Amazing Restoration: 1939 Caterpillar Generator Revival

Table of Contents:

1. Introduction
2. Project Background
3. The Condition of the Generator Set
4. Cleaning the Water Jacket
5. Removing the Cylinder Liners
6. Inspecting the Cylinder Liners
7. Cleaning the Cylinder Block
8. Cleaning the Water Jacket
9. Cleaning the Crankcase
10. Installing the Liners
11. Conclusion

Article:

Introduction

Welcome back to the Caterpillar generator set project! It's been quite some time since I last posted a video about this unit, but today we're going to dive back into it. In this article, we'll be focusing on the cleaning process for the water jacket in the block of the generator. Before we get started, let's take a quick look at the project background.

Project Background

The Caterpillar generator set has been sitting idle for about a year and a half now, and it's in need of some serious attention. While there are already existing videos that cover various aspects of the generator, today we'll be specifically addressing the cleaning of the water jacket. This is an essential step in the restoration process to ensure optimal performance and longevity of the generator.

The Condition of the Generator Set

As we take a walk around the generator, we can see that the block is relatively bare on the exterior. The front timing cover has been removed, revealing a coolant gallery that is in dire need of cleaning. Additionally, we can spot the areas where the gas pony engine would mount and drive the ring gear. Other components, such as the compression release lever, throttle lever, and the generator itself, are also visible.

Cleaning the Water Jacket

The main focus of this article is to clean out the water jacket in the block, a crucial component for proper cooling of the generator. The water jacket serves as a passage for coolant to flow through and dissipate heat from the engine. Over time, rust, scale, and other debris can accumulate, leading to blockages and inefficient cooling.

To begin the cleaning process, it's important to remove as much loose rust and scale as possible. This can be done by scraping the interior surfaces of the cylinder block with a piece of tin or sheet metal, focusing on the flat surfaces. A scraper or a flat head screwdriver can be used to clean the hard-to-reach nooks and crannies.

While it may be tedious and time-consuming, ensuring a thorough cleaning of the water jacket is necessary for optimal performance. The generator's slow turning speed of 900 rpm and the presence of an eight-pole generator end make it all the more crucial to maintain proper cooling.

Removing the Cylinder Liners

Before proceeding with the cleaning of the water jacket, it is necessary to remove the cylinder liners. This allows for better access to the interior of the block and ensures a more thorough cleaning process. In this case, all the liners have been removed, and their condition will be inspected later on.

Inspecting the Cylinder Liners

With the cylinder liners removed, it's time to inspect their condition. While some rough casting can be seen on the surface, there is no significant pitting present. Initially, the plan was to reuse the liners, but due to a noticeable ridge around the top of the piston stroke, it was decided to replace all six liners for optimal performance and reliability.

Cleaning the Cylinder Block

Once the liners have been removed, the next step is to clean the cylinder block itself. The interior surfaces of the block are coated with a fine powdery rust, indicating a severe build-up of debris. This build-up is likely a result of years of neglect and poor maintenance practices. However, despite the heavy build-up, the casting surfaces appear to be in remarkably good condition.

To remove the rust and debris, a combination of scraping, brushing, and vacuuming is employed. A small piece of tin or sheet metal is used to scrape the flat surfaces, while a wire brush is used to remove the loose debris. A vacuum is then used to suck up as much loose material as possible, minimizing the risk of contaminants entering the crankcase.

Cleaning the Water Jacket

Now that the cylinder block is relatively clean, it's time to focus on the water jacket. The goal is to remove any remaining rust, scale, and debris that could impede the flow of coolant. This part of the cleaning process requires the use of small wire brushes attached to die grinders. The wire brushes are used to buff out any aggressive loose powder and ensure that the water jacket is clean and free from blockages.

Cleaning the Crankcase

With the water jacket taken care of, the next step is to address the internals of the crankcase and timing gear area. Over the years, a thick sludge has accumulated, likely a result of using straight weight non-detergent oil. To clean this sludge, a unique approach is taken by turning the engine itself into its own parts washer. This involves adding diesel fuel and using a pump mechanism to circulate the fuel through the engine, effectively cleaning the surfaces. A 55-gallon drum is used as a particulate separator and filter to remove any sediment and sludge.

Installing the Liners

Once the cleaning process is complete, it's time to reassemble the generator set. Before installing the liners, the lower liner sealing area and the counterbore on the block need to be thoroughly inspected. Assuming they are in good condition, the liners can be replaced with new ones. This step ensures proper compression and prevents any leaks.

Conclusion

In conclusion, the cleaning process for the water jacket in the Caterpillar generator set is a vital part of the restoration project. By removing rust, scale, and other debris, we can ensure optimal cooling and performance. The thorough cleaning of the cylinder block and water jacket, as well as the inspection and replacement of the cylinder liners, will help restore this generator set to its former glory. Stay tuned for more updates on this exciting project!