Mastering the Art of Caterpillar Generator Set Repair
Table of Contents:
- Introduction
- Background of the Generator Set
- Description of the Caterpillar Generator Set
- Removal Process of the Generator
- Reasons for the Repair
- Usage History of the Generator
- Upgrades and Modifications
- Examination of the Generator Unit
- Analysis of the Engine and Parts
- Voltage Regulator and Power Supply
- Additional Components and Accessories
Introduction
Welcome to the Small Engine Mechanic Channel! In this video, I will be discussing the repair process for a Caterpillar generator set. This is part one of a series that will document the restoration and getting this unit running again. So, let's dive into the project and explore the fascinating world of antique generator sets.
Background of the Generator Set
Before we jump into the details of the repair process, let's take a moment to understand the history and background of this Caterpillar generator set. Built in 1938, it consists of a D 13,000 engine manufactured by Caterpillar and a generator end produced by General Electric. Originally installed in a dairy farm in Bartow, Pennsylvania, this unit served as a backup power source for their freezers. However, due to its limited capacity, it was eventually replaced with a larger generator.
Description of the Caterpillar Generator Set
The Caterpillar generator set is an impressive piece of machinery, measuring approximately 13 feet in length. It features a cast-iron sub base, which is a distinctive Caterpillar part. The engine has a 5 and three-quarter-inch bore and an eight-inch stroke, making it a powerful unit capable of generating 66 kilowatts of electricity. The generator itself is an eight-pole unit, operating at 900 rpm and producing 480 volts.
Removal Process of the Generator
In a previous video, I shared a quick slideshow of the removal process for this generator. It involved disconnecting various components, including the exhaust manifolds and one side of the intake manifold. Fortunately, none of the parts were lost during the removal process. The generator was then safely transported from the dairy farm to its current location.
Reasons for the Repair
The generator set encountered a major issue four years ago when water entered one of the cylinders through the exhaust pipe, causing the unit to lock up. As a result, the generator was no longer operational. Although it was no longer suitable for the dairy farm's needs, it presented an exciting restoration project for me. In this series, I will be documenting the repair process and sharing my progress along the way.
Usage History of the Generator
During its active years, this generator set faithfully served the long acres modern dairy. While it was not its original home, it was installed in 1940 or 1941. The unit was used within a boiler room slash maintenance shop, accumulating dust and dirt over time. Despite its current non-functional state, the generator still retains several original features, including a caterpillar belt plate and a range of gauges for monitoring various parameters.
Upgrades and Modifications
Over the years, the generator set has undergone a few upgrades and modifications. These include the installation of a more modern 50 MT Delco starter and a 2400 rpm cooling fan to address temperature issues. Although the radiator may require some attention, the core appears to be undamaged. These modifications were intended to enhance the generator's performance and reliability.
Examination of the Generator Unit
Now let's take a closer look at the generator unit itself. Despite years of use and neglect, the unit remains fairly complete. The commutator and brush gear show signs of wear and dirt accumulation, but they can be cleaned and restored. The unit features a compression release lever and field pressure adjustments for manual voltage adjustment. It also includes a water temperature gauge, although its accuracy is questionable.
Analysis of the Engine and Parts
The engine of the generator set is a D 13,000, known for its robust design and exceptional power output. With a large 5 and three-quarter-inch bore and eight-inch stroke, this engine is built to handle heavy loads and provide reliable electricity generation. The parts accompanying the engine, such as the intake manifold, exhaust pipe, and gear housing, will also be inspected and potentially restored.
Voltage Regulator and Power Supply
A crucial component of the generator set is the voltage regulator. This unit ensures a stable and controlled output of electricity, preventing damage to electrical equipment. Equipped with dual-scale meters, the voltage regulator can accommodate both 240 and 480 volts, depending on the configuration. The presence of a current compensation rheostat allows for manual or automatic voltage regulation.
Additional Components and Accessories
Lastly, the generator set comes with various additional components and accessories. These include the air filter housing, a battery charger maintainer, and a tungsten argon rectifier for the charger. While some parts may be missing or damaged, efforts will be made to locate suitable replacements to restore the unit to its original condition.
With a comprehensive understanding of the generator set's background, components, and history, we can now proceed to the repair process. Part two of this series will cover the disassembly and assessment of the individual components, ensuring we have a detailed plan for the restoration. Stay tuned for more exciting updates!
Highlights:
- Restoration of a Caterpillar generator set
- Unit built in 1938 with a D 13,000 engine and General Electric generator end
- Background and usage history of the generator
- Reasons for the repair and restoration process
- Examination of components, including voltage regulator, engine, and parts
- Upgrades and modifications made to the generator set
- Analysis of the generator's condition and potential improvements
- Additional components and accessories included
- Disassembly and assessment of individual components in part two
FAQ:
Q: What is the capacity of the Caterpillar generator set?
A: The generator set has a capacity of 66 kilowatts.
Q: Why was the generator set removed from the dairy farm?
A: The generator set was replaced because it could no longer provide enough backup power for the dairy farm's needs.
Q: What caused the generator to lock up?
A: The generator locked up after water entered one of the cylinders through the exhaust pipe.
Q: Are there any upgrades or modifications to the generator set?
A: Yes, the generator set has undergone upgrades, including the installation of a more modern starter and a cooling fan.
Q: What will be covered in part two of the series?
A: Part two will cover the disassembly and assessment of individual components for restoration.
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