Caterpillar G3516 - General Maintenance

Bearing (Ball) - Lubricate (Generator)

• Remove either the louver assembly or the rear plate from the rear of the generator housing.

• Remove the top grease pipe plug and remove the lower grease pipe plug.

• Install a grease fitting in the grease pipe.

• Grease the shielded ball bearings with 2S-3230 Bearing Lubricant (53.28 mL (1.8 ounces) to 59.20 mL (2.0 ounces)). Lubricate shielded ball bearings at 2000 hour intervals. Do not mix greases.

• Wipe off the excess grease. Remove the top grease fitting. Install the plug.

• Operate the generator for one hour. This will allow the grease to expand. The expanding grease will force the excess grease from the cavity. When the excess grease is forced from the cavity, the internal pressure will be reduced. The generator should continue to operate until the grease stops purging.

• Stop the engine. Install the plug in the bottom grease pipe. Wipe off the excess grease.

• Install the louver assembly or install the rear plate.

Engine Air Cleaner Element - Replace

• Release the fasteners for cover (1)

• Remove the cover and element (2).

• Cover air inlet (3) with tape in order to keep dirt out.

• Clean the inside of the cover and the body with a clean, dry cloth.

• Remove the tape for the air inlet. Install a new element or a clean element.

• Install the cover.

• If necessary, reset the air cleaner service indicator.

Replace the engine oil filters when any of the following conditions are met:

• • Every oil change

• • The engine oil filter differential pressure reaches 100 kPa (15 psi).

• • The engine oil filters have been used for 1000 operating hours.

Replacing the Engine Oil Filters With the Engine Stopped

• Connect a hose to drain (1). Place the other end of the hose into a suitable container in order to collect the oil.

• Open drain valve (2). Remove plug (3). Allow the oil to drain. Clean the plug and install the plug. Close the drain valve. Remove the hose from the drain.

• Remove bolts (4) and the washers in order to remove cover (5) and O-ring seal (6). Remove oil filter elements (7).

• Clean cover (5), O-ring seal (6), and the inside of the oil filter housing.

• Ensure that the new oil filter elements are in good condition. Install the new oil filter elements.

• Inspect O-ring seal (6). Ensure that the surfaces for the O-ring seal are clean. Install a new O-ring seal if the old O-ring seal is damaged or deteriorated.

• Install cover (5) and O-ring seal (6). Ensure that the cover’s retainer is properly seated.

• Start the engine. Check for oil leaks.

• Check the oil level on the “LOW IDLE” side of the oil level gauge. Maintain the oil level between the “ADD” and “FULL” marks on the “LOW IDLE” side of oil level gauge.

Replacing the Engine Oil Filters During Engine Operation

• Move the control valve to the “AUX RUN” position in order to change the main oil filter elements. Move the selector valve to the “MAIN RUN” position in order to change the auxiliary oil filter elements.

• Allow the oil pressure gauge for the oil filter that is being changed to reach a “ZERO” pressure reading.

• Perform Step 1 through Step 7 of “Replacing the Engine Oil Filters With the Engine Stopped”.

• Open the “FILL” valve for a minimum of five minutes in order to fill the new oil filter elements.

• Close the “FILL” valve. Rotate the control valve to the “RUN” position for the oil filter that was serviced.

Fumes Disposal Filter Element - Replace

• Remove three nuts and washers (1) in order to remove cover (2) from body (3).

• Remove element (4).

• Clean the inside of cover (2) and body (3).

• Install new element (4) into body (3).

• Place cover (2) in position and install three nuts and washers (1).

Generator - Dry

• Make an external power source.

• Refer to the above diagram. Disconnect “F1+” from the voltage regulator. Disconnect “F2-” from the voltage regulator. Disconnect the generator load. Connect the generator output leads “T0”, “T1”, “T2”, and “T3”. Install the clamp-on ammeter to generator output lead “T1”.

• Refer to the above diagram. Connect the rheostat. Adjust the rheostat to the maximum resistance value. Connect the external power source to wires “F1+” and “F2-”.

• Start the generator set. Run the generator set at idle speed.

• Monitor the phase current. Gradually increase the engine RPM. Increase the engine RPM until one of the following conditions are met: • The rated phase current is obtained. • The full generator set speed is obtained.

• If more phase current is still necessary, slowly turn the rheostat until the rated phase current is reached.

• On an hourly basis, stop the drying procedure. Check the insulation resistance. Repeat the above steps until the insulation resistance is acceptable.

Generator Set - Test

• Stop the generator. Remove the panels in order to allow access to the regulator and control terminal strips. Determine the part number for the regulator. Record the sensing voltage of the regulator. The sensing voltage is 120 V ± 3%, 240 V ± 3%, or 480 V ± 3%. If the multimeter has the capability, also record the frequency.

• Verify that the generator set is ready to start. Start the generator set and bring the generator set to rated speed. Measure the sensing voltage with the multimeter on terminals 20-22, 22-24, and 20-24. If these voltages match the sensing voltage of the regulator and if these voltages are nearly equal, then the output of the generator at the bus bar should be the correct value.

• If the voltages do not match the sensing voltage of the regulator, see the service manual for the regulator for further troubleshooting instructions.

Insulation - Test

• Take the generator out of service.

• Visually inspect the generator for moisture. If moisture exists, do not perform this insulation test. Dry the unit first. Refer to Special Instruction, SEHS9124, “Cleaning and Drying of Electric Set Generators”.

• Inspect the installation. Determine the equipment that will be tested by the insulation tester.

• Discharge the capacitance of the windings.

• Disconnect “T0” from ground.

• Disconnect the regulator sensing lead wires: “20”, “22”, and “24”.

• Connect the insulation tester’s RED lead to ground.

• Connect the insulation tester’s BLACK lead to “T0”.

• For units that are 600 volts or less, set the voltage to 500 Volts. For units that are more than 600 volts, set the voltage to 1000 Volts.

• Use the 30/60 Time Resistance Method: a. Apply voltage. b. Observe the readings at 30 seconds. Observe the readings at 60 seconds. c. Record the 60 second reading. This reading must be corrected for temperature. d. Record temperature. e. Record humidity. f. Remove voltage.

• Evaluate the readings. The actual value of the resistance may vary greatly between generators. For this reason, the insulation’s condition must be evaluated. Base this evaluation on the comparison between the 60 second resistance readings and the readings that were taken on previous dates. These two readings must be taken under similar conditions. If a 60 second resistance reading has a 50 percent reduction from the previous reading, the insulation may have absorbed too much moisture.

Rotating Rectifier - Test

• Set the digital multimeter on the diode range. Remove all leads from the rectifier block.

• To test the negative rectifier block, follow these steps:

• Place the red test lead on the negative “-” terminal. Place the black test lead on the following rectifier terminals: “AC1”(3), “AC2”(4), and “AC3”(5). All readings on the meter should be between 0.4 and 1.0.

• Place the black test lead on the negative “-” terminal. Place the red test lead on the following rectifier terminals: “AC1”(3), “AC2”(4), and “AC3”(5). In all cases, the meter should read “OL” (overload).

• To test the positive rectifier block, follow these steps:

• Place the red test lead on the positive “+” rectifier terminal. Place the black test lead on the following rectifier terminals: “AC1”(3), “AC2”(4), and “AC3”(5). In all cases, the meter should read “OL” (overload).

• Place the black test lead on the positive “+” rectifier terminal. Place the red test lead on the following rectifier terminals: “AC1”(3), “AC2”(4), and “AC3”(5). All readings on the meter should be between 0.4 and 1.0.

Space Heater - Check

• Stop the generator set.

• Remove the panels in order to allow access to the regulator and control terminal strips. Locate terminal strip “TS1”.

• For 240 V systems, use the multimeter to measure the voltage between terminal “H1” and terminal “H4”. If voltage is not present, disconnect the power source to terminal “H1” and terminal “H4”, and check for 3 to 12 ohms resistance. If there is no resistance, check the generator service manual for further information. For 120 V systems, use the multimeter to measure the voltage between terminal “H1” and terminal “H2”.

• If voltage is not present, disconnect the power source to terminal “H1”, terminal “H2”, terminal “H3”, and terminal “H4”, and check for 3 to 12 ohms resistance. If there is no resistance, check the generator service manual for further information.

Varistor - Test

• Disconnect either lead of the varistor (CR7).

• Place the test light across the varistor.

• Observe the results. The lamp should not light.

• Reverse the test light.

• Observe the results. The lamp should not light