CAT + Caterpillar 3208 Gen Set Engine Operation & Maintenance Manual by Heavy Equipment Manual

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual

CustomizedMaintenanceManagementProgram

YourauthorizedCaterpillardealercanassistyouintailoringthemaintenancemanagementschedules tomeettheneedsofyouroperatingenvironmentandeconomicgoalsthroughaCustomized MaintenanceManagement(CMM)Programconsistingofthefollowingitems:

MaintenanceScheduling

LetyourCaterpillardealerscheduleyourmaintenance,componentrepairs,andoverhaulsusingtheir computer.Agoodschedulingprogramhelpsensurethatserviceisperformedattherecommended intervalswhichhelpsminimizeunexpecteddowntimeandkeepsyouroperationrunningsmoothly.

Flat-RatedRepairs

Thecostofmostscheduledmaintenanceandrepairscanbepredetermined,allowingyoutoaccurately budgetfortheseexpenses.(Whenanengineisruntofailure,these"flatrate"or"firm"pricesare subjecttoadditionalchargesforfailedparts,cleaning,machining,etc.)

RepairOptions

YourCaterpillardealercanofferyouseveralchoicesformostmaintenanceandrepairneeds, includingthefollowingitems:

*GenuineCaterpillarReplacementComponents

*CaterpillarRemanufacturedComponents

*CaterpillarDealerExchangeComponents

*CaterpillarDealerRebuildUsingGenuineCaterpillarParts

Youmaybepleasantlysurprisedatyourdealer'spricesfortheseoptions,comparedtoyourowntotal coststodotherepairsyourself.

FinancialAnalysis

LetyourCaterpillardealershowyouthesavingsthatcanberealizedbyfollowingaCustomized MaintenanceManagementProgram.Acomputerprogramisusedtoshowyoufuel,oil,preventive

maintenance,componentrepair,andoverhaulcostsoverthelifeofyourengine.Thisallowsyouto moreeffectivelybudgetforyourtotalengineoperatingcost.

AskyourCaterpillardealerformoredetailsontheEngineInvestmentAnalysis(EIA)Program.

YourCaterpillardealerhasalltheelementsofacompletemaintenancemanagementprogramthatcan helpyoureduceengineoperatingcostsandrealizefullvaluefromyourinvestment.

MonJun2122:26:59UTC+05302021

Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual MAINTENANCEMANAGEMENTSCHEDULESFORRECOMMENDEDPREVENTIVE MediaNumber-SEBU6042-04PublicationDate-01/07/1997DateUpdated-11/10/2001

Foreword

TheobjectiveofthispublicationistoassistusersinestablishingaPreventiveMaintenanceProgram forStandbyGeneratorSetsorasanaidinevaluatingtheirpresentprograms.

StandbyGeneratorSetsmaynotbeneededveryoften,butwhentheyare,itisusuallyunder emergencyconditions.Maintenanceofthesestandbyunitsisveryimportant.Theymustalwaysbein excellentoperatingconditionandreadytoworkunderloadatanytime.

EstablishingaPreventiveMaintenanceProgramwillprovidemaximumavailabilityofastandby generatorsetwhenneeded,longerengineandgeneratorlife,andaminimumofexpensiverepairs.

TherecommendedWEEKLYmaintenancecheckscanbeperformedbyanoperator.AllYEARLY andTHREEYEARmaintenanceshouldbeperformedbyanauthorizedmechanicoryourCaterpillar dealer.

TheseguidelinesaretobeusedwiththeOperationandMaintenanceManualforyourengine.The OperationandMaintenanceManualwillprovidethenecessaryinformationonhowtoperformthe checksandroutinemaintenance.AdditionalinformationcanbeobtainedfromtheGeneratorand EngineServiceManuals,orcontactyourCaterpillardealerforassistance.

NOTICE

ThismanualisNOTtobeusedinplaceoftheOperationand MaintenanceManualforStandbyGeneratorSetEnginesthataresold strictlyforstandbyapplications.

However,thismanualisasupplementforIndustrialandGeneratorSet Enginesthatareoperatedinastandbygeneratorapplication.

YourCaterpillardealercanestablishanInspectionandPreventiveMaintenanceProgramforyour generatorsettoprovidemaximumreliability,increasedengineandgeneratorlife,andminimize expensiverepairs.ContactyourCaterpillardealerfordetails.

MonJun2122:26:17UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual

GeneralRecommendations

Safety

Alwaysmakerepairswiththeenginestoppedandthestartingsystemdisabled.Whenservicingthe generator,ensurethatswitchgearandautomatictransferswitcheswillnotpresentashockhazard. Lockthemoutonthegeneratorbeingserviced.

RecordKeeping

Maintainalogorrecordkeepingsystemtodocumentallgaugereadings,problems,repairs,and maintenanceperformedontheequipment.

SpaceHeaters

Moistureisanaturalenemyofgeneratorsandallelectricalequipment.Everyeffortmustbemadeto keepthegeneratorasdryaspossible.Spaceheatersshouldbeoperatedinsidethegeneratorwhenitis notinusetomaintaintheintegrityofthegeneratorwindings.Ifspaceheatersarenotprovidedwith generators,considerationshouldbegiventoaddingthem.

Thestop-manual-automaticswitchonthecrankingpanelmustbesetat "stop"positionwhenperformingmaintenanceorrepairworkona standbygeneratorset.Thispreventstheunitfromstartingifapower failureorvoltagedropshouldoccurwhileworkingontheunit.

Topreventpersonalinjuryduetoaccidentalstartingoftheengine, disconnectthebatteriesordisablethestartingsystembeforedoing maintenanceorrepairwork.

Lockoutallswitchgearandautomatictransferswitchesassociated withthegeneratorwhileperforminganygeneratormaintenanceor repairs.Ensurenoshockhazardexists.

This is the sample of the manual if you need complete manual Click Here to download

Failuretocomplycouldresultinpersonalinjuryordeath. ThemaintenanceschedulesincludedinthispublicationarealsoincludedintheOperationand Maintenance/OwnersManuals.RefertotheOperationandMaintenance/OwnersManualfor illustrationsandfurtherinformationtoaccomplisheachmaintenanceoperation.

MonJun2122:26:32UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual MAINTENANCEMANAGEMENTSCHEDULESFORRECOMMENDEDPREVENTIVE MediaNumber-SEBU6042-04PublicationDate-01/07/1997DateUpdated-11/10/2001

MaintenanceManagementScheduleTerminology

Check

Toobserveforsatisfactoryconditions,accuracy,safetyandperformance.

Inspect

Toexaminecloselyincriticalappraisalwhiletestingorevaluatingcomponentsorsystems.

Lubricate

Toapplyalubricant(oil,grease,etc)asspecifiedforreducingfriction,heatandwearbetween solidsurfaces.

Replace

Toinstallsomethingnew,remanufacturedorrebuiltinplaceofanexistingwornorfailing component.

Adjust Returntoservicemanualspecifications.

Becauseenginesmaybeequippedwithvariousoptionalcomponents,thechartsmayrecommend maintenanceforitemsnotinstalledonyourengine.Simplydisregardreferencetoanyextraneous items.Ifunsureofanyitem,consultyourCaterpillarDealer.

MonJun2122:27:29UTC+05302021

Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual

MAINTENANCEMANAGEMENTSCHEDULESFORRECOMMENDEDPREVENTIVE

MediaNumber-SEBU6042-04PublicationDate-01/07/1997DateUpdated-11/10/2001

MaintenanceManagement

Thispublicationcontainsmaintenancemanagementinformation.Themaintenanceitemsare organizedformanaginganeffectivepreventivemaintenanceprogram.Theimplementationofawellmanagedlubricationandmaintenanceprogramshouldhelpproducethefollowingresults:

*Minimizeddowntime

*Reducedengineoperatingcosts

*Increasedenginelife

Caterpillarhasdeterminedthatitisalmostalwaysmoreexpensivetoletacomponentorenginefail thantorepairitbeforefailure.Thisisespeciallytrueevenwhenrepairsbeforefailureareperformed attherecommendedconservativeintervals.Thereareseveralreasonsforthis:

*Costoftherepairorreplacementoffaileditemversusminimalrebuildcostifithasnotfailed

*Costofrelateddamage,causedbythefailure

*Costofadditionallabortorepairthefailureandtherelateddamage,andtocleanupthe engine

*Costof(unscheduled)downtimeandlostproductivitywhiletherepairisdone

*Costofadditionalwornordamagedpartsthatwouldhaveotherwisebeenreusable

Ifexcessivewearisidentifiedattherecommendedinterval,contactyourCaterpillardealer.The dealerwillreviewyourmaintenancepracticesandoperatingconditionstohelpyouestablishbefore failurerepairintervals,tomeetyourspecificoperatingsituation.Also,ifyourwearisminimalatthe recommendedinspection/maintenanceinterval,yourdealercanadviseyouwhetherlongerintervals arerecommended.

MonJun2122:26:46UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual

ScheduledOilSampling(S·O·S)

Caterpillar'sScheduledOilSampling(S·O·S)Programisaseriesofdiagnostictestsdesignedto identifyandmeasurecontaminationandconditionofoilinanengine'scrankcase.S·O·Sincorporates threebasictests:

WEARANALYSISwhichidentifiesandmeasurestheamountofwearparticlesintheoil.These wearparticlesarethencomparedagainstestablishedCaterpillarnormstodetermineacceptability.

CHEMICALandPHYSICALTESTSwhichdetectthepresenceofwater,fuelandantifreezeinthe oil.Iftheseitemsarefound,theirconcentrationsarecomparedagainstCaterpillarestablished maximumlimits.

OILCONDITIONANALYSISwhichidentifiesandmeasurestheamountofcontaminantssuchas soot,sulfur,oxidationandnitrationproducts.Thistestcanalsobeusedtocustomize(reduce,extend ormaintain)oilchangeintervals.

Caterpillar'sS·O·SProgramisagoodindicatortoidentifywhatistakingplaceinsidetheengine structure.Anearlywarningofunacceptableoilcontaminationcansaveconsiderableexpensein enginerepairs.Tobeeffectiveasanindicator,S·O·Smustbeperformedonacontinuingbasis. Intermittentsamplingwillnotallowwearratetrendlinestobeestablishedforaparticularengine, whichmakesidentifyingthebesttimetooverhaulanenginevirtuallyimpossible.Consultyour CaterpillardealerforcompleteinformationandassistanceinestablishinganS·O·SProgramforyour engine.

MonJun2122:27:13UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual

MAINTENANCEMANAGEMENTSCHEDULESFORRECOMMENDEDPREVENTIVE MediaNumber-SEBU6042-04PublicationDate-01/07/1997DateUpdated-11/10/2001

CaterpillarReferenceLiterature

OperationandMaintenanceManuals

*SEBU6123,"3114&3116Industrial,PrimePowerEPG&StandbyPowerEPGGenerator SetEngines"

*SEBU6367,"3208Industrial&GeneratorSetEngine"

*SEBU5779,"3304&3306IndustrialEngines"

*SEBU6328,"3304B&3306BIndustrial&EPGGeneratorSetEngines"

*SEBU6998,"3306BStandbyGeneratorSetEngine"

*SEBU6336,"3406B&3406CIndustrial&EPGGeneratorSetEngines"

*SEBU6999,"3406CGeneratorSetEngine"

*SEBU6945,"3408C&3412CIndustrialandEPGDieselEngines"

*SEBU6767,"3512EPGGeneratorSetEngine"

*SEBU6156,"3508,3512&3516StandbyGenerator"

*SEBU5405,"D346,D348&D349IndustrialEngines"

*SEBU5364,"D353IndustrialEngine"

*SEBU5698,"D379B,D398B,&D399Industrial&GeneratorSetEngines"

*SEBU5717,"SR4&SRCRGenerators"

*SEBU6150,"SR4GeneratorsandControlPanel"

*SEBU6918,"SR4BGeneratorSetEngine"

*SENU6918,Supplement,"GeneratorSetControlPanel"

*SEBU7050,"SR4BGeneratorsandControlPanels(ForgeneratorsetspackagedbyF.G. Wilson)"

ServiceInformationManual

*SEBU6126,"ElectricPowerGenerationProducts"

ServiceManuals

*SENR5359,"SR4BGenerator"

*SENR2180,"SR4Generator(Large)"

*SENR7968,"SR4Generator"

*SENR4676,"2301ASpeedControlGovernor"

*SENR6430,"524&1724ElectricallyPoweredGeneratorSystems"

Miscellaneous

*SEBD0518,"KnowYourCoolingSystem"

*SEHS7067,"FuelsforCaterpillarDieselEngines"

*SEBU0717,"DieselFuelsandYourEngine"

*SEBU5898,"ColdWeatherOperationGuide"

*SEBD0640,"OilandYourEngine"

*SEHS9031,"StorageProcedureforCaterpillarProducts"

*SEBF8029,"IndextoGuidelinesforReusablePartsandSalvageOperations"

*SEBU6234,Operation&MaintenanceManual,"CaterpillarAutomaticTransferSwitch (contractortype)"

*SEHS9124,SpecialInstruction,"CleaningandDryingofElectricSetGenerators"

*SEBU6251,Supplement,"CaterpillarDieselCommercialEnginesandMarineTransmission LubricationSpecifications"

*"EngineApplicationandInstallationGuide"(AppropriateforyourApplication)

YourCaterpillardealercanprovideanyliteraturerequiredtomaintainyourengine.

MonJun2122:28:51UTC+05302021

Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual

CustomerAssistance

USAandCanada

Whenaproblemarisesconcerningtheoperation,ortheserviceofanengine,theproblemwill normallybemanagedbythedealerinyourarea.

YoursatisfactionisaprimaryconcerntoCaterpillarandtoCaterpillardealers.Ifyouhaveaproblem thathasnotbeenhandledtoyourcompletesatisfaction,followthesesteps:

1.Discussyourproblemwithamanagerfromthedealership.

2.Ifyourproblemcannotberesolvedatthedealerlevelwithoutadditionalassistance,usethephone numberthatislistedbelowtotalkwithaFieldServiceCoordinator: 1-800-447-4986

Thenormalbusinesshoursarefrom8:00to4:30MondaythroughFridayCentralStandardTime.

3.Ifyourneedshavestillnotbeenmet,submitthematterinwritingtothefollowingaddress:

Caterpillar,Inc.

Manager,CustomerService,EngineDivision

MossvilleBldgA

P.O.Box600 Peoria,IL61552-0600

Pleasekeepinmind:probably,yourproblemwillultimatelybesolvedatthedealership,usingthe dealership'sfacilities,equipment,andpersonnel.Therefore,followthestepsinsequencewhena problemisexperienced.

OutsideoftheUSAandofCanada

IfaproblemarisesoutsidetheUSAandoutsideCanada,andiftheproblemcannotberesolvedatthe dealerlevel,consulttheappropriateCaterpillaroffice.

AustraliaandNewZealand

CaterpillarofAustraliaLtd.

1CaterpillarDrive PrivateMailBag4

Tullamarine,Victoria3043

Australia

Phone:03-9339-9333

Fax:03-9335-3366

Brazil,Bolivia,andParaguay

CaterpillarAmericasCo. BirmannII

RuaAleandreDumas,1.711-9.0

Chac.,Sto.Antonio

04717-004-SaoPaulo,SP

Phone:55-11-5505-3388

Fax:55-11-5505-1647

CentralAmericaandCaribbean

CaterpillarAmericasCo. 15550NW59thAvenue

MiamiLakes,FL33014

USA

Phone:305-816-3306

Fax:305-816-3307

China

CaterpillarChinaLtd. 1PacificPlace 88Queensway,Level8

G.P.O.Box3069

HongKong

Phone:852-2848-0333

Fax:852-2848-0440

Ecuador,Colombia,Venezuela,Guyana,andSuriname

CaterpillarAmericasCo. 15550NW59thAvenue

MiamiLakes,FL33014

USA

Phone:305-816-3306

Fax:305-816-3307

Europe,Africa,andMiddleEast

CaterpillarOverseasS.A. 76RoutedeFrontenex

P.O.Box6000 1211Geneva6

Switzerland

Phone:22-849-4444

Fax:22-849-4544

FarEast

CaterpillarAsiaPte.Ltd. 7TractorRoad

Jurong,Singapore627968

RepublicofSingapore

Phone:65-662-8333

Fax:65-662-8302

Japan

ShinCaterpillarMitsubishiLtd. 3700,Tana,Sagamihara-shi Kanagawa-ken,229

Japan

Phone:Sagamihara81-427-62-2112

Fax:81-427-62-8542

Japan

CaterpillarPowerSystems,Inc. JapanBranchSannoGrandBldg. 2-14-2Nagatacho Chiyoda-ku,Tokyo,100

Japan

Phone:81-335-93-3237

Fax:81-335-93-3238

Mexico

GrupoFinancieroCaterpillarMexico,S.A.deC.V. PrimerpisodelArcoOrientedeArcoBosquesCorporativa, BosquesdelAlisos45A BosquesdeLasLomas Mexico,D.F.05120

Phone(fromwithinMexico):915-258-1515

Fax(fromwithinMexico):915-258-1530

Phone(fromwithinUSA):011-525-258-1515

Fax(fromwithinUSA):011-525-258-1530

Peru,Chile,Argentina,andUruguay

CaterpillarAmericasCo. EdificioCentroSantaMaria

Av.LosConquistadores1700

Piso14,OficinaA

Santiago,Chile

Phone:011-562-231-0160

Fax:011-562-231-0159

MonJun2122:28:37UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual

MaintenanceLog

MonJun2122:28:23UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual MAINTENANCEMANAGEMENTSCHEDULESFORRECOMMENDEDPREVENTIVE MediaNumber-SEBU6042-04PublicationDate-01/07/1997DateUpdated-11/10/2001

MaintenanceManagementSchedule

Weekly:BeforeStartingEngine

PreventiveMaintenanceforStandbyGeneratorSetsToBePerformedByAnAuthorized Operator.

EngineCrankcase-Checkoillevel.MaintainoillevelbetweentheADDandFULLmarksonthe "EngineStopped"sideoftheoillevelgauge.

CoolingSystem-Checkcoolantlevel.Maintainlevelwithin13mm(1/2in)tobottomoffillerneck orproperlevelonsightgauge(ifequipped).

Walk-AroundInspection-Inspectengine,radiatorandgeneratorfordebris,looseorbrokenfittings, hosesorwiresandguards.Repairasnecessary.

AirCleanerIndicator(IfEquipped)-Checktheindicator.Changeelementsifindicatordiaphragm remainsinthelockedposition.

BatteryCharger-Checkforproperoperation.

FuelSystem-Checkforleaks.Drainwaterseparator(ifequipped).Checkfueltanklevel.Checkfuel filterindicator(ifequipped).

Belts-Inspectforworn,brokenorloosebelts.Adjustifnecessary.

Batteries-Cleantopofbatteries.Checkelectrolytelevel(unlessmaintenancefree).Checkforloose connections.

BlockHeater-Checkforproperoperation.Maintain32°C(90°F)coolanttemperatureintheblockat alltimes.

Governor-Checkandmaintainoillevel(ifrequired).

Gauges-Checktheconditionofallgauges.Repairorreplaceanybrokengauge.

AirSystem(IfEquipped)-Drainwater;checkairpressure.

ControlPanel-Visuallyinspect;checkforloose,brokenordamagedwiringorcomponents.

Generator-Checkformoisture,dust,oils,greases,anddebrisonmainstatorwindings,exciter,and PMG.Cleanasneeded.

GeneratorSpaceHeaters(IfEquipped)-Checkforproperoperation.

Weekly:WithEngineRunning

StarttheEngine-Thefollowingoperationalchecksareintendedtocheckthegeneratoroperation andtheenginestarting,lubricatingandfuelsystemsaswellasoveralloperation.Thechecksshould takenolongerthanfiveminutestocomplete.Longerperiodsofoperationarenotrequired.Amore beneficialtestwillbeperformedannuallywiththeengineoperatingunderload.

OilPressureGauge-Checkforproperoperatingoilpressure.RefertotheOperationand Maintenanceguideforthecorrectpressurereading.

FuelPressureGauge-Checkforproperoperatingfuelpressure.RefertotheOperationand Maintenanceguideforthecorrectpressurereading.

EngineCrankcase-Checktheoillevel.MaintaintheoillevelbetweentheADDandFULLmarks onthe"EngineRunning"sideofthedipstick.NOTE:Thismaintenancedoesnotapplyto3208 Engines,3114and3116Engines.

Frequency(rpm)andGeneratedVoltage-Checkandrecordreadings.NOTE:Theoperating voltageofacold(juststarted)generatorwillbeslightlyhigherthantheoperatingvoltageofa generatorthathasbeenunderloadandwarm.ThefullloadvoltageofaSR4Generatorwilldecrease amaximumof1%whenthisgeneratorstabilizesat100°C(212°F).Mostofthevoltagedecrease occursinabout30minutes.Generally,temperaturesofgeneratorsstabilizewithintwohours.

GeneratorLouvers-Checkforproperoperation(abletoopenandclosefreely).

GeneratorAirInletFilter(IfEquipped)-Ifdifferentialpressureexceeds0.6inchesofwater,stop theengineandcleantheelementsbysoakinginhotwaterwithdetergent.Rinsewithclearwater. Rechargetheelementswithathinlayeroflightweightmachineoil(WD-40orequivalent).

LeaksandNoises-Checkforleaksandunusualnoises.NOTE:Enginemustbestoppedbefore makingnecessaryrepairs.

MainStatorWindingTemperature(IfEquippedwithWindingDetectors)-Checkandrecord mainstatorwindingtemperatureswithengineunderload.NOTE:Nominaltemperaturevaluesfor standbyunitsare180°C(356°F)forthealarmand205°C(401°F)fortheshutdown.

BearingBracketTemperature(IfEquipped)-Checkandrecordbearingbrackettemperaturewith theengineunderload.NOTE:Nominaltemperaturevaluesforthebearingbracketare85°C(185°F) forthealarmand95°C(203°F)fortheshutdown.

AutomaticSwitches(IfEquipped)-Checkthatallswitchesareinproperpositionforautomatic start.

FuelTank-Checkthefuellevel;refillifbelow3/4full.

BatteryCharger-Recordchargingamperagereading.

Malfunctions-Reportanymalfunctionandmakenecessaryrepairs.

Yearly:BeforeStartingtheEngine

PreventiveMaintenanceForStandbyGeneratorSetsToBePerformedByAnAuthorized Mechanic.

PerformallWeeklyBeforeStartingtheEngineMaintenanceProceduresfirst.

Walk-AroundInspection-Inspectengine,radiatorandgeneratorfordebris,looseorbrokenfittings, hosesorwiresandguards.Repairasnecessary.

CoolingSystem-Checkcoolantlevel.Maintainlevelwithin13mm(1/2in)tobottomoffillerneck orproperlevelonsightgauge(ifequipped).Replacecoolantelement(ifequipped)oraddliquid coolantconditioner.

FuelSystem-Drainwaterandsedimentfromtank.Changefuelfilters.

AirCleanerElement-Inspectandcleanorreplaceelement.

Governor-Checkandmaintainoillevel(ifrequired).

EngineCrankcase-Checkoillevel.MaintainoillevelbetweentheADDandFULLmarksonthe "EngineStopped"sideofthedipstick.

CrankcaseBreather-Clean.

ValveLash-Check,adjustifnecessary.RefertotheengineServiceManualforproperprocedureand settings.

Linkages-Checkandadjustalllinkages,ifnecessary.LubricatealllinkagefittingswithMPGM grease.

EngineProtectiveDevices-Check;testforproperoperation.

Batteries-Cleantopofbatteries.Checkelectrolytelevel(unlessmaintenancefree).Checkforloose connections.

Engine-Wipedown;cleanasneeded.

Generator-Checkformoisture,dust,oils,greasesanddebrisonmainstatorwindings,exciter,and PMG.Cleanasneeded.Checkgeneratorwindingswithmegohmmeterandrecordreadingsfor reference1

GeneratorBearing-Inspectgeneratorbearingandbracket.Lubricategeneratorbearing2.Referto GeneratorServiceManual.

1RefertotheGeneratorServiceManualforinformationrelatingtouseofthemegohmmeterandlow resistancereadings.

23114and3116StandbyGeneratorsareequippedwithasealedprelubedbearing,andwillnotrequire lubrication.

Yearly:WithEngineRunning

PerformallWeekly:WithEngineRunningMaintenanceProceduresfirst.

StarttheEngine-Operatetheengineandcheckallgauges,oilpressure,fuelpressure,rpm (frequency),generatedvoltageandenginejacketwatertemperature,forcorrectreadings.

EngineCrankcase-Checktheoillevel.MaintaintheoillevelbetweentheADDandFULLmarks onthe"EngineRunning"sideofthedipstick.NOTE:Thismaintenancedoesnotapplyto3208 Engines,3114and3116Engines.

GeneratorLouvers-Checkforproperoperation(abletoopenandclosefreely).

EngineMounts-Inspectforproperinstallationandloosefasteners.Checkforpropertorque.

LeaksandNoises-Checkforleaksandunusualnoises.NOTE:Enginemustbestoppedbefore makingnecessaryrepairs.

LoadTest-Loadtheenginetominimumof30%ofratedload.Operateatthislevelforminimumof twohours.Afterapproximatelyonehour,recordthereadingsofallgauges:oilpressure,fuelpressure, oillevel,rpm(frequency),generatedvoltage,servicemeter,enginejacketwatertemperature,exhaust temperature(ifequipped)andmanifoldvacuum(ifequipped).Engineslobberingcanoccuriftheload testingisnotconducted.

MainStatorWindingTemperature(IfEquippedwithWindingDefectors)-Checkandrecord mainstatorwindingtemperatureswithengineunderload.NOTE:Nominaltemperaturevaluesfor standbyunitsare180°C(356°F)forthealarmand205°C(401°F)fortheshutdown.

Walk-AroundInspection-Repairoradjust.Makerepairsoradjustmentstotheengineandgenerator setasnecessary.Reportanymalfunctionandmakenecessaryrepairs.

ScheduledOilSampling(S·O·S)-Obtainsampleforanalysis.

EngineOilandFilter(s)-Changeoil.Replacefilter(s),cutoldfilteropenandinspectforforeign material.

GeneratorAirInletFilter(IfEquipped)-Removethefilterelementsandsoakinhotwaterwith detergentuntilclean.Rinsewithclearwater.Rechargetheelementswithathinlayeroflightweight machineoil(WD-40orequivalent).

FuelTank-Checkthefuellevel;refillifbelow3/4full.

BatteryCharger-Recordchargingamperageandvoltingreadings.

AutomaticSwitches(IfEquipped)-Checkthatallswitchesareinproperpositionforautomatic start.

EveryThreeYears:BeforeStartingtheEngine

PreventiveMaintenanceForStandbyGeneratorSetsToBePerformedByAnAuthorized Mechanic.

PerformallWeeklyandYearlyBeforeStartingtheEngineMaintenanceprocedures.

SpaceHeaters(IfEquipped)-Checkforproperoperation.

Generator-Checkformoisture,dust,oils,greases,anddebrisonmainstatorwindings,exciter,and PMG.Cleanasneeded.

CoolingSystem-Drain,cleanandflush.Replacethermostat(s).Refillwithcoolantsolutionand conditioner.

HosesandBelts-Replace;Itisrecommendedthatallhosesandbeltsbereplacedatthistimeto minimizedowntimeandadditionalrepaircostofcomponentfailurescausedbytheseitems.

Batteries-Replaceallbatteriesatthisinterval.

Turbocharger-Inspect/Check;Inspectforproperoperation.Checktheendplayandradialclearance ontheturbinewheelandshaft.

Engine-Performacompleteengineadjustmentandtune-up;RefertotheServiceManualofyour engineformoreinformation.

GeneratorBearing-Inspectgeneratorbearingandbracket.Lubricategeneratorbearing1;referto GeneratorServiceManual.

13114and3116StandbyGeneratorsareequippedwithasealedprelubedbearing,andwillnotrequire lubrication.

EveryThreeYears:WithEngineRunning

PerformallWeeklyandYearlyWithEngineRunningMaintenanceprocedures.

StarttheEngine-Operatetheengineandcheckallgauges,oilpressure,fuelpressure,rpm (frequency),generatedvoltageandenginejacketwatertemperature,forcorrectreadings.

EngineCrankcase-Checktheoillevel.MaintaintheoillevelbetweentheADDandFULLmarks onthe"EngineRunning"sideofthedipstick.NOTE:Thismaintenancedoesnotapplyto3208 Engines,3114and3116Engines.

GeneratorLouvers-Checkforproperoperation(abletoopenandclosefreely).

ExhaustSystem-Checkforleaks.Repairorreplacedefectivecomponentswithenginestopped.

LeaksandNoises-Checkforleaksandunusualnoises.NOTE:Enginemustbestoppedbefore makingnecessaryrepairs.

EveryThreeYears:AfterStoppingtheEngine

PerformallWeeklyandYearlyAfterStoppingtheEngineMaintenanceprocedures.

Walk-AroundInspection-Repairoradjust.Makerepairsoradjustmentstotheengineandgenerator setasnecessary.Reportanymalfunctionandmakenecessaryrepairs.

ScheduledOilSampling(S·O·S)-Obtainsampleforanalysis.

EngineOilandFilter(s)-Changeoil.Replacefilter(s),cutoldfilteropenandinspectforforeign material.

CoolantAnalysis-Obtainsampleforanalysis.

FuelTankLevel-Checkthefuellevel;refillifbelow3/4full.

BatteryCharger-Recordchargingamperagereading.

AutomaticSwitches(IfEquipped)-Checkthatallswitchesareinproperpositionforautomatic start.

MonJun2122:27:54UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual MAINTENANCEMANAGEMENTSCHEDULESFORRECOMMENDEDPREVENTIVE

MediaNumber-SEBU6042-04PublicationDate-01/07/1997DateUpdated-11/10/2001

MaintenanceRecords

Maintenancerecordsareakeyelementofawellmanagedmaintenanceprogram.Withaccurate maintenancerecords,yourCaterpillardealercanhelpyoufinetunetherecommendedmaintenance intervalstomeetyourspecificsituation.Thisshouldresultinalowerengineoperatingcost.

Documents

Thefollowingtypesofdocumentsshouldbekeptasproofofmaintenanceorrepairforwarrantyand shouldnotbedifficulttoobtainandkeepintheenginehistoryfile.Alldocumentsshouldshowdate, servicehours,gallonsoffuelconsumed,unitnumberandengineserialnumber.Iftheengineissold, transfertherecordswiththeengine.

1.Dealerworkordersanditemizedbills.

2.Owner'srepairorders.

3.Owner'sreceipts.

4.Maintenancelog(seefollowingexample).

RefertotheOperationandMaintenanceManualformoreinformationonmaintenancepertainingto fuelconsumptionandservicehours.

MonJun2122:28:09UTC+05302021

Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual SR4GENERATORSANDCONTROLPANELS

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

GeneralInformation

TheSR4BrushlessGeneratorissuitableforapplicationtoallkindsofloads,including,butnot limitedto:mixedloadsofmotorsandlights,SCR-controlledequipment,computercenters, communicationinstallations,andpetroleumdrillingapplications.Theeliminationofbrushesinthe fieldcircuitreducesmaintenance,improvesreliabilityandprovidesahigherdegreeofprotectionin potentiallyhazardousatmospheres.

Thegeneratorsetpackagescanbeutilizedforprimeorstand-bypowergeneration,inlandbasedor marineapplications.

SR4generatorsareutilizedinsinglephase,halfwaveexcitationandregulation,andthreephase,full waveexcitationandregulation.Thegeneratorsareeitherfourpoleorsixpoledesignwithfour,six, tenortwelveleadconfigurationdependingonframesize.Theyarecapableofproducingelectrical powerineither50Hzor60Hzapplications.

GeneratorIdentification

Thegeneratoridentificationandinformationplateislocatedontheleftsideofthegenerator.

Whenserviceisrequired,usetheinformationgivenontheseplates.Theinformationcontainsthe serialnumber,modelnumberandthegeneratorset(engineandgenerator)rating.Allpertinent generatordataisalsoincludedontheplatetoprovidethenecessaryinformationtoorderparts.

and

OutputLeadWiring

Allgeneratorleadwiringinformationcanbefoundontheinformationplate,oronadecalonthe powerleadsideofthegeneratorfortwelveleadgeneratorsets.Ifthegeneratorisequippedwitha circuitbreaker,thedecalwillbemountedonthesheetmetalofthecircuitbreakerpanel.

MonJun2122:31:33UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual SR4GENERATORSANDCONTROLPANELS

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

GeneratorExcitationSystems

PermanentMagnetExcitedGenerators

Permanentmagnetpilotexcited(PMPE)generatorsreceivepowerforthevoltageregulatorfroma pilotexciter,ratherthanthemainarmatureasinself-excitedgenerators.Thepilotexciterconsistsof permanentmagnet(PM)andPMarmature.Thepilotexciteroperatesindependentlyfromthe generatoroutputvoltage.Constantexcitationduringlargeloadapplicationispossible,becausethe irregularitiesthatoccuringeneratoroutputvoltage(causedbyloadconditions)arenotfedbackinto theexciter.Theindependentoperationalsoallowsthegeneratortobettersustainanoverloadfora shortduration.

Self-ExcitedGenerators

Self-Excitedgeneratorsreceivepowerforexcitationandvoltagesensingfortheregulatorfromthe mainarmature(stator)outputofthegenerator.Thevoltageregulatorsensesthegeneratoroutput voltageandprovidesregulatedoutputtothegeneratorexciter.Theexciterthenprovidespowertothe mainrotatingfield(rotor).Asthemainfieldrotates,avoltageisinducedintothemainarmature (stator)tocausesageneratoroutput.

MonJun2122:32:43UTC+05302021

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Product:GENSETENGINE

Model:3208GENSETENGINE5YF

Configuration:3208GeneratorSetEngine5YF00001-UP

OperationandMaintenanceManual SR4GENERATORSANDCONTROLPANELS

MediaNumber-SEBU6150-02PublicationDate-21/06/1994DateUpdated-14/05/2012

GeneratorLeadConnections

LeadNumbering

Eachcoilleadismarkedaccordingtothefollowingdiagrams.Thediagramscontainedshowthefour, six,ten,andtwelveleadconfigurationsavailableinpresentdaySR4generators.

Thestandardgeneratordiagramandtheterminalconnectionsareonthenameplateofeachgenerator. Numberingisclockwisefromthetopandfromtheoutsideinward.

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