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Product: GENERATOR
Model: SR4 GENERATOR 2ED00420
Configuration: SR4 Four-Pole Generators 2ED00420-UP

Engine News
1998/12/01
Media Number -SEBD9267-00 Publication Date -01/12/1998 Date Updated -01/12/1998

New M aintenance I nformation For Generators{4450}

SM CS - 4450

All SR4 And SR4B Generators

Reference: Operation And Maintenance Manual, SEBU6150, SR4 Generators And Control
Panels.

Reference: Operation And Maintenance Manual, SEBU6918, SR4B Generators And Control
Panels.

Reference: Operation And Maintenance Manual, SEBU7050, SR4B Generators And Control
Panels.

Reference: Service Manual Module, SENR5359, SR4B Generators.

Improved maintenance procedures have been released for SR4 and SR4B Generators. Properly
following the procedures and recommendations listed here, as well as adherence to the procedures
found in the references listed above, will result in increased long term performance.

1. Periodic insulation resistance (megger) checks must be performed as recommended in the

Operation and Maintenance Manuals.

2. The correct grease must be used on all applicable components of the generator.

3. The bearing inspection and replacement procedures presented here should be followed.

I nsulation Resistance (M egger) Checks

The SR4 and SR4B Operation and Maintenance Manuals recommend that the main rotor and main
stator winding be checked before the initial startup of the generator, and at 3 or 6 month intervals
depending on the environment. Caterpillar will request evidence that these checks were performed
when warranty claims are filed.

Proper Grease For Generator Bearings

The correct grease part number is stamped on the grease plate on all 3500 series generators. The
2L-4444 Roller Bearing used on some 800 frame or larger generators must be lubricated with 28.3
grams (1 oz) of 108-8611 Grease every 1000 hours. All other bearings (ball bearings) are to be
greased with 51 grams (1.8 oz) to 57 grams (2 oz) of 2S-3230 Grease every 2000 hours. The new

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154-3032 Ball Bearings used on some 800 frame or larger generators do not need to be greased.
Early production bearing support brackets (housings) did not have holes for grease fittings
because the bearings are greased for life. Holes for grease fittings are now provided for customers
who would prefer to add grease. In this case, 51 grams (1.8 oz) to 57 grams (2 oz) of 2S-3230
Grease is recommended every 2000 hours.

Bearing I nstallation

When installing a bearing on the shaft, it must be heated to 107 °C (225 °F) using an oven or
induction heater. Do not use a torch. Do not use an oil bath because it will wash the grease out of
the bearing. Be sure that the bracket bore is in good condition. The bore diameter is published in
the Operation And Maintenance Manual for the SR4B generators. The bore diameter in the
bracket for the new 154-3032 Ball Bearings is 280.007 ± .015 mm (11.024 ± .0006 in). Pack the
bearing bracket with grease as specified in the Operation And Maintenance Manual for SR4B
generators. When installing the 154-3032 Ball Bearing, use approximately 57 grams (2 oz) of 2S-
3230 Grease to coat the bracket bore.

Bearing I nspection Procedure

The Operation And Maintenance Manuals contain a procedure for inspecting bearings and
measuring wear. The following is an alternative method of performing the inspection: Bearing
clearance (lift) is measured by installing a dial indicator within 3 inches of the bearing. The shaft
must then be lifted using a jack or pry bar. The lift reading on the dial indicator must not
exceed .25 mm (.01 in). If the reading is greater, replace the bearing.

When replacing the bearing, ensure that the bore in the bearing support bracket is in good
condition. Some bearing brackets have sleeves that can be replaced. Check the sleeve condition
and replace if needed. The bore should not have a "wear step" and should not exceed the diameter
specified in the Operation And Maintenance Manual.

Bearing M onitoring

The 2L-4444 Roller Bearing should be monitored continuously using a temperature detector
and/or vibration monitors. If monitoring is not done, the bearings should be inspected using the
previous procedure every 2500 hours. It is also recommended that ball bearings be monitored
using temperature or vibration monitors. If monitoring is not done, the bearings should be ispected
using the previous procedure every 5000 hours.

Bearing Replacement

Caterpillar recommends that all bearings be replaced at or before 10000 hours.

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