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MAINTENANCE INTERVALS - Safety

1. Illustration 67 900736141 1 Coolant drain 3 Open coolant drain 1 NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL EAME phone 41 22 849 40 56 EAME fax 41 22 849 49 29 Clean the Cooling System 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the coolant drain NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Open the water inlet for the separate circuit aftercooler if equipped Fill the cooling system with clean water Install the radiator filler cap Operate the engine until the temperature reaches 49 C 120 F to 66 C 150 F 4 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Ensure that the engine will not start when the cooling system is drained Loosen t
2. Ji 7 AF ol ls o Illustration 64 The Lamp Test button is located on the top right side of the electronic control module Press and hold the Lamp Test button in order to test all of the LED lights and the display screen The LED lights and the display screen should remain on until the button is released If any of the components do not pass this test replace the faulty components before starting the engine Switch Panel The Panel Lights switch should turn on the panel lights Toggle the switch in order to ensure that the panel lights are working 92 Maintenance Section Cooling System Coolant DEAC Change SEBU7147 05 Annunciator Panel AL es i b u cuce E 8 p9 Illustration 65 g01101388 It is possible to test the LED indicators and the horn when the data link is connected and when the data link is not connected The Lamp Test button is located near the top of the annunciator panel Test both the horn and the indicators by pressing and holding the Lamp Test button Replace any faulty components before starting the engine 102062150 Cooling System Coolant DEAC Change SMCS Code 1350 044 Clean the cooling system before the recommended maintenance interval if
3. Second Top End Overhaul 22000 Service Hours 18000 Service Hours 15000 Service Hours 2920000 L 770000 US gal Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours 4380000 L 1155000 US gal 1 Fuel consumption is based on a load factor of approximately 60 percent Table 36 Maintenance Interval Schedule Service Hours and Fuel Consumption for 3516 and 3516B Engines Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM 250 Service Hours 44000 L 11600 US gal 53000 L 14000 US gal 64500 L 17000 US gal 500 Service Hours 88000 L 23200 US gal 106000 L 28000 US gal 129000 L 34000 US gal 1000 Service Hours 176000 L 46500 US gal 212000 L 56000 US gal 258000 L 68000 US gal 2000 Service Hours 352000 L 93000 US gal 424000 L 112000 US gal 516000 L 136000 US gal 3000 Service Hours 528700 L 139500 US gal 636700 L 168100 US gal 773000 L 204000 US gal 6000 Service Hours 1056000 L 279000 US gal 1272000 L 336000 US gal 1548000 L 408000 US gal Top End Overhaul 11000 Service Hours 9000 Service Hours 7500 Service Hours 1942000 L 512500 US gal Second Top End Overhaul 22000 Service Hours 18000 Service Hours 15000 Service Hours 3884000 L 1025000 US gal Major Overhaul 33000 Service Hours 27000 Ser
4. NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the cooling system drain Clean the cooling system drain plugs and install the cooling system drain plugs SEBU7 147 05 93 Maintenance Section Cooling System Coolant DEAC Change NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the radiator filler cap 4 Open the water inlet for the separate circuit aftercooler if equipped Start the engine Operate the engine for a minimum of 30 minutes with a coolant temperature of at least 82 C 180 F 5 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap Open the coolant drain Remove the cooling system drain plugs Allow the water to drain NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and oth
5. Oven Method Place the entire generator inside a forced air drying oven for four hours at 65 C 149 F NOTICE Use a forced air type oven rather than a radiant type oven Radiant type ovens can cause localized overheating 118 Maintenance Section Generator Inspect SEBU7147 05 Controlled Current Method Table 28 Tools Needed Part Description Qty Number 8T 0900 Clamp on ammeter 1200 1 amperes External Power Source 1 Rheostat 1 Heat can be used in order to dry the generator windings This heat can be created by allowing a controlled current to flow through the generator No high voltages are generated during the following procedure Therefore insulation breakdown will not occur T1 L4 CST T3 T2 UOS VOLTAGE ts L3 E REGULATOR AE AND OR 1 CR7 M RELATED I I R4 CRA COMPONENTS CR2 CR5 R y L CRS i L2 I I L1 F2 PMI N PM PM2 S PM3 900669571 Illustration 96 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
6. SEBU7147 05 Fill the Crankcase 1 Remove the oil filler cap Fill the crankcase through the oil filler tube only For the correct type and the amount of oil to use refer to this Operation and Maintenance Manual Maintenance Section Refill Capacities and Recommendations Clean the oil filler cap Install the oil filler cap NOTICE To prevent crankshaft or bearing damage crank en gine with fuel off to fill all filters before starting Do Not crank engine for more than 30 seconds 2 Close the fuel supply line and crank the engine until the oil pressure gauge indicates 70 kPa 10 psi Open the fuel supply line Allow the starting motor to cool for two minutes before cranking again 3 Follow the Operation and Maintenance Manual Operation Section Starting The Engine procedure Operate the engine at low idle for two minutes This will ensure that the lubrication system has oil and that the oil filters are filled with oil Inspect the engine for oil leaks Ensure that the oil level is at the FULL mark on the LOW IDLE side of the oil level gauge 4 Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes 5 Remove the oil level gauge and check the oil level Maintain the oil level to the FULL mark on the ENGINE STOPPED side of the oil level gauge 100626013 Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs mus
7. 9 08 OL eoubjsisey uonpbnsu PeAsasqg 3484002 OJ T L 3331 UOI DIUDA B9UD SIS9Y UO DINSUT xouddy 89 CE 0c 0 L0 0 b l 001 0001 11909 due UD S S M uoljo nsu 14 g00633226 Illustration 99 132 Maintenance Section Hoses and Clamps Inspect Replace SEBU7147 05 102121526 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions e Cracking Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Check for the following conditions End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the
8. AC1 3 27 4 and AC3 5 In all cases the meter should read OL overload b Place the black test lead on the positive rectifier terminal Place the red test lead on the following rectifier terminals AC1 3 AC2 4 and AC3 5 All readings on the meter should be between 0 4 and 1 0 Note A shorted diode can cause damage to the exciter rotor If a diode is shorted check the exciter rotor Refer to the Testing and Adjusting Winding Test and Testing and Adjusting Insulation Test Perform these tests Note This rectifier block also contains varistor CR7 CR7 can be checked by measuring the resistance between the positive rectifier terminal and the negative rectifier terminal The resistance should be a minimum of 15000 103724660 Space Heater Test SMCS Code 4450 081 HTR The space heater is attached to the rear bearing bracket The space heater is located in the generator s exciter end Wi s lan Q H1 H1 H2 115 VAC 230VAC H3 H3 H4 12 H4 12 g00610396 Illustration 103 Space Heater Connection Diagram An SR5 generator can operate in high humidity conditions without problems The humidity can be as high as 100 no condensing humidity However problems can occur when the generator is idle and the surrounding air is warmer than the generator Moisture can form on the windings Moisture wil
9. For 3508 and 3512 Engines inspect ONLY ONE of the components from each cylinder bank For 3516 Engines inspect ONLY TWO of the components from each cylinder bank This inspection will provide adequate examples of the condition of the other corresponding components If the results are questionable inspect more of the components 103101741 Overhaul Considerations SMCS Code 7595 043 Severe Operation Severe operation is the use of an engine that exceeds current published standards for that engine Caterpillar maintains standards for the following engine parameters Horsepower e Range of rpm e Fuel consumption e Fuel quality e Altitude e Maintenance intervals e Selection of oil e Selection of coolant e Environmental qualities Installation Refer to the standards for your engine or consult your Caterpillar dealer in order to determine if your engine is operating within the defined parameters Severe operation can accelerate component wear Engines that are operating under severe conditions may need more frequent maintenance intervals for the following reasons e Maximum reliability e Retention of full service life Because of individual applications it is not possible to identify all of the factors which can contribute to severe operation Consult your Caterpillar dealer about the maintenance that is needed for your specific engine The following factors can contribute to severe operation environment imprope
10. Note If the generator already has a visible grease point go to Step 4 1 Remove either the louver assembly or the rear plate from the rear of the generator housing 2 Remove the top grease pipe plug and remove the lower grease pipe plug 3 Install a grease fitting in the grease pipe 4 Grease the bearings with the appropriate grease from Table 29 Do not mix greases SEBU7 147 05 121 Maintenance Section Generator Bearing Lubricate Table 29 Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft Part Type Size Min Max Part Diameter Number Number 108 1760 321 BC 680 29 C 28 3230 Every 2000 51 2 g 59 mL 2 oz 105 0 mm Ball Bearing 225 0 mm 20 2 F Bearing service 1 8 oz 4 1 inch 8 9 inch minimum Lubricant hours or 12 OD months 80 C 105 0 mm 176 F 4 1 inch ID maximum 108 1761 322 BC 690 29 C 28 3230 Every 2000 51 2 g 59 mL 2 oz 110 0 mm Ball Bearing 240 0 mm 800 20 2 F Bearing service 1 8 oz 4 3 inch 9 4 inch Lubricant 1 hours or 12 OD 80 C months 176 F 110 0 mm 4 3 inch ID 139 0349 Roller 2900 40 C Mobilith Every 250 2 8 9 NA 127 0 mm Roller 2800 40 F SHC220 service 0 1 oz 5 0 inch Bearing hours 80 C 176 F 139 0350 Roller 2900 40 C Mobilith Every 250 2 8 g NA 127 0 mm Roller 2800 40 F SHC220 service 0 1 oz 5 0 inch Bearing hours 80 C 176 F 154 30
11. to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 72 g00281692
12. CI Ij dos E Illustration 88 900736656 1 Oil drain a Open oil drain 1 After the oil has drained close the oil drain b If a suction device is inserted into the oil pan ensure that the suction device is clean This will prevent dirt from entering into the oil pan Be careful not to strike the engine oil suction tubes or the piston cooling jets c f a suction device that attaches to the oil drain is used ensure that the suction device is clean Attach the suction device to the oil drain Open the oil drain After the oil has drained close the oil drain and remove the suction device Replace the Oil Filter Elements Replace the engine oil filters when either of the following conditions are met Every oil change SEBU7 147 05 111 Maintenance Section Engine Oil and Filter Change The engine oil filter differential pressure reaches 103 kPa 15 psi Service tools are available to aid in the service of oil filters Consult your Caterpillar dealer for the part names and the part numbers Follow the instructions that are supplied with the service tools If the service tools are not used perform the following appropriate procedure 7 A Illustration 89 g00736657 1 Drain 2 Drain valve Plug 4 Bolts 5 Cover Note Drain the oil into a suitable cont
13. Connect the secondary terminals that correspond to generator terminal T2 of both transformers together 2 Disconnect wires F1 and F2 from the voltage regulator Disconnect the generator from the load 3 Connect a 12 VDC automotive battery to wires F1 and F2 NOTICE Do not operate the generator set at a speed that is higher than one half of the rated speed Higher speeds under these test conditions can cause damage to the system 4 Operate the generator set at half the rated speed 5 Measure the AC voltage across the lovv voltage terminals of the transformer that correspond to the follovving generator terminals T1 and T2 T2 and T3 and T3 and T1 Record the voltages 6 Monitor the voltage betvveen any tvvo of the locations in step 5 Decrease the generator set speed by 10 Increase the generator set speed by 10 7 The voltages that were measured in Step 5 should be nearly equal These voltages should measure a minimum of 85 VAC 8 When the generator set speed is decreased by 10 the voltages that were measured in Step 6 should decrease by 10 When the generator set speed is increased by 10 the voltages that were measured in Step 6 should increase by 10 103100396 Generator Set Alignment Check Generator Sets SMCS Code 7002 024 The alignment between the engine and the driven equipment must be properly maintained in order to m
14. End Overhaul 11000 Service Hours 9000 Service Hours 7500 Service Hours 976000 L 257 500 US gal Second Top End 22000 Service Hours 18000 Service Hours 15000 Service Hours Overhaul 1952000 L 515000 US gal 33000 Service Hours Major Overhaul 27000 Service Hours 22500 Service Hours 2928000 L 772500 US gal 1 Fuel consumption is based on a load factor of approximately 60 percent 134 Maintenance Section Maintenance Recommendations SEBU7147 05 Table 35 Maintenance Interval Schedule Service Hours and Fuel Consumption for 3512 and 3512B Engines 0 Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM 250 Service Hours 33400 L 8800 US gal 41000 L 10800 US gal 48500 L 12800 US gal 500 Service Hours 66800 L 17600 US gal 82000 L 21600 US gal 97000 L 25600 US gal 1000 Service Hours 133500 L 35000 US gal 164000 L 43200 US gal 194000 L 51200 US gal 2000 Service Hours 267000 L 70000 US gal 328000 L 86400 US gal 388000 L 102400 US gal 3000 Service Hours 398000 L 105000 US gal 491000 L 129600 US gal 582000 L 153600 US gal 6000 Service Hours 796000 L 210000 US gal 982000 L 259200 US gal 1164000 L 307200 US gal Top End Overhaul 11000 Service Hours 9000 Service Hours 7500 Service Hours 1460000 L 385000 US gal
15. Generator Inspect 118 Generator Lead Check 124 Space Heater Test 22 142 Stator Winding Temperature Test 144 Voltage and Frequency Check 146 Initial 250 Service Hours Engine Speed Timing Sensor Clean Inspect 112 Engine Valve Lash Inspect Adjust 113 SEBU7 147 05 87 Maintenance Section Maintenance Interval Schedule Speed Sensor Clean Inspect 142 Every 250 Service Hours Battery Electrolyte Level Check 89 Belts Inspect Adjust Replace 90 Cooling System Supplemental Coolant Additive SCA Test Add eor 97 Engine Oil Sample Obtain 109 Fan Drive Bearing Lubricate 113 Hoses and Clamps Inspect Replace 132 Radiator Clean 140 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtains ier ode cete nin A 97 Every 500 Service Hours Cooling System Coolant Sample Level 1 G btall ETE E ftum eie 96 Engine Oil and Filter Change 110 Every 1000 Service Hours Engine Clean 100 Engine Crankcase Breather Clean 107 Engine Protective Devices Ch
16. Needed Part Number Part Name Quantity 300 8648 Insulation 1 Testing Gp Periodically use an insulation tester to check the insulation resistance of the generator s main stator winding The frequency of this test is determined by the generator s environment Previous insulation tester readings will also determine the frequency of this test Test the main stator windings with an insulation tester in the following situations The generator set is started for the first time e The generator set is removed from storage e The generator set is operating in a humid environment Test every three months e The generator set is not protected from the elements in an enclosed area Test every three months The generator set is installed in an enclosed area This area needs to be low in humidity and this area needs to have steady temperatures Test every twelve months minimum The generator set has not been run under load for three months Test the generator set weekly Use space heaters around the generator set if the generator is exposed to a sea water environment or if the humidity is above 75 percent Also use space heaters if a test result was below 3 megohms Space heaters must be used whenever the generator set is not under load Space heaters must also be used whenever salt is present or whenever high humidity is present Using a space heater in this fashion is the only way to maintain insulation tester read
17. Water Pump Inspect 5222 147 Between 7500 and 9000 Service Hours Overhaul Top End sense 137 Between 15 000 and 18 000 Service Hours Overhaul Top End see 137 Between 22 500 and 27 000 Service Hours Overhaul Major 135 Every 228 000 L 60 000 US gal of Fuel or 6000 Service Hours or 6 Years Standby Generator Set Maintenance Recommendations 143 Overhaul Generator Bearing Replace 123 Overhaul Considerations 138 88 Maintenance Section Alternator Inspect SEBU7147 05 102676048 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is w
18. air cleaner element that passes inspection will not be used the air cleaner element can be stored for future use Illustration 78 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the air cleaner elements in Volatile Corrosion Inhibited VCI paper 106 Maintenance Section Engine Air Cleaner Service Indicator Inspect SEBU7147 05 Place the air cleaner element into a box for storage For identification mark the outside of the box and mark the air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 101397712 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 A service indicator may be mounted on the air cleaner element or in a remote location M Illustration 79 900736586 1 Service indicator Some engines may be equipped with a different service indicator Observe the service indicator Clean the air cleaner element or replace the air cleaner element when the following conditions occur The yellow diaphragm enters the red zone e The red piston locks in the visible position e The air restriction reaches 6 kPa 25 inches of H O Test the Service Indicator Service indicators are important in
19. be cleaned up to six times if the element is properly cleaned and inspected The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 71 900736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Turbocharger air inlet 1 Remove the co
20. extremely cold or hot can damage components Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot inlet air reduces the performance capabilities of the engine Note See this Operation and Maintenance Manual Cold Weather Operation topic Operation Section or see Supplement SEBU5898 Cold Weather Recommendations Cleanliness Unless the equipment is cleaned regularly extended operation in a dirty environment and in a dusty environment can damage components Built up mud dirt and dust can encase components This can make maintenance difficult The buildup can contain corrosive chemicals Corrosive chemicals and salt can damage some components Improper Operating Procedures e Extended operation at low idle e Minimum cool down periods after high load factor operation Operating the engine beyond the guidelines for the engine rating Operating the engine at loads that are greater than the rated load Operating the engine at speeds that are greater than the rated speed Use of the engine for an application that is not approved Improper Maintenance Practices Extension of maintenance intervals Not using recommended fuel lubricants and coolant antifreeze 101981611 Overhaul Major SMCS Code 7595 020 MJ The maintenance intervals that are listed in this Operation and Maintenance Manual Maintenance Interval Schedule a
21. is deadheaded Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary For more detailed information on cleaning and inspection refer to Special Publication SEBD0518 Know Your Cooling System 102246950 Rotating Rectifier Check SMCS Code 4465 535 Check the exciter armature Ensure that the rotatin
22. load When Required Battery Recycle 88 Batteries Replace 2 88 Battery or Battery Cable Disconnect 90 Engine Air Cleaner Element Dual Element Clean Replace sss 101 Engine Air Cleaner Element Single Element Clean Replace sse 103 Fuel System Prime 114 Generator Bearing Lubricate 120 Generator Set Test 125 Generator Set Alignment Check 126 Generator Winding Test 128 Maintenance Recommendations 133 Rotating Rectifier Check 141 Varistor Test 1 eee eoe eet ORE 145 Daily Control Panel Inspect Test 91 Cooling System Coolant Level Check 96 Engine Air Cleaner Service Indicator Inspect 106 Engine Air Precleaner Clean 107 Engine Oil Level Check 5222 108 Fuel Tank Water and Sediment Drain 116 Generator Bearing Temperature Test Record 124 Generator Load Check 124 Walk Around Inspection 2222 146 Every Week Automatic Start Stop Inspect 88 Battery Charger Check 89 Electrical Connections Check 100
23. on the generator in order to confirm electrical integrity A minimum reading of one megohm would be expected with severely contaminated generators A zero megohm reading may indicate an insulation breakdown An insulation breakdown requires more than cleaning An insulation breakdown requires repair A high pressure wash is normally an effective way to clean windings This includes windings that have been exposed to flooding or windings that have been contaminated by salt A solution of hot water and detergent is used for this method of cleaning A high pressure wash sprays a high velocity fluid stream of this solution over the generator that is being cleaned This detergent washing is followed by multiple sprays of clean water The clean water is used in order to remove the detergent or the clean water is used in order to dilute the detergent Allow the generator to dry at room temperature Check the insulation resistance The insulation resistance should now be normal If the insulation resistance is not normal repeat the procedure It may be necessary to use solvents if the generator is contaminated with oil or if the generator is contaminated with grease Note For more information on drying methods refer to Special Instructions SEHS9124 Cleaning and Drying of Electric Set Generators 120 Maintenance Section Generator Bearing Inspect SEBU7147 05 103132339 Generator Bearing Inspect SMCS Code 4471 040 T
24. performed Choose the interval that occurs first in order to determine the correct maintenance interval fuel consumption service hours and calendar time Products that operate in severe operating conditions may require more frequent maintenance All of the following will affect the oil change interval operating conditions fuel type oil type and size of the oil sump Scheduled oil sampling analyzes used oil in order to determine if the oil change interval is suitable for your specific engine In the absence of scheduled oil sampling replace the engine oil and filters according to the following intervals If the engine has a shallow oil sump change the oil after every 250 service hours If the engine has a standard oil sump change the oil after every 500 service hours If the engine has a deep oil sump change the oil after every 1000 service hours Refer to this Operation and Maintenance Manual Engine Oil and Filter Change in order to determine the oil change interval that is suitable for your specific engine To determine the maintenance intervals for the overhauls refer to this Operation and Maintenance Manual Maintenance Recommendations Unless other instructions are provided perform maintenance and perform repairs under the following conditions The starting system is disabled The engine is stopped The generator does not pose an electrical shock hazard The generator is disconnected from the
25. supplied transformer 1 Make an external power source 2 Refer to the above diagram Disconnect F1 from the voltage regulator Disconnect F2 from the voltage regulator Disconnect the generator load Connect the generator output leads TO T1 T2 and T3 Install the clamp on ammeter to generator output lead T1 Note When the line current is measured on multiple lead units measure the current in each conductor per phase The currents can then be added 3 Refer to the above diagram Connect the rheostat Adjust the rheostat to the maximum resistance value Connect the external power source to wires F1 and F2 4 Start the generator set Run the generator set at idle speed 5 Monitor the phase current Gradually increase the engine RPM Increase the engine RPM until one of the following conditions are met e The rated phase current is obtained The full generator set speed is obtained 6 If more phase current is still necessary slowly turn the rheostat until the rated phase current is reached 7 On an hourly basis stop the drying procedure Check the insulation resistance Repeat the above steps until the insulation resistance is acceptable i01461264 Generator Inspect SMCS Code 4450 040 Personal injury or death can result from improper troubleshooting and repair procedures The following troubleshooting and repair proce dures should only be performed by quali
26. switch to the OFF position Remove the key and all electrical loads 2 Turn OFF the battery charger Disconnect the charger 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal 4 The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before connecting the cables ensure that the key start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the cable from the ground plane to the NEGATIVE battery terminal SEBU7 147 05 89 Maintenance Section Battery Charger Check 101039758 Battery Charger Check SMCS Code 1401 535 Checking Before Start Up Check the battery charger for proper operation If the batteries are properly charged the needle of the ammeter will register near 0 zero The battery charger must not produce excessive current during start up Alternatively the charger must be automatically disconnected for start up If the engine has an alternator the charger must be automatically disconnected during start up and during engine oper
27. 0 Illustration 81 g00736588 Typical precleaner 1 Wing nut 2 Cover 3 Body Remove wing nut 1 and cover 2 Check for an accumulation of dirt and debris in body 3 Clean the body if necessary After cleaning the precleaner install cover 2 and wing nut 1 Note When the engine is operated in dusty applications more frequent cleaning is required 101225429 Engine Crankcase Breather Clean SMCS Code 1317 070 If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage Illustration 82 900597463 1 Loosen clamp 1 Slide the clamp down on tube 2 2 Loosen clamps 3 Remove both breathers as a unit Illustration 83 900597465 3 Remove O ring seals 4 from the valve covers Inspect the O ring seals for good condition Obtain new O ring seals if necessary 7 6 Illustration 84 g00597466 4 Remove tvvo clamps 6 Remove both breathers 5 from hose tee 7 108 Maintenance Section Engine Mounts Check SEBU7147 05 Inspect the hose tee for cracks If the tee is cracked discard the old tee and obtain a new tee for installation 5 Turn the breathers upside down in order to inspect the condition of the breathe
28. 0 Pressurizing Pump in order to pressure test the radiator filler cap The correct pressure is stamped on the face of the radiator filler cap If the radiator filler cap does not maintain the correct pressure install a new radiator filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102482066 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Cat ELC Extended Life Coolant does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants The Cat ELC Extender only needs to be added once NOTICE Use only Cat Extended Life Coolant ELC Extender with Cat ELC Do NOT use conventional supplemental coolant addi tive SCA with Cat ELC Mixing Cat ELC with conven tional coolants and or conventional SCA reduces the Cat ELC service life Check the cooling system only when the engine is stopped and cool Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is
29. 1350 535 FLV Check the coolant level when the engine is stopped and cool 4 Illustration 68 g00285520 Cooling system filler cap Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass Illustration 69 g00103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and check the condition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap 4 Inspect the cooling system for leaks 102837191 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Cool
30. 32 326 BC 820 29 C 28 3230 Every 2000 51 2 g 59 mL 2 oz 130 0 mm Ball Bearing 280 0 mm 2600 20 2 F Bearing service 1 8 oz 5 1 inch 11 0 inch 2700 Lubricant hours or 12 OD 80 C months 176 F 130 0 mm 5 1 inch ID 241 4644 320 BC LC7 29 C UNIREX Every 4500 60g 2 10z NA 100 0 mm Bearing 215 0 mm 20 2 F N3 service 3 9 inch 8 5 inch hours or 12 OD 60 C months 140 F 100 0 mm 3 9 inch ID 243 5220 315 BB LC6100 29 C UNIREX Non Non Non 75 0 mm Bearing 160 0 mm 720 2 F N3 regreasable regreasable regreasable 3 0 inch 6 3 inch LC5000 bearing bearing bearing OD 60 C 140 F 75 0 mm 3 0 inch ID 261 3545 307 BB LC2000 29 C UNIREX Non Non Non 35 0 mm Bearing 80 0 mm 20 2 F N3 regreasable regreasable regreasable 1 4 inch 3 1 inch bearing bearing bearing OD 50 C 122 F O 35 0 mm 1 4 inch ID continued 122 Maintenance Section Generator Bearing Lubricate SEBU7147 05 Table 29 contd Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft Part Type Size Min Max Part Diameter Number Number 262 5921 307 BC LC2000 29 C UNIREX Non Non Non 35 0 mm Bearing 80 0 mm 20 2 F N3 regreasable regreasable regreasable 1 4 inch 3 1 inch bearing bearing bearing OD 60 C 140 F 35 0 mm 1 4 inch ID 263 01
31. 61 309 BC LC3000 29 C UNIREX Non Non Non 45 0 mm Bearing 100 0 mm 720 2 F N3 regreasable regreasable regreasable 1 8 inch 3 9 inch bearing bearing bearing OD 60 C 140 F O 45 0 mm 1 8 inch 5P 2448 315 BC 580 29 C 28 3230 Every 2000 51 2 g 59 mL 2 oz 75 0 mm Ball Bearing 160 0 mm 590 20 2 F Bearing service 1 8 oz 3 0 inch 6 3 inch Lubricant hours or 12 OD 80 C months 176 F 75 0 mm 3 0 inch ID 6Y 3955 220 BC 450 29 C 28 3230 Every 2000 51 2 g 59 mL 2 oz 100 0 mm Ball Bearing 180 0 mm 20 2 F Bearing service 1 8 oz 3 9 inch 7 1 inch Lubricant 1 hours or 12 OD 80 C months 176 F 100 0 mm 3 9 inch ID 6Y 6488 318 BC 597 29 C 28 3230 Every 2000 51 2 g 59 mL 2 oz 90 0 mm Ball Bearing 190 0 mm 20 2 F Bearing service 1 8 oz 3 5 inch 7 5 inch Lubricant hours or 12 OD 80 C months 176 F 90 0 mm 3 5 inch 311 0843 326 BC 1800 40 C EA6 Non Non Non 130 0 mm Ball Bearing 280 0 mm FR 40 F regreasable regreasable regreasable 5 1 inch 11 0 inch bearing bearing bearing OD 80 C 176 F 130 0 mm 5 1 inch ID 311 0844 322 BC 1600 40 C EA6 Non Non Non 110 0 mm Ball Bearing 240 0 mm FR 40 F regreasable regreasable regreasable 4 3 inch 9 4 inch bearing bearing bearing OD 80 C 176 F 110 0 mm 4 3 inch ID continued SEB
32. 98199 Fuel Control Linkage Check Lubricate SMCS Code 1257 086 1257 535 Check the fuel control linkage for proper operation If necessary adjust the fuel control linkage For the adjustment procedure see the Service Manual Module Systems Operation Testing and Adjusting and see the Service Manual Module Specifications 114 Maintenance Section Fuel System Prime SEBU7147 05 Illustration 92 g00736769 1 Rod ends Apply grease to the grease fittings on the rod ends Use a hand grease gun and lubricate the grease fittings with MPGM 101398238 Fuel System Prime SMCS Code 1250 548 1258 548 1 Open the fuel supply valve Ensure that the engine will not start during the priming procedure Turn the start switch to the OFF position a gt a f LB UIA O a H 4 Illustration 93 g00736817 1 Fuel priming pump plunger 2 Turn the fuel priming pump plunger counterclockwise in order to release the lock plate from the retainer 3 Operate the fuel priming pump until the air in the fuel system has been pumped through the fuel return line back to the fuel tank 4 Press the fuel priming pump plunger to the locking position Turn the fuel priming pump plunger clockwise in order to engage the lock plate in the retainer Note Enable the starting system onl
33. BU7147 05 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 5 inch below the bottom of the filler pipe 4 Clean the radiator filler cap Inspect the gaskets of the radiator filler cap If the gaskets of the radiator filler cap are damaged discard the old radiator filler cap and install a new radiator filler cap If the gaskets of the radiator filler cap are not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the radiator filler cap The correct pressure is stamped on the face of the radiator filler cap If the radiator filler cap does not maintain the correct pressure install a new radiator filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 102062273 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Use only clean water to flush the cooling system when Extended Life Coolant ELC is drained and replaced Drain the Cooling System 1 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Ensure that the engine will not start when the cooling system is drained 2 Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap
34. M or the EMCP 3 2 3 3 may be configured to SHUTDOWN An alarm is activated if the temperature of the bearing reaches 85 C 185 F A shutdown occurs if the temperature of the bearing reaches 95 C 203 F Infrared Thermometers Bearing temperatures can also be recorded with the use of an infrared thermometer Refer to Special Publication NENG2500 Caterpillar Dealer Service Tools Catalog for a variety of infrared thermometers Follow the instructions that come with your infrared thermometer 102517207 Generator Lead Check SMCS Code 4450 535 The generator set may have braided cables between the 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 housing for the breaker and the generator terminal box If the rubber mats or the insulation on the braided cables show signs of wear at points of contact with other surfaces replace the mats or the cable immediately If your generator set does not have rubber mats in place contact your Caterpillar dealer 101228480 Generator Load Check SMCS Code 4450 535 LA During normal operation monitor the power factor and monitor generator loading When a generator is installed or when a generator is reconnected ensure that the total current in any one phase does not exceed the nameplate rating Each phase should carry the same load This allows the generator to work at t
35. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved SEBU7147 05 CATERPILLAR rais Operation and Maintenance Manual 3508 3512 and 3516 Generator Sets 5PW1 Up Generator Set 6VVVV1 Up Ge rat r Se et 8TW1 Up Gen et SAFETY CAT COM 86 Maintenance Section Maintenance Interval Schedule SEBU7147 05 103736635 Maintenance Interval Schedule SMCS Code 1000 4450 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed An authorized operator may perform the maintenance items with daily intervals An authorized operator may perform the maintenance items with intervals of every week The maintenance that is recommended for all other maintenance intervals must be performed by an authorized service technician or by your Caterpillar dealer The user is responsible for the performance of all maintenance which includes the following items performing all adjustments using proper lubricants fluids and filters and replacing old components with new components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Before each consecutive interval is performed all maintenance from the previous intervals must be
36. MPONENTS CR jACRS i cR oC R8 i RS I I UEM mon TF L1 F2 PMI N PM PM2 S PM3 Illustration 105 900612004 PMPE Generator Wiring Diagram CR1 CR6 Diodes CR7 Varistor Exciter field stator Exciter armature rotor Main field rotor Main armature stator Pilot exciter armature PM Permanent magnet RFA Rotating field assembly CST Customer supplied transformer L1 L L L L ZAFONS L2 L3 L4 L5 Ohmmeter An ohmmeter can be used to check a varistor CR7 Place an ohmmeter across the varistor The resistance should be a minimum of 15000 ohms If the resistance is less than 15000 ohms the varistor is faulty 146 Maintenance Section Voltage and Frequency Check SEBU7147 05 Test Light BATTERIES 1 5 Volt 1 5 Volt Illustration 106 g00555113 Test Light Refer to the test light that is shown in Illustration 106 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 is a short in the varistor Replace any faulty varistors with varistors that have comparable operating chara
37. Not using recommended fuel lubricants and coolant antifreeze Overhaul Information An overhaul is replacing the major worn components of the engine An overhaul interval is a maintenance interval that is planned The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts An overhaul also includes the following maintenance Inspection of all the parts that are visible during the disassembly Replacement of the seals and gaskets that are removed Cleaning of the internal passages of the engine and the engine block Inspecting the alignment of the driven equipment Most owners will save money by overhauling the engine at the intervals that are recommended in this Operation and Maintenance Manual Consider the graph in Illustration 100 Illustration 100 g00745964 Y Cost X Time 1 Cost of maintenance and repair that is planned 2 Cost of maintenance and repair that is not planned In Illustration 100 line 1 represents the maintenance and repair costs for an owner that followed the recommendations for inspection maintenance and repair The peaks represent overhauls Line 2 represents the maintenance and repair costs for an owner that chose to operate beyond the recommended intervals The initial cost of the repair after failure philosophy is lower Also the first overhaul was delayed However the peaks are significantly higher than the peaks for the custom
38. Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements SEBU7 147 05 103 Maintenance Section Engine Air Cleaner Element Single Element Clean Replace Inspecting the Primary Air Cleaner Elements Illustration 73 g00281693 Inspect the clean dry primary air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If it is necessary in order to confirm the resul
39. OMPONENTS mene F1 L1 F2 PM FUSE L5 5 PM FUSE PM g01388839 Illustration 98 PMPE Generator wiring diagram for the family of 1800 frames CR1 C6 Diodes CR7 Varistor L1 Exciter stator L2 Exciter rotor L3 Main rotor L4 Main stator L5 Permanent magnet generator stator PM Permanent magnet RFA Rotating field assembly CT1 Optional voltage droop transformer TO T1 T2 T3 T7 T8 T9 Generator terminals Table 31 Quantity Needed Tool 1 Low ohmmeter Measure the resistance of the following windings L1 L2 L3 L4 and L5 The winding that is being tested must be disconnected from the other components before the resistance can be measured Note The winding temperature affects the resistance When the winding temperature increases the winding resistance increases When the winding temperature decreases the winding resistance decreases Therefore a correct measurement can be performed only when the winding is at room temperature The following resistance measurements are approximations If the measured value is not near the listed approximation the winding is probably damaged For a more precise resistance value consult the Technical Marketing Information TMI Refer to the generator arrangement that is in question The following windings have very little resistance L2 L4 and L5 The resistance of these windings will measure near 0 ohms Use a milliohmm
40. Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program These guidelines were developed in order to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts If the engine parts comply with the established inspection specifications the parts can be reused The use of out of spec parts could result in unscheduled downtime and or costly repairs The use of out of spec parts can also contribute to increased fuel consumption and reduction of engine efficiency New parts are not necessary if the old parts can be reused repaired or salvaged Otherwise the old parts can be replaced or exchanged Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost Overhaul Programs An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar remanufactured parts Caterpillar remanufactured parts are available at a fraction of the cost of new parts These parts have been rebuilt by Caterpillar and certified for use The following components are examples of the remanufactured parts e Cylinder heads Oil Pumps e Turbochargers e Water pumps Consult your Caterpillar dealer for details and for a list of the remanufactured parts t
41. U7 147 05 123 Maintenance Section Generator Bearing Replace Table 29 contd Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft Part Type Size Min Max Part Diameter Number Number 253 9789 320 BC 1400 29 C UNIREX Non Non Non 100 0 mm Bearing 215 0 mm FR 20 2 F N3 regreasable regreasable regreasable 3 9 inch 8 5 inch bearing bearing bearing OD 80 C 176 F 100 0 mm 3 9 inch ID 193 4070 018 BC 498 499 29 C 28 3230 Every 2000 51 2 g 59 mL 2 oz 90 0 mm Ball Bearing 140 0 mm 20 2 F Bearing service 1 8 oz 3 5 inch 5 5 inch Lubricant hours or 12 OD 80 C months 176 F 90 0 mm 3 5 inch ID 1 This temperature is for a generator set that is equipped with a resistive temperature detector RTD 2 Do not exceed 60 C 140 F above the ambient temperature 3 This bearing can not be greased Refer to this Operation and Maintenance Manual Generator Bearing Replace article for information concerning the replacement of these bearings 2 Do not exceed 50 C 122 F above the ambient temperature 5 Wipe off the excess grease Remove the top grease fitting Install the plug 6 Operate the generator for one hour This will allow the grease to expand The expanding grease will force the excess grease from the cavity When the excess grease is forced from the cavity the internal pr
42. ainer Dispose of the oil according to local regulations 1 Connect a hose to drain 1 Place the other end of the hose into a suitable container in order to collect the oil 2 Open drain valve 2 Remove plug 3 Allow the oil to drain Clean the plug and install the plug Close the drain valve Remove the hose from the drain Personal injury can result from parts and or cov ers under spring pressure Spring force will be released when covers are re moved Be prepared to hold spring loaded covers as the bolts are loosened Note Some oil will remain in the housing after the oil has been drained This oil will pour out of the housing when cover 5 is removed Prepare to catch the oil in a suitable container Clean up any spilled oil with rags DO NOT use absorbent particles to clean up the oil 3 Be alert to the spring force Gradually loosen but do not remove bolts 4 Before removing bolts 4 pry the cover 5 loose in order to relieve any spring pressure Remove cover 5 Remove the O ring seal on the inside of the cover 4 Clean cover 5 and clean the O ring seal Clean the inside of the oil filter housing NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating s
43. ance Section Engine Oil Sample Obtain ADD RS FULL ENGINE STOPPED ADD FULL LOW IDLE Illustration 87 g00736607 3 ENGINE STOPPED side 4 LOW IDLE side 5 ADD mark 6 FULL mark 1 Ensure that oil level gauge 2 is seated a If the engine is stopped remove oil level gauge 2 Observe the oil level on ENGINE STOPPED side 3 The oil level should be between ADD mark 5 and FULL mark 6 b If the engine is operating reduce the engine speed to low idle Remove oil level gauge 2 and observe the oil level on LOW IDLE side 4 The oil level should be between ADD mark 5 and FULL mark 6 NOTICE Operating your engine vvhen the oil level is above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of power 2 If necessary remove oil filler cap 1 and add oil For the correct oil to use see this Operation and Maintenance Manual Refill Capacities and Recommendations topic in the Maintenance Section Do not fill the crankcase above FULL mark 6 Clean the oil filler cap Install the oil filler cap 103542996 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar
44. ant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 Cat DEAC Diesel Engine Antifreeze Coolant e Commercial heavy duty coolant antifreeze Table 26 Recommended Interval Type of Coolant Level 1 Level 2 Every 250 Cat DEAC Hours Yearly Cat ELC Optional Yearly 1 This is the recommended interval for coolant samples for all conventional heavy duty coolant antifreeze This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC 1 specification for engine coolant 2 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis SEBU7 147 05 97 Maintenance Section Cooling System Coolant Sample Level 2 Obtain Obtain the sample of the coolant as close as possible to the recommended sampling interval In order
45. ariety of cleaning techniques are available The cleaning procedure that is used may be determined by one of the items on the following list e The extent of the cleaning procedure that is being attempted e The type of enclosure of the generator The voltage rating of the generator e The type of dirt that is being removed Cleaning Assembled Generators Cleaning may be required at the point of installation At this point complete disassembly of the generator may not be necessary or feasible In this case a vacuum cleaner should be used to pick up the following items dry dirt dust and carbon This will prevent the spreading of these contaminants A small nonconductive tube may need to be connected to the vacuum cleaner This will allow the vacuum cleaner to clean the surfaces that are not exposed After most of the dust has been removed a small brush may be attached to the vacuum hose in order to loosen dirt that is more firmly attached to the surface After the initial cleaning with a vacuum compressed air may be used to remove the remaining dust and dirt Compressed air that is used for cleaning should be free of moisture and free of oil Air pressure should be a maximum of 210 kPa 30 psi in order to prevent mechanical damage to the insulation If the above cleaning procedures are not effective consult a Caterpillar dealer Cleaning Disassembled Generators An initial insulation resistance check should be made
46. arm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge 101942284 Automatic Start Stop Inspect SMCS Code 4462 The generator set must be ready to operate under a load at any time After performing maintenance on the generator set inspect the position of the control switches Ensure the following conditions e The starting system is enabled e The control switches are in the correct position for automatic starting e The switchgear and the automatic transfer switches that are associated with the generator are enabled i00993589 Battery Recycle SMCS Code 1401 005 1401 510 1401 535 1401 561 1401 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations A battery supplier e An authorized battery collection facility Recycling facility 101041029 Batteries Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced 1 Turn the key start
47. ation Charging the Battery Never disconnect any charging unit circuit or bat tery circuit cable from the battery when the charg ing unit is operated A spark can cause an explo sion from the flammable vapor mixture of hydro gen and oxygen that is released from the elec trolyte through the battery outlets Injury to per sonnel can be the result Perform the following procedure to charge the battery 1 Ensure that the charger is turned OFF 2 Adjust the voltage of the charger in order to match the voltage of the battery 3 Connect the POSITIVE lead of the charger to the POSITIVE battery terminal Connect the NEGATIVE lead of the charger to the NEGATIVE battery terminal 4 Turn ON the battery charger Overcharging of Batteries Overcharging reduces the service life of batteries Use a battery charger that will not overcharge the battery DO NOT charge the battery if the meter of the battery charger is in the RED zone Overcharging is indicated by the following symptoms The battery is very warm to the touch e A strong odor of acid is present The battery emits smoke or a dense vapor gas Perform one of the following procedures if the battery shows symptoms of overcharging Reduce the rate of charging by a significant amount Complete the charging at the reduced rate Turn OFF the charger Table 25 describes the effects of overcharging on different types of batt
48. ause extensive damage Excessive vibration can lead to misalignment Excessive vibration of the engine and the driven equipment can be caused by the following conditions e Improper mounting e Misalignment of driven equipment Loose bolts Deterioration of the isolators Ensure that the mounting bolts are tightened to the proper torque For standard torques see Specifications SENR3130 Torque Specifications Ensure that the isolators are free of oil and contamination Inspect the isolators for deterioration Ensure that the bolts for adjusting the isolator are correctly adjusted and secured with the locking nut Correctly adjusted isolators provide even support for the engine base Each isolator should impose nearly identical force on the base rail Each isolator should bear the same portion of the weight of the genset Replace any isolator that shows deterioration For more information see the literature that is provided by the OEM of the isolators Also see the Application and Installation Guide for the engine Consult your Caterpillar dealer for assistance 102064762 Engine Oil Level Check SMCS Code 1348 535 FLV The most accurate check of the oil level is performed when the engine is stopped Perform this maintenance on a surface that is as level as possible 2 me m 7 i a S JJ X 4 JV X 7 ESS g00736608 Illustration 86 1 Oil filler cap 2 Oil level gauge SEBU7 147 05 109 Mainten
49. cannot contact the terminal When four 12 volt batteries are involved the negative side of two batteries must be disconnected 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables 102667833 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking Replace the belts if the belts are not in good condition Check the belt tension according to the information in the Service Manual Specifications Slippage of loose belts can reduce the efficiency of the driven components Vibration of loose belts can cause unnecessary wear on the following components e Belts e Pulleys e Bearings If the belts are too tight unnecessary stress is placed on the components This reduces the service life of the components SEBU7 147 05 91 Maintenance Section Control Panel Inspect Test Adjusting the Alternator Belt Illustration 63 g01092641 Typical alternator 1 Mounting bolt 2 Adjusting nuts 3 Mounting bolt 1 Remove the drive belt guard 2 Loosen mounting bolt 1 adjusting nuts 2 and mounting bolt 3 3 Turn adjusting nuts 2 in order to increase or decrease the drive belt tension 4 Tighten adjusting nuts 2 Tighten mounting bolt 3 Tighten mounting bolt 1 For the pro
50. cteristics Include the following information when a varistor is being ordered for replacement Part number of the varistor Serial number of the generator After the varistor has been replaced verify that the strapping of the field winding lead is securely wound on the shaft Also verify that the strapping of the field winding lead is securely tied 101189996 Voltage and Frequency Check SMCS Code 4450 535 EL Check for proper voltage and frequency setting Check for stability Refer to the generator set Serial Plate for correct voltage and frequency 102591373 Walk Around Inspection SMCS Code 1000 040 Personal injury or death can result from improper troubleshooting and repair procedures The following troubleshooting and repair proce dures should only be performed by qualified per sonnel familiar with this equipment Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engi
51. e factory This equipment is used in order to measure the main armature s winding temperature 101539769 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced SEBU7 147 05 145 Maintenance Section Varistor Test An inspection of t
52. e following criteria has been met The damper has been operated for 20000 hours e The engine is undergoing a major overhaul Removal and Installation Refer to the Disassembly and Assembly Manual Vibration Damper Remove and Install article or consult your Caterpillar dealer for information about damper replacement 101228274 Electrical Connections Check SMCS Code 4459 535 Check all exposed electrical connections for tightness Check the following devices for loose mounting or for physical damage e transformers e fuses e capacitors e lightning arrestors Check all lead wires and electrical connections for proper clearance i01646701 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF Lock out the starting controls and tag the controls DO NOT OPERATE NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Periodic cleaning of the engine is recommended Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits SEBU7 147 05 101 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace e Easy detection of fluid leaks Maximum heat
53. e overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to two articles in the Disassembly and Assembly Manual Water Temperature Regulators Remove and Water Temperature Regulators Install for the replacement procedure of the water temperature regulator or consult
54. e radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap Open the coolant drain Remove the cooling system drain plugs Allow the water to drain NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 6 Flush the cooling system with clean water until the water that drains is clean Close the cooling system drain Clean the cooling system drain plugs and install the cooling system drain plugs Fill the Cooling System Note For information about the proper coolant to use and for the capacity of the cooling system see this Operation and Maintenance Manual Refill Capacities and Recommendations NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze After filling the cooling system do not install the radiator filler cap 2 Open the water inlet for the separate circuit aftercooler if equipped Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the coolant to warm and allow the coolant level to stabilize Stop the engine 94 Maintenance Section Cooling System Coolant ELC Change SE
55. eck 112 Fuel Control Linkage Check Lubricate 113 Fuel System Primary Filter Clean Inspect R place a etie RR I 114 Fuel System Secondary Filter Replace 115 Generator Winding Insulation Test 129 Every 2000 Service Hours Crankshaft Vibration Damper Inspect 99 Engine Mounts Check 2222 108 Engine Valve Lash Inspect Adjust 113 Generator Set Vibration Test Record 127 Turbocharger Inspect 144 Every 2000 Service Hours or 6 Months Generator Dry scies 117 Stator Lead Check 144 Every Year Cooling System Coolant Sample Level 2 Obtalnez anette ea deco 97 Generator Bearing Inspect 120 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 92 Every 3000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 95 Every 6000 Service Hours or 6 Years Alternator Inspect ssssseseeeeeses 88 Cooling System Coolant ELC Change 94 Cooling System Water Temperature Regulator Replaces aad P 99 Engine Speed Timing Sensor Clean Inspect 112 Speed Sensor Clean Inspect 142 Starting Motor Inspect 144
56. ection Overhaul Top End Table 37 contd Major Overhaul Instructions Replace Camshaft bearings Connecting rod bearings Crankshaft seals Crankshaft thrust plates Fuel injectors Gear train bushings Main bearings Piston rings Seals and bellows for the exhaust manifold Seals and gaskets for the air Inlet manifold 1 For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module 2 For instructions on cleaning the core see this Operation and Maintenance Manual Aftercooler Core Clean Test topic 103139221 Overhaul Top End SMCS Code 7595 020 TE The maintenance intervals that are listed in this Operation and Maintenance Manual Maintenance Interval Schedule are expressed in service hours A more accurate figure to use is fuel consumption Fuel consumption corresponds more accurately to the engine load See this Operation and Maintenance Manual Maintenance Recommendations topic for figures that correspond to fuel consumption A top end overhaul involves the removal the inspection and the rework of the cylinder head components A few additional components are replaced and serviced The top end overhaul second interval involves the same service that is performed for the first interval Because of the number of service hours some additional components are inspected and
57. emove the cooling system filler cap slowly 2 If necessary drain some coolant in order to allow space for the addition of the SCA 3 Add the proper amount of SCA For the proper amount of SCA refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic The proper concentration of SCA depends on the type of coolant that is used For the proper concentration of SCA refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations 4 Clean the cooling system filler cap Install the cooling system filler cap Cooling Systems that Use Water and SCA Test the Concentration of the SCA Test the concentration of the SCA with a 298 5311 Coolant Nitrite Test Kit for SCA or perform an S O S Coolant Analysis The test kit includes the following items a tool for the testing 30 ampoules for testing nitrite instructions and a case 294 7420 Test Kit contains the refill ampoules for the 298 5311 Coolant Nitrite Test Kit Use the instructions that are included with the test kit in order to properly conduct the testing Refer to this Operation and Maintenance Manual Maintenance Interval Schedule for the times at which the procedures should be conducted Test the concentration of the SCA more frequently if more frequent testing is indicated by the results of the 5 5 Coolant Analysis NOTICE Do not exceed the recommended eight percent sup plemental coola
58. er that used the repair before failure philosophy The higher peaks result from two key factors Delaying an overhaul until a breakdown increases the chance of a catastrophic failure This type of failure requires more parts labor and cleanup Excessive wear means that fewer components will be reusable More labor may be required for salvage or repair of the components 140 Maintenance Section Radiator Clean SEBU7147 05 When all of the costs are considered repair before failure is the least expensive alternative for most components and engines It is not practical to wait until the engine exhibits symptoms of excessive wear or failure It is not less costly to wait A planned overhaul before failure may be the best value for the following reasons Costly unplanned downtime can be avoided e Many original parts can be reused according to the guidelines for reusable parts The service life of the engine can be extended without the risk of a major catastrophe due to engine failure Achieve the best cost value relationship per hour of extended service life Overhaul Inspection Refer to the Service Manual for the disassembly and assembly procedures that are necessary in order to perform the required maintenance on the items that are listed Consult your Caterpillar dealer for assistance To determine the reusability publications that are needed to inspect the engine refer to Guidelines for
59. er metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 6 Flush the cooling system with clean water until the water that drains is clean Close the coolant drain Clean the cooling system drain plugs and install the cooling system drain plugs Open the water inlet for the separate circuit aftercooler if equipped Cleaning a Cooling System that has Heavy Deposits or Plugging Note For the following procedure to be effective there must be an active flow through the cooling system components 1 After the cooling system has been drained flush the cooling system with clean water in order to remove any debris 2 Close the coolant drain Clean the cooling system drain plugs and install the cooling system drain plugs 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the radiator filler cap 4 Open the water inlet for the separate circuit aftercooler if equipped Start the engine Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 C 180 F 5 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Loosen th
60. eries Table 25 Effects of Overcharging Batteries Type of Battery Effect Caterpillar General Service All of the battery cells have Batteries a low level of electrolyte Caterpillar Premium High Output Batteries When the plates of the battery are inspected through the filler holes the plates may appear to be warped This is caused by an excessive temperature The battery may not pass a load test Caterpillar Maintenance Free Batteries The battery may not accept a charging current The battery may not pass a load test Checking After Stopping Ensure that the battery charger is connected properly Observe the meter of the charger Record the amperage 102601752 Battery Electrolyte Level Check SMCS Code 1401 535 FLV When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing 90 Maintenance Section Battery or Battery Cable Disconnect SEBU7147 05 All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use c
61. essure will be reduced The generator should continue to operate until the grease stops purging 7 Stop the engine Install the plug in the bottom grease pipe Wipe off the excess grease 8 Install the louver assembly or install the rear plate 103098183 Generator Bearing Replace SR5 Generator Bearings SMCS Code 4471 510 Standard Usage Caterpillar recommends replacement of the generator bearing at the major overhaul unless the generator is installed in any of the following conditions e High temperature environment refer to the temperature chart in this Operation and Maintenance Manual Generator Bearing Lubricate article e Condensing humidity e Coastal environment Chemical environment Abrasive environment If any of these conditions exist consult your Caterpillar dealer for the appropriate checks alignment environmental environmental exercising the generator temperature vibration Standby Usage The generator bearings are shielded and greased for the life of the bearing Some purging of the grease occurs normally with the bearings Carefully adhere to the recommendations for the following conditions temperature vibration contamination and alignment Over time the bearing grease may deteriorate This deterioration may cause the grease to loose lubricating properties 124 Maintenance Section Generator Bearing Temperature Test Record SEBU7147 05 Caterpillar reco
62. eter to measure the resistance of the windings Exciter rotor L2 Refer to Table 32 Main stator L4 less than 0 1 ohm Pilot exciter stator L5 less than 0 1 ohm Use a multimeter in order to measure the resistance of field windings L1 and L3 Exciter field stator L1 Refer to table 32 Main field rotor L3 approximately 0 35 ohms to 1 2 ohms Note There should be no continuity between any winding and ground There should be no continuity between any winding and another winding Table 32 L1 Exciter L2 Exciter Main Field Field Rotor forthe Rotor 1800 Frame 10 9 ohms 0 05 ohms 9 ohms 1600 Frame 10 ohms 0 06 ohms 5 ohms 1400 Frame 11 ohms 0 06 ohms 35 ohms SEBU7 147 05 129 Maintenance Section Generator Winding Insulation Test 103736629 Generator Winding Insulation Test SMCS Code 4453 081 4454 081 4457 081 4470 081 Recommended Periodic Insulation Tests The high voltage that is produced by an operating generator set can cause severe injury or death Before performing any maintenance or repairs ensure that the generator will not start Place the engine control switch in the OFF posi tion Attach DO NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Table 33 Tools
63. f S O S oil analysis change the engine oil and engine oil filters according to the interval that is listed in Table 27 Table 27 3500B Generator Set Engine Oil Change Intervals Engine Sump Capacity Oil Change Interval Engines With a Standard Sump 3508B 227 L 60 US gal 3512B 318 L 84 US gal 3516B 405 L 107 US gal Every 500 Service Hours Engines With a Deep Sump 3508B 443 L 117 US gal 3512B 625 L 165 US gal 3516B 807 L 213 US gal Every 1000 Service Hours Drain the Oil Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed when the cold oil is drained Drain the crankcase when the oil is warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will allow the waste particles to be recirculated through the engine lubrication system with the new oil 1 After the engine has been operated at normal operating temperature STOP the engine 2 Drain the oil according to the equipment on the engine Note Drain the oil into a suitable container Dispose of the oil according to local regulations LLL
64. ff the fuel supply valve to the engine NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 900736863 116 Maintenance Section Fuel Tank Water and Sediment Drain SEBU7147 05 3 Connect a hose to drain 1 Place the other end of the hose into a suitable container in order to collect the fuel 4 Open drain valve 2 Remove plug 3 Allow the fuel to drain Clean the plug and install the plug Close the drain valve Remove the hose from the drain Note Some fuel will remain in the housing after the fuel has been drained This fuel will pour out of the housing when cover 5 is removed Prepare to catch the fuel in a suitable container Clean up any spilled fuel with absorbent towels or pillows DO NOT use absorbent particles to clean up the fuel Personal injury can result from parts and or cov ers under spring pressure Spring force will be released when covers are re moved Be prepared to hold spring loaded covers as the bolts are loosened 5 Be alert to the spring force Gradually loosen but do not remove bolts 4 Before removing bolts 4 pry c
65. fied per sonnel familiar with this equipment Refer to Safety Section Generator Isolating for Maintenance for information regarding the procedure to safely isolate the generator SEBU7 147 05 119 Maintenance Section Generator Inspect Proper maintenance of electrical equipment requires periodic visual examination of the generator and periodic visual examination of the windings Proper maintenance of electrical equipment also requires appropriate electrical checks and appropriate thermal checks Insulation material should be examined for cracks The insulation material should be examined for accumulations of dirt and dust If there is an insulation resistance value that is below normal a conductive path may be present This conductive path may be made of one of the following materials e Carbon Salt e Metal dust Dirt that is saturated with moisture These contaminants will develop a conductive path which may produce shorts Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be seen If excess dirt is the cause of a restriction in the ventilation cleaning is also advisable Restricted ventilation will cause excessive heating NOTICE To avoid the possibility of deterioration to the genera tor windings do not clean the generator unless there is visual electrical or thermal evidence that dirt is present If harmful dirt accumulations are present a v
66. formance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog and to Special Publica tion GECJ0003 Cat Shop Supplies and Tools for tools and supplies suitable to collect and contain flu ids on Caterpillar products Dispose of all fluids according to applicable regula tions and mandates Note Caterpillar recommends an S O S coolant analysis Level 1 98 Maintenance Section SEBU7147 05 Cooling System Supplemental Coolant Additive SCA Test Add Cooling Systems that Use Conventional Coolant This maintenance procedure is required for conventional coolants such as DEAC This maintenance is NOT required for cooling systems that are filled with Extended Life Coolant Test the Concentration of the SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit 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 system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 R
67. g rectifier is tight If a failure of a rectifier is suspected proceed to the Testing a Three Diode Rectifier Block section Testing a Three Diode Rectifier Block Illustration 101 900610240 AC AC2 o A Y o ACS zx AC AC2 Q o Y o o ACS g00613971 Illustration 102 Three Diode Rectifier Block two pieces The following procedure tests all three diodes within a block Check the positive rectifier block and the negative rectifier block If any meter reading does not fall within the given ranges replace the rectifier block 1 Set the digital multimeter on the diode range Remove all leads from the rectifier block 2 To test the negative rectifier block follow these steps 142 Maintenance Section Space Heater Test SEBU7147 05 oy a Place the red test lead on the negative terminal Place the black test lead on the following rectifier terminals AC1 3 AC2 4 and AC3 5 All readings on the meter should be between 0 4 and 1 0 b Place the black test lead on the negative terminal Place the red test lead on the following rectifier terminals AC1 3 AC2 4 and AC3 5 In all cases the meter should read OL overload 3 To test the positive rectifier block follow these steps a Place the red test lead on the positive rectifier terminal Place the black test lead on the following rectifier terminals
68. gears Fuel system linkage Rear gear train gears Rocker arms Clean Note The driven equipment may also require service Clean when the engine is overhauled Refer to the literature Inspect that is provided by the OEM of the driven equipment Test A major overhaul includes all of the work that is done Inspect for the top end overhaul A major overhaul includes additional parts and labor Additional parts and labor are required in order to completely rebuild the engine For the major overhaul all of the bearings seals gaskets and components that wear are disassembled The parts are cleaned and inspected If necessary the parts are replaced The crankshaft is measured for wear The crankshaft may require regrinding Alternatively the crankshaft may be replaced with a Caterpillar replacement part Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating vvithin the appropriate specifications Inspect Rebuild The following definitions explain the terminology for Replace the services that are performed during an overhaul Inspect Inspect the components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index Connecting rods Cylinder head assemblies Fuel priming pump Fuel transfer pump Oil cooler core Pi
69. hat are available Your Caterpillar dealer may be offering a variety of overhaul options A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar engines Consult your Caterpillar dealer in order to schedule a before failure overhaul Overhaul Recommendation Caterpillar recommends a scheduled overhaul in order to minimize downtime A scheduled overhaul will provide the lowest cost and the greatest value Schedule an overhaul with your Caterpillar dealer Overhaul programs vary between dealers To obtain specific information about the types of overhaul programs and services consult your Caterpillar dealer 102559063 Radiator Clean SMCS Code 1353 070 Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary SEBU7 147 05 141 Maintenance Section Rotating Rectifier Check 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 purposes must be reduced to 205 kPa 30 psi when the air nozzle
70. he ball bearings that are used in LC5 LC6 and SR5 generators contain grease This grease is subiect to deterioration f the generator is stored more than one year vvithout rotating the rotor nevv ball bearings may be required These bearings are greased at the factory These bearings do not require any additional greasing in the field Remove any necessary covers in order to inspect the rear bearings of the generators Front bearings may be inspected through the fan screen Perform a visual inspection for obvious damage for corrosion or for an excessive amount of purged grease around the bearing sleeves Small amounts of purged grease are expected Grease that covers the brackets or the vvindings is excessive Bearing inspection should include the collection of vibration data Refer to this Operation and Maintenance Manual Generator Set Vibration Test Record for further information concerning checking the vibration levels Bearing temperature should also be measured and recorded as a part of this inspection Refer to this Operation and Maintenance Manual Generator Bearing Temperature Test Record for further information concerning checking the vibration levels f inspection indicates that bearings are free of rust or corrosion and no noise or excessive vibration occur on start up replacement is not necessary 103547528 Generator Bearing Lubricate SMCS Code 4471 086 Lubricating Process If Applicable
71. he radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap 5 Open the coolant drain Allow the coolant to drain Flush the cooling system with clean water Close the coolant drain 6 Repeat Steps 3 4 and 5 Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks SEBU7 147 05 95 Maintenance Section Cooling System Coolant Extender ELC Add 1 Fill the cooling system with Extended Life Coolant ELC For the correct capacity of the cooling system see this Operation and Maintenance Manual Refill Capacities and Recommendations Do not install the radiator filler cap 2 Open the water inlet for the separate circuit aftercooler if equipped Start the engine Operate the engine in order to purge the air from the cavities of the engine block Allow the ELC to warm and allow the coolant level to stabilize Stop the engine 3 Check the coolant level Maintain the coolant to the proper level on the sight gauge if equipped If a sight gauge is not equipped maintain the coolant within 13 mm 5 inch below the bottom of the filler pipe 4 Clean the radiator filler cap Inspect the gaskets of the radiator cap If the gaskets of the radiator filler cap are damaged discard the old radiator filler cap and install a new radiator filler cap If the gaskets of the radiator filler cap are not damaged use a 9S 814
72. he rated capacity If one phase current exceeds the nameplate amperage an electrical imbalance will occur An electrical imbalance can result in an electrical overload and an electrical imbalance can result in overheating The power factor can be referred to as the efficiency of the load This can be expressed as the ratio of kVA to actual kW The power factor can be calculated by dividing KW by kVA Power factor is expressed as a decimal Power factor is used to mean the portion of current that is supplied to a system that is doing useful work The portion of the current that is not doing useful work is absorbed in maintaining the magnetic field in motors This current reactive load can be maintained without engine power SEBU7 147 05 125 Maintenance Section Generator Set Test Electric sets normally have a low idle setting that is higher than industrial engines Low idle will be approximately 66 of the full speed that is achieved by 60 Hz units This would be equal to 80 of the full speed that is achieved by 50 Hz units Some electric sets are equipped with Woodward governors and some electric sets are equipped with Caterpillar electronic governors These electric sets have no low idle stop On electric sets with mechanical governors and natural gas electric sets the low idle is set at the factory Adjustment of the low idle on these machines should only be done by a Caterpillar dealer Note Operating the electric se
73. he turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is d
74. hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note Refer to the Specifications SENR3130 Torque Specifications in order to locate the proper torques 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s gaskets Replace the coo
75. hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 t may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations article for more information 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 96 Maintenance Section Cooling System Coolant Level Check SEBU7147 05 101197583 Cooling System Coolant Level Check SMCS Code
76. important for the following reasons The generator set must always be in excellent operating condition The generator set must be ready to work under load at any time Establishing a Preventive Maintenance Program will provide these benefits e Maximum availability of the standby generator set e Longer service life for the generator set e Minimum of expensive repairs Your Caterpillar dealer can help you to establish an effective Preventive Maintenance Program for your generator set Consult your Caterpillar dealer for details Maintenance and Operation Procedures The high voltage that is produced by an operating generator set can cause severe injury or death Before performing any maintenance or repairs ensure that the generator will not start Place the engine control switch in the OFF posi tion Attach DO NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator The recommended maintenance for the engine is listed in this Operation and Maintenance Manual Maintenance Interval Schedule Standby Generator Set Engines Maintenance Section For the recommended generator maintenance see the Operation and Maintenance Manual for the generator and the control panel Maintenance and Repair The maintenance that is recommended for Every Week can be performed by an a
77. ing drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Recommendations or consult your Caterpillar dealer 102839449 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and eyes Do not drink cooling system coolant additive NOTICE Excessive supplemental coolant additive concentra tion can form deposits on the higher temperature sur faces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high 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 water pump seal Do not exceed the recommended amount of supple mental coolant additive concentration NOTICE Care must be taken to ensure that fluids are contained during per
78. ings above one megohm Use space heaters only when the generator is not running For additional information refer to Special Instruction SEHS9124 Cleaning and Drying of Electric Set Generators Recommended Procedure for the Insulation Test Personal injury or death can result from electro cution The megohmmeter is applying a high voltage to the circuit To avoid electrocution do not touch the instru ment leads without first discharging them When finished testing also discharge the generator windings 1 Take the generator out of service 2 Visually inspect the generator for moisture If moisture exists do not perform this insulation test Dry the unit first Refer to Special Instruction SEHS9124 Cleaning and Drying of Electric Set Generators 3 Inspect the installation Determine the equipment that will be tested by the insulation tester 4 Discharge the capacitance of the windings 5 Disconnect TO from ground 6 Disconnect the sensing lead wires for the regulator This may be accomplished by unplugging the harness connectors 7 Disconnect the PT leads of the load share module 8 Connect the insulation tester s Black lead to ground 9 Connect the insulation tester s RED lead to TO 130 Maintenance Section Generator Winding Insulation Test SEBU7147 05 10 Set the voltage to the rated voltage of the generator 11 Use the 30 60 Time Resistance Method a App
79. inimize the following problems e Bearing problems e Vibration of the engine crankshaft e Vibration of the driven equipment Refer to the following information for more information about the alignment of the generator set e Special Instruction SEHS7654 Alignment General Instructions e Special Instruction SEHS7259 Alignment of Single Bearing Generators e Special Instruction REHS0177 Alignment of the Close Coupled Two Bearing Generators SEBU7 147 05 127 Maintenance Section Generator Set Vibration Test Record Keep a record of the measurement of the alignment The record may be used to check the trend of the alignment The record may be used to analyze the trend of the alignment The genset must be aligned when the genset is moved into a final position The genset must be aligned if the genset is moved into a different position 103643886 Generator Set Vibration Test Record SMCS Code 4450 081 VI Check for vibration damage Vibration may cause the following problems e Coupling wear Loose fittings Fatigue of the metal components of the engine Cracks in the cabinet which surrounds the generator e Cracks in welds Excessive noise e Cracked insulation The following areas are susceptible to vibration damage e Coupling for the generator set Generator bearings Stator output leads Protective sleeving Insulation Exposed electrical connections e Transforme
80. irected at the areas that are most prone to damage and deterioration The most prone areas to damage and deterioration are listed below Ground insulation Ground insulation is insulation that is intended to isolate components that are carrying current from components that are not carrying current Support insulation Support insulation is usually made from one of the following items a compressed lamination of fibrous materials polyester or felt pads that have been impregnated with various types of bonding agents There are many different types of damage that can occur in these areas Several of the different types of damage are listed below Thermal aging Thermal aging can cause the degradation of insulation or the deterioration of insulation An examination of the coils may reveal that the insulation has expanded into the ventilation ducts This is the result of a loss of bond which will cause the insulation material to separate The insulation material could also separate from the conductors on the windings Abrasion The surfaces of coils and the surfaces of connectors may be damaged by abrasion These surfaces may also be damaged by contamination from other sources An example of these sources would be chemicals or abrasive substances Cracking Cracking of insulation may result from mechanical stress The structure that is used to brace the stator winding will become loose if the problem is not corrected Fu
81. irty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 101494879 Varistor Test SMCS Code 4466 081 11 n CST T3 T2 ee VOLTAGE uS xY REGULATOR AND OR CR7 RELATED CRI Rd CO
82. l result in poor performance or even damage to the windings Whenever the generator is not active the optional space heaters should be operated An external source is required to operate the space heaters Both of the sources must be a single phase This source can be either 115 vac or 230 vac When the external source is 50 hertz 200 vac must be used Refer to Illustration 103 See your Caterpillar dealer for information on checking your Caterpillar generator 101472973 Speed Sensor Clean Inspect SMCS Code 1907 040 1907 070 22 a s Q Illustration 104 900293337 Typical speed sensor SEBU7 147 05 143 Maintenance Section Standby Generator Set Maintenance Recommendations 1 Remove the speed sensor from the flywheel housing Check the condition of the end of the speed sensor Check for signs of wear and contaminants 2 Clean the metal shavings and other debris from the face of the magnet 3 Install the speed sensor according to the information in the Service Manual Specifications 101038735 Standby Generator Set Maintenance Recommendations SMCS Code 4450 041 A standby generator set may not need to be used very often However the generator set is usually needed for operation in an emergency situation Maintenance of the standby generator set is very
83. lacement purposes Illustration 75 900735127 1 Cover 2 Air cleaner element 3 Turbocharger air inlet 1 Remove the air cleaner cover Remove the air cleaner element Note Refer to Cleaning the Air Cleaner Elements 2 Cover the air inlet with tape in order to keep dirt out 3 Clean the inside of the air cleaner cover and body with a clean dry cloth 4 Remove the tape for the air inlet Install an air cleaner element that is new or cleaned 5 Install the air cleaner cover 6 Reset the air cleaner service indicator Cleaning the Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The air cleaner element can be used u
84. lations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Note Failure to properly close the drain can allow air into the system which could have detrimental results to performance Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure SEBU7 147 05 117 Maintenance Section Generator Dry Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use sup
85. lean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 101492654 Battery or Battery Cable Disconnect SMCS Code 1401 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal at the battery that goes to the start switch Ensure that the cable
86. ling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks SEBU7 147 05 133 Maintenance Section Maintenance Recommendations 101979810 Maintenance Recommendations SMCS Code 1000 Service Hours and Fuel Consumption Experience has shown that maintenance intervals are most accurately based on fuel consumption Fuel consumption corresponds more accurately to the engine load Tables 34 35 and 36 list average ranges of fuel consumption and service hours for a load factor of approximately 60 percent Use the range of fuel consumption only as a guideline Table 34 Maintenance Interval Schedule Service Hours and Fuel Consumption for 3508 and 3508B Engines Interval Rated Up To 1300 RPM Rated 1301 To 1600 RPM Rated 1601 To 1800 RPM 250 Service Hours 22700 L 6000 US gal 27700 L 7200 US gal 32000 L 8500 US gal 500 Service Hours 45400 L 12000 US gal 54400 L 14400 US gal 64000 L 17000 US gal 1000 Service Hours 89000 L 23500 US gal 109000 L 28800 US gal 128000 L 34000 US gal 2000 Service Hours 178000 L 47000 US gal 218000 L 57600 US gal 257000 L 68000 US gal 3000 Service Hours 267500 L 70500 US gal 327500 L 84000 US gal 386500 L 102000 US gal 6000 Service Hours 535000 L 141000 US gal 654000 L 173000 US gal 774000 L 204000 US gal Top
87. lowing reasons The damper is dented cracked or leaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft The crankshaft bearings are showing excessive wear There is a large amount of gear train wear that is not caused by a lack of oil 100 Maintenance Section Electrical Connections Check SEBU7147 05 Dampers With Sampling Ports Illustration 70 g00819045 Some dampers have ports for fluid samples If the damper has no external damage collect a sample of the damper fluid The fluid should be analyzed in order to check for a loss of viscosity Use the results of the analysis to determine if the damper should be rebuilt or replaced Kits for fluid samples are available from the address that follows Return the kits to the same address for analysis Hasse amp Wrede GmbH Georg Knorr Strafse 4 12681 Berlin Germany Phone 49 30 9392 3135 Fax 49 30 9392 7 3135 Alternate phone 49 30 9392 3156 Alternate fax 49 30 9392 7 3156 The typical limit for the degradation of the damper fluid viscosity that is used by Hasse amp Wrede GmbH is 20 percent for the majority of applications The reports from Hasse amp Wrede should indicate that the fluid samples meet this viscosity limit Dampers Without Sampling Ports Some dampers do not have a port for a fluid sample These dampers must be rebuilt or the dampers must be replaced when one of th
88. lvent Allow the element to dry Inspect the element Install a new element if the old element is damaged or deteriorated 5 Clean the inside of the filter case Allow the filter case to dry 6 Inspect the O ring seals Obtain new seal rings if the old seal rings are damaged or deteriorated Ensure that the sealing surfaces for the seals are clean Install the seals NOTICE Do not fill the fuel filters with fuel before installing them The fuel would not be filtered and could be contami nated Contaminated fuel will cause accelerated wear to fuel system parts 7 Place the element in the filter case Slide the filter case over the mounting bolt 8 Install the nut 9 Open the fuel supply valve 10 Prime the fuel system See this Operation and Maintenance Manual Fuel System Prime topic 101398265 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Replace the secondary fuel filter element whenever the following conditions occur The fuel filter differential pressure gauge registers 103 kPa 15 psi The fuel filters have been used for 1000 service hours 1 Stop the engine Ensure that the engine will not start during this procedure 2 Shut o
89. ly voltage b Observe the readings at 30 seconds Observe the readings at 60 seconds c Record the 60 second reading This reading must be corrected for temperature d Record temperature e Record humidity f Remove voltage 12 Evaluate the readings The actual value of the resistance may vary greatly between generators For this reason the insulation s condition must be evaluated Base this evaluation on the comparison between the 60 second resistance readings and the readings that were taken on previous dates These two readings must be taken under similar conditions If a 60 second resistance reading has a 50 percent reduction from the previous reading the insulation may have absorbed too much moisture Switch the insulation tester to the OFF position This will discharge the insulation tester s leads Disconnect the insulation tester s leads Note The results from the insulation resistance checks indicate when cleaning and or repairing is becoming critical Generally insulation resistance will vary greatly with temperature Therefore always test at the same temperature and humidity Refer to Illustration 99 Engine Serial Number Serial Number for the Generator 131 Maintenance Section Generator Winding Insulation Test SEBU7 147 05 yac 071 yc ec 511 07 021 001 08 09 oy ty u 191 44209 eunjipuedue ayy Ag fjdninw
90. mmends the replacement of the bearing after ten years of service in a standby application in normal conditions If the bearing is installed in the following conditions Caterpillar recommends replacement of the bearing in 5 years e High temperature environment Refer to the temperature chart in this Operation and Maintenance Manual Generator Bearing Lubricate article e Condensing humidity Coastal environment Chemical environment Abrasive environment 103642839 Generator Bearing Temperature Test Record SMCS Code 4471 081 TA The monitoring of bearing temperature may prevent premature bearing failure A generator set should never operate above the recommended set points Keep records in order to monitor the changes in the temperature of the bearing Note Measure the bearing temperature after the generator reaches normal operating temperature Resistive Temperature Detectors RTDs Caterpillar Generators may be equipped with resistance temperature detectors for generator bearings These detectors are 100 ohm resistance temperature detectors A resistance temperature detector may be monitored by the optional monitor for the EMCP 3 2 3 3 resistance temperature detector A resistance temperature detector may be monitored by equipment that is provided by the customer Consult with your Caterpillar dealer about other methods of measuring the bearing temperature The EMCP 3 2 3 3 may be configured to ALAR
91. ne is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water e Ensure that cooling lines are properly clamped Check for leaks Check the condition of all pipes e Inspect the water pump for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract SEBU7 147 05 147 Maintenance Section Water Pump Inspect Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pump and the installation of water pump and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover Inspect the Closed Crankcase Ventilation CCV filter if equipped If the restriction indicator is visible service the CCV Inspect the fuel sy
92. nt additive concentration 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 system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly 2 If necessary drain some coolant in order to allow space for the addition of the SCA 3 Add the proper amount of SCA For the proper amount of SCA refer to this Operation and Maintenance Manual Refill Capacities and Recommendations topic For the proper concentration of SCA refer to Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations 4 Clean the cooling system filler cap Install the cooling system filler cap SEBU7 147 05 99 Maintenance Section Cooling System Water Temperature Regulator Replace 103645060 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime Refer to this Operation and Maintenance Manual Maintenance Interval Schedule for the proper maintenance interval A water temperature regulator that fails in a partially opened position can caus
93. nts help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected 104 Maintenance Section SEBU7147 05 Engine Air Cleaner Element Single Element Clean Replace The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for rep
94. ocedure to safely isolate the generator If the insulation resistance values are less than the recommended values one of the following drying procedures must be selected This decision should be based on the following factors e the size of the unit e the location of the unit e the equipment that is available e the experience of personnel Note For more information on drying methods refer to Special Instruction SEHS9124 Cleaning and Drying of Electric Set Generators Remove the voltage regulator Cover all of the inlet openings Cover all of the discharge holes Provide an opening at the top of the machine This opening will allow moisture to evaporate Preferably this opening will be located at the fan end Monitor the winding temperatures DO NOT APPLY HEAT TOO RAPIDLY Winding temperature should be raised gradually at a rate of 10 C 50 F per hour up to 85 C 185 F Measure insulation resistance at one hour intervals Typically the insulation resistance will slowly drop while the temperature is rising The insulation resistance will then start to increase at a slow rate until the insulation resistance reaches a constant level The following methods can be used for drying a generator e Self circulating air method e Oven method Controlled current method Self Circulating Air Method Run the engine and disconnect the generator load This will help circulate air Operate the generator space heaters
95. or serviced Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications Note The driven equipment may also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment The following definitions explain the terminology for the services that are performed during an overhaul Inspect Inspect the components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures New parts are not required if the existing parts can still be used reconditioned or repaired If the components are not in the reusability guidelines refer to the Service Manual Specifications module Rebuild The component is reconditioned in order to comply with reusability guidelines Replace The service life of the part is exhausted The part may fail before the next maintenance interval The part must be replaced with a part that meets functional specifications The replacement part may be a new part a CAT remanufactured part a rebuilt part or a used part Some worn components may be exchanged with
96. over 5 loose in order to relieve any spring pressure Remove cover 5 Remove the O ring seal on the inside of the cover Remove the fuel filter elements 6 Clean cover 5 and clean the O ring seal Clean the inside of the fuel filter housing 7 Install new fuel filter elements 8 Inspect the O ring seal Ensure that the surfaces for the O ring seal are clean Install a new O ring seal if the old O ring seal is damaged or deteriorated 9 Install cover 5 Ensure that the springs are seated properly between the cover and the fuel filter elements 10 Open the fuel supply valve Reconnect the battery 11 Prime the fuel system Refer to this Operation and Maintenance Manual Fuel System Prime topic Maintenance Section 103645042 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regu
97. p to six times if the element is properly cleaned and inspected When the air cleaner element is cleaned check for rips or tears in the filter material The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean air cleaner elements Pressurized air e Vacuum cleaning SEBU7 147 05 105 Maintenance Section Engine Air Cleaner Element Single Element Clean Replace Pressurized Air Pressurized air can be used to clean air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 76 g00281692 Note When the air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dir
98. peed timing sensor Check for signs of wear and contaminants 2 Clean the metal shavings and other debris from the face of the magnet 3 Install the engine speed timing sensor according to the information in the Service Manual Specifications SEBU7 147 05 113 Maintenance Section Engine Valve Lash Inspect Adjust 102939209 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 Note For procedures on adjusting the valve lash and adjusting the valve bridge see System Systems Operation Testing and Adjusting Valve Lash and Valve Bridge Adjustment Consult your Caterpillar dealer for assistance The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Valve Bridge Check the valve bridge and adjust the valve bridge if necessary Perform the procedure for both valve bridges for each cylinder After the valve bridge is checked for each cylinder proceed with the valve lash adjustment if nece
99. per torque see the Service Manual Specifications module 5 Reinstall the drive belt guard If new drive belts are installed check the drive belt tension again after 30 minutes of engine operation at the rated rpm Adjusting the Fan Drive Belt 1 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 AR Tighten the adjusting nut to the proper torque a Tighten the mounting bolt to the proper torque For the proper torque specifications refer to the Service Manual Specifications module Replacement For applications that require multiple drive belts replace the drive belts in matched sets Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched The additional load on the new drive belt could cause the new drive belt to fail 103736663 Control Panel Inspect Test SMCS Code 4490 040 4490 081 7451 040 7451 081 Inspect the condition of the panel If a component is damaged ensure that the component is repaired or that the component is replaced If equipped ensure that the electronic displays are operating properly Inspect the wiring for good condition Ensure that the wiring connections are secure Electronic Modular Control Panel 3 EMCP 3 o aa c RUIN AUTO STOP ARPAN
100. ply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A four micron c absolute filter for the breather vent on the fuel tank is also recommended Refer to Special Publication SENR9620 Improving Fuel System Durablity f a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank vvill also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used 101601944 Generator Dry SMCS Code 4450 569 Personal injury or death can result from improper troubleshooting and repair procedures The following troubleshooting and repair proce dures should only be performed by qualified per sonnel familiar with this equipment Refer to Safety Section Generator Isolating for Maintenance for information regarding the pr
101. r elements Clean the breather elements with clean nonflammable solvent If the breather elements remain contaminated after the cleaning discard the breathers and obtain new breathers Do not attempt to disassemble the breathers Allow the breather elements to dry before installation Note Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier 6 Place clamps 6 over the parts of hose tee 7 that will receive breathers 5 Install the breathers into the tee Tighten the clamps to the torque that is listed in the Service Manual Specifications 7 Coat O ring seals 4 with clean engine oil Place the O ring seals on the valve covers 8 Place clamps 3 around the parts of the breathers that will be attached to the valve covers Install both breathers as a unit Tighten the clamps 9 Place clamp 1 on the part of the hose tee that will receive tube 2 Install the tube into the hose tee Tighten the clamp to the torque that is listed in the Service Manual Specifications 103214182 Engine Mounts Check SMCS Code 1152 535 Illustration 85 901340704 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 equipment will c
102. r operating procedures and improper maintenance practices SEBU7 147 05 139 Maintenance Section Overhaul Considerations Environmental Factors Extreme Ambient Temperatures Extended operation in environments that are extremely cold or hot can damage components Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot inlet air reduces the performance capabilities of the engine Note See this Operation and Maintenance Manual Cold Weather Operation topic Operation Section or see Supplement SEBU5898 Cold Weather Recommendations Cleanliness Unless the equipment is cleaned regularly extended operation in a dirty environment and in a dusty environment can damage components Built up mud dirt and dust can encase components This can make maintenance difficult The buildup can contain corrosive chemicals Corrosive chemicals and salt can damage some components Improper Operating Procedures e Extended operation at low idle e Minimum cool down periods after high load factor operation Operating the engine beyond the guidelines for the engine rating Operating the engine at loads that are greater than the rated load Operating the engine at speeds that are greater than the rated speed Use of the engine for an application that is not approved Improper Maintenance Practices Extension of maintenance intervals
103. re expressed in service hours A more accurate figure to use is fuel consumption Fuel consumption corresponds more accurately to the engine load See this Operation and Maintenance Manual Maintenance Recommendations topic for figures that correspond to fuel consumption The need for a major overhaul is determined by several factors e An increase in oil consumption e An increase in crankcase blowby The total amount of fuel consumption The service hours of the engine The wear metal analysis of the lube oil e An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced An increase in the levels of noise and vibration indicates that rotating parts require service Note It is possible for oil analysis to indicate a decrease of wear metals in the lube oil The cylinder liners may be worn so that polishing of the bore occurs Also the increased use of lube oil will dilute the wear metals 136 Maintenance Section Overhaul Major SEBU7147 05 Monitor the engine as the engine accumulates Table 37 service hours Consult your Caterpillar dealer about scheduling a major overhaul Major Overhaul Instructions 0 Oil suction screen Aftercooler core 6 Camshafts Cylinder block Crankshaft vibration damper Driven equipment alignment Flywheel Front gear train
104. recommends using 5 5 oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine 5 5 oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information Engine model e Service hours on the engine The number of hours that have accumulated since the last oil change The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a vvarm vvell mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle incl
105. result in death or serious injury 126 Maintenance Section Generator Set Alignment Check SEBU7147 05 Dangerous voltages are present at the generator s output terminals Until the power is verified to be OFF there should not be any device that is connected to the following terminals T1 T2 and T3 The voltmeter must be connected to the generator through potential transformers Potential transformers provide a maximum of 600 volts to the voltmeter Table 30 Tools Needed Part Number Part Quantity Digital x Multimeter 1 12 VDC battery 1 Potential 1 Transformer The generator set functional test is a simplified test that can be performed in order to determine if the generator is functional The generator set functional test should be performed on a generator set that is under load The generator set functional test determines if the follovving statements happen A phase voltage is being generated The phase voltages are balanced The phase voltages change relative to engine speed The generator set functional test consists of the following steps 1 Stop the generator Connect the potential transformer s high voltage winding to the generator terminals T1 and T2 Connect the voltmeter to the low voltage winding If two transformers are available connect the high voltage winding of the second transformer to the generator terminals T1 and T3
106. rs e Fuses e Capacitors Lightning arresters When a generator set is installed a vibration plot should be recorded in order to assist in diagnosing potential problems This vibration plot should be updated yearly The vibration plot should also be updated when the generator set is moved and when the engine is overhauled This will allow the trend of the vibration to be monitored and analyzed A potential problem may be prevented by monitoring the trend of the vibration If the vibration is approaching the limit of the specification of the component the problem may be more imminent Refer to Data Sheet LEKQ4023 Linear Vibration for the allowable limits of vibration Caterpillar also recommends recording the vibration of the bearing at the generator bearing bracket If the vibration exceeds the EDS limits for vibration check the alignment Refer to this Operation and Maintenance Manual Generator Set Alignment Check for the alignment procedure Contact the Caterpillar Dealer Service Tools group for information on ordering a vibration analyzer that will meet your needs 128 Maintenance Section Generator Winding Test SEBU7147 05 103736530 Generator Winding Test SMCS Code 4453 081 4454 081 4457 081 4470 081 VOLTAGE REGULATOR AND OR RELATED C
107. rther mechanical damage or electrical damage may also result Erosion Erosion can be caused when foreign substances rub against the insulation that is on the surface of the coil 103543200 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure Other potential damage to the engine 148 Maintenance Section Water Pump Inspect SEBU7147 05 A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the disassembly and assembly procedure If it is necessary to remove the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed
108. ssary Engine Valve Lash NOTICE Only qualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the complete valve lash adjustment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life The valve bridge adjustment must be performed before making a valve lash adjustment If the valve lash is within the tolerance an adjustment of the valve lash is NOT necessary For the valve lash setting see the engine s Specifications manual For the procedure to set the valve lash see the engine s Systems Operation Testing and Adjusting manual 101552621 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD 1 Inspect the fan drive pulley assembly If the shaft is loose an inspection of the internal components should be made Illustration 91 g00736668 1 Grease fittings for the fan bearings Note If the engine is operated in hot environments dirty environments or humid environments lubricate the fan bearings more frequently 2 Lubricate the grease fittings for the fan bearings with Bearing Lubricant or with an equivalent grease 1013
109. stem for leaks Look for loose fuel line clamps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the engine to frame ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery e Check the condition of the gauges Replace any gauges that are cracked Replace any gauges that can not be calibrated Inspect the Generator Refer to Safety Section Generator Isolating for Maintenance for information regarding the procedure to safely isolate the generator A visual inspection should be initially d
110. ston pins of Publications on Reusability or Salvage of Used Parts The guidelines were developed in order Inspect to help Caterpillar dealers and customers avoid Replace unnecessary expenditures New parts are not required if the existing parts can still be used reconditioned or repaired If the components are not in the reusability guidelines refer to the Service Manual Specifications module Rebuild The component can be reconditioned in order to comply with reusability guidelines Replace The service life of the part is exhausted The part may fail before the next maintenance interval The part must be replaced with a part that meets functional specifications The replacement part may be a new part a CAT remanufactured part Camshatt lifters Camshaft thrust washers Crankshaft Cylinder liners Engine mounts Engine wiring harness Fuel pressure regulating valve Pistons Crowns and Skirts Pushrods Spacer plates a rebuilt part or a used part Some worn components may be exchanged with your Caterpillar dealer for credit on replacement parts Consult your Caterpillar dealer about repair options for your engine If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the recommendations in Table 37 Your Caterpillar dealer can provide these services and components continued SEBU7 147 05 137 Maintenance S
111. struments e Check for ease of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated rpm The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the fitting for the service indicator may be plugged Illustration 80 900351792 Porous filter A porous filter is part of a fitting that is used for mounting of the service indicator Inspect the filter for cleanliness Clean the filter if necessary Use compressed air or a clean nonflammable solvent The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in SEBU7 147 05 107 Maintenance Section Engine Air Precleaner Clean 101397717 Engine Air Precleaner Clean SMCS Code 1055 07
112. t compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 74 900281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information Date of cleaning e Number of cleanings Store the box in a dry location 101553508 Engine Air Cleaner Element Single Element Clean Replace SMCS Code 1051 1054 037 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner eleme
113. t at low idle speed for an extended time will cause some voltage regulators to shut off The electric set must be completely shut down and the electric set must be restarted This will allow the voltage regulator to again produce an output 101228520 Generator Set Test SMCS Code 4450 081 T1 n CST T3 T2 RED EE VOLTAGE i L3 gt REGULATOR 57 AND OR CR7 is RELATED I I CR4 COMPONENTS CR2 CRY i erag jo C8 i L2 i I I i OR Peces TF L1 F2 PMI N 2 PM2 S PM3 g00669571 Illustration 97 Generator Wiring Diagram CR1 CR6 Diodes CR7 Varistor Exciter field stator Exciter armature rotor Main field rotor Main armature stator Pilot exciter armature M Permanent magnet RFA Rotating field assembly CST Customer supplied transformer L1 L2 L3 L4 L5 P 4 DANGER Dangerous voltages are present at both the gen erator and the system bus Under no circumstances should any attempt be made to connect instrumentation to these points until you are certain all povver is off All instruments must be connected to the gener ator and the system bus through potential trans formers which provide a maximum of 600 volts to the instruments Failure to follow instructions will
114. t function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately 101537777 Engine Speed Timing Sensor Clean Inspect SMCS Code 1905 040 1905 070 1907 040 1907 070 22 if s o Illustration 90 900293337 Typical engine speed timing sensor 1 Remove the engine speed timing sensor from the flywheel housing Check the condition of the end of the engine s
115. the following conditions exist e The engine overheats frequently e The coolant is foaming Oil or fuel has entered the cooling system and the coolant is contaminated Drain the Cooling System 1 Stop the engine and allow the engine to cool Close the water inlet for the separate circuit aftercooler if equipped Ensure that the engine will not start when the cooling system is drained 2 Loosen the radiator filler cap slowly in order to relieve any pressure Remove the radiator filler cap a n He Illustration 66 g00750410 1 Coolant drain Note If the engine has a jacket water heater drain the coolant from the heater 3 Open the coolant drain Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tools Inside U S A 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL EAME phone 41 22 849 40 56 EAME fax 41 22 849 49 29 Clean the Cooling System
116. to help keep the windings dry When the generator is not active ensure that the space heaters are operating When the generator is operating turn OFF the space heaters 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 103230840 Stator Lead Check SMCS Code 4459 535 Ensure that the stator output leads are routed out of the generator in a manner that prevents the leads from rubbing against metal objects Visually inspect the following areas for cracking and physical damage e stator output leads protective sleeving insulation 103725200 Stator Winding Temperature Test SMCS Code 4453 081 TA Some generators are provided with optional 100 Ohm Resistance Temperature Detectors RTD When the temperature of the stator winding is suspected to be high measure the temperature If the generator is furnished with Resistance Temperature Detectors the detectors are installed in the slots of the main armature stator The detectors are used with equipment that is available from th
117. to receive the full effect of 5 5 analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see this Operation and Maintenance Manual Refill Capacities and Recommendations or consult your Caterpillar dealer 101987714 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are be
118. transfer characteristics Ease of maintenance Note Caution must be used in order to prevent electrical components from being damaged by excessive water when you clean the engine Avoid electrical components such as the alternator the starter and the ECM Engine Air Cleaner Element Dual Element Clean Replace SMCS Code 1051 1054 037 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element e Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may
119. ty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Air Cleaner Elements Inspecting the Air Cleaner Elements Illustration 77 g00281693 Inspect the clean dry air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the air cleaner element Rotate the air cleaner element Inspect the air cleaner element for tears and or holes Inspect the air cleaner element for light that may show through the filter material If it is necessary in order to confirm the result compare the air cleaner element to a new air cleaner element that has the same part number Do not use an air cleaner element that has any tears and or holes in the filter material Do not use an air cleaner element with damaged pleats gaskets or seals Discard damaged air cleaner elements Storing Air Cleaner Elements If an
120. udes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump 110 Maintenance Section Engine Oil and Filter Change SEBU7147 05 For instructions see Special Publication PEgj0047 How To Take A Good S O S Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an 5 5 program for your engine 103006778 Engine Oil and Filter Change SMCS Code 1318 510 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin The oil change interval will be affected by the following items e Air fuel ratio e Ambient air conditions e Engine application e Fuel type Oil type e Size of the oil sump The S O S oil analysis program analyzes used oil in order to determine if the oil change interval is suitable for your specific engine In the absence o
121. uthorized operator The maintenance that is recommended for the subsequent maintenance intervals must be performed by an authorized service technician or by your Caterpillar dealer Unless other instructions are provided perform maintenance and repairs under the following conditions e The engine is stopped The starting system is disabled The generator does not pose an electrical shock hazard Operation To ensure proper operation the generator set must be exercised regularly For instructions on operating the generator set see the Operation and Maintenance Manual for the generator set control panel For these operation procedures follow the instructions that are provided in this Operation and Maintenance Manual Operation Section starting the engine engine operation and stopping the engine 144 Maintenance Section Starting Motor Inspect SEBU7147 05 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 other electrical equipment Make every effort to keep the generator set as dry as possible Generators can operate without problems in humid environments However problems can occur when the generator is inactive Moisture can condense on the windings This can result in poor performance Also damage to the windings can occur Use space heaters in order
122. ver Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Cleaner Elements 3 Cover the turbocharger air inlet with tape in order to keep dirt out 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 102 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU7147 05 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator Cleaning the Primary Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage
123. vice Hours 22500 Service Hours 5826000 L 1537500 US gal 1 Fuel consumption is based on a load factor of approximately 60 percent Severe Operation Severe operation is the use of an engine that exceeds current published standards for that engine Caterpillar maintains standards for the following engine parameters e Horsepower Range of rpm e Fuel consumption Fuel quality Altitude e Selection of oil Selection of coolant Maintenance intervals SEBU7 147 05 135 Maintenance Section Overhaul Major e Environmental qualities e Installation Refer to the standards for your engine or consult your Caterpillar dealer in order to determine if your engine is operating within the defined parameters Severe operation can accelerate component wear Engines that are operating under severe conditions may need more frequent maintenance intervals for the following reasons e Maximum reliability Retention of full service life Because of individual applications it is not possible to identify all of the factors which can contribute to severe operation Consult your Caterpillar dealer about the maintenance that is needed for your specific engine The following factors can contribute to severe operation environment improper operating procedures and improper maintenance practices Environmental Factors Extreme Ambient Temperatures Extended operation in environments that are
124. y after all maintenance has been completed Priming Procedure for Dry Starting If the air cannot be completely purged from the fuel system and the engine will not start see Special Instruction SEHS9586 3500 EUI Fuel Priming Procedure 101398258 Fuel System Primary Filter Clean Inspect Replace SMCS Code 1260 510 1260 571 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 1 Stop the engine Ensure that the engine will not start during this procedure 2 Shut off the fuel supply valve to the engine NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately SEBU7 147 05 115 Maintenance Section Fuel System Secondary Filter Replace g00736845 Illustration 94 1 Filter case 2 Nut 3 Loosen nut 2 Hold filter case 1 and remove nut 2 Prepare to catch the fuel that is inside of the filter case with a suitable container Remove the filter case from the mounting bolt 4 Remove the element and wash the element in clean nonflammable so
125. your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 102871204 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 The crankshaft vibration damper limits the torsional vibration of the crankshaft The visconic damper has a weight that is located inside a fluid filled case Damage to the crankshaft vibration damper or failure of the damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive torsional vibrations A damper that is hot may be the result of excessive torsional vibration worn bearings or damage to the damper Use an infrared thermometer to monitor the temperature of the damper during operation Follow the instructions that are included with the infrared thermometer If the temperature reaches 100 C 212 F consult your Caterpillar dealer Inspect the damper for evidence of dents cracks and leaks of the fluid If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous and smooth If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace all of the seals Inspect the damper and repair or replace the damper for any of the fol
126. your Caterpillar dealer for credit on replacement parts Consult your Caterpillar dealer about repair options for your engine If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the recommendations in Table 38 138 Maintenance Section Overhaul Considerations SEBU7147 05 Table 38 Recommendations for Top End Overhauls Service Top End Top End Overhaul First Overhaul Interval Second Interval Clean Oil suction screen Clean Aftercooler core nspect Pressure test nspect Fuel system linkage s Connecting rod bearings 9 Cylinder liners 0 5 Piston crowns and skirts 6 5 Piston pins 6 Inspect Rocker arms Rebuild Inspect Cylinder head assemblies Rebuild Replace Fuel priming pump S Engine oil pump Fuel transfer pump B Prelube pump Scavenge oil pump Inspect Camshaft lifters Replace Engine wiring harness Fuel pressure regulating valve Pushrods Spacer plates Rebuild Turbochargers Replace Replace Fuel injectors Gaskets and seals for the air inlet manifold Seals and bellows for the exhaust manifold 1 For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module 2 For instructions on cleaning the core see this Operation and Maintenance Manual Aftercooler Core Clean Test topic 3
127. ystem Only use oil filters recommended by Caterpillar 5 Install new oil filter elements 6 Inspect the O ring seal Ensure that the surfaces for the O ring seal are clean Install a new O ring seal if the old O ring seal is damaged or deteriorated 7 Install cover 5 Ensure that the springs are seated properly between the cover and the oil filter elements Inspect the Used Oil Filter Elements Cut the used oil filter element open with a utility knife Remove the metal wrap Cut the filter element free from the end caps Spread apart the pleats and inspect the element for metal debris An excessive amount of debris in the element may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the element Ferrous metals may indicate wear on the steel and the cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts the brass parts or the bronze parts of the engine Parts that may be affected include the following components main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter element If an excessive amount of debris is found in the oil filter element consult your Caterpillar dealer in order to arrange for further oil analysis 112 Maintenance Section Engine Protective Devices Check

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