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Engine Protection Devices
Inspect for Proper Operation
Refer to the Service Manual for the procedure. All engine protective devices must be checked and maintained to provide the engine with proper protection if a component malfunction or failure should occur. Check all engine protective devices. Never use the Emergency Shutdown controls for a normal stopping procedure.SR4 Generator and Control Panel (If Equipped)
SR4 Generator
Before working inside the generator, make sure that the starting motor can not be activated by any automatic or manual signal.When the engine-generator is operating, voltages up to 600V are present in these areas near or on the regulator: 1. the regulator terminal strip2. the excitation transformer terminal strip (self-excited generator only)Do not short these terminals to ground with any part of the body or any conductive material. Loss of life or injury could result from electrical shock or injury from molten metal.
Electronic components in the regulator can be damaged during generator operation if contact is made between the part and ground.
Clean/Inspect Voltage Regulator
If moisture is allowed to remain in contact with an electrical winding, some of the moisture will eventually be absorbed. This will lower the resistance of the winding insulation. The insulation used on the windings of Caterpillar generators is moisture resistant, but constant exposure to moisture will gradually lower the insulation's resistance.Dirt can make the problem worse because it can hold the moisture in contact with the insulation. Salt (from coastal location sea air) can also make the problem much worse. This is because salt tends to absorb moisture from the air. When the salt and moisture combine, they make a good electrical conductor.* Clean the voltage regulator and generator of dirt and debris. Use a brush to loosen accumulations of dirt and a vacuum system for removal. Use of compressed air is not recommended, because of moisture present in the form of condensate.Carbon tracking on insulators can be caused by dirt or loose connections. These carbon paths must be cleaned or the insulators replaced. Failure to correct a carbon tracking problem will eventually result in a short in the electrical circuit.* Visually check for loose or broken wires and connections. Check the wires and connections on the regulator assembly. Check all wires and connections in the generator. Make any necessary repairs to the wiring as required.Visually inspect the generator and control panel. Check for loose, broken, or damaged wiring or components. The inspection only takes a few minutes and could avert a potential problem that could cause your generator set to fail.Operational Checks
Start the engine. Use the starting procedure found in the SR4 Generators and Control Panels Operation and Maintenance Manual, SEBU6150.The following operational checks include: * generator operation and engine starting* lubricating and fuel systems* overall operationThe checks should take no longer than five minutes to complete. A more thorough Performance Analysis should be performed every 3000 Service Hours with the engine operating under load.While operating, frequently observe all readings, especially the engine oil pressure and the water temperature.Check and Record Readings from Frequency (rpm) and Generated Voltage
The operating voltage of a cold (just started) generator will be slightly higher than the operating voltage of a generator that has been under load and warm. The full load voltage of an SR4 Generator will decrease a maximum of one percent when this generator temperature stabilizes at 100°C (212°F).Most of the voltage decrease occurs in about 30 minutes. Generally, voltages stabilize within two hours.Recommended Periodic Insulation Resistance Checks
Use a megohmmeter to check generator winding insulation resistance periodically. The frequency of the megohmmeter test is determined by the generator's environment and by previous megohmmeter test indications.The megohmmeter test is described in Service Manual for SR4 Generators, SENR3985 or Special Instruction, SEHS9124, Cleaning and Drying of Caterpillar Electric Set Generators, or contact your Caterpillar dealer.Your Caterpillar dealer has the trained personnel and equipment to provide this service for you.The shutoff controls must be checked so that they function properly when they are required. To prevent damage to the engine while performing the test, only authorized personnel or your Caterpillar dealer should perform the checks.Control Panel
Check Gauges
Check the condition of all readings on the Control Panel. Check the condition of all gauges. Repair or replace any broken gauge before it becomes a problem.* Water Temperature - Check for proper operating coolant temperature. It should normally indicate between 79°C (175°F) and 98°C (208°F). Maximum allowable temperature is 99°C (210°F) with the cooling system pressurized. Somewhat higher temperatures may occur under certain conditions.* Oil Pressure - Check for proper operating oil pressure. The pressure will be greatest after starting a cold engine. Oil pressure will decrease as the engine warms while idling. As the engine speed is increased to full load speed, oil pressure will increase and stabilize. Minimum oil pressure is 240 kPa (35 psi) at rated speed. If oil pressure fails to rise within 15 seconds after the engine starts, stop the engine and make necessary repairs.* Fuel Pressure - Check for proper operating fuel pressure. Minimum fuel pressure is 140 kPa (20 psi) at rated speed.While operating, frequently observe all readings, especially the engine oil pressure and the water temperature.Automatic Operation
Check that all switches are in proper position for automatic start. Refer to the Engine Protection Devices section of this publication for additional information.Fuel Control Linkage
Check/Lubricate Linkages
Check and adjust if necessary, all fuel control linkages. Refer to the Service Manual for check/adjust procedure.
Fuel Control Linkage Grease FittingsLubricate the grease fittings on the fuel control linkage. Caterpillar recommends Multipurpose Lithium Grease, part no. 1P0808, suitable for light duty applications where a high temperature up to 175°C (350°F) is required.