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MAINTENANCE INTERVALS - Safety

1. 87 Every 3000 Service Hours Cooling System Water Temperature Regulator Replace oed ete eri audere edel 88 Fuel Injection Nozzles Test Exchange 95 Water Pump Inspect 121 80 Maintenance Section Maintenance Interval Schedule SEBU8134 06 Every 3000 Service Hours or 2 Years Cooling System Water Temperature Regulator Replace iue bere e E Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change Overhaul Generator Bearing Inspect Replace Overhaul Considerations 86 SEBUS134 06 81 Maintenance Section Maintenance Interval Schedule 104727773 Maintenance Interval Schedule SMCS Code 1000 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance Maintenance includes all adjustments the use of proper lubricants fluids filters and the replacement of 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 Use mileage fuel consumption
2. battery terminal Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the key start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the cable from the ground plane to the NEGATIVE battery terminal 102601752 Battery Electrolyte Level Check SMCS Code 1401 535 When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean 84 Maintenance Section Battery or Battery Cable Disconnect SEBU8134 06 Clean the battery case with one of the following cleanin
3. The fuel filter is replaced new injection pump is installed Use the following procedure in order to remove air from the fuel system 1 Remove the cover for the fuel injectors Refer to the Disassembly and Assembly Manual 2 Turn the key switch to the RUN position Leave the key switch in the RUN position for three minutes 3 Turn the key switch to the OFF position g01003929 Illustration 82 Injector nuts Note Damage to the fuel injection pump to the battery and to the starter motor can occur if the starter motor is used excessively to purge the air from the fuel system 4 Loosen the flare nuts 1 for the high pressure fuel lines on all of the fuel injectors NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 5 Observe the connection at the flare nut Operate the starting motor and crank the engine until the fuel is free of air 6 Tighten the flare nuts 1 to a torque of 30 N m 22 Ib ft 7 The engine is now ready to start Operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system Note Running the engine for this period of time will help ensure that the pump is completely free of air 103547119 Fuel System SMCS Code 1258 548 S N D4B1 Up S N GLD1 Up
4. 110 Instrument Panel Inspect 115 Walk Around Inspection 120 Every Year Alternator Inspect 82 Alternator and Fan Belts Inspect Adjust 82 Cooling System Coolant Sample Level 2 Obta ill 5 etm teen ea 87 Engine Clean nieder 89 Engine Air Cleaner Element Single Element Replace onte de e edid eine 89 Engine Mounts Inspect 91 Engine Oil Sample Obtain 92 Engine Oil and Filter Change 92 Fuel System Primary Filter Water Separator Element Replace 99 Fuel System Secondary Filter Replace 100 Generator Set Vibration Test Record 112 Hoses and Clamps Inspect Replace 112 Insulation 115 Rotating Rectifier Check 119 Starting Motor Inspect 120 Water Pump Inspect 121 Every 3 Years Battery Replace 83 Cooling System Coolant Extender ELC Add 86 Cooling System Water Temperature Regulator ero me 88 Every 6
5. The quality of the fuel that is being used The operating conditions e The results of the S O S analysis Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h Ib per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons Costly unplanned downtime can be avoided Many original parts can be reused according to the standards for reusable parts The engine s service life can be extended without
6. Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death Refer to Operation and Maintenance Manual General Hazard Information and High Pressure Fuel Lines before adjustments and repairs are performed Note Refer to Systems Operation Testing and Adjusting Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training 98 Maintenance Section Fuel System Prime SEBU8134 06 NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again If air enters the fuel system the air must be purged from the fuel system before the engine can be started Air can enter the fuel system when the following events occur The fuel tank is empty or the fuel tank has been partially drained The low pressure fuel lines are disconnected e A leak exists in the low pressure fuel system The fuel filter has been replaced Hand Fuel Priming Pump Use the following procedures in order to remove air from the fuel system 1 Ensure
7. 102039199 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Return used batteries to one of the following locations A battery supplier An authorized battery collection facility e A recycling facility 02153996 Battery Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury Turn the key start switch to the OFF position Remove the key and all electrical loads N Turn OFF the battery charger Disconnect the charger 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal 4 The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE
8. F UNIREX N3 Every 4500 service hours or 12 months 60 g 2 1 oz 100 3 9 inch 243 5220 Bearing 315 BB 160 mm 6 3 inch OD 75 mm 3 0 inch ID LC6100 LC5000 95 C 203 F UNIREX N3 Sealed Sealed Sealed 75 mm 3 0 inch 253 9789 Bearing 320 BC 215 mm 8 5 inch OD 100 mm 3 9 inch ID 1400 85 C 185 UNIREX N3 Grease cannot be added to this bearing N A N A 100 mm 3 9 inch 253 9792 Bearing 226BC 230 mm 9 05 inch OD 130 mm 5 12 inch ID 1400 95 C 203 cannot be added to this bearing Grease cannot be added to this bearing Grease cannot be added to this bearing 140 mm 5 5 inch 261 3545 Bearing 307 BB 80 mm 3 1 inch OD 35 mm 1 4 inch ID LC2000 95 C 203 F UNIREX N3 Sealed Sealed Sealed 35 mm 1 4 inch 262 5921 Bearing 307 BC 80 mm 3 1 inch OD 35 mm 1 4 inch ID LC2000 95 C 203 UNIREX N3 Sealed Sealed Sealed 35 mm 1 4 inch 263 0161 Bearing 309 BC 100 mm 3 9 inch OD 45 mm 1 8 inch ID LC3000 95 203 UNIREX Sealed Sealed Sealed 45 mm 1 8 inch continued SEBUS8134 06 109 Maintenance Section Generator Bearing Lubricate Table 23 contd Bear
9. N Wn g m ee Fax Os Illustration 86 g01010637 1 Drain 2 Filter bowl 1 Close the valves for the fuel lines if equipped 2 Clean the outside of the fuel filter assembly Open the fuel drain 1 and drain the fuel into a suitable container Illustration 87 g01010595 3 O ring seal 4 Element 5 Filter head 3 Remove the filter bowl 2 from the filter head 5 Press on the element 4 Rotate the element counterclockwise in order to release the element for the filter bowl and remove the element from the bowl Discard the used element 4 Remove the O ring 3 from the filter bowl and clean the filter bowl Check that the threads of the filter bowl are not damaged 5 Install a new O ring seal 3 to the filter bowl 2 6 Locate a new filter element 4 into the filter bowl Press on the element and rotate the element clockwise in order to lock the element into the filter bowl 7 Install the filter bowl 4 into the top of the filter head 5 8 Tighten the filter bowl by hand until the filter bowl contacts the filter head Rotate the filter bowl through 90 degrees Note Do not use a tool to tighten the filter bowl 9 Open the valves for the fuel lines if equipped Spin on filter Turn the valves for the fuel lines if equipped to the OFF position before performing this maintenance Place a tray under the fuel f
10. NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates SEBUS134 06 103 Maintenance Section Generator Dry Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Note Failure to properly close the drain can allow air into the system which could have detrimental results to performance Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this pr
11. damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water Ensure that cooling lines are properly clamped and tight Check for leaks Check the condition of all pipes e Inspect the water pump for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pump and the installation of water pump and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover Inspect the fuel system for leaks Look for loose fuel line clamps Inspect the piping for the air inlet system and the
12. 110 mm 12 months 4 3 inch ID 109 7687 316 BC 580 85 C 185 F 28 3230 Every 51 2 9 59 mL 80 Bearing 170 Bearing 2000 1 8 oz 2 oz 3 15 inch 6 7 inch Lubricant service OD hours or 80 mm 12 months 3 15 inch ID 139 0349 Roller 2900 85 C 185 F 108 8611 Every 250 2 8 g N A 127 mm Roller 2800 service 0 1 oz 5 inch Bearing hours 139 0350 Roller 2900 85 C 185 108 8611 Every 250 2 8 g N A 127 mm Roller 2800 service 0 1 oz 5 inch Bearing hours 154 3032 326 BC 820 85 C 185 28 3230 Every 51 2 9 59 mL 130 Ball Bearing 280 18000 95 C 203 Bearing 2000 1 8 oz 2 oz 5 1 inch 11 inch 26009 85 C 185 F Lubricant service OD 27009 85 185 hours 130 12 5 1 inch ID continued 108 Maintenance Section Generator Bearing Lubricate SEBU8134 06 Table 23 contd Bearing Part Number Bearing Type Frame Size Temperature Maximum Grease Part Number Interval Weight Volume Shaft Diameter 193 4070 Ball Bearing 018 BC 140 mm 5 5 inch OD 90 mm 3 5 inch ID 498 499 85 C 185 F 28 3230 Bearing Lubricant Every 2000 service hours or 12 months 51 2 9 1 8 oz 59 mL 2 oz 90 3 5 inch 241 4644 Bearing 320 BC 215 mm 8 5 inch OD 100 mm 3 9 inch ID LC7 95 C 203
13. 19 L 5 US gallon 8T 5571 208 L 55 US gallon Obtain Coolant Analysis The concentration of supplemental coolant additive SCA should be checked regularly with test kits or with S O S Coolant Analysis Level 1 Further coolant analysis is recommended when the engine is overhauled For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals that were deposited on the engine over time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis can be obtained by consulting your local water utility company or an agricultural agent Private laboratories are also available for water analysis Caterpillar Inc recommends S O S Coolant Analysis Level Il S O S Coolant Analysis Level Il An S O S Coolant Analysis Level 11 is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level Il provides the following information e Complete S O S Coolant Analysis Level 1 Visual inspection of properties Identification of metal corrosion Identification of contaminants Identification of built up impurities corrosion and scale S O S Coolant Analysis Level Il provides a report o
14. For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating To accurately check the belt tension Gauge 144 0235 Belt Tension Gauge should be used Illustration 68 g01003936 Typical example 1 144 0235 Belt Tension Gauge Install the gauge 1 at the center of the belt between the alternator and the crankshaft pulley and check the belt tension The correct tension for a new belt is 400 N 90 Ib to 489 N 110 Ib The correct tension for a used belt that has been in operation for 30 minutes or more at the rated speed is 267 60 Ib to 356 80 Ib If twin belts are installed check and adjust the tension on both belts Adjustment Illustration 69 g01091158 Typical example 1 Adjusting bolt 2 Mounting bolts 1 Loosen the mounting bolts 2 and the adjusting bolt 1 SEBUS134 06 83 Maintenance Section Battery Recycle 2 Move the alternator in order to increase or decrease the belt tension Tighten the adjusting bolt 1 Tighten the mounting bolts 2 Refer to the Specifications Manual for the correct torque settings
15. Years Cooling System Coolant ELC Change 84 Overhaul Overhaul Considerations 117 82 Maintenance Section Alternator Inspect SEBU8134 06 102291834 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Refer to the Service Manual Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is warm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge 102226340 Alternator and Fan Belts Inspect Adjust SMCS Code 1357 025 1357 040 Inspection To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged
16. pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling System filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 86 Maintenance Section Cooling System Coolant Extender ELC Add SEBU8134 06 02482066 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Cat ELC Extended Life Coolant does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants The Cat ELC Extender only needs to be added once NOTICE Use only Cat Extended Life Coolant ELC Extender with Cat ELC Do NOT use conventional supplemental coolant addi tive SCA with Cat ELC Mixing Cat ELC with conven tional coolants and or conventional SCA reduces the Cat ELC service life Check the cooling system only when the engine is stopped and cool Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pres
17. service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Battery Recycle 83 Battery or Battery Cable Disconnect 84 Fuel System Prime 97 Fuel System Prime 97 Generator Dry sss 103 Generator Bearing Lubricate 106 Generator Load Check 110 Generator Set Test 111 Generator Set Alignment Check 111 Rotating Rectifier Test 120 Every Week Battery Electrolyte Level Check 83 Electrical Connections Check 88 Engine Air Cleaner Service Indicator Inspect 90 Engine Oil Level Check 91 Fuel System Primary Filter Water Separator Drain zt aliosque 100 Fuel Tank Water and Sediment Drain 102 Generator Inspect 104 Generator Bearing Temperature Test Record
18. the life of the windings 8 Install all of the external cover plates grills and louvers of the generator that were removed in order to access the bearings SEBU8 134 06 107 Maintenance Section Generator Bearing Lubricate Table 23 Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft Part Type Size Maximum Part Number Diameter Number 5P 2448 315 BC 580 85 C 185 F 25 3230 51 2 9 59 mL 75 Ball Bearing 160 590 Bearing 2000 1 8 oz 2 oz 3 inch 6 3 inch Lubricant service OD hours or 75 mm 12 months 3 inch ID 6Y 3955 220 BC 450 85 C 185 F 25 3230 51 2 9 59 mL 100 Ball Bearing 180 mm Bearing 2000 1 8 oz 2 oz 3 9 inch 7 1 inch Lubricant service OD hours or 100 mm 12 months 3 9 inch ID 6Y 6488 318 BC 597 85 C 185 F 25 3230 Every 51 2 9 59 mL 90 Ball Bearing 190 mm Bearing 2000 1 8 oz 2 oz 3 5 inch 7 5 inch Lubricant service OD hours or 90 mm 12 months 3 5 inch 108 1760 321 BC 680 85 C 185 F 2S 3230 Every 51 2 g 59 mL 105 mm Ball Bearing 225 mm Bearing 2000 1 8 oz 2 oz 4 1 inch 8 9 inch Lubricant service OD hours or 105 mm 12 months 4 1 inch ID 108 1761 322 BC 690 85 C 185 F 25 3230 51 2 9 59 mL 110 Bearing 240 mm 800 Bearing 2000 1 8 oz 2 oz 4 3 inch 9 4 inch Lubricant service OD hours or
19. Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval as stated in the maintenance interval schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC including the following coolants Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat DEAC Diesel Engine Antifreeze Coolant SEBUS134 06 87 Maintenance Section Cooling System Coolant Sample Level 2 Obtain Commercial heavy duty coolant antifreeze Table 22 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC Conventional heavy duty coolant Every 250 1 service hours Every year Commercial coolant that meets the requirements of the Caterpillar EC 1 standard Cat ELC or conventional Optional Every year EC 1 coolant 1 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may con
20. Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to Torque Specifications SENR3130 for more information on the correct torques Fill NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result engine damage 1 Fill the cooling system with Extended Life Coolant ELC Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 98 8140 Pressurizing Pump in order to
21. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR Operation Maintenance Manual C4 4 GEN SET C3 3 GEN SET and 4 4 GEN SET Electric Power Generation D4B1 Up Generator NCC1 Up Generator Se GLD1 Up Generator Se N4D1 Up Generator NCD1 Up Generator Se N4E1 Up Generator NCE1 Up Generator Se eR Ch Ch cR C o 6 SAFETY CAT COM SEBUS134 06 79 Maintenance Section Maintenance Interval Schedule 104727729 Maintenance Interval Schedule SMCS Code 1000 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance Maintenance includes all adjustments the use of proper lubricants fluids filters and the replacement of 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 Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the pre
22. als Check these components by interpreting the wear patterns on the following components Rod bearing Main bearings Note If the crankshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the crankshaft Inspect the camshaft for damage to the journals and to the lobes Note If the camshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the camshaft Inspect the following components for signs of wear or for signs of scuffing Camshaft bearings Valve lifters SEBUS134 06 119 Maintenance Section Rotating Rectifier Check Testing Test the following components during the overhaul e Fuel injection nozzles e Fuel injection pump Testing the fuel system during the overhaul will ensure that your engine operates at peak efficiency Your Caterpillar dealer can provide these services and components in order to ensure that your fuel system is operating within the appropriate specifications Cleaning Caterpillar Inc recommends the use of Hydrosolv Liquid Cleaners Table 26 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 26 HydrosolvLiquid Cleaners Part NOT 3 Number Description Size 10 8812 4 L 1 US gallon Hydrosolv4165 1U 5490 19 L 5 US gallon 8T 7570 208 L 55 US gallon 1U 8804 4 L 1 US gallon Hydrosolv100 1U 5492
23. ations on the lubrication plate if equipped or refer to Maintenance Schedule Generator Bearing Lubricate Whenever the bearings are greased repeat Step 1 DO MIX GREASES 104581792 Generator Bearing Lubricate SMCS Code 4471 086 Procedure for Bearing Service Perform periodic bearing lubrication at the intervals that are shown in Table 23 Use the following instructions as the suggested procedure in order to service the bearings of the generator Note If the generator already has a visible grease point go to Step 4 1 Stop the generator set Remove the required external cover plates grills and louvers of the generator in order to access the bearings 2 Remove the top grease pipe plug and the lower grease pipe plug If no grease pipes can be found then locate the insert for the grease pipe The insert is located on the bearing brackets Remove the inserts Install the grease pipes 3 Install a grease fitting in the top grease pipe 4 Use a 8F 9866 Grease Gun or equivalent grease gun to grease the bearings Use the appropriate type of grease and the quantity that is listed in Table 23 Avoid the use of alternate types of grease Usage of alternate types of grease could cause premature bearing failure Note Add only the amount of grease listed in Table 23 Do not continue to add grease until purging is observed Purging of grease will not always be observed 5 f grease fittings are
24. ave not been used for a period of time moisture can accumulate Therefore the insulation test should be performed on generators that have been idle If moisture is known to exist the windings must be dried prior to testing Refer to Testing And Adjusting Generator Dry The insulation test should be performed on generators that are being used for the first time The insulation test should be performed more frequently in the following cases The generator set is operating in a humid environment The generator set is not protected from the elements in an enclosed area The generator set has not been run under load for three months Note Space heaters may need to be used around the generator set in the following cases The generator set has not been run under load for three months The generator set is exposed to a sea water environment The humidity is above 75 percent e A test result was below megohms The winding needs to be reconditioned or the winding needs to be replaced in the following cases The measured insulation resistance falls below the specified amount The cleanup procedure does not correct the discrepancy The measured insulation resistance falls below the specified amount The drying procedure does not correct the discrepancy The specified insulation resistance is an approximate value It can be possible to operate the generator with less than the specifie
25. bearings are shipped as dry bearings and must be packed to 50 grease fill at time of installation Bearing Replacement Replace any bearing wear sleeves and lip seals when the bearings are replaced Refer to the appropriate publication for each specific generator for bearing replacement procedures Replace both bearings of a two bearing generator 110 Maintenance Section Generator Bearing Temperature Test Record SEBU8134 06 Except for the 341 7383 Ball Bearing replacement bearings are pre lubricated The pre lubricated bearings do not require additional grease at time of replacement The 341 7383 Ball Bearing is shipped as a dry bearing The 341 7383 Ball Bearing must be packed to 5096 grease fill at time of installation Old grease must be removed at the time of bearing replacement from the bearing bracket cavity After the bearing bracket cavity is cleaned the bearing bracket cavity must be packed with new grease from one third to one half full Note Generator set alignment is required after the bearings are replaced Additional Information Refer to Special Instruction REHS4892 Generator Bearing Service for further information 103642839 Generator Bearing Temperature Test Record SMCS Code 4471 081 TA The monitoring of bearing temperature may prevent premature bearing failure A generator set should never operate above the recommended set points Keep records in order to monitor the changes
26. ctrical components from being damaged by excessive water when you clean the engine Avoid electrical components such as the alternator the starter and the ECM 102398637 Engine Air Cleaner Element Single Element Replace SMCS Code 1051 1054 510 The high voltage that is produced by an operating generator set can cause severe injury or death Before performing any maintenance or repairs ensure that the generator will not start Place the engine control switch in the OFF posi tion Attach DO NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Perform the Operation and Maintenance Manual Engine Air Cleaner Service Indicator Inspect procedure before performing the following procedure NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Note This type of air cleaner is only available on open generator sets 90 Maintenance Secti
27. d correctly 103622961 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately SEBUS134 06 101 Maintenance Section Fuel System Secondary Filter Replace NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component If your engine is equipped with high pressure fuel lines you must wait for 60 seconds after the engine has stopped in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install Element filter Turn the valves for the fuel lines if equipped to the OFF position before performing this maintenance Place a tray under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel immediately A D
28. d value However a generator that has a low winding insulation resistance will be more likely to have a failure Personal injury or death can result from improper troubleshooting and repair procedures The following troubleshooting and repair proce dures should only be performed by qualified per sonnel familiar with this equipment The insulation test gives accurate results only when the generator windings are free of moisture and the generator windings are at room temperature Each winding must have a minimum insulation resistance of one megohm Main Armature Stator L4 1 Remove the load from the generator by either of the following Open the line circuit breaker Open the following load connections T1 T2 T3 and TO Prevent these wires from coming into contact with each other and prevent these wires from contacting ground 2 Isolate the main armature L4 from the voltage regulator by disconnecting the wires for voltage sensing If generator lead TO is connected to the generator frame or ground open the connection 3 Connect one test lead of the insulation tester megohmmeter to the generator enclosure ground 4 Connect the other test lead of the insulation tester megohmmeter to generator lead TO 5 The insulation resistance must be one megohm or more Exciter Field Stator L1 1 Isolate exciter field L1 from the voltage regulator by disconnecting wires 5 and 6 Prevent th
29. e also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEGJ0047 How To Take A Good 5 0 5 Oil Sample Consult your Cat dealer for complete information and assistance in establishing an S O S program for your engine 102293592 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Dispose of all fluids according to local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened compon
30. e Lash Inspect Adjust 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 0d Illustration 80 Y ADD mark X FULL mark 900998024 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge 03840829 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the complete valve lash adjustment procedure Operation of Caterpillar engines with improper valve adjustments can reduce eng
31. e drain cock or remove the drain plug on the radiator Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Dealer Service Tools Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to Torque Specifications SENR3130 for more information on the correct torques NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the engine at low idle until the temperature reaches 49 to 66 C 120 to 150 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain
32. e reassembling the generator Allow the generator to dry at room temperature Check the insulation resistance The insulation resistance should now be normal If the insulation resistance is not normal repeat the procedure Note For more information on drying methods refer to Special Instructions SEHS9124 Cleaning and Drying of Electric Set Generators 103099722 Generator Bearing Inspect Replace SR4 Generator SMCS Code 4471 040 4471 510 The following maintenance procedure for generator bearings should be followed at every major engine overhaul Inspect 1 Remove the bearing bracket Inspect the following items bracket bore bearing outer race and rolling elements On standby power units the bearing must be inspected and the grease must be replaced at three year intervals The sleeve in the bearing bracket should be inspected for out of roundness excessive wear and a bracket step that is less than 0 0762 mm 0 0030 inch If there is no sleeve in the bearing bracket inspect the bore of the bearing bracket The bearing should be inspected for damage to the outer race severe fretting and smoothness of operation When possible the bearing elements should be inspected Some double shielded ball bearings prevent visual inspection of the elements of the bearing Other double shielded ball bearings have a retaining ring This retaining ring can be removed in order to allow access for a visual inspection of t
33. e typically 10 C 18 F higher 2 1800 frame generators and 3000 frame generators shipped before 2012 use double shielded bearings with EA6 grease There are no threaded holes in the bearing brackets for the grease tubes that are used to add grease Therefore no grease can be added to the bearings Beginning in 2012 1800 frame generators and 3000 frame generators that are shipped will use a single shielded bearing with 25 3230 grease The front and rear brackets contain factory installed grease fittings therefore single shielded bearings must be lubricated periodically Reference the Parts Manual with package serial number to identify the bearing part number and to determine bearing lubrication requirements 3 All 2700 and 2600 frame generators regardless of ship date as well as 1800 and 3000 frame generators shipped beginning in 2012 use a single shielded bearing design Replacement bearings received from the Parts Division will have a shield on each side of the bearing The shield facing the outside of the generator must be removed when the new bearing is installed 4 Grease cannot be added to this bearing Refer to the Operation and Maintenance Manual Generator Bearing Replace article for information concerning the replacement of these bearings 5 The generator uses a non shielded bearing design Although replacement bearings may have a shield on each side both shields must be removed when the new bearing is installed Replacement
34. elbows for cracks and for loose clamps Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the engine to frame ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges which are cracked or can not be calibrated 102226958 Water Pump Inspect SMCS Code 1361 040 1361 A failed water pump may cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head piston seizure Other potential damage to the engine Note The water pump seal is lubricated by the coolant in
35. ent life SEBUS134 06 93 Maintenance Section Engine Oil and Filter Change Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained correctly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil Illustration 76 901003623 Oil drain plug After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil e f the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained turn the drain valve knob clockwise in order to close the drain valve If the engine is not equipped with a drain valve remove the oil drain plug 1 in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain plugs should be cleaned and installed If necessary renew the O ring seal on the drain plug Some typ
36. es of oil pans have oil drain plugs that are on both sides of the oil pan because of the shape of the pan This type of oil pan requires the engine oil to be drained from both plugs Replace the Spin on Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 10 8760 Chain Wrench Note The following actions can be carried out as part of the preventive maintenance program 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Gp Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find
37. ese wires from coming into contact with each other and prevent these wires from contacting ground SEBUS134 06 117 Maintenance Section Overhaul Considerations 2 Connect one test lead of the insulation tester megohmmeter to the generator enclosure ground 3 Connect one test lead of the insulation tester megohmmeter to exciter field lead 5 or 6 4 Measure the resistance of the exciter field winding insulation to ground The insulation resistance must be a minimum of 0 25 megohm 250000 ohms Exciter Armature Rotor L2 1 Isolate exciter armature L2 from the rectifier circuit Disconnect the three wires of the exciter armature from the rectifier blocks 2 Connect one test lead of the insulation tester megohmmeter to the rotor shaft 3 Connect one test lead of the insulation tester megohmmeter to any one exciter field lead 4 The insulation resistance must be a minimum of 0 25 megohm 250000 ohms 102299454 Overhaul Considerations SMCS Code 7595 043 Reduced hours of operation at full load will result in a lower average power demand A decreased average power demand should increase both the engine service life and the overhaul interval The need for an overhaul is generally indicated by increased fuel consumption and by reduced power The following factors are important when a decision is being made on the proper time for an engine overhaul The need for preventive maintenance
38. esel Engines Fluids Recommendations or consult your Caterpillar dealer 88 Maintenance Section Cooling System Water Temperature Regulator Replace SEBU8134 06 03645060 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime Refer to this Operation and Maintenance Manual Maintenance Interval Schedule for the proper maintenance interval A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar en
39. f the results of both the analysis and the maintenance recommendations For more information about coolant analysis see your Caterpillar dealer 101880286 Rotating Rectifier Check SMCS Code 4465 535 The high voltage that is produced by an operating generator set can cause severe injury or death Before performing any maintenance or repairs ensure that the generator will not start Place the engine control switch in the OFF posi tion Attach NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Check the exciter armature Ensure that the rotating rectifier is tight If a failure of a rectifier is suspected refer to Maintenance Procedure Rotating Rectifier Test 120 Maintenance Section Rotating Rectifier Test SEBU8134 06 02290281 Rotating Rectifier Test SMCS Code 4465 081 The high voltage that is produced by an operating generator set can cause severe injury or death Before performing any maintenance or repairs ensure that the generator will not start Place the engine control switch in the OFF posi tion Attach DO NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Il
40. following steps 1 Stop the generator Connect the potential transformer s high voltage winding to the generator terminals T1 and T2 Connect the voltmeter to the low voltage winding If two transformers are available connect the high voltage winding of the second transformer to the generator terminals T1 and T3 Connect the secondary terminals that correspond to generator terminal T2 of both transformers together 2 Disconnect wires and from the voltage regulator Disconnect the generator from the load 3 Connect a 12 VDC automotive battery to wires E and 4 Measure the AC voltage across the low voltage terminals of the transformer that correspond to the following generator terminals 1 and T2 2 and T3 and T3 and T1 Record the voltages 103956450 Generator Set Alignment Check Generator Sets SMCS Code 7002 024 The genset must be aligned when the genset is installed or moved into a different position If the generator set is run at the full continuous rating the alignment of the generator to the engine must be checked annually Properly maintain the alignment between the engine and the driven equipment in order to minimize the following problems Bearing problems Vibration of the engine crankshaft Vibration of the driven equipment Refer to the following information for more information about the alignment of t
41. fuel injection pump A cloth or similar material must be used in order to prevent fuel from spraying on the hot exhaust components Tighten each nut before loosening the next nut A faulty fuel injection nozzle be identified when a fuel line nut is loosened and the following conditions are present The exhaust smoke is partially eliminated or the exhaust smoke is completely eliminated Engine performance is not affected A fuel injection nozzle that is suspected of being faulty should be removed A new fuel injection nozzle should be installed in the cylinder in order to determine if the removed fuel injection nozzle is faulty Removal and Installation of the Fuel Injection Nozzles For the removal and the installation of fuel injection nozzles special tooling is required Refer to the Service Manual for more information Consult your Caterpillar dealer for assistance SEBUS134 06 97 Maintenance Section Fuel System Prime 102295879 Fuel System SMCS Code 1258 548 S N NCC1 Up S N N4D1 Up S N NCD1 Up S N N4E1 Up S N NCE1 Up If air enters the fuel system the air must be purged from the fuel system before the engine can be started Air can enter the fuel system when the following events occur The fuel tank is empty or the fuel tank has been partially drained The low pressure fuel lines are disconnected A leak exists in the low pressure fuel system
42. g conditions Replace any hose which exhibits any of the following conditions Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation Hoses which are cracked Hoses which are soft Outer covering that is chafed or cut SEBUS134 06 113 Maintenance Section Hoses and Clamps Inspect Replace Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed Armoring that is embedded in the outer covering Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps Inspect all clamps for the following conditions Replace any clamp which exhibits signs of any of the following conditions Cracking Looseness Damage Inspect all couplings for leaks Replace any coupling which exhibits signs of leaks Each installation application can be different The differences depend on the following factors of hose Type of fitting material Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen which can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Replace hoses that are cracked or soft Replace hoses that show signs of leakage Rep
43. g solutions A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water A mixture of 0 1 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 01492654 Battery or Battery Cable Disconnect SMCS Code 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal at the battery that goes to the start switch Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved the negative side of two batteries must be disconnected 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to recon
44. gines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to two articles in the Disassembly and Assembly Manual Water Temperature Regulators Remove and Water Temperature Regulators Install for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 102398768 Electrical Connections Check SMCS Code 4459 535 DANGER DANGER Shock Electrocution Hazard Do not op erate this equipment or work on this equipment unless you have read and understand the instruc tions and warnings in the Operation and Mainte nance Manual Failure to follow the instructions or heed the warnings will result in serious injury or death Checking the electrical connections is an important part of the maintenance for the generator set Improper connections may cause the generator set to malfunction Check all expo
45. he elements of the bearing On two bearing generators the front bearing can only be removed after the drive coupling is removed Refer to the Systems Operation Testing and Adjusting Disassembly and Assembly Coupling Remove for the generator for instructions for removing the drive coupling Replace 1 All ball bearings should be cleaned The cavity in the bracket should be repacked with 2S 3230 Grease Pack the ball bearings one third to one half of the volume of the cavity 2 Usean induction heater to heat the ball bearings to 107 224 6 F for ten minutes in order to install either of the following bearings ball bearings that are new and ball bearings that have been inspected Mount the bearings on the shaft To reinstall the hub heat the hub to 400 752 0 F for three hours Mount the hub to the shaft 3 Ensure that the tube of the grease gun is filled with grease 106 Maintenance Section Generator Bearing Lubricate SEBU8134 06 4 Remove the bracket drain plug and operate the generator for one hour This will allow the grease to expand The expanding grease will force the excess grease from the cavity When the excess grease is forced from the cavity the internal pressure will be reduced The generator should continue to operate until the grease stops purging 5 Stop the engine Install the bracket drain plug Wipe off the excess grease 6 For greasing intervals follow the recommend
46. he generator set e Special Instruction SEHS7654 Alignment General Instructions 112 Maintenance Section Generator Set Vibration Test Record SEBU8134 06 Special Instruction SEHS7259 Alignment of Single Bearing Generators e Special Instruction REHS0177 Alignment of the Close Coupled Two Bearing Generators Keep a record of the measurement of the alignment The record may be used to check the trend of the alignment The record may be used to analyze the trend of the alignment 03643886 Generator Set Vibration Test Record SMCS Code 4450 081 VI Check for vibration damage Vibration may cause the following problems Coupling wear Loose fittings Fatigue of the metal components of the engine Cracks in the cabinet which surrounds the generator Cracks in welds Excessive noise Cracked insulation The following areas are susceptible to vibration damage Coupling for the generator set Generator bearings Stator output leads Protective sleeving Insulation Exposed electrical connections Transformers e Fuses e Capacitors Lightning arresters When a generator set is installed a vibration plot should be recorded in order to assist in diagnosing potential problems This vibration plot should be updated yearly The vibration plot should also be updated when the generator set is moved and when the engine is overhauled This will allow t
47. he trend of the vibration to be monitored and analyzed A potential problem may be prevented by monitoring the trend of the vibration If the vibration is approaching the limit of the specification of the component the problem may be more imminent Refer to Data Sheet LEKQ4023 Linear Vibration for the allowable limits of vibration Caterpillar also recommends recording the vibration of the bearing at the generator bearing bracket If the vibration exceeds the EDS limits for vibration check the alignment Refer to this Operation and Maintenance Manual Generator Set Alignment Check for the alignment procedure Contact the Caterpillar Dealer Service Tools group for information on ordering a vibration analyzer that will meet your needs 104301694 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Hoses and clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine Take proper safety precautions before inspecting or replacing hoses and clamps Note Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death Leaks that are the size of a pin hole are included Refer to Operation and Maintenance Manual General Hazard Information for more information Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the followin
48. ifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps Note The bellows and the V clamps that are used on the bellows should never be reused 5 Start the engine Inspect the air lines for leaks i01917577 Instrument Panel Inspect SMCS Code 7451 040 Inspect the instrument panel for good condition Perform the self test All of the warning lamps should illuminate If warning lamp does not illuminate replace the bulb immediately If the alarm does not sound investigate the problem and correct the problem Check the condition of all of the gauges If a gauge is broken repair the gauge or replace the gauge immediately Frequently monitor the gauges during normal operation Record the data in a log Compare the new data to the data that was previously recorded Comparing the new data to the recorded data will help to establish the trends of engine performance A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge 103878716 Insulation Test SMCS Code 4453 081 4454 081 4457 081 4470 081 The high voltage that is produced by an operating generator set can cause severe injury or death Before performing any maintenance or repairs ensure that the generator will not start Place the engine control switch in the OFF posi tion Attach NOT OPERATE tags to all start ing contr
49. igh pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install Illustration 84 g01118416 1 Screw 2 Element 3 Glass bowl 4 Sensor connection 5 Drain 6 Bottom cover 1 Turn the fuel supply valve if equipped to the OFF position 2 Place a suitable container under the water separator Clean the outside of the water separator 3 Open the drain 5 Allow the fluid to drain into the container 4 Tighten the drain 5 by hand pressure only 5 Hold the element 2 and remove the screw 1 Remove the element and the glass bowl 3 from the base Discard the old element 6 Clean the glass bowl 4 Clean the bottom cover 6 7 Install the new ring seal Install the bottom cover onto the new element Install the assembly onto the base 8 Install the screw 1 and tighten the screw to a torque of 8 N m 6 Ib ft 100 Maintenance Section Fuel System Primary Filter Water Separator Drain SEBU8134 06 9 Remove the container and dispose of the fuel safely 10 Open the fuel supply valve 11 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System for more information 103622954 Fuel System Primary Filter Water Separator Drain SMCS Code 1260 543 1263 543 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible inju
50. ility publications The Special Publication SEBF8029 lists the reusability publications that are needed for inspecting the engine parts If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be dealt with in one of the following manners e Salvaging e Repairing Replacing Using out of spec parts can result in the following problems Unscheduled downtime Costly repairs Damage to other engine parts Reduced engine efficiency Increased fuel consumption Reduced engine efficiency and increased fuel consumption translates into higher operating costs Therefore Caterpillar Inc recommends repairing out of spec parts or replacing out of spec parts Inspection and or Replacement The following components may not last until the second overhaul Piston rings Thrust bearings Main bearings Connecting rod bearings Crankshaft seals Engine mounts Hoses Caterpillar Inc recommends the installation of new parts at each overhaul period Inspect these parts while the engine is disassembled for an overhaul Inspect the crankshaft for any of the following conditions Deflection Damage to the journals Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journ
51. ilter in order to catch any fuel that might spill Clean up any spilled fuel immediately 102 Maintenance Section Fuel Tank Water and Sediment Drain SEBU8134 06 Illustration 88 g01121396 1 Spin on filter 2 Drain 1 Clean the outside of the fuel filter assembly Open the fuel drain 3 and drain the fuel into a suitable container Use a suitable tool in order to remove the spin on filter 2 from the filter head 1 Ensure that the fuel drain 3 on the new spin on filter is closed Illustration 89 g01121723 4 Lubricate the sealing ring 4 with clean fuel oil 5 Install the spin on filter 2 into the top of the filter head 1 6 Tighten the spin on filter by hand until the sealing ring contacts the filter head Rotate the spin on filter through 90 degrees 7 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Prime 104363480 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication
52. in the temperature of the bearing Note Measure the bearing temperature after the generator reaches normal operating temperature Resistive Temperature Detectors RTDs Caterpillar Generators may be equipped with resistance temperature detectors for generator bearings These detectors are 100 ohm resistance temperature detectors A resistance temperature detector may be monitored by the optional monitor for the EMCP 3 2 3 3 resistance temperature detector A resistance temperature detector may be monitored by equipment that is provided by the customer Consult with your Caterpillar dealer about other methods of measuring the bearing temperature The EMCP 3 2 3 3 may be configured to ALARM or the EMCP 3 2 3 3 may be configured to SHUTDOWN An alarm is activated if the temperature of the bearing reaches 85 C 185 F A shutdown occurs if the temperature of the bearing reaches 95 C 203 F Infrared Thermometers Bearing temperatures can also be recorded with the use of an infrared thermometer Refer to Special Publication NENG2500 Caterpillar Dealer Service Tools Catalog for a variety of infrared thermometers Follow the instructions that come with your infrared thermometer 101878834 Generator Load Check SMCS Code 4450 535 LA Personal injury or death can result from high volt age When power generation equipment must be in op eration to make tests and or adjustments high voltage and current are pre
53. ine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life Ensure that the engine cannot be started while this maintenance is being performed To help prevent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information 102294260 Fuel Injection Nozzles Test Exchange SMCS Code 1254 013 1254 081 Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component The fuel injector 1 in illustration81 has no fuel return The fuel injector 2 has a fuel return 96 Maintenance Section Fuel Injection Nozzles Test Exchange SEBU8134 06 e 8 Illustration 81 901110422 Typical fuel injector nozzles Fuel injection nozzles are subject to tip wear Tip wear is a result of fuel contamination Tip wear can cause the following problems The e
54. ing Bearing Frame Temperature Grease Interval Weight Volume Shaft Part Type Size Maximum Part Number Diameter Number 281 3091 328 BC 30100 95 C 203 Grease Grease 140 mm Ball Bearing 300 mm 3020 cannot cannot cannot 5 5 inch 11 8 30420 be added be be added inch OD 30440 to this added to this 140 mm 30450 bearing to this bearing 5 5 inch bearing ID 311 0843 326 BC 18000 95 C 203 N A N A 130 mm Ball Bearing 280 mm cannot 5 1 inch 11 inch be added OD to this 130 mm bearing 5 1 inch ID 311 0844 322 BC 1600 95 C 203 F EA6 Grease N A N A 110 mm Ball Bearing 240 mm cannot 4 3 inch 9 4 inch be added OD to this 110 mm bearing 4 3 inch ID 341 7383 330 BC 30556 95 C 203 F Exxon Every 51 2 g 14 9 mL 150 Ball Bearing 320 mm 30669 Polyrex 1800 1 8 2 0 5 oz 5 9 inch 12 6 30686 EMBase service inch OD material is hours or 150 mm Polyurea 12 months 5 9 inch ID 375 3715 328 BC 301000 95 C 203 28 3230 Every 51 2g 59 mL 140 mm Ball Bearing 300 mm 302009 Bearing 2400 1 8 oz 2 oz 5 5 inch 11 8 30420 Lubricant service inch OD 30440 hours or 140 mm 304509 12 months 5 5 inch ID 1 Indicates the alarm temperature set point that the bearing should be continuously operated at on the specified generator frame size Shutdown set points ar
55. l system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and Assembly Fuel Injection Lines Install If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information 103622950 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servicing or repair is performed If your engine is equipped with high pressure fuel lines you must wait for 60 seconds after the engine has stopped in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any h
56. lace hoses that show signs of damage Replace hose clamps that are cracked or damaged Tighten or replace hose clamps which are loose Replace the Hoses and the Clamps NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Cooling System Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved Stop the engine N Allow the engine to cool Before servicing a coolant hose slowly loosen the filler cap for the cooling system in orde
57. ling System Coolant Sample Level 1 OBTAIN cies rri 86 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtain 87 Every 500 Service Hours Alternator and Fan Belts Inspect Adjust 82 Fuel System Secondary Filter Replace 100 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 83 Engine Air Cleaner Element Single Element fe teilt dius 89 Engine Oil Sample Obtain 92 Engine Oil and Filter Change 92 Fuel System Primary Filter Water Separator Element Replace 99 Hoses and Clamps Inspect Replace 112 Every 1000 Service Hours Engine Valve Lash Inspect Adjust 95 Every 1000 Service Hours or 1 Year Rotating Rectifier Check 119 Every 2000 Service Hours Alternator Inspect ssssssseseseeeee 82 Engine Mounts Inspect 91 Starting Motor Inspect 120 Every 2000 Service Hours or 6 Months Generator Set Vibration Test Record 112 Insulation TeSt n 115 Every Year Cooling System Coolant Sample Level 2
58. lustration 90 900992269 1 Positive DC terminal or Negative DC terminal 2 AC terminal 3 AC terminal 4 AC terminal The following procedure tests all three diodes within a block Check the positive rectifier block and the negative rectifier block If any meter reading does not fall within the given ranges replace the rectifier block 1 Set the digital multimeter on the diode range Remove all leads from the rectifier block 2 To test the negative rectifier block follow these steps a Place the red test lead on the negative terminal 1 Place the black test lead on the following rectifier terminals AC terminal 2 AC terminal 3 and AC terminal 4 All readings on the meter should be between 0 4 and 1 0 b Place the black test lead the negative terminal 1 Place the red test lead on the following rectifier terminals AC terminal 2 AC terminal 3 and AC terminal 4 In all cases the meter should read OL overload 3 To test the positive rectifier block follow these steps a Place the red test lead on the positive rectifier terminal 1 Place the black test lead on the following rectifier terminals AC terminal 2 AC terminal 3 and AC terminal 4 In all cases the meter should read OL overload b Place the black test lead on the positive rectifier terminal 1 Place the red test lead on the following rectifier terminals AC terminal 2 AC te
59. nect all of the cables 102292382 Cooling System Coolant ELC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats frequently Foaming is observed The oil has entered the cooling system and the coolant is contaminated The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap SEBU8 134 06 85 Maintenance Section Cooling System Coolant ELC Change o Illustration 70 Typical example 2 Open the drain cock or remove the drain plug 1 on the engine Open th
60. neral hazard Information Electric Fuel Priming Pump 1 Ensure that the fuel system is in working order Restore the fuel supply NOTICE The electric fuel priming pump will operate for 90 sec onds If necessary the electric fuel priming pump can be stopped during the 90 seconds of operation by op eration of the switch 2 Turn the keyswitch to the RUN position Operate the switch for the electric priming pump After 100 seconds of the electric fuel priming pump operation the fuel system will be primed and the electric fuel priming pump will turn off 3 The engine should now be able to start Note Do not loosen the high pressure fuel line in order to purge air from the fuel system This procedure is not required 4 Operate the engine starter and crank the engine After the engine has started operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system Note Operating the engine for this period of time will help ensure that the fuel system is free of air SEBUS134 06 99 Maintenance Section Fuel System Primary Filter Water Separator Element Replace After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fue
61. ngine will not start or the engine is difficult to start The engine misfires or the engine runs erratically The engine does not have enough power The engine has increased fuel consumption The engine emits black exhaust smoke The engine temperature is excessive e The engine knocks or there is vibration in the engine Fuel Injection nozzles should be cleaned inspected tested and replaced if necessary Do not use a wire brush to clean a fuel injection nozzle Refer to Special Instruction SEHS7292 for using the 88 2245 Injector Cleaning Tool Group Consult your Caterpillar dealer about cleaning the fuel injection nozzle and testing the fuel injection nozzle Work carefully around an engine that is running Engine parts that are hot or parts that are moving can cause personal injury Make sure that you wear eye protection at all times during testing When fuel injection nozzles are tested test fluids travel through the orifices of the nozzle tip with high pressure Under this amount of pressure the test fluid can pierce the skin and cause serious injury to the operator Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension Each fuel injection nozzle must be isolated one at a time in order to determine the malfunctioning fuel injection nozzle Start the engine N Loosen each fuel line nut one at a time at the
62. nsult your Caterpillar dealer 104051750 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6251 Caterpillar Commercial Di
63. ntenance program Caterpillar recommends using S O S analysis at regularly scheduled intervals S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine The number of hours that have accumulated since the last oil change The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions ar
64. ntilation cleaning is also advisable Restricted ventilation will cause excessive heating NOTICE To avoid the possibility of deterioration to the genera tor windings do not clean the generator unless there is visual electrical or thermal evidence that dirt is present If harmful dirt accumulations are present a variety of cleaning techniques are available The cleaning procedure that is used may be determined by one of the items on the following list e The extent of the cleaning procedure that is being attempted The type of enclosure of the generator The voltage rating of the generator The type of dirt that is being removed Cleaning Assembled Generators NOTICE Do not use water to clean the generator NOTICE Do not use trichloroethane perchlorethylene trichloroethane or any alkaline products to clean the generator Cleaning may be required at the point of installation At this point complete disassembly of the generator may not be necessary or feasible In this case a vacuum cleaner should be used to pick up the following items dry dirt dust and carbon This will prevent the spreading of these contaminants A small nonconductive tube may need to be connected to the vacuum cleaner This will allow the vacuum cleaner to clean the surfaces that are not exposed After most of the dust has been removed a small brush may be attached to the vacuum hose in order to loosen dirt that is mo
65. ocedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly Oil change Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A four micron c absolute filter for the breather vent on the fuel tank is also recommended If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used 103642821 Generator Dry SMCS Code 4450 569 NOTICE Do not operate the generator if the windings are wet If the generator is operated when the windings are wet damage can occur due to insulation b
66. ols Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Table 25 TOOLS NEEDED Part Number Tool Quantity 142 5055 Insulation Tester 1 Megohmmeter Personal injury or death can result from electro cution The megohmmeter is applying a high voltage to the circuit To avoid electrocution do not touch the instru ment leads without first discharging them When finished testing also discharge the generator windings The following materials will cause the winding insulation to deteriorate moisture water e dust grease other foreign matter within the generator This deterioration reduces the resistance of the insulation This test will measure the resistance of the winding insulation 116 Maintenance Section Insulation Test SEBU8134 06 The insulation tester megohmmeter produces a high potential voltage between the test leads During the test a small current flows The tester converts this current to a resistance reading The insulation test is performed as part of periodic maintenance in order to detect the deterioration of the winding insulation When there is a rapid decrease in the insulation resistance in a short amount of time the generator needs to be cleaned Note For information on generator cleaning refer to Special Instruction SEHS9124 When generators h
67. olt torque Engine vibration can be caused by the following conditions Improper mounting of the engine Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to Special Publication SENR3130 Torque Specifications for the recommended torques Refer to the OEM recommendations for more information 100623423 Engine Oil Level Check SMCS Code 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin C ADD FULL 900110310 Illustration 75 ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped 1 Maintain the oil level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of power 2 Remove the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap 92 Maintenance Section Engine Oil Sample Obtain SEBU8134 06 Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive mai
68. on Engine Air Cleaner Service Indicator Inspect SEBU8134 06 in Illustration 71 901197946 1 Unfasten latches 1 Remove cover 2 V SS CITY TTA NR NS MN Illustration 72 901197952 2 Remove air cleaner element 3 3 Inspect the replacement element for the following items damage dirt and debris Install a clean undamaged air filter element 3 Make sure that the element is properly seated in the air cleaner housing Sie Illustration 73 g01197946 4 Install cover 2 Fasten latches 1 Engine Air Cleaner Service Indicator Inspect If Equipped SMCS Code 7452 040 Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner housing or in a remote location SEBUS134 06 91 Maintenance Section Engine Mounts Inspect Illustration 74 900103777 Typical service indicator Ob
69. permanently installed ensure that the protective caps for the grease fittings are installed on the fittings when finished If a grease fitting was installed in Step 2 remove the top grease fitting and install the plug that was removed If applicable do not install the plug on the bottom grease location yet Wipe off the excess grease Note Do not allow grease to drip on the stator windings of the generator The stator windings that are exposed to grease could suffer degraded insulation The degraded insulation would cause a reduction in the life of the windings 6 Operate the generator set at rated speed for approximately 1 hour When running the engine more than 30 minutes the recommended engine load to apply is a minimum of 50 The procedure will allow the grease to expand The expanding grease will force the excess grease from the cavity The internal pressure will be reduced as the excess grease is forced from the cavity Operate the generator until no grease is forced out of the cavity 7 Stop the generator set Inspect the generator windings grease tubes and bearing housings Wipe off any excess grease If a grease pipe plug was removed in Step 2 install the plug in the bottom grease pipe Wipe off any excess grease Note Do not allow grease to drip on the stator windings of the generator The stator windings that are exposed to grease could suffer degraded insulation The degraded insulation would cause a reduction in
70. produced by an operating generator set can cause severe injury or death Before performing any maintenance or repairs ensure that the generator will not start Place the engine control switch in the OFF posi tion Attach DO NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Refer to Safety Section Generator Isolating for Maintenance for information regarding the procedure to safely isolate the generator Proper maintenance of electrical equipment requires periodic visual examination of the generator and periodic visual examination of the windings Proper maintenance of electrical equipment also requires appropriate electrical checks and appropriate thermal checks Insulation material should be examined for cracks The insulation material should be examined for accumulations of dirt and dust If there is an insulation resistance value that is below normal a conductive path may be present This conductive path may be made of one of the following materials Carbon e Salt e Metal dust Dirt that is saturated with moisture These contaminants will develop a conductive path which may produce shorts Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be seen If excess dirt is the cause of a restriction in the ve
71. r to relieve any pressure AR Remove the filler cap for the cooling system Drain the coolant from the cooling system to level that is below the hose that is being replaced Drain the coolant into a suitable clean container The coolant can be reused Remove the hose clamps 114 Maintenance Section Hoses and Clamps Inspect Replace SEBU8134 06 N Disconnect the old hose Replace the old hose with a new hose Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 10 Refill the cooling system 11 Clean the filler cap for the cooling system Inspect the gaskets on the filler cap Replace the filler cap if the gaskets are damaged Install the filler cap 12 Start the engine Inspect the cooling system for leaks Fuel System Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or dea
72. rator Set Test SMCS Code 4450 081 S N NCC1 Up Personal injury or death can result from high volt age When power generation equipment must be in op eration to make tests and or adjustments high voltage and current are present Improper test equipment can fail and present a high voltage shock hazard to its user Make sure the testing equipment is designed for and correctly operated for high voltage and cur rent tests being made When servicing or repairing electric power gener ation equipment Make sure the unit is off line disconnected from utility and or other generators power service and either locked out or tagged DO NOT OPERATE Make sure the generator engine is stopped Make sure all batteries are disconnected Make sure all capacitors are discharged Table 24 Tools Needed Part Number Part Quantity 6V 7070 mutimeter 12 VDC battery 1 Potential 4 Transformer The generator set functional test is a simplified test that can be performed in order to determine if the generator is functional The generator set functional test should be performed on a generator set that is under load The generator set functional test determines if the following statements happen phase voltage is being generated The phase voltages are balanced The phase voltages change relative to engine speed The generator set functional test consists of the
73. re firmly attached to the surface SEBUS134 06 105 Maintenance Section Generator Bearing Inspect Replace After the initial cleaning with a vacuum compressed air may be used to remove the remaining dust and dirt Compressed air that is used for cleaning should be free of moisture and free of oil Air pressure should be a maximum of 210 kPa 30 psi in order to prevent mechanical damage to the insulation If the above cleaning procedures are not effective consult a Caterpillar dealer Cleaning Disassembled Generators NOTICE Do not use water to clean the generator NOTICE Do not use trichloroethane perchlorethylene trichloroethane or any alkaline products to clean the generator An initial insulation resistance check should be made on the generator in order to confirm electrical integrity A minimum reading of one megohm would be expected with severely contaminated generators A zero megohm reading may indicate an insulation breakdown An insulation breakdown requires more than cleaning An insulation breakdown requires repair Use the following for cleaning the stator the rotor the exciter and the diode bridge Unleaded Gasoline Toluene e Benzene Ciclohexare Avoid permitting the solvent to run into the slots Apply the solvent with a brush Use a sponge on the windings frequently in order to remove the debris Dry the winding with a dry cloth Allow the solvent to evaporate befor
74. re that no fuel remains on or close to the engine Note Fuel must be added to the fuel system ahead of the fuel filter 7 Refill the fuel system Refer to this Operation and Maintenance Manual Fuel System Prime for information about priming the engine with fuel 8 Start the engine Inspect the fuel system for leaks Lubrication System Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 1 Drain the oil from the lubrication system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps SEBUS134 06 115 Maintenance Section Instrument Panel Inspect 6 Refill the lubrication system Refer to this Operation and Maintenance Manual Engine Oil Level Check in order to ensure that the lubrication system is filled with the proper amount of engine oil 7 Start the engine Inspect the lubrication system for leaks Air System 1 Remove the hose clamps 2 Disconnect the old hose 3 Replace the old hose with a new hose 4 Install hose clamps which have been inspected or install new hose clamps Refer to Spec
75. reakdown When moisture is present or when moisture is suspected in a generator the generator must be dried before being energized If the drying procedure does not restore the insulation resistance to an acceptable value the winding should be reconditioned Note For additional information refer to Special Instruction SEHS9124 Drying Methods The following methods can be used for drying a generator Self circulating air method Oven method NOTICE Do not allow the winding temperature to exceed 85 185 0 F Temperatures that are greater than 85 C 185 0 F will damage the winding insulation Self Circulating Air Method Note Disable the excitation before using this method Run the engine and disconnect the generator load This will help circulate air Operate the generator space heaters Oven Method Place the entire generator inside a forced air drying oven for four hours at 65 C 149 F 104 Maintenance Section Generator Inspect SEBU8134 06 NOTICE Use a forced air type oven rather than a radiant type oven Radiant type ovens can cause localized overheating 02283395 Generator Inspect SMCS Code 4450 040 Personal injury or death can result from improper troubleshooting and repair procedures The following troubleshooting and repair proce dures should only be performed by qualified per sonnel familiar with this equipment The high voltage that is
76. ring seal 5 Element 6 Filter head 4 Install a new O ring 4 onto the filter bowl and lubricate the O ring with clean engine oil Install the filter element 5 into the filter bowl 5 Install the filter bowl into the oil filter head 6 Tighten the filter bowl to the following torque 25 N m 18 Ib ft 6 Install a new seal onto the drain plug 1 and install the drain plug into the oil filter Tighten the drain plug to the following torque 12 N m 8 lb ft Note Some engines may have a horizontally mounted oil filter This oil filter has a drain plug that is located in the oil filter head Fill the Engine Crankcase 1 Remove the oil filler cap Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for more information on lubricant specifications Fill the crankcase with the correct amount of oil Refer to this Operation and Maintenance Manual Refill Capacities for more information on refill capacities NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds SEBUS134 06 95 Maintenance Section Engine Valv
77. rminal 3 and AC terminal 4 All readings on the meter should be between 0 4 and 1 0 Note A shorted diode can cause damage to the exciter rotor If a diode is shorted check the exciter rotor Refer to the Testing and Adjusting Winding Test and Testing and Adjusting Insulation Test Perform these tests 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 100632301 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided SEBUS134 06 121 Maintenance Section Water Pump Inspect For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed The guards must be in the proper place Repair
78. ry turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE The water separator is not a filter The water separa tor separates water from the fuel The engine should never be allowed to run with the water separator more than half full Engine damage may result NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system If your engine is equipped with high pressure fuel lines you must wait for 60 seconds after the engine has stopped in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install Illustration 85 901118416 1 Screw 2 Element 3 Glass bowl 4 Sensor connection 5 Drain 6 Bottom cover 1 Place a suitable container below the water separator 2 Open the drain 5 Allow the fluid to drain into the container 3 When clean fuel drains from the water separator close the drain 5 Tighten the drain by hand pressure only Dispose of the drained flui
79. sed electrical connections for tightness Check the following devices for loose mounting or for physical damage Transformers e Fuses Capacitors e Lightning arresters Check the connections for the following components Load cables Cables for the generator Potential transformers Current transformers Check all lead wires and electrical connections for proper clearance Inspect all cables for chafing abrasion and corrosion SEBUS134 06 89 Maintenance Section Engine Clean 102293096 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture could create paths of electrical conduc tivity Make sure the unit is off line disconnected from utility and or other generators locked out and tagged Do Not Operate NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine NOTICE Water or condensation can cause damage to gen erator components Protect all electrical components from exposure to water Periodic cleaning of the engine is recommended Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits Easy detection of fluid leaks Maximum heat transfer characteristics Ease of maintenance Note Caution must be used in order to prevent ele
80. sent Improper test equipment can fail and present a high voltage shock hazard to its user Make sure the testing equipment is designed for and correctly operated for high voltage and cur rent tests being made During normal operation monitor the power factor and monitor generator loading When a three phase generator is installed or when a three phase generator is reconnected ensure that the total current in any one phase does not exceed the nameplate rating Each phase should carry the same load This allows the three phase generator to work at the rated capacity If one phase current exceeds the nameplate amperage an electrical imbalance will occur An electrical imbalance can result in an electrical overload and an electrical imbalance can result in overheating on three phase generators This is not applicable to single phase generators The power factor can be referred to as the efficiency of the load This can be expressed as the ratio of to actual kW The power factor can be calculated by dividing KW by kVA Power factor is expressed as a decimal Power factor is used to mean the portion of current that is supplied to a system that is doing useful work The portion of the current that is not doing useful work is absorbed in maintaining the magnetic field in motors This current reactive load can be maintained without engine power SEBUS134 06 111 Maintenance Section Generator Set Test 01593517 Gene
81. serve the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur The yellow diaphragm enters the red zone The red piston locks the visible position Test the Service Indicator Service indicators are important instruments Check for ease of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 18 Ib in 102456872 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper b
82. small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 77 901003628 2 Filter head 3 O ring seal 3 Clean the sealing surface of the oil filter head 2 Ensure that the union not shown in the oil filter head is secure 94 Maintenance Section Engine Oil and Filter Change SEBU8134 06 4 Apply clean engine oil to the new oil filter seal 3 NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter until the oil filter seal contacts the cylinder block or the oil cooler Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Replace the Element for the Oil Filter Illustration 78 g01003662 1 Drain plug 2 Square hole 3 Filter bowl 1 Place a suitable container under the oil filter Remove the drain plug 1 and the seal from the oil filter 2 Locate a suitable wrench into the square hole 2 in order to remove the filter bowl 3 3 Remove the filter bowl 3 and remove the element from the filter bowl Clean the filter bowl g01003675 Illustration 79 4 O
83. sure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations article for more information 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 104035949
84. taminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see this Operation and Maintenance Manual Refill Capacities and Recommendations or co
85. th NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Note High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors High pressure fuel lines are constantly charged with high pressure Do not check the high pressure fuel lines with the engine or the starting motor in operation Wait for 10 minutes after the engine stops before you perform any service or repair on high pressure fuel lines Waiting for 10 minutes will to allow the pressure to be purged 1 Drain the fuel from the fuel system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 6 Carefully inspect the engine for any spilled fuel Make su
86. that the fuel system is in working order Restore the fuel supply Illustration 83 901448339 Typical example 2 Operate the fuel priming pump 1 Count the number of operations of the fuel priming pump After 100 depressions of the fuel priming pump stop 3 The engine fuel system should now be primed and the engine should now be able to start Note Do not loosen the high pressure fuel line in order to purge air from the fuel system This procedure is not required 4 Operate the engine starter and crank the engine After the engine has started operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system Note Operating the engine for this period of time will help ensure that the fuel system is free of air After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and Assembly Fuel Injection Lines Install If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual Ge
87. the cooling system It is normal for a small amount of leakage to occur as the engine cools down and parts contract Visually inspect the water pump for leaks Renew the water pump seal or the water pump if there is an excessive leakage of coolant Refer to the Disassembly and Assembly Manual Water Pump Remove and Install for the disassembly and assembly procedure
88. the risk of a major catastrophe due to engine failure The best cost value relationship per hour of extended life can be attained After Failure Overhaul Many options are available if a major engine failure occurs An overhaul should be performed if the engine block or the crankshaft can be repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be less than the cost of a new engine with a similar exchange core This lower cost can be attributed to these aspects e Caterpillar dealer exchange components 118 Maintenance Section Overhaul Considerations SEBU8134 06 e Caterpillar Inc remanufactured exchange components Overhaul Recommendation To minimize downtime Caterpillar Inc recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails This will provide you with the best cost value relationship Note Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life If an overhaul is performed without overhaul service from your Caterpillar dealer be aware of the following maintenance recommendations Rebuild or Exchange These components should be inspected according to the instructions that are found in various Caterpillar reusab
89. vious interval must be performed When Required Battery Recycle 83 Battery Replace 83 Battery or Battery Cable Disconnect 84 Engine Clean iiec dt ze e 89 Fuel System Prime 97 Fuel System Prime 97 Generator Dry 103 Generator Bearing Lubricate 106 Generator Set Test 111 Generator Set Alignment Check 111 Rotating Rectifier Test 120 Daily Electrical Connections Check 88 Engine Air Cleaner Service Indicator Inspect 90 Engine Oil Level Check 91 Fuel System Primary Filter Water Separator Drain octets EET 100 Generator Bearing Temperature Test Record 110 Generator Load Check 110 Walk Around Inspection 120 Every Week Generator 104 Instrument Panel Inspect 115 Every 50 Service Hours or Weekly Fuel Tank Water Sediment Drain 102 Every 250 Service Hours Coo

MAINTENANCE INTERVALS - Safety

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