Sebu8554 03

SEBU8554-03
Operation and
Maintenance
Manual
G3500 Generator Sets
S/N GZE1-UP ( G3520E GENERATOR SET)
http://engine.od.ua
Use the bookmarks for navigation inside of the manual

G3500 Generator Sets SEBU8554-03
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Foreword
Foreword 01/05/2010
Literature Information 01/05/2010
Safety 01/05/2010
Operation 01/05/2010
Maintenance 01/05/2010
Maintenance Intervals 01/05/2010
Overhaul 01/05/2010
California Proposition 65 Warning 01/05/2010
Safety Section
Safety Messages 01/05/2010
o Universal Warning(1) 01/05/2010
o Electrical Shock (2) 01/05/2010
o Hot Surface (3) 01/05/2010
o Hot Surface (4) 01/05/2010
o Electrocution (5) 01/05/2010
o Automatic Starting (6) 01/05/2010
o Lifting the Genset (7) 01/05/2010
Additional Messages 01/05/2010
General Hazard Information 01/05/2010
o Pressurized Air and Water 01/05/2010
o Fluid Penetration 01/05/2010
o Containing Fluid Spillage 01/05/2010
o Lines, Tubes, and Hoses 01/05/2010
o Inhalation 01/05/2010
 Exhaust 01/05/2010
 Asbestos Information 01/05/2010
o Softwrap 01/05/2010
o Dispose of Waste Properly 01/05/2010
Burn Prevention 01/05/2010
o Coolant 01/05/2010
o Oils 01/05/2010
o Batteries 01/05/2010
Fire Prevention and Explosion Prevention 01/05/2010
o Fire Extinguisher 01/05/2010
o Lines, Tubes and Hoses 01/05/2010
Crushing Prevention and Cutting Prevention 01/05/2010
Mounting and Dismounting 01/05/2010
Ignition Systems 01/05/2010
Before Starting Engine 01/05/2010
Engine Starting 01/05/2010
Engine Stopping 01/05/2010
Electrical System 01/05/2010
o Grounding Practices 01/05/2010
Generator Isolating for Maintenance 01/05/2010
Product Information Section

General Information 01/05/2010
Model View Illustrations 01/05/2010
Product Description 01/05/2010
o Intended Use 01/05/2010
o Engine Description 01/05/2010
 Fuel System (Air/Fuel Ratio Control) 01/05/2010
 Ignition System 01/05/2010
 Lubrication System 01/05/2010
 Cooling System 01/05/2010
o Description of the Generator 01/05/2010
o Island Mode 01/05/2010
Product Identification Information 01/05/2010
Plate Locations and Film Locations 01/05/2010
o Engine Information (1) 01/05/2010
o Engine Serial Number (2) 01/05/2010
o Generator Identification (3) 01/05/2010
Reference Information 01/05/2010
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Operation Section
Lifting and Storage 01/05/2010
Product Lifting 01/05/2010
o Lifting the Entire Package 01/05/2010
o Lifting the Engine Only 01/05/2010
o Lifting the Generator Only 01/05/2010
Product Storage 01/05/2010
o Generator Storage 01/05/2010
Installation 01/05/2010
Product Installation 01/05/2010
o Receiving Inspection 01/05/2010
o Unpacking and Storage 01/05/2010
 Moving the Generator 01/05/2010
o Storage 01/05/2010
 Short Time Storage 01/05/2010
 Long Time Storage 01/05/2010
o Bearing Inspection 01/05/2010
o Location 01/05/2010
o Electrical Measurements 01/05/2010
o Alignment 01/05/2010
o Protective Devices 01/05/2010
Features and Controls 01/05/2010
Alarms and Shutoffs 01/05/2010
o Testing Alarms and Shutoffs 01/05/2010
o Setpoints for Alarms and Shutoffs 01/05/2010
 Inlet Manifold Air Temperature 01/05/2010
 Cogeneration and Bio-Gas Fuel Applications 01/05/2010
 Engines Without A Caterpillar Remote Control Panel (Status) 01/05/2010
Battery Disconnect Switch - If Equipped 01/05/2010
Electronic Modular Control Panel II+ (EMCP II+) 01/05/2010
o Generator Set Control + (GSC+) 01/05/2010
 Functions and features of the GSC+ 01/05/2010
 Fault indicators 01/05/2010
 Display 01/05/2010
 Upper display 01/05/2010
 Lower display 01/05/2010
 Keypad 01/05/2010
o Alarm Module 01/05/2010
o Custom Alarm Module 01/05/2010
o Synchronizing Lights Module 01/05/2010
Sensors and Electrical Components 01/05/2010
o Electronic System 01/05/2010
 Governing of the Engine RPM 01/05/2010
 Control of Ignition 01/05/2010
 Control of Air/Fuel Ratio 01/05/2010
 Start/Stop Control 01/05/2010
 Monitoring Engine Operation 01/05/2010
o Sensors 01/05/2010
 Integrated Temperature Sensing Module (ITSM) 01/05/2010
Engine Diagnostics 01/05/2010
Configuration Parameters 01/05/2010
o Air/Fuel Ratio 01/05/2010
 Site Installation Parameters 01/05/2010
 Installation Before the Fuel Control Valve 01/05/2010
 Parallel Utility Applications 01/05/2010
 Island Mode 01/05/2010
o Oil Consumption 01/05/2010
Engine Starting 01/05/2010
Before Starting Engine 01/05/2010
o Walk-Around Inspection 01/05/2010
o Air Inlet System 01/05/2010
o Cooling System 01/05/2010
o Driven Equipment 01/05/2010
o Electrical System 01/05/2010
o Fuel System 01/05/2010
o Lubrication System 01/05/2010
o Starting System 01/05/2010
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 Air Starting Motor 01/05/2010

 Electric Starting Motor 01/05/2010
Cold Weather Starting 01/05/2010
Starting the Engine 01/05/2010
o Purging Unburned Gas 01/05/2010
o Automatic Starting 01/05/2010
o Parameters for the Start/Stop Control 01/05/2010
 Driven Equipment 01/05/2010
 Purge Cycle 01/05/2010
 Cycle Crank Time 01/05/2010
 Rest Cycle 01/05/2010
 Overcrank Time 01/05/2010
o Manual Starting 01/05/2010
Starting with Jump Start Cables 01/05/2010
After Starting Engine 01/05/2010
o Engaging the Driven Equipment 01/05/2010
Engine Operation 01/05/2010
Engine Operation 01/05/2010
o Operating the Engine and the Driven Equipment 01/05/2010
o Partial Load Operation 01/05/2010
Generator Operation 01/05/2010
Generator Operation 01/05/2010
o Loading of the Generator 01/05/2010
o Block Loading and Transient Capability 01/05/2010
o Power Factor 01/05/2010
o Excitation Systems 01/05/2010
 Permanent Magnet Pilot Excited Generators 01/05/2010
o Low Idle Adjustment 01/05/2010
o Standby Generator Sets 01/05/2010
o Options 01/05/2010
 Space Heaters 01/05/2010
 Embedded Temperature Detectors 01/05/2010
 Bearing Temperature Detectors 01/05/2010
Single Unit Operation 01/05/2010
o Initial Start-Up 01/05/2010
o Starting 01/05/2010
o Stopping 01/05/2010
Parallel Operation 01/05/2010
o Initial Start-Up 01/05/2010
o Starting Multiple Units 01/05/2010
o Paralleling Multiple Units 01/05/2010
o Speed Droop for the Load Division (If Equipped) 01/05/2010
o Parallel Operation Of Governors 01/05/2010
 Function of The Engine Governor 01/05/2010
 Summary on Governor Operation 01/05/2010
o Stopping 01/05/2010
o Circulating Currents 01/05/2010
Voltage Regulators 01/05/2010
o Cat Digital Voltage Regulator (Cat DVR) 01/05/2010
 Adjusting the Cat DVR 01/05/2010
Refill Capacities 01/05/2010

Refill Capacities 01/05/2010
o Lubricant Recommendations 01/05/2010
o Lubricant Capacities 01/05/2010
o Coolant Capacities 01/05/2010
Fluid Recommendations 01/05/2010
o Fuel Recommendations 01/05/2010
o Coolant Recommendations 01/05/2010
 Water 01/05/2010
 Glycol 01/05/2010
 Additives 01/05/2010
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Maintenance Section
Maintenance Recommendations 01/05/2010
General Maintenance Information 01/05/2010
o Space Heaters 01/05/2010
System Pressure Release 01/05/2010
o Coolant System 01/05/2010
o Fuel System 01/05/2010
 High Pressure Fuel Lines (If Equipped) 01/05/2010
o Engine Oil 01/05/2010
Welding on Engines with Electronic Controls 01/05/2010
Generator Start-up Checklist 01/05/2010
Maintenance Interval Schedule 01/05/2010
Maintenance Interval Schedule 01/05/2010
When Required
Battery - Recycle - 122 page
Battery - Replace - 123 page
Battery or Battery Cable - Disconnect - 128 page
Coolant Sample (Level 2) - Obtain - 142 page
Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace - 159 page
Generator - Dry - 209 page
Generator Bearing - Lubricate - 220 page
Generator Lead - Check - 228 page
Generator Set - Test - 230 page
Generator Set Alignment - Check - 232 page
Generator Winding - Test - 239 page
Overhaul Considerations - 270 page
Space Heater - Test - 281 page
Stator Winding Temperature - Test - 292 page
Throttle Control Valve - Check - 295 page
Daily
Air Tank Moisture and Sediment - Drain - 118 page
Coolant Level - Check - 140 page
Electrical Connections - Check - 157 page
Engine Air Cleaner Service Indicator - Inspect - 163 page
Engine Oil Level - Check - 176 page
Fuel Filter Differential Pressure - Check - 196 page
Fumes Disposal Filter Differential Pressure - Check - 201 page
Generator Bearing Temperature - Test/Record - 227 page
Generator Load - Check - 229 page
Jacket Water Heater - Check - 254 page
Power Factor - Check - 273 page
Voltage and Frequency - Check - 305 page
Walk-Around Inspection - 306 page
Every Week
Automatic Start/Stop - Inspect - 121 page
Every 250 Service Hours
Battery Charger - Check - 125 page
Battery Electrolyte Level - Check - 126 page
Cooling System Supplemental Coolant Additive (SCA) - Test/Add - 146 page
Engine Oil Sample - Obtain - 179 page
Fumes Disposal Filter - Drain - 199 page
Aftercooler Condensation - Drain - 117 page
Alternator - Inspect - 120 page
Belts - Inspect/Adjust/Replace - 129 page
Crankshaft Vibration Damper - Inspect Engine - 151 page
Engine Speed/Timing Sensor - Clean/Inspect - 182 page
Engine Valve Lash and Bridge - Check - 185 page
Gas Pressure Regulator Condensation - Drain - 205 page
Generator Winding Insulation - Test - 242 page
Hoses and Clamps - Inspect/Replace - 246 page
Inlet Air System - Check - 253 page
Radiator - Clean - 274 page
Valve Stem Projection - Measure/Record - 300 page
Water Pump - Inspect - 309 page
Compressor Bypass - Check - 132 page
Engine Oil - Change - 169 page
Engine Oil Filter - Change - 172 page
Flex ble Coupling - Inspect - 187 page
Generator - Inspect - 213 page
Generator Set Vibration - Test/Record - 233 page
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Stator Lead - Check - 291 page

Spark Plugs - Inspect/Replace - 283 page
Crankcase Blowby - Test/Record - 149 page
Cylinder Pressure - Test/Record - 155 page
Engine Mounts - Inspect - 167 page
Engine Protective Devices - Check Ignition - 181 page
Starting Motor - Inspect - 289 page
Coolant Temperature Regulator - Replace - 144 page
Fumes Disposal Filter Element - Replace - 203 page
Rotating Rectifier - Inspect/Test - 278 page
Turbocharger - Inspect - 296 page
Varistor - Check - 301 page
Every 10 000 Service Hours
Generator Bearing - Inspect - 216 page
Between 16 000 and 20 000 Service Hours
Overhaul (Top End) - 264 page
Overhaul (In-Frame) - 258 page
Every 24 000 Service Hours or 3 Years
Coolant (NGEC) - Change - 134 page
Overhaul (Major) - 261 page
Aftercooler Condensation - Drain 01/05/2010

Air Tank Moisture and Sediment - Drain 01/05/2010
Alternator - Inspect 01/05/2010
Automatic Start/Stop - Inspect 01/05/2010
Battery - Recycle 01/05/2010
Battery - Replace 01/05/2010
Battery Charger - Check 01/05/2010
Battery Electrolyte Level - Check 01/05/2010
Battery or Battery Cable - Disconnect 01/05/2010
Belts - Inspect/Adjust/Replace 01/05/2010
o Inspection 01/05/2010
o Adjusting the Alternator Belt 01/05/2010
o Adjusting the Fan Drive Belt 01/05/2010
o Replacement 01/05/2010
Compressor Bypass - Check 01/05/2010
Coolant (NGEC) - Change 01/05/2010
o Draining the Cooling System 01/05/2010
 Draining the Jacket Water 01/05/2010
 Draining the Separate Circuit 01/05/2010
o Clean the Cooling System 01/05/2010
o Cleaning a Cooling System that has Heavy Deposits or Plugging 01/05/2010
o Fill the Cooling System 01/05/2010
Coolant Level - Check 01/05/2010
Coolant Sample (Level 1) - Obtain 01/05/2010
Coolant Sample (Level 2) - Obtain 01/05/2010
Cooling System Supplemental Coolant Additive (SCA) - Test/Add 01/05/2010
o Test the Concentration of the SCA 01/05/2010
 Coolant/Antifreeze and SCA 01/05/2010
 Water and SCA 01/05/2010
o Add the SCA, If Necessary 01/05/2010
Crankcase Blowby - Test/Record 01/05/2010
Crankshaft Vibration Damper - Inspect - 1500 RPM G3520 engines (if equipped with an oil fed damper)
01/05/2010
Cylinder Pressure - Test/Record 01/05/2010
Electrical Connections - Check 01/05/2010
Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace 01/05/2010
o Servicing the Air Cleaner Elements 01/05/2010
o Inspecting Air Cleaner Elements 01/05/2010
 Storing Air Cleaner Elements 01/05/2010
Engine Air Cleaner Service Indicator - Inspect 01/05/2010
o Test the Service Indicator 01/05/2010
Engine Crankcase Breather - Clean 01/05/2010
Engine Mounts - Inspect 01/05/2010
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Engine Oil - Change 01/05/2010

Engine Oil Filter - Change 01/05/2010
o Replace the Oil Filter Elements 01/05/2010
o Inspect the Used Oil Filter Elements 01/05/2010
Engine Oil Level - Check 01/05/2010
Engine Oil Sample - Obtain 01/05/2010
o Obtain the Sample and the Analysis 01/05/2010
Engine Protective Devices - Check 01/05/2010
o Visual Inspection 01/05/2010
o Calibration Check 01/05/2010
Engine Speed/Timing Sensor - Clean/Inspect 01/05/2010
o Fixed head sensors (if equipped) 01/05/2010
o Slip head sensors (if equipped) 01/05/2010
Engine Valve Lash and Bridge - Check 01/05/2010
o Valve Bridge 01/05/2010
o Engine Valve Lash 01/05/2010
Flexible Coupling - Inspect 01/05/2010
o General Care 01/05/2010
o Preventive Maintenance Schedule 01/05/2010
Fuel Filter Differential Pressure - Check 01/05/2010
Fuel Metering Valve - Check - Tecjet 01/05/2010
Fumes Disposal Filter - Drain 01/05/2010
Fumes Disposal Filter Differential Pressure - Check 01/05/2010
Fumes Disposal Filter Element - Replace 01/05/2010
Gas Pressure Regulator Condensation - Drain 01/05/2010
Generator - Dry 01/05/2010
o Drying Methods 01/05/2010
 Self-Circulating Air Method 01/05/2010
 Oven Method 01/05/2010
 Controlled Current Method 01/05/2010
 Guidelines for Space Heaters 01/05/2010
Generator - Inspect 01/05/2010
o Cleaning (Assembled Generators) 01/05/2010
o Cleaning (Disassembled Generators) 01/05/2010
Generator Bearing - Lubricate 01/05/2010
o Lubricating Process (If Applicable) 01/05/2010
o Additional Information 01/05/2010
Generator Bearing Temperature - Test/Record 01/05/2010
o Resistive Temperature Detectors (RTDs) 01/05/2010
o Infrared Thermometers 01/05/2010
Generator Lead - Check 01/05/2010
Generator Load - Check 01/05/2010
Generator Set - Test 01/05/2010
Generator Set Alignment - Check - Generator Sets 01/05/2010
Generator Set Vibration - Inspect 01/05/2010
Generator Set Vibration - Test/Record 01/05/2010
Generator Winding - Test 01/05/2010
Generator Winding Insulation - Test 01/05/2010
o Recommended Periodic Insulation Tests 01/05/2010
o Recommended Procedure for the Insulation Test 01/05/2010
Hoses and Clamps - Inspect/Replace 01/05/2010
o Inspect the Hoses and the Clamps 01/05/2010
o Replace the Hoses and the Clamps 01/05/2010
 Cooling System 01/05/2010
 Fuel System 01/05/2010
 Lubrication System 01/05/2010
 Air System 01/05/2010
Ignition System Timing - Check/Adjust 01/05/2010
Inlet Air System - Check 01/05/2010
Jacket Water Heater - Check 01/05/2010
Overhaul (In-Frame) 01/05/2010
o Scheduling an In-Frame Overhaul 01/05/2010
o In-Frame Overhaul Information 01/05/2010
Overhaul (Major) 01/05/2010
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o Scheduling a Major Overhaul 01/05/2010

o Major Overhaul Information 01/05/2010
Overhaul (Top End) 01/05/2010
o Scheduling a Top End Overhaul 01/05/2010
o Top End Overhaul Information 01/05/2010
 Cleaning and Inspection of Components 01/05/2010
 Aftercooler and Oil Cooler 01/05/2010
 Oil Suction Screen 01/05/2010
 Transformers 01/05/2010
Overhaul Considerations 01/05/2010
o Overhaul Information 01/05/2010
 Overhaul Intervals 01/05/2010
 Overhaul Inspection 01/05/2010
 Overhaul Programs 01/05/2010
 Overhaul Recommendation 01/05/2010
Power Factor - Check 01/05/2010
Radiator - Clean 01/05/2010
Rotating Rectifier - Inspect/Test 01/05/2010
o Testing a Three-Diode Rectifier Block 01/05/2010
Space Heater - Test 01/05/2010
Starting Motor - Inspect 01/05/2010
o Electric Starting Motor 01/05/2010
o Air Starting Motor 01/05/2010
o Removal and Installation of the Starting Motor 01/05/2010
Stator Lead - Check 01/05/2010
Stator Winding Temperature - Test 01/05/2010
Throttle Control Valve - Check 01/05/2010
Turbocharger - Inspect 01/05/2010
Valve Stem Projection - Measure/Record 01/05/2010
Varistor - Check 01/05/2010
o Ohmmeter 01/05/2010
o Test Light 01/05/2010
Varistor - Inspect 01/05/2010
o Ohmmeter 01/05/2010
o Test Light 01/05/2010
Voltage and Frequency - Check 01/05/2010
Walk-Around Inspection 01/05/2010
o Inspect the Engine for Leaks and for Loose Connections 01/05/2010
o Inspect the Generator 01/05/2010
Water Pump - Inspect 01/05/2010
Reference Information Section

Customer Service 01/05/2010
Customer Assistance 01/05/2010
o USA and Canada 01/05/2010
o Outside of USA and of Canada 01/05/2010
Ordering Replacement Parts 01/05/2010
Reference Materials 01/05/2010
Maintenance Records 01/05/2010
Maintenance Log 01/05/2010
Valve Data Sheet 01/05/2010
Reference Material 01/05/2010
o Coolants 01/05/2010
o Fuels 01/05/2010
o Lubricants 01/05/2010
 Grease 01/05/2010
 Oil 01/05/2010
o Miscellaneous 01/05/2010
o Additional Reference Material 01/05/2010
Decommissioning and Disposal 01/05/2010
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Operation and Maintenance Manual

Media Number -SEBU8554-03
Publication Date -01/07/2012 Date Updated -31/07/2012
Foreword
Literature Information
This manual contains safety, operation instructions, lubrication and maintenance information. This
manual should be stored in or near the engine area in a literature holder or literature storage area.
Read, study and keep it with the literature and engine information.
English is the primary language for all Caterpillar publications. The English used facilitates
translation and consistency in electronic media delivery.
Some photographs or illustrations in this manual show details or attachments that may be different
from your engine. Guards and covers may have been removed for illustrative purposes.
Continuing improvement and advancement of product design may have caused changes to your
engine which are not included in this manual. Whenever a question arises regarding your engine,
or this manual, please consult with your Caterpillar dealer for the latest available information.
Safety
This safety section lists basic safety precautions. In addition, this section identifies hazardous,
warning situations. Read and understand the basic precautions listed in the safety section before
operating or performing lubrication, maintenance and repair on this product.
Operation
Operating techniques outlined in this manual are basic. They assist with developing the skills and
techniques required to operate the engine more efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the engine and its capabilities.
The operation section is a reference for operators. Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating and stopping the engine. This section also
includes a discussion of electronic diagnostic information.
Maintenance
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The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are
grouped by service hours and/or calendar time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that follow.
Use service hours to determine intervals. Calendar intervals shown (daily, annually, etc) may be
used instead of service meter intervals if they provide more convenient schedules and approximate
the indicated service meter reading.
Recommended service should always be performed at the service hour interval. The actual
operating environment of the engine also governs the maintenance schedule. Therefore, under
extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and
maintenance than is specified in the maintenance schedule may be necessary.
The maintenance schedule items are organized for a preventive maintenance management
program. If the preventive maintenance program is followed, a periodic tune-up is not required.
The implementation of a preventive maintenance management program should minimize
operating costs through cost avoidances resulting from reductions in unscheduled downtime and
failures.
Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. Each level and/or
individual items in each level should be shifted ahead or back depending upon your specific
maintenance practices, operation and application. We recommend that the maintenance schedules
be reproduced and displayed near the engine as a convenient reminder. We also recommend that a
maintenance record be maintained as part of the engine's permanent record.
See the section in the Operation and Maintenance Manual, "Maintenance Records" for information
regarding documents that are generally accepted as proof of maintenance or repair. Your
authorized Caterpillar dealer can assist you in adjusting your maintenance schedule to meet the
needs of your operating environment.
California Proposition 65 Warning

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands
after handling.
Overhaul
Major engine overhaul details are not covered in the Operation and Maintenance Manual except
for the interval and the maintenance items in that interval. Major repairs are best left to trained
personnel or an authorized Caterpillar dealer. Your Caterpillar dealer offers a variety of options
regarding overhaul programs. If you experience a major engine failure, there are also numerous
after failure overhaul options available from your Caterpillar dealer. Consult with your dealer for
information regarding these options.
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Media Number -SEBU8554-03 Publication Date -01/07/2012 Date Updated -31/07/2012
i03870549
Additional Messages
SMCS - 1000; 7405
S/N - GZE1-UP
S/N - SSR1-UP
The exact location of the message and the description of the message are reviewed in this section.
Make sure that the message is legible. Clean the message or replace the message if images are
unreadable. When you clean the message, use a cloth, water and soap. Do not use solvent,
gasoline, or other harsh chemicals to clean the message. Solvents, gasoline or other harsh
chemicals could loosen the adhesive that secures the message.
Replace the message if the message is damaged, or missing. If a message is attached to a part that
is replaced, install a message on the replacement part. Any Caterpillar dealer can provide a new
message.
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Illustration 1 g02113193
"No Step "
This label is located on both sides of the engine on top of the exhaust shields near the center of the
engine.
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i00659904
Before Starting Engine

SMCS - 1000
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that
the area is free of personnel.
Ensure that the engine is equipped with a lighting system that is suitable for the conditions. Ensure
that all lights work properly.
All protective guards and all protective covers must be installed if the engine must be started in
order to perform service procedures. To help prevent an accident that is caused by parts in
rotation, work around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The
circuits are provided in order to help prevent personal injury. The circuits are also provided in
order to help prevent engine damage.
On the initial start-up of a new engine or an engine that has been serviced, be prepared to stop the
engine if an overspeed condition occurs. This may be accomplished by shutting off the fuel supply
to the engine, or shutting off the ignition system.
See the Service Manual for repairs and for adjustments.
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i01480768
Burn Prevention
SMCS - 1000; 4450; 7405
Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the cooling system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause severe burns. Allow cooling system
components to cool before the cooling system is drained.
Check the coolant level after the engine has stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough
to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali
to contact the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact
the skin. Also, do not allow hot components to contact the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the
skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching
the batteries and connectors. Use of gloves is recommended.
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i01359666
Crushing Prevention and Cutting Prevention

SMCS - 1000; 4450; 7405
Support the component properly when work beneath the component is performed.
Unless other maintenance instructions are provided, never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed, reinstall the guards.
Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.
When objects are struck, wear protective glasses in order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure
that no one will be injured by flying debris.
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i02896515
Electrical System
SMCS - 1000; 1400
Never disconnect any charging unit circuit or battery circuit cable from the battery when the
charging unit is operating. A spark can cause the combustible gases that are produced by some
batteries to ignite.
Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed electrical wires before the engine is started.
Grounding Practices
Proper grounding is necessary for optimum engine performance and reliability. Improper
grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit
paths.
Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components. Uncontrolled electrical circuit paths can also cause
electrical activity that may degrade the engine electronics and communications.
Use a ground strap to ground the case of all control panels to the engine block.
Ground the engine block with a ground strap that is furnished by the customer. Connect this
ground strap to the ground plane.
Use a separate ground strap to ground the battery negative terminal for the control system to the
ground plane.
Rubber couplings may connect the steel piping of the cooling system and the radiator. This causes
the piping and the radiator to be electrically isolated. Ensure that the piping and the radiator is
continuously grounded to the engine. Use ground straps that bypass the rubber couplings.
Ensure that all grounds are secure and free of corrosion.
16
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i02136012
Engine Starting
SMCS - 1000
If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine
or move the controls. Consult with the person that attached the warning tag before the engine is
started.
All protective guards and all protective covers must be installed if the engine must be started in
order to perform service procedures. To help prevent an accident that is caused by parts in
rotation, work around the parts carefully.
If there is a possibility that unburned gas remains in the exhaust system, refer to the purge
procedure in this Operation and Maintenance Manual, "Engine Starting" topic in the Operation
Section.
Start the engine from the operator's compartment or from the engine start switch.
Always start the engine according to the procedure that is described in the Operation and
Maintenance Manual, "Engine Starting" topic in the Operation Section. Knowing the correct
procedure will help to prevent major damage to the engine components. Knowing the procedure
will also help to prevent personal injury.
To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is
working properly, check the water temperature and the oil temperature during heater operation.
Engine exhaust contains products of combustion which can be harmful to your health. Always
start the engine and operate the engine in a well ventilated area. If the engine is started in an
enclosed area, vent the engine exhaust to the outside.
17
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i00659907
Engine Stopping
SMCS - 1000
To avoid overheating of the engine and accelerated wear of the engine components, stop the
engine according to the instructions in this Operation and Maintenance Manual, "Engine
Stopping" topic (Operation Section).
Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the
engine until the problem that caused the emergency stop has been corrected.
On the initial start-up of a new engine or an engine that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
18
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i04823690
Fire Prevention and Explosion Prevention

SMCS - 1000; 4450; 7405
All fuels, most lubricants, and some coolant mixtures are flammable.
Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can
cause a fire. Fire may cause personal injury and property damage.
A flash fire may result if the covers for the engine crankcase are removed within 15 minutes after
an emergency shutdown.
Determine whether the engine will be operated in an environment that allows combustible gases to
be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal
injury, property damage, or engine damage could result.
19
___________________________________________________________________________________________________________________________
If the application involves the presence of combustible gases, consult your Cat dealer for
additional information about suitable protection devices.
Remove all flammable materials such as fuel, oil, and debris from the engine. Do not allow any
flammable materials to accumulate on the engine.
Store fuels and lubricants in properly marked containers away from unauthorized persons. Store
oily rags and any flammable materials in protective containers. Do not smoke in areas that are
used for storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in a line, a
hose, or a seal failure. Exhaust shields must be installed correctly.
Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines that contain
flammable fluid. Clean any such lines thoroughly with a nonflammable solvent prior to welding or
flame cutting.
Wiring must be kept in good condition. Ensure that all electrical wires are properly routed and
securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before
you operate the engine. Clean all electrical connections and tighten all electrical connections.
Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing or sparking.
Inspect all lines and hoses for wear or for deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Properly install all oil filters and fuel filters. The filter housings must be tightened to the proper
torque.
20
___________________________________________________________________________________________________________________________
Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery.
Do not smoke in battery charging areas.
Never check the battery charge by placing a metal object across the terminal posts. Use a
voltmeter or a hydrometer.
Improper jumper cable connections can cause an explosion that can result in injury. Refer to the
Operation Section of this manual for specific instructions.
Do not charge a frozen battery. Charging a frozen battery may cause an explosion.
The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be familiar with the operation of the fire
extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the
recommendations on the instruction plate.
Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install any lines that are
bent or damaged.
21
___________________________________________________________________________________________________________________________
Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Cat dealer for
repair or for replacement parts.
Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks. Use a board
or cardboard to check for leaks. Tighten all connections to the recommended torque.
Replace the parts if any of the following conditions are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible parts of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields are installed correctly to prevent vibration,
rubbing against other parts, and excessive heat.
22
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i04076154
General Hazard Information

SMCS - 1000; 4450; 7405
.Attach a "Do Not Operate" warning tag to the start switch or controls before the engine is
serviced or repaired. These warning tags (Special Instruction, SEHS7332) are available from your
Caterpillar dealer. Attach the warning tags to the engine and to each operator control station.
When appropriate, disconnect the starting controls.
Do not allow unauthorized personnel on the engine, or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion which may be harmful to your health. Always
start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed
area, vent the engine exhaust to the outside.
23
___________________________________________________________________________________________________________________________
Cautiously remove the following parts. To help prevent spraying or splashing of pressurized
fluids, hold a rag over the part that is being removed.
• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Use caution when cover plates are removed. Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure.
• Wear a hard hat, protective glasses, and other protective equipment, as required.
• When work is performed around an engine that is operating, wear protective devices for
ears in order to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the
engine.
• Ensure that all protective guards and all covers are secured in place on the engine.
• Never put maintenance fluids into glass containers. Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
24
___________________________________________________________________________________________________________________________
Unless other instructions are provided, perform the maintenance under the following
conditions:
• The engine is stopped. Ensure that the engine cannot be started.
• The protective locks or the controls are in the applied position.
• Disconnect the batteries when maintenance is performed or when the electrical system is
serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent
sparks.
• When starting a new engine or an engine which has not been started since service has been
performed, make provisions to stop the engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the fuel supply and/or the air supply to the
engine.
• Do not attempt any repairs that are not understood. Use the proper tools. Replace any
equipment that is damaged or repair the equipment.
• Start the engine with the operator controls. Never short across the starting motor terminals
or the batteries. This method of starting the engine could bypass the engine neutral start
system and/or the electrical system could be damaged.
California Proposition 65 Warning
Some engine exhaust constituents are known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Pressurized Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out which could result
in personal injury.
When pressurized air and/or pressurized water is used for cleaning, wear protective clothing,
protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.
The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip guarding (if applicable) and personal protective
equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
Always wear eye protection for cleaning the cooling system.
Fluid Penetration
25
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Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure
can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin
hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment
immediately. Seek treatment from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
NOTICE
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" or refer to Special Publication, PECJ0003, "Caterpillar
Shop Supplies and Tools Catalog" for tools and supplies suitable to
collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Lines, Tubes, and Hoses

Do not bend or strike high-pressure lines. Do not install lines, tubes, or hoses that are damaged.
Repair any fuel lines, oil lines, tubes, or hoses that are loose or damaged. Leaks can cause fires.
26
___________________________________________________________________________________________________________________________
Inspect all lines, tubes, and hoses carefully. Do not use bare hands to check for leaks. Always use
a board or cardboard for checking engine components for leaks. Tighten all connections to the
recommended torque.
Check for the following conditions:
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Wire that is exposed in reinforced hose
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and the heat shields are installed correctly. Correct
installation of these components will help to prevent these effects: vibration, rubbing against other
parts and excessive heat during operation.
Inhalation
Exhaust
Use caution. Exhaust fumes can be hazardous to your health. If you operate the equipment in an
enclosed area, adequate ventilation is necessary.
Asbestos Information
27
___________________________________________________________________________________________________________________________
Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat replacement parts. Use the following
guidelines when you handle any replacement parts that contain asbestos or when you handle
asbestos debris.
Use caution. Avoid inhaling dust that might be generated when you handle components that
contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that
may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some
gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in
some way. Normal handling is not hazardous unless airborne dust that contains asbestos is
generated.
If dust that may contain asbestos is present, there are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos materials.
• A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can
also be used.
• Use exhaust ventilation on permanent machining jobs.
• Wear an approved respirator if there is no other way to control the dust.
• Comply with applicable rules and regulations for the work place. In the United States, use
Occupational Safety and Health Administration (OSHA) requirements. These OSHA
requirements can be found in "29 CFR 1910.1001".
• Obey environmental regulations for the disposal of asbestos.
• Stay away from areas that might have asbestos particles in the air.
Softwrap
Keep the engine room ventilation operating at full capacity. Wear a National Institute of
Occupational Safety and Health (NIOSH) approved particulate respirator. Wear appropriate
protective clothing in order to minimize direct contact. Use good hygiene practices and wash
hands thoroughly after handling Softwrap. Do not smoke until washing hands thoroughly after
handling Softwrap. Clean up debris with a vacuum or by wet sweeping. Do not use pressurized air
to clean up debris.
ReferenceThe applicable material safety data sheets can be found at the following web site by
searching by the part number or the name of the product:
http://dsf2ws.cat.com/msds/servlet/
cat.cis.ecs.msdsSearch.controller.
UserIdentificationDisplayServlet
28
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Dispose of Waste Properly
Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down
a drain, or into any source of water.
29
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i01489970
Generator Isolating for Maintenance

SMCS - 4450
When you service an electric power generation set or when you repair an electric power
generation set, follow the procedure below:
1. Stop the engine.
2. Attach a "DO NOT OPERATE" or similar warning tag to the engine prime mover starting
circuit. Disconnect the engine starting circuit.
3. Disconnect the generator from the distribution system.
30
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4. Lock out the circuit breaker. Attach a "DO NOT OPERATE" or similar warning tag to the
circuit breaker. Refer to the electrical diagram. Verify that all points of possible reverse
power flow have been locked out.
5. For the following circuitry, remove the transformer's fuses:
◦ power
◦ sensing
◦ control
6. Attach a "DO NOT OPERATE" or similar warning tag to the generator excitation controls.
7. Remove the cover of the generator's terminal box.
8. Use an audio/visual proximity tester in order to verify that the generator is de-energized.
This tester must be insulated for the proper voltage rating. Follow all guidelines in order to
verify that the tester is operational.
9. Determine that the generator is in a de-energized condition. Add ground straps to the
conductors or terminals. During the entire work period, these ground straps must remain
connected to the conductors and to the terminals.
31
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i00702251
Ignition Systems
SMCS - 1550
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components
and wiring.
Do not attempt to remove the valve covers when the engine is operating. The transformers are
grounded to the valve covers. Personal injury or death may result and the ignition system will be
damaged if the valve covers are removed during engine operation. The engine will not operate
without the valve covers.
32
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i01377941
Mounting and Dismounting

SMCS - 1000; 4450; 7405
Generator sets in permanent installations may require the use of a ladder or a work platform in
order to provide access for normal maintenance. The owner and/or the user is responsible for
providing safe access that conforms to SAE J185 and/or local building codes.
Inspect the steps, the handholds, and the work area before mounting the generator set. Keep these
items clean and keep these items in good repair.
Mount the generator set and dismount the generator set only at locations that have steps and/or
handholds. Do not climb on the generator set, and do not jump off the generator set.
Face the generator set in order to mount the generator set or dismount the generator set. Maintain a
three-point contact with the steps and handholds. Use two feet and one hand or use one foot and
two hands. Do not use any controls as handholds.
Do not jump from an elevated platform. Do not jump from a ladder or stairs.
Do not stand on components which cannot support your weight. Use an adequate ladder or use a
work platform. Secure the climbing equipment so that the equipment will not move.
Do not carry tools or supplies when you mount the generator set or when you dismount the
generator set. Use a hand line to raise and lower tools or supplies.
33
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i03871954
Safety Messages
SMCS - 1000; 7405
S/N - GZE1-UP
S/N - SSR1-UP
34
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There are several specific safety messages on this engine. The exact location of the safety messages
and the description of the safety messages are reviewed in this section. Please become familiarized
with all safety messages.
Make sure that all of the safety messages are legible. Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the safety messages if the illustrations are not legible.
When you clean the safety messages, use a cloth, water and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could
loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to
fall.
Replace any safety message that is damaged, or missing. If a safety message is attached to a part that
is replaced, install a safety message on the replacement part. Any Caterpillar dealer can provide new
safety messages.
Universal Warning(1)
This safety message is located on the face of the EMCP II. This message is located on each side of
the generator on the terminal box. This safety message is also located on the valve cover of cylinder
number 3 and the valve cover of cylinder number 4.
35
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g01370904
Do not operate or work on this engine or generator set unless you have
read and understand the instructions and warnings in the Operation
and Maintenance Manuals.
Failure to follow the warnings and instructions could result in injury or

death. Contact any Caterpillar dealer for replacement manuals. Proper
care is your responsibility.
Electrical Shock (2)
This safety message for electrical shock is located on the base of the valve cover on each side of the
engine. This safety message is also located on the face of the EMCP II.
g01372247
36
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WARNING! Shock/Electrocution Hazard! Read and understand the

instructions and warnings in the Operation and Maintenance Manual.
Failure to follow the instructions or heed the warnings could cause
serious injury or death.
Hot Surface (3)
This safety message for hot surfaces is located on the barrel of the generator on each side of the
generator.
g01384734
Hot surfaces inside enclosure. Keep hands back.
Hot Surface (4)
This safety message for hot surfaces is located on the valve cover on each side of the engine.
37
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g01372256
Hot surface! Do not touch!
Electrocution (5)
This safety message for electrocution is located on each side of the generator on the terminal box of
the generator.
g01392482
Do not connect the generator to a utility electrical distribution system

unless it is isolated from the system. Electrical feedback into the
distribution system can occur and could cause personal injury or death.
Open and secure the main distribution switch, or if the connection is

permanent, install a double throw switch to prevent electrical feedback.
38
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Some generators are specifically approved by a utility to run in parallel

with the distribution system and isolation may not be required. Always
check with your utility for the applicable circumstances.
Automatic Starting (6)
This safety message for automatic starting is located on each side of the generator on the terminal box
of the generator.
g01392484
When the engine is in the AUTOMATIC mode, the engine can start at
any moment. To avoid personal injury, always remain clear of the the
engine when the engine is in the AUTOMATIC mode.
Lifting the Genset (7)
This safety message for lifting the genset is located on each side of the generator on the terminal box.
39
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g01433231
Crushing Hazard! Improper lifting could cause serious injury or death.

Follow the lifting instructions in the Operation and Maintenance
Manual for safe lifting procedures.
40
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i03871893
Model View Illustrations

SMCS - 1000
S/N - GZE1-UP
S/N - SSR1-UP
The illustrations show various typical features of G3520E. The illustrations do not show all of the
options that are available.
G3520E right side
41
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(1) Oil filler
(2) Engine control module
(3) Jacket water outlet
(4) Lifting eyes
(5) Aftercooler
(6) Throttle
(7) Air inlet
(8) Aftercooler drains
(9) Water inlet
(10) Engine oil drain
(11) Oil filters
G3520E left side
(4) Lifting eyes
(12) Exhaust stack
(13) Alternator
(14) Water pump
(15) Oil level gauge
(16) Electric starters
42
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i02022372
Plate Locations and Film Locations

SMCS - 1000; 4450
43
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Engine Information (1)

The Engine Information Plate is on the left side of the engine near the front of the block between
the number 2 cylinder and the front housing.
The Engine Information Plate contains the following information:
• Engine serial number ____________________
• Arrangement number ____________________
• Compression ratio ____________________
• Aftercooler temperature ____________________
• Power ____________________
44
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• Full load RPM ____________________
Engine Serial Number (2)

The Engine Serial Number Plate is on the left side of the cylinder block near the rear of the
engine.
The Engine Serial Number Plate contains the following information:
• Engine serial number ____________________
• Engine model number ____________________
• Arrangement number ____________________
Generator Identification (3)

The generator identification is located on the left side of the generator.
The generator identification film includes the following information:
• Generator serial number ____________________
• Generator model number ____________________
• Generator set rating ____________________
45
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i03898664
Product Description
SMCS - 1000; 4450; 4491
S/N - GZE1-UP
S/N - SSR1-UP
The Generator Set consists of an engine, a generator, and a control system.
Intended Use
This Power Generator is intended to be used to generate electrical power.
Engine Description
Fuel System (Air/Fuel Ratio Control)
The fuel system includes these components:
• Fuel metering valve
• Engine control module (ECM)
• Inlet Manifold Pressure Sensor
• Load Signal
• Inlet manifold temperature sensor
The fuel metering valve controls the flow of fuel to the engine. The ECM determines the
requirement for the mixture of air and fuel. The ECM sends a signal to the fuel metering valve.
The fuel metering valve controls the volume of the gas flow to the engine.
The fuel flows through the fuel metering valve into the air inlet elbow. The mixture of air and fuel
flows through the turbocharger compressor. The mixture enters the aftercooler through a throttle
46
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which is electronically controlled. The air/fuel mixture is cooled in the aftercooler. The mixture
then enters the inlet manifold.
The ECM sends an electronic throttle signal to the electronic actuator. The throttle is controlled by
the actuator.
Ignition System
The engine is equipped with an electronic ignition system. The system provides dependable firing
and low maintenance. The system provides precise control of the spark and the ignition timing for
each cylinder.
The system also provides diagnostic capability that enhances troubleshooting.
The engines are equipped with protection from detonation. A detonation sensor is located between
every two cylinders. The ignition timing is retarded for a cylinder when excessive detonation is
sensed in that cylinder. If the maximum retarded position is attained and detonation continues to
occur, the ECM shuts down the engine.
The engines are equipped with flame arresters. The flame arresters are located at the entrance of
each inlet port. If the engine backfires, the flame arresters prevent the fire from entering the intake
manifold.
Lubrication System
The engine lubrication oil is circulated by a gear-driven pump. The oil is cooled and filtered. A
bypass valve provides unrestricted flow of lubrication oil to the engine parts if the oil filter
elements become plugged.
Cooling System
The cooling system uses a water pump. The cooling system has temperature regulators that
regulate the temperature of the coolant. The temperature depends on the application.
The turbocharged engine has a Separate Circuit Aftercooler (SCAC). The temperature depends on
the engine rating and the application.
For a more detailed description, refer to the Systems Operation/Testing and Adjusting manual.
Description of the Generator

The SR4B brushless generator can be used with the following loads: mixed loads of motors and
lights, SCR-controlled equipment, computer centers and petroleum drilling applications.
The generator set packages can be utilized for prime power generation or standby power
generation.
SR4B generators are utilized in three-phase full-wave excitation and regulation. The generators
are either four pole or six pole design. The generators have six lead configuration or twelve lead
configuration. The generators are capable of producing electrical power in either 50 Hz or 60 Hz
applications.
47
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Island Mode
Island Mode refers to an application for Generator Sets that is not paralleled to a public utility. In
this operational state, the gas engine must maintain torque and crankshaft speed during steady
state operations.
48
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i01934436
Reference Information
SMCS - 1000; 4450
Identification of the items in Table 1 may be needed in order to obtain parts and service. Some of
the numbers are on the engine Serial Number Plate and/or Information Plate. Locate the
information for your engine. Record the information on the appropriate space in Table 1. Make a
copy of this list for a record. Retain the information for future reference.
The top level part numbers in the Parts Manual for the engine are listed with the engine
arrangement number.
The packaging arrangement may also be called a pricing arrangement or a customer arrangement.
This is the total package with attachments and options that are not included in the engine
arrangement.
The performance specification can be used by your Caterpillar dealer with the Technical
Marketing Information system. Before the engine leaves the factory, the engine performance is
tested. Detailed performance data is recorded. The performance specification number can be used
for obtaining the data.
Table 1
Reference Numbers
Engine Model
Generator Set Serial Number
Engine Serial Number
Generator Serial Number
Arrangement Number
Packaging Arrangement
Turbocharger
Fuel Filter Element
49
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Fuel Pressure Regulator

Oil Filter Element
Air Cleaner Element
Alternator Belt
Capacity of the Lubrication System
Capacity of the Cooling System
Performance Specification Number
Low Idle rpm
High Idle rpm
Power Rating
50
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i02247955
After Starting Engine

SMCS - 1000
For new installations and engines that are recently rebuilt, carefully monitor the engine in order to
detect any unusual engine performance.
After all systems are stabilized and normal, the engine rpm can be increased from low idle rpm to
rated rpm.
It may be necessary to apply some load in order to attain normal operating temperatures.
Engaging the Driven Equipment

1. Increase the engine speed to rated rpm.
2. Ensure that the operating parameters are in the normal ranges for the engine load.
3. Close the main circuit breaker in order to apply the load.
4. Refer to Special Instruction, REHS1438, "Installation and Initial Start-Up Procedure for
G3500C and G3500E Engines" in order to properly load the engine.
51
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i03898667
Alarms and Shutoffs

SMCS - 7400
Engines may be equipped with optional engine protective devices that are not included in this
section. This section contains some general information about the function of typical engine
protective devices.
Alarms and shutoffs are electronically controlled. The operation of all alarms and shutoffs utilize
components which are actuated by a sensing unit. The alarms and shutoffs are set at critical
operating temperatures, pressures, or speeds in order to protect the engine from damage.
The alarms function in order to warn the operator when an abnormal operating condition occurs.
The shutoffs function in order to shut down the engine when a more critical abnormal operating
condition occurs. The shutoffs help to prevent damage to the engine.
Shutoffs may cause unburned gas to remain in the air inlet and in the exhaust manifold.
Unburned gas in the air inlet and exhaust system may ignite when the
engine is started. Personal injury and/or property damage may result.
Before starting an engine that may contain unburned gas, purge the
unburned gas from the air inlet and exhaust system. Refer to the topic
on purging unburned gas in the "Starting the Engine" section.
If an engine protective device shuts off the engine, always determine the cause of the shutoff.
Make the necessary repairs before attempting to start the engine.
Become familiar with the following information:
• Types of the alarm and shutoff controls
52
___________________________________________________________________________________________________________________________
• Locations of the alarm and shutoff controls
• Conditions which cause each control to function
• Procedure for resetting that is required before starting the engine
Testing Alarms and Shutoffs

Alarms must function properly in order to provide timely warning to the operator. Shutoffs help to
prevent damage to the engine. It is impossible to determine if the engine protective devices are in
good working order during normal operation. Malfunctions must be simulated in order to test the
engine protective devices.
NOTICE
During testing, abnormal operating conditions must be simulated.
The tests must be performed correctly in order to prevent possible

damage to the engine.
Periodic testing of engine protective devices for proper operation is recommended maintenance.
To prevent damage to the engine, only authorized service personnel or your Caterpillar
dealer should perform the tests.
Setpoints for Alarms and Shutoffs

Inlet Manifold Air Temperature
Table 1 lists information on the operating temperatures and the shutdown temperatures for inlet
manifold air temperature. The temperatures are associated with different water temperature
regulators for separate circuit aftercoolers. The temperatures are also associated with different
types of gas engines.
Table 1
Approximate Operating Temperatures and Shutdown Temperatures for G3500 Inlet
Manifold Air Temperature
Opening Temperature for Approximate
Shutdown Shutdown
the Water Temperature Operating
Temperature (1) Temperature (2)
Regulator (SCAC) Temperature
43° C (109° F)
47° C (117° F) 75° C (167° F) 65° C (149° F)
Standard engine
54 °C (130 °F)
58° C (136° F) 75° C (167° F) 65° C (149° F)
Standard engine
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(1)
Engines that operate at less than 50 percent load
(2)
Engines that operate at more than 50 percent load
Cogeneration and Bio-Gas Fuel Applications
G3500 Engines that are in cogeneration and bio-gas applications operate with jacket water coolant
temperatures that are higher than normal. The protective system is optional for cogeneration
engines. The protective system is standard for engines that use bio-gas fuel .
Table 2 lists the setpoints for cogeneration engines.
Table 2
Setpoints For Cogeneration Engines
Condition Setpoint
Alarm signal of differential pressure of jacket water pressure
34.5 kPa (5 psi)
Alarm signal of jacket water coolant temperature
113° C (234° F)
Alarm signal of engine oil temperature
102 °C (215 °F)
Shutdown temperature of engine oil
113° C (234° F)
Shutdown temperature of inlet air manifold (2)
75° C (167° F)
Shutdown temperature of inlet air manifold (1)

65° C (149° F)
(2)
Engines that operate at less than 50 percent load
(1)
Engines that operate at more than 50 percent load
Engines Without A Caterpillar Remote Control Panel (Status)
The customer must provide the relay logic for engines that are not equipped with a Caterpillar
Remote Control Panel (Status). The customer must provide the relay logic for the following
parameters:
• Oil pressure (high idle limit)
• Oil pressure (low idle limit)
• Jacket water coolant temperature (high temperature)
• Overspeed
The specific limits are listed in Table 3. Relay logic must be provided for shutting off the engine
in case any of the limits are reached. Consult your Caterpillar dealer for assistance.
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Table 3
G3500 Engine Shutdown Setpoints
Rated RPM Minimum Oil Pressure Jacket Water (1) Overspeed RPM
Temp
High Idle RPM Low Idle RPM
1500 1770
276 kPa (40 psi) 103 kPa (15 psi) 117° C (243° F)
(1)
To prevent overheating, the coolant pressure must be a minimum of 27.6 kPa (4 psi).
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i04316506
Battery Disconnect Switch - If Equipped

SMCS - 1411
The battery disconnect switch is on the left side of the engine near the rear of the engine.
ON - To activate the electrical

system, insert the disconnect switch
key and turn the battery disconnect
switch clockwise. The battery
disconnect switch must be turned to
the ON position before you start the
engine.
OFF - To deactivate the electrical

system, turn the battery disconnect
switch counterclockwise to the OFF
position.
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The battery disconnect switch operates differently than the engine start switch. When the battery
disconnect switch is in the OFF position, the electrical system is disabled. When the battery
disconnect switch is in the ON position, the battery remains connected to the entire electrical
system. The battery remains connected even if the engine start switch is turned to the OFF
position.
Turn the battery disconnect switch to the OFF position and remove the disconnect switch key
when you service the electrical system. Turn the battery disconnect switch to the OFF position and
remove the disconnect switch key when you service components on the engine.
Turn the battery disconnect switch to the OFF position and remove the disconnect switch key if
you are not going to operate the engine for an extended period. Turning the battery disconnect
switch to the OFF position and removing the disconnect switch key will prevent drainage of the
battery.
NOTICE
Never move the battery disconnect switch to the OFF position while the
engine is operating. Serious damage to the electrical system could
result.
To ensure that no damage to the engine occurs, verify that the engine is fully operational before
cranking the engine. Do not crank an engine that is not fully operational.
Perform the following procedure in order to check the battery disconnect switch for proper
operation:
1. With the battery disconnect switch in the ON position, verify that electrical components in
the operator compartment are functioning. Verify that the hour meter is displaying
information. Verify that the engine will crank.
2. Turn the battery disconnect switch to the OFF position.
3. Verify that the following items are not functioning: electrical components in the operator
compartment, hour meter and engine cranking. If any of the items continue to function with
the battery disconnect switch in the OFF position, consult your Cat dealer.
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i02247953
Before Starting Engine

SMCS - 1000; 1400; 1450
Note: Certain procedures are required before an engine is started for the first time. See Special
Instruction, REHS1438, "Installation and Initial Start-Up Procedure for G3500C and G3500E
Engines".
Perform the required daily maintenance and other periodic maintenance before starting the engine.
This can prevent major repairs at a later date. See this Operation and Maintenance Manual,
"Maintenance Interval Schedule".
Walk-Around Inspection
NOTICE
For any type of leak, clean up the fluid. If leaking is observed, find the
source and correct the leak. If leaking is suspected, check the fluid
levels more often than recommended until the leak is found or fixed, or
until the suspicion of a leak is proved to be unwarranted.
To obtain maximum service life for your engine, make a thorough inspection before starting the
engine. Make a walk-around inspection of the installation. Look for items such as oil or coolant
leaks, loose bolts and trash buildup. Remove any trash. Make repairs, if necessary.
• The guards must be in the proper place. Repair damaged guards or replace missing guards.
• Ensure that the areas around the rotating parts are clear.
Air Inlet System
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• Ensure that the air inlet piping and the air filters are in place and clean.
• Ensure that all clamps and connections are secure.
• Inspect the air cleaner service indicator (if equipped). Service the air cleaner filter element
when the yellow diaphragm enters the red zone, or the red piston locks in the visible
position.
Cooling System
• Inspect the cooling system for leaks or loose connections. Inspect the condition of all the
hoses and pipes for the cooling system. Ensure that the connections are properly clamped.
• Inspect the water pumps for evidence of leaks.
• Check the coolant level. Add coolant, if necessary. For information on the proper coolant to
use, see this Operation and Maintenance Manual, "Refill Capacities and
Recommendations" (Maintenance Section).
Driven Equipment
• If necessary, check the oil levels of the driven equipment. Perform any maintenance that is
required for the driven equipment. Refer to the literature that is provided by the OEM of the
driven equipment.
• If the engine is equipped with a clutch, ensure that the clutch is disengaged.
• For generator set engines, ensure that the main circuit breaker is open.
Electrical System
Inspect the wiring for the following conditions:
• Loose connections
• Wiring that is worn or frayed
Inspect the gauge panel and the control panel for good condition. Reset any shutoff or alarm
components.
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Fuel System
NEVER use a flame to check for gas leaks. Use a gas detector.
An open flame can ignite mixtures of air and fuel. This will cause
explosion and/or fire which could result in severe personal injury or
death.
• Check the fuel lines for leaks with a gas detector.
• Inspect the fuel lines for loose fittings and leaks. Ensure that the fuel lines are properly
clamped.
• Ensure that the fuel is supplied to the engine at the correct pressure for the engine.
Lubrication System
Oil level gauge (dipstick)
(1) "ADD" mark
(2) "FULL" mark
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NOTICE
Excessive engine oil will increase oil consumption and result in

excessive deposits in the combustion chamber. Do not overfill the
engine with oil.
• Check the engine crankcase oil level. Maintain the oil level between the "ADD" and
"FULL" marks on the "ENGINE STOPPED WITH OIL COLD" side of the oil level gauge.
For information on the proper oil to use, see this Operation and Maintenance Manual,
"Refill Capacities and Recommendations" (Maintenance Section).
• Check for leaks at the following components: crankshaft seals, crankcase, oil filters, oil
gallery plugs, sensors and valve covers.
• Inspect the tubes, tee pieces, and clamps on the crankcase breathers.
Starting System
Note: If the engine is equipped with a system for external support, prepare the system before
starting the engine. Ensure that all of the systems for engine support are enabled. Perform all
prestart checks for the control system.
Air Starting Motor
• Drain moisture and sediment from the air tank and from any other air piping.
• Check the oil level in the lubricator. Keep the lubricator at least half full. Add oil, if
necessary.
• Check the air pressure for starting. The air starting motor requires a minimum of 690 kPa
(100 psi). The maximum allowable air pressure is 1030 kPa (150 psi). Open the air supply
valve.
Electric Starting Motor
• Disconnect any battery chargers that are not protected against the high current drain that is
created when the electric starting motor engages.
Inspect the wiring, the electrical cables, and the battery for the following conditions:
• Wires that are worn or frayed
• Corrosion
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i01934528
Cold Weather Starting

SMCS - 1000; 1250; 1450; 1453; 1456; 1900
NOTICE
Oil pan immersion heaters are not recommended for heating the lube
oil. To ensure the compatibility of the components, only use equipment
that is recommended by Caterpillar.
A jacket water heater is required to maintain a minimum starting temperature of 45 °C (113 °F).
The engine may be difficult to start if the jacket water coolant temperature is below 43 °C (110 °
F). The spark plugs may become fouled with moisture condensation if the engine is cranked and
the jacket water coolant temperature is below 43 °C (110 °F).
For air starting motors, a larger volume of starting air and/or a higher air pressure may be
necessary in order to start the engine at colder temperatures.
For electric starting, extra battery capacity may be necessary.
Consult your Caterpillar dealer for more information on the starting aids that are available for cold
weather starting.
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i04126309
Configuration Parameters
SMCS - 1000; 1900; 1901; 1902
S/N - GZE1-UP
S/N - SSR1-UP
Air/Fuel Ratio
The correct air/fuel ratio is important for the following considerations:
• Achieving optimum service life for the engine
• Control of emissions
• Detonation Margin
• Engine Performance
• Environmental Regulations
If the air/fuel ratio is not appropriate for the fuel and the operating conditions, a failure of the
engine may occur. The service life of the turbocharger, the valves, and other components may be
reduced.
Any changes to the air/fuel ratio will affect the exhaust emissions. After adjustment, use an
emissions analyzer to measure the exhaust emissions. Ensure that the engine is in compliance with
local regulations for emissions.
Site Installation Parameters
Site installation parameters will have a direct impact on engine performance and the ability to
achieve optimum service life for the engine. The following parameters should meet Service
Manual, "Application and Installation Guidelines"and Special Instruction, "Technical Data Sheet
Requirements"for this product:
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• Fuel Pressure
• Fuel Temperature
• Air Supply Temperature
• Inlet Air Restriction
• Exhaust Restriction
• Engine Room Pressure
• Engine Room Temperature
Installation Before the Fuel Control Valve
The fuel flows from the main gas supply through the fuel filter. Usually, the fuel filter is a
component of the design at the particular site. The customer is responsible for supplying clean, dry
fuel to the engine. The fuel filter may be supplied by Caterpillar or by the customer. To prevent
particles from entering the engine, a 1 micron filter is required. The filter must be the proper size
for the required gas pressure.
The recommended location for the installation of the fuel filter is close to the engine but before the
gas pressure regulator. Pressure gauges in the gas lines on each side of the fuel filter are
recommended in order to monitor the differential pressure of the filter. A manual shutoff valve in
the gas line before the fuel filter will facilitate servicing of the filter.
The filtered fuel flows to the Gas Shutoff Valve (GSOV). The solenoid for the GSOV may be
connected to the wiring harness of the engine or to a harness that is supplied by the customer. In
either case, the customer may install a switch that can interrupt the circuit.
The control system is configured for a GSOV that is energize-to-run. This means that the GSOV
must be energized in order for the engine to run. To enable the fuel flow, the ECM provides
+Battery voltage to the solenoid for the GSOV. The valve opens and the fuel flows to the engine.
When the control system shuts down the engine, the voltage is removed from the solenoid. The
valve closes and the fuel is shut off.
Parallel Utility Applications
The fuel flows through the GSOV to the gas pressure regulator. The regulator may be supplied by
Caterpillar or by the customer. A regulated pressure of 7 to 35 kPa (1 to 5 psi) is recommended.
Less pressure may result in reduced power. More pressure may result in instability. The required
stability for fuel pressure for parallel utility applications is ± 2 kPa (0.25 psi).
Island Mode
The minimum fuel pressure for Island Mode is 20 kPa (3 psi). The required stability for the steady
state fuel pressure for Island Mode is ±6.9 mbar (0.1 psi). The transient fuel pressure stability
requirement for Island Mode applications is ±48.2 mbar (0.7 psi).
Oil Consumption
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The rate of oil consumption is called Brake Specific Oil Consumption (BSOC). The unit of
measure is grams per brake kilowatt hour or pounds per brake horsepower hour. The BSOC
depends on the engine model, the aspiration, the operating load, and the oil that is used. For
information on calculating the BSOC, refer to Engine Data Sheet 96.2, LEKQ4028, "Oil
Consumption Data".
Table 1 lists the normal mid-life BSOC for G3500 Engines under the following conditions:
• Load factor of 100 percent
• Maintenance is performed according to this Operation and Maintenance Manual,

• Caterpillar NGEO is used.
Table 1
BSOC for G3500 Engines
Turbocharged Aftercooled Engine
0.183 g/bkw h (0.0003 lb/bhp h)
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i03643502
Electronic Modular Control Panel II+ (EMCP II+)

SMCS - 4490
Note: Your machine may not be equipped with all of the following controls.
Electronic Modular Control Panel II+ (EMCP II+)
(1) Generator set control + (GSC+)
(2) Engine control switch (ECS)
(3) Panel lights (PL)
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(4) Alarm module (ALM)
(5) Synchronizing lights module or Custom alarm module (CAM)
(6) Speed potentiometer (SP) or Governor switch
(7) Voltage adjust rheostat (VAR)
(8) Emergency stop push button (ESPB)
(9) Panel light switch (PLS)
The Electronic Modular Control Panel II+ (EMCP II+) is located above the generator distribution
housing. The control panel consists of the following components: a main panel with indicators,
meters and control switches. This control panel may be equipped with optional modules in order to
match the customers' needs and requirements.
The left side of the control panel contains the Generator Set Control + (GSC+). This is the main
component of the system. The GSC+ displays the following information: generator output, fault
conditions and key engine parameters. The center section of the control panel contains switches and
an optional alarm module. The right side of the control panel may be blank, or the right side of the
control panel may contain the Synchronizing Lights Module or the Custom Alarm Module.
Some components are optional. The optional components may not be required for your particular
application.
Generator Set Control + (1) - The generator set control + (GSC+) is the main component of the
EMCP II+. See the topic "Generator Set Control + (GSC+)" in this section.
Engine Control Switch (2) - The engine control switch (ECS) determines the status of the control
panel. In the AUTOMATIC position, the engine will start automatically when a remote initiated
contact is closed. The engine will be shutdown after the contact opens. The engine will be shutdown
after a cooldown period that is programmable has elapsed. The cooldown period can be programmed
to give a 0 to 30 minute cooldown period before the engine shuts down.
In the MANUAL START position, the engine will start. In the MANUAL START position, the
engine will run when ECS remains in the MANUAL START position.
In the STOP position, the engine is shutdown by the fuel solenoid after a programmable cool down
time period has elapsed.
In the OFF/RESET position (12 o'clock), the fault lights are reset and the engine shuts down
immediately.
NOTICE
The engine must be cranking before using the start aid switch. Damage
to the engine is possible if ether is released to the engine but not
exhausted or burned by the engine when cranking.
Panel Lights (3) - Panel lights (PL) are controlled by panel lights switch (9). The panel lights switch
is an ON/OFF switch.
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Alarm Module (4) - The alarm module (ALM) is optional. The ALM provides a visual warning. The
ALM provides an audible warning of engine conditions before these conditions become severe.
Engine conditions that are severe may cause the engine to shutdown. Engine conditions that are
severe may cause the engine not to start.
Synchronizing Lights Module (5) or Custom Alarm Module (5) - The synchronizing lights
module uses synchronizing lights for paralleling the generator sets. The synchronizing lights module
is optional. The custom alarm module (CAM) may be installed in the same opening on the control
panel. The CAM annunciates faults, alarms or other conditions from customer supplied inputs.
Speed Potentiometer (6) - The speed potentiometer (SP) is optional. The SP can be used with the
generator set that has an electronic governor. When the governor is equipped with a speed adjusting
motor, the governor switch (GS) can be mounted instead of the SP. The GS is used in order to raise
the engine speed and the frequency. The GS is used in order to lower the engine speed and the
frequency. The GS is also an option.
Voltage Adjust Rheostat (7) - The voltage adjust rheostat (VAR) is used to adjust the generator
output voltage to the desired level.
Emergency Stop Push Button (8) - The emergency stop push button (ESPB) is used to shut down
the engine during an emergency situation. If equipped, the ESPB shuts off the fuel and the ESPB
activates the optional air shutoff.
Panel Light Switch (9) - The panel lights switch turns on or the panel lights switch turns off the
panel lights.
Below, you can find the descriptions of the following main modules of the EMCP II+:
• Generator Set Control + (GSC+)
• Alarm Module (ALM)
• Custom Alarm Module (CAM)
• Synchronizing Lights Module
Generator Set Control + (GSC+)

Functions and features of the GSC+
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The location of the GSC+ on the control panel for the EMCP II+
The left side of the control panel contains the generator set control + (GSC+). The GSC+ is the main
component of the system. The GSC+ displays the following information: generator output, generator
set functions, fault conditions and key engine parameters. The GSC+ accepts information from the
following sources: operator, speed sensor, engine oil pressure sensor, water temperature sensor and
optional remote sources. This information is used to determine the following parameters: the "on/off"
state of the air for the engine, the "on/off" state of the fuel and the "on/off" state of the starter.
In the very basic operating conditions, the GSC+ receives a signal in order to run the generator set.
The GSC+ turns on the engine's fuel. The GSC+ turns on the engine's starter. When the engine speed
reaches the crank termination speed, the starter is disengaged. When the GSC+ receives a signal to
stop the engine, the GSC+ shuts off the fuel and the GSC+ shuts off the ignition.
The functions of the GSC+ are listed below:
• The GSC+ controls the normal starting and stopping of the engine.
• The GSC+ shows engine conditions and generator output information on two displays. The
displays also show the fault codes and the programming information for the GSC+.
• The GSC+ monitors the system for faults. If a fault occurs, the GSC+ performs a controlled
fault shutdown or the GSC+ provides a fault alarm annunciation. The GSC+ uses indicators
and displays in order to describe the fault.
• The GSC+ contains programmable features for certain applications or requirements for the
customer.
The features of the GSC+ are listed below:
• Cycle Crank: The GSC+ can be programmed to crank for adjustable time periods.
• Governor Control: When the engine oil pressure increases past the low oil pressure setpoint,
the GSC+ indicates that the governor should increase the engine speed from idle rpm to rated
RPM.
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• Cooldown: When the GSC+ receives a signal to perform a shutdown, there is a time delay
before the engine will stop running.
• Automatic Operation: When the GSC+ is in automatic mode, the GSC+ can be started by a
remote initiate signal (contact closure). Upon loss of the signal (contact opening), the GSC+
will perform a normal shutdown.
• Alarm Module Communication: The GSC+ can transmit fault conditions and alarm
conditions to an alarm module (AM). The GSC+ can also transmit the fault conditions and the
alarm conditions to a Customer Communication Module (CCM).
• Powerdown: The EMCP II+ system is designed to remove power from the GSC+ when the
engine control switch (ECS) is in the OFF/RESET mode and when the proper jumper wire is
removed. The GSC+ allows powerdown when the crank termination relay is off for 70 seconds
and the fuel control relay is off for 70 seconds. If the wire is not removed, the GSC+ will
remain powered. Refer to Technical Information Bulletin, TIBU3508 for additional
information on powerdown.
• Fuel Solenoid Type: The GSC+ can be programmed in order to work with a fuel system that is
energized to run. The GSC+ can also be programmed in order to work with a fuel system that is
energized to shutdown.
Fault indicators
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Display area of the GSC+
(13) Low oil pressure indicator
(14) Emergency stop indicator
(15) High water temperature indicator
(16) Engine overspeed indicator
(17) Overcrank indicator
(18) Spare 1 indicator
(21) Fault shutdown indicator
(22) Fault alarm indicator
(23) Dedicated shutdown indicators
(24) Spare fault indicators
(25) Upper display
(26) The key for the alarm codes
The fault indicators are used in order to show a fault that is present. The fault indicators are used in
order to describe a fault that is present. The fault indicators are divided into four groups. The four
groups are listed below:
• Fault alarm indicator (22)
• Fault shutdown indicator (21)
• Spare fault indicators (24)
• Dedicated shutdown indicators (23)
The yellow fault alarm indicator (22) FLASHES when the GSC+ detects an alarm fault. The alarm
fault does not cause the engine status to change. The engine can be started. The engine will continue
operating only if the engine is running at the time of the alarm fault. Fault alarm indicator (22) is
accompanied by an alarm fault code that is shown on the upper display (25) when the key for the
alarm codes (26) is pressed.
The red fault shutdown indicator (21) FLASHES when the GSC+ detects a shutdown fault. The
engine will be shut down if the engine is running. The engine will not be allowed to start. Fault
shutdown indicator (21) is accompanied by a fault code that is immediately shown on the upper
display (25) .
The yellow spare fault indicators (24) FLASH when the conditions that are associated with that spare
fault are active. The three spare faults can be programmed to show coolant loss, engine oil
temperature, spare fault condition or no assignment. The spare fault condition may be a customer
generated switch input. The yellow fault alarm indicator (22) or the red fault shutdown indicator (21)
will accompany the spare fault indicators (24). The spare fault indicators will tell whether the spare
fault input is programmed to be an alarm condition or a shutdown condition.
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The red dedicated shutdown indicators (23) represent the following shutdown faults: low engine oil
pressure, emergency stop, high water temperature, engine overspeed and engine overcrank. When the
GSC+ detects a fault in one of these areas, the dedicated shutdown indicator flashes. The engine is
shutdown if the engine is running, and the engine is not allowed to start. No fault codes are associated
with the dedicated shutdown indicators because each indicator has a descriptive label.
Many of the dedicated shutdown faults depend on certain setpoints in the GSC+.
The conditions that are required to activate the dedicated fault shutdowns and the results of each
dedicated fault are in the following list.
Low Oil Pressure - The engine oil pressure drops below the setpoints for low oil pressure shutdown
that are programmed into the GSC+. There are two low oil pressure setpoints. One setpoint is used
when the engine is at idle speed. The other setpoint is used when the engine is at rated speed. When a
low oil pressure fault occurs, the low oil pressure indicator FLASHES, and the engine is shut down.
The engine is not allowed to start until the fault is corrected.
Emergency Stop - The operator presses the emergency stop push button (ESPB) on the front panel.
When an emergency stop condition occurs, the emergency stop indicator FLASHES and the engine is
shut down. The engine is not allowed to start until the condition is corrected.
High Water Temperature - The engine coolant temperature rises above the setpoint for high water
temperature shutdown that is programmed into the GSC+. When the high water temperature fault
occurs, the high water temperature indicator FLASHES. The engine is shutdown and the engine is not
allowed to start until the fault is corrected.
Engine Overspeed - The engine speed exceeds the setpoint for engine overspeed that is programmed
into the GSC+. When the fault for engine overspeed occurs, the engine overspeed indicator flashes.
The engine is shutdown and the engine is not allowed to start until the fault is corrected.
Overcrank - The engine does not start within the setpoint for total cycle crank time that is
programmed into the GSC+. When the overcrank fault occurs, the overcrank indicator FLASHES.
The engine is not allowed to start until the fault is corrected.
Note: The GSC+ can be programmed to override the shutdown for low oil pressure and high water
temperature faults. When the operator overrides the shutdown faults, the GSC+ responds to the faults
as though the faults are alarm faults. The dedicated shutdown indicator is on continuously, and the
indicator will not be flashing. The engine continues to run and the engine can be restarted. When the
dedicated shutdown indicator is ON continuously, the setpoint for shutdown has been exceeded, but
the GSC+ is programmed to override the shutdown fault. The GSC+ does not treat the shutdown fault
as a shutdown fault. The GSC+ treats the shutdown fault as an alarm fault. At the factory, the GSC+
is programmed to treat a low oil pressure fault and a high water temperature fault as shutdown faults.
The operator or the service technician must decide to override these shutdown faults. The operator or
the service technician must program the GSC+ to treat the shutdown faults as alarm faults.
Display
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Display area of the GSC+
(25) Upper display
(27) Lower display
(28) The power meter key
(29) The AC meter key
(30) The engine meter key
The display consists of the upper display and the lower display. Both displays are used for
programming functions when the display is in the service mode.
Upper display
The upper display (25) shows: AC voltage, current and frequency. Several options are available on
the upper display for AC metering. These options can be viewed one at a time by pressing the AC
meter key (29) on the keypad. The options are listed below:
• Average voltage, generator frequency and total current
• Line to line voltage, generator frequency and line current for any one phase
• Line to line voltage for all three phases
• Line current for all three phases
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Note: When total current increases above "9999A", the GSC+ will show current in "kA" units.
• Line to neutral voltage for all three phases
Upper display (25) is also used to show the various fault codes for system faults.
Note: Line to neutral voltages are not shown when the setpoint P032 is set to 1 for delta generator
sets.
Lower display
The lower display (27) shows values for power metering, engine parameters and the relay status.
The left side of the lower display (27) serves as a power meter for the generator set. The following
functions will scroll automatically:
• Total real power (kW)
• Total reactive power (KVAR)
• Percentage of rated power (%kW)
• Power factor (average)
• Total energy output (kW/h)
The display will stop scrolling when the operator presses the power meter key for less than five
seconds. The display will show a particular parameter continuously. Additional power meter
functions will scroll, if the power meter key (28) is held for more than five seconds and then released.
The additional functions are shown below:
• Total real power (kW)
• Real power phase A (kW)
• Real power phase B (kW)
• Real power phase C (kW)
• Total apparent power (kVA)
• Total reactive power (KVAR)
• Percentage of rated power (%kW)
• Power factor (average)
• Power factor phase A
• Power factor phase B
• Power factor phase C
• Total energy output (kW/h)
• Total reactive energy output (kVAR/Hr)
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Note: All real power values are signed with a "+" or a "−". A negative value indicates reverse power.
Note: The Real power phase and the power factor phase are not shown when setpoint P032 is set to 1
for delta generator sets.
Note: Total energy output that is greater than 999,999 kW/h will be shown as MW/h in two steps in
order to maintain a resolution of 1 kW/h. The first step will show MW/h as a whole number up to six
places. The second step will show MW/h as a decimal to three places.
The right side of lower display (27) shows the value of certain engine parameters. The parameters are
listed below:
• Engine oil temperature (if equipped)
• System battery voltage
• Engine hours
• Engine speed
• Engine oil pressure
• Engine coolant temperature
The value for one of these conditions is shown on display (27) for two seconds. The display then
scrolls to the value for the next condition. A small pointer identifies the engine condition that
corresponds to the value that is showing. When the engine meter key (30) is pressed, the lower
display (27) stops scrolling. The lower display continuously shows one particular value. The pointer
flashes above the value that is showing on the display. When the engine meter key (30) is pressed for
the second time, the lower display will return to scrolling.
The relay status indicators are on the bottom of the lower display (27). When a relay for the GSC+ is
activated, the corresponding indicator is shown on the lower display (27). When a relay is not
activated, the corresponding indicator is not shown.
Keypad
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Keypad area of the GSC+
(21) Fault shutdown indicator
(22) Fault alarm indicator
(25) Upper display
(26) Key for the alarm codes
(27) Lower display
(28) Power meter key
(29) AC meter key
(30) Engine meter key
(31) Lamp test key
(32) Exit key
(33) Service mode key
(34) Keypad
Keypad (34) is used to control the information that is shown on the upper display (25) and lower
display (27). The seven keys have two sets of functions: normal functions and service functions. The
normal functions of the keys are described in the following paragraphs.
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Power Meter Key (28) - This key controls the viewing of power meter information. This information
is shown on the lower display. Pressing the key for at least five seconds causes all the power meter
data to scroll once. The default power meter data then resumes scrolling. If the key is pressed for less
than five seconds, the display stops scrolling.
AC Meter Key (29) - The AC meter key controls the viewing of the AC parameters on the upper
display. Pressing the key causes the display to show a different set of parameters.
Engine Meter Key (30) - This key controls the viewing of engine parameters on the lower display.
Pressing the key stops the scrolling of engine conditions. The value for one particular engine
condition will show continuously. The pointer flashes indicating that the scrolling is stopped. The
scrolling of the engine conditions will resume when the engine meter key is pressed again.
Lamp Test Key (31) - Pressing this key performs a lamp test on the GSC+ and the optional alarm
module. On the GSC+, the ten fault indicators are ON CONTINUOUSLY. Every segment of upper
display (5) and lower display (6) is ON. On the optional alarm module, all of the indicators are ON
and the horn sounds. The function for the lamp test automatically turns off if the operator presses the
key and the operator holds the key for ten seconds.
The Alarm Codes Key (26) - If fault alarm indicator (22) is FLASHING, pressing this key causes
the upper display (25) to show the corresponding alarm fault code. If this key is pressed again, the
generator AC output information will be shown on the upper display (25). If fault alarm indicator
(22) is OFF, this key has no function.
Exit Key (32) - This key only functions when the GSC+ is in Service Mode.
Service Mode Key (33) - Pressing this key causes the GSC+ to enter Service Mode.
Alarm Module
The location of the Alarm Module (ALM) on the control panel for the EMCP II+
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The alarm module (ALM) is optional. The alarm module provides a visual warning and the alarm
module provides an audible warning of engine conditions before the conditions become severe.
One basic alarm module is used to satisfy the requirements for the following modules: standby NFPA
99 alarm module, standby NFPA 110 alarm module, NFPA 99 remote annunciator panel and prime
power alarm.
The front of the alarm module consists of the following indicators:
• Four amber indicators, which can indicate High Coolant Temperature, Low Coolant
Temperature or Low Coolant Level, Low Oil Pressure, Generator On Load, Charger
Malfunction, Low Engine Oil Level and Low Fuel Level
• Four red indicators, which can indicate a Low DC Voltage, Air Damper Closed, Low Oil
Pressure Shutdown, Overcrank Shutdown, High Coolant Temperature Shutdown, and
Overspeed Shutdown
• An audible alarm and Acknowledge/Silence switch
Custom Alarm Module
The location of the Custom Alarm Module (CAM) on the control panel for the EMCP II+
The custom alarm module (CAM) is optional. The custom alarm module provides a visual warning
and the custom alarm module provides an audible warning of the conditions of the customer supplied
inputs before these conditions become severe. The CAM is equipped with the following items for the
customer: horn, alarm silence switch, lamp test switch and eight switched inputs
The front of the alarm module consists of the following indicators:
• Four amber indicators, which are used to display alarm conditions
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• Four red indicators, which are used to display shutdown conditions
Synchronizing Lights Module
The location of the Synchronizing Lights Module on the control panel for the EMCP II+
(35) Synchronizing lamps
(36) Synchronizing switch
The optional synchronizing lights module is mounted on the right side of the control panel. This
module is not used when the control panel is equipped with the 2301A governor.
The synchronizing lights module contains the synchronizing lights (35) and the synchronizing switch
(36) .
Synchronizing Lights (35) - The synchronizing lights (35) are used as an aid in paralleling units at
no load and under load. Each light is connected to the side with the load of the generator output
circuit breaker. The lights are used to indicate when the voltages are in-phase. Close the circuit
breaker in order to connect the generator with the load.
Synchronizing Switch (36) - The synchronizing switch has two positions, ON and OFF. When the
switch is in the ON position, the synchronizing lights are enabled. The generator circuit breaker can
be closed manually when the synchronizing switch is on and the lights are synchronized.
Note: Refer to Operation Section, "Parallel Operation" for information regarding the paralleling of
two generators.
When a reverse power relay is added to a synchronizing lights module, the original synchronizing
lights module will change in the following ways:
• The reverse power relay is mounted on the control panel interior.
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• A reverse power fault is indicated by the Fault Shutdown Indicator on the front of the GSC+.
The reverse power relay is a single phase protective relay. This relay is energized by power in only
one direction. In a reverse power fault, the relay contacts close and the engine shuts down. This will
take the generator off the line. The reverse power relay is equipped with a test switch and
adjustments.
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i02136151
Engine Operation
SMCS - 1000
Proper operation and maintenance are key factors in attaining the maximum service life and
economy for the engine. Follow the instructions in this Operation and Maintenance Manual in
order to minimize operating costs and maximize the service life of the engine.
Observe the gauges or the Caterpillar Electronic Technician (ET) frequently while the engine is
operating. Record the data from the gauges or the Cat ET in a log. It is best to record all Cat ET
data from the status screens. Record the time and the date for each event or each diagnostic.
Include the parameters that are listed in Table 1. Average the data that is recorded during
operation and record the average values for each day. Compare the data to the specifications for
normal engine operation. Comparing the data over time will help to detect trends in engine
performance.
Table 1
Engine Performance
Operator Date
Engine serial number Hour meter
Load RPM
Coolant temperature Oil pressure
Oil filter Air filter
differential pressure differential pressure
Inlet Inlet
manifold pressure manifold temperature
Exhaust Exhaust
temperatures pressure
Secondary transformer voltages Exhaust emissions
Throttle position Fuel valve position
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Investigate any significant change in the gauge or in the Cat ET readings. Monitor the engine
operation and take action when discrepancies are found.
Operating the Engine and the Driven Equipment

Check the gauges and the driven equipment frequently while the engine is operating under a load.
The engine can be operated continuously at full load.
Partial Load Operation

Extended operation at low idle or at a reduced load will cause increased oil consumption and
carbon buildup in the cylinders. Carbon buildup results in the following effects:
• Narrow margin for detonation
• Power loss
• Poor performance
• Accelerated wear of components
Caterpillar Engines can be operated at very light loads for limited times with no harmful effects.
Table 2 lists the limits for hours of operation at various loads.
After the time limit for reduced load operation has expired, operate the engine for a
minimum of two hours at a load that is more than 70 percent of the rated load.
For example, an engine is operating at 20 percent of the rated load. The engine may be operated at
this load factor for a maximum of one-half hour. After the one-half hour, operate this engine for at
least two hours at a load factor of more than 70 percent.
To help keep engine maintenance at a minimum, follow the guidelines that are listed in Table 2.
Table 2
Time Limits For Low Load Operation
Engine Load Time Limit
0 to 30 percent 1/2 hour
31 to 50 percent 2 hours
51 to 100 percent Continuous (1)
(1)
For continuous operation, the manifold air pressure must be greater than the atmospheric pressure.
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i04535324
Generator Lead Connections

SMCS - 4450
Lead Numbering
The Wye (Star) configurations and the Delta configurations are the most common generator lead
connections. The following three-phase connection diagrams illustrate the proper connection and
lead identification.
The leads are numbered clockwise from the top and from the outside inward. The diagrams show
lead numbering for the six and twelve lead generators.
Wye Configuration Diagrams
6 Lead
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6 Lead Wye Configuration
Terminals T4, T5, and T6 become neutral connection when the terminals are tied together.
12 Lead
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12 Lead Wye Configuration - High Voltage
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12 Lead Wye Configuration - Low Voltage
Delta Configuration Diagrams
6 Lead
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6 Lead Delta Configuration
12 Lead
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12 Lead Delta Configuration
Terminals T6 and T9 become the neutral connection when the terminals are tied together and grounded. This
position reflects the terminal T2 and T10 connection as the high phase.
Grounding the Frame

In any generator set installation, the frame of the generator is positively connected to an earth
ground. This connection is the first one that is made at the installation. This connection is the last
one that should be removed. The ground connection must be flexible in order to avoid possible
breakage in later operation.
Ground connection cable or straps should have at least the current carrying capacity of the largest
line lead to the connected load. Joints in cables or straps must be clean, free of electrical
resistance, and protected from possible oxidation. Bolted ground connection joints eventually
oxidize. The joints are frequent sources of radio frequency interference (RFI). Silver soldered and
bolted joints are electrically and mechanically sound.
Neutral Connections
The generators with grounded configuration usually have the neutral grounded when the generator
is installed. However, there are some cases when definite measures can be taken in order to
prevent ground faults on the load side. The purpose of the grounding of the neutral is to prevent
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load side equipment damage. The purpose of the grounding of the neutral is also to prevent harm
to personnel.
If the neutral wire is grounded and one of the phase leads becomes grounded, the excessive
current will open a load circuit breaker to isolate the fault. The excessive current will collapse the
generator voltage, if the circuit breaker does not trip first. The result depends on the particular
generator electrical characteristics, type of fault and trip rating of the circuit breaker. An
undervoltage device may be required in order to provide an adequate short circuit protection.
There are some instances in which grounding the neutral wire is undesirable. An ungrounded
generator neutral lead is acceptable in applications in which definite measures have been taken to
prevent grounds to the phase leads. Examples of such measures are ground fault protective
circuits. Ground fault protection requires that the entire group of distribution circuits should be
studied and treated as a system. The owner should engage a certified and registered consultant if a
new distribution system is being developed. The owner should also engage a certified and
registered consultant if an existing system should be modified for the ground fault protection.
Neutral resistors and reactors may be added to the system for two reasons: to provide protection
during faults and to limit neutral currents.
Single Units
In a three-phase, four-wire system, the neutral wire should be grounded according to local wiring
codes.
In applications, in which definite measures are taken in order to prevent grounds to the load leads,
an ungrounded neutral can be used. Be sure to check your local wiring codes.
Multiple Units
Operation of multiple generators in parallel, having all neutrals grounded, may result in the
circulating current through the neutral connections. In order to eliminate the possibility of
circulating currents, ground the neutral of only one generator. If multiple generators are alternated
on line, a switch should be installed in the neutral ground circuit of each generator. In this case all
neutral ground circuits except one can be opened. Be sure that one of the neutral ground circuits is
closed.
Parallel to Utility
When a Wye (Star) connected generator is going to operate in parallel with a utility system
(infinite bus) and when the secondary of the step-down transformer in the utility system is also a
Wye connection, the following may happen. The grounding of both Wye neutrals may result in
circulating currents through the neutrals. Also, the coordination of ground fault protection requires
an entire system study. A study should be done by a certified and registered consultant who is
familiar with generator systems. The study will determine which grounding method should be
used.
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i03899393
Generator Operation
SMCS - 4450
Loading of the Generator

When a generator is installed or reconnected, be sure that the total current in one phase does not
exceed the nameplate rating. Each phase should carry the same load. This allows the engine to
work at the rated capacity. An electrical unbalance can result in an electrical overload and
overheating if one phase current exceeds the nameplate amperage.
Allowable combinations of unbalanced loads are shown in Illustration 1. When you operate with
significant single-phase loads, the combinations of single-phase load and three-phase load may be
used. Such combinations should be located below the line on the graph.
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Allowable Combinations of Unbalanced Loads
Block Loading and Transient Capability

The block loading capability (transient response) of a generator set that is powered by a gas engine
is less than a generator set that is powered by a diesel engine. Most of this difference is directly
attributed to the inherently different fuel systems of the two engines. When the governor calls for
more power, a diesel engine reacts by adding fuel directly into the cylinder. This method permits
the diesel engine to accept 100% block loads with acceptable voltage dips and frequency changes.
When the governor on a gas engine calls for more power the throttle opens. This causes a larger
flow of the air/fuel mixture to move through the aftercooler core and the air intake manifold and
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into the cylinder. This time delay reduces the gas engine's capability for accepting large block
loads.
If a block load derating is required, refer to ISO 8528 Standards or SAE J1349 Standards.
Power Factor
The power factor represents the efficiency of the load. The power factor is the ratio of apparent
power to total power. This ratio is expressed as a decimal. The power factor represents the portion
of the current which is doing useful work. The portion of current which is not doing useful work is
absorbed in maintaining the magnetic field in motors. This current is called the reactive load.
Engine power is not required to maintain the reactive load.
In most applications, the power factor of the system is determined by these components: electric
motors, controls and transformers. Induction motors usually have a power factor that is no larger
than 0.8. Incandescent lighting is a resistive load of about 1.0 power factor, or unity. Controls can
operate at any power factor. Drivers that have variable frequency or variable speed can operate at
any power factor. An uninterruptible power supply can operate at any power factor. In this case,
the power factor can be between 0.4 and 1.0.
The power factor of a system may be measured with a power factor meter or determined by
calculations. Determine the power requirement in kW by multiplying the power factor by the kVA
that is supplied to the system. As the power factor increases, the total current that is supplied to a
constant power demand will decrease. With equal loads, a lower power factor will draw more
current. A high power factor will result in full engine load that is less than the generator's rated
amperage. A lower power factor increases the possibility of overloading the generator.
Note: Normally, Caterpillar generators are designed for a lagging power factor of 0.8. If operation
at less than 0.7 lagging power factor is desired, consult your Caterpillar dealer in order to check
the rating of the generator.
Excitation Systems
Permanent Magnet Pilot Excited Generators
Permanent Magnet Pilot Excited (PMPE) generators receive power for the voltage regulator from
a pilot exciter, rather than the main armature. The pilot exciter consists of a permanent magnet
rotor and a stator. The pilot exciter operates independently from the generator output voltage.
Constant excitation during a large load application is possible since irregularities in the output
voltage are not fed back into the system. Such irregularities can be caused by load conditions. The
independent operation also allows the generator to better sustain an overload for a short duration.
Low Idle Adjustment

Typically, the low idle on G3500E generator sets is 1100 rpm. On 60 Hz units, low idle will be
approximately 66 percent of the full load speed. On 50 Hz units, low idle will be approximately 80
percent of full load speed.
There is no low idle stop on generator sets with electronic governors. The low idle is set at the
factory on generator sets that have mechanical governors. The low idle is also set at the factory on
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generator sets that run on natural gas. The low idle should only be adjusted by your Caterpillar
dealer if adjustment is required.
Note: Operating the electric set at low idle speed for an extended time will cause some voltage
regulators to shut off. The electric set must be completely shut down. Then, the electric set must
be restarted. This will allow the voltage regulator to again produce an output.
Standby Generator Sets

Most standby units are automatic. Without an operator in attendance, standby units will perform
the following functions: start, pick up the load, run and stop.
Standby units will not change the settings for the governor speed control or the voltage level
automatically. The governor speed and voltage level must be preset for the proper operation of
that unit. Whenever the generator set is operated manually, ensure that the settings for the
governor speed and the voltage level are set correctly for automatic operation. Check all switches
for the proper setting. The "Start Selector Switch" should be in the AUTOMATIC position.
Emergency Stop Switches should be in RUN position.
Options
Space Heaters
Most of the SR4B generators are provided with space heaters. These space heaters are installed for
operation in all climates. The space heaters are especially for use in high humidity conditions. For
more information on space heaters, refer to Maintenance Section, "Space Heater - Check".
Embedded Temperature Detectors
SR4B generators are available with embedded temperature detectors. The detectors are installed in
the slots of the main armature. The main armature is also called a stator. The detectors are used
with the equipment that is provided by the customer. Thus, the temperature of the main armature
winding can be measured or monitored. Two types of temperature detectors are available: RTD
and thermocouple. Contact your Caterpillar dealer for more information.
Bearing Temperature Detectors
Bearing temperature detectors are available on generators with large frames. Bearing temperature
detectors measure the temperature of the main bearing. Thus, the temperature of the bearing can
be measured or monitored. Bearing temperature measurements may help to prevent premature
bearing failure. Two types of temperature detectors are available. Bearing temperature detectors
are used with equipment that is provided by the customer. Contact your Caterpillar dealer for more
information.
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i03899396
Parallel Operation
SMCS - 4450
S/N - GZE1-UP
S/N - SSR1-UP
Initial Start-Up
Preparing a generator for parallel operation requires special attention. Before you attempt to
parallel units for the first time, check all the units for the following three conditions.
• Same phase rotation
• Same alternating current frequency
• Same voltage adjustment
1. Check the phase rotation.
The phase rotation of the paralleled units must be equal. There are two methods that are
used in order to determine if the phase rotation of the incoming unit is equal to the phase
rotation of the on-line unit. These methods are listed below.
◦ Phase rotation meter
◦ Set of three light bulbs
The procedure for determining the proper phase rotation is described below.
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When servicing or repairing electric power generation equipment:
Make sure the unit is off-line (disconnected from utility and/or other
generators power service), and either locked out or tagged DO NOT
OPERATE. Remove all fuses.
a. Connect the light bulbs with rated voltage between the generator leads and the
corresponding line phase. For example, connect terminal 1 to line 1 across the open
circuit breaker.
b. Start the units. Bring the units up to speed. As the units approach the same speed, the
lights will start to blink.
◾ If the lights blink in sequence, one of the units is connected backward. In order
to correct the problem, stop the units. Remove generator leads 1 and 3 at the
circuit breaker. Exchange these generator leads. This reverses the direction of
phase rotation. Terminal 2 should always be connected to line 2. Go to 5.
◾ When the lights flash in unison, the phase rotation is equal. The first condition
of "Initial Start-Up" has been met.
2. Adjust the frequency.
The speed of the paralleled units must be equal. Speed is proportional to the alternating
current frequency.
a. Allow each electric set to run under load for about 30 minutes.
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b. Adjust the governor control in order to give rated frequency at full load.
c. Remove the load and check the high idle speed. The high idle speed should be
approximately 2 to 5 percent above full load speed for governors that are equipped
with droop. If these speeds can not be obtained, contact your Caterpillar dealer.
d. For the most consistent results, repeat 2.b and 2.c until the second condition of "Initial
Start-Up" has been met.
3. Adjust the voltage.
There are two basically different methods for reactive power equalization.
◦ Reactive droop compensation
◦ Cross current compensation
In the reactive droop compensation, the voltage regulator causes an individual generator
output voltage to change in proportion to the reactive current. The reactive current is
measured with a current transformer (CT).
The reactive current can be either lagging or leading. As the lagging reactive current
increases, the voltage regulator will cause the generator output voltage to droop
proportionally. As the leading reactive current increases, the voltage regulator will cause the
generator output voltage to rise proportionally.
This method will tend to reduce the reactive current for the better KVAR sharing with other
units. The reactive droop compensation is a standard method on the Caterpillar generator
sets. The following procedure for voltage adjustment is for the reactive droop compensation.
In the cross current compensation, the voltage regulator is forward biased by the difference
in reactive current outputs of the generators in parallel. Cross current compensation is very
similar to the reactive droop compensation. In cross current compensation, the secondary
circuits of the current transformers are connected in a series string. When one of the
generators carries more reactive current than other generators, a net difference voltage
signal will offset the generated voltage. This will also reduce the reactive current. Refer to
the Engine Data Sheet, LEKX8142, "Caterpillar Zero Droop Voltage for Parallel Operation"
for the adjustment procedure.
Note: The adjustment for the voltage level and voltage droop determine the amount of
circulating currents between the generators. The circulating currents between the generators
will be reduced when the voltage adjustments are carefully matched. Use the same
voltmeter to make adjustments on each unit which will be paralleled.
Note: Voltage droop is expressed as the percentage of voltage change from no load to full
load. Loads of 0.8 power factor require a voltage droop of about 5 percent. A droop
adjustment that causes a 2 percent droop in voltage to a 8 percent droop in voltage is usually
required for satisfactory division of ampere loading.
a. Adjust the voltage. Refer to the "Initial Start-Up" in the Operation Section, "Single
Unit Operation".
b. While the engine is running at rated speed, turn the voltage droop potentiometer
clockwise about 1/2 of full range.
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◾ If the driven load has the unity power factor, set the voltage droop
potentiometer on all generators at half of full range. Proceed to 3.g.
◾ If the driven load is approximately 0.8 power factor, proceed to 3.c.
c. Readjust the voltage level rheostat until the voltage is approximately 5 percent above
desired voltage.
d. Apply full load.
e. Readjust the voltage droop rheostat in order to obtain desired voltage with full load at
0.8 power factor. The voltage droop of each generator must be equal in order to
divide the reactive load.
f. Repeat 3.c, 3.d and 3.e for each generator until the following two conditions are met.
◾ The line voltage is equal to the desired level at full load.
◾ The voltage at no load is approximately 5 percent above the rated voltage.
g. Parallel the generators and apply the driven load. Check the output current of the
generator. If the sum of the amperes of the individual generator amperes exceeds the
total amperes that are going to the load by 10 percent at full load, adjust voltage droop
rheostats. This will lead to proportional current sharing between generators. Some
circulating current is permitted at light load. Some circulating current can be expected
when generators are cold.
NOTICE
Damage to the generator is possible. Do NOT exceed the rated ampere

load on any single generator.
h. Make the final adjustments after the generators that are parallel have been running at
full load for one hour. Tighten the locknuts on all controls. Install the access cover.
The last condition of "Initial Start-Up" has been met.
Starting Multiple Units

Refer to Operation Section, "Single Unit Operation".
Paralleling Multiple Units

Units may be paralleled at no load or units may be paralleled with units under load. After the
initial conditions for start-up are satisfied, verify for the following requirements.
• One of the governors can be an isochronous governor. Electronic load sharing governors are
an exception.
• Generators must have voltage droop compensation or cross current compensation.
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1. Start the unit which will be paralleled.
2. Turn on the synchronizer lights.
3. After the engine has run a few minutes, bring the engine up to synchronous speed.
Synchronous speed means that the frequency of the incoming unit will have the same
frequency of the unit that is on-line. The synchronizing lights will begin to blink.
Note: The frequency of the incoming unit should be slightly greater than the line frequency.
This will allow the incoming unit to assume part of the load.
4. Adjust the engine speed until the lights blink very slowly.
5. The lights turn off when the voltages of the two units are in-phase. At this point, very
quickly close the breaker while the lights are out.
6. Use governor controls in order to share kW load between engines.
7. Generator temperature will be stabilized in approximately four hours. After the generator
temperature has been stabilized, adjust the voltage droop rheostat of each generator in order
to share the reactive load. Adjust the voltage droop rheostat of each generator in order to
limit the circulating currents. Less droop increases the reactive current that is carried by the
generator. Adjusting the voltage droop rheostat in a counterclockwise direction will
decrease droop. Adjusting the voltage droop rheostat in a clockwise direction will increase
droop.
Speed Droop for the Load Division (If Equipped)

Once the two units have been paralleled, the share of the kW load is determined by the governor
control setting. If two units of the same capacity and the same governor characteristics have the
same governor control settings, the units will share the load equally. The total load must not
exceed the capacity of the one engine.
In order to transfer the load from one engine, follow the following procedure.
1. Increase the governor speed control of one unit in order to increase the load.
2. Reduce the governor speed control of the other unit in order to decrease the load on that
unit.
3. Raise or lower the governor speed control of both units in order to change system
frequency.
Parallel Operation Of Governors

The different governors that can be used on G3500E generator sets are shown below.
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Load Sharing Module (typical example)
The generator set load sharing module provides the droop load sharing for generators that are
paralleled. The generator set load sharing module provides the isochronous load sharing for
generators that are paralleled. The load sharing module has an input for the synchronizing parallel
module. The module provides the load sharing that is proportional. More information is available
in the System Operation, Testing and Adjusting, SENR6565, "Generator Set Load Sensor and
Generator Load Sharing Module".
Function of The Engine Governor
This section describes the function of the engine governor in relation to load division between
parallel electric sets. For detailed information on governor controls and adjustments, refer to the
Service Manual for additional information.
It is very important to understand two basic facts about load division between generator sets which
are operating in parallel.
1. The power which is supplied to the generator is a function of the engine. The engine
governor settings and the positions of the governor controls determine the amount of power
that is delivered by the engine. Therefore, the engine governor settings and the positions of
the governor controls determine the kW load which is carried by the generator. If the
governor control setting is advanced, the engine and the generator will assume more kW
load. Likewise, decreasing the governor control setting will result in a reduction of load on
the unit. Other units on the line will gain load or other units will lose load. These other units
will assume that no change in total load or no change in the governor settings of the other
units has taken place.
2. The division of power is not determined by generator excitation or terminal voltage. The
generator excitation will determine the power factor of the generator during operation when
the generator is in parallel with other generators.
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Governors that are used with Caterpillar powered electric sets can be of two types: governors with
fixed speed droop or governors with adjustable speed droop. The values of speed droop which are
commonly used are 3 percent and 0 percent. Governors with adjustable speed droop can be
adjusted so that the settings match the settings of the governors with fixed speed droop. If the
governor is adjusted for 0 percent speed droop operation, then the same speed from no load to full
load can be obtained.
Summary on Governor Operation
The preceding discussion of governor operation can be summarized below.
• The simplest governor combination for parallel generator sets is a speed droop of 3 percent
for each governor. If a constant frequency from no load to full load is required, one
governor can be adjusted for isochronous operation. This isochronous unit will be called a
"lead unit".
• In order for all paralleled units to accept the full share of the load, the following governor
adjustments are required. The governors should have the same full load speed. The
governors should have the same high idle speed in the case of governors which are adjusted
for speed droop operation. The controls for the governor should be set to the high idle
position so that the full range of the governor is available.
• Operation of a governor that is isochronous in parallel with speed droop governors requires
special techniques.
• Any number of electric sets can be operated in parallel. However, only one governor of the
group can be adjusted for isochronous operation. The exception will be some special cases
of electronic governors with an automatic load sharing governor.
Stopping
In order to remove a generator from the line, perform the following procedure.
1. Check the load. The load must be less than the rated capacity of the remaining units.
2. Be sure that the neutral of one of the remaining units is grounded.
3. Remove the load from the outgoing unit. Refer to the Parallel Operation, "Load Division -
Speed Droop". The amperage may never go to zero due to circulating currents.
4. Open the circuit breaker.
5. Allow the engine to cool for five minutes.
6. Stop the engine.
Circulating Currents
Understanding the circulating currents becomes very important when you parallel the units. These
circulating currents are flowing between generators that are paralleled. The circulating currents are
caused by voltage differences between the generators. The amount of the circulating current can
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be determined by subtracting the amperage which is going to the load from the total generator
amperage.
The circulating current may be as high as 25 percent of rated amperes with cold generator sets.
Such current may not even be considered harmful. The total generator current should not exceed
the amperage rating.
As the generators warm, the circulating currents will decrease. The ammeter readings should
decrease slightly, but the voltage meter readings should remain constant.
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i03676783
Product Installation
SMCS - 1000; 1404; 4450; 7002
Receiving Inspection
If the generator is received during cold weather, allow the unit to reach room temperature before
you remove the protective packing material. Warming the generator to room temperature will
prevent the following problems:
• Water condensation on cold surfaces
• Early failures due to wet windings
• Early failures due to wet insulating materials
Unpacking and Storage

Moving the Generator
Improper lift rigging can allow unit to tumble causing injury and
damage.
NOTICE
Do not use the engine lifting eyes to remove the engine and generator
together.
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Unpack the equipment with care in order to avoid scratching painted surfaces. Move the unit to
the mounting location. The unit can be moved by either of the following methods:
• Attach an overhead crane to the lifting eyes that are installed on the generator package.
• Use a lift truck in order to lift the generator.
The hoist and the hoist cables should have a rating that is greater than the weight of the generator.
When the unit is moved, ensure that the generator is completely supported by the lift truck's fork
tines. Also ensure that the generator is balanced on the lift truck's fork tines. Slide the fork tines
beneath the attached skid in order to lift the generator.
Storage
Short Time Storage
If the generator is not installed immediately, store the generator in a clean area. This area should
also have the following conditions: low humidity, stable humidity and stable temperature. Space
heaters must be energized in order to keep condensation from the windings. All accessory
equipment that is supplied with the unit should be stored with the generator. The combined unit
should be covered with a durable cover in order to protect against the following contaminants:
• Dust
• Dirt
• Moisture
Long Time Storage
A storage period in excess of six months should be preceded by the following preparation:
1. Install desiccant bags inside the exciter's cover and install desiccant bags inside the screen
of the fan.
2. Seal the unit in a covering of plastic or other material that has been designed for that
purpose.
3. Adequately tag the generator. This will ensure that preservative greases and desiccant bags
are removed before the unit is placed in operation.
Bearing Inspection
Ball bearing generators use grease. This grease is subject to deterioration. If the generator is stored
longer than one year, new ball bearings should be installed. These bearings should be greased to
the proper level prior to being put into operation. If inspection indicates that bearings are free of
rust or corrosion, and no noise or excessive vibration appear on start-up, replacement is not
necessary.
Location
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The location of the generator must comply with all local regulations. The location of the generator
must also comply with all special industrial regulations. Locate the generator in an area that meets
the following requirements:
• Clean
• Dry
• Well ventilated
• Easily accessible for inspection and maintenance
Do not obstruct air inlet openings. Do not obstruct discharge openings. Coolant flow must reach
these openings. If the generator is exposed to harsh environmental conditions, the generator can be
modified in the field in order to add filters and space heaters. In addition, a more rigid periodic
maintenance schedule should be established.
Note: For further information concerning the installation of this generator set, see the appropriate
Application and Installation Guide.
Electrical Measurements
Measure the insulation resistance of each winding if the generator was exposed to the following
conditions:
• Rapid changes in temperature
• Freezing
• Wet climate during shipment
• Wet climate during storage
Note: These tests should be conducted prior to any power connections that are being made. These
tests should be conducted prior to any control connections that are being made.
Refer to the Generator Maintenance section of this manual in order to measure the following
items:
• Exciter field (stator)
• Exciter armature (rotor)
• Generator field (rotor)
• Generator armature (stator)
Alignment
After the generator set has been placed in the final position, the generator must be aligned. Refer
to these publications:
• Special Instruction, SEHS7654, "Alignment - General Instructions"
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• Special Instruction, SEHS7259, "Alignment of Single-Bearing Generators"
• Special Instruction, REHS0177, "Alignment of the Close Coupled Two-Bearing

Generators"
Protective Devices
The output to the load of the generator should always be protected with an overload protection
device such as a circuit breaker or fuses. Determine the size of fuses or determine the size of
circuit breakers in accordance with NEMA, IEC, and Local Electrical Codes.
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i03643380
Product Lifting
SMCS - 7000; 7002
NOTICE
Never bend the eyebolts and the brackets. Only load the eyebolts and
the brackets under tension. Remember that the capacity of an eyebolt
is less as the angle between the supporting members and the object
becomes less than 90 degrees.
When it is necessary to remove a component at an angle, only use a

link bracket that is properly rated for the weight.
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Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the entire package.
Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables)
should be parallel to each other. The chains and cables should be perpendicular to the top of the
object that is being lifted.
Some removals require lifting fixtures in order to obtain proper balance. Lifting fixtures also help
to provide safety.
Lifting eyes are designed and installed for each package. Alterations to the lifting eyes and/or the
package make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that
proper lifting devices are provided. Consult your Caterpillar dealer for information regarding
fixtures for proper lifting.
Lifting the Entire Package

Do NOT use the engine lifting eyes or the generator lifting eyes to lift the entire package.
Lifting points (3) and (4) have been provided for lifting the entire package. However, lifting the
engine and the generator together requires special equipment and procedures. Consult your
Caterpillar dealer for information regarding fixtures for proper lifting of your complete package.
Lifting the Engine Only

To remove the engine ONLY, use lifting eyes (2) and (3) that are on the engine.
Lifting the Generator Only

Note: The control panel and the terminal box will need to be removed before attempting to lift the
generator.
To remove the generator ONLY, use lifting eyes (1) that are on the generator.
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i05324948
Product Storage
SMCS - 7002
If the engine will not be started for several weeks, the lubricating oil will drain from the cylinder
walls and from the piston rings. Rust can form on the cylinder liner surface, which will increase
engine wear which can reduce engine service life.
To help prevent excessive engine wear, use the following guidelines:
• Complete all of the lubrication recommendations that are listed in this Operation and
Maintenance Manual, "Maintenance Interval Schedule" (Maintenance Section).
• If freezing temperatures are expected, check the cooling system for adequate protection
against freezing. Refer to this Operation and Maintenance Manual, "Fluid
If an engine is out of operation and if use of the engine is not planned, special precautions should
be made. If the engine will be stored for more than 1 month, a complete protection procedure is
recommended.
Your Cat dealer will have instructions for preparing the engine for extended storage periods.
For more detailed information on engine storage, refer to Special Instruction, SEHS9031, "Storage
Procedure for Caterpillar Products".
Generator Storage
For information on generator storage, refer to this Operation and Maintenance Manual, "Generator
Set Installation" (Operation Section).
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i03898669
Sensors and Electrical Components

SMCS - 1900; 7400
S/N - GZE1-UP
S/N - SSR1-UP
Note: This section contains some general information about the engine electronic system and sensors.
For more information, refer to Systems Operation/Testing and Adjusting.
Electronic System
The Caterpillar Electronic System is a complete electronic control system for gas engines. The
following benefits are the most significant advantages of the electronic system:
• Air/Fuel ratio control
• Extensive system diagnostics
• Precise control of engine operation
• Protection from detonation
• Timing control of individual cylinders
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Junction box
Most of the functions of the electronic system are provided by the Engine Control Module (ECM).
The ECM is a sealed unit that is located inside a junction box at the rear of the engine.
Five primary functions are supported by the ECM:
• Governing of the engine rpm
• Control of ignition
• Control of the air/fuel ratio
• Start/stop control
• Monitoring and protection of the engine
Governing of the Engine RPM
The ECM receives a signal from the speed/timing sensor. The ECM maintains the desired engine rpm
through electrical control of the engine's throttle.
Control of Ignition
Each cylinder has an ignition transformer that is located on top of the valve cover. In order to initiate
combustion in each cylinder, the ECM sends a pulse to the primary coil of the ignition transformer at
the correct time. The time is based on firing order and engine speed. The transformer increases the
voltage which creates a spark across the spark plug electrode.
The transformers are grounded through the valve cover. Use caution when a valve cover is removed.
Always disconnect the ignition harness from the transformer when a valve cover is removed.
An ignition harness connects each transformer to the ECM.
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Control of Air/Fuel Ratio
The ECM determines the desired volumetric flow rate for fuel. The determination is based on the
components: actual engine speed, actual load, MAP, MAT and internal maps. Next, the ECM sends
information on the desired fuel flow to the fuel metering valve via the CAN data link. The ECM
adjusts the signal to the fuel metering valve in order to maintain emissions. The process is repeated
continuously during engine operation.
Start/Stop Control
The ECM contains the logic and the inputs for controlling the starting and stopping of the engine.
The logic for starting and stopping can be programmed by the customer. The ECM supplies positive
"+" battery voltage to the starting motor relay and the gas shutoff valve.
The engine uses an energize-to-run system. The gas shutoff valve must remain energized in order to
supply fuel to the engine. If power is removed from the gas shutoff valve, the fuel is shut off. The gas
shutoff valve may be controlled by the customer.
Monitoring Engine Operation
Sensors are used in order to monitor engine operation. Wiring harnesses connect the sensors to the
ECM. The ECM uses the information from the sensors in order to monitor the engine. The ECM also
uses the information from the sensors in order to control the engine. The information is also used to
generate event codes, and diagnostic codes. The codes can be read with a Caterpillar Electronic
Technician (ET).
Event - An event is a result of abnormal engine operation. If abnormal engine operation is detected,
the ECM generates an event code. The ECM can generate an alarm, a shutdown, or a warning of an
impending shutdown for abnormal engine operation. These conditions are some examples of events:
high inlet air temperature, low oil pressure and engine overspeed.
Diagnostic - A diagnostic code is a result of a problem with the operating system or with the
monitoring system. The ECM uses sensors and internal circuitry to monitor the system components.
If a problem develops in a component or a wiring harness, the control system will sense the problem.
The control system will notify the operator by creating a diagnostic code. Some examples of
conditions that activate diagnostics are a short in a circuit for a sensor, an open circuit, or a noisy
signal.
Note: For detailed information on event codes and diagnostic codes, refer to Troubleshooting.
Sensors
Sensors provide information to the ECM. The information enables the ECM to control the engine as
efficiently as possible over a wide range of operating conditions. The information is used for
monitoring engine operation and for protecting the engine.
Illustration 2 shows the locations of the sensors.
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(1) Engine oil temperature sensor
(2) Jacket water pressure switch (inlet)
(3) Pressure sensor for unfiltered oil
(4) Pressure sensor for filtered oil
(5) Manifold air temperature sensor
(6) Jacket water pressure sensor (outlet)
(7) Temperature sensor (jacket water coolant)
(8) Speed/timing sensor
(9) Detonation sensor
(10) Manifold air pressure sensor
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The functions of the sensors are described below.
Engine oil temperature sensor (1) - An oil temperature sensor monitors the engine oil temperature.
A high oil temperature will activate an alarm or a shutdown. The ECM compares the oil temperature
to the engine coolant temperature. A high difference between the two temperatures will activate an
alarm or a shutdown.
Jacket water pressure switch (2) - A pressure switch is located at the outlet of the oil cooler. The
jacket water pressure switch is a limit switch for the coolant that is entering the block.
Oil pressure sensors (3) and (4) - The engine oil pressure is measured before the oil filters and after
the oil filters. An alarm or a shutdown can be activated by any of the following occurrences: low
filtered oil pressure and high oil filter differential pressure.
Manifold air temperature sensor (5) - A sensor for monitoring the air inlet temperature is located in
the elbow before the number twenty cylinder head. Excessive inlet air temperature can activate an
alarm or a shutdown.
Jacket water pressure sensor (6) - A pressure sensor is located at the outlet for the engine jacket
water. If the outlet pressure is too low, the ECM will activate a shutdown.
Jacket water temperature sensor (7) - The temperature sensor is located in the water temperature
regulator housing. To monitor the coolant temperature, the element must be in contact with the
coolant. If overheating occurs due to low coolant level, the sensor will not function properly. A high
coolant temperature will activate an alarm or a shutdown. A low coolant temperature will only
activate an alarm. The setpoints for the activation can be programmed with the Cat ET. The engine
can be restarted after a shutdown due to high engine coolant temperature. However, another
shutdown will occur after one minute if the temperature remains high.
Speed/timing sensor (8) - The engine speed/timing sensor is located on the rear end of the left
camshaft. The engine speed/timing sensor provides accurate information to the ECM about the
position of the crankshaft and the engine rpm. The ECM uses the position of the crankshaft in order
to determine ignition timing.
Detonation sensors (9) - The detonation sensors monitor the engine for detonation in each cylinder.
To eliminate detonation, the ECM retards the timing of the cylinder. If excessive detonation
continues, the ECM will shut down the engine.
Manifold air pressure sensor (10) - A sensor for monitoring the air inlet pressure is located in the
back end of the manifold. Excessive inlet air temperature can activate an alarm or a shutdown.
Integrated Temperature Sensing Module (ITSM)
The ITSM monitors thermocouples that are located at the exhaust port of each cylinder.
Thermocouples are also mounted at the inlet and the outlet to the turbocharger. The temperatures are
broadcast over the Caterpillar data link for use with other modules.
The ITSM calculates the average temperature for each bank. Event codes are generated if the
following conditions occur:
• The temperature is higher than the limit that is programmed.
• The temperature of a cylinder deviates significantly from the average temperature for all of the
cylinders.
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i04010972
Single Unit Operation

SMCS - 4450
Initial Start-Up
Before the initial start-up, perform the megohmmeter test on the main stator winding. Refer to the
Special Instruction, SEHS9124, "Cleaning and Drying of Electric Set Generators" for the
procedure.
Starting
1. Make all of the preliminary checks listed in this Operation and Maintenance Manual,
"Before Starting Engine" topic.
2. Be sure that the main circuit breaker or the line circuit breaker is open.
3. Start the engine according to this Operation and Maintenance Manual, "Starting the Engine"
topic. Allow the engine to warm up.
4. Adjust to the full-load engine speed.
5. Close the main circuit breaker.
6. Apply the load. Apply the load in increments in order to maintain system frequency and
voltage at a constant level.
7. Readjust the governor for rated frequency.
Stopping
Refer to this Operation and Maintenance Manual, "Manual Stop Procedure" for the required
procedures for stopping the generator set.
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i02896656
Starting the Engine

SMCS - 1000; 1450
Engine exhaust contains products of combustion which may be harmful

to your health. Always start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust to the outside.
NOTICE
For initial start-up of a new or rebuilt engine, and for start-up of an

engine that has been serviced, make provision to shut the engine off
should an overspeed occur. This may be accomplished by shutting off
the fuel supply and/or the ignition to the engine.
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Note: Using the "EMERGENCY STOP" button will shut off both the fuel and the ignition.
Do not start the engine or move any of the controls if there is a "DO NOT OPERATE" warning
tag or similar warning tag attached to the start switch or to the controls.
Ensure that no one will be endangered before the engine is started and when the engine is started.
Perform the procedures that are described in this Operation and Maintenance Manual, "Before
Starting Engine".
Purging Unburned Gas

The following events cause unburned gas to remain in the air inlet and in the exhaust manifold:
• Emergency stop
• Engine overspeed
• The engine control is set to the STOP mode and the gas shutoff valve does not close.
• Unsuccessful successive attempts to start the engine
Unburned gas may remain in the air inlet and exhaust system after several unsuccessful attempts
to start the engine. The unburned gas may increase to a concentration that may ignite during a
successive attempt to start the engine.
Perform the following procedure in order to purge the unburned gas:
1. If the Caterpillar Electronic Technician (ET) is not connected to the engine, connect Cat ET
to the engine.
2. Verify that the value of the "Engine Purge Cycle" parameter is equal to ten seconds less
than the value of the "Crank Cycle" parameter.
3. Set the engine control to the START mode. The engine will crank for the "Engine Purge
Cycle" time. Then, the gas shutoff valve will be energized and the ignition will be enabled.
The engine will start.
4. Continue with your previous procedure.
Automatic Starting
When the engine is in the AUTOMATIC mode, the engine can start at
any moment. To avoid personal injury, always remain clear of the the
engine when the engine is in the AUTOMATIC mode.
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If the engine control switch is in the "AUTO" position, the engine will automatically start when
the remote start/stop initiate contact closes.
Parameters for the Start/Stop Control

Driven Equipment
Start-up is delayed until the switch for the driven equipment indicates that the driven equipment is
ready.
Purge Cycle
Note: The engine uses an energize-to-run system. The gas shutoff valve must remain energized in
order to supply fuel to the engine.
The purge cycle allows any unburned fuel to exit through the exhaust before the ignition system is
activated.
The purge cycle occurs under these conditions:
• The gas shutoff valve is de-energized.
• The ignition is off.
• The engine is cranked.
The purge cycle occurs before the crank cycle. The amount of time for the purge cycle is
programmable.
Cycle Crank Time
The maximum amount of time for activation of the starting motor and the gas shutoff valve for
starting is the cycle crank time. The amount of time is programmable.
Rest Cycle
If the engine does not start within the cycle crank time, starting is suspended for a rest cycle. The
amount of time for the rest cycle is equal to the cycle crank time.
Overcrank Time
The overcrank time includes the total purge cycle, the total cycle crank time, and the total rest
cycle. These functions are repeated until termination of the overcrank time.
If the engine does not start within the overcrank time, the engine control module generates an
event code.
Manual Starting
1. Ensure that fuel is supplied to the engine.
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2. Ensure that the driven equipment is ready. For generator set engines, ensure that the main
circuit breaker is open.
NOTICE
Do not engage the starting motor when flywheel is turning. Do not start
the engine under load.
If the engine fails to start within 30 seconds, release the starter switch
or button and wait two minutes to allow the starting motor to cool
before attempting to start the engine again.
3. Start the engine.
The crank terminate speed is programmable. When the engine rpm exceeds the crank
terminate speed, the engine control module disengages the starting motor.
4. Allow the engine speed to stabilize at low idle rpm. Check all of the pressure gauges.
Inspect the engine for leaks and listen for unusual noises. When all systems are normal, the
rpm may be increased.
Table 1
Rated RPM And Low Idle RPM
Rated rpm 1200 1500 1800
Low idle rpm 900 1000 1200
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i04471308
Starting with Jump Start Cables

SMCS - 1000; 1401; 1402; 1900
Improper jump start cable connections can cause an explosion resulting

in personal injury.
Prevent sparks near the batteries. Sparks could cause vapors to

explode. Do not allow jump start cable ends to contact each other or the
engine.
If the installation is not equipped with a backup battery system, an external electrical source may
be necessary to start the engine.
NOTICE
Using a battery source with the same voltage as the electric starting
motor. Use ONLY equal voltage for jump starting. The use of higher
voltage will damage the electrical system.
Do not reverse the battery cables. The alternator can be damaged.

Attach the negative cable last and remove first.
When using an external electrical source to start the engine, turn the
generator set control switch to the "OFF" position. Turn all electrical
accessories OFF before attaching the jump-start cables.
Ensure that the main power switch is in the OFF position before
attaching the jump-start cables to the engine being started.
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1. Turn the start switch to the OFF position. Turn off all accessories.
2. Connect one positive end of the jump-start cable to the positive cable terminal of the
discharged battery. Connect the other positive end of the jump-start cable to the positive
cable terminal of the electrical source.
3. Connect one negative end of the jump-start cable to the negative cable terminal of the
electrical source. Connect the other negative end of the jump-start cable to the engine block
or to the chassis ground. This procedure helps to prevent potential sparks from igniting
combustible gases that are produced by some batteries.
4. Start the engine.
5. Immediately after the stalled engine is started, disconnect the jump-start cables in reverse
order.
Note: If there is a problem with the alternator or the battery charger, the engine will not continue
to run after starting, unless the power to the engine control module is supplied by a separate
source.
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i05264083
Voltage Regulators
SMCS - 4467
S/N - GZE1-UP
S/N - SSR1-UP
Cat Digital Voltage Regulator (Cat DVR)
The Cat Digital Voltage Regulator presents an electrical

shock/electrocution hazard. This hazard will cause serious injury or
death.
Service by trained personnel only.
The terminals and heat sinks are live at hazardous voltages when power
is applied and for up to 8 minutes after power is removed.
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The Cat DVR is a microprocessor-based voltage regulator. Control power for the Cat DVR is
supplied from an external source of 24 VDC. The power stage of the Cat DVR is supplied from a
multiple pole high frequency permanent magnet generator which is mounted on the end of the
generator shaft. Connections to the Cat DVR are made through three connectors. The
communication between the Cat DVR and the service tool is accomplished by using a CANBUS
protocol.
The Cat DVR has the following features:
• Three control modes:
1. Automatic voltage regulation (AVR)
2. Power factor (PF) regulation
3. Reactive power (VAR) regulation
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• Programmable stability settings
• Soft start control with an adjustable time setting in AVR mode
• Dual slope voltage versus frequency (V/Hz) characteristic
• Three-phase or single-phase voltage sensing
• Single-phase current sensing
• Field current sensing and field voltage sensing
• Ten protection functions
Adjusting the Cat DVR
In order to view and configure the parameters of the Cat DVR, a PC with the Cat DVR software is
required.
Refer to Specifications, Systems Operation, Testing and Adjusting, RENR7941, "Cat Digital
Voltage Regulator" for complete information.
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i01721862
Aftercooler Condensation - Drain

SMCS - 1063
The air/fuel mixture that is compressed and warmed by the turbocharger compressor is directed
through the aftercooler core. The air/fuel mixture is cooled in the aftercooler.
Condensation can form in the housing of the aftercooler. A drain plug is provided for draining the
condensation.
Note: An automatic drain is available for use with 32° C (90 °F) separate circuit aftercoolers.
Consult your Caterpillar dealer for details.
Remove the drain plugs (1) from the ends of the plenum. Drain the moisture into a suitable
container. Reinstall the plugs.
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i04534752
Air Tank Moisture and Sediment - Drain

SMCS - 1466-543-M&S
Moisture and sediment in the air starting system can cause the following conditions:
• Freezing
• Corrosion of internal parts
• Malfunction of the air starting system
When opening the drain valve, wear protective gloves, a protective face
shield, protective clothing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal injury.
NOTICE

performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
Refer to Special Publication, NENG2500, "Cat Dealer Service Tool

Catalog" or refer to Special Publication, PECJ0003, "Cat Shop
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Supplies and Tools Catalog" for tools and supplies suitable to collect
and contain fluids on Cat products.
1. Open the drain valve that is on the bottom of the air tank. Allow the moisture and sediment
to drain.
2. Close the drain valve.
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i04342909
Alternator - Inspect
SMCS - 1405-040
Inspect the alternator for the following conditions:
• Proper connections
• Clean ports for cooling airflow
• Proper charging of the battery
Observe the ammeter during engine operation in order to ensure proper battery performance
and/or proper performance of the electrical system.
Make repairs, if necessary. See the Service Manual for service procedures. Consult your Cat
dealer for assistance.
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i01942284
Automatic Start/Stop - Inspect

SMCS - 4462
The generator set must be ready to operate under a load at any time. After performing maintenance
on the generator set, inspect the position of the control switches. Ensure the following conditions:
• The starting system is enabled.
• The control switches are in the correct position for automatic starting.
• The switchgear and the automatic transfer switches that are associated with the generator are
enabled.
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i02039199
Battery - Recycle
SMCS - 1401-005; 1401-510; 1401-535; 1401-561
Always recycle a battery. Never discard a battery. Return used batteries to one of the following
locations:
• A battery supplier
• An authorized battery collection facility
• A recycling facility
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i02710714
Battery - Replace
SMCS - 1401-510
Batteries give off combustible gases which can explode. A spark can
cause the combustible gases to ignite. This can result in severe personal
injury or death.
Ensure proper ventilation for batteries that are in an enclosure. Follow

the proper procedures in order to help prevent electrical arcs and/or
sparks near batteries. Do not smoke when batteries are serviced.
The battery cables or the batteries should not be removed with the
battery cover in place. The battery cover should be removed before any
servicing is attempted.
Removing the battery cables or the batteries with the cover in place
may cause a battery explosion resulting in personal injury.
1. Ensure that the engine is stopped. Refer to this manual, "Stopping the Engine". Ensure that
all electrical loads are removed.
2. Turn off any battery chargers. Disconnect any battery chargers.
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3. Remove the NEGATIVE "-" terminal connection on the battery. Ensure that the terminal
can not contact the terminal on the battery.
4. Remove the POSITIVE "+" terminal connection on the battery.
Note: Always recycle a battery. Never discard a battery. Return used batteries to an
appropriate recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the terminal connections are connected, ensure that the engine start switch is
OFF.
7. Connect the POSITIVE "+" connection to the POSITIVE "+" terminal on the battery.
8. Connect the NEGATIVE "-" terminal connection to the NEGATIVE "-" terminal on the
battery.
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i01942625
Battery Charger - Check

SMCS - 1401-535
Check the battery charger for proper operation. If the batteries are properly charged, the needle of
the ammeter will register near "0" (zero).
The batteries should be kept warm, when possible. The temperature of the battery will affect
cranking power. A battery that is too cold will not crank the engine, even if the engine is warm.
The batteries may not fully recharge when the engine is not run for long periods of time. The
batteries may not fully recharge if the engine only runs for short periods. Ensure a full charge in
order to help prevent the battery from freezing.
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i02601752
Battery Electrolyte Level - Check

SMCS - 1401-535-FLV
When the engine is not run for long periods of time or when the engine is run for short periods, the
batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from
freezing.
All lead-acid batteries contain sulfuric acid which can burn the skin and
clothing. Always wear a face shield and protective clothing when
working on or near batteries.
1. Remove the filler caps. Maintain the electrolyte level to the "FULL" mark on the battery.
If the addition of water is necessary, use distilled water. If distilled water is not available use
clean water that is low in minerals. Do not use artificially softened water.
2. Check the condition of the electrolyte with the 245-5829 Coolant Battery Tester
Refractometer .
3. Keep the batteries clean.
Clean the battery case with one of the following cleaning solutions:
◦ A mixture of 0.1 kg (0.2 lb) of baking soda and 1 L (1 qt) of clean water
◦ A mixture of 0.1 L (0.11 qt) of ammonia and 1 L (1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive
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removal of material can cause the clamps to not fit properly. Coat the clamps and the
terminals with 5N-5561 Silicone Lubricant, petroleum jelly or MPGM.
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i02857256
Battery or Battery Cable - Disconnect

SMCS - 1401; 1402-029
The battery cables or the batteries should not be removed with the
battery cover in place. The battery cover should be removed before any
servicing is attempted.
Removing the battery cables or the batteries with the cover in place
may cause a battery explosion resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF
position and remove the key and all electrical loads.
2. Turnoff any battery chargers. Disconnect any battery chargers.
3. Disconnect the negative battery terminal at the battery that goes to the start switch. Ensure
that the cable cannot contact the terminal. When four 12 volt batteries are involved, the
negative side of two batteries must be disconnected.
4. Tape the leads in order to help prevent accidental starting.
5. Proceed with necessary system repairs. Reverse the steps in order to reconnect all of the
cables.
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i02667833
Belts - Inspect/Adjust/Replace
SMCS - 1357-040; 1357-510; 1357-025
Inspection
Inspect the alternator belt and the fan drive belts for wear and for cracking. Replace the belts if the
belts are not in good condition.
Check the belt tension according to the information in the Service Manual, "Specifications".
Slippage of loose belts can reduce the efficiency of the driven components. Vibration of loose
belts can cause unnecessary wear on the following components:
• Belts
• Pulleys
• Bearings
If the belts are too tight, unnecessary stress is placed on the components. This reduces the service
life of the components.
Adjusting the Alternator Belt
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Typical alternator
(1) Mounting bolt
(2) Adjusting nuts
(3) Mounting bolt
1. Remove the drive belt guard.
2. Loosen mounting bolt (1) , adjusting nuts (2) and mounting bolt (3) .
3. Turn adjusting nuts (2) in order to increase or decrease the drive belt tension.
4. Tighten adjusting nuts (2) . Tighten mounting bolt (3) . Tighten mounting bolt (1) . For the
proper torque, see the Service Manual, "Specifications" module.
5. Reinstall the drive belt guard.
If new drive belts are installed, check the drive belt tension again after 30 minutes of engine
operation at the rated rpm.
Adjusting the Fan Drive Belt

1. Loosen the mounting bolt for the pulley.
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2. Loosen the adjusting nut for the pulley.
3. Move the pulley in order to adjust the belt tension.
4. Tighten the adjusting nut to the proper torque.
5. Tighten the mounting bolt to the proper torque.
For the proper torque specifications, refer to the Service Manual, "Specifications" module.
Replacement
For applications that require multiple drive belts, replace the drive belts in matched sets.
Replacing one drive belt of a matched set will cause the new drive belt to carry more load because
the older drive belts are stretched. The additional load on the new drive belt could cause the new
drive belt to fail.
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i02896718
Compressor Bypass - Check

SMCS - 1050-535
Hydraulically operated valve
Check for leaks. If necessary, remove the actuator according to the instructions in the Service
Manual, "Disassembly and Assembly" manual. Inspect the throat for wear marks. Check for free
movement of the butterfly valve. If necessary, replace the valve.
Inspect the gaskets for wear or damage. If necessary, replace the gaskets. Reinstall the actuator
according to the instructions in the Service Manual, "Disassembly and Assembly" manual.
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Inspect the coupling for the compressor bypass for wear and play. If necessary, replace the
coupling. Excessive wear in the coupling can cause low power or instability in the engine.
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i03906355
Coolant (NGEC) - Change

SMCS - 1350-044
Clean the cooling system before the recommended maintenance interval if the following
conditions exist:
• The engine overheats frequently.
• Foaming is observed.
• The oil has entered the cooling system and the coolant is contaminated.
• Coolant analysis indicates that the coolant has broken down.
Draining the Cooling System
NOTICE

performance of inspection, maintenance, testing, adjusting and repair
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Stop the engine and allow the engine to cool. Ensure that the engine will not start when the
cooling system is drained.
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For information regarding the disposal and the recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools Group:
Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL
NOTICE
Dispose of used engine coolant properly or recycle. Various methods

have been proposed to reclaim used coolant for reuse in engine cooling
systems. The full distillation procedure is the only method acceptable
by Caterpillar to reclaim the used coolant.
Draining the Jacket Water
1. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the
cooling system filler cap.
Locations of the vent and drain plugs
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(1) Coolant outlet
(2) Aftercooler drain plug
(3) Oil cooler drain plug
(4) Engine block drain plug
(5) Drain plug for the adapter
2. Remove the vent plug from coolant outlet (1). Open drain (2). Remove drain plugs (3), (4),
and (5) .
Draining the Separate Circuit
1. Remove vent plugs (6) .
2. Open coolant drain valve (7) .
Clean the Cooling System
NOTICE
Use of commercially available cooling system cleaners may cause

damage to cooling system components. Use only cooling system
cleaners that are approved for Caterpillar engines.
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1. After the cooling system has been drained, flush the cooling system with clean water in
order to remove any debris.
2. Close the cooling system drain valves. Clean the drain plugs and install the drain plugs.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to

avoid air locks.
NOTICE
If the aftercooler circuit has been drained, the vent plug must be
opened to allow the aftercooler to fill properly. Failure to do this will
cause an air lock resulting in engine damage.
3. When the separate circuit is filled, be sure to remove the vent plug.
4. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling
System Cleaner. Add 0.5 L (1 pt) of cleaner per 15 L (4 US gal) of the cooling system
capacity. Install the cooling system filler cap. Install vent plugs (1) .
5. Start the engine. Operate the engine for a minimum of 30 minutes with a coolant
temperature of at least 82 °C (180 °F).
6. Stop the engine and allow the engine to cool. For the jacket water and the separate circuit,
loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the
cooling system filler cap. Open the cooling system drain valves and remove the drain plugs.
Remove the vent plugs. Allow the cleaning solution to drain.
NOTICE
Improper or incomplete rinsing of the cooling system can result in

damage to copper and other metal components.
To avoid damage to the cooling system, make sure to completely flush

the cooling system with clear water. Continue to flush the system until
all signs of the cleaning agent are gone.
7. Flush the cooling system with clean water until the water that drains is clean. Close the
cooling system drain valves. Clean the drain plugs and install the drain plugs.
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Cleaning a Cooling System that has Heavy Deposits or

Plugging
Note: For the following procedure to be effective, there must be an active flow through the
cooling system components.
1. After the cooling system has been drained, flush the cooling system with clean water in
order to remove any debris.
2. Close the cooling system drain valves. Clean the drain plugs and install the drain plugs.
3. Remove the vent plugs.
4. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling
System Cleaner. Add 0.5 L (1 pt) of cleaner per 3.8 to 7.6 L (1 to 2 US gal) of the cooling
system capacity. Install the cooling system filler cap. Install the vent plugs.
5. Start the engine. Operate the engine for a minimum of 90 minutes with a coolant
temperature of at least 82 °C (180 °F).
6. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling system filler cap. Open the cooling
system drain valves and remove the drain plugs. Remove the vent plugs. Allow the cleaning
solution to drain.
NOTICE
Improper or incomplete rinsing of the cooling system can result in

damage to copper and other metal components.
To avoid damage to the cooling system, make sure to completely flush

the cooling system with clear water. Continue to flush the system until
all signs of the cleaning agent are gone.
7. Flush the cooling system with clean water until the water that drains is clean. Close the
cooling system drain valves. Clean the drain plugs and install the drain plugs.
Fill the Cooling System
NOTICE
It is recommended that the cooling system is filled from the bottom

with the cap removed from the expansion tank.
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NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to

avoid air locks.
Note: For information about the proper coolant to use, and for the capacity of the cooling system,
refer to this operation and maintenance manual, "Refill Capacities and
1. Remove the vent plugs.
2. Fill the cooling system with coolant or antifreeze. Install the vent plugs. Do not install the
cooling system filler cap yet.
3. Start the engine and operate the engine at low idle for 10 minutes.
4. Increase the engine speed to high idle until the thermostat opens and the coolant level is
stabilized.
5. Check the coolant level. Maintain the coolant to the proper level on the sight gauge (if
equipped). If the machine is not equipped with a sight gauge, maintain the coolant within 13
mm (0.5 inch) below the bottom of the filler pipe. Refer to Operation and Maintenance
Manual, "Coolant Level - Check".
6. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If
the gaskets of the cooling system filler cap are damaged, discard the old cooling system
filler cap and install a new cap.
7. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.
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i03852489
Coolant Level - Check

SMCS - 1395-082
NOTICE
Always use a designated pump for oil sampling, and use a separate
designated pump for coolant sampling. Using the same pump for both
types of samples may contaminate the samples that are being drawn.
This contaminate may cause a false analysis and an incorrect
interpretation that could lead to concerns by both dealers and
customers.
Obtain the sample of the coolant as close as possible to the recommended sampling interval.
Supplies for collecting samples can be obtained from your Caterpillar dealer.
Refer to this Operation and Maintenance Manual, "Cooling System Coolant Sample (Level 1) -
Obtain" (Maintenance Section) for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
For additional information about coolant analysis, see the Special Publication, SEBU6400,
"Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations" or consult your
Caterpillar dealer.
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i03852509
Coolant Sample (Level 1) - Obtain

SMCS - 1350-008; 1395-008; 1395-554; 7542
NOTICE
customers.
For conventional heavy-duty antifreeze/coolant, check the concentration of supplemental coolant

additive (SCA) regularly. The concentration of SCA can be checked with an S·O·S coolant
analysis (Level 1).
Obtain the sample of the coolant as close as possible to the recommended sampling interval. In
order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In
order to establish a pertinent history of data, perform consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from your Caterpillar dealer.
Use the following guidelines for proper sampling of the coolant:
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
• Keep the unused sampling bottles stored in plastic bags.
• Keep the lids on empty sampling bottles until you are ready to collect the sample.
• Complete the information on the label for the sampling bottle before you begin to take the
samples.
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• Obtain coolant samples directly from the coolant sample port. You should not obtain the
samples from any other location.
• In order to avoid contamination, immediately place the sample in the tube that is provided
for mailing.
Note: Level 1 results may indicate a need for Level 2 Analysis.
"Caterpillar Gas Engine Lubricant, Fuel and Coolant Recommendations" or consult your
Caterpillar dealer.
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i04318144
Coolant Sample (Level 2) - Obtain

SMCS - 1350-008; 1395-008; 1395-554; 7542
NOTICE
customers.
Obtain the sample of the coolant as close as possible to the recommended sampling interval.
Supplies for collecting samples can be obtained from your Cat dealer.
Refer to this Operation and Maintenance Manual, "Cooling System Coolant Sample (Level 1) -
Obtain" (Maintenance Section) for the guidelines for proper sampling of the coolant.
"Caterpillar Gas Engine Lubricant, Fuel, and Coolant Recommendations" or consult your Cat
dealer.
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i04688409
Coolant Temperature Regulator - Replace

SMCS - 1355-510
Replace the coolant temperature regulators (1) before the regulators fail. Replacing the coolant
temperature regulator is a recommended preventive maintenance practice. Replacing the coolant
temperature regulators reduces the chances for unscheduled downtime.
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A coolant temperature regulator that fails in a partially opened position can cause overheating or
overcooling of the engine.
A coolant temperature regulator that fails in the closed position can cause excessive overheating.
Excessive overheating could result in cracking of the cylinder head or a seizure of the pistons.
A coolant temperature regulator that fails in the open position will cause the engine operating
temperature to be too low during partial load operation. Low engine operating temperatures during
partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon
buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner. Also,
a low temperature can allow moisture to condense in the oil. The low temperatures can form
damaging acids.
NOTICE
Failure to replace the water temperature regulator on a regularly

scheduled basis could cause severe engine damage.
Never operate an engine without the water temperature regulator

installed.
If the water temperature regulator is installed incorrectly, the engine

may overheat, causing cylinder head damage. Ensure that the new
water temperature regulator is installed in the original position.
For the procedure to replace the coolant temperature regulators, see the Service Manual,
"Disassembly and Assembly" module. Consult your Cat dealer for assistance.
Note: If only the coolant temperature regulators are replaced, drain the coolant from the cooling
system to a level that is below the regulator housing.
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i02017557
Cooling System Supplemental Coolant Additive (SCA) -

Test/Add
SMCS - 1352-045; 1395-081
Cooling system coolant additive contains alkali. To help prevent

personal injury, avoid contact with the skin and eyes. Do not drink
cooling system coolant additive.
Note: Caterpillar recommends an S·O·S coolant analysis (Level 1).
Test the Concentration of the SCA

Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant

additive concentration.
Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Follow the
instructions that are provided in the kit.
Water and SCA
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NOTICE
Do not exceed the recommended eight percent supplemental coolant

Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Use the
instructions that follow:
1. Fill the syringe to the "1.0 ml" mark with the coolant.
2. Dispense the 1.0 mL coolant sample from the syringe into the empty mixing bottle.
3. Add tap water to the mixing bottle in order to bring the level up to the "10 ml" mark. Place
the cap on the bottle and shake the bottle.
4. Add 2 to 3 drops of the "NITRITE INDICATOR SOLUTION B" to the mixing bottle.
Move the bottle in a circular motion in order to mix the solution.
5. Add 1 drop of "NITRITE TEST SOLUTION A" to the mixing bottle. Move the bottle in a
circular motion in order to mix the solution.
6. Repeat 5 until the solution changes color from red to light gray, green, or blue. Record the
number of drops of "NITRITE TEST SOLUTION A" that were required to cause the color
change.
7. Use Table 1 to interpret the results.
Table 1
Number of Maintenance
Concentration of SCA
Drops Required
Less than the recommended concentration of Add SCA.
Less than 25
SCA Retest the coolant.
25 to 30 The recommended concentration of SCA None
Remove the coolant.
More than the recommended concentration Replace with water
More than 30
of SCA only
Retest the coolant.
Add the SCA, If Necessary
Pressurized System: Hot coolant can cause serious burns. To open the
cooling system filler cap, stop the engine and wait until the cooling
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system components are cool. Loosen the cooling system pressure cap
slowly in order to relieve the pressure.
1. Remove the cooling system filler cap slowly.
Note: Always dispose of fluids according to local regulations.
2. If necessary, drain some coolant in order to allow space for the addition of the SCA.
NOTICE
Excessive supplemental coolant additive concentration can form

deposits on the higher temperature surfaces of the cooling system,
reducing the engine's heat transfer characteristics. Reduced heat
transfer could cause cracking of the cylinder head and other high
temperature components.
Excessive supplemental coolant additive concentration could also result

in blockage of the heat exchanger, overheating, and/or accelerated
wear of the water pump seal.
Do not exceed the recommended amount of supplemental coolant

3. Add the proper amount of SCA. The concentration of the SCA depends on the type of
coolant that is used. To determine the proper amount, see this Operation and Maintenance
Manual, "Refill Capacities and Recommendations" topic.
4. Clean the cooling system filler cap. Install the cooling system filler cap.
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i04319789
Crankcase Blowby - Test/Record

SMCS - 1317-081
Measure the crankcase blowby of new engines. Record the data. Continue to measure the blowby
periodically. Comparing the recorded data to the new data provides information about the
condition of the engines.
Note: Crankcase blowby is one of the three factors that help to determine the in-frame overhaul
interval. For more information, see this Operation and Maintenance Manual, "Overhaul (In-
Frame)" topic.
After a new engine is used for a short time, the blowby can decrease as the piston rings are seated.
The blowby will gradually increase as the following components show wear:
• Piston rings
• Cylinder liners
Note: A problem with the piston rings causes the oil to deteriorate rapidly. Information regarding
the condition of the piston rings can be obtained from the measurement of the blowby and the
results of oil analysis.
The blowby of a worn engine may exceed the blowby of a new engine by two times or more.
A sudden increase in blowby could indicate a broken piston ring. The following conditions are
other potential sources of blowby:
• Worn valve guides
• A turbocharger seal that leaks
A rebuilt engine can have a high blowby due to the following factors:
• The piston rings are not seated properly.
• Worn parts such as valve guides were not replaced.
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Excessive blowby may indicate the need for an overhaul. By keeping a record of the results, a
gradual increase in the amount of the blowby will be noted until the amount has become
excessive.
To measure the blowby, use the 1U-8860 Large Engine Blowby Pickup Group with the 8T-2701
Blowby Indicator. For instructions, see Special Instruction, SEHS8984, "Using the 1U-8860 Large
Engine Blowby Pickup Group" and Special Instruction, SEHS8712, "Using the 8T-2700
Blowby/Air Flow Indicator ".
For assistance, consult your Cat dealer.
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i04249064
Crankshaft Vibration Damper - Inspect - 1500 RPM G3520

engines (if equipped with an oil fed damper)
SMCS - 1205-040
S/N - GZE1-UP
S/N - SSR1-UP
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1. Remove the damper.
2. Remove side plate (3) .
3. Separate the inner member of the damper (1) from the outer member (2) .
Note: Do not disassemble the damper spring assembly.
4. Clean all parts of the damper. Pay special attention to the oil supply and venting holes.
5. Replace all accessible rubber seal rings.
6. Replace all disc springs from bolts that have been removed.
7. Check for permissible wear of the Y-seal. Replace the seals whenever the damper is
disassembled, or there is evidence of leakage. Permissible wear on the sealing surface of the
Y-seals on each side of the inner star is 0.2 mm (0.007 inch).
8. Assemble inner member (1) and outer member (2) .
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9. Check wear of the spring blades. Use of a measuring wedge is required. If a measuring
wedge is not supplied, then a wedge is to be fabricated. Refer to illustration 2.
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(1) Spring packs
(2) Measuring wedge
(3) Inner star
1. Measure for wear. Refer to illustration 3
2. Measure every fourth spring pack.
3. Place the measuring wedge between the inner ends of the spring blades and the wedge is
touching the bottom of the groove. The measuring wedge end face and groove bottom must
be parallel.
4. Press by hand or use a soft face hammer to force the wedge along the inner star groove until
the spring tips rest on both groove faces.
The further the wedge can be pressed between the spring blades, the greater the wear on the inner
star groove and spring blades. If the wedge can be inserted to the "Not Go" section of the
measuring wedge, replace the damper.
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i04319794
Cylinder Pressure - Test/Record

SMCS - 1223-082-CC; 7450-081
Measure the cylinder pressure of new engines. Record the data. Continue to measure the cylinder
pressure periodically. Comparing the recorded data to the new data provides information about the
condition of the engine.
Cylinder pressure can be measured during inspection of the spark plugs. Use the following
guidelines for checking the cylinder pressure:
• Remove all of the spark plugs.
• Fully open the throttle plate.
• Minimize the cranking time to three or four revolutions which will enable a maximum
consistent cranking speed for the check. Also, the battery power will be conserved.
A loss of cylinder pressure or a change of pressure in one or more cylinders may indicate the
following conditions. These conditions may indicate a problem with lubrication:
• Excessive deposits
• Guttering of valves
• A broken valve
• A piston ring that sticks
• A broken piston ring
• Worn piston rings
• Worn cylinder liners
If the cylinder pressure has risen by one or more compression ratios, the engine needs a top end
overhaul in order to remove deposits. Failure to remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.
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To measure the cylinder pressure, use the 193-5859 Cylinder Pressure Gauge Gp. Follow the
procedure in the Special Instruction, NEHS0798 that is included with the gauge group. Record the
pressure for each cylinder. Use the Operation and Maintenance Manual, "Valve Data
Sheet" (Reference Materials Section).
Illustration 1 is a graph of typical cylinder pressures for engines with different compression ratios.
(Y) Cylinder pressure in kPa
(X) Compression ratio
(1) Normal range for cylinder pressure
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i02398768
Electrical Connections - Check

SMCS - 4459-535
DANGER: Shock/Electrocution Hazard-Do not operate this equipment

or work on this equipment unless you have read and understand the
instructions and warnings in the Operation and Maintenance Manual.
Failure to follow the instructions or heed the warnings will result in
serious injury or death.
Checking the electrical connections is an important part of the maintenance for the generator set.
Improper connections may cause the generator set to malfunction.
Check all exposed electrical connections for tightness.
Check the following devices for loose mounting or for physical damage:
• Transformers
• Fuses
• Capacitors
• Lightning arresters
Check the connections for the following components:
• Load cables
• Cables for the generator
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• Potential transformers
• Current transformers
Check all lead wires and electrical connections for proper clearance. Inspect all cables for chafing,
abrasion and corrosion.
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i04342930
Engine Air Cleaner Element (Single Element) -

Inspect/Clean/Replace
SMCS - 1051; 1054-040; 1054-070; 1054-510
NOTICE
Never run the engine without an air cleaner element installed. Never
run the engine with a damaged air cleaner element. Do not use air
cleaner elements with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to engine components.
Air cleaner elements help to prevent airborne debris from entering the
air inlet.
NOTICE
Never service the air cleaner element with the engine running since this
will allow dirt to enter the engine.
Note: Use of a platform may be necessary to reach the air cleaner element.
Clean the air cleaner elements or replace the air cleaner elements when the following conditions
occur:
• Inspect the air cleaner elements before the air filter restriction reaches 2.5 kPa (10 inches of
H2O). A loss of engine performance may occur when the air filter restriction exceeds this
limit.
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• The air cleaner elements must be cleaned or replaced before the air filter restriction exceeds
3.75 kPa (15 inches of H2O).
Note: The air filter restriction is measured before the air inlet to the turbocharger compressor.
Servicing the Air Cleaner Elements

Note: If the air cleaner is not manufactured by Caterpillar, follow the instructions that are
provided by the OEM of the air cleaner.
If the air cleaner element becomes plugged, the air can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine wear. Your Cat dealer has the proper air
cleaner elements for your application. Consult your Caterpillar dealer for the correct air cleaner
element.
• Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any
dirt and debris, as needed.
Replace the dirty paper air cleaner elements with clean air cleaner elements. Before installation,
thoroughly inspect the air cleaner elements for tears and/or holes in the filter material. Inspect the
gasket or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.
1. Remove the air cleaner cover. Remove the air cleaner element.
2. Cover the air inlet to the turbocharger with tape in order to keep dirt out.
3. Clean the inside of the air cleaner cover and body with a clean, dry cloth.
4. Remove the tape for the air inlet to the turbocharger. Install an air cleaner element that is
new or cleaned.
5. Install the air cleaner cover.
Inspecting Air Cleaner Elements
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Inspect the clean, dry air cleaner element. Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the element. Rotate the element. Inspect the element for tears and/or
holes. Inspect the element for light that may show through the filter material. If it is necessary in
order to confirm the result, compare the element to a new element that has the same part number.
Do not use an element that has any tears and/or holes in the filter material. Do not use an element
with damaged pleats, gaskets or seals. Discard damaged elements.
Storing Air Cleaner Elements
If an element that passes inspection will not be used, the element can be stored for future use.
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Do not use paint, a waterproof cover, or plastic as a protective covering for storage. Restricted air
flow may result. To protect against dirt and damage, wrap the elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the element into a box for storage. For identification, mark the outside of the box.
Store the box in a dry location.
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i01799090
Engine Air Cleaner Service Indicator - Inspect

SMCS - 7452-040
A service indicator may be mounted on the air cleaner element or in a remote location.
Some engines may be equipped with a different service indicator.
Observe the service indicator. Clean the air cleaner element or replace the element when any of
the following conditions occur:
• The yellow diaphragm enters the red zone.
• The red piston locks in the visible position.
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• The air restriction reaches 3.75 kPa (15 inch of H2O).
Test the Service Indicator

Service indicators are important instruments.
• Apply vacuum (suction) to the service indicator.
• Reset the service indicator.
If the yellow core does not latch at the greatest vacuum, or if service indicator does not reset
easily, obtain a new service indicator. If the new service indicator will not reset, the fitting for the
service indicator may be plugged.
A porous filter is part of the fitting that is used for mounting of the service indicator. Inspect the
filter for cleanliness. Clean the filter, if necessary. Use compressed air or a clean, nonflammable
solvent.
Note: When service indicator is installed, excessive tightening may crack the top of the service
indicator. Tighten the service indicator to a torque of 2 N·m (18 lb in).
Replace the service indicator annually regardless of the operating conditions.
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i02895754
Engine Crankcase Breather - Clean

SMCS - 1317-070
Clean the crankcase breather regularly in order to prevent excessive crankcase pressure that will
damage the engine's seals.
Perform this maintenance when the engine is stopped.
1. Loosen clamps (1) . Slide the clamps off tubes (2) . Remove the tubes.
2. Loosen clamps (3) . Remove each breather assembly (4) from the elbow assembly.
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3. Remove O-ring seals from the elbow assembly. Inspect the O-ring seals for good condition.
Obtain new O-ring seals, if necessary.
4. Turn the breathers upside-down in order to inspect the condition of the breather elements.
Note: Do not replace the breathers in the upside-down position. If breathers are not replaced
properly water could enter the crankcase and damage to the engine could result.
Clean the breather elements with clean, nonflammable solvent. If the breather elements
remain contaminated after the cleaning, discard the breather assemblies and obtain new
breather assemblies. Do not attempt to disassemble the breather assemblies.
Allow the breather elements to dry before installation.
Note: Lubricate the bore of the elbow assembly with clean engine oil and install the O-ring
seals.
5. Install breather assemblies (4) and tighten clamps (3) . Install elbows (2) and clamps (1) .
Tighten the clamps.
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i03852569
Engine Mounts - Inspect

SMCS - 1152-040
Typical configuration of mounting bolts for a Caterpillar genset
(1) Mounting bolts for the engine
(2) Mounting bolts for the generator
(3) Levelling bolts for the isolators
Misalignment of the engine and the driven equipment will cause extensive damage. Excessive
vibration can lead to misalignment. Excessive vibration of the engine and the driven equipment
can be caused by the following conditions:
• Improper mounting
• Misalignment of driven equipment
• Loose bolts
• Deterioration of the isolators
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Ensure that the mounting bolts are tightened to the proper torque. For standard torques, see
Specifications, SENR3130, "Torque Specifications".
Ensure that the isolators are free of oil and contamination. Inspect the isolators for deterioration.
Ensure that the bolts for adjusting the isolator are correctly adjusted and secured with the locking
nut. Correctly adjusted isolators provide even support for the engine base. Each isolator should
impose nearly identical force on the base rail. Each isolator should bear the same portion of the
weight of the genset.
Replace any isolator that shows deterioration. For more information, see the literature that is
provided by the OEM of the isolators. Also see the Application and Installation Guide for the
engine. Consult your Caterpillar dealer for assistance.
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i02017618
Engine Oil - Change

SMCS - 1348-044
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact skin.
NOTICE
Ensure that the engine is stopped before performing this procedure.

Attach a DO NOT OPERATE tag to the starting controls.
Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle on
the bottom of the oil pan. The waste particles are not removed when the cold oil is drained. Drain
the crankcase with the oil warm, immediately after the engine is stopped. This draining method
allows the waste particles that are suspended in the oil to be drained properly. Failure to follow
this recommended procedure will allow the waste particles to be recirculated through the engine
lubrication system with the new oil.
1. After the engine has been operated at normal operating temperature, STOP the engine.
Note: Drain the oil into a suitable container. Dispose of fluids according to local
regulations.
2. Drain the oil by using one of the following methods. Use the method that corresponds to the
equipment on the engine.
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Note: If a suction device is used in order to remove the oil from the oil pan, ensure
that the suction device is clean. This will prevent dirt from entering into the oil pan.
Be careful not to strike the engine oil suction tubes or the piston cooling jets.
a. If the engine has an oil drain valve, open the valve in order to drain the oil. After the
oil has drained, close the valve.
b. If the engine has a pump for removing dirty oil, connect a hose to the outlet of the
pump. Place the hose in a suitable container. Open the valve for the drain line.
Operate the pump until the crankcase is empty. Close the valve to the drain line.
Disconnect the hose.
c. If the oil drain valve has a "quick connect" coupling, attach the coupling. Open the
drain valve in order to drain the crankcase. After the oil has drained, close the drain
valve. Disconnect the coupling.
d. If the engine does not have a drain valve or a pump, remove an oil drain plug. Allow
the oil to drain. After the oil has drained, clean the drain plug and clean the fitting for
the drain plug. Install the drain plug. Tighten the drain plug to 145 ± 15 N·m (105 ±
10 lb ft).
Note: Ensure that the dirty oil is thoroughly drained from the pan. Caterpillar
recommends a thorough cleaning of the oil pan with a vacuum and with rags in order
to completely remove all of the old oil. This will help prevent inaccurate oil analysis
results and/or shortened life of the oil.
3. Replace the engine oil filter elements before filling the crankcase with new oil.
a. For the procedure to change the engine oil filters, refer to the Operation and
Maintenance Manual, "Engine Oil Filter - Change" topic (Maintenance Section).
NOTICE
Engine damage can occur if the crankcase is filled above the "FULL"
mark on the oil level gauge (dipstick).
An overfull crankcase can cause the crankshaft to dip into the oil. This
will reduce the power that is developed and also force air bubbles into
the oil. These bubbles (foam) can cause the following problems:
reduction of the oil's ability to lubricate, reduction of oil pressure,
inadequate cooling, oil blowing out of the crankcase breathers and
excessive oil consumption.
Excessive oil consumption will cause deposits to form on the pistons

and in the combustion chamber. Deposits in the combustion chamber
lead to the following problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylinder liner.
If the oil level is above the "FULL" mark on the oil level gauge, drain
some of the oil immediately.
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Note: For the appropriate oil to use, and for the amount of oil to use, refer to this Operation
and Maintenance Manual, "Refill Capacities and Recommendations" article (Maintenance
Section).
4. Remove the oil filler cap. Fill the crankcase through the oil filler tube only. Clean the oil
filler cap. Install the oil filler cap.
NOTICE
To prevent crankshaft damage and to prevent bearing damage,

manually operate the prelube pump or crank the engine with the fuel
supply line closed for 15 to 30 seconds. This will ensure that all of the
oil filters are filled with oil before the engine is started.
5. Close the fuel supply line. Crank the engine until the oil pressure gauge indicates 70 kPa (10
psi). Open the fuel supply line. Allow the starting motor to cool for two minutes before
cranking again.
6. Follow this Operation and Maintenance Manual, "Starting The Engine" procedure
(Operation Section). Operate the engine at low idle for two minutes. This will ensure that
the lubrication system and the oil filters are filled with oil. Inspect the engine for oil leaks.
Ensure that the oil level is between the "ADD" and the "FULL" marks on the "LOW IDLE"
side of the oil level gauge.
7. Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes.
8. Remove the oil level gauge and check the oil level. Maintain the oil level between the
"ADD" and the "FULL" marks on the "ENGINE STOPPED" side of the oil level gauge.
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i04795231
Engine Oil Filter - Change

SMCS - 1308-510; 1308
Replace the engine oil filters when any of the following conditions are met:
• The engine oil is changed.
• The engine oil filter differential pressure reaches 100 kPa (15 psi).
• The engine oil filters have been used for 1000 operating hours.
Replace the Oil Filter Elements
NOTICE
Ensure that the engine is stopped before performing this procedure.

Attach a DO NOT OPERATE tag to the starting controls.
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NOTICE

containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
1. Remove oil drain plug (1) . Drain the oil into a suitable container.
2. Remove spin-on oil filters (2) with a 185-3630 Strap Wrench Assembly .
3. Reinstall the oil drain plug.
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Mounting base and gasket
4. Clean the sealing surface of the mounting base. Ensure that all of the old gasket is removed.
5. Apply clean engine oil to the gasket of the new oil filter.
NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an

oil filter not recommended by Caterpillar could result in severe engine
damage to the engine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine lubricating
system. Only use oil filters recommended by Caterpillar.
6. Place the oil filter in position. Tighten the oil filter by hand until the gasket contacts the
base. Tighten the oil filter by hand for an additional 1 full turn (360 degrees). Do not
overtighten the oil filter.
7. Check the oil level according to the instructions in this Operation and Maintenance Manual,
"Engine Oil Level - Check".
Inspect the Used Oil Filter Elements

Cut the used oil filter element open with a 175-7546 Oil Filter Cutter Gp .
Remove the metal wrap. Cut the filter element free from the end caps. Spread apart the pleats and
inspect the element for metal debris. Due to normal wear and friction, small amounts of debris
may be found in the oil filter element. An excessive amount of debris in the element may indicate
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early wear or a pending failure. If an excessive amount of debris is found in the oil filter element,
consult your Cat dealer in order to arrange for further oil analysis.
Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found
in the element. Ferrous metals may indicate wear on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the aluminum parts, the brass parts, or the bronze parts of
the engine. Parts that may be affected include the following components: main bearings, rod
bearings, turbocharger bearings and cylinder heads.
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i02225089
Engine Oil Level - Check

SMCS - 1348-535-FLV
The most accurate check of the engine oil level is obtained when the engine is stopped.
(1) Engine oil level gauge (dipstick)
1. Remove the filler cap (not shown) in order to ensure that the crankcase pressure is equal to
the atmospheric pressure.
Excess pressure or a slight vacuum will affect engine oil level that is measured.
2. Ensure that engine oil level gauge (1) is seated.
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(3) "ENGINE STOPPED WITH OIL COLD" side
(4) "ENGINE AT LOW IDLE WITH WARM OIL" side
(5) "ADD" mark
(6) "FULL" mark
a. If the engine is stopped, remove the engine oil level gauge. Observe the engine oil
level on "ENGINE STOPPED WITH OIL COLD" side (3) .
b. If the engine is operating, reduce the engine speed to low idle. Remove the engine oil
level gauge and observe the engine oil level on "ENGINE AT LOW IDLE WITH
WARM OIL" side (4) .
The engine oil level should be between "ADD" mark (5) and "FULL" mark (6) .
NOTICE
Engine damage can occur if the crankcase is filled above the "FULL"
mark on the oil level gauge (dipstick).
An overfull crankcase can cause the crankshaft to dip into the oil. This
will reduce the power that is developed and also force air bubbles into
the oil. These bubbles (foam) can cause the following problems:
reduction of the oil's ability to lubricate, reduction of oil pressure,
inadequate cooling, oil blowing out of the crankcase breathers and
excessive oil consumption.
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Excessive oil consumption will cause deposits to form on the pistons

and in the combustion chamber. Deposits in the combustion chamber
lead to the following problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylinder liner.
If the oil level is above the "FULL" mark on the oil level gauge, drain
some of the oil immediately.
3. If necessary, add engine oil. For the correct engine oil to use, refer to this Operation and
Maintenance Manual, "Refill Capacities and Recommendations" topic (Maintenance
Section). Do not fill the crankcase above the "FULL" mark on the engine oil level gauge.
Clean the filler cap (2). Install the filler cap.
4. Record the amount of engine oil that is added. For the next engine oil sample and analysis,
include the total amount of engine oil that has been added since the previous oil change.
This will help to provide the most accurate analysis.
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i04237495
Engine Oil Sample - Obtain

SMCS - 1348-554-SM
In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil analysis provides infrared analysis, which is
required for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
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
• Service hours on the engine
• The number of hours that have accumulated since the last oil change
• The amount of oil that has been added since the last oil change
To ensure that the sample is representative of the oil in the crankcase, obtain a warm, mixed oil
sample.
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To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and
the consistency of the samples are better when the sampling valve is used. The location of the
sampling valve allows oil that is flowing under pressure to be obtained during normal engine
operation.
The 169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The fluid
sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also
provided.
NOTICE
customers.
If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump . The pump is
designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion
into the sump.
For instructions, see Special Publication, PEGJ0047, "How To Take A Good S·O·S Oil Sample".
Consult your Cat dealer for complete information and assistance in establishing an S·O·S program
for your engine.
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i02861779
Engine Protective Devices - Check

SMCS - 7400-535
Visual Inspection
Visually check the condition of all gauges, sensors and wiring. Look for wiring and components
that are loose, broken, or damaged. Damaged wiring or components should be repaired or replaced
immediately.
Calibration Check
NOTICE
During testing, abnormal operating conditions must be simulated.
The tests must be performed correctly in order to prevent possible

damage to the engine.
Alarms and shutoffs must function properly. Alarms provide timely warning to the operator.
Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine
protective devices are in good working order during normal operation. Malfunctions must be
simulated in order to test the engine protective devices. To prevent damage to the engine, only
authorized service personnel or your Caterpillar dealer should perform the tests.
Consult your Caterpillar dealer or refer to the Service Manual for more information.
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i03900462
Engine Speed/Timing Sensor - Clean/Inspect

SMCS - 1905-040; 1905-070; 1907-040; 1907-070
An engine speed/timing sensor is mounted in the housing of the camshaft at the rear of the engine.
The speed/timing sensor provides information about engine speed and the position of the
crankshaft to the ECM. There are two possible types of speed/timing sensors: fixed head and slip
head.
Fixed head sensors (if equipped)
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The fixed head sensor has a threaded end, and screws directly into the flywheel housing.
1. Remove the speed sensor (1) from the housing. Check the condition of the plastic end of the
speed sensors for wear and/or contaminants.
2. Clean the metal shavings and other debris from the face of the speed sensors.
3. Install the engine speed/timing sensor.
Slip head sensors (if equipped)

1. Remove engine speed/timing sensor (1). Inspect the condition of the end of the magnet.
Look for signs of wear and contaminants.
2. Clean any debris from the face of the magnet.
3. Check the tension of the slip head. Gently extend the slip head (2) for a minimum of 4 mm
(0.16 inch). Then push back the slip head.
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When the slip head has the correct tension, at least 22 N (5 lb) of force is required to push in
the slip head from the extended position.
NOTICE
The sliphead must be fully extended when the speed/timing sensor is

installed so that the sensor maintains the correct clearance with the
speed-timing wheel. If the correct clearance is not maintained, the
signal from the sensor will not be generated.
Do not install the sensor between the teeth of the speed-timing wheel.
Damage to the sensor would result. Before installing the sensor, ensure
that a tooth of the wheel is visible in the mounting hole for the sensor.
4. Install the engine speed/timing sensor.
a. Ensure that a tooth on the speed-timing wheel is visible in the mounting hole for the
sensor.
b. Extend the slip head (2) by a minimum of 4 mm (0.16 inch).
c. Coat the threads of the sensor with 4C-5597 Anti-Seize Compound .
Note: The slip head is designed to contact a tooth during the first revolution of the
speed-timing wheel. For the maximum allowable clearance between the slip head and
the tooth, refer to the engine's Specifications manual.
d. Install the sensor. Tighten the locknut to 40 ± 5 N·m (30 ± 4 lb ft).
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i03852589
Engine Valve Lash and Bridge - Check

SMCS - 1102-535; 1121-535
Ignition systems can cause electrical shocks. Avoid contacting the

ignition system components and wiring.
Do not attempt to remove the valve covers when the engine is operating.
The transformers are grounded to the valve covers. Personal injury or
death may result and the ignition system will be damaged if the valve
covers are removed during engine operation. The engine will not
operate without the valve covers.
For procedures on adjusting the valve bridge and the engine valve lash, refer to the following
publications:
• Special Instruction, REHS0128, "Using the 147-5482 Indicator Gauge for Valve Lash and
Valve Bridge Adjustment"
• The Systems Operation/Testing and Adjusting manual for the engine
• The Specifications manual for the engine
Consult your Caterpillar dealer for assistance.
Valve Bridge
Check the valve bridge and adjust the valve bridge, if necessary. Perform the procedure for both
valve bridges for each cylinder.
After the valve bridge for each cylinder is satisfactory, measure the valve lash.
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Engine Valve Lash
NOTICE
Only qualified service personnel should perform this maintenance.

Refer to the Service Manual or your Caterpillar dealer for the
complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve adjustments can

reduce engine efficiency. This reduced efficiency could result in
excessive fuel usage and/or shortened engine component life. Improper
valve lash may also lead to valve failure, and result in catastrophic
failure.
If the valve lash is within the tolerance, an adjustment of the valve lash is NOT necessary.
Perform valve lash adjustment if the dimension is not within the tolerance. The valve bridge
adjustment must be performed before making a valve lash adjustment.
Perform the valve lash setting when the engine is cold. After the engine has been shut down and
the valve covers are removed, the engine is considered cold.
Before performing maintenance, prevent the entry of foreign matter into the top of the cylinder
head and the valve mechanism. Thoroughly clean the area around the valve mechanism covers.
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i02653852
Flexible Coupling - Inspect

SMCS - 3279-040
S/N - GZE1-UP
S/N - SSR1-UP
Most torsional couplings use one or more torsional elements that are formed from rubber or from
other polymers with similar physical characteristics. The torsional couplings are placed in series in
order to achieve exact stiffness for reducing torsional vibration. The torsional couplings are also
used for adding tolerance to parallel offset. These types of rubber couplings are used in generator
sets.
General Care
The following factors will accelerate deterioration of rubber:
• Age
• Heat
• Ultraviolet light (UV light)
• Petroleum products
• Solvents
• Anaerobic adhesives (thread lock compound)
• Ozone
Anaerobic adhesives can also deteriorate the bond between rubber elements and the steel flange or
the hub.
In an environment that is free of aggressive chemicals and free of light, the main cause of any
acceleration of deterioration of the rubber is heat.
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There are five causes of heat buildup in rubber coupling elements:
• High ambient temperature
• Damping of torsional vibrations
• Compensation for angular misalignment
• Compensation for radial misalignment or for offset
• Compensation for axial misalignment or for movement
In a controlled environment, the destructive conditions can be minimized. The rubber couplings
can have a long useful life.
Flexible coupling
(1) Outer coupling
(2) Rubber element
(3) Hardness stamp
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Preventive Maintenance Schedule

Maintenance for the Rubber Flexible Coupling consists of four activities:
• Keep the coupling free of excessive heat, UV light, petroleum products, solvents, anaerobic
adhesives and ozone.
• Periodically inspect the rubber and the metal components for any imperfections, for stress,
and for wear.
• Check the torque for the fasteners periodically.
• Check the alignment periodically.
(1) Rubber areas that are peeling away from the steel hub
(2) Wear at the loaded side of the teeth
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Detail A
Cracks in the rubber
During visual inspection of the rubber element, note any rubber areas that are peeling away from
the steel hub. A wear of 3 to 4 mm (0.118 to 0.157 inch) at the loaded side of the teeth is
allowable. Refer to Illustration 2.
During visual inspection of the rubber element, note any tears or cracks in the center of the rubber
element. Refer to Illustration 3.
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i04684372
Fluid Recommendations
SMCS - 1280; 1348; 1395; 7560
Lubricant Recommendations
Due to significant variations in the quality and in the performance of commercially available oils,
Caterpillar makes the following recommendations:
• Cat NGEO (Natural Gas Engine Oil)
• Cat NGEO EL350 (Natural Gas Engine Oil)
The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during
cold engine start-up, and the maximum ambient temperature during engine operation. To
determine the oil viscosity that is required for starting a cold soaked engine, refer to the minimum
temperature in Table 1. To select the oil viscosity for operation at the highest anticipated ambient
temperature, refer to the maximum temperature in the Table. Use the highest oil viscosity that is
available in order to meet the required temperature during start-up.
Table 1
Engine Oil Viscosity
Cat NGEO Ambient Temperature

Grade of Viscosity Minimum Maximum
SAE 40 (1)
5 °C (41 °F) 50 °C (122 °F)
For applications that require starting below 5 °C (41 °F), oil heaters may be required. For more
information about low temperatures, see the Application and Installation Guide, LEKQ7256,
"Fuels, Fuel Systems".
For further information about oils, see Special Publication, SEBU6400, "Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations".
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Fuel Recommendations
Caterpillar gas engines will operate successfully on a broad range of gaseous fuels. Pipeline
natural gas has been used for many years. Commercial fuel gases are mixtures of gases. These
fuels consist primarily of hydrocarbons (combinations of hydrogen and carbon) and some inert
gases. The compositions of these gas mixtures have extreme variations. Fuels such as wellhead
gas, bio-gas, and manufactured gas are to be reviewed for acceptability. Analyze the fuel in order
to determine the following characteristics:
• Composition
• Contaminants
• Heat value
• Methane number
• Specific gravity
Field gas can have varying characteristics of combustion. Field gas can contain numerous harmful
impurities. The impurities can alter the BTU content. The impurities can also alter the methane
number. The impurities include everything from water up to complex hydrocarbons that can lead
to detonation and severe engine damage. To minimize these effects, Caterpillar recommends the
following guidelines:
1. Evaluate the fuel with the Caterpillar Methane Number Program, LEKQ6378. Consult your
Cat dealer for guidance on fuels below 55 methane number. Fuels below 55 methane
number require a Special Rating Request(SRR).
2. Reduce the oil change interval according to the results of the oil analysis.
For further information on fuels, see Special Publication, SEBU6400, "Caterpillar Gas Engine
Coolant Recommendations
During shipping and storage, the engine must be protected from damage that can be caused by
freezing of the cooling system. If the engine is shipped to a site with freezing temperatures and/or
if the engine is stored in a location with freezing temperatures, the cooling system must contain
antifreeze that will withstand the lowest ambient temperature. Frequently check the concentration
of glycol in the coolant/antifreeze. Make sure that the concentration is adequate in order to prevent
freezing. Otherwise, the cooling system is to be drained.
Coolant or antifreeze is normally composed of three elements: water, glycol and additives. Each
element must meet specific guidelines.
Water
Deionized water or distilled water is recommended for use in engine cooling systems. If
distilled water or deionized water is not available, use water with the properties that are listed in
Table 2.
Table 2
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Caterpillar Minimum Acceptable Water Requirements

Property Maximum Limit ASTM Test
Chloride (Cl) "D512", "D4327"

40 mg/L (2.4 gr per US gal)
Sulfate (SO4) "D516"

100 mg/L (5.9 gr per US gal)
Total Hardness "D1126"

170 mg/L (10 gr per US gal)
Total Solids "D1888"

340 mg/L (20 gr per US gal)
Acidity pH of 5.5 to 9.0 "D1293"
NOTICE
Use of water that does not meet the recommendations for the cooling
system will damage the cooling system.
Do not use these types of water in the cooling system: sea water,
softened water that has been conditioned with salt, hard water and tap
water.
Only use water that meets the recommendations for the cooling system.
If you are not sure about the properties of your water, consult one of the following sources for a
water analysis:
• Caterpillar dealer
• Local water utility company
• Agricultural agent
• Independent laboratory
Glycol
NOTICE
Do not use Extended Life Coolant (ELC) with Cat Gas Engines.
ELC was not formulated for use in Cat Gas Engines.
Do not use heat transfer fluids in Cat Gas Engines.
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Use only the coolant/antifreeze that is recommended.
Preferred - Cat NGEC (Natural Gas Engine Coolant)
Alternatively, use Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial heavy-duty

coolant/antifreeze that meets "ASTM D6210" or "ASTM D4985" specifications.
NOTICE
Do not use a commercial coolant/antifreeze that only meets the ASTM

"D3306" or equivalent specification. This type of coolant/antifreeze is
made for light duty automotive applications.
Use only the coolant/antifreeze that is recommended.
Acceptable - In applications that do not require protection from boiling or from freezing, a
mixture of Cat SCA and water that meets the properties that are listed in Table 2 is acceptable.
Note: The preferred coolant/antifreeze and the acceptable mixture of SCA and water require
different concentrations of SCA. Refer to the Special Publication, SEBU6400, "Caterpillar Gas
Engine Lubricant, Fuel, and Coolant Recommendations", "Supplemental Coolant Additive (SCA)"
topic.
Table 3 is a list of the coolant/antifreeze that is recommended for Caterpillar Gas Engines. The
service life of the coolant/antifreeze that is used in Caterpillar Gas Engines is also listed. To
achieve this service life, the coolants are to be properly maintained. The maintenance
program includes S·O·S coolant analysis.
Table 3
Recommended Coolant/Antifreeze and Service Life of the Coolant/Antifreeze
Coolant/Antifreeze Service Life (1)
Cat NGEC
Three Years
Cat DEAC
Commercial Heavy-Duty Coolant/Antifreeze that meets "ASTM D6210" Two Years
Commercial Heavy-Duty Coolant/Antifreeze that meets "ASTM D4985" One Year
Cat SCA and Water Two Years
Commercial SCA and Water One Year
(1)
The service life of coolant is also limited by use (service hours). Refer to the specific engine Operation and
Maintenance Manual, "Maintenance Interval Schedule".
Additives
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Preferred - Cat SCA (Supplemental Coolant Additive)
Acceptable - A commercial SCA that provides 1200 mg/L (70 gr per US gal) or 1200 ppm of
nitrites in the final mixture of coolant/antifreeze
Note: A 50/50 concentration of Cat NGEC or of Cat DEAC does not require a treatment
with an SCA at the initial fill. Commercial heavy-duty coolant or antifreeze that meets "ASTM
D6210" or "ASTM D4985" specifications may require a treatment with an SCA at the initial fill.
Read the label or the instructions that are provided by the OEM of the product.
To ensure that the correct amount of SCA is in the cooling system, the concentration of SCA must
be tested on a scheduled basis. Obtain an S·O·S coolant analysis (Level 1) or use a test kit to
check the concentration of the SCA according to this Operation and Maintenance Manual,
For further information on coolant, see Special Publication, SEBU6400, "Caterpillar Gas Engine
202
___________________________________________________________________________________________________________________________

i03857889
Fuel Filter Differential Pressure - Check

SMCS - 1261-535-PX
A fuel pressure gauge that measures fuel filter differential pressure must be installed in order to
determine when the fuel filter requires service. This gauge and the fuel filter are supplied by the
customer.
A fuel pressure gauge that measures filter differential pressure indicates the difference in fuel
pressure between the inlet side and the outlet side of the fuel filter. The differential pressure
increases as the fuel filter becomes plugged.
Operate the engine at the rated rpm and at the rated load. Check the fuel filter differential pressure.
Service the fuel filter when the fuel filter differential pressure reaches 1.7 kPa (0.25 psi).
For instructions, refer to Special Instruction, SEHS9298, "Installation and Maintenance of

Gaseous Fuel Filters". Consult your Caterpillar dealer for assistance.
203
___________________________________________________________________________________________________________________________

i03900464
Fuel Metering Valve - Check - Tecjet

SMCS - 1741-535
S/N - GZE1-UP
S/N - SSR1-UP
204
___________________________________________________________________________________________________________________________
Top view of the engine
(1) Fuel metering valve
For information regarding the fuel metering valve, refer to Installation and Operation Manual,
KENR9195, "Installation and Operation Manual for Tecjet 52 Regulation".
205
___________________________________________________________________________________________________________________________

i01857938
Fumes Disposal Filter - Drain

SMCS - 1074
Note: Always disconnect power to the fumes collector prior to servicing. The motor is protected
by a thermal protector. If the motor is shut down due to excessive heat, the motor will
automatically restart when the protector resets.
1. Shut down the engine and the fumes disposal filter.
206
___________________________________________________________________________________________________________________________
(1) Drip leg
(2) Condensation trap drain valve
2. Open drip leg (1) and drain the fluid into a suitable container.
If the filter is installed and maintained properly, no more than 28 g (1 ounce) of fluid will be
drained.
If more than one 28 g (1 ounce) is drained, make sure that the filter is installed according to
the instructions in Special Instruction, REHS0883. Ensure that the system is operating
properly.
3. Close the drip leg.
4. Open condensation trap drain valve (2) and drain the fluid into a suitable container.
5. Close the condensation trap drain valve.
Resume normal operation.
207
___________________________________________________________________________________________________________________________

i01601766
Fumes Disposal Filter Differential Pressure - Check

SMCS - 1074
Pressure gauge on top of the filter
Check the differential pressure across the filter element. Observe the pressure that is indicated by
the pressure gauge on top of the filter. Record the measurement.
The restriction of a new element is approximately 1.7 kPa (7 inches of H2O).
The normal restriction of the element is approximately 5.7 to 9.95 kPa (23 to 40 inches of H2O).
• Replace the filter element when the differential pressure reaches 11.2 kPa (45 inches of
H2O).
208
___________________________________________________________________________________________________________________________
• Replace the element after every year regardless of the differential pressure.
209
___________________________________________________________________________________________________________________________

i01749518
Fumes Disposal Filter Element - Replace

SMCS - 1074
Note: Always disconnect power to the fumes collector prior to servicing. The motor is protected
by a thermal protector. If the motor is shut down due to excessive heat, the motor will
automatically restart when the protector resets.
210
___________________________________________________________________________________________________________________________
(1) Nuts and washers
(2) Cover
(3) Body
(4) Filter element
Note: The filter element is mounted above the engine. A ladder or a platform will be
required for servicing the element.
1. Remove three nuts and washers (1) in order to remove cover (2) from body (3) .
2. Remove element (4) .
3. Clean the inside of cover (2) and body (3) .
4. Install new element (4) into body (3) .
5. Place cover (2) in position and install three nuts and washers (1) .
211
___________________________________________________________________________________________________________________________

i01950516
Gas Pressure Regulator Condensation - Drain

SMCS - 1270-543
To collect condensation, drip legs should be installed in the following locations:
• Supply line for the gas pressure regulator
• Balance line for the gas pressure regulator
• Supply line to the gas shutoff valve
Cap on the drip leg for the gas supply line to the gas pressure regulator
212
___________________________________________________________________________________________________________________________
1. Close the main gas supply valve.
2. Remove the caps from the drip legs.
3. Allow the moisture to drain into a suitable container. Inspect the drip legs for debris. Clean
the drip legs, if necessary.
4. Clean the caps. Install the caps.
5. Open the main gas supply valve.
213
___________________________________________________________________________________________________________________________

i01135057
General Maintenance Information

SMCS - 4450; 7000
Note: Read the warnings and read the instructions that are contained in the Safety Section of this
manual. These warnings and instructions must be understood before you perform any operation or
any maintenance procedures.
Rotating electric machines are complex structures that are exposed to the following forms of
stress:
• mechanical
• electrical
• thermal
• environmental
These stresses may be of varying magnitudes. The insulation systems are very susceptible to
damage that is caused by the stresses that are listed above. Exposure to these stresses may shorten
the effective life of the insulation system. Therefore, the service life of an electric machine will
largely depend on the serviceability of the insulation systems. An inspection program and a testing
procedure are recommended. An inspection program and a testing procedure will ensure that the
equipment is maintained in satisfactory condition. This will increase field reliability.
A regular maintenance and inspection program can provide an evaluation of the present condition
of the equipment. A regular maintenance program and a regular inspection program can also
reveal future problems. The frequency of this maintenance program will depend on the following
factors:
• application
• environmental conditions
• operator's experience
• operator's philosophy
214
___________________________________________________________________________________________________________________________
A regular maintenance program is strongly recommended. This program would involve the
following steps:
• periodic disassembly
• knowledgeable visual examination of the equipment
• the application of electrical tests
Never perform a test over the rated potential. These tests can damage insulation that is
contaminated or insulation that is in marginal condition. For more information, refer to "I.E.E.E.
Standard 432-1992" or consult a Caterpillar dealer.
Space Heaters
The SR4B generator is capable of operating in high humidity conditions without problems.
However, problems can occur when the generator is idle and the surrounding air is warmer than
the generator. Moisture can form on the windings that will result in poor performance from the
windings. Moisture can also result in damage to the windings. Whenever the generator is not
active, ensure that the space heaters are in operation.
Whenever the generator is operating, ensure that the space heaters are disconnected.
An external source of either 115 VAC or 230 VAC is required to operate the space heaters.
Space heater connection to external source (H1), (H2), (H3) and (H4) terminals.
If a 115 VAC source is available, connect both heaters in parallel across the source. If a 230 VAC
source is available, connect both heaters in series across the source. Refer to Illustration 1.
215
___________________________________________________________________________________________________________________________

i03214248
Generator - Dry
SMCS - 4450-569
NOTICE
Do not operate the generator if the windings are wet. If the generator is
operated when the windings are wet, damage can occur due to
insulation breakdown.
Personal injury or death can result from improper troubleshooting and

repair procedures.
The following troubleshooting and repair procedures should only be

performed by qualified personnel familiar with this equipment.
Refer to Safety Section, "Generator Isolating for Maintenance" for information regarding the
procedure to safely isolate the generator.
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.
216
___________________________________________________________________________________________________________________________
Drying Methods
The following methods can be used for drying a generator:
• Self-circulating air method
• Oven method
• Controlled current method
• Energize the optional space heaters.
NOTICE
Do not allow the winding temperature to exceed 85 °C (185.0 °F).

Temperatures that are greater than 85 °C (185.0 °F) will damage the
winding insulation.
Self-Circulating Air Method
Run the engine and disconnect the generator load. This will help circulate air. Operate the
generator space heaters.
Oven Method
Place the entire generator inside a forced air drying oven for four hours at 65 °C (149 °F).
NOTICE
Use a forced air type oven rather than a radiant type oven.
Radiant type ovens can cause localized overheating.
Controlled Current Method
217
___________________________________________________________________________________________________________________________
External Power Source Circuit
(1) Battery (12 VDC)
(2) Rheostat (15 ohm 25 watt)
(3) Exciter Field (Stator "L1")
Table 1
TOOLS NEEDED
Quantity Part Number Description
1 225-8266 Clamp-on ammeter (1200 amperes)
1 External power source circuit
Heat can be used in order to dry the generator windings. This heat can be created by allowing a
controlled current to flow through the generator. No high voltages are generated during the
following procedure. Therefore, insulation breakdown will not occur.
1. Make an external power source. Refer to Illustration 1.
2. Disconnect F1+ from the voltage regulator. Disconnect F2- from the voltage regulator.
Disconnect the generator load. Connect the generator output leads T0, T1, T2, and T3
together. Install the clamp-on ammeter to generator output lead T1.
Note: When the line current is measured on multiple lead units, measure the current in each
conductor per phase. The currents can then be added.
3. Refer to Illustration 1. Adjust the rheostat to the maximum resistance value. Connect the
external power source to wires F1+ and F2-.
4. Start the generator set. Run the generator set at idle speed.
218
___________________________________________________________________________________________________________________________
NOTICE
Do not exceed the rated phase current that is listed on the generator
nameplate. Exceeding the rated phase current will easily damage the
generator windings.
5. Monitor the phase current. In order to maintain use of the circuits for the protection of
safety, use the control panel for the "EMCP 3" to gradually increase the engine rpm.
Increase the engine rpm until one of the following conditions are met:
◦ The rated phase current is obtained.
◦ The full generator set speed is obtained.
6. If more phase current is necessary, slowly turn the rheostat. Turn the rheostat until the rated
phase current is reached.
7. On an hourly basis, stop the drying procedure. Check the insulation resistance. Repeat the
above steps until the insulation resistance is acceptable.
Guidelines for Space Heaters
1. Energize the space heaters when the generator is not operating.
2. Maintain the winding temperature at least 5 °C (9 °F) over the ambient temperature. In order
to maintain the desired temperature in some conditions, a supplemental heat source or
temporary covers may be required.
3. Check the insulation resistance until the resistance is acceptable.
Note: For more information on drying methods, refer to Special Instruction, SEHS9124,
"Cleaning and Drying of Electric Set Generators".
219
___________________________________________________________________________________________________________________________

i01880220
Generator - Inspect
SMCS - 4450-040

repair procedures.

The high voltage that is produced by an operating generator set can

cause severe injury or death. Before performing any maintenance or
repairs, ensure that the generator will not start.
Place the engine control switch in the "OFF" position. Attach "DO
NOT OPERATE" tags to all starting controls. Disconnect the batteries
or disable the starting system. Lock out all switchgear and automatic
transfer switches that are associated with the generator.
procedure to safely isolate the generator.
Proper maintenance of electrical equipment requires periodic visual examination of the generator
and periodic visual examination of the windings. Proper maintenance of electrical equipment also
requires appropriate electrical checks and appropriate thermal checks. Insulation material should
220
___________________________________________________________________________________________________________________________
be examined for cracks. The insulation material should be examined for accumulations of dirt and
dust. If there is an insulation resistance value that is below normal, a conductive path may be
present. This conductive path may be made of one of the following materials:
• Carbon
• Salt
• Metal dust
• Dirt that is saturated with moisture
These contaminants will develop a conductive path which may produce shorts. Cleaning is
advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be
seen. If excess dirt is the cause of a restriction in the ventilation, cleaning is also advisable.
Restricted ventilation will cause excessive heating.
NOTICE
To avoid the possibility of deterioration to the generator windings, do

not clean the generator unless there is visual, electrical, or thermal
evidence that dirt is present.
If harmful dirt accumulations are present, a variety of cleaning techniques are available. The
cleaning procedure that is used may be determined by one of the items on the following list:
• The extent of the cleaning procedure that is being attempted
• The type of enclosure of the generator
• The voltage rating of the generator
• The type of dirt that is being removed
Cleaning (Assembled Generators)

Cleaning may be required at the point of installation. At this point, complete disassembly of the
generator may not be necessary or feasible. In this case, a vacuum cleaner should be used to pick
up the following items: dry dirt, dust and carbon. This will prevent the spreading of these
contaminants.
A small nonconductive tube may need to be connected to the vacuum cleaner. This will allow the
vacuum cleaner to clean the surfaces that are not exposed. After most of the dust has been
removed, a small brush may be attached to the vacuum hose in order to loosen dirt that is more
firmly attached to the surface.
After the initial cleaning with a vacuum, compressed air may be used to remove the remaining
dust and dirt. Compressed air that is used for cleaning should be free of moisture and free of oil.
Air pressure should be a maximum of 210 kPa (30 psi) in order to prevent mechanical damage to
the insulation. If the above cleaning procedures are not effective, consult a Caterpillar dealer.
221
___________________________________________________________________________________________________________________________
Cleaning (Disassembled Generators)

An initial insulation resistance check should be made on the generator in order to confirm
electrical integrity. A minimum reading of one megohm would be expected with severely
contaminated generators. A zero megohm reading may indicate an insulation breakdown. An
insulation breakdown requires more than cleaning. An insulation breakdown requires repair.
A high pressure wash is normally an effective way to clean windings. This includes windings that
have been exposed to flooding or windings that have been contaminated by salt. A solution of hot
water and detergent is used for this method of cleaning.
A high pressure wash sprays a high velocity fluid stream of this solution over the generator that is
being cleaned. This detergent washing is followed by multiple sprays of clean water. The clean
water is used in order to remove the detergent or the clean water is used in order to dilute the
detergent.
Allow the generator to dry at room temperature. Check the insulation resistance. The insulation
resistance should now be normal. If the insulation resistance is not normal, repeat the procedure. It
may be necessary to use solvents if the generator is contaminated with oil or if the generator is
contaminated with grease.
Note: For more information on drying methods, refer to Special Instructions, SEHS9124,
"Cleaning and Drying of Electric Set Generators".
222
___________________________________________________________________________________________________________________________

i04131890
Generator Bearing - Inspect

SMCS - 4471-040
The following maintenance procedure for generator bearings should be followed:
1. Remove the bearing bracket. Inspect the following items: bracket bore, bearing outer race
and rolling elements. On standby power units, the bearing must be inspected and the grease
must be replaced at 3 yr intervals. The sleeve in the bearing bracket should be inspected for
out of roundness, excessive wear, and a bracket step that is less than 0.0762 mm (0.0030
inch). If there is no sleeve in the bearing bracket, inspect the bore of the bearing bracket.
The bearing should be inspected for damage to the outer race, severe fretting, and
smoothness of operation. When possible, the bearing elements should be inspected. Some
double shielded ball bearings prevent visual inspection of the elements of the bearing. Other
double shielded ball bearings have a retaining ring. This retaining ring can be removed in
order to allow access for a visual inspection of the elements of the bearing.
On two-bearing generators, the front bearing can only be removed after the hub is removed.
In order to remove the hub, cut off the hub with a saw. Do not use a torch to remove the
hub. Do not pull on the hub. Pulling the hub will damage the shaft.
Note: Bearings that are being removed for failure analysis should not be cut off with a
torch.
2. All ball bearings should be cleaned. The cavity in the bracket should be repacked with 2S-
3230 Grease. Pack the ball bearings (one-third to one-half of the volume of the cavity).
Refer to Table 1
To reinstall the ball bearings, use an induction heater to heat the ball bearings to 107 °C
(224.6 °F) for 10 minutes. Mount the bearings on the shaft. To reinstall the hub, heat the
hub to 400 °C (752.0 °F) for 3 hours. Mount the hub to the shaft.
3. Ensure that the tube of the grease gun is filled with grease.
4. Remove the bracket drain plug and operate the generator for 1 hour. Operating the generator
will allow the grease to expand. The expanding grease will force the excess grease from the
223
___________________________________________________________________________________________________________________________
cavity. When the excess grease is forced from the cavity, the internal pressure will be
reduced. The generator should continue to operate until the grease stops purging.
5. Stop the engine. Install the bracket drain plug. Wipe off the excess grease.
6. For greasing intervals, follow the recommendations on the lubrication plate (if equipped) or
refer to Maintenance Schedule, "Generator Bearing - Lubricate". Whenever the bearings are
greased, repeat Step 4. DO NOT MIX GREASES.
For additional information, refer to Special Instructions, REHS 4892, "Generator Bearing
Service".
Table 1
Bearing Bearing Bearing Bearing Rotor
Bearing
Outside Inside Part Generator Bore in Cavity Shaft
Shield
Diameter Diameter Number Frame Bracket Grease Diameter
(Type)
mm mm Size mm mL (oz) mm
(inch) (inch) (inch) (inch)
225.003 105.029
mm 139.12 mm
(8.8584 mL (4.7 (4.1350
inch) oz) inch)
225 mm 105 mm 6V-0410
680 (1) to Single to to
(8.8582 (4.1338
inch) inch)
225.034 230.88 105.034
mm mL (7.8 mm
(8.8596 oz) (4.1352
inch) inch)
225.003 105.029
mm 148.00 mm
(8.8584 mL (5.0 (4.1350
inch) oz) inch)
225 mm 105 mm 108- Double
680 (1) to to to
(8.8582 (4.1338 1760
inch) inch)
225.034 236.80 105.034
mm mL (8.0 mm
(8.8596 oz) (4.1352
inch) inch)
108- 690 (1) Double
240 mm 110 mm 1761 240.002 207.20 110.012
(9.4488 (4.3307 mm mL (7.0 mm
inch) inch) (9.4489 oz) (4.3312
inch) to inch)
to to
296.00
240.033 mL 110.028
mm (10.0 mm
(9.4501 oz) (2) (4.3318
inch) inch)
224
___________________________________________________________________________________________________________________________
414.40
mL
(14.0 oz)
to
621.60
mL (21
oz) (3)
240.002 110.012
mm 145.04 mm
(9.4489 mL (4.9 (4.3312
inch) oz) inch)
240 mm 110 mm 6V-3310
(9.4488 (4.3307
inch) inch)
240.033 239.76 110.028
mm mL (8.1 mm
(9.4501 oz) (4.3318
inch) inch)
240.002 110.012
mm 145.04 mm
(9.4489 mL (4.9 (4.3312
inch) oz) inch)
240 mm 110 mm 6V-6752
(9.4488 (4.3307
inch) inch)
240.033 239.76 110.028
mm mL (8.1 mm
(9.4501 oz) (4.3318
inch) inch)
240.002 110.012
mm 148.00 mm
(9.4489 mL (5.0 (4.3312
inch) oz) inch)
240 mm 110 mm 108- Double
800 (1) to to to
(9.4488 (4.3307 1761
inch) inch)
240.033 236.80 110.028
mm mL (8.0 mm
(9.4501 oz) (4.3318
inch) inch)
154- 820 Double N/A
280 mm 130 mm 3032 280.002 130.028
(11.024 (5.1181 mm mm
inch) inch) (11.0237 (5.1192
inch) inch)
to to
280.032 130.051
mm mm
225
___________________________________________________________________________________________________________________________
(11.0249 (5.1201
inch) inch)
(1)
Inboard bearing
(2)
This bearing is on the same end as the exciter.
(3)
This bearing is on the drive end of the generator.
226
___________________________________________________________________________________________________________________________

i05032881
Generator Bearing - Lubricate

SMCS - 4471-086
Procedure for Bearing Service

Perform periodic bearing lubrication at the intervals that are shown in Table 1. Use the following
instructions as the suggested procedure in order to service the bearings of the generator.
Note: If the generator already has a visible grease point, go to Step 4.
1. Stop the generator set. Remove the required external cover plates, grills, and louvers of the
generator in order to access the bearings.
2. Remove the top grease pipe plug and the lower grease pipe plug. If no grease pipes can be found,
then locate the insert for the grease pipe. The insert is located on the bearing brackets. Remove
the inserts. Install the grease pipes.
3. Install a grease fitting in the top grease pipe.
4. Use a Cat® 8F-9866 Grease Gun or equivalent grease gun to grease the bearings. Use the
appropriate type of grease and the quantity that is listed in Table 1. Avoid the use of alternate
types of grease. Usage of alternate types of grease could cause premature bearing failure.
Note: Add only the amount of grease listed in Table 1. Do not continue to add grease until
purging is observed. Purging of grease will not always be observed.
5. If grease fittings are permanently installed, ensure that the protective caps for the grease fittings
are installed on the fittings when finished. If a grease fitting was installed in Step 2, remove the
top grease fitting and install the plug that was removed. If applicable, do not install the plug on
the bottom grease location yet. Wipe off the excess grease.
Note: Do not allow grease to drip on the stator windings of the generator. The stator windings
that are exposed to grease could suffer degraded insulation. The degraded insulation would cause
a reduction in the life of the windings.
6. Operate the generator set at rated speed for approximately 1 hour. When running the engine more
than 30 minutes, the recommended engine load to apply is a minimum of 50%. The procedure
will allow the grease to expand. The expanding grease will force the excess grease from the
227
___________________________________________________________________________________________________________________________
cavity. The internal pressure will be reduced as the excess grease is forced from the cavity.
Operate the generator until no grease is forced out of the cavity.
7. Stop the generator set. Inspect the generator windings, grease tubes, and bearing housings. Wipe
off any excess grease. If a grease pipe plug was removed in Step 2, install the plug in the bottom
grease pipe. Wipe off any excess grease.
Note: Do not allow grease to drip on the stator windings of the generator. The stator windings
that are exposed to grease could suffer degraded insulation. The degraded insulation would cause
a reduction in the life of the windings.
8. Install all of the external cover plates, grills, and louvers of the generator that were removed in
order to access the bearings.
Table 1
Bearing Grease
Temperature Shaft
Part Bearing Frame Part Interval Weight Volume
Maximum (1) Diameter
Number Type Size Number
315 BC
Every
160 mm
2000
5P-2448 (6.3 2S-3230
service
Ball inch) 580 Bearing 51.2 g 59 mL
85° C (185° hours or 75 mm (3
Bearing OD 590 Lubricant (1.8 oz) (2 oz)
F) 12 inch)
months
75 mm
(3 inch)
ID
220 BC
180 mm Every
(7.1 2000
6Y-3955 2S-3230
inch) service
Ball Bearing 51.2 g 59 mL 100 mm
OD 450 85° C (185° hours or
Bearing Lubricant (1.8 oz) (2 oz) (3.9 inch)
F) 12
100 mm months
(3.9
inch) ID
6Y-6488 318 BC 597 2S-3230 Every

Ball 85° C (185° Bearing 2000 51.2 g 59 mL 90 mm
Bearing 190 mm F) Lubricant service (1.8 oz) (2 oz) (3.5 inch)
(7.5 hours or
inch) 12
OD months
90 mm
228
___________________________________________________________________________________________________________________________
(3.5
inch)
321 BC
225 mm Every
108- (8.9 2000
2S-3230
1760 inch) service
Bearing 51.2 g 59 mL 105 mm
Ball OD 680 85° C (185° hours or
Lubricant (1.8 oz) (2 oz) (4.1 inch)
Bearing F) 12
105 mm months
(4.1
inch) ID
322 BC
240 mm Every
108- (9.4 2000
2S-3230
1761 inch) service
690 Bearing 51.2 g 59 mL 110 mm
Ball OD 85° C (185° hours or
800 Lubricant (1.8 oz) (2 oz) (4.3 inch)
Bearing F) 12
110 mm months
(4.3
inch) ID
316 BC
170 mm Every
109- (6.7 2000
2S-3230
7687 inch) service
Bearing 51.2 g 59 mL 80 mm
Ball OD 580 85° C (185° hours or
Lubricant (1.8 oz) (2 oz) (3.15
Bearing F) 12
inch)
80 mm months
(3.15
inch) ID
139-
Every
0349
Roller 2900 1p0808 250 2.8 g 127 mm
Roller 85° C (185° N/A
2800 service (0.1 oz) (5 inch)
Bearing F)
hours
139-
Every
0350
Roller 2900 1p0808 250 2.8 g 127 mm
Roller 85° C (185° N/A
2800 service (0.1 oz) (5 inch)
Bearing F)
hours
154- 326 BC 820 2S-3230 Every

3032 1800 (2) (3) 85° C (185° Bearing 2000 51.2 g 59 mL 130 mm
Ball 280 mm 2600 (3) F) Lubricant service (1.8 oz) (2 oz) (5.1 inch)
Bearing (11 2700 (3) hours or
inch) 95° C (203° 12
OD F)
229
___________________________________________________________________________________________________________________________
months
130 mm 85° C (185°
(5.1 F)
inch) ID
85° C (185°
F)
018 BC
140 mm Every
193- (5.5 2000
2S-3230
4070 inch) service
498 Bearing 51.2 g 59 mL 90 mm
499 Lubricant (1.8 oz) (2 oz) (3.5 inch)
Bearing F) 12
90 mm months
(3.5
inch) ID
320 BC
215 mm Every
(8.5 4500
241-
inch) service
4644 UNIREX 60 g 100 mm
OD LC7 95° C (203° hours or N/A
Bearing N3 (2.1 oz) (3.9 inch)
F) 12
100 mm months
(3.9
inch) ID
315 BB
160 mm
(6.3
243-
inch) LC6100
5220 UNIREX Sealed (4) Sealed Sealed 75 mm
OD LC5000 95° C (203°
Bearing N3 (3.0 inch)
F)
75 mm
(3.0
inch) ID
320 BC
215 mm
Grease
(8.5
253- cannot
inch)
9789 UNIREX be added 100 mm
OD 1400 85° C (185° N/A N/A
Bearing N3 to this (3.9 inch)
F)
bearing.
100 mm
(3.9
inch) ID
253- 226BC 1400 EA6 Grease Grease Grease

9792 cannot cannot cannot 140 mm
230
___________________________________________________________________________________________________________________________
Bearing 230 mm be added be be (5.5 inch)

(9.05 95° C (203° to this added added
inch) F) bearing. to this to this
OD bearing. bearing.
130 mm
(5.12
inch) ID
307 BB
80 mm
(3.1
261-
inch)
3545 LC2000 UNIREX Sealed (4) Sealed Sealed 35 mm
OD 95° C (203°
F)
35 mm
(1.4
inch) ID
307 BC
80 mm
(3.1
262-
inch)
OD 95° C (203°
F)
35 mm
(1.4
inch) ID
309 BC
100 mm
(3.9
263-
inch)
OD 95° C (203°
F)
45 mm
(1.8
inch) ID
281- 328 BC 3010 (2) EA6 Grease Grease Grease

3091 3020 (2) 95° C (203° cannot cannot cannot 140 mm
Ball 300 mm 3042 (2) F) be added be be (5.5 inch)
Bearing (11.8 3044 (2) to this added added
inch) 3045 (2) bearing. to this to this
OD bearing. bearing.
140 mm
(5.5
inch) ID
231
___________________________________________________________________________________________________________________________
326 BC
280 mm
Grease
311- (11
cannot
0843 inch)
1800 (2) be added 130 mm
Ball OD 95° C (203° EA6 N/A N/A
to this (5.1 inch)
Bearing F)
bearing.
130 mm
(5.1
inch) ID
322 BC
240 mm
Grease
311- (9.4
cannot
0844 inch)
be added 110 mm
Ball OD 1600 95° C (203° EA6 N/A N/A
to this (4.3 inch)
Bearing F)
bearing.
110 mm
(4.3
inch) ID
330 BC
320 mm Exxon Every

341- (12.6 Polyrex 1800
3055 (5)
7383 inch) EMBase service
3066 (5) 51.2 g 14.9 150 mm
Ball OD 95° C (203° material hours or
3068 (5) (1.8 oz) mL (0.5 (5.9 inch)
Bearing F) is 12
oz)
150 mm Polyurea. months
(5.9
inch) ID
328 BC
300 mm Every
3010 (2) (3)
375- (11.8 2400
3020 (2) (3) 2S-3230
3715 inch) service
3042 (2) (3) Bearing 51.2 g 59 mL 140 mm
3044 (2) (3) Lubricant (1.8 oz) (2 oz) (5.5 inch)
Bearing (2) (3) F) 12
3045
140 mm months
(5.5
inch) ID
(1)
Indicates the alarm temperature set point that the bearing should be continuously operated at on the specified generator
frame size. Shutdown set points are typically 10° C (18° F) higher.
(2)
1800 frame generators and 3000 frame generators shipped before 2012 use double-shielded bearings with EA6 grease.
There are no threaded holes in the bearing brackets for the grease tubes that are used to add grease. Therefore, no grease
can be added to the bearings. Beginning in 2012, 1800 frame generators and 3000 frame generators that are shipped will
use a single-shielded bearing with 2S-3230 grease. The front and rear brackets contain factory installed grease fittings,
therefore, single-shielded bearings must be lubricated periodically. Reference the Parts Manual with package serial
number to identify the bearing part number and to determine bearing lubrication requirements.
232
___________________________________________________________________________________________________________________________
(3)
All 2600, 2700, 1800 and 3000 frame generators shipped beginning in 2012, use a single-shielded bearing design.
Replacement bearings received from the Parts Division will have a shield on each side of the bearing. The shield facing
the outside of the generator must be removed when the new bearing is installed.
(4)
Grease cannot be added to this bearing. Refer to the Operation and Maintenance Manual, "Generator Bearing -
Replace" article for information concerning the replacement of these bearings.
(5)
The generator uses a non-shielded bearing design. Although replacement bearings may have a shield on each side, both
shields must be removed when the new bearing is installed. Replacement bearings are shipped as dry bearings and must
be packed to 50% grease fill at time of installation.
Bearing Replacement
Refer to the appropriate publication for each specific generator for bearing replacement procedures.
Replace both bearings of a two-bearing generator.
Replace any bearing wear sleeves and lip seals when the bearings are replaced.
Except for the 341-7383 Ball Bearing, replacement bearings are pre-lubricated. The pre-lubricated
bearings do not require additional grease at time of replacement. The 341-7383 Ball Bearing is shipped
as a dry bearing. The 341-7383 Ball Bearing must be packed to 50% grease fill at time of installation.
Old grease must be removed at the time of bearing replacement from the bearing bracket cavity. After
the bearing bracket cavity is cleaned, the bearing bracket cavity must be packed with new grease from
one-third to one-half full.
Note: Generator set alignment is required after the bearings are replaced.
Additional Information
Refer to Special Instruction, REHS4892, "Generator Bearing Service" for further information.
233
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i03873412
Generator Bearing Temperature - Test/Record

SMCS - 4471-081-TA
The monitoring of bearing temperature may prevent premature bearing failure. A generator set
should never operate above the recommended set points. Keep records in order to monitor the
changes in the temperature of the bearing.
Note: Measure the bearing temperature after the generator reaches normal operating temperature.
Resistive Temperature Detectors (RTDs)

Caterpillar Generators may be equipped with resistance temperature detectors for generator
bearings. These detectors are 100 ohm resistance temperature detectors. A resistance temperature
detector may be monitored by equipment that is provided by the customer. Consult with your
Caterpillar dealer about other methods of measuring the bearing temperature.
Infrared Thermometers
Bearing temperatures can also be recorded with the use of an infrared thermometer. Refer to
Special Publication, NENG2500, "Caterpillar Dealer Service Tools Catalog" for a variety of
infrared thermometers. Follow the instructions that come with your infrared thermometer.
234
___________________________________________________________________________________________________________________________

i05325030
Generator Lead - Check

SMCS - 4450-535
Check for signs of wear along the generator leads. Pay particular attention to the leads at the
housing for the breaker and the generator terminal box.
If the rubber mats or the insulation on the leads show signs of wear at points of contact with other
surfaces, replace immediately. If your generator set does not have rubber mats in place, contact
your Cat dealer.
235
___________________________________________________________________________________________________________________________

i05264201
Generator Load - Check

SMCS - 4450-535-LA
During normal operation, monitor the power factor and monitor generator loading.
When a generator is installed or when a generator is reconnected, ensure that the total current in
any one phase does not exceed the nameplate rating. Each phase should carry the same load,
which allows the generator to work at the rated capacity. If one phase current exceeds the
nameplate amperage, an electrical imbalance will occur. An electrical imbalance can result in an
electrical overload and an electrical imbalance can result in overheating.
The power factor can be referred to as the efficiency of the load, which can be expressed as the
ratio of kVA to actual kW. The power factor can be calculated by dividing kW by kVA. Power
factor is expressed as a decimal. Power factor is used to mean the portion of current that is
supplied to a system that is doing useful work. The portion of the current that is not doing useful
work is absorbed in maintaining the magnetic field in motors. This current (reactive load) can be
maintained without engine power.
Generator sets normally have a low idle setting that is higher than industrial engines. Low idle will
be approximately 66 percent of the full speed that is achieved by 60 Hz units. This would be equal
to 80 percent of the full speed that is achieved by 50 Hz units.
Some generator sets are equipped with Woodward governors and some generator sets are
equipped with Cat electronic governors. These generator sets have no low idle stop. On generator
sets with mechanical governors and generators that are natural gas, the low idle is set at the
factory. Adjustment of the low idle on these machines should only be done by a Cat dealer.
Note: Operating the generator set at low idle speed for an extended time will cause some voltage
regulators to shut off. The generator set must be completely shut down and the generator set must
be restarted. This will allow the voltage regulator to produce an output again.
236
___________________________________________________________________________________________________________________________

i01754617
Generator Set - Test

SMCS - 4450-081
Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests

and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock
hazard to its user.
Make sure the testing equipment is designed for and correctly operated
for high voltage and current tests being made.
When servicing or repairing electric power generation equipment:
• Make sure the unit is off-line (disconnected from utility and/or

other generators power service), and either locked out or tagged
DO NOT OPERATE.
• Make sure the generator engine is stopped.
• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
Table 1
Tools Needed (1)
Part Number Part Quantity
237
___________________________________________________________________________________________________________________________
6V-7070 Digital Multimeter 1

146-4080 Digital Multimeter 1
9U7330 Digital Multimeter 1
(1)
Any one of these multimeters may be used.
The generator set functional test is a simplified test that can be performed in order to determine if
the generator is functional. The generator set functional test should be performed on a generator
set that is not under load. The generator set functional test determines if the generator is operating
at expected voltage and frequency levels. Perform this test at the regulator and terminal strips. Do
not perform this test at the output connections.
The generator set functional test consists of the following steps:
1. Stop the generator. Remove the panels in order to allow access to the regulator and control
terminal strips. Determine the part number for the regulator. Record the sensing voltage of
the regulator. The sensing voltage is 120 V ± 3%, 240 V ± 3%, or 480 V ± 3%. If the
multimeter has the capability, also record the frequency.
2. Verify that the generator set is ready to start. Start the generator set and bring the generator
set to rated speed. Measure the sensing voltage with the multimeter on terminals 20-22, 22-
24, and 20-24. If these voltages match the sensing voltage of the regulator and if these
voltages are nearly equal, then the output of the generator at the bus bar should be the
correct value.
3. If the voltages do not match the sensing voltage of the regulator, see the service manual for
the regulator for further troubleshooting instructions.
238
___________________________________________________________________________________________________________________________

i03956450
Generator Set Alignment - Check - Generator Sets

SMCS - 7002-024
The genset must be aligned when the genset is installed or moved into a different position. If the
generator set is run at the full continuous rating, the alignment of the generator to the engine must
be checked annually.
Properly maintain the alignment between the engine and the driven equipment in order to
minimize the following problems:
• Bearing problems
• Vibration of the engine crankshaft
• Vibration of the driven equipment
Refer to the following information for more information about the alignment of the generator set:
• Special Instruction, SEHS7259, "Alignment of Single Bearing Generators"
• Special Instruction, REHS0177, "Alignment of the Close Coupled Two Bearing Generators"
Keep a record of the measurement of the alignment. The record may be used to check the trend of
the alignment. The record may be used to analyze the trend of the alignment.
239
___________________________________________________________________________________________________________________________

i05264208
Generator Set Vibration - Test/Record

SMCS - 4450-081-VI
Check for vibration damage.
Vibration may cause the following problems:
• Coupling wear
• Loose fittings
• Fatigue of the metal components of the engine
• Cracks in the cabinet which surrounds the generator
• Cracks in welds
• Excessive noise
• Cracked insulation
The following areas are susceptible to vibration damage:
• Coupling for the generator set
• Generator bearings
• Stator output leads
• Protective sleeving
• Insulation
• Exposed electrical connections
• Transformers
• Fuses
240
___________________________________________________________________________________________________________________________
• Capacitors
• Lightning arresters
When a generator set is installed, a vibration plot should be recorded in order to assist in
diagnosing potential problems. This vibration plot should be updated yearly. The vibration plot
should also be updated when the generator set is moved and when the engine is overhauled. This
will allow the trend of the vibration to be monitored and analyzed. A potential problem may be
prevented by monitoring the trend of the vibration. If the vibration is approaching the limit of the
specification of the component, the problem may be more imminent. Refer to Data Sheet,
LEKQ4023, "Linear Vibration" for the allowable limits of vibration.
Caterpillar also recommends recording the vibration of the bearing at the generator bearing
bracket.
If the vibration exceeds the EDS limits for vibration, check the alignment. Refer to this Operation
and Maintenance Manual, "Generator Set Alignment - Check" for the alignment procedure.
Contact the Cat Dealer Service Tools group for information on ordering a vibration analyzer that
will meet your needs.
241
___________________________________________________________________________________________________________________________

i03643560
Generator Start-up Checklist

SMCS - 4450
Table 1
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: Arrangement Number:
___________________________________ ___________________
Generator Serial Number: Arrangement Number:
_________________________________ ___________________
GENERATOR NAME PLATE INFORMATION
Voltage: ___________________ Package (prime, continuous, standby):
_________________
Amperage: _________________ Kilowatts:
________________________________________
Storage Location:
Generator Alignment:
Main Stator Megohmmeter Before Storage: After Storage:
Reading:
Generator dried for 24 hours prior to (Y/N) Drying method:
start-up?
SPACE HEATERS Yes No Comments
Space heaters operating
properly?
Space heater operated 48
hrs. before start-up?
242
___________________________________________________________________________________________________________________________
MEGOHMMETER 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments

TEST (SEHS9124) reading reading corrected corrected temp.
Beginning Main Stator

of Storage
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Start-up Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Regulator Voltage Amps Comments
No Load F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
Full Load Generator DC Compare with F1 to F2
Excitation
Name Plate
Information:
F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
243
___________________________________________________________________________________________________________________________
Table 2
GENERATOR START-UP CHECKLIST (CONT.)
ELECTRICAL Yes No Comments
Unit properly grounded
Check diodes
Over current protection
Over voltage protection
Check for loose wiring
Adjust voltage
Adjust frequency
Verify kilowatt transducer (if
applicable)
MECHANICAL Data Comments
Bearing temperature readings at Front __________ Rear

full load ___________
Stator temperature readings at full A0 _______ B0 _______ C0
load _______
Air gap on main stator Top __________ Bottom
__________
Air gap on exciter stator Top __________ Bottom
__________
Air gap of PMG Top __________ Bottom
__________
Ambient air to generator at full Temperature
load ____________________
Supplier air opening to generator Size of Opening
_________________
SWITCH GEAR/PARALLEL OPERATION
Manufacturer:
Setting 1 Setting 2 Setting 3 Comments
Circuit breaker type
Overload setting
Reverse power
relay
244
___________________________________________________________________________________________________________________________
VAR/PF Controller
Load share
INSTALLATION & LOAD INFORMATION
Neutral grounding system UPS
Enclosure type Size
Motor: Other loads:
- Total SKVA - Lighting
- Total HP - Computers
- Welding
- Non-linear
- Other
FULL LOAD DATA

Voltage Amps kW KVARS P.F.
245
___________________________________________________________________________________________________________________________

i03736530
Generator Winding - Test

SMCS - 4453-081; 4454-081; 4457-081; 4470-081
246
___________________________________________________________________________________________________________________________
PMPE Generator wiring diagram for the family of 1800 frames
(CR1-C6) Diodes
(CR7) Varistor
(L1) Exciter stator
(L2) Exciter rotor
(L3) Main rotor
(L4) Main stator
(L5) Permanent magnet generator stator
247
___________________________________________________________________________________________________________________________
(PM) Permanent magnet
(RFA) Rotating field assembly
(CT1) Optional voltage droop transformer
(T0, T1, T2, T3, T7, T8, T9) Generator terminals
Table 1
Quantity Needed Tool
1 Low ohmmeter
Measure the resistance of the following windings: (L1), (L2), (L3), (L4) and (L5). The winding
that is being tested must be disconnected from the other components before the resistance can be
measured.
Note: The winding temperature affects the resistance. When the winding temperature increases,
the winding resistance increases. When the winding temperature decreases, the winding resistance
decreases. Therefore, a correct measurement can be performed only when the winding is at room
temperature.
The following resistance measurements are approximations. If the measured value is not near the
listed approximation, the winding is probably damaged. For a more precise resistance value,
consult the Technical Marketing Information (TMI). Refer to the generator arrangement that is in
question.
The following windings have very little resistance: (L2), (L4) and (L5). The resistance of these
windings will measure near 0 ohms. Use a milliohmmeter to measure the resistance of the
windings.
Exciter rotor (L2) - Refer to Table 2.
Main stator (L4) - less than 0.1 ohm
Pilot exciter stator (L5) - less than 0.1 ohm
Use a multimeter in order to measure the resistance of field windings (L1) and (L3) .
Exciter field (stator) (L1) - Refer to table 2.
Main field (rotor) (L3) - approximately 0.35 ohms to 1.2 ohms
Note: There should be no continuity between any winding and ground. There should be no
continuity between any winding and another winding.
Table 2
L1 Exciter Field L2 Exciter Rotor Main Field for the Rotor
1800 Frame 10.9 ohms 0.05 ohms .9 ohms
1600 Frame 10 ohms 0.06 ohms .5 ohms
1400 Frame 11 ohms 0.06 ohms .35 ohms
248
___________________________________________________________________________________________________________________________

i03736629
Generator Winding Insulation - Test

SMCS - 4453-081; 4454-081; 4457-081; 4470-081
Recommended Periodic Insulation Tests
The high voltage that is produced by an operating generator set can

cause severe injury or death. Before performing any maintenance or
repairs, ensure that the generator will not start.
Place the engine control switch in the "OFF" position. Attach "DO
NOT OPERATE" tags to all starting controls. Disconnect the batteries
or disable the starting system. Lock out all switchgear and automatic
transfer switches that are associated with the generator.
Table 1
Tools Needed
Part Number Part Name Quantity
300-8648 Insulation Testing Gp 1
Periodically, use an insulation tester to check the insulation resistance of the generator's main
stator winding. The frequency of this test is determined by the generator's environment. Previous
insulation tester readings will also determine the frequency of this test.
Test the main stator windings with an insulation tester in the following situations:
• The generator set is started for the first time.
249
___________________________________________________________________________________________________________________________
• The generator set is removed from storage.
• The generator set is operating in a humid environment. Test every three months.
• The generator set is not protected from the elements in an enclosed area. Test every three
months.
• The generator set is installed in an enclosed area. This area needs to be low in humidity and
this area needs to have steady temperatures. Test every twelve months (minimum).
• The generator set has not been run under load for three months. Test the generator set
weekly. Use space heaters around the generator set if the generator is exposed to a sea water
environment or if the humidity is above 75 percent. Also use space heaters if a test result
was below 3 megohms.
Space heaters must be used whenever the generator set is not under load. Space heaters must also
be used whenever salt is present or whenever high humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester readings above one megohm. Use space
heaters only when the generator is not running.
For additional information, refer to Special Instruction, SEHS9124, "Cleaning and Drying of
Electric Set Generators".
Recommended Procedure for the Insulation Test
Personal injury or death can result from electrocution.
The megohmmeter is applying a high voltage to the circuit.
To avoid electrocution, do not touch the instrument leads without first

discharging them. When finished testing also discharge the generator
windings.
1. Take the generator out of service.
2. Visually inspect the generator for moisture. If moisture exists, do not perform this insulation
test. Dry the unit first. Refer to Special Instruction, SEHS9124, "Cleaning and Drying of
Electric Set Generators".
3. Inspect the installation. Determine the equipment that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Disconnect "T0" from ground.
6. Disconnect the sensing lead wires for the regulator. This may be accomplished by
unplugging the harness connectors.
250
___________________________________________________________________________________________________________________________
7. Disconnect the PT leads of the load share module.
8. Connect the insulation tester's Black lead to ground.
9. Connect the insulation tester's RED lead to "T0".
10. Set the voltage to the rated voltage of the generator.
11. Use the 30/60 Time Resistance Method:
a. Apply voltage.
b. Observe the readings at 30 seconds. Observe the readings at 60 seconds.
c. Record the 60 second reading. This reading must be corrected for temperature.
d. Record temperature.
e. Record humidity.
f. Remove voltage.
12. Evaluate the readings. The actual value of the resistance may vary greatly between
generators. For this reason, the insulation's condition must be evaluated. Base this
evaluation on the comparison between the 60 second resistance readings and the readings
that were taken on previous dates. These two readings must be taken under similar
conditions. If a 60 second resistance reading has a 50 percent reduction from the previous
reading, the insulation may have absorbed too much moisture.
Switch the insulation tester to the "OFF" position. This will discharge the insulation tester's leads.
Disconnect the insulation tester's leads.
Note: The results from the insulation resistance checks indicate when cleaning and/or repairing is
becoming critical. Generally, insulation resistance will vary greatly with temperature. Therefore,
always test at the same temperature and humidity. Refer to Illustration 1.
Engine Serial Number
Serial Number for the Generator
251
___________________________________________________________________________________________________________________________
252
___________________________________________________________________________________________________________________________

i05373687
Hoses and Clamps - Inspect/Replace

SMCS - 7554-040; 7554-510
Hoses and clamps must be inspected periodically and replaced at the recommended interval to
ensure safe and continuous operation of the engine. Failure to replace a fuel hose at the
recommended change interval may result in a hazardous situation. Take proper safety precautions
before inspecting or replacing hoses and clamps.
Note: Always use a board or cardboard when the engine components are checked for leaks.
Leaking fluid that is under pressure can cause serious injury or possible death. Leaks that are the
size of a pin hole are included. Refer to Operation and Maintenance Manual, "General Hazard
Information" for more information.
Inspect the Hoses and the Clamps

Inspect all hoses for leaks that are caused by the following conditions. Replace any hose which
exhibits any of the following conditions. Failure to replace a hose which exhibits any of the
following conditions may result in a hazardous situation.
• Hoses which are cracked
• Hoses which are soft
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
• Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps
253
___________________________________________________________________________________________________________________________
Inspect all clamps for the following conditions. Replace any clamp which exhibits signs of any of
the following conditions.
• 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:
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the fittings
Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to
loosen which can result in leaks. A constant torque hose clamp will help to prevent loose hose
clamps.
Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps that are cracked or damaged. Tighten or replace
hose clamps which are loose.
Replace the Hoses and the Clamps
NOTICE

containing fluids.
Refer to Special Publication, NENG2500, "Cat Dealer Service Tool

Catalog" or refer to Special Publication, PECJ0003, "Cat Shop
Supplies and Tools Catalog" for tools and supplies suitable to collect
and contain fluids on Cat products.
Cooling System
254
___________________________________________________________________________________________________________________________
Pressurized System: Hot coolant can cause serious burns. To open the
cooling system filler cap, stop the engine and wait until the cooling
system components are cool. Loosen the cooling system pressure cap
slowly in order to relieve the pressure.
Personal injury can result from removing hoses or fittings in a pressure

system.
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the

system has been relieved.
1. Stop the engine.
2. Allow the engine to cool.
3. Before servicing a coolant hose, slowly loosen the filler cap for the cooling system in order
to relieve any pressure.
4. Remove the filler cap for the cooling system.
5. Drain the coolant from the cooling system to a level that is below the hose that is being
replaced. Drain the coolant into a suitable clean container. The coolant can be reused.
6. Remove the hose clamps.
7. Disconnect the old hose.
8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or install new hose clamps. Refer to
Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about
selecting and installing the proper hose clamps.
10. Refill the 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.
12. Start the engine. Inspect the cooling system for leaks.
255
___________________________________________________________________________________________________________________________
Fuel System
Personal injury can result from removing hoses or fittings in a pressure

system.
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the

system has been relieved.
Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.
NOTICE
Do not bend or strike high pressure lines. Do not install bent or

damaged lines, tubes or hoses. Repair any loose or damaged fuel and
oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the recommended
torque.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a
suitable cover over any disconnected fuel system components.
Note: High-pressure fuel lines may be installed between the high-pressure fuel pump and
the fuel injectors. High-pressure fuel lines are constantly charged with high pressure. Do not
check the high-pressure fuel lines with the engine or the starting motor in operation. Wait
256
___________________________________________________________________________________________________________________________
for 10 minutes after the engine stops before you perform any service or repair on high-
pressure fuel lines. Waiting for 10 minutes will to allow the pressure to be purged.
1. Drain the fuel from the fuel system to a level that is below the hose that is being replaced.
6. Carefully inspect the engine for any spilled fuel. Make sure that no fuel remains on or close
to the engine.
Note: Fuel must be added to the fuel system ahead of the fuel filter.
7. Refill the fuel system. Refer to this Operation and Maintenance Manual, "Fuel System -
Prime" for information about priming the engine with fuel.
8. Start the engine. Inspect the fuel system for leaks.
Lubrication System
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
1. Drain the oil from the lubrication system to a level that is below the hose that is being
replaced.
6. Refill the lubrication system. Refer to this Operation and Maintenance Manual, "Engine Oil
Level - Check" in order to ensure that the lubrication system is filled with the proper amount
of engine oil.
7. Start the engine. Inspect the lubrication system for leaks.
257
___________________________________________________________________________________________________________________________
Air System
Note: The bellows and the V-clamps that are used on the bellows should never be reused.
5. Start the engine. Inspect the air lines for leaks.
258
___________________________________________________________________________________________________________________________

i03460071
Ignition System Timing - Check/Adjust

SMCS - 1550-025; 1550-535
Ignition timing for gas engines varies with the gas chemistry. Obtain a fuel analysis in order to
determine if the timing for the ignition system is correct. Enter the data from the fuel analysis into
the Caterpillar Software Program, LEKQ6378, "Methane Number Program". Alternatively, you
may provide the results of a gas analysis to your Caterpillar dealer for assistance in determining
the correct timing for your application.
Use the Caterpillar Electronic Technician (ET) to adjust the timing. Adjust the timing according to
the instructions in Special Instruction, REHS1438, "Installation and Initial Start-Up Procedures for
G3500C and G3500E Engines". Consult your Caterpillar dealer for assistance.
259
___________________________________________________________________________________________________________________________

i04342943
Inlet Air System - Check

SMCS - 1058-535; 1071-535; 1087-535
Use of a platform may be necessary to inspect the following components of the air inlet system:
• Piping between the air cleaner and the turbocharger
• Rubber hoses in the air lines
• Turbocharger
• Piping between the turbocharger and the aftercooler
• Aftercooler
• Connection of the aftercooler to the air plenum
• Connection of the air plenum to the cylinder head
Inspect the components for the following conditions:
• Cracks
• Leaks
• Debris
Ensure that all of the connections are secure. Ensure that the components are in good condition
and free of debris.
Make repairs, if necessary. For information regarding removal and installation of the components,
refer to Service Manual, "Disassembly and Assembly". Consult your Cat dealer for assistance.
260
___________________________________________________________________________________________________________________________

i03230758
Jacket Water Heater - Check

SMCS - 1383-535
Jacket water heaters help to improve startability in ambient temperatures that are below 21 °C (70
°F). All installations that require automatic starting should have jacket water heaters.
Check the operation of the jacket water heater. Check the operation of the circulation pump, if
equipped. For an ambient temperature of 0 °C (32 °F), the heater should maintain the jacket water
coolant temperature at approximately 32 °C (90 °F).
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i04678174
Maintenance Interval Schedule

SMCS - 1000; 4450; 7500
S/N - GZE1-UP
S/N - SSR1-UP
Ensure that all safety information, warnings, and instructions are read and understood before any
operation or any maintenance procedures are performed. The user is responsible for the
performance of all maintenance including the following procedures: all adjustments, the use of
proper lubricants, fluids, filters and the installation of new components due to normal wear and
aging . The performance of this product may be diminished if proper maintenance intervals and
procedures are not followed. Components may experience accelerated wear if proper maintenance
intervals and procedures are not followed.
Note: Use whichever of the following that occurs first in order to determine the maintenance
intervals: fuel consumption, service hours and calendar time . Before each consecutive interval is
performed, all maintenance from the previous intervals must be performed.
Products that operate in severe operating conditions may require more frequent maintenance.
When Required
Battery - Recycle - 122 page

Battery - Replace - 123 page
Battery or Battery Cable - Disconnect - 128 page
Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace - 159 page
Generator - Dry - 209 page
Generator Lead - Check - 228 page
Generator Set - Test - 230 page
Generator Set Alignment - Check - 232 page
Generator Winding - Test - 239 page
Overhaul Considerations - 270 page
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Space Heater - Test - 281 page

Throttle Control Valve - Check - 295 page
Daily
Air Tank Moisture and Sediment - Drain - 118 page

Coolant Level - Check - 140 page
Electrical Connections - Check - 157 page
Engine Air Cleaner Service Indicator - Inspect - 163 page
Engine Oil Level - Check - 176 page
Fuel Filter Differential Pressure - Check - 196 page
Fumes Disposal Filter Differential Pressure - Check - 201 page
Generator Bearing Temperature - Test/Record - 227 page
Generator Load - Check - 229 page
Jacket Water Heater - Check - 254 page
Power Factor - Check - 273 page
Voltage and Frequency - Check - 305 page
Walk-Around Inspection - 306 page
Every Week
Automatic Start/Stop - Inspect - 121 page

Battery Charger - Check - 125 page
Battery Electrolyte Level - Check - 126 page
Cooling System Supplemental Coolant Additive (SCA) - Test/Add - 146 page
Engine Oil Sample - Obtain - 179 page
Fumes Disposal Filter - Drain - 199 page

Aftercooler Condensation - Drain - 117 page
Alternator - Inspect - 120 page
Belts - Inspect/Adjust/Replace - 129 page
Crankshaft Vibration Damper - Inspect Engine - 151 page
Engine Speed/Timing Sensor - Clean/Inspect - 182 page
Engine Valve Lash and Bridge - Check - 185 page
Gas Pressure Regulator Condensation - Drain - 205 page
Generator Winding Insulation - Test - 242 page
Hoses and Clamps - Inspect/Replace - 246 page
Inlet Air System - Check - 253 page
Radiator - Clean - 274 page
Valve Stem Projection - Measure/Record - 300 page
Water Pump - Inspect - 309 page
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Compressor Bypass - Check - 132 page
Engine Oil - Change - 169 page
Engine Oil Filter - Change - 172 page
Flexible Coupling - Inspect - 187 page
Generator - Inspect - 213 page
Generator Set Vibration - Test/Record - 233 page
Stator Lead - Check - 291 page

Spark Plugs - Inspect/Replace - 283 page
Crankcase Blowby - Test/Record - 149 page

Cylinder Pressure - Test/Record - 155 page
Engine Mounts - Inspect - 167 page
Engine Protective Devices - Check Ignition - 181 page
Starting Motor - Inspect - 289 page
Coolant Temperature Regulator - Replace - 144 page

Fumes Disposal Filter Element - Replace - 203 page
Rotating Rectifier - Inspect/Test - 278 page
Turbocharger - Inspect - 296 page
Varistor - Check - 301 page
Every 10 000 Service Hours
Generator Bearing - Inspect - 216 page
Overhaul (Top End) - 264 page
Overhaul (In-Frame) - 258 page
Every 24 000 Service Hours or 3 Years

Coolant (NGEC) - Change - 134 page
Overhaul (Major) - 261 page
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i03910789
Overhaul (In-Frame)
SMCS - 1000-020
S/N - GZE1-UP
S/N - SSR1-UP
Scheduling an In-Frame Overhaul

Scheduling an in-frame overhaul normally depends on the following three conditions:
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease and a variation of cylinder compression
Each individual condition may not indicate a need for an overhaul. However, evaluating the three
conditions together is the most accurate method of determining when an overhaul is necessary.
The engine does not require an overhaul if the engine is operating within acceptable limits for oil
consumption, crankcase blowby, and cylinder compression.
Periodically measure each of the three conditions. The first measurement should occur during the
engine commissioning. The first measurement establishes a baseline for future measurements.
Additional measurements are scheduled at regular intervals in order to determine a schedule for
the next in-frame overhaul.
The following changes in the three conditions normally require a scheduled overhaul:
• A 300 percent increase in oil consumption
• A 200 percent increase in crankcase blowby
• A 20 percent loss of cylinder compression
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Note: These indications do not require an engine to be shut down for service. These indications
only mean that an engine should be scheduled for service soon. If the engine operation is
satisfactory, an immediate overhaul is not a requirement.
Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Usually, an in-frame overhaul does not require removal of the engine. Instead, the service is
performed with the engine in place. If the customer requires a minimum disruption in the
production of power, the engine can be replaced with a rebuilt model of identical specifications.
Note: The generator or the driven equipment may also require service when the engine overhaul is
performed. Refer to the literature that is provided by the OEM of the driven equipment.
In-Frame Overhaul Information

An in-frame overhaul includes all of the work that is done for a top end overhaul. Additionally,
some other components that wear are replaced. The condition of components is inspected. Those
components are replaced, if necessary.
Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can
ensure that the components are operating within the appropriate specifications.
The following definitions explain the terminology for the services that are performed during an
overhaul:
Inspect - Inspect the components according to the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index
of Publications on Reusability or Salvage of Used Parts". The guidelines were developed in order
to help Caterpillar dealers and customers to avoid unnecessary expenditures. New parts are not
required if the existing parts can still be used, reconditioned, or repaired. If the components are not
in the reusability guidelines, refer to the Service Manual, "Specifications" module.
Rebuild - The component can be reconditioned in order to comply with reusability guidelines.
Replace - The service life of the part is exhausted. The part may fail before the next maintenance
interval. The part must be replaced with a part that meets functional specifications. The
replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part.
Some worn components may be exchanged with your Caterpillar dealer. Consult your Caterpillar
dealer about repair options for your engine.
If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the
recommendations in Table 1.
Table 1
In-Frame Overhaul
Oil suction screen
Clean
Spark arrestor
Clean
Inspect Aftercooler core
Test
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Compressor bypass valve and actuator

Exhaust system
Fuel metering valve
Inspect Oil cooler
Rebuild
Replace Oil pump
Pistons
Throttle
Transformers and extenders
Prelube pump
Starting motor
Rebuild
Turbochargers
Water pumps
Connecting rod bearings
Cylinder head assemblies
Cylinder liners
Replace
Main bearings
Piston rings
Water temperature regulators
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i03910780
Overhaul (Major)
SMCS - 7595-020-MJ
S/N - GZE1-UP
S/N - SSR1-UP
Scheduling a Major Overhaul

The need for a major overhaul is determined by several factors. Some of those factors are the same
factors that determine the in-frame overhaul:
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease and variation of cylinder compression
Other factors must also be considered for determining a major overhaul:
• Power output
• The service hours of the engine
• Reduced oil pressure
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration
An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear
may need serviced. An increase in the levels of noise and vibration indicates that rotating parts
require service.
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Note: Oil analysis can indicate a decrease of wear metals in the lube oil. The cylinder liners may
be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute the
wear metals.
Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Note: The generator or driven equipment may also require service when the engine is overhauled.
Refer to the literature that is provided by the OEM of the driven equipment.
Major Overhaul Information

A major overhaul includes all of the work that is done for top end overhauls and in-frame
overhauls. Additional parts and labor are required in order to rebuild the engine. In some cases,
the engine is relocated for disassembly.
For the major overhaul, all of the bearings, seals, gaskets, and components that wear are
disassembled. The parts are cleaned. The parts are inspected. If necessary, the parts are replaced.
The crankshaft is measured for wear. The crankshaft may require regrinding. Alternatively, the
crankshaft may be replaced with a Caterpillar replacement part.
Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can
ensure that the components are operating within the appropriate specifications.
overhaul:
recommendations in Table 1. Your Caterpillar dealer can provide these services and components.
Table 1
Major Overhaul
Clean Oil suction screen
Clean
Inspect Aftercooler core
Test
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Camshafts
Camshaft followers
Compressor bypass valve and actuator
Connecting rods
Crankshaft
Exhaust system
Inspect Fuel metering valve
Rebuild
Replace Gear train
Inlet air piping
Oil cooler
Oil pump
Pistons
Throttle valve
Transformers and extenders
Prelube pump
Starting motor
Rebuild Turbochargers
Water pumps
Vibration damper
Camshaft bearings
Connecting rod bearings
Coupling (tandem engines)
Cylinder liners
Gaskets and seals
Replace
Gear train bushings
Main bearings
Piston rings
Wiring harnesses
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i03906477
Overhaul (Top End)

SMCS - 7595-020-TE
Scheduling a Top End Overhaul

Top end overhauls are scheduled according to the recession of the exhaust valve stems. This
measurement provides an accurate indication of the rate of valve wear. This measurement can be
used to predict when a cylinder head requires replacement.
To determine a baseline, measure the projection of the exhaust valve stems after 100 to 250
service hours. The baseline is a reference for subsequent measurements. Continue to measure the
projection periodically.
Plan for the top end overhaul as the valve stem projection approaches the maximum limit. Perform
the top end overhaul when the valve stem projection has increased by a total of 2.3 mm (.09 inch).
Do not allow the projection of the exhaust valve stems to exceed this limit.
Note: Generally, cylinder heads wear out at different rates. In some cases, servicing the cylinder
heads at different times may be the most economic decision. This decision depends on the valve
stem projection of the individual cylinders. However, this decision must include the costs of
additional downtime that is caused by this procedure. Perform an economic analysis in order to
determine if cylinder heads should be serviced as a group or divided into smaller groups.
Note: The generator or the driven equipment may also require service when the engine overhaul is
performed. Refer to the literature that is provided by the OEM of the driven equipment.
Top End Overhaul Information

A top end overhaul involves servicing the cylinder heads and turbochargers. Also, some other
engine components are inspected.
Top end overhauls require more tools than preventive maintenance. The following tools are
needed for restoring the engine to factory specifications:
• Torque wrenches
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• Dial indicators
• Accurate measurement tools
• Cleaning equipment
• Rebuilding equipment
Caterpillar dealers are equipped with these tools. Caterpillar dealers can provide a flat rate price
for a top end overhaul.
Unexpected problems may be found during a top end overhaul. Plan to correct these problems, if
necessary.
• Build up in the cylinders from excessive oil consumption
• Build up in the cylinders from contamination of the fuel
• Plugging of the aftercooler from coolant that is poorly maintained
• Plugging of the aftercooler from contamination of the inlet air
• Degradation of the oil cooler from the hydrogen sulfide in the fuel
• Deterioration of exhaust manifold components
overhaul:
recommendations in Table 1. Your Caterpillar dealer can provide these services and components.
Your Caterpillar dealer can ensure that the components are operating within the appropriate
specifications.
Table 1
Top End Overhaul
Clean Oil suction screen
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Clean Aftercooler core

Inspect Oil cooler core
Test Exhaust manifolds
Transformers
Inspect
Flexible coupling
Prelube pump
Starting motor
Rebuild
Turbochargers
Water pumps
Cylinder head assemblies
Replace Spark plugs
Cleaning and Inspection of Components
Aftercooler and Oil Cooler
Clean the aftercooler core and the oil cooler core. Perform pressure tests on the components.
Replace the components, if necessary.
Note: If the cooling system is not properly maintained, cleaning of the aftercooler can be difficult.
The tank that is opposite of the inlet port and the outlet port cannot be removed for cleaning.
Note: This procedure may be used for cleaning both the aftercooler core and the oil cooler core.
1. Remove the core.
2. Turn the core upside-down in order to remove debris.
NOTICE
Do not use a high concentration of caustic cleaner to clean the core. A

high concentration of caustic cleaner can attack the internal metals of
the core and cause leakage. Only use the recommended concentration
of cleaner.
3. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv liquid cleaner. Consult your Caterpillar dealer
for part numbers and sizes of containers.
Use a 2 to 5 percent concentration of the cleaner at temperatures up to 93°C (200°F).
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4. Steam clean the core in order to remove any residue. Flush the fins of the core. Remove any
other trapped debris.
5. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
6. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.
Note: The test pressure for the oil cooler is 790 kPa (115 psi). The maximum differential
pressure of water for the aftercooler is 44 kPa (6 psi). The maximum differential pressure of
air for the aftercooler is 5.1 kPa (0.74 psi).
7. Inspect the core in order to ensure cleanliness. Perform a pressure test of the core. Many
shops that service radiators are equipped to perform pressure tests. If necessary, repair the
core.
8. Install the core.
For more information on cleaning the cores, consult your Caterpillar dealer.
Oil Suction Screen
Clean the oil suction screen after the engine oil pan has been drained.
Note: Approximately 1 L (1 qt) of engine oil will remain in the housing after the sump has
been drained. This engine oil will pour out of the housing when cover (1) is removed.
Prepare to catch the engine oil in a pan. Clean up any spills with absorbent towels or
pillows. DO NOT use absorbent particles.
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(1) Cover
(2) O-ring seal
(3) Screen assembly
1. Loosen the bolts from cover (1). Remove cover (1) and O-ring seal (2). Discard the seal.
Remove screen assembly (3) .
2. Wash screen assembly (3) in clean nonflammable solvent. Allow the screen assembly to dry
before installation.
3. Clean the engine oil sump. Remove the side covers in order to gain access to the sump.
After the sump is clean, install the side covers.
4. Inspect screen assembly (3) for good condition. Obtain a new screen assembly, if necessary.
Install the screen assembly. Install a new O-ring seal (2). Install cover (1) .
Transformers
The transformers produce a voltage increase. For good operation, the connections must be clean
and secure. Inspect the transformers for the following conditions:
• Damaged O-rings
• Dirty insulator
• Loose connector
• Moisture
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Measure the voltage of the diode for the primary circuit and measure the resistance of the
secondary circuit according to Troubleshooting, "G3500C Engines". Consult your Caterpillar
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i01950926
Overhaul Considerations
SMCS - 7595-043
Overhaul Information
An overhaul is replacing the major worn components of the engine. An overhaul is a maintenance
interval that is planned. The engine is rebuilt with certain rebuilt parts or new parts that replace the
worn parts.
An overhaul also includes the following maintenance:
• Inspection of all the parts that are visible during the disassembly
• Replacement of the seals and gaskets that are removed
• Cleaning of the internal passages of the engine and the engine block
Most owners will save money by overhauling the engine at the intervals that are recommended in
the Operation and Maintenance Manual. It is not practical to wait until the engine exhibits
symptoms of excessive wear or failure. It is not less costly to wait. A planned overhaul before
failure may be the best value for the following reasons:
• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the guidelines for reusable parts.
• The service life of the engine can be extended without the risk of a major catastrophe due to
engine failure.
• Achieve the best cost/value relationship per hour of extended service life.
Overhaul Intervals
Top end overhauls are determined by the projection of exhaust valve stems. In-frame overhauls
are determined by cylinder compression, crankcase blowby, and oil consumption. Major overhauls
are determined by the in-frame tests, and by results of S·O·S oil analysis.
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Some other factors that are important for determining the overhaul intervals include the following
considerations:
• Performance of preventive maintenance
• Use of recommended lubricants
• Use of recommended coolants
• Use of recommended fuels
• Proper installation
• Operating conditions
• Operation within acceptable limits
• Engine load
• Engine speed
Note: To avoid oil problems, engines that are turbocharged and aftercooled must be operated at a
minimum of 60 percent of rated load.
Generally, engines that are operated at a reduced load and/or speed achieve more service life
before an overhaul. However, this is for engines that are properly operated and maintained.
Overhaul Inspection
Refer to the Service Manual for the disassembly and assembly procedures that are necessary in
order to perform the required maintenance on the items that are listed. Consult your Caterpillar
To determine the reusability publications that are needed to inspect the engine, refer to Guidelines
for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or
Salvage of Used Parts".
The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar
parts reusability program. These guidelines were developed in order to assist Caterpillar dealers
and customers reduce costs by avoiding unnecessary expenditures for new parts. If the engine
parts comply with the established inspection specifications, the parts can be reused. New parts are
not necessary if the old parts can be reused, repaired, or salvaged.
If the parts are not within the inspection specifications, the parts should be salvaged, repaired,
replaced, or exchanged. The use of out-of-spec parts could result in unscheduled downtime and/or
costly repairs. The use of out-of-spec parts can also contribute to increased fuel consumption and
reduction of engine efficiency.
Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least
possible cost.
Overhaul Programs
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An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar
remanufactured parts. Caterpillar remanufactured parts are available at a fraction of the cost of
new parts. These parts have been rebuilt by Caterpillar and certified for use. The following
components are examples of the remanufactured parts:
• Alternators
• Connecting rods
• Crankshafts
• Cylinder heads
• Oil Pumps
• Starting motors
• Turbochargers
• Water pumps
Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are
available.
Your Caterpillar dealer may be offering a variety of overhaul options.
A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul. Flat rate
prices on preventive maintenance programs or major repair options are available from many
servicing dealers for all Caterpillar Engines. Consult your Caterpillar dealer in order to schedule a
before failure overhaul.
Overhaul Recommendation
Caterpillar recommends a scheduled overhaul in order to minimize downtime. A scheduled

overhaul will provide the lowest cost and the greatest value. Schedule an overhaul with your
Caterpillar dealer.
Overhaul programs vary between dealers. To obtain specific information about the types of
overhaul programs and services, consult your Caterpillar dealer.
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i01216962
Power Factor - Check

SMCS - 4450-535-PWR
The power factor of a system can be determined by a power factor meter or by calculations. The
power factor can be calculated by dividing kW by kVA. Power factor is expressed as a decimal.
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i04020194
Radiator - Clean
SMCS - 1353-070
Note: Adjust the frequency of cleaning according to the effects of the operating environment.
Inspect the radiator for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and
other debris. Clean the radiator, if necessary.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.
The maximum air pressure for cleaning purposes must be reduced to

205 kPa (30 psi) when the air nozzle is deadheaded.
Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite
direction of the air flow. Hold the nozzle approximately 6 mm (0.25 inch) away from the fins.
Slowly move the air nozzle in a direction that is parallel with the tubes. This movement will
remove debris that is between the tubes.
Pressurized water may also be used for cleaning. The maximum water pressure for cleaning
purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean
the core from both sides.
Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the
core with detergent and hot water. Thoroughly rinse the core with clean water.
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After cleaning, start the engine and accelerate the engine to high idle rpm. This procedure will
help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the
core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.
Inspect the fins for damage. Bent fins may be opened with a "comb". Inspect these items for good
condition: welds, mounting brackets, air lines, connections, clamps and seals. Make repairs, if
necessary.
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i04684371
Refill Capacities
SMCS - 1000; 1348; 1395; 7560
Lubricant Capacities
The capacity of the engine crankcase includes the capacity of the oil filters that are installed at the
factory.
Table 1
Lubrication System
Approximate Refill Capacities
Engine Liters US Gallons
G3512E 307 81
G3520E
541 141
G3520C Landfill
Coolant Capacities
To maintain the cooling system, the total cooling system capacity must be determined. The total
cooling system capacity will vary between individual installations. The total cooling system
capacity equals the capacity of the jacket water circuit plus the aftercooler circuit plus the external
system capacity. The external system capacity includes the following components: expansion
tank, heat exchanger, radiator and piping. Refer to the specifications that are provided by
Caterpillar or by the OEM of the equipment. Record the total cooling system capacity in the
following Table:
Table 2
Cooling System
Approximate Refill Capacities
System G3512E G3520E G3520C Landfill
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Jacket Water Circuit

150 L (40 US gal) 344 L (91 US gal) 371 L (98 US gal)
Aftercooler Circuit 47.5 L (12.5 US gal) 73.7 L (19.5 US gal)

30 L (8 US gal)
External System
Total Cooling System
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i03852810
Rotating Rectifier - Inspect/Test

SMCS - 4465-040; 4465-081
Check the exciter armature. Ensure that the rotating rectifier is tight. If a failure of a rectifier is
suspected, proceed to the "Testing a Three-Diode Rectifier Block" section.
Testing a Three-Diode Rectifier Block
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Three-Diode Rectifier Block (two pieces)
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.
1. Set the digital multimeter on the diode range. Remove all leads from the rectifier block.
2. To test the negative rectifier block, follow these steps:
a. Place the red test lead on the negative "-" terminal. Place the black test lead on the
following rectifier terminals: "AC1" (3), "AC2" (4) and "AC3" (5). All readings on
the meter should be between 0.4 and 1.0.
b. Place the black test lead on the negative "-" terminal. Place the red test lead on the
following rectifier terminals: "AC1" (3), "AC2" (4) and "AC3" (5). In all cases, the
meter should read "OL" (overload).
3. To test the positive rectifier block, follow these steps:
a. Place the red test lead on the positive "+" rectifier terminal. Place the black test lead
on the following rectifier terminals: "AC1" (3), "AC2" (4) and "AC3" (5). In all cases,
the meter should read "OL" (overload).
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b. Place the black test lead on the positive "+" rectifier terminal. Place the red test lead
on the following rectifier terminals: "AC1" (3), "AC2" (4) and "AC3" (5). All
readings on the meter should be between 0.4 and 1.0.
Note: A shorted diode can cause damage to the exciter rotor. If a diode is shorted, check the
exciter rotor. Refer to the Testing and Adjusting, "Winding - Test" and Testing and Adjusting,
"Insulation - Test". Perform these tests.
Note: This rectifier block also contains varistor "CR7". "CR7" can be checked by measuring the
resistance between the positive "+" rectifier terminal and the negative "-" rectifier terminal. The
resistance should be a minimum of 15000.
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i03857792
Space Heater - Test

SMCS - 4450-081-HTR
The space heater is attached to the rear bearing bracket. The space heater is located in the
generator's exciter end.
Space Heater Connection Diagram
An SR4 generator can operate in high humidity conditions without problems. However, problems
can occur when the generator is idle and the surrounding air is warmer than the generator.
Moisture can form on the windings. Moisture will result in poor performance or even damage to
the windings. Whenever the generator is not active, the optional space heaters should be operated.
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An external source is required to operate the space heaters. Both of the sources must be a single
phase. This source can be either 115 vac or 230 vac. When the external source is 50 hertz, 200 vac
must be used. Refer to Illustration 1.
See your Caterpillar dealer for information on checking your Caterpillar generator.
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i04125973
Spark Plugs - Inspect/Replace

SMCS - 1555-040; 1555-510
Note: Condensation can form in spark plugs that have precombustion chambers and can cause
difficulty for cold start-ups. To avoid condensation, maintain the coolant in the cylinder block at a
minimum temperature of 43 °C (110 °F) continuously.
The service life of the spark plugs is affected by fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also affected by voltage. Higher voltage is required
by higher inlet manifold air pressure, leaner air to fuel operation, a higher compression ratio, and
retardation of the timing. Higher voltage reduces the service life of components such as spark
plugs, wires, and transformers.
The service life of the spark plug is different for different applications. To help predict the service
life of the spark plug, use Cat Electronic Technician (ET) to monitor the "Cylinder #X
Transformer Secondary Output Voltage Percentage" parameter. The value of this parameter will
increase as the spark plug gap wears over time. Experience at the particular site will help to
determine the proper interval for replacement of the spark plugs.
If a diagnostic code is generated for the secondary circuit of the ignition transformer, the spark
plug may need replaced. Misfire and a cold cylinder are other indications of a worn spark plug.
Use Cat ET to monitor the exhaust port temperatures in order to locate a cold cylinder.
Removing the Spark Plug
Ignition systems can cause electrical shocks. Avoid contacting the

ignition system components and wiring.
Do not attempt to remove the valve covers when the engine is operating.
The transformers are grounded to the valve covers. Personal injury or
death may result and the ignition system will be damaged if the valve
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covers are removed during engine operation. The engine will not
operate without the valve covers.
(1) Cover
(2) Wiring harness
(3) Transformer
(4) Seal
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(5) Spark plug
(6) Valve cover
1. Remove cover (1).
2. Remove wire harness (2) from transformer (3) .
3. Remove the two remaining bolts that secure transformer (3). Remove transformer (3) from
valve cover (6) .
4. Inspect O-ring seal (4). If the seal is hard, cracked, or melted, install a new seal.
Pressurized air can cause personal injury. When pressurized air is used
for cleaning, wear a protective face shield, protective clothing, and
protective shoes.
Note: Excessive buildup of oil in the spark plug well is an indication of a damaged lip seal
on the transformer.
5. Debris may have collected in the spark plug well. Thoroughly remove any debris. Use
compressed air. The maximum air pressure for cleaning purposes must be below 207 kPa
(30 psi). Ensure that the area around the spark plug is clean and free of dirt and debris.
6. Use a 216-1685 deep well socket, an extension, and a breaker bar to loosen spark plug (5).
After the spark plug has been loosened, use the socket and extension to remove the spark
plug by hand. Removing the spark plug by hand will help to detect problems with the
threads. After the spark plug has been removed, discard the used spark plug gasket.
If the spark plug resists removal by hand, apply penetrating oil to the threads. To help the oil
penetrate the threads, turn the spark plug back and forth until the spark plug is loose.
If the spark plug could not be removed by hand, clean the threads with a Spark Plug Seat Cleaner.
This tool scrapes debris from the seat and from the threads in the cylinder head. Be sure to clean
any debris from the cylinder.
NOTICE
Do not use a thread tap. A thread tap will remove metal unnecessarily.
The threads could be stripped and the cylinder head could be
damaged.
Inspecting the Spark Plug
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(7) Terminal post
(8) Insulator
(9) Shell
(10) Gasket
(11) Hole in the precombustion chamber
Inspect the spark plug closely for damage. The condition of the spark plug can indicate the
operating condition of the engine.
Terminal post (7) must not move. If the terminal post can be moved by hand, carefully tighten the
post into the threads of the insulator. If the post cannot be tightened, discard the spark plug.
Insulator (8) is covered with Teflon. If the cover is cracked or loose, discard the spark plug.
Faint marks may extend from shell (9) onto the insulator. The marks may be a result of a corona
that forms at the top of the shell. The conductor will develop a corona when a high voltage
potential ionizes the air. This corona is a normal condition and is not an indication of leakage
between the shell and the insulator.
Inspect shell (9) for damage. Cracks can be caused by overtightening the spark plug.
Overtightening can also yield the metal which loosens the shell. Discard any spark plug that has a
shell that is cracked or loose.
Inspect the precombustion chamber for deposits. Make sure that holes (11) in the precombustion
chamber are not blocked.
A light brown deposit or a beige deposit is produced by normal operation.
Deposits that are gray or black may be caused by the following substances:
• Excessive oil
• Use of the wrong oil
• A substance that is introduced through the fuel system or the air system
• Poor combustion because of a rich air/fuel mixture
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A spark plug can operate despite a buildup of ash. Large deposits may retain heat which can cause
premature fuel ignition. Premature fuel ignition can lead to uncontrollable detonation.
Cleaning the Spark Plug

Do not use glass beads to clean the spark plug. The beads could enter the precombustion
chamber through the holes. The beads could clog the holes in the precombustion chamber.
Use a brass wire brush to clean the spark plug. Be careful not to damage the Teflon cover.
Installing the Spark Plug

Note: Do not use anti-seize compound on spark plugs. Most of the heat is transferred
through the threads and the seat area of the spark plug. Contact of the metal surfaces must
be maintained in order to provide the heat transfer that is required.
1. Ensure that the spark plug is clean and free of dirt and oil.
2. Always use a new gasket when a spark plug is installed. If a used spark plug is installed,
place a new gasket on the spark plug. Orient the tabs of the gasket toward the
precombustion chamber. Otherwise, the gasket may not seat properly. If a gasket for a spark
plug is installed incorrectly, do not increase the torque on the spark plug in order to improve
the seal. Do not reuse the gasket. Install a new gasket.
NOTICE
Do not overtighten the spark plug. The shell can be cracked and the
gasket can be deformed. The metal can deform and the gasket can be
damaged. The shell can be stretched. This will loosen the seal that is
between the shell and the insulator, allowing combustion pressure to
blow past the seal. Serious damage to the engine can occur.
Use the proper torque.
3. Install spark plug (5) by hand until the spark plug contacts the gasket. Torque the spark plug
to the proper specification. Refer to Specifications, "Spark Plug" for the proper torque
specification.
4. Ensure that the transformer and the extension are clean and free from dirt and oil. Lubricate
O-ring seal (4) with one of the following lubricants:
◦ Dielectric Grease
◦ Silicone Lubricant
5. Install transformer (3). Orient the transformer toward wiring harness (2). Connect the wiring
harness.
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6. Install cover (1) .
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i04342950
Starting Motor - Inspect

SMCS - 1451-040; 1453-040
If the starting motor fails, the engine may not start in an emergency situation. A scheduled
inspection of the starting motor is recommended.
The starting motor pinion and the flywheel ring gear must be in good condition in order for the
engine to start properly. The engine will not start if the starting motor pinion does not engage the
flywheel ring gear. The teeth of the starting motor pinion and the flywheel ring gear can be
damaged because of irregular engagement.
Inspect the starting motor for proper operation. Listen for grinding when the engine is started.
Inspect the teeth of the starting motor pinion and the flywheel ring gear. Look for patterns of wear
on the teeth. Look for teeth that are broken or chipped. If damaged teeth are found, the starting
motor pinion and the flywheel ring gear must be replaced.
Electric Starting Motor

Note: Problems with the electric starting motor can be caused by the following conditions:
malfunction of the solenoid and malfunction of the electric starting system.
Inspect the electrical system for the following conditions:
• Corrosion
• Wires that are worn or frayed
• Cleanliness
Make repairs, if necessary.
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Air Starting Motor
Personal injury or death can result from improperly checking for a

leak.
Always use a board or cardboard when checking for a leak. Escaping

air or fluid under pressure, even a pin-hole size leak, can penetrate
body tissue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated immediately by a

doctor familiar with this type of injury.
Inspect all of the components in the air circuit for the starting motor. Inspect all of the air lines and
connections for leaks.
If the teeth of the starting motor pinion and/or the flywheel ring gear are damaged, the air circuit
for the starting motor must be examined in order to determine the cause of the problem.
Removal and Installation of the Starting Motor

Refer to the Service Manual, "Disassembly and Assembly" module for information on removing
the starting motor and installing the starting motor.
Consult your Cat dealer for assistance.
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i03230840
Stator Lead - Check

SMCS - 4459-535
Ensure that the stator output leads are routed out of the generator in a manner that prevents the
leads from rubbing against metal objects.
Visually inspect the following areas for cracking and physical damage:
• stator output leads
• protective sleeving
• insulation
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i03852818
Stator Winding Temperature - Test

SMCS - 4453-081-TA
Some generators are provided with optional 100 Ohm Resistance Temperature Detectors (RTD).
When the temperature of the stator winding is suspected to be high, measure the temperature. If
the generator is furnished with Resistance Temperature Detectors, the detectors are installed in the
slots of the main armature (stator). The detectors are used with equipment that is available from
the factory. This equipment is used in order to measure the main armature's winding temperature.
299
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i02909163
System Pressure Release

SMCS - 1250; 1300; 1350; 5050
Coolant System
Pressurized system: Hot coolant can cause serious burn. To open cap,
stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
To relieve the pressure from the coolant system, turn off the engine. Allow the cooling system
pressure cap to cool. Remove the cooling system pressure cap slowly in order to relieve pressure.
Fuel System
To relieve the pressure from the fuel system, turn off the engine.
High Pressure Fuel Lines (If Equipped)
Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.
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The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the
high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder
head. These fuel lines are different from fuel lines on other fuel systems.
This is because of the following differences:
• The high pressure fuel lines are constantly charged with high pressure.
• The internal pressures of the high pressure fuel lines are higher than other types of fuel
system.
Before any service or repair is performed on the engine fuel lines, perform the following tasks:
1. Stop the engine.
2. Wait for ten minutes.
Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system.
Engine Oil
To relieve pressure from the lubricating system, turn off the engine.
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i02293325
Throttle Control Valve - Check

SMCS - 1269-535
If a decrease in performance is observed or if the Engine Control Module signals that there is a
problem with the manifold pressure, check the throttle.
Check the throttle for leaks. If necessary, remove the throttle according to the instructions in the
Disassembly and Assembly manual. Inspect the throat of the throttle for wear marks. Check for
free movement of the butterfly valve.
Inspect the gaskets for wear or damage. If necessary, replace the gaskets. Reinstall the throttle
according to the instructions in the Disassembly and Assembly manual.
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i03900897
Turbocharger - Inspect
SMCS - 1052-040
S/N - GZE1-UP
S/N - SSR1-UP
Periodic inspection and cleaning is recommended for the turbocharger. Fouling of the turbine
wheels can contribute to loss of engine power and overall loss of engine efficiency.
If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine cylinder. This can cause additional damage to the
pistons, the valves, and the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter

the air inlet and exhaust systems. Loss of engine lubricant can result in
serious engine damage.
Minor leakage of a turbocharger housing under extended low idle

operation should not cause problems as long as a turbocharger bearing
failure has not occurred.
When a turbocharger bearing failure is accompanied by a significant

engine performance loss (exhaust smoke or engine rpm up at no load),
do not continue engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize unscheduled downtime. Also, the chance for
potential damage to other engine parts is reduced.
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Note: Turbocharger components require clearances that are precise. The turbocharger cartridge
must be balanced due to high rpm.
The following conditions can cause the turbocharger to be out-of-balance:
• The buildup of deposits
• Chipping and/or flaking of deposits
If the turbocharger must be removed for inspection, use caution. Do not break deposits from the
turbine wheel. Do not attempt to clean the turbine wheel. For information regarding removal and
installation, see the Disassembly and Assembly manual or consult your Caterpillar dealer. For
information about repair of the turbocharger or about replacement of the turbocharger, consult
your Caterpillar dealer.
1. Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger.
Visually inspect the piping for the presence of oil.
2. Turn the compressor wheel and the turbine wheel by hand. The assembly should turn freely.
Inspect the compressor wheel and the turbine wheel for contact with the turbocharger
housing. There should not be any visible signs of contact between the turbine wheel or
compressor wheel and the turbocharger housing. If there is any indication of contact
between the rotating turbine wheel or the compressor wheel and the turbocharger housing,
the turbocharger should be reconditioned.
3. Check the compressor wheel for cleanliness. If only the inlet side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering system. If oil is found only on the back
side of the wheel, there is a possibility of a failed turbocharger oil seal.
The presence of oil may be the result of extended engine operation at low idle. The presence
of oil may also result from restriction of the inlet air (plugged air filters). This causes oil to
leak past the seal for the turbocharger compressor.
If oil is found on the compressor wheel and/or at the air inlet, the source of the oil is the fuel
compressor or the PCV system.
Note: Deposits of ash and silicone can accumulate on the turbine wheel. Turbine wheel will
become unbalanced when the deposits flake off. The turbocharger cartridge must be
replaced when this occurs. However, remove deposits from the housing. This will prevent
wear on the blades of the new turbine wheel.
4. Inspect the turbine wheel and the nozzle for deposits of ash and silicone. If deposits of 1.6
mm (0.06 inch) thickness are found or if the turbine is in contact with the housing, the
turbocharger must be disassembled and cleaned. Removal of the deposits can be difficult.
5. Inspect the bore of the turbine housing for corrosion and deposits.
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Axial clearance
Note: The axial clearance is the free axial displacement of the rotor. The rotor is moved
back and forth with an approximate force between 150 N (34 lb) and 200 N (45 lb).
Tolerances are shown in Table 1. The deflection of the measuring device corresponds to the
axial clearance.
Radial clearance
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Note: Radial clearance is the maximum possible deflection at the hub of the impeller at
reciprocal neutralizing of the radial bearing clearance. Radial clearance is measured with the
measuring device on the hub of the compressor wheel. Tolerances are shown in Table 2.
The rotor is tilted with an approximate force between 150 N (34 lb) and 200 N (45 lb). The
total deflection corresponds to the radial clearance.
Note: Axial clearance and radial clearance must be measured after the cartridge group has
been removed, but prior to reinstallation.
6. Check the axial clearance and radial clearance.
7. Clean the turbocharger compressor housing with standard shop solvents and a soft bristle
brush.
8. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.
Table 1
Axial Clearance (1)
Min Max
TPS57
0.12 ± 0.04 mm (0.0047 ± 0.0015 inch) 0.21 ± 0.04 mm (0.0083 ± 0.0015 inch)
(1)
The clearances apply to new parts and used parts. Oil films are not taken into account. The values in the table are
valid at an ambient temperature of 20° C (68° F). The clearances take account of manufacturing tolerances of the
applicable components.
Table 2
Radial Clearance (1)
Min Max
TPS57
−.72 ± 0.265 mm (0.0283 ± 0.0104 1.31 ± 0.265 mm (0.0515 ± 0.0104 inch)
inch)
(1)
The clearances apply to new parts and used parts. Oil films are not taken into account. The values in the table are
valid at an ambient temperature of 20° C (68° F). The clearances take account of manufacturing tolerances of the
applicable components.
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i03470080
Valve Stem Projection - Measure/Record

SMCS - 1105-082
Valve Recession - The valves and the valve seats are worn over time. This causes the valves to
recede into the cylinder head. This condition is called "valve recession".
The top end overhaul is typically scheduled according to the amount of valve recession. The
amount of valve recession should be monitored on both intake and exhaust valves. However, it is
difficult to measure the actual valve recession in the cylinder head. A simpler method is used to
determine the valve recession:
• Measure the projection of the valve rotator above the cylinder head.
Measure the projection of the exhaust valve rotators with a 155-1536 Valve Recession Tool
Group. Follow the instructions that are provided with the tool group.
Record the measurements on the Operation and Maintenance Manual, "Valve Data
Sheet" (Reference Materials Section).
• Measure the projection of the exhaust valve rotators after 250 service hours. This
measurement is the baseline. The baseline is a reference for subsequent measurements.
• Measure the projection of the exhaust valve rotators at the first 1000 service hours.
• Plan for the top end overhaul as the projection of the valve rotator approaches the maximum
limit. Perform the top end overhaul when the projection of the valve rotator has increased by
a total of 2.3 mm (0.09 inch). Do not allow the recession of the exhaust valves to exceed
this limit. The valve head can break. This will cause severe damage in the combustion
chamber.
• Check the measurement data for a difference in the valve recession that is greater than 1 mm
(0.039 inch) for the valves that share a valve bridge. If this measurement is exceeded for
two successive measurements, replacement of the cylinder head is necessary.
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i03852820
Varistor - Check
SMCS - 4466-535
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PMPE Generator Wiring Diagram
(CR1-CR6) Diodes
(CR7) Varistor
(L1) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer
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Ohmmeter
An ohmmeter can be used to check a varistor (CR7). Place an ohmmeter across the varistor. The
resistance should be a minimum of 15000 ohms. If the resistance is less than 15000 ohms, the
varistor is faulty.
Test Light
Test Light
Refer to the test light that is shown in Illustration 2. Follow these steps in order to test the varistor:
1. Disconnect either lead of the varistor (CR7) .
2. Place the test light across the varistor.
3. Observe the results. The lamp should not light.
4. Reverse the test light.
5. Observe the results. The lamp should not light.
If the test light illuminates in either direction, there is a short in the varistor. Replace any faulty
varistors with varistors that have comparable operating characteristics. Include the following
information when a varistor is being ordered for replacement:
• Part number of the varistor
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• Serial number of the generator
After the varistor has been replaced, verify that the strapping of the field winding lead is securely
wound on the shaft. Also, verify that the strapping of the field winding lead is securely tied.
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i01189996
Voltage and Frequency - Check

SMCS - 4450-535-EL
Check for proper voltage and frequency setting. Check for stability.
Refer to the generator set Serial Plate for correct voltage and frequency.
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i05264229
Walk-Around Inspection
SMCS - 1000-040

repair procedures.

Inspect the Engine for Leaks and for Loose Connections

A walk-around inspection should only take a few minutes. When the time is taken to perform
these checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough inspection of the engine compartment before
starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose
connections, and trash buildup. Make repairs, as needed:
• The guards must be in the proper place. Repair damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is serviced in order to reduce the chance of
system contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the fluid. If
leaking is observed, find the source and correct the leak. If leaking is
suspected, check the fluid levels more often than recommended until
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the leak is found or fixed, or until the suspicion of a leak is proved to be

unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is a fire hazard.

Remove this debris with steam cleaning or high pressure water.
• Ensure that cooling lines are properly clamped. Check for leaks. Check the condition of all
pipes.
• Inspect the water pump for coolant leaks.
Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down and the parts contract.
Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal
of water pump and the installation of water pump and/or seals, refer to the Service Manual for the
engine or consult your Cat dealer.
• Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal,
the oil pan, the oil filters, and the valve cover.
• Inspect the Closed Crankcase Ventilation (CCV) filter, if equipped. If the restriction
indicator is visible, service the CCV.
• Inspect the fuel system for leaks. Look for loose fuel line clamps.
• Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps.
• Inspect the alternator belt and the accessory drive belts for cracks, breaks, or other damage.
Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced,
the belt will carry more load than the belts that are not replaced. The older belts are stretched. The
additional load on the new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks on a 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.
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• Check the condition of the gauges. Replace any gauges that are cracked. Replace any
gauges that cannot be calibrated.
Inspect the Generator

procedure to isolate the generator safely.
A visual inspection should be initially directed at the areas that are most prone to damage and
deterioration. The most prone areas to damage and deterioration are listed below:
Ground insulation - Ground insulation is insulation that is intended to isolate components that
are carrying current from components that are not carrying current.
Support insulation - Support insulation is made from one of the following items: a compressed
lamination of fibrous materials, polyester, or felt pads that have been impregnated with various
types of bonding agents.
There are many different types of damage that can occur in these areas. Several of the different
types of damage are listed below:
Thermal aging - Thermal aging can cause the degradation of insulation or the deterioration of
insulation. An examination of the coils may reveal that the insulation has expanded into the
ventilation ducts. This is the result of a loss of bond which will cause the insulation material to
separate. The insulation material could also separate from the conductors on the windings.
Abrasion - The surfaces of coils and the surfaces of connectors may be damaged by abrasion.
These surfaces may also be damaged by contamination from other sources. An example of these
sources would be chemicals or abrasive substances.
Cracking - Cracking of insulation may result from mechanical stress. The structure that is used to
brace the stator winding will become loose if the problem is not corrected. Further mechanical
damage or electrical damage may also result.
Erosion - Erosion can be caused when foreign substances rub against the insulation that is on the
surface of the coil .
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i01985173
Water Pump - Inspect

SMCS - 1361-040
A failed water pump might cause severe engine overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential damage to the engine.
Visually inspect the water pump for leaks. If leaking of the water pump seals is observed, replace
all of the water pump seals. Refer to the Service Manual for the disassembly and assembly
procedure.
Inspect the water pump for wear, cracks, pin holes and proper operation. Refer to the Service
Manual or consult your Caterpillar dealer if repair is needed or replacement is needed.
316
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Some water pumps have a filter in the weephole (1). This filter helps prevent dirt from entering
the water pump. Inspect the filter with a flashlight in order to ensure that the filter is clean.
Replace the filter annually or replace the filter when the filter becomes plugged.
317
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i05264113
Welding on Engines with Electronic Controls

SMCS - 1000
NOTICE
Because the strength of the frame may decrease, some manufacturers

do not recommend welding onto a chassis frame or rail. Consult the
OEM of the equipment or your Cat dealer regarding welding on a
chassis frame or rail.
Proper welding procedures are necessary in order to avoid damage to the engine ECM, sensors,
and associated components. When possible, remove the component from the unit and then weld
the component. If removal of the component is not possible, the following procedure must be
followed when you weld on a unit that is equipped with a Cat Electronic Engine. The following
procedure is considered to be the safest procedure to weld on a component. This procedure should
provide a minimum risk of damage to electronic components.
NOTICE
Do not ground the welder to electrical components such as the ECM or

sensors. Improper grounding can cause damage to the drive train, the
bearings, hydraulic components, electrical components, and other
components.
Do not ground the welder across the centerline of the package.

Improper grounding could cause damage to the bearings, the
crankshaft, the rotor shaft, and other components.
Clamp the ground cable from the welder to the component that will be
welded. Place the clamp as close as possible to the weld. This will help
reduce the possibility of damage.
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Note: Perform the welding in areas that are free from explosive hazards.
1. Stop the engine. Turn the switched power to the OFF position.
2. Disconnect the negative battery cable from the battery. If a battery disconnect switch is
provided, open the switch.
3. Disconnect the J1/P1 and J2/P2 connectors from the ECM. Move the harness to a position
that will not allow the harness to move back accidentally, and contact any of the ECM pins.
Use the example above. The current flow from the welder to the ground clamp of the welder will not damage
any associated components.
319
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(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
4. Connect the welding ground cable directly to the part that will be welded. Place the ground
cable as close as possible to the weld in order to reduce the possibility of welding current
damage to bearings, hydraulic components, electrical components, and ground straps.
Note: If electrical/electronic components are used as a ground for the welder, or

electrical/electronic components are located between the welder ground and the weld,
current flow from the welder could severely damage the component.
5. Protect the wiring harness from welding debris and spatter.
6. Use standard welding practices to weld the materials.
320
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i05133089
Customer Assistance
SMCS - 1000; 4450
USA and Canada

If a problem arises concerning the operation or service of an engine, the problem will be managed
by the dealer in your area.
Your satisfaction is a primary concern to Caterpillar and to Cat dealers. If you have a problem that
has not been handled to your complete satisfaction, follow these steps:
1. Discuss your problem with a manager from the dealership.
2. If your problem cannot be resolved at the dealer without additional assistance, use the phone
number below to talk with a Field Service Coordinator:
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday through Friday Central Standard Time.
3. If your needs have not been met still, submit the matter in writing to the following address:
Caterpillar Inc.
Electric Power North America
Attn: Product Support Manager
AC 6109
Mossville, Illinois 61552
Keep in mind: probably, your problem will ultimately be solved at the dealership, using the
dealership facilities, equipment, and personnel. Therefore, follow the steps in sequence
when a problem is experienced.
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i03989612
Decommissioning and Disposal

SMCS - 1000
When the product is removed from service, local regulations for the product decommissioning will
vary. Disposal of the product will vary with local regulations. Consult the nearest Cat dealer for
additional information.
322
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i03905196
Maintenance Log
SMCS - 1000; 4450
Table 1
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Hours Service Item Date Authorization
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i05264255
Maintenance Records
SMCS - 1000; 4450
Caterpillar Inc. recommends the retention of accurate maintenance records. Accurate maintenance
records can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other engines that are operated in the same
environment.
• Show compliance with the required maintenance practices and maintenance intervals.
Maintenance records can be used for various other business decisions that are related to engine
maintenance.
Maintenance records are a key element of a maintenance program that is managed. Accurate
maintenance records can help your Cat dealer to fine-tune the recommended maintenance intervals
in order to meet the specific operating situation. This should result in a lower engine operating
cost.
Records should be kept for the following items:
Fuel Consumption - A record of fuel consumption is essential in order to determine when the
load sensitive components should be inspected or repaired. Fuel consumption also determines
overhaul intervals.
Service Hours - A record of service hours is essential to determine when the speed sensitive
components should be inspected or repaired.
Documents - These items should be easy to obtain, and these items should be kept in the engine
history file. All of the documents should show this information: date, service hours, fuel
consumption, unit number and engine serial number. The following types of documents should be
kept as proof of maintenance or repair for warranty:
Keep the following types of documents as proof of maintenance for warranty. Also, keep these
types of documents as proof of repair for warranty:
325
___________________________________________________________________________________________________________________________
• Dealer work orders and itemized bills
• Owner repair costs
• Owner receipts
• Maintenance log
326
___________________________________________________________________________________________________________________________

i01028392
Ordering Replacement Parts

SMCS - 4450; 7567
When replacement parts are required for this product Caterpillar

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

damage, personal injury or death.
Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date. The parts stocks include all of the parts that
are normally needed to protect your Caterpillar engine investment.
When you order parts, please specify the following information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number, please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance and/or repair, provide the dealer with all the
information that is stamped on the Information Plate. This information is described in this
Operation and Maintenance Manual (Product Information Section).
327
___________________________________________________________________________________________________________________________
Discuss the problem with the dealer. Inform the dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when the problem occurs. This will help the dealer
in troubleshooting the problem and solving the problem faster.
328
___________________________________________________________________________________________________________________________

i04678212
Reference Material
SMCS - 1000; 4450
The following literature can be obtained through any Caterpillar dealer.
Coolants
• Data Sheet, PEHJ0040, "Cat NGEC (Natural Gas Engine Coolant)"
• Special Publication, PEHJ0191, "Cat S·O·S Fluid Analysis"
• Special Publication, SEBD0518, "Know Your Cooling System"
• Special Publication, SEBU6400, "Caterpillar Gas Engine Lubricant, Fuel, and Coolant
Recommendations"
Fuels
• Application and Installation Guide, LEKQ7256, "Fuels, Fuel Systems"
• Application and Installation Guide, LEKQ7260, "Low Energy Fuels"
• Data Sheet, LEKQ2364, "US Stationary Engine Regulations/Spark Ignited Emissions"
• Data Sheet, LEKQ5404, "Fuels Specifications Changes"
• Data Sheet, LEKQ9360, "Internal Combustion Engine Fuel Gases"
Recommendations"
Lubricants
Grease
329
___________________________________________________________________________________________________________________________
• Data Sheet, NEHP6010, "Cat Ultra 5Moly Grease"
• Data Sheet, NEHP6011, "Cat Arctic Platinum Grease"
• Data Sheet, NEHP6012, "Cat Desert Gold Grease"
• Data Sheet, NEHP6015, "Cat High Speed Ball Bearing Grease"
• Data Sheet, PEHJ0088, "Cat Multipurpose Grease"
• Data Sheet, PEHP0002, "Cat Advanced 3Moly Grease"
• Special Publication, PEGJ0035, "Grease Selection Guide"
Oil
• Data Sheet, PEHJ0006, "Cat NGEO (Natural Gas Engine Oil) EL350 (SAE 40)"
• Data Sheet, PEHP0004, "Cat NGEO (Natural Gas Engine Oil) (SAE 30, SAE 40)"
• Special Publication, PEHJ0191, "Cat S·O·S Fluid Analysis"
• Special Publication, PEHP6001, "How To Take A Good Oil Sample"
Recommendations"
Miscellaneous
• Application and Installation Guide, LEKQ7250, "Air Intake"
• Data Sheet, LEKQ4023, "Linear Vibration"
• Disassembly and Assembly, RENR5980, "G3500C and G3500E Engines"
• Engine Performance, LEBQ6117, "G3500 Industrial"
• Engine Performance, LEBQ6169, "G3500 Generator Set"
• Installation and Operation Manual, SEBU7630, "Raptor Gas Regulation and Metering
Valve/Actuator System for Caterpillar"
• Operation and Calibration Manual, SEBU7631, "Tecjet Gas Control Valve"
• Schematic, RENR5955, "G3520C and G3520E Engine Electrical System"
• Schematic, RENR5981, "G3520C Generator Electrical System "
• Schematic, RENR5982, "G3516C and G3516E Engines"
• Schematic, RENR8103, "G3500C and G3500E Generator with wall mount EMCPII+"
• Service Manual, RENR5975, "G3500C and G3500E Generator Sets"
• Software Program, LEKQ6378, "Methane Number Program"
330
___________________________________________________________________________________________________________________________
• Special Instruction, REHS1438, "Installation and Initial Start-up Procedure for G3500C and
G3500E Engines".
• Special Instruction, SEHS9124, "Cleaning & Drying of Electric Set Generators"
• Special Instruction, GMG00694, "Analyzing Cylinder Condition By Measuring Air Flow"
• Special Instruction, REHS0128, "Using the 147-5482 Valve Lash Gauge Group For Valve
Lash and Valve Bridge Adjustment"
• Special Instruction, REHS0177, "Alignment of the Close Coupled Two-Bearing

Generators"
• Special Instruction, SEHS7259, "Alignment of Single-Bearing Generators"
• Special Instruction, SEHS7332, "Do Not Operate Tag"
• Special Instruction, SEHS7633, "Battery Test Procedure"
• Special Instruction, SEHS8712, "Using the 8T-2700 Blowby/Air Flow Indicator "
• Special Instruction, SEHS8984, "Using the 1U-8860 Blowby Pickup Group "
• Special Instruction, SEHS9031, "Storage Procedure for Caterpillar Products"
• Special Instruction, SEHS9298, "Installation and Maintenance of Gaseous Fuel Filters"
• Special Publication, NEHS0526, "Service Technician Application Guide"
• Special Publication, NENG2500, "Cat dealer Service Tools Catalog"
• Special Publication, PECP9067, "One Safe Source"
• Special Publication, SEBF8029, "Index to Guidelines for Reusable Parts and Salvage
Operations"
• Special Publication, SEBF8062, "Procedure to Inspect and Clean Air Filters"
• Specifications, RENR5977, "G3500C and G3500E Engines"
• Specifications, SENR3130, "Torque Specifications"
• Systems Operation/Testing and Adjusting, RENR5978, "G3500C and G3500E Engines"
• Systems Operation/Testing and Adjusting, SENR5833, "Digital Voltage Regulator"
• Troubleshooting, RENR5944, "G3516C and G3516E Engines"
• Troubleshooting, RENR5979, "G3520C and G3520E Engines"
331
___________________________________________________________________________________________________________________________

i01745150
Valve Data Sheet

SMCS - 1000
Table 1
Serial
Engine Model Service Hours Authorization
Number
Valve Stem Rotator
Cylinder Cylinder Current Wear
Location Baseline Baseline
Pressure Measure
1 Pushrod Side
Inlet
Manifold
2 Pushrod Side
Inlet
Manifold
3 Pushrod Side
Inlet
Manifold
4 Pushrod Side
Inlet
Manifold
5 Pushrod Side
332
___________________________________________________________________________________________________________________________
Inlet
Manifold
6 Pushrod Side
Inlet
Manifold
7 Pushrod Side
Inlet
Manifold
8 Pushrod Side
Inlet
Manifold
9 Pushrod Side
Inlet
Manifold
10 Pushrod Side
Inlet
Manifold
11 Pushrod Side
Inlet
Manifold
12 Pushrod Side
Inlet
Manifold
Pushrod Side
13
Inlet
Manifold
Pushrod Side
14
Inlet
Manifold
15
333
___________________________________________________________________________________________________________________________
Pushrod Side
Inlet
Manifold
Pushrod Side
16
Inlet
Manifold
Pushrod Side
17
Inlet
Manifold
Pushrod Side
18
Inlet
Manifold
Pushrod Side
19
Inlet
Manifold
Pushrod Side
20
Inlet
Manifold
334
Technical Library
http://engine.od.ua
335

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SEBU8554-03

S/N GZE1-UP ( G3520E GENERATOR SET)

Use the bookmarks for navigation inside of the manual

Product Information Section

 Air Starting Motor 01/05/2010

Refill Capacities 01/05/2010

Stator Lead - Check - 291 page

Aftercooler Condensation - Drain 01/05/2010

Engine Oil - Change 01/05/2010

o Scheduling a Major Overhaul 01/05/2010

Reference Information Section

Operation and Maintenance Manual

Media Number -SEBU8554-03

Publication Date -01/07/2012 Date Updated -31/07/2012

California Proposition 65 Warning

Operation and Maintenance Manual

"No Step "

Operation and Maintenance Manual

Before Starting Engine

Inspect the engine for potential hazards.

See the Service Manual for repairs and for adjustments.

Operation and Maintenance Manual

Operation and Maintenance Manual

Crushing Prevention and Cutting Prevention

Operation and Maintenance Manual

Ensure that all grounds are secure and free of corrosion.

Operation and Maintenance Manual

Operation and Maintenance Manual

Operation and Maintenance Manual

Fire Prevention and Explosion Prevention

Do not expose the engine to any flame.

Lines, Tubes, and Hoses

Replace the parts if any of the following conditions are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Operation and Maintenance Manual

General Hazard Information

• Use all cleaning solutions with care.

• Report all necessary repairs.

• The engine is stopped. Ensure that the engine cannot be started.

• The protective locks or the controls are in the applied position.

California Proposition 65 Warning

Pressurized Air and Water

Containing Fluid Spillage

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Dispose of all fluids according to local regulations and mandates.

Lines, Tubes, and Hoses

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.