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3406C Generator Sets - Maintenance Intervals - Safety

1. 171 Turbocharger 2226 175 Every 6 Years Cooling System Coolant ELC Change 131 122 Maintenance Section Maintenance Interval Schedule SEBU7828 10 Every 190 000 L 50 000 US gal of Fuel or 5000 Service Hours Alternator 123 Commissioning Generator Set Alignment Check 160 SEBU7828 10 123 Maintenance Section Aftercooler Core Clean Test 101546702 Aftercooler Core Clean Test SMCS Code 1064 070 1064 081 1 Remove the core Refer to the Service Manual for the procedure 2 Turn the aftercooler core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 24 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 24 Hydrosolv Liquid Cleaners Part Number Description Size 1U 5490 Hydrosolv 4165 19 L 5 US gallon 174 6854 Hydrosolv 100 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar de
2. 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 164 Maintenance Section Instrument Panel Inspect SEBU7828 10 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 Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 5 Start the engine Inspect the air lines for leaks 101917577 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 a warning lamp does not illuminate replace the bulb immediately If the alarm does not s
3. Oil Cooler Core During an overhaul Caterpillar Inc recommends the removal of the oil cooler core Clean the oil cooler core Then pressure test the oil cooler core NOTICE Do not use caustic cleaners to clean the core Caustic cleaners can attack the internal metals of the core and cause leakage Note Use this cleaning procedure to clean the oil cooler core 1 Remove the oil cooler core 2 Remove any debris from the oil cooler core To remove debris from the oil cooler core turn the oil cooler core onto one end 3 Flush the oil cooler core internally with cleaner in order to loosen foreign substances This will also help to remove oil from the oil cooler core Note Caterpillar Inc recommends the use of Hydrosolv Liquid Cleaners Table 31 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 31 HydrosolvLiquid Cleaners d Description Size 1U 8812 4 L 1 US gallon 1U 5490 Hydrosolv4165 19 L 5 US gallon 8T 7570 208 L 55 US gallon 1U 8804 4 L 1 US gallon 1U 5492 Hydrosolv100 19 L 5 US gallon 8T 5571 208 L 55 US gallon 4 Use steam to clean the oil cooler core This removes any remaining residue from the cleaner Flush the fins of the oil cooler core Remove any other trapped debris 5 Wash the oil cooler core with hot soapy water Rinse the oil cooler core thoroughly with clean water Personal injury
4. 3 Crank the engine If the engine starts and the engine runs rough run the engine at low idle Continue running the engine until the engine runs smoothly NOTICE During periodic service DO NOT remove the fuel filter plug that is in the fuel filter base in order to purge air from the fuel system The periodic removal of the fuel filter plug will result in increased wear on the threads in the fuel filter base This wear leads to fuel leakage 4 Open the vent valve if equipped on the fuel injection pump s housing 5 Operate the priming pump until the flow of fuel from the vent valve is continuous and the flow of fuel is free of air bubbles If the engine does not have a fuel priming pump crank the engine Crank the engine until the fuel flows freely and until the fuel is free of air bubbles 6 Close the vent valve Then push in the plunger Hand tighten the plunger 7 Crank the engine If the engine starts and if the engine runs rough run the engine at low idle Continue running the engine until the engine runs smoothly Note If the engine will not start more priming is necessary If the engine continues to run rough more priming is necessary as well NOTICE Do not let the tops of fuel nozzles turn when the fuel line nuts are loosened or tightened The nozzles will be damaged if the top of the nozzle turns in the body The engine will be damaged if a defective fuel injec tion nozzle is used becau
5. or consult your Caterpillar dealer 102456600 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Note Test the concentration of the Supplemental Coolant Additive SCA or test the SCA concentration as part of an 5 5 Coolant Analysis Test for SCA Concentration Coolant and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Use the 8T 5296 Coolant Conditioner Test Kit or use the 4C 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for more information Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Refer to the Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations for more information S O S Coolant Analysis 5 5 coolant samples can be analyzed at your Caterpillar dealer 5 5 Coolant Analysis is a program that is based on periodic samples Level 1 Level 1 is a basic analysis of the coolant The following items are tested
6. 137 Generator Inspect 153 Generator Lead Flat Braided Cable Check 158 Instrument Panel Inspect 164 Space Heater Check 173 Stator VVinding Temperature Measure Record 174 Voltage and Frequency Check 176 Every 2000 Service Hours Generator Lead Round Cable Check 158 Every 2000 Service Hours or 6 Months Generator Set Vibration Test Record 161 Insulation Test 164 Stator Lead Check 174 Every Year Alternator Inspect 123 Fan Drive Bearing Lubricate 146 Generator Set Vibration Inspect 160 Varistor Check 176 Varistor 1 176 Every 3 Years Turbocharger 2222 175 First 9500 L 2500 US gal of Fuel or 250 Service Hours Engine Valve Lash Inspect Adjust 145 Every 9500 L 2500 US gal of Fuel or 250 Service Hours or Yearly Aftercooler Core Clean Test 123 Battery Electrolyte Level Check 127 Belts Inspect Adjust Replace 128 Cooling System Coolant Sample Level 1 OBLA Me 134 Cooling System
7. 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 176 Maintenance Section Varistor Check SEBU7828 10 6 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 103291822 Varistor Check SMCS Code 4466 535 The varistor must be checked at regular intervals Refer to Systems Operation Testing and Adjusting KENR5284 Varistor Test for instructions 103291802 Varistor Inspect SMCS Code 4466 040 The varistor must be visually inspected at regular intervals For generator sets with 1400 or with 1600 frames discoloration of the varistor indicates that replacement of the varistor is necessary For generator sets with 1800 frames physical signs of failure indicate that replacement of the varistor is necessary 101491868 Voltage and Frequency Check SMCS Code 4450 535 EL Check for the proper voltage set
8. If the engine has an alternator the charger must be automatically disconnected during start up and during engine operation Charging the Battery Never disconnect any charging unit circuit or bat tery circuit cable from the battery when the charg ing unit is operated A spark can cause an explo sion from the flammable vapor mixture of hydro gen and oxygen that is released from the elec trolyte through the battery outlets Injury to per sonnel can be the result Perform the following procedure to charge the battery 1 Ensure that the charger is turned OFF SEBU7828 10 127 Maintenance Section Battery Electrolyte Level Check 2 Adjust the voltage of the charger in order to match the voltage of the battery 3 Connect the POSITIVE lead of the charger to the POSITIVE battery terminal Connect the NEGATIVE lead of the charger to the NEGATIVE battery terminal 4 Turn ON the battery charger Overcharging of Batteries Overcharging reduces the service life of batteries Use a battery charger that will not overcharge the battery DO NOT charge the battery if the meter of the battery charger is in the RED zone Overcharging is indicated by the following symptoms The battery is very warm to the touch e A strong odor of acid is present e The battery emits smoke or a dense vapor gas Perform one of the following procedures if the battery shows symptoms of overcharging
9. Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber
10. Storage Procedure for Caterpillar Products Storing the engine for 1 yr to 2 years For information about engine storage refer to Special Instruction SEHS5001 The Long Term Storage and Recovery of Certain Commercial Engines 102501318 Space Heater Check SMCS Code 4450 535 HTR A Caterpillar generator is capable of operating in high humidity conditions without problems However problems can occur when the generator is idle and the surrounding air is warmer than the generator Moisture can form on the windings that will result in poor performance from the windings Moisture can also result in damage to the windings Whenever the generator is not active ensure that the space heaters are in operation Table 32 Tools Needed Part Number Part Quantity Digital 237 5130 Multimeter 1 Stop the generator set 2 Remove the panels in order to allovv access to the regulator and control terminal strips Locate terminal strip TS1 3 For 240 V systems use the multimeter to measure the voltage betvveen terminal H1 and terminal H4 If voltage is not present disconnect the power source to terminal H1 and terminal H4 and check for 3 to 12 ohms resistance f there is no resistance check the generator service manual for further information For 120 V systems use the multimeter to measure the voltage between terminal H1 and terminal H2 If voltage is not pre
11. e Reduce the rate of charging by a significant amount Complete the charging at the reduced rate e Turn OFF the charger Table 26 describes the effects of overcharging on different types of batteries Table 26 Effects of Overcharging Batteries Type of Battery Effect Caterpillar General Service All of the battery cells have Batteries a low level of electrolyte Caterpillar Premium High Output Batteries When the plates of the battery are inspected through the filler holes the plates may appear to be warped This is caused by an excessive temperature The battery may not pass a load test Caterpillar Maintenance Free Batteries The battery may not accept a charging current The battery may not pass a load test Checking After Stopping Ensure that the battery charger is connected properly Observe the meter of the charger Record the amperage 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
12. Flush the cooling system with clean water in order to remove any debris Note If equipped be sure to flush the heater and any related supply and return lines 132 Maintenance Section Cooling System Coolant Extender ELC Add SEBU7828 10 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 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 Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC See Special Publication SEBU6251 Caterpillar Commercial Diesel Eng
13. 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 reconnect all of the cables 102200198 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection ustration 82 900750216 The belt cover must be removed for inspection adjustment and replacement 1 Mounting bolts 2 Adjustment bolt 3 Typical belt tension gauge To maximize the engine performance inspect the b elt for wear and for cracking Check the belt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the life of the belt For the correct tension on the belt refer to Specifications Belt Tension Chart Adjustment 1 Remove the belt cover 2 Loosen mounting bolts 1 and adjusting bolt 2 3 Slide the alternator in the direction that will give the correct tension 4 Tighten adjusting bolt 2 Tighten mounting bolts 1 For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications Reinstall the b
14. C 28 3230 Every 2000 51 2 g 59 mL 100 0 mm Ball Bearing 180 0 mm 20 2 F Bearing service 1 8 oz 2 oz 3 9 inch 7 1 inch Lubricant hours or 12 OD 80 C months 176 F 100 0 mm 3 9 inch ID continued SEBU7828 10 157 Maintenance Section Generator Bearing Lubricate Table 28 contd Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft Part Type Size Min Max Part Diameter Number Number 6Y 6488 318 BC 597 29 C 28 3230 Every 2000 51 2 g 59 mL 90 0 mm Ball Bearing 190 0 mm 20 2 F Bearing service 1 8 oz 2 oz 3 5 inch 7 5 inch Lubricant hours or 12 OD 80 C months 176 F 90 0 mm 3 5 inch 311 0843 326 BC 1800 40 C EA6 Non Non Non 130 0 mm Ball Bearing 280 0 mm FR 40 F regreasable regreasable regreasable 5 1 inch 11 0 inch bearing bearing bearing OD 80 C 176 F 130 0 mm 5 1 inch ID 311 0844 322 BC 1600 40 C EA6 Non Non Non 110 0 mm Ball Bearing 240 0 mm FR 40 F regreasable regreasable regreasable 4 3 inch 9 4 inch bearing bearing bearing OD 80 C 176 F 110 0 mm 4 3 inch ID 253 9789 320 BC 1400 29 C UNIREX Non Non Non 100 0 mm Bearing 215 0 mm FR 20 2 F N3 regreasable regreasable regreasable 3 9 inch 8 5 inch bearing bearing bearing OD 80 C 176 F 100 0 mm 3 9 inch ID 193 4070
15. Do not mix greases Table 28 Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft Part Type Size Min Max Part Diameter Number Number 108 1760 321 BC 680 29 C 28 3230 Every 2000 51 2 g 59 mL 105 0 mm Ball Bearing 225 0 mm 20 2 F Bearing service 1 8 oz 2 oz 4 1 inch 8 9 inch minimum Lubricant hours or 12 OD months 80 C 105 0 mm 176 F 4 1 inch ID maximum 108 1761 322 BC 690 29 C 28 3230 Every 2000 51 2 g 59 mL 110 0 mm Ball Bearing 240 0 mm 800 20 2 F Bearing service 1 8 oz 2 oz 4 3 inch 9 4 inch i Lubricant hours or 12 OD 80 C months 176 F 110 0 mm 4 3 inch ID 139 0349 Roller 2900 40 C Mobilith Every 250 2 8 g NA 127 0 mm Roller 2800 740 F SHC220 service 0 1 oz 5 0 inch Bearing hours 80 C 176 F 139 0350 Roller 2900 40 C Mobilith Every 250 2 8 g NA 127 0 mm Roller 2800 40 F SHC220 service 0 1 oz 5 0 inch Bearing hours 80 C 176 F continued 156 Maintenance Section Generator Bearing Lubricate SEBU7828 10 Table 28 contd Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft Part Type Size Min Max Part Diameter Number Number 154 3032 326 BC 820 29 C 28 3230 Every 2000 51 2 g 59 mL 130 0 mm Ball Bearing 280 0 mm 2600 20 2 F Bearing service 1 8 oz 2 oz 5 1 inch 11 0 inch 2700 Lubr
16. Engine Mounts Inspect SEBU7828 10 Illustration 91 g00812591 Typical example 1 Hose clamp 2 Cover clamp 3 Crankcase breather cover 1 Loosen hose clamp 1 and remove the hose from crankcase breather 2 2 Remove the crankcase breather 2 3 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 4 Install a breather element that is clean and dry Install the crankcase breather 2 Refer to the Operation and Maintenance Manual for the proper torque 5 Install the hose Install hose clamp 1 Refer to the Operation and Maintenance Manual for the proper torques 102139969 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper bolt 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 the Specifications Manual SENR3130 Torque Specifications Refer to your Caterpillar dealer 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 07 C ADD FULL 900110310 Illustration 92 Y ADD mark X FULL mark NOTICE Perform thi
17. 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 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 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 101917570 Battery Charger Check SMCS Code 1401 535 Checking Before Start Up Check the battery charger for proper operation If the batteries are properly charged the needle of the ammeter will register near 0 zero The battery charger must not produce excessive current during start up Alternatively the charger must be automatically disconnected for start up
18. 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 e Costly unplanned downtime can be avoided e Many original parts can be reused according to the standards for reusable parts e The engine s service life can be extended without the risk of a major catastrophe due to engine failure e The best cost value relationship per hour of extended life can be attained After Failure Overhaul If a major engine failure occurs and the engine must be removed many options are available An overhaul should be performed if the engine block or the crankshaft needs to be repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects Specially designed Caterpillar engine features Caterpillar dealer exchange components e Caterpillar Inc remanufactured exchan
19. can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 170 Maintenance Section Povver Factor Check SEBU7828 10 6 Dry the oil cooler core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the components in order to ensure cleanliness The oil cooler core should be pressure tested Repair the oil cooler core if necessary Install the oil cooler core For more information about cleaning the cores consult your Caterpillar dealer Obtain Coolant Analysis The concentration of supplemental coolant additive SCA should be checked regularly with test kits or with 5 5 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
20. elements will allow dirt to pass through Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements e Pressurized air e Vacuum cleaning 140 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU7828 10 Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 87 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning w
21. gas electric sets the low idle is set at the factory Adjustment of the low idle on these machines should only be done by a Caterpillar dealer Note Operating the electric set at low idle speed for an extended time will cause some voltage regulators to shut off The electric set must be completely shut down and the electric set must be restarted This will allow the voltage regulator to again produce an output 101593517 Generator Set Test SMCS Code 4450 081 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 160 Maintenance Section Generator Set Alignment Check SEBU7828 10 Table 29 Tools Needed Part Number Part Quantity Digital 6v 7070 Multimeter 1 12 VDC battery 1 Potential 1 Transfor
22. laboratories are also available for water analysis Caterpillar Inc recommends an S O S Coolant Analysis Level 2 5 5 Coolant Analysis Level 2 An 5 5 Coolant Analysis Level 2 is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level 2 provides the following information Complete 5 5 Coolant Analysis Level 1 Visual inspection of properties Identification of metal corrosion Identification of contaminants Identification of built up impurities corrosion and scale 5 5 Coolant Analysis Level 2 provides a report of the results of both the analysis and the maintenance recommendations For more information about coolant analysis see your Caterpillar dealer 101191656 Power Factor Check SMCS Code 4450 535 PWR The power factor of a system can be determined by a power factor meter or by calculations The power factor can be calculated by dividing kW by kVA Power factor is expressed as a decimal 104020194 Radiator Clean SMCS Code 1353 070 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary Personal injury can result from air pressure Personal injury can result without following prop er procedure W
23. problems and repairs Space Heaters Moisture causes damage to generators and other electrical equipment Make every effort to keep the generator set as dry as possible Generators can operate without problems in humid environments However problems can occur when the generator is inactive Moisture can condense on the windings This can result in poor performance Also damage to the windings can occur Use space heaters in order to help keep the windings dry When the generator is not active ensure that the space heaters are operating When the generator is operating turn OFF the space heaters 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 103230840 Stator Lead Check SMCS Code 4459 535 Ensure that the stator output leads are routed out of the generator in a manner that prevents the leads from rubbing against metal objects Visually inspect the following areas for cracking and physical damage e stator output leads e protective sleeving insulation Stator Winding Temp
24. require more frequent maintenance When Required Battery Recycle sese 126 Battery Replace sese 126 Battery or Battery Cable Disconnect 128 Circuit Breakers Reset l es 129 Cooling System Coolant Sample Level 2 ODI se 135 Engine Clean eene 138 Engine Air Cleaner Element Dual Element Clean Replace 138 Ether Starting Aid Cylinder Replace 146 Fuel System Prime 146 Generator Dry 151 Generator Bearing Lubricate 155 Generator Set Test 0 159 Generator Set Alignment Check 160 Rotating Rectifier Test 171 Severe Service Application Check 172 Daily Annunciator Panel Inspect 123 Cooling System Coolant Level Check 133 Engine Air Cleaner Service Indicator Inspect 141 Engine Oil Level Check 142 Fuel System Primary Filter VVater Separator 149 Generator Bearing Temperature Test Record 158 Generator Load Check 159 Power Factor Check 170 Walk Around Inspection 176 Every Week Electrical Connections Check
25. system Lock out all switchgear and automatic transfer switches that are associated with the generator The recommended maintenance for the generator set is listed in this Operation and Maintenance Manual Maintenance Interval Schedule Standby Generator Sets Maintenance Section 174 Maintenance Section Starting Motor Inspect SEBU7828 10 Maintenance and Repair The maintenance that is recommended for Every Week can be performed by an authorized operator The maintenance that is recommended for the subsequent maintenance intervals must be performed by an authorized service technician or by your Caterpillar dealer Unless other instructions are provided perform maintenance and repairs under the following conditions e The engine is stopped The starting system is disabled e The generator does not pose an electrical shock hazard The generator is disconnected from the load Operation To ensure proper operation the generator set must be exercised regularly For instructions on operating the generator set see the Operation and Maintenance Manual for the generator set control panel For these operation procedures follow the instructions that are provided in this Operation and Maintenance Manual Operation Section starting the engine engine operation and stopping the engine Record Keeping Maintain a record in order to document these items gauge readings maintenance that is performed
26. testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately 103840829 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 engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine com
27. the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement SEBU7828 10 139 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace Illustration 86 g00736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Turbocharger air inlet 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Cleaner Elements 3 Cover the turbocharger air inlet with tape in order to keep dirt out 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator Cleaning the Primary Air C
28. the new fuel filter 2 Spin the fuel filter onto the fuel filter base until the gasket contacts the base Use the rotation index marks on the filters as a guide for proper tightening Tighten the filter for an additional 3 4 turn by hand Do not overtighten the filter NOTICE Do not fill the fuel filters with fuel before installing them The fuel would not be filtered and could be contami nated Contaminated fuel will cause accelerated wear to fuel system parts 10 Install the clean fuel filter bowl 1 on the new fuel filter NOTICE The water separator is under suction during normal engine operation Ensure that the vent plug is tight ened securely to help prevent air from entering the fu el system 11 Open the fuel tank supply valve 12 Start the engine and check for leaks Run the engine for one minute Stop the engine and check the engine for leaks again Detection of leaks is very difficult especially if the engine is running The primary filterAvater separator is under suction A leak will allow air to enter the fuel The air in the fuel can cause low power due to aeration of the fuel If air enters the fuel check the components for overtightening or undertightening SEBU7828 10 149 Maintenance Section Fuel System Primary Filter Water Separator Drain 101254694 Fuel System Primary Filter Water Separator Drain SMCS Code 1260 543 1263 543 se
29. 0 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 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 Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques SEBU7828 10 131 Maintenance Section Cooling System Coolant ELC Change Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Refill Capacitites 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 1500 rpm Run the engine at high idle for one minute in order to purge the air from the c
30. 018 BC 498 29 C 28 3230 Every 2000 51 2 g 59 mL 90 0 mm Ball Bearing 140 0 mm 499 20 2 F Bearing service 1 8 oz 2 oz 3 5 inch 5 5 inch Lubricant hours or 12 OD 80 C months 176 F 90 0 mm 3 5 inch ID 1 This temperature is for a generator set that is equipped vvith a resistive temperature detector RTD 2 Do not exceed 60 C 140 F above the ambient temperature 3 This bearing cannot be greased Refer to this Operation and Maintenance Manual Generator Bearing Replace article for information concerning the replacement of these bearings 2 Do not exceed 50 C 122 F above the ambient temperature 5 VVipe off the excess grease Remove the top grease fitting Install the plug 6 Operate the generator for 1 hour This process 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 Additional Information The generator should continue to operate until the grease stops purging 7 Stop the engine Install the plug in the bottom grease pipe Wipe off the excess grease 8 Install the louver assembly or install the rear plate Refer to Special Instruction REHS4892 Generator Bearing Service for further information 158 Maintenance Section Generator Bearing Temperature Test Record SEBU7828 10 103642839 Generator Bearing T
31. 30 seconds clean the windings and thoroughly dry the windings Refer to Special Instruction REHS9124 Cleaning and Drying of the Generator for more information Note Caterpillar recommends a minimum acceptable insulation resistance of 1 megohm for generators which operate with less than 1000 V of operating or rated voltage Generators which operate at 1000 V of operating or rated voltage should have a minimum insulation resistance as determined by the following equation R V 1000 M R is the minimum insulation resistance V is the rated voltage M is 1 megohm These values are approximate t may be possible to operate a generator vvith less resistance External Heat Ovens The best oven is a forced air drying oven for drying electrical equlpment Radiant ovens sometimes cause localized overheating NOTICE Do not heat the generator too quickly Try to limit the rise in temperature of the insulation and windings to 11 11 C 20 F per hour Failure to do so may cause equipment damage Note Many electrical shops are equipped with baking ovens Heat the generator to approximately 75 C 167 F Never exceed 75 C 167 F until the insulation tester tests correctly for insulation resistance at least 4 hours Alternate Method A tent formed by a tarp or a canvas with heated lamps or a portable space heater may be used as an alternate method A hole should be left in the top
32. 4 hours when either external or internal heat is used to dry the generator Check the windings very hour when circulating current is used to dry the generator Refer to Special Instruction REHS9124 Cleaning and Drying of the Generator for more information Drying is complete when the tests show no increase in resistance and the resistance is above the minimum Record these readings and compare these readings Keep these records for future reference 152 Maintenance Section Generator Dry SEBU7828 10 30 sec 60 sec Illustration 101 g0 1696934 Curve of insulation resistance for windings in good condition 1 Resistance after 30 seconds 2 Resistance after 60 seconds Illustration 101 indicates the curve of the resistance of a normal high resistance in the windings over a period of 60 seconds The resistance after 60 seconds will be greater than the resistance or equal to the resistance after 30 seconds Note If the insulation resistance after 60 seconds is not higher than the resistance after 30 seconds the insulation may be weak 30 sec 60 sec Illustration 102 g01697074 Curve of insulation resistance for windings that are wet or dirty 1 Resistance after 30 seconds 2 Resistance after 60 seconds Illustration 102 indicates the curve of the resistance that is decaying over a period of 60 seconds If the insulation resistance after 60 seconds is not higher than the resistance after
33. CE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines 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 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Note If equipped be sure to drain the heater and any related supply and return lines 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 C
34. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR m Operation and Maintenance Manual 3406C Generator Set ZKC1 Up Generator Set C2G1 Up Generator Set C5G1 Up Generator Set C8G1 Up Generator Set NKM1 Up Generator Set C2Y1 Up Generator Set SAFETY CAT COM SEBU7828 10 119 Maintenance Section Maintenance Interval Schedule 104002881 Maintenance Interval Schedule Prime 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 all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may
35. Record humidity f Remove voltage 10 Evaluate the readings The actual value of the resistance may vary greatly between generators For this reason the insulation s condition must be evaluated Base this evaluation on the comparison between the 60 second resistance readings and the readings that were taken on previous dates These two readings must be taken under similar conditions If a 60 second resistance reading has a 50 percent reduction from the previous reading the insulation may have absorbed too much moisture Switch the insulation tester to the OFF position This will discharge the insulation tester s leads Disconnect the insulation tester s leads Note The results from the insulation resistance checks indicate when cleaning and or repairing is becoming critical Generally insulation resistance will vary greatly with temperature Therefore always test at the same temperature and humidity Refer to Illustration 105 Serial Number Engine Serial Number Generator SEBU7828 10 166 Maintenance Section Insulation Test yac Ot nzos dw buipuiM yc 012 GLI 07 021 001 08 09 oy ty u 191 44209 ay Ag fdnny 2 08 OL eduD sisey uonbinsuT PeAsasqg 3484002 OJ T L 3331 yim UOI DIUDA B9UD SIS9Y UO DINSUT xouddy 89 CE 0c 0 100 b l 001 0001 11909 d
36. Supplemental Coolant Additive SGA Test Add 135 Engine Crankcase Breather Clean 141 Engine Oil Sample Obtain 142 Engine Oil and Filter Change 143 Fuel System Secondary Filter Replace 149 Fuel Tank Water and Sediment Drain 150 Hoses and Clamps Inspect Replace 161 Magnetic Pickups Clean Inspect 167 Radiator Clean 170 Rotating Rectifier Check 171 Every 19 000 L 5000 US gal of Fuel or 250 Service Hours Fan Drive Bearing Lubricate 146 120 Maintenance Section Maintenance Interval Schedule SEBU7828 10 Every 19 000 L 5000 US gal of Fuel or 500 Service Hours Fuel System Primary Filter Water Separator Element Replace 2 8 148 Every 28 400 L 7500 US gal of Fuel or 1000 Service Hours Engine Protective Devices Check 145 Every 114 000 L 30 000 US gal of Fuel or 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 129 Cooling System Coolant Extender ELC Add 132 Cooling System Coolant Sample Level 2 Obtain M 135 Cooling System Water Temperature Regulator Replace rite Saa Aes au 136 Crankshaft Vibration Damper Inspect 137 Engi
37. age Generator Amperage Comments 101942284 Automatic Start Stop Inspect SMCS Code 4462 The generator set must be ready to operate under a load at any time After performing maintenance on the generator set inspect the position of the control switches Ensure the following conditions e The starting system is enabled e The control switches are in the correct position for automatic starting e The switchgear and the automatic transfer switches that are associated with the generator are enabled 126 Maintenance Section Battery Recycle SEBU7828 10 102039199 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e A recycling facility 102153996 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
38. aler for more information 4 Steam clean the core in order to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8 Install the core Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer 102676048 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 Check the alternator and the battery charger for proper operation If the batteries are proper
39. aterpillar dealer or consult Caterpillar Dealer Service Tool Group 130 Maintenance Section Cooling System Coolant DEAC Change SEBU7828 10 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 the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 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 sys
40. avities 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 perform a pressure test A 9S 8140 Pressurizing Pump is used to perform the pressure test 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 102215595 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 e 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 th
41. c IJ 900668636 Illustration 98 1 Bowl 2 Element 3 Drain Bowl 1 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close drain 3 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 101250684 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 2 EE 9 E 1 s LH y 58 y 2 o 1 Illustration 99 g00410343 1 Fuel priming pump 2 Fuel filter 3 Fuel block 4 Fuel filter air purge plug 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 NOTICE Use a suitable container
42. cause the insulation material to separate The insulation material could also separate from the conductors on the windings Abrasion The surfaces of coils and the surfaces of connectors may be damaged by abrasion These surfaces may also be damaged by contamination from other sources An example of these sources would be chemicals or abrasive substances Cracking Cracking of insulation may result from mechanical stress The structure that is used to brace the stator winding will become loose if the problem is not corrected Further mechanical damage or electrical damage may also result Erosion Erosion be caused when foreign substances rub against the surfaces of the insulation 103543200 Water Pump Inspect SMCS Code 1361 040 1361 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure Other potential damage to the engine A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the disassembly and assembly procedure If it is necessary
43. ceeds 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 103847809 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 This includes leaks that are the size of a pin hole Refer to Operation and Maintenance Manual General Hazard Information for more information 162 Maintenance Section Hoses and Clamps Inspect Replace SEBU7828 10 Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following 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 e Hoses which are cracked e Hoses which are soft e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally Flexible pa
44. ck the generator set s vibration level by using a broad spectrum analyzer 103643886 Generator Set Vibration Test Record SMCS Code 4450 081 VI Check for vibration damage Vibration may cause the follovving problems e Coupling wear Loose fittings Fatigue of the metal components of the engine Cracks in the cabinet which surrounds the generator e Cracks in welds Excessive noise e Cracked insulation The following areas are susceptible to vibration damage e Coupling for the generator set e Generator bearings e Stator output leads e Protective sleeving Insulation Exposed electrical connections Transformers e Fuses e Capacitors e 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 the 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 ex
45. e Glycol Concentration e Concentration of SCA e pH e Conductivity The results are reported and recommendations are made according to the results Consult your Caterpillar dealer for information on the benefits of managing your equipment with an 5 5 Coolant Analysis Level 2 This level coolant analysis is recommended when the engine is overhauled Refer to this Operations and Maintenance Manual Overhaul Considerations for further information 136 Maintenance Section Cooling System Water Temperature Regulator Replace SEBU7828 10 Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supplemental coolant additive and the spin on element if equipped at the same time The use of those additives together could result in supplemental coolant additive concen tration exceeding the recommended maximum Pressurized System Hot coolant can cause seri ous burns To open the cooling system fill
46. e 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 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove the cooling system drain plugs 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 Caterpillar Dealer Service Tool Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1
47. ecial 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 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 order to relieve any pressure AR Remove the filler cap for the cooling system a Drain the coolant from the cooling system to a level that is below the hose that is being replaced Drain the coolant into a suitable clean container The coolant can be reused o Remove the hose clamps SEBU7828 10 163 Maintenance Section Hoses and Clamps Inspect Replace Disconnect the old hose co Replace the old h
48. elt cover SEBU7828 10 129 Maintenance Section Circuit Breakers Reset If new belts are installed check the belt adjustment again after 30 minutes of engine operation at the rated rom Replacement of Multiple Drive Belts 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 belts are stretched The additional load on the new belt could cause the new belt to break 102456186 Circuit Breakers Reset SMCS Code 1417 529 1420 529 A B C 60 Q9 901225779 Illustration 83 Push in on the circuit breaker in order to reset the circuit breaker A 60 Amp Circuit Breaker This circuit breaker is for the battery charger and the circuit for the alternator B 15 Amp Circuit Breaker This circuit breaker is for the Electronic Control Module ECM C 20 Amp Circuit Breaker This circuit breaker is for the control panel 102139869 Cooling System Coolant DEAC 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 e The engine overheats frequently e 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 NOTI
49. emperature 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 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 SHUTDOVVN 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 thermome
50. ent with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if
51. er 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 Slowly loosen the cooling system filler cap in order to relieve the pressure Remove the cooling system filler cap Note Always discard drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the proper amount of SCA Refer to the Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Recommendations for more information on SCA requirements 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 103645060 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 overc
52. erator loading When a generator is installed or when a 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 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 The power factor can be referred to as the efficiency of the load This can be expressed as the ratio of KVA 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 Electric sets normally have a low idle setting that is higher than industrial engines Low idle will be approximately 6696 of the full speed that is achieved by 60 Hz units This would be equal to 80 of the full speed that is achieved by 50 Hz units Some electric sets are equipped with Woodward governors and some electric sets are equipped with Caterpillar electronic governors These electric sets have no low idle stop On electric sets with mechanical governors and natural
53. erature Measure Record SMCS Code 4453 082 TA Some generators are equipped with optional 100 Ohm Resistance Temperature Detectors RTD that are mounted in slots of the main stator When the generator set is equipped with RTD modules that are interfaced to an EMCP 3 2 or EMCP 3 3 the RTD modules can be interfaced in order to measure the temperature of the stator Alternately there are measuring devices in the open market that can be interfaced with the RTD Caterpillar recommends the continuous monitoring of the RTD Refer to the specifications in table 33 for the maximum temperatures of the setpoints SEBU7828 10 175 Maintenance Section Turbocharger Inspect Table 33 Maximum Recommended Temperatures for the Setpoint Generator set Alarm Shutdown application Standby 180 C 190 C 356 F 374 F Continuous 155 C 165 C 311 F 329 F 1 If the trend of the operating temperature of the main stator is measured and the temperature is much lower than the recommended setpoints adjust the alarm setpoint and the shutdown setpoint to a lower value in order to ensure that unusual temperature variances are recognized promptly 101539769 Turbocharger Inspect SMCS Code 1052 040 1052 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products f
54. f 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 SEBU7828 10 133 Maintenance Section Cooling System Coolant Level Check 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 pressure 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 contai
55. 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 procedure 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 e 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 Refer to Special Publication SENR9620 Improvi
56. g System Coolant Level Check 133 Electrical Connections Check 137 Engine Air Cleaner Service Indicator Inspect 141 Engine Oil Level Check 142 Fuel Tank Water and Sediment Drain 150 Generator Inspect 8 l 153 Generator Bearing Temperature Test Record 158 Generator Lead Flat Braided Cable Check 158 Jacket Water Heater Check 167 Power Factor Check 170 Space Heater Check 173 Standby Generator Set Maintenance Recommendations 173 Stator VVinding Temperature Measure Record 174 Voltage and Frequency Check 176 Every 6 Months Cooling System Coolant Sample Level 1 Obtaiti 1 nivel ge Ee doeet ee ab 134 Generator Lead Round Cable Check 158 Stator Lead Check 174 Every Year Alternator Inspect l 123 Belts Inspect Adjust Replace 128 Cooling System Coolant Sample Level 2 Obtaihi reden et reete oc ce ee Na 135 Cooling System Supplemental Coolant Additive SCA Test Add 135 Crankshaft Vibration Damper Inspect 137 Engine Clean eret 138 Engine Air Cleaner Element Dual E
57. ge If the shaft is loose an inspection of the internal components should be performed Refer to the Systems Operation Testing and Adjusting Manual for additional information 100891826 Fuel System Prime SMCS Code 1258 548 Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters SEBU7828 10 147 Maintenance Section Fuel System Prime Prime the fuel system in order to fill dry fuel filters You must also prime the fuel system after any one of the following conditions exist The fuel system has run dry e The engine has been in prolonged storage The fuel filter has been cleaned e The fuel filter has been replaced Note If the engine does not have a fuel priming pump refer to Step 4 1 Unlock the priming pump and operate the priming pump until a resistance is felt This procedure will probably require a considerable amount of priming 2 Push in the plunger and hand tighten the plunger NOTICE Do not crank the engine for more than 30 seconds Al low the starter to cool for two minutes before cranking again Turbocharger damage can result if the engine rpm is not kept low until the oil gauge display verifies that the oil pressure is sufficient
58. ge 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 Cylinder Head Assembly Cylinder Packs Oil Pump and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability 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 e Replacing Using out of spec parts can result in the following problems e Unscheduled downtime e Costly repairs Damage to other engine parts e Reduced e
59. hen 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 e Vibration of the engine crankshaft e Vibration of the driven equipment Refer to the following information for more information about the alignment of the generator set Special Instruction SEHS7654 Alignment General Instructions e 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 101228545 Generator Set Vibration Inspect SMCS Code 4450 040 VI Check for vibration damage Vibration may cause the following problems loose fittings loose bolts e excessive noise e cracked insulation SEBU7828 10 161 Maintenance Section Generator Set Vibration Test Record The following areas are susceptible to vibration damage e stator output leads e protective sleeving insulation exposed electrical connections transformers e fuses e capacitors e lightning arrestors Che
60. hen using pressure air wear a pro tective face shield and protective clothing The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This movement will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water SEBU7828 10 171 Maintenance Section Rotating Rectifier Check After cleaning start the engine and accelerate the engine to high idle rpm This procedure will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make
61. icant hours or 12 OD 80 C months 176 F 130 0 mm 5 1 inch ID 241 4644 320 BC LC7 29 C UNIREX Every 4500 60 g NA 100 0 mm Bearing 215 0 mm 20 2 F N3 service 2 1 oz 3 9 inch 8 5 inch hours or 12 OD 60 C months 140 F 2 100 0 mm 3 9 inch ID 243 5220 315 BB LC6100 29 C UNIREX Non Non Non 75 0 mm Bearing 160 0 mm 720 2 F N3 regreasable regreasable regreasable 3 0 inch 6 3 inch LC5000 bearing bearing bearing OD 60 C 140 F 2 75 0 mm 3 0 inch ID 261 3545 307 BB LC2000 29 C UNIREX Non Non Non 35 0 mm Bearing 80 0 mm 720 2 F N3 regreasable regreasable regreasable 1 4 inch 3 1 inch bearing bearing bearing OD 50 C 122 0 35 0 mm 1 4 inch ID 262 5921 307 BC LC2000 29 C UNIREX Non Non Non 35 0 mm Bearing 80 0 mm 720 2 F N3 regreasable regreasable regreasable 1 4 inch 3 1 inch bearing bearing bearing OD 60 C 140 F 35 0 mm 1 4 inch ID 263 0161 309 BC LC3000 29 C UNIREX Non Non Non 45 0 mm Bearing 100 0 mm 720 2 F N3 regreasable regreasable regreasable 1 8 inch 3 9 inch bearing bearing bearing OD 60 C 140 F 45 0 mm 1 8 inch 5P 2448 315 BC 580 29 C 28 3230 Every 2000 51 2 g 59 mL 75 0 mm Ball Bearing 160 0 mm 590 20 2 F Bearing service 1 8 oz 2 oz 3 0 inch 6 3 inch Lubricant hours or 12 OD 80 C months 176 F 75 0 mm 3 0 inch ID 6Y 3955 220 BC 450 29
62. ine 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 well 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 are 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 instruct
63. ine Fluids Recommendations 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 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 102482066 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Cat ELC Extended Life Coolant does not require the frequent additions o
64. ing 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 the 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 Usean induction heater to heat the ball bearings to 107 C 224 6 F for ten minutes in order to install either of the following bearings ball bearings that are
65. ion 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 e Check the condition of the gauges Replace any gauges which are cracked or replace any gauges that can not be calibrated Inspect the Insulation A visual inspection should be initially directed at the areas that are most prone to damage and deterioration The most prone areas to damage and deterioration are listed below e Ground Insulation Ground insulation is insulation that is intended to isolate components that are carrying current from components that are not carrying current e Support Insulation Support insulation is usually made from one of the following items a compressed lamination of fibrous materials polyester or felt pads that have been impregnated with various types of bonding agents There are many different types of damage that can occur in these areas Several of the different types of damage are listed below Thermal Aging Thermal aging can cause the degradation of insulation or the deterioration of insulation An examination of the coils may reveal that the insulation has expanded into the ventilation ducts This is the result of a loss of bond which will
66. ions see Special Publication PEgi0047 How To Take A Good S O S Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 102107152 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 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 properly 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 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 If 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 in order to allow the oil to drain If the engine is equipped
67. ith pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements Inspecting the Primary Air Cleaner Elements Illustration 88 g00281693 Inspect the clean dry primary air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 89 900281694 SEBU7828 10 141 Maintenance Section Engine Air Cleaner Service Indicator Inspect Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protec
68. leaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged
69. lement Clean Replace sss 138 Engine Crankcase Breather Clean 141 Engine Mounts Inspect 2 142 Engine Oil Sample Obtain 142 Engine Oil and Filter Change 143 Engine Performance Test 144 Engine Protective Devices Check 145 Engine Valve Lash Inspect Adjust 145 Fan Drive Bearing Lubricate 146 Fuel System Primary Filter VVater Separator Element Replace 148 Fuel System Secondary Filter Replace 149 Generator Dry sese 151 Generator Set Vibration Inspect 160 Generator Set Vibration Test Record 161 Hoses and Clamps Inspect Replace 161 Insulation 6 164 Magnetic Pickups Clean Inspect 167 Radiator Clean stoce e aea 170 Starting Motor Inspect 174 Varistor Check diete edge tels 176 Varistor 1 176 Water Pump Inspect 2222 177 Every 3 Years Cooling System Coolant DEAC Change 129 Cooling System Coolant Extender ELC Add 132 Cooling System VVater Temperature Regulator Replace A eel i 136 Rotating Rectifier Check
70. lerate valve face wear and valve seat wear and shorten valve life If a damaged rotator is not replaced valve face guttering could result and cause pieces of the valve to fall into the cylinder This can cause piston and cylinder head damage If a valve fails to rotate consult your Caterpillar dealer 100805059 Ether Starting Aid Cylinder Replace If Equipped SMCS Code 1456 510 CD Illustration 94 900104888 Typical example 1 Loosen the ether cylinder clamp Unscrew and remove the empty ether cylinder 2 Remove the used gasket Install the new gasket that is provided with each new ether cylinder 3 Install the new ether cylinder Hand tighten the ether cylinder Tighten the ether cylinder clamp securely 102784507 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD Some of the fan drives have grease fittings and some of the fan drives do not have grease fittings If there is no grease fitting periodic lubrication is not required The fan drive requires grease only if the fan drive is equipped with a zerk Illustration 95 900746166 Typical location of the grease fitting if equipped that is for the fan drive bearing The pulley is shown with the belt guards that have been removed Lubricate the grease fitting that is on the fan drive bearing with High Speed Ball Bearing Grease or the equivalent Inspect the fan drive pulley assembly for wear or for dama
71. ly 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 101148030 Annunciator Panel Inspect SMCS Code 4490 040 Inspect the annunciator panel for good condition Perform a lamp test All of the warning lamps should illuminate If a 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 following parameters during normal engine operation Engine Oil Pressure Engine Coolant Temperature 124 Maintenance Section Annunciator Panel Inspect SEBU7828 10 e Inlet Air Restriction e Exhaust Temperature 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 establish the normal gauge readings for the engine A gauge reading that is abnormal may indica
72. mer 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 A phase voltage is being generated The phase voltages are balanced e The phase voltages change relative to engine speed The generator set functional test consists of the 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 E and E from the voltage regulator Disconnect the generator from the load 3 Connect a 12 VDC automotive battery to wires E and E 4 Measure the AC voltage across the low voltage terminals of the transformer that correspond to the following generator terminals T1 and T2 T2 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 w
73. nal 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 1 Take the generator out of service 2 Visually inspect the generator for moisture If moisture exists do not perform this insulation test Dry the unit first Refer to Special Instruction SEHS9124 Cleaning and Drying of Electric Set Generators 3 Inspect the installation Determine the equipment that will be tested by the insulation tester 4 Discharge the capacitance of the windings 5 solate the stator windings of the generator by disconnecting all other leads and cables from the generator terminals This includes connections to the voltage regulator the control panel the Switchgear or other devices 6 Connect the insulation tester s RED lead to ground 7 Connect the insulation tester s BLACK lead to the wye point or star point of the generator s windings 8 For units that are 600 volts or less set the voltage to 500 Volts For units that are more than 600 volts set the voltage to 1000 Volts 9 Use the 30 60 Time Resistance Method a Apply voltage b Observe the readings at 30 seconds Observe the readings at 60 seconds c Record the 60 second reading This reading must be corrected for temperature d Record temperature e
74. ndicate an insulation breakdown An insulation breakdown requires more than cleaning An insulation breakdown requires repair A high pressure wash is normally an effective way to clean windings This includes windings that have been exposed to flooding or windings that have been contaminated by salt A solution of hot water and detergent is used for this method of cleaning A high pressure wash sprays a high velocity fluid stream of this solution over the generator that is being cleaned This detergent washing is followed by multiple sprays of clean water The clean water is used in order to remove the detergent or the clean water is used in order to dilute the detergent 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 It may be necessary to use solvents if the generator is contaminated with oil or if the generator is contaminated with grease 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 bear
75. ne Mounts Inspect 142 Engine Valve Lash Inspect Adjust 145 Engine Valve Rotators Inspect 145 Every 114 000 L 30 000 US gal of Fuel or 3000 Service Hours or 3 Years Cooling System Coolant DEAC Change 129 Crankshaft Vibration Damper Inspect 137 Every 190 000 L 50 000 US gal of Fuel or 5000 Service Hours Alternator 123 Magnetic Pickups Clean Inspect 167 Starting Motor Inspect 174 Turbocharger 175 Water Pump Inspect 177 Every 228 000 L 60 000 US gal of Fuel or 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 131 Overhaul Generator Bearing Inspect Replace 154 Overhaul Considerations 167 SEBU7828 10 121 Maintenance Section Maintenance Interval Schedule 104002886 Maintenance Interval Schedule Standby 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 all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installa
76. new and ball bearings that have been inspected Mount the bearings on the shaft To reinstall the hub heat the hub to 400 C 752 0 F for three hours Mount the hub to the shaft Ensure that the tube of the grease gun is filled with grease 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 Stop the engine Install the bracket drain plug Wipe off the excess grease SEBU7828 10 155 Maintenance Section Generator Bearing Lubricate For greasing intervals follow the recommendations on the lubrication plate if equipped or refer to Maintenance Schedule Generator Bearing Lubricate Whenever the bearings are greased repeat Step 1 DO NOT MIX GREASES 103997526 Generator Bearing Lubricate SMCS Code 4471 086 Lubricating Process If Applicable Note If the generator already has a visible grease point go to Step 4 1 Remove either the louver assembly or the rear plate from the rear of the generator housing 2 Remove the top grease pipe plug and remove the lower grease pipe plug 3 Install a grease fitting in the grease pipe 4 Grease the bearings with the appropriate grease from Table 28
77. ng Fuel System Durablity f 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 SEBU7828 10 151 Maintenance Section Generator Dry 103997990 Generator Dry SMCS Code 4450 569 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 Refer to this Operation and Maintenance Manual Generator Isolating for Maintenance for information regarding the procedure to isolate the generator in a safe manner Refer to Special Instruction REHS9124 Cleaning and Drying of the Generator for further necessary information Of the following methods for drying the generator the use of external heat is preferred e External heat e Internal heat e Combination of external and internal heat e Circulating current External heat is the most preferable method Insulation drying time can vary from a few hours to several days The drying time depends on the moisture content and the process for drying that is used Note Drying sometimes does not produce the req
78. ngine efficiency e 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 Crankshaft Bearings Valve Rotators and Crankshaft Seals The following components may not last until the second overhaul SEBU7828 10 169 Maintenance Section Overhaul Considerations e Thrust bearings e Main bearings e Rod bearings e Valve rotators e Crankshaft seals 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 e Deflection e Damage to the journals Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e Rod bearing e Main bearings 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 e Camshaft bearings Camshaft followers Caterpillar Inc recommends replacing the crankshaft vibration damper
79. ngine which operates outside of normal conditions is operating in a severe service application An engine that operates in a severe service application may need more frequent maintenance intervals in order to maximize the following conditions e Reliability e Service life The number of individual applications cause the impossibility of identifying all of the factors which may contribute to severe service operation Consult your Caterpillar dealer for the unique maintenance that may be necessary for your engine An application is a severe service application if any of the following conditions apply Severe Environmental Factors e Frequent operation in dirty air Frequent operation at an altitude which is above 1525 m 5000 ft Frequent operation in ambient temperatures which are above 32 C 90 F Frequent operation in ambient temperatures which are below 0 C 32 F Severe Operating Conditions e Frequent operation with inlet air which has a corrosive content Operation with inlet air which has a combustible content Operation which is outside of the intended application Operation with a plugged fuel filter Extended operation at low idle more than 2096 of hours Frequent cold starts at temperatures below 0 C 32 F Frequent dry starts starting after more than 72 hours of shutdown Frequent hot shutdowns shutting down the engine without the minimum of 2 minutes to 5 minutes of cool down time Opera
80. ning 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 101197583 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool 4 Illustration 84 g00285520 Cooling system filler cap 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 Remove the cooling system filler cap slowly in order to relieve pres
81. 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 consult your Caterpillar dealer SEBU7828 10 135 Maintenance Section Cooling System Coolant Sample Level 2 Obtain 101987714 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 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 Diesel Engines Fluids Recommendations
82. of the tarp for ensuring proper circulation through the generator and for permitting the moisture to exhaust Heat the generator to approximately 75 C 167 F Never exceed 75 C 167 F until the insulation tester tests correctly for insulation resistance at least 4 hours Internal Heating If generators operate under one of the following conditions the electric space heaters should be installed as part of the generator SEBU7828 10 153 Maintenance Section Generator Inspect Generators are in damp environments and go for long periods of time without operation e Generators operate regularly in an environment with moisture laden air Circulating Current Drying can be accomplished by circulating low voltage current through the windings Since the voltage is low the breakdown of the insulation will not occur as the breakdown might have occurred with normal operation and wet insulation Refer to Special Instruction REHS9124 Cleaning and Drying of the Generator for this procedure 101461264 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 Refer to Safety Section Generator Isolating for Maintenance for information regarding the procedure to safely isolate the generator Prope
83. on Test the Service Indicator Service indicators are important instruments e 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 N m 18 Ib in 101564253 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE Perform this maintenance with the engine stopped If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage 142 Maintenance Section
84. on Engine Clean SEBU7828 10 101866598 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 Water or condensation can cause damage to gen erator components Protect all electrical components from exposure to water 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 Do not steam clean the generator Water may damage the generator Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Easy detection of fluid leaks Maximum heat transfer characteristics Ease of maintenance 101553486 Engine Air Cleaner Element Dual Element Clean Replace SMCS Code 1054 037 1054 510 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 elem
85. on The assembly can use a 12 volt battery or a variable DC power supply as a power source Refer to Step 3 for an assembly that uses a 12 Volt battery Refer to Step 4 for an assembly that uses a variable DC power supply Illustration 108 901015807 A Exciter Field B Diode 1 Amp C Rheostat 50 Ohms 300 Watts 3 Connect a 12 volt battery in series with a rheostat C of 50 Ohms 300 Watts and a diode B on both wires for the exciter field 5 and 6 Go to step 5 Illustration 109 901015808 D AC supply E Variable power supply F Exciter field G Diode bridge 4 Connect a variable power supply and a diode bridge to both of the wires for the exciter field 5 and 6 5 The assembly should have characteristics that are compatible with the power for the field excitation of the generator 172 Maintenance Section Severe Service Application Check SEBU7828 10 6 Operate the generator set at rated speed 7 Gradually increase the current of the exciter field by adjusting the rheostat or the variable power supply Measure the output voltage and the current at no load Measure the output voltage and measure the current at no load 8 The generator is operating properly when the output voltage is at the rated value and the output voltage is balanced within one percent for the rated level of excitation 103937573 Severe Service Application Check SMCS Code 1000 535 An e
86. ooling 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 engines 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 deale
87. ose 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 death 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 disconnec
88. ound 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 101951994 Insulation Test SMCS Code 4453 081 4454 081 4457 081 4470 081 Recommended Periodic Insulation Tests 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 Table 30 Tools Needed 142 5055 Insulation Testing Gp 9U 6003 Insulation Testing Gp Periodically use an insulation tester to check the insulation resistance of the generator s main stator winding The frequency of this test is determined by the generator s environment Previous insulation tester readings will also determine the f
89. ponent life Ensure thatthe 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 101597115 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to help prevent being burned by hot oil or spray Engine valve rotators rotate the valves when the engine runs This helps to prevent deposits from building up on the valves and the valve seats Perform the following steps after the engine valve lash is set but before the valve covers are installed 1 Start the engine according to Operation and Maintenance Manual Engine Starting Operation Section for the procedure 146 Maintenance Section Ether Starting Aid Cylinder Replace SEBU7828 10 2 Operate the engine at low idle 3 Observe the top surface of each valve rotator The valve rotators should turn slightly when the valves close NOTICE A valve rotator which does not operate properly will acce
90. 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 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 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 SEBU7828 10 177 Maintenance Section Water Pump Inspect 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 connect
91. r SEBU7828 10 137 Maintenance Section Crankshaft Vibration Damper Inspect 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 100894991 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Rubber Damper Your engine may be equipped with a rubber damper The rubber damper uses a ring which is mounted in rubber in order to reduce vibrations in the crankshaft Inspect the damper and repair or replace the damper for any of the following reasons e There is deterioration and cracking of the rubber There is slippage of the outer ring from the original position The engine has had a failure because of a broken crankshaft Analysis of the oil has revealed that the front main bearing is badly worn There is a large amount of gear train wear that is not caused by lack of oil Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement Vi
92. r 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 ventilation 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 e The type of enclosure of the generator The vol
93. repairs if necessary 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 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 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 101936391 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 Use the following procedure in order to test the rotating rectifier 1 Stop the generator set Disconnect the wires for the AVR and isolate the wires for the AVR 2 Make an assembly for separate excitati
94. requency of this test Test the main stator windings with an insulation tester in the following situations The generator set is started for the first time The generator set is removed from storage e The generator set is operating in a humid environment Test every three months The generator set is not protected from the elements in an enclosed area Test every three months The generator set is installed in an enclosed area This area needs to be low in humidity and this area needs to have steady temperatures Test every twelve months minimum SEBU7828 10 165 Maintenance Section Insulation Test e The generator set has not been run under load for three months Test the generator set vveekly Use space heaters around the generator set if the generator is exposed to a sea vvater environment or if the humidity is above 75 percent Also use space heaters if a test result vvas belovv 3 megohms Space heaters must be used whenever the generator set is not under load Space heaters must also be used whenever salt is present or whenever high humidity is present Using a space heater in this fashion is the only vvay to maintain insulation tester readings above one megohm Use space heaters only when the generator is not running For additional information refer to Special Instruction SEHS9124 Cleaning and Drying of Electric Set Generators Recommended Procedure for A Periodic Insulation Test Perso
95. rom oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge
96. rt of the hose that is kinked or crushed Armoring that is embedded in the outer covering e 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 e Cracking e 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 Type 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 This 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 Replace 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 open ing any compartment or disassembling any compo nent containing fluids Refer to Sp
97. s 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 X 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 Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels SEBU7828 10 143 Maintenance Section Engine Oil and Filter Change 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 Engine model e Service hours on the eng
98. sconic Damper Your engine may be equipped with a visconic damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional vibration Inspect the damper for evidence of fluid leaks If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous smooth and difficult to remove from surfaces If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace the crankshaft seals Inspect the damper and repair or replace the damper for any of the following reasons The damper is dented cracked or leaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft Analysis of the oil has revealed that the front main bearing is badly worn There is a large amount of gear train wear that is not caused by a lack of oil Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement 101228274 Electrical Connections Check SMCS Code 4459 535 Check all exposed electrical connections for tightness Check the following devices for loose mounting or for physical damage e transformers e fuses e capacitors lightning arrestors Check all lead wires and electrical connections for proper clearance 138 Maintenance Secti
99. se the shape of fuel spray pattern that comes out of the nozzles will not be cor rect 900290109 Illustration 96 8 Loosen the fuel line nuts at the valve cover base Loosen these line nuts one at a time 9 Operate the priming pump until the flow of fuel from the fuel line is continuous and the flow of fuel is free of air bubbles 10 Push in the plunger and hand tighten the plunger If the engine does not have a fuel priming pump crank the engine 11 Tighten each fuel line nut before you loosen the next fuel line nut Tighten the fuel line nuts to a torque of 40 7 N m 30 5 Ib ft Continue this procedure until all of the fuel lines have been cleared of any air Before you start the engine make sure that the fuel line nuts are properly tightened Also make sure that the priming is locked 148 Maintenance Section SEBU7828 10 Fuel System Primary Filter Water Separator Element Replace 102049797 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Water in the fuel can cause the engine to run rough Water in the fuel may cause an electronic unit injector to fail If the fuel has been contaminated with water the element should be changed before the regularly scheduled interval The primary filter water separator also provides filtration in order to help extend the life of the secondary fuel filter The element should be changed regularl
100. sent disconnect the povver source to terminal H1 terminal H2 terminal H3 and terminal H4 and check for 3 to 12 ohms resistance If there is no resistance check the generator service manual for further information 103108463 Standby Generator Set Maintenance Recommendations SMCS Code 4450 041 A standby generator set may not need to be used very often However the generator set is usually needed for operation in an emergency situation Maintenance of the standby generator set is very important for the following reasons The generator set must always be in excellent operating condition The generator set must be ready to work under load at any time Establishing a Preventive Maintenance Program will provide these benefits e Maximum availability of the standby generator set e Longer service life for the generator set e Minimum of expensive repairs Your Caterpillar dealer can help you to establish an effective Preventive Maintenance Program for your generator set Consult your Caterpillar dealer for details Maintenance and Operation Procedures 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
101. sure 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass Illustration 85 g00103639 Typical filler cap gaskets 134 Maintenance Section Cooling System Coolant Sample Level 1 Obtain SEBU7828 10 3 Clean the cooling system filler cap and check the condition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap 4 Inspect the cooling system for leaks 104035949 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 Cat DEAC Diesel Engine Antifreeze Coolant e Commercial heavy duty coolant antifreeze Table 27 Recommended Interval Type of Coolant Level 1 Level 2 Ca
102. t 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 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 101042067 Engine Performance Test SMCS Code 1000 081 Operate the engine for a minimum of two hours at a minimum load of 60 percent e Monitor the operation of the generator set Observe the gauges Ensure that the gauges are in the normal ranges SEBU7828 10 145 Maintenance Section Engine Protective Devices Check Record the data Maintain a record of the data for the engine performance Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During
103. t 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 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 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
104. t against dirt and damage wrap the primary air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 101900118 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 Illustration 90 900103777 Typical service indicator Observe 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 e The red piston locks in the visible positi
105. tage rating of the generator The type of dirt that is being removed Cleaning Assembled Generators 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 more firmly attached to the surface 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 154 Maintenance Section Generator Bearing Inspect Replace SEBU7828 10 Cleaning Disassembled Generators 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 i
106. te a problem with engine operation Abnormal gauge readings may also indicate a possible problem with the gauge Record the Performance of the Engine Table 25 is offered as an example for use as a daily engine log Record the engine performance regularly Retain the recorded information for reference Compare the recorded data in order to provide an indication of engine condition Records of engine performance are an important element of a maintenance program Record information about the engine operation on a daily basis This will help to reveal the trends of the engine performance Records of engine performance will also provide a baseline for evaluating the mechanical condition of the engine The data on engine performance can help to predict problems with operation This data can provide your Caterpillar dealer with information that is useful for recommending maintenance management information A maintenance program that is properly managed will provide your engine with an optimum service life SEBU7828 10 125 Maintenance Section Automatic Start Stop Inspect Table 25 Daily Engine Log Date Authorization Engine Serial Number Engine Hours Engine Speed Percent Load Ambient Temperature Inlet Air Restriction Engine Coolant Temperature Engine Oil Temperature Engine Oil Pressure System Battery Voltage Exhaust Manifold Temperature Generator Volt
107. ted 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 in order to allow 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 sure 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
108. tem filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water If equipped be sure to flush the heater and any related supply and return lines Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques Cooling Systems with Heavy Deposits or Plugging Note For the following procedure to be effective there must be some active flow through the cooling system components 1 Flush the cooling system with clean water in order to remove any debris Note If equipped be sure to flush the heater and any related supply and return lines 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque Specifications for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 0 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 90 minutes The coolant temperature should be at least 82 C 18
109. ter 104032220 Generator Lead Flat Braided Cable Check SMCS Code 4450 535 oe ih i K lil MILI Illustration 103 902146533 Typical flat braided conductor The generator set may have braided square conductors or multiple round cables between the generator and the breaker Check braided conductors for signs of wear Pay particular attention to the conductor protective sleeve insulation at the housing for the breaker and in the generator terminal box Replace the mats or the cable immediately if the rubber mats or the insulation on the braided cables show signs of wear at points of contact If your generator set does not have rubber mats in place contact your Cat dealer 104032349 Generator Lead Round Cable Check SMCS Code 4450 535 The generator set may have braided square conductors or multiple round cables between the generator and the breaker SEBU7828 10 159 Maintenance Section Generator Load Check Illustration 104 g02223453 Round generator lead cables Ensure that the generator output leads are routed out of the generator in a manner that prevents the leads from rubbing against metal objects Visually inspect the following areas for cracking and physical damage e Stator output leads e Protective sleeving Insulation 101228480 Generator Load Check SMCS Code 4450 535 LA During normal operation monitor the power factor and monitor gen
110. ter for an additional 3 4 turn by hand Do not overtighten the filter 6 Open the fuel tank supply valve and prime the fuel system 103645042 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 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 PECJO003 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 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
111. 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 128 Maintenance Section Battery or Battery Cable Disconnect SEBU7828 10 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 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 101492654 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
112. ting and check for the proper frequency setting Check for stability For the correct voltage and frequency refer to the generator set s Serial Plate 101908686 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 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 e The guards must be in the proper place Repair 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 e Ensure that cooling lines are properly clamped Check for leaks Check the condition of all pipes e Inspect the water
113. tion of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Battery Recycle sese 126 Circuit Breakers Reset 129 Cooling System Coolant Sample Level 2 Obtain aa Real 135 Ether Starting Aid Cylinder Replace 146 Fuel System Prime 146 Fuel System Primary Filter VVater Separator DEA Ree etu terere pete a 149 Generator Bearing Lubricate 155 Generator Load Check 159 Generator Set Test l 159 Rotating Rectifier Test 171 Every VVeek Automatic Start Stop Inspect 125 Battery Charger Check 2 26 126 Battery Electrolyte Level Check 127 Coolin
114. tion above the engine rated speed Operation below the peak torque speed Operating with fuel which does not meet the standards for distillate diesel fuel as stated in Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations Distillate Diesel Fuel Operating with fuel which contains greater than 1000 ppm 0 1 sulfur Operating with a blend of distillate fuel which contains more than 5 percent biodiesel Improper Maintenance Procedures Maintenance Procedures Which May Contribute to a Severe Service Application Inadequate maintenance of fuel storage tanks from causes such as excessive water sediment and microorganism growth Extending maintenance intervals beyond the recommended intervals Using fluids which are not recommended in Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations Extending maintenance intervals for changing the engine oil and engine coolant without S O S validation Extending maintenance intervals for changing air filters oil filters and fuel filters SEBU7828 10 173 Maintenance Section Space Heater Check Failure to use a water separator Using filters which are not recommended by Special Publication PEWJ0074 2008 Cat Filter and Fluid Application Guide Storing the engine for more than 3 months but less than 1 yr For information about engine storage refer to Special Publication SEHS9031
115. tion at full load will result in a lower average power demand and reduced fuel consumption 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 increased oil consumption excessive engine blowby and reduced power Arctic temperatures extremely high temperatures corrosive environments or extremely dusty conditions contribute to premature wear and the need for an overhaul The following factors are important when a decision is being made on the proper time for an engine overhaul e The need for preventive maintenance The quality of the fuel that is being used e The operating conditions The results of the S O S analysis Oil Consumption as an Overhaul ndicator 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 168 Maintenance Section Overhaul Considerations SEBU7828 10 The oil consumption rate brake specific oil consumption is measured in grams per kW h Ib per bhp The
116. to catch any fuel that might spill Clean up any spilled fuel immediately t may necessary to relieve residual fuel pressure from the fuel system before removing the fuel filter Loosen the fuel filter air purge plug 4 in order to purge any residual pressure NOTICE Do not loosen fuel lines or fittings at the fuel manifold or ECM The engine components may be damaged 2 Remove the used fuel filter 3 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 4 Apply clean diesel fuel to the new fuel filter gasket NOTICE In order to maximize fuel system life and prevent premature wear out from abrasive particles in the fuel a two micron absolute high efficiency fuel filter is required for all Caterpillar Electronic Unit Injectors Caterpillar High Efficiency Fuel Filters meet these requirements Consult your Caterpillar dealer for the proper part numbers 150 Maintenance Section Fuel Tank VVater and Sediment Drain SEBU7828 10 NOTICE Do not fill the secondary fuel filter with fuel before in stalling The fuel would not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts 5 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Use the rotation index marks on the filters as a guide for proper tightening Tighten the fil
117. to remove the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed
118. ue UD S S M uoljo nsu 14 g00633226 Illustration 105 SEBU7828 10 167 Maintenance Section Jacket Water Heater Check 101917546 Jacket Water Heater Check Standby Generator Sets If Equipped SMCS Code 1383 535 Jacket water heaters help to improve startability in ambient temperatures that are below 21 C 70 F All installations that require automatic starting should have jacket water heaters Check the operation of the jacket water heater For an ambient temperature of 0 C 32 F the heater should maintain the jacket water coolant temperature at approximately 32 C 90 F Magnetic Pickups Clean Inspect SMCS Code 1907 040 7400 040 7400 070 UI 5 g00422322 Illustration 106 1 Magnetic pickup 2 Flywheel housing 22 2 Illustration 107 g00293337 Typical magnetic pickup 1 Remove the magnetic pickup 1 from the flywheel housing Check the condition of the end of the magnetic pickup Check for signs of wear and contaminants 2 Clean the metal shavings and other debris from the face of the magnet 3 Install the magnetic pickup and adjust the magnetic pickup Refer to the Service Manual for the installation procedure 102436705 Overhaul Considerations SMCS Code 7595 043 Reduced hours of opera
119. uired results The use of a qualified rebuild shop may be necessary for dipping and drying the generator OE 74100 80 60 4 G 2440 56728810420 38 2 20 12 M 4 HA Gf 8 24405672881041 20 3 g02175752 a Illustration 100 Typical curves of the resistance in the insulation that is drying 1 Curve of the temperature in the vvindings 2 Heat turned off 3 Drying time in hours 4 Temperature in degrees celsius 5 Curve of insulation resistance during drying process 6 Insulation resistance in megohms Note When new insulation or very damp insulation is being dried the resistance will probably fall rapidly The rapid fall in resistance is the result of the temperature being raised to a value for drying After reaching a minimum for a given temperature the resistance will again rise as moisture is driven out of the insulation The actual values will vary with each situation Refer to Illustration 101 If the windings or insulation are wet during the resistance measurement use a 5 megohm resistor for protection in series with red positive lead This procedure limits the voltage across the circuit under the test Use this method until drying is well in progress and the resistance has reached an acceptable level Check the windings after every
120. ult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 93 g00103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket 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 gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations for more information 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 2 Start the engine and run the engine a
121. 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 144 Maintenance Section Engine Performance Test SEBU7828 10 Replace the 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 1U 8760 Chain Wrench 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 small amounts of debris in the oil filter Cons
122. y Install a vacuum gauge Change the element for the primary filterAvater separator if the pressure is at 50 to 70 kPa 15 to 20 inches Hg Replace the Element 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 D g00668636 Illustration 97 1 Bowl 2 Element 3 Drain 1 Stop the engine 2 Turn the start switch to the OFF position 3 Shut off the fuel tank supply valve to the engine 4 If the primary fuel filter is equipped with a drain valve 3 open the drain valve in order to drain any fuel from the filter case Close the drain valve 3 NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 5 Remove the fuel filter bowl 1 and wash the fuel filter bowl with clean diesel fuel 6 Remove the fuel filter 2 7 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 8 Apply clean diesel fuel to the new fuel filter gasket NOTICE In order to maximize fuel system life and prevent pre mature wear out from abrasive particles in the fuel use Caterpillar fuel filters Consult your Caterpillar dealer for proper part num bers 9 Install

3406C Generator Sets - Maintenance Intervals - Safety

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