C2.2 Sebu8137-04 M

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
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© 2010 Caterpillar
All Rights Reserved
SEBU8137-04
April 2010
Operation and
Maintenance
Manual
C2.2 Generator Sets
NCB1-Up (Generator Set)
GBE1-Up (Generator Set)
XYE1-Up (Generator Set)
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56 SEBU8137-04
Maintenance Section
Maintenance Interval Schedule
i03879425 Cooling System Coolant Extender (ELC) - Add .... 63

Engine - Clean ...................................................... 65
Maintenance Interval Schedule Engine Air Cleaner Element (Single Element) -
(Standby) Replace ...............................................................
Engine Mounts - Inspect .......................................
65
66
SMCS Code: 1000; 7500 Engine Oil Sample - Obtain .................................. 67
Engine Oil and Filter - Change ............................. 68
Ensure that all safety information, warnings, Fuel System Primary Filter (Water Separator)
and instructions are read and understood before Element - Replace .............................................. 72
any operation or any maintenance procedures Fuel System Secondary Filter - Replace .............. 74
are performed. The user is responsible for Hoses and Clamps - Inspect/Replace .................. 80
the performance of maintenance, including all Insulation - Test ..................................................... 83
adjustments, the use of proper lubricants, fluids, Rotating Rectifier - Check ..................................... 87
filters, and the installation of new components Starting Motor - Inspect ........................................ 88
due to normal wear and aging. The performance Water Pump - Inspect ........................................... 89
of this product may be diminished if proper
maintenance intervals and procedures are not Every 3 Years
followed. Components may experience accelerated
Battery - Replace .................................................. 60
wear if proper maintenance intervals and procedures
are not followed. Cooling System Coolant Extender (ELC) - Add .... 63
Cooling System Water Temperature Regulator -
Replace ............................................................... 64
Note: Use whichever of the following that occurs
first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time Every 6 Years
. Before each consecutive interval is performed, all Cooling System Coolant (ELC) - Change ............. 61
maintenance from the previous intervals must be
performed.
Products that operate in severe operating conditions

may require more frequent maintenance.
When Required
Battery or Battery Cable - Disconnect .................. 61
Fuel System - Prime ............................................. 71
Generator - Dry ..................................................... 77
Generator Load - Check ....................................... 79
Generator Set - Test ............................................. 79
Rotating Rectifier - Test ........................................ 87
Every Week
Alternator - Inspect ............................................... 59
Battery Electrolyte Level - Check .......................... 61
Cooling System Coolant Level - Check ................ 63
Electrical Connections - Check ............................. 65
Engine Air Cleaner Service Indicator - Inspect ..... 66
Engine Oil Level - Check ...................................... 66
Fuel Tank Water and Sediment - Drain ................. 76
Generator - Inspect ............................................... 77
Instrument Panel - Inspect .................................... 82
Walk-Around Inspection ........................................ 88
Every 500 Service Hours or 1 Year

Engine Air Cleaner Element (Single Element) -
Replace ............................................................... 65
Every Year
Alternator - Inspect ............................................... 59
Alternator Belt - Inspect/Adjust/Replace ............... 59
SEBU8137-04 57
Maintenance Section
i03879424 Every 250 Service Hours

Maintenance Interval Schedule Engine Oil Sample - Obtain .................................. 67
(Prime Power) Every 250 Service Hours or 6 Months
SMCS Code: 1000; 7500 Alternator Belt - Inspect/Adjust/Replace ............... 59
Ensure that all safety information, warnings, Every 500 Service Hours
and instructions are read and understood before
any operation or any maintenance procedures Fuel System Secondary Filter - Replace .............. 74
are performed. The user is responsible for
the performance of maintenance, including all Every 500 Service Hours or 1 Year
adjustments, the use of proper lubricants, fluids,
filters, and the installation of new components Battery Electrolyte Level - Check .......................... 61
due to normal wear and aging. The performance Engine Air Cleaner Element (Single Element) -
of this product may be diminished if proper Replace ............................................................... 65
maintenance intervals and procedures are not Engine Oil and Filter - Change ............................. 68
followed. Components may experience accelerated Fuel System Primary Filter (Water Separator)
wear if proper maintenance intervals and procedures Element - Replace .............................................. 72
are not followed. Hoses and Clamps - Inspect/Replace .................. 80
Note: Use whichever of the following that occurs Every 1000 Service Hours
first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time Alternator Belt - Inspect/Adjust/Replace ............... 59
. Before each consecutive interval is performed, all Engine Valve Lash - Inspect/Adjust ...................... 69
maintenance from the previous intervals must be
performed. Every 1000 Service Hours or 1 Year
Products that operate in severe operating conditions Rotating Rectifier - Check ..................................... 87
may require more frequent maintenance.
Every 2000 Service Hours
When Required Alternator - Inspect ............................................... 59
Engine Mounts - Inspect ....................................... 66
Battery - Replace .................................................. 60
Starting Motor - Inspect ........................................ 88
Battery or Battery Cable - Disconnect .................. 61
Engine - Clean ...................................................... 65
Engine Air Cleaner Element (Single Element) - Every 2000 Service Hours or 6 Months
Replace ............................................................... 65 Insulation - Test ..................................................... 83
Fuel System - Prime ............................................. 71
Generator - Dry ..................................................... 77
Every Year
Generator Set - Test ............................................. 79
Rotating Rectifier - Test ........................................ 87 Engine Air Cleaner Element (Single Element) -
Replace ............................................................... 65
Daily
Every 3000 Service Hours
Cooling System Coolant Level - Check ................ 63
Electrical Connections - Check ............................. 65 Fuel Injection Nozzles - Test/Exchange ................ 70
Engine Air Cleaner Service Indicator - Inspect ..... 66 Water Pump - Inspect ........................................... 89
Engine Oil Level - Check ...................................... 66
Fuel System Primary Filter/Water Separator - Every 3000 Service Hours or 2 Years
Drain ................................................................... 73
Generator Load - Check ....................................... 79 Cooling System Water Temperature Regulator -
Walk-Around Inspection ........................................ 88 Replace ............................................................... 64
Every Week Every 6000 Service Hours or 3 Years

Generator - Inspect ............................................... 77 Cooling System Coolant Extender (ELC) - Add .... 63
Instrument Panel - Inspect .................................... 82
Every 12 000 Service Hours or 6 Years
Every 50 Service Hours or Weekly
Cooling System Coolant (ELC) - Change ............. 61
Fuel Tank Water and Sediment - Drain ................. 76
58 SEBU8137-04
Maintenance Section
Overhaul
Overhaul Considerations ...................................... 84
SEBU8137-04 59
Maintenance Section
Alternator - Inspect
i02676048
Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection

of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required.
Check the alternator and the battery charger for

g01003936
proper operation. If the batteries are properly Illustration 43
charged, the ammeter reading should be very near Typical example
zero. All batteries should be kept charged. The (1) 144-0235 Belt Tension Gauge
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold, Install the gauge (1) at the center of the belt between
the battery will not crank the engine. The battery will the alternator and the crankshaft pulley and check
not crank the engine, even if the engine is warm. the belt tension. The correct tension for a new belt is
When the engine is not run for long periods of time 400 N (90 lb) to 489 N (110 lb). The correct tension
or if the engine is run for short periods, the batteries for a used belt that has been in operation for 30
may not fully charge. A battery with a low charge will minutes or more at the rated speed is 267 N (60 lb)
freeze more easily than a battery with a full charge. to 356 N (80 lb).
i02305688
If twin belts are installed, check and adjust the
tension on both belts.
Alternator Belt -
Inspect/Adjust/Replace Adjustment Procedure
SMCS Code: 1357-036; 1357-510
Inspection Procedure
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
For applications that require multiple drive belts,

replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched.
The additional load on the new belt could cause the
new belt to break.
If the belts are too loose, vibration causes

unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
To accurately check the belt tension, Gauge

144-0235 Belt Tension Gauge should be used. Illustration 44
g01091158
Typical example
(1) Adjusting bolt
(2) Mounting bolts
1. Loosen the mounting bolts (2) and the adjusting

bolt (1).
60 SEBU8137-04
Maintenance Section
Battery - Replace
2. Move the alternator in order to increase or i02153996

decrease the belt tension.
Battery - Replace
3. Tighten the adjusting bolt (1). Tighten the mounting
bolts (2). Refer to the Specifications Manual for SMCS Code: 1401-510
the correct torque settings.
Replacement Procedure
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.
g01091158
Illustration 45
Typical example 1. Turn the key start switch to the OFF position.
(1) Adjusting bolt Remove the key and all electrical loads.
(2) Mounting bolts
2. Turn OFF the battery charger. Disconnect the
For applications that require multiple drive belts, charger.
replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to 3. The NEGATIVE “-” cable connects the NEGATIVE
carry more load because the older belt is stretched. “-” battery terminal to the ground plane. Disconnect
The additional load on the new belt could cause the the cable from the NEGATIVE “-” battery terminal.
new belt to break.
4. The POSITIVE “+” cable connects the POSITIVE
Note: When new belts are installed, check the belt “+” battery terminal to the starting motor.
tension again after 20 hours of engine operation. Disconnect the cable from the POSITIVE “+”
battery terminal.
Refer to the Disassembly and Assembly Manual for
the installation procedure and the removal procedure Note: Always recycle a battery. Never discard a
for the belt. battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that

the key start switch is OFF.
7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.
SEBU8137-04 61
Maintenance Section
Battery Electrolyte Level - Check
8. Connect the cable from the ground plane to the i01492654

NEGATIVE “-” battery terminal.
Battery or Battery Cable -
i02601752
Disconnect
Battery Electrolyte Level - SMCS Code: 1402-029
Check
SMCS Code: 1401-535
The battery cables or the batteries should not be
When the engine is not run for long periods of time or removed with the battery cover in place. The bat-
when the engine is run for short periods, the batteries tery cover should be removed before any servic-
may not fully recharge. Ensure a full charge in order ing is attempted.
to help prevent the battery from freezing.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face 1. Turn the start switch to the OFF position. Turn the
shield and protective clothing when working on or ignition switch (if equipped) to the OFF position
near batteries. and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the

1. Remove the filler caps. Maintain the electrolyte battery that goes to the start switch. Ensure that
level to the “FULL” mark on the battery. the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
If the addition of water is necessary, use distilled two batteries must be disconnected.
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially 3. Tape the leads in order to help prevent accidental
softened water. starting.
2. Check the condition of the electrolyte with the 4. Proceed with necessary system repairs. Reverse
245-5829 Coolant Battery Tester Refractometer. the steps in order to reconnect all of the cables.
3. Keep the batteries clean.

i02822203
Clean the battery case with one of the following
cleaning solutions:
Cooling System Coolant (ELC)
- Change
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water SMCS Code: 1350-070; 1395-044
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L Clean the cooling system and flush the cooling
(1 qt) of clean water system before the recommended maintenance
interval if the following conditions exist:
Thoroughly rinse the battery case with clean water.
• The engine overheats frequently.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items • Foaming is observed.
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal • The oil has entered the cooling system and the
of material can cause the clamps to not fit properly. coolant is contaminated.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM. • The fuel has entered the cooling system and the
coolant is contaminated.
Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained and
replaced.
62 SEBU8137-04
Maintenance Section
Cooling System Coolant (ELC) - Change
Note: Inspect the water pump and the water 4. Start and run the engine at low idle until the
temperature regulator after the cooling system has temperature reaches 49 to 66 °C (120 to 150 °F).
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and 5. Stop the engine and allow the engine to cool.
the hoses, if necessary. Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
Drain cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
Pressurized System: Hot coolant can cause seri- plugs. Refer to Torque Specifications, SENR3130
ous burns. To open the cooling system filler cap, for more information on the correct torques.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- Fill
sure.
NOTICE
Do not fill the cooling system faster than 5 L
1. Stop the engine and allow the engine to cool. (1.3 US gal) per minute to avoid air locks.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling Cooling system air locks may result in engine damage.
system filler cap.
2. Open the cooling system drain valve (if equipped). 1. Fill the cooling system with Extended Life Coolant
If the cooling system is not equipped with a drain (ELC). Refer to this Operation and Maintenance
valve, remove the cooling system drain plugs. Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
Allow the coolant to drain. on cooling system specifications. Do not install the
cooling system filler cap.
NOTICE
Dispose of used engine coolant properly or recycle. 2. Start and run the engine at low idle. Increase the
Various methods have been proposed to reclaim used engine rpm to high idle. Run the engine at high
coolant for reuse in engine cooling systems. The full idle for one minute in order to purge the air from
distillation procedure is the only method acceptable by the cavities of the engine block. Stop the engine.
Caterpillar to reclaim the used coolant.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
For information regarding the disposal and the pipe for filling. Maintain the coolant level within
recycling of used coolant, consult your Caterpillar 13 mm (0.5 inch) to the proper level on the sight
dealer or consult Dealer Service Tools. glass (if equipped).
Flush 4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If
1. Flush the cooling system with clean water in order the gasket that is on the cooling system filler cap
to remove any debris. is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
2. Close the drain valve (if equipped). Clean the the gasket that is on the cooling system filler cap is
drain plugs. Install the drain plugs. Refer to Torque not damaged, use a 9S-8140 Pressurizing Pump
Specifications, SENR3130 for more information in order to pressure test the cooling system filler
on the correct torques. cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
NOTICE does not retain the correct pressure, install a new
Do not fill the cooling system faster than 5 L cooling system filler cap.
(1.3 US gal) per minute to avoid air locks.
5. Start the engine. Inspect the cooling system for
Cooling system air locks may result in engine damage. leaks and for proper operating temperature.
3. Fill the cooling system with clean water. Install the

cooling system filler cap.
SEBU8137-04 63
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i02482066
NOTICE
Cooling System Coolant Care must be taken to ensure that fluids are contained
Extender (ELC) - Add during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
SMCS Code: 1352-045; 1395-081 collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Cat ELC (Extended Life Coolant) does not require nent containing fluids.
the frequent additions of any supplemental cooling
additives which are associated with the present Refer to Special Publication, NENG2500, “Caterpillar
conventional coolants. The Cat ELC Extender only Dealer Service Tool Catalog” for tools and supplies
needs to be added once. suitable to collect and contain fluids on Caterpillar
products.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender Dispose of all fluids according to local regulations and
with Cat ELC. mandates.
Do NOT use conventional supplemental coolant addi- 1. Loosen the cooling system filler cap slowly in
tive (SCA) with Cat ELC. Mixing Cat ELC with conven- order to relieve pressure. Remove the cooling
tional coolants and/or conventional SCA reduces the system filler cap.
Cat ELC service life.
2. It may be necessary to drain enough coolant from
Check the cooling system only when the engine is the cooling system in order to add the Cat ELC
stopped and cool. Extender.
3. Add Cat ELC Extender according to the

requirements for your engine's cooling system
capacity. Refer to the Operation and Maintenance
Personal injury can result from hot coolant, steam Manual, “Refill Capacities and Recommendations”
and alkali. article for more information.
At operating temperature, engine coolant is hot 4. Clean the cooling system filler cap. Inspect the
and under pressure. The radiator and all lines gaskets on the cooling system filler cap. Replace
to heaters or the engine contain hot coolant or the cooling system filler cap if the gaskets are
steam. Any contact can cause severe burns. damaged. Install the cooling system filler cap.
Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and i01197583
cooling system pressure cap is cool enough to

touch with your bare hand.
Cooling System Coolant Level
- Check
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing SMCS Code: 1395-082
burns.
Check the coolant level when the engine is stopped
Cooling System Coolant Additive contains alkali. and cool.
Avoid contact with skin and eyes.
64 SEBU8137-04
Maintenance Section
Cooling System Water Temperature Regulator - Replace
i03645060
Cooling System Water

Temperature Regulator -
Replace
SMCS Code: 1355-510
Replace the water temperature regulator before

the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime. Refer to this
Operation and Maintenance Manual, “Maintenance
g00285520
Illustration 46 Interval Schedule” for the proper maintenance
Cooling system filler cap interval.
A water temperature regulator that fails in a

partially opened position can cause overheating or
overcooling of the engine.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, A water temperature regulator that fails in the closed
stop the engine and wait until the cooling system position can cause excessive overheating. Excessive
components are cool. Loosen the cooling system overheating could result in cracking of the cylinder
pressure cap slowly in order to relieve the pres- head or piston seizure problems.
sure.
A water temperature regulator that fails in the open
1. Remove the cooling system filler cap slowly in position will cause the engine operating temperature
order to relieve pressure. to be too low during partial load operation. Low
engine operating temperatures during partial loads
2. Maintain the coolant level within 13 mm (0.5 inch) could cause an excessive carbon buildup inside the
of the bottom of the filler pipe. If the engine is cylinders. This excessive carbon buildup could result
equipped with a sight glass, maintain the coolant in an accelerated wear of the piston rings and wear
level to the proper level in the sight glass. of the cylinder liner.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling

system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
g00103639 the water temperature regulator vent hole is open.
Illustration 47
Typical filler cap gaskets Do not use liquid gasket material on the gasket or
cylinder head surface.
3. Clean the cooling system filler cap and check the
condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are Refer to two articles in the Disassembly and
damaged. Reinstall the cooling system filler cap. Assembly Manual, “Water Temperature Regulators
- Remove and Water Temperature Regulators -
4. Inspect the cooling system for leaks. Install” for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
dealer.
SEBU8137-04 65
Maintenance Section
Electrical Connections - Check
Note: If only the water temperature regulators are Periodic cleaning of the engine is recommended.
replaced, drain the coolant from the cooling system to Steam cleaning the engine will remove accumulated
a level that is below the water temperature regulator oil and grease. A clean engine provides the following
housing. benefits:
i01595880
• Easy detection of fluid leaks
Electrical Connections - Check • Maximum heat transfer characteristics
SMCS Code: 4459-535 • Ease of maintenance
Check all exposed electrical connections for Note: Caution must be used in order to prevent
tightness. electrical components from being damaged by
excessive water when you clean the engine. Avoid
Check the following devices for loose mounting or electrical components such as the alternator, the
for physical damage: starter, and the ECM.
Note: For more information on cleaning and drying

• transformers electric generators, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
• fuses Generators”.
• capacitors
i02309550
• lightning arrestors
Engine Air Cleaner Element
Check all lead wires and electrical connections for
proper clearance.
(Single Element) - Replace
SMCS Code: 1051; 1054-510
i02305808
Engine - Clean NOTICE

Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
SMCS Code: 1000-070
Personal injury or death can result from high volt-

age.
Moisture could create paths of electrical conduc-

tivity.
Make sure the unit is off line (disconnected from

utility and/or other generators), locked out and
tagged "Do Not Operate".
NOTICE g00109823
Water or condensation can cause damage to gen- Illustration 48
erator components. Protect all electrical components (1) Air cleaner element. (2) Clamp.
from exposure to water.
1. Loosen clamp (2) which fastens air cleaner
element (1) to the air inlet. Remove the dirty air
NOTICE cleaner element and clamp.
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid 2. Install clamp (2) on new air cleaner element (1).
spills whenever a significant quantity accumulates on
the engine. 3. Install new air cleaner element (1) to the air
inlet and tighten clamp (2). Refer to Torque
Specifications, SENR3130 for the correct torque.
66 SEBU8137-04
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
i01900118 • Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
Engine Air Cleaner Service The yellow core should latch approximately at the
Indicator - Inspect greatest vacuum that is attained.
(If Equipped) If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
SMCS Code: 7452-040 the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
Some engines may be equipped with a different indicator may be plugged.
service indicator.
The service indicator may need to be replaced
Some engines are equipped with a differential gauge frequently in environments that are severely dusty, if
for inlet air pressure. The differential gauge for inlet necessary. Replace the service indicator annually
air pressure displays the difference in the pressure regardless of the operating conditions. Replace the
that is measured before the air cleaner element and service indicator when the engine is overhauled, and
the pressure that is measured after the air cleaner whenever major engine components are replaced.
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is Note: When a new service indicator is installed,
equipped with a different type of service indicator, excessive force may crack the top of the service
follow the OEM recommendations in order to service indicator. Tighten the service indicator to a torque
the air cleaner service indicator. of 2 N·m (18 lb in).
The service indicator may be mounted on the air

cleaner housing or in a remote location. i02456872
Engine Mounts - Inspect

SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for

proper bolt torque. Engine vibration can be caused
by the following conditions:
• Improper mounting of the engine

• Deterioration of the engine mounts
Any engine mount that shows deterioration should be
replaced. Refer to Special Publication, SENR3130,
Illustration 49
g00103777 “Torque Specifications” for the recommended
torques. Refer to the OEM recommendations for
Typical service indicator
more information.
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element i00623423
should be replaced when one of the following
conditions occur: Engine Oil Level - Check
• The yellow diaphragm enters the red zone. SMCS Code: 1348-535-FLV
• The red piston locks in the visible position.
Test the Service Indicator Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
Service indicators are important instruments. contact the skin.
• Check for ease of resetting. The service indicator

should reset in less than three pushes.
SEBU8137-04 67
Maintenance Section
Engine Oil Sample - Obtain
• Service hours on the engine

• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the

last oil change
Illustration 50
g00110310 To ensure that the sample is representative of the
(Y) “ADD” mark. (X) “FULL” mark. oil in the crankcase, obtain a warm, well mixed oil
sample.
NOTICE To avoid contamination of the oil samples, the tools
Perform this maintenance with the engine stopped. and the supplies that are used for obtaining oil
samples must be clean.
1. Maintain the oil level between “ADD” mark (Y) and
“FULL” mark (X) on oil level gauge (1). Do not fill Caterpillar recommends using the sampling valve
the crankcase above “FULL” mark (X). in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
NOTICE valve allows oil that is flowing under pressure to be
Operating your engine when the oil level is above the obtained during normal engine operation.
“FULL” mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft The 169-8373 Fluid Sampling Bottle is
dipping into the oil reduces the oil's lubricating char- recommended for use with the sampling valve. The
acteristics and could result in the loss of power. fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
2. Remove the oil filler cap and add oil, if necessary. also provided.
Clean the oil filler cap. Install the oil filler cap.
NOTICE
Always use a designated pump for oil sampling, and
i03542996
use a separate designated pump for coolant sampling.
Engine Oil Sample - Obtain Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
SMCS Code: 1000-008; 1348-554-SM; contaminate may cause a false analysis and an incor-
7542-554-OC, SM rect interpretation that could lead to concerns by both
dealers and customers.
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil If the engine is not equipped with a sampling valve,
analysis at regularly scheduled intervals in order use the 1U-5718 Vacuum Pump. The pump is
to monitor the condition of the engine and the designed to accept sampling bottles. Disposable
maintenance requirements of the engine. S·O·S oil tubing must be attached to the pump for insertion
analysis provides infrared analysis, which is required into the sump.
for determining nitration and oxidation levels.
For instructions, see Special Publication, PEgj0047,
Obtain the Sample and the Analysis “How To Take A Good S·O·S Oil Sample”. Consult
your Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,

PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
• Engine model
68 SEBU8137-04
Maintenance Section
Engine Oil and Filter - Change
i02309553 Replace the Oil Filter

Engine Oil and Filter - Change
NOTICE
SMCS Code: 1318-510; 1348-044 Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
Hot oil and hot components can cause personal the engine lubricating system. Only use oil filters
injury. Do not allow hot oil or hot components to recommended by Caterpillar.
contact the skin.
1. Remove the oil filter with a 1U-8760 Chain

NOTICE Wrench.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Note: The following actions can be carried out as
ing, adjusting and repair of the product. Be prepared to part of the preventive maintenance program.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 2. Cut the oil filter open with a 175-7546 Oil Filter
nent containing fluids. Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount
Dispose of all fluids according to local regulations and of metal debris in the oil filter may indicate early
mandates. wear or a pending failure.
Use a magnet to differentiate between the ferrous

NOTICE metals and the nonferrous metals that are found in
Keep all parts clean from contaminants. the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Contaminants may cause rapid wear and shortened
component life. Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
Do not drain the oil when the engine is cold. As the oil the engine. Parts that may be affected include
cools, suspended waste particles settle on the bottom the following items: main bearings, rod bearings,
of the oil pan. The waste particles are not removed turbocharger bearings, and cylinder heads.
with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the Due to normal wear and friction, it is not
oil warm. This draining method allows the waste uncommon to find small amounts of debris in the
particles that are suspended in the oil to be drained oil filter. Consult your Caterpillar dealer in order
correctly. to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Drain the Engine Oil

After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
• If the engine is equipped with a drain valve, turn the

drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
• If the engine is not equipped with a drain valve,

remove the oil drain plug in order to allow the oil to
drain. After the oil has drained, the oil drain plug
should be cleaned and installed.
SEBU8137-04 69
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer's recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at “LOW

IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back to

g01091799
Illustration 51 the sump for a minimum of ten minutes.
(1) Oil cooler
(2) Adapter
(3) Oil filter
Note: The oil cooler (1) and the adapter (2) are
installed to the C2.2/3024CT engine only.
3. Clean the sealing surface of the cylinder block or

the oil cooler (1). g00110310
Illustration 52
4. Apply clean engine oil to the new oil filter seal (3).
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the “ADD”
NOTICE and “FULL” marks on the oil level gauge.
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to i03840829
engine components.
Engine Valve Lash -
5. Install the oil filter. Tighten the oil filter until the
Inspect/Adjust
oil filter seal contacts the cylinder block or the oil
SMCS Code: 1102-025
cooler. Tighten the oil filter by hand according to
the instructions that are shown on the oil filter. Do
The initial valve lash adjustment on new engines,
not overtighten the oil filter.
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
Fill the Engine Crankcase adjustment is necessary due to the initial wear of
the valve train components and to the seating of the
1. Remove the oil filler cap. Refer to this Operation valve train components.
and Maintenance Manual , “Refill Capacities
and Recommendations” for more information on This maintenance is recommended by Caterpillar
lubricant specifications. Fill the crankcase with the as part of a lubrication and preventive maintenance
correct amount of oil. Refer to this Operation and schedule in order to help provide maximum engine
Maintenance Manual , “Refill Capacities” for more life.
information on refill capacities.
70 SEBU8137-04
Maintenance Section
Fuel Injection Nozzles - Test/Exchange
• Misfire
NOTICE
Only qualified service personnel should perform this • Rough running
maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, “Valve Lash and Valve Bridge Fuel Injection nozzles should be cleaned, inspected,
Adjustment” article or consult your Caterpillar dealer tested, and replaced, if necessary. Refer to Special
for the complete valve lash adjustment procedure. Instruction, SEHS7292 for using the 8S-2245
Injection Cleaning Tool Group. Consult your
Operation of Caterpillar engines with improper valve Caterpillar dealer about cleaning the fuel injection
adjustments can reduce engine efficiency. This re- nozzle and testing the fuel injection nozzle.
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. NOTICE
Never wire brush or scrape a fuel injection nozzle.
Wire brushing or scraping a fuel injection nozzle will
damage the finely machine orifice. Proper tools for
cleaning and testing the fuel injection nozzles can be
Ensure that the engine cannot be started while this obtained from Caterpillar dealers.
maintenance is being performed. To help prevent
possible injury, do not use the starting motor to
turn the flywheel. The following items are symptoms of a malfunction of
the fuel injection nozzle:
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea- • Abnormal engine operation
suring/adjusting valve lash clearance.
• Smoke emission
Ensure that the engine is stopped before measuring • Engine knock
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is Each fuel injection nozzle must be isolated one at
performed. a time in order to determine the malfunctioning fuel
injection nozzle.
Refer to the Service Manual for more information.
1. Start the engine.
i00626014
2. Loosen each fuel line nut one at a time at the fuel
Fuel Injection Nozzles - injection pump. A cloth or similar material must be
used in order to prevent fuel from spraying on the
Test/Exchange hot exhaust components. Tighten each nut before
loosening the next nut.
SMCS Code: 1254-013; 1254-081
3. A defective fuel injection nozzle may be identified
when a fuel line nut is loosened and the following
conditions are present:
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. • The exhaust smoke is partially eliminated or the
exhaust smoke is completely eliminated.
NOTICE • Engine performance is not affected.

Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that A fuel injection nozzle that is suspected of being
will be disconnected. Fit a suitable cover over discon- defective should be removed. A new fuel injection
nected fuel system component. nozzle should be installed in the cylinder in order
to determine if the removed fuel injection nozzle
is defective.
Fuel injection nozzles are subject to tip wear. Tip
wear is a result of fuel contamination. Tip wear can
cause the following problems:
• Increased fuel consumption

• Black smoke
SEBU8137-04 71
Maintenance Section
Fuel System - Prime
Removal and Installation of the

Fuel Injection Nozzles
For the removal and the installation of fuel injection
nozzles, special tooling is required. Refer to the
Service Manual for more information. Consult your
Caterpillar dealer for assistance.
i02309556
Fuel System - Prime

SMCS Code: 1258-548
If air enters the fuel system, the air must be purged

from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
• The fuel tank is empty or the fuel tank has been

partially drained. g01122124
Illustration 53
Fuel filter with element
• The low pressure fuel lines are disconnected.
(1) Fuel valve
(2) Vent screw
• A leak exists in the low pressure fuel system.
• The fuel filter is replaced.
NOTICE
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Dispose of all fluids according to local regulations and

mandates.
There are two types of fuel filter that may be installed

on these engines. The procedure to prime the
fuel system will depend on the type of filter that is
installed on the engine and the type of connector that
is installed on the fuel injection pump. Both types of
filter and connections are shown.
g01122125
Illustration 54
Use the following procedure in order to prime the fuel
Fuel filter with canister
system:
(3) Vent screw
1. Ensure that the fuel valve (1) for the fuel filter that
has an element is in the ON position. The fuel
valve for the fuel filter that has a canister may be
located away from the engine. Refer to the OEM
information for further details.
2. Loosen the vent screw (2) or (3).
3. Operate the hand primer. When fuel free from air

flows from the vent screw tighten the vent screw.
72 SEBU8137-04
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
6. Try to start the engine.
Note: Do not operate the starting motor for more

than 15 seconds. If the engine does not start after 15
seconds, stop and wait for 30 seconds before trying
again.
i03622950
Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
Illustration 55
g01122126 vent possible injury, turn the start switch off when
Connector that is installed on 2 and 3 cylinder engines
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
(4) Connector bolt
(5) Fuel return hose for the injector
Note: Refer to Testing and Adjusting Manual
, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.
NOTICE
Ensure that the engine is stopped before any servicing
or repair is performed.
If your engine is equipped with high pressure fuel

lines you must wait for 60 seconds after the engine
has stopped, in order to allow the fuel pressure to
be purged from the high pressure fuel lines before
any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked.
Refer to Disassembly and assembly Manual, “Fuel
Illustration 56
g01122127 Injection Lines - Install”.
Connector that is installed on 4 cylinder engines
(6) Connector bolt
4. Loosen the connector (4) or (6) at the fuel injection

pump.
Note: For illustration 55, the fuel return hose (5) may
need to be removed at the fuel injection pump.
5. Operate the hand primer. When fuel free from air

flows from the connector tighten the connector
bolt.
SEBU8137-04 73
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
9. Remove the container and dispose of the fuel

safely.
10. Open the fuel supply valve.
11. Prime the fuel system. Refer to the Operation and

Maintenance Manual, “Fuel System - Prime” for
more information.
i02323086
Fuel System Primary

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

vent possible injury, turn the start switch off when
NOTICE
g01118416 The water separator is not a filter. The water separator
Illustration 57
separates the water from the fuel. The engine should
(1) Screw never be run when the water separator is more than
(2) Element
(3) Glass bowl
half full of water. Engine damage may result.
(4) Sensor connection
(5) Drain
(6) Bottom cover
1. Turn the fuel supply valve (if equipped) to the OFF

position.
2. Place a suitable container under the water

separator. Clean the outside of the water
separator.
3. Open the drain (5). Allow the fluid to drain into

the container.
4. Tighten the drain (5) by hand pressure only.
5. Hold the element (2) and remove the screw (1).

Remove the element and the glass bowl (3) from
the base. Discard the old element.
6. Clean the glass bowl (4). Clean the bottom cover

(6).
g01161067
Illustration 58
7. Install the new O ring seal. Install the bottom cover (1) Vent
onto the new element. Install the assembly onto (2) Vent
the base. (3) Nylon Gauze Filter
(4) Drain valve
(5) Transparent body
8. Install the screw (1) and tighten the screw to a
torque of 8 N·m (6 lb ft).
74 SEBU8137-04
Maintenance Section
Fuel System Secondary Filter - Replace
1. Open vent (1). Allow any trapped air to escape.

When fuel free from air flows from the vent, close NOTICE
the vent. Care must be taken to ensure that fluids are contained
2. Open the other vent (2) and repeat the process. ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
3. Open the drain valve (4). Drain the water into opening any compartment or disassembling any com-
a suitable container. When fuel free from water ponent containing fluids.
flows, close the drain valve, and dispose of the
water properly. Dispose of all fluids according to local regulations and
mandates.
Note: Only clean the nylon gauze filter (3) at the
correct maintenance interval. Clean the nylon gauze
filter, if the fuel supply is known to have been Fuel Filter With Canister
contaminated.
1. Close the fuel supply valve.
4. Close the fuel shutoff valve. Open the drain (4).
Drain the fuel into a suitable container. Unscrew
the transparent body(5) of the water separator and
remove the nylon gauze filter (3).
5. Remove any sediment and wash the nylon gauze

filter in clean fuel.
6. Replace the nylon gauze filter in the body of the

water separator. Replace the transparent body
and open the fuel shutoff valve.
7. Open the air vents(1 and 2) until fuel free from air
flows from the vents. Close the vents.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system.
g01122129
Illustration 59
i02226986
2. Clean the outside of the fuel filter assembly.
Fuel System Secondary Filter -
Replace 3. Open the fuel drain (2) in the bottom of the
filter assembly, if equipped. Drain the fuel into a
SMCS Code: 1261-510-SE suitable container.
4. Loosen the setscrew (1).
5. Remove the canister (3).

vent possible injury, turn the start switch off when
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
SEBU8137-04 75
Maintenance Section
Fuel System Secondary Filter - Replace
g01122130
Illustration 61
2. Clean the outside of the fuel filter assembly.
3. Loosen the locking ring (3).
4. Remove the casing for the filter (2) and the

element.
g00917937
Illustration 60
6. Assemble the following items: seals (8), seal (7),

canister (9), and base (10). Place washer (5) and
seal (6) on setscrew (4).
7. Fasten the assembly to the fuel filter base with

setscrew (4).
The fuel system will need to be primed after the

new filter is installed. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime”.
Fuel Filter With Element

1. Close the fuel supply valve (1).
76 SEBU8137-04
Maintenance Section
Fuel Tank Water and Sediment - Drain
i03645042
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
NOTICE
collect the fluid with suitable containers before open-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and

mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
Illustration 62
g01122131 the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
5. Assemble the following items: seal (5), filter
element (6) and casing (7). Drain the Water and the Sediment
6. Install the assembled items to the filter head (4). Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
7. Install the locking ring (8) to the filter head. Rotate fuel tanks.
the locking ring in order to lock the assembly.
Open the drain valve on the bottom of the fuel tank
The fuel system will need to be primed after the in order to drain the water and the sediment. Close
new filter is installed. Refer to this Operation and the drain valve.
Maintenance Manual, “Fuel System - Prime”.
Note: Failure to properly close the drain can allow air
into the system, which could have detrimental results
to performance.
Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
SEBU8137-04 77
Maintenance Section
Generator - Dry
Fill the fuel tank after operating the engine in Drying Methods
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The The following methods can be used for drying a
fuel expands as the fuel gets warm. The tank may generator:
overflow.
• Self-circulating air method
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel • Oven method
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If NOTICE
the engine is equipped with this system, regular Do not allow the winding temperature to exceed 85 °C
maintenance of the fuel system filter is important. (185.0 °F). Temperatures that are greater than 85 °C
(185.0 °F) will damage the winding insulation.
Fuel Storage Tanks
Drain the water and the sediment from the fuel Self-Circulating Air Method
storage tank during the following conditions:
Note: Disable the excitation before using this method.
• Weekly
Run the engine and disconnect the generator load.
• Oil change This will help circulate air. Operate the generator
space heaters.
• Refill of the tank
Oven Method
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel Place the entire generator inside a forced air drying
tank. A four micron(c) absolute filter for the breather oven for four hours at 65 °C (149 °F).
vent on the fuel tank is also recommended. Refer
to Special Publication, SENR9620, “Improving Fuel NOTICE
System Durablity”. Use a forced air type oven rather than a radiant type
oven.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to Radiant type ovens can cause localized overheating.
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
i02283395
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. Generator - Inspect
i03642821
SMCS Code: 4450-040
Generator - Dry
SMCS Code: 4450-569 Personal injury or death can result from improper
troubleshooting and repair procedures.
NOTICE
Do not operate the generator if the windings are wet. If The following troubleshooting and repair proce-
the generator is operated when the windings are wet, dures should only be performed by qualified per-
damage can occur due to insulation breakdown. sonnel familiar with this equipment.
When moisture is present or when moisture is

suspected in a generator, the generator must be
dried before being energized.
If the drying procedure does not restore the insulation

resistance to an acceptable value, the winding should
be reconditioned.
Note: For additional information, refer to Special

Instruction, SEHS9124 .
78 SEBU8137-04
Maintenance Section
Generator - Inspect
• The type of enclosure of the generator
The high voltage that is produced by an operating • The voltage rating of the generator
generator set can cause severe injury or death.
Before performing any maintenance or repairs, • The type of dirt that is being removed
ensure that the generator will not start.
Cleaning (Assembled Generators)
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start- NOTICE
ing controls. Disconnect the batteries or disable
Do not use water to clean the generator.
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator. NOTICE
Do not use trichloroethane, perchlorethylene,
Refer to Safety Section, “Generator Isolating for trichloroethane or any alkaline products to clean the
Maintenance” for information regarding the procedure generator.
to safely isolate the generator.
Cleaning may be required at the point of installation.
Proper maintenance of electrical equipment requires At this point, complete disassembly of the generator
periodic visual examination of the generator and may not be necessary or feasible. In this case,
periodic visual examination of the windings. Proper a vacuum cleaner should be used to pick up the
maintenance of electrical equipment also requires following items: dry dirt, dust, and carbon. This will
appropriate electrical checks and appropriate thermal prevent the spreading of these contaminants.
checks. Insulation material should be examined for
cracks. The insulation material should be examined A small nonconductive tube may need to be
for accumulations of dirt and dust. If there is an connected to the vacuum cleaner. This will allow the
insulation resistance value that is below normal, a vacuum cleaner to clean the surfaces that are not
conductive path may be present. This conductive exposed. After most of the dust has been removed,
path may be made of one of the following materials: a small brush may be attached to the vacuum hose
in order to loosen dirt that is more firmly attached to
• Carbon the surface.
• Salt After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
• Metal dust dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure
• Dirt that is saturated with moisture should be a maximum of 210 kPa (30 psi) in order to
prevent mechanical damage to the insulation. If the
These contaminants will develop a conductive path above cleaning procedures are not effective, consult
which may produce shorts. Cleaning is advisable if a Caterpillar dealer.
heavy accumulations of dirt can be seen or if heavy
accumulations of dust can be seen. If excess dirt is
the cause of a restriction in the ventilation, cleaning Cleaning (Disassembled
is also advisable. Restricted ventilation will cause Generators)
excessive heating.
NOTICE
NOTICE Do not use water to clean the generator.
To avoid the possibility of deterioration to the genera-
tor windings, do not clean the generator unless there
is visual, electrical, or thermal evidence that dirt is NOTICE
present. Do not use trichloroethane, perchlorethylene,
trichloroethane or any alkaline products to clean the
If harmful dirt accumulations are present, a variety generator.
of cleaning techniques are available. The cleaning
procedure that is used may be determined by one of
the items on the following list:
• The extent of the cleaning procedure that is being

attempted
SEBU8137-04 79
Maintenance Section
Generator Load - Check
An initial insulation resistance check should be When a three-phase generator is installed or when
made on the generator in order to confirm electrical a three-phase generator is reconnected, ensure that
integrity. A minimum reading of one megohm would the total current in any one phase does not exceed
be expected with severely contaminated generators. the nameplate rating. Each phase should carry the
A zero megohm reading may indicate an insulation same load. This allows the three-phase generator
breakdown. An insulation breakdown requires more to work at the rated capacity. If one phase current
than cleaning. An insulation breakdown requires exceeds the nameplate amperage, an electrical
repair. imbalance will occur. An electrical imbalance can
result in an electrical overload and an electrical
Use the following for cleaning the stator, the rotor, the imbalance can result in overheating on three-phase
exciter and the diode bridge: generators. This is not applicable to single-phase
generators.
• Unleaded Gasoline
The power factor can be referred to as the efficiency
• Toluene of the load. This can be expressed as the ratio of kVA
to actual kW. The power factor can be calculated by
• Benzene dividing kW by kVA. Power factor is expressed as a
decimal. Power factor is used to mean the portion
• Ciclohexare of current that is supplied to a system that is doing
useful work. The portion of the current that is not
Avoid permitting the solvent to run into the slots. doing useful work is absorbed in maintaining the
Apply the solvent with a brush. Use a sponge on the magnetic field in motors. This current (reactive load)
windings frequently in order to remove the debris. can be maintained without engine power.
Dry the winding with a dry cloth. Allow the solvent to
evaporate before reassembling the generator.
i01593517
Allow the generator to dry at room temperature.

Check the insulation resistance. The insulation
Generator Set - Test
resistance should now be normal. If the insulation SMCS Code: 4450-081
resistance is not normal, repeat the procedure.
Note: For more information on drying methods, refer

to Special Instructions, SEHS9124, “Cleaning and
Drying of Electric Set Generators”. Personal injury or death can result from high volt-
age.
i01878834 When power generation equipment must be in op-

eration to make tests and/or adjustments, high
Generator Load - Check voltage and current are present.
SMCS Code: 4450-535-LA Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for

Personal injury or death can result from high volt- and correctly operated for high voltage and cur-
age. rent tests being made.
When power generation equipment must be in op- When servicing or repairing electric power gener-
eration to make tests and/or adjustments, high ation equipment:
voltage and current are present.
• Make sure the unit is off-line (disconnected
Improper test equipment can fail and present a from utility and/or other generators power
high voltage shock hazard to its user. service), and either locked out or tagged DO
NOT OPERATE.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur- • Make sure the generator engine is stopped.
rent tests being made.
• Make sure all batteries are disconnected.
During normal operation, monitor the power factor
and monitor generator loading. • Make sure all capacitors are discharged.
80 SEBU8137-04
Maintenance Section
Hoses and Clamps - Inspect/Replace
Table 8 i03847809
Tools Needed Hoses and Clamps -

Part Number Part Quantity Inspect/Replace
Digital
6V-7070 1 SMCS Code: 7554-040; 7554-510
Multimeter
12 VDC battery 1
Hoses and clamps must be inspected periodically
Potential in order to ensure safe operation and continuous
1
Transformer operation of the engine. Take proper safety
precautions before inspecting or replacing hoses and
The generator set functional test is a simplified test clamps.
that can be performed in order to determine if the
generator is functional. The generator set functional Note: Always use a board or cardboard when the
test should be performed on a generator set that is engine components are checked for leaks. Leaking
under load. fluid that is under pressure can cause serious
injury or possible death. This includes leaks that
The generator set functional test determines if the are the size of a pin hole. Refer to Operation and
following statements happen: Maintenance Manual, “General Hazard Information”
for more information.
• A phase voltage is being generated.
Inspect the Hoses and the Clamps
• The phase voltages are balanced.
Inspect all hoses for leaks that are caused by the
• The phase voltages change relative to engine following conditions. Replace any hose which exhibits
speed. any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions
The generator set functional test consists of the may result in a hazardous situation.
following steps:
• Hoses which are cracked
1. Stop the generator. Connect the potential
transformer's high voltage winding to the • Hoses which are soft
generator terminals (T1) and (T2). Connect
the voltmeter to the low voltage winding. If two • Outer covering that is chafed or cut
transformers are available, connect the high
voltage winding of the second transformer to the • Exposed wire that is used for reinforcement
generator terminals (T1) and (T3). Connect the
secondary terminals that correspond to generator • Outer covering that is ballooning locally
terminal (T2) of both transformers together.
• Flexible part of the hose that is kinked or crushed
2. Disconnect wires “E+” and “E-” from the voltage
regulator. Disconnect the generator from the load. • Armoring that is embedded in the outer covering
3. Connect a 12 VDC automotive battery to wires • Hoses which exhibit signs of leakage which are not
“E+” and “E-”. the result of loose couplings or clamps
4. Measure the AC voltage across the low voltage Inspect all clamps for the following conditions.
terminals of the transformer that correspond to the Replace any clamp which exhibits signs of any of the
following generator terminals: “T1” and “T2”, “T2” following conditions.
and “T3”, and “T3” and “T1”. Record the voltages.
• Cracking
• Looseness
• Damage
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
Each installation application can be different. The

differences depend on the following factors:
SEBU8137-04 81
Maintenance Section
Hoses and Clamps - Inspect/Replace
• Type of hose
• Type of fitting material Personal injury can result from removing hoses or
fittings in a pressure system.
• Anticipated expansion and contraction of the hose
Failure to relieve pressure can cause personal in-
• Anticipated expansion and contraction of the jury.
fittings
Do not disconnect or remove hoses or fittings un-
Due to extreme temperature changes, the hose will
til all pressure in the system has been relieved.
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. 1. Stop the engine.
Replace hoses that are cracked or soft. Replace 2. Allow the engine to cool.
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps 3. Before servicing a coolant hose, slowly loosen the
that are cracked or damaged. Tighten or replace filler cap for the cooling system in order to relieve
hose clamps which are loose. any pressure.
Replace the Hoses and the Clamps 4. Remove the filler cap for the cooling system.
5. Drain the coolant from the cooling system to a

NOTICE level that is below the hose that is being replaced.
Care must be taken to ensure that fluids are contained Drain the coolant into a suitable clean container.
during performance of inspection, maintenance, test- The coolant can be reused.
collect the fluid with suitable containers before open- 6. Remove the hose clamps.
nent containing fluids. 7. Disconnect the old hose.
Refer to Special Publication, NENG2500, “Caterpillar 8. Replace the old hose with a new hose.
Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and 9. Install hose clamps which have been inspected or
Tools Catalog” for tools and supplies suitable to col- install new hose clamps. Refer to Specifications,
lect and contain fluids on Caterpillar products. SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
Dispose of all fluids according to local regulations and installing the proper hose clamps.
mandates.
10. Refill the cooling system.
Cooling System 11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap
if the gaskets are damaged. Install the filler cap.
Pressurized System: Hot coolant can cause seri- 12. Start the engine. Inspect the cooling system for
ous burns. To open the cooling system filler cap, leaks.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Fuel System
pressure cap slowly in order to relieve the pres-
sure.
Personal injury can result from removing hoses or

fittings in a pressure system.
Failure to relieve pressure can cause personal in-

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

til all pressure in the system has been relieved.
82 SEBU8137-04
Maintenance Section
Instrument Panel - Inspect
Lubrication System
Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol- Hot oil and hot components can cause personal
low these inspection, maintenance and service in- injury. Do not allow hot oil or hot components to
structions may cause personal injury or death. contact the skin.
NOTICE 1. Drain the oil from the lubrication system to a level

Do not bend or strike high pressure lines. Do not in- that is below the hose that is being replaced.
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and 2. Remove the hose clamps.
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec- 3. Disconnect the old hose.
ommended torque.
4. Replace the old hose with a new hose.
NOTICE 5. Install hose clamps which have been inspected or

Do not allow dirt to enter the fuel system. Thoroughly install new hose clamps. Refer to Specifications,
clean the area around a fuel system component that SENR3130, “Torque Specifications”, “Hose
will be disconnected. Fit a suitable cover over any dis- Clamps” for information about selecting and
connected fuel system components. installing the proper hose clamps.
6. Refill the lubrication system. Refer to this

Note: High pressure fuel lines may be installed
Operation and Maintenance Manual, “Engine
between the high pressure fuel pump and the fuel
Oil Level - Check” in order to ensure that the
injectors. High pressure fuel lines are constantly
lubrication system is filled with the proper amount
charged with high pressure. Do not check the high
of engine oil.
pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
7. Start the engine. Inspect the lubrication system
engine stops before you perform any service or repair
for leaks.
on high pressure fuel lines in order to allow pressure
to be purged.
Air System
1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced. 1. Remove the hose clamps.
2. Remove the hose clamps. 2. Disconnect the old hose.
3. Disconnect the old hose. 3. Replace the old hose with a new hose.
4. Replace the old hose with a new hose. 4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
5. Install hose clamps which have been inspected or SENR3130, “Torque Specifications”, “Hose
install new hose clamps. Refer to Specifications, Clamps” for information about selecting and
SENR3130, “Torque Specifications”, “Hose installing the proper hose clamps.
Clamps” for information about selecting and
installing the proper hose clamps. 5. Start the engine. Inspect the air lines for leaks.
6. Carefully inspect the engine for any spilled fuel. i01917577

Make sure that no fuel remains on or close to the
engine. Instrument Panel - Inspect
Note: Fuel must be added to the fuel system ahead SMCS Code: 7451-040
of the fuel filter.
Inspect the instrument panel for good condition.
7. Refill the fuel system. Refer to this Operation and Perform the self test. All of the warning lamps should
Maintenance Manual, “Fuel System - Prime” for illuminate. If a warning lamp does not illuminate,
information about priming the engine with fuel. replace the bulb immediately. If the alarm does
not sound, investigate the problem and correct the
8. Start the engine. Inspect the fuel system for leaks. problem.
SEBU8137-04 83
Maintenance Section
Insulation - Test
Check the condition of all of the gauges. If a gauge • dust

is broken, repair the gauge or replace the gauge
immediately. • grease
Frequently monitor the gauges during normal • other foreign matter within the generator
operation.
This deterioration reduces the resistance of the
Record the data in a log. Compare the new data to insulation. This test will measure the resistance of
the data that was previously recorded. Comparing the winding insulation.
the new data to the recorded data will help to
establish the trends of engine performance. A gauge The insulation tester (megohmmeter) produces a
reading that is abnormal may indicate a problem with high potential voltage between the test leads. During
operation or a problem with the gauge. the test, a small current flows. The tester converts
this current to a resistance reading.
i03878716
The insulation test is performed as part of periodic
Insulation - Test maintenance in order to detect the deterioration of the
winding insulation. When there is a rapid decrease
SMCS Code: 4453-081; 4454-081; 4457-081; in the insulation resistance in a short amount of time,
4470-081 the generator needs to be cleaned.
Note: For information on generator cleaning, refer to

Special Instruction, SEHS9124.
The high voltage that is produced by an operating When generators have not been used for a period
generator set can cause severe injury or death. of time, moisture can accumulate. Therefore, the
Before performing any maintenance or repairs, insulation test should be performed on generators
ensure that the generator will not start. that have been idle. If moisture is known to exist,
the windings must be dried prior to testing. Refer to
Place the engine control switch in the “OFF” posi- Testing And Adjusting, “Generator - Dry”.
tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable The insulation test should be performed on
the starting system. Lock out all switchgear and generators that are being used for the first time. The
automatic transfer switches that are associated insulation test should be performed more frequently
with the generator. in the following cases:
Table 9 • The generator set is operating in a humid

environment.
TOOLS NEEDED
Part Number Tool Quantity • The generator set is not protected from the
elements in an enclosed area.
142-5055 Insulation Tester 1
Megohmmeter
• The generator set has not been run under load for
three months.
Note: Space heaters may need to be used around

Personal injury or death can result from electro- the generator set in the following cases:
cution.
• The generator set has not been run under load for
The megohmmeter is applying a high voltage to three months.
the circuit.
• The generator set is exposed to a sea water
To avoid electrocution, do not touch the instru- environment.
ment leads without first discharging them. When
finished testing also discharge the generator • The humidity is above 75 percent.
windings.
• A test result was below 3 megohms.
The following materials will cause the winding The winding needs to be reconditioned or the winding
insulation to deteriorate: needs to be replaced in the following cases:
• moisture (water)
84 SEBU8137-04
Maintenance Section
Overhaul Considerations
• The measured insulation resistance falls below the Exciter Field (Stator L1)
specified amount. The cleanup procedure does not
correct the discrepancy. 1. Isolate exciter field (L1) from the voltage regulator
by disconnecting wires 5+ and 6-. Prevent these
• The measured insulation resistance falls below the wires from coming into contact with each other
specified amount. The drying procedure does not and prevent these wires from contacting ground.
correct the discrepancy.
2. Connect one test lead of the insulation tester
The specified insulation resistance is an approximate (megohmmeter) to the generator enclosure
value. It can be possible to operate the generator with (ground).
less than the specified value. However, a generator
that has a low winding insulation resistance will be 3. Connect one test lead of the insulation tester
more likely to have a failure. (megohmmeter) to exciter field lead (5+ or 6-).
4. Measure the resistance of the exciter field winding

insulation to ground. The insulation resistance
must be a minimum of 0.25 megohm (250000
Personal injury or death can result from improper ohms).
troubleshooting and repair procedures.
The following troubleshooting and repair proce- Exciter Armature (Rotor L2)
dures should only be performed by qualified per-
sonnel familiar with this equipment. 1. Isolate exciter armature (L2) from the rectifier
circuit. Disconnect the three wires of the exciter
armature from the rectifier blocks.
The insulation test gives accurate results only when
the generator windings are free of moisture and the 2. Connect one test lead of the insulation tester
generator windings are at room temperature. (megohmmeter) to the rotor shaft.
Each winding must have a minimum insulation 3. Connect one test lead of the insulation tester
resistance of one megohm. (megohmmeter) to any one exciter field lead.
Main Armature (Stator L4) 4. The insulation resistance must be a minimum of

0.25 megohm (250000 ohms).
1. Remove the load from the generator by either of
the following:
i01437994
• Open the line circuit breaker. Overhaul Considerations

• Open the following load connections: T1, T2, SMCS Code: 7595-043
T3, and T0.
Reduced hours of operation at full load will result in a
Prevent these wires from coming into contact lower average power demand. A decreased average
with each other and prevent these wires from power demand should increase both the engine
contacting ground. service life and the overhaul interval.
2. Isolate the main armature (L4) from the voltage The need for an overhaul is generally indicated by
regulator by disconnecting the wires for voltage increased fuel consumption and by reduced power.
sensing. If generator lead (T0) is connected to the
generator frame or ground, open the connection. The following factors are important when a decision
is being made on the proper time for an engine
3. Connect one test lead of the insulation tester overhaul:
(megohmmeter) to the generator enclosure
(ground). • The need for preventive maintenance
4. Connect the other test lead of the insulation tester • The quality of the fuel that is being used
(megohmmeter) to generator lead (T0).
• The operating conditions
5. The insulation resistance must be one megohm
or more. • The results of the S·O·S analysis
SEBU8137-04 85
Maintenance Section
Oil Consumption as an Overhaul • Caterpillar Inc. remanufactured exchange

components
Indicator
Oil consumption, fuel consumption, and maintenance Overhaul Recommendation
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil To minimize downtime, Caterpillar Inc. recommends
consumption can also be used to estimate the a scheduled engine overhaul by your Caterpillar
required capacity of a makeup oil tank that is suitable dealer before the engine fails. This will provide you
for the maintenance intervals. with the best cost/value relationship.
Oil consumption is in proportion to the percentage Note: Overhaul programs vary according to the
of the rated engine load. As the percentage of the engine application and according to the dealer that
engine load is increased, the amount of oil that is performs the overhaul. Consult your Caterpillar
consumed per hour also increases. dealer for specific information about the available
overhaul programs and about overhaul services for
The oil consumption rate (brake specific oil extending the engine life.
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) If an overhaul is performed without overhaul service
depends on the engine load. Consult your Caterpillar from your Caterpillar dealer, be aware of the following
dealer for assistance in determining the typical oil maintenance recommendations.
consumption rate for your engine.
Rebuild or Exchange
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal These components should be inspected according to
wear, an engine overhaul should be scheduled. the instructions that are found in various Caterpillar
There may be a corresponding increase in blowby reusability publications. The Special Publication,
and a slight increase in fuel consumption. SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
Overhaul Options
If the parts comply with the established inspection
Before Failure Overhaul specifications that are expressed in the reusable
parts guideline, the parts should be reused.
A planned overhaul before failure may be the best
value for the following reasons: Parts that are not within the established inspection
specifications should be dealt with in one of the
• Costly unplanned downtime can be avoided. following manners:
• Many original parts can be reused according to the • Salvaging

standards for reusable parts.
• Repairing
• The engine's service life can be extended without
the risk of a major catastrophe due to engine • Replacing
failure.
Using out-of-spec parts can result in the following
• The best cost/value relationship per hour of problems:
extended life can be attained.
• Unscheduled downtime
After Failure Overhaul
• Costly repairs
Many options are available if a major engine failure
occurs. An overhaul should be performed if the • Damage to other engine parts
engine block or the crankshaft can be repaired.
• Reduced engine efficiency
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be less than • Increased fuel consumption
the cost of a new engine with a similar exchange
core. Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
This lower cost can be attributed to these aspects: Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
• Caterpillar dealer exchange components
86 SEBU8137-04
Maintenance Section
Inspection and/or Replacement Testing

The following components may not last until the Test the following components during the overhaul.
second overhaul.
• Fuel injection nozzles
• Piston rings
• Fuel injection pump
• Thrust bearings
Testing the fuel system during the overhaul will
• Main bearings ensure that your engine operates at peak efficiency.
Your Caterpillar dealer can provide these services
• Connecting rod bearings and components in order to ensure that your
fuel system is operating within the appropriate
• Crankshaft seals specifications.
• Engine mounts Cleaning

• Hoses Caterpillar Inc. recommends the use of Hydrosolv
Liquid Cleaners. Table 10 lists the Hydrosolv Liquid
Caterpillar Inc. recommends the installation of new Cleaners that are available from your Caterpillar
parts at each overhaul period. dealer.
Inspect these parts while the engine is disassembled Table 10
for an overhaul.
HydrosolvLiquid Cleaners
Inspect the crankshaft for any of the following Part
Description Size
conditions: Number
• Deflection
1U-8812 4 L (1 US gallon)
• Damage to the journals
Hydrosolv4165
• Bearing material that has seized to the journals 1U-5490 19 L (5 US gallon)
Check the journal taper and the profile of the 8T-7570 208 L (55 US gallon)
crankshaft journals. Check these components by
interpreting the wear patterns on the following 1U-8804 4 L (1 US gallon)
components:
Hydrosolv100
1U-5492 19 L (5 US gallon)
• Rod bearing
8T-5571 208 L (55 US gallon)
• Main bearings
Note: If the crankshaft is removed for any reason, Obtain Coolant Analysis
use the magnetic particle inspection process to check
for cracks in the crankshaft. The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits
Inspect the camshaft for damage to the journals and or with S·O·S Coolant Analysis (Level I). Further
to the lobes. coolant analysis is recommended when the engine
is overhauled.
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for For example, considerable deposits are found in the
cracks in the camshaft. water jacket areas on the external cooling system, but
the concentrations of coolant additives were carefully
Inspect the following components for signs of wear or maintained. The coolant water probably contained
for signs of scuffing: minerals that were deposited on the engine over time.
• Camshaft bearings
• Valve lifters
SEBU8137-04 87
Maintenance Section
Rotating Rectifier - Check
A coolant analysis can be conducted in order to verify i02290281

the condition of the water that is being used in the
cooling system. A full water analysis can be obtained Rotating Rectifier - Test
by consulting your local water utility company or
an agricultural agent. Private laboratories are also SMCS Code: 4465-081
available for water analysis.
Caterpillar Inc. recommends an S·O·S Coolant

Analysis (Level II). The high voltage that is produced by an operating
generator set can cause severe injury or death.
S·O·S Coolant Analysis (Level II) Before performing any maintenance or repairs,
ensure that the generator will not start.
An S·O·S Coolant Analysis (Level II) is a
comprehensive coolant analysis which completely Place the engine control switch in the “OFF” posi-
analyzes the coolant and the effects on the cooling tion. Attach “DO NOT OPERATE” tags to all start-
system. An S·O·S Coolant Analysis (Level II) provides ing controls. Disconnect the batteries or disable
the following information: the starting system. Lock out all switchgear and
automatic transfer switches that are associated
• Complete S·O·S Coolant Analysis (Level I) with the generator.
• Visual inspection of properties

• Identification of metal corrosion
• Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
S·O·S Coolant Analysis (Level II) provides a report of

the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see

your Caterpillar dealer. Illustration 63
g00992269
(1) Positive DC terminal or Negative DC terminal

i01880286 (2) AC terminal
(3) AC terminal
Rotating Rectifier - Check (4) AC terminal
SMCS Code: 4465-535 The following procedure tests all three diodes within
a block. Check the positive rectifier block and the
negative rectifier block. If any meter reading does not
fall within the given ranges, replace the rectifier block.
The high voltage that is produced by an operating 1. Set the digital multimeter on the diode range.
generator set can cause severe injury or death. Remove all leads from the rectifier block.
Before performing any maintenance or repairs,
ensure that the generator will not start. 2. To test the negative rectifier block, follow these
steps:
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start- a. Place the red test lead on the negative “-”
ing controls. Disconnect the batteries or disable terminal (1). Place the black test lead on the
the starting system. Lock out all switchgear and following rectifier terminals: AC terminal (2), AC
automatic transfer switches that are associated terminal (3), and AC terminal (4). All readings
with the generator. on the meter should be between 0.4 and 1.0.
Check the exciter armature. Ensure that the rotating

rectifier is tight. If a failure of a rectifier is suspected,
refer to Maintenance Procedure, “Rotating Rectifier -
Test”.
88 SEBU8137-04
Maintenance Section
Starting Motor - Inspect
b. Place the black test lead on the negative “-” For maximum engine service life, make a thorough
terminal (1). Place the red test lead on the inspection of the engine compartment before starting
following rectifier terminals: AC terminal (2), AC the engine. Look for items such as oil leaks or coolant
terminal (3), and AC terminal (4). In all cases, leaks, loose bolts, worn belts, loose connections and
the meter should read “OL” (overload). trash buildup. Make repairs, as needed:
3. To test the positive rectifier block, follow these • The guards must be in the proper place. Repair
steps: damaged guards or replace missing guards.
a. Place the red test lead on the positive “+” • Wipe all caps and plugs before the engine is
rectifier terminal (1). Place the black test lead serviced in order to reduce the chance of system
on the following rectifier terminals: AC terminal contamination.
(2), AC terminal (3), and AC terminal (4). In all
cases, the meter should read “OL” (overload). NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
b. Place the black test lead on the positive “+” fluid. If leaking is observed, find the source and correct
rectifier terminal (1). Place the red test lead on the leak. If leaking is suspected, check the fluid levels
the following rectifier terminals: AC terminal more often than recommended until the leak is found
(2), AC terminal (3), and AC terminal (4). All or fixed, or until the suspicion of a leak is proved to be
readings on the meter should be between 0.4 unwarranted.
and 1.0.
Note: A shorted diode can cause damage to the NOTICE

exciter rotor. If a diode is shorted, check the exciter Accumulated grease and/or oil on an engine or deck is
rotor. Refer to the Testing and Adjusting, “Winding - a fire hazard. Remove this debris with steam cleaning
Test” and Testing and Adjusting, “Insulation - Test”. or high pressure water.
Perform these tests.
• Ensure that cooling lines are properly clamped and
i00651416 tight. Check for leaks. Check the condition of all
pipes.
Starting Motor - Inspect
• Inspect the water pump for coolant leaks.
SMCS Code: 1451-040; 1453-040
Note: The water pump seal is lubricated by coolant
Caterpillar Inc. recommends a scheduled inspection in the cooling system. It is normal for a small amount
of the starting motor. If the starting motor fails, the of leakage to occur as the engine cools down and
engine may not start in an emergency situation. the parts contract.
Check the starting motor for proper operation. Check Excessive coolant leakage may indicate the need
the electrical connections and clean the electrical to replace the water pump seal. For the removal of
connections. Refer to the Service Manual for more water pump and the installation of water pump and/or
information on the checking procedure and for seals, refer to the Service Manual for the engine or
specifications or consult your Caterpillar dealer for consult your Caterpillar dealer.
assistance.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
i00632301
pan, the oil filters and the valve cover.
Walk-Around Inspection
• Inspect the fuel system for leaks. Look for loose
SMCS Code: 1000-040 fuel line clamps.
• Inspect the piping for the air inlet system and the
Inspect the Engine for Leaks and elbows for cracks and for loose clamps.
for Loose Connections
• Inspect the alternator belt and the accessory drive
A walk-around inspection should only take a few belts for cracks, breaks or other damage.
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
SEBU8137-04 89
Maintenance Section
Water Pump - Inspect
Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection and

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

good connection and for good condition.
• Disconnect any battery chargers that are not

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

gauges which are cracked or can not be calibrated.
i02226958
Water Pump - Inspect

SMCS Code: 1361-040; 1361
A failed water pump may cause severe engine

overheating problems that could result in the following
conditions:
• Cracks in the cylinder head

• A piston seizure
• Other potential damage to the engine
Note: The water pump seal is lubricated by the
coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and parts contract.
Visually inspect the water pump for leaks. Renew

the water pump seal or the water pump if there
is an excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, “Water Pump
- Remove and Install” for the disassembly and
assembly procedure.

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MAINTENANCE INTERVALS

Operation and Maintenance

i03879425 Cooling System Coolant Extender (ELC) - Add .... 63

Products that operate in severe operating conditions

Every 500 Service Hours or 1 Year

i03879424 Every 250 Service Hours

Every Week Every 6000 Service Hours or 3 Years

Caterpillar recommends a scheduled inspection

Check the alternator and the battery charger for

For applications that require multiple drive belts,

If the belts are too loose, vibration causes

To accurately check the belt tension, Gauge

1. Loosen the mounting bolts (2) and the adjusting

2. Move the alternator in order to increase or i02153996

Ensure proper ventilation for batteries that are in

The battery cables or the batteries should not be

Removing the battery cables or the batteries with

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure that

7. Connect the cable from the starting motor to the

8. Connect the cable from the ground plane to the i01492654

All lead-acid batteries contain sulfuric acid which

2. Disconnect the negative battery terminal at the

3. Keep the batteries clean.

Note: When the cooling system is cleaned, only

Flush 4. Clean the cooling system filler cap. Inspect the

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

3. Add Cat ELC Extender according to the

Remove cooling system pressure cap slowly to

cooling system pressure cap is cool enough to

Cooling System Water

Replace the water temperature regulator before

A water temperature regulator that fails in a

Caterpillar engines incorporate a shunt design cooling

If the water temperature regulator is installed incor-

Electrical Connections - Check • Maximum heat transfer characteristics

SMCS Code: 4459-535 • Ease of maintenance

Note: For more information on cleaning and drying

Engine - Clean NOTICE

Personal injury or death can result from high volt-

Moisture could create paths of electrical conduc-

Make sure the unit is off line (disconnected from

i01900118 • Check the movement of the yellow core when the

The service indicator may be mounted on the air

Engine Mounts - Inspect

Inspect the engine mounts for deterioration and for

• Improper mounting of the engine

• The red piston locks in the visible position.

• Check for ease of resetting. The service indicator

• Service hours on the engine

• The amount of oil that has been added since the

Hot oil and hot components can cause personal

Before you take the oil sample, complete the Label,

i02309553 Replace the Oil Filter

1. Remove the oil filter with a 1U-8760 Chain

Use a magnet to differentiate between the ferrous

Drain the Engine Oil

• If the engine is equipped with a drain valve, turn the