Caterpillar Gas Generator G3516 ManualFull description
Generator Service and Preventive Maintenance Concept of Planned Maintenance Planned maintenance can be defined as performing service, maintenance, inspections and testing on a generator set on a pre-determined schedule. Each maintenance program should include inspections for the status listed below:
Calendar Cycle Schedule – Schedule – Depending Depending on manufacturer recommendations and applications, cycles can be divided into weekly, monthly, quarterly, semi-annual and annual requirements.
Operating Inspections – Inspections – Inspections Inspections to be performed on generator when operating. Critical operations can be monitored 100% of operating time. Non-criti cal operations can have basic checks performed as determined by application.
Layup – Layup – Generator Generator are placed in layup when no longer l onger in active use. Basic outline outli ne of steps for generator layup.
Visual Checks
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 120°F (50°C) before removing pressure cap. Heated coolant spray or steam can cause injury. All planned maintenance charts define checks to be completed at a calendar interval. interval. Coolant, lubricating oil and coolant levels can be at normal levels, but can be contaminated (Figure 2). When performing normal maintenance inspections look for the following:
Air Restriction Indicator Indicator – – Indicates Indicates when air restriction to intake is greater than manufacturer specifications. Red in color means change air filter (scheduled or not). Generally indictor located on air filter housing. Can be reset after filter change.
Fuel Water Separator – Separator – This This filter separates water from fuel contami nated with water. Water is routed to bottom bowl and can drain via valve. Thi s can indicate main fuel source supply is contaminated.
Water Indicating Paste – Paste – Used Used to test main fuel supply. Spread on tank level stick. Pink in color with no water. Turns red when fuel is contaminated with water. Generally water at the lower section of tank.
Oil in Coolant – Coolant – Oil Oil floating on the coolant when cooling system is at ambient temperature. Can appear milky after engine operation. Engine lubricating oil leak into cooling system. Can be cylinder head gasket, defective engine block or cylinder head. Defect is where oil pressure is higher than coolant pressure.
Coolant in Oil – Oil – Oil Oil has milky color on dipstick. Coolant leak into engine lubricating oil. Can be cylinder head gasket, defective engine block or cylinder head. Defect is where coolant pressure is higher than oil pressure.
Figure 2, Visual Inspections
Calendar Cycle Schedule All generator manufacturers publish maintenance schedules broken down by a calendar schedule. Standard Maintenance Schedule is illustrated in (Table 1):
Events Emergency standby generator systems should have at least two maintenance events per year performed. Examples listed below:
Load Bank Testing – Generator is placed under load for a period of time using an external load bank tester.
Confidence Test – Generator is placed under load for a period of time using facility as a load.
Fluid Analysis – Lubricating oil, coolant and fuel analysis performed by laboratory.
Always follow manufacturer’s guidelines when performing maintenance, inspections and testing.
Operating Inspections The application the generator is used in defines the inspections that need to be performed while in operation. Each application requires development of a different i nspection. Basic inspections are provided in (Table 2):
