Manual de Grupo Electrógeno Caterpillar

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7572-06July 2010

Operation andMaintenanceManualG3406 and G3412 Generator SetsGNA1-Up (Generator Set)R7A1-Up (Generator Set)R7E1-Up (Generator Set)KAP1-Up (Generator Set)KAR1-Up (Generator Set)

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SEBU7572-06 83Maintenance Section

Maintenance Interval Schedule

i03996922

Maintenance Interval Schedule(Standby)SMCS Code: 1000; 4450; 7500

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible for theperformance of all maintenance including thefollowing procedures: all adjustments, the use ofproper lubricants, fluids, filters, and the installationof new components due to normal wear and aging .The performance of this product may be diminished ifproper maintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occursfirst in order to determine the maintenance intervals:fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, allmaintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Recycle .................................................. 93Battery or Battery Cable - Disconnect .................. 95Bearing - Inspect ................................................... 96Generator - Dry ................................................... 120Generator Set Alignment - Check ....................... 125Rotating Rectifier - Test ...................................... 143Varistor - Inspect ................................................. 149Varistor - Test ...................................................... 150Winding - Test ..................................................... 152

Every Week

Air Starting Motor Lubricator Oil Level - Check .... 92Air Tank Moisture and Sediment - Drain ............... 92Automatic Start/Stop - Inspect .............................. 93Battery Charger - Check ....................................... 93Battery Electrolyte Level - Check .......................... 94Bearing Temperature - Measure/Record .............. 99Control Panel - Inspect ....................................... 100Cooling System Coolant Level - Check .............. 102Electrical Connections - Check ........................... 107Engine Air Cleaner Service Indicator - Inspect .... 110Engine Air Precleaner - Clean ............................. 111Engine Oil Level - Check ..................................... 113Fuel System Fuel Filter Differential Pressure -Check ................................................................. 119Generator - Inspect ............................................. 122Generator Lead - Check ..................................... 123Generator Load - Check ..................................... 123

Jacket Water Heater - Check .............................. 136Power Factor - Check ......................................... 142Space Heater - Check ........................................ 144Standby Generator Set MaintenanceRecommendations ............................................ 145Stator Winding Temperature - Measure/Record .. 147Voltage and Frequency - Check ......................... 150Walk-Around Inspection ...................................... 151

Every Year

Actuator Control Linkage - Lubricate .................... 91Air Starting Motor Lubricator Bowl - Clean ........... 91Alternator - Inspect ............................................... 92Bearing (Ball) - Lubricate ...................................... 95Belts - Inspect/Adjust/Replace .............................. 99Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 104Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 104Crankcase Blowby - Measure/Record ................ 105Crankshaft Vibration Damper - Inspect ............... 106Cylinder Pressure - Measure/Record ................. 106Engine - Clean .................................................... 108Engine Air Cleaner Element - Replace ............... 108Engine Crankcase Breather - Clean .................... 112Engine Mounts - Check ....................................... 112Engine Oil Sample - Obtain ................................. 113Engine Oil and Filter - Change ............................ 114Engine Performance - Test .................................. 116Engine Protective Devices - Check ..................... 116Engine Speed/Timing Sensor - Clean/Inspect ..... 117Engine Valve Lash - Inspect/Adjust ..................... 117Engine Valve Rotators - Inspect .......................... 118Exhaust Piping - Inspect ...................................... 119Gas Pressure Regulator - Check ......................... 119Gas Pressure Regulator Condensation - Drain .. 120Generator Set - Test ........................................... 124Generator Set Vibration - Test/Record ................ 125Hoses and Clamps - Replace ............................. 126Ignition System Spark Plugs - Inspect/Replace .. 126Ignition System Timing - Check/Adjust ............... 131Ignition System Transformer Resistance - Test .. 132Inlet Air System - Inspect .................................... 132Insulation - Test ................................................... 132Radiator - Clean .................................................. 142Speed Sensor - Clean/Inspect ............................ 144Starting Motor - Inspect ...................................... 146Stator Lead - Check ............................................ 146Valve Stem Projection - Measure/Record ........... 148Varistor - Check .................................................. 149Varistor - Inspect ................................................. 149Water Pump - Inspect ......................................... 152

Every 3 Years

Batteries - Replace ............................................... 93Cooling System Coolant (NGEC) - Change ........ 100Exhaust Bypass - Inspect .................................... 118Governor - Inspect .............................................. 126Hoses and Clamps - Replace ............................. 126Ignition System Spark Plug Wires - Replace ...... 126

84 SEBU7572-06Maintenance SectionMaintenance Interval Schedule

Ignition System Transformer Resistance - Test .. 132Rotating Rectifier - Check ................................... 142Turbocharger - Inspect (S/N: CRE1-Up; CRF1-Up;CTP1-Up; CTS1-Up) ......................................... 147

Commissioning

Generator Set Alignment - Check ....................... 125



i03996896

Maintenance Interval Schedule(Turbocharged Aftercooled)SMCS Code: 1000; 4450; 7500

S/N: R7E1-Up; CRE1-Up

S/N: R7A1-Up; CRF1-Up

S/N: KAP1-Up; CTP1-Up

S/N: KAR1-Up; CTS1-Up




When Required

Battery - Recycle .................................................. 93Battery or Battery Cable - Disconnect .................. 95Engine Air Cleaner Element - Replace ............... 108Engine Oil and Filter - Change ............................ 114Generator - Dry ................................................... 120Generator Set - Test ........................................... 124Generator Set Alignment - Check ....................... 125Overhaul Considerations .................................... 140Rotating Rectifier - Test ...................................... 143Valve Stem Projection - Measure/Record ........... 148Varistor - Inspect ................................................. 149Varistor - Test ...................................................... 150Winding - Test ..................................................... 152

Daily

Air Starting Motor Lubricator Oil Level - Check .... 92Air Tank Moisture and Sediment - Drain ............... 92Bearing Temperature - Measure/Record .............. 99Control Panel - Inspect ....................................... 100Cooling System Coolant Level - Check .............. 102Electrical Connections - Check ........................... 107

Engine Air Cleaner Service Indicator - Inspect .... 110Engine Air Precleaner - Clean ............................. 111Engine Oil Level - Check ..................................... 113Fuel System Fuel Filter Differential Pressure -Check ................................................................. 119Generator - Inspect ............................................. 122Generator Load - Check ..................................... 123Power Factor - Check ......................................... 142Stator Winding Temperature - Measure/Record .. 147Voltage and Frequency - Check ......................... 150Walk-Around Inspection ...................................... 151

Every Week

Generator Lead - Check ..................................... 123

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 103


Actuator Control Linkage - Lubricate .................... 91Battery Electrolyte Level - Check .......................... 94Belts - Inspect/Adjust/Replace .............................. 99Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 104Crankcase Blowby - Measure/Record ................ 105Crankshaft Vibration Damper - Inspect ............... 106Engine - Clean .................................................... 108Engine Crankcase Breather - Clean .................... 112Engine Mounts - Check ....................................... 112Engine Oil Sample - Obtain ................................. 113Engine Protective Devices - Check ..................... 116Engine Valve Lash - Inspect/Adjust ..................... 117Engine Valve Rotators - Inspect .......................... 118Exhaust Piping - Inspect ...................................... 119Gas Pressure Regulator - Check ......................... 119Ignition System Spark Plugs - Inspect/Replace .. 126Ignition System Timing - Check/Adjust ............... 131Inlet Air System - Inspect .................................... 132Radiator - Clean .................................................. 142

Initial 750 Service Hours

Cylinder Pressure - Measure/Record ................. 106Engine Speed/Timing Sensor - Clean/Inspect ..... 117Speed Sensor - Clean/Inspect ............................ 144Valve Stem Projection - Measure/Record ........... 148


Gas Pressure Regulator Condensation - Drain .. 120


Bearing (Ball) - Lubricate ...................................... 95

Every Year

Varistor - Check .................................................. 149Varistor - Inspect ................................................. 149



Air Starting Motor Lubricator Bowl - Clean ........... 91Alternator - Inspect ............................................... 92Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 104Cylinder Pressure - Measure/Record ................. 106Engine Speed/Timing Sensor - Clean/Inspect ..... 117Generator Set Vibration - Test/Record ................ 125Ignition System Transformer Resistance - Test .. 132Speed Sensor - Clean/Inspect ............................ 144Starting Motor - Inspect ...................................... 146Stator Lead - Check ............................................ 146Water Pump - Inspect ......................................... 152


Insulation - Test ................................................... 132Rotating Rectifier - Check ................................... 142Turbocharger - Inspect ........................................ 147

Between 8000 and 12 000 Service Hours

Overhaul (Top End) ............................................. 138

Between 16 000 and 24 000 Service Hours

Overhaul (Major) ................................................. 136


Bearing - Inspect ................................................... 96

Every 24 000 Service Hours or 3 Years

Cooling System Coolant (NGEC) - Change ........ 100Hoses and Clamps - Replace ............................. 126



i03996895

Maintenance Interval Schedule(Naturally Aspirated)SMCS Code: 1000; 4450; 7500








When Required

Battery - Recycle .................................................. 93Battery or Battery Cable - Disconnect .................. 95Engine Air Cleaner Element - Replace ............... 108Engine Oil and Filter - Change ............................ 114Generator - Dry ................................................... 120Generator Set - Test ........................................... 124Generator Set Alignment - Check ....................... 125Overhaul Considerations .................................... 140Rotating Rectifier - Test ...................................... 143Valve Stem Projection - Measure/Record ........... 148Varistor - Inspect ................................................. 149Varistor - Test ...................................................... 150Winding - Test ..................................................... 152

Daily

Air Starting Motor Lubricator Oil Level - Check .... 92Air Tank Moisture and Sediment - Drain ............... 92Bearing Temperature - Measure/Record .............. 99Control Panel - Inspect ....................................... 100Cooling System Coolant Level - Check .............. 102Electrical Connections - Check ........................... 107

Engine Air Cleaner Service Indicator - Inspect .... 110Engine Air Precleaner - Clean ............................. 111Engine Oil Level - Check ..................................... 113Fuel System Fuel Filter Differential Pressure -Check ................................................................. 119Generator - Inspect ............................................. 122Generator Load - Check ..................................... 123Power Factor - Check ......................................... 142Stator Winding Temperature - Measure/Record .. 147Voltage and Frequency - Check ......................... 150Walk-Around Inspection ...................................... 151

Every Week



Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 103


Actuator Control Linkage - Lubricate .................... 91Battery Electrolyte Level - Check .......................... 94Belts - Inspect/Adjust/Replace .............................. 99Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 104Crankcase Blowby - Measure/Record ................ 105Crankshaft Vibration Damper - Inspect ............... 106Engine - Clean .................................................... 108Engine Crankcase Breather - Clean .................... 112Engine Mounts - Check ....................................... 112Engine Oil Sample - Obtain ................................. 113Engine Protective Devices - Check ..................... 116Exhaust Piping - Inspect ...................................... 119Gas Pressure Regulator - Check ......................... 119Ignition System Spark Plugs - Inspect/Replace .. 126Ignition System Timing - Check/Adjust ............... 131Inlet Air System - Inspect .................................... 132Radiator - Clean .................................................. 142






Bearing (Ball) - Lubricate ...................................... 95Engine Valve Lash - Inspect/Adjust ..................... 117Engine Valve Rotators - Inspect .......................... 118

Every Year




Air Starting Motor Lubricator Bowl - Clean ........... 91Alternator - Inspect ............................................... 92Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 104Cylinder Pressure - Measure/Record ................. 106Engine Speed/Timing Sensor - Clean/Inspect ..... 117Generator Set Vibration - Test/Record ................ 125Ignition System Transformer Resistance - Test .. 132Speed Sensor - Clean/Inspect ............................ 144Starting Motor - Inspect ...................................... 146Stator Lead - Check ............................................ 146Water Pump - Inspect ......................................... 152


Insulation - Test ................................................... 132Rotating Rectifier - Check ................................... 142


Overhaul (Top End) ............................................. 138


Overhaul (Major) ................................................. 136


Bearing - Inspect ................................................... 96





i03996897

Maintenance Interval Schedule(Bio-Gas)SMCS Code: 1000; 4450; 7500

S/N: GNA1-Up; J1E1-Up




When Required

Battery - Recycle .................................................. 93Battery or Battery Cable - Disconnect .................. 95Engine Oil and Filter - Change ............................ 114Generator - Dry ................................................... 120Generator Set Alignment - Check ....................... 125Overhaul Considerations .................................... 140Rotating Rectifier - Test ...................................... 143Valve Stem Projection - Measure/Record ........... 148Varistor - Inspect ................................................. 149Varistor - Test ...................................................... 150Winding - Test ..................................................... 152

Daily

Air Starting Motor Lubricator Oil Level - Check .... 92Air Tank Moisture and Sediment - Drain ............... 92Bearing Temperature - Measure/Record .............. 99Control Panel - Inspect ....................................... 100Cooling System Coolant Level - Check .............. 102Electrical Connections - Check ........................... 107Engine Air Cleaner Service Indicator - Inspect .... 110Engine Air Precleaner - Clean ............................. 111Engine Oil Level - Check ..................................... 113Fuel System Fuel Filter Differential Pressure -Check ................................................................. 119Generator - Inspect ............................................. 122Generator Load - Check ..................................... 123

Power Factor - Check ......................................... 142Stator Winding Temperature - Measure/Record .. 147Voltage and Frequency - Check ......................... 150Walk-Around Inspection ...................................... 151

Every Week



Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 103Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 104


Actuator Control Linkage - Lubricate .................... 91Battery Electrolyte Level - Check .......................... 94Belts - Inspect/Adjust/Replace .............................. 99Crankcase Blowby - Measure/Record ................ 105Crankshaft Vibration Damper - Inspect ............... 106Engine - Clean .................................................... 108Engine Air Cleaner Element - Replace ............... 108Engine Crankcase Breather - Clean .................... 112Engine Mounts - Check ....................................... 112Engine Oil Sample - Obtain ................................. 113Engine Protective Devices - Check ..................... 116Gas Pressure Regulator - Check ......................... 119Ignition System Spark Plugs - Inspect/Replace .. 126Ignition System Timing - Check/Adjust ............... 131Inlet Air System - Inspect .................................... 132Radiator - Clean .................................................. 142





Before Harvest

Radiator - Clean .................................................. 142


Bearing (Ball) - Lubricate ...................................... 95Engine Valve Lash - Inspect/Adjust ..................... 117

Every Year



Air Starting Motor Lubricator Bowl - Clean ........... 91


Alternator - Inspect ............................................... 92Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 104Cylinder Pressure - Measure/Record ................. 106Engine Speed/Timing Sensor - Clean/Inspect ..... 117Ignition System Transformer Resistance - Test .. 132Speed Sensor - Clean/Inspect ............................ 144Starting Motor - Inspect ...................................... 146Stator Lead - Check ............................................ 146Water Pump - Inspect ......................................... 152

Between 7000 and 11 000 Service Hours

Overhaul (Top End) ............................................. 138


Insulation - Test ................................................... 132Rotating Rectifier - Check ................................... 142


Overhaul (Major) ................................................. 136


Bearing - Inspect ................................................... 96




Actuator Control Linkage - Lubricate

i01600724

Actuator Control Linkage -LubricateSMCS Code: 1265-086

g00709892Illustration 62Grease fittings

Apply grease to the grease fittings. Use a handgrease gun and lubricate the grease fittings withMPGM.

Check the LinkageCheck the linkage for proper operation. Adjustthe linkage, if necessary. Refer to the engine'sSpecifications.

i02654935

Air Starting Motor LubricatorBowl - CleanSMCS Code: 1451-070

If the engine is equipped with an air starting motor,use the following procedure:

Personal injury can result from removing hoses orfittings 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.

1. Ensure that the air supply to the lubricator is OFF.

g01333332Illustration 63(1) Filler plug(2) Bowl(3) Drain valve

2. Slowly loosen filler plug (1) in order to release thepressure from the lubricator.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

3. Place a suitable container under bowl (2) andopen drain valve (3) in order to drain the oil fromthe bowl.

4. Remove bowl (2). Clean the bowl with warm water.

5. Dry the bowl. Inspect the bowl for cracks. If thebowl is cracked, replace the damaged bowl witha new bowl. Inspect the gasket. If the gasket isdamaged, replace the gasket.

6. Install the bowl.

7. Make sure that drain valve (3) is closed.

8. For instructions on filling the lubricator, see thisOperation and Maintenance Manual, “Air StartingMotor Lubricator Oil Level - Check” topic.

92 SEBU7572-06Maintenance SectionAir Starting Motor Lubricator Oil Level - Check

i02654969

Air Starting Motor LubricatorOil Level - CheckSMCS Code: 1451-535

NOTICENever allow the lubricator bowl to become empty. Theair starting motor will be damaged by a lack of lubrica-tion. Ensure that sufficient oil is in the lubricator bowl.

g01333366Illustration 64

1. Observe the oil level in sight gauge (3). If the oillevel is less than 1/2, add oil to the lubricator bowl.

Personal injury can result from removing hoses orfittings 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.

2. Ensure that the air supply to the lubricator is OFF.Slowly loosen filler plug (4) in order to releasepressure from the lubricator bowl.

3. Remove filler plug (4). Pour oil into the lubricatorbowl. Use nondetergent SAE 10W oil fortemperatures that are greater than 0 °C (32 °F).Use air tool oil for temperatures that are below0 °C (32 °F).

4. Install filler plug (4).

Adjust the LubricatorNote: Adjust the lubricator with a constant rate of airflow. After the adjustment, the lubricator will releaseoil in proportion to variations of the air flow.

1. Ensure that the fuel supply to the engine is OFF.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

2. Operate the air starting motor. Observe the dropsof oil that are released in dome (1).

Note: Some lubricators have an adjustment screwrather than a knob.

3. If necessary, adjust the lubricator in orderto release from one to three drops of oil persecond. To increase the rate, turn knob (2)counterclockwise. To decrease the rate, turn theknob clockwise.

i00351324

Air Tank Moisture andSediment - DrainSMCS Code: 1466-543-M&S

Moisture and sediment in the air starting system cancause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

When opening the drain valve, wear protectivegloves, a protective face shield, protective cloth-ing, and protective shoes. Pressurized air couldcause debris to be blown and result in personalinjury.

1. Open the drain valve that is on the bottom of theair tank. Allow the moisture and sediment to drain.

2. Close the drain valve.

i02084374

Alternator - InspectSMCS Code: 1405-040

Inspect the alternator for the following conditions:

• Proper connections


Automatic Start/Stop - Inspect

• Clean ports for cooling airflow

• Proper charging of the battery

Observe the ammeter during engine operation inorder to ensure proper battery performance and/orproper performance of the electrical system.

Make repairs, if necessary. See the Service Manualfor service procedures. Consult your Caterpillardealer for assistance.

i01039675

Automatic Start/Stop - Inspect(Generator Set)SMCS Code: 4462

The generator set must be ready to operate under aload at any time. After performing maintenance onthe generator set, inspect the position of the controlswitches. Ensure the following conditions:

• The starting system is enabled.

• The control switches are in the correct position forautomatic starting.

• The switchgear and the automatic transfer switchesthat are associated with the generator are enabled.

For more information, see the Operation andMaintenance Manual for the generator and thecontrol panel.

i01041029

Batteries - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. 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 inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the ground plane. Disconnectthe 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 abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before connecting the cables, ensure that thekey start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.

8. Connect the cable from the ground plane to theNEGATIVE “-” battery terminal.

i02039199

Battery - RecycleSMCS Code: 1401-005; 1401-510; 1401-535;1401-561; 1401

Always recycle a battery. Never discard a battery.Return used batteries to one of the followinglocations:

• A battery supplier

• An authorized battery collection facility

• A recycling facility

i01039758

Battery Charger - CheckSMCS Code: 1401-535

Checking Before Start-UpCheck the battery charger for proper operation. Ifthe batteries are properly charged, the needle of theammeter will register near “0” (zero).

94 SEBU7572-06Maintenance SectionBattery Electrolyte Level - Check

The battery charger must not produce excessivecurrent during start-up. Alternatively, the chargermust be automatically disconnected for start-up.If the engine has an alternator, the charger mustbe automatically disconnected during start-up andduring 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 thebattery:

1. Ensure that the charger is turned OFF.

2. Adjust the voltage of the charger in order to matchthe voltage of the battery.

3. Connect the POSITIVE “+” lead of the chargerto the POSITIVE “+” battery terminal. Connectthe NEGATIVE “-” lead of the charger to theNEGATIVE “-” 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 thebattery. DO NOT charge the battery if the meter ofthe battery charger is in the RED zone.

Overcharging is indicated by the following symptoms:

• The battery is very warm to the touch.

• A strong odor of acid is present.

• The battery emits smoke or a dense vapor (gas).

Perform one of the following procedures if the batteryshows symptoms of overcharging:

• Reduce the rate of charging by a significantamount. Complete the charging at the reducedrate.

• Turn OFF the charger.

Table 22 describes the effects of overcharging ondifferent types of batteries.

Table 22

Effects of Overcharging Batteries

Type of Battery Effect

All of the battery cells havea low level of electrolyte.

When the plates of thebattery are inspectedthrough the filler holes, theplates may appear to bewarped. This is caused byan excessive temperature.

Caterpillar General ServiceBatteriesCaterpillar Premium HighOutput Batteries

The battery may not passa load test.

The battery may not accepta charging current.

Caterpillar MaintenanceFree Batteries

The battery may not passa load test.

Checking After StoppingEnsure that the battery charger is connectedproperly. Observe the meter of the charger. Recordthe amperage.

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535-FLV

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.


Battery or Battery Cable - Disconnect

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and1 L (1 qt) of clean water

• 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 theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

i02857256

Battery or Battery Cable -DisconnectSMCS Code: 1401; 1402-029

The battery cables or the batteries should not beremoved 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 withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Turnoff any battery chargers. Disconnect anybattery chargers.

3. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative side oftwo batteries must be disconnected.

4. Tape the leads in order to help prevent accidentalstarting.

5. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i02023749

Bearing (Ball) - Lubricate(Generator)SMCS Code: 4471-086

The following ball bearings must be lubricated:no shield and single shield. Double shielded ballbearings may not require lubrication. Refer to theinstructions that are located on the machine.

For ball bearings, use Caterpillar 2S-3230 BearingLubricant. This grease is an NLGI No. 2 Grade.There is Polyurea (a thickener) in this grease. Thetemperature range of Caterpillar 2S-3230 BearingLubricant is −29 °C (−20.2 °F) to 177 °C (350.6 °F).For extremely low temperatures, use either NLGI No.1 Grade or NLGI No. 0 Grade.

Lubricating Process1. Remove either the louver assembly or the rearplate from the rear of the generator housing.

2. Remove the top grease pipe plug and remove thelower grease pipe plug.

3. Install a grease fitting in the grease pipe.

4. Grease the shielded ball bearings with 2S-3230Bearing Lubricant (53.28 mL (1.8 ounces) to59.20 mL (2.0 ounces)). Lubricate shielded ballbearings at 2000 hour intervals. Do not mixgreases.

Note: Some two-bearing generators have sphericalroller bearings in the front bracket and ball bearings inthe rear bracket. These units should use a common108-8611 Grease Cartridge. This grease should beused for the front bearing and the rear bearing.

5. Wipe off the excess grease. Remove the topgrease fitting. Install the plug.

6. Operate the generator for one hour. This will allowthe grease to expand. The expanding grease willforce the excess grease from the cavity. Whenthe excess grease is forced from the cavity, theinternal pressure will be reduced. The generatorshould continue to operate until the grease stopspurging.

7. Stop the engine. Install the plug in the bottomgrease pipe. Wipe off the excess grease.

8. Install the louver assembly or install the rear plate.

96 SEBU7572-06Maintenance SectionBearing - Inspect

i02230503

Bearing - InspectSMCS Code: 4471-040

The following maintenance procedure for generatorbearings should be followed at every major engineoverhaul:

1. Remove the bearing bracket. Inspect the followingitems: bracket bore, bearing outer race, androlling elements. On standby power units, thebearing must be inspected and the grease mustbe replaced at three year intervals. The sleevefor the bearing bracket should be inspected forout of roundness, excessive wear, and a bracketstep that is less than 0.0762 mm (0.0030 inch). Ifthere is no sleeve for the bearing bracket, inspectthe bore for the bearing bracket. The bearingshould be inspected for damage to the outer race,severe fretting, and smoothness of operation.When possible, the bearing elements should beinspected. Some double shielded ball bearingsprevent visual inspection of the ball bearings.Other double shielded ball bearings have aretaining ring. This retaining ring can be removedin order to allow access for a visual inspection ofthe ball bearings.

On two-bearing generators, the front bearing canonly be removed after the hub is removed. In orderto remove the hub, cut off the hub. Pulling the hubwill damage the shaft.

Note: Bearings that are being removed for failureanalysis should not be cut off with a torch.

2. Spherical Roller Bearing should be cleaned andrepacked with 108-8611 Grease. Pack thebearing and pack the cavity (one-third to one-halfof the volume of the cavity). The bearing shouldbe filled with 88.8 mL (3 ounces) to 118.4 mL(4 ounces) of grease. The cavity should be filledwith 118.4 mL (4 ounces) to 148.0 mL (5 ounces)of grease. Refer to Table 23.

3. All ball bearings should be cleaned. The cavityof the bracket should be repacked with 2S-3230Grease. Pack the bearings (one-third to one-halfof the volume of the cavity). Refer to Table 23.

To reinstall bearings, heat the bearings to 107 °C(224.6 °F) for ten minutes. Mount the bearingson the shaft. To reinstall the hub, heat the hub to400 °C (752.0 °F) for three hours. Mount the hubto the shaft.

4. Ensure that the tube that supplies grease to thebearing is filled with grease.

5. Remove the bracket drain plug and operate thegenerator for one hour. This will allow the greaseto expand. The expanding grease will force theexcess grease from the cavity. When the excessgrease is forced from the cavity, the internalpressure will be reduced. The generator shouldcontinue to operate until the grease stops purging.

6. Stop the engine. Install the bracket drain plug.Wipe off the excess grease.

7. For greasing intervals, follow the recommendationson the lubrication plate (if equipped) or refer toMaintenance Schedule, “Bearing - Lubricate”.Whenever the bearings are greased, repeat Step5. DO NOT MIX GREASES.


Bearing - Inspect

Table 23

BearingOutsideDiametermm (inch)

BearingInsideDiametermm (inch)

PartNumber

GeneratorFrameSize

Bearing Borein Bracketmm (inch)

BearingShield(Type)

BearingCavityGreasemL (oz)

Rotor ShaftDiametermm (inch)

100.000 mm(3.9370 inch)

45.000 mm(1.7717 inch)

5P-1977 All 360 100.000 mm(3.9370 inch)

to100.025 mm(3.9380 inch)

Double 29.6 mL(1 oz)

45.004 mm(1.7718inch)to

45.019 mm(1.7724inch)

140.000 mm(5.5118 inch)

65.000 mm(2.5591 inch)

3N-1965 440(round

laminated)

140.002 mm(5.5119 inch)

to140.028 mm(5.5129 inch)

Double 53.280 mL(1.8 oz)(1)

to94.720 mL(3.2 oz)(2)

65.004 mm(2.5592inch)to

65.021 mm(2.5599inch)

160.000 mm(6.2992 inch)

75.000 mm(2.9527 inch)

5P-2448 580(2)590(1)

160.002 mm(6.2993 inch)

to160.028 mm(6.3003 inch)

Double 100.64 mL(3.4 oz)to

168.72 mL(5.7 oz)

75.004 mm(2.9529inch)to

75.021 mm(2.9536inch)

170.000 mm(6.6929 inch)

80.000 mm(3.1496 inch)

4L-6677(3) 580(1) 170.002 mm(6.6930 inch)

to170.028 mm(6.6940 inch)

Single 97.68 mL(3.3 oz)to

162.80 mL(5.5 oz)

80.002 mm(3.1497inch)to

80.020 mm(3.1504inch)

170.000 mm(6.6929 inch)

80.000 mm(3.1496 inch)

109-7687(3) 580(1) 170.002 mm(6.6930 inch)

to170.028 mm(6.6940 inch)


162.80 mL(5.5 oz)

80.002 mm(3.1497inch)to

80.020 mm(3.1504inch)

180.000 mm(7.0866 inch)

100.000 mm(3.9370 inch)

6Y-3955 440(squarelaminated)

179.992 mm(7.0863 inch)

to180.017 mm(7.0873 inch)


230.88 mL(7.8 oz)

100.012 mm(3.9375inch)to

100.028 mm(3.9381inch)

190.000 mm(7.4803 inch)

90.000 mm(3.5433 inch)

6Y-6488 590(1)589 PM

190.002 mm(7.4804 inch)

to190.028 mm(7.4814 inch)


162.80 mL(5.5 oz)

90.012 mm(3.5438inch)to

90.028 mm(3.5444inch)(continued)

98 SEBU7572-06Maintenance SectionBearing - Inspect

(Table 23, contd)



PartNumber

GeneratorFrameSize


BearingShield(Type)



225.000 mm(8.8582 inch)

105.000 mm(4.1338 inch)

6V-0410 680(1) 225.003 mm(8.8584 inch)

to225.034 mm(8.8596 inch)


230.88 mL(7.8 oz)

105.029 mm(4.1350inch)to

105.034 mm(4.1352inch)

225.000 mm(8.8582 inch)

105.000 mm(4.1338 inch)

108-1760 680(1) 225.003 mm(8.8584 inch)

to225.034 mm(8.8596 inch)


236.80 mL(8.0 oz)

105.029 mm(4.1350inch)to

105.034 mm(4.1352inch)

230.000 mm(9.0551 inch)

130.000 mm(5.1181 inch)

2L-4444(4) 8084 pole(1)

229.992 mm(9.0548 inch)

to230.022 mm(9.0560 inch)

Open 177.60 mL(6.0 oz)to

266.40 mL(9.0 oz)

130.028 mm(5.1192 inch)

to130.051 mm(5.1201inch)

230.000 mm(9.0551 inch)

130.000 mm(5.1181 inch)

2L-4444(4) 820(1) 229.992 mm(9.0548 inch)

to230.022 mm(9.0560 inch)

Open 236.8 mL(8.0 oz)to

355.20 mL(12.0 oz)

130.028 mm(5.1192 inch)

to130.051 mm(5.1201inch)

240.000 mm(9.4488 inch)

110.000 mm(4.3307 inch)

108-1761 690(1) 240.002 mm(9.4489 inch)

to240.033 mm(9.4501 inch)


296.00 mL(10.0 oz)(2)414.40 mL(14.0 oz)

to621.60 mL(21 oz)(3)

110.012 mm(4.3312inch)to

110.028 mm(4.3318inch)

240.000 mm(9.4488 inch)

110.000 mm(4.3307 inch)

6V-3310 800(1) 240.002 mm(9.4489 inch)

to240.033 mm(9.4501 inch)


239.76 mL(8.1 oz)

110.012 mm(4.3312inch)to

110.028 mm(4.3318inch)

240.000 mm(9.4488 inch)

110.000 mm(4.3307 inch)

6V-6752 800(1) 240.002 mm(9.4489 inch)

to240.033 mm(9.4501 inch)


239.76 mL(8.1 oz)

110.012 mm(4.3312inch)to

110.028 mm(4.3318inch)(continued)


Bearing Temperature - Measure/Record

(Table 23, contd)



PartNumber

GeneratorFrameSize


BearingShield(Type)



240.000 mm(9.4488 inch)

110.000 mm(4.3307 inch)

108-1761 800(1) 240.002 mm(9.4489 inch)

to240.033 mm(9.4501 inch)


236.80 mL(8.0 oz)

110.012 mm(4.3312inch)to

110.028 mm(4.3318inch)

280.000 mm(11.024 inch)

130.000 mm(5.1181 inch)

154-3032 820 280.002 mm(11.0237 inch)

to280.032 mm(11.0249 inch)

Double N/A 130.028 mm(5.1192 inch)

to130.051 mm(5.1201inch)

(1) Inboard bearing(2) Outboard bearing(3) 109-7687 bearing is preferred.(4) This bearing is a spherical roller bearing. This bearing is greased from the bracket's front side. All of the other bearings are ball bearings.(2) This bearing is on the same end as the exciter.(3) This bearing is on the drive end of the generator.

i03212480

Bearing Temperature -Measure/RecordSMCS Code: 4471-082-TA

Bearing temperature detectors are optional on allCaterpillar generators. These detectors are 100ohm resistance temperature detectors. The optionalmonitoring for the generator bearing temperaturemay be available in the EMCP 3 control panel.Bearing temperature detectors may be used withequipment that has been provided by the customer inorder to measure the bearing temperature. Bearingtemperature detectors may help to prevent prematurebearing failure.

A sudden increase in bearing temperature mayindicate impending bearing failure.

i02667833

Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510

InspectionInspect the alternator belt and the fan drive belts forwear and for cracking. Replace the belts if the beltsare not in good condition.

Check the belt tension according to the information inthe Service Manual, “Specifications”.

Slippage of loose belts can reduce the efficiencyof the driven components. Vibration of loose beltscan cause unnecessary wear on the followingcomponents:

• Belts

• Pulleys

• Bearings

If the belts are too tight, unnecessary stress is placedon the components. This reduces the service life ofthe components.

100 SEBU7572-06Maintenance SectionControl Panel - Inspect

Adjusting the Alternator Belt

g01092641Illustration 65Typical alternator

(1) Mounting bolt(2) Adjusting nuts(3) Mounting bolt

1. Remove the drive belt guard.

2. Loosen mounting bolt (1), adjusting nuts (2) andmounting bolt (3).

3. Turn adjusting nuts (2) in order to increase ordecrease the drive belt tension.

4. Tighten adjusting nuts (2). Tighten mounting bolt(3). Tighten mounting bolt (1). For the propertorque, see the Service Manual, “Specifications”module.

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belttension again after 30 minutes of engine operation atthe rated rpm.

Adjusting the Fan Drive Belt1. Loosen the mounting bolt for the pulley.

2. Loosen the adjusting nut for the pulley.

3. Move the pulley in order to adjust the belt tension.

4. Tighten the adjusting nut to the proper torque.

5. Tighten the mounting bolt to the proper torque.

For the proper torque specifications, refer to theService Manual, “Specifications” module.

ReplacementFor applications that require multiple drive belts,replace the drive belts in matched sets. Replacingone drive belt of a matched set will cause the newdrive belt to carry more load because the older drivebelts are stretched. The additional load on the newdrive belt could cause the new drive belt to fail.

i01762721

Control Panel - InspectSMCS Code: 4490-040; 7451-040

Inspect the condition of the panel. If a component isdamaged, ensure that the component is repaired orthat the component is replaced. If equipped, ensurethat the electronic displays are operating properly.

Inspect the wiring for good condition. Ensure that thewiring connections are secure.

Record the Data and Review theDataIf equipped, check the gauges and check theindicators frequently during normal operation. Recordthe data in a log. Compare the new data to the datathat was previously recorded. Comparing the newdata to the recorded data will establish the normalgauge readings for the engine. A gauge reading thatis abnormal may indicate a problem with operationor with the gauge.

i02518440

Cooling System Coolant(NGEC) - ChangeSMCS Code: 1350-044

Clean the cooling system before the recommendedmaintenance interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• Oil has entered the cooling system and the coolantis contaminated.


Cooling System Coolant (NGEC) - Change

Drain the Cooling System1. Stop the engine and allow the engine to cool.Ensure that the engine will not start when thecooling system is drained.


(1) Filler cap(2) Drain valve

2. Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

g00719034Illustration 67Engine block drain plug

3. Open the cooling system drain valve. Remove theengine block drain plug.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Dealer Service ToolsGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Clean the Cooling System1. After the cooling system has been drained, flushthe cooling system with clean water in order toremove any debris.

2. Close the cooling system drain valve. Clean theengine block drain plug and install the plug.

NOTICEUse 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.

NOTICEFill 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 cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start the engine. Operate the engine for aminimum of 30 minutes with a coolant temperatureof at least 82 °C (180 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the cooling system drainvalve. Remove the engine block drain plug.

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

6. Allow the water to drain. Flush the cooling systemwith clean water until the water that drains isclean. Close the cooling system drain valve. Cleanthe engine block drain plug and install the plug.

102 SEBU7572-06Maintenance SectionCooling System Coolant Level - Check

Cleaning a Cooling System thathas Heavy Deposits or PluggingNote: For the following procedure to be effective,there must be an active flow through the coolingsystem components.

1. After the cooling system has been drained, flushthe cooling system with clean water in order toremove any debris.

2. Close the cooling system drain valve. Clean theengine block drain plug and install the plug.

NOTICEUse 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.


3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.Install vent plug (4).

4. Start the engine. Operate the engine for aminimum of 90 minutes with a coolant temperatureof at least 82 °C (180 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the cooling system drainvalve. Remove the engine block drain plug. Allowthe water to drain.

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

6. Flush the cooling system with clean water untilthe water that drains is clean. Close the coolingsystem drain valve. Clean the engine block drainplug and install the plug.

Fill the Cooling System


Note: For information about the proper coolantto use, or for the capacity of the cooling system,refer to this Operation and Maintenance Manual,“Refill Capacities and Coolant Recommendations”(Maintenance Section).

1. Fill the cooling system with coolant/antifreeze. Donot install the cooling system filler cap.

2. Start the engine. Operate the engine in order topurge the air from the cavities of the engine block.Allow the coolant to warm and allow the coolantlevel to stabilize. Stop the engine.

3. Check the coolant level. Maintain the coolant tothe proper level on the sight gauge (if equipped).If a sight gauge is not equipped, maintain thecoolant within 13 mm (0.5 inch) below the bottomof the filler pipe.

4. Clean the cooling system filler cap. Inspectthe gaskets of the cooling system filler cap. Ifthe gaskets of the cooling system filler cap aredamaged, discard the old cooling system filler capand install a new cooling system filler cap. If thegaskets of the cooling system filler cap are notdamaged, use a 9S-8140 Pressurizing Pump inorder to pressure test the cooling system filler cap.The correct pressure is stamped on the face ofthe cooling system filler cap. If the cooling systemfiller cap does not maintain the correct pressure,install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i01197583

Cooling System Coolant Level- CheckSMCS Code: 1350-535-FLV

Check the coolant level when the engine is stoppedand cool.


Cooling System Coolant Sample (Level 1) - Obtain

g00285520Illustration 68Cooling 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 systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.


Typical filler cap gaskets

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i02064894

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

For conventional heavy-duty coolant/antifreeze,check the concentration of supplemental coolantadditive (SCA) regularly. The concentration of SCAcan be checked with an S·O·S coolant analysis(Level 1).

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

• Keep the unused sampling bottles stored in plasticbags.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• In order to avoid contamination, immediately placethe sample in the tube that is provided for mailing.

Submit the sample for Level 1 analysis.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

104 SEBU7572-06Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

For additional information about coolant analysis,see the Special Publication, SEBU6400, “CaterpillarGas Engine Lubricant, Fuel and CoolantRecommendations” or consult your Caterpillar dealer.

i02168823

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collecting samples can be obtained from yourCaterpillar dealer.

Refer to this Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”(Maintenance Section) for the guidelines for propersampling of the coolant.

Submit the sample for Level 2 analysis.

For additional information about coolant analysis,see the Special Publication, SEBU6400, “CaterpillarGas Engine Lubricant, Fuel, and CoolantRecommendations” or consult your Caterpillar dealer.

i02017557

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and eyes. Do not drink cooling systemcoolant additive.

Note: Caterpillar recommends an S·O·S coolantanalysis (Level 1).

Test the Concentration of the SCA

Coolant/Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Follow the instructionsthat are provided in the kit.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Use the instructionsthat follow:

1. Fill the syringe to the “1.0 ml” mark with thecoolant.

2. Dispense the 1.0 mL coolant sample from thesyringe into the empty mixing bottle.

3. Add tap water to the mixing bottle in order to bringthe level up to the “10 ml” mark. Place the cap onthe bottle and shake the bottle.

4. Add 2 to 3 drops of the “NITRITE INDICATORSOLUTION B” to the mixing bottle. Move the bottlein a circular motion in order to mix the solution.

5. Add 1 drop of “NITRITE TEST SOLUTION A” tothe mixing bottle. Move the bottle in a circularmotion in order to mix the solution.

6. Repeat 5 until the solution changes color from redto light gray, green, or blue. Record the number ofdrops of “NITRITE TEST SOLUTION A” that wererequired to cause the color change.

7. Use Table 24 to interpret the results.


Crankcase Blowby - Measure/Record

Table 24

Number ofDrops

Concentrationof SCA

MaintenanceRequired

Less than 25 Less than therecommendedconcentration ofSCA

Add SCA.Retest thecoolant.

25 to 30 Therecommendedconcentration ofSCA

None

More than 30 More than therecommendedconcentration ofSCA

Remove thecoolant.Replace withwater onlyRetest thecoolant.

Add the SCA, If Necessary

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Remove the cooling system filler cap slowly.

Note: Always dispose of fluids according to localregulations.

2. If necessary, drain some coolant in order to allowspace for the addition of the SCA.

NOTICEExcessive supplemental coolant additive concentra-tion can form deposits on the higher temperature sur-faces of the cooling system, reducing the engine'sheat transfer characteristics. Reduced heat transfercould cause cracking of the cylinder head and otherhigh temperature components.

Excessive supplemental coolant additive concentra-tion could also result in blockage of the heat exchang-er, overheating, and/or accelerated wear of the waterpump seal.

Do not exceed the recommended amount of supple-mental coolant additive concentration.

3. Add the proper amount of SCA. The concentrationof the SCA depends on the type of coolant thatis used. To determine the proper amount, seethis Operation and Maintenance Manual, “RefillCapacities and Recommendations” topic.

4. Clean the cooling system filler cap. Install thecooling system filler cap.

i01333307

Crankcase Blowby -Measure/RecordSMCS Code: 1317

Note: For a new G3400 Engine, the typical range forcrankcase blowby is approximately 22 to 37 L/Bkw-hr(0.6 to 1.0 cu ft/Bhp-hr).

Measure the crankcase blowby of new engines.Record the data. Continue to periodically measurethe blowby. Comparing the recorded data to the newdata provides information about the condition of theengine.

Note: Crankcase blowby is one of the three factorsthat help to determine the major overhaul interval.For more information, see this Operation andMaintenance manual, “Overhaul (Major)” topic(Maintenance Section).

After a new engine is used for a short time, theblowby can decrease as the piston rings are seated.The blowby will gradually increase as the followingcomponents show wear:

• piston rings

• cylinder liners

Note: A problem with the piston rings causes theoil to deteriorate rapidly. Information regarding thecondition of the piston rings can be obtained fromthe measurement of the blowby and the results ofoil analysis.

The blowby of a worn engine may exceed the blowbyof a new engine by two times or more.

A sudden increase in blowby could indicate a brokenpiston ring. The following conditions are otherpotential sources of blowby:

• Worn valve guides

• A turbocharger seal that leaks

A rebuilt engine can have a high blowby due to thefollowing factors:

• The piston rings are not seated properly.

• Worn parts such as valve guides were not replaced.

106 SEBU7572-06Maintenance SectionCrankshaft Vibration Damper - Inspect

Excessive blowby may indicate the need for anoverhaul. By keeping a record of the results, agradual increase in the amount of the blowby will benoted until the amount has become excessive.

To measure the blowby, use the 8T-2700 Blowby/AirFlow Indicator. Refer to Special Instruction,SEHS8712, “Using the 8T-2700 Blowby/AirflowIndicator Group”. The instruction is provided with thetool.

Keep a record of the results.

For more information, see the Service Manual,“Systems Operation/Testing and Adjusting”. Forassistance, consult your Caterpillar dealer.

i00894991

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

Damage to the crankshaft vibration damper or failureof the crankshaft vibration damper can increasetorsional vibrations. This can result in damage tothe crankshaft and to other engine components. Adeteriorating damper can cause excessive gear trainnoise at variable points in the speed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.

Rubber DamperYour engine may be equipped with a rubber damper.The rubber damper uses a ring which is mounted inrubber in order to reduce vibrations in the crankshaft.

Inspect the damper and repair or replace the damperfor any of the following reasons:

• There is deterioration and cracking of the rubber.

• There is slippage of the outer ring from the originalposition.

• The engine has had a failure because of a brokencrankshaft.

• Analysis of the oil has revealed that the front mainbearing is badly worn.

• There is a large amount of gear train wear that isnot caused by lack of oil.

Refer to the Service Manual or consult yourCaterpillar dealer for information about damperreplacement.

Visconic DamperYour engine may be equipped with a visconicdamper. The visconic damper has a weight that islocated inside a fluid filled case. The weight moves inthe case in order to limit torsional vibration.

Inspect the damper for evidence of fluid leaks. Ifa fluid leak is found, determine the type of fluid.The fluid in the damper is silicone. Silicone hasthe following characteristics: transparent, viscous,smooth, and difficult to remove from surfaces.

If the fluid leak is oil, inspect the crankshaft seals forleaks. If a leak is observed, replace the crankshaftseals.

Inspect the damper and repair or replace the damperfor 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 brokencrankshaft.

• Analysis of the oil has revealed that the front mainbearing is badly worn.

• There is a large amount of gear train wear that isnot caused by a lack of oil.

Refer to the Service Manual or consult yourCaterpillar dealer for information about damperreplacement.

i01664707

Cylinder Pressure -Measure/RecordSMCS Code: 1223-082-CC; 1223; 7450-082

Measure the cylinder pressure of new engines.Record the data. Continue to periodically measurethe cylinder pressure. Comparing the recorded datato the new data provides information about thecondition of the engine.

Cylinder pressure can be measured during inspectionof the spark plugs. Use the following guidelines forchecking the cylinder pressure:

• Remove all of the spark plugs.


Electrical Connections - Check

• Fully open the throttle plate.

• Minimize the cranking time to 3 or 4 revolutions.This will enable a maximum consistent crankingspeed for the check. Also, the battery power willbe conserved.

A loss of cylinder pressure or a change of pressurein one or more cylinders may indicate the followingconditions. These conditions may indicate a problemwith lubrication:

• Excessive deposits

• Guttering of valves

• A broken valve

• A piston ring that sticks

• A broken piston ring

• Worn piston rings

• Worn cylinder liners

If the cylinder pressure has risen by one or morecompression ratios, the engine needs a top endoverhaul in order to remove deposits. Failure toremove the deposits will increase the chance fordetonation. Severe guttering of the valves will occur.

To measure the cylinder pressure, use the 193-5859Cylinder Pressure Gauge Gp. Follow the procedurein the Special Instruction, NEHS0798 that is includedwith the gauge group. Record the pressure foreach cylinder. Use the Operation and MaintenanceManual, “Valve Data Sheet” (Reference MaterialsSection).

Illustration 70 is a graph of typical cylinder pressuresfor engines with different compression ratios.


(Y) Cylinder pressure in kPa(X) Compression ratio(1) Normal range for cylinder pressure

i01217164

Electrical Connections - CheckSMCS Code: 4459-535

Check all exposed electrical connections fortightness.

Check the following devices for loose mounting orphysical damage:

• transformers

• fuses

• capacitors

• lightning arrestors

Check all lead wires and electrical connections forproper clearance.

108 SEBU7572-06Maintenance SectionEngine - Clean

i01664717

Engine - CleanSMCS 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 fromutility and/or other generators), locked out andtagged "Do Not Operate".

NOTICEWater or condensation can cause damage to gen-erator components. Protect all electrical componentsfrom exposure to water.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: For more information on cleaning and dryingelectric generators, refer to Special Instruction,SEHS9124, “Cleaning and Drying of Electric SetGenerators”.

i01749609

Engine Air Cleaner Element -ReplaceSMCS Code: 1051-510; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner ElementsIf the air cleaner element becomes plugged, the airpressure can split the filter material of the element.Unfiltered air will drastically accelerate internalengine wear. Your Caterpillar dealer has the properair cleaner elements for your application.

The air cleaner may be mounted high above theengine. If necessary, use a ladder or a platform toreach the air cleaner.

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

• The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

Replace the dirty paper elements with cleanelements. Before installation, thoroughly inspect theelement for tears and/or holes in the filter material.Inspect the gasket or the seal of the element fordamage. Maintain a supply of suitable elements forreplacement purposes.


Engine Air Cleaner Element - Replace

g00317608Illustration 71Fasteners for the air cleaner cover

g00781084Illustration 72(1) Cover(2) Element(3) Air inlet

1. Release the fasteners for cover (1).

2. Remove the cover and element (2).

3. Cover air inlet (3) with tape in order to keep dirtout.

4. Clean the inside of the cover and the body witha clean, dry cloth.

5. Remove the tape for the air inlet. Install a newelement or a clean element.

6. Install the cover.

7. If necessary, reset the air cleaner service indicator.

Cleaning the Primary Air CleanerElementsThe primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the element is cleaned, check thefilter material for rips or tears. Replace the elementat least one time per year regardless of the numberof cleanings.

Use clean elements while dirty elements are beingcleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the elements before cleaning. Inspectthe elements for damage to the seal, the gaskets,and the outer cover. Discard any damaged elements.

Air cleaner elements can be cleaned with pressurizedair and with a vacuum.

Pressurized Air

Pressurized air can be used to clean elementsthat have not been cleaned more than two times.Pressurized air will not remove deposits of carbonand oil. Use filtered, dry air with a maximum pressureof 207 kPa (30 psi).


Note:When the elements are cleaned, always beginwith the clean side (inside) in order to force dirtparticles toward the dirty side (outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced into the pleats.

110 SEBU7572-06Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningelements which require daily cleaning because of adry, dusty environment. Cleaning with pressurized airis recommended prior to vacuum cleaning. Vacuumcleaning will not remove deposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Inspecting the Primary Air CleanerElements


Inspect the clean, dry element. Use a 60 watt bluelight in a dark room or in a similar facility. Placethe blue light in the element. Rotate the element.Inspect the element for tears and/or holes. Inspectthe element for light that may show through the filtermaterial. If it is necessary in order to confirm theresult, compare the element to a new element thathas the same part number.

Do not use an element that has any tears and/orholes in the filter material. Do not use an element withdamaged pleats, gaskets or seals. Discard damagedelements.

Storing Primary Air Cleaner Elements

If an element that passes inspection will not be usedimmediately, store the element for future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. Restricted air flowmay result. To protect against dirt and damage, wrapthe elements in Volatile Corrosion Inhibited (VCI)paper.

Place the element into a cardboard box for storage.For identification, mark the outside of the containerand mark the element. Include the followinginformation:

• Date of cleaning

• Number of cleanings

Store the container in a dry location.

For more detailed information on cleaning the primaryair cleaner element, refer to Special Publication,SEBF8062, “Procedure to Inspect and Clean AirFilters”.

i01505252

Engine Air Cleaner ServiceIndicator - InspectSMCS Code: 7452-040

A service indicator may be mounted on the aircleaner element or in a remote location.


Engine Air Precleaner - Clean

g00517797Illustration 76Service indicator

Some engines may be equipped with a differentservice indicator.

Observe the service indicator. Clean the air cleanerelement or replace the element when the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

• The air restriction reaches 3.7 kPa(15 inches of H2O).

Inspect the service indicator daily for cracks, holes, orloose fittings. If any of these conditions are present,repair the service indicator or replace the serviceindicator.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated rpm.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,replace the service indicator. If the new serviceindicator will not reset, the fitting for the serviceindicator may be plugged.

g00351792Illustration 77Porous filter

A porous filter is part of a fitting that is used formounting of the service indicator. Inspect the filterfor cleanliness. Clean the filter, if necessary. Usecompressed air or a clean, nonflammable solvent.

The service indicator may need to be replacedfrequently in environments that are severely dusty.Replace the service indicator annually regardlessof the operating conditions. Replace the serviceindicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

i01397717

Engine Air Precleaner - CleanSMCS Code: 1055-070

g00736588Illustration 78Typical precleaner(1) Wing nut(2) Cover(3) Body

112 SEBU7572-06Maintenance SectionEngine Crankcase Breather - Clean

Remove wing nut (1) and cover (2). Check for anaccumulation of dirt and debris in body (3). Clean thebody, if necessary.

After cleaning the precleaner, install cover (2) andwing nut (1).

Note: When the engine is operated in dustyapplications, more frequent cleaning is required.

i02263740

Engine Crankcase Breather -CleanSMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may causecrankshaft seal leakage.


Typical example

(1) Hose clamp(2) Breather assembly(3) Retaining clamp(4) Seal

1. Loosen hose clamp (1) and remove the hose frombreather assembly (2).

2. Loosen retaining clamp (3). Remove the breatherassembly and seal (4).

3. Wash the breather element in solvent that is cleanand nonflammable. Allow the breather element todry before installation.

4. Install a breather element that is clean and dry.Install the seal, the breather assembly, and theclamp. Refer to the Specifications, SENR3130 inorder to locate the proper torques.

5. Install the hose. Install the hose clamp. Refer tothe Specifications, SENR3130 in order to locatethe proper torques.

i03214182

Engine Mounts - CheckSMCS Code: 1152-535


Typical configuration of mounting bolts for a Caterpillar genset(1) Mounting bolts for the engine(2) Mounting bolts for the generator(3) Levelling bolts for the isolators

Misalignment of the engine and the driven equipmentwill cause extensive damage. Excessive vibrationcan lead to misalignment. Excessive vibration of theengine and the driven equipment can be caused bythe following conditions:

• Improper mounting

• Misalignment of driven equipment

• Loose bolts

• Deterioration of the isolators

Ensure that the mounting bolts are tightenedto the proper torque. For standard torques, seeSpecifications, SENR3130, “Torque Specifications”.

Ensure that the isolators are free of oil andcontamination. Inspect the isolators for deterioration.Ensure that the bolts for adjusting the isolator arecorrectly adjusted and secured with the locking nut.Correctly adjusted isolators provide even support forthe engine base. Each isolator should impose nearlyidentical force on the base rail. Each isolator shouldbear the same portion of the weight of the genset.

Replace any isolator that shows deterioration. Formore information, see the literature that is providedby the OEM of the isolators. Also see the Applicationand Installation Guide for the engine. Consult yourCaterpillar dealer for assistance.


Engine Oil Level - Check

i02147972

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

The most accurate check of the oil level isperformed when the engine is stopped. Perform thismaintenance on a surface that is as level as possible.

Note: For engines with positive crankcase ventilation,remove the oil filler cap. Allow the crankcase pressureto stabilize before checking the engine oil level.

g00781190Illustration 81(1) Oil level gauge (dipstick)(2) Oil filler cap


(3) “ENGINE STOPPED WITH OIL COLD” side(4) “ENGINE AT LOW IDLE WITH OIL WARM” side(5) “ADD” mark(6) “FULL” mark

1. Ensure that oil level gauge (1) is seated.

a. If the engine is stopped, remove oil levelgauge (1). Observe the oil level on “ENGINESTOPPED” side (3).

b. If the engine is operating, reduce the enginespeed to low idle. Remove oil level gauge (1)and observe the oil level on “LOW IDLE” side(4).

The oil level should be between “ADD” mark(5) and “FULL” mark (6).

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can cause the crankshaft to dipinto the oil. This will reduce the power that is devel-oped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil's ability to lubricate, reduction of oilpressure, inadequate cooling, oil blowing out of thecrankcase breathers, and excessive oil consumption.

Excessive oil consumption will cause deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil levelgauge, drain some of the oil immediately.

2. If necessary, remove oil filler cap (2) and addoil. For the correct oil to use, see this Operationand Maintenance Manual, “Refill Capacities andRecommendations” topic. Do not fill the crankcaseabove “FULL” mark (6). Clean the oil filler cap.Install the oil filler cap.

3. Record the amount of oil that is added. For thenext oil sample and analysis, include the totalamount of oil that has been added since theprevious oil change. This will help to provide themost accurate oil analysis.

i03542996

Engine Oil Sample - ObtainSMCS Code: 1348-554-SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

114 SEBU7572-06Maintenance SectionEngine Oil and Filter - Change

Obtain the Sample and the Analysis

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.


If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEgj0047,“How To Take A Good S·O·S Oil Sample”. Consultyour Caterpillar dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i04009197

Engine Oil and Filter - ChangeSMCS Code: 1318-510

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

NOTICEEnsure that the engine is stopped before performingthis procedure. Attach a DONOTOPERATE tag to thestarting controls.

Refer to this Operation and Maintenance Manual,“Engine Oil Sample - Obtain” for information aboutthe timing of the engine oil and filter change.Changing the engine oil and filter should be based onthe results of the S·O·S oil testing. Always changethe oil filter when the engine oil is changed.

Do not drain the oil when the engine is cold. As the oilcools, suspended waste particles settle on the bottomof the oil pan. The waste particles are not removedwhen the cold oil is drained. Drain the crankcase withthe oil warm, immediately after the engine is stopped.This method of draining allows the waste particlesthat are suspended in the oil to be drained.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.


Engine Oil and Filter - Change

g00781251Illustration 83(1) Oil filler cap(2) Oil filter(3) Oil level gauge (dipstick)(4) Oil drain

Drain the Engine Oil1. After the engine has been operated at normaloperating temperature, STOP the engine.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Dealer Ser-vice Tool Catalog” for tools and supplies suitable tocollect and contain fluids on Cat products.

Dispose of all fluids according to local regulations andmandates.

2. Drain the oil.

a. If the engine has an oil drain valve, open thevalve in order to drain the oil. After the oil hasdrained, close the valve.

b. If the engine does not have a drain valve,remove an oil drain plug. Allow the oil to drain.

Replace the Oil Filter1. Remove the oil filter with a 1U-8760 ChainWrench.

2. Cut the oil filter open with a 175-7546 CutterGroup. Break apart the pleats and inspect the oilfilter for metal debris.

An excessive amount of metal debris in the oilfilter may indicate early wear or a pending failure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil filter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts, or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Aluminum debris may indicate problems with thebearings of the front gears. If you find aluminumdebris, inspect the vibration damper and the idlergear bearings.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter element. If an excessive amount of debrisis found in the oil filter element, consult yourCaterpillar dealer in order to arrange for furtheroil analysis.

g00103713Illustration 84Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasket isremoved.

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

4. Apply clean engine oil to the new oil filter gasket.

116 SEBU7572-06Maintenance SectionEngine Performance - Test

NOTICEDo 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 toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions that areshown on the oil filter. Do not overtighten the oilfilter.

Fill the Engine Crankcase

NOTICEOnly use oils that are recommended by Caterpillar.For the proper oil to use, refer to this Operation andMaintenance Manual, “Refill Capacities and Recom-mendations” topic (Maintenance Section).

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can cause the crankshaft to dipinto the oil. This will reduce the power that is devel-oped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil's ability to lubricate, reduction of oilpressure, inadequate cooling, oil blowing out of thecrankcase breathers, and excessive oil consumption.

Excessive oil consumption will cause deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil levelgauge, drain some of the oil immediately.

1. Remove the oil filler cap. Fill the crankcase withthe proper amount of oil. Refer to the Operationand Maintenance Manual, “Refill Capacities andRecommendations” topic (Maintenance Section).

NOTICETo prevent crankshaft damage or bearing damage,crank the engine with the fuel supply line closed. Thiswill ensure that all of the oil filters are filled with oil be-fore the engine is started. Do not crank the engine formore than 30 seconds. Allow the starting motor to coolfor two minutes before cranking again.

2. Close the fuel supply line. Crank the engine untilnormal oil pressure shows on the oil pressuregauge. Open the fuel supply line.

3. Start the engine according to this Operatingand Maintenance Manual, “Starting the Engine”procedure (Operation Section). Operate theengine at low idle rpm for 2 minutes.

The 2 minutes of operation ensure that thelubrication system has oil and that the oil filtersare filled. Inspect the engine for oil leaks.

4. Stop the engine and allow the oil to drain back tothe sump for a minimum of 10 minutes.

5. Remove the oil level gauge and check the oillevel. Maintain the oil level between the “ADD”and “FULL” marks on the “ENGINE STOPPED”side of the oil level gauge.

i01042067

Engine Performance - TestSMCS Code: 1000-081

Operate the engine for a minimum of two hours at aminimum load of 60 percent.

• Monitor the operation of the generator set.

• Observe the gauges. Ensure that the gauges arein the normal ranges.

• Record the data. Maintain a record of the data forthe engine performance.

i00626013

Engine Protective Devices -CheckSMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarmsprovide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

A calibration check of the engine protective deviceswill ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.


Engine Speed/Timing Sensor - Clean/Inspect

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Visual InspectionVisually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, broken, or damaged. Damaged wiringor components should be repaired or replacedimmediately.

i01536564

Engine Speed/Timing Sensor -Clean/InspectSMCS Code: 1905-040; 1905-070; 1907-040;1907-070


Engine speed/timing sensor in the front cover of the governor drive(G3406 Engine)

g00798212Illustration 86Engine speed/timing sensor in the front cover for the timing disc(G3412 Engine)

1. Remove the sensor from the cover. Check thecondition of the end of the magnet. Check forsigns of wear and contaminants.

2. Clean the metal shavings and other debris fromthe face of the magnet.

3. Install the sensor and adjust the sensor accordingto the engine's Specifications.

i02526257

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

118 SEBU7572-06Maintenance SectionEngine Valve Rotators - Inspect

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenance isperformed.

Refer to the engine's Specification manual for morethe valve lash settings, or the engine's SystemsOperation/Testing and Adjusting manual for thesettings and the procedure.

i01765711

Engine Valve Rotators - InspectSMCS Code: 1109-040

NOTICEA valve rotator which does not operate properly willaccelerate valve face wear and valve seat wear andshorten valve life. If a damaged rotator is not replaced,valve face guttering could result and cause pieces ofthe valve to fall into the cylinder. This can cause pistonand cylinder head damage.

Note: Use of a platform may be necessary to reachthe engine valve rotators.

Perform this procedure after the valve lash has beenset.

1. Mark the tops of the valve rotators with apermanent marker. Note the position of the marks.

2. Install the valve covers. See the Service Manualfor the procedure.

3. Start the engine. Operate the engine for 5 minutes.Stop the engine.

4. Remove the valve covers. Observe the position ofthe marks that are on the valve rotators.

If a valve fails to rotate, consult your Caterpillardealer.

i01505507

Exhaust Bypass - InspectSMCS Code: 1057-040

For instructions on removal and installation, see theService Manual, “Disassembly and Assembly”.

1. Remove the exhaust bypass valve.

The exhaust bypass valve cover is under springcompression. To prevent personal injury, use cau-tion when removing the cover.

2. Disassemble the valve.

g00781274Illustration 87Exhaust bypass valve(1) Diaphragm(2) Valve stem(3) Breather

3. Inspect diaphragm (1). If the diaphragm is worn orcracked, replace the diaphragm.

4. Inspect valve stem (2) and the valve guide. If theparts are excessively worn, replace the parts.

5. Clean breather (3).

6. Assemble the valve.

7. Install the valve.


Exhaust Piping - Inspect

i00721010

Exhaust Piping - InspectSMCS Code: 1061-040

Hot engine components can cause injury fromburns. Before performing maintenance on theengine, allow the engine and the components tocool.

Inspect the components of the exhaust system.Repair the components or replace the components ifany of the following conditions occur:

• Damage

• Cracks

• Leaks

• Loose connections

Consult your Caterpillar dealer for assistance.

Water Cooled Exhaust ManifoldsThe water cooled exhaust manifolds do not requiremaintenance unless excessive deposits build up inthe exhaust passages. Buildup of deposits causean increase in back pressure that will cause thefollowing conditions:

• Increased fuel consumption

• Reduced boost pressure

If excessive deposits build up in the exhaustpassages, clean the passages in order to removethe deposits.

i01505536

Fuel System Fuel FilterDifferential Pressure - CheckSMCS Code: 1261-535

A fuel filter differential pressure gauge must beinstalled in order to determine when the fuel filterrequires service. This gauge and the fuel filter aresupplied by the customer.

A fuel filter differential pressure gauge indicates thedifference in fuel pressure between the inlet sideand the outlet side of the fuel filter. The differentialpressure increases as the fuel filter becomesplugged.

Operate the engine at the rated speed and at thenormal operating temperature. Check the fuel filterdifferential pressure. Service of the fuel filter dependson the pressure of the fuel system:

• For low pressure gas fuel systems, service thefuel filter when the fuel filter differential pressurereaches 1.7 kPa (0.25 psi).

• For high pressure gas fuel systems, service thefuel filter when the fuel filter differential pressurereaches 34 kPa (5 psi).

For instructions, see Special Instruction, SEHS9298,“Installation and Maintenance of Gaseous FuelFilters”. Consult your Caterpillar dealer for assistance.

i02536498

Gas Pressure Regulator -CheckSMCS Code: 1270-535

Check the fuel pressure to the gas pressure regulator.For low pressure gas, fuel pressure of 10 kPa(1.5 psi) to 34.5 kPa (5 psi) is required for the gaspressure regulator.

Pressure of the Fuel Supply To theCarburetorThe gas pressure regulator maintains a pressuredifferential between the air and the fuel that issupplied to the carburetor. After setting, the gaspressure regulator will maintain the pressuredifferential in response to changes in the air pressure.

Use a water manometer for measuring the pressuredifferential. Obtain the measurement when theengine is operating at high idle rpm. After a loadis applied, the fuel pressure will usually decreaseby approximately 0.1 to 0.25 kPa (0.50 to 1 inchesof H2O). If the performance of the gas pressureregulator is erratic, the gas pressure regulator mayrequire service.

Natural Gas

Set the pressure of the fuel supply to a maximum of1 to 1.2 kPa (4 to 4.5 inches of H2O) HIGHER thanthe ambient air pressure.

120 SEBU7572-06Maintenance SectionGas Pressure Regulator Condensation - Drain

Negative Gas Pressure Regulator(Propane)

If the engine has a dual fuel system with anegative gas pressure regulator for propane, set thepressure of the fuel supply to −0.37 ± −0.06 kPa(−1.5 ±0.250 inches of H2O) LOWER than theambient air pressure.

Liquid Propane Regulator and Vaporizer

If the G3406 engine is equipped with aregulator/vaporizer for a liquid propane application,the regulator controls the pressure to the carburetorand no adjustments can be made.

i01950516

Gas Pressure RegulatorCondensation - DrainSMCS Code: 1270-543

To collect condensation, drip legs should be installedin the following locations:

• Supply line for the gas pressure regulator

• Balance line for the gas pressure regulator

• Supply line to the gas shutoff valve


Cap on the drip leg for the gas supply line to the gas pressureregulator

1. Close the main gas supply valve.

2. Remove the caps from the drip legs.

3. Allow the moisture to drain into a suitablecontainer. Inspect the drip legs for debris. Cleanthe drip legs, if necessary.

4. Clean the caps. Install the caps.

5. Open the main gas supply valve.

i01831525

Generator - DrySMCS Code: 4450-569

Personal injury or death can result from impropertroubleshooting 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 forMaintenance” for information regarding the procedureto safely isolate the generator.

If the insulation resistance values are less than therecommended values, one of the following dryingprocedures must be selected. This decision shouldbe based on the following factors:

• the size of the unit

• the location of the unit

• the equipment that is available

• the experience of personnel

Note: For more information on drying methods, referto Special Instruction, SEHS9124, “Cleaning andDrying of Electric Set Generators”.

Remove the voltage regulator. Cover all of the inletopenings. Cover all of the discharge holes. Providean opening at the top of the machine. This openingwill allow moisture to evaporate. Preferably, thisopening will be located at the fan end. Monitor thewinding temperatures. DO NOT APPLY HEAT TOORAPIDLY. Winding temperature should be raisedgradually at a rate of 10 °C (50 °F) per hour up to85 °C (185 °F). Measure insulation resistance at onehour intervals. Typically, the insulation resistancewill slowly drop while the temperature is rising. Theinsulation resistance will then start to increase at aslow rate until the insulation resistance reaches aconstant level .

The following methods can be used for drying agenerator:

• Self-circulating air method

• Oven method


Generator - Dry

• Controlled current method

Self-Circulating Air MethodRun the engine and disconnect the generator load.This will help circulate air. Operate the generatorspace heaters.

Oven MethodPlace the entire generator inside a forced air dryingoven for four hours at 65 °C (149 °F).

NOTICEUse a forced air type oven rather than a radiant typeoven.

Radiant type ovens can cause localized overheating.

Controlled Current MethodTable 25

Tools Needed

PartNumber

Description Qty

8T-0900 Clamp on ammeter (0 -1200 amperes)

1

External 12 Volt DC PowerSource

1

Rheostat 1

Switch 1

Heat can be used in order to dry the generatorwindings. This heat can be created by allowing acontrolled current to flow through the generator. Nohigh voltages are generated during the followingprocedure. Therefore, insulation breakdown will notoccur.


Generator Wiring Diagram

(A) Clamp-on ammeter(B) Rotating field assembly(C) Rheostat(D) External 12 Volt DC Power Source(E) Switch(CR1-CR6) Diodes(CR7) Varistor(L1) Exciter field (stator)(L2) Exciter armature (rotor)(L3) Main field (rotor)(L4) Main armature (stator)

1. Obtain an external 12 Volt DC power source.

2. Refer to the above diagram. Disconnect “F1+”from the voltage regulator. Disconnect “F2-” fromthe voltage regulator.

3. Disconnect the generator load. Connect thegenerator output leads “T0”, “T1”, “T2”, and“T3” together. Install the clamp-on ammeter togenerator output lead “T1”.

Note: When the line current is measured onmultiple-lead units, measure the current in eachconductor for each phase. Add the currents together.

4. Refer to the above diagram. Connect rheostat (C).Adjust rheostat (C) to the maximum resistancevalue. Connect the external power source towires“F1+” and “F2-” with switch (E) in the openposition.

122 SEBU7572-06Maintenance SectionGenerator - Inspect

5. Start the generator set. Run the generator set atidle speed.

6. Monitor the phase current. Gradually increase theengine RPM. Increase the engine RPM until oneof the following conditions are met:

• The rated phase current is obtained.

• The full generator set speed is obtained.

7. If more phase current is still necessary, run thegenerator at idle speed and close switch (E).Slowly turn rheostat (C) until the rated phasecurrent is reached.

8. On an hourly basis, stop the drying procedure.Check the insulation resistance. Repeat the abovesteps until the insulation resistance is acceptable.

i01461264

Generator - InspectSMCS Code: 4450-040



Refer to Safety Section, “Generator Isolating forMaintenance” for information regarding the procedureto safely isolate the generator.

Proper maintenance of electrical equipment requiresperiodic visual examination of the generator andperiodic visual examination of the windings. Propermaintenance of electrical equipment also requiresappropriate electrical checks and appropriate thermalchecks. Insulation material should be examined forcracks. The insulation material should be examinedfor accumulations of dirt and dust. If there is aninsulation resistance value that is below normal, aconductive path may be present. This conductivepath may be made of one of the following materials:

• Carbon

• Salt

• Metal dust

• Dirt that is saturated with moisture

These contaminants will develop a conductive pathwhich may produce shorts. Cleaning is advisable ifheavy accumulations of dirt can be seen or if heavyaccumulations of dust can be seen. If excess dirt isthe cause of a restriction in the ventilation, cleaningis also advisable. Restricted ventilation will causeexcessive heating.

NOTICETo avoid the possibility of deterioration to the genera-tor windings, do not clean the generator unless thereis visual, electrical, or thermal evidence that dirt ispresent.

If harmful dirt accumulations are present, a varietyof cleaning techniques are available. The cleaningprocedure that is used may be determined by one ofthe items on the following list:

• The extent of the cleaning procedure that is beingattempted

• The type of enclosure of the generator

• The voltage 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 generatormay not be necessary or feasible. In this case,a vacuum cleaner should be used to pick up thefollowing items: dry dirt, dust, and carbon. This willprevent the spreading of these contaminants.

A small nonconductive tube may need to beconnected to the vacuum cleaner. This will allow thevacuum cleaner to clean the surfaces that are notexposed. After most of the dust has been removed,a small brush may be attached to the vacuum hosein order to loosen dirt that is more firmly attached tothe surface.

After the initial cleaning with a vacuum, compressedair may be used to remove the remaining dust anddirt. Compressed air that is used for cleaning shouldbe free of moisture and free of oil. Air pressureshould be a maximum of 210 kPa (30 psi) in order toprevent mechanical damage to the insulation. If theabove cleaning procedures are not effective, consulta Caterpillar dealer.


Generator Lead - Check

Cleaning (DisassembledGenerators)An initial insulation resistance check should bemade on the generator in order to confirm electricalintegrity. A minimum reading of one megohm wouldbe expected with severely contaminated generators.A zero megohm reading may indicate an insulationbreakdown. An insulation breakdown requires morethan cleaning. An insulation breakdown requiresrepair.

A high pressure wash is normally an effective wayto clean windings. This includes windings that havebeen exposed to flooding or windings that have beencontaminated by salt. A solution of hot water anddetergent is used for this method of cleaning.

A high pressure wash sprays a high velocity fluidstream of this solution over the generator that isbeing cleaned. This detergent washing is followed bymultiple sprays of clean water. The clean water isused in order to remove the detergent or the cleanwater is used in order to dilute the detergent.

Allow the generator to dry at room temperature.Check the insulation resistance. The insulationresistance should now be normal. If the insulationresistance is not normal, repeat the procedure. Itmay be necessary to use solvents if the generatoris contaminated with oil or if the generator iscontaminated with grease.

Note: For more information on drying methods, referto Special Instructions, SEHS9124, “Cleaning andDrying of Electric Set Generators”.

i02517207

Generator Lead - CheckSMCS Code: 4450-535

The generator set may have braided cables betweenthe generator and the breaker instead of wire cables.Check for signs of wear along the braided cables.Pay particular attention to the cables at the housingfor the breaker and the generator terminal box.

If the rubber mats or the insulation on the braidedcables show signs of wear at points of contactwith other surfaces, replace the mats or the cableimmediately. If your generator set does not haverubber mats in place, contact your Caterpillar dealer.

i03642825

Generator Load - CheckSMCS Code: 4450-535-LA

During normal operation, monitor the power factorand monitor generator loading.

When a generator is installed or when a generatoris reconnected, ensure that the total current in anyone phase does not exceed the nameplate rating.Each phase should carry the same load. This allowsthe generator to work at the rated capacity. If onephase current exceeds the nameplate amperage,an electrical imbalance will occur. An electricalimbalance can result in an electrical overload and anelectrical imbalance can result in overheating.

The power factor can be referred to as the efficiencyof the load. This can be expressed as the ratio of kVAto actual kW. The power factor can be calculated bydividing kW by kVA. Power factor is expressed as adecimal. Power factor is used to mean the portionof current that is supplied to a system that is doinguseful work. The portion of the current that is notdoing useful work is absorbed in maintaining themagnetic field in motors. This current (reactive load)can be maintained without engine power.

Generator sets normally have a low idle setting thatis higher than industrial engines. Low idle will beapproximately 66 percent of the full speed that isachieved by 60 Hz units. This would be equal to 80percent of the full speed that is achieved by 50 Hzunits.

Some generator sets are equipped with Woodwardgovernors and some generator sets are equippedwith Caterpillar electronic governors. Thesegenerator sets have no low idle stop. On generatorsets with mechanical governors and generators thatare natural gas, the low idle is set at the factory.Adjustment of the low idle on these machines shouldonly be done by a Caterpillar dealer.

Note: Operating the generator set at low idle speedfor an extended time will cause some voltageregulators to shut off. The generator set must becompletely shut down and the generator set mustbe restarted. This will allow the voltage regulator toagain produce an output.

124 SEBU7572-06Maintenance SectionGenerator Set - Test

i03292462

Generator Set - TestSMCS 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, highvoltage and current are present.

Improper test equipment can fail and present ahigh voltage shock hazard to its user.

Make sure the testing equipment is designed forand 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 (disconnectedfrom utility and/or other generators powerservice), and either locked out or tagged DONOT OPERATE.

• Make sure the generator engine is stopped.

• Make sure all batteries are disconnected.

• Make sure all capacitors are discharged.

DANGER: Shock/Electrocution Hazard-Do not op-erate this equipment or work on this equipmentunless you have read and understand the instruc-tions and warnings in the Operation and Mainte-nance Manual. Failure to follow the instructions orheed the warnings will result in serious injury ordeath.

Table 26

Tools Needed

Part Number Part Quantity

237-5130 DigitalMultimeter 1

12 VDC Battery 1

PotentialTransformer 1

The generator set functional test is a simplified testthat can be performed in order to determine if thegenerator is functional. The generator set functionaltest should be performed on a generator set that isunder load.

The generator set functional test determines if thefollowing statements happen:

• A phase voltage is being generated.

• The phase voltages are balanced.

• The phase voltages change relative to enginespeed.

The generator set functional test consists of thefollowing steps:

1. Stop the generator. Connect the potentialtransformer's high voltage winding to thegenerator terminals (T1) and (T2). Connectthe voltmeter to the low voltage winding. If twotransformers are available, connect the highvoltage winding of the second transformer to thegenerator terminals (T1) and (T3). Connect thesecondary terminals that correspond to generatorterminal (T2) of both transformers together.

2. Disconnect wires “F1+” and “F2-” from the voltageregulator. Disconnect the generator from the load.

3. Connect a 12 VDC automotive battery to wires“F1+” and “F2-”.

NOTICEDo not operate the generator set at a speed that ishigher than one-half of the rated speed.

Higher speeds under these test conditions can causedamage to the system.

4. Operate the generator set at half the rated speed.

5. Measure the AC voltage across the low voltageterminals of the transformer that correspond to thefollowing generator terminals: “T1” and “T2”, “T2”and “T3”, and “T3” and “T1”. Record the voltages.

6. Monitor the voltage between any two of thelocations in step 5. Decrease the generator setspeed by 10 percent. Increase the generator setspeed by 10 percent.

7. The voltages that were measured in Step 5 shouldbe nearly equal. These voltages should measurea minimum of 85 VAC.


Generator Set Alignment - Check

8. When the generator set speed is decreased by10 percent, the voltages that were measured inStep 6 should decrease by 10 percent. When thegenerator set speed is increased by 10 percent,the voltages that were measured in Step 6 shouldincrease by 10 percent.

i03956450

Generator Set Alignment -Check(Generator Sets)SMCS Code: 7002-024

The genset must be aligned when the genset isinstalled or moved into a different position. If thegenerator set is run at the full continuous rating, thealignment of the generator to the engine must bechecked annually.

Properly maintain the alignment between the engineand the driven equipment in order to minimize thefollowing problems:

• Bearing problems

• Vibration of the engine crankshaft

• Vibration of the driven equipment

Refer to the following information for more informationabout the alignment of the generator set:

• Special Instruction, SEHS7654, “Alignment -General Instructions”

• Special Instruction, SEHS7259, “Alignment ofSingle Bearing Generators”

• Special Instruction, REHS0177, “Alignment of theClose Coupled Two Bearing Generators”

Keep a record of the measurement of the alignment.The record may be used to check the trend of thealignment. The record may be used to analyze thetrend of the alignment.

i03643886

Generator Set Vibration -Test/RecordSMCS Code: 4450-081-VI

Check for vibration damage.

Vibration may cause the following problems:

• Coupling wear

• Loose fittings

• Fatigue of the metal components of the engine

• Cracks in the cabinet which surrounds thegenerator

• Cracks in welds

• Excessive noise

• Cracked insulation

The following areas are susceptible to vibrationdamage:

• Coupling for the generator set

• Generator bearings

• Stator output leads

• Protective sleeving

• Insulation

• Exposed electrical connections

• Transformers

• Fuses

• Capacitors

• Lightning arresters

When a generator set is installed, a vibration plotshould be recorded in order to assist in diagnosingpotential problems. This vibration plot should beupdated yearly. The vibration plot should also beupdated when the generator set is moved andwhen the engine is overhauled. This will allowthe trend of the vibration to be monitored andanalyzed. A potential problem may be prevented bymonitoring the trend of the vibration. If the vibrationis approaching the limit of the specification of thecomponent, the problem may be more imminent.Refer to Data Sheet, LEKQ4023, “Linear Vibration”for the allowable limits of vibration.

Caterpillar also recommends recording the vibrationof the bearing at the generator bearing bracket.

If the vibration exceeds the EDS limits for vibration,check the alignment. Refer to this Operation andMaintenance Manual, “Generator Set Alignment -Check” for the alignment procedure.

126 SEBU7572-06Maintenance SectionGovernor - Inspect

Contact the Caterpillar Dealer Service Tools groupfor information on ordering a vibration analyzer thatwill meet your needs.

i01041704

Governor - InspectSMCS Code: 1264-040

Inspect the governor for oil leaks.

For service information, see the literature that isprovided by the OEM of the governor.

i02149548

Hoses and Clamps - ReplaceSMCS Code: 1380-510

Note: For instructions on draining the cooling systemand filling the cooling system, see this Operationand Maintenance Manual, “Cooling System Coolant(NGEC) - Change” topic (Maintenance Section).

1. Drain the cooling system.

2. Remove the used hoses and clamps. Discard theitems.

3. Install new hoses and clamps. For thecorrect torque to use on the hose clamps,see the Specifications, RENR3130, “TorqueSpecifications”, “Hose Clamps” topic.

4. Fill the cooling system.

5. Start the engine. Inspect the hose connections forleaks.

i01042052

Ignition System Spark PlugWires - Replace(Standard Ignition Systems)SMCS Code: 1558-510

Ignition systems can cause electrical shocks.Avoid contacting the ignition system componentsand wiring during operation.

NOTICEPulling on the wiring harness may break the wires. Donot pull on the wiring harness.

1. Disconnect the spark plug wire assembly from thetransformer.

2. Disconnect the wire assembly from the spark plug.Discard the wire assembly.

3. Connect the new wire assembly to the spark plug.

4. Connect the wire assembly to the transformer.

i02536524

Ignition System Spark Plugs -Inspect/ReplaceSMCS Code: 1555-535

Ignition systems can cause electrical shocks.Avoid contacting the ignition system componentsand wiring.

Do not attempt to remove the valve covers whenthe engine is operating. The transformers aregrounded to the valve covers. Personal injury ordeath may result and the ignition system will bedamaged if the valve covers are removed duringengine operation. The engine will not operatewithout the valve covers.

Maintenance of the spark plugs is required in orderto achieve the following benefits:

• Normal fuel consumption

• Normal level of emissions

• Maximum service life of the spark plugs

• Stable operation

The service life of the spark plugs is affected byfouling due to deposits from the oil and by peakvoltage. Maintenance of the ignition system is alsoaffected by voltage. Higher voltage is requiredby higher inlet manifold air pressure, a highercompression ratio, and a leaner air/fuel ratio. Highervoltage reduces the service life of components suchas spark plugs, wires, and transformers.


Ignition System Spark Plugs - Inspect/Replace

Removing the Spark Plug

Standard Ignition System

g00798356Illustration 90(1) Wire for the secondary circuit(2) Transformer assembly(3) Boot(4) Seal(5) Spark plug(A) Section view of boot


1. Disconnect wire (1) from transformer assembly(2). The wire may break if you pull on the wire.

2. Remove boot (3).

Pressurized air can cause personal injury. Whenpressurized air is used for cleaning, wear a pro-tective face shield, protective clothing, and pro-tective shoes.

3. Ensure that the area around the spark plug isclean and free of dirt and debris. Thoroughlyremove any debris. Use compressed air. Themaximum air pressure for cleaning purposes mustbe below 207 kPa (30 psi). The spark plug canalso be cleaned with a nonmetallic brush.

4. Use a deep well socket with an extension in orderto remove spark plug (5). After the spark plug hasbeen loosened, remove the spark plug by hand inorder to detect problems with the threads. Afterthe spark plug has been removed, discard theused spark plug gasket.

NOTICEDo not use a thread tap. A thread tap will removemetalunnecessarily. The threads could be stripped and thecylinder head could be damaged.

If the spark plug resists removal by hand, applypenetrating oil to the threads. To help the oil penetratethe threads, use the wrench and turn the spark plugback and forth until the spark plug is loose.

If the spark plug cannot be removed by hand, cleanthe internal threads with the 9U-7511 Spark PlugSeat Cleaner. This tool scrapes debris from the seatand from the threads in the cylinder head. Be sure toclean any debris from the cylinder.

CSA Ignition System


(1) Wiring harness(2) Boot(3) Transformer(4) Spacer(5) Spark plug

1. Unscrew wiring harness (1) from the threadedconnector.

2. Remove boot (2).

3. Unscrew transformer (3) from spark plug (5) inorder to remove the transformer.

128 SEBU7572-06Maintenance SectionIgnition System Spark Plugs - Inspect/Replace




Note: Ensure that you keep copper spacer (4) that isinstalled between the end of the transformer and thetop of the hex on the spark plug.



If the spark plug cannot be removed by hand, cleanthe internal threads with the 9U-7511 Spark PlugSeat Cleaner. This tool scrapes debris from the seatand from the threads in the cylinder head. Be sure toclean any debris from the cylinder.

Electronic Ignition System


(1) Valve cover(2) Wiring harness(3) Transformer assembly(4) Spark plug(5) O-ring seal

1. Remove valve cover (1).


2. Disconnect wiring harness (2) from transformerassembly (3).

3. Remove transformer assembly (3).

4. Inspect O-ring seal (5). If the O-ring seal is hard,cracked, or melted, install a new O-ring seal.





Ignition System Spark Plugs - Inspect/Replace



If the spark plug cannot be removed by hand, cleanthe threads with the 9U-7511 Spark Plug SeatCleaner. This tool scrapes debris from the seat andfrom the threads in the cylinder head. Be sure toclean any debris from the cylinder.

Inspecting the Spark PlugNote: Some spark plugs have electrodes witha single ground strap. Some spark plugs haveelectrodes with two ground straps.


Typical spark plug with a single ground strap(1) Terminal post(2) Insulator(3) Shell(4) Gasket(5) Electrode

g00829527Illustration 94Section view and bottom view of a spark plug with two groundstraps

Inspect the spark plug closely for damage. Thecondition of the spark plug can indicate the operatingcondition of the engine.

Inspect insulator (2) for cracks. If a crack is found,discard the spark plug.

Faint marks may extend from shell (3) onto theinsulator. The marks may be a result of a coronathat forms at the top of the shell. The conductor willdevelop a corona when a very high voltage potentialionizes the air. This is a normal condition. This is notan indication of leakage between the shell and theinsulator.

Inspect shell (3) for damage. Cracks can be causedby overtightening the spark plug. Overtightening canalso loosen the shell. Discard any spark plug that hasa shell that is cracked or loose.

Caterpillar spark plugs have precious metal tips onthe ends of the electrodes. This material will graduallyerode. Use extreme care when you set the electrodegap. Maintain even spacing and proper alignmentbetween the precious metal surfaces.

Replace the spark plug if the precious metal is wornoff.

A light brown deposit or a beige deposit is producedby normal operation.

Deposits that are gray or black may be caused bythe following substances:

• Excessive oil

• Use of the wrong oil

• A substance that is introduced through the fuelsystem or the air system

A spark plug can operate despite a buildup of ash.However, a buildup of ash can cover the electrodegap. This will cause misfire. Large deposits mayretain heat which can cause premature fuel ignition.This can lead to uncontrollable detonation.

Cleaning the Spark PlugThoroughly clean the spark plug. Do not use a wirebrush. Glass beads are the preferred method forcleaning.

Follow these guidelines for using glass beads:

• Always use clean glass beads.

• Use care in order to clean only the electrode andthe insulator near the electrode.

• Do not use glass beads on the outside of the shellor on the upper part of the insulator.

130 SEBU7572-06Maintenance SectionIgnition System Spark Plugs - Inspect/Replace

Checking the Spark PlugAfter the spark plug is clean, measure the sparkplug's electrode gap.

Note: Use the 9U-7516 Spark Plug Gauge tomeasure the electrode gap. Do not use a flat feelergauge for measuring the electrode gap of used sparkplugs. A feeler gauge will incorrectly measure theactual electrode gap because the used preciousmetal tips are curved.

Adjust the electrode gap by bending the groundelectrode at the existing bend. Then bend the strapnear the weld in order to achieve proper alignmentand even spacing between the two precious metalsurfaces. Measure the electrode gap after thealignment. Correct the electrode gap, if necessary.

• For G3406 Engines, set the electrode gap to0.38 mm (0.015 inch).

• For G3412 Engines with a compression ratio of8.5:1 (low emissions), set the electrode gap to0.38 ± 0.05 mm (0.015 ± 0.002 inch).

• For G3412C Engines with a compression ratio of11.4:1 (low emissions), set the electrode gap to0.28 ± 0.05 mm (0.011 ± 0.002 inch).

Installing the Spark PlugNote: Do not use anti-seize compound on sparkplugs. Most of the heat is transferred through thethreads and the seat area of the spark plug. Thesurfaces must be in contact in order to provide theheat transfer that is required.

Ensure that the spark plug is clean and free of dirtand oil.

Always use a new gasket when a spark plug isinstalled. Orient the tabs of the gasket toward thecombustion chamber. Otherwise, the gasket may notseat properly. If a gasket for a spark plug is installedincorrectly, do not increase the torque on the sparkplug in order to improve the seal. Do not reuse thegasket. Install a new gasket.

Standard Ignition System

g00798356Illustration 95(1) Wire for the secondary circuit(2) Transformer(3) Boot(4) Seal(5) Spark plug(A) Section view of boot

NOTICEDo not overtighten the spark plug. The shell can becracked and the gasket can be deformed. The met-al can deform and the gasket can be damaged. Theshell can be stretched. This will loosen the seal that isbetween the shell and the insulator, allowing combus-tion pressure to blow past the seal. Serious damageto the engine can occur.

Use the proper torque.

1. Install spark plug (5) by hand until the spark plugbottoms out. Tighten the spark plug to 30 ± 4 N·m(22 ± 3 lb ft).

2. Inspect boot (3) and wire (1). If the componentsare in good condition, install the components. Ifthe components are not in good condition, installnew components.


Ignition System Timing - Check/Adjust

CSA Ignition System

g00798357Illustration 96(1) Wiring harness(2) Boot(3) Transformer(4) Spacer(5) Spark plug

1. Place spacer (4) on top of the spark plug's hex.Install spark plug (5) by hand until the spark plugbottoms out. Tighten the spark plug to 30 ± 4 N·m(22 ± 3 lb ft).

2. Screw transformer (3) onto spark plug (5) untilthe transformer is finger tight. Then tighten thetransformer for an additional one-eighth turn (45degrees).

3. Inspect boot (2) and wiring harness (1). If thecomponents are in good condition, install thecomponents. If a component is not in goodcondition, replace the old component with a newcomponent.

Electronic Ignition System


(1) Valve cover(2) Wiring harness(3) Transformer assembly(4) Spark plug(5) O-ring seal

1. Install spark plug (4). Tighten the spark plug to30 ± 4 N·m (22 ± 3 lb ft).

2. Ensure that the transformer assembly is clean andfree of dirt and oil. Lubricate O-ring seal (5) withone of the following lubricants:

• 4C-9504 Dielectric Grease

• 5N-5561 Silicone Lubricant

• 8T-9020 Dielectric Grease

3. Install transformer assembly (3). Ensure that thetransformer assembly is aligned with the socketfor the wiring harness. Ensure that the socket forthe wiring harness is oriented toward the centerof the engine.

4. Connect wiring harness (2).

5. Install valve cover (1).

i01005974

Ignition System Timing -Check/AdjustSMCS Code: 1550-025; 1550-535

After maintenance has been performed on theignition system, check the timing of the ignitionsystem. Adjust the timing, if necessary.

The optimum ignition timing for a gas engine variesaccording to several factors:

• Compression ratio of the engine

132 SEBU7572-06Maintenance SectionIgnition System Transformer Resistance - Test

• Inlet air temperature

• Methane number of the gas

For the proper timing, see the Engine Performancepublication for the engine.

Adjust the timing according to the Service Manual,“Systems Operation/Testing and Adjusting” module.Consult your Caterpillar dealer for assistance.

i00682407

Ignition System TransformerResistance - TestSMCS Code: 1550-081

The transformers produce a voltage increase. Forgood operation, the connections must be clean andsecure. Inspect the transformers for the followingconditions. If any of the conditions are found, correctthe condition:

• Corrosion

• Dirty insulator


• Moisture

• Open circuits

• Short circuits

Test the resistance of the transformers. Test eachtransformer at both the side with high voltage andthe side with low voltage. See the Service Manual,“Specifications” module for the procedure. Consultyour Caterpillar dealer for assistance.

i01113853

Inlet Air System - InspectSMCS Code: 1058-040; 1071-040; 1087-040

Inspect the components of the air inlet system forthe following conditions:

• Cracks

• Leaks


Inspect the following components:

• Piping between the air cleaner and the turbocharger

• Turbocharger

• Piping between the turbocharger and theaftercooler

• Aftercooler

• Connection of the aftercooler to the air plenum

• Connection of the air plenum to the cylinder head

Ensure that all of the connections are secure. Ensurethat the components are in good condition.

Make repairs, if necessary. For information regardingremoval and installation of the components, seethe Service Manual, “Disassembly and Assembly”module. Consult your Caterpillar dealer forassistance.

i03642858

Insulation - TestSMCS Code: 4453-081; 4454-081; 4457-081;4470-081

Recommended Periodic InsulationTests

The high voltage that is produced by an operatinggenerator 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 disablethe starting system. Lock out all switchgear andautomatic transfer switches that are associatedwith the generator.

Table 27

Tools Needed

Part Number Part Name Quantity

300-8648 InsulationTesting Gp

1

Periodically, use an insulation tester to check theinsulation resistance of the generator's main statorwinding. The frequency of this test is determined bythe generator's environment. Previous insulationtester readings will also determine the frequency ofthis test.


Insulation - Test

Test the main stator windings with an insulation testerin the following situations:

• The generator set is started for the first time.

• The generator set is removed from storage.

• The generator set is operating in a humidenvironment. Test every three months.

• The generator set is not protected from theelements in an enclosed area. Test every threemonths.

• The generator set is installed in an enclosed area.This area needs to be low in humidity and this areaneeds to have steady temperatures. Test everytwelve months (minimum).

• The generator set has not been run under loadfor three months. Test the generator set weekly.Use space heaters around the generator set if thegenerator is exposed to a sea water environment orif the humidity is above 75 percent. Also use spaceheaters if a test result was below 3 megohms.

Space heaters must be used whenever the generatorset is not under load. Space heaters must also beused whenever salt is present or whenever highhumidity is present. Using a space heater in thisfashion is the only way to maintain insulation testerreadings above one megohm. Use space heatersonly when the generator is not running.

For additional information, refer to Special Instruction,SEHS9124, “Cleaning and Drying of Electric SetGenerators”.

Recommended Procedure for theInsulation Test

Personal injury or death can result from electro-cution.

The megohmmeter is applying a high voltage tothe circuit.

To avoid electrocution, do not touch the instru-ment leads without first discharging them. Whenfinished testing also discharge the generatorwindings.

1. Take the generator out of service.

2. Visually inspect the generator for moisture. Ifmoisture exists, do not perform this insulationtest. Dry the unit first. Refer to Special Instruction,SEHS9124, “Cleaning and Drying of Electric SetGenerators”.

3. Inspect the installation. Determine the equipmentthat will be tested by the insulation tester.

4. Discharge the capacitance of the windings.

5. Disconnect “T0” from ground.

6. Disconnect the sensing lead wires for theregulator. This may be accomplished byunplugging the harness connectors.

7. Disconnect the PT leads of the load share module.

8. Connect the insulation tester's Black lead toground.

9. Connect the insulation tester's RED lead to “T0”.

10.Set the voltage to the rated voltage of thegenerator.

11.Use the 30/60 Time Resistance Method:

a. Apply voltage.

b. Observe the readings at 30 seconds. Observethe readings at 60 seconds.

c. Record the 60 second reading. This readingmust be corrected for temperature.

d. Record temperature.

e. Record humidity.

f. Remove voltage.

12.Evaluate the readings. The actual value of theresistance may vary greatly between generators.For this reason, the insulation's condition must beevaluated. Base this evaluation on the comparisonbetween the 60 second resistance readings andthe readings that were taken on previous dates.These two readings must be taken under similarconditions. If a 60 second resistance readinghas a 50 percent reduction from the previousreading, the insulation may have absorbed toomuch moisture.

Switch the insulation tester to the “OFF” position.This will discharge the insulation tester's leads.Disconnect the insulation tester's leads.

134 SEBU7572-06Maintenance SectionInsulation - Test

Note: The results from the insulation resistancechecks indicate when cleaning and/or repairing isbecoming critical. Generally, insulation resistancewill vary greatly with temperature. Therefore, alwaystest at the same temperature and humidity. Refer toIllustration 98.

Engine Serial Number_____________________________________

Serial Number for the Generator________________________


Insulation - Test


136 SEBU7572-06Maintenance SectionJacket Water Heater - Check

i03230758

Jacket Water Heater - CheckSMCS Code: 1383-535

Jacket water heaters help to improve startability inambient temperatures that are below 21 °C (70 °F).All installations that require automatic starting shouldhave jacket water heaters.

Check the operation of the jacket water heater. Checkthe operation of the circulation pump, if equipped. Foran ambient temperature of 0 °C (32 °F), the heatershould maintain the jacket water coolant temperatureat approximately 32 °C (90 °F).

i02206267

Overhaul (Major)SMCS Code: 7595-020-MJ

Scheduling a Major OverhaulThe need for a major overhaul is determined byseveral factors.

• An increase of oil consumption

• An increase of crankcase blowby

• A decrease and variation of cylinder compression

The following changes in the three conditionsnormally require a scheduled overhaul:

• A 300 percent increase in oil consumption

• A 200 percent increase in crankcase blowby

• A 20 percent loss of cylinder compression

Note: These indications do not require an engineto be shut down for service. These indicationsonly mean that an engine should be scheduled forservice in the near future. If the engine operationis satisfactory, an immediate overhaul is not arequirement.

The engine does not require an overhaul if theengine is operating within acceptable limits foroil consumption, crankcase blowby, and cylindercompression.

Other factors must also be considered for determininga major overhaul:

• The service hours of the engine

• The wear metal analysis of the lube oil

• An increase in the levels of noise and vibration

An increase of wear metals in the lube oil indicatesthat the bearings and the surfaces that wear mayneed to be serviced. An increase in the levels ofnoise and vibration indicates that rotating partsrequire service.

Note: It is possible for oil analysis to indicate adecrease of wear metals in the lube oil. The cylinderliners may be worn so that polishing of the boreoccurs. Also, the increased use of lube oil will dilutethe wear metals.

Monitor the engine as the engine accumulatesservice hours. Consult your Caterpillar dealer aboutscheduling a major overhaul.

Note: The driven equipment may also require servicewhen the engine is overhauled. Refer to the literaturethat is provided by the OEM of the driven equipment.

Major Overhaul InformationA major overhaul includes all of the work that is donefor top end overhauls. A major overhaul includesadditional parts and labor. Additional parts andlabor are required in order to completely rebuild theengine. In some cases, the engine is relocated fordisassembly.

For the major overhaul, all of the bearings,seals, gaskets, and components that wear aredisassembled. The parts are cleaned and inspected.If necessary, the parts are replaced. The crankshaftis measured for wear. The crankshaft may requireregrinding. Alternatively, the crankshaft may bereplaced with a Caterpillar replacement part.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of thefollowing recommendations.

The following definitions explain the terminology forthe services that are performed during an overhaul:


Overhaul (Major)

Inspect – Inspect the components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”. The guidelines were developed in order tohelp Caterpillar dealers and customers to avoidunnecessary expenditures. New parts are notrequired if the existing parts can still be used,reconditioned, or repaired. If the components arenot in the reusability guidelines, refer to the ServiceManual, “Specifications” module.

Rebuild – The component can be reconditioned inorder to comply with reusability guidelines.

Replace – The service life of the part is exhausted.The part may fail before the next maintenanceinterval. The part must be replaced with a part thatmeets functional specifications. The replacementpart may be a new part, a CAT remanufactured part,a rebuilt part, or a used part. Some worn componentsmay be exchanged with your Caterpillar dealer.Consult your Caterpillar dealer about repair optionsfor your engine.

Replacing of Components

Note: The cylinder head may be rebuilt, whenpossible.

Replace the following components during the majoroverhaul.

• Alternator

• Alternator and fan drive belts

• Camshaft bearings

• Connecting rod bearings

• Crankshaft bearings

• Crankshaft seals

• Crankshaft vibration damper

• Cylinder liners

• Cylinder head and gaskets

• Exhaust manifold

• Gaskets and seals

• Gear train bearings

• Governor

• Hoses and clamps

• Main bearings

• Piston rings

• Rod ends for the control linkage of the actuator

• Spark plugs

• Spark plug wires

• Transformers

• Valve rotators

• Water temperature regulators

• Wiring harnesses

Rebuilding of Components

Rebuild the following components during the majoroverhaul. If the components cannot be rebuilt,replace the components.

• Carburetor

• Cylinder packs

• Exhaust bypass

• Gas regulator

• Inlet air piping

• Oil pump

• Starting motor

• Turbocharger

• Water pumps

Inspecting Components

Inspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

• Aftercooler

• Camshafts

• Camshaft followers

• Connecting rods

• Crankshaft

138 SEBU7572-06Maintenance SectionOverhaul (Top End)

• Gears of the gear train

• Gear train bushings

• Governor

• Inlet air piping

• Oil cooler

• Oil pump

• Pistons

• Transformers

i02206264

Overhaul (Top End)SMCS Code: 7595-020-TE

Scheduling a Top End OverhaulTop end overhauls are scheduled according tothe recession of the exhaust valve stems. Thismeasurement provides an accurate indication of therate of valve wear. This measurement can be used topredict when a cylinder head requires replacement.For more information, refer to this Operation andMaintenance Manual, “Valve Stem Projection -Measure/Record” topic.

Note: The generator or the driven equipment mayalso require service when the engine overhaul isperformed.

Top End Overhaul InformationA top end overhaul involves servicing the cylinderheads and turbochargers. Also, some other enginecomponents are inspected.

Top end overhauls require more tools than preventivemaintenance. The following tools are needed forrestoring the engine to factory specifications:

• Torque wrenches

• Dial indicators

• Accurate measurement tools

• Cleaning equipment

• Rebuilding equipment

Caterpillar dealers are equipped with these tools.Caterpillar dealers can provide a flat rate price fora top end overhaul.

Unexpected problems may be found during a topend overhaul. Plan to correct these problems, ifnecessary.

• Buildup in the cylinders from excessive oilconsumption

• Buildup in the cylinders from contamination of thefuel

• Plugging of the aftercooler from coolant that ispoorly maintained

• Plugging of the aftercooler from contamination ofthe inlet air

• Degradation of the oil cooler from hydrogen sulfidein the fuel

Inspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of thefollowing recommendations.

The following definitions explain the terminology forthe services that are performed during an overhaul:

Inspect – Inspect the components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”. The guidelines were developed in order tohelp Caterpillar dealers and customers to avoidunnecessary expenditures. New parts are notrequired if the existing parts can still be used,reconditioned, or repaired. If the components arenot in the reusability guidelines, refer to the ServiceManual, “Specifications” module.

Rebuild – The component can be reconditioned inorder to comply with reusability guidelines.

SEBU7572-06 139Maintenance SectionOverhaul (Top End)

Replace – The service life of the part is exhausted.The part may fail before the next maintenanceinterval. The part must be replaced with a part thatmeets functional specifications. The replacementpart may be a new part, a CAT remanufactured part,a rebuilt part, or a used part. Some worn componentsmay be exchanged with your Caterpillar dealer.Consult your Caterpillar dealer about repair optionsfor your engine.

Replacing of Components

Note: The cylinder head may be rebuilt, whenpossible.

Replace the following components during a top endoverhaul.

• Alternator and fan drive belts

• Cylinder heads and gaskets

• Forward bearing of the fan drive

• Hoses and clamps

• Rod ends for the control linkage of the actuator

• Spark plugs

• Spark plug wires

• Water temperature regulator

Rebuilding of Components

Rebuild the following components during a top endoverhaul:

• Carburetor

• Gas regulator

• Starting motor

• Turbocharger

• Water pumps

Note: Periodic inspection of the turbocharger isrecommended for determining when the turbochargerwill require an overhaul. In a few applications, theturbocharger may require rebuilding prior to the topend overhaul. An example is an application withloads that vary frequently. In these cases, rebuildingthe turbocharger normally occurs separately fromrebuilding the cylinder heads. Some applicationscan operate longer before the turbocharger requiresrebuilding. Only experience can determine the actualneed.

Inspecting of Components

Clean the following components. Pressure test thecomponents. Replace the components, if necessary:

• Aftercooler core (if equipped)

• Oil cooler core

Note: It is difficult to clean the aftercooler core whenmaintenance is not performed.

Note: This procedure may be used for cleaning boththe aftercooler core and the oil cooler core.

1. Remove the core. For the procedure, refer to theService Manual, “Disassembly and Assembly”module.

2. Turn the core upside-down in order to removedebris.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

NOTICEDo not use a high pressure spray for cleaning the finsof the core. A high pressure spray can damage thesurface of the fins and reduce the flow of air throughthe core.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Use a two to five percentconcentration of the cleaner at temperatures upto 93 °C (200 °F). Refer to Application Guide,NEHS0526 or consult your Caterpillar dealer formore information.

4. Steam clean the core in order to remove anyresidue. Flush the fins of the core. Remove anyother trapped debris.

5. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.

140 SEBU7572-06Maintenance SectionOverhaul Considerations

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 lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the air inthe reverse direction of the normal flow.

Note: The test pressure for the oil cooler is 790 kPa(115 psi). The maximum differential pressure of waterfor the aftercooler is 44 kPa (6 psi). The maximumdifferential pressure of air for the aftercooler is5.1 kPa (0.74 psi).

7. Inspect the core in order to ensure cleanliness.Pressure test the core. Many shops that serviceradiators are equipped to perform pressure tests.If necessary, repair the core.

8. Install the core. For the procedure, refer to theService Manual, “Disassembly and Assembly”module.

For more information on cleaning the cores, consultyour Caterpillar dealer.

Exhaust Bypass

Inspect the condition of the exhaust bypass (ifequipped). Recondition the component, if necessary.Refer to this Operation and Maintenance Manual,“Exhaust Bypass - Inspect” topic (MaintenanceSection).

Governor

Inspect the governor for proper operation. Make anyrepairs that are necessary.

Transformers

The transformers produce a voltage increase. Forgood operation, the connections must be clean andsecure. Inspect the transformers for the followingconditions:

• Dirty insulator


• Loose connector

• Moisture

• Corrosion

Test the resistance of the transformers according tothe Service Manual, “Specifications” module. Consultyour Caterpillar dealer for assistance.

i02049051

Overhaul ConsiderationsSMCS Code: 7595-043

Overhaul InformationAn overhaul is replacing the major worn componentsof the engine. An overhaul is a maintenance intervalthat is planned. The engine is rebuilt with certainrebuilt parts or new parts that replace the worn parts.

An overhaul also includes the following maintenance:

• Inspection of all the parts that are visible duringthe disassembly

• Replacement of the seals and gaskets that areremoved

• Cleaning of the internal passages of the engineand the engine block

Most owners will save money by overhauling theengine at the intervals that are recommended inthis Operation and Maintenance Manual. It is notpractical to wait until the engine exhibits symptomsof excessive wear or failure. It is not less costly towait. A planned overhaul before failure may be thebest value for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to theguidelines for reusable parts.

• The service life of the engine can be extendedwithout the risk of a major catastrophe due toengine failure.

• Achieve the best cost/value relationship per hourof extended service life.

Overhaul Intervals

Top end overhauls are determined by the projection ofexhaust valve stems. Major overhauls are determinedby cylinder compression, crankcase blowby, oilconsumption, and results of S·O·S oil analysis.

Some other factors that are important for determiningthe overhaul intervals include the followingconsiderations:


Overhaul Considerations

• Performance of preventive maintenance

• Use of recommended lubricants

• Use of recommended coolants

• Use of recommended fuels

• Proper installation

• Operating conditions

• Operation within acceptable limits

• Engine load

• Engine speed

Note: To avoid oil problems, engines that areturbocharged and aftercooled must be operated at aminimum of 60 percent of rated load.

Generally, engines that are operated at a reducedload and/or speed achieve more service life beforean overhaul. However, this is for engines that areproperly adjusted, operated and maintained.

Overhaul Inspection

Refer to the Service Manual for the disassembly andassembly procedures that are necessary in orderto perform the required maintenance on the itemsthat are listed. Consult your Caterpillar dealer forassistance.

To determine the reusability publications that areneeded to inspect the engine, refer to Guidelines forReusable Parts and Salvage Operations, SEBF8029,“Index of Publications on Reusability or Salvage ofUsed Parts”.

The Guidelines For Reusable Parts and SalvageOperations is part of an established Caterpillarparts reusability program. These guidelines weredeveloped in order to assist Caterpillar dealers andcustomers reduce costs by avoiding unnecessaryexpenditures for new parts. If the engine parts complywith the established inspection specifications, theparts can be reused. New parts are not necessary ifthe old parts can be reused, repaired, or salvaged.

If the parts are not within the inspection specifications,the parts should be salvaged, repaired, replaced,or exchanged. The use of out-of-spec parts couldresult in unscheduled downtime and/or costly repairs.The use of out-of-spec parts can also contribute toincreased fuel consumption and reduction of engineefficiency.

Your Caterpillar dealer can provide the parts that areneeded to rebuild the engine at the least possiblecost.

Overhaul Programs

An economical way to obtain most of the partsthat are needed for overhauls is to use Caterpillarremanufactured parts. Caterpillar remanufacturedparts are available at a fraction of the cost of newparts. These parts have been rebuilt by Caterpillarand certified for use. The following components areexamples of the remanufactured parts:

• Alternators

• Connecting rods

• Crankshafts

• Cylinder heads

• Oil Pumps

• Starting motors

• Turbochargers

• Water pumps

Consult your Caterpillar dealer for details and for alist of the remanufactured parts that are available.

Your Caterpillar dealer may be offering a variety ofoverhaul options.

A Flat Rate Overhaul guarantees the maximum pricethat you will pay for an overhaul. Flat rate prices onpreventive maintenance programs or major repairoptions are available from many servicing dealersfor all Caterpillar Engines. Consult your Caterpillardealer in order to schedule a before failure overhaul.

Overhaul Recommendation

Caterpillar recommends a scheduled overhaul inorder to minimize downtime. A scheduled overhaulwill provide the lowest cost and the greatest value.Schedule an overhaul with your Caterpillar dealer.

Overhaul programs vary between dealers. To obtainspecific information about the types of overhaulprograms and services, consult your Caterpillardealer.

142 SEBU7572-06Maintenance SectionPower Factor - Check

i01216962

Power Factor - CheckSMCS Code: 4450-535-PWR

The power factor of a system can be determined bya power factor meter or by calculations. The powerfactor can be calculated by dividing kW by kVA.Power factor is expressed as a decimal.

i02559063

Radiator - CleanSMCS Code: 1353-070

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the radiator for these items: damaged fins,corrosion, dirt, grease, insects, leaves, oil, and otherdebris. Clean the radiator, if necessary.

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.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fan's air flow. Hold the nozzle approximately6 mm (0.25 inch) away from the fins. Slowly move theair nozzle in a direction that is parallel with the tubes.This will remove debris that is between the tubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Inspect the fins for damage. Bent fins may be openedwith a “comb”. Inspect these items for good condition:welds, mounting brackets, air lines, connections,clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning andinspection, refer to Special Publication, SEBD0518,“Know Your Cooling System”.

i01880286

Rotating Rectifier - CheckSMCS Code: 4465-535



Check the exciter armature. Ensure that the rotatingrectifier is tight. If a failure of a rectifier is suspected,refer to Maintenance Procedure, “Rotating Rectifier -Test”.


Rotating Rectifier - Test

i03316580

Rotating Rectifier - TestSMCS Code: 4465-081

Testing A Brushless ExciterRotating Rectifier With AnOhmmeterTable 28

Tools Needed

Part Number Part Name Quantity

237-5130 DigitalMultimeter

1

257-9140 Multimeter 1

146-4080 DigitalMultimeter(RS-232)

1

7X-1710 Multimeter ProbeGroup

1


If the failure of a rectifier is suspected, use thefollowing procedure.

1. Remove the cover from the exciter.

2. Remove the nut that secures the rectifier to theheat sink.

3. Remove the diode lead.

4. Lift the rectifier from the heat sink.

5. Refer to Illustration 99. Connect the ohmmeter'sleads across the rectifier. Note the meter reading.

6. Reverse the ohmmeter leads. Note the meterreading.

The ohmmeter should indicate a low resistancewhen the ohmmeter leads are across the rectifier inone direction. The ohmmeter should indicate a highresistance when the leads are reversed.

If the ohmmeter indicates a low resistance in bothdirections, the rectifier is shorted. A high resistancein both directions indicates an open rectifier.

Replace any faulty rectifiers with rectifiers that havecomparable operating characteristics. Include thefollowing information when a rectifier is being orderedfor replacement:

• Part Number of the rectifier

• Model number of the exciter

• Type of the exciter

• Serial number of the generator

Testing a Brushless ExciterRotating Rectifier With A Test Light

g00555113Illustration 100Test Light

If an ohmmeter is not available, a rectifier can betested by using a test light. A test light consists oftwo standard flashlight batteries and a flashlight bulb.Refer to Illustration 100.

If the failure of a rectifier is suspected, use thefollowing procedure.

1. Remove the cover from the exciter.

2. Remove the nut that secures the rectifier to theheat sink.

3. Remove the diode lead.

4. Lift the rectifier from the heat sink.

144 SEBU7572-06Maintenance SectionSpace Heater - Check

5. Connect the leads of the test light across therectifier. Notice if the bulb is illuminated.

6. Reverse the leads of the test light across therectifier. Notice if the bulb is illuminated.

The bulb should be illuminated when the leads of thetest light are across the rectifier in one direction. Thebulb should not be illuminated when the leads arereversed.

If the bulb is illuminated in both directions, the rectifieris shorted. If the bulb is not illuminated in eitherdirection, the rectifier is open.

Replace any faulty rectifiers with rectifiers that havecomparable operating characteristics. Include thefollowing information when a rectifier is being orderedfor replacement:

• Part Number of the rectifier

• Model number of the exciter

• Type of the exciter


i02985289

Space Heater - CheckSMCS Code: 4450-535-HTR

The space heater is attached to the rear bearingbracket. The space heater is located in thegenerator's exciter end.


Space Heater Connection Diagram

An SR5 generator can operate in high humidityconditions without problems. The humidity can be ashigh as 100% non-condensing humidity. However,problems can occur when the generator is idle andthe surrounding air is warmer than the generator.Moisture can form on the windings. Moisture willresult in poor performance or even damage to thewindings. Whenever the generator is not active, theoptional space heaters should be operated.

An external source is required to operate the spaceheaters. Both of the sources must be a single phase.This source can be either 115 vac or 230 vac. Whenthe external source is 50 hertz, 200 vac must beused. Refer to Illustration 101.

See your Caterpillar dealer for information onchecking your Caterpillar generator.

i01511915

Speed Sensor - Clean/InspectSMCS Code: 1907-040; 1907-070

g00784740Illustration 102Speed sensors

1. Remove the speed sensor from the flywheelhousing. Check the condition of the end ofthe magnet. Check for signs of wear andcontaminants.

2. Clean the metal shavings and other debris fromthe face of the magnet.

3. Install the speed sensor and adjust the speedsensor according to the engine's Specificationsmodule.


Standby Generator Set Maintenance Recommendations

i01038735

Standby GeneratorSet MaintenanceRecommendationsSMCS Code: 4450-041

A standby generator set may not need to be usedvery often. However, the generator set is usuallyneeded for operation in an emergency situation.Maintenance of the standby generator set is veryimportant for the following reasons:

• The generator set must always be in excellentoperating condition.

• The generator set must be ready to work underload at any time.

Establishing a Preventive Maintenance Program willprovide these benefits:

• Maximum availability of the standby generator set

• Longer service life for the generator set

• Minimum of expensive repairs

Your Caterpillar dealer can help you to establish aneffective Preventive Maintenance Program for yourgenerator set. Consult your Caterpillar dealer fordetails.

Maintenance and OperationProcedures



The recommended maintenance for the engine islisted in this Operation and Maintenance Manual,“Maintenance Interval Schedule (Standby GeneratorSet Engines)” (Maintenance Section).

For the recommended generator maintenance, seethe Operation and Maintenance Manual for thegenerator and the control panel.

Maintenance and Repair

The maintenance that is recommended for EveryWeek can be performed by an authorized operator.The maintenance that is recommended for thesubsequent maintenance intervals must beperformed by an authorized service technician or byyour Caterpillar dealer.

Unless other instructions are provided, performmaintenance and repairs under the followingconditions:

• The engine is stopped.

• The starting system is disabled.

• The generator does not pose an electrical shockhazard.

Operation

To ensure proper operation, the generator set must beexercised regularly. For instructions on operating thegenerator set, see the Operation and MaintenanceManual for the generator set control panel.

For these operation procedures, follow theinstructions that are provided in this Operation andMaintenance Manual, “Operation Section”: startingthe engine, engine operation, and stopping theengine.

Record Keeping

Maintain a record in order to document these items:gauge readings, maintenance that is performed,problems, and repairs.

Space Heaters

Moisture causes damage to generators and otherelectrical equipment. Make every effort to keep thegenerator set as dry as possible.

Generators can operate without problems in humidenvironments. However, problems can occur whenthe generator is inactive. Moisture can condense onthe windings. This can result in poor performance.Also, damage to the windings can occur.

Use space heaters in order to help keep the windingsdry. When the generator is not active, ensure that thespace heaters are operating. When the generator isoperating, turn OFF the space heaters.

146 SEBU7572-06Maintenance SectionStarting Motor - Inspect

i01113939

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

If the starting motor fails, the engine may not start inan emergency situation. A scheduled inspection ofthe starting motor is recommended.

The starting motor pinion and the flywheel ring gearmust be in good condition in order for the engineto start properly. The engine will not start if thestarting motor pinion does not engage the flywheelring gear. The teeth of the starting motor pinion andthe flywheel ring gear can be damaged because ofirregular engagement.

Inspect the starting motor for proper operation. Listenfor grinding when the engine is started. Inspect theteeth of the starting motor pinion and the flywheelring gear. Look for patterns of wear on the teeth. Lookfor teeth that are broken or chipped. If damaged teethare found, the starting motor pinion and the flywheelring gear must be replaced.

Electric Starting MotorNote: Problems with the electric starting motor canbe caused by the following conditions: malfunction ofthe solenoid and malfunction of the electric startingsystem.

Inspect the electrical system for the followingconditions:


• Corrosion

• Wires that are worn or frayed

• Cleanliness

Make repairs, if necessary.

Air Starting Motor

Personal injury or death can result from improp-erly checking for a leak.

Always use a board or cardboard when checkingfor a leak. Escaping air or fluid under pressure,even a pin-hole size leak, can penetrate body tis-sue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treatedimmediately by a doctor familiar with this type ofinjury.

Inspect all of the components in the air circuit forthe starting motor. Inspect all of the air lines andconnections for leaks.

If the teeth of the starting motor pinion and/or theflywheel ring gear are damaged, the air circuit forthe starting motor must be examined in order todetermine the cause of the problem.

Removal and Installation of theStarting MotorRefer to the Service Manual, “Disassembly andAssembly” module for information on removing thestarting motor and installing the starting motor.


i03230840

Stator Lead - CheckSMCS Code: 4459-535

Ensure that the stator output leads are routed out ofthe generator in a manner that prevents the leadsfrom rubbing against metal objects.

Visually inspect the following areas for cracking andphysical damage:

• stator output leads

• protective sleeving

• insulation


Stator Winding Temperature - Measure/Record

i02514961

Stator Winding Temperature -Measure/RecordSMCS Code: 4453-082-TA

Some generators are provided with optional 100 OhmResistance Temperature Detectors (RTD). When thetemperature of the stator winding is suspected to behigh, measure the temperature. If the generator isfurnished with Resistance Temperature Detectors,the detectors are installed in the slots of the mainarmature (stator). The detectors are used withequipment that is available from the factory. Thisequipment is used in order to measure the mainarmature's winding temperature.

i03365620

Turbocharger - InspectSMCS Code: 1052-040





Periodic inspection and cleaning is recommendedfor the turbocharger.

Fouling of the turbine wheels can contribute to loss ofengine power and overall loss of engine efficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel could allow partsfrom the compressor wheel to enter an enginecylinder. This can cause additional damage to thepistons, the valves, and the cylinder head.

NOTICETurbocharger 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 enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired orreplaced.

An inspection of the turbocharger can minimizeunscheduled downtime. Also, the chance for potentialdamage to other engine parts is reduced.

Note: Turbocharger components require clearancesthat are precise. The turbocharger cartridge must bebalanced due to high rpm.

The following conditions can cause the turbochargerto be out-of-balance:

• The buildup of deposits

• Chipping and/or flaking of deposits

If the turbocharger must be removed for inspection,use caution. Do not break deposits from the turbinewheel. Do not attempt to clean the turbine wheel. Foroptions regarding removal, installation, repair andreplacement, see the Service Manual or consult yourCaterpillar dealer.

1. Remove the exhaust outlet piping and removethe air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil.

2. Turn the compressor wheel and the turbine wheelby hand. The assembly should turn freely. Inspectthe compressor wheel and the turbine wheel forcontact with the turbocharger housing. Thereshould not be any visible signs of contact betweenthe turbine wheel or compressor wheel and theturbocharger housing. If there is any indication ofcontact between the rotating turbine wheel or thecompressor wheel and the turbocharger housing,the turbocharger should be reconditioned.

3. Check the compressor wheel for cleanliness.If only the blade side of the wheel is dirty, dirtand/or moisture is passing through the air filteringsystem. If oil is found only on the back side of thewheel, there is a possibility of a failed turbochargeroil seal.

148 SEBU7572-06Maintenance SectionValve Stem Projection - Measure/Record

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the line forthe inlet air (plugged air filters), which causes theturbocharger to slobber.

Note: Deposits can accumulate on the turbine wheel.The turbine wheel will become unbalanced when thedeposits flake off. The turbocharger cartridge mustbe replaced when this occurs. However, removedeposits from the housing. This will prevent wear onthe blades of the turbine wheel.

4. Inspect the turbine wheel for deposits. If depositsof 1.6 mm (0.0625 inch) thickness are found orif the turbine is in contact with the housing, theturbocharger must be disassembled and cleaned.Removal of these deposits can be very difficult.

5. Inspect the bore of the turbine housing forcorrosion and deposits.

6. Clean the turbocharger compressor housing withstandard shop solvents and a soft bristle brush.

7. Check the clearances of the turbocharger bearing.Compare the clearances to the Service Manual,“Specifications”. If the clearances are not withinthe specifications, the turbocharger must berepaired.

8. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.

i01360109

Valve Stem Projection -Measure/RecordSMCS Code: 1105-082

Valve Recession – The valves and the valve seatsare worn over time. This causes the valves to recedeinto the cylinder head. This condition is called “valverecession”.

The exhaust valves and valve seats show thegreatest wear due to high operating temperatures.The top end overhaul is normally scheduledaccording to the exhaust valve recession.

It is difficult to obtain an accurate measurement ofvalve recession inside the cylinder head. Use thefollowing method in order to determine the valverecession:

1. Remove the valve cover. For instructions, see theService Manual, “Disassembly and Assembly”module.

2. Move the rocker arm from the top of the valvestem.

3. Use a depth micrometer. Obtain the measurementfrom the tip of the valve stem to the cylinder head.Obtain this measurement for each exhaust valve.

Make several copies of this Operation andMaintenance Manual, “Valve Data Sheet” (ReferenceMaterials Section). Record the measurements onthe sheets.

• The projection of the exhaust valve stemsshould be measured after completion of the initialstart-up tests and the engine commissioning. Thismeasurement is the baseline. The baseline is areference for subsequent measurements.

• Measure the projection of the exhaust valverotators at the first oil change interval. Illustration103 shows schedules for determining subsequentintervals.


Varistor - Check


(A) Schedule(B) Schedule(C) Schedule

(Y) Valve recession in millimeters (inches)(X) Hours of operation(1) 0.254 mm (0.0100 inch)

(2) 0.218 mm (0.0086 inch)(3) 0.152 mm (0.0060 inch)

To determine intervals, use the point on the graph inIllustration 103 that is closest to the measurement foreach cylinder.

For example, suppose that the measurement thatwas obtained at the initial oil change shows a valverecession of approximately 0.152 mm (0.0060 inch).According to Schedule (C), the next interval formeasuring that cylinder is at 5000 service hours.Another cylinder may have a valve recession ofapproximately 0.254 mm (0.0100 inch). Accordingto Schedule (A), the next interval for measuring thatcylinder is at 3000 service hours.

• After 70 percent of the maximum limit has beenreached, measure the projection of the exhaustvalve stems at every 750 hours of operation(turbocharged engines). For Naturally aspiratedengines, perform the measurement at every 1500hours of operation.

• Plan for the top end overhaul as the valvestem projection approaches the maximum limit.Perform the top end overhaul when the valve stemprojection has increased by a total of 2.3 mm(0.09 inch). Do not allow the valve recessionto exceed this limit. The valve head can break.This will cause severe damage in the combustionchamber and the turbocharger.


i03291822

Varistor - CheckSMCS Code: 4466-535

The varistor must be checked at regular intervals.Refer to Systems Operation/Testing and Adjusting,KENR5284, “Varistor - Test” for instructions.

i03291802

Varistor - InspectSMCS Code: 4466-040

The varistor must be visually inspected at regularintervals. For generator sets with 1400 or with1600 frames, discoloration of the varistor indicatesthat replacement of the varistor is necessary. Forgenerator sets with 1800 frames, physical signs offailure indicate that replacement of the varistor isnecessary.

150 SEBU7572-06Maintenance SectionVaristor - Test

i01494879

Varistor - TestSMCS Code: 4466-081


PMPE Generator Wiring Diagram(CR1-CR6) Diodes(CR7) Varistor(L1) Exciter field (stator)(L2) Exciter armature (rotor)(L3) Main field (rotor)(L4) Main armature (stator)(L5) Pilot exciter armature(PM) Permanent magnet(RFA) Rotating field assembly(CST) Customer supplied transformer

OhmmeterAn ohmmeter can be used to check a varistor(CR7). Place an ohmmeter across the varistor. Theresistance should be a minimum of 15000 ohms. Ifthe resistance is less than 15000 ohms, the varistoris faulty.

Test Light

g00555113Illustration 105Test Light

Refer to the test light that is shown in Illustration 105.Follow these steps in order to test the varistor:

1. Disconnect either lead of the varistor (CR7).

2. Place the test light across the varistor.

3. Observe the results. The lamp should not light.

4. Reverse the test light.

5. Observe the results. The lamp should not light.

If the test light illuminates in either direction, there isa short in the varistor. Replace any faulty varistorswith varistors that have comparable operatingcharacteristics. Include the following informationwhen a varistor is being ordered for replacement:

• Part number of the varistor


After the varistor has been replaced, verify that thestrapping of the field winding lead is securely woundon the shaft. Also, verify that the strapping of the fieldwinding lead is securely tied.

i01189996

Voltage and Frequency - CheckSMCS Code: 4450-535-EL

Check for proper voltage and frequency setting.Check for stability.

Refer to the generator set Serial Plate for correctvoltage and frequency.


Walk-Around Inspection

i02591373

Walk-Around InspectionSMCS Code: 1000-040



Inspect the Engine for Leaks andfor Loose ConnectionsA walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that cooling lines are properly clamped.Check for leaks. Check the condition of all pipes.

• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofwater pump and the installation of water pump and/orseals, refer to the Service Manual for the engine orconsult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the valve cover.

• Inspect the Closed Crankcase Ventilation (CCV)filter, if equipped. If the restriction indicator isvisible, service the CCV.

• Inspect the fuel system for leaks. Look for loosefuel line clamps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps.

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Inspect the engine-to-frame ground strap for agood connection and for good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges that are cracked. Replace any gauges thatcan not be calibrated.

Inspect the GeneratorRefer to Safety Section, “Generator Isolating forMaintenance” for information regarding the procedureto safely isolate the generator.

152 SEBU7572-06Maintenance SectionWater Pump - Inspect

A visual inspection should be initially directed atthe areas that are most prone to damage anddeterioration. The most prone areas to damage anddeterioration are listed below:

Ground insulation – Ground insulation is insulationthat is intended to isolate components that arecarrying current from components that are notcarrying current.

Support insulation – Support insulation is usuallymade from one of the following items: a compressedlamination of fibrous materials, polyester, or felt padsthat have been impregnated with various types ofbonding agents.

There are many different types of damage that canoccur in these areas. Several of the different types ofdamage are listed below:

Thermal aging – Thermal aging can cause thedegradation of insulation or the deterioration ofinsulation. An examination of the coils may revealthat the insulation has expanded into the ventilationducts. This is the result of a loss of bond whichwill cause the insulation material to separate. Theinsulation material could also separate from theconductors on the windings.

Abrasion – The surfaces of coils and the surfacesof connectors may be damaged by abrasion. Thesesurfaces may also be damaged by contaminationfrom other sources. An example of these sourceswould be chemicals or abrasive substances.

Cracking – Cracking of insulation may result frommechanical stress. The structure that is used to bracethe stator winding will become loose if the problemis not corrected. Further mechanical damage orelectrical damage may also result.

Erosion – Erosion can be caused when foreignsubstances rub against the insulation that is on thesurface of the coil .

i02624237

Water Pump - InspectSMCS Code: 1361-040

A failed water pump might cause severe engineoverheating problems that could result in cracks inthe cylinder head, a piston seizure or other potentialdamage to the engine.

Visually inspect the water pump for leaks. If leakingof the water pump seals is observed, replace all ofthe water pump seals. Refer to two articles in theDisassembly and Assembly Manual, “Water Pump- Disassemble and Water Pump - Assemble” forthe disassembly and assembly procedure. If it isnecessary to remove the water pump, refer to twoarticles in the Disassembly and Assembly Manual,“Water Pump - Remove and Water Pump - Install”.

Inspect the water pump for wear, cracks, pin holesand proper operation. Refer to the Parts Manualfor the correct part numbers for your engine orconsult your Caterpillar dealer if repair is needed orreplacement is needed.

i01787397

Winding - TestSMCS Code: 4453-081; 4454-081; 4457-081;4470-081


PMPE Generator Wiring Diagram(CR1-CR6) Diodes(CR7) Varistor(L1) Exciter field (stator)(L2) Exciter armature (rotor)(L3) Main field (rotor)(L4) Main armature (stator)(L5) Pilot exciter armature(PM) Permanent magnet(RFA) Rotating field assembly(CST) Customer supplied transformer


Winding - Test

Table 29

Tools Needed

Part Number Part(1) Quantity

6V-7070 DigitalMultimeter 1

146-4080Digital

Multimeter(RS232)

1

(1) Only one multimeter is necessary for this test. Either of themultimeters that are shown will work.



Measure the resistance of the following windings:(L1), (L2), (L3), (L4), and (L5). The winding thatis being tested must be disconnected from theother components before the resistance can bemeasured. The following resistance measurementsare approximations. If the measured value isnot near the listed approximation, the winding isprobably damaged. For a more precise resistancevalue, consult the Technical Marketing Information(TMI). Refer to the generator arrangement that is inquestion.

Note: The winding temperature affects theresistance. When the winding temperature increases,the winding resistance also increases. Whenthe winding temperature decreases, the windingresistance also decreases. Therefore, a correctmeasurement can be performed only when thewinding is at room temperature.

The following armature windings have very littleresistance: (L2), (L4), and (L5). The resistance ofthese windings will measure near 0 ohms. Use amilliohmmeter to measure the resistance of thearmature windings.

Exciter Armature (Rotor) (L2) – less than 0.1 ohm

Main armature (Stator) (L4) – less than 0.1 ohm

Pilot Exciter Armature (L5) – less than 0.1 ohm

Use a multimeter in order to measure the resistanceof field windings (L1) and (L3).

Exciter Field (Stator) (L1) – approximately 3.0ohms to 6.0 ohms

Main Field (Rotor) (L3) – approximately 0.75 ohmsto 2.0 ohms

Note: There should be no continuity between anywinding and ground. There should be no continuitybetween any winding and another winding.

Manual de Grupo Electrógeno Caterpillar

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