Owner’s Manual

Cat® 3500 Dynamic Gas Blending Upgrade Kit

©2012 Caterpillar®
All rights reserved
 FOREWORD
Caterpillar has developed upgrade kits for select ratings of its 3500 family of generator sets
for the petroleum industry. The upgrade kits allow the operation if diesel engines in a
Dynamic Gas Blending (DGB) mode, thus enabling the units to run on gas and diesel fuels
simultaneously. This owner’s manual offers a description of the system components and their
operation, fuel guidelines, service requirements, and warranty information.

This manual focuses on the system description of the DGB components. Additional engine
systems, components, and dynamics are addressed in Caterpillar’s Application and
Installation Guides. Engine-specific information and data are available from a variety of
sources. For more information, contact the Caterpillar dealer nearest you.

The information is this document is the property of Caterpillar Inc. and/or its subsidiaries. Any copying,
distribution, transmission, or other use except that for which it is loaned is prohibited without written
permission.

CAT®, CATERPILLAR®, ADEM™A4, their respective logos, “Caterpillar Yellow” and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be
used without permission.

©2012 Caterpillar®
All rights reserved
TABLE OF CONTENTS

1. SAFETY ............................................................................................................................................... 1
2. INTRODUCTION ................................................................................................................................ 1
3. DGB SYSTEM DESCRIPTION .......................................................................................................... 3
3.1. Natural Gas Fuel System............................................................................................................... 4
3.2. Natural Gas Fuel Heater ................................................................................................................ 4
3.3. Gas Shutoff Valve ......................................................................................................................... 4
3.4. Natural Gas Pressure Regulator .................................................................................................... 5
3.5. Fuel Control Valve (FCV) ............................................................................................................ 7
3.6. Natural Gas Fuel Mixer................................................................................................................. 7
3.7. Natural Gas Fuel Filter.................................................................................................................. 7
3.8. DGB Control System .................................................................................................................... 8
3.9. Control Panel ................................................................................................................................ 8
3.10. EMCP 4.4 Panel ........................................................................................................................ 9
3.11. Integrated Sensor Module (ISM) ............................................................................................ 10
3.12. Engine Control Module (ECM) .............................................................................................. 10
3.13. Diesel Oxidation Catalyst (DOC) ........................................................................................... 11
4. FUELING PROCEDURE ................................................................................................................... 11
4.1. Natural Gas Composition ............................................................................................................ 11
4.2. Contaminants .............................................................................................................................. 12
4.3. Sulfur compounds ....................................................................................................................... 12
4.4. Inert Compounds ......................................................................................................................... 12
4.5. Methane Number and Detonation ............................................................................................... 13
4.6. DGB Natural Gas Fuel Requirements ......................................................................................... 14
4.7. Fuel Treatment Options .............................................................................................................. 14
4.8. Diesel Fuel System ..................................................................................................................... 14
4.9. Diesel Fuel Requirements ........................................................................................................... 15
5. MAINTENANCE INTERVAL SCHEDULE..................................................................................... 15
5.1. When Required ........................................................................................................................... 16
5.2. Daily............................................................................................................................................ 16
5.3. Every Week ................................................................................................................................. 17

©2012 Caterpillar®
All rights reserved
 5.4. Initial 250 Service Hours ............................................................................................................ 17
5.5. Initial 1000 Service Hours .......................................................................................................... 17
5.6. Every 250 Service Hours ............................................................................................................ 17
5.7. Every 500 Service Hours ............................................................................................................ 17
5.8. Every 500 Service Hours or 1 Year ............................................................................................ 17
5.9. Every 1000 Service Hours .......................................................................................................... 17
5.10. Every 2000 Service Hours ...................................................................................................... 18
5.11. Every Year .............................................................................................................................. 18
5.12. Every 3000 Service Hours ...................................................................................................... 18
5.13. Every 3000 Service Hours or 3 Years ..................................................................................... 18
5.14. Every 4000 Service Hours ...................................................................................................... 18
5.15. Every 6000 Service Hours or 6 Years ..................................................................................... 18
5.16. Every 12 000 Service Hours or 6 Years .................................................................................. 18
5.17. Overhaul .................................................................................................................................. 19
5.18. Commissioning ....................................................................................................................... 19
6. PARTS AND SERVICE ..................................................................................................................... 19
6.1. Dealer Contact Information ........................................................................................................ 20
7. WARRANTY ..................................................................................................................................... 21

©2012 Caterpillar®
All rights reserved
1. SAFETY
Do not operate or work on a generator set unless you have read and understood the
instructions and warnings in the Operation and Maintenance Manual. Failure to follow these
instructions may result in injury or death. Contact your Cat Dealer for access to additional
literature such as Owning and Maintenance Manuals, Applications and Installation Guides,
technical information, or other.

Proper care during the installation, setup, operation, and maintenance is your responsibility.
Electrical components are sensitive to electrostatic discharge (ESD). An electrostatic charge
can damage some components resulting in breakdown or improper operations. Take the
following precautions while installing/removing/handling any electrical components:

Handle equipment correctly. Use ESD protective packaging and material handling containers
that are anti-static and provide discharge protection and electric field suppression.

Use protective devices: ESD-protective workstations and/or work surfaces (grounding mat or
anti-static wrist strap).

Keep all plastic items away from the electrical devices. Any plastic item is a potential static
generator. This includes candy wrappers, foam cups, synthetic carpet, foam cushions, etc.

NOTE: Locking out the generator set does not remove the voltage on the EMCP panel at the
bus voltage sensing leads.

2. INTRODUCTION

Caterpillar has developed a Dynamic Gas Blending (DGB) option as a complete generator set
or retrofit kit. The DGB system allows diesel engines to operate on diesel fuel and natural
gas simultaneously. This is accomplished through our DGB specific system which includes
all the required hardware and software in order to utilize both fuels.

DGB is not the same as dual fuel, bi-fuel, or flex-fuel. Our DGB systems use Caterpillar-
proprietary software designed to interface with Caterpillar designed hardware and integrate
seamlessly with Caterpillar engines.

©2012 Caterpillar® Page | 1

All rights reserved
 A DGB engine, or a Caterpillar engine with the DGB retrofit kit installed, is able to safely
and successfully operate on 100% diesel or a combination of diesel and natural gas, with a
maximum natural gas percent substitution of 70%.

The DGB system is able to maximize diesel fuel saving via gas substitution that is
continuously optimized throughout the engine’s entire operating range (including transient
loading conditions). Integrated feedback systems allow the generator set to react to incoming
gas quality and modulate diesel and gas fuel controls to maximize fuel savings and protect
the engine without affecting the power output of the engine. This is accomplished across a
wide range of gas quality and varying gas quality during operation.

Simplified operations that include fully automatic gas detection are part of the DGB system.
This automatic gas detection allows the system to turn on or off the gas blending system
when the minimum gas supply pressure is detected or not detected.

The DGB system does not require re-commissioning when the generator set is moved from
one site to another. The generator set will not need to be re-commissioned if a change in fuel
gas quality occurs. The DGB system has enables high fuel flexibility that allows for lower
methane and higher inert fuel gas which are typical characteristics of well head gas.

The DGB system allows for consistent performance of the generator set during transient
loading, either operating on diesel or gas blending mode. No compromise in rating will be
incurred during operation of the DGB system. One major benefit to Caterpillar’s DGB
system is that is maintains the engine’s current factory-certified emissions levels.

Caterpillar has specifically designed the generator sets and DGB systems for the
environments encountered in oil and gas applications. The DGB system is unique for each
rating and is optimized for certain engines and power settings. Each DGB system is
specifically designed for an engine size and rating.

©2012 Caterpillar® Page | 2

All rights reserved
3. DGB SYSTEM DESCRIPTION
The following section describes the components of the DGB system and provides an
explanation of each component’s operation in the system.

©2012 Caterpillar® Page | 3

All rights reserved
 3.1. Natural Gas Fuel System

The DGB natural gas system is referred to as a low pressure gas system. In the DGB low
pressure gas system, gas enters the fuel system through a shutoff valve and then passes
through the fuel heater, the gas pressure regulator and then the gas valve. After passing
through the gas valve, the fuel enters the air inlet system, just prior to the turbochargers.
The fuel is combined with the incoming air through the use of specifically-designed
mixing tubes that add the appropriate amount of natural gas to the air stream. After being
mixed with the incoming air, the air/fuel mixture then enters the compression side of the
turbochargers and is compressed to the desired pressure. The air/fuel mixture then
continues through the air inlet system through the aftercooler and into the combustion
chamber through the air inlet valves.

3.2. Natural Gas Fuel Heater

The temperature of the inlet gas is an important parameter because low inlet gas
temperature can cause freezing downstream of the pressure regulator, liquid hydrocarbon
dropout, and engine damage. Gas fuel streams are typically made up of a mixture of
many different hydrocarbon gas fractions, each with their own qualities. Many of the
heavier fractions tend to exist as liquids at lower temperatures, making control of fuel
stream temperature an important tool in preventing the unwanted dropout of
hydrocarbon liquids in the fuel delivery system. To resolve this issue, all DGB engines
and kits include a heat exchanger installed in the fuel delivery system to serve as a fuel
heater. The DGB fuel heater uses the jacket water system on the engine as a source of
energy to heat up the incoming gas fuel stream. It is mounted close to the engine and
regulator and installed between the regulator and the gas shutoff valve.

3.3. Gas Shutoff Valve

The gas shut-off valve (GSOV) is one of the most important safety devices in the fuel
system. Its role is to allow gas to the engine only when the engine is ready to use the gas.
If the DGB system has been turned off or the load is below 25%, the GSOV positively

©2012 Caterpillar® Page | 4

All rights reserved
 blocks the gas supply line to prevent/stop gas flow. The GSOV is an electrically driven
solenoid-actuated valve. Electrical power to operate this valve comes from on-engine
sources (“self-powered” valves).

The GSOV that is include on the DGB engine or in the DGB kit is an energize-to-run
GSOV. This means that power must be provided to the GSOV before it will open and
allow gas to flow. This ensures that the GSOV is defaulted to the shutdown condition.

During normal operation of the engine the GSOV will open and close as signaled by the
engine ECM when the appropriate conditions of load and DGB system operation are
met. In an emergency shutdown, the GSOV is closed immediately. If equipped, the air
shutoff will be activated and the diesel system will be shut down. This is done to stop
rotation of the engine as quickly as possible, but it can leave unburned fuel in the engine
and exhaust system. This unburned gas poses a hazard at restart as it can be ignited by
hot exhaust gases leaving the engine, resulting in an exhaust stack explosion. As a result,
the DGB system shuts down when the emergency stop button is activated. Once the
engine components come to a rest, the DGB system will activate the starter and purge
the fuel lines and exhaust system for 10 seconds with the GSOV closed and the diesel
fuel system disabled.

During startup for DGB generator sets, the GSOV will be closed to prevent any natural
gas fuel from entering the system. The starters will engage and purge the fuel lines,
manifold, and exhaust system for 10 seconds with the GSOV and diesel fuel system
disabled. After purging for 10 seconds, the starters will be disengaged and allow the
engine to stop turning. The DGB system will then automatically engage the starters and
activate the diesel fuel system to start the system normally. The GSOV will open when
the DGB generator set reaches the minimum load for DGB operation.

3.4. Natural Gas Pressure Regulator

The gas pressure regulator controls the supply of fuel from the customer fuel supply line
to the on-engine fuel system. This function is critical to the on-engine fuel system

©2012 Caterpillar® Page | 5

All rights reserved
 because the fuel metering depends directly on the pressure of the fuel supply. To fulfill
its role in the system, the gas pressure regulators must perform the following functions:

· Step gas pressure down to a value appropriate for the on-engine fuel system

· Dampen out any fluctuations in the supply pressure to stabilize the supply to the
engine

As with gas filters and other components in the gas stream, the proper regulator for a
given application depends on the specific installation, including details such as gas
specific gravity, temperature, pressure, flow rate, and desired outlet pressure. The DGB
regulator has been specifically chosen to work in the appropriate DGB application with
the fuel limitations for each engine. If the external supply pressure is too high to
accomplish the desired pressure reduction in a single step (high pressure gas on a low
pressure package), or if the pressure fluctuations in the external supply are too large, a
knockdown pressure regulator may be required prior to the fuel filter to deliver the
desired gas pressure to the engine pressure regulator.

The following guidelines can be applied for a successful gas pressure regulator
installation:

· To prevent pressure buildup (“dead head” condition), avoid providing gas inlet
pressures above the maximum downstream pressure rating for a regulator.

· Install the regulator in the correct gas flow direction and downstream of the fuel
filter

· Piping to the gas regulator must be at least as large as the regulator inlet/outlet
ports

· The pressure regulator must be adjusted at the installation site

As noted above, the gas pressure regulator works closely with the fuel-air mixer to make
the fuel system function properly. The gas pressure regulator setup should be matched to
the needs of the fuel-air mixer and engine requirements. Appropriate pressure to the
natural gas regulator must be achieved per the DGB guidelines. In the event that pressure
is too low, the DGB system will not operate. Minimum fuel pressure to the DGB system

©2012 Caterpillar® Page | 6

All rights reserved
 is 83 kPa (12 psi). Maximum fuel pressure to the DGB system is 241kPa (35 psi). If the
fuel pressure is too high, there is a potential for damage to the engines natural gas fuel
system. A knock-down regulator is recommended if the fuel pressure exceeds the
maximum for the DGB system.

3.5. Fuel Control Valve (FCV)

The DGB natural gas fuel system incorporates a fuel control valve. The FCV has been
specifically designed is to control the flow of gas fuel into the combustion chambers.
This valve is controlled by the by the engine ECM in order maximize the substitution
rate based the fuel quality and the operating point.

During startup, the FCV will be closed along with the GSOV and will not open until
25% load has been achieved. Once 25% load has been achieved, the FCV will open via a
signal from the ECM to allow for maximum/optimal substitution or to achieve the
customer preferences.

3.6. Natural Gas Fuel Mixer

The natural gas fuel is distributed into the intake air piping prior to the turbochargers by
means of a natural gas fuel mixer. This component has been specifically designed for
each engine model to optimize fuel delivery into the air inlet and subsequently into the
combustion chamber.

3.7. Natural Gas Fuel Filter

Gas engines, like most engines, require a fuel supply free from dirt and other foreign
matter (including water). Undesirable solids and liquids are removed from the gas stream
using filters and coalescers. For that reason, Caterpillar recommends adding a filter
designed to remove 99% of all particles larger than 1 micron to the fuel system. The
filter should be mounted upstream of the GSOV to ensure that natural gas fuel delivered
to the engine is free from contaminants.

©2012 Caterpillar® Page | 7

All rights reserved
 Gas filters restrict the flow of gas in the supply line and must be included in supply
restriction calculations. To ensure proper pressure at the gas pressure regulator, the fuel
pressure supplied to the fuel filter must be equal to the requirement at the pressure
regulator plus the maximum restriction of the fuel filter and pipe restriction between the
pressure regulator and fuel filter.

Gas filters are not designed to handle liquids. Liquids in the fuel supply must be
removed using equipment designed for that purpose.

3.8. DGB Control System

The DGB control system processes engine and generator data and determines the
optimum gas fuel requirements to allow for seamless adjustment of gas and diesel ratio
during operation. The DGB control system is comprised of the EMCP4.4, Engine
Control Module, engine and generator sensors, and Integrated Sensor Module.

3.9. Control Panel

The DGB kit and engine includes the EMCP 4.4 control panel, 6 direct gauge readout
displays, and an emergency stop button. The panel is connected to the rest of the
generator set through a supplied interconnect harness that connects to the generator
terminal box and also the Engine Control Module (ECM). The panel has the capability
for Direct Rack Input connections via 4-20 mA to PWM signal conversion. The panel
also allows for integration into existing drill rig control systems. It also allows for “plug
and play” connection to the engine and the generator via the standard CDL or Cat ET
connections.

The analog style gauges are meant to offer the operator a quick glance at the engine and
include the following. The figure below shows the parameters available through the
analog gauges.

©2012 Caterpillar® Page | 8

All rights reserved
 (24) Oil Temperature Gauge
(25) Engine Percent Load Gauge
(26) Engine Oil Pressure Gauge
(27) Coolant Temperature Gauge
(28) Diesel Fuel Pressure Gauge
(29) Voltmeter

Control panel with analog gauges, EMCP 4.4

control panel, and emergency stop button

EMCP 4.4 panel

3.10. EMCP 4.4 Panel

The DGB generator sets and retrofit kits utilize an EMCP4.4 panel to integrate the
operator to the DGB controls. The EMCP 4.4 has a user friendly display panel that
includes analog gauges along with a 5.5 inch graphical display. The EMCP 4.4 has
intuitive menus and plain text alarm and faults. The EMCP 4.4 panel has a remote E-stop
and a start/stop capability. The panel is capable of CAN, MODBUS, and Ethernet

©2012 Caterpillar® Page | 9

All rights reserved
 communications. The primary function of the EMCP 4.4 panel is for control and
monitoring of the complete engine and generator system.

With the addition of DGB, the panel interfaces and controls the DGB system with
certain operator inputs. Those inputs include DGB system status (off or on) and the
substitution rate. Substitution rate can be programmed by percentages (20%, 25%, etc)
or maximum substitution rate as determined by the ADEM 4 ECM. The EMCP 4.4 panel
also displays the actual DGB substitution rate. The EMCP 4.4 panel will display the
substitution rate based on diesel energy that is actually replaced by natural gas energy.
The maximum substitution would show that

70% of the required energy is from natural gas fuel and that 30% of the required energy
is from diesel fuel. Depending on the natural gas fuel quality, 70% may not be able to be
achieved. Also note that since the substitution rate is energy based, the actual liquid fuel
requirement may not be reduced by exactly 70%.

3.11. Integrated Sensor Module (ISM)

DGB engines and retrofit kits include an Integrated Sensor Module (ISM). The ISM
monitors combustion and communicates date to the Engine Control Module (ECM) and
controls system to adjust and protect the engine. The ISM’s primary source of
combustion monitoring is via the detonation sensors and the exhaust temperature
monitoring. The ISM communicates with the engine ECM via J1939 protocol.

3.12. Engine Control Module (ECM)

Engine control is performed from the Engine Control Module (ECM), which runs on the
ADEM™ A4 software (Advanced Digital Engine Management). The ADEM 4 ECM
allows the DGB system to operate at the maximum efficiency possible to insure timely
adjustments to the diesel and natural gas fuel system. The ADEM 4 ECM for the DGB
system controls the flow of the natural gas fuel via the control of the FCV. The control
of natural gas flow is derived from the ECM monitoring the engines detonation levels
(input from the ISM), exhaust temperatures (input from the ISM), inlet manifold

©2012 Caterpillar® Page | 10

All rights reserved
 temperatures, inlet manifold pressures, and other parameters. The ECM evaluates all of
the above parameters to control diesel fuel injection and gas fuel substitution.

3.13. Diesel Oxidation Catalyst (DOC)

In order to maintain some United States EPA diesel emissions certifications, a Diesel

Oxidation Catalyst (DOC) is required, and included in the DGB retrofit kits when sold in

the United States and Canada.

4. FUELING PROCEDURE
A source of continuous gas fuel flow must be provided to the DGB system and must be
securely connected to the DGB gas inlet connection by means of a flexible line. The
connection at the gas inlet is 2 inch NPT. Gas fuel quality must follow the guidelines
described in this section. Pressure and temperature must be within the guidelines described
in section 3.

4.1. Natural Gas Composition

The following forms of natural gas fuels are often used in internal combustion engines:

· Field or well head gas

· Associated gas
· Biogas
· Landfill gas,
· Pipeline natural gas

The unique use of using diesel fuel and natural gas fuel in the same engine requires that
the natural gas or gaseous fuel meets certain quality requirements. All gas fuels must
meet the requirements set forth in the Gaseous Fuel A&I Guide.

©2012 Caterpillar® Page | 11

All rights reserved
 4.2. Contaminants

Contaminants may be introduced into the engine as chemical compounds carried in the
fuel or air. These contaminants may cause damage to the engine through corrosion,
abrasion, or formation of deposits. The amount of each allowed to enter the engine must
be limited to protect the engine from damage. Contaminants in the fuel could be water,
particulates, silicon, ammonia, sulfur, etc. A complete list of contaminants and their
limits is included in the Gaseous Fuels A&I Guide.

4.3. Sulfur compounds

One major contaminant is sulfur compounds. Sulfur compounds are formed during the
decomposition of organic waste. The primary compound of concern is hydrogen sulfide

(H2S), although any compound containing sulfur should be considered when comparing
sulfur intake to engine limits. A complete list of sulfur compounds can be found in the
Gaseous Fuels A&I Guide. Sulfur compounds which condense out of the fuel gas are
highly corrosive and will quickly damage and fail bright metal engine components.
Condensation of the air fuel mixture in the after cooler will lead to failure of the after
cooler core. Even more significant, sulfur compounds dissolved in the engine oil from
blow-by gas will corrode the oil cooler, bronze and brass bushings and bearings and any
internal engine components containing copper. Even trace amounts of sulfur can
significantly damage engine components.

Since H2S is the primary sulfur compound of concern in gaseous fuels, the sulfur limits
are expressed as maximum H2S content. Maximum H2S content is defined for each
engine type and model. For the DGB engines, the maximum H2S content is 0.14
micrograms/BTU, which translates into 0.0004 mole percentage or 4 ppm (part per
million).

4.4. Inert Compounds

Inert gases are compounds in the natural gas fuel that have no combustions properties.

©2012 Caterpillar® Page | 12

All rights reserved
 The most common inert gases are Nitrogen, Carbon Dioxide, and Helium. With gas
burning engines, inert gases offset the volume of methane and other burning compounds
and reduce the efficiency of the combustion process. Some inert gases such as Carbon
Dioxide cause increased exhaust temperatures. DGB generator sets can handle high
amounts of inert gases in the gaseous fuel because of the blending with the diesel fuel.
The maximum total relative volume of inert gases that the DGB engine can accept is
55%.

4.5. Methane Number and Detonation

Cat DGB engines can operate on gaseous fuels from a wide range of sources; from
associated gas to pipeline natural gas.

The key property that determines suitability of a fuel for use in an engine is the ability of
the fuel gas to resist detonation. Detonation and pre-ignition are forms of abnormal
combustion processes that involve uncontrolled burning of the fuel-air mixture in the
cylinder. Pre-ignition is the term used to describe premature ignition of the fuel-air
mixture before the combustion process is meant to start – in the case of the DGB system
is the diesel fuel injection. Detonation describes the scenario where the fuel-air mixture
is ignited at the proper time by the diesel fuel injection and a second ignition event takes
place in the unburned fuel-air mixture before the normal combustion sequence can go to
completion. Both events are potentially damaging to the engine due to their ability to
produce localized high temperatures and sharp rises in cylinder pressure. Left
unchecked, detonation has the potential to cause significant engine damage. For this
reason, having a measure of this detonation resistance property provides a valuable tool
for assessing the suitability of a gas to use as engine fuel. The Caterpillar Methane
Number provides a measure of detonation resistance of a fuel. Calculating the methane
number requires a set of complicated computations; therefore, Caterpillar developed a
computer program to perform these calculations and allow field determination of the
methane number. The Caterpillar Methane Number program is the only program that can
provide the methane number required for Caterpillar engines. GERP (Gas Engine Rating
Pro) includes the latest version of the Caterpillar Methane Number program. The

©2012 Caterpillar® Page | 13

All rights reserved
 Caterpillar Methane Number program not only determines the methane number for the
fuel, but also the percentage of inert gases and H2S, which are needed to determine
feasibility of the fuel for DGB engines. Contact your local Cat dealer to assess the
quality of the fuel available at the site through GERP.

4.6. DGB Natural Gas Fuel Requirements

For all DGB 3500 “B” series generator sets, the minimum methane number is 30 and the
maximum lower heating value is 2300 BTU/scf.

For the DGB 3500 “C” series generator set, the minimum methane number is 30 and the
maximum lower heating value is 1260 BTU/scf.

4.7. Fuel Treatment Options

If the natural gas fuel does not meet the minimum requirements for the DGB system,
fuel treatment recommendations are available from Caterpillar. Please contact your local
Cat dealer and/or Caterpillar’s Application Support Center for fuel treatment
recommendations.

4.8. Diesel Fuel System

DGB engines can only use Low Sulfur Diesel (LSD) or Ultra-Low Sulfur Diesel
(ULSD) fuels. Low Sulfur Diesel (LSD) fuel is defined by the U.S. EPA as diesel fuel
having sulfur content not to exceed 0.05% by weight or 500 parts per million (ppm).
Ultra-Low Sulfur Diesel (ULSD) fuel is defined by the U.S. EPA as diesel fuel having
sulfur content not to exceed 15 parts per million or 0.0015 percent by weight. Heavy
Fuel Oil (crude), Marine Diesel Oil, Biodiesel, Blended Fuel Oil, Residual Fuel,
Kerosene, and Aircraft Jet Fuels are not recommended for use with DGB engines. Only
ASTM No.2 diesel fuel (LSD or ULSD) is recommended.

For further information in diesel fuel requirements for Caterpillar engines, consult the
Application and Installation Guide.

©2012 Caterpillar® Page | 14

All rights reserved
 4.9. Diesel Fuel Requirements

The choice of fuel depends on the specific engine model. Please refer to the following
list for choice of appropriate diesel duel type:

· 3512B generator sets – Low Sulfur Fuel (LSF)

· 3516B generator sets - Low Sulfur Fuel (LSF)
· 3512C generator sets – Ultra Low Sulfur Fuel (ULSD)

Use of fuels with higher than recommended and/or maximum allowed fuel sulfur levels
can result in increased overall operating costs and/or reduced engine life. Refer to the
applicable engine Operating and Maintenance Manual and the Caterpillar Commercial
Diesel Engine Fluids Recommendations for further diesel fuel requirements.

5. MAINTENANCE INTERVAL SCHEDULE

Ensure that all safety information, warnings, and instructions are read and understood before
any operation or any maintenance procedures are performed. An authorized operator may
perform the maintenance items with daily intervals. An authorized operator may perform the
maintenance items with intervals of every week. The maintenance that is recommended for
all other maintenance intervals must be performed by an authorized service technician or by
your Cat dealer.

The user is responsible for the performance of all maintenance which includes the following
items: performing all adjustments, using proper lubricants, fluids, and filters, and replacing
old components with new components due to normal wear and aging. Failure to adhere to
proper maintenance intervals and procedures may result in diminished performance of the
product and/or accelerated wear of components. Before each consecutive interval is
performed, all maintenance from the previous intervals must be performed. Choose the
interval that occurs first in order to determine the correct maintenance interval: fuel
consumption, service hours, and calendar time. Products that operate in severe operating
conditions may require more frequent maintenance. All of the following will affect the oil
change interval: operating conditions, fuel type, oil type, and size of the oil sump. Scheduled

©2012 Caterpillar® Page | 15

All rights reserved
 oil sampling analyzes used oil in order to determine if the oil change interval is suitable for
your specific engine. Refer to the Operation and Maintenance Manual, “Engine Oil and Filter
- Change” in order to determine the oil change interval that is suitable for your specific
engine.

To determine the maintenance intervals for the overhauls, refer to the Operation and
Maintenance Manual, “Maintenance Recommendations.” Unless other instructions are
provided, perform maintenance and perform repairs under the following conditions:

· The starting system is disabled

· The engine is stopped
· The generator does not pose an electrical shock hazard
· The generator is disconnected from the load

The items below are the recommended maintenance activities for optimum performance of
DGB generator sets. Refer to the Owning and Maintenance Manual for full procedures and
explanations.

5.1. When Required

Battery - Recycle
Battery - Replace
Battery or Battery Cable - Disconnect
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace
Fuel System - Prime
Fuel System Primary Filter/Water Separator – Drain
Generator - Dry
Generator Bearing - Lubricate
Generator Set - Test
Generator Set Alignment - Check
Generator Winding - Test
Maintenance Recommendations

5.2. Daily
Air Inlet Filter - Inspect/Clean/Test
Air Starting Motor Lubricator Oil Level - Check
Air Tank Moisture and Sediment - Drain
Battery Charger - Check
Control Panel - Inspect/Test
Coolant Level - Check
Electrical Connections - Check

©2012 Caterpillar® Page | 16

All rights reserved
 Engine Air Cleaner Service Indicator - Inspect
Engine Air Precleaner - Check/Clean
Engine Oil Level - Check
Fuel Tank Water and Sediment - Drain
Generator Bearing Temperature - Test/Record
Generator Load - Check
Jacket Water Heater - Check
Power Factor - Check
Voltage and Frequency - Check
Walk-Around Inspection

5.3. Every Week

Generator - Inspect
Generator Lead - Check
Space Heater - Test
Stator Winding Temperature – Test

5.4. Initial 250 Service Hours

Engine Valve Lash - Check
Fuel Injector - Inspect/Adjust
Crankcase Pressure – Measure

5.5. Initial 1000 Service Hours

Valve Stem Protection – Measure/Record
Crankcase Pressure - Measure

5.6. Every 250 Service Hours

Air Shutoff - Test
Battery Electrolyte Level - Check
Belts - Inspect/Adjust/Replace
Coolant Sample (Level 1) - Obtain
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add
Engine Oil Sample - Obtain
Hoses and Clamps - Inspect/Replace
Radiator - Clean

5.7. Every 500 Service Hours

Engine Oil and Filter - Change

5.8. Every 500 Service Hours or 1 Year

Fan Drive Bearing - Lubricate

5.9. Every 1000 Service Hours

Coolant Sample (Level 2) - Obtain
Engine - Clean

©2012 Caterpillar® Page | 17

All rights reserved
 Engine Crankcase Breather - Clean/Replace
Engine Protective Devices - Check
Fuel System Primary Filter (Water Separator)
Element - Replace
Fuel System Secondary Filter - Replace
Gas Pressure Regulator Condensation - Drain
Generator Winding Insulation - Test
Oxygen Sensor - Calibrate
Rotating Rectifier - Inspect/Test

5.10. Every 2000 Service Hours

Air Starting Motor Lubricator Bowl - Clean
Crankshaft Vibration Damper - Inspect
Engine Mounts - Inspect
Generator Set Vibration - Test/Record
Stator Lead - Check
Turbocharger - Inspect

5.11. Every Year

Generator Bearing - Inspect
Varistor - Check
Varistor - Inspect

5.12. Every 3000 Service Hours

Turbocharger - Inspect

5.13. Every 3000 Service Hours or 3 Years

Coolant (DEAC) - Change

5.14. Every 4000 Service Hours

Engine Valve Lash - Check
Fuel Injector - Inspect/Adjust
Valve Stem Projection – Measure/Record

5.15. Every 6000 Service Hours or 6 Years

Alternator - Inspect
Coolant Extender (ELC) - Add
Coolant Temperature Regulator - Replace
Engine Speed/Timing Sensor - Clean/Inspect
Prelube Pump - Inspect
Starting Motor - Inspect
Water Pump - Inspect

5.16. Every 12 000 Service Hours or 6 Years

Coolant (ELC) - Change

©2012 Caterpillar® Page | 18

All rights reserved
 5.17. Overhaul
Aftercooler Core - Inspect/Clean/Test
Generator Bearing - Replace
Overhaul (Major)
Overhaul (Top End)
Overhaul Considerations

5.18. Commissioning
Fan Drive Bearing – Lubricate

6. PARTS AND SERVICE

Parts and service for the DGB generator sets are available through the Cat dealer network. A
comprehensive list of all Cat dealers in the US is available below. Alternatively, individual
dealers can be found by using the dealer locator tool at http://www.cat.com/dealer-locator .

©2012 Caterpillar® Page | 19

All rights reserved
 6.1. Dealer Contact Information

DEALER NAME ADDRESS STATE PHONE NUMBER

ALBAN ENGINE POWER SYSTEMS 6387 OLD WASHINGTON RD ELKRIDGE MD 21075-5308 MARYLAND 1 (410) 796-8000
ALTORFER INC. 2600 6TH ST SW CEDAR RAPIDS IA 52404-3504 IOWA 1 (319) 365-0551
BLANCHARD MACHINERY CO. 3151 CHARLESTON HWY WEST COLUMBIA SC 29172-2723 SOUTH CAROLINA 1 (803) 791-7100
BUTLER MACHINERY COMPANY 3401 33 ST SW FARGO ND 58104-8804 NORTH DAKOTA 1 (701) 280-3100
CAROLINA TRACTOR & EQUIPMENT 9000 STATESVILLE RD CHARLOTTE NC 28269-7680 NORTH CAROLINA 1 (704) 596-6700
CARTER MACHINERY COMPANY, INC. 1330 LYNCHBURG TPKE SALEM VA 24153-5416 VIRGINIA 1 (540) 387-1111
CASHMAN EQUIPMENT COMPANY 3300 SAINT ROSE PKWY HENDERSON NV 89052-3985 NEVADA 1 (702) 649-8777
CECIL I. WALKER MACHINERY CO. 1400 E DUPONT AVE BELLE WV 25015-1217 WEST VIRGINIA 1 (304) 949-6400
CLEVELAND BROTHERS EQUIPMENT 5300 PAXTON ST HARRISBURG PA 17111-2525 PENNSYLVANIA 1 (717) 564-2121
EMPIRE MACHINERY 1725 S COUNTRY CLUB DR MESA AZ 85210-6003 ARIZONA 1 (480) 633-4000
FABCO EQUIPMENT, INC. 11200 W SILVER SPRING RD MILWAUKEE WI 53225-3198 WISCONSIN 1 (414) 461-9100
FOLEY, INCORPORATED 855 CENTENNIAL AVE PISCATAWAY NJ 08854-3912 NEW JERSEY 1 (732) 885-5555
GILES & RANSOME INC. 2975 GALLOWAY RD BENSALEM PA 19020-2320 PENNSYLVANIA 1 (215) 639-4300
GREGORY POOLE EQUIPMENT CO. 4807 BERYL RD RALEIGH NC 27606-1406 NORTH CAROLINA 1 (919) 828-0641
H.O. PENN MACHINERY CO., INC. H.O. PENN MACHINERY CO., INC. POUGHKEEPSIE NY 12603-2950 NEW YORK 1 (845) 452-1200
HAWTHORNE MACHINERY CO. HAWTHORNE MACHINERY CO. SAN DIEGO CA 92127-2405 CALIFORNIA 1 (858) 674-7000
HAWTHORNE PACIFIC CORP. HAWTHORNE PACIFIC CORP. WAIPAHU HI 96797-2201 HAWAII 1 (808) 677-9111
HOLT OF CALIFORNIA HOLT OF CALIFORNIA STOCKTON CA 95206-1112 CALIFORNIA 1 (209) 466-6000
HOLT TEXAS LTD. HOLT TEXAS LTD. SAN ANTONIO TX 78222-4843 TEXAS 1 (210) 648-1111
J.A. RIGGS TRACTOR COMPANY 9125 INTERSTATE 30 LITTLE ROCK AR 72209-3703 ARKANSAS 1 (501) 570-3100
JOHN FABICK TRACTOR COMPANY 1 FABICK DR FENTON MO 63026-2986 MISSOURI 1 (636) 343-5900
JOHNSON MACHINERY CO. 800 E LA CADENA DR RIVERSIDE CA 92507-8715 CALIFORNIA 1 (951) 686-4560
KELLY TRACTOR CO. 8255 NW 58TH ST MIAMI FL 33166-3406 FLORIDA 1 (305) 592-5360
LOUISIANA MACHINERY COMPANY 3799 W AIRLINE HWY RESERVE LA 70084-5717 LOUISIANA 1 (985) 536-1121
MACALLISTER MACHINERY CO., INC 7515 E 30TH ST INDIANAPOLIS IN 46219-1192 INDIANA 1 (317) 860-3300
MACHINERY POWER & EQUIPMENT CO. 16711 W VALLEY HWY TUKWILA WA 98188-5521 WASHINGTON 1 (425) 251-6400
MICHIGAN TRACTOR AND 24800 NOVI RD NOVI MI 48375-2414 MICHIGAN 1 (248) 349-4800
MUSTANG DEALERSHIP OF TEXAS, LLC 12800 NORTHWEST FWY HOUSTON TX 77040-6302 TEXAS 1 (713) 460-2000
N C MACHINERY CO. 17035 W VALLEY HWY TUKWILA WA 98188-5519 WASHINGTON 1 (425) 251-9800
NEBRASKA MACHINERY COMPANY 11002 SAPP BROTHERS DR OMAHA NE 68138-4812 NEBRASKA 1 (402) 891-8600
OHIO MACHINERY CO. 3993 E ROYALTON RD BROADVIEW HEIGHTS OH 44147-2929 OHIO 1 (440) 526-6200
PANTROPIC POWER INC. 8205 NW 58TH ST MIAMI FL 33166-3406 FLORIDA 1 (305) 592-4944
PATTEN INDUSTRIES, INC. 635 W LAKE ST ELMHURST IL 60126-1465 ILLINOIS 1 (630) 279-4400
PETERSON MACHINERY CO. 2300 HENDERSON AVE EUGENE OR 97403-2227 OREGON 1 (541) 302-9199
PETERSON POWER SYSTEMS 2828 TEAGARDEN ST SAN LEANDRO CA 94577-5700 CALIFORNIA 1 (510) 895-8400
PUCKETT MACHINERY COMPANY 3263 HIGHWAY 80 W JACKSON MS 39204-2229 MISSISSIPPI 1 (601) 969-6000
QUINN COMPANY 10006 ROSE HILLS RD CITY OF INDUSTRY CA 90601-1702 CALIFORNIA 1 (562) 463-4000
RING POWER CORPORATION 500 WORLD COMMERCE PKWY SAINT AUGUSTINE FL 32092-3788 FLORIDA 1 (904) 737-7730
SOUTHWORTH-MILTON, INC. 100 QUARRY DR MILFORD MA 01757-1729 MASSACHUSETTS 1 (508) 634-3400
STOWERS MACHINERY CORPORATION 6301 OLD RUTLEDGE PIKE KNOXVILLE TN 37924-4831 TENNESSEE 1 (865) 546-1414
THOMPSON MACHINERY COMMERCE 1245 BRIDGESTONE PKWY LA VERGNE TN 37086-3510 TENNESSEE 1 (615) 256-2424
THOMPSON TRACTOR CO., INC. 2401 PINSON HWY BIRMINGHAM AL 35217-2051 ALABAMA 1 (205) 841-8601
TRACTOR & EQUIPMENT COMPANY 1835 HARNISH BLVD BILLINGS MT 59101-6293 MONTANA 1 (406) 656-0202
WAGNER EQUIPMENT CO. 18000 E SMITH RD AURORA CO 80011-3511 COLORADO 1 (303) 739-3000
WARREN POWER & MACHINERY, INC. 10325 YOUNGER RD MIDLAND TX 79706-2622 TEXAS 1 (432) 571-4200
WESTERN STATES EQUIPMENT 500 E OVERLAND RD MERIDIAN ID 83642-6606 IDAHO 1 (208) 888-2287
WHAYNE POWER SYSTEMS 1400 CECIL AVE LOUISVILLE KY 40211-1622 KENTUCKY 1 (502) 774-4441
WHEELER MACHINERY CO. 4901 W 2100 S SALT LAKE CITY UT 84120-1227 UTAH 1 (801) 974-0511
WYOMING MACHINERY COMPANY 5300 W OLD YELLOWSTONE HWY CASPER WY 82604-1954 WYOMING 1 (307) 472-1000
YANCEY POWER SYSTEMS 259 LEE INDUSTRIAL BLVD AUSTELL GA 30168-7437 GEORGIA 1 (770) 941-2424
ZIEGLER, INC. 901 W 94TH ST MINNEAPOLIS MN 55420-4299 MINNESOTA 1 (952) 888-4121

©2012 Caterpillar® Page | 20

All rights reserved
7. WARRANTY
Please note there is an alternative fuel conversion system warranty on your Dynamic Gas
Blending Kit. Caterpillar provides warranty for the alternative fuel conversion system of your
kit for regulatory terms of 5 years/3000 hours, whichever comes first, in the U.S. and 12
months Caterpillar New Parts terms for rest of world provided there has been no abuse,
neglect or improper maintenance of the kit or your engine.

Registration of the upgrade will be required in order to obtain full warranty on the upgrade
kit. Please see the section above “Registering the Upgrade” for complete details.

Complete warranty information can be found on warranty.cat.com. For questions regarding

warranty administration, please review the Global Warranty Guide. For additional questions,
please contact global_warranty@cat.com.

©2012 Caterpillar® Page | 21

All rights reserved
LEBW0025-00 (01/13) ©2012 Caterpillar® All rights reserved