Caterpillar G3516 - Weekly Maintenance

Air Inlet Filter - Check

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

• Slowly loosen filler plug (1) in order to release the pressure from the lubricator.

• Place a suitable container under bowl (2) and open drain valve (3) in order to drain the oil from the bowl.

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

• Dry the bowl. Inspect the bowl for cracks. If the bowl is cracked, replace the damaged bowl with a new bowl. Inspect the gasket. If the gasket is damaged, replace the gasket.

• Install the bowl.

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

• For instructions on filling the lubricator, see this Operation and Maintenance Manual, “Air Starting Motor Lubricator Oil Level - Check” topic.

Air Starting Motor Lubricator Oil Level - Check

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

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

• Remove filler plug (4). Pour oil into the lubricator bowl. Use nondetergent SAE 10W oil for temperatures that are greater than 0 °C (32 °F). Use air tool oil for temperatures that are below 0 °C (32 °F).

• Install filler plug (4).

Air Tank Moisture and Sediment - Drain

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

• Close the drain valve.

Bearing Temperature - Measure/Record

• Bearing temperature detectors are optional on all SR4B generators. These detectors are 100 ohm resistance temperature detectors.

• Bearing temperature detectors are used with equipment that has been provided by the customer in order to measure the bearing temperature.

• Bearing temperature detectors may help to prevent premature bearing failure.

Cooling System Coolant Level - Check

• Stop the engine. Allow the engine to cool.

• Remove the cooling system filler cap slowly in order to relieve any pressure. Pour the proper coolant mixture into the filler pipe.

• Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets are damaged, replace the old cooling system filler cap with a new cooling system filler cap. Install the cooling system filler cap.

• Start the engine. Inspect the cooling system for leaks.

Electrical Connections - Check the following devices for loose mounting or physical damage:

• Transformers

• Fuses

• Capacitors

• Lightning arrestors

• Check all lead wires and electrical connections for proper clearance.

Electrohydraulic System - Inspect the conditions of these items for the electrohydraulic system:

• Oil level

• Filter indicator

• Hoses, lines, connections, and components

Engine Air Cleaner Service Indicator - Inspect

• A service indicator may be mounted on the air cleaner element or in a remote location.

• Some engines may be equipped with a different service indicator.

• Observe the service indicator. Clean the air cleaner element or replace the element when any of the following conditions occur:

• • The yellow diaphragm enters the red zone.

• • The red piston locks in the visible position.

• • The air restriction reaches 3.75 kPa (15 inch of H2O).

Engine Air Precleaner - Clean

• Remove wing nut (1) and cover (2). Check for an accumulation of dirt and debris in body (3). Clean the body, if necessary.

• After cleaning the precleaner, install cover (2) and wing nut (1).

Engine Oil Level - Check

• Remove filler cap (2) in order to ensure that the crankcase pressure is equal to the atmospheric pressure. Excess pressure or a slight vacuum will affect engine oil level that is measured.

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

• If the engine is stopped, remove the engine oil level gauge. Observe the engine oil level on “ENGINE STOPPED WITH OIL COLD” side (3).

• If the engine is operating, reduce the engine speed to low idle. Remove the engine oil level gauge and observe the engine oil level on “ENGINE AT LOW IDLE WITH WARM OIL” side (4).

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

• If necessary, add engine oil. For the correct engine oil to use, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section). Do not fill the crankcase above the “FULL” mark on the engine oil level gauge. Clean the filler cap (2). Install the filler cap.

• Record the amount of engine oil that is added. For the next engine oil sample and analysis, include the total amount of engine oil that has been added since the previous oil change. This will help to provide the most accurate analysis.

Fuel System Fuel Filter Differential Pressure - Check

• A fuel filter differential pressure gauge must be installed in order to determine when the fuel filter requires service. This gauge and the fuel filter are supplied by the customer.

• A fuel filter differential pressure gauge indicates the difference in fuel pressure between the inlet side and the outlet side of the fuel filter. The differential pressure increases as the fuel filter becomes plugged.

• Operate the engine at the rated rpm and at the rated load. Check the fuel filter differential pressure. Service the fuel filter when the fuel filter differential pressure reaches 1.7 kPa (0.25 psi).

• For instructions, refer to Special Instruction, SEHS9298, “Installation and Maintenance of Gaseous Fuel Filters”. Consult your Caterpillar dealer for assistance.

Jacket Water Heater - Check

• Jacket water heaters help to improve startability in ambient temperatures that are below 21 °C (70 °F). All installations that require automatic starting should have jacket water heaters.

• Check the operation of the jacket water heater. For an ambient temperature of 0 °C (32 °F), the heater should maintain the jacket water temperature at approximately 32 °C (90 °F).

Power Factor - Check

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

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.

Stator Winding Temperature - Measure/Record

• Some SR4B generators are provided with optional 100 Ohm Resistance Temperature Detectors (RTD). When the temperature of the stator winding is suspected to be high, measure the temperature

• If the generator is furnished with Resistance Temperature Detectors, the detectors are installed in the slots of the main armature (stator). The detectors are used with equipment that is available from the factory. This equipment is used in order to measure the main armature’s winding temperature.

Voltage and Frequency - Check

• Check for proper voltage and frequency setting. Check for stability

• Refer to the generator set Serial Plate for correct voltage and frequency

Walk-Around Inspection

• A visual inspection should be initially directed at the areas that are most prone to damage and deterioration. The most prone areas to damage and deterioration are listed below:

• Ground insulation – Ground insulation is insulation that is intended to isolate components that are carrying current from components that are not

• Support insulation – Support insulation is usually made from one of the following items: a compressed lamination of fibrous materials, polyester, or felt pads that have been impregnated with various types of bonding agents.

• There are many different types of damage that can occur in these areas. Several of the different types of damage are listed below:

• Thermal aging – Thermal aging can cause the degradation of insulation or the deterioration of insulation. An examination of the coils may reveal that the insulation has expanded into the ventilation ducts. This is the result of a loss of bond which will cause the insulation material to separate. The insulation material could also separate from the conductors on the windings.

• Abrasion – The surfaces of coils and the surfaces of connectors may be damaged by abrasion. These surfaces may also be damaged by contamination from other sources. An example of these sources would be chemicals or abrasive substances.

• Cracking – Cracking of insulation may result from mechanical stress. The structure that is used to brace the stator winding will become loose if the problem is not corrected. Further mechanical