The CAT C18 diesel generator set is a high-performance power solution widely used for industrial and commercial backup power. This document provides a comprehensive guide to its installation, operation, and maintenance. Proper installation involves securing the base, connecting fuel lines, exhaust components, battery, output cables, and grounding, while ensuring adequate ventilation and a clean environment. Pre-start inspections include checking coolant, oil, fuel lines, air filters, belts, and electrical connections. The generator supports both manual and automatic start modes and requires a warm-up period before loading.
During operation, key parameters such as voltage, frequency, oil pressure, and exhaust emissions must be monitored. Loading should follow a large-to-small load sequence to avoid sudden speed changes. Regular shutdown procedures include disconnecting loads and using cooldown functions, while emergency shutdowns are triggered by faults such as low oil pressure or overheating.
Routine maintenance is crucial for performance and longevity. Checks and servicing intervals are scheduled at 12, 50, 250, 500, 1000, 2000, 3000, and 6000 operating hours, covering filters, fluids, belts, sensors, and electrical systems. Adhering to these guidelines ensures safe, efficient, and reliable generator operation.
CAT C18 Generator Set
CAT C18 Diesel Generator Set Installation
- Place the power generation room onto the mounting foundation, which should have a level surface.
- The base for installing the unit in the power generation room should be firm, with good contact on the supporting surface, and fastened with bolts.
- Install the exhaust pipe and muffler, tighten the connection screws, and connect the muffler with the support frame.
- Connect the diesel fuel inlet and return pipes, and tighten the joints to prevent leakage.
- Connect the battery and starter line (first positive then negative).
- Connect the output cable line and tighten the connecting screws.
- Install the grounding wire of the equipment.
- Maintain good ventilation conditions in the power generation room and keep the environment of the power generation room clean and dry.
CAT C18 Diesel Generator Set Pre-start Inspection
- Check that the cooling system coolant level meets the requirements.
- Check whether the oil level is between the upper and lower limit scales of the dipstick.
- Check the fuel system, cooling system and lubricating oil seals of the unit for leakage.
- Check the air filter to ensure that the air inlet and outlet of the machine room are not blocked.
- Check the tensioning of the water pump belt and charger belt and re-tighten if necessary.
- Check all hoses to ensure that they are not loose or worn, otherwise they should be tightened or replaced.
- Check that the generator output circuit is connected correctly, make sure that the air switch is in the “OFF” position and the handle is down.
- Check that the switch on the starting control panel is flexible and reliable.
- Check the battery power and electrolyte level.
- Check that the charging and starting electrical wiring is correctly wired, in good contact, and not loose or detached.
- Check the reliability of the fasteners and the throttle adjustment system to ensure that the maneuvering mechanism is flexible, light and reliable.
- Exhaust the air in the fuel system, if it has not been started for a few weeks, the fuel system should be filled with oil.
- Check the fuel supply, drain the water from the oil-water separator and open the fuel supply valve.
CAT C18 Diesel Generator Startup
Automatic Startup
1. For EMCPII and EMCPII+ control panels, the engine control switch must be in the “AUTO” position. For switchgear changeover operator panels, the engine control switch must be in the “REMOTE” position. 2.
2. Close the generator set’s main circuit breaker.
3.When the unit detects a signal, the generator set automatically starts and delivers power.
4.When the unit fails to detect the signal, the generator set stops automatically after a certain delay.
Manual start
1.The engine control switch is in the “MANSTART” position.
2.Start the generator set.
3.Observe the voltage and frequency of the generator set.
4.Let the generator set warm up for 3~5 minutes, pay attention to the oil pressure, listen to whether there is any abnormal sound, pay attention to whether there is any oil leakage, water leakage, smoke leakage and other abnormal phenomena.
5.Turn on the power.
Note: If the generator is started in cold weather (below 0℃), it should be warmed up first before starting it according to normal steps!
CAT C18 diesel generator set Operation and loading
- Check the unit for abnormal noise and vibration, and whether the smoke exhaust is normal.
- Check whether there is liquid leakage.
- When the unit is normal, then enter the rated speed and observe the meter indication.
- Check the output voltage and frequency.
- When the generator set is loaded, in order to avoid violent change of rotational speed, it should close the load with larger current first, and then close the load with smaller current.
- load, should always pay attention to the lubricating oil pressure changes, oil, water temperature, exhaust smoke color and sound abnormalities.
CAT C18 Diesel generator set operation precautions. - It is prohibited to run the generator when the tachometer, oil pressure gauge and temperature gauge are damaged or in short supply.
- Do not allow sudden increase or decrease of the load of the diesel engine under non-special circumstances.
- Non-emergency stopping with load is strictly prohibited.
CAT C18 Diesel Generator set Shutdown
Normal shutdown of the diesel generator set
1.Open the main circuit breaker in order to disconnect the slave equipment and unload it.
2.Turn the unit control switch to the “OFF/RESET” position to stop the generator set.
3.If the generator set is carrying a large load, the generator set control switch can be turned to the COOLDOWNSTOP position, and the generator set will stop automatically after 5 minutes of no-load operation.
Note: non-emergency, it is strictly prohibited to shut down the generator set with load!
Emergency shutdown of diesel generator sets
1.Press the “emergency stop” button, the unit automatically shut down the throttle shutdown, while the red “emergency stop” indicator light. (The button needs to be re-turned out to restart the diesel generator set).
2.When one of the following conditions occurs, emergency shutdown is necessary.
The oil pressure is low and the fault light is red.
- High temperature fault light is on red.
- When the unit speed exceeds the rated speed.
- When the unit makes an abnormal knocking sound.
- When the unit output voltage exceeds the rated voltage.
- When there is a fire, power leakage or other natural disaster that may jeopardize the safety of the unit and the operator.
Note: Under normal circumstances, it is strictly prohibited to stop the machine by emergency stop!
CAT C18 Diesel Generator Set Disassembly
- Disassemble and connect the battery and starter line (negative first, then positive).
- Disassemble the exhaust pipe and muffler, tighten the connecting screws, and remove the connecting screws between the muffler and the support frame.
- Disassemble the diesel fuel inlet and return pipes, wrap the joints to prevent dirt from entering.
- Remove the output cable, and install the connecting bolts.
- Remove the ground wire.
CAT C18 Diesel Generator Set Maintenance
Every 12h of operation
- Fill in the equipment operation and maintenance records.
- Check the diesel engine pipeline for oil, water and air leakage, and keep the surface of the diesel generator set clean.
- Check the fuel level of the fuel tank (tank).
- Check the oil level of lubricating oil in the oil sump; keep it between the upper and lower limit scales.
- Check the amount of coolant in the expansion tank.
- Observe the air filter service indicator. Clean or replace the air filter when the yellow spacer bar enters the red zone, or the red piston is in a visible position.
- pay attention to observe the changes in the diesel generator operation process, especially the lubricant pressure, oil temperature, water temperature, smoke and abnormal ringing situation; such as the discovery of abnormal changes in the phenomenon, it should be carefully examined in order to facilitate the early discovery of the accident factors and timely elimination.
- prohibit water flushing diesel generator set, in order to prevent damage to the diesel generator set.
Every 50h of operation
- Check and adjust the fan belt tightness.
- Check the generator and electronic control part of the wiring wire is secure.
- Check the sensor line connectors for looseness and wear.
- Check and adjust the DC generator (charging) motor belt.
- Check the crankcase ventilation pipe.
- Check battery condition and electrolyte level.
- Check the gauges.
Note: Be careful of steam burns when checking the water level in the water tank!
Every 250h of operation
- Check the fuel filter and replace if necessary.
- Check the oil and oil filter and replace if necessary.
- Blow out air filter with compressed air, replace if necessary.
- Check and adjust the fan drive belt.
- Check the fan drive bearing temperature is normal, bearing lubrication.
- Check and clean the radiator, there is no damaged heat sink, with 0.25Mpa compressed air to remove dirt.
- Check and adjust the valve lash.
Note: New machine or overhaul the machine for the first time after running to 50h, should replace the oil and oil, diesel filter!
Every 500h of operation
- Change the engine oil.
- Change the oil filter.
- Replace the diesel fuel filter.
- Replace the air filter (if the working environment is dusty, replace it in advance).
- Clean and check the crankcase ventilation filter and pipeline, and keep them unobstructed.
- Check and adjust the valve lash.
- Check and adjust the synchronous generator belt tightness.
Every 1000h of operation
- Check the electrolyte density of the battery and replenish the electrolyte if necessary.
- Check the generator excitation and control lines, and tighten the connection screws.
Every 2000h of operation
- Clean and replace the coolant filter.
- Check the coolant, filter or replace the coolant if necessary.
- Clean and check the thermostat valve.
Every 3000h of operation
- Sample and test coolant, replace or add additives if necessary.
- Dismantle and inspect starter motor, remove dirt and replace if necessary.
- Grease generator bearings.
Every 6000h of operation
- Replace the coolant of the cooling system; when using antifreeze, filter it according to the test condition before use.
- Disassemble and inspect the cooling system thermostat; replace if necessary.
- Disassemble and inspect the speed sensor: check the condition of the end of the speed sensor, check for wear and remove contaminants.
- Disassemble and inspect the electric motor: check the starting system circuit for loose connections, rust, broken connecting wires and uncleanliness; check the meshing condition of the pinion gear with the flywheel gear rim, the meshing marks on the gear teeth, and any breakage, and replace if necessary.
Kind Reminder:
The above information on the CAT C18 diesel generator set is provided for general reference only. Installation, operation, and maintenance may vary depending on your specific application and site conditions. For accurate technical advice, customized solutions, or detailed product specifications, we recommend speaking directly with a professional. Please feel free to leave your contact information below—our sales team will be happy to assist you with personalized support and the latest pricing details. We’re here to help you find the most reliable power solution for your needs.
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