. Ensure that all of the systems for engine on the starting aids that are available for cold weather
support are enabled. Perform all prestart checks for starting.
the control system.
44 SEBU7681-22
Operation Section
Starting the Engine
Rest Cycle
If the engine does not start within the cycle crank Improper jump start cable connections can cause
time, starting is suspended for a rest cycle. The an explosion resulting in personal injury.
amount of time for the rest cycle is equal to the cycle
crank time. Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
Overcrank Time
If the installation is not equipped with a backup
The overcrank time includes the total purge cycle, the battery system, an external electrical source may be
total cycle crank time, and the total rest cycle. These necessary to start the engine.
functions are repeated until termination of the
overcrank time.
NOTICE
If the engine does not start within the overcrank time, Using a battery source with the same voltage as the
the engine control module generates an event code. electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Manual Starting
Do not reverse the battery cables. The alternator can
1. Ensure that fuel is supplied to the engine. be damaged. Attach the negative cable last and re-
move first.
2. Ensure that the driven equipment is ready. For
generator set engines, ensure that the main circuit When using an external electrical source to start the
breaker is open. engine, turn the generator set control switch to the
OFF position. Turn all electrical accessories OFF
before attaching the jump-start cables.
NOTICE
Do not engage the starting motor when flywheel is Ensure that the main power switch is in the OFF posi-
turning. Do not start the engine under load. tion before attaching the jump-start cables to the en-
gine being started.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to 1. Turn the start switch to the OFF position. Turn off
start the engine again.
all accessories.
2. Connect one positive end of the jump-start cable to
3. Start the engine.
the positive cable terminal of the discharged
The crank terminate speed is programmable. battery. Connect the other positive end of the
When the engine rpm exceeds the crank terminate jump-start cable to the positive cable terminal of
speed, the engine control module disengages the the electrical source.
starting motor.
3. Connect one negative end of the jump-start cable
4. Allow the engine speed to stabilize at low idle rpm. to the negative cable terminal of the electrical
Check all of the pressure gauges. Inspect the source. Connect the other negative end of the
engine for leaks and listen for unusual noises. jump-start cable to the engine block or to the
When all systems are normal, the rpm may be chassis ground. This procedure helps to prevent
increased. potential sparks from igniting combustible gases
that are produced by some batteries.
46 SEBU7681-22
Operation Section
After Starting Engine
i02247955
Observe the gauges or the Caterpillar Electronic Narrow margin for detonation
Technician (ET) frequently while the engine is
operating. Record the data from the gauges or the Power loss
Cat ET in a log. It is best to record all Cat ET data
from the status screens. Record the time and the Poor performance
date for each event or each diagnostic. Include the
parameters that are listed in Table 8 . Average the Accelerated wear of components
data that is recorded during operation and record the
Caterpillar Engines can be operated at very light
average values for each day. Compare the data to
loads for limited times with no harmful effects. Table 9
the specifications for normal engine operation. lists the limits for hours of operation at various loads.
Comparing the data over time will help to detect
trends in engine performance. After the time limit for reduced load operation
Table 8 has expired, operate the engine for a minimum of
two hours at a load that is more than 70 percent
Engine Performance
of the rated load.
Operator Date
For example, an engine is operating at 20 percent of
Engine serial number Hour meter the rated load. The engine may be operated at this
load factor for a maximum of one-half hour. After the
Load RPM one-half hour, operate this engine for at least two
hours at a load factor of more than 70 percent.
Coolant temperature Oil pressure
Generator Operation
i02896671
Generator Operation
SMCS Code: 4450
Illustration 32 g00627416
Allowable Combinations of Unbalanced Loads
If a block load derating is required, refer to ISO 8528 Note: Normally, Caterpillar generators are designed
Standards or SAE J1349 Standards. for a lagging power factor of 0.8. If operation at less
than 0.7 lagging power factor is desired, consult your
Power Factor Caterpillar dealer in order to check the rating of the
generator.
The power factor represents the efficiency of the
load. The power factor is the ratio of apparent power Excitation Systems
to total power. This ratio is expressed as a decimal.
The power factor represents the portion of the current
which is doing useful work. The portion of current Permanent Magnet Pilot Excited
which is not doing useful work is absorbed in Generators
maintaining the magnetic field in motors. This current
is called the reactive load. Engine power is not Permanent Magnet Pilot Excited (PMPE) generators
required to maintain the reactive load. receive power for the voltage regulator from a pilot
exciter, rather than the main armature. The pilot
In most applications, the power factor of the system exciter consists of a permanent magnet rotor and a
is determined by these components: electric motors, stator. The pilot exciter operates independently from
controls and transformers. Induction motors usually the generator output voltage. Constant excitation
have a power factor that is no larger than 0.8. during a large load application is possible since
Incandescent lighting is a resistive load of about 1.0 irregularities in the output voltage are not fed back
power factor, or unity. Controls can operate at any into the system. Such irregularities can be caused by
power factor. Drivers that have variable frequency or load conditions. The independent operation also
variable speed can operate at any power factor. An allows the generator to better sustain an overload for
uninterruptible power supply can operate at any a short duration.
power factor. In this case, the power factor can be
between 0.4 and 1.0.
Low Idle Adjustment
The power factor of a system may be measured with
a power factor meter or determined by calculations. Typically, the low idle on 3500C generator sets is
Determine the power requirement in kW by 1100 rpm. On 60 Hz units, low idle will be
multiplying the power factor by the kVA that is approximately 66 percent of the full load speed. On
supplied to the system. As the power factor 50 Hz units, low idle will be approximately 80 percent
increases, the total current that is supplied to a of full load speed.
constant power demand will decrease. With equal
loads, a lower power factor will draw more current. A There is no low idle stop on generator sets with
high power factor will result in full engine load that is electronic governors. The low idle is set at the factory
less than the generator's rated amperage. A lower on generator sets that have mechanical governors.
power factor increases the possibility of overloading The low idle is also set at the factory on generator
the generator. sets that run on natural gas. The low idle should only
be adjusted by your Caterpillar dealer if adjustment is
required.
Note: Operating the electric set at low idle speed for
an extended time will cause some voltage regulators
to shut off. The electric set must be completely shut
down. Then, the electric set must be restarted. This
will allow the voltage regulator to again produce an
output.
Standby units will not change the settings for the Bearing Temperature Detectors
governor speed control or the voltage level
automatically. The governor speed and voltage level Bearing temperature detectors are available on
must be preset for the proper operation of that unit. generators with large frames. Bearing temperature
Whenever the generator set is operated manually, detectors measure the temperature of the main
ensure that the settings for the governor speed and bearing. Thus, the temperature of the bearing can be
the voltage level are set correctly for automatic measured or monitored. Bearing temperature
operation. Check all switches for the proper setting. measurements may help to prevent premature
The Start Selector Switch should be in the bearing failure. Two types of temperature detectors
AUTOMATIC position. Emergency Stop Switches are available. Bearing temperature detectors are
should be in RUN position. used with equipment that is provided by the
customer. Contact your Caterpillar dealer for more
Options information.
i04010972
Space Heaters
Most of the SR4B generators are provided with Single Unit Operation
space heaters. These space heaters are installed for SMCS Code: 4450
operation in all climates. The space heaters are
especially for use in high humidity conditions. For
more information on space heaters, refer to Initial Start-Up
Maintenance Section, Space Heater - Check.
Before the initial start-up, perform the megohmmeter
Embedded Temperature Detectors test on the main stator winding. Refer to the Special
Instruction, SEHS9124, Cleaning and Drying of
SR4B generators are available with embedded Electric Set Generators for the procedure.
temperature detectors. The detectors are installed in
the slots of the main armature. The main armature is
also called a stator. The detectors are used with the
Starting
equipment that is provided by the customer. Thus,
the temperature of the main armature winding can be 1. Make all of the preliminary checks listed in this
measured or monitored. Two types of temperature Operation and Maintenance Manual, Before
detectors are available: RTD and thermocouple. Starting Engine topic.
Contact your Caterpillar dealer for more information.
2. Be sure that the main circuit breaker or the line
circuit breaker is open.
3. Start the engine according to this Operation and
Maintenance Manual, Starting the Engine topic.
Allow the engine to warm up.
4. Adjust to the full-load engine speed.
5. Close the main circuit breaker.
6. Apply the load. Apply the load in increments in
order to maintain system frequency and voltage at
a constant level.
SEBU7681-22 51
Operation Section
Parallel Operation
Stopping
Refer to this Operation and Maintenance Manual,
Manual Stop Procedure for the required procedures
for stopping the generator set.
i02896680
Parallel Operation
SMCS Code: 4450
1. Check the phase rotation. a. Connect the light bulbs with rated voltage
between the generator leads and the
The phase rotation of the paralleled units must be corresponding line phase. For example, connect
equal. There are two methods that are used in
order to determine if the phase rotation of the terminal 1 to line 1 across the open circuit
incoming unit is equal to the phase rotation of the breaker.
on-line unit. These methods are listed below.
b. Start the units. Bring the units up to speed. As
Phase rotation meter the units approach the same speed, the lights
will start to blink.
Set of three light bulbs
If the lights blink in sequence, one of the
The procedure for determining the proper phase units is connected backward. In order to
rotation is described below. correct the problem, stop the units. Remove
generator leads 1 and 3 at the circuit
breaker. Exchange these generator leads.
This reverses the direction of phase
rotation. Terminal 2 should always be
connected to line 2. Go to 5.
Reactive droop compensation If the driven load has the unity power factor,
set the voltage droop potentiometer on all
Cross current compensation generators at half of full range. Proceed to
3.g.
In the reactive droop compensation, the voltage
regulator causes an individual generator output If the driven load is approximately 0.8
voltage to change in proportion to the reactive power factor, proceed to 3.c.
current. The reactive current is measured with a
current transformer (CT).
c. Readjust the voltage level rheostat until the
The reactive current can be either lagging or voltage is approximately 5 percent above
leading. As the lagging reactive current increases, desired voltage.
the voltage regulator will cause the generator
output voltage to droop proportionally. As the d. Apply full load.
leading reactive current increases, the voltage
regulator will cause the generator output voltage to
e. Readjust the voltage droop rheostat in order to
rise proportionally.
obtain desired voltage with full load at 0.8 power
This method will tend to reduce the reactive factor. The voltage droop of each generator
current for the better KVAR sharing with other must be equal in order to divide the reactive
units. The reactive droop compensation is a load.
standard method on the Caterpillar generator sets.
The following procedure for voltage adjustment is f. Repeat 3.c, 3.d and 3.e for each generator until
for the reactive droop compensation. the following two conditions are met.
In the cross current compensation, the voltage
regulator is forward biased by the difference in The line voltage is equal to the desired level
reactive current outputs of the generators in at full load.
parallel. Cross current compensation is very
similar to the reactive droop compensation. In The voltage at no load is approximately 5
cross current compensation, the secondary percent above the rated voltage.
circuits of the current transformers are connected
in a series string. When one of the generators g. Parallel the generators and apply the driven
carries more reactive current than other
generators, a net difference voltage signal will load. Check the output current of the generator.
offset the generated voltage. This will also reduce If the sum of the amperes of the individual
the reactive current. Refer to the Engine Data generator amperes exceeds the total amperes
Sheet, LEKX8142, Caterpillar Zero Droop Voltage that are going to the load by 10 percent at full
for Parallel Operation for the adjustment load, adjust voltage droop rheostats. This will
procedure.
lead to proportional current sharing between
Note: The adjustment for the voltage level and generators. Some circulating current is
voltage droop determine the amount of circulating permitted at light load. Some circulating current
currents between the generators. The circulating can be expected when generators are cold.
currents between the generators will be reduced
when the voltage adjustments are carefully matched.
Use the same voltmeter to make adjustments on
each unit which will be paralleled.
SEBU7681-22 53
Operation Section
Parallel Operation
2. Turn on the synchronizer lights. 2. Reduce the governor speed control of the other
unit in order to decrease the load on that unit.
3. After the engine has run a few minutes, bring the
engine up to synchronous speed. Synchronous 3. Raise or lower the governor speed control of both
speed means that the frequency of the incoming units in order to change system frequency.
unit will have the same frequency of the unit that is
on-line. The synchronizing lights will begin to blink. Parallel Operation Of Governors
Note: The frequency of the incoming unit should be The different governors that can be used on G3500C
slightly greater than the line frequency. This will allow generator sets are shown below.
the incoming unit to assume part of the load.
Illustration 34 g00630841
Load Sharing Module (typical example)
54 SEBU7681-22
Operation Section
Parallel Operation
The generator set load sharing module provides the The simplest governor combination for parallel
droop load sharing for generators that are paralleled. generator sets is a speed droop of 3 percent for
The generator set load sharing module provides the each governor. If a constant frequency from no
isochronous load sharing for generators that are load to full load is required, one governor can be
paralleled. The load sharing module has an input for adjusted for isochronous operation. This
the synchronizing parallel module. The module isochronous unit will be called a lead unit .
provides the load sharing that is proportional . More
information is available in the System Operation, In order for all paralleled units to accept the full
Testing and Adjusting, SENR6565, Generator Set share of the load, the following governor
Load Sensor and Generator Load Sharing Module. adjustments are required. The governors should
have the same full load speed. The governors
Function of The Engine Governor should have the same high idle speed in the case
of governors which are adjusted for speed droop
This section describes the function of the engine operation. The controls for the governor should be
governor in relation to load division between parallel set to the high idle position so that the full range of
electric sets. For detailed information on governor the governor is available.
controls and adjustments, refer to the Service Manual
for additional information. Operation of a governor that is isochronous in
It is very important to understand two basic facts parallel with speed droop governors requires
about load division between generator sets which are special techniques.
operating in parallel.
Any number of electric sets can be operated in
1. The power which is supplied to the generator is a parallel. However, only one governor of the group
function of the engine. The engine governor can be adjusted for isochronous operation. The
settings and the positions of the governor controls exception will be some special cases of electronic
determine the amount of power that is delivered by governors with an automatic load sharing
the engine. Therefore, the engine governor governor.
settings and the positions of the governor controls
determine the kW load which is carried by the Stopping
generator. If the governor control setting is
advanced, the engine and the generator will In order to remove a generator from the line, perform
the following procedure.
assume more kW load. Likewise, decreasing the
governor control setting will result in a reduction of 1. Check the load. The load must be less than the
load on the unit. Other units on the line will gain rated capacity of the remaining units.
load or other units will lose load. These other units
2. Be sure that the neutral of one of the remaining
will assume that no change in total load or no
units is grounded.
change in the governor settings of the other units
has taken place. 3. Remove the load from the outgoing unit. Refer to
the Parallel Operation, Load Division - Speed
2. The division of power is not determined by
Droop. The amperage may never go to zero due
generator excitation or terminal voltage. The
to circulating currents.
generator excitation will determine the power
factor of the generator during operation when the 4. Open the circuit breaker.
generator is in parallel with other generators.
5. Allow the engine to cool for five minutes.
Governors that are used with Caterpillar powered 6. Stop the engine.
electric sets can be of two types: governors with fixed
speed droop or governors with adjustable speed
droop. The values of speed droop which are Circulating Currents
commonly used are 3 percent and 0 percent.
Governors with adjustable speed droop can be Understanding the circulating currents becomes very
adjusted so that the settings match the settings of the important when you parallel the units. These
governors with fixed speed droop. If the governor is circulating currents are flowing between generators
adjusted for 0 percent speed droop operation, then that are paralleled. The circulating currents are
the same speed from no load to full load can be caused by voltage differences between the
obtained. generators. The amount of the circulating current can
be determined by subtracting the amperage which is
Summary on Governor Operation going to the load from the total generator amperage.
The circulating current may be as high as 25 percent The digital voltage regulator (DVR) is a
of rated amperes with cold generator sets. Such microprocessor based voltage regulator. The
current may not even be considered harmful. The parameters are preset at the factory or the
total generator current should not exceed the parameters can be modified in order to meet the
amperage rating. specific requirements on the site. Certain system
parameters can also be monitored on the display (1)
As the generators warm, the circulating currents will of the DVR. Keypad (5) is used to change the
decrease. The ammeter readings should decrease information that is shown on the display. J1
slightly, but the voltage meter readings should remain connector (6) is used to join the DVR to a personal
constant. computer. Screw terminals (7) are used to join the
DVR to the generator and various customer options.
i01718527
Table 10
Parameter Code Parameter Value
:01 0480
0481
0482
0483
:02 0001
0002
0003
0004
:03 0004
0003
0002
:04 0100
0099
0100
0101
i02849541
NOTICE
Stopping the engine immediately after the engine has
been operating under a load can result in overheating
and accelerated wear of the engine components.
Allow the engine to gradually cool before stopping
the engine.
i02508920
NOTICE
Only use antifreeze/coolant mixtures recommended
in the Refill Capacities and Recommendations sec-
tion of this manual. Failure to do so can cause engine
damage.
(continued)
60 SEBU7681-22
Maintenance Section
Fluid Recommendations
For further information about oils, see Special For further information on fuels, see Special
Publication, SEBU6400, Caterpillar Gas Engine Publication, SEBU6400, Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations. Lubricant, Fuel, and Coolant Recommendations.
NOTICE
Use of water that does not meet the recommenda-
tions for the cooling system will damage the cooling
system.
Do not use these types of water in the cooling sys-
tem: sea water, softened water that has been condi-
tioned with salt, hard water and tap water.
Only use water that meets the recommendations for
the cooling system.
environmental conditions
operator's experience
operator's philosophy
A regular maintenance program is strongly
recommended. This program would involve the
following steps:
periodic disassembly
If a 115 VAC source is available, connect both Do not loosen the high pressure fuel lines in order to
heaters in parallel across the source. If a 230 VAC remove air pressure from the fuel system.
source is available, connect both heaters in series
across the source. Refer to Illustration 37 .
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
off the engine.
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050 i05909227
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
Contact with high pressure fuel may cause fluid can cause damage to the drive train, the bearings,
penetration and burn hazards. High pressure fuel hydraulic components, electrical components, and
spray may cause a fire hazard. Failure to follow other components.
these inspection, maintenance and service in-
structions may cause personal injury or death. Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
The high pressure fuel lines are the fuel lines that are to the bearings, the crankshaft, the rotor shaft, and
between the high pressure fuel pump and the high other components.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These Clamp the ground cable from the welder to the com-
fuel lines are different from fuel lines on other fuel ponent that will be welded. Place the clamp as close
systems. as possible to the weld. This will help reduce the pos-
sibility of damage.
This is because of the following differences:
The high pressure fuel lines are constantly Note: Perform the welding in areas that are free from
charged with high pressure. explosive hazards.
The internal pressures of the high pressure fuel 1. Stop the engine. Turn the switched power to the
lines are higher than other types of fuel system. OFF position.
Before any service or repair is performed on the 2. Disconnect the negative battery cable from the
engine fuel lines, perform the following tasks: battery. If a battery disconnect switch is provided,
1. Stop the engine. open the switch.
2. Wait for ten minutes.
64 SEBU7681-22
Maintenance Section
Welding on Engines with Electronic Controls
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the
the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as
not allow the harness to move back accidentally, close as possible to the weld. This location will
and contact any of the ECM pins. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
4. Disconnect any component with a microprocessor
components, and ground straps.
from the engine harness, such as:
Note: If electrical/electronic components are used as
Engine ECM a ground for the welder, current flow from the welder
could severely damage the component. Current flow
Product Link
from the welder could also severely damage
electrical/electronic components that are located
Cell/Sat Radio
between the welder ground and the weld.
DOC Identity Modules
6. Protect the wiring harness from welding debris and
spatter.
7. Use standard welding practices to weld the
materials.
Illustration 38 g01075639
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
SEBU7681-22 65
Maintenance Section
Generator Start-up Checklist
i03643560
Table 16
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________ Arrangement Number: ___________________
Storage Location:
Generator Alignment:
No Load F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
(continued)
66 SEBU7681-22
Maintenance Section
Generator Start-up Checklist
Table 17
GENERATOR START-UP CHECKLIST (CONT.)
Check diodes
Over current protection
Adjust voltage
Adjust frequency
Overload setting
VAR/PF Controller
Load share
(continued)
SEBU7681-22 67
Maintenance Section
Generator Start-up Checklist
- Total HP - Computers
- Welding
- Non-linear
- Other
An authorized operator may perform the Fuel Metering Valve - Check . . . . . . . . . . . . . . . 100
maintenance items with daily intervals. An authorized
operator may perform the maintenance items with Generator - Dry. . . . . . . . . . . . . . . . . . . . . . . . . . 102
intervals of every week. The maintenance that is
Generator Lead - Check. . . . . . . . . . . . . . . . . . . 112
recommended for all other maintenance intervals
must be performed by an authorized service Generator Set - Test . . . . . . . . . . . . . . . . . . . . . . 113
technician or by your Cat dealer.
Generator Set Alignment - Check . . . . . . . . . . . 113
The user is responsible for the performance of all
maintenance which includes the following items: Generator Winding - Test . . . . . . . . . . . . . . . . . . 114
performing all adjustments , using proper lubricants,
fluids, and filters and replacing old components with Overhaul Considerations . . . . . . . . . . . . . . . . . . 126
new components due to normal wear and aging .
Space Heater - Test . . . . . . . . . . . . . . . . . . . . . . 129
Failure to adhere to proper maintenance intervals
and procedures may result in diminished Stator Winding Temperature - Test . . . . . . . . . . 133
performance of the product and/or accelerated wear
of components. Throttle Control Valve - Check . . . . . . . . . . . . . . 133
An authorized operator may perform the Fuel Metering Valve - Check . . . . . . . . . . . . . . . 100
maintenance items with daily intervals. An authorized
operator may perform the maintenance items with Generator - Dry. . . . . . . . . . . . . . . . . . . . . . . . . . 102
intervals of every week. The maintenance that is
Generator Set - Test . . . . . . . . . . . . . . . . . . . . . . 113
recommended for all other maintenance intervals
must be performed by an authorized service Generator Set Alignment - Check . . . . . . . . . . . 113
technician or by your Cat dealer.
Generator Winding - Test . . . . . . . . . . . . . . . . . . 114
The user is responsible for the performance of all
maintenance which includes the following items: Space Heater - Test . . . . . . . . . . . . . . . . . . . . . . 129
performing all adjustments , using proper lubricants,
fluids, and filters and replacing old components with Stator Winding Temperature - Test . . . . . . . . . . 133
new components due to normal wear and aging .
Throttle Control Valve - Check . . . . . . . . . . . . . . 133
Failure to adhere to proper maintenance intervals
and procedures may result in diminished
performance of the product and/or accelerated wear Daily
of components.
Engine Oil Level - Check . . . . . . . . . . . . . . . . . . . 96
Before each consecutive interval is performed, all
maintenance from the previous intervals must be Fumes Disposal Filter Differential Pressure -
performed. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fuel Metering Valve - Check . . . . . . . . . . . . . . . 100 Fumes Disposal Filter - Drain . . . . . . . . . . . . . . 101
Air Tank Moisture and Sediment - Drain . . . . . . . 78 Flexible Coupling - Inspect. . . . . . . . . . . . . . . . . 100
Between 7500 and 8000 Service Between 37 500 and 40 000 Service
Hours Hours
Overhaul (Top End) . . . . . . . . . . . . . . . . . . . . . . . 123 Overhaul (Major) . . . . . . . . . . . . . . . . . . . . . . . . . 122
Air Tank Moisture and Sediment - Drain . . . . . . . 78 Engine Speed/Timing Sensor - Clean/Inspect . . 98
Engine Air Cleaner Service Indicator - Inspect . . 91 Flexible Coupling - Inspect. . . . . . . . . . . . . . . . . 100
Engine Air Cleaner Service Indicator - Inspect . . 91 Engine Oil Sample - Obtain . . . . . . . . . . . . . . . . . 97
i01721862
i04342909
Alternator - Inspect
Illustration 39 g00885207 SMCS Code: 1405-040
Remove the drain plugs (1) from the ends of the Inspect the alternator for the following conditions:
plenum. Drain the moisture into a suitable container.
Reinstall the plugs. Proper connections
i04534752
Clean ports for cooling airflow
Proper charging of the battery
Air Tank Moisture and
Sediment - Drain Observe the ammeter during engine operation in
order to ensure proper battery performance and/or
SMCS Code: 1466-543-M&S proper performance of the electrical system.
Moisture and sediment in the air starting system can Make repairs, if necessary. See the Service Manual
cause the following conditions: for service procedures. Consult your Cat dealer for
assistance.
Freezing
i01942284
Corrosion of internal parts
Malfunction of the air starting system Automatic Start/Stop - Inspect
SMCS Code: 4462
The generator set must be ready to operate under a
load at any time. After performing maintenance on
the generator set, inspect the position of the control
switches. Ensure the following conditions:
SEBU7681-22 79
Maintenance Section
Battery - Recycle
5. Tighten the mounting bolt to the proper torque. Inspect the gaskets for wear or damage. If
For the proper torque specifications, refer to the necessary, replace the gaskets. Reinstall the
Service Manual, Specifications module. actuator according to the instructions in the Service
Manual, Disassembly and Assembly manual.
Replacement Inspect the coupling for the compressor bypass for
wear and play. If necessary, replace the coupling.
For applications that require multiple drive belts, Excessive wear in the coupling can cause low power
replace the drive belts in matched sets. Replacing or instability in the engine.
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
i03906355
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
Coolant (NGEC) - Change
i02904927
SMCS Code: 1350-044
Carburetor Air/Fuel Ratio - Clean the cooling system before the recommended
maintenance interval if the following conditions exist:
Check/Adjust
SMCS Code: 1266; 1266-535 The engine overheats frequently.
An engine failure may occur if the air/fuel ratio is not Foaming is observed.
appropriate for the fuel and for the operating
conditions. The service life of the turbocharger, of the The oil has entered the cooling system and the
valves, and of the other components may be coolant is contaminated.
reduced.
Coolant analysis indicates that the coolant has
Refer to the Systems Operation, Testing and broken down.
Adjusting for the correct procedure.
82 SEBU7681-22
Maintenance Section
Coolant (NGEC) - Change
Illustration 43 g01445599
2. Open coolant drain valve (7). 7. Flush the cooling system with clean water until the
water that drains is clean. Close the cooling
Clean the Cooling System system drain valves. Clean the drain plugs and
install the drain plugs.
NOTICE
Use of commercially available cooling system Cleaning a Cooling System that
cleaners may cause damage to cooling system com- has Heavy Deposits or Plugging
ponents. Use only cooling system cleaners that are
approved for Caterpillar engines.
Note: For the following procedure to be effective,
there must be an active flow through the cooling
1. After the cooling system has been drained, flush system components.
the cooling system with clean water in order to
remove any debris. 1. After the cooling system has been drained, flush
the cooling system with clean water in order to
2. Close the cooling system drain valves. Clean the remove any debris.
drain plugs and install the drain plugs.
2. Close the cooling system drain valves. Clean the
NOTICE drain plugs and install the drain plugs.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. 3. Remove the vent plugs.
4. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
NOTICE Cleaner. Add 0.5 L (1 pt) of cleaner per
If the aftercooler circuit has been drained, the vent
plug must be opened to allow the aftercooler to fill 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
properly. Failure to do this will cause an air lock re- capacity. Install the cooling system filler cap.
sulting in engine damage. Install the vent plugs.
5. Start the engine. Operate the engine for a
3. When the separate circuit is filled, be sure to minimum of 90 minutes with a coolant temperature
remove the vent plug. of at least 82 C (180 F).
4. Fill the cooling system with a mixture of clean 6. Stop the engine and allow the engine to cool.
water and Caterpillar Fast Acting Cooling System Loosen the cooling system filler cap slowly in
Cleaner. Add 0.5 L (1 pt) of cleaner per 15 L order to relieve any pressure. Remove the cooling
(4 US gal) of the cooling system capacity. Install system filler cap. Open the cooling system drain
the cooling system filler cap. Install vent plugs (1). valves and remove the drain plugs. Remove the
5. Start the engine. Operate the engine for a vent plugs. Allow the cleaning solution to drain.
minimum of 30 minutes with a coolant temperature
of at least 82 C (180 F). NOTICE
Improper or incomplete rinsing of the cooling system
6. Stop the engine and allow the engine to cool. For can result in damage to copper and other metal
components.
the jacket water and the separate circuit, loosen
the cooling system filler cap slowly in order to To avoid damage to the cooling system, make sure to
relieve any pressure. Remove the cooling system completely flush the cooling system with clear water.
filler cap. Open the cooling system drain valves Continue to flush the system until all signs of the
and remove the drain plugs. Remove the vent cleaning agent are gone.
plugs. Allow the cleaning solution to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal
components.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
cleaning agent are gone.
84 SEBU7681-22
Maintenance Section
Coolant Level - Check
7. Flush the cooling system with clean water until the 7. Start the engine. Inspect the cooling system for
water that drains is clean. Close the cooling leaks and for proper operating temperature.
system drain valves. Clean the drain plugs and
install the drain plugs. i04696591
Add Coolant
Note: For the proper coolant mixture to use, see this
Operation and Maintenance Manual, Fluid
Recommendations topic and this Operation and
Maintenance Manual, Refill Capacities topic.
Illustration 45 g00103639
Filler cap gaskets
i03852509
NOTICE
NOTICE Always use a designated pump for oil sampling, and
Overfilling the overflow tank (if equipped) will result in use a separate designated pump for coolant sam-
damage to the cooling system. pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
If the cooling system has an overflow tank, maintain drawn. This contaminate may cause a false analysis
the coolant level in the tank below 1/2 full in order to and an incorrect interpretation that could lead to con-
avoid damage to the cooling system.
cerns by both dealers and customers.
Observe the coolant level in the sight gauge (if
equipped). When the engine is running at normal For conventional heavy-duty antifreeze/coolant,
operating temperature, the coolant should be in the check the concentration of supplemental coolant
upper half of the sight gauge. If the coolant level is additive (SCA) regularly. The concentration of SCA
low, add the proper coolant mixture. can be checked with an SOS coolant analysis
(Level 1).
86 SEBU7681-22
Maintenance Section
Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible Refer to this Operation and Maintenance Manual,
to the recommended sampling interval. In order to Cooling System Coolant Sample (Level 1) - Obtain
receive the full effect of SOS analysis, you must (Maintenance Section) for the guidelines for proper
establish a consistent trend of data. In order to sampling of the coolant.
establish a pertinent history of data, perform
consistent samplings that are evenly spaced. Submit the sample for Level 2 analysis.
Supplies for collecting samples can be obtained from
your Caterpillar dealer. For additional information about coolant analysis, see
the Special Publication, SEBU6400, Caterpillar Gas
Use the following guidelines for proper sampling of Engine Lubricant, Fuel, and Coolant
the coolant: Recommendations or consult your Cat dealer.
Never collect samples from expansion bottles. i05870232
A sudden increase in blowby could indicate a broken A damper that is hot is typically due to excessive
piston ring. The following conditions are other torsional vibration. A hot damper can also be due to
potential sources of blowby: the operating environment. See the Service Manual,
Application and Installation Guideline. Monitor the
Worn valve guides temperature of the damper during operation.
A turbocharger seal that leaks The 8T-2821 Temperature Indicator or the
8T-2822 Temperature Indicator are recommended
A rebuilt engine can have a high blowby due to the for monitoring the temperature of the damper. Evenly
following factors: space four of the adhesive indicators around the
outer diameter of the damper.
The piston rings are not seated properly.
Note: If you use an infrared thermometer to monitor
Worn parts such as valve guides were not the temperature of the damper, use the thermometer
replaced. during operation with similar loads and speeds. Keep
a record of the data. If the temperature begins to rise,
Excessive blowby may indicate the need for an reduce the interval for inspecting the damper and
overhaul. By keeping a record of the results, a
gradual increase in the amount of the blowby will be install temperature indicator strips for more accurate
noted until the amount has become excessive. readings.
To measure the blowby, use the 1U-8860 Large If the temperature of the damper reaches 90 C
Engine Blowby Pickup Group with the 8T-2701 (194 F), reduce the interval for inspecting the
Blowby Indicator. For instructions, see Special damper. If the temperature of the damper reaches
Instruction, SEHS8984, Using the 1U-8860 Large 100 C (212 F), consult your Caterpillar dealer.
Engine Blowby Pickup Group and Special
Instruction, SEHS8712, Using the 8T-2700 Inspect the damper for evidence of dents, cracks,
Blowby/Air Flow Indicator. and leaks of the fluid.
If a fluid leak is found, repair the damper or replace
For assistance, consult your Cat dealer. the damper. The fluid in the damper is silicone.
Silicone has the following characteristics:
i01601829 transparent, viscous, smooth and sticky.
Crankcase Pressure - Measure Inspect the damper and repair or replace the damper
for any of the following reasons.
(Engines with Fumes Disposal
The damper is dented, cracked, or leaking.
Filters)
The paint on the damper is discolored from heat.
SMCS Code: 1074
Measure the crankcase pressure during normal The temperature swatch has been tripped for
operation. temperatures greater than 100 C (212 F).
With a fumes disposal filter that is properly installed, Fluid analysis indicates the silicon fluid has
the crankcase pressure will be within 0.25 kPa degraded from its original viscosity by greater than
(1 inch of H2O) of the atmospheric pressure. 30 percent.
SMCS Code: 1205-040 There is a large amount of gear train wear that is
not caused by a lack of oil.
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has
a weight that is located inside a fluid filled case.
Damage to the crankshaft vibration damper or failure
of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
engine components. A deteriorating damper can
cause excessive gear train noise at variable points in
the speed range.
SEBU7681-22 89
Maintenance Section
Crankshaft Vibration Damper - Inspect
i06720204
Illustration 47 g06074060
1. Remove the damper. 4. Clean all parts of the damper. Pay special attention
to the oil supply and venting holes.
2. Remove side plate (3).
5. Replace all accessible rubber seal rings.
3. Separate the inner adapter of the damper (2) from
the spring assembly (1). 6. Replace all disc springs from bolts that have been
removed.
Note: Do not disassemble the damper spring
assembly.
90 SEBU7681-22
Maintenance Section
Cylinder Pressure - Test/Record
7. Check for permissible wear of the Y-seal. Replace 1. Measure for wear. Refer to illustration 49
the seals whenever the damper is disassembled,
2. Measure every spring pack.
or there is evidence of leakage.
3. Place the measuring wedge between the inner
8. Assemble inner adapter (2) and spring assembly
ends of the spring blades and the wedge is
(1).
touching the inner adapter. The measuring wedge
end face and groove bottom must be parallel.
4. Press by hand or use a soft face hammer to force
the wedge along the inner star groove until the
spring tips rest on both groove faces.
The further the wedge can be pressed between the
spring blades, the greater the wear on the inner star
groove and spring blades. If the wedge can be
inserted to the "Not Go" section of the measuring
wedge, replace the damper.
i04319794
A broken valve
A piston ring that sticks
Illustration 50 g00828960
(Y) Cylinder pressure in kPa
(X) Compression ratio
(1) Normal range for cylinder pressure
i01799090
i03852569 i02017618
Illustration 54 g01340704
Typical configuration of mounting bolts for a NOTICE
Ensure that the engine is stopped before performing
Caterpillar genset this procedure. Attach a DO NOT OPERATE tag to
(1) Mounting bolts for the engine the starting controls.
(2) Mounting bolts for the generator
(3) Levelling bolts for the isolators Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the
Misalignment of the engine and the driven equipment bottom of the oil pan. The waste particles are not
will cause extensive damage. Excessive vibration removed when the cold oil is drained. Drain the
can lead to misalignment. Excessive vibration of the crankcase with the oil warm, immediately after the
engine and the driven equipment can be caused by engine is stopped. This draining method allows the
the following conditions: waste particles that are suspended in the oil to be
drained properly. Failure to follow this recommended
Improper mounting procedure will allow the waste particles to be
recirculated through the engine lubrication system
Misalignment of driven equipment with the new oil.
Loose bolts 1. After the engine has been operated at normal
operating temperature, STOP the engine.
Deterioration of the isolators
Ensure that the mounting bolts are tightened to the Note: Drain the oil into a suitable container. Dispose
proper torque. For standard torques, see of fluids according to local regulations.
Specifications, SENR3130, Torque Specifications.
2. Drain the oil by using one of the following methods.
Ensure that the isolators are free of oil and Use the method that corresponds to the
contamination. Inspect the isolators for deterioration. equipment on the engine.
Ensure that the bolts for adjusting the isolator are
correctly adjusted and secured with the locking nut. Note: If a suction device is used in order to remove
Correctly adjusted isolators provide even support for the oil from the oil pan, ensure that the suction
the engine base. Each isolator should impose nearly device is clean. This will prevent dirt from entering
identical force on the base rail. Each isolator should into the oil pan. Be careful not to strike the engine
bear the same portion of the weight of the genset.
oil suction tubes or the piston cooling jets.
Replace any isolator that shows deterioration. For
more information, see the literature that is provided a. If the engine has an oil drain valve, open the
by the OEM of the isolators. Also see the Application valve in order to drain the oil. After the oil has
and Installation Guide for the engine. Consult your drained, close the valve.
Caterpillar dealer for assistance.
b. If the engine has a pump for removing dirty oil,
connect a hose to the outlet of the pump. Place
the hose in a suitable container. Open the valve
for the drain line. Operate the pump until the
crankcase is empty. Close the valve to the drain
line. Disconnect the hose.
c. If the oil drain valve has a quick connect
coupling, attach the coupling. Open the drain
valve in order to drain the crankcase. After the
94 SEBU7681-22
Maintenance Section
Engine Oil Filter - Change
NOTICE
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to
the starting controls.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, Dealer
Service Tool Catalog for tools and supplies suitable
to collect and contain fluids on Cat products. Illustration 56 g00103713
Mounting base and gasket
Dispose of all fluids according to local regulations
and mandates. 4. Clean the sealing surface of the mounting base.
Ensure that all of the old gasket is removed.
5. Apply clean engine oil to the gasket of the new oil
filter.
NOTICE
Caterpillar oil filters are built to Caterpillar specifica-
tions. Use of an oil filter not recommended by Cater-
pillar could result in severe engine damage to the
engine bearings, crankshaft, etc., as a result of the
larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom-
mended by Caterpillar.
i02225089
3. If necessary, add engine oil. For the correct engine Caterpillar recommends using the sampling valve in
oil to use, refer to this Operation and Maintenance order to obtain oil samples. The quality and the
Manual, Refill Capacities and Recommendations consistency of the samples are better when the
topic (Maintenance Section). Do not fill the sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
crankcase above the FULL mark on the engine obtained during normal engine operation.
oil level gauge. Clean the filler cap (2). Install the
filler cap. The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
4. Record the amount of engine oil that is added. For fluid sampling bottle includes the parts that are
the next engine oil sample and analysis, include needed for obtaining oil samples. Instructions are
the total amount of engine oil that has been added also provided.
since the previous oil change. This will help to
provide the most accurate analysis. NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
i04237495 pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
Engine Oil Sample - Obtain drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
SMCS Code: 1348-554-SM cerns by both dealers and customers.
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil If the engine is not equipped with a sampling valve,
analysis at regularly scheduled intervals. SOS oil use the 1U-5718 Vacuum Pump. The pump is
analysis provides infrared analysis, which is required designed to accept sampling bottles. Disposable
for determining nitration and oxidation levels. tubing must be attached to the pump for insertion into
the sump.
Obtain the Sample and the
For instructions, see Special Publication, PEGJ0047,
Analysis How To Take A Good SOS Oil Sample. Consult
your Cat dealer for complete information and
assistance in establishing an SOS program for your
engine.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to i04688489
contact the skin.
Engine Oil Temperature
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order to Regulator - Replace
help obtain the most accurate analysis, provide the SMCS Code: 1330-510
following information:
The oil temperature regulators divert the engine oil to
Engine model the oil cooler in order to maintain engine oil
temperature.
Service hours on the engine
For instructions on replacing the oil temperature
The number of hours that have accumulated since regulators, see the Service Manual, Disassembly
the last oil change and Assembly module.
The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, 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.
98 SEBU7681-22
Maintenance Section
Engine Protective Devices - Check
i02861779
Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that are
loose, broken, or damaged. Damaged wiring or
components should be repaired or replaced
immediately.
Illustration 59 g00760464
Calibration Check
Fixed head sensors (if equipped)
NOTICE
During testing, abnormal operating conditions must
be simulated.
The tests must be performed correctly in order to pre-
vent possible damage to the engine.
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible to
determine if the engine protective devices are in
good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices. To prevent damage to the
engine, only authorized service personnel or your
Caterpillar dealer should perform the tests.
Consult your Caterpillar dealer or refer to the Service
Manual for more information. Illustration 60 g00293337
i03852589
i01724567
Illustration 63 g00886284
(1) Fuel metering valve
SEBU7681-22 101
Maintenance Section
Fumes Disposal Filter - Drain
For information regarding the fuel metering valve, 5. Close the condensation trap drain valve.
refer to Installation and Operation Manual,
SEBU7630, Raptor Gas Regulation and Metering Resume normal operation.
Valve/Actuator System for Caterpillar.
i01601766
i01857938
Fumes Disposal Filter
Fumes Disposal Filter - Drain Differential Pressure - Check
SMCS Code: 1074
SMCS Code: 1074
Illustration 64 g00947065
Replace the element after every year regardless
of the differential pressure.
(1) Drip leg
(2) Condensation trap drain valve
i01749518
2. Open drip leg (1) and drain the fluid into a suitable
container. Fumes Disposal Filter Element
If the filter is installed and maintained properly, no - Replace
more than 28 g (1 ounce) of fluid will be drained. SMCS Code: 1074
If more than one 28 g (1 ounce) is drained, make
sure that the filter is installed according to the
instructions in Special Instruction, REHS0883.
Ensure that the system is operating properly. Hot oil and components can cause personal
injury.
3. Close the drip leg.
Do not allow hot oil or components to contact
4. Open condensation trap drain valve (2) and drain skin.
the fluid into a suitable container.
102 SEBU7681-22
Maintenance Section
Gas Pressure Regulator Condensation - Drain
Illustration 67 g01014926
Cap on the drip leg for the gas supply line to the gas
pressure regulator
Note: The filter element is mounted above the 4. Clean the caps. Install the caps.
engine. A ladder or a platform will be required for 5. Open the main gas supply valve.
servicing the element.
i03214248
1. Remove three nuts and washers (1) in order to
remove cover (2) from body (3).
Generator - Dry
2. Remove element (4).
SMCS Code: 4450-569
3. Clean the inside of cover (2) and body (3).
4. Install new element (4) into body (3). NOTICE
Do not operate the generator if the windings are wet.
5. Place cover (2) in position and install three nuts If the generator is operated when the windings are
and washers (1). wet, damage can occur due to insulation breakdown.
i01950516
Gas Pressure Regulator Personal injury or death can result from improper
Condensation - Drain troubleshooting and repair procedures.
SMCS Code: 1270-543 The following troubleshooting and repair proce-
dures should only be performed by qualified per-
To collect condensation, drip legs should be installed sonnel familiar with this equipment.
in the following locations:
Refer to Safety Section, Generator Isolating for
Supply line for the gas pressure regulator Maintenance for information regarding the
procedure to safely isolate the generator.
Balance line for the gas pressure regulator
When moisture is present or when moisture is
Supply line to the gas shutoff valve 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.
SEBU7681-22 103
Maintenance Section
Generator - Dry
NOTICE
Do not exceed the rated phase current that is listed
on the generator nameplate. Exceeding the rated
phase current will easily damage the generator
windings.
Personal injury or death can result from improper The extent of the cleaning procedure that is being
troubleshooting and repair procedures. attempted
The following troubleshooting and repair proce- The type of enclosure of the generator
dures should only be performed by qualified per-
sonnel familiar with this equipment. The voltage rating of the generator
After the initial cleaning with a vacuum, compressed 1. Remove the bearing bracket. Inspect the following
air may be used to remove the remaining dust and items: bracket bore, bearing outer race and rolling
dirt. Compressed air that is used for cleaning should elements. On standby power units, the bearing
be free of moisture and free of oil. Air pressure must be inspected and the grease must be
should be a maximum of 210 kPa (30 psi) in order to
prevent mechanical damage to the insulation. If the replaced at 3 yr intervals. The sleeve in the
above cleaning procedures are not effective, consult bearing bracket should be inspected for out of
a Cat dealer. roundness, excessive wear, and a bracket step
that is less than 0.0762 mm (0.0030 inch). If there
Cleaning (Disassembled is no sleeve in the bearing bracket, inspect the
bore of the bearing bracket. The bearing should be
Generators) inspected for damage to the outer race, severe
An initial insulation resistance check should be made fretting, and smoothness of operation. When
on the generator in order to confirm electrical possible, the bearing elements should be
integrity. A minimum reading of two megohm would inspected. Some double shielded ball bearings
be expected with severely contaminated generators. prevent visual inspection of the elements of the
A zero megohm reading may indicate an insulation bearing. Other double shielded ball bearings have
breakdown. An insulation breakdown requires more
than cleaning. An insulation breakdown requires a retaining ring. This retaining ring can be
repair. removed to allow access for a visual inspection of
the elements of the bearing.
A high-pressure wash is normally an effective way to
clean windings. This includes windings that have On two-bearing generators, the front bearing can
been exposed to flooding or windings that have been only be removed after the hub is removed. To
contaminated by salt. A solution of hot water and remove the hub, cutoff the hub with a saw. Do not
detergent is used for this method of cleaning. use a torch to remove the hub. Do not pull on the
hub. Pulling the hub will damage the shaft.
A high-pressure wash sprays a high velocity fluid
stream of this solution over the generator that is Note: Bearings that are being removed for failure
being cleaned. This detergent washing is followed by analysis should not be cutoff with a torch.
multiple sprays of clean water. The clean water is
used in order to remove the detergent or the clean 2. All ball bearings should be cleaned. The cavity in
water is used in order to dilute the detergent. the bracket should be repacked, refer to Special
Instruction, REHS4892, Generator Bearing
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation Service. Pack the ball bearings (one-third to one-
resistance should now be normal. If the insulation half of the volume of the cavity). Refer to Table 21
resistance is not normal, repeat the procedure. It may
be necessary to use solvents if the generator is To reinstall the ball bearings, use an induction
contaminated with oil or if the generator is heater to heat the ball bearings to 107 C
contaminated with grease. (224.6 F) for 10 minutes. Mount the bearings on
the shaft. To reinstall the hub, heat the hub to
Note: For more information on drying methods, refer 400 C (752.0 F) for 3 hours. Mount the hub to
to Special Instructions, SEHS9124, Cleaning and the shaft.
Drying of Electric Set Generators. 3. Ensure that the tube of the grease gun is filled with
grease.
i06612696
4. Remove the bracket drain plug and operate the
Generator Bearing - Inspect generator for 1 hour. Operating the generator will
allow the grease to expand. The expanding grease
SMCS Code: 4471-040
will force the excess grease from the cavity. When
The following maintenance procedure for generator the excess grease is forced from the cavity, the
bearings should be followed: internal pressure will be reduced. The generator
should continue to operate until the grease stops
purging.
5. Stop the engine. Install the bracket drain plug.
Wipe off the excess grease.
106 SEBU7681-22
Maintenance Section
Generator Bearing - Inspect
(continued)
SEBU7681-22 107
Maintenance Section
Generator Bearing - Lubricate
6Y-3955 220 BC 450 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 100 mm
Ball Bearing 180 mm Instruction, service (1.8 oz) (3.9 inch)
(7.1 inch) REHS4892, hours or 12
OD Generator months
100 mm Bearing Service
(3.9 inch)
ID
6Y-6488 318 BC 597 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 90 mm (3.5 inch)
Ball Bearing 190 mm Instruction, service (1.8 oz)
(7.5 inch) REHS4892, hours or 12
OD Generator months
90 mm Bearing Service
(3.5 inch)
108-1760 321 BC 680 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 105 mm
Ball Bearing 225 mm Instruction, service (1.8 oz) (4.1 inch)
(8.9 inch) REHS4892, hours or 12
OD Generator months
105 mm Bearing Service
(4.1 inch)
ID
108-1761 322 BC 690 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 110 mm
Ball Bearing 240 mm 800 Instruction, service (1.8 oz) (4.3 inch)
(9.4 inch) REHS4892, hours or 12
OD Generator months
110 mm Bearing Service
(4.3 inch)
ID
(continued)
SEBU7681-22 109
Maintenance Section
Generator Bearing - Lubricate
(continued)
110 SEBU7681-22
Maintenance Section
Generator Bearing - Lubricate
(continued)
SEBU7681-22 111
Maintenance Section
Generator Bearing Temperature - Test/Record
Old grease must be removed at the time of bearing The monitoring of bearing temperature may prevent
replacement from the bearing bracket cavity. After premature bearing failure. A generator set should
the bearing bracket cavity is cleaned, the bearing never operate above the recommended set points.
Keep records in order to monitor the changes in the
bracket cavity must be packed with new grease from
temperature of the bearing.
one-third to one-half full.
Note: Measure the bearing temperature after the
generator reaches normal operating temperature.
112 SEBU7681-22
Maintenance Section
Generator Lead - Check
Resistive Temperature Detectors The power factor can be referred to as the efficiency
of the load, which can be expressed as the ratio of
(RTDs) kVA to actual kW. The power factor can be calculated
by dividing kW by kVA. Power factor is expressed as
Caterpillar Generators may be equipped with a decimal. Power factor is used to mean the portion
resistance temperature detectors for generator of current that is supplied to a system that is doing
bearings. These detectors are 100 ohm resistance useful work. The portion of the current that is not
temperature detectors. A resistance temperature doing useful work is absorbed in maintaining the
detector may be monitored by equipment that is magnetic field in motors. This current (reactive load)
provided by the customer. Consult with your can be maintained without engine power.
Caterpillar dealer about other methods of measuring
the bearing temperature. Generator sets normally have a low idle setting that is
higher than industrial engines. Low idle will be
Infrared Thermometers approximately 66 percent of the full speed that is
achieved by 60 Hz units. This would be equal to 80
Bearing temperatures can also be recorded with the percent of the full speed that is achieved by 50 Hz
use of an infrared thermometer. Refer to Special units.
Publication, NENG2500, Caterpillar Dealer Service
Tools Catalog for a variety of infrared thermometers. Some generator sets are equipped with Woodward
Follow the instructions that come with your infrared governors and some generator sets are equipped
thermometer. with Cat electronic governors. These generator sets
have no low idle stop. On generator sets with
mechanical governors and generators that are
i05325030
natural gas, the low idle is set at the factory.
Adjustment of the low idle on these machines should
Generator Lead - Check only be done by a Cat dealer.
SMCS Code: 4450-535 Note: Operating the generator set at low idle speed
Check for signs of wear along the generator leads. for an extended time will cause some voltage
Pay particular attention to the leads at the housing for regulators to shut off. The generator set must be
the breaker and the generator terminal box. completely shut down and the generator set must be
restarted. This will allow the voltage regulator to
If the rubber mats or the insulation on the leads show produce an output again.
signs of wear at points of contact with other surfaces,
replace immediately. If your generator set does not
have rubber mats in place, contact your Cat dealer.
i05264201
i05264206 i03736530
Loose belts
Excessive noise
Cracked insulation
The following areas are susceptible to vibration
damage:
Insulation
Exposed electrical connections
Transformers
Fuses
Capacitors
Lightning arresters
When a generator set is installed a vibration plot
should be recorded in order to assist in diagnosing
potential problems. This vibration plot should be
updated yearly. The vibration plot should also be
updated when the generator set is moved. Refer to
Data Sheet, LEKQ4023, Linear Vibration for the
allowable limits of vibration.
Contact the Cat Dealer Service Tools group for Illustration 69 g01388839
information on ordering a vibration analyzer that will PMPE Generator wiring diagram for the family of
meet your needs. 1800 frames
(CR1-C6) Diodes
(CR7) Varistor
(L1) Exciter stator
(L2) Exciter rotor
(L3) Main rotor
(L4) Main stator
(L5) Permanent magnet generator stator
(PM) Permanent magnet
(RFA) Rotating field assembly
(CT1) Optional voltage droop transformer
(T0, T1, T2, T3, T7, T8, T9) Generator terminals
SEBU7681-22 115
Maintenance Section
Generator Winding Insulation - Test
Table 24
Quantity Needed Tool i03736629
1 Low ohmmeter
Generator Winding Insulation -
Measure the resistance of the following windings: Test
(L1), (L2), (L3), (L4) and (L5). The winding that is
being tested must be disconnected from the other SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
components before the resistance can be measured. 081
Use a multimeter in order to measure the resistance Periodically, use an insulation tester to check the
of field windings (L1) and (L3). insulation resistance of the generator's main stator
winding. The frequency of this test is determined by
Exciter field (stator) (L1) Refer to table 25 . the generator's environment. Previous insulation
tester readings will also determine the frequency of
Main field (rotor) (L3) approximately 0.35 ohms to this test.
1.2 ohms
Test the main stator windings with an insulation tester
in the following situations:
Note: There should be no continuity between any
winding and ground. There should be no continuity The generator set is started for the first time.
between any winding and another winding.
The generator set is removed from storage.
Table 25
L2 Exciter Main Field for
The generator set is operating in a humid
L1 Exciter Field
Rotor the Rotor environment. Test every three months.
1800 Frame 10.9 ohms 0.05 ohms .9 ohms The generator set is not protected from the
1600 Frame 10 ohms 0.06 ohms .5 ohms
elements in an enclosed area. Test every three
months.
1400 Frame 11 ohms 0.06 ohms .35 ohms
The generator set is installed in an enclosed area.
This area needs to be low in humidity and this
area needs to have steady temperatures. Test
every twelve months (minimum).
116 SEBU7681-22
Maintenance Section
Generator Winding Insulation - Test
The generator set has not been run under load for 11. Use the 30/60 Time Resistance Method:
three months. Test the generator set weekly. Use
space heaters around the generator set if the a. Apply voltage.
generator is exposed to a sea water environment
or if the humidity is above 75 percent. Also use b. Observe the readings at 30 seconds. Observe
space heaters if a test result was below 3 the readings at 60 seconds.
megohms.
c. Record the 60 second reading. This reading
Space heaters must be used whenever the generator must be corrected for temperature.
set is not under load. Space heaters must also be
used whenever salt is present or whenever high d. Record temperature.
humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester e. Record humidity.
readings above one megohm. Use space heaters
only when the generator is not running. f. Remove voltage.
For additional information, refer to Special 12. Evaluate the readings. The actual value of the
Instruction, SEHS9124, Cleaning and Drying of resistance may vary greatly between generators.
Electric Set Generators. For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
Recommended Procedure for the between the 60 second resistance readings and
Insulation Test 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,
Personal injury or death can result from the insulation may have absorbed too much
electrocution. moisture.
Switch the insulation tester to the OFF position.
The megohmmeter is applying a high voltage to This will discharge the insulation tester's leads.
the circuit. Disconnect the insulation tester's leads.
To avoid electrocution, do not touch the instru- Note: The results from the insulation resistance
ment leads without first discharging them. When
finished testing also discharge the generator checks indicate when cleaning and/or repairing is
windings. becoming critical. Generally, insulation resistance will
vary greatly with temperature. Therefore, always test
at the same temperature and humidity. Refer to
1. Take the generator out of service. Illustration 70 .
2. Visually inspect the generator for moisture. If Engine Serial Number
moisture exists, do not perform this insulation test.
Dry the unit first. Refer to Special Instruction, Serial Number for the Generator
SEHS9124, Cleaning and Drying of Electric Set
Generators.
3. Inspect the installation. Determine the equipment
that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Disconnect T0 from ground.
6. Disconnect the sensing lead wires for the
regulator. This may be accomplished by
unplugging the harness connectors.
7. Disconnect the PT leads of the load share module.
8. Connect the insulation tester's Black lead to
ground.
9. Connect the insulation tester's RED lead to T0 .
10. Set the voltage to the rated voltage of the
generator.
SEBU7681-22 117
Maintenance Section
Generator Winding Insulation - Test
118 SEBU7681-22
Maintenance Section
Hoses and Clamps - Inspect/Replace
Illustration 70 g00633226
i06825542 Looseness
Note: Ensure that the hose is compatible with the Replace hoses that are cracked or soft. Replace
application. hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
Inspect Tubes, Hoses, Bellows, and hose clamps which are loose.
Clamps
Replace the Hoses and the Clamps
Inspect all tubes and hoses for leaks that are caused
by the following conditions. Replace any tube or hose
which exhibits any of the following conditions. Failure NOTICE
Care must be taken to ensure that fluids are con-
to replace a tube or hose which exhibits any of the tained during performance of inspection, mainte-
following conditions may result in a hazardous nance, testing, adjusting, and repair of the product.
situation. Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
Hoses which are cracked bling any component containing fluids.
Hoses which are soft Refer to Special Publication, NENG2500, Cat Dealer
Service Tool Catalog or refer to Special Publication,
Outer covering that is chafed or cut PECJ0003, Cat Shop Supplies and Tools Catalog
for tools and supplies suitable to collect and contain
Exposed wire that is used for reinforcement fluids on Cat products.
Outer covering that is ballooning locally Dispose of all fluids according to local regulations
and mandates.
Flexible part of the hose that is kinked or crushed
Personal injury can result from removing hoses Contact with high pressure fuel may cause fluid
or fittings in a pressure system. penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
Failure to relieve pressure can cause personal these inspection, maintenance and service in-
injury. structions may cause personal injury or death.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
NOTICE
Do not bend or strike high pressure lines. Do not in-
1. Stop the engine. stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
2. Allow the engine to cool. hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
3. Before servicing a coolant hose, slowly loosen the recommended torque.
filler cap for the cooling system to relieve any
pressure.
NOTICE
4. Remove the filler cap for the cooling system. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
5. Drain the coolant from the cooling system to a will be disconnected. Fit a suitable cover over any
level that is below the hose that is being replaced. disconnected fuel system components.
Drain the coolant into a suitable clean container.
The coolant can be reused.
Note: High-pressure fuel lines may be installed
6. Remove the hose clamps. between the high-pressure fuel pump and the fuel
7. Disconnect the old hose. injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the high-
8. Replace the old hose with a new hose. pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
9. Install hose clamps which have been inspected or engine stops before you perform any service or
install new hose clamps. Refer to Specifications, repair on high-pressure fuel lines. Waiting for 10
SENR3130, Torque Specifications Hose minutes will allow the pressure to be purged.
Clamps for information about selecting and
installing the proper hose clamps. 1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced.
10. Refill the cooling system.
2. Remove the hose clamps.
11. Clean the coolant filler cap. Inspect the gaskets
on the filler cap. Inspect the gasket seat. Inspect 3. Disconnect the old hose.
the vacuum valve and seat for debris or damage.
Replace the filler cap if the gaskets are damaged. Note: When servicing fuel system, use cap/s or
cover/s as required to protect the system and
Install the filler cap.
maintain fuel system cleanliness.
12. Start the engine. Inspect the cooling system for
leaks. 4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
Fuel System install new hose clamps. Refer to Specifications,
SENR3130, Torque Specifications Hose
Clamps for information about selecting and
installing the proper hose clamps.
Personal injury can result from removing hoses
or fittings in a pressure system. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Failure to relieve pressure can cause personal engine.
injury.
Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved.
120 SEBU7681-22
Maintenance Section
Ignition System Timing - Check/Adjust
7. Refill the fuel system. Refer to this Operation and 5. Start the engine. Inspect the air lines for leaks.
Maintenance Manual, Fuel System - Prime for
information about priming the engine with fuel. i06024073
Note: The bellows and the V-clamps that are used on Leaks
the exhaust bellows should never be reused.
Loose connections
Debris
Ensure that all of the connections are secure. Ensure
that the components are in good condition and free of
debris.
SEBU7681-22 121
Maintenance Section
Jacket Water Heater - Check
Make repairs, if necessary. For information regarding A 20 percent loss of cylinder compression
removal and installation of the components, refer to
Service Manual, Disassembly and Assembly. Note: These indications do not require an engine to
Consult your Cat dealer for assistance. be shut down for service. These indications only
mean that an engine should be scheduled for service
i03230758 in the near future. If the engine operation is
satisfactory, an immediate overhaul is not a
Jacket Water Heater - Check requirement.
Consult your Caterpillar dealer about repair options Other factors must also be considered for
for your engine. determining a major overhaul:
Power output
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the The service hours of the engine
recommendations in Table 27 .
Table 27 Reduced oil pressure
In-Frame Overhaul The wear metal analysis of the lube oil
Clean Oil suction screen
An increase in the levels of noise and vibration
Clean Aftercooler core
Inspect An increase of wear metals in the lube oil indicates
Test that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
Inspect Compressor bypass valve noise and vibration indicates that rotating parts
Rebuild require service.
Replace Exhaust system (landfill)
SMCS Code: 7595-020-MJ Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
Scheduling a Major Overhaul appropriate specifications.
Generally, a major overhaul is performed for every The following definitions explain the terminology for
fifth top end overhaul. The need for a major overhaul the services that are performed during an overhaul:
is determined by several factors. Some of those
factors are the same factors that determine the in- Inspect Inspect the components according to the
frame overhaul: instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts
An increase of oil consumption and Salvage Operations, SEBF8029, Index of
Publications on Reusability or Salvage of Used
An increase of crankcase blowby Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
A decrease and variation of cylinder compression unnecessary expenditures. New parts are not
SEBU7681-22 123
Maintenance Section
Overhaul (Top End)
required if the existing parts can still be used, (Table 28, contd)
reconditioned, or repaired. If the components are not Major Overhaul
in the reusability guidelines, refer to the Service
Manual, Specifications module. Replace Camshaft bearings
Vibration damper
(continued)
124 SEBU7681-22
Maintenance Section
Overhaul (Top End)
The following definitions explain the terminology for Clean the aftercooler core and the oil cooler core.
the services that are performed during an overhaul: Perform pressure tests on the components. Replace
the components, if necessary.
Inspect Inspect the components according to the
instructions that are in Caterpillar reusability Note: If the cooling system is not properly
publications. Refer to Guidelines for Reusable Parts maintained, cleaning of the aftercooler can be
and Salvage Operations, SEBF8029, Index of difficult. The tank that is opposite of the inlet port and
Publications on Reusability or Salvage of Used the outlet port cannot be removed for cleaning.
Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid Note: This procedure may be used for cleaning both
unnecessary expenditures. New parts are not the aftercooler core and the oil cooler core.
required if the existing parts can still be used,
reconditioned, or repaired. If the components are not 1. Remove the core.
in the reusability guidelines, refer to the Service
Manual, Specifications module.
SEBU7681-22 125
Maintenance Section
Overhaul (Top End)
NOTICE
Do not use a high concentration of caustic cleaner to Hot oil and components can cause personal
clean the core. A high concentration of caustic injury.
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen- Do not allow hot oil or components to contact
tration of cleaner. skin.
Clean the oil suction screen after the engine oil pan
3. Back flush the core with cleaner. has been drained.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Consult your Caterpillar dealer for Note: Approximately 1 L (1 qt) of engine oil will
part numbers and sizes of containers. remain in the housing after the sump has been
drained. This engine oil will pour out of the housing
Use a 2 to 5 percent concentration of the cleaner when cover (1) is removed. Prepare to catch the
at temperatures up to 93C (200F). engine oil in a pan. Clean up any spills with
absorbent towels or pillows. DO NOT use absorbent
4. Steam clean the core in order to remove any particles.
residue. Flush the fins of the core. Remove any
other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
6. Dry the core with compressed air. Direct the air in Illustration 71 g00760655
7. Inspect the core in order to ensure cleanliness. 2. Wash screen assembly (3) in clean nonflammable
Perform a pressure test of the core. Many shops solvent. Allow the screen assembly to dry before
that service radiators are equipped to perform installation.
pressure tests. If necessary, repair the core. 3. Clean the engine oil sump. Remove the side
8. Install the core. covers in order to gain access to the sump. After
the sump is clean, install the side covers.
For more information on cleaning the cores, consult
your Caterpillar dealer. 4. Inspect screen assembly (3) for good condition.
Obtain a new screen assembly, if necessary.
Install the screen assembly. Install a new O-ring
seal (2). Install cover (1).
126 SEBU7681-22
Maintenance Section
Overhaul Considerations
Inspection of all the parts that are visible during Generally, engines that are operated at a reduced
the disassembly load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
Replacement of the seals and gaskets that are properly operated and maintained.
removed
Overhaul Inspection
Cleaning of the internal passages of the engine
and the engine block Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order to
Most owners will save money by overhauling the perform the required maintenance on the items that
engine at the intervals that are recommended in the are listed. Consult your Caterpillar dealer for
Operation and Maintenance Manual. It is not practical assistance.
to wait until the engine exhibits symptoms of
excessive wear or failure. It is not less costly to wait. To determine the reusability publications that are
A planned overhaul before failure may be the best needed to inspect the engine, refer to Guidelines for
value for the following reasons: Reusable Parts and Salvage Operations, SEBF8029,
Index of Publications on Reusability or Salvage of
Costly unplanned downtime can be avoided. Used Parts.
Crankshafts
Cylinder heads Personal injury can result from air pressure.
Use a degreaser and steam for removal of oil and Testing a Three-Diode Rectifier
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the Block
core with clean water.
After cleaning, start the engine and accelerate the
engine to high idle rpm. This procedure 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.
i05072489
Illustration 73 g00613971
Three-Diode Rectifier Block (two pieces)
a. Place the red test lead on the positive + An SR4 generator can operate in high humidity
rectifier terminal. Place the black test lead on conditions without problems. However, problems can
the following rectifier terminals: AC1 (3), AC2 occur when the generator is idle and the surrounding
air is warmer than the generator. Moisture can form
(4) and AC3 (5). In all cases, the meter should on the windings. Moisture will result in poor
read OL (overload). performance or even damage to the windings.
Whenever the generator is not active, the optional
b. Place the black test lead on the positive + space heaters should be operated.
rectifier terminal. Place the red test lead on the
following rectifier terminals: AC1 (3), AC2 (4) An external source is required to operate the space
and AC3 (5). All readings on the meter should heaters. Both of the sources must be a single phase.
This source can be either 115 vac or 230 vac. When
be between 0.4 and 1.0. the external source is 50 hertz, 200 vac must be
used. Refer to Illustration 74 .
Note: A shorted diode can damage the exciter rotor.
If a diode is shorted, check the exciter rotor. Refer to See your Caterpillar dealer for information on
the Testing and Adjusting, Winding - Test and checking your Caterpillar generator.
Testing and Adjusting, Insulation - Test. Perform
these tests. i04125973
Note: This rectifier block also contains varistor CR7 Spark Plugs - Inspect/Replace
. CR7 can be checked by measuring the resistance
between the positive + rectifier terminal and the SMCS Code: 1555-040; 1555-510
negative - rectifier terminal. The resistance should
be a minimum of 15000 ohms. Note: Condensation can form in spark plugs that
have precombustion chambers and can cause
i03857792
difficulty for cold start-ups. To avoid condensation,
maintain the coolant in the cylinder block at a
minimum temperature of 43 C (110 F)
Space Heater - Test continuously.
SMCS Code: 4450-081-HTR
The service life of the spark plugs is affected by
The space heater is attached to the rear bearing fouling due to deposits from the oil and by peak
bracket. The space heater is located in the voltage. Maintenance of the ignition system is also
generator's exciter end. affected by voltage. Higher voltage is required by
higher inlet manifold air pressure, leaner air to fuel
operation, a higher compression ratio, and
retardation of the timing. Higher voltage reduces the
service life of components such as spark plugs,
wires, and transformers.
130 SEBU7681-22
Maintenance Section
Spark Plugs - Inspect/Replace
Illustration 75 g00925913
(1) Cover
(2) Wiring harness
(3) Transformer
(4) Seal
(5) Spark plug
(6) Valve cover
Note: Excessive buildup of oil in the spark plug well Insulator (8) is covered with Teflon. If the cover is
is an indication of a damaged lip seal on the cracked or loose, discard the spark plug.
transformer.
Faint marks may extend from shell (9) onto the
5. Debris may have collected in the spark plug well. insulator. The marks may be a result of a corona that
Thoroughly remove any debris. Use compressed forms at the top of the shell. The conductor will
develop a corona when a high voltage potential
air. The maximum air pressure for cleaning ionizes the air. This corona is a normal condition and
purposes must be below 207 kPa (30 psi). Ensure is not an indication of leakage between the shell and
that the area around the spark plug is clean and the insulator.
free of dirt and debris.
Inspect shell (9) for damage. Cracks can be caused
6. Use a 216-1685 deep well socket, an extension, by overtightening the spark plug. Overtightening can
and a breaker bar to loosen spark plug (5). After also yield the metal which loosens the shell. Discard
any spark plug that has a shell that is cracked or
the spark plug has been loosened, use the socket loose.
and extension to remove the spark plug by hand.
Removing the spark plug by hand will help to Inspect the precombustion chamber for deposits.
detect problems with the threads. After the spark Make sure that holes (11) in the precombustion
chamber are not blocked.
plug has been removed, discard the used spark
plug gasket. A light brown deposit or a beige deposit is produced
If the spark plug resists removal by hand, apply by normal operation.
penetrating oil to the threads. To help the oil
penetrate the threads, turn the spark plug back and Deposits that are gray or black may be caused by the
forth until the spark plug is loose. following substances:
2. Always use a new gasket when a spark plug is Inspect the starting motor for proper operation. Listen
installed. If a used spark plug is installed, place a for grinding when the engine is started. Inspect the
new gasket on the spark plug. Orient the tabs of teeth of the starting motor pinion and the flywheel
the gasket toward the precombustion chamber. ring gear. Look for patterns of wear on the teeth.
Look for teeth that are broken or chipped. If damaged
Otherwise, the gasket may not seat properly. If a teeth are found, the starting motor pinion and the
gasket for a spark plug is installed incorrectly, do flywheel ring gear must be replaced.
not increase the torque on the spark plug in order
to improve the seal. Do not reuse the gasket. Electric Starting Motor
Install a new gasket.
Note: Problems with the electric starting motor can
NOTICE be caused by the following conditions: malfunction of
Do not overtighten the spark plug. The shell can be the solenoid and malfunction of the electric starting
cracked and the gasket can be deformed. The metal system.
can deform and the gasket can be damaged. The
shell can be stretched. This will loosen the seal that Inspect the electrical system for the following
is between the shell and the insulator, allowing com- conditions:
bustion pressure to blow past the seal. Serious dam-
age to the engine can occur. Loose connections
Use the proper torque. Corrosion
3. Install spark plug (5) by hand until the spark plug Wires that are worn or frayed
contacts the gasket. Torque the spark plug to the Cleanliness
proper specification. Refer to Specifications,
Spark Plug for the proper torque specification. Make repairs, if necessary.
4. Ensure that the transformer and the extension are Air Starting Motor
clean and free from dirt and oil. Lubricate O-ring
seal (4) with one of the following lubricants:
Dielectric Grease
Personal injury or death can result from improp-
Silicone Lubricant erly checking for a leak.
5. Install transformer (3). Orient the transformer Always use a board or cardboard when checking
toward wiring harness (2). Connect the wiring for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis-
harness. sue causing serious injury, and possible death.
6. Install cover (1).
If fluid is injected into your skin, it must be
treated immediately by a doctor familiar with this
i04342950 type of injury.
Starting Motor - Inspect Inspect all of the components in the air circuit for the
starting motor. Inspect all of the air lines and
SMCS Code: 1451-040; 1453-040 connections for leaks.
If the starting motor fails, the engine may not start in If the teeth of the starting motor pinion and/or the
an emergency situation. A scheduled inspection of flywheel ring gear are damaged, the air circuit for the
the starting motor is recommended. starting motor must be examined in order to
determine the cause of the problem.
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine to
start properly. The engine will not start if the starting Removal and Installation of the
motor pinion does not engage the flywheel ring gear. Starting Motor
The teeth of the starting motor pinion and the
flywheel ring gear can be damaged because of Refer to the Service Manual, Disassembly and
irregular engagement. Assembly module for information on removing the
starting motor and installing the starting motor.
SEBU7681-22 133
Maintenance Section
Stator Lead - Check
i03230840
An inspection of the turbocharger can minimize Note: Deposits of ash and silicone can accumulate
unscheduled downtime. Also, the chance for on the turbine wheel. Turbine wheel will become
potential damage to other engine parts is reduced. unbalanced when the deposits flake off. The
turbocharger cartridge must be replaced when the
Note: Turbocharger components require clearances turbine wheel becomes unbalanced. However,
that are precise. The turbocharger cartridge must be removing deposits from the housing will prevent wear
balanced due to high rpm. on the blades of the new turbine wheel.
The following conditions can cause the turbocharger
to be out-of-balance: 4. Inspect the turbine wheel and the nozzle for
deposits of ash and silicone. If deposits of 1.6 mm
The buildup of deposits (0.06 inch) thickness are found or if the turbine is
in contact with the housing, the turbocharger must
Chipping and/or flaking of deposits be disassembled and cleaned. Removal of the
If the turbocharger must be removed for inspection, deposits can be difficult.
use caution. Do not break deposits from the turbine 5. Inspect the turbine wheel and nozzle vanes for
wheel. Do not attempt to clean the turbine wheel. For
information regarding removal and installation, see damage or bent blades. Do not attempt to repair
the Disassembly and Assembly manual or consult the turbine wheel or nozzle vanes. Replace the
your Caterpillar dealer. For information about repair damaged parts.
of the turbocharger or about replacement of the
turbocharger, consult your Caterpillar dealer. 6. Inspect the bore of the turbine housing for
corrosion and deposits.
1. Remove the exhaust outlet piping and remove the
air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger should be reconditioned. Inspect
the compressor wheel for damage or bent blades.
Do not attempt to repair the damaged blades. Illustration 78 g01955362
Replace the cartridge or turbocharger if the blades Axial clearance
are damaged.
Note: The axial clearance is the free axial
3. Check the compressor wheel for cleanliness. If displacement of the rotor. The rotor is moved back
only the inlet side of the wheel is dirty, dirt and/or and forth with an approximate force between 150 N
moisture is passing through the air filtering (34 lb) and 200 N (45 lb). Tolerances are shown in
system. If oil is found only on the back side of the Table 30 . The deflection of the measuring device
wheel, there is a possibility of a failed turbocharger corresponds to the axial clearance.
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also result from restriction of the inlet air
(plugged air filters). This causes oil to leak past the
seal for the turbocharger compressor.
A restriction in the oil drain tube may result in an
oil leak. Remove and inspect the oil drain tube for
restrictions.
If oil is found on the compressor wheel and/or at
the air inlet, the source is the fuel compressor or
the PCV system.
SEBU7681-22 135
Maintenance Section
Valve Stem Projection - Measure/Record
Table 31
Radial Clearance(1)
Thermal aging Thermal aging can cause the Some water pumps have a filter in the weephole (1).
degradation of insulation or the deterioration of This filter helps prevent dirt from entering the water
insulation. An examination of the coils may reveal pump. Inspect the filter with a flashlight in order to
that the insulation has expanded into the ventilation ensure that the filter is clean. Replace the filter
ducts. This is the result of a loss of bond which will annually or replace the filter when the filter becomes
cause the insulation material to separate. The plugged.
insulation material could also separate from the
conductors on the windings.
i01028392
Part name
Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
140 SEBU7681-22
Reference Information Section
Reference Materials
Owner receipts
Maintenance log
i03905196
Maintenance Log
SMCS Code: 1000; 4450
Table 32
Engine Model Customer Identifier
Service
Service Item Date Authorization
Hours
(continued)
142 SEBU7681-22
Reference Information Section
Valve Data Sheet
i01745150
S/N: GZC1Up
S/N: TJC1Up
S/N: F6D1Up
S/N: FZD1Up
S/N: MAD1Up
S/N: NWD1Up
S/N: F6E1Up
S/N: FZE1Up
S/N: F6F1Up
S/N: FZF1Up
S/N: F6G1Up
S/N: FZG1Up
S/N: GZG1Up
S/N: GZH1Up
S/N: GZJ1Up
S/N: GZK1Up
S/N: GZL1Up
S/N: HAL1Up
S/N: F6M1Up
S/N: GZM1Up
S/N: GZN1Up
S/N: B9P1Up
S/N: RLP1Up
SEBU7681-22 143
Reference Information Section
Valve Data Sheet
Table 33
Engine Model Serial Number Service Hours Authorization
Inlet Manifold
5 Pushrod Side
Inlet Manifold
6 Pushrod Side
Inlet Manifold
7 Pushrod Side
Inlet Manifold
8 Pushrod Side
Inlet Manifold
9 Pushrod Side
Inlet Manifold
10 Pushrod Side
Inlet Manifold
11 Pushrod Side
Inlet Manifold
12 Pushrod Side
Inlet Manifold
13 Pushrod Side
Inlet Manifold
14 Pushrod Side
Inlet Manifold
15 Pushrod Side
Inlet Manifold
16 Pushrod Side
Inlet Manifold
17 Pushrod Side
Inlet Manifold
18 Pushrod Side
Inlet Manifold
(continued)
144 SEBU7681-22
Reference Information Section
Reference Material
Inlet Manifold
20 Pushrod Side
Inlet Manifold
Special Publication, SEBU6400, Caterpillar Gas Installation and Operation Manual, SEBU7630,
Engine Lubricant, Fuel, and Coolant Raptor Gas Regulation and Metering Valve/
Recommendations Actuator System for Caterpillar
Data Sheet, PEHJ0006, Cat NGEO (Natural Gas Special Instruction, GMG00694, Analyzing
Engine Oil) EL350 (SAE 40) Cylinder Condition By Measuring Air Flow
Data Sheet, PEHP0004, Cat NGEO (Natural Gas Special Instruction, REHS0128, Using the
Engine Oil) (SAE 30, SAE 40) 147-5482 Valve Lash Gauge Group For Valve
Lash and Valve Bridge Adjustment
Special Publication, PEHJ0191, Cat SOS Fluid
Analysis Special Instruction, REHS0177, Alignment of the
Close Coupled Two-Bearing Generators
Special Publication, PEHP6001, How To Take A
Good Oil Sample Special Instruction, SEHS7259, Alignment of
Single-Bearing Generators
Special Publication, SEBU6400, Caterpillar Gas
Engine Lubricant, Fuel, and Coolant Special Instruction, SEHS7332, Do Not Operate
Recommendations Tag
Special Instruction, SEHS7633, Battery Test
Miscellaneous Procedure
Data Sheet, LEKQ4023, Linear Vibration Special Instruction, SEHS8712, Using the
8T-2700 Blowby/Air Flow Indicator
Disassembly and Assembly, RENR5980,
G3500C and G3500E Engines Special Instruction, SEHS8984, Using the
1U-8860 Blowby Pickup Group
Engine Performance, LEBQ6117, G3500
Industrial Special Instruction, SEHS9031, Storage
Procedure for Caterpillar Products
Engine Performance, LEBQ6169, G3500
Generator Set Special Instruction, SEHS9298, Installation and
Maintenance of Gaseous Fuel Filters
146 SEBU7681-22
Reference Information Section
Decommissioning and Disposal
Special Publication, NEHS0526, Service The American Petroleum Institute Publication No.
Technician Application Guide 1509 can be obtained from the following locations:
local technological society, local library and local
Special Publication, NENG2500, Cat dealer college. If necessary, consult API at the following
Service Tools Catalog address:
S/N: GZC1Up
S/N: TJC1Up
S/N: F6D1Up
S/N: FZD1Up
S/N: MAD1Up
S/N: NWD1Up
S/N: F6E1Up
S/N: FZE1Up
S/N: F6F1Up
S/N: FZF1Up
S/N: F6G1Up
S/N: FZG1Up
S/N: GZG1Up
S/N: GZH1Up
S/N: GZJ1Up
S/N: GZK1Up
S/N: GZL1Up
S/N: HAL1Up
S/N: F6M1Up
S/N: GZM1Up
S/N: GZN1Up
S/N: B9P1Up
S/N: RLP1Up
S/N: GAS1Up
S/N: LGS1Up
S/N: NGS1Up
S/N: HAT1Up
S/N: CWW1Up
S/N: CWY1Up
S/N: SLY1Up
S/N: SXY1Up
S/N: GZZ1Up
When the product is removed from service, local
regulations for the product decommissioning will
vary. Disposal of the product will vary with local
regulations. Consult the nearest Cat dealer for
additional information.
148 SEBU7681-22
Index Section
Index
A Draining the Cooling System ....................... 82
Fill the Cooling System ................................ 84
After Starting Engine ....................................... 46
Coolant Level - Check ............................... 8485
Engaging the Driven Equipment.................. 46
Add Coolant ........................................... 8485
After Stopping Engine ..................................... 58
Coolant Sample (Level 1) - Obtain.................. 85
Aftercooler Condensation - Drain.................... 78
Coolant Sample (Level 2) - Obtain.................. 86
Air Tank Moisture and Sediment - Drain ......... 78
Cooling System Supplemental Coolant
Alarms and Shutoffs ........................................ 27
Additive (SCA) - Test/Add.............................. 86
Setpoints for Alarms and Shutoffs ............... 27
Add the SCA, If Necessary .......................... 87
Testing Alarms and Shutoffs........................ 27
Test the Concentration of the SCA .............. 86
Alternator - Inspect .......................................... 78
Crankcase Blowby - Test/Record .................... 87
Automatic Start/Stop - Inspect ........................ 78
Crankcase Pressure - Measure (Engines
with Fumes Disposal Filters) ......................... 88
B Crankshaft Vibration Damper - Inspect........... 88
Battery - Recycle ............................................. 79 Damper Fluid Sampling ............................... 89
Battery - Replace............................................. 79 Removal and Installation ............................. 89
Battery Electrolyte Level - Check .................... 79 Crankshaft Vibration Damper - Inspect
Battery or Battery Cable - Disconnect............. 80 (1500 RPM G3520 engines (if equipped
Before Starting Engine .............................. 14, 42 with an oil fed damper)) ................................. 89
Air Inlet System............................................ 42 Crushing Prevention and Cutting Prevention.. 13
Cooling System............................................ 42 Customer Assistance .................................... 138
Driven Equipment ........................................ 42 Outside of USA and of Canada ................. 138
Electrical System ......................................... 42 USA and Canada....................................... 138
Fuel System................................................. 42 Customer Service.......................................... 138
Lubrication System ...................................... 43 Cylinder Pressure - Test/Record ..................... 90
Starting System ........................................... 43
Walk-Around Inspection .............................. 42 D
Belts - Inspect/Adjust/Replace ........................ 80
Declaration of Conformity................................ 20
Adjusting the Alternator Belt ........................ 80
Decommissioning and Disposal.................... 146
Adjusting the Fan Drive Belt ........................ 81
Inspection .................................................... 80
Replacement................................................ 81 E
Burn Prevention................................................11 Electrical System............................................. 15
Batteries....................................................... 12 Grounding Practices .................................... 15
Coolant .........................................................11 Electronic Modular Control Panel II+
Oils............................................................... 12 (EMCP II+)..................................................... 28
Alarm Module............................................... 34
C Custom Alarm Module ................................. 35
Generator Set Control + (GSC+) ................. 30
Carburetor Air/Fuel Ratio - Check/Adjust........ 81
Synchronizing Lights Module ...................... 35
Cold Weather Starting ..................................... 43
Emergency Stopping....................................... 57
Compressor Bypass - Check .......................... 81
Emergency Stop Button............................... 57
Configuration Parameters ............................... 40
Unplanned Shutdowns ................................ 57
Air/Fuel Ratio ............................................... 40
Engine Air Cleaner Service Indicator -
Oil Consumption .......................................... 41
Inspect ........................................................... 91
Coolant (NGEC) - Change .............................. 81
Test the Service Indicator ............................ 91
Clean the Cooling System ........................... 83
Engine Crankcase Breather - Clean ............... 92
Cleaning a Cooling System that has Heavy
Engine Diagnostics ......................................... 40
Deposits or Plugging.................................. 83
SEBU7681-22 149
Index Section
Fuel System................................................. 63
T
Table of Contents .............................................. 3
Throttle Control Valve - Check ...................... 133
Turbocharger - Inspect .................................. 133
V
Valve Data Sheet........................................... 142
Valve Stem Projection - Measure/Record ..... 135
Voltage and Frequency - Check.................... 136
Voltage Regulators .......................................... 55
Adjustment Procedure for the Voltage
Regulators.................................................. 55
W
Walk-Around Inspection ................................ 136
Inspect the Engine for Leaks and for Loose
Connections ............................................. 136
Inspect the Generator................................ 137
Water Pump - Inspect.................................... 137
Welding on Engines with Electronic
Controls ......................................................... 63
Product and Dealer Information
Note: For product identification plate locations, see the section Product Identification Information in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
SEBU7681 CAT, CATERPILLAR, their respective logos, Caterpillar Yellow, and the POWER EDGE trade
2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.