We are a small rural water company and have a CAT 125kW Generator that has overheated and seized. The repair tech that works for the dealer came out and recommended that we replace it, as the engine probably needs to be replaced because it overheated and has now seized. He didn't take it apart to confirm this. He had a sales rep. come out the same day to take a look at it and they quoted $21,706 for a new one. After some push back from us, they sent the repair tech's supervisor out who also said the engine would need to be replaced even though he didn't take it apart either... He then quoted $16,958.28 for an Engine Overhaul with Caterpillar Remanufactured Long Block. I'm still not convinced that the engine is the problem but admittedly know nothing about generators, engines etc. I just want to ensure that this dealer is being straight with me. Unfortunately there are no other dealers nearby to confirm this and after many calls, no one in the area seems to work on these CAT generators other than the dealer I am working with... I have told the dealer that I want a quote to troubleshoot the problem before we replace, repair or anything else. They said they are sure it's the engine and I would be paying at least $2000 and probably more in labor to take it apart and troubleshoot the problem, but they are willing to do that if I insist. So, the question is... what are the chances that the engine doesn't need to be replaced and that there is a less costly repair to fix it? Please help, thanks!

How old is the unit and how many hours are on it ?

That's a good question. We can't find any records on it and none of the employees have been around longer than 10 yrs. We've had it at least that long. The dealer doesn't have the records either, but they say its 20+ yrs. Old (no dates anywhere on the unit). The hours read 41.5, but not sure if that is an accurate reading or not. I'm told we have run it no more than average of 8 hrs. a year in the past 10 yrs. Don't use it often, but we have three 50 hp water pumps and have to keep one running during a power outage. Based on the low usage, I probably don't need the best generator on the market if I have to replace it, so will shop around, but I'm told we need a minimum of 125kW for the pumps and business office during an outage. Thanks

gmount, just a suggestion but if money is not an object I would go with the CAT 125 kw with a 5 year warranty. I work with a univerisity in North Carolina and we just purchased a new 100 kw CAT with a 200gal fuel belly tank in a sound attenuated enclosure with the 5 year warranty for 27,500 it's a nice unit very quite and is user friendly. I also suggest setting up a PM ( preventive maintenance ) program on a monthly basis. I do a monthly checks on batteries fluid levels belts hoses and also perform a load test on the ATS and generator to keep things in working condition and on the operation of the equipment. Also set the generator up on a weekly timer to exersise once a week with no load for about 15 min. If you need or want a copy of my PM check list just shoot me an email at [email protected] and I will send it to you. Hope I covered everything for you if not let me know. P.S that unit has long lived and is probley not worthy of repair.