CATERPILLAR" SEBU7577-01

October 2004

Operation and
Maintenance
Manual
3054 and 3056 Marine Generator Sets
CHNI-Up (Generator Set)
TCNI-Up (Generator Set)
SNXI-Up (Generator Set)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
r
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bod~iyinjury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER, "WARNING" or "CAUTION". The Safety Alert "WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 SEBU7577-01
Table of Contents

Table of Contents Maintenance Interval Schedule (3054 Naturally

Aspirated Marine Generator Set Engine) ............84

Foreword .............................................................. 4 Maintenance Interval Schedule (3054 Turbocharged

Marine Generator Set Engine) ............................85
Safety Section
Maintenance Interval Schedule (3056 Turbocharged
Safety Messages .................................................. 6 Marine Generator Set Engine) ............................87

General Hazard Information ...................................

8 Reference Information Section
Burn Prevention ....................................................
10 Customer Service ............................................... 130
Fire Prevention and Explosion Prevention ............. 11 Reference Materials ............................................132

Crushing Prevention and Cutting Prevention ........ 13 Index Section

Mounting and Dismounting ................................. 13 Index ...................................................................
136

Before Starting Engine ..........................................

13

Engine Starting .....................................................14

Engine Stopping ...........................
....................14
Electrical System ................................................ 14

Generator Isolating for Maintenance ....................15

Product lnformation Section
Model Views .........................................................
16

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

Operation Section
Lifting and Storage ...............................................24

Installation .......................
.............................26
Features and Controls ........................................ 27

Engine Starting ................................................. 51

Engine Operation ................................................ 63

Engine Stopping ...............................................65

Cold Weather Operation ..................................... 74

Generator Operation .......................................... 76

Maintenance Section
I ..
...................................................78
Refill Capac~t~es

Maintenance Recommendations .......................... 81

4
Foreword
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 delively.
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 produd.
Operation
Operating techniques outlined in this manual &e'
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
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
bv fuel consum~tion,service hours andlor calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
follow.
Use fuel consumption or 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.
I
I
!
!
Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment I
I
of the engine also governs the Maintenance Interval
Schedule. Therefore. under extremelv severe, I
dusty, wet or freezing cold operating conditions, i
more frequent lubrication and maintenance than is I
specified in the Maintenance Interval 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 !
I
Perform maintenance on items at multiples of the
original requirement. Each level andlor individual
items in each level should be shifled ahead or back
depending upon your specific maintenance practices,
operation and application. We recommend that
the maintenance schedules be re~roducedand
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.
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 lefl 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 afler failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
 5
Foreword

) California Proposition 65 Warning

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

Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.
Safety Section
Safety Messages

Safety Section Read the Operation and

Maintenance Manual

Safety Messages
SMCS Code: 1000; 7405

There may be several specific warning signs on

an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all waming
signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if
the words cannot be read or if the pictures are not Illustration 1
go0750994
visible. When the warning signs are cleaned, use a
cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the warning signs.
Solvents, gasoline, or harsh chemicals could loosen
The label for reading the Operation and Maintenance
Manual is located on the top of the inlet and exhaust 11
the adhesive that secures the warning signs. The
warning signs that are loosened could drop off of
the engine.
manifold.
II
Replace any damaged warning signs or missing
warning signs. If a waming sign is attached to a part
of the engine that is replaced, install a new warning
sign on the replacement part. Any Caterpillar dealer
can provide new warning signs.

Do not work on the engine and do not operate the

engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
Proper care is your responsibility. Failure to follow
the instructions or failure to heed the warnings could
result in injury or in death.

The warning labels that may be found on the engine Before operating the engine, read the Operation and
are illustrated and described. Maintenance Manual and understand the Operation
and Maintenance Manual.
 7
Safety Section
Safety Messages

Starting Aid Draining the Coolant

Illustration 2 900751369 Illustration 3 900750994

The warning label for the starting aid is located on The label for draining the coolant is located on the
the air cleaner or near the air cleaner. top of the inlet and exhaust manifold.

If the engine is equipped with an air inlet heater

for cold weather starting, do not use starting aids
that contain an aerosol such as ether. Using such
types of starting aids could result in an explosion and
personal injury.

Do not drain the engine coolant prior to reading

and understanding the Operation and Maintenance
Manual.
8
Safety Section
General Hazard Information

Electrical System Attach a "Do Not Operate" warning tag or a similar

warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
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 it is 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
go0750997
Illustration 4 area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
The warning for the electrical system is located on
top of the cover for the alternator. 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

SOME 12 VOLT COMPONENTS. Pressure taps

REFER TO THE WIRING
Breathers

Drain plugs

Use caution when cover plates are removed.

This electrical system contains some 12 volt
components. Refer to Schematic, RENR2408.
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, ply the cover loose in order to
relieve any spring pressure or other pressure.

1013772d8

General Hazard Information

SMCS Code: 1000; 7405

g00702020
Illustration 6

Wear a hard hat, protective glasses, and other

protective equipment, as required.

go0104545 When work is performed around an engine that is

Illustration 5 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 ail necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
The engine is stopped. Ensure that the engine
cannot be started.
Disconnect the batteries when maintenance
is performed or when the electrical system is
se~iced.Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
Pressure Air and Water'
Pressurized air andlor water can cause debris
andlor hot water to be blown out. This could result in
personal injury.
When pressure air andlor pressure water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Ey'e protection includes goggles
or a protective face shield. .
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
I
go0687600
Illustration 7
9
Safety Section
General Hazard lnformation
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
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Tools and
Shop Products Guide" for the following items:
Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
Asbestos Information
Illustration B go0702022
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
10
Safety Section
Burn Prevention

Use caution. Avoid inhaling dust that might be Dispose of Waste Properly
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. go0706404

Illustration 9

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.
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.

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.
Burn Prevention
SMCS Code: 1000; 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 bums. Allow cooling system components to
cool before the cooling system is drained.

Check the coolant level afler 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 selvicing
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
101372254
Fire Prevention and Explosion
Prevention
SMCS Code: 1000; 7405
g00704000
Illustration 10
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 fifteen 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.
11
Safety Section
Fire Prevention and Explosion Prevention
If the application involves the presence of combustible
gases, consult your Caterpillar dealer for additional
information about suitable protection devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame,
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a tube, 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 or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. All electrical
wires must be 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. DQnot bypass any fuses
andlor 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. The hoses must be properly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all ,connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
torque.
12
Safety Section
Fire Prevention and Explosion Prevention
Illustration 11 go0704059
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not .
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Illustration 12 goo704135
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. This 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 enaine is ooerated.
Fire Extinguisher
~ a k sure
e 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.
Ether
Ether is flammable and poisonous
Use ether in well ventilated areas. Do not smoke
while vou are re~lacinaan ether cvlinder or while vou
are using an ether spray.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders
in direct sunlight or in temperatures above 49 "C
(120 OF). Keep ether cylinders away from open
flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather
starting.
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar 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.
, locations that have steps andlor handholds. Do not
Outer coverings are chafed or cut.
Wires are exposed.
Outer coverings are ballooning.
Flexible part 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. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
101359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 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 s t ~ c kBefore
. objects are struck, ensure that no
one will be injured by flying debris.
I01372247
Mounting and Dismounting
SMCS Code: 1000; 7405
lnspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
13
Safety Section
Crushing Prevention and Cutting Prevention
Mount the engine and dismount the engine only at
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. 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 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
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
Before Starting Engine
SMCS Code: 1000
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
air andlor fuel supply to the engine.
Overspeed shutdown should occur automatically.
If automatic shutdown does not occur, press the
emergency stop button in order to cut the fuel andlor
air to the engine.
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.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
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.
 14
Safety Section
Engine Starting
See the Service Manual for repairs and for
adjustments.
i02136012
Engine Starting
SMCS Code: 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)
andlor 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.
~oio~aaoa
Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to 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.
a'a
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 condition occurs. This may be
accomplished by shutting off the fuel supply andlor
the air supply to the engine.
101392624
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative "-"jump start cable should be connected
last from the external power source to the negative
"-"terminal of the starting motor. If the starting motor
is not equipped with a negative "-" terminal, connect
the jump start cable to the engine block.
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. See
the Operation and Maintenance Manual for specific
starting insiruciions.
Grounding Practices
The electrical system for the vessel and the engine
must be properly grounded. 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 noise. Electrical noise may degrade the
performance of the vessel and of the radio.
The alternator, the starting motor, and all of the
electrical systems MUST be grounded to the negative
battery terminal. The alternator must meet marine
isolation requirements. The starting motor must also
meet marine isolation requirements.
 15
Safety Section
Generator Isolating for Maintenance

For engines which have an alternator that is grounded power

to an engine component, a ground strap MUST
connect that component to the negative battery sensing
terminal and the component MUST be electrically
isolated from the engine. control

A bus bar with a direct path to the negative battery

"+"
terminal is permissible and recommended for use
for all components that require a negative "-" battery
connection. The bus bar should be directly connected
to the negative "-" battery terminal. A bonding cable
should also be connected from the cylinder block to
the bus bar on the negative "-" battery connection.
Refer to the Installation Guide for additional
information on grounding procedures.
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 audiolvisual 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
Generator Isolating for or terminals. During the entire work period, these
ground straps must remain connected to the
Maintenance conductors and to the terminals.
SMCS Code: 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.

Illustration 13

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

tag to the engine prime mover starting circuit.
Disconnect the engine starting circuit.

3. Disconnect the generator from the distribution

system.

4. Lock out the circuit breaker. Attach a "DO NOT

OPERATE or similar warning tag to the circuit
breaker. Refer to the electrical diagram. Verify
that all points of possible reverse power flow have
been locked out.

5. For the following circuitry, remove the

transformer's fuses:
Product Information Section
Model Views

Product lnformation
Section

Model Views
101580161

Model View Illustrations

SMCS Code: 1000
The model views show a typical arrangement for a
turbocharged 3056 Marine Generator Set engine.
Due to individual applications, your engine may
appear different from the illustrations.

go0820443
Illustration 14
Right side view of the 3056 Marine Generator Set Engine
(1) Expansion tank (6) Engine lifting eye (11) Fuel injection pump
(2) Valve cover (7) Engine air cleaner (12) Heat exchanger
(3) Fuel injection nozzle (8) Precleaner (13) Water temperature regulator housing
(4) Manual sump pump (9) Engine iifling eye (14) Engine oil filters
(5) Fuel filter (10) Jacket water pump

Illustration 15
Left side of 3056 Marine' Generator Set Engine
(15) Air inlet heater (17) Belt cover
(16) Turbocharger (18) Starting motor
101580187
Generator Set Description
SMCS Code: 7002
The 3054 Marine Generator Set is available as a
naturally aspirated arrangement or as a turbocharged
arrangement.
The 3056 Marine Generator Set is available as a
turbocharged arrangement.
The brushless generator is used for various marine
applications. The elimination of brushes in the
field circuit reduces maintenance with increased
reliability. Also, the elimination of brushes provides a
higher degree of protection in potentially hazardous
atmospheres. The generator set packages can be
utilized for prime power generation or standby power
generation.
17
Product Information Section
Model Views
go0820445
(19) Crankshaft vibration damper
(20) Alternator
The generators can be configured for three-phase
power or single-phase power. The generators have
full-wave excitation and regulation. The generators
have lwelve leads that can be connected in various
configurations. The generators are capable of
producing electrical power in either 50 Hz or 60 Hz
applications.
The engines are powered with direct fuel injection. A
mechanical governor controls the fuel injection pump
output in order to maintain the engine speed that is
selected by the operator.
Fuel is metered and pumped by the fuel injection
pump under high pressure to the fuel injection
nozzles (one per cylinder). The automatic timing
advance provides the best fuel injection timing over
the full range of engine speed.
The cooling system consists of the following
components:
18
Product Information Section
Model Views

A centrifugal pump that is driven by a gear Table 1

One water temperature regulator which regulates

the engine coolant temperature

Heat exchanger for the closed water circuit

. Auxiliary water pump

I Stroke 1
100.0 mm (4.00 inch)
127.0 mm (5.00 inch) I

i
Expansion tank
Aspiration
The engine lubricating oil is supplied by a gear
type pump. The engine lubricating oil is cooled on Compression ratio 16:l
models that are equipped with the optional oil cooler.
Bypass valves provide unrestricted flow of lubrication Di~~la~ement 4 L 1243 in3)
oil to the engine parts when oil viscosity is high.
Bypass valves can also provide unrestricted flow
I Firing Order 1 1-3-4-2 1
of lubrication oil to the engine parts if the oil cooler
should become plugged or if the oil filter element
Rotation that is viewed
from the flvwheel I Counterclockwise /
should become plugged. I Valve Lash Setting (Inlet) 1 0.20 mm (0.008 inch) I
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
Valve Lash Setting
(Exhaustl 1 0.45 mm (0.018 inch) I
operation and maintenance recommendations. (') The operating rpm is dependent on the engine rating and the
Engine performance and efficiency also depend on application.
the use of recommended fuels, lubrication oils, and (2) Naturally Aspirated
coolants. Refer to the Operation and Maintenance
Manual, "Maintenance Interval Schedule" for more
information on maintenance items. 3056 Marine Generator Set Engine

Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The lefl and the right side
of the engine are determined from the flywheel end.
The No. 1 cylinder is the front cylinder.

3054 Marine Generator Set Engine

go0774394
Illustration 17
(A) Exhaust valves
(6) Inlet valves
( C ) Rear of the engine
(D) Front of the engine

go0823478
illustration 16
(A) Exhaust valves
(6) Inlet valves
(C) Rear of the engine
(D) Front of the engine
 19
Product Infomlation Section
Model Views

Table 2
3056 Marine Generator Set Engine Specifications
Operating Range (rpm) 1500 to 2600m
I Number of Cviinders I 6 in-Line I
I Bore 1 100.0 mm (4.00 inch) I

I Firing Order I 1-5-3-6-24 I

Rotat~onthat is viewed
from the flvwheel I Counterclockwise I
I Valve Lash Setting (inlet) 1 0.20 mrn (0.008 inch) I
Valve Lash Setting
(Exhaust)
1 0.45 mm (0.018 inch)
I
(11The operating rpm is dependent an the engine rating and the
application.
(2)Turbocharged
20
Product lnformation Section
Product ldentification Information

Product ldentification When service is required, the information that is

given on this plate should be used. The generator
lnformation identification and information plate includes the
following information: serial number, winding
information, and the frame size of the generator set.
101028428

Engine ldentification i00722073

SMCS Code: 1000 Serial Number Plate II

Caterpillar engines are identified with serial numbers, SMCS Code: 1000 1
with performance specification numbers, and with
arrangement numbers. In some of the cases,
modification numbers are used. These numbers
are shown on the Serial Number Plate and the
lnformation Plate that are mounted on the engine.

Caterpillar dealers need these numbers in order to

determine the components that were included with
the engine. This permits accurate identification of NUMBER
replacement part nuinbers.

101595829

Generator ldentification ..
SMCS Code: 1404

The Serial Number Plate is located on the left side of

the cylinder block near the rear of the engine.

The following information is stamped on the Serial I

Number Plate: engine serial number, model, and
arrangement number.

101441466

lnformation Plate
SMCS Code: 1000

CAT sER. ENCllit MODEL

M I X U1
FULL LOAD
RPY IIDTdTIOH

FUEL P"YP/CIV
AR NO.
900827063 INJECTOR
Illustration 18
B l l l i TWO
(1) Locationof the generator identification plate and the information HI IDLE RPY lURB0

plate
POWER w L I

The generator set consists of the engine and

generator. The location of the generator identification
and information plate is shown in illustration 18.
 21
Product lnformation Section
Product Identification lnformation

The lnformation Plate is on the valve cover. The 102212299

following information is stamped on the lnformation
Plate: engine's maximum altitude, horsepower, high Generator Lead Connections
idle, full load rpm, fuel settings, and other information.
SMCS Code: 4450

101592590
Lead Numbering
Reference Numbers
SMCS Code: 1000

lnformation for the following items may be needed to

order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.

Record for Reference

Engine Model

Engine Serial Number

Engine Arrangement Number

Modification Number

Engine Low Idle rpm gO0661863

Illustration 21
Engine Full Load rpm 12 Lead Wye Configuration for High Voltage
Terminals T10, T11, and T I 2 become a neutral connection when
Part Number for the Primary Fuel Filter the terminals are tied together.

Part Number for the Water Separator Element

Part Number for the secondary Fuel Filter Element

Part Number for the Lubrication Oil Filter Element

Total Lubrication System Capacity

Total Cooling System Capacity

Part Number for the Air Cleaner Element

'
Part Number for the Fan Drive Belt

Part Number for the Alternator Belt

Model Number of the Generator

Illustration 22 g00611608
Serial Number of the Generator
) 12 Lead Wye Configuration for Low Voltage
Arrangement Number of the Generator Terminals T4, T5, T6, T10. T I 1 and T I 2 become a neutral
connection when the terminals are tied together.
Part Number for the Control Panel
LL
Product Information Section
Product Identification lnformation
Illustration 23 ,
go0669312
12 Lead Delta Configuration
Terminals T6 and T9 become a neutral connection when the
terminals are tied together and tne term'nals are groundea. This
reflects tne terminal T2 ana T I 0 connection as the h:gn phase.
Grounding the Frame
In any generator set installation, the frame of the
generator must be positively connected to an earth
ground or to the hull of a vessel. This connection is
the first connection that is made at the installation.
This connection is the last connection that should be
removed. If the generator set is on flexible mounting
pads, 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 canying 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 ioints eventuallv oxidize. The ioints are
frequent sources of radio iequency inteierence
(RFI). Joints that are silver soldered and bolted are
preferred.
Neutral Connections
The generators with a Wye Configuration usually
have the neutral ground when the generator is
installed. Grounding the neutral is for preventing
damage to equipment.
If the neutral wire is grounded and one of the phase
leads becomes grounded, the excessive current
will open a load circuit breaker. Also, the excessive
ai,I
..
current will cause the generator voltage to collapse.
The result depends on the following items: electrical
characteristics of the generator, 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 cases when the neutral wire is not
grounded. An ungrounded generator neutral lead is
acceptable when the possibility of grounds to the
phase leads has been eliminated. An example of
such measures are ground fault protective circuits.
Ground fault protection requires the entire.group
of distribution circuits to be treated as a system.
The owner should contact a certified consultant if
a new distribution system is being developed. The
owner should also contact a certified consultant if an
existing system should be modified for the ground
fault protection.
Single Units
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
Be sure to check your local wiring codes.
101592415
Voltage Connections
SMCS Code: 4450
The three voltage connections that are available are
shown in the following diagrams.
The terminals must be connected securely. The
terminals must also be insulated with a good quality
electrical taDe.
 23
Product lnformation Section
P r o d u c t Identification lnformation

go0637319 g00626130
illustration 24 Illustration 26
Typical Series Wye Configuration at 60 Hz with 12 Leads Typical Delta Configuration at 60 Hz with 12 Leads
This is a typical high voltage connection.

go0637320
Illustration 25
Typical Parallel Wye Configuration at 60 Hz with 12 Leads
Operation Section
Lifting and Storage

Operation Section Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
andlor the engine make the lifling eyes and the lifting
fixtures obsolete. If alterations are made, ensure
Lifting and Storage that proper lifting devices are provided. Consult your
- -
Cater~illardealer for information regarding fixtures
for proper engine lifting.
i02196315

Product Lifting Generator Set

SMCS Code: 1000; 1404; 7002 NOTICE
Do not use the engine lifting eyes to remove the en-
Engine Only gine and generator together.

A lifting plate is provided with the package generator

set. Instructions for lifting the package generator set
are stamped on the lifting plate.

Consult your Caterpillar dealer for information

regarding proper fixtures and lifting devices.

A countemeight can be added between the package

frame rails whenever the application requires frequent
relocation of the unit. For complete information about
adding the countelweight, consult your Caterpillar
dealer.

g00103219
Illustration 27
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets undertension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes 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.
The single point lifting eye is secured from the
factory before the enclosure is shipped. The correct
orientation of the single point lifting eye will allow you
to look through the eye when you stand at the side of
the enclosure. The lifting eye may stretch when the
package is lifted. This may cause the locking nuts
to loosen. This could cause the lifting eye to swivel.
Ensure that the lifting eye is correctly oriented on the
packaged generator set. Ensure that the lifting eye
is tightened to the'correct torque before you lift the
packaged generator set.

Use a hoist to remove heavy components. Use

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

Some removals require lifting fixtures in order to

obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.
 25
Operation Section
Lifting and Storage

- Product Storage
SMCS Code: 1000; 1404; 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. See this Operation and Maintenance
Manual, "Refill Capacities and Recommendations"
(Maintenance Section).

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 one.month,
a complete protection procedure is recommended.

Your Caterpillar dealer will have instructions for

preparing the engine for extended storage periods.

For more detailed information on engine storage, see

Special Instruction, SEHS9031, "Storage Procedure
for Caterpil!ar Products".

Generator Storage
For information on generator storage, see the
literature that is provided by the OEM of the
generator. Consult your Caterpillar dealer for
assistance.
26
Operation Section ,
Installation

Installation Electrical Measurements

Measure the insulation resistance of each winding
101593490 if the generator was exposed to the following
conditions:
Generator Set Installation
SMCS Code: 7002
. Rapid changes in temperature

Freezing
Receiving Inspection
Wet climate during shipment
If the generator is received during cold weather,
allow the unit to reach room temperature before you Wet climate during storage
remove the protective packing material. Warming
the generator to room temperature will prevent the Note: These tests should be conducted prior to
following problems: any power connections that are being made. These

- Water condensation on cold surfaces

tests should be conducted prior to completing any
connections of controls.

Early failures due to wet windings
Early failures due to wet insulating materials
Bearing lnspection
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
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:
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)
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. Fuses should be sized
by using the lowest possible current rating. However,
this rating must be above the current rating for full
load. A common recommendation is 115 percent
of rated current. Determine the size of fuses or
determine the size of circuit breakers in accordance
with NEMA, IEC, and Local Electrical Codes.

Clean

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.
 27
Operation Section
Features and Controls

Features and Controls

Control Panel
SMCS Code: 7451

There are three control panels that are available for

the generator set. The standard control panel has
mechanical gauges and an electronic control with
indicators. This panel does not have a digital display.

The premium control panel does not have any

mechanical gauges. This panel has a digital display.
The gauges are included in the electronic control
and the gauges are digital. The MCS control panel
does not have any mechanical gauges. This panel
has a digital display. The gauges are included in the
electronic control and the gauges are digital. The
operation of the three control panels are described
below.

Standard Control Panel

Note: TYPE 1 & 2
28
Operation Section
Features and Controls

0 0 0 0
Illustration 28 g008274;

Standard control panel (Type 1)

(1) Temperature gauge ( 5 ) DC voltmeter
(2) Oil pressure gauge (6) Horn
(3) Control module (generator set) (7) Emergency stop push button
(4) Hour meter (8) Alarm silence switch

Illustration 29
Standard control panel (Type 2)
(1) Temperature gauge
(2) Oil pressure gauge
(3) Control module (generator set)
(4) Hour meter
(5) D C voltmeter
(6) Horn
(7) Emergency stop button
(8) Alarm silence switch
-
Temperature Gauge (1) The water temperature
gauge (WTG) shows the engine water temperature.
The engine should operate within the range of 78 "C
(172 OF) to 90 "C (194 OF). The water temperature
may vary according to load. However, the water
temperature should never exceed the boiling
temperature for the pressurized system that is being
used. The water temperature is regulated by the
engine thermostats in the system. Do not operate the
engine if no thermostats are installed on the engine.
If the engine is operating and a high water
temperature reading is observed, perform the
following steps:
Reduce the load.
Inspect the engine for coolant leaks.
- lnspect the engine for a plugged radiator.
Determine if the engine should be shutdown.
29
Operation Section
Features and Controls
The WTG is powered whenever the engine is
operating. The value which is shown on the WTG
is proportional to the flow of current through the
VVTG. The current flow is controlled by the resistance
of the water temperature sending unit (WTSU).
As the water temperature changes there is a
corresponding change in the resistance of the WTSU.
A corresponding change is shown in the value on
the WTG.
Note: If the WTSU is not fully submerged because of
low water level, the temperature reading will be false.
Oil Pressure Gauge (2) -The oil pressure gauge
(OPG) shows engine oil pressure. The oil pressure
will be greatest after a cold engine is started. Oil
pressure will decrease as the engine is idling. As
the engine speed is increased to full load speed, oil
pressure will increase and oil pressure will stabilize.
Normal operating engine oil pressure should be
290 kPa (42 psi) to 448 kPa (65 psi) when the
engine is running at rated engine speed. The SAE
10W-30 oil should be at 93 "C (199.4 OF) to 125 "C
(257 "F) operating oil temperature. The engine water
operating temperature should be normal. A lower
pressure of 186 kPa (27 psi) to 344 kPa (50 psi) is
normal at low idle speed. .
If the gauge reading is fluctuating and the load has
become stable, perform the following steps:
. Remove the load.
Check and maintain oil level.
The OPG is powered whenever the engine is
operating. The value that is shown on the OPG is
proportional to the flow of current through the OPG.
The current flow is controlled by the resistance of the
oil pressure sending unit (OPSU). As the oil pressure
changes, there is a corresponding change in the
resistance of the OPSU. Therefore, a corresponding
change in the value is shown on the OPG.
Generator Control Module (3) -See Systems
Operation, RENR5854 or Systems Operation,
RENR5855 for more information on programming
the indicators.
-
Hour Meter (4) The service hour meter shows
the total operating hours of the engine. The meter is
powered whenever the engine is operating.
DC Voltmeter (5) -The DC voltmeter (VM) shows
the voltage of the starting system.
Horn (6) -The horn activates when one of the fault
indicators is illuminated. The horn can be silenced by
pressing the alarm silence switch.
30
Operation Section
Features and Controls

Emergency Stop Push Button (7) The -

emergency stop push button (ESPB) is used to shut
down the engine during an emergency situation. The
ESPB shuts off the fuel.

Alarm Silence Switch (8) -The alarm silence

switch is used in conjunction with the hom. The alarm
silence switch silences the horn.

Standard Control Module

Note: TYPE 1 & 2

Illustration 30
Standard control module (Type 1)
(9) Programmable indicators
(10) lndicator for a remote start signal that
is present
(11) indicator for oil pressure
(12) Indicator for coolant temperature
(13) Indicator for engine overspeed
, (14) lndicator for engine overcrank
(15) Indicator for emergency stop
(16) indicator for alarm
(17) Automatic stalt position
(18) M a n ~ astan
l pos't on
(19) Engine control swdch
(20) Stop (Reset) position
 31
Operation Section
Features and Controls

I I

illustration 31 go1110812

Standard control module (Type 2)

(9) Programmable indicators
(10) Indicator for a remote start signal that
is present
(11) Indicator for oil pressure
(12) indicator for coolant temperature
(13) indicator for engine overspeed
(14) Indicator for engine overcrank
(15) Indicator for emergency stop
(16) Indicator for alarm
(17) Automatic start position
(18) Manual start position
(19) Engine control switch
(20) Stop (Reset) position

The control panel has six indicators that correspond to
certain fault conditions. An indicator illuminates when
the corresponding problem exists. Each indicator has
a label that identifies the corresponding condition.
The ECS must be turned to the OFFIRESET position
in order to turn OFF the indicators. The ECS must
be turned to the OFFIRESET position in order to
reset the control panel. The control panel has four
indicators that are spare indicators.
lndicator For Coolant Temperature (12) -This
indicator lights when the engine water temperature
has risen above the upper limit of the water
temperature switch (WTS).
lndicator For Engine Overspeed (13) -This
indicator lights when the control board has
determined that the engine speed has exceeded the
overspeed setpoint.

-
Programmable Indicators (9) The control panel
has four indicators that are spare indicators. These
indicators can be programmed in order to alert the
operator to various conditions. See the Systems
Operation, RENR5854 and Systems Operations,
RENR5855 for more information on programming
the indicators.
Indicator For Engine Overcrank (14) This -
indicator lights when the engine fails to start after
exceeding the limit for cranking.
Indicator For Emergency Stop (15) -This indicator
lights when the control module has determined that
the emergency stop push button has been pressed.

Indicator For Remote Start Signal (10) -This
indicator is resewed. This indicates that the remote
start signal is present.
Indicator For Oil Pressure (11) -This indicator
lights when the engine oil pressure has fallen below
the low limit of the engine oil pressure switch (OPS).
Indicator For Alarm (16) -This indicator lights when
the control module has received any signals that
have been programmed to light the alarm indicator.
When the alarm indicator is ON, the problem is a
warning. When the alarm indicator is flashing, the
problem is a shutdown fault.
32
Operation Section
Features and Controls

If the circuit for the oil pressure switch has failed, the
alarm indicator will illuminate. This is not a warning
of low oil pressure. The indicator for low oil pressure
illuminates when the pressure is low.

If the generator fails to stop after the cooldown

period, the alarm indicator will illuminate. The control
module determines that the generator is stopped
when the oil pressure is low and the engine speed
sensor indicates that no speed exists.

If the signal from the speed sensor fails during

cranking, the generator will shut down. The alarm
indicator will illuminate.

Automatic Start Position (17) -When the ECS

is in the AUTOMATIC position, the engine will start
automatically whenever the remote initiating contact
is closed. When the ECS is in the AUTOMATIC
position, the engine will shut down automatically
whenever the remote initiating contact is open.

Manual Start Position (18) -When the ECS is in

the MANUAL START position, the engine will start.
The engine will run while the ECS remains in this
position.

Engine Control Switch (19) -The engine control

switch (ECS) selects the status of the control panel.

Stop Position (Reset) (20) -When the ECS is in

the OFFIRESET position, the fault indicators are
reset and the engine shuts down immediately.

Premium Control Panel

Note: TYPE 1 & 2
 33
Operation Section
Features and Controls
34
Operation Section
Features and Controls

illustration 33 go1110860

Premium control panel (Type 2)

(1) Control module with display
121
~ -Horn
,
~

(3) Emergency stop button

(4) Alarm s:lence switch

Premium Control Module With display(l) - The

control module controls the functions of the generator
set.

Horn (2) -The horn activates when one of the fault

indicators is illuminated. The horn can be silenced by
pressing the alarm silence switch.

Emergency Stop Push Button (3) The -

emergency stop push button (ESPB) is used to shut
down the engine during an emergency situation. The
ESPB shuts off the fuel.

Alarm Cancel Switch (4) -The alarm silence switch

is used in conjunction with the horn. The alarm
silence switch silences the horn.

Premium Control Module With Display

Note: TYPE 1 & 2
 35
Operation Section
Features and Controls

go0827469
Illustration 34
Premium control module with display (Type 1)
(5) UP key (11) Mode select key (17) Stop key (reset)
161 DOWN kev 1121Indicator for the information mode 1181Start kev
i 7 i Disolav a k a i13i Indicator for the alarm mode
~ ~ ~~~ i19i
~ ~, Manual
~ - - mode
- - - kev
i 8 j ~r&dmmable indicators i14j lnoicator for the engine status mode (20) A~tomalicmodeiey
(9) Inoicator for alarm (15) In0 cator for the generator status mode (21) -amp test key
(10) Indicator for the contgJraton mooe (16) Inoicato: for tne event log mode
36
Operation Section
Features and Controls

go1110878
Illustration 35
Premium control module wi!h display (Type 2)
(5) UP key (11) Mode select key (17) Stop key (reset)
(6) DOWN key (12) Indicator for the information mode .
(18) Start key
171
~ , Disolav
- - . ~area
~~, ~~
1131 Indicator for the alarm mode 1191 Manual mode kev
(8) Programmable indicators i14j Indicator for the eng'ne statLs mode i20j A~tomaticmooe key
(9) Indicator for alarm (15) Indicator for tne generator s1att.s mode (21) Lamp test key
(10) Indicator for the ConflgLraton mooe (16) Indicator forthe event log mode

The control module with a display is operated by
keys on the panel. The four keys at the bottom of
the module (17), (18), (19), and (20) control the
starting of the generator set and the stopping of the
generator set. Three smaller keys (5),(6), and (11)
allow the operator to access additional information
about the generator set. This information is shown
on the display (7).
UP Key (5) -When the UP key is pressed, the
display area will scroll upward.
Programmable Indicators (8) -The programmable
indicators are available for use by the customer. See
Systems Operation, RENR5855 for more information
on programming the indicators.
Alarm lndicator (9) -The alarm indicator lights for
several different reasons. When the alarm indicator
is ON, the problem is a warning. When the alarm
indicator is flashing, the problem is a shutdown fault.
When any alarm occurs, the display changes to the
Alarm Mode.

DOWN Key (6) -When the DOWN key is pressed,

the display will scroll downward.

-
Display Area (7) The display area shows
information about the generator set.

Operator Configuration Mode Indicator (10) -The
operation configuration mode indicator illuminates
when the module is in the configuration mode.
When the UP key and the DOWN key are pressed
together, the module enters the configuration mode.
The language can be changed. The contrast of the
display can be adjusted.
Mode Select Key (11) -The mode select key
changes the mode of the display area. When a mode
is active, the indicator above the appropriate symbol
(12), (13), (14), (15) or (16) is illuminated.
Information Mode Indicator (12) -The information
mode is active when the information mode indicator
is illuminated. This is the normal mode for the
display area. The display indicates the status of the
generator. An example is "GENERATOR AT REST".
If the display is in another mode, the dispiay will
automatically change back to the information mode
after a set period of inactivity.
Alarm Mode lndicator (13) -The alarm mode is
active when the alarm mode indicator is illuminated.
The display shows the information for any active.
alarms. An example is "SHUTDOWN LOW OIL
PRESSURE".
Engine Status Mode Indicator (14) -The engine
status mode is active when the engine status mode
indicator is illuminated. The display shows the
information regarding the engine. An example is
"ENGINE SPEED and "OIL PRESSURE".
Generator Status Mode lndicator (15) The -
generator status mode is active when the generator
status mode indicator is illuminated. The display
shows the information reaardina the aenerator.
An example is "GENERAYOR ~ O L T ~ Gand E below the setting for low oil pressure (warning), the
"GENERATOR CURRENT'.
Event Log Mode Indicator (16) -The event log
mode is active when the event log mode indicator
is illuminated. The display shows the information
regarding the last 25 alarms (shutdown). In the
memory, older alarms are replaced by newer alarms.
Stop Key (Reset) (17) -The stop key shuts down
the engine when the engine is running.
Start Key (18) -The start key begins the starting
sequence. The control module must be in the manual
mode in order for the start key to function.
Manual Mode Key (19) -The manual mode key is
used to start the generator. After the manual mode
key is pressed, the generator will be in the manual
mode. In this mode, when the start key is pressed
the engine will start.
37
Operation Section
Features and Controls
-
Automatic Mode Key (20) The auto key places
the generator in the automatic mode. When the
generator is in the automatic mode, the engine will
start after receiving a signal for remote starting.
Alarm Mute Key (21) -The alarm mute key turns
off the alarm.
Warnings
"WARNING CHARGE ALT FAILURE" If the -
control module does not detect voltage from the
alternator, the display will show "WARNING CHARGE
ALT FAILURE". The alarm indicator will illuminate.
"WARNING LOW BATTERY VOLTAGE" -
If the
control module detects voltage from the alternator
that is below the setting for low voltage, the display
will show "WARNING LOW BATTERY VOLTAGE".
The alarm indicator illuminates.
"WARNING HlGH BATTERY VOLTAGE" -
If the
control module detects voltage from the alternator
that is above the setting for high voltage, the display
will show "WARNING HlGH BATTERY VOLTAGE".
The alarm indicator illuminates.
-
"FAIL TO STOP" If the control module determines
that the signal from the oil pressure sender indicates
that the engine is running but the engine should not
be running, the display will show "FAIL TO STOP".
The alarm indicator illuminates. Also, the control
module can be configured in order for the engine to
start only if the signal that is from the oil pressure
sender indicates that the pressure is low.
-
"WARNING LOW OIL PRESSURE" If the control
module detects engine oil pressure that has fallen
display will show "WARNING LOW OIL PRESSURE".
The alarm indicator illuminates. This warning is only
active after the engine has exceeded the Safety On
Timer.
-
"WARNING HlGH COOLANT TEMP" If the control
module detects engine cooiant temperature that has
exceeded the setting for high cooiant temperature
(warning), the display will show "WARNING HlGH
COOLANT TEMP". The alarm indicator iiluminates.
This warning is only active after the engine has
exceeded the Safety On Timer.
-
"WARNING OVERSPEED" If the engine speed
exceeds the setting for engine overspeed (warning),
the dispiay will show "WARNING OVERSPEED". The
alarm indicator iiluminates.
38
Operation Section
Features andcontrols
-
"WARNING UNDERSPEED" If the engine speed
is below the setting for the engine underspeed
(warning), the display will show "WARNING
UNDERSPEED". The alarm indicator illuminates.
This warning is only active after the engine has
exceeded the Safety On Timer.
"WARNING GENERATOR HlGH FREQUENCY"
If the control module detects a output frequency
for the generator that exceeds the setting for high
generator frequency (warning), the display will show
"WARNING GENERATOR HlGH FREQUENCY". The
alarm indicator illuminates.
"WARNING GENERATOR LOW FREQUENCY"
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (warning), the display will show
"WARNING GENERATOR LOW FREQUENCY. The
alarm indicator illuminates.
"GENERATOR HlGH VOLTAGE WARNING" - "SHUTDOWN UNDERSPEED" If the engine -
If the control module detects a output voltage for
the generator that exceeds the setting for high
generator voltage (warning), the display will show
"GENERATOR HlGH VOLTAGE WARNING". The
alarm indicator illuminates.
"GENERATOR LOW VOLTAGE WARNING" - "SHUTDOWN GENERATOR HlGH
If the control module detects a output voltage for
the generator that is less than the setting for low
generator voltage (warning), the display will show
"GENERATOR LOW VOLTAGE WARNING". The
alarm indicator illuminates.
"MAINTENANCE DUE ALARM" Maintenance-
intervals can be programmed into the control module.
When the hour meter reaches a maintenance setting,
the display will show "MAINTENANCE DUE ALARM".
The alarm indicator illuminates.
Shutdowns
-
"SHUTDOWN FAlL TO START" If the engine
does not start after a preset number of attempts, the
display will show "SHUTDOWN FAlL TO START".
The alarm indicator will flash.
"SHUTDOWN EMERGENCY STOP" If the -
voltage signal at the input for the emergency stop is
disconnected, the display will show "SHUTDOWN
EMERGENCY STOP". The generator set will not
start until the emergency stop push button has been
reset. Power is removed from the fuel solenoid and
the starter solenoid. The alarm indicator will flash.
"SHUTDOWN LOW OIL PRESSURE" If the -
control module detects engine oil pressure that
has fallen below the setting for low oil pressure
(shutdown), the display will show "SHUTDOWN LOW
OIL PRESSURE. The alarm indicator will flash. This
warning is only active after the engine has exceeded
the Safety On Timer.
-
"SHUTDOWN HlGH COOLANT TEMP" If the -
control module detects engine coolant temperature
that has exceeded the setting for high coolant
temperature (shutdown), the display will show
"SHUTDOWN HlGH COOLANT TEMP". The alarm
indicator will flash. This warning is only active after
- the engine has exceeded the Safety On Timer.
-
"SHUTDOWN OVERSPEED" If the engine speed
exceeds the setting for engine overspeed (shutdown),
the display will show "SHUTDOWN OVERSPEED".
The alarm indicator will flash.
speed falls below the setting for the engine
underspeed (shutdown), the display will show
'
"SHUTDOWN UNDERSPEED". The alarm indicator
will flash. This warning is only active after the engine
has exceeded the Safety On Timer.
-
FREQUENCY" If.the control module detects a
output frequency for the generator that exceeds the
setting for high generator frequency (shutdown), the
display will show "SHUTDOWN GENERATOR HlGH
FREQUENCY". The alarm indicator will flash.
"SHUTDOWN GENERATOR LOW FREQUENCY" -
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (shutdown), the display will show
"SHUTDOWN GENERATOR LOW FREQUENCY".
The alarm indicator will flash.
"GENERATOR HlGH VOLTAGE SHUTDOWN" -
If the control module detects a output voltage for
the generator that exceeds the setting for high
generator voltage (shutdown), the display will show
"GENERATOR HlGH VOLTAGE SHUTDOWN". The
alarm indicator will flash.
"GENERATOR LOW VOLTAGE SHUTDOWN" -
If the control module detects a output voltage for
the generator that is less than the setting for low
generator voltage (shutdown), the display will show
"GENERATOR LOW VOLTAGE SHUTDOWN. The
alarm indicator will flash.
 39
Operation Section
Features and Controls

"OIL PRESSURE SENDER OPEN CIRCUIT" If -

the control module detects an open circuit in the
wiring for the oil pressure sender, the display will
show "OIL PRESSURE SENDER OPEN CIRCUIT".
The alarm indicator will flash. The shutdown is
immediate.

-
"GENERATOR EARTH FAULT" If the control
module detects current that exceeds a limit that
has been programmed and the control module
determines that a short to ground exists, the display
will show "GENERATOR EARTH FAULT". The alarm
indicator will flash.

"GENERATOR PHASE SEQUENCE WRONG" -

If the control module detects a problem with the
phase rotat~onof the generator, the display will show
"GENERATOR PHASE SEQUENCE WRONG". The
alarm indicator will flash.

-
"AUXILIARY INPUTS" If an auxiliary input has
been configured to shut down the engine, the display
will show the message that has been programmed.
The alarm indicator will flash.

MCS Control Panel

Note: TYPE 1 & 2 Illustration 36
MCS Control Panel (Type 1)
(1) Shutdown override key switch
(2) Emergency stop push button
(3) Horn
(4) Control module with dlsplay
40
Operation Section
Features and Controls

Illustration 37
MCS Control Panel (Type 2)
(1) Shutdown override key switch (3) Horn
(2) Emergency stop push button (4) Control module with display

Shutdown Override Key Switch (1) -This should
be switched to the off position for normal use and the
key should be removed for safe keeping. Activation,
of this key switch will enable the engine to continue
to run even when a shutdown signal is received.
Emergency Stop Push Button (2) The -
emergency stop push button (ESPB) is used to shut
down the engine during an emergency situation. The
ESPB shuts off the fuel.
Horn (3) -The horn activates when one of the
faults (alarm or shutdown signal) is received by
the contraller and the fault is indicated with text on
the controller display. The horn can be silenced by
pressing the ACK or the acknowledge button on the
controller.
MCS Control Module With Display (4) -The
control module controls the functions of the generator
set.
SEBU7577-01 41
Operation Section
Features and Controls

Illustration 38
MCS Control Module With Display (Type 1)
(5)Alarm indication Light REDfor Shutdown. (12) Mode key (19) lndicator l:ght for alarm inhibit
'
GREEN for Alarm (13) Indicator light for control in automatic (20) Control er statLs inaicator light
(6) information key mode (21) Control er power inoicator l~ght
(7) Alarm acknowledge key (14) Back key (22) Menu navigation key UP
(8) Start key (15) Lamp test key (23) Menu navigation key LEFT
(9) Stop key (reset) (16) Menu navigation key DOWN (24j Jump key -
(10) Indicator light for engine running (17) Menu select key (25) Log key
(11) Generator status indicator light (18) Menu navigation key RiGHT (26) Display area
42
Operation Section
Features and Controls

I
Illustration 39
MCS Control Module Display (Type 2)
(5)Alarm Indication Light RED for Shutdown, (12) Mode key (19) Indicator light for alarm inhibit
GREEN for Alarm (13) Indicator light for control in automatic (20) Controller status indicator light
(6) Information key mode (21) Controller power indicator light
(7) Alarm acknowledge key (14) Back key (22) Menu navigation key UP
(8) Start key (15) Lamp test key (23) Menu navigation key LEFT
(9) Stop key (reset) (16) Menu navigation key DOWN (24) Jump key
(10) Indicator light for engine running (17) Menu select key (25) Log key
(11) Generator status indicator light (18) Menu navigation key RIGHT (26) Display area

The control module with a display is operated by keys
on the panel. Three keys (8, 9, and 12) control'the
starting and the stopping of the generator set. Other
keys (6, 14, 16, 17, 18, 22, 23, 24, and 25) allow
the operator to access additional information about
the generator set. This information is shown on the
display (26) .
-
Alarm lndication Light (5) LED flashing indicates
that unacknowledged alarms are present. LED fixed
light indicates that ALL alarms are acknowledged.
RED LED for Shutdown, GREEN LED for Alarm
Alarm Acknowledge Key (7) -When the alarm
indication light is illuminated an alarm will be
displayed in the Display Area. Pressing the alarm
acknowledge key will stop the Alarm lndication light
from flashing to show that the alarm is still present,
but it has been acknowledged. If more than one
alarm is present, the process will be repeated with
the alarm to continue to flash until all alarms have
been acknowledged. All alarms are retained in the
event log list. The list holds 100 events. These events
are erased when the main unit is switched off.

lnformation Key (6) -Shifts the display 3 lower

-
Start key (8) The start key begins the starting
sequence. The control module must be in the manual
lines to show the alarm list (up to 30 alarms can be mode in order for the start key to function, with Auto
in the list). Light (13) not illuminated. To switch off the Auto light,
press Mode key (12).
Ik'
Stop key (reset) (9) -The stop key shuts down the
engine when the engine is running.

Indicator Light for Engine Running (10) - Light I

indicates that the generator is running. I

'
-
Generator Status lndicator Light (11) Light
indicates that the voltage/frequency is present and
OK.
-
Mode Key (12) Switches mode between LOCAL
START and STOP control and AUTO (REMOTE)
START and STOP control. Light (13) is illuminated
for AUTO control.
lndicator Light for Control In Automatic Mode
(13) -The light illuminated through operation of
Mode key (12)
I Back Key (14) -Jumps one step backwards in the
menu (to previous display or to the entry window).
-
Lamp Test Key (15) Illuminates all seven lights
while the key is pressed, only to show lights are
functioning correctly.
Menu Navigation Key DOWN (16) -Decreases the
value of the selected set point (in the setting menus).
In the daily use'display it is used for scrolling the
second line that displays the generator values.
-
I
(1
Menu Select Key (17) Is used to select the chosen
function iunderscored selection in the lower line of
the display).
-
Menu Navigation Key RIGHT (18) Moves the
cursor right to maneuver in the menus
lndicator Light for Alarm Inhibit (19) -Light once
illuminated will indicate that the inhibit input is ON.
Controller Status lndicator Light (20) -Light
when illuminated indicates that the unit is running
a self-check and is OK.
Controller Power lndicator Light (21) Light-
indicates that the auxiliary DC battery supply is
switched on.
Menu Navigation Key UP (22) -Increases the
value of the selected set point (in the setting menus).
In the daily use display it is used for scrolling the
second line displaying of generator values.
I Menu Mavigation Key LEFT (23) -Moves the
cursor to the left for maneuvering in the menus.'
-
Jump Key (24) Enter a menu number selection.
All settings have a specific number attached to the
settings. Using the JUMP button enables the user to
select and display any setting without navigating all
(@ the way through the menus.
-
Log Key (25) Shifts the display three lower lines
to show the event and alarm list. The list holds 100
events. These events are erased when the main unit
is switched off.
43
Operation Section
Features and Controls
Display Area (26) -The display area shows
information about the generator set.
Warnings
"WARNING BATTERY VOLTAGE" - If the control
module detects voltage from the alternator that is
below the setting for low voltage, the display will show
"BATTERY LOW V". The alarm indicator illuminates,
and an audible alarm is activated.
"WARNING CHARGE ALT FAILURE" If the -
control module does not detect voltage from the
alternator, the display will show "Flu FAILURE. The
alarm indicator will illuminate, and an audible alarm
is activated.
-
"FAIL TO STOP" If the control module determines
that the signal from the oil pressure sender indicates
thatthe engine is running but the engine should not
be running, the display will show "STOP FAIL". The
alarm indicator illuminates, and an audible alarm is
activated.
-
"WARNING LOW OIL PRESSURE" If the control
module detects engine oil pressure that has fallen
below the setting for low oil pressure (warning),
the display will show "LOW OIL PRESS". The
alarm indicator illuminates, and an audible alarm is
activated. Thiswarning is only active after the engine
has exceeded the Safety On Timer.
-
IIWARNING HlGH COOLANT TEMP" If the control
module detects engine coolant temperature that has
exceeded the setting for high coolant temperature
(warning), the display will show "HIGH ENGINE
TEMP". The alarm indicator illuminates, and an
audible alarm is activated. This warning is only active
after the engine has exceeded the Safety On Timer.
-
"WARNING OVERSPEED" If the engine speed
exceeds the setting for engine overspeed (warning),
the display will show "OVERSPEED". The alarm
indicator illuminates, and an audible alarm is
activated.
"WARNING GENERATOR HlGH FREQUENCY" -
If the control module detects a output frequency
for the generator that exceeds the setting for high
generator frequency (warning), the display will show
"Flu FAILURE. The alarm indicator illuminates, and
an audible alarm is activated.
"WARNING GENERATOR LOW FREQUENCY" -
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (warning), the display will show
"Flu FAILURE". The alarm indicator illuminates, and
an audible alarm is activated.
44
Operation Section
Features and Controls
"GENERATOR HlGH VOLTAGE WARNING If - "WATER IN FUEL ALARM OPTIONAL" If the
the control module detects a output voltage for the
generator that exceeds the setting for high generator
voltage (warning), the display will show "OVER
VOLTAGE. The alarm indicator illuminates, and an
audible alarm is activated.
"GENERATOR LOW VOLTAGE WARNING" -
If the control module detects a output voltage for
the generator that is less than the setting for low
generator voltage (warning), the display will show
"UNDER VOLTAGE. The alarm indicator illuminates,
and an audible alarm is activated.
"LUB OIL HlGH TEMPERATURE ALARM" - If the
control module detects a lube oil high temperature in
excess of 120 degrees centigrade for four cylinder
engines and in excess of 130 degrees centigrade for
six cylinder gensets (warning), the display will show
"LUB OIL HIGH. The alarm indicator illuminates.
-
"SHUTDOWN OVERRIDE" If the control module
detects shutdown override when the shutdown
override key switch has been switched on (warning),
the display will show "SID OVERRIDE". The alarm
indicator illuminates, and an audible alarni is
activated.
"STARTING AIR PRESSURE LOW ALARM
-
OPTIONAL" If the control module detects low
starting air pressure (warning), the display will show
"START AIR P LOW". The alarm indicator illuminates,
and an audible alarm is activated.
"GENERATOR WINDING OR BEARING OVER
TEMPERATURE ALARM OPTIONAL" If the . - afler the engine has exceeded the Safety On Timer.
control module detects a generator bearing over
temperature (warning), the display will show "GEN
BRG OVER TEMP". The alarm indicator illuminates,
and an audible alarm is activated.
"EXTERNAL FUEL TANK LEVEL ALARM
-
OPTIONAL" If the control module detects that
an external fuel tank level is below a desired level
(warning), the display will show "EXT FUEL T LOW".
The alarm indicator illuminates, and an audible alaml
is activated.
"HIGH EXHAUST TEMPERATURE ALARM
-
OPTIONAL" If the control module detects that
a high exhaust temperature (warning), the display
will show "HIGH EXH TEMP. The alarm indicator
illuminates, and an audible alarm is activated.
"HIGH PRESSURE FUEL LEAK ALARM
-
OPTIONAL" If the control module detects that
a high pressure fuel leak (warning), the display
will show "H P FUEL LEAK". The alarm indicator
illuminates, and an audible alarm is activated.
-
control module detects that a water in fuel signal
(warning), the display will show "WATER IN FUEL".
The alarm indicator illuminates, and an audible alarm
is activated.
Shutdowns
-
"SHUTDOWN FAIL TO START" If the engine
does not start afler a preset number of attempts, the
display will show "Flu FAIL". The alarm indicator will
flash, and an audible alanil is activated.
"SHUTDOWN EMERGENCY STOP" If the -
voltage signal at the input for the emergency stop is
disconnected, the display will show "E-STOP". The
generator set will not start until the emergency stop
push button has been reset. Power is removed from
the fuel solenoid and the starter solenoid. The alarm
indicator will flash, and an audible alarm is activated.
"SHUTDOWN LOW OIL PRESSURE" If the -
control module detects engine oil pressure that
has fallen below the setting for low oil pressure
(shutdown), the display will show "LOW 0 P
SIDOWN". The alarm indicator will flash, and an
audible alarm is activated. This warning is only active
after the engine has exceeded the Safety On Timer.
"SHUTDOWN HlGH COOLANT TEMPERATURE" -
If the control module detects engine coolant
temperature that has exceeded the setting for high
coolant temperature (shutdown), the display will show
"HET SIDOWN. The alarm indicator will flash, and an
audible alarm is activated. This warning is only active
-
"SHUTDOWN OVERSPEED" If the engine speed
exceeds the setting for engine overspeed (shutdown),
the dis~lavwill show "Flu FAIL". The alarm indicator
will flash, Lnd an audible alarm is activated.
"SHUTDOWN UNDERSPEED" If the engine -
speed falls below the setting for engine underspeed
(shutdown), the display will show "Flu FAIL". The
alarm indicator will flash, and an audible alarm is
activated. This warning is only active after the engine
has exceeded the Safety On Timer.
"SHUTDOWN GENERATOR HIGH
-
FREQUENCY" If the control module detects a
output frequency for the generator that exceeds the
setting for high generator frequency (shutdown), the
display will show "Flu FAIL". The alarm indicator will
flash, and an audible alarm is activated.
 45
Operation Section
Features and Controls

_) 'SHUTDOWN GENERATOR LOW FREQUENCY"

If the control module detects a output frequency
- Temperature Switch for the Timing
for the generator that 1s below the setting for low
generator frequency (shutdown), the display will
show "Flu FAIL". The alarm indicator will flash, and
an audible alarm is activated.
"GENERATOR HIGH VOLTAGE SHUTDOWN" If -
the control module detects a output voltage for the
generator that exceeds the setting for high generator
voltage (shutdown), the display will show "HIGH
VOLT SID". The alarm indicator will flash, and an
audible alarm is activated.
Advance
The temperature switch for the timing advance is
mounted horizontally in the back of the water pump.
The water pump is located on the front left of the
engine.
The temperature switch for the timing advance is
normally open. The signal determines if the fuel
injection pump timing will be advanced or if the fuel
injection pump timing will be retarded.

"GENERATOR LOW VOLTAGE SHUTDOWN" - Oil Pressure Switch

If the control module detects a output voltage for
The oil pressure switch is located in the middle of the
the generator that is less than the setting for low cylinder block on the left side.
generator voltage (shutdown), the display will show
"LOW
- - VOLT SID". The alarm indicator will flash. and
The oil pressure switch performs several functions.
an audiie alarm is activated The oil pressure switch will illuminate a warning lamp
on the instrument panel when the oil pressure is
"ELECTRONIC GOVERNOR FAILURE
-
SHUTDOWN" If the control module detects an
too low. An audible alarm will also sound when the
oil pressure is too low. The oil pressure switch also
electronic governor failure (shutdown), the display sends an analog signal to the oil pressure gauge on
will show "GOV FAIL SIDOWN". The alarm indicator
the instrument panel.
illuminates, and an audible alarm is activated.

Failure of Sensors
Y
Sensors and Electrical All Sensors
Components A failure of any of the sensors may be caused by one
of the following malfunctions:
SMCS Code: 1900; 7400
Sensor output is open.
Sensor Locations and Sensor
Sensor output is shorted to "- battery" or "+ battery".
Functions
Coolant Temperature Sender
The coolant temperature sender is mounted vertically
in the cylinder head. The coolant temperature sender
is located on the top left of the front of the cylinder
head.

The coolant temperature sender monitors engine

coolant temperature. The coolant temperature sender
sends an analog signal to the instrument,panel. The
final readout is in the form of an analog gauge.

Coolant Temperature Switch

The coolant temperature switch is mounted
horizontally in the water outlet manifold The water
outlet manifold is on the top front of the engine.

A warning lamp on the instrument panel will be

illuminated when the temperature is too high. An
audible alarm will also sound when the temperature
is too high.
46
Operation Section
Features and Controls

The sensor is out of specification.

I
 47
Operation Section
Features and Controls

3 Alarm Switches
101592594

SMCS Code: 1900; 7400

The engines are equipped with alarms in order

to alert the operator when undesirable operating
conditions occur. When an alarm is activated,
corrective measures must be made before the
situation becomes an emergency.

Alarm systems are electrically operated. The

operation of all electric alarms utilize components
that actuate switches in a sensing unit. Alarms are
set at critical operating temperatures, operating
pressures, operating levels, or operating speeds.

The switch can be connected to a visual signal (lamp)

andlor an audio signal (bell or horn). The signal will
continue until the condition is corrected. The control
panels for the engines are equipped with an audio
alarm for the low oil pressure and an audio alarm
for the high coolant temperature. The control panels
for the engines are also equipped with a warning
lamp for the low oil pressure and a warning lamp
for the high coolant temperature. Refer to Operation
and Maintenance Manual, "Control Panel" for the
) locations and types of warning lamps.
48
Operation Section
Features and Controls

i01511475 101595817

Warning Alarm Voltage Regulators

SMCS Code: 7451 SMCS Code: 4467

Warning alarms are activated by a switch. The

switches are wired to the control panel. Your engine
may be equipped with the following switches:

-
Engine oil pressure The engine oil pressure
switch indicates when oil pressure drops below rated
system pressure.

-
Coolant temperature The coolant temperature
switch indicates high jacket water coolant
temperature.

Note: The sensing element of the coolant

temperature switch must be submerged in coolant
in order to operate.

Engines may be equipped with warning alarms

in order to alert the operator when undesirable
operating conditions occur.

NOTICE Illustration 40
When an alarm is activated, corrective measures must R438 Voltage Regulator
be taken before the situation becomes an emergency
in order to avoid possible engine damage.

If corrective measures are not'taken within a

reasonable time, engine damage could result. The
warning alarm will continue until the condition is
corrected. The warning alarm may need to be reset.

A switch may be installkd in the warning alarm while

the engine is stopped for repairs. Before the engine
is started, ensure that the switch is moved to the ON
position and that the warning lights are flashing. The
engine will not be protected if the switch is left in the
OFF position.
 49
Operation Section
Features and Controls

Exciter field
Series connection (SHUNT)
White
I R,,,- I

Exciter field
Parallel connection (AREP I PMG)
m,,-

ST4 -~xtemalpotentlometer
opum 10, wlfsge adjustment

Illustration 41
R438 Voltage Regulator with components

The voltage regulator is powered by two auxilialy

windings. These windings are independent from
the circuit for detection of voltage. The first winding
is labelled as 'XI" and 'X2" in illustration 41. This
winding has a voltage that is proportional with the
output voltage of the generator. The second winding
is labelled as "ZI" and "22"in illustration 41. This
winding has a voltage that is proportional to the
current of the stator. The voltage from the power
supply is rectified and filtered before being used by
the regulator monitoring transistor. This principle
1) ensures that regulation is not affected by interference
that is generated by the load.
50 SEBU7577-01
Operation Section
Features and. Controls

Table 3
I Short circuit current 1 3 x In for 10 seconds I
I Standard power supply I TWOauxiiiarv windings 1
I Shunt supply I max 48V at 50160 Hz I
I Rated overload current 1 8 amperes for 10 seconds I
Electronic protection
(overload, short-circuit
I Excitation ceiing current
for 10 seconds than return
opening on voltage to approximately 1 ampere.
detection) THE GENERATOR
MUSTBESTOPPED
IN ORDER TO RESET
THE PROTECTION.
I Fuse "FINon i n ~ uside
t I "XI" and "X2
I Fuse "F2" on output side I "E+" and "E-" I
Voltage detection 5 ACV isolated by the
transformer
1 0-110 ACV terminals 1 95 to 140 ACV I
1 0-220 ACV terminals 1 170 to 260 ACV I
1 0-380 ACV terminals 1 340 to 520 ACV I
Voltage regulation 1 *I%
Rapid or normal response time via strap "ST2"
Voltage adjustment via potentiometer "P2"(other voltages
via the step down transformer)

I Underspeed protection and freq~encythreshold

ad~ustmentvia potentiometer "P4" I
Maximum excitation current adjustmentvia potentiometer
"P5" 14.5 to 10 amperes)
1 50 or 50 Hz selection via iumper "STY I
The voltage regulator has an optional remote voltage
adjustment potentiometer. This potentiometer is
450 ohms, 0.5W minimum. The adjustment range
is 5%. The range is limited by the internal voltage
potentiometer "P2". Remove "ST4" to connect the
potentiometer. A 1000 ohm potentiometer can also
be used to extend the adjustment range.

3 Engine Starting
101813646
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Perform the required daily maintenance and other
periodic maintenance before the engine is started.
lnspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to
the Operation and Maintenance Manual for more
information.
For the maximum service life of the engine, make
a thorough inspection before starting the'engine.
Look for the following items: oil leaks, coolant
leaks, loose bolts, and trash buildup. Remove trash
buildup and arrange for repairs, as needed.
. lnspect the cooling system hoses for cracks and
for loose clamps.
lnspect the alternator and accessory drive belts for
cracks, breaks, and other damage.
) lnspect the wiring for loose connections and for
worn wires or frayed wires.
Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply valve.
NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage. , .
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may
have entered the filter housing. Also, when fuel filters
have been changed, some air space will be left in the
housing. In these instances, prime the fuel system.
Refer to the Operation and Maintenance Manual,
"Fuel System-Prime" for more information on priming
the fuel system.
Engine exhaust contains products of combustion
(ff which may be harmful t o your health. Always start
and operate the engine i n a well ventilated area
and, if in an enclosed area, vent the exhaust t o the
outside.
51
Operation Section
Engine Starting
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 the areas around the rotating parts are
clear.
All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
andlor missing guards.
Disconnect any battery chargers that are not .
protected against the high current drain that
is created when the electric starting motor (if
equipped) is engaged. Check electrical cables
and check the battery for poor connections and
for corrosion.
Reset all of the shutoffs or alarm components,
Check the engine lubrication oil level. Maintain the
oil level between the "ADD" mark and the "FULL"
mark on the oil level gauge.
Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
the coolant level to the "FULL" mark on the coolant
recovery tank.
If the engine is not equipped with a coolant
recovery tank maintain the coolant level within
31.75 mm (1.250 inch) of the bottom of the filer
pipe. If the engine is equipped with a sight glass,
maintain the coolant level in the sight glass.
Observe the air cleaner service indicator (if
equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.
Ensure that any driven equipment has been
disengaged. Remove any electrical loads.
Starting the Engines, Operating the
Engines, and Stopping the Engines
that are Equipped with Control
Panels
For information regarding the generator control panel
that is used, refer to the Operation and Maintenance
Manual, "Control Panel". For information regarding
starting the engine, refer to the Operation and
Maintenance Manual, "Starting the Engine". For
information regarding stopping the engine, refer to
the Operation and Maintenance Manual, "Stopping
the Engine".
 52
Operation Section
Engine Starting

102214073

Starting the Engine

SMCS Code: 1000; 1450

Standard Control Panel

Note: TYPE 1 & 2

Illustration 43 ~01112146
3' 4' 5' Standard control panel (Type 2)
Illustration 42 go0823728 (1) Gauges
(2) Control module
Standard control panel (Type 1) (3) Horn
(1) Gauges (4) Emergency stop button
(2) Control module (5) Alarm silence
(3) Horn
(4) Emergency stop button
' (5) Alarm silence

i 8' 9

Illustration 44 ~00829218
Close up of the control module (Type 1)
(6) Automatic position
(7) StoplReset
(8) Engine control switch
(9) Manual start po~ition

Illustration 45
Close up of the control module (Type 2)
(6) Automatic position (8) Engine control switch
(7) StoplReset (9) Manual start position
Local Operation
Use the following procedure in order to start the
engine.
1. Turn engine control switch (8) to manual start
position (9).
2. If the preheat timer is configured, then the preheat
timer will be initiated. After the preheat timer has
expired, the engine will begin to crank.
Note: When the engine starts, the starting motor is
disengaged and the starting motor is locked out.
3. If the engine did not start, then control module
(2) will permit the starting motor to cool down
for a predetermined amount of time. Once the
cooldown timer has expired, the engine will crank.
Note: The "Failed to Start" fault will be displayed
after the predetermined number of attempts to start
the engine fails. An LED indicator will flash. If this
occurs, engine control switch (8) must be moved
to StopIReset position (7). Determine the reason
I that the engine failed to start before making further
attempts.
53
Operation Section
Engine Starting
I
Q~IIIZE.~
4. After the engine has started, the safety timer is
activated. This function allows the engine to warm
up so that no faults will occur. Once the safety
timer has expired, fault protection is available. The
generator load may now be applied to the engine.
Remote Operation
Use the following procedure in order to start the
engine.
1. Engine control switch (8) must be in automatic
position (6). The LED for the remote start will
illuminate. The start delay is initiated.
Note: If the remote start signal is removed during the
start delay, then the unit will return to standby.
2. If the preheat timer is configured, then the preheat
timer will be initiated. After the preheat timer has
expired, the engine will begin to crank.
Note: When the engine starts, the starting motor is
disengaged and the starting motor is locked out.
54
Operation Section
Engine Starting

3. If the engine did not start, then control module

(1) will permit the starting motor to cool down
for a predetermined amount of time. Once the
cooldown timer has expired, the engine will crank.

Note: The "Failed to Start" fault will be displayed

afler the predetermined number of attempts to start
the engine fails. An LED indicator will flash. If this
occurs, engine control switch (8) must be moved
to StoplReset position (7). Determine the reason
that the engine failed to start before making further
attempts.

4. Afler the engine has started, the safety timer is

activated. The safety timer function allows the
engine to warm up so that no faults will occur.
Once the safety timer has expired, full fault
protection is available. Once the generator is
running at the correct speed, the warm-up timer
is initiated.

Premium Control Panel

Note: TYPE 1 & 2

Illustration 46 go0829205

Premium Conlrol panel (Type 1 )

(1) Control module
(2)Horn
i3j Emergency stop bunon
(4) Alarm silence
 55
Operation Section
Engine Starting

1 Illustration 47
Premium Control panel (Type 2)
g01110860

(1) Control module (3) Emergency stop button

(2) Hom (4).Alarm silence

g01115368
Illustration 48
Close up of the control module (Type 1)
( 5 ) StoplReset bunon (7) Manual mode button
(6) Start button (8) Automatic mode button
56
Operation Section
Engine Starting

Illustration 49
Close up of the control module (Type 2)
(5) StopIReset button (7) Manual mode button
( 6 ) Start buttqn (8) Automatic mode button

Local Operation
Use the following procedure in order to start the
engine.
1. Press manual mode button (7). The LED above
the manual mode button will illuminate. The
LCD display will indicate "MANUAL MODE". The
LCD display will then indicate "GENERATOR AT
REST'.
2. Press start button (6) until the LCD display shows
"START". If the preheat timer is configured, then
the preheat timer is initiated. The LCD display will
indicate "PRE-HEATING". Afler the preheat timer
has expired, the engine will begin to crank. The
LCD display will indicate "Fuel ON". Then, the
LCD display will indicate "CRANKING attempt 1".
3. If the engine did not start, control module (1)
will permit the starting motor to cool down for a
predetermined amount of time. Once the cooldown
timer has expired, the engine will crank. The LCD
display will indicate "CRANKING attempt 2 .
Note: The LCD display will indicate
"SHUTDOWN-FAILED TO START' afler the
predetermined number of attempts to start the engine
fails. An LED indicator will flash. If this occurs,
StoplReset button (5) must be pressed. Determine
the reason that the engine failed to start before
making further attempts.

Note: When the engine starts, the starting motor is

disengaged and the starting motor is locked out.
 57
Operation Section
Engine Starting

1 4. After the engine has started, the safety timer

is activated and the LCD display will indicate
MCS Control Panel
"WAITING FOR SAFETY ON". This function Note: TYPE 1 & 2
allows the engine to warm up so that no faults
will occur. Once the safety timer has expired, full
fault protection is available. The LCD display will
indicate "GENERATOR AVAILABLE IN MANUAL".
The generator load may now be applied to the
engine.

Remote Operation
Use the following procedure in order to start the
engine.

1. Press.automaticmode button (8). The LED above

the automatic mode button will illuminate and the
LCD display will indicate "AUTO MODE". The
LCD display will then indicate "GENERATOR AT
REST'. The start delay timer is initiated. The LCD
display will indicate "START DELAY".

2. If the preheat timer is configured, then the preheat

timer is initiated. The LCD display will indicate
"PRE-HEATING. After the preheat timer tias
expired, the engine will begin to crank. The LCD
display will indicate "Fuel ON. Then, the LCD
3
-
display will indicate "CRANKING attempt 1".

Note: When the engine starts, the starting motor is

disengaged and the starting motor is locked out.
3. If the engine did not start, then control module (1)
will permit the starting motor to cool down for a
predetermined amount of time. Once the cooldown
timer has expired, the engine will crank. The LCD
display will indicate "CRANKING attempt 2 .
Illustration 50
MCS Control Panel (Type 1)
(1) Shutdown override key switch
(2) Emergency stop push button
(3) Horn
(4) Control Module with display

Note: The LCD display will indicate

"SHUTDOWN-FAILED TO START" after the
predetermined number of attempts to start the engine
fails. An LED indicator will flash. If this occurs,
StoplReset button (5) must be pressed. Determine
the reason that the engine failed to start before
making further attempts.

4. After the engine has started, the safety timer

is activated and the LCD display will indicate
"WAITING FOR SAFETY ON". This function,
allows the engine to warm up so that no faults
will occur. Once the safety timer has expired,
full fault protection is available. The warm up
timer is initiated once the generator is running at
the correct speed. The LCD display will indicate
"WARMING UP. After the warm-up timer has
9 expired, control module (I) will open the mains
contactor relay, The contactor for the generator
will close and-the LCD display will indicate
"GENERATOR AVAILABLE".
58 SEBU7577-01
Operation Section
Engine Starting

Illustration 51 g01110984

MCS Control Panel (Type 2)

(1) Shutdown override key switch (3) Horn
(2) Emergency slop push bunon (4) Control Module with display

Shutdown Override Key Switch (I)-This should -

be switched to the off position for normal use and the
key should be removed for safe keeping. Activation
of this key switch will enable the engine to continue
to run even when a shutdown signal is received.
Emergency Stop Push Button (2) The -
emergency stop push button (ESPB) is used to shut
down the engine during an emergency situation. The
ESPB shuts off the fuel.
Horn (3) The horn activates when one of the
a fault (alaml or shutdown signal) is received by
the controller and the fault is indicated with text on
the controller display. The horn can be silenced by
pressing the ACK or acknowledge button on the
--... -..-. .
rnntrnllar
MCS Control Module With Display (4) -The
control module controls the functions of the generator
set.
 59
Operation Section
Engine Starting

g01112681 ,
Illustration 52
Close up of the control module (Type 1)
(5) Start Button (6) StopIReset Button (7) Mode Selection Button
60
Operation Section
Engine Starting
Illustration 53
Close up of the control module (Type 2 )
(5) Start Button (6) StopIReset Button
Local Operation
Use the following procedure to start the engine.
1. Press manual mode button (7) to ensure that the
controller is not in a remote or automatic mode
of operation. To ensure that the controller is in
the manual mode, the Auto LED will NOT be
illuminated. Ensure that SHUTDOWN OVERRIDE
(2) key switch has not been selected and is in the
"OFF position. If the key switch is in the "ON"
position, SHUTDOWN O'RIDE will appear in the
controller display.
2. Press start button (5) until the LCD display shows
START. If the preheat timer is configured, then
the preheat timer is initiated. The LCD display will
indicate PRE-HEAT. After the preheat timer has
expired, the engine will begin to crank. The LCD
display will indicate FUEL ON. Then, the LCD
display will indicate START.
Note: When the engine starts, the starting motor is
disengaged and the starting motor is locked out.
go1112696
(7) Mode Selection Button
3. If the engine did not start, control module (1)
will permit the control module to cool down for a
predetermined amount of time. Once cooldown
timer has expired, the engine will crank. The LCD
display will indicate START.
Note: c he "Failed to Start" fault will be displayed
after the predetermined number of attempts to start
the engine fails. An LED indicator will flash and an
audible alarm is activated. If this occurs, StoplReset
button (6) must be pressed. Determine the reason
that the engine failed to start before making further
attempts.
4. Affer the engine has started, the safety timer is
activated. This function allows the engine to warm
up so that no faults will occur. Once the safety
timer has expired, fault protection is available. The
generator load may now be applied to the engine.
Remote Operation
Use the following procedure to start the engine.

1. Mode Selection Button (7) must be in pressed so
that the AUTO LED is illuminated to indicate that
the genset is in the Remote situation. If customer
connections are made and a remote signal is
detected to the device, the start delay is initiated.
Note: If the remote start signal is removed during the
start delay, then the unit will return to standby.
2. If the preheat timer is configured, then the preheat
timer will be initiated. After the preheat timer has
expired, the engine will begin to crank.
Note: When the engine starts, the starting motor is
disengaged and the starting motor is locked out.
3. If the engine did not start, then control module
(1) will permit the starting motor to cool down
for a predetermined amount of time. Once the
cooldown timer has expired, the engine will crank.
Note: The "Failed to Start" fault will be displayed
afler the predetermined number of attempts to start
the engine fails. An LED indicator will flash and an
audible alarm is activated. If this occurs, StoplReset
button (6) must be pressed. Determine the reason
that the engine failed to start before making further
attempts.
4. Afler the engine has started, the safety timer is
activated. The safety timer function allows the
engine to warm up so that no faults will occur.
Once the safety timer has expired, full fault
protection is available. Once the generator is
running at the correct speed, the warm-up timer
is initiated.
Starting with Jump Start
Cables
SMCS Code: 1000; 1401; 1402; 1900
Improper jump start cable connections can cause
an explosion resulting i n personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors t o 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, it may be necessary to start the
engine from an external electrical source.
61
Operation Section
Engine Starting
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that
are severely discharged. The batteries must be
charged to the proper voltage with a battery charger.
For information on testing and charging, refer to
the Special Instruction, SEHS7633, "Battery Test
Procedure".
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 ground cable last and remove
first.
When using an external electrical source to start the
engine, turn the engine control switch to the "OFF"
position. Tum all electrical accessories OFF before
attaching the jump start cables.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
gine being started.
1. Turn the start switch on the stalled engine 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 chassis ground. This
procedure helps to prevent potential sparks from
igniting combustible gases that are produced by
some batteries.
4. Start the engine. Refer to the Operation and
Maintenance Manual, "Starting the Engine" for the
correct procedure.
5. Immediately after the stalled engine is started,
disconnect the jump start cables in reverse order.
Refer to the Electrical Schematic for your engine.
Consult your Caterpillar dealer for more information.
62
Operation Section
Engine Starting

101592696

After Starting Engine

SMCS Code: 1000

Note: In temperatures from 0 to 60 "C (32 to 140 OF),

the warm-up time is approximately five minutes. In
temperatures below 0 "C (32 OF), additional warm-up
time may be required.

Note: Ensure that the self test for the monitoring

system is completed before you operate the engine
under load.

1. The control panel will begin the "Warm-Up Timer"

once the engine has been started.

2. Perform these checks during the warm-up:

. Check for any fluid leaks and for any air leaks.

. Check all the gauges.

Observe the gauges and record the data frequently

while the engine is operating. Comparing the
data over time will help to determine normal
readings for each gauge. This will also help detect
abnormal operating developments. Investigate
any significant changes in the readings.

3. Once the "Warm-Up Timer" has expired, the

control panel will engage the generator.

NOTICE
To avoid engine overheating and possible engine
damage, ensure that water discharge is visible at the
sea water outlet andlorthe water flow is not restricted.

If the water flow is restricted andlor water discharge

is not visible at the sea water outlet, follow the recom-
mended procedure.

4. Observe the water discharge at the sea water

outlet. If water discharge is not visible or the water
flow is restricted, perform the following procedure:

a. Stop the engine immediately.

b. Inspect the inlet screen and the sea water

strainer for debris. Remove any debris that is
found.

c. lnspect the cooling system and the auxilialy

water pumps for evidence of leaks.

5. Check for any fluid leaks and for any air leaks.

Engine Operation
101646252
Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors
in obtaining the maximum life and economy of
the engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.
The time that is needed for the engine to reach
normal operating temperature can be less than the
time taken for a walk-around inspection of the engine.
The engine can be operated at the rated rpm after
the engine is started and after the engine reaches
operating temperature. The engine will reach normal
operating temperature sooner during a low engine
speed (rpm) and during a low power demand. This
procedure is more effective than idling the engine
at no load. The engine should reach operating
temperature in a few minutes.
Gauge readings should be observed and the data
should be recorded frequently while the engine
is operating. Comparing the data over time will
help to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
100613522
Engine Warm-up . One defective battery cell will ovelwork the alternator.
SMCS Code: 1000
1. Run the engine at low idle for three to five minutes,
or run the.engine at low idle until the jacket water
temperature starts to rise.
More time may be necessary when the
temperature is below -18°C (0°F).
2. Check all of the gauges during the warmlup
period.
3. Perform another walk-around inspection. Check
the engine for fluid leaks and air leaks.
4. Increase the rpm to the rated rpm. Check for fluid
leaks and air leaks. The engine may be operated
at full rated rpm and at full load when the jacket
water temperature reaches 60°C (140°F).
63
Operation Section
Engine Operation
101060957
Fuel conservation Practices
SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. Caterpillar's design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life
of the engine.
Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. The fuel lines should be repaired if there is
evidence of failure.
Be aware of the properties of the different fuels.
Use only the recommended fuels.
Avoid unnecessary idling.
Shut off the engine rather than idle for long periods of
time.
Observe the service indicator frequently. Keep the
air cleaner elements clean.
Ensure that the turbochargers are operating
correctly so that the proper airlfuel ratio is
maintained. Clean exhaust indicates proper
functioning.
Maintain a good electrical system.
This will consume excess power and excess fuel.
Ensure that the belts are properly adjusted. The
belt should be in good condition.
Ensure that all of the connections of the hoses are
tight. The connections should not leak.
When possible, utilize the heat of the jacket water
system and the energy from the heat of the exhaust
system.
Keep keel coolers, heat exchangers, and water
pumps clean. Keep the components in good repair.
Ensure that all of the accessory pumps are
repaired. The pumps should operate efficiently,
Do not exceed the maximum oil level.
Never operate without water temperature
regulators.
64
Operation Section
Engine Operation

Water temperature regulators regulate the

temperature of the coolant. Water temperature
regulators help to provide efficient operating
temperatures. Cold engines consume excessive
fuel. Water temperature regulators also help prevent
engine overheating.

Cruising Speed
The recommended cruising speed of the engine is
I
300 to 400 rpm below the rated speed of the engine.

Operating at the recommended cruising speed will

help to provide the maximum engine service life and
the most economical operation.
 65
Operation Section
Engine Stopping

9 Engine Stopping
Stopping the Engine
SMCS Code: 1000; 7000

NOTICE
Stopping the engine immediately alter it has been
working under load can result in overheating and ac-
celerated wear of the engine components.

If the engine has been operating at high rpm and/or

high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature
before stopping the engine.

Avoiding hot engine shutdowns will maximize tur-

bocharger shaft and bearing life.

Standard Control Panel

- Note: TYPE 1 & 2

Illustration 55 go1112146

Standard wntrol panel (Type 2)

(1) Gauges
(2) Control module
(3) Horn
(4) Emergency stop button
(5) Alarm silence

3 4 5
go0823728
Illustration 54
Standard wntrol panel (Type 1)
(1) Gauges
(2) Control module
(3) Horn
(4) Emergency stop push button
(5) A l a n silence

Illustration 56 go0829218

Close up of the control module (Type 1)

(6) Automatic posltion
(7)StopIReset posltion
(8)Engine control switch
(9) Manual start posltion
66
Operation Section
Engine Stopping

go1112155
Illustration 57
Close up of the control module (Type 2)
(6) Automatic position (8) Engine control switch
(7) StoplReset (9) Manual stalt position

Manual Operation Premium Control Panel

1. Turn engine control switch (8) to automatic Note: TYPE 1 & 2
position (6). When the remote stop delay timer
expires, the load is disconnected. The generator
will turn off. The engine will then run at idle auring
the cooldown timer.

Note: If the remote start signal is removed, then the

engine will continue to run until engine control switch
(8) is turned to automatic position (6).

2. Turn engine control switch (8) to StoplReset

position (7).

~ut'omatic
Operation
1. Remove the remote start signal. When the remote
stop delay timer expires, the load is disconnected.
The generator will turn off. The engine will then
run at idle during the cooldown timer.

2. Turn engine control switch (8) to StoplReset

position (7).
 67
Operation Section
Engine Stopping

0 0

\
J

ors
0 0
0 0 0 0
0 0 0 0

Illustration 58 go0829205

Premium control panel (Type 1)

(1) Control module
(2) Horn
(3) Emergency stop push button
(4) Alarm silence

Illustration 59 gD1110860

Premium Control panel (Type 2)

(1) Control module (3) Emergency stop button
(2) Horn (4) Alarm silence
68
Operation Section
Engine Stopping

illustration 60
Close up of the control module (Type 1)
go1115369 I
(5) StoplReset button (7) Manual mode button
(6) Start button (8) Automatic mode button
 69
Operation Section
Engine Stopping

go1112313
Illustration 61
Close up of the control module (Type 2)
(5) StopIReset button (7) Manual mode button
(6) Start button (8) Automatic mode button

Manual Operation 2. The LCD display will indicate "STOPPING.

1. Press StoplReset button (5). The LCD display will Note: If the engine fails to stop running, the LCD
indicate "STOPIRESET". The engine will then slow display will indicate "SHUTDOWN FAIL TO STOP.
down. The LCD display will indicate "STOPPING". The alarm will sound.

Note: If the engine fails to stop running, the LCD 3. Once the engine has stopped, the LCD display
display will indicate "SHUTDOWN FAIL TO STOP. will indicate "GENERATOR AT REST'.
The alarm will sound.

2. Once the engine has stopped, the LCD display

MCS Control Panel
will indicate "GENERATOR AT REST". Note: TYPE 1 & 2

Automatic Operation
3 1. Once the return timer has expired, the control
module will de-energize the load transfer output.
The cool down timer will start. This will allow the
engine to cool down properly. The LCD display
will indicate "COOLING DOWN".
70
Operation Section
Engine Stopping

Illustration 62
MCS Control Panel (Type 1)
(1) Sh~loownoverride key switch
(2) Emergency slop pusn b.lion
(3) Horn
(4) Control Module with display

Illustration 63
MCS Control Panel (Type 2)
(1) Shutdown override key switch (3) Horn
(2) Emergency stop push button (4) Control Module with display
Shutdown Override Key Switch (1) -This should
be switched to the off position for normal use and the
key should be removed for safe keeping, Activation
of this key switch will enable the engine to continue
to run even when a shutdown signal is received.
Emergency Stop Push Button (2) -The
emergency stop push button (ESPB) is used to shut
down the engine during an emergency situation. The
ESPB shuts off the fuel.
71
Operation Section
Engine Stopping
-
Horn (3) The horn activates when one of the
a fault (alarm or shutdown signal) is received by
the controller and the fault is indicated with text on
the controller display. The horn can be silenced by
pressing the ACK or acknowledge button on the
controller.
MCS Control Module With Display (4) -The
control module controls the functions of the generator
set.
72
Operation Section
Engine Stopping

Illustration 64 go1112681

Close up of the control module (Type 1)

(5) Start Button (6) StopIReset Button (7) Mode Selection Button
 73
Operation Section
Engine Stopping

I
1' Illustration 65
Close up of the control module (Type 2)
g01112696 .
( 5 ) Start Button (6) StopIReset Button (7) Mode Selection Button

Manual Operation 4. Once the engine has stopped, the LCD display
will indicate "STOPPED".
1. Press StoDIReset button ( . .
61.The LCD disDlaV will
~,
indicate "STOPPING.

Note: If the engine fails'to stop running, the LCD

display will indicate "STOP FAILURE". The alarm
will sound.

2. Once the engine has stopped, the LCD display

will indicate "STOPPED".

Automatic Operation
1. Once the return timer has expired, the control
module will de-energize the load transfer output.

2. The cool down timer will start. This will allow the
engine to cool down properly. The LCD display will

-
indicate "COOL DOWN".

3. The LCD display

. . will indicate "STOPPING".

Note: If the engine fails to stop running, the LCD

display will indicate "STOP FAILURE". The alarm
will sound.
74
Operation Section
Cold Weather Operation

Cold Weather Operation When No. 2 diesel fuel is used the following
components provide a means of minimizing problems
in cold weather:
101190421

Fuel and the Effect from Cold

Starting aids
I
Weather Engine oil pan heaters

Engine coolant heaters

I
SMCS Code: 1000; 1250

The following fuels are the grades that are available Fuel heaters
for Caterpillar engines:

No. 1
Fuel line insulation

For more information on cold weather operation, see

I
No. 2 Operation and Maintenance Manual, SEBU5898,
"Cold Weather Recommendations".
Blend of No. 1 and No. 2

No. 2 diesel fuel is the most commonly used fuel.

Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold weather operation.

Quantities of No. 1 diesel fuel are limited. No. 1 diesel

fuels are usually available during the months of the
winter in the colder climates. During cold weather
operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary.

There are three major differences between No. 1 and

No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:

Lower cloud point

Lower pour point

Lower rating of kJ (BTU) per unit volume of fuel

When No. 1 diesel fuel is used, a decrease in power

and in fuel efficiency may be noticed. Other operating
effects should not be experienced.

The cloud point is the temperature when a cloud of

wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is
the temperature when diesel fuel will thicken. The
diesel fuel becomes more resistant to flow through
fuel pumps and through fuel lines. .
Be aware of these values when diesel fuel is
purchased. Anticipate the average ambient
temperature within the area that the engine will be
operated. Engines that are fueled in one climate
may not operate well if the engines are moved to
another climate. Problems can result due to changes
in temperature.

Before troubleshooting for low power or for poor

performance in the winter, check the type of fuel that
is being used.
 75
Operation Section
Cold Weather Operation

3 Fuel Related Components in

100078412

Cold Weather
SMCS Code: 1000; 1250

Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks afler operating the engine.

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.

Some fuel tanks use supply lines that take fuel

directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.

Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, oil changes,
and refueling of the fuel tank. This will help prevent

3 water andlor sediment from being pumped from the

fuel storage tank and into the engine fuel tank.

Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet.

The micron rating and the location of a primary fuel

filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel:

The micron rating and the location of the primary fuel

filter should only be low enough to protect the fuel
transfer pump. A primary filter with a low micron rating
can be plugged by wax crystals in cold weather.

Note: Refer to the Parts Manual for this engine in

order to determine the part numbers that are required
for the fuel filters.
76
Operation Section
Generator Operation

Generator Operation

Generator Operation
SMCS Code: 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 66. When you operate with
significant single-phase loads, the combinations of
single-phase load and three-phase load may be
used. Such combinations should be located below
the line on the graph.

SINGLE-PHASE L O A D A S A PERCENT, OF
THREE-PHASE KV-A R A T I N G

Illustration 66 go0627416

Allowable Combinations of Unbalanced Loads

. .
Block Loading
The block loading is the instantaneous application of
an electrical load to a generator set. This load mav be
anywhere from a moderate percentage of the rated
load up to the rated load.

The block loading capability of a generator set

depends on the following factors.

Engine transient response

Voltage regulator response

Type of the voltage regulator

Altitude of operation of the generator set

Type of load

The amount of load

 77
Operation Section
Generator Operation

) IfI Sderating is required in order to block load, refer to

0 3046 or SAE J1349 Standards. Also, reference
Engine Data Sheet, LEKX4066, "Loading Transient
Response" and Engine Data Sheet, LEKX4067,
"Block and Transient Response".
Standby Electric Sets
Most standby units are installed with controls for
automatic starting. Standby units start without an
operator in attendance.

Note: I S 0 stands for International Standards Standby units can not automatically change the
Organization. governor speed. Standby units can not automatically
change the setting of the voltage level. The governor
speed and voltage level must be preset for the
Power Factor proper operation of that unit. Whenever the generator
is operated manually, ensure that the settings for
The power factor is the ratio of apparent power to
governor speed and voltage level are correct for
total power. The power factor is expressed as a
automatic operation. Check all switches on the
decimal. The power factor represents that portion of
Standard Control Panel for the proper setting. Check
the current which is doing useful work. The portion of
all push buttons on the Premium Control Panel for the
current which is not doing useful work is absorbed
proper setting. On the Standard Control Panel, the
in maintaining the magnetic field in motors or other
Start Selector Switch should be in the AUTOMATIC
devices. This current is called the reactive load.
position. On the Premium Control Panel, the "AUTO"
This current does not require engine power to be
push button is pressed.
maintained.
In most applications, electric motors and transformers Generator Options
determine the power factor of the system. Induction
motors usually have a power factor of 0.8 or less. Battery Disconnect Switch
Incandescent lighting is a resistive load of about 1.0
power factor, or unity. This switch is a single-pole switch. This switch cannot
) The power factor of a system may be determined by
a power factor meter or by calculations. Determine
be used with dual electric starters.

the power requirement in kW by multiplying the power Space Heaters

factor by the kVA that is supplied to the system. As
the power factor goes up, the total current that is The generator can be equipped with space heaters.
supplied to a constant power demand will go down. A The space heater is installed for operation in high
100 kW load that is at 0.8 power factor will draw more humidity conditions. 120 volt and 240 volt space
current than a 100 kW load that is at 0.9 power factor. heaters are available.
A high power factor will result in a full engine load
at less than the generator rated amperage. A lower Radio Frequency Interference (RFI) Filter
power factor increases the possibility of overloading
the generator. This filter is available for applications that require a.
filter.
Note: The Caterpillar generators are rated at a
power factor of 0.8 unless the generator is specified Instrumentation
otherwise.
Three different remote starVstop panels are available.
Excitation System Extensions for the wiring harness are available in
order to mount the panels. Contact your Caterpillar
The generator uses the AREP excitation system. dealer for more information.
This system does not use a permanent magnet.
The voltage regulator is powered by two auxiliary
windings. These windings are independent of the
circuit for detecting voltage. The first winding is
labelled as "XI" and "XZ".This winding has a
voltage that is proportional to the output voltage of
the generator. The second winding is labelled as
?I8' and "22".This winding has a voltage that is
proportionalto the current of the stator. The voltage
from the power supply is rectified and filtered before
being used by the regulator monitoring transistor.
This principle ensures that regulation is not affected
by interference that is generated by the load.
Maintenance Section
Refill Capacities

Maintenance Section Refer to Table 6 (maximum temperature) in order to

select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
I
Refill Capacities Generally, use the highest oil viscosity that is
available to meet the requirement for the temperature
at start-up. I
102198020
Table 6
Refill Capacities and Engine Oil Viscosity
Recommendations Caterpillar DEO Ambient Temperature
Multigrade
SMCS Code: 1348; 1395; 7560 API CH-4
API CG-4 Minimum Maximum
'
Lubrication System Viscosity Grade
SAE OW-20 -40 "C (-40 "F) 10 "C (50 'FI
Lubrication C a p a c i t i e s I SAE OW-30 I -40 'C (-40 "F) 1 30 "C (86 "F) I
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter.
Table 4 I SAE 15W-40 I -9.5 "C(15 'F) I 50 "C (122 "F) I
Approximate Refill Capacity of the For additional information on selecting an
oil, refer to Special Publication, SEBU6251,
"Caterpillar Commercial Diesel Engine Fluids
Recommendations".
Standard Sump(')
(4) These values are the approximate capacities for the crankcase
oil sump which include the standard factory installed oil filters. Fuel
Engines with auxiliary'oii filters will require additional oil. Refer

Table 5
to the OEM specifications for the capacity of the auxilialy oil
filter.
3056 Marine Generator Set Engine
Approximate Refill Capacity of the
Compartment or System
Standard Sumpfl) 15 1 16
(4) These values are the approximate capacities for the crankcase
oil sump which include the standard factory installed oil filters.
Enaines with auxiliaiv oil filters will reauire additional oil. Refer
to ihe OEM specificitions for the capacity of the auxiliaty oil
filter.
Lubricant Viscosity Recommendations
for Direct Injection (Dl) Diesel Engines
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.
Refer to Table 6 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
engine.
Fuel Recommendations
Diesel engines have the ability to burn a wide variety
I1
of fuels. These fuels are divided into two general
groups. The two groups are called the preferred fuels
and the permissible fuels.
I
I
The preferred fuels provide maximum engine service
1 life and performance. The preferred fuels are distillate
fuels. These fuels are commonly called diesel fuel,
furnace fuel, gas oil, or kerosene.
The permissible fuels are crude oils or blended fuels.
Use of these fuels can result in higher maintenance
costs and in reduced engine service life.
In North America, diesel fuel that is identified as No.
I - D or No. 2-D in "ASTM D975" generally meet the
1
specifications. Diesel fuels from other sources could
exhibit detrimental properties that are not defined or
controlled by this specification.
I
Refer to Special Publication, SEBU6251, "Caterpillar I
Commercial Diesel Engine Fluids Recommendations"
for additional information that relates to diesel fuel. I
I
i
 79
Maintenance Section
Refill Capacities

Acceptable -
Caterpillar Diesel Engine

1 Coolant Capacities
AntifreezelCoolant (DEAC) or a commercial
heavy-duty coolanffantifreeze that meets "ASTM
D4985" or "ASTM D5345" specifications
To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate Caterpillar recommends a 1:Imixture of water and
capacity for the engine cooling system is listed. glycol. This mixture will provide optimum heavy-duty
External System capacities will vary among performance as a coolanffantifreeze.
applications. Refer to the OEM specifications for the
External System capacity. This capacity information Note: Caterpillar DEAC DOES NOT require a
will be needed in order to determine the amount treatment with an SCA at the initial fill. Commercial
of coolanffantifreeze that is required for the Total heavy-duty coolanffantifreeze that meets "ASTM
Cooling System. D4985" or "ASTM D5345" specifications MAY require
a treatment with an SCA at the initial fill. Read the
Table 7 label or the instructions that are provided by the OEM
of the product.
3054 Marine Generator Set Engines
Approximate Refill Capacity of the Cooling System Table 9
Compartment or System Liters Quarts / Caterpillar Minimum Acceptable Water Requirements I
Engine Only 13 13.7 Property Maximum Limit ASTM Test
External Svsternlll 18 19 40 mg/L "D512",
Chloride ('I)
I Total Cooling SvsternR I I I (2.4 grains/US gal) "D4327"
1') The External Svstem includes an exoansion tank wilh the
following components: heat exchanger, aflercooler, piping, and
keel cooling system.
(21 Add the capacity for the Engine Only to the capacity for the Hardness 170 mg/L "D1126"
External System. Enter the total in this row. (10 g r a i n s / ~gal)
~

Table 8 Solids 340 mglL "D1888"

(20 grain/^^ gal)

I 3056 Marine Generator Set Engine

Approximate Refill Capacity of the Coolina Svstem I Acidity pH of 5.5 to 9.0 "D1293"
I Compartment or System I Liters I Quarts I In stationary engine applications and marine engine
Engine Only 19 ( 20 applications that do not require protection from
External SvstemFl 24 25 boiling or freezing, a mixture of SCA and water is
acceptable. Caterpillar recommends a minimum
I Total Coolina Svstemn I I I o f six percent t o a maximum of eight percent
F l The External System includes an expansion tank with the SCA concentration i n those cooling systems.
following components: heat exchanger, aftercooler, piping, and Distilled water or deionized water is preferred. Water
keel cooling system. which has the required properties may be used. For
(21 Add the capacity for the Engine Only to the capacity for the the water properties, refer to Special Publication,
External System. Enter the total in this row. SEBU6251, "Caterpillar Commercial Diesel Engine

I Coolant Recommendations
I NOTICE .
Do not use a commercial coolanffantifreeze that only
meets the ASTM D3306 or D4656 specification. This
type of coolanffantifreeze is made for light duty auto-
motive applications.
The following coolants are the primary types of
coolants that are used in Caterpillar Engines:
Fluids Recommendations"for additional information
that relates coolant.
Note: The service life of coolant is limited by use
of service hours. Refer to the specific engine's
Operation and Maintenance Manual, "Maintenance
Interval Schedule" (Maintenance Section). To
achieve this service life, the coolants must be
properly maintained. The maintenance program
includes S.0.S coolant analysis.

-
Preferred Caterpillar Extended Life Coolant (ELC)
or a commercial extended life coolant that meets the
Caterpillar EC-1 specification
80
Maintenance Section
Refill Capacities

Table 10
Coolant Service Life
Coolant Type Service Life (1)
Caterpillar ELC Six Years
Caterpillar DEAC Three Years
I I
I Commercial Heaw-Dutv
~oolantl~ntifreezk
thai
meets "ASTV D5345"
I Two Years

Commercial Heavy-Duty
CoolanVAntifreeze that One Year
meets 'ASTM D4985"
I Caterpillar SCA and
Water
1 Two Years
I
I Commercial SCA and
Water
I One Year I
I I I
(1) The service life of coolant is also limited by use (service hours).
Refer to the specific engine's Operation and Maintenance
Manual. 'Maintenance Interval Schedule" (Maintenance
Section).
 81
Maintenance Section
Maintenance Recommendations

) Maintenance
Recommendations

1I
iD1595911

Generator Start-up Checklist

SMCS Code: 4450
Table 11
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 ~ocation:
I Main Stator Megohmmeter Reading: I Before Storage: I Afler Storage:
Generator dried for 24 hours prior to startup? (Y/N) Drying method:
SPACE HEATERS Yes No Comments
S ~ a c eheaters oDeratina Dro~erlv?
Space heater 'operated 48 hrs. before
-.
startuo?
-. I
MEGOHMMETER TEST (SEHS9124) 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments
reading reading corrected corrected temp.
Beginning of Main Stator
Storage
Main Rotor 1 I I I i I
Exciter Stator
Exciter Rotor
PMG Stator
Start-up Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Regulator Voltage Amps Comments
No Load I E+ to E- DC

0 to 220 AC
0 to 380 AC
(continued)
82
Maintenance Section
Maintenance Recommendations

(Table 11, conld)

GENERATOR START-UP CHECKLIST
e li
Full Load Generator Excitation Name
Plate Information: I DCI I Compare with F1 to F2

20 to 24 AC
22 to 24 AC
24 to 30 (SE only) AC
26 to 28 (PM only) AC
26 to 30 (PM only) AC
28 to 30 (PM only) AC
 83
Maintenance Section
Maintenance Recommendations

Table 12

I GENERATOR START-UP CHECKLIST (CONT.) I

I ELECTRICAL I yes I NO / Comments 1
Unit properly grounded
u
I Over current ~rotection I I I I
I Over voltage protection I I I I
I Check for loose wiring
MECHANICAL Data Comments
Bearing temperature readings at full load Front Rear
Stator temperature readings at full load A0 BO co -
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 load Temperature
Supplier air opening to generator Size of Opening
INSTALLATION B LOAD INFORMATION
Neutral grounding system I UPS
Enclosure t v ~ e I - size
I Motor: I Other loads: 1
1 - Total SKVA I - Lighting I
- Total HP - Computers
- Welding
- Non-linear
1 I - Other I
I FULL LOAD DATA I
Voltage Amps KW I WARS' I P. F.
84
Maintenance Section
Maintenance Interval Schedule

102195434 First 300 L (80 US gal) o f Fuel o r First 20 to

40 Service Hours
()
Maintenance Interval Schedule
-
(3054 Naturally Aspirated
Marine Generator Set Engine)
Belts InspectlAdjusffReplace.............................. 91
Engine Valve Lash - Inspect/Adjust .................... 108
I
SMCS Code: 1000; 7500
SIN: CHNI-Up
Every 3000 L (800 US gal) of Fuel or 400
Service Hours o r 1 Year
Auxiliary Water Pump (Rubber Impeller) -
I
Inspect .............................................................. 89
Note: Before uetformina anv . -
. oueration or -
Battery Electrolyte Level Check .......................... 90
maintenance procedures, ensure that the Safety Cooling System Supplemental Coolant Additive
Information, warnings,
- and instructions are read -
(SCA) TesffAdd .................................................98
and understood. Crankshafl Vibration Damper - Inspect ................. 99
Engine Air Cleaner Element (Dual Element) -
To deterniine the maintenance intervals, use fuel CleanlReplace .................................................. 101
consumption, service hours, or calendar time, -
Engine Mounts Inspect .....................................106
whichever occurs first. Experience has shown that Engine Oil Sample - Obtain ................................106
maintenance intervals are most accurately scheduled Engine Oil and Filter - Change ........................... 107
on the basis of fuel consumption. Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 111
Before each consecutive interval is performed, all Fuel System Secondary Filter Replace .............'112 -
of the maintenance items from the previous interval Fuel Tank Water and Sediment - Drain ................113
must also be performed. -
Fuel Transfer Pump Strainer Clean ...................114
-
Heat Exchanger Inspect ....................................118
When Required -
Hoses and Clamps InspectlReplace ................. 119
Battery - Replace ......................... ....................... 89
Every 45 000 L (12 000 US gal) of Fuel or
-
Battery or Battery Cable Disconnect .................. 90
6000 Sewice Hours
-
Engine Clean ............................ ...................... 100
-
Fuel System Prime ........................................... 110
-
Generator Set Test ........................................... 118
-
Rotating Rectifier Test ......................................126
Cooling System Coolant (ELC) Change - ............. 94 1
Every 7500 L (2000 US gal) of Fuel or 1000
Service Hours
Daily
-
-
Cooling System Coolant Level Check ................ 97
Electrical Connections - Check .......................... 100
-
Engine Air Cleaner Service Indicator Inspect ... 103
Engine Valve Lash InspecffAdjust ....................108
-
Rotating Rectifier Check ...................................125
I
Engine Oil Level - Check ....................................106
Generator Load -Check ......................................117
WalkAround Inspection ......................................128
Every 15 000 L (4000 US gal) of Fuel or 2000
Service Hours or 2 Years
Alternator - Inspect ...............................................89
1
Every Week
Cooling System Coolant (DEAC) Change .......... 91 -
Cooling System Water Temperature Regulator -
Replace .............................................................. 99
-
Generator Inspect ..............................................116
Engine Crankcase Breather CleanlReplace ..... 104 -
Every 100 Service H o u r s or 3 Months
-
Fuel Injection Nozzles TesffExchange .............. 109
-
Generator Dly ................................................... 114
-
Insulation Test ..................................................
: 120 -
Starting Motor Inspect ......................................127
-
Turbocharger lnspecffclean .............................127
Every 500 Service H o u r s Water Pump - Inspect ......................................... 129

Cooling System Coolant Sample (Level 1) - Every 75 000 L (20 000 US gal) o f Fuel o r 10
Obtain ................................................................97 000 Service Hours

Every Year Overhaul Considerations .................................... 123

Cooling System Coolant Sample (Level 2) - Every 22 800 L (6000 US gal) of Fuel or 3000
Obtain ............................................................ 98 Service Hours
Cooling System Coolant Extender (ELC) - Add .... 96
I
 85
Maintenance Section
Maintenance Interval Schedule

3 Maintenance Interval Schedule

102206974
First 470 L (125 US gal) of Fuel o r First 20 t o
40 Sewice Hours

(3054 Turbocharged Marine -

Generator Set Engine)
SMCS Code: 1000; 7500
SIN: TCNI -Up
Note: Before performing any operation or
maintenance procedures, ensure that the Safety
Information, warnings, and instructions are read
and understood.
To determine the maintenance intervals, use fuel
consumption, service hours, or calendar time,
whichever occurs first . Experience has shown that
maintenance intervals are most accurately scheduled
on the basis of fuel consumption.
Belts InspecffAdjusffReplace . 91
Engine Valve Lash - InspecUAdjust ....................108
Every 4450 L (1175 U S gal) o f Fuel or 250
S e w i c e Hours or I Year
Cooling System Supplemental Coolant Additive
-
(SCA) TesffAdd .................................................98
Every 4700 L (1250 U S gal) o f Fuel or 400
Service Hours or 1 Year
Auxiliary Water Pump (Rubber Impeller) -
lnspect ..............................................................89
-
Battery Electrolyte Level Check ..........................90
Cooling System Supplemental Coolant Additive
-
(SCA) TesUAdd .............................................. 98
Crankshaft Vibration Damper - lnspect .................99
Engine Air Cleaner Element (Dual Element) -

I Before each consecutive interval is performed, all

of the maintenance items from the previous interval
must also be performed.
CleanlReplace .........'....................................... 101
-
Engine Mounts lnspect .....................................106
-
Engine Oil Sample Obtain ................................106
Engine Oil and Filter - Change ...........................107
When Required Fuel System Primary Filter (Water Separator)
- -
Element Replace 111
Battery Replace ..............................................89
'
Fuel System Secondary Filter - Replace ............. 112 .
-
Battery or Battery Cable Disconnect ..................90 -
Fuel Tank Water and Sediment Drain ................113
-
Engine Clean .................................................100 Fuel Transfer Pump'Strainer - Clean ...................114
Fuel System Prime - . . 110 -
Heat Exchanger lnspect .................................... 118
-
Generator Set Test ........................................... 118 Hoses and Clamps - InspecffReplace ................. 119
-
Rotating Rectifier Test .......................................126
Every 23 500 L (6250 US gal) o f Fuel or 2000
Daily Sewice Hours or 2 Years
Cooling System Coolant Level - Check ................ 97 Alternator - lnspect .......................:................
-
Electrical Connections Check ...........................100
Engine Air Cleaner Service Indicator lnspect ... 103- Cooling System Coolant (DEAC) Change .......... 91 -
89

Engine Oil Level - Check ....................................106

Cooling System Water Temperature Regulator -
Replace ............................................................
99
Generator Load - Check ......................................117 Engine Crankcase Breather - CleanIReplace ..... 104
Walk-Around Inspection ......................................128 -
Engine Valve Lash InspecUAdjust .................... 108
Fuel Injection Nozzles - TesUExchange .............. 109
Every Week Generator - Dry ..................................................114
Starting Motor - lnspect ..................... . ............. 127
-
Generator lnspect ............................................. 116
-
Turbocharger InspecWClean .............................127
Water Pump - lnspect ....129
Every 100 S e w i c e Hours or 3 Months
Insulation -Test ................................................. 120 Every 70 500 L (18 750 US gal) of Fuel o r
6000 Sewice Hours
Every 500 Sewice Hours -
Cooling System Coolant (ELC) Change ............. 94
Cooling System Coolant Sample (Level 1) -
- Obtain .............................................................97 Every 7500 L (2000 US gal) of Fuel or 1000
Sewice Hours
.very year
\
-
Rotating Rectifier Check ................................... 125
Cooling System Coolant Sample (Level 2) -
Obtain .................................................................98
86
Maintenance Section
Maintenance Interval Schedule

Every 117 500 L (31 250 US gal) of Fuel or

10 000 Service Hours
Overhaul Considerations 123

Every 28 500 L (7500 US gal) of Fuel or 3000

Service Hours
-
Cooling System Coolant Extender (ELC) Add .... 96

ap Maintenance Interval Schedule
(3056 Turbocharged Marine
Generator Set Engine)
I SMCS Code: 1000; 7500
I SIN: SNXI-Up
Note: Before performing any operation or
maintenance procedures. ensure that the Safety
Information. warnings. and instructions are read
and understood . Crankshaft Vibration Damper - Inspect ................. 99
1 To determine the maintenance intervals. use fuel
consumption. service hours. or calendar time.
whichever occurs first . Experience has shown that
1 maintenance intervals are most accurately scheduled
on the basis of fuel consumption.
Before each consecutive interval is performed. all
II of the maintenance items from the previous interval
must also be performed.
When Required
#. $ Battery .Replace ................................................ 89
Battery or Battery Cable .Disconnect ............:..... 90
Engine .Clean ..................................................100
Fuel System .Prime ............................................
Generator Set .Test ............................................ 118
Rotating Rectifier .Test ......................................126
I .
Daily
Cooling System Coolant Level .Check ................ 97
Electrical Connections .Check ...........................100
Engine Air Cleaner Service Indicator .Inspect ... 103
Engine Oil Level .Check .................................... 108
Generator Load .Check ......................................117
Walk-Around Inspection ......................................128
I Every Week
1 Generator .Inspect ............................................
I Every 100 Service Hours or 3 Months
I Insulation .Test ..................................................120
I Every 500 Service Hours
Cooling System Coolant Sample (Level 1) .
Obtain .................................................................
Cooling System Coolant Sample (Level 2) .
Obtain ...............................................................
87
Maintenance Section
Maintenance Interval Schedule
102206976 First 700 L (185 US gal) of Fuel or First 20 to
40 Sewice Hours
Belts .InspectlAdjusffReplace.............................. 91
Engine Valve Lash .InspectlAdjust .................... 108
Every 4450 L (1175 US gal) of Fuel or 250
Service Hours or 1 Year
Auxiliary Water Pump (Rubber Impeller) .
Inspect ................................................................89
-
Battery Electrolyte Level Check .......................... 90
Cooling System Supplemental Coolant Additive
-
(SCA) TestlAdd .................................................98
Engine Air Cleaner Element (Dual Element) -
CleanlReplace ..................................................101
-
Engine Mounts Inspect .....................................106
Engine Oil Sample - Obtain ................................106
-
Engine Oil and Filter Change ...........................107
Fuel System Primary Filter (Water Separator)
-
Element Replace .............................................111
Fuel System Secondary Filter - Replace .............112
-
Fuel Tank Water and Sediment Drain ................113
Fuel Transfer Pump Strainer - Clean ................... 114
-
Heat Exchanger Inspect ....................................118
Hoses and Clamps - InspectlReplace .................119
Every 4700 L (1250 US gal) of Fuel or 400
Service Hours or 1 Year
110 Cooling System Supplemental Coolant ~dditive
(SCA) .TestlAdd .................................................98
Every 36 000 L (9500 US gal) of Fuel or 2000
Service Hours or 1 Year
. 89
Alternator -Inspect ...............................................
-
Water Pump Inspect .........................................129
Every 36 000 L (9500 US gal) of Fuel or 2000
Service Hours or 2 Years
Cooling System Coolant (DEAC) .Change .......... 91
Cooling System Water Temperature Regulator .
Replace ............................................................. 99
116 Engine Valve Lash .InspectlAdjust ....................108
Fuel Injection Nozzles .TestlExchange .............. 109
Generator, Dry ........................:.......................... 114
Starting Motor .Inspect ....................... . . .......... 127
Turbocharger .InspectlClean .............................127
Every 43 200 L (11 250 US gal) of Fuel or 3000
Service Hours or 2 Years
97
Cooling System Coolant Extender (ELC) .Add .... 96
Every 108 000 L (28 500 US gal) of Fuel or
6000 Service Hours
98
Cooling System Coolant (ELC) .Change ............. 94
88
Maintenance Section
Maintenance Interval Schedule

Every 7500 L (2000 US gal) of Fuel or 1000

Service Hours
-
Rotating Rectifier Check ................................... 125

Every 180 000 L (47 500 US gal) of Fuel or

10 000 Service Hours
Overhaul Considerations .................................... 123

-
Alternator lnspect -
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection
of the alternator. lnspect the alternator for loose
connections and proper battery charging. lnspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance andlor
proper performance of the electrical system. Make
repairs, as required. Refer to the Service Manual.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
'3 Auxiliary Water Pump (Rubber 101041983
Impeller) - Inspect
SMCS Code: 1371-040
Impellers and seals require periodic inspection.
lm~ellershave a service life that is limited. The
sehice life depends on the engine operating
conditions. . .
lnspect the components more frequently when the
pump is exposed to debris, sand, or other abrasive
materials. lnspect the components if the pump is
operating at a differential pressure of more than
103 kPa (15 psi).
Check the following components for wear or damage:
Bearings
Impeller
Seals
Wear date
) If wear 0; damage is found, replace the components
which are worn or damaged. Use the proper repair
kit for the pump. Refer to the Disassembly and
Assembly for more information on servicing the
auxiliary water pump.
89
Maintenance Section
Alternator - lnspect
101505178
-
Battery Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures i n or-
der t o help prevent electrical arcs andlor sparks
near batteries. Do not smoke when batteries are
se~iced.
--
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting i n personal injury.
1. Tum the key start switch to the OFF position.
Remove the key and all electrical loads.
2. Tum OFF the battery charger. Disconnect the
charger.
3. The NEGATIVE "-" cable connects the NEGATIVE
"-" battery terminal to the NEGATIVE "- VE"
terminal on the starter motor. Disconnect the cable
from the NEGATIVE "-" battery terminal.
4. The POSITIVE "+" cable connects the POSITIVE
"+" battery terminal to the POSITIVE "+" terminal
on the starting motor. Disconnect the cable from
the POSITIVE "+" battely terminal.
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 cables are connected, ensure that
the key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE "+" battery terminal.
90
Maintenance Section
-
Battery Electrolyte Level Check

8. Connect the cable from the NEGATIVE "- VE" I01492884 0

terminal on the starter motor to the NEGATIVE
"-" battery terminal. Battery or Battery Cable -
Disconnect
I
Battery Electrolyte Level -
102213936
SMCS Code: 1402-029
I
Check
SMCS Code: 1401-535 The battery cables or the batteries should not be
removed with the battery cover i n place. The bat-
When the engine is not run for long periods of time or tery cover should be removed before any servic-
when the engine is run for short periods, the batteries ing is attempted.
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries Removing the battery cables or the batteries with
are properly charged, ammeter reading should be the cover in place may cause a battery explosion
very near zero. resulting i n personal injury.

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

All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear aface
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.
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. 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.
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.

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 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.
 Maintenance Section
Belts - lnspecffAdjusffReplace

If new belts are installed, check the belt adjustment

-
Belts lnspectlAdjust/Replace again afler 30 minutes of engine operation at the
rated rpm.
SMCS Code: 1357-025; 1357-040; 1357-510
Replacement of Multiple Drive Belts
Inspection For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry
more load because the older belts are stretched. The
additional load on the new,belt could cause the new
belt to break.

102200274

Cooling System Coolant

(DEAC) Change-
SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the cooling

system before the recommended maintenance
inrerval if the following conditions exist:

The engine overheats frequently.

Foaming is observed. '

g00750216
Illustration 67
The oil has entered the cooling system and the
The belt cover must be removed for inspection, adjustment and
replacement. coolant is contsminated.
(1) Mounting bolts
(2) Adjustment bolt The fuel has entered the cooling system and the
(3) Typical belt tension gauge coolant is contaminated.

To maximize the engine performance, inspect the NOTICE

belt for wear and for cracking. Check the belt tension.
Adjust the belt tension in order to minimize belt
slippage. Belt slippage will decrease the life of the
belt.
For the correct tension on the belt, refer to
Specifications, "Belt Tension Chart".
Adjustment
I.Remove the belt cover.
2. Loosen mounting bolts (1) and adjusting bolt (2).
3. Slide the alternator in the direction that will give
the correct tension.
4. Tighten adjusting bolt (2). Tighten mounting
bolts (1). For the proper torque, refer to the
Specifications Manual, SENR3130, "Torque
Specifications".
5. Reinstall the belt cover.
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
Note: Inspect the water pump and the water
temperature regulator afler the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
92
Maintenance Section
Cooling System Coolant (DEAC) - Change

lllustration 68 go0740037
lllustration 71
go0822695 1
Typical example (5) Drain plug on the water cooled exhaust manifold for the 3056
(1) Expansion tank Marine Generator Set
(2) Cooling system filler cap

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

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system tiller cap.

, ,
go0822687
lllustration 72
Engine oil cooler for the 3054 Marine Generator Set
(6) Hose for the outlet of the coolant
(7) Hose for the inlet of the coolant

lllustration 69
(3) Drain plug on the cylinder block

go0822694
lllustration 73
(8) Heat exchanger for the 3056 Marine Generator Set
(9) Drain plug for the heat exchanger

Illustration 7 0
go0822686 2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
(4) Drain on the water cooled exhaust manifold for Ule 3054
Marine Generator Set
valve, remove the cooling system drain plugs.

9
- Remove the drain plug from the cylinder block
(3). Remove the drain plug for the water cooled
exhaust manifold (4) or (5). Remove the hoses
for the engine oil cooler (6) and (7), if equipped.
Remove hose for the heat exchanger on the
3054 engine. Remove the drain plug for the heat
exchanger on the 3056 engine. Allow the coolant
to drain.
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.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
Group:
Outside Illinois: 1-800-542-8665
Inside Illinois: 1-800-541-8665
Canada: 1-800-523-8665
Flush
1. Flush the coolina svstem with clean water in order
to remove any debiis.
2. Close the drain valve (if equipped). Clean the
drain plugs. lnstall the drain plugs. For the
proper torque, refer to the Specifications Manual,
SENR3130, "Torque Specifications".
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. lnstall
the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 30 minutes with a coolant temperature of qt
least 82°C (180°F).
NOTICE
lmproper or incomplete rinsing of the cooling system
3- can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
93
Maintenance Section
Cooling System Coolant (DEAC) Change-
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve
(if equipped). Clean the drain plugs. Install the
drain plugs. For the proper torque, refer to the
Specifications Manual, SENR3130, "Torque
Specifications".
Cooling Systems with Heavy
Deposits or Plugging
..
Note: For the following procedure to be effective,
there must be some active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. lnstall the drain plugs. For the
proper torque, refer to the Specifications Manual,
SENR3130, "Torque Specifications".
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. lnstall the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 90 minutes. The coolant temperature should be
at least 82°C (180°F).
NOTICE
lmproper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
94
Maintenance Section
Cooling System Coolant (ELC) - Change

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

Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve
(if equipped). Clean the drain plugs. Install the
drain plugs. For the proper torque, refer to the
Specifications Manual, SENR3130, "Torque
Specifications".
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the system to the top with the mixture of
coolantlantifreezethat is recommended. Refer to
the Operation and Maintenance Manual for more
information on cooling system specifications. Do
not install the cooling system filler cap.
2. Start and run the engine at low idle. lndrease the
engine rpm to 1500 rpm. Run the engine at 1500
p m for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
Cooling System Coolant (ELC)
102214231 c
-Change
SMCS Code: 1350-070; 1395-044
When the cooling system is cleaned, only clean water
is needed when the ELC is drained and replaced.
Note: lnspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order t o relieve the pres-
sure.

3. Add coolantlantifreeze into the cooling system

until the cooling system is full to the top.

4. Clean the cooling system filler cap. lnspect

the gasket for the cooling system filler cap. If
the gasket for the cooling system filler cap is '
damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket for the cooling system filler cap is not
damaged, use a 9s-8140 Pressurizing Pump in,
order to pressure test the cooling system filler cap.
The correct pressure for the cooling system filler
cap is stamped on the face of the cooling system Illustration 74
filler cap. If the cooling system filler cap does not Typical example
retain the correct pressure, install a new cooling
(1) Expansion tank
system tiller cap. (2) Cooling system filler cap

5. Pour coolantlantifreeze into the recovety tank until I.Stop the engine and allow the engine to cool.
the coolant reaches "COLD FULL" mark. Do not Loosen cooling system filler cap (2) slowly in order
fill the recovety tank above "COLD FULL" mark. to relieve any pressure. Remove cooling system
filler cap (2).
6. Clean the filler cap for the expansion tank. Install
the filler cap for the expansion tank. Start the
engine. lnspect the cooling system for leaks and
for proper operating temperature.
 95
Maintenance Section
Cooling System Coolant (ELC) Change -

Illustration 78 go0622687

(3) Drain plug on the cylinder block Engine oil cooler

(6) Hose for the outlet of the coolant
(7) Hose for the inlet of the coolant

lllustration 76 go0822686

(4) Drain on the water cooled exhaust manifold for the 3054
Marine Generator Set lllustration 79 go0822694

(8) Heat exchanger for the 3056 Marhe Generator Set

(9) Dra n plug for tne heat excnanger

2. Open the cooling system drain valve (if equipped).

If the cooling system is not equipped with a drain
valve, remove the cooling system drain plugs.

Remove the drain plug from cylinder block (3).

Remove the drain plug for water cooled exhaust
manifold (4) or (5). Remove the hoses for engine
oil cooler (6) and (7), if equipped. Remove hose
for the heat exchanger on the 3054 engine.
Remove the drain plug for the heat exchanger on
the 3056 engine. Allow the coolant to drain.
go0822695
lllustration 77
(5) Drain plug on the water cooled exhaust manifold for the 3056
NOTICE
Marine Generator Set 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.

For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
Group:
96
Maintenance Section
Cooling System Coolant Extender (ELC) -Add
Outside Illinois: 1-800-542-8665
Inside Illinois: 1-800-541-8665
Canada: 1-800-523-8665
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. lnstall the drain plugs. For the
proper torque, refer to the Specifications Manual,
SENR3130, "Torque Specifications".
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with clean water. lnstall the
cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66°C (120 to 150°F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if .
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve
(if equipped). Clean the drain plugs. lnstall the
drain plugs. For the proper torque, refer to the
Specifications Manual, SENR3130, "Torque
Specifications".
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system to the top with the
ELC. Refer to the Operation and Maintenance
Manual for more information on cooling system
specifications. Do not install the cooling system
filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at 1500
rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Add the ELC into the cooling system until the
cooling system is full to the top.
4. Clean the cooling system filler cap. lnspect
the gasket for the cooling system filler cap. If
the gasket for the cooling system filler cap is
damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket for the cooling system filler cap is not
damaged, use a 9s-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap.
The correct pressure for the cooling system filler
cap is stamped on the face of the cooling system
filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling
system filler cap.
5. Pour the ELC into the recovery tank until the
coolant reaches the "COLD FULL" mark. Do not
fill the tank above "COLD FULL" mark.
6. Clean the cooling system filler cap. lnstall the
cooling system filler cap. Start the engine. lnspect
the cooling system for leaks and for proper
operating temperature.
102106346
Cooling System Coolant
Extender (ELC) Add -
,
SMCS Code: 1352-045; 1395-081
Caterpillar Extended Life Coolant (ELC) does not
require the frequent Supplemental Coolant Additive
(SCA) additions which are associated with the
present conventional coolants. The Extender only
needs to be added once.
Check the cooling system only when the engine is
stopped and cool.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling I
system filler cap.
I
2. It may be necessary to drain enough coolant from
the cooling system in order to add the Extender.
3. Add Extender according to the requirements for
1
your engine's cooling system capacity. Refer
to the Operation and Maintenance Manual,
"Refill Capacities and Recommendations" in
the Maintenance Section for more information
concerning the Caterpillar ELC Extender additions.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. lnstall the cooling system filler cap. I
I
I

-
Cooling System Coolant Level
-Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
1. Observe the coolant level in the coolant recovery
tank. Maintain the coolant level to "COLD FULL"
mark on the coolant recovery tank.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
2. Loosen filler cap slowly in order to relieve any
pressure. Remove the filler cap.
,$ 3. Pour the proper coolant mixture into the tank.
Refer to the Operation and Maintenance Manual,
"Refill Capacities and Recommendations" for
information on the correct mixture and type of
coolant. Refer to the Operation and Maintenance
Manual, "Refill Capacities and Recommendations"
for the cooling system capacity. Do not fill the
coolant recovery tank above "COLD FULL" mark.
--
lllustratian 80
goo103639
4. Clean filler c a and
~ the receptacle. Reinstall the
filler cap and inspect the cooling system for leaks.
1 Submit the sample for Level 1 analysis.
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
and cool, the coolant will return to the engine.
97
Maintenance Section
-
Cooling System Coolant Level Check
i01987707
Cooling System Coolant
Sample (Level I) Obtain -
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
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 incor-
Note: Level 1 results may indicate a need for
Level 2 Analysis.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of S.0.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 gujdelines for proper sampling of
the coolant:
Complete the information on the label for the
sampling bottle before you begin to take the
samples.
Keep the unused sampling bottles stored in plastic
bags.
Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
Keep the lids on empty sampling bottles until you
are ready to collect the sample.
Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
Never collect samples from expansion bottles.
Never collect samples from the drain for a system.
For additional information about coolant analysis,
see Special Publication, SEBU6251, "Caterpillar
Commercial Diesel Engine Fluids Recommendations"
or consult your Caterpillar dealer.
98
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

101987714 Water and SCA

Cooling System Coolant
Sample (Level 2) Obtain - NOTICE
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling..
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 incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Do not exceed the recommended eight percent sup-
~lementalcoolant additive concentration.
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.

Refer to Operation and Maintenance Manual, 3. Add tap water to the mixing bottle in order to bring
"Cooling System Coolant Sample (Level 1) - Obtain" the level up to the "10 ml" mark. Place the cap on
for the guidelines for proper sampling of the coolant. the bottle and shake the bottle.

Submit the sample for Level 2 analysis.
For additional information about coolant
analysis, see Special Publication, SEBU6251,
"Caterpillar Commercial Diesel Engines Fluids
Recommendations" or consult your Caterpillar dealer.
102017557
Cooling System Supplemental
Coolant Additive (SCA)
TestlAdd
- drops of "NITRITE TEST SOLUTION A" that were
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
required to cause the color change.

7. Use Table 13 to interpret the results.

SMCS Code: 1352-045; 1395-081 Table 13

Number of Concentration
of SCA I Maintenance
Reouired
Less than 25 Less than the Add SCA.
Cooling system coolant additive contains alkali. recommended Retest the
To help prevent personal injury, avoid contact with concentration of coolant.
the skin and eyes. Do not drink cooling system SCA
coolant additive.
The None
recommended

r
Note: Caterpillar recommends an S.0.S coolant concentration of
analysis (Level 1). SCA
More than 30 More than the Remove the
Test the Concentration of the SCA recommended coolant.
concentration of Replace with
SCA water only
CoolanffAntifreeze and SCA Retest the
I coolant.
NOTICE
Do not exceed the recommended six percent supple-
mental 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.

1 -@ Add the SCA, If Necessary
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly i n order t o relieve the pres-
sure.
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 concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
1 If the water temperature regulator is installed incor-
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
er, overheating, andlor accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supple-
mental coolant additive concentration.
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.
100912898
Cooling System Water
Temperature Regulator - -Inspect
Replace
SMCS Code: 1355-510
3 Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime.
99
Maintenance Section
Cooling System Water Temperature Regulator - Replace
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator installed.
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or
cylinder head surface.
Refer to the Service Manual for the replacement
procedure of the water temperature regulator, or
. consult your Caterpillar dealer.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
100934535
Crankshaft vibration Damper
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to
the crankshaft and to other engine components. A
damper that is damaged can cause excessive gear
train noise at variable points in the speed range.
100
Maintenance Section
-
Electrical Connections Check

The damper is mounted to the crankshaft which is Check all lead wires and electrical connections for
located behind the belt guard on the front of the proper clearance.
engine.

Visconic Damper
The visconic damper has a weight that is located
Engine Clean -
inside a fluid filled case. The weight moves in the SMCS Code: 1000-070
case in order to limit torsional vibration.

lnspect the damper for evidence of fluid leaks. If

a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous,
smooth, and difficult to remove from surfaces.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
seals.
lnspect the damper and repair or replace the damper
for any of the following reasons:
The damper is dented, cracked, or leaking.
The paint on the damper is discolored from heat.
The engine has had a failure because of a broken
crankshaft.
Analysis of the oil has revealed that the front main
bearing is badly worn.
There is a large amount of gear train wear that is
not caused by a lack of oil.
Personal injury or death can result from high volt-
age.
Moisture can create paths of electrical conductiv-
ity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls "DO
NOT OPERATE".
NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
s ~ i l l swhenever a significant
- quantity accumulates on
the engine.
Periodic cleaning of.the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
Easy detection of fluid leaks

Refer to the Service Manual or consult your Maximum heat transfer characteristics
Caterpillar dealer for information about damper
replacement. . Ease of maintenance

Note: Caution must be used in order to prevent

Electrical Connections Check
SMCS Code: 4459-535
101595880 electrical components from being damaged by
- excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.

Check all exposed electrical connections for

tightness.

Check the following devices for loose mounting or

for physical damage:

transformers

fuses

capacitors

lightning arrestors

Engine Air Cleaner Element (Dual Element) CleanlReplace
101553486
Engine Air Cleaner Element
(Dual Element) CleanIReplace-
SMCS Code: 1054-037; 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 air-
borne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
runnina since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements
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 Caterpillar 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.
Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner
element. ..
The air cleaner element may be cleaned up to
six times if the element is properly cleaned and
inspected.
The air cleaner element should be replaced at least
one time per year. This replacement should be
performed regardless of the number of cleanings.
Replace the dirty paper air cleaner elements with
clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked
for tears andlor 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.
101
Maintenance Section
-
Dual Element Air Cleaners
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
should be removed and discarded for every three
. cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
Illustration 81
900736431
( I )Cover
(2) Primany air cleaner element
(3) Secondary air cleaner element
(4) Turbocharger air inlet
1. Remove the cover. Remove the primary air
cleaner element.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings
of the primary air cleaner element.
Note: Refer to "Cleaning the Primary Air Cleaner
Elements".
3. Cover the turbocharger air inlet with tape in order
to keep dirt out.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned.
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
102
Maintenance Section
Engine Air Cleaner Element (Dual Element) - CleanlReplace

Cleaning the Primary Air Cleaner Pressurized Air

Elements
. . - -. .-
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Cateroillar cleanina orocess uses Droven orocedures
to assure consisteit'quality and sifficient k~terlife.
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).

Observe the following guidelines if you attempt to

clean the filter element:

Do not tap or strike the filter element in order to re-

move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets; or
seals. Dirt entering the engine will cause damage to
engine components.
go0281692
illustration 82
Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).

Aim the hose so that the air flows inside the element
The primary air cleaner element can be used up
along the length of the filter in order to help prevent
to six times if the element is properly cleaned and
damage to the paper pleats. Do not aim the stream
inspected. When the primary air cleaner element is
of air directly at the primary air cleaner element. Dirt
cleaned, check for rips or tears in the filter material.
could be forced further into the pleats.
The primary air cleaner element should be replaced
at least one time per year. This replacement should
Note: Refer to "lnspecting the Primary Air. Cleaner
be performed regardless of the number of cleanings.
Elements".
, .
Use clean primary air cleaner elements while dirty
elements are being cleaned. Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
NOTICE primary air cleaner elements which require daily
Do not clean the air cleaner elements by bumping or cleaning because of a dly, dusty environment.
tapping. This could damage the seals. Do not use el- Cleaning with pressurized air is recommended prior
ements with damaged pleats, gaskets or seals. Dam- to vacuum cleaning. Vacuum cleaning will not remove
aged elements will allow dirt to pass through. Engine deposits of carbon and oil.
damage could result.
Note: Refer to "Inspecting the Primary Air Cleaner
Visually inspect the primary air cleaner elements . Elements":
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.

There are two common methods that are used to

clean primary air cleaner elements:

Pressurized air

Vacuum cleaning

1 -@ Inspecting the Primary Air Cleaner
Elements
go0281693
Illustration 83
lnspect the clean, dry primary air cleaner element.
Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
lnspect the primary air cleaner element for tears
andlor holes. lnspect the primary air cleaner element
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare
the primary air cleaner element to a new primary air
cleaner element that has the same part number.
Do not use a primary air cleaner element that has
any tears andlor holes in the filter material. DO not
use a primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
Storing Primary Air Cleaner Elements
If a primary air cleaner element that passes inspection
will not be used, the primary air cleaner element can
be stored for future use.
go0281694
Illustration 84
103
Maintenance Section
Engine Air Cleaner Service Indicator - lnspect
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
Date of cleaning
Number of cleanings
Store the box in a dry location.
i01900118
Engine Air Cleaner Service
Indicator lnspect -
(If Equipped)
SMCS Code: 7452-040
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differentialgauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner housing or in a remote location.
go0103777
Illustration 85
Typical service indicator
104
Maintenance Section
-
Engine Crankcase Breather CleanlReplace

Observe the service indicator. The air cleaner

-
101585200
element should be cleaned or the air cleaner element
should be replaced when one of the following Engine Crankcase Breather
conditions occur:

The yellow diaphragm enters the red zone.

The red piston locks in the visible position.

SMCS Code: 1317-070; 1317-510
I I
Test the Service Indicator
Service indicators are important instruments.
3054 Marine Generator Set
II
Check for ease of resetting. The service indicator
should reset in less than three pushes.
. Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.

If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged.

The service indicator may need to be replaced

frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components-are replaced.

Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 N.m (18 lb in). ,.

go0749578
Illustration 86
(1) Valve
(2) Clips
(3) Element
(4) Clip retainers
(5) Baffles
(6j Gasket
(7) Elbow

Note: Clean the body of the breather, the cover, and

the baffle (5) and replace the element (3) at 2000
Service Hours. Replace the valve (1) at 4000 Service
Hours.

The crankcase breather removes the combustion

gases from the engine crankcase. The crankcase
breather directs the gases to the induction system.

3 An internal port in the rocker cover allows the gases
in the crankcase to pass into the breather body
through an element (3). The gases flow through a
series of baffles (5) and into the valve cover through
holes at the bottom of the chamber for the baffles.
Valve (1) controls the flow of gases which pass from
the breather through the plastic outlet elbow (7) to
the intake manifold.
The valve cover and the breather assembly are made
of a composite material. The valve cover and the
breather assembly should be removed and installed
with care.
Disassembly
NOTICE
Do not use excessive force to removethe hose from
the breather outlet elbow. If the breather outlet elbow
breaks away from the breather body, see the proce-
dure to repair the connection for the breather outlet
elbow.
1. Release the hose clamp and carefully remove the
hose from elbow (7).
) 2. Remove the valve cover Refer to the Service
Manual for more information.
NOTICE
Use care not to damage the breather cover or the
breather body with a pry bar.
3. Remove the bolts and carefully remove the .
breather cover from the breather body. It may
be necessary to use a suitable pry bar in order
to remove the breather cover from the breather
body. Ensure that the pry bar does not damage
the breather cover or the breather body. Gasket'
(6) should be removed and discarded.
4. Release clip retainers (2) on valve (1). Push valve
( I ) out of the breather cover.
5. Element (3) should be removed and discarded.
NOTICE
To prevent damage to the breather valve, remove the
breather valve before the cover is washed.
NOTICE
3 Ensure that all the cleaning fluid is removed before the
breather is assembled.
6. Use a clean nonflammable solvent to wash the
body of the breather, the cover, baffle (5), and
elbow (7). Thoroughly dry the components afler
cleaning the components.
I
105
Maintenance Section
Engine Crankcase Breather - CleanlReplace
7. Ensure that the holes in the bottom of the chamber
for baffles (5 ) are not restricted. If necessary,
clean the holes.
Assembly
1. lnstall baffles (5) into the grooves in the breather
body.
2. lnstall a new element (3) into the breather body.
3. lnstall a new valve ( I ) into the breather cover.
Ensure that clip retainers (2) are engaged
correctly.
4. lnstall a new gasket (6). The gasket is installed
dry. Put the cover and valve assembly into position
on the breather body. Loosely install the bolts.
Tighten the bolts gradually and tighten the bolts
evenly to a torque of 3 N.m (27 lb in).
NOTICE
Do not use excessive force to fit the hose to the
breather outlet elbow.
5. Ensure that there is no restriction in elbow (7) or
in the breather hose. Carefully install the breather
hose on elbow (7). Tighten the hose clamps that
fasten the hose to the elbow.
Procedure to Repair the Connection for
the Outlet Elbow of the Breather
If the outlet elbow for the crankcase breather breaks,
then use the following procedure in order to repair
the elbow.
NOTICE
Thoroughly clean the inside of the breather body afler
it has been drilled.
1. Ensure that the breather body is secure. Use a
22.5 mm (0.89 inch) drill in order to drill to a depth
of 10.0 mm (0.39 inch). Drill the depth in order to
remove the broken connection of the outlet elbow.
Thoroughly clean the inside of the breather body.
2. Thoroughly clean the contact faces of the elbow
(7) and the breather cover.
3. lnstall elbow (7). Ensure that the contact surface
of the connection for the elbow has a rough finish.
Put the elbow into position on the breather body.
4. Apply PertnabondB E3524 adhesive. Refer to the
instructions on the adhesive. The adhesive will
secure the elbow to the breather body.
106
Maintenance Section
Engine Mounts - lnspect
3056 Marine Generator Set
The closed crankcase ventilation system (CCV) on
the 3056 Marine Generator Set is maintenance free.
No maintenance is required.
i00259257
Engine Mounts lnspect - 2. Remove the oil filler cap and add oil, if necessary.
SMCS Code: 1152-040
lnspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions:
Improper mounting of the engine
Deterioration of the engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the Service Manual for
the recommended torques. Refer to the OEM
recommendations for more information.
100623423
Engine Oil Level Check - Obtain the Sample and the Analysis
SMCS Code: 1348-535-FLV
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
ADD 1 1 FULL
Illustration 87
(Y) " A D D mark. (X) 'FULL" mark.
NOTICE
Perform this maintenance with the engine stopped.
1. Maintain the oil level between "ADD" mark (Y) and
"FULL" mark (X) on oil level gauge (1). Do not fill
the crankcase above "FULL" mark (X).
NOTICE
Operating your engine when the oil level is above the
"FULL" mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.
Clean the oil filler cap. Install the oil filler cap.
101935337
Engine Oil Sample Obtain -
SMCS Code: 1000-008; 1346-554-SM;
7542-554-OC, SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S.0.S oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. S.0.S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
GI(1
Hot oil and hot components can cause personal
injury. Do not allow hot oil o r hot components t o
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:
i
Engine model
Service hours on the engine
The number of hours that have accumulated since
I
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, well mixed oil
II
sam~le.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
 107
Maintenance Section
-
Engine Oil and Filter Change

-@ Caterpillar recommends using the sampling valve

in order to obtain oil samples. The quality and the
Drain the Engine Oil
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
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 incor-
rect interpretation that could lead to concerns by both
dealers and customers.
900749474
If the engine is not equipped with a sampling valve, Illustration 88
use the 1U-5718 Vacuum Pump. The pump is Manual sump pump for the engine oil
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion 1. Connect a suitable hose to the outlet of the manual
) into the sump. sump pump for the engine oil. Place the opposite
end of the hose into a suitable container. The .
For instructions, see S~ecialPublication. PEHP6001. ' container should hold at least 18 L (19 qt) of oil.
"How To Take A ~ o o d ' o iSample".
l consult your
Caterpillar dealer for complete information and 2. Pump the handle of the manual sump pump until
assistance in establishing an S . 0 6 program for your the oil has been removed from the engine into
engine. the suitable container. Dispose of the used oil in
accordance with local regulations.
102201300

Engine Oil and Filter Change - Replace the Oil Filter

SMCS Code: 1318-510; 1348-044 NOTICE

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components t o
contact the skin.
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.

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
with the draining cold oil. Drain the crankcase w~th
the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
properly.
I.~ e m o v ethe oil filter with a 111-8760 Chain
Wrench.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter. Break apart the pleats and inspect the oil
filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early wear
or a pending failure.

Failure to follow this recommended procedure will Use a magnet to differentiate between the ferrous
cause the waste particles to be recirculated through metals and the nonferrous metals that are found in
the engine lubrication system with the new oil. the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.

-
108
Maintenance Section
-
Engine Valve Lash InspecffAdjust
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
lliuslralion 89
Typical mounting base for the oil filter and oil filter gasket
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
removed.
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
filter.
Fill the Engine Crankcase
1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual, "Refill Capacitites
and Recommendations" for more information on
the proper type of oil. Fill the crankcase with
the proper amount of oil. Refer to the Operation
and Maintenance Manual, "Refill Capacitites and
Recommendations" for the proper amount of oil.
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer's recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshafl bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at "LOW
IDLE" for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the "ADD"
g00741009 and "FULL"marks on the oil level gauge.
;
Engine Valve Lash -
Inspect/Adjust.
SMCS Code: 1102-025
The initial valve lash adjustment on new engines,
I
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of
the valve train components and to the seating of the
valve train components.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve
(
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
andlor shortened engine component life.
,'
:
3

) @- @ ! "
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine t o cool before mea-
suringladjusting valve lash clearance.
I Ensure that the engine is stopped before measuring
1 the valve lash. To obtain an accurate measuremeni,
aliow the valves to cool before this maintenance is
performed.
Refer to the Service Manual for more information.
100626014
Fuel lnjection Nozzles - 1. Start the engine.
TestlExchange
SMCS Code: 1254-013; 1254-081
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Fuel injection nozzles are subject to tip wear. Tip
wear is a result of fuel contamination. Tip wear can
cause the following problems:
Increased fuel consumption
Black smoke .
Misfire
Rough running
Fuel lnjection nozzles should be cleaned, inspected,
tested, and replaced, if necessary. Refer to Special
Instruction, SEHS7292 for using the 8s-2245
3 lnjection Cleaning Tool Group. Consult your
Caterpillar dealer about cleaning the fuel injection
nozzle and testing the fuel injection nozzle.
109
Maintenance Section
-
Fuel lnjection Nozzles TestlExchange
NOTICE
Never wire brush or scrape a fuel injection nozzle.
Wire brushing or scraping a fuel injection nozzle will
damage the finely machine orifice. Proper tools for
cleaning and testing the fuel injection nozzles can be
obtained from Catemillar dealers.
~~ ~ ~
The following items are symptoms of a malfunction of
the fuel injection nozzle:
Abnormal engine operation
Smoke emission
Engine knock
Each fuel injection nozzle must be isolated one at
a time in order to determine the malfunctioning fuel
injection nozzle.
2. Loosen each fuel line nut one at a time at the fuel
injection pump. A cloth or similar material must be
used in order to prevent fuel from spraying on the
hot exhaust components. Tighten each nut before
loosening the next nut.
3. A defective fuel injection nozzle may be identified
when a fuel line nut is loosened and the following
conditions are present:
The exhaust smoke is partially eliminated or the
exhaust smoke is completely eliminated.
Engine performance is not affected.
A fuel injection nozzle that is suspected of being
defective should be removed. A new fuel injection
nozzle should be installed in the cylinder in order
to determine if the removed fuel injection nozzle is
defective.
Removal and Installation of the
Fuel lnjection Nozzles
For the removal and the installation of fuel injection
nozzles, special tooling is required. Refer to the
Service Manual for more information. Consult your
Caterpillar dealer for assistance.
110
Maintenance Section
Fuel System Prime -

101539174 3. Loosen banjo bolt (1).

Fuel System Prime - Note: The priming lever of the fuel transfer pump
cannot be operated if the cam is at the maximum lift
SMCS Code: 1258-548 position. If this occurs, the crankshaft must be rotated
one revolution.
Priming the fuel system fills the fuel filter. Priming
the fuel system removes air bubbles from the fuel 4. Operate the priming lever for the fuel transfer
system. Prime the fuel system under the following pump until the flow of fuel from banjo bolt (1) is
conditions: continuous and free of air bubbles.
Fuel system that is run dry

Storage

Fuel filter maintenance

- Disconnectingfuel lines and installing fuel lines

. Repair of leaks in the fuel lines

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean u p fuel spills immediately.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
Illustration 91 go0286060
Priming lever for the fuel transfer pump
Note: The priming lever of the fuel transfer pump '
cannot be operated if the cam is at the maximum lift
position. If this occurs, the crankshaft must be rotated
one revolution.
5. Operate the priming lever for the fuel transfer
pump until the flow of fuel from the vent is
continuous and free of air bubbles. Tighten the
bolt at the top of the fuel filter.

go0799465
lllustration 90

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly lllustration 92 go0266061
clean the area around a fuel system component that Nut for the fuel Inlet line at the fuel injection pump
will be disconnected. Fit a suitable cover over discon-
nected fuel system component. 6. Loosen the nut for the fuel inlet line at the fuel
injection pump in order to open a vent. I
1. Loosen vent (2).

2. Tighten vent (2).

 111
Maintenance Section
-
Fuel System Primary Filter (Water Separator) Element Replace

) @ 7. ,Ensure that the manual stop control (if equipped)

IS in the RUN position. Turn the start switch to the
i02214246

RUN position. Operate the priming lever for the Fuel System Primary Filter
fuel transfer pump until the flow of fuel from the
vent is continuous and free of air bubbles. Tighten
(Water Separator) Element -
the nut for the fuel inlet line. Replace
! SMCS Code: 1260-510-FQ; 1263-510-FQ

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

I I I,
g00266062
illustration 93
Fuel line nuts at the fuel injection nozzles
8. Loosen two of the fuel line nuts at two of the fuel
injection nozzles in order to open two vents.
@ NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Turn the fuel supply valve to the OFF position before
perfomling this maintenance. Place a tray under the
fuel filter in order to catch any fuel that might spill.
Clean up any spilled fuel immediately.

9. Ensure that the manual stop control (if equipped)

is in the RUN position. Crank the starting motor
until the flow of fuel from the vents is continuous
and free of air bubbles. Tighten the fuel line nuts.

10. Ensure that all fuel line connections are secure

and tightened to the proper torque. Ensure that
any spilled fuel is cleaned up.
.
11. Start the engine. The engine may run rough.
Run the engine at low idle until the engine runs go0741109
smoothly. If the engine will not start, further Illustration 94
priming may be necessary. If the engine starts and (1) Cap
if the engine continues to misfire or smoke, one or (2) Locking ring
(3) Element
more of the following conditions may be present: (4) Water separator bowl
(5) Drain '
The fuel system requires more priming.
1. Close the fuel supply valve.
There may be an air leak in the fuel system.
2. Clean the outside of the fuel filter assembly. Drain
the fuel into a suitable container by using the
fuel drain on the bottom of element (3). Drain
the water from water separator (4) into a suitable
container. Not all engines are equipped with a
water separator.
112
Maintenance Section
Fuel System Secondary Filter - Replace

Note: The fuel level in element (3) should be reduced

before removal of the element. Remove cap (1) if the
element is not equipped with a drain on the bottom.
Remove the nylon insert in order to reduce the level
of fuel in the element. A reduction in the level of fuel
in the element will help prevent fuel from being spilled
when the element is removed.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

NOTICE Turn the fuel supply valve to the OFF position before
Do not use a tool in order to remove the fuel filter. performing this maintenance. Place a tray under the
Attempting to remove the fuel filter with a filter wrench fuel filter in order to catch any fuel that might spill.
or a filter strap could damage the locking ring. Clean up any spilled fuel immediately.

3. Hold element (3) and rotate locking ring (2)

counterclockwise. Remove locking ring (2). The
used element should be removed and discarded.
3
Note: If the element is equipped with a sediment
bowl. remove the sediment bowl from the element.
~ h o r b u ~clean
h l ~ the sediment bowl. Inspect the
O-ring seals for wear or damage. Install new O-ring
seals, if necessary. Install the sediment bowl onto the
new element. Hand tighten the sediment bowl. Hand
tightening is the only method that should be used.

NOTICE ' Illustration 95 go0802952

Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
4. Ensure that the filter head is clean. Push a new
element fully into the filter head. .
5. Hold the element in place. Fit locking ring (2) into
position. Rotate the locking ring clockwise in order
to fasten the element to the filter head.
Note: If the nylon insert was removed, install the
nylon insert and install cap (1).
6. Prime the fuel system. Refer to the Operation and
Maintenance Manual, "Fuel System - Prime" for
more information.
(1) Cap
(2) Fuel filter base
(3) Quick release collar '
(4) Fuel filter
(5j Drain valve for fuel filter
1. Close the fuel supply valve.
2. Clean the outside of the fuel filter assembly. Open
drain valve (5) and drain the fuel and water from
fuel filter (4) into a suitable container.
Note: If the fuel filter element is not equipped with
a drain, remove cap (1). Remove the nylon insert
in order to reduce the level of fuel in the fuel filter
element. A reduction in the level of fuel in the fuel
filter element will help prevent fuel from being spilled
when the element is removed.

1017~3207 NOTICE
Fuel System Secondary Filter - Do not use a tool in order to remove the fuel filter.
Attempting to remove the fuel filter with a filter wrench
Replace or a filter strap could damage the locking ring.

SMCS Code: 1261-510-SE 3. Hold fuel filter (4) and rotate auick release collar I
(3) counterclock\;vise. ~ e m o v equick release collar
(3). The used element should be removed and
discarded. 6 (8
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

Note: If the element is equipped with a sediment
bowl, remove the sediment bowl from the element.
Thoroughly clean the sediment bowl. Inspect the
O-ring seals. Install new O-ring seals, if necessaly.
Install the sediment bowl to the new element. Hand
tighten the sediment bowl. Hand tightening is the
only method that should be used.
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system Darts.
4. Ensure that the fuel filter base is clean. Push a
new fuel filter fully into the fuel filter base.
5. Hold the fuel filter in place. Fit locking ring (3) into
position. Rotate the locking ring clockwise in order
to fasten the fuel filter to the fuel filter base.
Note: If the nylon insert was removed, install the
nylon insert and install cap (1).
6. Prime the fuel system. Refer to Operation and
Maintenance Manual, "Fuel System Prime".-
101877350
Fuel Tank Water and Sediment
-Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepareci to
collect the fluid with suitable containers before oDen-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" fortools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
113
Maintenance Section
-
Fuel Tank Water and Sediment Drain
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment
' Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Check the fuel daily. Drain the water and sediment
from the fuel tank afler operating the engine or drain
the water and sediment from the fuel tank afler the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
Fill the fuel tank afler operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks
Drain the water and the sediment from the fuel
storage tank during the following conditions:
Weekly
Oil change
Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank.
114
Maintenance Section
Fuel Transfer Pump Strainer - Clean

If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
101190897
Fuel Transfer Pump Strainer - does not enter the fuel system.
2. Use nonflammable solvent in order to clean the
strainer, the cover, and the seal. Carefully wash
any sediment from the chamber of the fuel transfer
pump.
3. Assemble the clean, dry fuel transfer pump.
I
NOTICE
Ensure that the lift pump cover is secure so that air II

Clean
SMCS Code: 1256-070-STR
4. Tum'the fuel supply to the ON position.

5. Prime the fuel system. Refer to the Operation

I
and Maintenance Manual for more information on
priming the fuel system.

Fuel leaked or spilled onto hot surfaces or elec- 1

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters o r water separator elements.
Clean u p fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Cleaning the Strainer and the
Sediment Chamber for the Fuel
Transfer Pump
Turn the fuel supply valve to the OFF position before
the maintenance is performed.
101593502
Generator Dry -
SMCS Code: 4450-569 I
Personal injury or death can result from improper
troubleshooting and repair procedures. C '3
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this eaui~ment.
Refer to Safety Section, "Generator Isolating fo
Maintenance"for information regarding the procedure
.
. the generator.
to safely isolate
If the insulation resistance values are less than the
recommended values, one of the following drying
procedures must be selected. This decision should
be based on the following factors:
the size of the unit

the location of the unit

the equipment that is available

the experience of personnel

Note: For more information on drying methods, refer

to Special Instruction, SEHS9124, "Cleaning and
900286056 Drying of Electric Set Generators".
Illustration 96
(1) Fuel transfer pump
(2) Cover and seal
(3) Strainer

1. Remove the cover and seal (2) from the top of fuel
transfer pump (1). Remove strainer (3).
 115
Maintenance Section
Generator Dry-

@ Remyve the voltage regulator. Cover all of the inlet

openings. Cover all of the discharge holes. Provide
Heat can be used in order to dry the generator
windings. This heat can be created by allowing a
an opening at the top of the machine. This opening controlled current to flow through the generator. No
will allow moisture to evaporate. Preferably, this high voltages are generated during the following
opening will be located at the fan end. Monitor the procedure. Therefore, insulation breakdown will not
winding temperatures. DO NOT APPLY HEAT TOO occur.
RAPIDLY. Winding temperature should be raised
gradually at a rate of 10 "C (50 OF) per hour up to
85 "C (185 OF). Measure insulation resistance at one
hour intervals. Typically, the insulation resistance
will slowly drop while the temperature is rising. The
insulation resistance will then start to increase at a
slow rate until the insulation resistance reaches a
constant level.
VOLTAGE
The following methods can be used for drying a REGULATOR
generator: AND/OR

1 Self-circulating air method

RELATED
COMPONENTS

( Oven method

Controlled current method

Self-circulating Air Method

Run the engine and disconnect the generator load.
) This will help circulate air. Operate the generator
space heaters.

I Oven Method
WINDINGS

I
Place the entire generator inside a forced air drying
I oven for four hours at 65 "C (149 O F ) . Illustration 97 900845638
Generator Wiring Diagram

I1 NOTICE
Use a forced air type oven rather than a radiant type
oven.
(CR1-CRG) Diodes
(CR7) Varistor
(LI) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)

11 Radiant type ovens can cause localized overheating.

Controlled Current Method

(L4) Main armature (stator)
(RFA) Rotating field assembly
(CST) Customer supplied transformer

1. Make an extemal power source.

Table 14
2. Refer to the above diagram. Disconnect "F1+"
Tools Needed from the voltage regulator. Disconnect "F2-"from

1 part
Number
1 Description the voltage regulator. Disconnect the generator
load. Connect the generator output leads "TO",
"TI", "TZ", and "T3". Install the clamp-on ammeter
I 8~-0900 I Clamp on ammeter (1200 1 1 I to generator output lead "TI".
amperes)
External Power Source 1 1 Note: When the line current is measured on
1
multiple-lead units, measure the current in each
Rheostat conductor per phase. The currents can then be
added.

3. Refer to the above diagram. Connect the rheostat.

Adjust the rheostat to the maximum resistance
value. Connect the extemal power source to wires
"FI+" and "F2-".
116
Maintenance Section
Generator - lnspect
4. Start the generator set. Run the generator set at
idle speed.
5. Monitor the phase current. Gradually increase the
engine RPM. Increase the engine RPM until one
of the following conditions are met:
The rated phase current is obtained.
The full generator set speed is obtained.
6. If more phase current is still necessary, slowly
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.
I01880220
Generator lnspect -
SMCS Code: 4450-040
Personal injury or death can result from improper
troubleshooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
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 i n the "OFF" posi-
tion. Attach "DO NOT OPERATE" tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Refer to Safety Section, "Generator Isolating for
Maintenance" for information regarding the 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 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 genera-
tor 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.
C
 117
Maintenance Section
Generator Load - Check

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. Afler 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.
Afler 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.
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.
Generator Load Check -
SMCS Code: 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. This 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. This 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.

A high pressure wash is normally an effective way

to clean windinas. This includes windinas that have
been exposed ib flooding or windings thgt 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".
118
Maintenance Section
-
Generator Set Test

101593517 The phase voltages change relative to engine

Generator Set Test - speed.

The generator set functional test consists of the

SMCS Code: 4450-081 following steps:

1. Stop the generator. Connect the potential

Personal injury or death can result from high volt-
age.
When power generation equipment must be i n op-
eration to make tests andlor adjustments, high
voltage and current are present.
Improper test equipment can fail and present a
high voltage shock hazard t o its user.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
rent tests being made.
transformer's high voltage winding to the
generator terminals (TI) and (T2). Connect
the voltmeter to the low voltage winding. If two
transformers are available, connect the high
voltage winding of the second transformer to the
generator terminals (TI) and (T3). Connect the
secondaiy terminals that correspond to generator
terminal (T2) of both transformers together.
2. Disconnect wires "E+" and "E-" from the voltage
regulator. Disconnect the generator from the load.
3. Connect a 12 VDC automotive battery to wires
"E+" and "E-",

When servicing or repairing electric power gener-
ation equipment:
Make sure the unit is off-line (disconnected
from utility andlor other generators power
service), and either locked out or tagged DO
NOT OPERATE.
4. Measure the AC voltage across the low voltage
terminals of the transformer that correspond to the
following generator terminals: "TI" and "T2", "T2"
and "T3, and " T 3 and "TI". Record the voltages.
101592749

Make sure the generator engine is stopped.

Heat Exchanger Inspect -
SMCS Code: 1379-040
Make sure all batteries are disconnected.
The interval for the maintenance of the tube type heat
Make sure all capacitors are discharged. exchanger depends on the operating environment of
the vessel and on the operating time. The sea water
Table 15 that is circulated through the heat exchanger and the
amount of operating time of the vessel affects the
Tools Needed following items:
I Part Number I Part I Quantity I
Cleanliness of the tubes for the heat exchanger
1 6v-7070 1 Digital
Muitimeter . Effectiveness of the heat exchanger system
I 1 12 VDC batten/ I 1 I
Operating in water that contains silt, sediment, salt,
I Potential
Transformer algae, etc will adversely affect the heat exchanger
system. In addition, intermittent use of the vessel will
adversely affect the heat exchanger system.
The generator set functional test is a simplified test
that can be performed in order to determine if the The following items indicate that the heat exchanger
generator is functional. The generator set functional may require cleaning:
test should be performed on a generator set that is
under load. Increased coolant temperature
The generator set functional test determines if the Engine overheating
following statements happen:
Excessive pressure drop between the water inlet
A phase voltage is being generated. and the water outlet
The phase voltages are balanced.

@ An operator that is familiar with the normal operating
temperature of the coolant can determine when
the coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger
I
are required if the engine is overheating.
Cleaning the Heat Exchanger
I 1. Remove the heat exchanger. Refer to the Service
Manual for the procedure.
I
I 2. Turn the heat exchanger core upside-down in
order to remove debris.
I
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.
1 3. Back flush the core with cleaner.
I Caterpillar recommends the use of Hydrosolv
liauid cleaner. Table 16 lists Hvdrosolv liauid
cleaners that are available from your caterpillar
dealer
Table 16
Hydrosolv Liauid Cleaners(l1
I Part
Number 1 Description I Size
1 174-6654 1 Hydrosolv 100 1 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner at
temoeratures uo to 93°C i200"FI. Refer to Ao~licatlon
~ u i d e~, ~ ~ $ 0 or
5 consult
2 6 yo;r ~aterpiiiar'deaierfor more
information.
4. Steam clean the core in order to remove any
residue. Flush the tubes of the heat exchanger
core. Remove any other trapped debris.
I 5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
I Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, weara pro-
)@ tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
.
119
Maintenance Section
-
Hoses and Clamps InspecffReplace
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
7. lnspect the core in order to ensure cleanliness.
Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests.
If necessary, repair the core.
8. Install the heat exchanger. Refer to the Service
Manual for the procedure.
For more information on cleaning the core, consult
your Caterpillar dealer.
. 102121526
Hoses and Clamps -
InspectlReplace
SMCS Code: 7554-040;7554-510
Inspect all hoses for leaks that are caused by the
following conditions:
Cracking
. Softness
. Loose clamps
Replace hoses that are cracked or soft. Tighten any
I loose clamps.
NOTICE
I Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. lnspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque.
Check for the following conditions:
End fittings that are damaged or leaking
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
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.
120
Maintenance Section
-
Insulation Test
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Each installation application can be different. The
differences depend on the following factors:
Type of hose
Type of fitting material
Anticipated expansion and contraction of the hose
Anticipated expansion and contraction of the
fittings
Replace the Hoses and the Clamps
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooliiig system
pressure cap slowly in order t o relieve the pres-
sure.
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
7. Install the hose clamps with a torque wrench.
Note: Refer to the Specifications, SENR3130,
"Torque Specifications" in order to locate the proper
torques.
8. Refill the cooling system.
9. Clean the cooling system filler cap. lnspect the
cooling system filler cap's gaskets. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
10. Start the engine. lnspect the cooling system for
leaks.
i01593535
Insulation Test -
SMCS Code: 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 i n the "OFF" posi-
tion. Attach "DO NOT OPERATE" tags t o all start-
ing controls. Disconnect the batteries o r disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the aenerator.
Table 17
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 insulationtester
in the following situations:
The generator set is started for the first time.
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".
~ecommendedProcedure for A
Periodic Insulation Test
1 Personal injury or death can result from electro-
cution.
The megohmrneter is applying a high voltage t o
the circuit.
To avoid electrocution, do not touch the instru-
ment leads without first discharging them. When
finished testing also discharge the generator
windings.
1 I.Take the generator but 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.
1 4. Discharge the capacitance of the windings.
1I 5. Disconnect "101" from ground.
6. Disconnect the regulator sensing lead wires: "0".
"110", "220", and 380.
I
1 I . Connect the insulation tester's RED lead to
ground.
I 8. Connect the insulation tester's BLACK lead to
"101".
121
Maintenance Section
-
Insulation Test
9. For units that are 600 volts or less, set the voltage
to 500 Volts. For units that are more than 600
volts, set the voltage to 1000 Volts.
10. Use the 30160 Time Resistance Method:
a. Apply voltage.
b. Observe the readings at 30 seconds. Observe
the readings at 60 seconds.
c. Record the 60 second reading. This reading
must be corrected for temperature.
d. Record temperature.
e. Record humidity.
f. Remove voltage.
11. Evaluate the readings. The actual value of the
resistance may vary greatly between generators.
For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
the readings that were taken on previous dates.
These two readings must be taken under similar
conditions. If a 60 second resistance reading
has a 50 percent reduction from the previous '
reading, the insulation may have absorbed too
much moisture.
Switch the insulation tester to the "OFF position.
This will discharge the insulation.tester's leads.
Disconnect the insulation tester's leads.
Note: The results from the insulation resistance
checks indicate when cleaning andlor repairing is
becoming critical. Generally, ilisulation resistance
will vary greatly with temperature. Therefore, always
test at the same temperature and humidity. Refer to
Illustration 98.
Serial Number (Engine)
Serial Number (Generator)
Approx. I n s u l a t i o n Resistance V a r i a t i o n
with Temperature ( I E E E 43-1974)

Winding Temperature (Degrees)


\ $@ 101585907
Overhaul Considerations
/ SMCS Code: 7595-043
Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
The following factors are important when a decision
is being made on the proper time for an engine
1 Overhaul:
I - The need for preventive maintenance
/1 The quality of the fuel that is being used
The operating conditions
1 Oil Consumption as an Overhaul
The results of the S.0.S analysis
@1
Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consuniption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is ,
consumed per hour also increases.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (Ib per
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
$1 Overhaul Options
I Before Failure Overhaul
A planned overhaul before failure may be the best
value for the following reasons:
123
Maintenance Section
Overhaul Considerations
Costly unplanned downtime can be avoided.
Many original parts can be reused according to the
standards for reusable parts.
The engine's service life can be extended without
the risk of a major catastrophe due to engine
failure.
The best cosffvalue relationship per hour of
extended life can be attained.
After Failure Overhaul
If a major engine failure occurs and the engine must
be removed from the hull, many options are available.
An overhaul should be performed if the engine block
or the crankshaft needs to be repaired.
If the engine block is repairable andlor the crankshaft
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
with a similar exchange core.
This lower cost can be attributed to three aspects:
Specially designed Caterpillar engine features
Caterpillar dealer exchange components
Caterpillar remanufactured exchange components
Overhaul Recommendation
To minimize downtime, Caterpillar recommends a
scheduled engine overhaul by your Caterpillar dealer
before the engjne fails. This will provide you with the
best cosffvalue relationship.
Note: Overhaul programs vary according to the
engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
overhaul programs and about overhaul services for
extending the engine life.
If an overhaul is performed without overhaul service
from yourcaterpillar dealer, be,aware of the following
maintenance recommendations.
Rebuild or Exchange
Cylinder Head Assembly, Oil Pump, and Fuel
Transfer Pump
These components should be inspected according to
the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
124
Maintenance Section
Overhaul Considerations

If the parts comply with the established inspection
specifications that are expressed in the reusable
parts guideline, the parts should be reused.
Parts that are not within the established inspection
specifications should be dealt with in one of the
following manners:
Salvaging
Bearing material that has seized to the journals
Check the journal taper and the profile of the
crankshaft journals. Check these components by
interpreting the wear patterns on the following
components:
Rod bearing

. Repairing
Main bearings

Note: If the crankshaft is removed for any reason,

Replacing use the magnetic particle inspection process to check
for cracks in the crankshaft.
Using out-of-spec parts can result in the following
problems: lnspect the camshaft for damage to the journals and
to the lobes.
Unscheduled downtime
Note: If the camshaft is removed for any reason, use
Costly repairs the magnetic particle inspection process to check for
cracks in the camshaft.
Damage to other engine parts
lnspect the following components for signs of wear or
Reduced engine efficiency for signs of scuffing:

a' Increased fuel consumption Camshaft bearings

Reduced engine efficiency and increased fuel Camshaft followers

consumption translates into higher operating
costs. Therefore, Caterpillar recommends repairing Caterpillar recommends replacing the crankshaft
out-of-spec parts or replacing out-of-spec parts. vibration damper.

Inspection andlor Replacement Oil Cooler Core and Heat Exchanger Core

Crankshaft Bearings, Crankshaft Seals, Thrust During an overhaul, Caterpillar recommends the
Bearings, Main Bearings, and Rod Bearings removal of the oil cooler core and the heat exchanger.
Clean the cores. Then, pressure test the cores.
The following components may not last until the
second overhaul. NOTICE
Do not use caustic cleaners to clean the core.
Thrust bearings
Caustic cleaners can attack the internal metals of the
Main bearings core and cause leakage.
Rod bearings
Note: Use this cleaning procedure to clean the oil
Crankshaft seals cooler core and the heat exchanger core.

Caterpillar recommends the installation of new parts 1. Remove the oil cooler core and the heat
at each overhaul period. exchanger core.

lnspect these parts while the engine is disassembled
for an overhaul.
lnspect the crankshaft for any of the following
conditions:
2. Remove any debris from the cores. To remove
debris from the oil cooler core, turn the oil cooler
core onto one end. To remove debris from the
heat exchanger core, turn the heat exchanger
core onto one end.

Deflection 3. Flush the cores internally with cleaner in order to

loosen foreign substances. This will also help to
Damage to the journals remove oil from the oil cooler core.
 125
Maintenance Section
Rotating Rectifier - Check

@ Note: Caterpillar recommends the use of Hydrosolv

Liquid Cleaners. Table 18 lists the Hydrosolv Liquid
For example, considerable deposits are found in the
water jacket areas on the external cooling system, but
Cleaners that are available from your Caterpillar the concentrations of coolant additives were carefully
dealer. maintained. The coolant water probably contained
minerals that were deposited on the engine over time.
1 Table 18

Hydrosolv Liquid Cleanerst') A coolant analysis can be conducted in order to verify

II Part
Number
1U-5490
Description

1 Hydrosolv 4165 1
Size

19 L (5 US gallon)
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or
an agricultural agent. Private laboratories are also
available for water analysis.
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner at Caterpillar recommends an S . 0 6 Coolant Analysis
temperatures up to 93'C (200°F). Refer to Application (Level 11).
Guide, NEHS0526 or consult vour Caterpillar dealer for more

I information
S.0.S Coolant Analysis (Level II)
1 4. Use steam to clean the cores. This removes any
remaining residue from the cleaner. Flush the fins An S.0.S Coolant Analysis (Level II) is a
comprehensive coolant analysis which completely
I of each of the cores. Remove any other trapped
debris. analyzes the coolant and the effects on the cooling
system. An S.0.S Coolant Analysis (Level II) provides
the following information:
5. Wash the cores with hot, soapy water. Rinse the
cores thoroughly with clean water.
Complete S.06 Coolant Analysis (Level I)

Visual inspection of properties

I 'l'iy Personal injury can result from air pressure. ldentification of metal corrosion

Personal injury can result without following prop-

er procedure. When using pressure air, weara pro-
. ldentification of contaminants

tective face shield and protective clothing. ldentification of built up impurities (corrosion and
scale)
Maximum air pressure at the nozzle must be less
than 205 kPa (30 ~ s ifor
) cleanina DurDoses. S.0.S Coolant Analysis (Level II) provides a report of
the results of both the analysis and the maintenance
recommendations.
6. Dry the cores with compressed air. Direct thea,ir
in the reverse direction of the normal flow. , For more information about coolant analysis, see
your Caterpillar dealer.
7. Inspect the components in order to ensure
cleanliness. The oil cooler core and the heat
exchanger core should be pressure tested. Repair 101593539
cores, if necessary. Install the oil cooler core and
the heat exchanger core. Rotating Rectifier Check -
For more information about cleaning the cores, SMCS Code: 4465-535
consult your Caterpillar dealer.
Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
Obtain Coolant Analysis refer to Maintenance Procedure, "Rotating Rectifier -
Test".
The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits
or with S.0.S Coolant Analysis (Level I). Further
coolant analysis is recommended when the engine
is overhauled.
 126
Maintenance Section
Rotating Rectifier Test -

i01593540 The ohmmeter should indicate a low resistance

Rotating Rectifier Test - when the ohmmeter leads are across the rectifier in
one direction. The ohmmeter should indicate a high
resistance when the leads are reversed.
SMCS Code: 4465-081
If the ohmmeter indicates a low resistance in both
Testing A Brushless Exciter directions, the rectifier is shorted. A high resistance
in both directions indicates an open rectifier.
Rotating Rectifier With An
Ohmmeter Replace any faulty rectifiers with rectifiers that have
comparable operating characteristics. Include the
Table 1 9 following information when a rectifier is being ordered
I Tools Needed I for replacement:
I Part Number I Part Name I Quantity I Part Number of the rectifier
6V-7070 Digital 1
Multirneter Model number of the exciter
1 9U-7330 1 Multirneter I 1 1 Type of the exciter

Serial number of the generator

Testing a Brushless Exciter

Rotating Rectifier With A Test Light

CATHODE

1.5 Volt 1.5 Volt

REVERSE
DIODE
. STANDARD
DIODE
ANODE
A LAMP

' Illustration 99 g00555106

lllustration 100
Test Light
If the failure of a rectifier is suspected, use the
following procedure. If an ohmmeter is not available, a rectifier can be
tested by using a test light. A test light consists of
1. Remove the cover from the exciter. two standard flashlight batteries and a flashlight bulb.
Refer to lllustration 100.
2. Remove the nut that secures the rectifier to the
heat sink. If the failure of a rectifier is susbected, use the
following procedure.
3. Remove the diode lead.
1. Remove the cover from the exciter.
4. Lift the rectifier from the heat sink.
2. Remove the nut that secures the rectifier to the
5. Refer to lllustration 99. Connect the ohmmeter's heat sink.
leads across the rectifier. Note the meter reading.
3. Remove the diode lead.
6. Reverse the ohmmeter leads. Note the meter
reading. 4. Lift the rectifier from the heat sink.

5. Connect the leads of the test light across the
rectifier. Notice if the bulb is illuminated.
6. Reverse the leads of the test light across the
rectifier. Notice if the bulb is illuminated.
The bulb should be illuminated when the leads of the
test light are across the rectifier in one direction. The
bulb should not be illuminated when the leads are
reversed.
If the bulb is illuminated in both directions, the rectifier
is shorted. If the bulb is not illuminated in either
direction, the rectifier is open.
Replace any faulty rectifiers with rectifiers that have
comparable operating characteristics. Include the
following information when a rectifier is being ordered
for replacement:
Part Number of the rectifier
Model number of the exciter
Type of the exciter
Serial number of the generator
100651416
Starting Motor Inspect - Note: Turbocharger components require precision
SMCS Code: 1451-040; 1453-040
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Caterpillar dealer for
assistance.
101411756
Turbocharger InspectIClean -
SMCS Code: 1052-571
Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
127
Maintenance Section
Starting Motor - Inspect
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
andlor to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
head.
-
-
NOTICE
Turbocharger bearing failures can cause large quan-
tities 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 ex-
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
curred.
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. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the cartridge.
Removal and Installation
For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the
procedure and specifications.
Cleaning and Inspecting
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. lnspect
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 must be reconditioned.
128
Maintenance Section
Walk-Around lnspection
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt
andlor 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 be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
5. lnspect the bore of the turbine housing for
corrosion.
6. Clean the turbocharger housing and clean the
backing plate of the cartridge with standard shop
solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
i01585919
Walk-Around lnspection
SMCS Code: 1000-040
lnspect 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
sewiced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, orfuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease andlor 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 and
that cooling lines are tight. Check for leaks. Check
the condition of all pipes.
lnspect the water pumps 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 pumps and the installation of water pumps
andlor seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer.
lnspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
lnspect the fuel system for leaks. Look for loose
fuel line clamps.
lnspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
lnspect the alternator belt and the accessoly 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.
lnspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
lnspect the ground strap for a good connection and
for good condition.
 SEBU7577-01 129
Maintenance Section
-
Water Pump Inspect

1( . Disconnect any battery chargers that are not

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

Check the condition of the gauges. Replace any

gauges which are cracked or any gauges that can
not be calibrated.

1 Water Pump Inspect -

101057943

1 SMCS C h i 1361-040: 1361

A failed water pump might cause severe engine

overheating problems that could result in the following
conditions:

Cracks in the cylinder head

A piston seizure

1 Other potential damage to the engine

Visually inspect the water pump for leaks. If any

{@ leaking is observed, replace the water pump seal
or the water pump assembly. Refer to the Service
Manual forthe disassembly and assembly procedure.

Note: Refer to the Service Manual or consult your

Caterpillar dealer if any repair is needed or any
replacement is needed.
Reference lnformation Section
Customer Service

Reference lnformation Latin America, Mexico, Carribean

Caterpillar Americas Co.
Section 701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Customer Service Fax: 305-476-6801

Europe, Africa, and Middle East

Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation of Far East
an engine or concerning the service of an engine, Caterpillar Asia Pte. Ltd.
the problem will normally be managed by the dealer 7 Tractor Road
in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level without additional assistance, use the phone Hong Kong
number that is listed below to talk with a Field Phone: 852-2848-0333
Service Coordinator: Fax: 852-2848-0440

Japan
Shin Caterpillar Mitsubishi Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Manager, Customer Service, Engine Division Japan
Mossville Bldg AC Caterpillar Power Systems, Inc.
P.O. Box 610- SBS Tower (14th floor)
Mossville, Illinois 61552-0610 4-10-1. Yoaa
setagaya-ku, Tokyo 158-0097
Please keep in mind: probably, your problem will Phone: 81-3-5797-4300
ultimately be solved at the dealership, using the Fax: 81-3-5797-4359
dealership's facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Outside of the USA and of Canada Private Mail Bag 4
Tullamarine, Victoria 3043
If a problem arises outside the USA and outside Australia
Canada, and if the problem cannot be resolved at the Phone: 03-9953-9333
dealer level, consult the appropriate Caterpillar office. Fax: 03-9335-3366
 131
Reference lnformation Section
Customer Service

101028392

Ordering Replacement Parts

SMCS Code: 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.

Failure t o heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.

When you order parts, please specify the following

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

andlor repair, provide the dealer with all the
information that is stamoed on the Information Plate.
This information is-describedin this Operation and
Maintenance Manual (Product lnformation Section).

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and the
nature of the problem. Infoml the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
132
Reference Information Section
Reference Materials

Reference Materials Special Publication, SEBD0970, "Coolant and Your

Engine"
i02202115 Label, PEEP5027, "Extended Life
CoolantlAntifreeze"
Reference Material
SMCS Code: 1000 Miscellaneous
The following literature can be obtained through any Service Manual, RENR2405, "3054 and 3056
Caterpillar dealer. Marine Generator Set Engines"

Systems Operation, Tesiing and Adjusting,

Lubricants
Special Publication, PEHP8038, "Data Sheet -
Caterpillar Diesel Engine Oils (DEO) (CH-4) (North
America)"
Special Publication, PEHP9536, "Data Sheet
- Caterpillar Diesel Engine Oil (DEO) (CF-4)
(Internationalonly)"
Special Publication, NEDG6022, "Cat Lubricating
Grease"
Special Publication, PEHP0002, "Data Sheet -
Molybdenum (MPGM) Grease"
Special Publication, NEHP6015, "Data Sheet -
Caterpillar Special Purpose Grease (SPG)"
Special Publication, SEBD0640, "Oil and Your
Engine"
Operation and Maintenance Manual, SEBU5898,
"Cold Weather Recommendations"
Operation and Maintenance Manual, SEBU6251,
"Caterpillar Commercial Diesel Engine Fluids
Recomendations"
Special Publication, PEHP6001, "How To Take A
Good Oil Sample"
Fuels
RENR2403, "3054 and 3056 Marine Generator
Set Engines"
Specifications, RENR2407, "3054 and 3056 Marine
Generator Set Engines"
Disassembly and Assembly, RENR2402, "3054
and 3056 Marine Generator Set Engines"
Schematic, RENR2408, "3054 and 3056 Marine
Generator Set Engines"
Specifications, SENR3130, "Torque Specifications"
Special Publication, PECP9067, "One Safe
Source" English language for use in non NACD
and non COSA
Special Publication, LEDM5615, "Caterpillar
Marine Parts and Service Locations Directory"
Special Publication, SEBF8029, "Index to
Guidelines for Reusable Parts and Salvage
Operations"
Special Publication, SEBF8062, "Procedure to
Inspect and Clean Air Filters"
Special Instruction, SEHS9031, "Storage
Procedure for Caterpillar Products"
Special Publication, NEHS0526, "Service
Technician Application Guide"

Special Publication, SEBD0717, "Diesel Fuels and Special Publication, SEBU6251, "Caterpillar
Your Engine" Commercial Diesel Engine Fluids Recomendations"

Special Instruction, SEHS7633, "Battery Test

Coolants Procedure"
Special Publication, PEHP4036, "Data Sheet - Label, SEHS7332, "Danger Do Not Operate"
Extended Life Coolant"

Special Publication, PEHP7057, "Data Sheet -

S.0.S Coolant Analysis"

Special Publication, SEBD0518, "Know Your

Cooling System"
 133
Reference Information Section
Reference Materials

Emissions Warranty International Organization for Standardization

(ISO)
This engine may be Certified and this engine 1, rue de VarembB
may be covered by an Emissions Warranty. A Case postale 56
detailed explanation of the Emissions Warranty CH-1211 Geneve 20
that is applicable to Certified engines is found Switzerland
in Supplement, SMBU6981, "Emissions Control Telephone: +41 22 749 01 11
Warranty Information". The engine is Certified if Facsimile: +41 22 733 34 30
the engine has a special label that verifies the E-mail: central@iso.ch
certification. A Caterpillar dealer can also inform you Web site: http:llw.iso.ch
if the engine is certified.
European classifications are established by the
Additional Reference Material Counseil lnternational Des Machines a Combustion
(CIMAC) (International Council on Combustion
The "EMA Lubricating Oils Data Book" can Engines).
be obtained from the followina locations: local
technological society, local libFary, and local college. CIMAC Central Secretariat
If necessary, consult EMA at the following address: Lyoner Strasse 18
60528 Frankfurt
Engine Manufacturers Associaton Germany
401 N. Michigan Ave. Telephone: +49 69 6603 1567
Chicago, IL, USA 60611 Facsimile: +49 69 6603 1566
Telephone: (312) 644-6610 ext. 3626
100912149
The "Society of Automotive Engineers (SAE)
Specifications" can be found in your SAE handbook. Maintenance Records
This publication can also be obtained from the
following locations: local technological society, local SMCS Code: 1000
library, and local college. If necessary, consult SAE
at the following address: Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
SAE lnternational can be used for the following purposes:
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001 Determine operating costs. '

Telephone: (724) 776-4841

The "American Petroleum Institute Publication No.
1509" can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:
American Petroleum lnstitute
1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000
The International Organization for Standardization
(ISO) offers information and customer service
regarding international standards and standardizing
activities. IS0 can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of IS0 in your country.
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 a variety of
other business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar 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.
134
Reference Information Section
Reference Materials

-
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:

Dealer work orders and itemized bills

Owner's repair costs

Owner's receipts

Maintenance'log
 135
Reference Information Section
Reference Materials

I1 Maintenance Log
SMCS Code: 1000
1 Table 20
Index
Afler Starting Engine .............................................62
Alarm Switches ...................................................47
Alternator .Inspect ................................................89
Auxiliary Water Pump (Rubber Impeller).Inspect.. 89
Battery .Replace...................................................89
Battely Electrolyte Level .Check .......................... 90
Battery or Battery Cable .Disconnect ................... 90
Before Starting Engine ................... :................ 13. 51
Starting the Engines. Operating the Engines. and
Stopping the Engines that are Equipped with
Control Panels..................................................51
Belts .InspecUAdjusUReplace.............................. 91
Adjustment .........................................................91
Inspection.............. . ........................................91
Replacement of Multiple Drive Belts .................. 91
Burn Prevention................................................... 10
Batteries..............................................................11
Coolant............................................................... 10
Oils.................................................................... 11
Cold Weather Operation .......................................74
Control Panel.........................................................27
MCS Control Panel ............................................39
Premium Control Panel......................................32
Standard Control Panel......................................27
Cooling System Coolant (DEAC) .Change........... 91
Cooling Systems with Heavy Deposits or
Plugging ......................................................... 93
Drain ..................................................................91
Fill ......................................................................94
Flush ..................................................................93
Cooling System Coolant (ELC) .Change.............. 94
Drain .................................................................. 94
Fill ......................................................................96
Flush ..................................................................96
Cooling System Coolant Extender (ELC) .Add ..... 96
Cooling System Coolant Level .Check ................. 97
Cooling System Coolant Sample (Level 1) .
Obtain ..................................................................97
Cooling System Coolant Sample (Level 2) .
Obtain .................................................................. 98
Cooling System Supplemental Coolant Additive
(SCA) .TestlAdd ..................................................98
Add the SCA, If Necessary ................................ 99
Test the Concentration of the SCA.....................98
Cooling System Water Temperature Regulator .
Replace................................................................ 99
Crankshafl Vibration Damper .Inspect ................. 99
Visconic Damper.............................................. 100
Crushing Prevention and Cutting Prevention ........ 13
Customer Assistance ........................................... 130
Outside of the USA and of Canada..................130
USA and Canada .......................................... 130
Customer Service ............................................... 130
Electrical Connections .Check.......................... 100
Electrical System ................................................ 14
Grounding Practices ......................... . ........... 14
Engine .Clean.................................................... 100
Engine Air Cleaner Element (Dual Element) .
CleanlReplace ...................................................101
Cleaning the Primary Air Cleaner Elements .... 102
Servicing the Air Cleaner Elements ................. 101
Engine Air Cleaner Service Indicator .lnspect (If
Equipped) ..........................................................103
Test the Service Indicator.................. . ........... 104
-
Engine Crankcase Breather CleanlReplace...... 104
3054 Marine Generator Set .............................104
3056 Marine Generator Set .............................106
Engine Identification..............................................20
Engine Mounts .Inspect...................... . ............ 106
Engine Oil and Filter .Change ............................107
Drain the Engine Oil .........................................107
Fill the Engine Crankcase ................................ 108
Replace the Oil Filter ....................................... 107
Engine Oil Level .Check ..................................... 106
Engine Oil Sample .Obtain .........:....................... 106
Obtain the Sample and the Analysis ................ 106
Engine Operation................................................... 63
Engine Starting ................................................14. 51
Engine Stopping ...:.......................................... 14, 65
Engine Valve Lash .InspecUAdjust ..................... 108
Engine Warm-up................................................... 63
Features and Controls ......................................... 27
Fire Prevention and Explosion Prevention ............. 11
Ether .................................................................12
Fire Extinguisher ................................................ 12
Lines. Tubes and Hoses ....................................12
Foreword ................................................................ 5
California Proposition 65 Waming .......................5
Literature Information.........................................4
Maintenance ......................................................4
Maintenance Intervals.......................................... 4
Operation ......................................................... 4
Overhaul .............................................................. 4
Safety ...................................................................4
Fuel and the Effect from Cold Weather ................. 74
Fuel Conservation Practices................................. 63
.
.
~ ~
Cruising Speed ................................ ............. 64
r
SEBU7577-01
Fuel Injection Nozzles .TestlExchange...............109
I
Removal and Installation of the Fuel lnjection
i Nozzles ..........................................................109
Fuel Related Components in Cold Weather .......... 75
Fuel Filters .........................................................
75
..
Fuel Tanks......................... ............................75
i
!
Fuel System .Prime .............................................
Fuel System Primary Filter (Water Separator)
Element .Replace ..............................................111
Fuel System Secondary Filter .Replace .............. 112
110
I Fuel Tank Water and Sediment .Drain ................113
Drain the Water and the Sediment....................113
! Fuel Storage Tanks ...........................................113
Fuel Tank ..........................................................
113
I
1 Fuel Transfer Pump Strainer .Clean....................114
Cleaning the Strainer and the Sediment Chamber
for the Fuel Transfer Pump .............................114
General Hazard Information ....................................8
Asbestos Information...........................................9
Containing Fluid Spillage ..................................... 9
Dispose of Waste Properly .................................10
Fluid Penetration..................................................9
Pressure Air and Water ........................................9
Generator .Dry................................................... 114
Controlled Current Method...........................: ... 115
Oven Method .................................................... 115
Self-circulating Air Method ...............................115
Generator .Inspect...............................................116
Cleaning (Assembled Generators)....................116
Cleaning (Disassembled Generators) ............... 117
Generator Identification.........................................20
Generator Isolating for Maintenance ..................... 15
Generator Lead Connections ................................21
Grounding the Frame.........................................22
Lead Numbering ................................................21
Neutral Connections ..........................................22
Single Units........................................................22
Generator Load .Check ...................................... 117
Generator Operation..............................................76
Block Loading ....................................................76
Excitation System ............................................ 77
Generator Options .............................................77
Loading of the Generator ................................... 76
Power Factor......................................................77
Standby Electric Sets .........................................77
Generator Set .Test ............................................. 118
Generator Set Description..................................... 17
Engine Specifications......................................... 18
Generator Set Installation......................................26
Bearing Inspection............................................. 26
Electrical Measurements................................. 26
Location ............................................................26
Protective Devices ............................................. 26
Receiving Inspection.......................................... 26
Generator Start-up Checklist ................................. 81
137
Index Section
H
Heat Exchanger .Inspect .....................................118
Cleaning the Heat Exchanger ...........................119
Hoses and Clamps .InspecVReplace ..................119
Replace the Hoses and the Clamps ................ 120
Important Safety Information ...................................2
Information Plate ...................................................20
Installation.........................................................26
Insulation .Test ...................................................120
Recommended Periodic Insulation Tests ......... 120
Recommended Procedure for A Periodic Insulation
Test............................................................... 121
Lifting and Storage ................................................24
Maintenance Interval Schedule (3054 Naturally
Aspirated Marine Generator Set Engine)............. 84
Maintenance Interval Schedule (3054 Turbocharged
Marine Generator Set Engine).......................... 85
Maintenance Interval Schedule (3056 Turbocharged
Marine Generator Set Engine)........................... 87
Maintenance Log ............................................... 135
Maintenance Recommendations...........................81
Maintenance Records........................................ 133
.
.
Maintenance Section ........................ ............... 78
Model View Illustrations........................................ 16
Model Views ...:......................................................16
Mounting and Dismounting................. . ............... 13
Operation Section.............................................. 24
Ordering Replacement Parts ............... . ............ 131
Overhaul Considerations .................... . . ............ 123
Oil Consumption as an Overhaul Indicator ...... 123
Overhaul Recommendation .............................123
Product Identification Information..........................20
Product Information Section ..................................16
Product Lifling........................................................24
Engine Only .......................................................24
Generator Set .................................................... 24
Product Storage.....................................................25
Generator Storage ........................................... 25
138
Index Section

Reference Information Section ............................130 Walk-Around Inspection ...................................... 128

Reference Material ........................................... 132 lnspect the Engine for Leaks and for Loose
Additional Reference Material.......................... 133 Connections ................................................... 128
Coolants.......................................................... 132 Warning Alarm ....................................................... 48
Emissions Warranty ...................................... 133 Water Pump .Inspect..........................................129
Fuels ............................................................... 132
Lubricants ....................................................... 132
Miscellaneous ..................................................132
Reference Materials ............................................ 132
Reference Numbers ..............................................21
Record for. .Reference......................................... 21
Refill Capac~t~es .....................................................78
Refill Capacities and Recommendations...............78
Cooling System .................................................. 79
Fuel ....................................................................78
Lubrication System ........................................... 78
Rotating Rectifier .Check .................................... 125
Rotating Rectifier .Test ...................................... 126
Testing a Brushless Exciter Rotating Rectifier With
A Test Light .................................................126
Testing A Brushless Exciter Rotating Rectifier With
An Ohmmeter.................................................126

Safety Messages.....................................................6
Safety Section ....................................................... 6
Sensors and Electrical Components .....................45
Failure of Sensors ..............................................45
Sensor Locations and Sensor Functions ........... 45
Serial Number Plate ............................... :........ 20
Starting Motor .Inspect .......................................127
Starting the Engine ...............................................52
MCS Control Panel ............................................57
Premium Control Panel...................................... 54
Standard Control Panel......................................52
Starting with Jump Start Cables ............................ 61
Stopping the Engine ..............................................65
MCS Control Panel ............................................69
Premium Control Panel..............................1. . . . 66
Standard Control Panel................................... 65

Table of Contents................................................... 3
Turbocharger .InspecffClean.............................. 127
Cleaning and Inspecting ................................. 127
Removal and Installation................................ 127

Voltage Connections............................................. 22
Voltage Regulators ................................................48
 Product and Dealer lnformation
Note: For product identification plate locations. see the section 'Product ldentif~cationlnformation' in the Operation
and Maintenance Manual.

Delivery Date:

Product lnformation
Model:

Product identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

- Customer Equipment Number:

.. I Dealer Equipment Number:

Dealer lnformation
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
02004 Caterpillar
All Rights Reserved Printed in U S.A.