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Maintenance Intervals: Operation and Maintenance Manual Excerpt
Maintenance Intervals: Operation and Maintenance Manual Excerpt
® ®
© 2010 Caterpillar
All Rights Reserved
SEBU8132-06
June 2009
Operation and
Maintenance
Manual
C3.3 and C4.4 Rental Generator Sets
X3B1-Up (Generator Set)
XYC1-Up (Generator Set)
D4D1-Up (Generator Set)
XYD1-Up (Generator Set)
GLE1-Up (Generator Set)
N4R1-Up (Generator Set)
N3X1-Up (Generator Set)
N4X1-Up (Generator Set)
SAFETY.CAT.COM
82 SEBU8132-06
Maintenance Section
Maintenance Interval Schedule
Cooling System Coolant Level - Check ................ 89 Every 2000 Service Hours or 6 Months
Electrical Connections - Check ............................. 91
Engine Air Cleaner Service Indicator - Inspect ..... 93 Generator Set Vibration - Test/Record ................. 114
Engine Oil Level - Check ...................................... 94
Fuel System Primary Filter/Water Separator - Every Year
Drain ................................................................. 103
Generator Bearing Temperature - Test/Record .... 112 Cooling System Coolant Sample (Level 2) -
Generator Load - Check ...................................... 112 Obtain ................................................................. 90
Walk-Around Inspection ...................................... 121
Every 3000 Service Hours
Every Week
Fuel Injection Nozzles - Test/Exchange ................ 98
Generator - Inspect ............................................. 107 Water Pump - Inspect ......................................... 122
Instrument Panel - Inspect ................................... 115
Every 3000 Service Hours or 2 Years
Every 50 Service Hours or Weekly
Cooling System Water Temperature Regulator -
Fuel Tank Water and Sediment - Drain ............... 105 Replace ............................................................... 91
SEBU8132-06 83
Maintenance Section
Maintenance Interval Schedule
Overhaul
Generator Bearing - Inspect/Replace ................. 108
Overhaul Considerations ..................................... 117
84 SEBU8132-06
Maintenance Section
Maintenance Interval Schedule
Every Week
Battery Electrolyte Level - Check .......................... 86
Cooling System Coolant Level - Check ................ 89
Electrical Connections - Check ............................. 91
Engine Air Cleaner Service Indicator - Inspect ..... 93
Engine Oil Level - Check ...................................... 94
Fuel System Primary Filter/Water Separator -
Drain ................................................................. 103
Fuel Tank Water and Sediment - Drain ............... 105
Generator - Inspect ............................................. 107
Generator Bearing Temperature - Test/Record .... 112
Instrument Panel - Inspect ................................... 115
Walk-Around Inspection ...................................... 121
Every Year
Alternator - Inspect ............................................... 85
Alternator Belt - Inspect/Adjust/Replace ............... 85
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 90
SEBU8132-06 85
Maintenance Section
Alternator - Inspect
i02291834
Alternator - Inspect
SMCS Code: 1405-040
i02391504
If twin belts are installed, check and adjust the
tension on both belts.
Alternator Belt -
Inspect/Adjust/Replace Adjustment
SMCS Code: 1357-036; 1357-510
Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
Typical example
(1) Adjusting bolt
(2) Mounting bolts
2. Move the alternator in order to increase or Note: Before the cables are connected, ensure that
decrease the belt tension. the key start switch is OFF.
3. Tighten the adjusting bolt (1). Tighten the mounting 7. Connect the cable from the starting motor to the
bolts (2). Refer to the Specifications Manual for POSITIVE “+” battery terminal.
the correct torque settings.
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
i02153996
The battery cables or the batteries should not be 1. Remove the filler caps. Maintain the electrolyte
removed with the battery cover in place. The bat- level to the “FULL” mark on the battery.
tery cover should be removed before any servic-
ing is attempted. If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
Removing the battery cables or the batteries with water that is low in minerals. Do not use artificially
the cover in place may cause a battery explosion softened water.
resulting in personal injury.
2. Check the condition of the electrolyte with the
1. Turn the key start switch to the OFF position. 245-5829 Coolant Battery Tester Refractometer.
Remove the key and all electrical loads.
3. Keep the batteries clean.
2. Turn OFF the battery charger. Disconnect the
charger. Clean the battery case with one of the following
cleaning solutions:
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane. Disconnect • A mixture of 0.1 kg (0.2 lb) of baking soda and
the cable from the NEGATIVE “-” battery terminal. 1 L (1 qt) of clean water
4. The POSITIVE “+” cable connects the POSITIVE • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
“+” battery terminal to the starting motor. (1 qt) of clean water
Disconnect the cable from the POSITIVE “+”
battery terminal. Thoroughly rinse the battery case with clean water.
Note: Always recycle a battery. Never discard a Use a fine grade of sandpaper to clean the
battery. Return used batteries to an appropriate terminals and the cable clamps. Clean the items
recycling facility. until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
5. Remove the used battery. of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
6. Install the new battery. Silicone Lubricant, petroleum jelly or MPGM.
SEBU8132-06 87
Maintenance Section
Battery or Battery Cable - Disconnect
i02292382
• The fuel has entered the cooling system and the For information regarding the disposal and the
coolant is contaminated. recycling of used coolant, consult your Caterpillar
dealer or consult Dealer Service Tools:
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and Outside Illinois: 1-800-542-TOOL
replaced. Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
88 SEBU8132-06
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Cooling system air locks may result in engine damage. 5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
Cooling system air locks may result in engine damage. Check the cooling system only when the engine is
stopped and cool.
1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
on cooling system specifications. Do not install the
cooling system filler cap.
i01197583
NOTICE g00285520
Care must be taken to ensure that fluids are contained Illustration 70
during performance of inspection, maintenance, test- Cooling system filler cap
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.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Refer to Special Publication, NENG2500, “Caterpillar
stop the engine and wait until the cooling system
Dealer Service Tool Catalog” for tools and supplies
components are cool. Loosen the cooling system
suitable to collect and contain fluids on Caterpillar
pressure cap slowly in order to relieve the pres-
products.
sure.
Dispose of all fluids according to local regulations and
mandates. 1. Remove the cooling system filler cap slowly in
order to relieve pressure.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling 2. Maintain the coolant level within 13 mm (0.5 inch)
system filler cap. of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
2. It may be necessary to drain enough coolant from level to the proper level in the sight glass.
the cooling system in order to add the Cat ELC
Extender.
g00103639
Illustration 71
Typical filler cap gaskets
90 SEBU8132-06
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
3. Clean the cooling system filler cap and check the Obtain the sample of the coolant as close as possible
condition of the filler cap gaskets. Replace the to the recommended sampling interval. In order
cooling system filler cap if the filler cap gaskets are to receive the full effect of S·O·S analysis, you
damaged. Reinstall the cooling system filler cap. must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
4. Inspect the cooling system for leaks. consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
i02837191
Cooling System Coolant Use the following guidelines for proper sampling of
the coolant:
Sample (Level 1) - Obtain
• Complete the information on the label for the
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 sampling bottle before you begin to take the
samples.
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with Cat • Keep the unused sampling bottles stored in plastic
ELC (Extended Life Coolant). Cooling systems that bags.
are filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval • Obtain coolant samples directly from the coolant
that is stated in the Maintenance Interval Schedule. sample port. You should not obtain the samples
from any other location.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant • Keep the lids on empty sampling bottles until you
instead of Cat ELC. This includes the following are ready to collect the sample.
types of coolants:
• Place the sample in the mailing tube immediately
• Commercial long life coolants that meet the after obtaining the sample in order to avoid
Caterpillar Engine Coolant Specification -1 contamination.
(Caterpillar EC-1)
• Never collect samples from expansion bottles.
• Cat DEAC (Diesel Engine Antifreeze/Coolant)
• Never collect samples from the drain for a system.
• Commercial heavy-duty coolant/antifreeze
Submit the sample for Level 1 analysis.
Table 21
Recommended Interval For additional information about coolant analysis,
see this Operation and Maintenance Manual, “Refill
Type of Coolant Level 1 Level 2 Capacities and Recommendations” or consult your
Every 250 Caterpillar dealer.
Cat DEAC Yearly(1)(2)
Hours(1)
Cat ELC Optional(2) Yearly(2) i01987714
(1) This is the recommended interval for coolant samples for all
conventional heavy-duty coolant/antifreeze. This is also the
Cooling System Coolant
recommended interval for coolant samples of commercial
coolants that meet the Cat EC-1 specification for engine
Sample (Level 2) - Obtain
coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a SMCS Code: 1350-008; 1395-008; 1395-554; 7542
problem is suspected or identified.
NOTICE
NOTICE Always use a designated pump for oil sampling, and
Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.
use a separate designated pump for coolant sampling. Using the same pump for both types of samples may
Using the same pump for both types of samples may contaminate the samples that are being drawn. This
contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incor-
contaminate may cause a false analysis and an incor- rect interpretation that could lead to concerns by both
rect interpretation that could lead to concerns by both dealers and customers.
dealers and customers.
Refer to Operation and Maintenance Manual,
Note: Level 1 results may indicate a need for “Cooling System Coolant Sample (Level 1) - Obtain”
Level 2 Analysis. for the guidelines for proper sampling of the coolant.
SEBU8132-06 91
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Submit the sample for Level 2 analysis. Refer to two articles in the Disassembly and
Assembly Manual, “Water Temperature Regulators
For additional information about coolant - Remove and Water Temperature Regulators -
analysis, see Special Publication, SEBU6251, Install” for the replacement procedure of the water
“Caterpillar Commercial Diesel Engines Fluids temperature regulator, or consult your Caterpillar
Recommendations” or consult your Caterpillar dealer. dealer.
• Transformers
NOTICE
Failure to replace your water temperature regulator • Fuses
on a regularly scheduled basis could cause severe
engine damage. • Capacitors
Caterpillar engines incorporate a shunt design cooling • Lightning arresters
system and require operating the engine with a water
temperature regulator installed. Check the connections for the following components:
If the water temperature regulator is installed incor- • Load cables
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg- • Cables for the generator
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open. • Potential transformers
Do not use liquid gasket material on the gasket or • Current transformers
cylinder head surface.
Check all lead wires and electrical connections for
proper clearance. Inspect all cables for chafing,
abrasion and corrosion.
92 SEBU8132-06
Maintenance Section
Engine - Clean
i02293096 i02398637
• Ease of maintenance
Note: This type of air cleaner is only available on
Note: Caution must be used in order to prevent open generator sets.
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.
SEBU8132-06 93
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
g01197946 g01197946
Illustration 72 Illustration 74
1. Unfasten latches (1). Remove cover (2). 4. Install cover (2). Fasten latches (1).
i01900118
i02456872
i03542996
NOTICE
Engine Oil Sample - Obtain Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
SMCS Code: 1000-008; 1348-554-SM;
Using the same pump for both types of samples may
7542-554-OC, SM
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
In addition to a good preventive maintenance
rect interpretation that could lead to concerns by both
program, Caterpillar recommends using S·O·S oil
dealers and customers.
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil If the engine is not equipped with a sampling valve,
analysis provides infrared analysis, which is required use the 1U-5718 Vacuum Pump. The pump is
for determining nitration and oxidation levels. designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
Obtain the Sample and the Analysis
For instructions, see Special Publication, PEgj0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Caterpillar dealer for complete information and
Hot oil and hot components can cause personal assistance in establishing an S·O·S program for your
injury. Do not allow hot oil or hot components to engine.
contact the skin.
i02293592
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order Engine Oil and Filter - Change
to help obtain the most accurate analysis, provide
the following information: SMCS Code: 1318-510; 1348-044
• Engine model
• Service hours on the engine Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
• The number of hours that have accumulated since contact the skin.
the last oil change
• The amount of oil that has been added since the NOTICE
last oil change Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
To ensure that the sample is representative of the ing, adjusting and repair of the product. Be prepared to
oil in the crankcase, obtain a warm, well mixed oil collect the fluid with suitable containers before open-
sample. ing any compartment or disassembling any compo-
nent containing fluids.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil Dispose of all fluids according to local regulations and
samples must be clean. mandates.
Do not drain the oil when the engine is cold. As the oil Replace the Spin-on Oil Filter
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
NOTICE
with the draining cold oil. Drain the crankcase with
Caterpillar oil filters are built to Caterpillar speci-
the engine stopped. Drain the crankcase with the
fications. Use of an oil filter not recommended by
oil warm. This draining method allows the waste
Caterpillar could result in severe engine damage to
particles that are suspended in the oil to be drained
the engine bearings, crankshaft, etc., as a result of
correctly.
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
Failure to follow this recommended procedure will
recommended by Caterpillar.
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
1. Remove the oil filter with a 1U-8760 Chain
Drain the Engine Oil Wrench.
Illustration 77
g01003623 Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
Oil drain plug
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
After the engine has been run at the normal operating
turbocharger bearings, and cylinder heads.
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
• If the engine is equipped with a drain valve, turn the oil filter. Consult your Caterpillar dealer in order
drain valve knob counterclockwise in order to drain
to arrange for a further analysis if an excessive
the oil. After the oil has drained, turn the drain valve
amount of debris is found in the oil filter.
knob clockwise in order to close the drain valve.
After the oil has drained, the oil drain plugs should
be cleaned and installed. If necessary, renew the O
ring seal on the drain plug.
Some types of oil pans have oil drain plugs that are
on both sides of the oil pan, because of the shape of
the pan. This type of oil pan requires the engine oil to
be drained from both plugs. Illustration 78
g01003628
4. Apply clean engine oil to the new oil filter seal (3).
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter seal contacts the cylinder block or the oil
cooler. Tighten the oil filter by hand according to
the instructions that are shown on the oil filter. Do
not overtighten the oil filter.
g01003675
Illustration 80
Replace the Element for the Oil (4) O ring seal
Filter (5) Element
(6) Filter head
5. Install the filter bowl into the oil filter head (6).
Tighten the filter bowl to the following torque
25 N·m (18 lb ft).
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
98 SEBU8132-06
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
• The fuel tank is empty or the fuel tank has been 7. The engine is now ready to start. Operate the
partially drained. engine at low idle for a minimum of five minutes
immediately after air has been removed from the
• The low pressure fuel lines are disconnected. fuel system.
• A leak exists in the low pressure fuel system. Note: Running the engine for this period of time will
help ensure that the pump is completely free of air.
• The fuel filter is replaced.
i03547119
• A new injection pump is installed.
Use the following procedure in order to remove air
Fuel System - Prime
from the fuel system: SMCS Code: 1258-548
1. Remove the cover for the fuel injectors. Refer to S/N: D4D1-Up
the Disassembly and Assembly Manual.
S/N: GLE1-Up
2. Turn the key switch to the RUN position. Leave the
key switch in the RUN position for three minutes.
3. Turn the key switch to the OFF position. Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
• The fuel tank is empty or the fuel tank has been After the engine has stopped, you must wait for
partially drained. 60 seconds in order to allow the fuel pressure to
be purged from the high pressure fuel lines before
• The low pressure fuel lines are disconnected. any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
• A leak exists in the low pressure fuel system. Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
• The fuel filter has been replaced. Replace any high pressure fuel line that has leaked.
Refer to Disassembly and Assembly, “Fuel Injection
Hand Fuel Priming Pump Lines - Install”.
Use the following procedures in order to remove air If you inspect the engine in operation, always use
from the fuel system: the proper inspection procedure in order to avoid
a fluid penetration hazard. Refer to Operation and
1. Ensure that the fuel system is in working order. Maintenance Manual, “General hazard Information”.
Restore the fuel supply.
Electric Fuel Priming Pump
1. Ensure that the fuel system is in working order.
Restore the fuel supply.
NOTICE
The electric fuel priming pump will operate for 90 sec-
onds. If necessary the electric fuel priming pump can
be stopped during the 90 seconds of operation, by op-
eration of the switch.
i03622950
g01118416
Fuel leaked or spilled onto hot surfaces or elec- Illustration 85
trical components can cause a fire. To help pre- (1) Screw
vent possible injury, turn the start switch off when (2) Element
changing fuel filters or water separator elements. (3) Glass bowl
(4) Sensor connection
Clean up fuel spills immediately. (5) Drain
(6) Bottom cover
If your engine is equipped with high pressure fuel 4. Tighten the drain (5) by hand pressure only.
lines you must wait for 60 seconds after the engine
has stopped, in order to allow the fuel pressure to 5. Hold the element (2) and remove the screw (1).
be purged from the high pressure fuel lines before Remove the element and the glass bowl (3) from
any service or repair is performed on the engine the base. Discard the old element.
fuel lines. If necessary, perform minor adjustments.
Repair any leaks from the low pressure fuel system 6. Clean the glass bowl (4). Clean the bottom cover
and from the cooling, lubrication or air systems. (6).
Replace any high pressure fuel line that has leaked.
Refer to Disassembly and assembly Manual, “Fuel 7. Install the new O ring seal. Install the bottom cover
Injection Lines - Install”. onto the new element. Install the assembly onto
the base.
i03622954
NOTICE
The water separator is not a filter. The water separa- g01118416
Illustration 86
tor separates water from the fuel. The engine should
never be allowed to run with the water separator more (1) Screw
(2) Element
than half full. Engine damage may result. (3) Glass bowl
(4) Sensor connection
(5) Drain
NOTICE (6) Bottom cover
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight- 1. Place a suitable container below the water
ened securely to help prevent air from entering the fuel separator.
system.
2. Open the drain (5). Allow the fluid to drain into
the container.
If your engine is equipped with high pressure fuel
lines you must wait for 60 seconds after the engine
3. When clean fuel drains from the water separator
has stopped, in order to allow the fuel pressure to
close the drain (5). Tighten the drain by hand
be purged from the high pressure fuel lines before pressure only. Dispose of the drained fluid
any service or repair is performed on the engine
correctly.
fuel lines. If necessary, perform minor adjustments.
Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems. i03622961
Replace any high pressure fuel line that has leaked.
Refer to Disassembly and assembly Manual, “Fuel Fuel System Secondary Filter -
Injection Lines - Install”. Replace
SMCS Code: 1261-510-SE
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.
Element filter
g01010595
Illustration 88
Turn the valves for the fuel lines (if equipped) to the (3) O ring seal
OFF position before performing this maintenance. (4) Element
Place a tray under the fuel filter in order to catch (5) Filter head
any fuel that might spill. Clean up any spilled fuel
immediately. 3. Remove the filter bowl (2) from the filter head
(5). Press on the element (4). Rotate the element
counterclockwise in order to release the element
for the filter bowl and remove the element from the
bowl. Discard the used element.
7. Install the filter bowl (4) into the top of the filter
head (5).
2. Clean the outside of the fuel filter assembly. Open Spin-on filter
the fuel drain (1) and drain the fuel into a suitable
container. Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel filter in order to catch
any fuel that might spill. Clean up any spilled fuel
immediately.
SEBU8132-06 105
Maintenance Section
Fuel Tank Water and Sediment - Drain
g01121723
Illustration 90
5. Install the spin-on filter (2) into the top of the filter
head (1).
g01121396
Illustration 89
6. Tighten the spin-on filter by hand until the sealing
(1) Spin-on filter ring contacts the filter head. Rotate the spin-on
(2) Drain
filter through 90 degrees.
1. Clean the outside of the fuel filter assembly. Open 7. Prime the fuel system. Refer to Operation and
the fuel drain (3) and drain the fuel into a suitable Maintenance Manual, “Fuel System - Prime”.
container.
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.
Fill the fuel tank after operating the engine in Note: For additional information, refer to Special
order to drive out moist air. This will help prevent Instruction, SEHS9124 .
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may Drying Methods
overflow.
The following methods can be used for drying a
Some fuel tanks use supply pipes that allow water generator:
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that • Self-circulating air method
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular • Oven method
maintenance of the fuel system filter is important.
NOTICE
Fuel Storage Tanks Do not allow the winding temperature to exceed 85 °C
(185.0 °F). Temperatures that are greater than 85 °C
Drain the water and the sediment from the fuel (185.0 °F) will damage the winding insulation.
storage tank during the following conditions:
• Oil change Run the engine and disconnect the generator load.
This will help circulate air. Operate the generator
• Refill of the tank space heaters.
This will help prevent water or sediment from being Oven Method
pumped from the storage tank into the engine fuel
tank. A four micron(c) absolute filter for the breather Place the entire generator inside a forced air drying
vent on the fuel tank is also recommended. Refer oven for four hours at 65 °C (149 °F).
to Special Publication, SENR9620, “Improving Fuel
System Durablity”.
SEBU8132-06 107
Maintenance Section
Generator - Inspect
Personal injury or death can result from improper If harmful dirt accumulations are present, a variety
troubleshooting and repair procedures. of cleaning techniques are available. The cleaning
procedure that is used may be determined by one of
The following troubleshooting and repair proce- the items on the following list:
dures should only be performed by qualified per-
sonnel familiar with this equipment.
• The extent of the cleaning procedure that is being
attempted
Place the engine control switch in the “OFF” posi- Cleaning (Assembled Generators)
tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable NOTICE
the starting system. Lock out all switchgear and Do not use water to clean the generator.
automatic transfer switches that are associated
with the generator.
NOTICE
Refer to Safety Section, “Generator Isolating for Do not use trichloroethane, perchlorethylene,
Maintenance” for information regarding the procedure trichloroethane or any alkaline products to clean the
to safely isolate the generator. generator.
Proper maintenance of electrical equipment requires Cleaning may be required at the point of installation.
periodic visual examination of the generator and At this point, complete disassembly of the generator
periodic visual examination of the windings. Proper may not be necessary or feasible. In this case,
maintenance of electrical equipment also requires a vacuum cleaner should be used to pick up the
appropriate electrical checks and appropriate thermal following items: dry dirt, dust, and carbon. This will
checks. Insulation material should be examined for prevent the spreading of these contaminants.
cracks. The insulation material should be examined
for accumulations of dirt and dust. If there is an A small nonconductive tube may need to be
insulation resistance value that is below normal, a connected to the vacuum cleaner. This will allow the
conductive path may be present. This conductive vacuum cleaner to clean the surfaces that are not
path may be made of one of the following materials: exposed. After most of the dust has been removed,
a small brush may be attached to the vacuum hose
• Carbon in order to loosen dirt that is more firmly attached to
the surface.
• Salt
• Metal dust
108 SEBU8132-06
Maintenance Section
Generator Bearing - Inspect/Replace
NOTICE Inspect
Do not use water to clean the generator.
1. Remove the bearing bracket. Inspect the following
items: bracket bore, bearing outer race, and
NOTICE rolling elements. On standby power units, the
Do not use trichloroethane, perchlorethylene, bearing must be inspected and the grease must
trichloroethane or any alkaline products to clean the be replaced at three year intervals. The sleeve
generator. in the bearing bracket should be inspected for
out of roundness, excessive wear, and a bracket
step that is less than 0.0762 mm (0.0030 inch). If
An initial insulation resistance check should be there is no sleeve in the bearing bracket, inspect
made on the generator in order to confirm electrical the bore of the bearing bracket. The bearing
integrity. A minimum reading of one megohm would should be inspected for damage to the outer race,
be expected with severely contaminated generators. severe fretting, and smoothness of operation.
A zero megohm reading may indicate an insulation When possible, the bearing elements should be
breakdown. An insulation breakdown requires more inspected. Some double shielded ball bearings
than cleaning. An insulation breakdown requires prevent visual inspection of the elements of the
repair. bearing. Other double shielded ball bearings
have a retaining ring. This retaining ring can be
Use the following for cleaning the stator, the rotor, the removed in order to allow access for a visual
exciter and the diode bridge: inspection of the elements of the bearing.
• Unleaded Gasoline On two-bearing generators, the front bearing
can only be removed after the drive coupling
• Toluene is removed. Refer to the Systems Operation
Testing and Adjusting Disassembly and Assembly,
• Benzene “Coupling - Remove” for the generator for
instructions for removing the drive coupling.
• Ciclohexare
Avoid permitting the solvent to run into the slots. Replace
Apply the solvent with a brush. Use a sponge on the
windings frequently in order to remove the debris. 1. All ball bearings should be cleaned. The cavity
Dry the winding with a dry cloth. Allow the solvent to in the bracket should be repacked with 2S-3230
evaporate before reassembling the generator. Grease. Pack the ball bearings (one-third to
one-half of the volume of the cavity).
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation 2. Use an induction heater to heat the ball bearings to
resistance should now be normal. If the insulation 107 °C (224.6 °F) for ten minutes in order to install
resistance is not normal, repeat the procedure. either of the following bearings: ball bearings
that are new and ball bearings that have been
Note: For more information on drying methods, refer inspected. Mount the bearings on the shaft. To
to Special Instructions, SEHS9124, “Cleaning and reinstall the hub, heat the hub to 400 °C (752.0 °F)
Drying of Electric Set Generators”. for three hours. Mount the hub to the shaft.
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Table 22
Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Type Size Min/Max(1) Part Diameter
Number Number
108-1760 321 BC 680 −29 °C 2S-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 2S-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 hours or 12
OD 80 °C months
(176 °F)
110.0 mm
(4.3 inch) ID
(continued)
110 SEBU8132-06
Maintenance Section
Generator Bearing - Lubricate
5. Wipe off the excess grease. Remove the top Infrared Thermometers
grease fitting. Install the plug.
Bearing temperatures can also be recorded with the
6. Operate the generator for one hour. This will allow use of an infrared thermometer. Refer to Special
the grease to expand. The expanding grease will Publication, NENG2500, “Caterpillar Dealer Service
force the excess grease from the cavity. When Tools Catalog” for a variety of infrared thermometers.
the excess grease is forced from the cavity, the Follow the instructions that come with your infrared
internal pressure will be reduced. The generator thermometer.
should continue to operate until the grease stops
purging.
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Personal injury or death can result from high volt-
Generator Bearing age.
Temperature - Test/Record
When power generation equipment must be in op-
SMCS Code: 4471-081-TA eration to make tests and/or adjustments, high
voltage and current are present.
The monitoring of bearing temperature may prevent
premature bearing failure. A generator set should Improper test equipment can fail and present a
never operate above the recommended set points. high voltage shock hazard to its user.
Keep records in order to monitor the changes in the
temperature of the bearing. Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
Note: Measure the bearing temperature after the rent tests being made.
generator reaches normal operating temperature.
During normal operation, monitor the power factor
Resistive Temperature Detectors and monitor generator loading.
(RTDs) When a three-phase generator is installed or when
a three-phase generator is reconnected, ensure that
Resistance temperature detectors for generator
the total current in any one phase does not exceed
bearings are optional on all Caterpillar Generators.
the nameplate rating. Each phase should carry the
These detectors are 100 ohm resistance temperature
same load. This allows the three-phase generator
detectors. A resistance temperature detector
to work at the rated capacity. If one phase current
may be monitored by the optional monitor for the
exceeds the nameplate amperage, an electrical
EMCP 3.2/3.3 resistance temperature detector. A
imbalance will occur. An electrical imbalance can
resistance temperature detector may be monitored by
result in an electrical overload and an electrical
equipment that is provided by the customer. Consult
imbalance can result in overheating on three-phase
with your Caterpillar dealer about other methods of
generators. This is not applicable to single-phase
measuring the bearing temperature.
generators.
The EMCP 3.2/3.3 may be configured to “ALARM”
The power factor can be referred to as the efficiency
or the EMCP 3.2/3.3 may be configured to
of the load. This can be expressed as the ratio of kVA
“SHUTDOWN”. An alarm is activated if the
to actual kW. The power factor can be calculated by
temperature of the bearing reaches 85 °C (185 °F).
dividing kW by kVA. Power factor is expressed as a
A shutdown occurs if the temperature of the bearing
decimal. Power factor is used to mean the portion
reaches 95 °C (203 °F).
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.
SEBU8132-06 113
Maintenance Section
Generator Set - Test
When servicing or repairing electric power gener- 4. Measure the AC voltage across the low voltage
ation equipment: terminals of the transformer that correspond to the
following generator terminals: “T1” and “T2”, “T2”
• Make sure the unit is off-line (disconnected and “T3”, and “T3” and “T1”. Record the voltages.
from utility and/or other generators power
service), and either locked out or tagged DO
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NOT OPERATE.
Generator Set Alignment -
• Make sure the generator engine is stopped.
Check
• Make sure all batteries are disconnected. (Generator Sets)
• Make sure all capacitors are discharged. SMCS Code: 7002-024
Keep a record of the measurement of the alignment. When a generator set is installed, a vibration plot
The record may be used to check the trend of the should be recorded in order to assist in diagnosing
alignment. The record may be used to analyze the potential problems. This vibration plot should be
trend of the alignment. updated yearly. The vibration plot should also be
updated when the generator set is moved and
The genset must be aligned when the genset is when the engine is overhauled. This will allow
moved into a final position. The genset must be the trend of the vibration to be monitored and
aligned if the genset is moved into a different position. 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
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component, the problem may be more imminent.
Generator Set Vibration - Refer to Data Sheet, LEKQ4023, “Linear Vibration”
for the allowable limits of vibration.
Test/Record
Caterpillar also recommends recording the vibration
SMCS Code: 4450-081-VI of the bearing at the generator bearing bracket.
Check for vibration damage. If the vibration exceeds the EDS limits for vibration,
check the alignment. Refer to this Operation and
Vibration may cause the following problems: Maintenance Manual, “Product Alignment - Check”
for the alignment procedure.
• Coupling wear
Contact the Caterpillar Dealer Service Tools group
• Loose fittings for information on ordering a vibration analyzer that
will meet your needs.
• Fatigue of the metal components of the engine
• Cracks in the cabinet which surrounds the i02121526
generator
Hoses and Clamps -
• Cracks in welds Inspect/Replace
• Excessive noise SMCS Code: 7554-040; 7554-510
• Cracked insulation Inspect all hoses for leaks that are caused by the
following conditions:
The following areas are susceptible to vibration
damage: • Cracking
• Coupling for the generator set • Softness
• Generator bearings • Loose clamps
• Stator output leads Replace hoses that are cracked or soft. Tighten any
loose clamps.
• Protective sleeving
NOTICE
• Insulation Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
• Exposed electrical connections any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
• Transformers and hoses carefully. Tighten all connections to the rec-
ommended torque.
• Fuses
• Capacitors Check for the following conditions:
• Outer covering that is ballooning locally Note: Refer to the Specifications, SENR3130,
“Torque Specifications” in order to locate the proper
• Flexible part of the hose that is kinked or crushed torques.
• Armoring that is embedded in the outer covering 8. Refill the cooling system.
A constant torque hose clamp can be used in place 9. Clean the cooling system filler cap. Inspect the
of any standard hose clamp. Ensure that the constant cooling system filler cap's gaskets. Replace
torque hose clamp is the same size as the standard the cooling system filler cap if the gaskets are
clamp. damaged. Install the cooling system filler cap.
Due to extreme temperature changes, the hose will 10. Start the engine. Inspect the cooling system for
heat set. Heat setting causes hose clamps to loosen. leaks.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
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Place the engine control switch in the “OFF” posi- When generators have not been used for a period
tion. Attach “DO NOT OPERATE” tags to all start- of time, moisture can accumulate. Therefore, the
ing controls. Disconnect the batteries or disable insulation test should be performed on generators
the starting system. Lock out all switchgear and that have been idle. If moisture is known to exist,
automatic transfer switches that are associated the windings must be dried prior to testing. Refer to
with the generator. Testing And Adjusting, “Generator - Dry”.
• other foreign matter within the generator Each winding must have a minimum insulation
resistance of one megohm.
This deterioration reduces the resistance of the
insulation. This test will measure the resistance of Main Armature (Stator L4)
the winding insulation.
1. Remove the load from the generator by either of
the following:
Exciter Armature (Rotor L2) The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
1. Isolate exciter armature (L2) from the rectifier bhp). The brake specific oil consumption (BSOC)
circuit. Disconnect the three wires of the exciter depends on the engine load. Consult your Caterpillar
armature from the rectifier blocks. dealer for assistance in determining the typical oil
consumption rate for your engine.
2. Connect one test lead of the insulation tester
(megohmmeter) to the rotor shaft. When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
3. Connect one test lead of the insulation tester wear, an engine overhaul should be scheduled.
(megohmmeter) to any one exciter field lead. There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
4. The insulation resistance must be a minimum of
0.25 megohm (250000 ohms). Overhaul Options
Before Failure Overhaul
• Costly unplanned downtime can be avoided. Parts that are not within the established inspection
specifications should be dealt with in one of the
• Many original parts can be reused according to the following manners:
standards for reusable parts.
• Salvaging
• The engine's service life can be extended without
the risk of a major catastrophe due to engine • Repairing
failure.
• Replacing
• The best cost/value relationship per hour of
extended life can be attained. Using out-of-spec parts can result in the following
problems:
After Failure Overhaul
• Unscheduled downtime
Many options are available if a major engine failure
occurs. An overhaul should be performed if the • Costly repairs
engine block or the crankshaft can be repaired.
• Damage to other engine parts
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be less than • Reduced engine efficiency
the cost of a new engine with a similar exchange
core. • Increased fuel consumption
This lower cost can be attributed to these aspects: Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
• Caterpillar dealer exchange components Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
• Caterpillar Inc. remanufactured exchange
components Inspection and/or Replacement
Overhaul Recommendation The following components may not last until the
second overhaul.
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar • Piston rings
dealer before the engine fails. This will provide you
with the best cost/value relationship. • Thrust bearings
Note: Overhaul programs vary according to the • Main bearings
engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar • Connecting rod bearings
dealer for specific information about the available
overhaul programs and about overhaul services for • Crankshaft seals
extending the engine life.
• Engine mounts
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following • Hoses
maintenance recommendations.
Caterpillar Inc. recommends the installation of new
Rebuild or Exchange parts at each overhaul period.
Caterpillar Inc. recommends the use of Hydrosolv S·O·S Coolant Analysis (Level II)
Liquid Cleaners. Table 25 lists the Hydrosolv Liquid
Cleaners that are available from your Caterpillar An S·O·S Coolant Analysis (Level II) is a
dealer. comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level II) provides
the following information:
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Check the exciter armature. Ensure that the rotating a. Place the red test lead on the negative “-”
rectifier is tight. If a failure of a rectifier is suspected, terminal (1). Place the black test lead on the
refer to Maintenance Procedure, “Rotating Rectifier - following rectifier terminals: AC terminal (2), AC
Test”. terminal (3), and AC terminal (4). All readings
on the meter should be between 0.4 and 1.0.
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b. Place the black test lead on the negative “-”
Rotating Rectifier - Test terminal (1). Place the red test lead on the
following rectifier terminals: AC terminal (2), AC
SMCS Code: 4465-081 terminal (3), and AC terminal (4). In all cases,
the meter should read “OL” (overload).
SMCS Code: 1000-040 • Inspect the fuel system for leaks. Look for loose
fuel line clamps.
Inspect the Engine for Leaks and
• Inspect the piping for the air inlet system and the
for Loose Connections elbows for cracks and for loose clamps.
A walk-around inspection should only take a few • Inspect the alternator belt and the accessory drive
minutes. When the time is taken to perform these belts for cracks, breaks or other damage.
checks, costly repairs and accidents can be avoided.
Belts for multiple groove pulleys must be replaced as
For maximum engine service life, make a thorough matched sets. If only one belt is replaced, the belt will
inspection of the engine compartment before starting carry more load than the belts that are not replaced.
the engine. Look for items such as oil leaks or coolant The older belts are stretched. The additional load on
leaks, loose bolts, worn belts, loose connections and the new belt could cause the belt to break.
trash buildup. Make repairs, as needed:
• Drain the water and the sediment from fuel tanks
• The guards must be in the proper place. Repair on a daily basis in order to ensure that only clean
damaged guards or replace missing guards. fuel enters the fuel system.
• Wipe all caps and plugs before the engine is • Inspect the wiring and the wiring harnesses for
serviced in order to reduce the chance of system loose connections and for worn wires or frayed
contamination. wires.
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