Caterpillarengine - generator setuninterruptible pwr su

Caterpillar UPS 300

Maintenance schedule, common problems & OEM parts breakdown

The Caterpillar UPS 300, catalogued as UPS 300Z, is a stationary, battery-free uninterruptible power supply module rated 300 kVA / 240 kW at 480 VAC, 60 Hz. It has no internal combustion engine, no undercarriage, and no fuel, coolant, or hydraulic system to service; it bridges electrical load using a spinning flywheel paired with an IGBT bi-directional converter until a separately supplied standby diesel generator set comes online. A single module weighs 3,063 kg (6,750 lb) and measures 865 mm (34.0 in) deep, 3,226 mm (127.0 in) wide, and 2,438 mm (96.0 in) tall. It is the base building block of Cat's UPS Z-Series line, which scales by paralleling additional 300Z modules up to 600Z, 900Z, and 1200Z capacity tiers rather than through separate model generations. Configurations include standalone operation, N+1 paralleled module groups, static and maintenance bypass switching, and an optional GenStart module for generator cranking assist.

What differs across a UPS 300 installation is configuration, not model generation: module count in a paralleled Z-Series bank, presence of a GenStart module, and the monitoring package (touchscreen, SNMP/MODBUS, Ethernet remote notification) fitted at commissioning. The flywheel-based, battery-free design itself marks the departure from older VRLA battery UPS architecture, trading periodic battery testing and replacement for a sealed mechanical bearing and vacuum-housing service cycle on a much longer interval. In the used and parts market this module is valued for critical-power applications backed by standby generators, where buyers weigh run-hour and spin-down history, firmware revision and support status, enclosure condition, and dealer-verified bearing and vacuum integrity well ahead of any parts-availability concern, since there is no engine parts catalog behind it.

Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.

Caterpillar UPS 300 specifications

Engine

Power module typeBattery-free flywheel energy storage system with IGBT-based bi-directional converter; no internal combustion engine and no battery bank.
Generator set integrationOptional generator set start module plus harmonic cancellation allow the unit to insulate a standby generator set from block loads/transients and improve starting reliability when paired with a genset.
Emissions tierNot applicable — stationary power-conditioning equipment, no combustion engine.

Weights

Shipping/operating weight, UPS 300Z single module3,063 kg (6,750 lb)
Shipping subassembly noteUnit ships split into an input/output cabinet, a system (control) cabinet, and module cabinet sections per the factory installation drawing; individual section weights vary with how many modules are ordered.
Ground pressureNot applicable — floor-mounted stationary electrical equipment, not a mobile machine.

Dimensions

Depth865 mm (34.0 in)
Width3,226 mm (127.0 in)
Height2,438 mm (96.0 in)
FootprintMarketed as the smallest footprint in its class among flywheel UPS systems; a precise square-footage figure is not consistently published and is omitted here rather than guessed.
Cable entryTop and bottom conduit entry panels on the enclosure.

Performance

Rated output300 kVA / 240 kW at 60 Hz
Output voltage480 VAC, 3-phase, 3-wire plus ground (4-wire optional); matches input source.
Output current (nominal)361 A
Input current302 A nominal, 400 A maximum continuous, 420 A maximum non-continuous
System efficiency97% (300Z module); larger 600Z/900Z/1200Z multi-module builds are rated 98%
Voltage regulationSteady-state within ±1% of nominal for ±10% input swing; transient recovery within ±1% in 50 milliseconds for a 100% load step; ±1% steady state while running on flywheel power
Frequency regulation60 Hz, mains-synchronized in normal operation, ±0.2% free-running; slew rate adjustable from 0.2 to 3.0 Hz/second
Power factor0.99 at rated load and nominal voltage
Overload capabilityUp to 105% continuous; 125% for 10 minutes; 150% for 2 minutes; 200% for 30 seconds; over 200% for 10 milliseconds
Flywheel ride-through time (no utility power)About 14 seconds at 100% load, 19 seconds at 75% load, 28 seconds at 50% load, 52 seconds at 25% load
Surge withstandMeets IEEE 587 / ANSI C62.41
Operating temperature range0 to 40°C (32 to 104°F); storage range -25 to 70°C (-13 to 158°F)
Humidity range5% to 95%, non-condensing
Maximum operating altitude914 m (3,000 ft)
Acoustical noiseUnder 72 dBA at 1 meter for the 300Z/600Z frame size

Service capacities (summary)

Fuel, hydraulic, engine oil, coolant capacitiesNot applicable. The unit is a battery-free flywheel UPS with no engine, hydraulic circuit, engine oil, or coolant system to service.
Heat rejection (for HVAC sizing)29,612 BTU/hr (8.7 kW) for the 300Z module

Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.

Caterpillar UPS 300 maintenance schedule

Service intervalTasks
Every 50 h
  • Walk the enclosure and confirm the touchscreen HMI shows no active alarms
  • Verify cooling fan operation and unobstructed intake/exhaust airflow
  • Check ambient room temperature stays within 0-40°C (32-104°F)
  • Confirm enclosure doors, latches, and cable glands are sealed
  • Note flywheel spin status and load level on the status display
Every 250 h
  • Confirm SNMP/MODBUS heartbeat to the building management or monitoring system
  • Inspect the enclosure exterior and base pad for corrosion or water intrusion
  • Verify the 8-LED status panel matches HMI-reported condition
  • Check that the EPO (emergency power off) circuit reads normal, not tripped
  • Review the alarm history log for repeat or unacknowledged events
Every 500 h
  • Inspect visible wiring terminations and cabinet hardware for looseness
  • Check intake filters or vents for dust loading and clean or replace as needed
  • Confirm control firmware revision is current and still under dealer support
  • Review ride-through time trend data against the rated 100%-load baseline
  • Check for unusual noise or vibration at the flywheel housing from outside the sealed enclosure
Every 1,000 h
  • Functionally test transfer to the maintenance bypass without dropping the protected load
  • Verify paralleling bus communication if the module runs in an N+1 group with other Z-Series modules
  • Inspect grounding and back-feed protection circuits
  • Confirm any installed GenStart module wiring and cranking-assist signal path are intact
  • Log a full diagnostic export from the HMI for the service record
Every 2,000 h
  • Schedule a dealer-level annual inspection of the module
  • Run a load-bank or step-load test where facility conditions allow
  • Compare bearing noise/vibration signature to the prior year's baseline
  • Confirm no capacity de-rate is present at current ambient conditions
  • Reconcile the year's alarm and bypass-event history with maintenance records
Every 50,000 h
  • Open the mid-life bearing service window (typically 5 to 8 years of continuous energization)
  • Coordinate a maintenance-bypass shutdown with the paired standby generator schedule
  • Have the dealer inspect or replace the sealed flywheel bearings
  • Verify post-service spin-down time still meets the rated ride-through curve before returning to line
Every 75,000 h
  • Open the vacuum-housing service window (typically 8 to 10 years of continuous energization)
  • Schedule dealer service of the flywheel's vacuum pump and housing seal under maintenance bypass
  • Retest vacuum integrity after service to confirm rated spin loss is not increased
  • Re-baseline bearing wear trend data following the vacuum service

Servicing the UPS 300 beyond the schedule

Predictive Maintenance & Fluid Analysis

No fluid analysis applies to the UPS 300 - there is no engine oil, coolant, or hydraulic fluid to sample. Predictive maintenance instead means condition monitoring: tracking HMI and SNMP/MODBUS alarm trends, watching ride-through time against the rated 100%-load curve, and logging bearing noise or vibration signatures at the sealed flywheel housing over time. A slow drift in spin-down time or a new vibration signature is the earliest warning sign of bearing wear, well before a bypass event forces the issue.

Corrective & Common Repairs

Field repairs on a UPS 300 center on the power-conditioning and control path, not an engine. Common corrective work includes clearing static bypass switch faults, resetting nuisance alarms, restoring dropped SNMP/MODBUS or Ethernet notification links, and swapping cooling fans or control cards flagged by the HMI. Any repair that requires opening the sealed flywheel housing or interrupting live conversion must route through the maintenance bypass first so the protected load stays covered.

Overhaul & Rebuild Points

There is no engine or undercarriage to overhaul on the UPS 300; the equivalent wear points are the sealed flywheel bearings and the vacuum-housing pump. Bearings typically reach their service or replacement window around 5 to 8 years of continuous energization, with vacuum-pump service following around 8 to 10 years. Both jobs require the maintenance bypass to carry the load while the module is off-line, and both should end with a spin-down/ride-through verification before the module returns to service.

Seasonal & Environmental Servicing

The UPS 300 is rated for 0-40°C (32-104°F) and is built for an indoor, climate-controlled space rather than outdoor duty cycles. Seasonal servicing is limited to confirming the room stays inside that temperature band, checking enclosure seals and cable glands for humidity or dust ingress, and keeping intake filters and cooling fans clear. There is no cold-weather fuel or coolant prep and no seasonal fluid change, since none of those systems exist on this module.

UPS 300 common service parts

Part numberPart
180-6264Filter Element As-Encl AirCheck fitment →
180-6265Filter Element As-Encl AirCheck fitment →
240-2526Filter Element-Encl AirCheck fitment →
259-3199Board As-CircuitCheck fitment →
180-6228Board AsCheck fitment →

Always confirm against your machine's serial number — cross-check any part in Heavy Parts AI before ordering.

UPS 300 attachments & work tools

Bypass switching

Built-in static bypass switch (thyristor/SCR assembly) isolates the module from the utility grid and shifts the critical load onto the flywheel/converter path if input power goes out of tolerance. A parallel electrically-operated bypass breaker plus an internal maintenance bypass let technicians isolate the module for service without dropping the connected load.

Multi-module paralleling / capacity expansion

The 300 kVA unit is the single-module building block of Cat's flywheel UPS line; the modular design lets additional 300 kVA modules be paralleled on site to grow protected capacity (for example the multi-module systems built from 300 kVA modules to reach roughly 600 kVA N+1). Reported paralleling limits vary by series and generation, so treat any specific module-count as configuration-dependent and confirm with a current factory arrangement drawing.

Generator set start (GenStart) module

Optional accessory used in continuous/hybrid power configurations: it takes AC output from the UPS and converts it to DC to provide redundant engine-cranking power for the paired generator set, wired in parallel with the genset's normal starting batteries through an isolation diode. Adds starting reliability rather than acting as a work tool; only fitted when the UPS is paired with a Cat generator set in a continuous-power arrangement.

Monitoring, control and communications package

Standard control/communication set on this class includes a color touch-screen operator interface, programmable input/output contacts, an integral modem, RS232/RS485 serial ports, and Ethernet/e-mail based remote notification with real-time monitoring software. These are configuration/integration accessories for building a monitored power-protection system, not mechanical attachments.

Cabling, cooling and enclosure configuration

Factory configuration options on this size class include top or bottom cable entry (site-dependent) and redundant cooling fans for the converter/flywheel enclosure. No mobile-machine style work-tool coupler exists on this product.

Protection and safety features

Back-feed protection and a local Emergency Power Off (EPO) control are standard safety provisions built into the module rather than optional add-on tooling.

All UPS 300 assemblies by section

Every catalogued assembly group for the Caterpillar UPS 300. Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.

Electrical And Starting System
255-6649 Adapter Gp-Communication -Ethernet Hub
22***05Adapter Group-Communication; -Ethernet Hub1
25***49Adapter Group-Communication; -Ethernet Hub1
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255-6648 Adapter Gp-Communication -Ethernet Hub
22***95Adapter Group-Communication; -Ethernet Hub1
25***48Adapter Group-Communication; -Ethernet Hub1
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248-8796 Adapter Gp-Communication -Ethernet
24***96Adapter Group-Communication; -Ethernet1
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206-8863 Adapter Gp-Communication
228-4090 Adapter Gp-Communication -Ethernet
22***90Adapter Group-Communication; -Ethernet1
22***95Adapter Group-Communication; -Ethernet Hub1
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228-4094 Adapter Gp-Communication -Ethernet
22***94Adapter Group-Communication; -Ethernet1
22***05Adapter Group-Communication; -Ethernet Hub1
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228-4105 Adapter Gp-Communication -Ethernet Hub
22***95Adapter Group-Communication; -Ethernet Hub1
22***05Adapter Group-Communication; -Ethernet Hub1
26***28Cable; (6-Foot)1
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228-4095 Adapter Gp-Communication -Ethernet Hub
22***95Adapter Group-Communication; -Ethernet Hub1
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255-6646 Adapter Gp-Communication -Ethernet Hub
24***09Transformer1
25***46Adapter Group-Communication; -Ethernet Hub1
30***89Adapter-Communication; (Ethernet Hub), Hexagon Head Cap Screw; M10 X 1.50 X 551
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228-4089 Adapter Gp-Communication -Ethernet
22***89Adapter Group-Communication; -Ethernet1
22***05Adapter Group-Communication; -Ethernet Hub1
24***09Transformer1
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255-6647 Adapter Gp-Communication -Ethernet Hub
22***05Adapter Group-Communication; -Ethernet Hub1
24***09Transformer1
25***47Adapter Group-Communication; -Ethernet Hub1
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242-7424 Board As-Circuit
201-2190 Board As-Circuit -System Input/Output
18***60Fuse; (2-Ampere)2
20***73Fuse; (1-Ampere)1
20***90Board As-Circuit; -System Input/Output1
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201-3177 Board As-Circuit -Power Distribution
18***55Fuse; (3-Ampere)(Output)5
20***67Fuse; (1-Ampere)5
20***69Fuse; (2-Ampere)1
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259-3199 Board As-Circuit -Emi Filter
24***51Capacitor6
25***99Board As-Circuit; -Emi Filter1
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259-3201 Board As-Circuit -Interface
24***46Fuse; (3.15-Ampere)1
25***01Board As-Circuit; -Interface1
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243-2251 Board As-Circuit -Controller
20***71Diskette1
20***76Diskette1
23***29Battery; (Lithium)1
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201-2604 Board As-Circuit -Ac Interface
18***60Fuse; (2-Ampere)1
20***04Board As-Circuit; -Ac Interface1
23***53Fuse; (5-Ampere)4
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201-2188 Board As-Circuit -System Input/Output
18***60Fuse; (2-Ampere)4
19***04Fuse; (3-Ampere)1
20***88Board As-Circuit; -System Input/Output1
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180-6221 Board As-Circuit -Static Switch Interface
18***21Board As-Circuit; -Static Switch Interface1
29***60Cable As1
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242-9378 Board As-Circuit -Fan Monitor
24***46Fuse; (3.15-Ampere)6
24***78Board As-Circuit; -Fan Monitor1
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235-6333 Board As-Circuit -Electro Magnetic Interference
23***51Capacitor3
23***33Board As-Circuit; -Electro Magnetic Interference1
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226-5486 Board As-Circuit -System I/O, Daughter
20***26Resistor; -Termination1
22***86Board As-Circuit; -System I/O, Daughter1
23***95Connector1
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243-2250 Board As-Circuit -Controller
23***29Battery; (Lithium)1
24***50Board As-Circuit; -Controller1
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201-2605 Board As-Circuit -Fan Monitor
20***05Board As-Circuit; -Fan Monitor1
24***46Fuse; (3.15-Ampere)6
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226-5485 Board As-Circuit -System I/O, Daughter
20***59Cable As1
20***60Cable As1
22***85Board As-Circuit; -System I/O, Daughter1
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201-2706 Board As-Circuit -Power Distribution
18***54Fuse; (20-Ampere)(Output)2
19***99Fuse; (10-Ampere)4
20***67Fuse; (1-Ampere)2
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206-5380 Box Gp-Connection
20***80Box Group-Connection1
23***95Parts Group-Miscellaneous; (Genset Start Driver)1
23***34Parts Group-Miscellaneous; (Genset Start Driver)1
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204-0303 Box Gp-Connection
18***28Board As; (Emi Filter)(Flywheel)1
19***75Fuse; (1000-Ampere)1
19***78Capacitor; (50vdc, Scr Term)2
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207-8642 Box Gp-Connection
20***42Box Group-Connection1
23***19Clamp1
23***20Diode2
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208-2265 Box Gp-Junction
205-3120 Bus Bar Gp
203-4297 Cable As-Communication
203-4227 Cable As-Communication
203-4296 Cable As-Communication
203-5546 Cable Gp
18***67Cable As-Ribbon; (Ac Interface)1
18***70Cable As-Ribbon; (System Input, Output 1)1
18***72Cable As-Ribbon; (Static Switch)1
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249-5618 Circuit Breaker Gp -Generator Start, Dual
24***18Circuit Breaker Group; -Generator Start, Dual1
25***67Cable As2
29***59Kit-Circuit Breaker; (40-Ampere)2
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249-5620 Circuit Breaker Gp -Generator Start, Dual
24***20Circuit Breaker Group; -Generator Start, Dual1
25***67Cable As2
29***26Circuit Breaker; (40-Ampere)2
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249-5619 Circuit Breaker Gp -Generator Start Module
24***19Circuit Breaker Group; -Generator Start Module1
25***67Cable As1
29***26Circuit Breaker; (40-Ampere)1
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249-5622 Circuit Breaker Gp -Generator Start, Dual
24***22Circuit Breaker Group; -Generator Start, Dual1
25***67Cable As2
29***26Circuit Breaker; (40-Ampere)2
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249-5621 Circuit Breaker Gp -Generator Start Module
24***21Circuit Breaker Group; -Generator Start Module1
25***67Cable As1
29***26Circuit Breaker; (40-Ampere)1
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249-5617 Circuit Breaker Gp -Generator Start Module
24***17Circuit Breaker Group; -Generator Start Module1
25***67Cable As1
29***26Circuit Breaker; (40-Ampere)1
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203-4683 Conduit Gp
226-4883 Conduit Gp
22***83Conduit Group1
27***83Cable; (24-Ga)2
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226-4887 Conduit Gp
22***87Conduit Group1
27***83Cable; (24-Ga)2
27***84Cable; (24-Ga)1
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207-4323 Conduit Gp
20***23Conduit Group1
22***87Conduit Group1
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207-4315 Conduit Gp
20***15Conduit Group1
22***83Conduit Group1
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207-4320 Conduit Gp
20***20Conduit Group1
22***86Conduit Group1
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207-8641 Conduit Gp
20***41Conduit Group1
22***88Conduit Group; (Fourth Enclosure)1
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226-4886 Conduit Gp
22***86Conduit Group1
27***83Cable; (24-Ga)2
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203-5456 Connection Gp-Electrical
20***56Connection Group-Electrical1
23***75Harness As-Wiring; (Ground)1
25***84Panel Group-Electrical1
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203-4292 Connector -Ethernet
200-8330 Contact As-Electrical
20***30Contact As-Electrical1
24***25Contact1
24***26Bracket1
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228-4114 Conversion Gp-Communication
228-4112 Conversion Gp-Communication
229-2890 Conversion Gp-Communication -Modbus Functionality
22***90Conversion Group-Communication; -Modbus Functionality1
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229-2889 Conversion Gp-Communication -Protocol Functionality
22***89Conversion Group-Communication; -Protocol Functionality1
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226-5484 Conversion Gp-Communication
203-3971 Diskette
203-3976 Diskette
243-9258 Fuse Gp
18***54Fuse; (20-Ampere)(Output)1
19***99Fuse; (10-Ampere)2
23***55Fuse; (7-Ampere)2
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180-6295 Ground Gp-Electrical -Electrical Drain
18***95Ground Group-Electrical; -Electrical Drain1
20***30Contact As-Electrical1
23***35Seal-O-Ring1
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203-4293 Installation Gp-Adapter
20***93Installation Group-Adapter1
24***09Transformer1
30***89Adapter-Communication; (Ethernet Hub), Hexagon Head Cap Screw; M10 X 1.50 X 551
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293-5402 Kit-Switch -Emergency Power Off
28***13Switch As-Push Button; (Emergency Power Off)1
29***02Kit-Switch; -Emergency Power Off1
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293-5403 Kit-Switch -Emergency Power Off
28***13Switch As-Push Button; (Emergency Power Off)1
29***03Kit-Switch; -Emergency Power Off1
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203-5458 Panel Gp-Circuit Breaker
20***31Cable As; (Thyristor)1
20***90Fuse; (600-Ampere)1
20***71Diskette1
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207-8726 Resistor -Termination
222-5438 Resistor As
259-3200 Switch As -Static Bypass
18***21Board As-Circuit; -Static Switch Interface1
20***39Cable As; (Static Switch Thermistor)1
24***22Thyristor3
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250-5523 Switch As -Static Bypass
18***21Board As-Circuit; -Static Switch Interface1
20***39Cable As; (Static Switch Thermistor)1
20***89Suppressor As-Arc; (Static Switch)3
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251-4572 Switch As -Static Bypass
20***77Fuse; (200-Ampere)3
20***31Cable As; (Thyristor)1
20***06Board As; (Bypass Cabinet Control)2
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203-5547 Switch As -Emergency Module Off
20***06Cable As; (System Cabinet Emo)1
20***47Switch As; -Emergency Module Off1
22***41Cover; (Switch)1
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199-5096 Switch As -Static Bypass-Static
18***21Board As-Circuit; -Static Switch Interface1
19***96Switch As; -Static Bypass-Static1
20***61Switch; (Static)1
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294-5574 Switch As-Push Button -Emergency Power Off
28***13Switch As-Push Button; (Emergency Power Off)1
29***74Switch As-Push Button; -Emergency Power Off1
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294-7319 Switch As-Push Button -Emergency Power Off
28***13Switch As-Push Button; (Emergency Power Off)1
29***19Switch As-Push Button; -Emergency Power Off1
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203-4323 Switch Gp-Disconnect
20***07Varistor As; (Surge Protector)(Ac)2
20***08Disconnect; (400-Ampere, 3-Pole)4
20***23Switch Group-Disconnect1
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203-4325 Switch Gp-Disconnect
20***07Varistor As; (Surge Protector)(Ac)2
20***08Disconnect; (400-Ampere, 3-Pole)8
20***25Switch Group-Disconnect1
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307-6546 Switch Gp-Disconnect
24***07Handle1
25***57Shaft1
30***46Switch Group-Disconnect1
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203-4324 Switch Gp-Disconnect
20***07Varistor As; (Surge Protector)(Ac)2
20***08Disconnect; (400-Ampere, 3-Pole)6
20***24Switch Group-Disconnect1
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183-9379 Switch Gp-Remote
18***79Switch Group-Remote1
25***72Switch-Push Button; (Remote Emergency Stop)1
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254-9922 Transformer As
24***23Transformer1
25***22Transformer As1
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261-1004 Varistor As
Enclosures, Guards And Bases
199-5106 Fan As-Circulating
19***06Fan As-Circulating1
20***61Switch-Limit; (Fan)1
26***63Impeller; (230-Volt)1
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203-1007 Fan Gp-Circulating
19***25Damper As; (Fan)1
19***06Fan As-Circulating1
20***29Screen; (Fan)1
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203-5453 Fastener Gp-Enclosure -Template
20***53Fastener Group-Enclosure; -Template1
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203-5451 Fastener Gp-Enclosure
203-5452 Fastener Gp-Enclosure
258-8806 Handle As
24***13Handle; (Maintenance Bypass)3
25***06Handle As1
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258-8805 Handle As
24***13Handle; (Maintenance Bypass)3
25***05Handle As1
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203-4320 Kickplate
203-4319 Kickplate
203-4322 Kickplate
203-4321 Kickplate
206-8862 Kickplate
203-4318 Kickplate
Operator Station
201-7672 Control As-Synchronizing
20***63Fuse; (1.5-Ampere)3
20***72Control As-Synchronizing1
24***20Block-Fuse; (3-Pole)1
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130-3349 Control Gp-Alarm Module
13***49Control Group-Alarm Module1
3J***54Packing,Preformed Part Of Kit P/N 5r***271
9S***02Plug-O-Ring; (Straight Thread O-Ring)1
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207-8751 Conversion Gp-Load Cell
18***35Bearing As; (Upper Flywheel)1
20***51Conversion Group-Load Cell1
22***42Seal-O-Ring1
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202-7510 Filter As-Electrical -Phase C
18***43Resistor As; (Bleeder)4
20***46Capacitor16
20***10Filter As-Electrical; -Phase C1
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259-3197 Filter As-Electrical -Ac
24***42Capacitor; (600-Volt)6
25***97Filter As-Electrical; -Ac1
25***98Cable2
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227-4834 Filter As-Electrical
20***28Capacitor12
22***34Filter As-Electrical1
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250-5511 Filter As-Electrical -Ac
24***42Capacitor; (600-Volt)12
25***11Filter As-Electrical; -Ac1
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202-7508 Filter As-Electrical -Phase B
18***43Resistor As; (Bleeder)4
20***46Capacitor16
20***08Filter As-Electrical; -Phase B1
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222-5440 Filter As-Electrical
22***38Resistor As6
22***39Capacitor; (600vac)12
22***40Filter As-Electrical1
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202-7507 Filter As-Electrical -Phase A
18***43Resistor As; (Bleeder)4
20***46Capacitor16
20***07Filter As-Electrical; -Phase A1
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202-9760 Flywheel Gp-Power Supply
18***95Ground Group-Electrical; -Electrical Drain1
20***52. Coller, Sensor-Vacuum; (Flywheel Bearing)1
20***60Flywheel Group-Power Supply1
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227-7457 Flywheel Gp-Power Supply
19***80Kit-Shim; (Includes 15-Shims)(Upper Bearing)1
20***52. Coller, Sensor-Vacuum; (Flywheel Bearing)1
22***41Screw; (5/16-18x0.875-In)16
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244-1409 Flywheel Gp-Power Supply
22***41Screw; (5/16-18x0.875-In)16
22***42Seal-O-Ring1
22***90Kit-Shim; (Includes 5-Shims)(Lower Bearing)1
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250-5510 Module As -Field Coil Driver
202-7596 Module As -System User Interface
18***86Cable As-Ribbon; (User Interface Lcd)1
20***31Switch-Push Button; (Emergency Module Off)1
20***33Switch; (Key)(Emergency Stop)1
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259-3195 Module As -Controller
24***67Capacitor; (1200-Volt)3
24***68Capacitor; (500-Volt)6
25***95Module As; -Controller1
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259-3196 Module As -Utility
24***67Capacitor; (1200-Volt)3
24***68Capacitor; (500-Volt)6
25***96Module As; -Utility1
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201-2679 Module As -Systems User Interface
20***31Switch-Push Button; (Emergency Module Off)1
20***32Switch-Push Button; (Horn Silence)1
20***33Switch; (Key)(Emergency Stop)1
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250-7959 Module Gp-Alarm
13***49Control Group-Alarm Module1
19***39Film-Control Panel1
24***68Switch-Push Button; (Alarm Test)1
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200-6276 Module Gp-Converter -Lh
20***76Module Group-Converter; -Lh1
20***90Board As; (Skiip Interface)1
23***64Module-Converter; (Lh)(Left Skiip)1
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200-6274 Module Gp-Converter -Rh
20***74Module Group-Converter; -Rh1
20***90Board As; (Skiip Interface)1
32***95Board-Electronic; (Right Skiip)1
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209-5506 Module Gp-Maintenance Bypass
20***06Module Group-Maintenance Bypass1
24***07Handle3
25***18Panel Group-Electrical1
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203-2745 Module Gp-Maintenance Bypass
20***45Module Group-Maintenance Bypass1
24***07Handle3
25***18Panel Group-Electrical1
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203-2747 Module Gp-Static Bypass
20***77Fuse; (200-Ampere)3
20***38Module-Thyristor1
20***69Contactor1
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203-5446 Module Gp-Static Bypass
18***21Board As-Circuit; -Static Switch Interface1
20***36Thyristor3
20***90Fuse; (600-Ampere)3
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203-4221 Module-External Modem -Interface
20***21Module-External Modem; -Interface1
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203-4222 Module-External Modem -Interface
20***22Module-External Modem; -Interface1
24***09Transformer1
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203-4295 Module-External Modem -Interface
20***95Module-External Modem; -Interface1
24***09Transformer1
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206-8858 Module-External Modem -Interface
20***58Module-External Modem; -Interface1
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206-8861 Module-External Modem
20***88Board As-Circuit; -System Input/Output1
20***27Cable As-Communication1
20***61Module-External Modem1
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206-8859 Module-External Modem -Interface
20***59Module-External Modem; -Interface1
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203-3974 Module-External Modem -Interface
20***74Module-External Modem; -Interface1
24***09Transformer1
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263-3457 Module-External Modem
24***09Transformer1
26***57Module-External Modem1
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263-3458 Module-External Modem
24***09Transformer1
26***58Module-External Modem1
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263-3455 Module-External Modem
24***09Transformer1
26***55Module-External Modem1
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203-3975 Module-External Modem -Interface
20***75Module-External Modem; -Interface1
24***09Transformer1
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206-8857 Module-External Modem -Interface
20***57Module-External Modem; -Interface1
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206-8860 Module-External Modem -Interface
20***88Board As-Circuit; -System Input/Output1
20***60Module-External Modem; -Interface1
24***09Transformer1
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263-3721 Module-External Modem
24***09Transformer1
26***21Module-External Modem1
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263-3330 Module-Internal Modem
20***26Cable As-Communication1
24***09Transformer1
24***55Modem As1
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206-8855 Module-Internal Modem
20***55Module-Internal Modem1
24***09Transformer1
24***54Modem As1
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263-3453 Module-Internal Modem
24***09Transformer1
24***55Modem As1
26***53Module-Internal Modem1
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203-3972 Module-Internal Modem
20***72Module-Internal Modem1
24***09Transformer1
24***55Modem As1
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203-3973 Module-Internal Modem
20***73Module-Internal Modem1
24***09Transformer1
24***54Modem As1
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206-8852 Module-Internal Modem
20***52Module-Internal Modem1
24***09Transformer1
24***54Modem As1
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263-3454 Module-Internal Modem
24***09Transformer1
24***54Modem As1
26***54Module-Internal Modem1
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203-4224 Module-Internal Modem
20***24Module-Internal Modem1
24***09Transformer1
24***54Modem As1
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206-8856 Module-Internal Modem
20***56Module-Internal Modem1
24***09Transformer1
24***55Modem As1
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203-4225 Module-Internal Modem
20***25Module-Internal Modem1
24***09Transformer1
24***55Modem As1
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263-3459 Module-Internal Modem
20***26Cable As-Communication1
24***09Transformer1
24***54Modem As1
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206-8854 Module-Internal Modem
20***54Module-Internal Modem1
24***09Transformer1
24***55Modem As1
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236-4958 Panel Ar-Control
23***48Panel Group-Control; -Generator Start2
23***50Bracket4
23***58Panel Ar-Control; -Generator Start, Dual1
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236-4957 Panel Ar-Control
23***48Panel Group-Control; -Generator Start1
23***50Bracket2
23***57Panel Ar-Control; -Generator Start, Single1
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236-4955 Panel Ar-Control
23***48Panel Group-Control; -Generator Start1
23***50Bracket2
23***55Panel Ar-Control1
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236-4956 Panel Ar-Control
23***48Panel Group-Control; -Generator Start2
23***50Bracket4
23***56Panel Ar-Control1
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252-4932 Panel As-Electrical -Lh
20***77Fuse; (200-Ampere)1
20***69Indicator; (Fuse)1
22***07Board As-Circuit; (Zig Zag Controller)1
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256-3008 Panel As-Electrical -Static Bypass
18***21Board As-Circuit; -Static Switch Interface1
20***90Fuse; (600-Ampere)3
20***69Indicator; (Fuse)3
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240-2510 Panel As-Electrical -Power Supply
20***77Fuse; (200-Ampere)1
20***69Contactor1
20***69Indicator; (Fuse)1
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203-4299 Panel Gp-Annunciator
20***59Cable As1
20***60Cable As1
20***99Panel Group-Annunciator1
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230-7666 Panel Gp-Annunciator
23***66Panel Group-Annunciator1
25***59Module Group-Alarm1
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233-7648 Panel Gp-Control
23***48Panel Group-Control; -Generator Start1
23***53Capacitor2
23***57Fuse; (0.25-Ampere)2
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203-5455 Panel Gp-Electrical
20***55Panel Group-Electrical1
23***76Panel Group-Electrical1
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251-9618 Panel Gp-Electrical
20***82Switch Group-Disconnect3
24***81Holder; (Fuse)3
25***57Shaft2
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256-7282 Panel Gp-Electrical
25***82Panel Group-Electrical1
25***03Panel Group-Electrical; -Disconnect Switch1
25***05Handle As1
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9e-5987 Panel Gp-Electrical
251-3584 Panel Gp-Electrical
23***32Relay; (1.8-Ampere, 3-Pole)(Overload)1
23***34Block-Terminal1
23***72Transformer; (10-Ampere)1
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203-5457 Panel Gp-Electrical
20***57Panel Group-Electrical1
25***32Panel As-Electrical; -Lh1
25***22Transformer As1
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227-4833 Panel Gp-Electrical
22***33Panel Group-Electrical1
22***34Filter As-Electrical1
22***35Resistor2
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258-8803 Panel Gp-Electrical -Disconnect Switch
24***12Switch-Disconnect; (Maintenance Bypass)3
24***14Shaft1
24***15Shaft2
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202-7511 Panel Gp-Electrical
18***09Resistor; (13-Watt)12
18***22Board As; (Dc Interface)1
20***28Capacitor12
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258-8802 Panel Gp-Electrical
25***02Panel Group-Electrical1
25***03Panel Group-Electrical; -Disconnect Switch1
25***06Handle As1
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250-5521 Panel Gp-Electrical
20***32Power Supply; (350-Watt)2
25***21Panel Group-Electrical1
25***07Capacitor2
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258-9961 Panel Gp-Electrical
24***10Panel As-Electrical; -Power Supply1
25***22Transformer As1
25***61Panel Group-Electrical1
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236-4176 Panel Gp-Electrical
23***32Relay; (1.8-Ampere, 3-Pole)(Overload)1
23***34Block-Terminal1
23***72Transformer; (10-Ampere)1
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203-3912 Panel Gp-Power Supply
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
19***89Contactor2
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203-4375 Panel Gp-Power Supply
20***07Varistor As; (Surge Protector)(Ac)2
20***08Disconnect; (400-Ampere, 3-Pole)8
20***75Panel Group-Power Supply1
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251-0043 Panel Gp-Power Supply
20***65Fuse; (4-Ampere)2
20***66Fuse; (7-Ampere)2
20***74Module Group-Converter; -Rh3
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230-7667 Panel Gp-Power Supply
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
19***89Contactor2
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266-5937 Panel Gp-Power Supply
19***97Fuse; (3-Ampere)2
20***67Fuse; (1-Ampere)3
20***69Circuit Breaker As; (1200-Ampere)1
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203-4385 Panel Gp-Power Supply
18***55Fuse; (3-Ampere)(Output)3
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
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248-5467 Panel Gp-Power Supply
24***23Transformer1
24***11Handle; (Door)1
24***24Ring1
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203-4373 Panel Gp-Power Supply
20***07Varistor As; (Surge Protector)(Ac)2
20***08Disconnect; (400-Ampere, 3-Pole)4
20***73Panel Group-Power Supply1
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258-9866 Panel Gp-Power Supply
24***11Capacitor; (Oil-Filled)1
24***23Transformer1
24***24Contactor1
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319-4158 Panel Gp-Power Supply
18***46Kit-Pump; (Vacuum)1
19***06Fan As-Circulating6
20***65Fuse; (4-Ampere)2
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266-5936 Panel Gp-Power Supply
19***97Fuse; (3-Ampere)2
20***67Fuse; (1-Ampere)3
20***69Circuit Breaker As; (1200-Ampere)1
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203-4382 Panel Gp-Power Supply
18***55Fuse; (3-Ampere)(Output)3
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
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251-2177 Panel Gp-Power Supply
19***97Fuse; (3-Ampere)2
20***67Fuse; (1-Ampere)3
20***61Panel As; (Input/Output)1
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252-0570 Panel Gp-Power Supply
19***97Fuse; (3-Ampere)4
20***63Fuse; (1.5-Ampere)2
20***49Power Supply; (150-Watt)2
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203-4383 Panel Gp-Power Supply
18***55Fuse; (3-Ampere)(Output)3
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
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252-5011 Panel Gp-Power Supply
19***97Fuse; (3-Ampere)2
20***67Fuse; (1-Ampere)3
20***69Circuit Breaker As; (1200-Ampere)2
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202-7660 Panel Gp-Power Supply
20***40Door-Front1
20***48Panel-Access; (Top)1
20***80Panel As-Side1
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259-3194 Panel Gp-Power Supply
18***50Fuse; (300-Ampere)(Utility)3
20***65Fuse; (4-Ampere)2
20***66Fuse; (7-Ampere)2
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248-5465 Panel Gp-Power Supply
20***65Fuse; (4-Ampere)2
20***66Fuse; (7-Ampere)2
20***74Module Group-Converter; -Rh3
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202-7659 Panel Gp-Power Supply
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
19***97Fuse; (3-Ampere)4
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255-0609 Panel Gp-Power Supply
25***09Panel Group-Power Supply1
25***65Panel Group-Power Supply1
25***94Panel Group-Power Supply1
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250-6034 Panel Gp-Power Supply
25***34Panel Group-Power Supply1
25***59Module Group-Alarm1
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258-9865 Panel Gp-Power Supply
20***48Panel-Access; (Top)1
24***11Capacitor; (Oil-Filled)1
24***24Contactor1
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203-4384 Panel Gp-Power Supply
18***55Fuse; (3-Ampere)(Output)3
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
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202-7658 Panel Gp-Power Supply
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
19***89Contactor2
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248-5466 Panel Gp-Power Supply
20***48Panel-Access; (Top)1
24***11Capacitor; (Oil-Filled)1
24***11Handle; (Door)1
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251-2175 Panel Gp-Power Supply
20***65Fuse; (4-Ampere)2
20***66Fuse; (7-Ampere)2
20***52. Coller, Sensor-Vacuum; (Flywheel Bearing)1
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250-3437 Panel Gp-Power Supply
19***97Fuse; (3-Ampere)2
20***67Fuse; (1-Ampere)3
20***69Circuit Breaker As; (1200-Ampere)1
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250-3438 Panel Gp-Power Supply
19***97Fuse; (3-Ampere)2
20***67Fuse; (1-Ampere)3
20***61Panel As; (Input/Output)1
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255-0608 Panel Gp-Power Supply
25***08Panel Group-Power Supply1
25***66Panel Group-Power Supply1
25***94Panel Group-Power Supply1
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203-4374 Panel Gp-Power Supply
20***07Varistor As; (Surge Protector)(Ac)2
20***08Disconnect; (400-Ampere, 3-Pole)6
20***74Panel Group-Power Supply1
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237-0175 Panel Gp-Power Supply
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
19***97Fuse; (3-Ampere)2
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250-3439 Panel Gp-Power Supply
19***97Fuse; (3-Ampere)2
20***67Fuse; (1-Ampere)3
20***69Circuit Breaker As; (1200-Ampere)2
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202-7645 Power Gp-Uninterruptible
20***59Film Group1
20***45Power Group-Uninterruptible1
20***58Panel Group-Power Supply1
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202-7647 Power Gp-Uninterruptible
20***58Film Group1
20***47Power Group-Uninterruptible, .. Axle1
20***58Panel Group-Power Supply2
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202-7646 Power Gp-Uninterruptible
20***59Film Group1
20***46Power Group-Uninterruptible1
20***58Panel Group-Power Supply1
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202-7650 Power Gp-Uninterruptible
20***57Film Group1
20***50Power Group-Uninterruptible1
20***58Panel Group-Power Supply3
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204-0304 Power Gp-Uninterruptible
18***64Filter Element As-Encl Air1
18***65Filter Element As-Encl Air1
19***89Contactor2
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202-7649 Power Gp-Uninterruptible
20***57Film Group1
20***49Power Group-Uninterruptible1
20***58Panel Group-Power Supply3
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202-7643 Power Gp-Uninterruptible
20***43. Gear; Internal, Power Group-Uninterruptible1
20***60Panel Group-Power Supply1
20***12Panel Group-Power Supply1
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202-7644 Power Gp-Uninterruptible
20***44Power Group-Uninterruptible1
20***60Panel Group-Power Supply1
20***12Panel Group-Power Supply1
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202-7648 Power Gp-Uninterruptible
20***58Film Group1
20***48Power Group-Uninterruptible1
20***58Panel Group-Power Supply2
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234-7687 Power Supply Gp
20***32Power Supply; (350-Watt)1
23***87Power Supply Group1
23***88Capacitor; (450-Volt)2
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231-3504 Pump & Motor Gp-Vacuum
18***46Kit-Pump; (Vacuum)1
23***04Pump & Motor Group-Vacuum1
24***65Ring4
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Service Equipment And Supplies
200-1856 Film Gp
13***39Film-Stripe; (Red)(625cm)0
20***44Film; (Electric Power)1
20***56Film Group1
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200-1858 Film Gp
13***39Film-Stripe; (Red)(625cm)0
20***44Film; (Electric Power)1
20***58Film Group1
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203-4716 Film Gp
20***16Film Group1
22***51Film; (Cat)1
22***52Film; (Electric Power)1
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200-1859 Film Gp
13***39Film-Stripe; (Red)(625cm)0
20***44Film; (Electric Power)1
20***59Film Group1
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200-1845 Film Gp
12***94Film-Stripe; (Black)(56cm)0
20***24Film; (Electric Power)1
20***25Film-Stripe; (Red)(44cm)0
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200-1857 Film Gp
13***39Film-Stripe; (Red)(625cm)0
20***44Film; (Electric Power)1
20***57Film Group1
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245-0559 Kit-Sensor & Mounting
250-6033 Parts Gp-Miscellaneous
18***54Fuse; (20-Ampere)(Output)5
18***55Fuse; (3-Ampere)(Output)5
18***60Fuse; (2-Ampere)10
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261-8122 Parts Gp-Miscellaneous
18***21Board As-Circuit; -Static Switch Interface1
18***50Fuse; (300-Ampere)(Utility)3
18***54Fuse; (20-Ampere)(Output)2
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230-4161 Parts Gp-Miscellaneous
18***54Fuse; (20-Ampere)(Output)5
18***55Fuse; (3-Ampere)(Output)5
18***60Fuse; (2-Ampere)10
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230-4162 Parts Gp-Miscellaneous
18***55Fuse; (3-Ampere)(Output)10
18***60Fuse; (2-Ampere)10
18***61Fuse; (5-Ampere)10
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203-5448 Parts Gp-Miscellaneous
18***55Fuse; (3-Ampere)(Output)10
18***60Fuse; (2-Ampere)10
18***61Fuse; (5-Ampere)10
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250-6032 Parts Gp-Miscellaneous
18***55Fuse; (3-Ampere)(Output)10
18***60Fuse; (2-Ampere)10
19***04Fuse; (3-Ampere)10
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203-5447 Parts Gp-Miscellaneous
18***22Board As; (Dc Interface)1
18***49Fuse; (250-Ampere)(Flywheel)3
18***54Fuse; (20-Ampere)(Output)5
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UPS 300 serial number reference

The rating/PIN plate on a Cat flywheel UPS module is mounted on the front access panel or side of the enclosure cabinet, generally near the main circuit breaker or control touchscreen, not on an engine or chassis since the unit has no engine of its own. Read the first three characters of the serial number as the model/vintage prefix, followed by the sequential unit number; match that prefix against Cat's electrical-system-schematic media-number index to identify which wiring-diagram document set applies to the unit, and confirm the exact model split with your dealer since several of these document sets cover more than one UPS model under a single media number.

PrefixIdentifies
CNJ, APZSingle-module UPS 250 & UPS 300 electrical system (combined listing)
CSE, CNM, CPM, or CPZMulti-module UPS system (UPS 250 through UPS 900 line)

Frequently asked questions

What engine does the Caterpillar UPS 300 use?

None. The UPS 300 (UPS 300Z) is a battery-free, flywheel-based uninterruptible power supply module with no internal combustion engine. It stores ride-through energy mechanically in a spinning flywheel and converts it through an IGBT bi-directional converter, not through an engine-driven generator.

What is the operating weight of the UPS 300?

A single UPS 300 module weighs 3,063 kg (6,750 lb), per the factory spec sheet. This is the mass of one standalone module; paralleled Z-Series banks (600Z, 900Z, 1200Z) add weight in multiples as additional 300Z modules are combined.

What replaced the Caterpillar UPS 300?

Nothing has superseded it in Cat's current lineup. The UPS 300 (300Z) is the base module of the ongoing UPS Z-Series line and scales upward by paralleling additional 300Z modules into 600Z, 900Z, and 1200Z capacity tiers rather than being replaced by a successor model.

What UPS 300 owners discuss

What does flywheel bearing and vacuum-housing service look like on this unit?
The energy-storage flywheel spins inside a sealed vacuum housing, with magnetic field coils providing lift to reduce bearing load and windage losses. Bearings on this class of unit are sealed and require no routine lubrication, but plan on replacement around 5 to 8 years of service, with vacuum-pump servicing typically due near the 8 to 10 year mark. Annual inspections can usually be performed with the unit online, but full bearing or vacuum-seal work calls for a maintenance bypass so the critical load stays on utility or generator power during the job. Because this involves a high-speed rotating mass under vacuum, have your dealer verify bearing condition and vacuum integrity before returning the unit to service.
How does a battery-free flywheel UPS compare to a traditional battery UPS in daily operation?
Facilities running this type of flywheel system report going years without the periodic battery inspection, capacity testing, and replacement cycle that VRLA battery UPS installations demand, along with a smaller footprint since there is no battery cabinet. The tradeoff is a comfort-level shift for staff: instead of monitoring cell voltages they are monitoring a large spinning mechanical assembly, and some facility managers note it took time to trust a big moving part the way they trusted a battery string. Reported uptime has generally been favorable where the module is paired with disciplined generator testing, since the flywheel is only meant to bridge the gap until the generator set is online.
How much ride-through time does the module actually deliver under real load?
Expect on the order of 15 to 30 seconds of ride-through at full load, tapering shorter as connected load rises toward the module's rating. That window is sized to cover brief utility disturbances and to bridge into a diesel generator set reaching rated voltage and frequency, not to run a facility through an extended outage. If a generator fails to start or takes longer than expected, load will drop once the flywheel's stored energy is exhausted, so generator starting reliability ends up being the real limiting factor on total protected runtime, not the UPS itself.
Can multiple UPS 300 modules be paralleled for capacity or redundancy?
Yes, this Z-Series module is designed to parallel with other Z-Series units to build N+1 redundancy or add capacity within a single system. Z-Series modules are not mixed with other Cat flywheel UPS series in the same parallel set, so a facility planning to grow capacity later should standardize on the same series when adding modules rather than assuming any Cat flywheel UPS can be paralleled together.
What should be considered when integrating this UPS with a standby generator?
The module is built to be generator-set friendly, with low input current distortion and harmonic cancellation intended to avoid oversizing the genset just to satisfy the UPS load. An optional generator-start module can trigger genset starting the moment utility power is lost, which shortens the gap the flywheel has to cover and improves overall starting reliability. Because the whole scheme depends on the generator reaching rated output before the flywheel discharges, generator maintenance and load-bank testing matter just as much as servicing the UPS module itself.
What are the practical commissioning and installation considerations for this module?
Site prep calls for a level pad capable of supporting the module's mass with allowance for vibration during flywheel spin-up, indoor climate-controlled space to protect the electronics and vacuum system, and clearance for service access around the enclosure. Installers commonly wire in a maintenance bypass path so utility power can carry the critical load directly during commissioning checks or later service without dropping the load offline. Startup includes running the flywheel up to speed and verifying the static bypass switch operates correctly before the module is trusted with live critical load.
What should a buyer check when looking at a used UPS 300 module?
Ask for the unit's run-hour and spin-down history, since bearing and vacuum-pump life track hours in service rather than calendar age alone, and a module that sat idle with the flywheel parked for a long stretch needs a startup inspection before being trusted. Check the control system firmware revision and confirm it is still supported, since older revisions may lack current monitoring or communication features. Inspect the enclosure for corrosion or water intrusion, confirm cooling fans and filters are present and functional, and ask for prior service and commissioning records. Given that the flywheel is a high-speed rotating assembly under vacuum, have your dealer verify bearing condition, vacuum integrity, and run a full load-bank test before putting a used module into critical service.

Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.

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