G3408 and G3412 Engines Maintenance Intervals

MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt © 2010 Caterpillar All Rights Reserved ® ® SEBU6682-08 May 2006 Operation and Maintenance Manual G3408 and G3412 Engines 6NB1-Up (Engine) 7DB1-Up (Engine) 6RJ1-Up (Engine) 3NK1-Up (Engine) SEBU6682-08 69 Maintenance Section Maintenance Interval Schedule i02522249 Maintenance Interval Schedule (Turbocharged Aftercooled Engines) 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. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICHEVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Belts - Inspect/Adjust/Replace .............................. 82 Cooling System Coolant Sample (Level 1) Obtain ................................................................. 86 Cooling System Supplemental Coolant Additive (SCA) - Test/Add ................................................. 87 Crankshaft Vibration Damper - Inspect ................. 89 Engine - Clean ...................................................... 91 Engine Oil and Filter - Change ............................. 99 Engine Valve Lash - Inspect/Adjust .................... 101 Engine Valve Rotators - Inspect ......................... 102 Exhaust Piping - Inspect ..................................... 103 Gas Pressure Regulator - Check ........................ 103 Hoses and Clamps - Replace ............................. 107 Ignition System Spark Plugs - Check/Adjust/ Replace ............................................................. 108 Ignition System Timing - Check/Adjust ................ 113 Inlet Air System - Inspect ..................................... 113 Radiator - Clean .................................................. 123 Initial 750 Service Hours Valve Stem Projection - Measure/Record ........... 127 Every 1500 Service Hours Actuator Control Linkage - Lubricate .................... 74 Carburetor Air/Fuel Ratio - Check/Adjust ............. 83 Crankcase Blowby - Measure/Record .................. 88 Cylinder Pressure - Measure/Record ................... 89 Engine Crankcase Breather - Clean ..................... 95 Engine Oil Filter (Auxiliary) - Change ................... 96 Engine Protective Devices - Check .................... 101 Engine Speed/Timing Sensor - Clean/Inspect .... 101 Speed Sensor - Clean/Inspect ............................ 123 When Required Batteries - Replace ............................................... 77 Engine Air Cleaner Element - Replace ................. 91 Overhaul Considerations .................................... 121 Valve Stem Projection - Measure/Record ........... 127 Every 3000 Service Hours Air Starting Motor Lubricator Bowl - Clean ........... 75 Cooling System Coolant Sample (Level 2) Obtain ................................................................. 87 Driven Equipment - Check .................................... 90 Engine Mounts - Check ........................................ 95 Ignition System Transformer Resistance - Test ... 113 Inlet Air System - Inspect ..................................... 113 Starting Motor - Inspect ...................................... 125 Water Pump - Inspect ......................................... 131 Daily Air Starting Motor Lubricator Oil Level - Check .... 75 Air Tank Moisture and Sediment - Drain ............... 76 Control Panel - Inspect ......................................... 83 Cooling System Coolant Level - Check ................ 86 Driven Equipment - Inspect/Replace/Lubricate ... 91 Engine Air Cleaner Service Indicator - Inspect ..... 93 Engine Air Precleaner - Clean .............................. 94 Engine Oil Level - Check ...................................... 97 Fuel System Fuel Filter Differential Pressure Check ................................................................ 103 Instrument Panel - Inspect ................................... 113 Walk-Around Inspection ...................................... 129 Every 4000 Service Hours Alternator - Inspect ............................................... 76 Every 8000 Service Hours Turbocharger - Inspect ........................................ 126 Every 250 Service Hours Engine Oil Sample - Obtain .................................. 98 Between 9000 and 12 000 Service Hours Overhaul (Top End) .............................................. 119 Every 750 Service Hours Aftercooler Core - Clean/Test ............................... 74 Battery Electrolyte Level - Check .......................... 78 Between 18 000 and 24 000 Service Hours Overhaul (Major) .................................................. 117 .... 84 .....Change ..70 Maintenance Section Maintenance Interval Schedule SEBU6682-08 Every 24 000 Service Hours or 3 Years Cooling System Coolant (NGEC) . ................................... 89 Engine Crankcase Breather ...........Inspect/Replace/Lubricate .... 93 Engine Air Precleaner ....... fuel consumption........Lubricate ......Inspect ................... 91 Engine Air Cleaner Service Indicator .... 123 When Required Batteries . filters.... service hours........ 131 Daily Air Starting Motor Lubricator Oil Level .Drain ....Inspect/Adjust ......................... 87 Driven Equipment ... 108 Ignition System Timing ............... 96 Engine Protective Devices ............. 82 Cooling System Coolant Sample (Level 1) Obtain ....................................Inspect ................ 86 Every 24 000 Service Hours or 3 Years Cooling System Coolant (NGEC) ......Change ................ 95 Engine Oil Filter (Auxiliary) .......Measure/Record .................................................Check ...................................Inspect/Adjust/Replace .. 101 102 103 127 Every 1500 Service Hours Actuator Control Linkage ................Measure/Record ............................. 97 Fuel System Fuel Filter Differential Pressure Check .........Inspect ............ fluids.Check ....... 86 Driven Equipment ....... including all adjustments............... Products that operate in severe operating conditions may require more frequent maintenance.......................... 74 Carburetor Air/Fuel Ratio .......Change ......................................... 103 Speed Sensor ........................ 76 Between 10 000 and 14 000 Service Hours Overhaul (Top End) ...........Replace .............. 99 Exhaust Piping ...............................Check/Adjust ...................................Clean .Inspect ............... The user is responsible for the performance of maintenance............Check ......................... 113 Starting Motor ....... 103 Hoses and Clamps ... 121 Valve Stem Projection ...................................... 91 Engine Oil and Filter ...............Inspect/Adjust ........................... or calendar time................SEBU6682-08 71 Maintenance Section Maintenance Interval Schedule i02522248 Maintenance Interval Schedule (Naturally Aspirated Engines) SMCS Code: 1000.....Check .......... 87 Crankshaft Vibration Damper .Inspect ......................Inspect .................. 113 Radiator .................. Use mileage................... 7500 Ensure that all safety information.....Change .............Clean/Inspect .............Replace .............................. 107 Ignition System Spark Plugs ......................... 75 Air Tank Moisture and Sediment ................Replace ..............................Check/Adjust/ Replace ........... 117 Every 750 Service Hours Battery Electrolyte Level ..... 125 Water Pump .....................Clean/Inspect ....... 78 Belts .......... 123 Initial 750 Service Hours Engine Valve Lash ............Measure/Record ...... 101 Engine Valve Rotators ............Check ..............................Clean ..... 101 Engine Speed/Timing Sensor ....... 127 Every 3000 Service Hours Air Starting Motor Lubricator Bowl .....Check/Adjust ...........................Inspect .....Test/Add ......Measure/Record ........................... in order to determine the maintenance intervals.. WHICHEVER OCCURS FIRST............................Check .. 101 Engine Valve Lash ...... 75 Cooling System Coolant Sample (Level 2) Obtain ....... 119 Every 250 Service Hours Engine Oil Sample .................Inspect ..Inspect ... the use of proper lubricants...... 76 Control Panel ........... Cooling System Supplemental Coolant Additive (SCA) .............Clean ... 113 Walk-Around Inspection .............. 4450....... 88 Cylinder Pressure ...........Clean ..............Clean ......... Note: Before each consecutive interval is performed................................. 103 Instrument Panel ....... Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.......................... and the replacement of components due to normal wear and aging.Check ..Obtain . 83 Cooling System Coolant Level ..................... 89 Engine .............................................Check ........................... 91 Overhaul Considerations . Engine Valve Rotators ................ 102 Gas Pressure Regulator ................................................ 84 .... 77 Engine Air Cleaner Element ....... all maintenance from the previous interval must be performed.. Gas Pressure Regulator ...... 94 Engine Oil Level ..........Inspect ......Test ...........Inspect .................... 95 Ignition System Transformer Resistance . 113 Inlet Air System ..................... 83 Crankcase Blowby ....... 129 Every 4000 Service Hours Alternator . 90 Engine Mounts ......................... Valve Stem Projection ............. 98 Between 20 000 and 28 000 Service Hours Overhaul (Major) ..........Inspect ........ warnings and instructions are read and understood before any operation or any maintenance procedures are performed... 113 Inlet Air System .Check . ....... 131 When Required Generator ................ 113 Inlet Air System .............. 76 Battery Charger .................. 91 Engine Crankcase Breather .............. all maintenance from the previous interval must be performed........................ 75 Alternator ........................ 91 Engine Air Cleaner Element ................. 103 Governor ................Inspect ........................................Replace ........... fluids.......Inspect ................Inspect .............Check ................................................Inspect .....Test/Add .................................................... fuel consumption............. 107 Hoses and Clamps ...........................Inspect ....Inspect .Check .....Inspect .............. 101 Engine Valve Rotators ..Clean/Inspect ......Clean . 94 Engine Oil Level .....Check .................................Clean/Inspect . 95 Engine Mounts .Check ......................Check .....................Inspect .......................................... 97 Fuel System Fuel Filter Differential Pressure Check ... 107 ........................ Note: Before each consecutive interval is performed.. 126 Water Pump .......... 89 Engine .................. 102 Gas Pressure Regulator ........ Products that operate in severe operating conditions may require more frequent maintenance........ 113 Jacket Water Heater . 104 106 129 132 Daily Generator Load . WHICHEVER OCCURS FIRST...... 84 Exhaust Bypass .. 123 Speed Sensor ............................ service hours................Clean ........ 7500 Ensure that all safety information...Check ........... 77 Battery Electrolyte Level ......Inspect/Adjust ............................. Use mileage.........................................................................Inspect ...... 83 Cooling System Coolant Sample (Level 1) Obtain . 123 Standby Generator Set Maintenance Recommendations ..................................... 123 Starting Motor ................. 124 Walk-Around Inspection .... 101 Engine Valve Lash ....Inspect ..... filters...................... Space Heater ..........Measure/Record .....................Check ................ Varistor ............Test .. The user is responsible for the performance of maintenance..................Check ................. 76 Bearing (Ball) ...............................................Drain .................Clean ............ Generator Set .. in order to determine the maintenance intervals. 99 Every 6 Months Stator Lead ................ 103 Instrument Panel ...............................Check ..................................................................................Measure/Record .............. 105 Power Factor ................. Winding .......Measure/Record ..................... 125 Every Year Actuator Control Linkage .......... 103 Generator Set Vibration .....Clean/Test ........................ or calendar time..............Check ...... 78 Belts .............. including all adjustments......................... 130 Every 250 Service Hours or 1 Year Engine Oil and Filter .. warnings and instructions are read and understood before any operation or any maintenance procedures are performed.......... 125 Turbocharger ....... 83 Cooling System Coolant Level ... 75 Air Tank Moisture and Sediment ......................... the use of proper lubricants.. 74 Air Starting Motor Lubricator Bowl ....Check/Adjust ...Inspect ....... and the replacement of components due to normal wear and aging......................Clean .......................Inspect/Adjust/Replace ... 101 Engine Speed/Timing Sensor ..............Test .Check/Adjust/ Replace ... 117 Every 3 Years Batteries .............. 108 Ignition System Timing ......Test ............Inspect ..................72 Maintenance Section Maintenance Interval Schedule SEBU6682-08 i02522245 Maintenance Interval Schedule (Standby Generator Set Engines) SMCS Code: 1000.............. 87 Crankcase Blowby ....Inspect ..... Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.. 4450................... 93 Engine Air Precleaner .. 107 Ignition System Spark Plugs .........Obtain .....Change ........................ 78 Bearing Temperature ... 86 Engine Air Cleaner Service Indicator .............. 122 Stator Winding Temperature ............................................................... 114 Radiator .......Test ...............Replace ........Check ..............Check ............................................... 95 Engine Oil Sample .Check/Adjust ......Inspect .....Check ... 102 Exhaust Piping ............................................ 82 Control Panel ................................................................. 82 Carburetor Air/Fuel Ratio ........................................... 98 Engine Performance ...................Dry ........... 76 Automatic Start/Stop .......................Lubricate ............. 88 Crankshaft Vibration Damper ........................... 74 Aftercooler Core ........Clean ..... 87 Cooling System Supplemental Coolant Additive (SCA) .........Lubricate .......Inspect .....................Measure/Record ....Replace .......................... 89 Cylinder Pressure ................... 126 Every Week Air Starting Motor Lubricator Oil Level ...................Change .................. 77 Cooling System Coolant (NGEC) .... 101 Engine Protective Devices ......................... 86 Cooling System Coolant Sample (Level 2) Obtain .......................... 113 Insulation .Test ........... ........ 113 Water Temperature Regulator ................. 131 Overhaul Bearing .......Replace ..Inspect ... 79 .............Replace ......................Test .. 107 Ignition System Transformer Resistance ..SEBU6682-08 73 Maintenance Section Maintenance Interval Schedule Ignition System Spark Plug Wires . corrosion. Personal injury can result from air pressure. wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. insects. Inspect these items for good condition: welds. mounting brackets. Repeat the cleaning. start the engine and accelerate the engine to high idle rpm. The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Check the Linkage Check the linkage for proper operation. Use pressurized water in order to soften mud. leaves. a leak test is highly recommended. For more detailed information on cleaning and inspection. if necessary. This will remove debris that is between the tubes. air lines. connections. Pressurized water may also be used for cleaning. and other debris. Inspect the fins for damage. Thoroughly rinse the core with clean water. Personal injury can result without following proper procedure. This will help in the removal of debris and drying of the core. grease. Use a degreaser and steam for removal of oil and grease. For instructions on adjustment of the linkage. Wash the core with detergent and hot water. Clean both sides of the core. SEBD0518. 1064 Note: Adjust the frequency of cleaning according to the effects of the operating environment. Adjust the linkage. Make repairs. Slowly move the air nozzle in a direction that is parallel with the tubes. and seals. Illustration 59 Grease fitting on the linkage for the throttle control g00836635 Illustration 58 g00836634 Grease fitting on the linkage for the governor control lever Lubricate the grease fittings with MPGM. When using pressure air. Hold the nozzle approximately 6 mm (0. oil. dirt.Clean/Test (Air-To-Air Aftercooler) SMCS Code: 1064-070. Note: If parts of the aftercooler system are repaired or replaced. refer to the engine’s Specifications. if necessary. Direct the air in the opposite direction of the fan’s air flow. Use a light bulb behind the core in order to inspect the core for cleanliness.25 inch) away from the fins. if necessary. 1064-081. Bent fins may be opened with a “comb”. . see Special Publication. Stop the engine. clamps.Lubricate SEBU6682-08 i01616158 Actuator Control Linkage Lubricate SMCS Code: 1265-086 Inspect the aftercooler for these items: damaged fins. Clean the aftercooler. use the same methods that are used for cleaning radiators. i01371758 Aftercooler Core . Pressurized air is the preferred method for removing loose debris. “Know Your Cooling System”. After cleaning. For air-to-air aftercoolers. Clean the core from both sides.74 Maintenance Section Actuator Control Linkage . if necessary. replace the gasket.Check SMCS Code: 1451-535 NOTICE Never allow the lubricator bowl to become empty. “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. If the bowl is cracked. Refer to Special Publication. Personal injury can result from removing hoses or fittings in a pressure system. . NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.Check” topic. i02213914 Air Starting Motor Lubricator Oil Level . If the gasket is damaged. 8. Place a suitable container under bowl (2) and open drain valve (3) in order to drain the oil from the bowl. Observe the oil level in sight gauge (3). 4. Failure to relieve pressure can cause personal injury. 5. 7.SEBU6682-08 75 Maintenance Section Air Starting Motor Lubricator Bowl . Inspect the gasket. adjusting and repair of the product. see this Operation and Maintenance Manual. Illustration 61 g00745561 1. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dry the bowl.Clean SMCS Code: 1451-070 If the engine is equipped with an air starting motor. Inspect the bowl for cracks. 6. Ensure that sufficient oil is in the lubricator bowl. add oil to the lubricator bowl. “Air Starting Motor Lubricator Oil Level . use the following procedure: 3. If the oil level is less than 1/2. The air starting motor will be damaged by a lack of lubrication. Illustration 60 (1) Filler plug (2) Bowl (3) Drain valve g00745554 2. testing. Ensure that the air supply to the lubricator is OFF. Remove bowl (2). Slowly loosen filler plug (1) in order to release the pressure from the lubricator. replace the damaged bowl with a new bowl. NENG2500. maintenance. Install the bowl. For instructions on filling the lubricator.Clean i02344769 Air Starting Motor Lubricator Bowl . Make sure that drain valve (3) is closed. Clean the bowl with warm water. NOTICE Do not crank the engine continuously for more than 30 seconds. Pressurized air could cause debris to be blown and result in personal injury. inspect the position of the control switches. Ensure the following conditions: Air Tank Moisture and Sediment . Install filler plug (4).Inspect (Generator Set) SMCS Code: 4462 The generator set must be ready to operate under a load at any time. Open the drain valve that is on the bottom of the air tank. Allow the starting motor to cool for two minutes before cranking the engine again. if necessary. 4. 2. Ensure that the fuel supply to the engine is OFF. Observe the drops of oil that are released in dome (1). If necessary. • The control switches are in the correct position for automatic starting. After the adjustment. After performing maintenance on the generator set. protective clothing. Use nondetergent SAE 10W oil for temperatures that are greater than 0 °C (32 °F).76 Maintenance Section Air Tank Moisture and Sediment . i01039675 Automatic Start/Stop . When opening the drain valve. Close the drain valve. Operate the air starting motor. .Drain SMCS Code: 1466-543-M&S Moisture and sediment in the air starting system can cause the following conditions: • The starting system is enabled. See the Service Manual for service procedures. 3. Consult your Caterpillar dealer for assistance. Remove filler plug (4). i02084374 • Corrosion of internal parts • Malfunction of the air starting system Alternator . 2. Failure to relieve pressure can cause personal injury. Use air tool oil for temperatures that are below 0 °C (32 °F). adjust the lubricator in order to release from one to three drops of oil per second. wear protective gloves. and protective shoes. To increase the rate. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved. Slowly loosen filler plug (4) in order to release pressure from the lubricator bowl. Allow the moisture and sediment to drain. the lubricator will release oil in proportion to variations of the air flow. i00351324 • Proper connections • Clean ports for cooling airflow • Proper charging of the battery Observe the ammeter during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Note: Some lubricators have an adjustment screw rather than a knob. To decrease the rate. Ensure that the air supply to the lubricator is OFF. 1. Pour oil into the lubricator bowl. 1. 3. turn knob (2) counterclockwise.Inspect SMCS Code: 1405-040 Inspect the alternator for the following conditions: Adjust the Lubricator Note: Adjust the lubricator with a constant rate of air flow.Drain SEBU6682-08 • Freezing Personal injury can result from removing hoses or fittings in a pressure system. turn the knob clockwise. Make repairs. 2. a protective face shield. Connect the POSITIVE “+” lead of the charger to the POSITIVE “+” battery terminal. Perform the following procedure to charge the battery: 1. Disconnect the cable from the NEGATIVE “-” battery terminal.Replace • The switchgear and the automatic transfer switches that are associated with the generator are enabled.Replace SMCS Code: 1401-510 Batteries give off combustible gases which can explode. • A strong odor of acid is present. Batteries . Turn ON the battery charger. Overcharging of Batteries Overcharging reduces the service life of batteries. Connect the NEGATIVE “-” lead of the charger to the NEGATIVE “-” battery terminal. Return used batteries to an appropriate recycling facility. Adjust the voltage of the charger in order to match the voltage of the battery. A spark can cause the combustible gases to ignite. • The battery emits smoke or a dense vapor (gas). The battery charger must not produce excessive current during start-up.Check SMCS Code: 1401-535 For more information. the needle of the ammeter will register near “0” (zero). Remove the key and all electrical loads. 7. 3. If the batteries are properly charged. i01039758 Battery Charger . 3. ensure that the key start switch is OFF. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. The POSITIVE “+” cable connects the POSITIVE “+” battery terminal to the starting motor. 6. Alternatively. Do not smoke when batteries are serviced. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Install the new battery. This can result in severe personal injury or death. Never discard a battery. Disconnect the charger. Connect the cable from the starting motor to the POSITIVE “+” battery terminal. Remove the used battery. Ensure that the charger is turned OFF. Note: Before connecting the cables. Injury to personnel can be the result.SEBU6682-08 77 Maintenance Section Batteries . Use a battery charger that will not overcharge the battery. 2. i01041029 Checking Before Start-Up Check the battery charger for proper operation. 2. the charger must be automatically disconnected during start-up and during engine operation. Connect the cable from the ground plane to the NEGATIVE “-” battery terminal. Ensure proper ventilation for batteries that are in an enclosure. 5. Disconnect the cable from the POSITIVE “+” battery terminal. Charging the Battery Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. Turn OFF the battery charger. 8. Turn the key start switch to the OFF position. 4. DO NOT charge the battery if the meter of the battery charger is in the RED zone. Note: Always recycle a battery. 4. the charger must be automatically disconnected for start-up. If the engine has an alternator. . see the Operation and Maintenance Manual for the generator and the control panel. The NEGATIVE “-” cable connects the NEGATIVE “-” battery terminal to the ground plane. 1. Overcharging is indicated by the following symptoms: • The battery is very warm to the touch. 2 Grade. Caterpillar Maintenance Free Batteries The battery may not accept a charging current. use either NLGI No. Clean the items until the surfaces are bright or shiny. 1 Grade or NLGI No. If distilled water is not available use clean water that is low in minerals. Table 21 describes the effects of overcharging on different types of batteries. Do not use artificially softened water.11 qt) of ammonia and 1 L Thoroughly rinse the battery case with clean water. The temperature range of Caterpillar 2S-3230 Bearing Lubricant is −29 °C (−20. Complete the charging at the reduced rate. • A mixture of 0. the batteries may not fully recharge. The battery may not pass a load test. Refer to the instructions that are located on the machine. 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. i02023749 Checking After Stopping Ensure that the battery charger is connected properly. use Caterpillar 2S-3230 Bearing Lubricant. Record the amperage. Keep the batteries clean.Check SEBU6682-08 Perform one of the following procedures if the battery shows symptoms of overcharging: • Reduce the rate of charging by a significant amount.Lubricate (Generator) SMCS Code: 4471-086 The following ball bearings must be lubricated: no shield and single shield.6 °F). 0 Grade. Maintain the electrolyte level to the “FULL” mark on the battery. 1. Double shielded ball bearings may not require lubrication. use distilled water. ammeter reading should be very near zero. Clean the battery case with one of the following cleaning solutions: • Turn OFF the charger. 3. This grease is an NLGI No. For ball bearings. when the engine is in operation. This is caused by an excessive temperature. Table 21 Effects of Overcharging Batteries Type of Battery Caterpillar General Service Batteries Caterpillar Premium High Output Batteries Effect All of the battery cells have a low level of electrolyte. If the addition of water is necessary. Check the condition of the electrolyte with the 245-5829 Coolant Battery Tester Refractometer.1 L (0. Ensure a full charge in order to help prevent the battery from freezing. Always wear a face shield and protective clothing when working on or near batteries. For extremely low temperatures. i02340858 Bearing (Ball) . Excessive removal of material can cause the clamps to not fit properly. The battery may not pass a load test. Observe the meter of the charger.2 lb) of baking soda and 1 L (1 qt) of clean water (1 qt) of clean water • A mixture of 0. There is Polyurea (a thickener) in this grease. 2. All lead-acid batteries contain sulfuric acid which can burn the skin and clothing.2 °F) to 177 °C (350. . If batteries are properly charged.78 Maintenance Section Battery Electrolyte Level . DO NOT remove material excessively. Coat the clamps and the terminals with 5N-5561 Silicone Lubricant.1 kg (0. the plates may appear to be warped. petroleum jelly or MPGM. Use a fine grade of sandpaper to clean the terminals and the cable clamps. Remove the filler caps. When the plates of the battery are inspected through the filler holes. Grease the shielded ball bearings with 2S-3230 Bearing Lubricant (53. and smoothness of operation.4 mL (4 ounces) to 148. Stop the engine. Install the plug. Install a grease fitting in the grease pipe. the bearing elements should be inspected. and rolling elements. Install the bracket drain plug. Remove the top grease fitting. excessive wear.20 mL (2. Some double shielded ball bearings prevent visual inspection of the ball bearings. 7. The generator should continue to operate until the grease stops purging. All ball bearings should be cleaned. Inspect the following items: bracket bore.0762 mm (0. The cavity should be filled with 118. Spherical Roller Bearing should be cleaned and repacked with 108-8611 Grease. 3. This will allow the grease to expand. The generator should continue to operate until the grease stops purging. the internal pressure will be reduced. the front bearing can only be removed after the hub is removed.8 ounces) to 59. Wipe off the excess grease. 5. Note: Some two-bearing generators have spherical roller bearings in the front bracket and ball bearings in the rear bracket. the internal pressure will be reduced. inspect the bore for the bearing bracket. heat the hub to 400 °C (752. On two-bearing generators.28 mL (1. These units should use a common 108-8611 Grease Cartridge.6 °F) for ten minutes. Note: Bearings that are being removed for failure analysis should not be cut off with a torch. On standby power units. and a bracket step that is less than 0. The bearing should be filled with 88. 2. Remove the top grease pipe plug and remove the lower grease pipe plug. severe fretting. Pack the bearing and pack the cavity (one-third to one-half of the volume of the cavity). Remove the bracket drain plug and operate the generator for one hour. Lubricate shielded ball bearings at 2000 hour intervals. Pack the bearings (one-third to one-half of the volume of the cavity). Install the plug in the bottom grease pipe. heat the bearings to 107 °C (224. Refer to Table 22.0 mL (5 ounces) of grease. Remove the bearing bracket. When the excess grease is forced from the cavity. Ensure that the tube that supplies grease to the bearing is filled with grease. Wipe off the excess grease. cut off the hub. Install the louver assembly or install the rear plate. 8. 5. Remove either the louver assembly or the rear plate from the rear of the generator housing.Inspect Lubricating Process 1.0030 inch). Bearing . bearing outer race. In order to remove the hub. To reinstall bearings. The expanding grease will force the excess grease from the cavity. Other double shielded ball bearings have a retaining ring. i02230503 1. To reinstall the hub. Wipe off the excess grease. Do not mix greases. This will allow the grease to expand. 2. Stop the engine.0 ounces)). Operate the generator for one hour. Mount the hub to the shaft. Pulling the hub will damage the shaft. The bearing should be inspected for damage to the outer race.4 mL (4 ounces) of grease. 4. Refer to Table 22. 6. This retaining ring can be removed in order to allow access for a visual inspection of the ball bearings.SEBU6682-08 79 Maintenance Section Bearing . When the excess grease is forced from the cavity. 3.8 mL (3 ounces) to 118. The cavity of the bracket should be repacked with 2S-3230 Grease. 4. 6. the bearing must be inspected and the grease must be replaced at three year intervals.Inspect SMCS Code: 4471-040 The following maintenance procedure for generator bearings should be followed at every major engine overhaul: . The expanding grease will force the excess grease from the cavity. If there is no sleeve for the bearing bracket.0 °F) for three hours. When possible. Mount the bearings on the shaft. The sleeve for the bearing bracket should be inspected for out of roundness. This grease should be used for the front bearing and the rear bearing. 012 mm (3.992 mm (7.000 mm (6.2 oz)(2) 160.280 mL (1.4803 inch) 90.6929 inch) 80.1504 inch) 100.000 mm (3.5 oz) 170.5 oz) .017 mm (7.7724 inch) 65.9380 inch) Bearing Shield (Type) Double Bearing Cavity Grease mL (oz) 29.6 mL (1 oz) Rotor Shaft Diameter mm (inch) 45.000 mm (2.4 oz) to 168.021 mm (2.80 Maintenance Section Bearing .002 mm (5.0863 inch) to 180.002 mm (6.Inspect SEBU6682-08 7.5592 inch) to 65.1497 inch) to 80.6940 inch) Single 97.000 mm (6.002 mm (6.5591 inch) 3N-1965 440 (round laminated) 140.1496 inch) 4L-6677(3) 580(1) 170.019 mm (1.004 mm (1.80 mL (5.028 mm (3.000 mm (3. Table 22 Bearing Outside Diameter mm (inch) 100.000 mm (7. repeat Step 5.000 mm (3.028 mm (6.68 mL (3.5599 inch) 75.000 mm (3.000 mm (1.2993 inch) to 160.720 mL (3.1496 inch) 109-7687(3) 580(1) 170.004 mm (2.7 oz) 170.8 oz) 190.028 mm (3.000 mm (2.9370 inch) to 100.9375 inch) to 100. DO NOT MIX GREASES.Lubricate”.9527 inch) 5P-2448 580(2) 590(1) 160.5 oz) 180.002 mm (6.5118 inch) 65.004 mm (2.021 mm (2.68 mL (3.5444 inch) (continued) 5P-1977 140.5129 inch) Double 53.68 mL (3.000 mm (7.5438 inch) to 90.7 oz) to 230.3003 inch) Double 100.6929 inch) 80.028 mm (6.000 mm (3.3 oz) to 162.6930 inch) to 170.6930 inch) to 170.80 mL (5.9370 inch) 6Y-3955 440 (square laminated) 179.7717 inch) Part Number Generator Frame Size All 360 Bearing Bore in Bracket mm (inch) 100. Whenever the bearings are greased.002 mm (7.88 mL (7. follow the recommendations on the lubrication plate (if equipped) or refer to Maintenance Schedule.8 oz)(1) to 94.020 mm (3.9370 inch) Bearing Inside Diameter mm (inch) 45.7718 inch) to 45.9529 inch) to 75.3 oz) to 162.4804 inch) to 190.025 mm (3.64 mL (3.72 mL (5.5119 inch) to 140.000 mm (3.028 mm (5.000 mm (6.028 mm (7.002 mm (3.1497 inch) to 80.6940 inch) Double 97.12 mL (4.002 mm (3.0866 inch) 100.9381 inch) 90. “Bearing .1504 inch) 80.4814 inch) Double 97.0873 inch) Double 139.000 mm (5.80 mL (5.020 mm (3.2992 inch) 75. For greasing intervals.028 mm (6.012 mm (3.5433 inch) 6Y-6488 590(1) 589 PM 190.9536 inch) 80.3 oz) to 162. 4501 inch) Single 145.033 mm (9.002 mm (9.0551 inch) 130.1192 inch) to 130.0 oz) to 266.8 oz) Rotor Shaft Diameter mm (inch) 105.0551 inch) 130.20 mL (12.1338 inch) Part Number Generator Frame Size 680(1) Bearing Bore in Bracket mm (inch) 225.20 mL (7.76 mL (8.60 mL (21 oz)(3) 145.3312 inch) to 110.12 mL (4.04 mL (4.8596 inch) Bearing Shield (Type) Single Bearing Cavity Grease mL (oz) 139.8584 inch) to 225.3312 inch) to 110.9 oz) to 239.000 mm (4.003 mm (8.000 mm (5.80 mL (8.992 mm (9.76 mL (8.012 mm (4.000 mm (4.000 mm (4.1352 inch) 130.002 mm (9.000 mm (9.4501 inch) Open 177.0560 inch) 229.3307 inch) 6V-6752 800(1) 240.8582 inch) Bearing Inside Diameter mm (inch) 105.029 mm (4.0 oz) 207.051 mm (5.4489 inch) to 240.1 oz) 230.1181 inch) 2L-4444(4) 820(1) Open 240.7 oz) to 230.0 oz) 230.40 mL (14.0 oz) to 355.60 mL (6.000 mm (5.00 mL (10.051 mm (5.3307 inch) 6V-3310 800(1) 240.1201 inch) 110.4488 inch) 110.8582 inch) 105.8584 inch) to 225.033 mm (9.3307 inch) 108-1761 690(1) Double 240.028 mm (4.000 mm (9.000 mm (4.3318 inch) (continued) 240.3312 inch) to 110.0 oz) to 621.1350 inch) to 105.034 mm (4.028 mm (4.00 mL (5.0 oz) 236. contd) Bearing Outside Diameter mm (inch) 225.0560 inch) 240.0 oz) to 296.1352 inch) 105.028 mm (5.88 mL (7.034 mm (4.1181 inch) 2L-4444(4) 808 4 pole(1) 229.0548 inch) to 230.003 mm (8.3318 inch) 110.1192 inch) to 130.4489 inch) to 240.000 mm (9.028 mm (5.000 mm (8.3318 inch) 6V-0410 225.034 mm (8.40 mL (9.012 mm (4.Inspect (Table 22.022 mm (9.0 oz) to 236.8 mL (8.4488 inch) 110.034 mm (8.000 mm (9.022 mm (9.000 mm (9.4501 inch) Single 110.992 mm (9.9 oz) to 239.SEBU6682-08 81 Maintenance Section Bearing .1 oz) .04 mL (4.4488 inch) 110.1201 inch) 130.012 mm (4.029 mm (4.033 mm (9.4489 inch) to 240.028 mm (4.0548 inch) to 230.002 mm (9.8596 inch) Double 148.000 mm (8.1350 inch) to 105.1338 inch) 108-1760 680(1) 225.0 oz)(2) 414.000 mm (4. 00 mL (5. Replace the belts if the belts are not in good condition. This bearing is a spherical roller bearing. “Specifications”.1201 inch) 108-1761 280.0 oz) to 236.032 mm (11. unnecessary stress is placed on the components. Bearing temperature detectors are used with equipment that has been provided by the customer in order to measure the bearing temperature.3318 inch) 130.0 oz) Rotor Shaft Diameter mm (inch) 110.Inspect/Adjust/Replace SMCS Code: 1357-025.0249 inch) Double N/A (1) (2) (3) (4) (2) (3) Inboard bearing Outboard bearing 109-7687 bearing is preferred.000 mm (4. contd) Bearing Outside Diameter mm (inch) 240.1192 inch) to 130.000 mm (5. This bearing is on the same end as the exciter.1181 inch) 154-3032 820 280.033 mm (9.024 inch) 130.000 mm (9.012 mm (4. Check the belt tension according to the information in the Service Manual.0237 inch) to 280.4488 inch) Bearing Inside Diameter mm (inch) 110. Bearing Temperature Measure/Record SMCS Code: 4471-082-TA Bearing temperature detectors are optional on all SR4B generators. Bearing temperature detectors may help to prevent premature bearing failure. Slippage of loose belts can reduce the efficiency of the driven components.028 mm (5.3307 inch) Part Number Generator Frame Size 800(1) Bearing Bore in Bracket mm (inch) 240. This reduces the service life of the components. This bearing is greased from the bracket’s front side.80 mL (8.3312 inch) to 110.051 mm (5.028 mm (4. All of the other bearings are ball bearings. i02509091 Belts . This bearing is on the drive end of the generator.000 mm (11.002 mm (9. i01219565 • Belts • Pulleys • Bearings If the belts are too tight.4489 inch) to 240. 1357-040. Vibration of loose belts can cause unnecessary wear on the following components: .Measure/Record SEBU6682-08 (Table 22. 1357-510 Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking.002 mm (11.82 Maintenance Section Bearing Temperature . These detectors are 100 ohm resistance temperature detectors.4501 inch) Bearing Shield (Type) Double Bearing Cavity Grease mL (oz) 148. Inspect the wiring for good condition. Loosen the adjusting nut for the pulley. Loosen the mounting bolt for the pulley. Record the data in a log. 2.Inspect SMCS Code: 4490-040.SEBU6682-08 83 Maintenance Section Carburetor Air/Fuel Ratio . Loosen mounting bolt (1). 3. Turn adjusting nuts (2) in order to increase or decrease the drive belt tension. . Adjusting the Fan Drive Belt 1. Move the pulley in order to adjust the belt tension. “Specifications” module. ensure that the electronic displays are operating properly. Tighten the adjusting nut. If equipped. A gauge reading that is abnormal may indicate a problem with operation or with the gauge. Reinstall the drive belt guard. Tighten the mounting bolt. of the valves. For information on adjusting the carburetor. 2. The service life of the turbocharger. “Systems Operation/Testing and Adjusting”. 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. 7451-040 Inspect the condition of the panel. Tighten mounting bolt (3). 5. see the Service Manual. ensure that the component is repaired or that the component is replaced. 1266 An engine failure may occur if the air/fuel ratio is not appropriate for the fuel and for the operating conditions. adjusting nuts (2) and mounting bolt (3). refer to the Service Manual. 5. Comparing the new data to the recorded data will establish the normal gauge readings for the engine. Remove the drive belt guard. 4. The additional load on the new drive belt could cause the new drive belt to fail. Control Panel . or refer to the Special Instruction. Record the Data and Review the Data If equipped. i01005891 Carburetor Air/Fuel Ratio Check/Adjust SMCS Code: 1266-535. If new drive belts are installed. Tighten adjusting nuts (2). check the drive belt tension again after 30 minutes of engine operation at the rated rpm. and of the other components may be reduced. Tighten mounting bolt (1). If a component is damaged. Compare the new data to the data that was previously recorded. For the proper torque. “Installation and Initial Start-Up Procedure”. i01762721 1. 3.Check/Adjust Adjusting the Alternator Belt Replacement For applications that require multiple drive belts. check the gauges and check the indicators frequently during normal operation. replace the drive belts in matched sets. 4. Illustration 62 Typical alternator (1) Mounting bolt (2) Adjusting nuts (3) Mounting bolt g01092641 Ensure that the carburetor is adjusted properly so that the air/fuel ratio is correct. Ensure that the wiring connections are secure. Change SMCS Code: 1350-044 Clean the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. Stop the engine and allow the engine to cool. 2.Change SEBU6682-08 i02150881 Cooling System Coolant (NGEC) . NOTICE Dispose of used engine coolant properly or recycle. Remove the cooling system filler cap. Close the cooling system drain valve. Drain the Cooling System 1. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. Use only cooling system cleaners that are approved for Caterpillar engines. Clean the drain plugs and install the plugs. Ensure that the engine will not start when the cooling system is drained. Remove the drain plugs. • Oil has entered the cooling system and the coolant is contaminated. flush the cooling system with clean water in order to remove any debris. and elbows g00719046 3. consult your Caterpillar dealer or consult Dealer Service Tools Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL Illustration 63 g00781022 2.84 Maintenance Section Cooling System Coolant (NGEC) . Clean the Cooling System 1. Open the cooling system drain valve. Loosen the cooling system filler cap slowly in order to relieve any pressure. NOTICE Use of commercially available cooling system cleaners may cause damage to cooling system components. Illustration 64 Drain plugs on the oil cooler. water pumps. After the cooling system has been drained. • Foaming is observed. For information regarding the disposal and the recycling of used coolant. . Note: For information about the proper coolant to use and for the capacity of the cooling system. Add 0. NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. 5. Remove the drain plugs. Stop the engine. Install the cooling system filler cap. To avoid damage to the cooling system. Do not install the cooling system filler cap. Close the cooling system drain valve. NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. Clean the drain plugs and install the plugs.8 to 7. Allow the water to drain. After the cooling system has been drained. Start the engine. Stop the engine and allow the engine to cool. Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 °C (180 °F). Operate the engine for a minimum of 30 minutes with a coolant temperature of at least 82 °C (180 °F).5 L (1 pint) of cleaner per 3. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Add 0. 2. 1. Close the cooling system drain valve. Start the engine. Fill the cooling system with coolant/antifreeze. Flush the cooling system with clean water until the water that drains is clean. Allow the water to drain. make sure to completely flush the cooling system with clear water. Flush the cooling system with clean water until the water that drains is clean.see this Operation and Maintenance Manual. Clean the drain plugs and install the plugs. make sure to completely flush the cooling system with clear water. there must be an active flow through the cooling system components. Remove the cooling system filler cap. 5. Continue to flush the system until all signs of the cleaning agent are gone. Clean the drain plugs and install the plugs. To avoid damage to the cooling system. Stop the engine and allow the engine to cool. Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the drain plugs. Continue to flush the system until all signs of the cleaning agent are gone. Loosen the cooling system filler cap slowly in order to relieve any pressure. “Refill Capacities and Recommendations” (Maintenance Section). 4. 2. flush the cooling system with clean water in order to remove any debris. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner.SEBU6682-08 85 Maintenance Section Cooling System Coolant (NGEC) . 3. 3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Close the cooling system drain valve.6 L (1 to 2 US gal) of the cooling system capacity. NOTICE Use of commercially available cooling system cleaners may cause damage to cooling system components. Operate the engine in order to purge the air from the cavities of the engine block. 4. 6. Open the cooling system drain valve. Cleaning a Cooling System that has Heavy Deposits or Plugging Note: For the following procedure to be effective. 1. Start the engine.Change NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Allow the coolant to warm and allow the coolant level to stabilize.5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. Open the cooling system drain valve. 6. Remove the cooling system filler cap. Use only cooling system cleaners that are approved for Caterpillar engines. . Install the cooling system filler cap. Pressurized System: Hot coolant can cause serious burns. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis. Clean the cooling system filler cap. discard the old cooling system filler cap and install a new cooling system filler cap. 4. .86 Maintenance Section Cooling System Coolant Level . i02064894 Cooling System Coolant Sample (Level 1) . Inspect the cooling system for leaks.Obtain SMCS Code: 1350-008. 1395-008. use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system filler cap. Remove the cooling system filler cap slowly in order to relieve pressure. Maintain the coolant level within 13 mm (0. install a new cooling system filler cap. If the engine is equipped with a sight glass. Start the engine. 3. you must establish a consistent trend of data. and use a separate designated pump for coolant sampling. Illustration 66 Typical filler cap gaskets g00103639 Cooling System Coolant Level . Inspect the cooling system for leaks and for proper operating temperature. i01197583 2. The concentration of SCA can be checked with an S·O·S coolant analysis (Level 1). Reinstall the cooling system filler cap.5 inch) below the bottom of the filler pipe.Check SEBU6682-08 3. If the cooling system filler cap does not maintain the correct pressure. 1.Check SMCS Code: 1350-535-FLV Check the coolant level when the engine is stopped and cool. Supplies for collecting samples can be obtained from your Caterpillar dealer. maintain the coolant level to the proper level in the sight glass. Replace the cooling system filler cap if the filler cap gaskets are damaged. Clean the cooling system filler cap and check the condition of the filler cap gaskets. If a sight gauge is not equipped. maintain the coolant within 13 mm (0. check the concentration of supplemental coolant additive (SCA) regularly. stop the engine and wait until the cooling system components are cool. Maintain the coolant to the proper level on the sight gauge (if equipped). If the gaskets of the cooling system filler cap are not damaged. To open the cooling system filler cap. 5. 7542 NOTICE Always use a designated pump for oil sampling. Check the coolant level. If the gaskets of the cooling system filler cap are damaged. perform consistent samplings that are evenly spaced. Using the same pump for both types of samples may contaminate the samples that are being drawn. Loosen the cooling system pressure cap slowly in order to relieve the pressure. In order to establish a pertinent history of data. 1395-554. Illustration 65 Cooling system filler cap g00285520 For conventional heavy-duty coolant/antifreeze. Inspect the gaskets of the cooling system filler cap. The correct pressure is stamped on the face of the cooling system filler cap. 4.5 inch) of the bottom of the filler pipe. • Never collect samples from the drain for a system. immediately place the sample in the tube that is provided for mailing. Fuel. For additional information about coolant analysis. Water and SCA NOTICE Do not exceed the recommended eight percent supplemental coolant additive concentration.Obtain Use the following guidelines for proper sampling of the coolant: Submit the sample for Level 2 analysis. see the Special Publication. 1395-081 • Obtain coolant samples directly from the coolant sample port. Follow the instructions that are provided in the kit. avoid contact with the skin and eyes. Submit the sample for Level 1 analysis. i02168823 Test the Concentration of the SCA Coolant/Antifreeze and SCA NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration. “Cooling System Coolant Sample (Level 1) . SEBU6400. Cooling System Supplemental Coolant Additive (SCA) Test/Add SMCS Code: 1352-045. Fuel and Coolant Recommendations” or consult your Caterpillar dealer. Dispense the 1. Note: Caterpillar recommends an S·O·S coolant analysis (Level 1).SEBU6682-08 87 Maintenance Section Cooling System Coolant Sample (Level 2) . Do not drink cooling system coolant additive. Using the same pump for both types of samples may contaminate the samples that are being drawn. Note: Level 1 results may indicate a need for Level 2 Analysis. i02017557 • Never collect samples from expansion bottles. 2. SEBU6400. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. • In order to avoid contamination. “Caterpillar Gas Engine Lubricant. and use a separate designated pump for coolant sampling. For additional information about coolant analysis. 3.0 mL coolant sample from the syringe into the empty mixing bottle. “Caterpillar Gas Engine Lubricant. • Keep the lids on empty sampling bottles until you are ready to collect the sample. • Keep the unused sampling bottles stored in plastic bags.Obtain SMCS Code: 1350-008. Place the cap on the bottle and shake the bottle. Refer to this Operation and Maintenance Manual. Supplies for collecting samples can be obtained from your Caterpillar dealer.Obtain” (Maintenance Section) for the guidelines for proper sampling of the coolant. Cooling System Coolant Sample (Level 2) . To help prevent personal injury. 1395-008. . 1395-554.0 ml” mark with the coolant. You should not obtain the samples from any other location. Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Fill the syringe to the “1. Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. see the Special Publication. • Complete the information on the label for the sampling bottle before you begin to take the samples. Cooling system coolant additive contains alkali. and Coolant Recommendations” or consult your Caterpillar dealer. Obtain the sample of the coolant as close as possible to the recommended sampling interval. Use the instructions that follow: 1. 7542 NOTICE Always use a designated pump for oil sampling. Add tap water to the mixing bottle in order to bring the level up to the “10 ml” mark. 5. Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger. see this Operation and Maintenance manual. Comparing the recorded data to the new data provides information about the condition of the engine. To open the cooling system filler cap. 2. and/or accelerated wear of the water pump seal. The concentration of the SCA depends on the type of coolant that is used. 4. Continue to periodically measure the blowby. Add 2 to 3 drops of the “NITRITE INDICATOR SOLUTION B” to the mixing bottle. see this Operation and Maintenance Manual. “Overhaul (Major)” topic (Maintenance Section). Add the proper amount of SCA. reducing the engine’s heat transfer characteristics. After a new engine is used for a short time. the blowby can decrease as the piston rings are seated. or blue. Measure the crankcase blowby of new engines.6 to 1. 7. Move the bottle in a circular motion in order to mix the solution. None 3. Note: Crankcase blowby is one of the three factors that help to determine the major overhaul interval. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. i01333307 25 to 30 More than 30 Remove the coolant. If Necessary Pressurized System: Hot coolant can cause serious burns. To determine the proper amount. • piston rings • cylinder liners . If necessary.88 Maintenance Section Crankcase Blowby . stop the engine and wait until the cooling system components are cool. Do not exceed the recommended amount of supplemental coolant additive concentration. “Refill Capacities and Recommendations” topic. Repeat 5 until the solution changes color from red to light gray.0 cu ft/Bhp-hr). Install the cooling system filler cap. Loosen the cooling system pressure cap slowly in order to relieve the pressure. The blowby will gradually increase as the following components show wear: Add the SCA.Measure/Record SEBU6682-08 4. Use Table 23 to interpret the results. Number of Drops Less than 25 Concentration of SCA Less than the recommended concentration of SCA The recommended concentration of SCA More than the recommended concentration of SCA Maintenance Required Add SCA. For more information. the typical range for crankcase blowby is approximately 22 to 37 L/Bkw-hr (0. Record the number of drops of “NITRITE TEST SOLUTION A” that were required to cause the color change. 1. Clean the cooling system filler cap. Remove the cooling system filler cap slowly. Retest the coolant. green. Note: Always dispose of fluids according to local regulations. Add 1 drop of “NITRITE TEST SOLUTION A” to the mixing bottle. overheating. Crankcase Blowby Measure/Record SMCS Code: 1317 Note: For a new G3400 Engine. 6. Table 23 NOTICE Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system. Move the bottle in a circular motion in order to mix the solution. drain some coolant in order to allow space for the addition of the SCA. Record the data. Replace with water only Retest the coolant. i01664707 Cylinder Pressure Measure/Record SMCS Code: 1223-082-CC. Excessive blowby may indicate the need for an overhaul. inspect the crankshaft seals for leaks. “Using the 8T-2700 Blowby/Airflow Indicator Group”. “Systems Operation/Testing and Adjusting”. determine the type of fluid. • There is a large amount of gear train wear that is not caused by a lack of oil. the battery power will be conserved. see the Service Manual. Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement. A deteriorating damper can cause excessive gear train noise at variable points in the speed range. cracked. The blowby of a worn engine may exceed the blowby of a new engine by two times or more. Also. By keeping a record of the results. This can result in damage to the crankshaft and to other engine components. Keep a record of the results. For more information. The fluid in the damper is silicone. Comparing the recorded data to the new data provides information about the condition of the engine. The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine. a gradual increase in the amount of the blowby will be noted until the amount has become excessive. • Fully open the throttle plate. . SEHS8712. i01333457 • The damper is dented. Inspect the damper for evidence of fluid leaks. smooth. Cylinder pressure can be measured during inspection of the spark plugs. Silicone has the following characteristics: transparent. viscous. If the fluid leak is oil. 7450-082 Measure the cylinder pressure of new engines. Information regarding the condition of the piston rings can be obtained from the measurement of the blowby and the results of oil analysis. and adhesive. Refer to Special Instruction. If a fluid leak is found. Continue to periodically measure the cylinder pressure. • The paint on the damper is discolored from heat. A sudden increase in blowby could indicate a broken piston ring. Inspect the damper and repair or replace the damper for any of the following reasons: • Worn valve guides • A turbocharger seal that leaks A rebuilt engine can have a high blowby due to the following factors: • The piston rings are not seated properly. • Minimize the cranking time to 3 or 4 revolutions. • Worn parts such as valve guides were not replaced.Inspect Note: A problem with the piston rings causes the oil to deteriorate rapidly. The following conditions are other potential sources of blowby: Visconic Damper The visconic damper has a weight that is located inside a fluid filled case. or leaking. Record the data. consult your Caterpillar dealer. To measure the blowby. If a leak is observed. replace the crankshaft seals.SEBU6682-08 89 Maintenance Section Crankshaft Vibration Damper . This will enable a maximum consistent cranking speed for the check. The weight moves in the case in order to limit torsional vibration. • Remove all of the spark plugs. The instruction is provided with the tool. For assistance. • The engine has had a failure because of a broken crankshaft. use the 8T-2700 Blowby/Air Flow Indicator. Use the following guidelines for checking the cylinder pressure: Crankshaft Vibration Damper . 1223.Inspect SMCS Code: 1205-040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations. • Analysis of the oil has revealed that the front main bearing is badly worn. 90 Maintenance Section Driven Equipment - Check SEBU6682-08 A loss of cylinder pressure or a change of pressure in one or more cylinders may indicate the following conditions. These conditions may indicate a problem with lubrication: • Excessive deposits • Guttering of valves • A broken valve • A piston ring that sticks • A broken piston ring • Worn piston rings • Worn cylinder liners If the cylinder pressure has risen by one or more compression ratios, the engine needs a top end overhaul in order to remove deposits. Failure to remove the deposits will increase the chance for detonation. Severe guttering of the valves will occur. To measure the cylinder pressure, use the 193-5859 Cylinder Pressure Gauge Gp. Follow the procedure in the Special Instruction, NEHS0798 that is included with the gauge group. Record the pressure for each cylinder. Use the Operation and Maintenance Manual, “Valve Data Sheet” (Reference Materials Section). Illustration 67 is a graph of typical cylinder pressures for engines with different compression ratios. Illustration 67 (Y) Cylinder pressure in kPa (X) Compression ratio (1) Normal range for cylinder pressure g00828960 i00449093 Driven Equipment - Check SMCS Code: 3279-535 To minimize bearing problems and vibration of the engine crankshaft and the driven equipment, the alignment between the engine and driven equipment must be maintained properly. Check the alignment according to the instructions that are provided by the following manufacturers: • Caterpillar • OEM of the coupling • OEM of the driven equipment SEBU6682-08 91 Maintenance Section Driven Equipment - Inspect/Replace/Lubricate i00935098 Driven Equipment Inspect/Replace/Lubricate SMCS Code: 3279-040 Observe the driven equipment during operation. Look for the following items: NOTICE Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on the engine. Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following benefits: • Unusual noise and vibration • Loose connections • Damaged parts Perform any maintenance that is recommended by the OEM of the driven equipment. Refer to the literature of the OEM of the driven equipment for the following service instructions. • Easy detection of fluid leaks • Maximum heat transfer characteristics • Ease of maintenance Note: For more information on cleaning and drying electric generators, refer to Special Instruction, SEHS9124, “Cleaning and Drying of Electric Set Generators”. i01749609 • Inspection • Lubricating grease and lubricating oil requirements • Specifications for adjustment • Replacement of components • Requirements for ventilation i01664717 Engine Air Cleaner Element Replace SMCS Code: 1051-510; 1054-510 NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne 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. Engine - Clean SMCS Code: 1000-070 Personal injury or death can result from high voltage. Moisture could create paths of electrical conductivity. Make sure the unit is off line (disconnected from utility and/or other generators), locked out and tagged "Do Not Operate". NOTICE Water or condensation can cause damage to generator components. Protect all electrical components from exposure to water. Servicing the Air Cleaner Elements If the air cleaner element becomes plugged, the air pressure can split the filter material of the element. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has the proper air cleaner elements for your application. The air cleaner may be mounted high above the engine. If necessary, use a ladder or a platform to reach the air cleaner. • Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any dirt and debris, as needed. 92 Maintenance Section Engine Air Cleaner Element - Replace SEBU6682-08 • Operating conditions (dust, dirt and debris) may require more frequent service of the air cleaner element. 4. Clean the inside of the cover and the body with a clean, dry cloth. 5. Remove the tape for the air inlet. Install a new element or a clean element. 6. Install the cover. 7. If necessary, reset the air cleaner service indicator. • The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected. one time per year. This replacement should be performed regardless of the number of cleanings. • The air cleaner element should be replaced at least Replace the dirty paper elements with clean elements. Before installation, thoroughly inspect the element for tears and/or holes in the filter material. Inspect the gasket or the seal of the element for damage. Maintain a supply of suitable elements for replacement purposes. Cleaning the Primary Air Cleaner Elements The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. When the element is cleaned, check the filter material for rips or tears. Replace the element at least one time per year regardless of the number of cleanings. Use clean 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 elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result. Visually inspect the elements before cleaning. Inspect the elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged elements. Air cleaner elements can be cleaned with pressurized air and with a vacuum. Illustration 68 Fasteners for the air cleaner cover g00317608 Pressurized Air Pressurized air can be used to clean 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 69 (1) Cover (2) Element (3) Air inlet g00781084 1. Release the fasteners for cover (1). 2. Remove the cover and element (2). 3. Cover air inlet (3) with tape in order to keep dirt out. Illustration 70 g00281692 dry element. Note: Refer to “Inspecting the Primary Air Cleaner Elements”. Do not use an element that has any tears and/or holes in the filter material. Discard damaged elements. Engine Air Cleaner Service Indicator . Use a 60 watt blue light in a dark room or in a similar facility. Vacuum Cleaning Vacuum cleaning is a good method for cleaning elements which require daily cleaning because of a dry. Note: Refer to “Inspecting the Primary Air Cleaner Elements”. For more detailed information on cleaning the primary air cleaner element. mark the outside of the container and mark the element. SEBF8062. “Procedure to Inspect and Clean Air Filters”. refer to Special Publication. always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside).Inspect Note: When the elements are cleaned. Do not aim the stream of air directly at the primary air cleaner element. gaskets or seals. 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. Place the blue light in the element. If it is necessary in order to confirm the result. dusty environment. Dirt could be forced into the pleats. To protect against dirt and damage. compare the element to a new element that has the same part number. Rotate the element. Do not use an element with damaged pleats. Place the element into a cardboard box for storage. a waterproof cover. For identification. Restricted air flow may result.SEBU6682-08 93 Maintenance Section Engine Air Cleaner Service Indicator . Vacuum cleaning will not remove deposits of carbon and oil. wrap the elements in Volatile Corrosion Inhibited (VCI) paper. Illustration 72 g00281694 Do not use paint. Cleaning with pressurized air is recommended prior to vacuum cleaning. Include the following information: Inspecting the Primary Air Cleaner Elements • Date of cleaning • Number of cleanings Store the container in a dry location. Inspect the element for light that may show through the filter material. i01505252 Illustration 71 g00281693 Inspect the clean. Storing Primary Air Cleaner Elements If an element that passes inspection will not be used immediately. or plastic as a protective covering for storage. . Inspect the element for tears and/or holes.Inspect SMCS Code: 7452-040 A service indicator may be mounted on the air cleaner element or in a remote location. store the element for future use. Test the Service Indicator Service indicators are important instruments. • Check the movement of the yellow core when the engine is accelerated to the engine rated rpm. Replace the service indicator when the engine is overhauled. Replace the service indicator annually regardless of the operating conditions. If the new service indicator will not reset. holes. if necessary. Observe the service indicator. If the service indicator does not reset easily.Clean SEBU6682-08 Illustration 73 Service indicator g00517797 Illustration 74 Porous filter g00351792 Some engines may be equipped with a different service indicator. the fitting for the service indicator may be plugged. The yellow core should latch approximately at the greatest vacuum that is attained. Engine Air Precleaner . The service indicator may need to be replaced frequently in environments that are severely dusty.7 kPa (15 inches of H2O). Clean the filter.94 Maintenance Section Engine Air Precleaner . The service indicator should reset in less than three pushes. nonflammable solvent. Tighten the service indicator to a torque of 2 N·m (18 lb in). i01397717 • The yellow diaphragm enters the red zone. Inspect the service indicator daily for cracks. Clean the air cleaner element or replace the element when the following conditions occur: A porous filter is part of a fitting that is used for mounting of the service indicator. If any of these conditions are present. • The red piston locks in the visible position. Illustration 75 Typical precleaner (1) Wing nut (2) Cover (3) Body g00736588 . repair the service indicator or replace the service indicator. Use compressed air or a clean. Inspect the filter for cleanliness. replace the service indicator. and whenever major engine components are replaced. or loose fittings. • The air restriction reaches 3.Clean SMCS Code: 1055-070 • Check for ease of resetting. excessive force may crack the top of the service indicator. Note: When a new service indicator is installed. or if the yellow core does not latch at the greatest vacuum. Clean the body. SENR3130 in order to locate the proper torques. more frequent cleaning is required. see the literature that is provided by the OEM of the isolators. i02263740 4. Install the hose. i02017664 Engine Crankcase Breather Clean SMCS Code: 1317-070 NOTICE Perform this maintenance with the engine stopped. Ensure that the isolators are free of oil and contamination. Install the seal. Wash the breather element in solvent that is clean and nonflammable. Also see the Application and Installation Guide for the engine. Illustration 76 Typical example (1) (2) (3) (4) Hose clamp Breather assembly Retaining clamp Seal g01136454 1. install cover (2) and wing nut (1). .Check SMCS Code: 1152-535 Illustration 77 (1) Mounting bolts for the engine (2) Mounting bolts for the generator (3) Levelling bolts for the isolators g00736591 Misalignment of the engine and the driven equipment will cause extensive damage. the crankcase breather will become plugged. if necessary. Excessive vibration can lead to misalignment. Allow the breather element to dry before installation. Refer to the Specifications. the breather assembly. Install the hose clamp. Note: When the engine is operated in dusty applications. Install a breather element that is clean and dry. 5. Check for an accumulation of dirt and debris in body (3). Remove the breather assembly and seal (4). and the clamp.Clean Remove wing nut (1) and cover (2). SENR3130 in order to locate the proper torques. 2. see Specifications. Excessive vibration of the engine and the driven equipment can be caused by the following conditions: • Improper mounting • Loose bolts • Deterioration of the isolators Ensure that the mounting bolts are tightened to the proper torque.SEBU6682-08 95 Maintenance Section Engine Crankcase Breather . Loosen retaining clamp (3). 3. For more information. After cleaning the precleaner. Replace any isolator that shows deterioration. Loosen hose clamp (1) and remove the hose from breather assembly (2). Ensure that the bolts for the isolators are tightened to the proper torque. For standard torques. SENR3130. If the crankcase breather is not maintained on a regular basis. A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage. Refer to the Specifications. Engine Mounts . Inspect the isolators for deterioration. Consult your Caterpillar dealer for assistance. “Torque Specifications”. 3. 1. remove vent plug (1). Illustration 78 Auxiliary oil filter housing (1) Vent plug (2) Drain plug g00787079 Illustration 79 (1) Vent plug (2) Drain plug (3) Nut (4) Washer (5) Plug (6) Bolt (7) Cover (8) Cover gasket (9) Nut (10) Spring retainer (11) Spring (12) Bolt (13) Washer (14) Spider (15) Plate g00787105 1. 2. Allow the oil to drain. and the spring. Remove drain plug (2). Remove 12 nuts (3). Remove cover (7) and gasket (8).Change SEBU6682-08 i02017678 Engine Oil Filter (Auxiliary) Change SMCS Code: 1318 Note: An auxiliary oil filter system enables the oil capacity of the engine to be increased. Remove nut (9). clean the drain plug.96 Maintenance Section Engine Oil Filter (Auxiliary) . . the spring retainer. Use of the auxiliary oil filter elements is not recommended. Do not damage the gasket. spring retainer (10). Be prepared to hold the spring retainer as the nut is loosened. Perform this procedure after the oil has been drained from the auxiliary oil filter housing. and bolts (6). If the engine is equipped with an auxiliary oil filter system. After the oil has drained. Possible injury can occur during the removal of the nut. Spring force will be released when the nut and the spring retainer are removed. Hold spring retainer (10) as nut (9) is loosened. and spring (11). washers (4). 6. Tighten the drain plug to 70 ± 14 N·m (50 ± 10 lb ft). Install vent plug (1). b.Change” topic (Maintenance Section). Remove oil level gauge (1) and observe the oil level on “LOW IDLE” side (4). Tighten nut (9) in order to compress spring (11) until the spring retainer bottoms out on bolt (12). replace the old cover gasket with a new cover gasket. For instructions on inspecting the oil filter elements. reduce the engine speed to low idle. Ensure that oil level gauge (1) is seated. washers (4). 7.Check SMCS Code: 1348-535-FLV The most accurate check of the oil level is performed when the engine is stopped. install new elements. “Engine Oil Filter . 12. 13.SEBU6682-08 97 Maintenance Section Engine Oil Level . breaks. If the engine is operating. or other damage.Check 4. Install spring retainer (10) and nut (9) on bolt (12). remove oil level gauge (1). . “Refill Capacities and Recommendations” topic (Maintenance Section). 10. Install twelve bolts (6). a. Tighten nuts sequentially around the cover until the nuts are snug. For the correct amount of oil. 15. Perform this maintenance on a surface that is as level as possible. Note: Use of the auxiliary oil filter elements is not required. Engine Oil Level . Fill the oil filter housing with oil. Install spring (11) on spider (14). Do not overtighten the nut. and bolt (12). i02150939 Illustration 80 (1) Oil level gauge (dipstick) (2) Oil filler g00788953 Illustration 81 (3) (4) (5) (6) “ENGINE STOPPED” side “LOW IDLE” side “ADD” mark “FULL” mark g00735162 1. Clean the inside of the oil filter housing. Remove the oil filter elements if the oil filters have been installed. Ensure that plug (5) is tight. 11. and nuts (3). refer to the Operation and Maintenance Manual. Remove washer (13) and spider (14). Install cover gasket (8). Inspect the oil filter elements if the oil filters have been installed. washer (13). Install cover (7). refer to the Operation and Maintenance Manual. 8. Install plate (15). Install drain plug (2). Inspect cover gasket (8) for tears. If the engine is stopped. Tighten the nuts to 100 ± 15 N·m (75 ± 11 lb ft). Remove bolt (12). If the cover gasket is damaged. 5. Observe the oil level on “ENGINE STOPPED” side (3). Remove plate (15). 14. 9. spider (14). The oil level should be between “ADD” mark (5) and “FULL” mark (6). If the use of auxiliary oil filter elements is desired. Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. Clean the oil filler cap. For the correct oil to use. include the total amount of oil that has been added since the previous oil sample. The bottle group includes the parts that are needed for obtaining oil samples. If necessary. . Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury. 2. Do not allow hot oil or hot components to contact the skin. remove oil filler cap (2) and add oil. Do not fill the crankcase above “FULL” mark (6). Disposable tubing must be attached to the pump for insertion into the sump. “How To Take A Good Oil Sample”. provide the following information: • Engine model • Service hours on the engine • The oil’s hours of use • 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. A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken. packing of carbon under the piston rings. Record the amount of oil that is added. Always use a designated pump for oil sampling and a designated pump for coolant sampling. and wear of the cylinder liner. “Refill Capacities and Recommendations” topic (Maintenance Section). Caterpillar recommends using the sampling valve in order to obtain oil samples. Instructions are also provided. Engine Oil Sample . i01363663 Before taking the sample. see this Operation and Maintenance Manual.Obtain SMCS Code: 1348-554-SM In addition to a good preventive maintenance program. This will reduce the power that is developed and also force air bubbles into the oil. see Special Publication. These bubbles (foam) can cause the following problems: reduction of the oil’s ability to lubricate. The quality and the consistency of the samples is 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 pump is designed to accept sampling bottles. inadequate cooling. Deposits in the combustion chamber lead to the following problems: guttering of the valves. The 8T-9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve. To help obtain the most accurate analysis. This will help to provide the most accurate oil analysis. To avoid contamination of the oil samples. If the engine is not equipped with a sampling valve.98 Maintenance Section Engine Oil Sample . 3. For the next oil sample and analysis. Install the oil filler cap. oil blowing out of the crankcase breathers. complete the Label. the tools and the supplies that are used for obtaining oil samples must be clean. drain some of the oil immediately. well mixed oil sample. PEEP5031 for identification of the sample. PEHP6001. An overfull crankcase can cause the crankshaft to dip into the oil. Failure to do so may cause a false analysis which could lead to customer and dealer concerns. obtain a warm. If the oil level is above the “FULL” mark on the oil level gauge. NOTICE Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples. use the 1U-5718 Vacuum Pump. reduction of oil pressure.Obtain SEBU6682-08 NOTICE Engine damage can occur if the crankcase is filled above the “FULL” mark on the oil level gauge (dipstick). and excessive oil consumption. Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber. For instructions. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your engine. open the valve in order to drain the oil. If the engine has an oil drain valve. Parts that may be affected include the following items: main bearings. suspended waste particles settle on the bottom of the oil pan. consult your Caterpillar dealer in order to arrange for further oil analysis. Break apart the pleats and inspect the oil filter for metal debris. brass parts or bronze parts of the engine. adjusting and repair of the product. NOTICE Ensure that the engine is stopped before performing this procedure.Change i02523743 Engine Oil and Filter . Refer to Special Publication. Attach a DO NOT OPERATE tag to the starting controls. Remove the oil filter with a 1U-8760 Chain Wrench. After the oil has drained. close the valve. Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil. Replace the Oil Filter 1. . Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. b. inspect the vibration damper and the idler gear bearings.Change SMCS Code: 1318-510 Hot oil and hot components can cause personal injury. Do not drain the oil when the engine is cold. immediately after the engine is stopped. rod bearings. Aluminum debris may indicate problems with the bearings of the front gears. testing. and cylinder heads. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. NENG2500. After the engine has been operated at normal operating temperature. Drain the oil. 2. Dispose of all fluids according to local regulations and mandates. Do not allow hot oil or hot components to contact the skin. This method of draining allows the waste particles that are suspended in the oil to be drained.SEBU6682-08 99 Maintenance Section Engine Oil and Filter . Cut the oil filter open with a 4C-5084 Oil Filter Cutter. Ferrous metals may indicate wear on the steel and cast iron parts of the engine. If an excessive amount of debris is found in the oil filter element. If the engine does not have a drain valve. Drain the Engine Oil 1. As the oil cools. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Due to normal wear and friction. The waste particles are not removed when the cold oil is drained. STOP the engine. Allow the oil to drain. Drain the crankcase with the oil warm. a. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure. Illustration 82 (1) (2) (3) (4) Oil Oil Oil Oil filler cap filter level gauge (dipstick) drain g00781251 Nonferrous metals may indicate wear on the aluminum parts. 2. remove an oil drain plug. maintenance. it is not uncommon to find small amounts of debris in the oil filter element. turbocharger bearings. If you find aluminum debris. An overfull crankcase can cause the crankshaft to dip into the oil. Remove the oil level gauge and check the oil level. Refer to the Operation and Maintenance Manual. Tighten the oil filter by hand according to the instructions that are shown on the oil filter. 5. Allow the starting motor to cool for two minutes before cranking again. For the proper oil to use. Start the engine according to this Operating and Maintenance Manual. 2. Deposits in the combustion chamber lead to the following problems: guttering of the valves. Maintain the oil level between the “ADD” and “FULL” marks on the “ENGINE STOPPED” side of the oil level gauge. Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes. If the oil level is above the “FULL” mark on the oil level gauge. These bubbles (foam) can cause the following problems: reduction of the oil’s ability to lubricate. Inspect the engine for oil leaks. Do not overtighten the oil filter.. crank the engine with the fuel supply line closed. “Starting the Engine” procedure (Operation Section). packing of carbon under the piston rings. . NOTICE Caterpillar oil filters are built to Caterpillar specifications. etc. This oil would not be filtered and could be contaminated. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings. oil blowing out of the crankcase breathers. “Refill Capacities and Recommendations” topic (Maintenance Section). Open the fuel supply line. Illustration 83 Typical filter mounting base and filter gasket g00103713 3. Remove the oil filler cap. NOTICE Do not fill the oil filters with oil before installing them. Contaminated oil can cause accelerated wear to engine components. Install the oil filter. Apply clean engine oil to the new oil filter gasket. Tighten the oil filter until the oil filter gasket contacts the base. Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber. Clean the sealing surface of the filter mounting base. Close the fuel supply line. inadequate cooling. Crank the engine until normal oil pressure shows on the oil pressure gauge. Fill the crankcase with the proper amount of oil. 4. as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Caterpillar. This will ensure that all of the oil filters are filled with oil before the engine is started. refer to this Operation and Maintenance Manual. Ensure that all of the old oil filter gasket is removed. Fill the Engine Crankcase NOTICE Only use oils that are recommended by Caterpillar. reduction of oil pressure. This will reduce the power that is developed and also force air bubbles into the oil. “Refill Capacities and Recommendations” topic (Maintenance Section). 5. and excessive oil consumption. NOTICE To prevent crankshaft damage or bearing damage.100 Maintenance Section Engine Oil and Filter . This will ensure that the lubrication system has oil and that the oil filters are filled. crankshaft.Change SEBU6682-08 NOTICE Engine damage can occur if the crankcase is filled above the “FULL” mark on the oil level gauge (dipstick). 4. Operate the engine at low idle rpm for two minutes. 3. drain some of the oil immediately. 1. Do not crank the engine for more than 30 seconds. and wear of the cylinder liner. To prevent damage to the engine. Check for signs of wear and contaminants. i02526257 Engine Valve Lash Inspect/Adjust SMCS Code: 1102-025 This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life. A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints. Shutoffs help to prevent damage to the engine. i00626013 Engine Protective Devices Check SMCS Code: 7400-535 Alarms and shutoffs must function properly. 2. Visual Inspection Visually check the condition of all gauges. Ensure that the gauges are in the normal ranges. 1907-040. Clean the metal shavings and other debris from the face of the magnet. Look for wiring and components that are loose. • Record the data. 1905-070. It is impossible to determine if the engine protective devices are in good working order during normal operation. sensors and wiring. Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjustment procedure. Remove the sensor from the cover. 1907-070 • Monitor the operation of the generator set. Illustration 84 g00798212 Engine speed/timing sensor in the front cover for the timing disc 1. NOTICE Only qualified service personnel should perform this maintenance. abnormal operating conditions must be simulated. 3. or damaged. Install the sensor and adjust the sensor according to the engine’s Specifications. . Alarms provide timely warning to the operator. Malfunctions must be simulated in order to test the engine protective devices. • Observe the gauges. Damaged wiring or components should be repaired or replaced immediately. Engine Speed/Timing Sensor Clean/Inspect SMCS Code: 1905-040. Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency.SEBU6682-08 101 Maintenance Section Engine Performance . The tests must be performed correctly in order to prevent possible damage to the engine. Ensure that the engine protective devices are functioning properly. Maintain a record of the data for the engine performance.Test SMCS Code: 1000-081 Operate the engine for a minimum of two hours at a minimum load of 60 percent. NOTICE During testing. Check the condition of the end of the magnet. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life. broken.Test i01042067 i01616208 Engine Performance . only authorized service personnel or your Caterpillar dealer should perform the tests. 4.102 Maintenance Section Engine Valve Rotators . Mark the tops of the valve rotators with a permanent marker. 5. replace the diaphragm. If the parts are excessively worn. allow the valves to cool before this maintenance is performed. consult your Caterpillar dealer. Observe the position of the marks that are on the valve rotators. If the diaphragm is worn or cracked. 6. Inspect diaphragm (1). The exhaust bypass valve cover is under spring compression. 3.Inspect SMCS Code: 1057-040 For instructions on removal and installation. . Install the valve covers. Assemble the valve. To obtain an accurate measurement. “Disassembly and Assembly”. valve face guttering could result and cause pieces of the valve to fall into the cylinder. See the Service Manual for the procedure. Illustration 85 Exhaust bypass valve (1) Diaphragm (2) Valve stem (3) Breather g00781274 3. Hot engine components can cause burns. Operate the engine for 5 minutes. 7. use caution when removing the cover. Inspect valve stem (2) and the valve guide. Perform this procedure after the valve lash has been set. Refer to the engine’s Specification manual for more the valve lash settings. Note: Use of a platform may be necessary to reach the engine valve rotators. If a valve fails to rotate. see the Service Manual. 2. do not use the starting motor to turn the flywheel. Note the position of the marks. Engine Valve Rotators .Inspect SEBU6682-08 i01505507 Ensure that the engine can not be started while this maintenance is being performed. 2. Stop the engine. or the engine’s Systems Operation/Testing and Adjusting manual for the settings and the procedure. replace the parts. Disassemble the valve. Install the valve. This can cause piston and cylinder head damage. Clean breather (3). If a damaged rotator is not replaced. Remove the valve covers. 4. Start the engine. 1. To prevent personal injury. To help prevent possible injury. i01765711 Exhaust Bypass . Remove the exhaust bypass valve. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance.Inspect SMCS Code: 1109-040 NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life. Ensure that the engine is stopped before measuring the valve lash. 1. This gauge and the fuel filter are supplied by the customer. • For high pressure gas fuel systems. service the • Damage • Cracks • Leaks • Loose connections Consult your Caterpillar dealer for assistance. i02108745 Water Cooled Exhaust Manifolds The water cooled exhaust manifolds do not require maintenance unless excessive deposits build up in the exhaust passages. Table 24 lists the fuel pressure that is required for the gas pressure regulator. “Installation and Maintenance of Gaseous Fuel Filters”. see Special Instruction. service the fuel filter when the fuel filter differential pressure reaches 1. Pressure of the Fuel Supply To the Carburetor The gas pressure regulator maintains a pressure differential between the air and the fuel that is supplied to the carburetor.3 to 34 ± 2 kPa (1.25 psi). Table 24 • Increased fuel consumption • Reduced boost pressure If excessive deposits build up in the exhaust passages.Check SMCS Code: 1261-535 A fuel filter differential pressure gauge must be installed in order to determine when the fuel filter requires service. The differential pressure increases as the fuel filter becomes plugged.7 kPa (0. Inspect the components of the exhaust system. i01505536 Requirements for Fuel Pressure To the Gas Pressure Regulator Fuel System Low pressure gas Naturally Aspirated High pressure gas Pressure 10. Before performing maintenance on the engine. After setting.50 to 5 ± 0.25 psi) 172 to 207 ± 7 kPa (25 to 30 ± 1 psi) Fuel System Fuel Filter Differential Pressure . the gas pressure regulator will maintain the pressure differential in response to changes in the air pressure. allow the engine and the components to cool.Inspect SMCS Code: 1061-040 A fuel filter differential pressure gauge indicates the difference in fuel pressure between the inlet side and the outlet side of the fuel filter.Inspect i00721010 Exhaust Piping . Operate the engine at the rated speed and at the normal operating temperature. Consult your Caterpillar dealer for assistance. Repair the components or replace the components if any of the following conditions occur: • For low pressure gas fuel systems. For instructions. Buildup of deposits cause an increase in back pressure that will cause the following conditions: Gas Pressure Regulator Check SMCS Code: 1270-535 Check the fuel pressure before the gas pressure regulator and after the gas pressure regulator. fuel filter when the fuel filter differential pressure reaches 34 kPa (5 psi). SEHS9298. Service of the fuel filter depends on the pressure of the fuel system: Hot engine components can cause injury from burns. clean the passages in order to remove the deposits. Check the fuel filter differential pressure.SEBU6682-08 103 Maintenance Section Exhaust Piping . . Radiant type ovens can cause localized overheating.250 inches of H2O) LOWER than the ambient air pressure. Typically. Note: For more information on drying methods. the gas pressure regulator may require service. one of the following drying procedures must be selected. Controlled Current Method Table 25 Tools Needed Part Number 8T-0900 Description Clamp on ammeter (1200 amperes) External Power Source Rheostat Qty 1 1 1 • the size of the unit • the location of the unit • the equipment that is available • the experience of personnel . This opening will allow moisture to evaporate.Dry SEBU6682-08 Use a water manometer for measuring the pressure differential.37 ± −0. Winding temperature should be raised gradually at a rate of 10 °C (50 °F) per hour up to 85 °C (185 °F). This decision should be based on the following factors: Place the entire generator inside a forced air drying oven for four hours at 65 °C (149 °F). If the performance of the gas pressure regulator is erratic. refer to Special Instruction. SEHS9124. “Generator Isolating for Maintenance” for information regarding the procedure to safely isolate the generator. DO NOT APPLY HEAT TOO RAPIDLY. This will help circulate air. Monitor the winding temperatures. Preferably.1 to 0. Refer to Safety Section.2 kPa (4 to 4. The insulation resistance will then start to increase at a slow rate until the insulation resistance reaches a constant level.50 to 1 inches of H2O). The following methods can be used for drying a generator: Natural Gas Set the pressure of the fuel supply to a maximum of 1 to 1. the insulation resistance will slowly drop while the temperature is rising. the fuel pressure will usually decrease by approximately 0. Obtain the measurement when the engine is operating at high idle rpm. “Cleaning and Drying of Electric Set Generators”. i01730803 • Self-circulating air method • Oven method • Controlled current method Generator . The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment. this opening will be located at the fan end. Oven Method Personal injury or death can result from improper troubleshooting and repair procedures. Measure insulation resistance at one hour intervals. the vaporizer/regulator will regulate the fuel supply pressure at the correct level. No adjustment is required. If the insulation resistance values are less than the recommended values.25 kPa (0. Remove the voltage regulator.104 Maintenance Section Generator . Cover all of the inlet openings. After a load is applied. Note: If the engine is equipped with a vaporizer/regulator for liquid propane fuel supply.06 kPa (−1.5 ±0.5 inches of H2O) HIGHER than the ambient air pressure. Provide an opening at the top of the machine. Propane Set the pressure of the fuel supply to −0. Cover all of the discharge holes. NOTICE Use a forced air type oven rather than a radiant type oven.Dry SMCS Code: 4450-569 Self-Circulating Air Method Disconnect the generator load and run the engine. An electrical imbalance can result in an electrical overload and an electrical imbalance can result in overheating. Repeat the above steps until the insulation resistance is acceptable. 6. Gradually increase the engine RPM. stop the drying procedure. On an hourly basis. Power factor is used to mean the portion of current that is supplied to a system that is doing useful work. .Check Heat can be used in order to dry the generator windings. “T2”. Connect the rheostat. Connect the external power source to wires “F1+” and “F2-”. insulation breakdown will not occur. Refer to the above diagram. This current (reactive load) can be maintained without engine power. This heat can be created by allowing a controlled current to flow through the generator. Disconnect the generator load. 5. 4. The currents can then be added. Increase the engine RPM until one of the following conditions are met: • The rated phase current is obtained. The portion of the current that is not doing useful work is absorbed in maintaining the magnetic field in motors. This allows the generator to work at the rated capacity. 7. This can be expressed as the ratio of kVA to actual kW. Disconnect “F2-” from the voltage regulator. The power factor can be referred to as the efficiency of the load. Monitor the phase current. Connect the generator output leads “T0”. Adjust the rheostat to the maximum resistance value. Low idle will be approximately 66 percent of the full speed that is achieved by 60 Hz units. “T1”. Start the generator set. Electric sets normally have a low idle setting that is higher than industrial engines. ensure that the total current in any one phase does not exceed the nameplate rating. Power factor is expressed as a decimal. 1. Each phase should carry the same load. The power factor can be calculated by dividing kW by kVA. Note: When the line current is measured on multiple-lead units. • The full generator set speed is obtained. Illustration 86 Generator Wiring Diagram (CR1-CR6) Diodes (CR7) Varistor (L1) Exciter field (stator) (L2) Exciter armature (rotor) (L3) Main field (rotor) (L4) Main armature (stator) (L5) Pilot exciter armature (PM) Permanent magnet (RFA) Rotating field assembly (CST) Customer supplied transformer g00669571 When a generator is installed or when a generator is reconnected.SEBU6682-08 105 Maintenance Section Generator Load . an electrical imbalance will occur. Install the clamp-on ammeter to generator output lead “T1”.Check SMCS Code: 4450-535-LA During normal operation. Disconnect “F1+” from the voltage regulator. slowly turn the rheostat until the rated phase current is reached. Make an external power source. monitor the power factor and monitor generator loading. Run the generator set at idle speed. This would be equal to 80 percent of the full speed that is achieved by 50 Hz units. Therefore. Refer to the above diagram. If one phase current exceeds the nameplate amperage. Check the insulation resistance. No high voltages are generated during the following procedure. If more phase current is still necessary. i01473721 Generator Load . and “T3”. 2. 3. measure the current in each conductor per phase. Test SEBU6682-08 Some electric sets are equipped with Woodward governors and some electric sets are equipped with Caterpillar electronic governors. and “T3” and “T1”. These electric sets have no low idle stop. • The phase voltages are balanced. 3. Adjustment of the low idle on these machines should only be done by a Caterpillar dealer. Note: Operating the electric set at low idle speed for an extended time will cause some voltage regulators to shut off. This will allow the voltage regulator to again produce an output. Disconnect the generator from the load. high voltage and current are present. On electric sets with mechanical governors and natural gas electric sets. Stop the generator. Personal injury or death can result from high voltage. the low idle is set at the factory. i01473730 Table 26 Tools Needed Part Number 6V-7070 Part Digital Multimeter 12 VDC battery Potential Transformer Quantity 1 1 1 The generator set functional test is a simplified test that can be performed in order to determine if the generator is functional. . Operate the generator set at half the rated speed. The generator set functional test consists of the following steps: 1. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. Connect a 12 VDC automotive battery to wires “F1+” and “F2-”. “T2” and “T3”. • Make sure all capacitors are discharged. and either locked out or tagged DO NOT OPERATE. Higher speeds under these test conditions can cause damage to the system. The generator set functional test should be performed on a generator set that is under load. Connect the potential transformer’s high voltage winding to the generator terminals (T1) and (T2). • Make sure the generator engine is stopped. Improper test equipment can fail and present a high voltage shock hazard to its user. 4. Disconnect wires “F1+” and “F2-” from the voltage regulator. Connect the voltmeter to the low voltage winding. 2. If two transformers are available. • Make sure the unit is off-line (disconnected from utility and/or other generators power service). NOTICE Do not operate the generator set at a speed that is higher than one-half of the rated speed. 5. connect the high voltage winding of the second transformer to the generator terminals (T1) and (T3). When servicing or repairing electric power generation equipment: • The phase voltages change relative to engine speed. Record the voltages.106 Maintenance Section Generator Set . • Make sure all batteries are disconnected. Connect the secondary terminals that correspond to generator terminal (T2) of both transformers together. When power generation equipment must be in operation to make tests and/or adjustments.Test SMCS Code: 4450-081 • A phase voltage is being generated. The electric set must be completely shut down and the electric set must be restarted. Measure the AC voltage across the low voltage terminals of the transformer that correspond to the following generator terminals: “T1” and “T2”. The generator set functional test determines if the following statements happen: Generator Set . This vibration plot should be updated yearly. Decrease the generator set speed by 10 percent.Change” topic. Inspect the hose connections for leaks. Ignition System Spark Plug Wires . Remove the used hoses and clamps. the voltages that were measured in Step 6 should increase by 10 percent. Install new hoses and clamps. Monitor the voltage between any two of the locations in step 5. see the literature that is provided by the OEM of the governor. 7. When the generator set speed is decreased by 10 percent.Replace (Standard Ignition Systems) SMCS Code: 1558-510 Ignition systems can cause electrical shocks. Discard the items. . Drain the cooling system. “Cooling System Coolant (NGEC) . For service information. The vibration plot should also be updated when the generator set is moved. “Linear Vibration” for the allowable limits of vibration. 1. i01042052 • Loose fittings • Loose belts • Excessive noise • Cracked insulation The following areas are susceptible to vibration damage: • Stator output leads • Protective sleeving • Insulation • Exposed electrical connections • Transformers • Fuses • Capacitors • Lightning arresters When a generator set is installed a vibration plot should be recorded in order to assist in diagnosing potential problems.Inspect SMCS Code: 1264-040 Inspect the governor for oil leaks. “Torque Specifications”. 3. see this Operation and Maintenance Manual. 2. i01041704 Governor . Fill the cooling system. 5. i02211917 Contact the Caterpillar Dealer Service Tools group for information on ordering a vibration analyzer that will meet your needs. Refer to Data Sheet. The voltages that were measured in Step 5 should be nearly equal. 4. When the generator set speed is increased by 10 percent. i02523792 Generator Set Vibration Inspect SMCS Code: 4450-040-VI Check for vibration damage. Increase the generator set speed by 10 percent. see the Specifications. 8. Vibration may cause the following problems: Hoses and Clamps . These voltages should measure a minimum of 85 VAC. “Hose Clamps” topic.SEBU6682-08 107 Maintenance Section Generator Set Vibration . For the correct torque to use on the hose clamps.Inspect 6. LEKQ4023. SENR3130.Replace SMCS Code: 1380-510 Note: For instructions on draining the cooling system and filling the cooling system. Avoid contacting the ignition system components and wiring during operation. Start the engine. the voltages that were measured in Step 6 should decrease by 10 percent. 3. Pressurized air can cause personal injury.Check/Adjust/Replace SEBU6682-08 NOTICE Pulling on the wiring harness may break the wires. 3. After the spark plug has been loosened. 4. After the spark plug has been removed. 2. protective clothing. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. Do not pull on the wiring harness. Remove boot (3) and the extension. Maintenance of the ignition system is also affected by voltage. Thoroughly remove any debris. Disconnect the wire assembly from the spark plug. remove the spark plug by hand in order to detect problems with the threads. Removing the Spark Plug Altronic Ignition System Note: The Altronic ignition system has a transformer which is mounted separately from the spark plug. and protective shoes. A nonmetallic brush can also be used. The wire may break if you pull on the wire. . Higher voltage reduces the service life of components such as spark plugs. Maintenance of the spark plugs is required in order to achieve the following benefits: NOTICE Pulling on the wiring harness may break the wires. Use compressed air. 1. Discard the wire assembly. discard the used spark plug gasket. wires. and transformers. Disconnect wire (1) from transformer assembly (2). 2. Higher voltage is required by higher inlet manifold air pressure and a higher compression ratio. 1. Ensure that the area around the spark plug is clean and free of dirt and debris. 4. wear a protective face shield. i01617983 Ignition System Spark Plugs Check/Adjust/Replace SMCS Code: 1555-535 Illustration 87 (1) (2) (3) (4) (5) Wire for the secondary circuit Transformer assembly Boot Seal Spark plug g00837559 There is a strong electrical shock hazard when the crankshaft is rotating. Use a deep well socket with an extension in order to remove spark plug (5). Disconnect the spark plug wire assembly from the transformer.108 Maintenance Section Ignition System Spark Plugs . Do not pull on the wiring harness. The maximum air pressure for cleaning purposes must be below 207 kPa (30 psi). Connect the new wire assembly to the spark plug. • Normal fuel consumption • Normal level of emissions • Maximum service life of the spark plugs The service life of the spark plugs is affected by fouling due to deposits from the oil and by peak voltage. Connect the wire assembly to the transformer. When pressurized air is used for cleaning. If the spark plug cannot be removed by hand. NOTICE Do not use a thread tap. Fairbanks Morse Ignition System Illustration 88 (1) (2) (3) (4) (5) Wiring harness Boot Transformer Spacer Spark plug g00798357 Note: The Fairbanks Morse ignition system has an integral transformer that screws directly onto the spark plug. If the spark plug cannot be removed by hand. clean the internal threads with the 9U-7511 Spark Plug Seat Cleaner. A thread tap will remove metal unnecessarily. This tool scrapes debris from the seat and from the threads in the cylinder head. The maximum air pressure for cleaning purposes must be below 207 kPa (30 psi). To help the oil penetrate the threads. . use the wrench and turn the spark plug back and forth until the spark plug is loose.Check/Adjust/Replace If the spark plug resists removal by hand. After the spark plug has been removed. CSA Ignition System (Altronic) Note: The CSA ignition system is equipped with an integral transformer. To help the oil penetrate the threads. 4. discard the used spark plug gasket. apply penetrating oil to the threads. After the spark plug has been loosened. The transformer and the spark plug are installed separately. Remove boot (2). The threads could be stripped and the spark plug adapter could be damaged. 1. use the wrench and turn the spark plug back and forth until the spark plug is loose. The transformer screws onto the spark plug. NOTICE Do not use a thread tap. Use a deep well socket with an extension in order to remove spark plug (5). Pressurized air can cause personal injury. and protective shoes. wear a protective face shield. If the spark plug resists removal by hand. Ensure that the area around the spark plug is clean and free of dirt and debris. When pressurized air is used for cleaning. 5. The transformer and the spark plug are removed as an assembly. Be sure to clean any debris from the cylinder. 3. The transformer and the spark plug are removed separately. Unscrew transformer (3) from spark plug (5) in order to remove the transformer. A nonmetallic brush can also be used. apply penetrating oil to the threads. Unscrew wiring harness (1) from the threaded connector. 2. Thoroughly remove any debris. protective clothing. The threads could be stripped and the spark plug adapter could be damaged. Use compressed air. clean the internal threads with the 9U-7511 Spark Plug Seat Cleaner. Be sure to clean any debris from the cylinder. remove the spark plug by hand in order to detect problems with the threads. This tool scrapes debris from the seat and from the threads in the cylinder head.SEBU6682-08 109 Maintenance Section Ignition System Spark Plugs . A thread tap will remove metal unnecessarily. Note: Ensure that you keep copper spacer (4) that is installed between the end of the transformer and the top of the hex on the spark plug. 110 Maintenance Section Ignition System Spark Plugs . Illustration 91 g00829527 Section view and bottom view of a spark plug with two ground straps Inspect the spark plug closely for damage. The conductor will develop a corona when a very high voltage potential ionizes the air. If a crack is found. This material will gradually erode. discard the spark plug. Faint marks may extend from shell (3) onto the insulator. Cracks can be caused by overtightening the spark plug. Note: Ensure that you keep copper spacer (5) that is installed between the end of the transformer and the top of the hex on the spark plug. Inspecting the Spark Plug Note: Some spark plugs have electrodes with a single ground strap. Inspect insulator (2) for cracks. . Use extreme care when you set the electrode gap. Remove the spark plug from the transformer. This is a normal condition. Discard any spark plug that has a shell that is cracked or loose. 2. The condition of the spark plug can indicate the operating condition of the engine. Remove transformer (3) and spark plug (4) as a unit. Some spark plugs have electrodes with two ground straps. Replace the spark plug if the precious metal is worn off. Overtightening can also loosen the shell. 4. Maintain even spacing and proper alignment between the precious metal surfaces.Check/Adjust/Replace SEBU6682-08 Illustration 90 Typical spark plug with a single ground strap (1) (2) (3) (4) (5) Terminal post Insulator Shell Gasket Electrode g00830138 Illustration 89 (1) (2) (3) (4) (5) Wiring harness Boot Transformer Spark plug Spacer g00837582 1. 3. This is not an indication of leakage between the shell and the insulator. Disconnect wiring harness (1). Remove boot (2). Inspect shell (3) for damage. Caterpillar spark plugs have precious metal tips on the ends of the electrodes. The marks may be a result of a corona that forms at the top of the shell. 28 mm (0. if necessary.38 mm (0. Checking the Spark Plug After the spark plug is clean.Check/Adjust/Replace A light brown deposit or a beige deposit is produced by normal operation.SEBU6682-08 111 Maintenance Section Ignition System Spark Plugs . This will loosen the seal that is between the shell and the insulator. Most of the heat is transferred through the threads and the seat area of the spark plug. Measure the electrode gap after the alignment. Glass beads are the preferred method for cleaning. Do not use a wire brush. adjust the electrode gap to 0. Follow these guidelines for using glass beads: Altronic Ignition System • Always use clean glass beads. Adjust the electrode gap by bending the ground electrode at the existing bend. Install a new gasket. .011 inch). • Excessive oil • Use of the wrong oil • A substance that is introduced through the fuel system or the air system A spark plug can operate despite a buildup of ash. If a gasket for a spark plug is installed incorrectly. The shell can be cracked and the gasket can be deformed. The metal can deform and the gasket can be damaged. Orient the tabs of the gasket toward the combustion chamber. Ensure that the spark plug is clean and free of dirt and oil. • Use care in order to clean only the electrode and the insulator near the electrode. A feeler gauge will incorrectly measure the actual electrode gap because the used precious metal tips are curved. This can lead to uncontrollable detonation. the gasket may not seat properly. Serious damage to the engine can occur. Large deposits may retain heat which can cause premature fuel ignition. Do not reuse the gasket. Then bend the strap near the weld in order to achieve proper alignment and even spacing between the two precious metal surfaces. Cleaning the Spark Plug Thoroughly clean the spark plug. The surfaces must be in contact in order to provide the heat transfer that is required. Always use a new gasket when a spark plug is installed. The shell can be stretched. adjust the spark plug gap to 0. Use the proper torque. a buildup of ash can cover the electrode gap. For stoichiometric engines.015 inch). Note: Use the 9U-7516 Spark Plug Gauge to measure the electrode gap. • Do not use glass beads on the outside of the shell or on the upper part of the insulator. do not increase the torque on the spark plug in order to improve the seal. allowing combustion pressure to blow past the seal. Deposits that are gray or black may be caused by the following substances: Installing the Spark Plug Note: Do not use anti-seize compound on spark plugs. For low emission engines. measure the spark plug’s electrode gap. Do not use a flat feeler gauge for measuring the electrode gap of used spark plugs. Illustration 92 (1) (2) (3) (4) (5) Wire for the secondary circuit Transformer assembly Boot Seal Spark plug g00837559 NOTICE Do not overtighten the spark plug. Correct the electrode gap. This will cause misfire. However. Otherwise. tighten the spark plug to 30 ± 4 N·m (22 ± 3 lb ft).112 Maintenance Section Ignition System Spark Plugs . If the components are in good condition. 2. 2. If the components are in good condition. boot (3). If a component is not in good condition. For spark plugs with a single ground strap. install the components. Install spark plug (4) and transformer (3) as a unit.Check/Adjust/Replace SEBU6682-08 1. If the components are in good condition. Install spark plug (5) by hand until the spark plug bottoms out. For spark plugs with two ground straps. Tighten the spark plug to 47 ± 3 N·m (35 ± 2 lb ft). 2. tighten the spark plug to 25 ± 5 N·m (18 ± 4 lb ft). install the components. install new components. tighten the spark plug to 30 ± 4 N·m (22 ± 3 lb ft). 3. replace the old component with a new component. For spark plugs with a single ground strap. tighten the spark plug to 30 ± 4 N·m (22 ± 3 lb ft). Inspect boot (2) and wiring harness (1). replace the old component with a new component. If a component is not in good condition. Place spacer (5) on top of the spark plug’s hex. Inspect seal (4). Inspect boot (2) and wiring harness(1). install the components. Place spacer (4) on top of the spark plug’s hex. Then tighten the transformer for an additional one-eighth turn (45 degrees). Screw transformer (3) onto spark plug (5) until the transformer is finger tight. If the components are not in good condition. For spark plugs with two ground straps. Install spark plug (5) by hand until the spark plug bottoms out. . For spark plugs with a single ground strap. Fairbanks Morse Ignition System CSA Ignition System Illustration 94 (1) (2) (3) (4) (5) Wiring harness Boot Transformer Spark plug Spacer g00837582 Illustration 93 (1) (2) (3) (4) (5) Wiring harness Boot Transformer Spacer Spark plug g00798357 1. For spark plugs with two ground straps. and wire (1). tighten the spark plug to 25 ± 5 N·m (18 ± 4 lb ft). Install spark plug (4) into transformer (3). tighten the spark plug to 25 ± 5 N·m (18 ± 4 lb ft). 3. 1. Test SMCS Code: 1550-081 The transformers produce a voltage increase. Inspect the transformers for the following conditions. For good operation.Check/Adjust i01005974 i01113853 Ignition System Timing Check/Adjust SMCS Code: 1550-025. check the timing of the ignition system. Ensure that the components are in good condition. Consult your Caterpillar dealer for assistance. Test each transformer at both the side with high voltage and the side with low voltage. if necessary. “Systems Operation/Testing and Adjusting” module. 1071-040. repair the gauge or replace the gauge immediately. Instrument Panel . The optimum ignition timing for a gas engine varies according to several factors: Inlet Air System . If any of the conditions are found. Check the condition of all of the gauges. if necessary. “Disassembly and Assembly” module. Make repairs. “Specifications” module for the procedure. Adjust the timing. Consult your Caterpillar dealer for assistance.Inspect SMCS Code: 7451-040 Inspect the instrument panel for good condition. See the Service Manual. 1087-040 Inspect the components of the air inlet system for the following conditions: • Cracks • Leaks • Loose connections Inspect the following components: • Compression ratio of the engine • Inlet air temperature • Methane number of the gas For the proper timing. Consult your Caterpillar dealer for assistance.SEBU6682-08 113 Maintenance Section Ignition System Timing . Adjust the timing according to the Service Manual. see the Service Manual.Inspect SMCS Code: 1058-040. For information regarding removal and installation of the components. i01021379 Ignition System Transformer Resistance . i00682407 • Piping between the air cleaner and the turbocharger • Turbocharger • Piping between the turbocharger and the aftercooler • Aftercooler • Connection of the aftercooler to the air plenum • Connection of the air plenum to the cylinder head Ensure that all of the connections are secure. correct the condition: • Corrosion • Dirty insulator • Loose connections • Moisture • Open circuits • Short circuits Test the resistance of the transformers. see the Engine Performance publication for the engine. the connections must be clean and secure. Frequently monitor the following parameters during normal operation: • Fuel filter differential pressure • Inlet air restriction • Inlet manifold air temperature • Jacket water temperature . 1550-535 After maintenance has been performed on the ignition system. If a gauge is broken. Table 27 Space heaters must be used whenever the generator set is not under load. Using a space heater in this fashion is the only way to maintain insulation tester readings above one megohm.114 Maintenance Section Insulation . . Comparing the new data to the recorded data will establish the normal gauge readings for the engine. Also use space heaters if a test result was below 3 megohms. Discharge the capacitance of the windings. Insulation . Space heaters must also be used whenever salt is present or whenever high humidity is present. Inspect the installation. Test the generator set weekly. do not perform this insulation test. If moisture exists. Determine the equipment that will be tested by the insulation tester. 4. Previous insulation tester readings will also determine the frequency of this test. A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge. Place the engine control switch in the “OFF” position. Before performing any maintenance or repairs. 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. Disconnect the batteries or disable the starting system. for three months. Visually inspect the generator for moisture.Test SMCS Code: 4453-081. i01494696 • The generator set is operating in a humid environment. This area needs to be low in humidity and this area needs to have steady temperatures. Periodically. 4457-081. Test every twelve months (minimum). SEHS9124. 4470-081 • The generator set has not been run under load Recommended Periodic Insulation Tests The high voltage that is produced by an operating generator set can cause severe injury or death. Recommended Periodic Insulation Test Procedure Tools Needed Part Number 142-5055 9U-6003 Part Name Insulation Testing Gp Insulation Testing Gp Quantity 1 1 Personal injury or death can result from electrocution. Test every three months. The frequency of this test is determined by the generator’s environment. do not touch the instrument leads without first discharging them. 1. SEHS9124. To avoid electrocution. • The generator set is not protected from the elements in an enclosed area. For additional information. Attach “DO NOT OPERATE” tags to all starting controls. Use space heaters only when the generator is not running. • The generator set is installed in an enclosed area. Test the main stator windings with an insulation tester in the following situations: • The generator set is started for the first time. Dry the unit first. 3. Take the generator out of service. use an insulation tester to check the insulation resistance of the generator’s main stator winding. The megohmmeter is applying a high voltage to the circuit. Compare the new data to the data that was previously recorded. Refer to Special Instruction. 2. Lock out all switchgear and automatic transfer switches that are associated with the generator.Test SEBU6682-08 • Oil filter differential pressure • Oil pressure Record the data in a log. When finished testing also discharge the generator windings. ensure that the generator will not start. • The generator set is removed from storage. refer to Special Instruction. Test every three months. “Cleaning and Drying of Electric Set Generators”. 4454-081. “Cleaning and Drying of Electric Set Generators”. These two readings must be taken under similar conditions. d. Connect the insulation tester’s BLACK lead to “T0”. Disconnect the regulator sensing lead wires: “20”. The actual value of the resistance may vary greatly between generators. Connect the insulation tester’s RED lead to ground. Evaluate the readings. ____________________________ Engine Serial Number_________ Generator Serial Number_________ ________________________ . Observe the readings at 30 seconds. Therefore.Test 5. and “24”. e. This reading must be corrected for temperature. Remove voltage. If a 60 second resistance reading has a 50 percent reduction from the previous reading. Record temperature. For this reason. This will discharge the insulation tester’s leads. c. Record humidity. For units that are more than 600 volts. 9. 10. Use the 30/60 Time Resistance Method: a. 7.SEBU6682-08 115 Maintenance Section Insulation . Note: The results from the insulation resistance checks indicate when cleaning and/or repairing is becoming critical. Observe the readings at 60 seconds. For units that are 600 volts or less. f. 8. Generally. set the voltage to 1000 Volts. set the voltage to 500 Volts. the insulation may have absorbed too much moisture. Disconnect “T0” from ground. insulation resistance will vary greatly with temperature. Refer to Illustration 95. Apply voltage. Base this evaluation on the comparison between the 60 second resistance readings and the readings that were taken on previous dates. 6. Switch the insulation tester to the “OFF” position. “22”. the insulation’s condition must be evaluated. always test at the same temperature and humidity. 11. Record the 60 second reading. Disconnect the insulation tester’s leads. b. 116 Maintenance Section Insulation .Test SEBU6682-08 Illustration 95 g00633226 . The following definitions explain the terminology for the services that are performed during an overhaul: • An increase of oil consumption • An increase of crankcase blowby • A decrease and variation of cylinder compression The following changes in the three conditions normally require a scheduled overhaul: • A 300 percent increase in oil consumption • A 200 percent increase in crankcase blowby • A 20 percent loss of cylinder compression Note: These indications do not require an engine to be shut down for service. The crankshaft is measured for wear. These indications only mean that an engine should be scheduled for service in the near future. Monitor the engine as the engine accumulates service hours. In some cases. Major Overhaul Information A major overhaul includes all of the work that is done for top end overhauls. Alternatively. and components that wear are disassembled.Check SMCS Code: 1383-535 Jacket water heaters help to improve startability in ambient temperatures that are below 21 °C (70 °F). The crankshaft may require regrinding. For an ambient temperature of 0 °C (32 °F). A major overhaul includes additional parts and labor. the heater should maintain the jacket water temperature at approximately 32 °C (90 °F). The parts are cleaned and the parts are inspected. and cylinder compression. The cylinder liners may be worn so that polishing of the bore occurs. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications. Jacket Water Heater . Also. i02064343 Overhaul (Major) SMCS Code: 7595-020-MJ Scheduling a Major Overhaul The need for a major overhaul is determined by several factors. An increase in the levels of noise and vibration indicates that rotating parts require service. be aware of the following recommendations.SEBU6682-08 117 Maintenance Section Jacket Water Heater . If the engine operation is satisfactory. the parts are replaced. Your Caterpillar dealer can provide these services and components. the increased use of lube oil will dilute the wear metals. Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube oil. gaskets. seals. Note: The driven equipment may also require service when the engine is overhauled. an immediate overhaul is not a requirement. Additional parts and labor are required in order to completely rebuild the engine. all of the bearings. If you elect to perform an overhaul without the services of a Caterpillar dealer. Consult your Caterpillar dealer about scheduling a major overhaul. All installations that require automatic starting should have jacket water heaters.Check i01042517 • 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. If necessary. Check the operation of the jacket water heater. Other factors must also be considered for determining a major overhaul: • The service hours of the engine • The wear metal analysis of the lube oil . the crankshaft may be replaced with a Caterpillar replacement part. The engine does not require an overhaul if the engine is operating within acceptable limits for oil consumption. crankcase blowby. Refer to the literature that is provided by the OEM of the driven equipment. For the major overhaul. the engine is relocated for disassembly. “Index of Publications on Reusability or Salvage of Used Parts”. reconditioned. • Carburetor • Cylinder packs • Exhaust bypass • Gas regulator • Inlet air piping • Oil pump • Starting motor • Turbocharger • Water pumps Inspecting Components Inspect the following components according to the instructions that are in Caterpillar reusability publications. a CAT remanufactured part. replace the components. The replacement part may be a new part. or a used part. SEBF8029. Replacing of Components Note: The cylinder head may be rebuilt. • Alternator • Alternator and fan drive belts • Camshaft bearings • Connecting rod bearings • Crankshaft bearings • Crankshaft seals • Crankshaft vibration damper • Cylinder liners • Cylinder head and gaskets • Exhaust manifold • Gaskets and seals • Gear train bearings • Governor • Hoses and clamps • Aftercooler • Camshafts • Camshaft followers • Connecting rods • Crankshaft . Replace the following components during the major overhaul. refer to the Service Manual.118 Maintenance Section Overhaul (Major) SEBU6682-08 Inspect – Inspect the components according to the instructions that are in Caterpillar reusability publications. • Main bearings • Piston rings • Rod ends for the control linkage of the actuator • Spark plugs • Spark plug wires • Transformers • Valve rotators • Water temperature regulators • Wiring harnesses Rebuilding of Components Rebuild the following components during the major overhaul. “Specifications” module. Replace – The service life of the part is exhausted. SEBF8029. or repaired. Some worn components may be exchanged with your Caterpillar dealer. “Index of Publications on Reusability or Salvage of Used Parts”. New parts are not required if the existing parts can still be used. The part must be replaced with a part that meets functional specifications. a rebuilt part. Rebuild – The component can be reconditioned in order to comply with reusability guidelines. when possible. Consult your Caterpillar dealer about repair options for your engine. If the components cannot be rebuilt. Refer to Guidelines for Reusable Parts and Salvage Operations. The part may fail before the next maintenance interval. If the components are not in the reusability guidelines. The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. Refer to Guidelines for Reusable Parts and Salvage Operations. Refer to Guidelines for Reusable Parts and Salvage Operations. “Specifications” module. This measurement can be used to predict when a cylinder head requires replacement. New parts are not required if the existing parts can still be used. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications. “Valve Stem Projection Measure/Record” topic. Your Caterpillar dealer can provide these services and components.SEBU6682-08 119 Maintenance Section Overhaul (Top End) • Gears of the gear train • Gear train bushings • Governor • Inlet air piping • Oil cooler • Oil pump • Pistons • Transformers i02064373 Unexpected problems may be found during a top end overhaul. “Index of Publications on Reusability or Salvage of Used Parts”. be aware of the following recommendations. Note: The generator or the driven equipment may also require service when the engine overhaul is performed. refer to this Operation and Maintenance Manual. refer to the Service Manual. . Also. This measurement provides an accurate indication of the rate of valve wear. The following tools are needed for restoring the engine to factory specifications: • Torque wrenches • Dial indicators • Accurate measurement tools • Cleaning equipment • Rebuilding equipment Caterpillar dealers are equipped with these tools. If the components are not in the reusability guidelines. The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. Refer to Guidelines for Reusable Parts and Salvage Operations. some other engine components are inspected. Top End Overhaul Information A top end overhaul involves servicing the cylinder heads and turbochargers. Rebuild – The component can be reconditioned in order to comply with reusability guidelines. 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. • Buildup in the cylinders from excessive oil consumption fuel • Buildup in the cylinders from contamination of the • Plugging of the aftercooler from coolant that is poorly maintained the inlet air in the fuel • Plugging of the aftercooler from contamination of • Degradation of the oil cooler from hydrogen sulfide Inspect the following components according to the instructions that are in Caterpillar reusability publications. if necessary. For more information. SEBF8029. Top end overhauls require more tools than preventive maintenance. “Index of Publications on Reusability or Salvage of Used Parts”. Overhaul (Top End) SMCS Code: 7595-020-TE Scheduling a Top End Overhaul Top end overhauls are scheduled according to the recession of the exhaust valve stems. If you elect to perform an overhaul without the services of a Caterpillar dealer. or repaired. SEBF8029. reconditioned. Plan to correct these problems. Caterpillar dealers can provide a flat rate price for a top end overhaul. In these cases. 3. Some applications can operate longer before the turbocharger requires rebuilding. Back flush the core with cleaner. The replacement part may be a new part. a rebuilt part. Rinse the core thoroughly with clean water. the turbocharger may require rebuilding prior to the top end overhaul. NOTICE Do not use a high concentration of caustic cleaner to clean the core. when possible. Pressure test the components. Replace the components. 4. In a few applications. 1. Only experience can determine the actual need. Replace the following components during a top end overhaul. 5. For the procedure. refer to the Service Manual. NOTICE Do not use a high pressure spray for cleaning the fins of the core. Wash the core with hot. Refer to Application Guide. soapy water. if necessary: • Aftercooler core (if equipped) • Oil cooler core Note: It is difficult to clean the aftercooler core when maintenance is not performed. a CAT remanufactured part. 2. NEHS0526 or consult your Caterpillar dealer for more information. Replacing of Components Note: The cylinder head may be rebuilt. Consult your Caterpillar dealer about repair options for your engine.120 Maintenance Section Overhaul (Top End) SEBU6682-08 Replace – The service life of the part is exhausted. The part may fail before the next maintenance interval. . Remove the core. A high pressure spray can damage the surface of the fins and reduce the flow of air through the core. rebuilding the turbocharger normally occurs separately from rebuilding the cylinder heads. Turn the core upside-down in order to remove debris. Note: This procedure may be used for cleaning both the aftercooler core and the oil cooler core. Steam clean the core in order to remove any residue. Only use the recommended concentration of cleaner. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. An example is an application with loads that vary frequently. or a used part. • Alternator and fan drive belts • Cylinder heads and gaskets • Forward bearing of the fan drive • Hoses and clamps • Rod ends for the control linkage of the actuator • Spark plugs • Spark plug wires • Water temperature regulator Rebuilding of Components Rebuild the following components during a top end overhaul: • Carburetor • Gas regulator • Starting motor • Turbocharger • Water pumps Note: Periodic inspection of the turbocharger is recommended for determining when the turbocharger will require an overhaul. Some worn components may be exchanged with your Caterpillar dealer. The part must be replaced with a part that meets functional specifications. Flush the fins of the core. Remove any other trapped debris. Inspecting of Components Clean the following components. Caterpillar recommends the use of Hydrosolv liquid cleaner. “Disassembly and Assembly” module. Use a two to five percent concentration of the cleaner at temperatures up to 93 °C (200 °F). • Many original parts can be reused according to the guidelines for reusable parts. “Exhaust Bypass . An overhaul also includes the following maintenance: • Inspection of all the parts that are visible during the disassembly removed • Replacement of the seals and gaskets that are • Cleaning of the internal passages of the engine and the engine block Most owners will save money by overhauling the engine at the intervals that are recommended in this Operation and Maintenance Manual. Pressure test the core. Consult your Caterpillar dealer for assistance. The maximum differential pressure of air for the aftercooler is 5. The maximum differential pressure of water for the aftercooler is 44 kPa (6 psi). oil consumption. crankcase blowby. Governor Inspect the governor for proper operation. of extended service life. i02049051 Overhaul Considerations SMCS Code: 7595-043 Overhaul Information An overhaul is replacing the major worn components of the engine. An overhaul is a maintenance interval that is planned. Dry the core with compressed air. Inspect the transformers for the following conditions: Test the resistance of the transformers according to the Service Manual. It is not less costly to wait. Some other factors that are important for determining the overhaul intervals include the following considerations: • Dirty insulator • Loose connections • Loose connector • Moisture • Performance of preventive maintenance . Exhaust Bypass Inspect the condition of the exhaust bypass (if equipped). 6. Refer to this Operation and Maintenance Manual. Inspect the core in order to ensure cleanliness. Major overhauls are determined by cylinder compression. Make any repairs that are necessary. • Achieve the best cost/value relationship per hour Overhaul Intervals Top end overhauls are determined by the projection of exhaust valve stems. wear a protective face shield and protective clothing. It is not practical to wait until the engine exhibits symptoms of excessive wear or failure. • The service life of the engine can be extended without the risk of a major catastrophe due to engine failure.1 kPa (0.74 psi).SEBU6682-08 121 Maintenance Section Overhaul Considerations Personal injury can result from air pressure. If necessary. For more information on cleaning the cores. A planned overhaul before failure may be the best value for the following reasons: • Costly unplanned downtime can be avoided. Transformers The transformers produce a voltage increase. if necessary. For good operation. refer to the Service Manual. Note: The test pressure for the oil cooler is 790 kPa (115 psi). Recondition the component. consult your Caterpillar dealer. When using pressure air. and results of S·O·S oil analysis. repair the core. “Disassembly and Assembly” module. Many shops that service radiators are equipped to perform pressure tests. 8. the connections must be clean and secure.Inspect” topic (Maintenance Section). “Specifications” module. Direct the air in the reverse direction of the normal flow. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts. Personal injury can result without following proper procedure. Install the core. 7. For the procedure. Overhaul programs vary between dealers. The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program. New parts are not necessary if the old parts can be reused. Consult your Caterpillar dealer in order to schedule a before failure overhaul. To obtain specific information about the types of overhaul programs and services. Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar Engines. 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. i01216962 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. the parts should be salvaged. A scheduled overhaul will provide the lowest cost and the greatest value. These guidelines were developed in order to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts. “Index of Publications on Reusability or Salvage of Used Parts”. this is for engines that are properly adjusted. Overhaul Recommendation Caterpillar recommends a scheduled overhaul in order to minimize downtime. Generally. replaced. A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul.122 Maintenance Section Power Factor . If the engine parts comply with the established inspection specifications.Check SEBU6682-08 • Use of recommended lubricants • Use of recommended coolants • Use of recommended fuels • Proper installation • Operating conditions • Operation within acceptable limits • Engine load • Engine speed Note: To avoid oil problems. refer to Guidelines for Reusable Parts and Salvage Operations. operated and maintained. To determine the reusability publications that are needed to inspect the engine. These parts have been rebuilt by Caterpillar and certified for use. Your Caterpillar dealer may be offering a variety of overhaul options. However.Check SMCS Code: 4450-535-PWR The power factor of a system can be determined by a power factor meter or by calculations. or salvaged. Consult your Caterpillar dealer for assistance. If the parts are not within the inspection specifications. Power Factor . engines that are operated at a reduced load and/or speed achieve more service life before an overhaul. Caterpillar remanufactured parts are available at a fraction of the cost of new parts. Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost. Power factor is expressed as a decimal. Overhaul Programs An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar remanufactured parts. or exchanged. The following components are examples of the remanufactured parts: • Alternators • Connecting rods • Crankshafts • Cylinder heads • Oil Pumps • Starting motors • Turbochargers • Water pumps Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are available. repaired. The power factor can be calculated by dividing kW by kVA. the parts can be reused. repaired. consult your Caterpillar dealer. engines that are turbocharged and aftercooled must be operated at a minimum of 60 percent of rated load. Schedule an overhaul with your Caterpillar dealer. SEBF8029. . Pressurized air is the preferred method for removing loose debris. start the engine and accelerate the engine to high idle rpm. grease. For more detailed information on cleaning and inspection. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. Personal injury can result without following proper procedure. clamps. Use a light bulb behind the core in order to inspect the core for cleanliness. Install the speed sensor and adjust the speed sensor according to the engine’s Specifications module.Check SMCS Code: 4450-535-HTR An SR4B generator is capable of operating in high humidity conditions without problems. Moisture can form on the windings that will result in poor performance from the windings. and other debris. problems can occur when the generator is idle and the surrounding air is warmer than the generator. insects. air lines. Clean the metal shavings and other debris from the face of the magnet. Remove the speed sensor from the flywheel housing. dirt. i01511915 Personal injury can result from air pressure. Clean the core from both sides. Wash the core with detergent and hot water. Use a degreaser and steam for removal of oil and grease. if necessary. Inspect the fins for damage. Repeat the cleaning. leaves. This will remove debris that is between the tubes. ensure that the space heaters are in operation. if necessary. Check the condition of the end of the magnet. Hold the nozzle approximately 6 mm (0. Slowly move the air nozzle in a direction that is parallel with the tubes. 3.Clean SMCS Code: 1353-070 Note: Adjust the frequency of cleaning according to the effects of the operating environment. “Know Your Cooling System”. Thoroughly rinse the core with clean water. This will help in the removal of debris and drying of the core. Pressurized water may also be used for cleaning.SEBU6682-08 123 Maintenance Section Radiator . After cleaning. 1907-070 Illustration 96 Speed sensors g00784740 1. Check for signs of wear and contaminants. Moisture can also result in damage to the windings. Direct the air in the opposite direction of the fan’s air flow. Space Heater .Clean/Inspect SMCS Code: 1907-040. However. oil. if necessary. Inspect these items for good condition: welds. and seals. wear a protective face shield and protective clothing. . Clean both sides of the core. refer to Special Publication. Inspect the radiator for these items: damaged fins. mounting brackets. Use pressurized water in order to soften mud. The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). SEBD0518. 2. connections. Whenever the generator is not active. corrosion. Stop the engine. When using pressure air. Bent fins may be opened with a “comb”. Make repairs. Clean the radiator.Clean i01604510 i01218154 Radiator . Speed Sensor .25 inch) away from the fins. Maintenance of the standby generator set is very important for the following reasons: • The engine is stopped. and repairs. Moisture can condense on the windings. The maintenance that is recommended for the subsequent maintenance intervals must be performed by an authorized service technician or by your Caterpillar dealer. However. damage to the windings can occur. . Moisture causes damage to generators and other electrical equipment. perform maintenance and repairs under the following conditions: Standby Generator Set Maintenance Recommendations SMCS Code: 4450-041 A standby generator set may not need to be used very often. problems can occur when the generator is inactive. For the recommended generator maintenance. Lock out all switchgear and automatic transfer switches that are associated with the generator. Consult your Caterpillar dealer for details. The recommended maintenance for the engine is listed in this Operation and Maintenance Manual. Unless other instructions are provided. follow the instructions that are provided in this Operation and Maintenance Manual. Maintenance and Operation Procedures Space Heaters The high voltage that is produced by an operating generator set can cause severe injury or death. engine operation. see the Operation and Maintenance Manual for the generator set control panel. • The generator set must always be in excellent operating condition. “Operation Section”: starting the engine. For these operation procedures. Attach “DO NOT OPERATE” tags to all starting controls. maintenance that is performed. • The generator does not pose an electrical shock hazard. the generator set is usually needed for operation in an emergency situation. When the generator is operating. Generators can operate without problems in humid environments. ensure that the space heaters are operating. Before performing any maintenance or repairs. When the generator is not active. and stopping the engine. Record Keeping Maintain a record in order to document these items: gauge readings. Place the engine control switch in the “OFF” position. Use space heaters in order to help keep the windings dry. the generator set must be exercised regularly. problems. load at any time. • Maximum availability of the standby generator set • Longer service life for the generator set • Minimum of expensive repairs Your Caterpillar dealer can help you to establish an effective Preventive Maintenance Program for your generator set. Also. see the Operation and Maintenance Manual for the generator and the control panel. turn OFF the space heaters. However. “Maintenance Interval Schedule (Standby Generator Set Engines)” (Maintenance Section). Make every effort to keep the generator set as dry as possible. ensure that the generator will not start. This can result in poor performance. • The starting system is disabled. Disconnect the batteries or disable the starting system. • The generator set must be ready to work under Establishing a Preventive Maintenance Program will provide these benefits: Operation To ensure proper operation.124 Maintenance Section Standby Generator Set Maintenance Recommendations SEBU6682-08 i01038735 Maintenance and Repair The maintenance that is recommended for Every Week can be performed by an authorized operator. For instructions on operating the generator set. Check SMCS Code: 4459-535 Visually inspect the following areas for cracking and physical damage: • stator output leads • protective sleeving • insulation . can penetrate body tissue causing serious injury. The starting motor pinion and the flywheel ring gear must be in good condition in order for the engine to start properly. Always use a board or cardboard when checking for a leak.Inspect i01113939 Air Starting Motor Starting Motor . Inspect all of the components in the air circuit for the starting motor. Inspect the starting motor for proper operation. 1453-040 If the starting motor fails. Look for teeth that are broken or chipped. even a pin-hole size leak. Look for patterns of wear on the teeth. Consult your Caterpillar dealer for assistance. and possible death. the starting motor pinion and the flywheel ring gear must be replaced. Listen for grinding when the engine is started.Inspect SMCS Code: 1451-040. Escaping air or fluid under pressure. Inspect all of the air lines and connections for leaks. Electric Starting Motor Note: Problems with the electric starting motor can be caused by the following conditions: malfunction of the solenoid and malfunction of the electric starting system. If fluid is injected into your skin. if necessary. i01218172 • Loose connections • Corrosion • Wires that are worn or frayed • Cleanliness Make repairs. “Disassembly and Assembly” module for information on removing the starting motor and installing the starting motor. A scheduled inspection of the starting motor is recommended. If the teeth of the starting motor pinion and/or the flywheel ring gear are damaged. The engine will not start if the starting motor pinion does not engage the flywheel ring gear. Stator Lead . Inspect the teeth of the starting motor pinion and the flywheel ring gear. the engine may not start in an emergency situation.SEBU6682-08 125 Maintenance Section Starting Motor . it must be treated immediately by a doctor familiar with this type of injury. The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement. If damaged teeth are found. the air circuit for the starting motor must be examined in order to determine the cause of the problem. Personal injury or death can result from improperly checking for a leak. Inspect the electrical system for the following conditions: Removal and Installation of the Starting Motor Refer to the Service Manual. The assembly should turn freely. and the cylinder head. Turbocharger . Do not break deposits from the turbine wheel. the detectors are installed in the slots of the main armature (stator). The following conditions can cause the turbocharger to be out-of-balance: • The buildup of deposits • Chipping and/or flaking of deposits If the turbocharger must be removed for inspection. Inspect the turbine wheel for deposits. If the turbocharger fails during engine operation. Turn the compressor wheel and the turbine wheel by hand. If deposits of 25 mm (1/16 inch) thickness are found or if the turbine is in contact with the housing. NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems. If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing. Visually inspect the piping for the presence of oil. 2. When the temperature of the stator winding is suspected to be high. Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger. An inspection of the turbocharger can minimize unscheduled downtime. the chance for potential damage to other engine parts is reduced. 4. If the generator is furnished with Resistance Temperature Detectors.126 Maintenance Section Stator Winding Temperature . which causes the turbocharger to slobber. The presence of oil may be the result of extended engine operation at low idle. . the turbocharger should be reconditioned. do not continue engine operation until the turbocharger is repaired or replaced. i01012850 Note: Turbocharger components require clearances that are precise. Inspect the bore of the turbine housing for corrosion and deposits. The deposits can be very difficult to remove. Also. the valves. The detectors are used with equipment that is available from the factory. the turbocharger must be disassembled and cleaned. However.Measure/Record SEBU6682-08 i02514961 Stator Winding Temperature Measure/Record SMCS Code: 4453-082-TA Some generators are provided with optional 100 Ohm Resistance Temperature Detectors (RTD). Note: Deposits can accumulate on the turbine wheel. For options regarding removal. Check the compressor wheel for cleanliness. When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine rpm up at no load). If oil is found only on the back side of the wheel. repair and replacement. installation. damage to the turbocharger compressor wheel and/or to the engine may occur. If only the blade side of the wheel is dirty. there is a possibility of a failed turbocharger oil seal. see the Service Manual or consult your Caterpillar dealer. dirt and/or moisture is passing through the air filtering system. use caution. The presence of oil may also be the result of a restriction of the line for the inlet air (plugged air filters). Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder.Inspect SMCS Code: 1052-040 Periodic inspection and cleaning is recommended for the turbocharger. 3. Fouling of the turbine wheels can contribute to loss of engine power and overall loss of engine efficiency. Loss of engine lubricant can result in serious engine damage. Minor leakage of a turbocharger housing under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occurred. remove deposits from the housing. The turbocharger cartridge must be replaced when this occurs. This equipment is used in order to measure the main armature’s winding temperature. The turbine wheel will become unbalanced when the deposits flake off. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing. This can cause additional damage to the pistons. Do not attempt to clean the turbine wheel. The turbocharger cartridge must be balanced due to high rpm. Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing. 1. measure the temperature. This will prevent wear on the blades of the turbine wheel. 5. 2. i01360109 Valve Stem Projection Measure/Record SMCS Code: 1105-082 Valve Recession – The valves and the valve seats are worn over time. see the Service Manual. Obtain this measurement for each exhaust valve. The baseline is a reference for subsequent measurements. The exhaust valves and valve seats show the greatest wear due to high operating temperatures. If the clearances are not within the specifications. 8. Clean the turbocharger compressor housing with standard shop solvents and a soft bristle brush. Use the following method in order to determine the valve recession: 1. “Specifications”. “Disassembly and Assembly” module. the turbocharger must be repaired. Obtain the measurement from the tip of the valve stem to the cylinder head. Make several copies of this Operation and Maintenance Manual. Illustration 97 shows schedules for determining subsequent intervals. It is difficult to obtain an accurate measurement of valve recession inside the cylinder head. Record the measurements on the sheets. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.SEBU6682-08 127 Maintenance Section Valve Stem Projection . This causes the valves to recede into the cylinder head. Remove the valve cover. • The projection of the exhaust valve stems should be measured after completion of the initial start-up tests and the engine commissioning. The top end overhaul is normally scheduled according to the exhaust valve recession. 7. 3. Use a depth micrometer. rotators at the first oil change interval.Measure/Record 6. Compare the clearances to the Service Manual. This condition is called “valve recession”. Move the rocker arm from the top of the valve stem. “Valve Data Sheet” (Reference Materials Section). • Measure the projection of the exhaust valve . Check the clearances of the turbocharger bearing. This measurement is the baseline. For instructions. 218 mm (0. Do not allow the valve recession to exceed this limit.254 mm (0. The valve head can break.0100 inch) (2) 0.152 mm (0. • Plan for the top end overhaul as the valve . • After 70 percent of the maximum limit has been reached.Measure/Record SEBU6682-08 Illustration 97 (A) Schedule (B) Schedule (C) Schedule (Y) Valve recession in millimeters (inches) (X) Hours of operation (1) 0. For example. Another cylinder may have a valve recession of approximately 0. For Naturally aspirated engines. measure the projection of the exhaust valve stems at every 750 hours of operation (turbocharged engines). the next interval for measuring that cylinder is at 5000 service hours. use the point on the graph in Illustration 97 that is closest to the measurement for each cylinder. the next interval for measuring that cylinder is at 3000 service hours. According to Schedule (C). This will cause severe damage in the combustion chamber and the turbocharger.0060 inch) g00320513 To determine intervals. stem projection approaches the maximum limit.254 mm (0.128 Maintenance Section Valve Stem Projection . perform the measurement at every 1500 hours of operation.3 mm (0.0100 inch).09 inch). According to Schedule (A).0086 inch) (3) 0. Perform the top end overhaul when the valve stem projection has increased by a total of 2. Consult your Caterpillar dealer for assistance.152 mm (0.0060 inch). suppose that the measurement that was obtained at the initial oil change shows a valve recession of approximately 0. Observe the results. The lamp should not light.SEBU6682-08 129 Maintenance Section Varistor . costly repairs and accidents can be avoided. Place the test light across the varistor. the varistor is faulty. 3. verify that the strapping of the field winding lead is securely wound on the shaft. there is a short in the varistor.Test SMCS Code: 4466-081 Illustration 99 Test Light g00555113 Refer to the test light that is shown in Illustration 99. . 4.Test i01494879 Test Light Varistor . 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. Place an ohmmeter across the varistor. The lamp should not light. Disconnect either lead of the varistor (CR7). i01492446 Ohmmeter An ohmmeter can be used to check a varistor (CR7). Illustration 98 PMPE Generator Wiring Diagram (CR1-CR6) Diodes (CR7) Varistor (L1) Exciter field (stator) (L2) Exciter armature (rotor) (L3) Main field (rotor) (L4) Main armature (stator) (L5) Pilot exciter armature (PM) Permanent magnet (RFA) Rotating field assembly (CST) Customer supplied transformer g00677004 If the test light illuminates in either direction. verify that the strapping of the field winding lead is securely tied. 2. Also. Observe the results. The resistance should be a minimum of 15000 ohms. Walk-Around Inspection SMCS Code: 1000-040 Inspect the Engine for Leaks and for Loose Connections A walk-around inspection should only take a few minutes. Reverse the test light. Replace any faulty varistors with varistors that have comparable operating characteristics. 5. If the resistance is less than 15000 ohms. Follow these steps in order to test the varistor: 1. When the time is taken to perform these checks. 2. Use a gas detector. thoroughly inspect the engine room before starting the engine. the oil filters and the valve covers. “Disassembly and Assembly” module for the engine or consult your Caterpillar dealer. or fuel) clean up the fluid. NEVER use a flame to check for gas leaks. Replace any gauge that can not be calibrated. Look for leaks. Look for loose fuel line clamps. NOTICE Accumulated grease and/or oil on an engine or deck is a fire hazard. • Inspect the ground straps for good connections • Check the condition of the gauges. Use a gas detector. If leaking is suspected. Perform an inspection of the installation after the engine is started. check the fluid levels more often than recommended until the leak is found or fixed. • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires. “Before Starting Engine” topic (Operation Section). loose bolts. make repairs. NEVER use a flame to check for gas leaks. operating at low idle rpm. Check for leaks. • Inspect the exhaust system for leaks. 3. and for good condition. refer to the Service Manual. For instructions on removal and installation of water pumps and/or seals. find the source and correct the leak. Look for items such as leaks. If leaking is suspected. If a leak is NOTICE For any type of leak. 1. • The guards must be in the proper place. as needed. lube. An open flame can ignite mixtures of air and fuel. or until the suspicion of a leak is proved to be unwarranted. This will cause explosion and/or fire which could result in severe personal injury or death. It is normal for a small amount of leakage to occur when the engine cools and the parts contract. loose connections and trash buildup. Observe the oil level on the “LOW IDLE” side of the oil level gauge (dipstick). the oil pan. Listen for unusual noises. An open flame can ignite mixtures of air and fuel. find the source and correct the leak. Make repairs. If leaking is observed. If leaking is observed. • Check the engine oil level when the engine is • Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps. Replace any • Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination. found. NOTICE For any type of leak (coolant. Start the engine according to the instructions in this Operation and Maintenance Manual. • Check the fuel system for leaks.130 Maintenance Section Walk-Around Inspection SEBU6682-08 For maximum engine service life. gauge that is damaged. the rear crankshaft seal. i01041757 Walk-Around Inspection (Exercise Inspection of Standby Generator Set Engines) SMCS Code: 1000-040 • Ensure that cooling lines are properly clamped. . Check the condition of all pipes. “Engine Starting” topic (Operation Section). or until the suspicion of a leak is proved to be unwarranted. • Inspect the lubrication system for leaks at the front crankshaft seal. This will cause explosion and/or fire which could result in severe personal injury or death. Remove this debris with steam cleaning or high pressure water. clean up the fluid. Excessive coolant leakage may indicate the need to replace the water pump seal. Note: The water pump seal is lubricated by coolant in the cooling system. • Inspect the water pumps for coolant leaks. Perform the procedures that are described in this Operation and Maintenance Manual. check the fluid levels more often than recommended until the leak is found or fixed. Repair damaged guards or replace missing guards. inspect the louvers for proper operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders.Inspect • Inspect the lubrication system for leaks at the oil pan. A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Consult your Caterpillar dealer for assistance. causing cylinder head damage. Excessive overheating could result in cracking of the cylinder head or a seizure of the pistons. i01023425 • Inspect the cooling system for leaks at the hose • Check the fuel system for leaks with a gas • Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps. see the Service Manual. Inspect the water pump for wear. the engine may overheat.Inspect SMCS Code: 1361-040 A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head. If the water temperature regulator is installed incorrectly.SEBU6682-08 131 Maintenance Section Water Pump . • Record the data for the performance of the 4. cracks. “Engine Stopping” topic (Operation Section). • Observe the gauges. a piston seizure or other potential damage to the engine. Replacing the water temperature regulators reduces the chances for unscheduled downtime. “Disassembly and Assembly” module. generator. drain the coolant from the cooling system to a level that is below the water temperature regulator housing. For the procedure to replace the water temperature regulators. Refer to the Service Manual for the disassembly and assembly procedure. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner. This is a recommended preventive maintenance practice. • Inspect the exhaust system for leaks. Record the engine oil pressure and the jacket water temperature. stop the engine according to this Operation and Maintenance Manual. . i00524084 Water Pump . Visually inspect the water pump for leaks. Never operate the engine without the water temperature regulators installed. Note: If only the water temperature regulators are replaced. detector. If leaking of the water pump seals is observed. 5. A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine. After exercising the generator set. • If the enclosure has louvers. This can form damaging acids. Ensure that the new water temperature regulator is installed in the original position. Ensure that the control switches are in the correct position for automatic starting of the generator set. See the Operation and Maintenance Manual for the generator and the control panel. NOTICE Failure to replace the water temperature regulators on a regularly scheduled basis could cause severe engine damage. a low temperature can allow moisture to condense in the oil. Ensure the correct readings for the engine rpm. connections. A water temperature regulator that fails in the closed position can cause excessive overheating. Refer to the Service Manual or consult your Caterpillar dealer if repair is needed or replacement is needed. Also. and the valve covers. Water Temperature Regulator Replace SMCS Code: 1355-510 Replace the water temperature regulators before the water temperature regulators fail. replace all of the water pump seals. the oil filter. 6. pin holes and proper operation. “After Stopping Engine” topic (Operation Section). Perform the procedures that are described in this Operation and Maintenance Manual. For a more precise resistance value. Disconnect the batteries or disable the starting system. a correct measurement can be performed only when the winding is at room temperature. (L3).132 Maintenance Section Winding . The winding that is being tested must be disconnected from the other components before the resistance can be measured. and (L5). Place the engine control switch in the “OFF” position. Refer to the generator arrangement that is in question.1 ohm Main armature (Stator) (L4) – less than 0. the winding is probably damaged. 4470-081 The high voltage that is produced by an operating generator set can cause severe injury or death.0 ohms Main Field (Rotor) (L3) – approximately 0. Exciter Field (Stator) (L1) – approximately 3. Note: The winding temperature affects the resistance. There should be no continuity between any winding and another winding. ensure that the generator will not start. (L2). The resistance of these windings will measure near 0 ohms. .75 ohms to 2. (L4). consult the Technical Marketing Information (TMI). 4454-081. Before performing any maintenance or repairs.0 ohms to 6.0 ohms Note: There should be no continuity between any winding and ground. and (L5). the winding resistance also decreases. the winding resistance also increases. If the measured value is not near the listed approximation. Measure the resistance of the following windings: (L1). 4457-081. Only one multimeter is necessary for this test.1 ohm Pilot Exciter Armature (L5) – less than 0.Test SMCS Code: 4453-081. Either of the multimeters that are shown will work. Lock out all switchgear and automatic transfer switches that are associated with the generator. The following resistance measurements are approximations. Attach “DO NOT OPERATE” tags to all starting controls. The following armature windings have very little resistance: (L2). Use a milliohmmeter to measure the resistance of the armature windings. (L4).Test SEBU6682-08 i01787397 Winding . When the winding temperature decreases. When the winding temperature increases. Exciter Armature (Rotor) (L2) – less than 0.1 ohm Illustration 100 PMPE Generator Wiring Diagram (CR1-CR6) Diodes (CR7) Varistor (L1) Exciter field (stator) (L2) Exciter armature (rotor) (L3) Main field (rotor) (L4) Main armature (stator) (L5) Pilot exciter armature (PM) Permanent magnet (RFA) Rotating field assembly (CST) Customer supplied transformer Table 28 g00677004 Tools Needed Part Number 6V-7070 146-4080 (1) Part(1) Digital Multimeter Digital Multimeter (RS232) Quantity 1 1 Use a multimeter in order to measure the resistance of field windings (L1) and (L3). Therefore.