SEBU8607-01 March 2013
Operation and Maintenance Manual C4.4 (Mech) Marine Generator tor Set MCS3 L1K 1-Up (Generator Set) S1M 1-Up (Generator Set)
SAFETY.CAT.COM
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Important Important Safety Safety Informati Informatio on Most accidents accidents that involve product product operation, operation, maintenan maintenance ce and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing recognizing potentially hazardous situations situations before an accident occurs. occurs. A person person must be alert to potential potential hazards, hazards, including human human factors that can affect safety. safety. This person person should also have the necessary necessary training, skills and tools to perform perform these functions properly. properly. Improper Improper operation, operation, lubricatio lubrication, n, maintenance maintenance or repair of this product product can be dangerous dangerous and could result result in injury injury or death. death. Do not operate operate or perform perform any lubrica lubrication, tion, maintenance maintenance or repair repair on on this product, product, until you verify verify that you are authorize authorized d to perform perform this work, work, and have read read and understood understood the operation, operation, lubrication, maintenance and repair information. Safety precautio precautions ns and warnings warnings are provided provided in this manual and on the product. product. If these hazard warnings warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified identified by the “Safety Alert Symbol” and followed followed by a “Signal Word” Word” such as “DANGER”, “DANGER”, “WARNING” “WARNING” or “CAUTION”. “CAUTION”. The Safety Alert “WARNING” “WARNING” label is shown below. below.
The meaning meaning of this safety alert symbol symbol is as follows: Attention! Attention! Become Alert! Alert! Your Safety is Involved. Involved. The message message that appears under the warning warning explains explains the hazard and can be either written or pictorially pictorially presented. A non-exhaustive list of operations that may cause product damage are identified by NOTICE labels on the product product and in this publication. publication. “
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Caterp Caterpilla illarr cannot cannot anticip anticipate ate every every possib possible le circum circumsta stance nce that that might might involv involve e a potential potential hazard hazard.. The warnings warnings in this publication publication and on the product product are, therefore therefore,, not all inclusive. inclusive. You must not use this this product product in any manner manner different different from that that considered considered by this this manual manual without without first satisfying satisfying yourself yourself that you have have consid considered ered all safety safety rules and precau precautions tions applicable applicable to the operation operation of the product product in the location of use, including including site-speci site-specific fic rules and precaution precautions s applicable applicable to the worksi worksite. te. If a tool, tool, proced procedure ure,, work work method method or operating operating techni technique que that that is not specif specifica icall lly y recommende recommended d by Caterpill Caterpillar ar is used, you you must satisfy satisfy yourself yourself that it is safe for you you and for others. others. You should also ensure that you are authorized to perform this work, and that the product will not be damaged damaged or become unsafe unsafe by the operation, lubrication lubrication,, maintenance maintenance or repair repair procedures procedures that you intend intend to use. use. The information, information, specificatio specifications, ns, and illustrations illustrations in this publication publication are on the basis of information information that was available available at the time that the publication publication was written. The specification specifications, s, torques, torques, pressures, pressures, measurements, adjustments, illustrations, and other items can change at any any time. These changes changes can affect affect the service that that is given to the product. product. Obtain the the complete complete and most current current information information before you you start any job. job. Cat dealers dealers have have the most most current current information information available. available.
When When replac replaceme ement nt parts parts are requir required ed for this product Caterpillar recommends using Cat replacement placement parts or parts with equivalent equivalent specifications including, but not limited to, physical dimensions, dimensions, type, strength strength and material. material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. In the United United States, the maintenanc maintenance, e, replacem replacement, ent, or repair repair of the emission emission control control devices devices and systems systems may be performed performed by any repair establishme establishment nt or individual of the owner's choosing. choosing.
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3 Table of Contents
Table of Contents
Engine Stopping ....................... ...................... 73
Foreword.............................. ............................. 4
Maintenance Maintenance Section Section
Safety Safety Sectio Section n
Refill Capacities....................... ....................... 77
Safety Messages Messages .............. ................... ......... .... .............. ..................... ......... .. 5 General General Hazard Information Information .............. .............. .......... ............. ... 10 Burn Prevention....................... ....................... 13 Fire Prevention Prevention and Explosi Explosion on Prevention Prevention ... .. 13 Crushi Crushing ng Prevent Prevention ion and Cutting Cutting Preven Preventio tion n . 15 Mounting Mounting and Dismounting..... Dismounting............ .......... ... .............. 15
Maintenance Maintenance Recommendatio Recommendation ns .......... .......... .......... .......... 84 Maintenance Maintenance Interval Interval Schedule Schedule (Naturally (Naturally Aspirated Marine Generator Sets) ........ ........ 91 Maintenance Maintenance Interval Interval Schedule Schedule (Turbocha (Turbocharged rged Marine Marine Genera Generator tor Set Without Without Afterco Aftercoole oler). r)... . 92 Maintenance Maintenance Interval Interval Schedule Schedule (Turbocha (Turbocharged rged Aftercooled Marine Generator Sets Rated at 50 Hz 86 ekW and 60 Hz 93 ekW)........... ekW)........... .......... 94
Engine Starting........................ ....................... 16
Maintenance Maintenance Interval Interval Schedule Schedule (Turbocha (Turbocharged rged Aftercooled Marine Generator Set Rated at 50 Hz 69 ekW and 60 Hz 76 ekW)........... ekW)........... .......... 95
Engine Stopping ....................... ...................... 17
Warranty Warranty Section Section
Electrical Electrical System................. System...................... ..... ............. ................... ......... ... 17
Warranty Warranty Information Information........ ............. .......... ..... .................. .................. 150
Genera Generator tor Isolati Isolating ng for Maintena Maintenance nce ....... ....... ....... ....... 17
Reference Reference Informatio Information n Section Section
Product Product Information Information Section Section
Engine Ratings ....................... ...................... 151
General Information.... ................ .................... 19
Customer Customer Service Service .............. ..................... ....... .............. ................... ....... 152
Product Product Identification Identification Information.......... Information.......... ......... ......... 26
Reference Reference Materials Materials .............. .................. .... ............ ................... ....... 154
Operation Operation Section Section
Index Section
Lifting Lifting and Storage.... Storage.......... ........... ........... ...... .............. ..................... ....... 31
Index................... Index........................... ............ .... ............ ................... ............. ........... ..... 157
Before Starting Starting Engine Engine ............ ................. ..... .................. .................. 16
Installation ........................... ........................... 35 Features Features and Controls ............ .................. ...... .................. .................. 36 Engine Diagnostics..................... .................... 46 Engine Starting........................ ....................... 48 Engine Operation...................... ...................... 53 Generator Generator Operation... Operation.......... ............. .......... .... ............. ................... ...... 54 Cold Weather Operation.......... Operation................. ....... ............... ................. 71
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Foreword
Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Cat publications. The English used facilitates translation and consistency in electronic media delivery. Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Cat dealer for the latest available information.
Safety This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.
Operation Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.
Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary. The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.
Maintenance Intervals Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record. See the section in the Operation and Maintenance Manual, “Maintenance Records” for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Cat dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.
Overhaul
The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.
Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs are best left to trained personnel or an authorized Cat dealer. Your Cat dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available from your Cat dealer. Consult with your dealer for information regarding these options.
Maintenance
California Proposition 65 Warning
The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by fuel consumption, service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Use fuel consumption or service hours to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading.
Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
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Safety Section Safety Messages
Safety Section i03904028
Safety Messages SMCS Code: 1000; 7405 There may be several specific safety messages on your engine. The exact location and a description of the safety messages are reviewed in this section. Please become familiar with all of the messages. Ensure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap for cleaning the safety messages. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety messages. The safety messages that are loosened could drop off the engine. Replace any safety message that is damaged or missing. If a safety message is attached to a part of the engine that is replaced, install a new safety message on the replacement part. Your Caterpillar dealer can provide new safety messages.
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Safety Section Safety Messages
Illustration 1
Typical example
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7 Safety Section Safety Messages
Illustration 2
Typical example
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Safety Section Safety Messages
(1) Universal Universal Warning Warning The Universal Warning label is located in the following following location. location. Top cover of the MCS panel
Illustration 4
Illustration 3
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Do not operate or work on this equipment unless you have have read read and unders understand tand the instru instructi ctions ons and warnings in the Operation and Maintenance Manuals. Manuals. Failure Failure to follow the instructio instructions ns or heed heed the the warn warnin ings gs coul could d resu result lt in seri seriou ous s inju injury ry or death.
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Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation Operation and Maintenanc Maintenance e Manual before performing any cooling cooling system system maintenance. maintenance.
Do Not Use Ether (3) Hot Flui Fluid d Under Under Pressu Pressure re (2)
The safety message for no ether is located on the rain cap for the air cleaner.
This safety message is located in the following location. location. Top of the expansion expansion tank
Illustration 5
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Explosion hazard! Do not use ether! This machine is equipped with an air inlet heater. Using ether can create explosions explosions or fires that can cause personal injury or death. Read and follow the starting proc proced edur ure e in the Oper Operat ation ion and and Main Mainten tenan ance ce Manual.
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9 Safety Section Safety Messages
Electrocution (4) This safety message is located on the following six different locations. Top cover of the MCS panel, top of the generator and on each of the four sides of generator
Illustration 7
Illustration 6
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DANGER: Shock/Electrocution Hazard-Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death.
Do not connect generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal in jury or death. Open and secure main distribution system switch, or if the connection is permanent, install a double throw transfer switch to prevent electrical feedback. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circumstances.
Automatic Starting (5) This safety message is located on the following location. Top cover of the MCS panel
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When the engine is in the AUTOMATIC mode, the engine can start at any moment. To avoid personal injury, always remain clear of the the engine when the engine is in the AUTOMATIC mode.
Lifting the Generator Set (6) This safety message is located on the following two different locations. On the base on the open generator sets, close to one of the front engine mounts and on the base on the open generator sets, close to the generator.
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Safety Section General Hazard Information
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General Hazard Information SMCS Code: 1000; 4450; 7405
Illustration 9 Illustration 8
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Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls. “
Crushing Hazard! Improper lifting could cause serious injury or death. Follow the lifting instructions in the Operation and Maintenance Manual for safe lifting procedures.
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Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced. Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside. Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed. • Filler caps • Grease fittings • Pressure taps • Breathers • Drain plugs Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure.
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11 Safety Section General Hazard Information
The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.
Illustration 10
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• Wear a hard hat, protective glasses, and other protective equipment, as required.
Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.
• When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing. • Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. • Ensure that all protective guards and all covers are secured in place on the engine. • Never put maintenance fluids into glass containers. Glass containers can break. • Use all cleaning solutions with care. • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions: • The engine is stopped. Ensure that the engine cannot be started. • Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks. • Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.
Illustration 11
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Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids.
Pressurized Air and Water
Refer to Special Publication, NENG2500, Dealer Service Tool Catalog for the following items:
Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.
• Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids
When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.
• Tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids.
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Safety Section General Hazard Information
Asbestos Information
• Never use compressed air for cleaning. • Avoid brushing materials that contain asbestos. • Avoid grinding materials that contain asbestos. • Use a wet method in order to clean up asbestos materials. • A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be used. • Use exhaust ventilation on permanent machining jobs.
Illustration 12
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Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Caterpillar replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris. Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.
• Wear an approved respirator if there is no other way to control the dust. • Comply with applicable rules and regulations for the work place. In the United States , use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in 29 CFR 1910.1001. • Obey environmental regulations for the disposal of asbestos. • Stay away from areas that might have asbestos particles in the air.
Dispose of Waste Properly
If dust that may contain asbestos is present, there are several guidelines that should be followed:
Illustration 13
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Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations. Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.
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13 Safety Section Burn Prevention
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Burn Prevention SMCS Code: 1000; 4450; 7405 Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the hydraulic system, in the lubrication system, in the fuel system, or in the cooling system before any lines, fittings or related items are disconnected.
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Fire Prevention and Explosion Prevention SMCS Code: 1000; 4450; 7405
Coolant When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level after the engine has stopped and the engine has been allowed to cool. Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
Oils Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.
Batteries Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.
Illustration 14
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Use of personal protection equipment (PPE) may be needed. All fuels, most lubricants, and some coolant mixtures are flammable. Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a product when a fire hazard exists. Contact your Cat dealer for service. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage. A flash fire may result if the covers for the engine crankcase are removed within 15 minutes after an emergency shutdown. Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result. If the application involves the presence of combustible gases, consult your Cat dealer for additional information about suitable protection devices. Remove all flammable materials such as fuel, oil, and debris from the engine. Do not allow any flammable materials to accumulate on the engine. All fluids that are captured in the fluid spill containment basin should be cleaned up immediately. Failure to clean up spilled fluids can cause a fire. Fire may cause personal injury and property damage.
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Safety Section Fire Prevention and Explosion Prevention
Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials. Do not expose the engine to any flame. Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in a line, a tube, or a seal failure. Exhaust shields must be installed correctly. Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting. Wiring must be kept in good condition. Properly route and attach all electrical wires. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections. Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers. Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking.
Illustration 15
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Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.
Inspect all lines and hoses for wear or for deterioration. Properly route all hoses. The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires. Properly install all oil filters and fuel filters. The filter housings must be tightened to the proper torque.
Illustration 16
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Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer. Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions.
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15 Safety Section Crushing Prevention and Cutting Prevention
Do not charge a frozen battery. Charging a frozen battery may result in an explosion. The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.
• End fittings are damaged or leaking. • Outer coverings are chafed or cut. • Wires are exposed. • Outer coverings are ballooning.
Fire Extinguisher
• Flexible parts of the hoses are kinked.
Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.
• Outer covers have embedded armoring.
Ether
• End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly in order to prevent vibration, rubbing against other parts, and excessive heat.
Ether is flammable and poisonous.
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Use ether in well ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray.
Crushing Prevention and Cutting Prevention
Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49 °C (120 °F). Keep ether cylinders away from open flames or sparks.
SMCS Code: 1000; 4450; 7405
Dispose of used ether cylinders properly. Do not puncture an ether cylinder. Keep ether cylinders away from unauthorized personnel. Do not spray ether into an engine if the engine is equipped with a thermal starting aid for cold weather starting.
Support the component properly when work beneath the component is performed. Unless other maintenance instructions are provided, never attempt adjustments while the engine is running. Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards.
Lines, Tubes, and Hoses
Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.
Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are bent or damaged.
When objects are struck, wear protective glasses in order to avoid injury to the eyes.
Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Cat dealer for repair or for replacement parts.
Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris.
Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque. Replace the parts if any of the following conditions are present:
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Mounting and Dismounting SMCS Code: 1000; 4450; 7405 Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair. Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.
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Safety Section Before Starting Engine
Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.
See the Service Manual for repairs and for adjustments.
Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.
Engine Starting
Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.
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SMCS Code: 1000
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.
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Before Starting Engine SMCS Code: 1000
If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.
NOTICE For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the air and/or fuel supply to the engine.
All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.
Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside. Inspect the engine for potential hazards. Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar warning tag attached to the start switch or to the controls. “
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Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel. If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully. Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage.
Start the engine from the operators compartment or from the engine start switch. Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing that the correct procedure will help to prevent major damage to the engine components. Knowing that the procedure will also help to prevent personal injury. To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge and/or the oil temperature gauge during the heater operation. Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside. Note: The engine is equipped with a device for cold starting. If the engine will be operated in cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation. These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting.
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17 Safety Section Engine Stopping
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To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine ground to the frame.
To avoid overheating of the engine and accelerated wear of the engine components, stop the engine according to this Operation and Maintenance Manual, “Engine Stopping” topic (Operation Section).
All grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative - battery terminal. For the grounding a wire that is adequate to handle the full charging current of the alternator must be used.
Engine Stopping SMCS Code: 1000
Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. DO NOT use the Emergency Stop Button for engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected. On the initial start-up of a new engine or an engine that has been serviced, make provisions to stop the engine if an overspeed condition occurs. To stop an electronic controlled engine, cut the power to the engine and/or the air supply to the engine.
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Generator Isolating for Maintenance SMCS Code: 4450 When you service an electric power generation set or when you repair an electric power generation set, follow the procedure below: 1. Stop the engine.
i03905591
Electrical System SMCS Code: 1000; 1400 Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite. To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative − jump-start cable should be connected last from the external power source to the negative − terminal of the starting motor. If the starting motor is not equipped with a negative − terminal, connect the jump-start cable to the engine block. “
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Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions.
Grounding Practices
Illustration 17
g00104545
2. Attach DO NOT OPERATE or similar warning tag to the engine prime mover starting circuit. Disconnect the engine starting circuit. “
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3. Disconnect the generator from the distribution system.
Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.
4. Lock out the circuit breaker. Attach DO NOT OPERATE or similar warning tag to the circuit breaker. Refer to the electrical diagram. Verify that all points of possible reverse power flow have been locked out.
Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components.
5. For the following circuitry, remove the fuses of the transformer:
Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge.
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• power • sensing
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Safety Section Generator Isolating for Maintenance
• control 6. Attach DO NOT OPERATE or similar warning tag to the generator excitation controls. “
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7. Remove the terminal box cover of the generator. 8. Use an audio/visual proximity tester in order to verify that the generator is de-energized. This tester must be insulated for the proper voltage rating. Follow all guidelines in order to verify that the tester is operational. 9. Determine that the generator is in a de-energized condition. Add ground straps to the conductors or terminals. During the entire work period, these ground straps must remain connected to the conductors and to the terminals.
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19 Product Information Section Model View Illustrations
Product Information Section General Information i03903864
Model View Illustrations SMCS Code: 1000 These model views show typical features of C4.4 (Mech)marine generator sets . Due to your individual applications, your engine may appear different from the illustrations.
Sea Water Cooled
Illustration 18
g02162614
Typical example (1) Expansion tank (2) Filler for engine coolant (3) Aftercooler (4) Air cleaner (5) Indicator for the air cleaner
(6) Rain cap for air cleaner (7) MCS control panel (8) Generator terminal box (9) Crankcase breather (10) Duplex fuel filters
(11) Fuel priming pump (12) Duplex oil filters (13) Water inlet for auxiliary water pump
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General Information Model View Illustrations
Illustration 19
g02163145
Typical example (14) Engine alternator
(15) Exhaust manifold
(16) Intercooler
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21 General Information Model View Illustrations
A Keel Cooled System
Illustration 20
g02162615
Typical example (1)Cover for belts (2) Top oil filler cap (3) Aftercooler (4) Air cleaner (5) Indicator for the air cleaner
(6) Rain cap for air cleaner (7) MCS control panel (8) Generator terminal box (9) Crankcase breather (10) Duplex fuel filters
(11) Fuel priming pump (12) Duplex oil filters (13) Water pump
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General Information Model View Illustrations
Illustration 21
g02163146
Typical example (14) Engine alternator (15) Exhaust manifold
(16) Intercooler (17) Electric starting motor
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23 General Information Model View Illustrations
Radiator Cooled System
Illustration 22
g02168837
Typical example (1) Water temperature regulator (2) Vent lines for cooling system
(3) Filler cap for radiator (4) Air to air aftercooler
(5) Tube from aftercooler to the inlet manifold
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General Information Product Description
Illustration 23
g02168874
Typical example (6) Cover on tube for the boost pressure i03901119
Product Description SMCS Code: 1000; 4450; 4491 The Caterpillar C4.4 (Mech)marine generator sets are available in the following types of aspiration: • Naturally aspirated • Turbocharged • Turbocharged aftercooled
Engine Specifications Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder.
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25 General Information Product Description
• Gear-driven centrifugal water pump • Water temperature regulator which regulates the engine coolant temperature • Auxiliary water pump • Sea water cooled • Keel cooled system • Radiator cooled • Gear-driven oil pump (gear type) • Oil cooler Illustration 24
g00984281
A typical example of the layout of the valves (A) Inlet valves (B) Exhaust valves Table 1 C4.4 (Mech)Marine Generator Set Specifications Number of Cylinders
4 In-Line
Bore
105 mm (4.134 inch)
Stroke
127 mm (5.0 inch)
Aspiration
Naturally aspirated Turbocharged Turbocharged aftercooled
Compression Ratio
NA 19.3:1 T, TA 18.2:1
Displacement
4.4 L (268 in 3 )
Firing Order
1342
Rotation (flywheelend)
Counterclockwise
Valve Lash Setting(Inlet)
0.20 mm (0.008inch)
Valve Lash Setting (Exhaust)
0.45 mm (0.018 inch)
Engine Cooling and Lubrication The cooling system consists of the following components:
The engine lubricating oil is supplied by a gear type pump. The engine lubricating oil is cooled and the engine lubricating oil is filtered. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high. Bypass valves can also provide unrestricted flow of lubrication oil to the engine parts if the oil cooler should become plugged or if the oil filter element should become plugged. Engine efficiency, efficiency of emission controls, and engine performance depend on adherence to proper operation and maintenance recommendations. Engine performance and efficiency also depend on the use of recommended fuels, lubrication oils, and coolants. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information on maintenance items.
Engine Service Life Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations. In addition, use recommended fuels, coolants, and lubricants. Use the Operation and Maintenance Manual as a guide for required engine maintenance. Expected engine life is predicted by the average power that is demanded. The average power that is demanded is based on fuel consumption of the engine over a time period. Reduced hours of operation at the full throttle and/or operating at reduced throttle settings result in a lower average power demand. Reduced hours of operation will increase the length of operating time before an engine overhaul is required.
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Product Identification Information Plate Locations and Film Locations
Product Identification Information i05042129
Plate Locations and Film Locations SMCS Code: 1000; 4450 Cat products are identified with serial numbers and with arrangement numbers. In some of the cases, modification numbers are used. These numbers are shown on the serial number plates and the Engine Information Plates. The numbers are shown on the Generator Identification plates that are mounted on the product. Cat dealers need these numbers in order to determine the components that were included with the product. The Cat dealers can accurately obtain replacement part numbers.
Illustration 25
Typical example
g02162619
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27 Product Identification Information Plate Locations and Film Locations
Engine Information Plate 1 The engine information plate is located on the left side of the cylinder block behind the engine oil gauge.
Illustration 26
g01332986
Cat dealers need all of these numbers in order to determine the components that were included with the engine. The Cat dealers can accurately obtain replacement part numbers.
Serial Number Plate 2 The serial number plate is located on the left-hand side of the base frame. Cat dealers need all of these numbers in order to determine the components that were included with the engine. The Cat dealers can accurately obtain replacement part numbers.
Generator Identification Plate 3 The generator identification plate is located on the left-hand side of the terminal box. Cat dealers need all of these numbers in order to determine the components that were included with the engine. The Cat dealers can accurately obtain replacement part numbers.
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Product Identification Information Declaration of Conformity
i03903992
Declaration of Conformity SMCS Code: 1000 Table 2 An EC Declaration of Conformity document was provided with the product if the product was manufactured to comply with specific requirements for the European Union. In order to determinethe details of the applicable Directives, review the complete EC Declarationof Conformity provided with the product. The extract shown below from an EC Declaration of Conformity for products that are declared compliant to 2006/42/EC applies only to those products originally CE marked by the manufacturer listed and which have not since been modified. “
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EC DECLARATION OF CONFORMITY OF PRODUCTS
Manufacturer:CATERPILLAR INC . 100 N.E. ADAMS STREET PEORIA, IL 61629 USA Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of European Union Member States on request: Standards & Regulations Manager,Caterpillar France S.A.S 40 Avenue Leon-Blum,B.P. 55, 38041 Grenoble Cedex 9, France I, the undersigned, _________, hereby certify that the equipmentspecified hereunder Description:
GenericDenomination:
Power Generation Equipment
Function:
Power Generator
Model/Type:
C4.4
Serial Number: Commercial Name:
Caterpillar
Fulfills all the relevant provisions of the following Directives
Directives
Notified Body
2006/42/EC
N/A
2006/95/EC
N/A
2004/108/EC
N/A
2000/14/EC amended by 2005/88/EC, Note (1)
Note (2)
Document No.
Note (1) Annex -_____ GuaranteedSound Power Level -_____dB (A) Representative Equipment Type Sound Power Level - _____dB (A) Engine Power per ____-____ kW Rated engine speed - _____ rpm Technical Documentation accessible through the person listed above authorizedto compile the Technical File Note (2) Notified body name and address
Done at:
Signature
Date:
Name/Position
Note: The above information was correct as of July, 2009, but may be subject to change, please refer to the individual declaration of conformity issued with the product for exact details.
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29 Product Identification Information Generator Set Intended for Stationary Use Only
i01297919
Generator Set Intended for Stationary Use Only SMCS Code: 1000; 7002 THE FOLLOWING NOTICE IS INTENDED ONLY FOR UNITS SHIPPED INTO THE UNITED STATES OF AMERICA, CANADA OR UNITED STATES TERRITORIES For units marked as being intended for stationary use only, which are used in the United States of America, United States Territories or Canada, the following restrictions apply: This generating set may only be used in stationary applications, as defined by the Environmental Protection Agency (EPA) Regulation in Title 40 of the Code of Federal Regulations (40 CFR Part 89.2(2)). The definition of stationary, per the regulations, is that a) the unit will remain at a single site at a building, structure, facility or installation for more than 12 consecutive months, or b) will remain at a seasonal source during it's full annual operation period, as defined in 40 CFR 89.2(2)(iii). The following United States Territories must comply with United States EPA regulations: Puerto Rico, Virgin Islands, Guam, American Somoa and the Commonwealth of the Northern Mariana Islands. i03903859
Emissions Certification Film SMCS Code: 1000; 7405 Note: This information is pertinent in the United States, in Canada, and in Europe.
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Product Identification Information Reference Information
Illustration 27
g02163676
Typical example The IMO label is mounted on the engine.
Supplemental Coolant Additive Maintenance Element Number (Optional) i03903750
Total Lubrication System Capacity
Reference Information
Total Cooling System Capacity
SMCS Code: 1000; 4450
Air Cleaner Element Number
Information for the following items may be needed to order parts for your marine engine. Locate the information for your engine. Record the information on the appropriate space. Make a copy of this list for a record. Keep this information for future reference.
Alternator Belt Number
Record for Reference Engine Model Engine Serial Number Engine Arrangement Number Modification Number Engine Low Idle rpm Engine Full Load rpm Performance Specification Number Primary Fuel Filter Number Water Separator Element Number Secondary Fuel Filter Element Number Lubrication Oil Filter Element Number Auxiliary Oil Filter Element Number
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31 Operation Section Product Lifting
Operation Section Lifting and Storage i03903754
Product Lifting SMCS Code: 7000; 7002 NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight. Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted. Some removals require lifting fixtures in order to obtain proper balance. Lifting fixtures also help to provide safety. Lifting eyes are designed and installed for the specific engine arrangement. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your Caterpillar dealer for information regarding fixtures for proper engine lifting.
Engine Views
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Lifting and Storage Product Lifting
MCS
Illustration 28
Typical example
g02163637
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33 Lifting and Storage Product Storage
Lifting the Entire Package
• Dust
Do NOT use the engine lifting eyes or the generator lifting eyes to lift the entire package. Lifting points (3) have been provided on the base rails of the generator set for lifting the entire package. However, lifting the engine and the generator together requires special equipment and procedures. Consult your Caterpillar dealer for information regarding fixtures for proper lifting of your complete package.
• Dirt • Moisture • Other airborne abrasive substances
Long Time Storage Engine Storage
Lifting the Engine Only
If the engine will not be started for several weeks, the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder liner surface, which will increase engine wear which can reduce engine service life. To help prevent excessive engine wear, use the following guidelines: • Complete all of the lubrication recommendations that are listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).
Illustration 29
g01625206
Typical example To remove the engine ONLY, use lifting eyes (2) that are on the engine. Refer to illustration 29 . The engine lifting eyes have blanks (4) that must be removed before the engine lifting eyes are used. Refer to 29 . These blanks must be installed after use.
Lifting the Generator Only To remove the generator ONLY, use lifting eyes (1) that are on the generator. The generator lifting eyes have blanks (4) that must be removed before the generator lifting eyes are used. Refer to illustration 29 . These blanks must be installed after use.
• If freezing temperatures are expected, check the cooling system for adequate protection against freezing. See this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section). If an engine is out of operation and if use of the engine is not planned, special precautions should be made. If the engine will be stored for more than 1 month, a complete protection procedure is recommended. Your Caterpillar dealer will have instructions for preparing the engine for extended storage periods. For more detailed information on engine storage, see Special Instruction, SEHS9031, “Storage Procedure for Caterpillar Products”.
Generator Storage i03902896
Product Storage SMCS Code: 7002
Short Time Storage If the generator is not installed immediately, store the generator in a clean area. This area should also have the following conditions: low humidity, stable humidity and stable temperature. Space heaters must be energized in order to keep condensation from the windings. All accessory equipment that is supplied with the unit should be stored with the generator. The combined unit should be covered with a durable cover in order to protect against the following contaminants:
A storage period in excess of 6 months should be preceded by the following preparation: 1. Install desiccant bags inside the exciter's cover and install desiccant bags inside the screen of the fan. 2. Seal the unit in a covering of plastic or other material that has been designed for that purpose. 3. Adequately tag the generator. This will ensure that preservative greases and desiccant bags are removed before the generator is placed in operation.
34 Lifting and Storage Product Storage
Bearing Inspection Ball bearing generators use grease. This grease is subject to deterioration. If the generator is stored more than 1 year, new ball bearings may be required. These bearings should be greased prior to being put into operation. If inspection indicates that bearings are free of rust or corrosion, and no noise or excessive vibration appear on start-up, replacement is not necessary.
Electrical Measurements Measure the insulation resistance of each winding if the generator was exposed to the following conditions: • Rapid changes in temperature • Freezing • Wet climate during storage Note: These tests should be conducted prior to any power connections that are being made. These tests should be conducted prior to any control connections that are made. Refer to the Generator Maintenance section of this manual in order to measure the following items: • Exciter Field (Stator) • Exciter Armature (Rotor) • Generator Field (Rotor) • Generator Armature (Stator) For additional information on generator storage, consult your Caterpillar dealer for assistance.
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35 Installation Product Installation
Installation
Location i03903752
Product Installation SMCS Code: 1000; 1404; 4450; 7002
The location of the generator must comply with all local regulations. The location of the generator must also comply with all special industrial regulations. Locate the generator in an area that meets the following requirements: • Clean
Receiving Inspection If the generator is received during cold weather, allow the unit to reach room temperature before you remove the protective packing material. Warming the generator to room temperature will prevent the following problems:
• Dry • Well ventilated • Easily accessible for inspection and maintenance
• Early failures due to wet insulating materials
Do not obstruct air inlet openings. Do not obstruct discharge openings. Coolant flow must reach these openings. If the generator is exposed to harsh environmental conditions, the generator can be modified in the field in order to add filters and space heaters. In addition, a more rigid periodic maintenance schedule should be established.
Unpacking
Electrical Measurements
Moving the Generator
Measure the insulation resistance of each winding if the generator was exposed to the following conditions:
• Water condensation on cold surfaces • Early failures due to wet windings
Unpack the equipment with care in order to avoid scratching painted surfaces.
• Rapid changes in temperature • Freezing
Improper lift rigging can allow unit to tumble causing injury and damage.
NOTICE Do not use the engine lifting eyes to remove the engine and generator together. Move the unit to the mounting location. The unit can be moved by either of the following methods: • Attach an overhead crane to the eyebolts that are installed on the generator frame.
• Wet climate during shipment • Wet climate during storage Note: These tests should be conducted prior to any power connections that are being made. These tests should be conducted prior to any control connections that are being made. Refer to the Generator Maintenance section of this manual in order to measure the following items: • Exciter field (stator) • Exciter armature (rotor)
• Use a lift truck in order to lift the generator.
• Generator field (rotor)
Refer to the Operation and Maintenance Manual, “Product Lifting” section.
• Generator armature (stator)
The hoist and the hoist cables should have a rating that is greater than the weight of the generator. When the unit is moved, ensure that the generator is supported by the lift truck's fork tines. Also ensure that the generator is balanced on the lift truck's fork tines. Slide the fork tines beneath the attached skid in order to lift the generator, if equipped.
Protective Devices The output to the load of the generator should always be protected with an overload protection device such as a circuit breaker or fuses. Fuses should be sized by using the lowest possible current rating. However, this rating must be above the current rating for full load. A common recommendation is 115 percent of rated current. Determine the size of fuses or determine the size of circuit breakers in accordance with NEMA , IEC, and Local Electrical Codes.
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Features and Controls Alarms and Shutoffs
Features and Controls
Coolant level – The low coolant level switch indicates when the coolant level is low. i03905629
Alarms and Shutoffs SMCS Code: 7400 This section contains some general information about the function of typical engine protective devices. The alarms and shutoffs are set at critical operating temperatures, pressures, fluid levels, or speeds in order to protect the engine from damage. An alarm warns the operator when an abnormal operating condition occurs. The shutoffs shut down the engine if a more critical operating condition occurs. The shutoffs help to prevent damage to the engine. If an engine protective device shuts off the engine, always determine the cause of the shutoff. Always make the necessary repairs before attempting to start the engine. Become familiar with the following information: • Types of the alarms and shutoffs • Locations of the alarm and shutoff controls • Conditions which cause each control to function • The procedure that is required before starting the engine
Shutoffs The shutoffs are electrically operated or mechanically operated. The alarms for the MCS are controlled by the control panel. The particular shutoff may need to be reset before the engine will start. NOTICE Always determine the cause of the engine shutdown. Make necessary repairs before attempting to restart the engine.
Alarms The alarms are electrically operated. The operation of the alarms are controlled by the control panel. The alarm is operated by a sensor or by a switch. When the sensor or the switch is activated a signal is sent to the control panel. An event code is created by the control panel. The control panel will send a signal in order to illuminate the lamp. Your engine may be equipped with the following sensors or switches:
Coolant temperature – The coolant temperature sensor indicates high jacket water coolant temperature. Engine oil pressure – The engine oil pressure sensor indicates when oil pressure drops below rated system pressure, at a set engine speed. Engine overspeed – The primary speed/timing sensor checks the engine speed. Note: The sensing element of the coolant temperature switch must be submerged in coolant in order to operate. Engines may be equipped with alarms in order to alert the operator when undesirable operating conditions occur. NOTICE When an alarm is activated, corrective measures must be taken before the situation becomes an emergency in order to avoid possible engine damage. If corrective measures are not taken within a reasonable time, engine damage could result. The alarm will continue until the condition is corrected. The alarm may need to be reset.
Testing Alarms and Shutoffs Alarms must function properly in order to provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation. Malfunctions must be simulated in order to test the engine protective devices. Refer to this Operation and Maintenance Manual, “Engine Protective Devices Check” for more information.
Prevention of Start-up The engine will not start if any of the conditions that cause a shutoff are present. An overcrank will also prevent starting of the engine. If any situation that causes a shutoff occurs, the following conditions must be met before the engine can be started: • The condition that prevented starting is not present. • The fault must be reset or cleared in the controller.
SEBU8607
37 Features and Controls Control Panel
i03902899
Control Panel SMCS Code: 7451
Marine Classification Society (MCS) Control Panel Note: The power for the panel is supplied by the isolator keyswitch .
Illustration 30
(1) Emergency stop push button (2) Control panel (3) High coolant temperature shutdown indicator (4) High oil temperature shutdown indicator
g02160513
(5) Low oil pressure shutdown indicator (6) Isolator Keyswitch (7) Glow plug circuit breaker (8) Engine harness connector DC and starter (9) Generator harness connector
(10) Engine harness connector DC and governor (11) AC isolator jacket water heater (if equipped)
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Features and Controls Control Panel
Illustration 31
(1) Circuit breaker F1 Main controller (2) Circuit breaker F2 Shutdown controls (3) Circuit breaker F3 Sensor feeds (4) Power dip capacitor (5) Relay K1 Generator running 1
g02160517
(6) Relay K2 Primary power on (7) Relay K3 Alternator charging (8) Relay K4 Generator running 2 (9) Glow plug relay (10) Glow plug earth relay
(11) Starter relay (12) Engine shutdown override switch (13) Backup start/stop switch
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39 Features and Controls Control Panel
Illustration 32
(1) Alarmindicator (2) Display (3) LOG (4) VIEW (5) Menu key for UP (6) Indicator lamp for the power status of the controller (7) Indicator lamp for the status of the controller “
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g02160519
(8) Alarmindicator (9) Menu key for RIGHT (10) Menu key for SELECT (11) Lamp test switch (12) Menu key for DOWN (13) BACK key (14) Menu key for LEFT (15) Indicator lamp for control in remote mode “
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The MCS control panel is operated by keys on the control panel. The keys (4), (5), and (10) control the starting and the stopping of the generator set. The keys (2), (3), (12), (13), (14), (15), (16), (20), (21), and (22) allow the operator to access additional information about the generator set. Alarm Indicator (1) – A flashing LED indicates that alarms that have not been acknowledged are still present. A fixed LED indicates that all alarms are acknowledged. A red LED indicates shutdown. A green LED is for an alarm. Display Area (2) – The display area shows information about the generator set. LOG Key (3) – This key shifts the display to the three lower lines in order to show the event and a list “ “
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(16) MODE key (17) Indicator lamp for the status of the generator (18) Engine operating indicator (19) STOP key (reset) (20) START key (21) JUMP key (22) INFO key “
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of alarms. The list holds 100 events. These events are erased when the main unit is switched off. VIEW Key (4) – Enter a menu number selection. All settings have a specific number. The VIEW key enables the user to select any setting. The VIEW key enables the user to display any setting without navigating through all of the menus. “
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Menu Key for UP(5) – This key increases the value of the selected set point in the setting menus. This key is also used for scrolling to the second line that displays the values for the generator in the display for daily use. Indicator for Status of the Controller (7) – This light indicates that the unit is running a self-check and the unit is functioning properly.
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Features and Controls Control Panel
Indicator Light for Alarm Inhibit (8) – This light indicates that inhibit input is on. “ “
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Setting the Password
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Menu Key for RIGHT(9) – This key moves the cursor to the right in order to maneuver in the menus.
Setting the password can only be accomplished by using the JUMP key. “
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SEL Key (10) – This key is used to select the function that has been chosen. The function that has been chosen is the underlined selection in the lower line of the display.
Note: Keep a record of the password. If the password is forgotten, it will not be possible to enter the menus.
Lamp Test Switch (11) – The lamp test switch is used to test indicators on the control panel.
1. Press the JUMP key.
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Menu Key for DOWN(12) – This key decreases the value of the selected set point in the setting menus. This key is also used for scrolling to the second line that displays the values for the generator in the display for daily use. BACK Key (13) – The BACK key jumps one step backward in the menu to previous display or to the entry screen. “ “
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Menu Key for LEFT(14) – This key moves the cursor to the left for maneuvering in the menus.
Use the following procedure to change the password. “
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2. Use the Menu key for UP and the Menu key for DOWN In order to step to channel 4976. 3. Press the SEL key. “
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Note: The password must be re-entered when the display has not been used for 3 minutes.
Service Menu Accessing the Service Menu can only be accomplished by using the JUMP key. “
Indicator Light for Control in Remote Mode (15) – The indicator illuminated through operation of the Mode key. (12)
Use the following procedure to access the Service Menu.
MODE Key (16) – The MODE key switches the system between LOCAL START/STOP and REMOTE START/STOP . Light (13) is illuminated for REMOTE control.
1. Press the JUMP key.
Generator Status Indicator (17) – This light indicates that the voltage and frequency is present and OK.
3. Press the SEL key.
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Engine Operating Indicator (18) – Light indicates that the generator is running. STOP Key (reset) (19) – The STOP key shuts down the engine when the engine is running. Pressing the STOP key bypasses the cooldown period. “ “
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START Key (20) – The START key begins the starting sequence. The PPU must be in manual mode in order for the START key to function. The remote indicator light (15) cannot be illuminated. To switch off the remote indicator light, press MODE key (14). “ “
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JUMP Key (21) – The JUMP key is used to enter a number in order to select a menu. Every setting has a specific number. Use the JUMP key in order to select any setting and display any setting without navigating all the way through the menus. “ “
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INFO Key (22) – This shifts the display in order to show the list of alarms. The list has a maximum of 30 alarms. A history that displays the last 30 alarms can be viewed. “ “
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2. Use the Menu key for UP and the Menu key for DOWN In order to step to channel 4980. “
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4. Choose the desired functions, timers, inputs, or outputs by moving the cursor and pressing the SEL key. “
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Alarms The following steps describe the function of the alarm. 1. An alarm occurs. The alarm light starts flashing. 2. The display automatically shows the alarm information. 3. Move the cursor to ACK and press the SEL key in order to acknowledge the alarm. Take the necessary action for the alarm. “
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4. The alarm will disappear when the condition that caused the alarm is no longer present. 5. Alarms that have not been acknowledged are still present if the alarm light flashes. 6. Use the navigation keys in order to step through the list of alarms.
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41 Features and Controls Control Panel
Warnings WARNING BATTERY VOLTAGE – If the control module detects voltage from the alternator that is below the setting for low voltage, the display will show BATTERY LOW V . The alarm indicator illuminates, and an audible alarm is activated. “ “
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engines and in excess of 130 degrees celsius for six cylinder engines (warning), the display will show LUB OIL HIGH . The alarm indicator illuminates. “
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SHUTDOWN OVERRIDE – If the control module detects an override for an engine shutdown and the switch is set to OVERRIDE, the display will show S/ D OVERRIDE . The alarm indicator illuminates, and an audible alarm is activated. “
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FAIL TO STOP – If the control module determines that the signal from the engine speed sensor indicates that the engine is running but the engine should not be running, the display will show STOP FAIL . The alarm indicator illuminates, and an audible alarm is activated. “ “
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WARNING LOW OIL PRESSURE – If the control module detects engine oil pressure that has fallen below the setting for low oil pressure (warning), the display will show LOW OIL PRESS . The alarm indicator illuminates, and an audible alarm is activated. This warning is only active after the engine has exceeded the Safety On Timer. “ “
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WARNING HIGH COOLANT TEMP – If the control module detects engine coolant temperature that has exceeded the setting for high coolant temperature (warning), the display will show HIGH ENGINE TEMP . The alarm indicator illuminates, and an audible alarm is activated. This warning is only active after the engine has exceeded the Safety On Timer. “ “
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STARTING AIR PRESSURE LOW ALARM OPTIONAL – If the control module detects low starting air pressure (warning), the display will show START AIR P LOW . The alarm indicator illuminates, and an audible alarm is activated. “
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GENERATOR WINDING OR BEARING OVER TEMPERATURE ALARM OPTIONAL – If the control module detects a generator bearing over temperature (warning), the display will show GEN BRG OVER TEMP . The alarm indicator illuminates, and an audible alarm is activated. “
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EXTERNAL FUEL TANK LEVEL ALARM OPTIONAL – If the control module detects a low fuel level in an external fuel tank, the display will show EXT FUEL T LOW . The alarm indicator illuminates, and an audible alarm is activated. “
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WARNING OVERSPEED – If the engine speed exceeds the setting for an engine overspeed (warning), the display will show OVERSPEED . The alarm indicator illuminates, and an audible alarm is activated. “ “
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HIGH EXHAUST TEMPERATURE ALARM OPTIONAL – If the control module detects a high exhaust temperature (warning), the display will show HIGH EXH TEMP . The alarm indicator illuminates, and an audible alarm is activated. “
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HIGH PRESSURE FUEL LEAK ALARM OPTIONAL – If the control module detects a high pressure fuel leak (warning), the display will show H P FUEL LEAK . The alarm indicator illuminates, and an audible alarm is activated. “
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WARNING GENERATOR HIGH FREQUENCY – If the control module detects an output frequency for the generator that exceeds the setting for high generator frequency (warning), the display will show Hz/V FAILURE . The alarm indicator illuminates, and an audible alarm is activated. “ “
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WARNING GENERATOR LOW FREQUENCY – If the control module detects an output frequency for the generator that is below the setting for low generator frequency (warning), the display will show Hz/V FAILURE . The alarm indicator illuminates, and an audible alarm is activated. “ “
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GENERATOR HIGH VOLTAGE WARNING – If the control module detects an output voltage for the generator that exceeds the setting for high generator voltage (warning), the display will show OVER VOLTAGE . The alarm indicator illuminates, and an audible alarm is activated. “ “
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GENERATOR LOW VOLTAGE WARNING – If the control module detects an output voltage for the generator that is less than the setting for low generator voltage (warning), the display will show UNDER VOLTAGE . The alarm indicator illuminates, and an audible alarm is activated. “ “
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LUB OIL HIGH TEMPERATURE ALARM – If the control module detects a high lube oil temperature in excess of 120 degrees celsius for four cylinder “ “
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WATER IN FUEL ALARM OPTIONAL – If the control module detects a signal for water in fuel (warning), the display will show WATER IN FUEL . The alarm indicator illuminates, and an audible alarm is activated.
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Shutdowns SHUTDOWN FAIL TO START – If the engine does not start after a preset number of attempts, the display will show Hz/V FAILURE . The alarm indicator will flash, and an audible alarm is activated. “
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SHUTDOWN EMERGENCY STOP – If the voltage signal at the input for the emergency stop is disconnected, the display will show E-STOP . The generator set will not start until the emergency stop push button has been reset. Power is removed from the fuel solenoid and the starter solenoid. The alarm indicator will flash, and an audible alarm is activated. “
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SHUTDOWN LOW OIL PRESSURE – If the control module detects engine oil pressure that has fallen below the setting for low oil pressure (shutdown), the display will show LOW O P S/ DOWN . The alarm indicator will flash, and an “
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Features and Controls Gauges and Indicators
audible alarm is activated. This warning is only active after the engine has exceeded the Safety On Timer. SHUTDOWN HIGH COOLANT TEMPERATURE – If the control module detects engine coolant temperature that has exceeded the setting for high coolant temperature (shutdown), the display will show HET S/DOWN . The alarm indicator will flash, and an audible alarm is activated. This warning is only active after the engine has exceeded the Safety On Timer. “ “
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SHUTDOWN OVERSPEED – If the engine speed exceeds the setting for an engine overspeed (shutdown), the display will show Hz/V FAILURE . The alarm indicator will flash, and an audible alarm is activated. “ “
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SHUTDOWN UNDERSPEED – If the engine speed falls below the setting for engine underspeed (shutdown), the display will show F/U FAIL . The alarm indicator will flash, and an audible alarm is activated. This warning is only active after the engine has exceeded the Safety On Timer. “ “
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SHUTDOWN GENERATOR LOW FREQUENCY – If the control module detects an output frequency for the generator that is below the setting for low generator frequency (shutdown), the display will show Hz/V FAILURE . The alarm indicator will flash, and an audible alarm is activated. “ “
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Gauges and Indicators SMCS Code: 7450 Your engine may not have the same gauges or all of the gauges that are described. For more information about the gauge package, see the literature that is from the OEM of the vessel. Most gauges and the indicator will be contained within a control panel. Refer to Operation and Maintenance Manual, “Control Panel” for more information. Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over a time period.
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SHUTDOWN GENERATOR HIGH FREQUENCY – If the control module detects an output frequency for the generator that exceeds the setting for high generator frequency (shutdown), the display will show Hz/V FAILURE . The alarm indicator will flash, and an audible alarm is activated. “
i03903869
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GENERATOR HIGH VOLTAGE SHUTDOWN – If the control module detects an output voltage for the generator that exceeds the setting for high generator voltage (shutdown), the display will show HIGH VOLT S/D . The alarm indicator will flash, and an audible alarm is activated. “ “
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Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications. Determine and correct the cause of any significant change in the readings. Consult your Caterpillar dealer for assistance. Some engine applications are equipped with Indicator Lamps. Indicator lamps can be used as a diagnostic aid. There are two lamps. One lamp has an orange lens and the other lamp has a red lens. These indicator lamps can be used in two ways: • The indicator lamps can be used to identify the current operational status of the engine. The indicator lamps can also indicate that the engine has a fault. This system is automatically operated via the ignition switch.
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GENERATOR LOW VOLTAGE SHUTDOWN – If the control module detects an output voltage for the generator that is less than the setting for low generator voltage (shutdown), the display will show LOW VOLT S/D . The alarm indicator will flash, and an audible alarm is activated. “ “
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ELECTRONIC GOVERNOR FAILURE SHUTDOWN – If the control module detects an electronic governor failure (shutdown), the display will show GOV FAIL S/DOWN . The alarm indicator illuminates, and an audible alarm is activated.
• The indicator lamps can be used to identify active diagnostic codes. This system is activated by pressing the Flash Code button. NOTICE If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result.
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Engine Oil Pressure – The oil pressure should be greatest after a cold engine is started. The typical engine oil pressure with SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at rated rpm. A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure: 1. Remove the load. 2. Stop the engine.
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43 Features and Controls Overspeed
3. Check and maintain the oil level.
Table 3
Jacket Water Coolant Temperature – Typical temperature range is 83° to 95°C (181.4° to 171°F). The maximum allowable temperature at sea level with the pressurized cooling system at 48 kPa (7 psi) is 103 °C (217.4 °F). Higher temperatures may occur under certain conditions. The water temperature reading may vary according to load. The temperature reading should never exceed 7 °C (44.6 °F) below the boiling point for the pressurized system that is being used. If the engine is operating above the normal range and steam becomes apparent, perform the following procedure: 1. Reduce the load and the engine rpm.
C4.4 (Mech)marine generator set Hertz (Hz)
Alarm
Shutdown
60 Hz
110%
120%
50 Hz
110%
110%
If an overspeed condition occurred, an event code will be logged in the control panel. i03903891
Sensors and Electrical Components (MCS Switches and Alarms) SMCS Code: 1900; 7400
2. Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load. 3. Inspect the cooling system for leaks. Tachometer – This gauge indicates engine speed (rpm). When the throttle control lever is moved to the full throttle position without load, the engine is running at high idle. The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load.
Locations of Electrical Components Coolant Level Switch 1
NOTICE To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. Operation at speeds exceeding high idle rpm should be kept to a minimum. Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit. Operation of the indicator should be to the + side of 0 (zero). “ “
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Service Hour Meter – The gauge indicates total operating hours of the engine. Illustration 33 i03903871
Overspeed SMCS Code: 1900; 1907; 1912; 7427 The engine overspeed for the marine C4.4 (Mech) marine generator set will depend on the operating frequency for the generator.
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Typical example The coolant level switch is powered from the panel. An alarm can be activated by a signal from the coolant level switch. There are two different types of coolant level switch. One switch is used on an expansion tank. The other switch is design in order to be used on a radiator.
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Features and Controls Sensors and Electrical Components
Coolant Differential Pressure Switch 2
Illustration 34
High Coolant Temperature Transmitter 4
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Typical example The coolant differential pressure switch is powered from the panel. If an incorrect signal is received, an alarm will be activated by the control panel when a signal is received from the coolant differential pressure switch.
Illustration 35
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Typical example
Raw Water Differential Pressure Switch 3 The raw water differential pressure switch is powered from the panel. If an incorrect signal is received, an alarm will be activated by the control panel when a signal is received from the raw water differential pressure switch.
The coolant temperature transmitter is powered from the panel. The coolant temperature transmitter is used to display coolant temperature and trigger the alarm setpoint.
High Coolant Temperature Switch (Shutdown) 5 A signal will be sent to the panel if high coolant temperature occurs.
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Features and Controls Sensors and Electrical Components
Low Fuel Pressure Switch 6
The oil pressure transmitter is powered from the panel. If an incorrect signal is received, an alarm will be activated by the control panel when a signal is received from the oil pressure transmitter .
Oil Pressure Switch 9 Shutdown The oil pressure switch can send a signal to the control panel in order to shut down the engine.
Oil Filter Differential Pressure Switch 10 The inlet pressure and the outlet pressure of the oil filter is monitored.
Oil Temperature Sender 11
Illustration 36
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Typical example The fuel pressure switch is powered by the panel.
Fuel Differential Pressure Switch 7 The inlet pressure and the outlet pressure of the fuel filters are monitored.
Oil Pressure Transmitter 8 Illustration 38
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Typical example The sender will signal the panel if high oil temperature occurs. Note: The magnetic pickup is used in order to shut down the engine if an overspeed condition occurs.
Illustration 37
Typical example
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Engine Diagnostics Diagnostic Lamp
Engine Diagnostics i03903102
Diagnostic Lamp SMCS Code: 1000; 1900; 1901; 1902; 7451 The C4.4 (Mech)marine generator set is equipped with one control panel that has a direct readout of the diagnostic code. The following panel that is installed
In most cases, stopping the engine may not be necessary because of an intermittent code. The operator should retrieve the logged fault codes. The operator should reference the appropriate information in order to identify the nature of the fault. The operator should log any observation that could have caused the lamp to light. i03905710
Configuration Parameters (Customer Specified Parameters) SMCS Code: 1000; 1900; 1901; 1902
• MCS panel The control panel for the MCS has a diagnostic lamp. i03905681
Engine Operation with Active Diagnostic Codes
System configuration parameters are parameters that affect the emissions and the power of the engine. Default values for the parameters are programmed at the factory. Some parameters may be changed by the customer in order to suit the needs of the specific application.
Engine Rating Parameter
SMCS Code: 1000; 1900; 1901; 1902
Rating Number
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Control Panel for MCS
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The Rating Number corresponds to the selected set of performance maps for the application. Factory passwords are required in order to change the Rating Number . “
If a diagnostic lamp illuminates during normal engine operation, the system has identified a situation that is not within the specification. Use the Caterpillar electronic service tool (ET) in order to check the active diagnostic codes. Contact your Caterpillar dealer for more information. The active diagnostic code should be investigated. The cause of the problem should be corrected as soon as possible. If the cause of the active diagnostic code is repaired and there is only one active diagnostic code, the diagnostic lamp will turn off. Operation of the engine and performance of the engine can be limited as a result of the active diagnostic code that is generated. Acceleration rates may be significantly slower and power outputs may be automatically reduced. i03905704
Engine Operation with Intermittent Diagnostic Codes SMCS Code: 1000; 1900; 1901; 1902
Control Panel for MCS
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ECM Identification Parameter Equipment ID Equipment ID is the identification of the equipment that is assigned by the customer. This parameter allows the customer to enter a description into the ECM in order to identify the engines application. A maximum of 17 characters can be entered in the field. “
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Miscellaneous Monitoring Mode Shutdowns Monitoring Mode Shutdowns controls the shutdown feature that is associated with the engine monitoring feature. “
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Configurable Inputs Overspeed Protection The Overspeed Protection speed is the engine rpm when a shutdown will occur. Overspeed protection is used in order to protect the engine from damage. Overspeed protection must be enabled in Monitoring Mode Shudowns . “
If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts OFF, an intermittent fault may have occurred.
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Engine Diagnostics Configuration Parameters
Configurable Governor Droop Configurable Governor Droop allows the engine to run in droop mode when the genset is operated in parallel with other gensets. “
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Coolant Level Sensor If this parameter is programmed to Enabled and the coolant level falls below the measured level, E2143-3 event code will be displayed. “
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User Defined Switch Installation Status A user-defined shutdown switch is an optional switch input. If this parameter is programmed to Enabled and the user-defined shutdown switch closes, the engine will shut down. “
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Engine Starting Before Starting Engine
Engine Starting
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Cold Weather Starting SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Before Starting Engine SMCS Code: 1000; 1400; 1450 Perform the required daily maintenance and other periodic maintenance before the engine is started. Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information. • Before you start the engine refer to this Operation and Maintenance Manual, “Walk-Around Inspection” .
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. Startability will be improved at temperatures below −18 °C (0 °F) from the use of a jacket water heater or extra battery capacity. Disengage any driven equipment. The control panel will automatically control the cold starting of the engine.
• Ensure that the engine has an adequate fuel supply. • Open the fuel supply valve (if equipped).
i03902851
NOTICE All valves in the fuel return line must be open before and during engine operation to help prevent high fuel pressure. High fuel pressure may cause filter housing failure or other damage. If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may have entered the filter housing. Also, when fuel filters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information on priming the fuel system.
Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside. • Do not start the engine if there is a DO NOT OPERATE warning tag or similar warning tag attached to the start switch. “
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• Do not move any of the controls if there is a DO NOT OPERATE warning tag or similar warning tag attached to the controls. “
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• Reset all of the shutoffs or alarm components. • Ensure that any driven equipment has been disengaged. Minimize electrical loads or remove any electrical loads.
Starting the Engine SMCS Code: 1000; 1450 The marine C4.4 (Mech)marine generator set has one type of control panel.
Marine Certification Society (MCS) Control Panel
SEBU8607
49 Engine Starting Starting the Engine
Starting Procedure
Illustration 39
Typical example (1) Isolator Keyswitch
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Engine Starting Starting the Engine
Illustration 40
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Typical example (2) Start Key
(3) Stop Key
(4) Mode Key
Use the following procedure for Marine Certification Society control panels in order to start the engine.
If V3 is selected, the display will indicate the status in the start/run cycle. The display will show start prepare and start relay on . “
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1. Turn the Isolator keyswitch (1) for the Generator Set to the ON position.
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The Power LED will illuminate immediately. The Self Check OK LED will illuminate after a few seconds. The Generator Set is now ready to start. “
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If the timer (preheat) is configured, then the timer (preheat) will be initiated. After the timer (preheat) has expired, the engine will begin to crank.
Line 4 on the display will read SETUP V3 V2 V1 .
Note: When the engine starts, the starting motor is disengaged and the starting motor is locked out.
The view that is being displayed is underlined. Use the left arrow button and the right arrow button to scroll between the four screens of the display.
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2. Make sure that the Auto LED is off. If the Auto LED is on press the Mode key once in order to extinguish the Auto LED and gain local control. “
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3. Press the Start key. “
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If the engine did not start, then the control module will permit the starting motor to cool down for a predetermined amount of time. Once the cooldown timer has expired, the engine will crank.
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51 Engine Starting Starting with Jump Start Cables
Note: The Failed to Start fault will be displayed in V3 after three failed attempts to start the engine. The Alarm LED indicator will flash. If the Alarm LED indicator is flashing, move the cursor to ACK and press the SEL key in order to reset the alarm. Determine the reason that the engine failed to start before making further attempts. “
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After the engine has started, the timer (safety) is activated, unless the timer has been set to 0. This function allows the engine to warm up so that no faults will occur. Once the timer (safety) has expired, fault protection is available. The generator load may now be applied to the engine.
4. To stop the engine, open the circuit breaker and remove the load from the generator. Press and release the STOP key. “
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Note: Pressing the Stop key will bypass the cooldown period. “
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Starting with Jump Start Cables SMCS Code: 1000; 1401; 1402; 1900
Improper jump start cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start cable ends to contact each other or the engine. If the installation is not equipped with a backup battery system, it may be necessary to start the engine from an external electrical source. For information on troubleshooting the charging system, refer to Special Instruction, REHS0354, “Charging System Troubleshooting”. Many batteries which are considered unusable are still rechargeable. After jump starting, the alternator may not be able to recharge batteries that are severely discharged. The batteries must be charged to the proper voltage with a battery charger. For information on testing and charging, refer to the Special Instruction, SEHS7633, “Battery Test Procedure”.
NOTICE Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage the electrical system. Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove first. When using an external electrical source to start the engine, turn the generator set control switch to the OFF position. Turn all electrical accessories OFF before attaching the jump start cables. “
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Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started. 1. Turn the start switch on the stalled engine to the OFF position. Turn off all the engines accessories. 2. Connect one positive end of the jump-start cable to the positive cable terminal of the discharged battery. Connect the other positive end of the jumpstart cable to the positive cable terminal of the electrical source. 3. Connect one negative end of the jump-start cable to the negative cable terminal of the electrical source. Connect the other negative end of the jump-start cable to the engine block or to the chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that are produced by some batteries. 4. Start the engine. 5. Immediately after the engine is started, disconnect the jump-start cables in reverse order. After jump starting, the alternator may not be able to recharge batteries that are severely discharged. The batteries must be replaced or charged to the proper voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maintenance Manual, “Battery - Replace” and Testing and Adjusting Manual, “Battery - Test”. Refer to the Electrical Schematic for your engine. Consult your Caterpillar dealer for more information.
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Engine Starting After Starting Engine
i03902850
After Starting Engine SMCS Code: 1000 Note: In ambient temperatures from 0 to 60°C (32 to 140°F), the warm-up time is approximately 3 minutes. In temperatures below 0°C (32°F), additional warm-up time may be required. When the engine is in operation, observe the following conditions: Do not check the high pressure fuel lines with the engine or the starting motor in operation. If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”. • Check for any fluid leaks at idle rpm and at onehalf full rpm (no load on the engine) before operating the engine under load. Check for any air leaks at idle rpm and at one-half full rpm (no load on the engine) before operating the engine under load. This is not possible in some applications. Note: Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated.
SEBU8607
53 Engine Operation Engine Operation
Engine Operation
• Ensure that the belts are properly adjusted. The belts should be in good condition. Refer to the Specifications manual for further information. i03902852
• Ensure that all of the connections of the hoses are tight. The connections should not leak.
Engine Operation SMCS Code: 1000 Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance Manual are followed, costs can be minimized and engine service life can be maximized. The time that is needed for the engine to reach normal operating temperature can be less than the time taken for a walk-around inspection of the engine. Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated. i03902853
Fuel Conservation Practices SMCS Code: 1000; 1250 The efficiency of the engine can affect the fuel economy. Caterpillar's design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine. • Avoid spilling fuel. Fuel expands when the fuel is warmed up. The fuel may overflow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed. • Be aware of the properties of the different fuels. Use only the recommended fuels. Refer to the Operations and Maintenance Manual, “Fuel Recommendations”for further information. • Observe the service indicator frequently. Keep the air cleaner elements clean. • Ensure that the turbocharger is operating correctly so that the proper air/fuel ratio is maintained. Clean exhaust indicates proper functioning. • Maintain a good electrical system. One faulty battery cell will overwork the alternator. This will consume excess power and excess fuel.
• Ensure that the driven equipment is in good working order. •
Keep cooling system components clean and keep cooling system components in good repair. Never operate the engine without water temperature regulators. All of these items will help maintain operating temperatures.
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Generator Operation Generator Operation
Generator Operation
Block Loading
Generator Operation
When an electrical load is applied to a generator set, block loading occurs. This load may be anywhere from a moderate percentage of the rated load up to the rated load.
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SMCS Code: 4450
The block loading capability of a generator set depends on the following factors:
Loading of the Generator
• Engine transient response
When a generator is installed or reconnected, be sure that the total current in one phase does not exceed the nameplate rating. Each phase should carry the same load. This allows the engine to work at the rated capacity. An electrical unbalance can result in an electrical overload and overheating if one phase current exceeds the nameplate amperage.
• Voltage regulator response
Allowable combinations of unbalanced loads are shown in Illustration 41 . When you operate with significant single-phase loads, the combinations of single-phase load and three-phase load may be used. Such combinations should be located below the line on the graph.
• The amount of load that is already present
• Type of the voltage regulator • Altitude of operation of the generator set • Type of load
If a block load derating is required, refer to ISO 8528 Standards or SAE J1349 Standards. Also, reference Engine Data Sheet, LEKX4066, Loading Transient Response and Engine Data Sheet, LEKX4067, Block and Transient Response.
Power Factor Power factor (PF) determines the relationship between true power and apparent power. The true power is also known as the active power. The apparent power is also called kVA. The true power (kW) is the work that is done on the load by the engine. The true power determines the amount of power that is available for the load to do work. The apparent power (kVA) is the total power that is produced by the generator. Power factor can be calculated by using the following formula. PF = kW / kVA, • kilowatt (kW) • kilovolt ampere (kVA) • kVARkilovolt ampere reactive power is a unit of measurement. Note: The generator does NOTcontrol power factor. Power factor is determined by the load. In most applications, electric motors, solid-state controls, and transformers determine the power factor of the system. Induction motors usually have a power factor that is no larger than 0.8. Incandescent lighting is a resistive load of about 1.0 power factor, or unity. Solid-state controls, variable frequency drivers, variable speed drivers, and systems for the UPS can operate at any power factor, leading or lagging. In this case, the power factor can be between 0.4 and 1.0. Illustration 41
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Allowable Combinations of Unbalanced Loads
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Generator Operation Single Unit Operation
The power factor of a system may be determined by a power factor meter or by calculations. Determine the power requirement in kW by multiplying the power factor by the kVA that is supplied to the system. As the power factor increases, the total current that is supplied to a constant power demand will decrease. With equal loads, a lower power factor will draw more current. A high-power factor will result in full engine load that is less than the generators rated amperage. A lower power factor increases the possibility of overloading the generator. Note: Normally, Caterpillar generators are designed for a power factor of 0.8 lagging. Consult your Caterpillar dealer in order to check the generator rating if the operation at less than 0.7 lagging power factor or operation at a leading power factor of 0.8 is desired.
Excitation Systems Refer to the Operation and Maintenance Manual, “Voltage Regulators” for information on excitation systems.
Standby Generator Sets Most standby units are automatic. Without an operator in attendance, standby units will perform the following functions: start, pick up the load, run and stop. Standby units will not change the governor speed control or the settings of the voltage levels automatically. The governor speed and voltage level must be preset for the proper operation of that unit. Whenever the set is operated manually, ensure that the governor speed and the settings of the voltage levels are set correctly for automatic operation. Check all switches for the proper setting. The start switch should be in the AUTOMATIC position. Emergency stop switches should be in RUN position.
Bearing Temperature Detectors Temperature detectors for the bearings are available on large frame generators. These temperature detectors measure the main bearing temperature. Thus, the temperature of the bearing can be measured or monitored. Bearing temperature measurements may help to prevent premature bearing failure. Temperature detectors for the bearings are used with equipment that has been provided by the customer. Contact your Caterpillar dealer for more information. i03902892
Single Unit Operation SMCS Code: 4450
Initial Start-Up Measure the insulation resistance of each winding if the generator was exposed to the following conditions: • Rapid changes in temperature • Freezing • Wet climate during shipment • Wet climate during storage Refer to this Operation and Maintenance Manual, “Insulation - Test”. Note: These tests should be conducted prior to any power connections or control connections that are being made.
Starting
Options for the Generator
1. Make all preliminary engine starting checks.
Space Heaters
2. Be sure that the main circuit breaker or the line circuit breaker is open.
Most of the generators are provided with space heaters. These space heaters are installed for operation in all climates. For more information on space heaters, refer to Maintenance Section, “Space Heater - Check”.
Embedded Temperature Detectors Some generators are available with embedded temperature detectors. The detectors are installed in the slots of the main armature. The main armature is also called a stator. The detectors are used with the equipment that is provided by the customer. Thus, the temperature of the main armature winding can be measured or monitored. RTD temperature detectors are available. Contact your Caterpillar dealer for more information.
3. Start the engine. 4. Close the main circuit breaker. 5. Apply the load. Do not try to apply the full load. Apply the load in increments in order to maintain system frequency at a constant level. 6. Readjust the governor for rated frequency.
Adjust the Voltage Adjust the voltage regulator in order to obtain the proper voltage. Refer to Operation and Maintenance Manual, “Voltage Regulators” for more information about the voltage regulator.
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Generator Operation Parallel Operation
1. Turn the remote adjustment potentiometer to the center position, if equipped.
3. Allow the engine to run for 5 minutes in order to cool.
2. Connect an analog voltmeter that is calibrated for 100 VDC on terminal E+ and terminal E-.
4. Stop the engine.
3. Connect a voltmeter that is calibrated for 300 VAC to 500 VAC or 1000 VAC to the output terminals of the generator. 4. Make sure that the ST3 wire is positioned on the desired frequency. Also, the engine speed must be changed from the factory setting in order to change the frequency of the generator. 5. Turn voltage potentiometer (P2) to a full counterclockwise position. 6. Turn frequency potentiometer (P4) to a full clockwise position. 7. Turn stability potentiometer (P3) counterclockwise to about 1/3 of the total rotation for the potentiometer. 8. Start the engine and set the engine speed to a frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz. 9. Adjust the output voltage to the correct value with potentiometer P2. This voltage should be the rated voltage UN for single operation or UN plus 2% to 4% for parallel operation with a current transformer. Use potentiometer P3 to make adjustments if the voltage oscillates. Adjust potentiometer P3 in both directions while you observe the voltage between E+ and E-. The voltage between E+ and E- should be approximately 10 VDC. The best response times are obtained at the limit of the instability. Try cutting or replacing the wire ST2 if no stable position can be obtained. 10. Check the LAM operation. ST5 must be closed. 11. Turn potentiometer (P4) slowly counterclockwise until there is a significant voltage drop. The voltage drop should be approximately 15 %. 12. Vary the frequency around 48 Hz or 58 Hz according to the operating frequency. Check the change in the voltage that was previously observed.
Stopping 1. Remove the load in increments. 2. Open the circuit breaker.
i03902893
Parallel Operation SMCS Code: 4450
Initial Start-Up Preparing a generator for parallel operation requires special attention. Before you attempt to parallel units for the first time, check all the units for the following three conditions. • Same phase rotation • Same alternating current frequency • Same voltage adjustment 1. Check the phase rotation. Units that operate in parallel must have the same phase rotation. There are two methods that may be used in order to determine if the incoming unit and the unit that is on-line have the same phase rotation. These methods are listed below: • Using a phase rotation meter • Using a set of three light bulbs Use the procedure below to determine the proper phase rotation by using three light bulbs.
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SEBU8607
Generator Operation Parallel Operation
Illustration 42
b.
Adjust the governor control in order to give the rated frequency at full load.
c.
Remove the load and check the high idle speed. The high idle speed should be approximately 2 to 5 percent above full load speed for governors that are equipped with droop. If these speeds cannot be obtained, contact your Caterpillar dealer.
d.
For the most consistent results, repeat 2.b. and 2.c. until the second condition of “Initial Start-Up” has been met.
g00695380
3. Adjust the voltage.The potentiometers should be at the initial settings. Refer to Operation and Maintenance Manual, “Voltage Regulators”. When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE. Remove all fuses. a.
Connect the light bulbs with rated voltage between the generator leads and the corresponding line phase. For example, connect terminal 1 to line 1 across the open circuit breaker.
b.
Start the units that will be in operating in parallel. Bring the units up to speed. As the units approach the same speed, the lights will start to blink. • If the lights blink in sequence, one of the units is connected backward. In order to correct the problem, stop the units. Remove generator leads 1 and 3 at the circuit breaker. Exchange these generator leads. This reverses the direction of phase rotation. Terminal 2 should always be connected to line 2. Go to 5. • Both generators have the same phase rotation when the lights blink in unison. The first condition of “Initial Start-Up” has been met.
2. Adjust the frequency. The units that will be operating in parallel must operate at the same speed. Speed is proportional to the alternating current frequency. a.
Allow each electric set to run under load for about 30 minutes.
Note: Make sure that the speed droop is identical for all of the engines before adjustments are made to the generator. a.
Preset the unit for parallel operation by connecting the current transformer to S1 and S2 of the connector J2. Set potentiometer P1 for quadrature droop in the center position. Apply the rated load. The voltage should drop for 2% to 3%. Switch the positions of the two incoming secondary wires of the current transformer if the voltage increases.
b.
The no-load voltages should be identical for all the generators that are operating in parallel. Connect the generators in parallel. Try to obtain a 0 kW power exchange by adjusting the speed of the generator. Try to minimize the circulating currents between generators by altering the voltage setting with potentiometer P2 or Rhe on one of the generators.
Note: Do not change the voltage settings after this step. c.
Apply the available load. The setting is correct only if a reactive load is available. Equalize the Kilowatts or divide the rated power of the units proportionally by altering the speed. Alter the quadrature droop potentiometer (P1) in order to equalize the currents or divide the currents.
Starting Multiple Units Use the procedure for starting single units in order to start multiple units. Refer to Operation Section, “Single Unit Operation”.
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Generator Operation Parallel Operation
Paralleling Multiple Units Units may be paralleled at no load. Units may also be paralleled with units under load. After the initial conditions for start-up are satisfied, verify for the following requirements: • One of the governors can be an isochronous governor. Electronic load sharing governors are an exception. • Generators must have voltage droop compensation or cross current compensation. 1. Start the unit which will be paralleled.
In order to transfer the load from one engine to another engine, use the following procedure: 1. Increase the governor speed control of one unit in order to increase the load. 2. Reduce the governor speed control of the other unit in order to decrease the load on that unit. 3. Raise the governor speed control or lower the governor speed control of both units in order to change system frequency.
Parallel Operation Of Governors
2. Turn on the synchronizer lights. 3. After the engine has run a few minutes, bring the engine up to synchronous speed. This means that the frequency of the incoming unit will be the same frequency as the unit that is on-line. The synchronizing lights will begin to blink. Note: The frequency of the incoming unit should be slightly greater than the line frequency. This will allow the incoming unit to assume some of the load instead of adding to the system load. 4. By using the governor control, adjust the engine speed until the lights blink slowly. 5. The lights are off when the voltages of the two units are in-phase. Quickly close the breaker while the lights are out. 6. Use the governor controls in order to share kW load between engines. 7. Generator temperature will be stabilized in approximately 1 hour. After the generator temperature has been stabilized, adjust the voltage droop rheostat of each generator. This will share the reactive load and this will limit the circulating currents. Less droop increases the reactive current that is carried by the generator. Adjusting the voltage droop rheostat in a counterclockwise direction will decrease the droop. Adjusting the voltage droop rheostat in a clockwise direction will increase droop.
Illustration 43
g00630841
Load Sharing Module (Typical Example) The generator set load sharing module provides either the droop load sharing or the isochronous load sharing for parallel applications. The load sharing module has a synchronizing parallel module SPM-A input. The module provides the proportional load sharing. More information is available in the System Operation, Testing and Adjusting, SENR6565, Generator Set Load Sensor and Generator Load Sharing Module.
Load Division and Speed Droop (If Equipped) Once two units have been paralleled, the units share of the kW load is determined by the governor control setting. If two units of the same capacity and the same governor characteristics have the same governor control settings, the units will share the load equally. The total load must not exceed the capacity of the one engine.
Illustration 44
(1) Droop potentiometer
g00637397
SEBU8607
59 Generator Operation Parallel Operation
The Speed brick converter changes the analog signal of the speed potentiometer into a pulse width modulated signal. The engine electronic control can recognize this signal. The converter is mounted on the subpanel which is located within the control panel.
Function of The Engine Governor This section describes the function of the engine governor in relation to load division between parallel electric sets. It is important to understand two basic facts about load division between generator sets which are operating in parallel. 1. The power which is supplied to the generator and to the load is a function of the engine. The setting of the engine governor and the position of the engine governor control determine the amount of power that is delivered by the engine. Therefore, the governor setting and the position of the governor control determine the kW load which is carried by the generator. A change in the engine power of any one of the units in a parallel operation will result in the same change in engine power for each of the other units in that parallel operation. In other words, the units that are in parallel operation will stay in parallel operation. 2. The division of power is not determined by generator excitation or terminal voltage. The excitation will determine the power factor for a generator when the generator is operating in parallel with other generators. Governors that are used with Caterpillar powered electric sets can be of two types: • Governors with fixed speed droop • Governors with adjustable speed droop The values of speed droop which are commonly used are 3 percent and 0 percent. Governors with adjustable speed droop can be adjusted so the characteristics match closely with the characteristics of governors with fixed speed droop. If the governor is adjusted for 0 percent speed droop or isochronous operation, then the same speed from no load to full load can be obtained.
Summary on Governor Operation The preceding discussion of governor operation can be summarized below:
• Each governor should have a 3 percent speed droop in order to provide the simplest combination of governors for electric sets that are connected in parallel. If a constant frequency from no load to full load is required, one governor can be adjusted for isochronous operation. This isochronous unit will be called a lead unit . “
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• In order for all paralleled units to accept the full share of the load, the following governor adjustments are required. The governors should have the same full load speed. The governors should have the same high idle speed in the case of governors which are adjusted for speed droop operation. Governor controls should be set to the high idle position so that the full range of the governor is available. • Operating an isochronous governor in parallel with a speed droop governor requires special techniques. • Any number of electric sets can be operated in parallel. However, only one governor of the group can be adjusted for isochronous operation. The exception will be some special cases of electronic governors with automatic load sharing.
Stopping In order to remove a generator from the line, perform the following procedure. 1. Check the load. The load must be less than the rated capacity of the remaining units. 2. Be sure that the neutral of one of the remaining units is grounded. 3. Remove the load from the outgoing unit. See the Parallel Operation, “Load Division - Speed Droop”. The amperage may never go to zero due to circulating currents. 4. Open the circuit breaker. 5. Allow the engine to cool for 5 minutes. 6. Stop the engine.
Circulating Currents Understanding the circulating currents becomes important when you parallel the units. These circulating currents are flowing between generators in parallel operation. The circulating currents are caused by voltage differences between the generators. The circulating currents are not doing useful work. The amount of the circulating current can be determined by subtracting the amperage which is going to the load from the total generator amperage.
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Generator Operation Voltage Regulators
The circulating current may be as high as 25 percent of rated amperes with cold generator sets. Such current may not even be considered harmful. The total generator current should not exceed the amperage rating. As the generators warm, the circulating currents will decrease. The ammeter readings should decrease slightly, but the voltage meter readings should remain constant.
Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.
i03902840
Voltage Regulators SMCS Code: 4467
Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: •
Make sure the unit is off-line (disconnected from utility and/or other generators power service) , and either locked out or tagged DO NOT OPERATE.
• Remove all fuses. • Make sure the generator engine is stopped.
Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. For generators with Auxiliary Winding Regulation Excitation Principle (AREP), the voltage regulator is powered by two auxiliary windings. These windings are independent from the voltage sensing circuit. The first winding is Labeled as X1 and X2 . This winding has a voltage that is proportional with the output voltage of the generator. The second winding is Labeled as Z1 and Z2 . This winding has a voltage that is proportional to the current of the stator. The voltage from the power supply is rectified and filtered before being used by the AVR monitoring transistor. The generator has a capacity of 3 IN for 10 seconds for a short circuit current. The generator also has good immunity to distortion from the generator load. “
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For generators with PMG excitation, a permanent magnet generator is added to the generator at the rear of the generator. The PMG supplies the voltage regulator with a voltage that is independent of the main generator winding. The generator has a capacity of 3 IN for 10 seconds for a short circuit current. The generator also has good immunity to distortion from the generator load. The voltage regulator monitors the output voltage of the generator. The voltage regulator corrects the output voltage by adjusting the excitation current.
• Make sure all batteries are disconnected.
Table 4
• Make sure all capacitors are discharged.
Sustained short circuit capacity (AREP and PMG)
Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.
”
3 IN for 10 seconds
Standard power supply (AREP) Two auxiliary windings Supply for s hunt
max 140 VAC at 50/60 Hz
Rated overloadcurrent
10 A for 10 seconds
Electronic protection for overExcitation ceiling current for 10 load and loss of voltage sensing seconds and return to approximately 1 A THE GENERATOR MUST BE STOPPED IN ORDER TO RESET THE PROTECTION. Fuse F1 on the input side “
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X1 and X2
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(continued)
SEBU8607
61 Generator Operation Voltage Regulators
(Table 4, contd) Voltage s ensing
5 VA that is isolated b y the transformer
0-110V terminals
95 to 140 V
0-220V terminals
170 to 260 V
0-380V terminals
340 to 520 V
Voltage regulation
±0.5%
Rapid response time or normal response time from the location of jumper wire (ST2) Voltage adjustment via potentiometer (P2) Quadrature droop adjustment via potentiometer (P1) Underspeed protection and adjustment of the frequency threshold via potentiometer (P4) (Factory setting) Maximum adjustment for excitationvia potentiometer (P5) (4 to 10 A) 50 Hz or 60 Hz selection with jumper wire (ST3)(1) . (1)
The engine speed setting must be changed in order to change the frequency of the generator set.
These voltage regulators may have an optional remote potentiometer for voltage adjustment. This potentiometer is 470 ohms 3 W minimum. The adjustment range is 5%. The voltage range is limited by the internal potentiometer P2 . Remove jumper wire ST4 in order to connect the potentiometer. A 1000 ohm potentiometer can also be used to extend the adjustment range. “
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62
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Generator Operation Voltage Regulators
R448 Adjustments
Illustration 45
g01015862
Illustration 46
Connections for AREP excitation
g00995995
SEBU8607
63 Generator Operation Voltage Regulators
10. Check the operation of the Load Adjustment Module (LAM). ST5 must be jumpered. The LAM can be adjusted to 15% or 25% voltage dip by moving the ST10 jumper wire. “
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“
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11. Turn the potentiometer P4 slowly counterclockwise until there is a significant voltage drop. The voltage drop should be approximately 15%. “
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12. Vary the frequency around 48 Hz or 58 Hz according to the operating frequency. Check the change in the voltage that was previously observed. Illustration 47
g00996011
Connections for PMG excitation
Adjustments for Stand-alone Generators 1. Remove jumper wire ST4 and turn the remote adjustment potentiometer to the center position. “
13. Readjust the speed of the unit to the rated no-load value.
Adjustments for Generators in Parallel Operation
”
2. Connect an analog voltmeter that is calibrated for 100 VDC on terminal E+ and terminal E- . “
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“
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3. Connect a voltmeter that is calibrated for 300 VAC to 500 VAC or 1000 VAC to the output terminals of the generator. 4. Make sure that the ST3 jumper wire is positioned on the desired frequency. “
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5. Turn the potentiometer P2 to a full counterclockwise position. “
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6. Turn the potentiometer P4 to a full clockwise position. “
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7. Turn the stability potentiometer P3 counterclockwise to about 1/3 of the total rotation for the potentiometer. “
Note: Make sure that the speed droop is identical for all of the engines before adjustments are made to the generator.
”
1. Preset the unit for parallel operation by connecting the current transformer to S1 and S2 of the connector J2 . Set quadrature droop potentiometer P1 to the center position. Apply the rated load. The voltage should drop by 2% to 3%. Switch the positions of the two incoming secondary wires of the current transformer if the voltage increases. “
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9. Adjust the output voltage to the correct value with the potentiometer P2 . This voltage should be the rated voltage UN for single operation or UN plus 2% to 4% for parallel operation with a current transformer. Adjust the potentiometer P3 in both directions while you observe the voltage between E+ and E- . The voltage between E+ and E- should be approximately 10 VDC. The best response times are obtained at the limit of the instability. Try cutting or replacing the jumper wire ST2 if no stable position can be obtained. “
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2. The no-load voltages should be identical for all the generators that are intended to be run in parallel. Connect the generators in parallel. Try to obtain a 0 kW power exchange by adjusting the speed of the generator. Try to minimize the circulating currents between generators by altering the voltage setting with the potentiometer P2 or Rhe on one of the generators. “
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8. Start the engine and set the engine speed to a frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz.
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”
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Note: Do not change the voltage settings after this step. 3. Apply the available load. The setting is correct only if a reactive load is available. Equalize the kilowatts or divide the rated power of the units proportionally by altering the speed. Alter the quadrature droop potentiometer P1 in order to equalize the currents or divide the currents. “
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Generator Operation Voltage Regulators
R448 Adjustment for Maximum Excitation
1. Open switch D . The excitation current should increase up to the preset maximum value and the excitation current should remain at the preset maximum value for approximately 10 seconds. The current will decrease to less than one Amp. “
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2. Open switch A in order to reset the internal protection. “
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Note: The voltage must be adjusted after the maximum excitation current has been set.
Special Use
Illustration 48
g01016266
The maximum factory setting corresponds to an excitation current that is required to obtain a threephase short circuit current of 3 IN at 50 Hz for industrial power, unless specified. The maximum level of excitation may be reduced by a static method. The static method is safer for the generator and the installation. Use the following steps to reduce the maximum excitation level. 1. Disconnect the power supply wires X1 , X2 Z1 and Z2 . “
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2. Disconnect sensing leads 0V, 110V, 220V and 380V on the generator.
Illustration 49
g00952821
The exciter is switched off by disconnecting the power supply to the voltage regulator. The connection is identical for resetting the internal protection for the voltage regulator.
3. Connect the main power supply 200V-240V to X1 and X2 , as shown. “
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4. Install a ten Amp DC ammeter in series with the exciter field. 5. Turn the potentiometer P5 to a full counterclockwise position and activate the power supply. If there is no output current from the voltage regulator, turn the potentiometer P2 clockwise until the ammeter indicates a stable current. “
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“
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6. Switch off the power supply. Switch on the power supply. Turn the potentiometer P5 until the required maximum current is obtained. The maximum current must not be greater than ten Amps. “
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Use the following steps in order to check the internal protection.
Illustration 50
g00952830
Use a 12 VDC power source in order to energize the field, if necessary. Refer to the following table. Table 5 Applications Voltage build up
B Volts
Time
12 (1A)
1 - 2 seconds
(continued)
SEBU8607
65 Generator Operation Generator Lead Connections
(Table 5, contd) De-energized parallel operation
12 (1A)
1 - 2 seconds
Standstill paralleloperation
24 (2A)
5 - 10 seconds
Frequency starting
48 (4A)
5 - 10 seconds
Voltage that is sustained at overload
48 (4A)
5 - 10 seconds
Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.
i03906109
Generator Lead Connections
Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.
SMCS Code: 4450
Grounding the Frame DANGER: Shock/Electrocution Hazard-Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death.
Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: •
Make sure the unit is off-line (disconnected from utility and/or other generators power service) , and either locked out or tagged DO NOT OPERATE.
• Remove all fuses. • Make sure the generator engine is stopped. • Make sure all batteries are disconnected. • Make sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.
In any generator set installation, the frame of the generator must be positively connected to an earth ground or to the hull of a vessel. This connection is the first connection that is made at the installation. This connection is the last connection that should be removed. If the generator set is on flexible mounting pads, the ground connection must be flexible in order to avoid possible breakage in later operation. Ground connection cable or straps should have at least the current carrying capacity of the largest line lead to the connected load. Joints in cables or straps must be clean, free of electrical resistance, and protected from possible oxidation. Bolted ground connection joints eventually oxidize. The joints are frequent sources of radio frequency interference (RFI). Joints that are silver soldered and bolted are preferred.
Neutral Connections The generators with a Wye Configuration usually have the neutral ground when the generator is installed. Grounding the neutral is for preventing damage to equipment. If the neutral wire is grounded and one of the phase leads becomes grounded, the excessive current will open a load circuit breaker. Also, the excessive current will cause the generator voltage to collapse. The result depends on the following items: electrical characteristics of the generator , type of fault and trip rating of the circuit breaker. An undervoltage device may be required in order to provide an adequate short circuit protection.
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Generator Operation Generator Lead Connections
There are some cases when the neutral wire is not grounded. An ungrounded generator neutral lead is acceptable when the possibility of grounds to the phase leads has been eliminated. An example of such measures are ground fault protective circuits. Ground fault protection requires the entire group of distribution circuits to be treated as a system. The owner should contact a certified consultant if a new distribution system is being developed. The owner should also contact a certified consultant if an existing system should be modified for the ground fault protection.
Wiring Code A for Three-Phase Configuration
Single Units Each unit should be connected to a common ground. In a three-phase, four-wire system, the neutral wire should be grounded according to local wiring codes. Be sure to check your local wiring codes.
Connection Diagrams
Illustration 51
Illustration 52
g00952030
Illustration 53
g00952058
g02160959
Typical example The generator lead connections are located in the terminal box on the generator or in the enclosure for the control panel (1). Change the position of the wire terminals in order to modify the connection. The code for the winding is specified on the nameplate.
Factory connection for A wiring code “
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Table 6 L-LVoltage for Wiring Code A Winding
50 Hz
60 Hz
6
190-208
190-240
7
220-230
-
8
-
190-208
SEBU8607
67 Generator Operation Generator Lead Connections
R 230 voltage sensing – 0 => (T8) / 110 V => (T11) R 438 LS voltage sensing – 0 => (T3) / 220 V => (T2)
Wiring Code B for Single-Phase Configuration or Three-Phase Configuration NOTICE This configuration is not possible for LSA 44.2 generator models.
Illustration 54
g00952097
Illustration 55
g00952196
Factory connection for B wiring code “
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Table 7 L-LVoltage for Wiring Code B Winding
50 Hz
60 Hz
6
110-120
120
7
120-130
-
8
-
110-120
R 230 voltage sensing – 0 => (T8) / 110 V => (T11)
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SEBU8607
Generator Operation Generator Lead Connections
R 438 LS voltage sensing – 0 => (T3) / 110 V => (T2)
Wiring Code D for Three-Phase Configuration
Table 8 L-LVoltage for Wiring Code D Winding
50 Hz
60 Hz
6
380-415
380-480
7
440-460
-
8
-
380-416
R 230 voltage sensing – 0 => (T8) / 110 V => (T11) R 438 LS voltage sensing – 0 => (T3) / 380 V => (T2)
Wiring Code F for Single-Phase Configuration or Three-Phase Configuration
Illustration 56
g00952201
Illustration 58
Voltage LM equals one half of voltage LL.
Illustration 57
g00952365
Factory connection for D wiring code “
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g00952381
SEBU8607
69 Generator Operation Generator Lead Connections
Illustration 59
g00952390
Illustration 61
g00952430
Factory connection for F wiring code
Factory connection for FF wiring code
Table 9
Table 10
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L-LVoltage for Wiring Code F
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L-LVoltage for Wiring Code FF
Winding
50 Hz
60 Hz
Winding
50 Hz
60 Hz
6
220-240
220-240
6
220-240
220-240
7
250-260
-
7
250-260
-
8
200
220-240
8
200
220-240
R 230 voltage sensing – 0 => (T8) / 110 V => (T11)
R 230 voltage sensing – 0 => (T1) / 110 V => (T4)
R 438 LS voltage sensing – 0 => (T3) / 220 V => (T2)
R 438 LS voltage sensing – 0 => (T10) / 220 V => (T1)
Wiring Code FF for Single-Phase Configuration
Illustration 60
Voltage LM equals one half of voltage LL.
g00952416
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SEBU8607
Generator Operation Generator Lead Connections
Connections for Exciter Field
R 791 T Interference Suppression
Connections for Series (SHUNT)
Illustration 64
Illustration 62
g01153397
(WHT) White (BLU) Blue (BLK) Black (RED) Red
Parallel Connection for Auxiliary Winding Regulation Excitation Principle (AREP) and Permanent Magnet Generator (PMG)
Illustration 63
(WHT) White (BLU) Blue (BLK) Black (RED) Red
g01147978
g00953025
Connect the interference suppression, as shown. The letters in the circles represent the wiring codes for the generators. (BLK) Black (BLU) Blue (WHT) White (A) Wiring code A (B) Wiring code B (D) Wiringcode D (F) Wiring code F (FF) Wiring code FF “
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SEBU8607
71 Cold Weather Operation Fuel and the Effect from Cold Weather
Cold Weather Operation
• Starting aids • Engine oil pan heaters
i03902887
Fuel and the Effect from Cold Weather SMCS Code: 1000; 1250; 1280 The following fuels are the grades that are available for Caterpillar engines:
• Engine coolant heaters • Fuel heaters • Fuel line insulation For more information on cold weather operation, see Special Publication, SEBU5898, “Cold Weather Recommendations”.
• No. 1 • No. 2
i03902889
• Blend of No. 1 and No. 2
Fuel Related Components in Cold Weather
No. 2 diesel fuel is the most commonly used fuel. Either No. 1 diesel fuel or a blend of No. 1 and No. 2 is best suited for cold weather operation.
SMCS Code: 1000; 1250; 1280
Quantities of No. 1 diesel fuel are limited. No. 1 diesel fuels are available during the months of the winter in the colder climates. During cold weather operation, if No. 1 diesel fuel is not available, use No. 2 diesel fuel, if necessary.
Condensation can form in partially filled fuel tanks. Top off the fuel tanks after operating the engine.
There are three major differences between No. 1 and No. 2 diesel fuel. No. 1 diesel fuel has the following properties: • Lower cloud point • Lower pour point • Lower rating of kJ (BTU) per unit volume of fuel When No. 1 diesel fuel is used, a decrease in power and in fuel efficiency may be noticed. Other operating effects should not be experienced. The cloud point is the temperature when a cloud of wax crystals begins to form in the fuel. These crystals can cause the fuel filters to plug. The pour point is the temperature when diesel fuel will thicken. The diesel fuel becomes more resistant to flow through fuel pumps and through fuel lines. Be aware of these values when diesel fuel is purchased. Anticipate the average ambient temperature of the area. Engines that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result due to changes in temperature. Before troubleshooting for low power or for poor performance in the winter, check the type of fuel that is being used. When No. 2 diesel fuel is used the following components provide a means of minimizing problems in cold weather:
Fuel Tanks
Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks. Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important. Drain the water and sediment from any fuel storage tank at the following intervals: • Weekly • Oil changes • Refueling of the fuel tank This will help prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank.
Fuel Filters NOTICE Do not fill the fuel filters with fuel before installing them. The fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
72 Cold Weather Operation Fuel Related Components in Cold Weather
NOTICE In order to maximize fuel system life and prevent premature wear out from abrasive particles in the fuel, a four micron[c] absolute high efficiency fuel filter is required for all Caterpillar Hydraulic Electronic Unit In jectors. Caterpillar High Efficiency Fuel Filters meet these requirements. Consult your Caterpillar dealer for the proper part numbers. When the engine is equipped with a primary filter/ water separator, the primary filter/water separator must use a 10 micron filter to a 15 micron filter. The filters are becoming more critical as fuel injection pressures increase to 209 MPa (30000 psi) and higher psi. For more information on priming the fuel system, see the Operation and Maintenance Manual, “Fuel System - Prime” topic (Maintenance Section).
Fuel Heaters Fuel heaters help to prevent fuel filters from plugging in cold weather due to waxing. A fuel heater should be installed in order for the fuel to be heated before the fuel enters the primary fuel filter. Select a fuel heater that is mechanically simple, yet adequate for the application. The fuel heater should also help to prevent overheating of the fuel. High fuel temperatures reduce engine performance and the availability of engine power. Choose a fuel heater with a large heating surface. The fuel heater should be practical in size. Small heaters can be too hot due to the limited surface area. Disconnect the fuel heater in warm weather. Note: Fuel heaters that are controlled by the water temperature regulator or self-regulating fuel heaters should be used with this engine. Fuel heaters that are not controlled by the water temperature regulator can heat the fuel in excess of 65° C (149° F). A loss of engine power can occur if the fuel supply temperature exceeds 37° C (100° F). Note: Heat exchanger type fuel heaters should have a bypass provision in order to prevent overheating of the fuel in warm-weather operation. For further information on fuel heaters, consult your Caterpillar dealer.
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SEBU8607
73 Engine Stopping Stopping the Engine
Engine Stopping i03902854
Stopping the Engine SMCS Code: 1000 Note: Individual applications will have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine. 1. Remove the load from the engine. 2. Press the stop button on the control panel. Turn isolator keyswitch to OFF position. i03902856
Emergency Stopping SMCS Code: 1000; 7418 NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure. Ensure that any components for the external system that support the engine operation are secured after the engine is stopped.
Emergency Stop Button
Illustration 65
Typical example
g02148927
The emergency stop button (1) is in the OUT position for normal engine operation. Push the emergency stop button. The engine will not start when the button is locked. Turn the button clockwise in order to reset.
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Engine Stopping Manual Stop Procedure
i03902885
Manual Stop Procedure SMCS Code: 1000; 7418
Stopping Procedure for the MCS Control Panel
Illustration 66
Typical example (1) Isolator Keyswitch
g02162627
SEBU8607
75 Engine Stopping Manual Stop Procedure
Illustration 67
Typical example (2) Stop key
g02162635
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Engine Stopping After Stopping Engine
• Allow the engine to cool. Check the coolant level. 1. Open the circuit breaker and remove the load from the generator. 2. When possible, allow the engine to operate without load for 3 minutes, in order to cool the engine. Note: Pressing the stop key bypasses the cooldown period.
• Perform all required periodic maintenance on all driven equipment. This maintenance is outlined in the instructions from the OEM.
3. Press and release the Stop key (2). “
”
4. The LCD display will indicate STOPPING . “
”
Note: If the engine fails to stop running, the LCD display will indicate STOP FAILURE . The alarm will sound. “
”
5. Once the engine has stopped, the LCD display will indicate STOPPED . “
”
Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. 6. Turn the isolator keyswitch (1) to the OFF position. i03902886
After Stopping Engine SMCS Code: 1000 Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. • Check the crankcase oil level. Maintain the oil level between the MIN mark and the MAX mark on the oil level dipstick. “
”
“
• If freezing temperatures are expected, check the coolant for the correct antifreeze protection. The cooling system must be protected against freezing to the lowest expected outside temperature. Add the correct coolant/water mixture, if necessary.
”
• If necessary, perform minor adjustments. Repair any leaks and tighten any loose bolts. • Note the required service interval. Perform the maintenance that is in the Operation and Maintenance Manual, “Maintenance Interval Schedule”. • Fill the fuel tank to help prevent accumulation of moisture in the fuel. Do not overfill the fuel tank. NOTICE Only use antifreeze/coolant mixtures recommended in the Refill Capacities and Recommendations topic that is in this Operation and Maintenance Manual. Failure to do so can cause engine damage.
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Maintenance Maintenance Section Section Refill Capacities and Recommendations
Maintena Maintenance nce Section Section Refill Refill Capacitie Capacities s i03903094
(Table 11, contd) (1) API CH-4 CH-4 and CI-4 oils oils are acceptabl acceptable e if the requirem requirements ents of Caterpillar's Caterpillar's ECF-1 (Engine Crankcase Fluid specificationspecification1) are are met. met. CH-4 and CI-4 CI-4 oils that have not met the requirerequirements of Caterpillar's Caterpillar's ECF-1 Specification Specification may cause reduced engine engine life. life. (2) The oil CD-2 CD-2 is for a two-cycle two-cycle diesel diesel engine. engine. Caterpill Caterpillar ar does not sell sell engines engines that utilize utilize CD-2 oil. oil.
Refill Refill Capaci Capacitie ties s and Recommendations
Note: When oil meets more than one API classificatio classification, n, the applicable applicable footnote is determined by the highest API classificati classification on that is met.
SMCS Code: 1348; 1395; 7560
Example – Example – An oil meets both the API CH-4 and the API CF oil classifications. In this case, the API CH-4 applies.
Engi Engine ne Oil Oil NOTICE These recommendations are subject to change without notice notice.. Contact Contact your your local Caterp Caterpilla illarr dealer dealer for the most up to date recommendations.
API Oils The Engine Oil Licensing Licensing and Certification System by the Amer America ican n Petrole Petroleum um Institu Institute te (API) (API) is recognized recognized by Caterpillar Caterpillar . For detailed information information about this system, see the latest edition of the API publication publication No. 1509. Engine oils that bear the API symbol symbol are authorized authorized by API.
Cat Cat DEO DEO (Die (Diese sell Engi Engine ne Oil) Oil) Caterpillar Oils have been developed developed and tested in order to provide the the full performance performance and service service life that has been designed and built into Caterpillar Engines Engines . Caterpillar Caterpillar Oils are currently currently used to fill diesel engines at the factory. These oils are offered by Caterpillar dealers for continued use when the engine oil is changed. Consult your Caterpillar dealer for more information information on these oils. Due to significant significant variations variations in the quality and and in the performance of commercially commercially available oils, Caterpillar makes the following recommendations: recommendations: • Cat DEO (Diesel (Diesel Engine Engine Oil) (10W-3 (10W-30) 0) • Cat DEO (Diesel (Diesel Engine Engine Oil) (15W-4 (15W-40) 0) Caterpillar Caterpillar multigrade multigrade DEO is formulated formulated with the correc correctt amount amounts s of deterg detergent ents, s, disper dispersan sants, ts, and alkalinity alkalinity in order to provide superior superior performanc performance e in Caterpillar Caterpillar Diesel Diesel Engines . Caterpillar Caterpillar multigrade multigrade DEO is available available in in various various viscosity grades that include SAE 10W-30 and SAE 15W-40. To To choose the correct viscosity grade for the ambient ambient temperature, temperature, see Table Table 12 . Multigrade Multigrade oils provide provide the correct viscosity viscosity for a broad range range of operating operating temperatures temperatures..
Illustration 68
g00546535
Typical API symbol Diesel engine oils CC, CD, CD-2, and CE have not been API authorized authorized classificatio classifications ns since January January 1, 1996. Table 11 API Classifications Current
Obsolete
CH-4(1) CI-4
CE, CC, CD
-
CD-2 (2)
(continued)
Multigrade Multigrade oils are effective effective in maintaining maintaining low oil consumption consumption and low levels of piston deposits. deposits. Caterpillar Caterpillar multigrade multigrade DEO can can be used used in in other other diesel engines and in gasoline engines. See the engine manufacturers guide for the recommended specificatio specifications. ns. Compare Compare the specificatio specifications ns to the the specificatio specifications ns of Caterpillar Caterpillar multigrade multigrade DEO. The current current industry industry standards standards for Caterpillar Caterpillar DEO are listed on the product label and on the data sheets for the product. Consult your Caterpillar dealer for part numbers and for available sizes of containers.
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Note: Caterpillar SAE 15W-40 multigrade DEO exceeds the performance requirements for the following following API classifications classifications:: CI-4, CH-4, CG-4, CF-4 and CF. CF. The Caterpilla Caterpillarr multigrade multigrade DEO exceeds exceeds the requiremen requirements ts of the Caterpill Caterpillar ar specificati specification on that is ECF-1(Engine Crankcase Fluid-1). The Caterpillar SAE 15W-40 multigrade DEO passes the following proprietary proprietary tests: sticking sticking of the piston ring, oil control tests, wear tests and soot tests. Proprietary Proprietary tests help ensure ensure that Caterpillar Caterpillar multigrade multigrade oil provides provides superior superior performance performance in Caterpillar Caterpillar Diesel Diesel Engines. Engines. In addition, addition, Caterpillar Caterpillar multigrade multigrade oil exceeds exceeds many of of the performance performance requirements requirements of other manufacturers manufacturers of diesel engines. engines. Therefore, Therefore, this oil is an excellent excellent choice for many mixed fleets. True fleets. True high performance performance oil is produced produced with a combination combination of the followin following g factors factors:: indust industry ry standa standard rd tests, tests, proprietary proprietary tests, field tests and prior experienc experience e with similar formulation formulations. s. The design and the development development of Caterpilla Caterpillarr lubricants lubricants that are both high performance performance and high high quality quality are based based on these factors. Note: Non-Caterp Non-Caterpillar illar commercial commercial oils are second second choice oils.
Commercia Commerciall Oils Note: If Caterpillar Caterpillar Multigrade Multigrade DEO is not used, used, use use only commercial oils that meet the following classifications. • API CH-4 CH-4 multigra multigrade de oils and API CI-4 CI-4 multigra multigrade de oils are acceptable acceptable if the requirements requirements of Caterpillar's ECF-1 (Engine Crankcase Fluid specification-1) are met. CH-4 oils and CI-4 oils that have not met the requirements of Caterpillar's ECF-1 Specification may cause reduced engine life. • API CF-4 multigrade multigrade oils are are not recomme recommended nded for for this series of diesel engines. For all other smaller commercial commercial diesel diesel engines, the oil drain interval interval should not not exceed exceed 50 percent percent of the standard standard oil drain interval interval for your engine. engine. NOTICE In selecting oil for any engine application, both the oil viscosity and oil performance classification/specification as specified by the engine manufacturer must be defined and satisfied. Using only one of these parameter eters s will will not not suff suffic icie ientl ntly y defin define e oil oil for for an engi engine ne application.
requirements requirements of Caterpillar's Caterpillar's ECF-1 (Engine (Engine Crankcase Fluid specification-1) are met. API CH-4 – CH-4 – API CH-4 oils were developed developed in order order to protect protect low emissions emissions diesel engines engines that use a 0.05 percent percent level of fuel sulfur. sulfur. However, However, API CH-4 oils may be used with higher sulfur fuels. API CH-4 oils are acceptable acceptable if the requirements requirements of Caterpillar's Caterpillar's ECF-1 (Engine Crankcase Fluid specification-1) are met. Note: CH-4 oils and and CI-4 oils oils that have not met met the requirements of Caterpillar's ECF-1 Specification may cause reduced reduced engine life. NOTICE Fail Failure ure to follo follow w thes these e oil oil reco recomm mmen end datio ations ns can can cause shortened engine service life due to deposits and/or excessive excessive wear. Special Publication, Publication, SEBU6251, SEBU6251, Note: Refer to Special “Caterpillar “Caterpillar Commercial Commercial Diesel Engine Engine Fluids Recommenda Recommendations tions ” for additional additional information information that relates to lubrication lubrication for your engine.
Lubricant Lubricant Viscosity Viscosity Recommenda Recommendations tions The proper SAE viscosity viscosity grade of oil is determined by the the minimum minimum ambient ambient temperature temperature during cold engine start-up, start-up, and the maximum maximum ambient ambient temperature temperature during engine operation. Refer to Table Table 12 (minimum (minimum temperature) temperature) in order order to determine determine the required required oil viscosity viscosity for for starting starting a cold engine. Refer to Table Table 12 (maximum (maximum temperature) temperature) in order order to select the oil viscosity viscosity for engine operation operation at the highest highest ambient temperature temperature that is anticipated. anticipated. Note: Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up. If ambient temperature temperature conditions conditions at engine start-up start-up require the use of multigrad multigrade e SAE 0W oil, SAE 0W-40 0W-40 viscosity viscosity grade is preferred over SAE 0W-20 or SAE 0W-30 . Table 12 Engine Oil Viscosities Viscosities for Ambient Ambient Temperatures Temperatures Ambient Temperature Viscosity Grade
In order to make the proper choice choice of a commercial commercial oil, refer refer to the following following explanatio explanations: ns: API CI-4 – CI-4 – API CI-4 oils were developed developed in order order to meet the requirements of high performance diesel engines that use cooled Exhaust Gas Recirculation (EGR). API CI-4 oils are acceptable acceptable if the
Minimum
Maximum
SAE 0W-20
−40 °C (−40 °F) °F)
10 °C (50 (50 °F)
SAE 0W-30
−40 °C (−40 °F) °F)
30 °C (86 (86 °F)
(continued)
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79 Refill Capacities Refill Capacities and Recommendations
(Table 12, contd)
Table 13
SAE 0W-40
−40 −40 °C (−40 (−40 °F) °F)
40 °C (104 (104 °F) °F)
SAE 5W-30
−30 °C (−22 −22 °F) °F)
30 °C (86 °F)
SAE 5W-40
−30 −30 °C (−22 (−22 °F) °F)
50 °C (122 (122 °F) °F)
SAE 10W-30
−18 °C (0 °F)
40 °C (104 °F)
SAE 10W-40
−18 °C (0 °F)
50 °C (122 °F)
SAE 15W-40
−9.5 9.5 °C (15 °F)
50 °C (122 (122 °F) °F)
Engine Refill Refill Capacitie Capacities s Compartment Compartment or System System Crankcase Oil Sump(1) (1)
Note: Supplemental heat is recommended below the minimum minimum recommended recommended ambient ambient temperature temperature..
S·O·S Oil Analys Analysis is Caterpillar has developed a tool for maintenance maintenance management management that evaluates evaluates oil degradation degradation and the tool also detects the early signs of wear on internal components. components. The Caterpilla Caterpillarr tool for for oil analys analysis is is called S·O·S Oil Analysis Analysis and the tool tool is part of the S·O·S Services Services program. program. S·O·S Oil Analysis Analysis divides divides oil analysis into three categories: • Wear Wear Analys Analysis is • Oil condit condition ion • Additio Additional nal tests tests The wear analysis analysis monitors monitors metal particles, particles, some oil additives, additives, and some contaminants contaminants..
Minim Minimum um
Maxim Maximum um
7.5 7.5 L (8 qt) qt)
9 L (9.5qt) (9.5qt)
These values are the approximate approximate capacities for the crankcase crankcase oil sump (aluminum)which (aluminum)which includes includes the standard standard factory factory installed stalled oil filters. filters. Engines Engines with auxiliar auxiliary y oil filters filters will require require additional oil. Refer to the OEM OEM specifications specifications for the capacity of the auxiliary oil filter. filter.
Lubricating Lubricating Grease Caterpillar Caterpillar provides provides a range of moderate moderate greases greases to extremely extremely high performance performance greases greases in order to service service the entire line of Caterpillar Caterpillar products products that operate operate throughout throughout the wide wide variety variety of climates. climates. From this variety variety of Caterpillar Caterpillar grease grease products, products, you will will find at least least one of the Caterpilla Caterpillarr greases greases that will satisfy the performan performance ce requirements requirements for any machine machine or equipment equipment application application.. Before selecting selecting a grease for any application, application, the performance requirements must be determined. Consult the grease recommendations that are made by the OEM for the the equipment equipment when the equipme equipment nt is operated operated in the expected expected conditions. conditions. Then, consult consult with your your Caterpillar Caterpillar dealer for for a list of greases greases and the following following related related characteris characteristics. tics. • Perform Performanc ance e specifi specificat cation ions s • Available Available sizes of containers containers
Oil condition uses uses infrared (IR) analysis to evaluate the chemistry chemistry of the oil. Infrared Infrared analysis analysis is also used to detect certain types of contamination.
• Part Part numb numbers ers
Additional tests are used to measure contamination levels from water, water, fuel, or coolant. Oil viscosity and corrosion corrosion protection protection can be evaluated, evaluated, as needed. needed.
Always choose a grease that satisfies the recommendations that are specified by the equipment manufacturer manufacturer for the application. application.
Refer to Special Publication, SEBU6251, Caterpillar Commercial Diesel Engine Fluids Recommendations Recommendations or contact contact your local Caterpillar Caterpillar dealer for for additional additional information information concerning concerning the S·O·S Oil Analysis Analysis program.
Refill Refill Capacities Capacities for the Lubric Lubrication ation System The refill capacities capacities for the engine engine crankcase reflect reflect the approximate approximate capacity capacity of the crankcase crankcase or sump plus standard standard oil filters. filters. Auxiliary Auxiliary oil filter systems systems will require require additional additional oil. Refer to the OEM specification specifications s for the capacity of the auxiliary oil filter.
Note: If it is necessary necessary to choose choose a single grease grease to use for all of the equipment at one site, always choose choose a grease that satisfies satisfies the requirement requirements s of the most demanding demanding applicatio application. n. Do not use the cost per pound as the only factor when you choose a grease. Use the grease that yields the lowest lowest total cost of operation. operation. The cost analysis analysis should include the following following factors: factors: • Part Parts s • Labo Labor r • Down Downti time me • Cost Cost of the grease grease Greases Greases that barely meet the minimum performance performance requirements requirements can be expected expected to barely produce produce the minimum life of the parts. parts.
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Note: Take care when you change the type of grease. Take care when you change to a different supplier of grease. Some greases are not chemically compatible. Some brands of grease can not be interchanged. If you are in doubt about the compatibility of the old grease and the new grease, purge all of the old grease from the joint. Consult your supplier in order to determine if the greases are compatible. Note: All Caterpillar greases are compatible with each other. Note: Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations ” for additional information that relates to lubrication for your engine.
General Fuel Information Diesel fuels that meet the Caterpillar Specification for Distillate Diesel Fuel are recommended. These fuels will help to provide maximum engine service life and performance. In North America, diesel fuel that is identified as No. 1-D or No. 2-D in ASTM D975 generally meet the specifications. Diesel fuels from other sources could exhibit detrimental properties that are not defined or controlled by this specification. NOTICE Operating with fuels that do not meet Caterpillar's recommendations can cause the following effects: starting difficulty, poor combustion, deposits in the fuel injectors, reduced service life of the fuel system, deposits in the combustion chamber and reduced service life of the engine. Note: Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations ” for the Caterpillar Specification for distillate fuel and for additional information that relates to fuel for your engine.
Refill Capacities for the Fuel System Refer to the Operation and Maintenance Manual that is provided by the OEM for capacities of the fuel system.
General Coolant Information NOTICE These recommendations are subject to change without notice. Contact your local Caterpillar dealer for the most up to date fluids recommendations.
NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first.
NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature or drained completely to prevent damage.
NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti-boil protection. Clean the cooling system for the following reasons: • Contamination of the cooling system • Overheating of the engine • Foaming of the coolant Note: Air pockets can form in the cooling system if the cooling system is filled at a rate that is greater than 5 L (1.3 US gal) per minute. After you drain the cooling system and after you refill the cooling system, operate the engine. Operate the engine without the filler cap until the coolant reaches normal operating temperature and the coolant level stabilizes. Ensure that the coolant is maintained to the proper level. NOTICE Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators. Refer to Special Instruction, SEBD0518, “Know Your Cooling System” and Special Instruction, SEBD0970, “Coolant and Your Engine” for more detailed information. Many engine failures are related to the cooling system. The following problems are related to cooling system failures: overheating, leakage of the water pump, plugged radiators or heat exchangers and pitting of the cylinder liners. These failures can be avoided with proper cooling system maintenance. Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system. Quality of the coolant is as important as the quality of the fuel and the lubricating oil. Coolant is normally composed of three elements: water, additives and glycol.
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81 Refill Capacities Refill Capacities and Recommendations
Water
• Corrosion
NOTICE Never use water alone without Supplemental Coolant Additives (SCA) or without inhibited coolant. Water alone is corrosive at engine operating temperatures. Water alone does not provide adequate protection against boiling or freezing. Water is used in the cooling system in order to transfer heat. Distilled water or deionized water is recommended for use in engine cooling systems. DO NOT use the following types of water in cooling systems: hard water, softened water that has been conditioned with salt and sea water. If distilled water or deionized water is not available, use water with the properties that are listed in Table 14 . Table 14
Caterpillar Minimum Acceptable Water Requirements Property Chloride(Cl)
Maximum Limit
ASTM Test
40 mg/L (2.4 grains/US gal) D512, D4327
• Formation of mineral deposits • Rust • Scale • Pitting and erosion from cavitation of the cylinder liner • Foaming of the coolant Many additives are depleted during engine operation. These additives must be replaced periodically. This can be done by adding Supplemental Coolant Additives (SCA) to Diesel Engine Antifreeze/Coolant (DEAC) or by adding ELC Extender to Extended Life Coolant (ELC). Additives must be added at the proper concentration. Overconcentration of additives can cause the inhibitors to drop out-of-solution. The deposits can enable the following problems to occur: • Formation of gel compounds • Reduction of heat transfer • Leakage of the water pump seal
Sulfate (SO4)
100 mg/L (5.9 grains/US gal)
D516
• Plugging of radiators, coolers, and small passages
Total Hardness
170 mg/L (10 grains/US gal)
D1126
Glycol
Total Solids
340 mg/L (20 grain/US gal)
Acidity
pH of 5.5 to 9.0
D1888 D1293
For a water analysis, consult one of the following sources: • Caterpillar dealer • Local water utility company • Agricultural agent • Independent laboratory
Additives Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives or insufficient amounts of additives enable the following conditions to occur:
Glycol in the coolant helps to provide protection against the following conditions: • Boiling • Freezing • Cavitation of the water pump and the cylinder liner For optimum performance, Caterpillar recommends a 1:1 mixture of a water/glycol solution. Note: Use a mixture that will provide protection against the lowest ambient temperature. Note: 100 percent pure glycol will freeze at a temperature of −23 °C (−9 °F). Most conventional heavy-duty antifreezes use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture with water, ethylene and propylene glycol provide similar protection against freezing and boiling. See Tables 15 and 16 .
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Refer to Special Publication, SEBU6251, Caterpillar Commercial Diesel Engine Fluids Recommendations for additional information that relates to coolant.
Table 15
Ethylene Glycol
Freeze Protection
Boil Protection
50 Percent
−36 °C (−33 °F)
106 °C (223 °F)
60 Percent
−51 °C (−60 °F)
111 °C (232 °F)
Concentration
NOTICE Do not use propylene glycol in concentrations that exceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol. Use ethylene glycol in conditions that require additional protection against boiling or freezing.
Propylene Glycol
50 Percent
Table 17
Recommended Interval
(1)
Type of Coolant
Level 1
Level 2
DEAC
Every 250 Hours
Yearly(1)
ELC
Not Required
Yearly
The Level 2 Coolant Analysis should be performed sooner if a problem is identified by a Level 1 Coolant Analysis.
S·O·S Coolant Analysis (Level 1)
Table 16
Concentration
S·O·S Coolant Analysis
Freeze Protection
Anti-Boil Protection
−29 °C (−20 °F)
106 °C (223 °F)
To check the concentration of glycol, use the 1U-7298 Coolant/Battery Tester (Degrees Celsius) or use the 1U-7297 Coolant/Battery Tester (Degrees Fahrenheit). The testers give readings that are immediate and accurate. The testers can be used with ethylene or propylene glycol.
A coolant analysis (Level 1) is a test of the properties of the coolant. The following properties of the coolant are tested: • Glycol concentration for freeze protection and boil protection • Ability to protect from erosion and corrosion • pH • Conductivity
Coolant Recommendations
• Visual analysis
NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 specification. This type of coolant/antifreeze is made for light duty automotive applications.
• Odor analysis
The following two coolants are used in Caterpillar diesel engines: Preferred – Caterpillar Extended Life Coolant (ELC) or a commercial extended life coolant that meets the Caterpillar EC-1 specification Acceptable – Caterpillar Diesel Engine Antifreeze (DEAC) or a commercial heavy-duty antifreeze that meets ASTM D4985, or ASTM D6210 specifications Caterpillar recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as a antifreeze. Note: Caterpillar DEAC does not require a treatment with an SCA at the initial fill. A commercial heavy-duty antifreeze that meets ASTM D4985 or ASTM D6210 specifications MAY require a treatment with an SCA at the initial fill. These coolants WILL require a treatment with an SCA on a maintenance basis.
The results are reported, and appropriate recommendations are made. Refer to the Maintenance Interval Schedule in this Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” for a sampling location and the maintenance interval for collecting the coolant samples. S·O·S Coolant Analysis (Level 2) A coolant analysis (Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of the cooling system. The S·O·S Coolant Analysis has the following features:
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• Full coolant analysis (Level 1) • Identification of the source of metal corrosion and of contaminants • Water hardness • Identification of buildup of the impurities that cause corrosion • Identification of buildup of the impurities that cause scaling The results are reported, and appropriate recommendations are made. Refer to the Maintenance Interval Schedule in this Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 2) - Obtain” for a sampling location and the maintenance interval for collecting the coolant samples. Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and from corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling and from freezing. The S·O·S Coolant Analysis can be done at your Caterpillar dealer. Caterpillar S·O·S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system. S·O·S Coolant Analysis is a program that is based on periodic samples. Refer to Special Publication, SEBU6251, Caterpillar Commercial Diesel Engine Fluids Recommendations for additional information.
Refill Capacity of the Cooling System To maintain the cooling system, the Total Cooling System capacity must be known. The approximate capacity for the Engine Only cooling system is listed. External System capacities will vary among applications. Refer to the OEM specifications for the External System capacity. This capacity information will be needed in order to determine the amount of antifreeze that is required for the Total Cooling System. “
”
Table 18
Engine Refill Capacities Compartment or System
Liters
Engine Only (Minimum)
16.5 L (17.5 qt)
Engine Only (Maximum)
18 L (19 qt)
External System Per OEM(1) (1)
The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specifications. Enter the value for the capacity of the External System in this row.
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Maintenance Recommendations General Maintenance Information
Maintenance Recommendations
• periodic disassembly • knowledgeable visual examination of the equipment i05264090
General Maintenance Information SMCS Code: 4450; 7000 Note: Read the warnings and read the instructions that are contained in the Safety Section of this manual. These warnings and instructions must be understood before you perform any operation or any maintenance procedures. Rotating electric machines are complex structures that are exposed to the following forms of stress:
• the application of electrical tests Never perform a test over the rated potential. These tests can damage insulation that is contaminated or insulation that is in marginal condition. For more information, refer to I.E.E.E. Standard 432-1992 or consult a Cat dealer. i03903087
System Pressure Release SMCS Code: 1250; 1300; 1350; 5050
Coolant System
• mechanical • electrical • thermal • environmental These stresses may be of varying magnitudes. The electrical insulation systems are susceptible to damage that is caused by the stresses that are listed above. Exposure to these stresses may shorten the effective life of the electrical insulation system. Therefore, the service life of an electric machine will largely depend on the serviceability of the electrical insulation systems. An inspection program and a testing procedure are recommended. An inspection program and a testing procedure will ensure that the equipment is maintained in satisfactory condition. This will increase field reliability. A regular maintenance and inspection program can provide an evaluation of the present condition of the equipment. A regular maintenance program and a regular inspection program can also reveal future problems. The frequency of this maintenance program will depend on the following factors:
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. To relieve the pressure from the coolant system, turn off the engine. Allow the cooling system pressure cap to cool. Remove the cooling system pressure cap slowly in order to relieve pressure.
Fuel System To relieve the pressure from the fuel system, turn off the engine.
Engine Oil To relieve pressure from the lubricating system, turn off the engine.
• application i05264113
• environmental conditions • experience level of the operator • philosophy of the operator A regular maintenance program is strongly recommended. This program would involve the following steps:
Welding on Engines with Electronic Controls SMCS Code: 1000 NOTICE Because the strength of the frame may decrease, some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equipment or your Cat dealer regarding welding on a chassis frame or rail.
SEBU8607
85 Maintenance Recommendations Welding on Engines with Electronic Controls
Proper welding procedures are necessary in order to avoid damage to the engine ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component is not possible, the following procedure must be followed when you weld on a unit that is equipped with a Cat Electronic Engine . The following procedure is considered to be the safest procedure to weld on a component. This procedure should provide a minimum risk of damage to electronic components. NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train, the bearings, hydraulic components, electrical components, and other components. Do not ground the welder across the centerline of the package. Improper grounding could cause damage to the bearings, the crankshaft, the rotor shaft, and other components. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage. Note: Perform the welding in areas that are free from explosive hazards. 1. Stop the engine. Turn the switched power to the OFF position. 2. Disconnect the negative battery cable from the battery. If a battery disconnect switch is provided, open the switch. 3. Disconnect the J1/P1 and J2/P2 connectors from the ECM. Move the harness to a position that will not allow the harness to move back accidentally, and contact any of the ECM pins.
Illustration 69
g01075639
Use the example above. The current flow from the welder to the ground clamp of the welder will not damage any associated components. (1) Engine (2) Welding electrode (3) Keyswitch in the OFF position (4) Battery disconnectswitch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic component (8) Minimum distance between the component that is being welded and any electrical/electronic component (9) The component that is being welded (10) Current path of the welder (11) Ground clamp for the welder
4. Connect the welding ground cable directly to the part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings, hydraulic components, electrical components, and ground straps. Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the welder ground and the weld, current flow from the welder could severely damage the component. 5. Protect the wiring harness from welding debris and spatter.
86 Maintenance Recommendations Welding on Engines with Electronic Controls
6. Use standard welding practices to weld the materials.
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SEBU8607
87 Maintenance Recommendations Generator Start-up Checklist
i03860683
Generator Start-up Checklist SMCS Code: 4450 Table 19
GENERATOR START-UP CHECKLIST RATING INFORMATION Engine Serial Number: ___________________________________
Arrangement Number: ___________________
Generator Serial Number: _________________________________
Arrangement Number: ___________________
GENERATOR NAME PLATE INFORMATION Voltage: ___________________
Package (prime,continuous, standby): _________________
Amperage: _________________
Kilowatts: ________________________________________
Storage Location: Main Stator Megohmmeter Reading:
Before Storage:
Generator dried for 24 hours prior to startup?
After Storage:
(Y/N)
SPACE HEATERS
Drying method:
Yes
No
30 sec. reading
60 sec. reading
Comments
Space heaters operating properly? Space heater operated 48 hours before startup? MEGOHMMETER TEST Special Instruction, SEHS9124
30 sec. corrected
60 sec. corrected
Ambient temp.
Comments
Main Stator Main Rotor Beginning of Storage
Exciter Stator Exciter Rotor PMG Stator Main Stator Main Rotor
Start-up
Exciter Stator Exciter Rotor PMG Stator
Table 20 GENERATOR START-UP CHECKLIST (CONT.) Regulator
Voltage F1 to F2
DC
E1 to E2
AC
E1 to E3
AC
E2 to E3
AC
Amps
Comments
All Frames No Load
2400, 2500, PM1 to PM4 2800, and 2900 Frames
AC
(continued)
88
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Maintenance Recommendations Generator Start-up Checklist
(Table 20, contd)
2600 Frame
PM1 to PM2
AC
PM1 to PM3
AC
PM2 to PM3
AC
Generator Excitation DC Name Plate Information: All Frames
Full Load
F1 to F2
DC
E1 to E2
AC
E1 to E3
AC
E2 to E3
AC
2400, 2500, PM1 to PM4 2800, and 2900 Frames
AC
PM1 to PM2
AC
PM1 to PM3
AC
PM2 to PM3
AC
2600 Frame
Compare with F1 to F2
Table 21 GENERATOR START-UP CHECKLIST (CONT.) ELECTRICAL
Yes
No
Comments
Unit properly grounded Check diodes Over current protection Over voltage protection Check for loose wiring Adjust voltage Adjust frequency
Table 22 GENERATOR START-UP CHECKLIST (CONT.) MECHANICAL
Data
Comments
Bearingtemperaturereadings at full load
Front __________ Rear ___________
Stator temperature readings at full load
A0 _______ B0 _______ C0 _______
Air gap on main stator
Top __________ Bottom __________
Air gap on exciter stator
Top __________ Bottom __________
Air gap of PMG
Top __________ Bottom __________
Ambient air to generator at full load
Temperature ____________________
Supplier a ir opening to generator
Size of Opening _ ________________
SWITCH GEAR/PARALLEL OPERATION Manufacturer: Setting 1
Setting 2
Setting 3
Comments
(continued)
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89 Maintenance Recommendations Severe Service Application
(Table 22, contd) Type of Circuit breaker Overload setting Reverse power relay VAR/PF Controller Load share INSTALLATION & LOAD INFORMATION Neutral grounding system
UPS
Enclosure type
- Size
Motor:
Other loads:
- Total SKVA
- Lighting
- Total HP
- Computers - Welding - Non-linear - Other
FULL LOAD DATA Voltage
Amps
KW
i05256872
Severe Service Application SMCS Code: 1000 Severe service is the application of an engine that exceeds the current published standards for that engine. Caterpillar maintains standards for the following engine parameters: • Performance such as power range, speed range, and fuel consumption • Fuel quality • Operational Altitude • Maintenance intervals • Oil selection and maintenance • Coolant type and maintenance • Environmental qualities • Installation • The temperature of the fluid in the engine Refer to the standards for the engine or consult your Cat dealer in order to determine if the engine is operating within the defined parameters.
KVARS
P.F.
Severe service operation can accelerate component wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life. Due to individual applications, identification all of the factors which can contribute to severe service operation is not possible. Consult your Cat dealer for the unique maintenance that is necessary for the engine. The operating environment, incorrect operating procedures, and incorrect maintenance procedures can be factors which contribute to a severe service application.
Environmental Factors Ambient temperatures – The engine may be exposed to extended operation in cold environments or hot environments. Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in cold temperatures. Hot intake air reduces engine performance. Quality of the air – The engine may be exposed to extended operation in an environment that is dirty or dusty. Unless the equipment is cleaned regularly, mud, dirt, and dust can encase components. Maintenance can be difficult. The buildup can contain corrosive chemicals. Buildup – Compounds, elements, corrosive chemicals, and salt can damage some components.
90 Maintenance Recommendations Severe Service Application
Altitude – Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be made.
Incorrect Operating Procedures • Extended operation at low idle • Frequent hot shutdowns • Operating at excessive loads • Operating at excessive speeds • Operating outside the intended application
Incorrect Maintenance Procedures • Extending the maintenance intervals • Failure to use recommended fuel, lubricants, and coolant/antifreeze
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91 Maintenance Recommendations Maintenance Interval Schedule
i05278850
Maintenance Interval Schedule (Naturally Aspirated Marine Generator Sets)
“Walk-Around Inspection”..................................... 148
Every Week “Automatic Start/Stop - Inspect” ..............................97
SMCS Code: 1000; 4450; 7500
“Standby Generator Set Maintenance Recommendations” .............................................. 146
S/N: L1K1–Up
Every 250 Service Hours
Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.
“Coolant Sample (Level 1) - Obtain”..................... 105
The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance.
Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems) “Coolant Sample (Level 2) - Obtain”..................... 106
Every 500 Service Hours or 1 Year “Cooling System Supplemental Coolant Additive (SCA) - Test/Add”.................................................. 107
Every 1000 Service Hours “Engine Speed/Timing Sensor - Clean/Inspect”... 123
Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.
Every 1000 Service Hours or 1 Year
When Required
Every Year
“Battery - Replace”............. ......................................98
“Coolant Sample (Level 2) - Obtain”..................... 106
“Battery or Battery Cable - Disconnect”................ 100 “Engine - Clean”.................................................... 108
Every 3000 Service Hours or 3 Years
“Fuel System - Prime”...........................................123
“Engine Protective Devices - Check”.................... 122
“Generator - Dry”................................................... 129 “Generator Set - Test” ........................................... 133
Every 6000 Service Hours or 3 Years
“Generator Winding Insulation - Test”................... 134
“Coolant Extender (ELC) - Add” ....................... .... 103
“Rotating Rectifier - Inspect/Test” ......................... 143
Every 8000 Service Hours
Daily
“Engine Crankcase Breather - Replace” ...............113
“Belts - Inspect/Adjust/Replace” ........................... 100 “Coolant Level - Check” ........................................104
Every 12 000 Service Hours or 6 Years
“Electrical Connections - Check” .......................... 108
“Coolant (ELC) - Change”..................................... 101
“Engine Air Cleaner Service Indicator - Inspect” ...112 “Engine Oil Level - Check”.....................................115
Every 4150 L (1100 US gal) of Fuel or 500 Service Hours or 1 Year
“Generator Load - Check”.....................................133
“Auxiliary Water Pump - Inspect”.............................97
“Power Factor - Check”................................ ......... 143
“Auxiliary Water Pump - Inspect”.............................98
“Battery Charger - Check”........................................99
92
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Maintenance Recommendations Maintenance Interval Schedule
“Battery Electrolyte Level - Check” ..........................99 “Engine Air Cleaner Element (Dual Element) Inspect/Clean/Replace”........................................109 “Engine Air Cleaner Element (Single Element) Inspect/Clean/Replace”.........................................112 “Engine Mounts - Inspect” .....................................114 “Engine Oil Sample - Obtain”.................................115 “Engine Oil and Filter - Change” ............................116 “Engine Oil and Filter - Change”........................... 120 “Fuel System Primary Filter (Water Separator) Element - Replace” ............................................... 126 “Fuel System Secondary Filter - Replace” ........... 127 “Fuel Tank Water and Sediment - Drain” .............. 129 “Heat Exchanger - Inspect/Clean”........................ 139 “Hoses and Clamps - Inspect/Replace”.............. .. 139
Every 8300 L (2190 US gal) of Fuel or 1000 Service Hours or 1 Year “Engine Valve Lash - Check” ................................ 123
Every 16 600 L (4390 US gal) of Fuel or 2000 Service Hours or 2 Years “Alternator - Inspect” ................................................97 “Coolant Temperature Regulator - Replace” ........ 106 “Generator - Inspect” ............................................ 131
Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.
When Required “Battery - Replace”.............. .....................................98 “Battery or Battery Cable - Disconnect”................ 100 “Engine - Clean”.................................................... 108 “Fuel System - Prime”........................................... 123 “Generator - Dry”..................... .............................. 129 “Generator Set - Test” ...........................................133 “Generator Winding Insulation - Test”...................134 “Rotating Rectifier - Inspect/Test” ......................... 143
“Generator Set Vibration - Inspect”.......................134
Daily
“Rotating Rectifier - Check” ..................................143
“Belts - Inspect/Adjust/Replace”........................... 100
“Starting Motor - Inspect”...................................... 147
“Coolant Level - Check” ........................................ 104
“Water Pump - Inspect”......................................... 149
“Electrical Connections - Check” .......................... 108
Every 99 600 L (26 310 US gal) of Fuel or 12 000 Service Hours
“Engine Air Cleaner Service Indicator - Inspect” ...112
“Overhaul Considerations” ................................... 140
“Generator Load - Check”..................................... 133
“Engine Oil Level - Check”.....................................115
“Power Factor - Check”......................................... 143 i05256782
Maintenance Interval Schedule (Turbocharged Marine Generator Set Without Aftercooler) SMCS Code: 1000; 4450; 7500 S/N: S1M1–Up
“Walk-Around Inspection”..................................... 148
Every Week “Automatic Start/Stop - Inspect” ..............................97 “Standby Generator Set Maintenance Recommendations” .............................................. 146
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93 Maintenance Recommendations Maintenance Interval Schedule
Every 250 Service Hours
“Engine Oil and Filter - Change”............................116
“Coolant Sample (Level 1) - Obtain”..................... 105
“Engine Oil and Filter - Change”........................... 120
Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)
“Fuel System Primary Filter (Water Separator) Element - Replace”............................................... 126
“Coolant Sample (Level 2) - Obtain”..................... 106
Every 500 Service Hours or 1 Year “Cooling System Supplemental Coolant Additive (SCA) - Test/Add”............. ..................................... 107
Every 1000 Service Hours “Engine Speed/Timing Sensor - Clean/Inspect”... 123
Every 1000 Service Hours or 1 Year
“Fuel System Secondary Filter - Replace” ........... 127 “Fuel Tank Water and Sediment - Drain” .............. 129 “Heat Exchanger - Inspect/Clean” ........................139 “Hoses and Clamps - Inspect/Replace”................ 139 “Sea Water Strainer - Clean/Inspect” ...................144
Every 8300 L (2190 US gal) of Fuel or 1000 Service Hours or 1 Year “Belts - Inspect/Adjust/Replace”........................... 100
“Battery Charger - Check”........................................99
Every 11 100 L (2930 US gal) of Fuel or 1000 Service Hours or 1 Year
Every Year
“Engine Valve Lash - Check”................................ 123
“Coolant Sample (Level 2) - Obtain”..................... 106
Every 3000 Service Hours or 3 Years
Every 22 200 L (5860 US gal) of Fuel or 2000 Service Hours or 2 Years “Alternator - Inspect” ................................................97
“Engine Protective Devices - Check”....................122
“Coolant Temperature Regulator - Replace” ........ 106
Every 6000 Service Hours or 3 Years
“Generator - Inspect” ............................................131
“Coolant Extender (ELC) - Add” ........................... 103
“Rotating Rectifier - Check” .................................. 143
Every 12 000 Service Hours or 6 Years
“Starting Motor - Inspect”......................................147
“Coolant (ELC) - Change”.....................................101
Every 5550 L (1470 US gal) of Fuel or 500 Service Hours or 1 Year “Auxiliary Water Pump - Inspect” .............................97 “Auxiliary Water Pump - Inspect” .............................98
“Generator Set Vibration - Inspect”....................... 134
“Turbocharger - Inspect” .......................................147 “Water Pump - Inspect”.........................................149
Every 88 800 L (23 460 US gal) of Fuel or 8000 Service Hours “Engine Crankcase Breather - Replace” ...............113
“Battery Electrolyte Level - Check” ..........................99
Every 133 200 L (35 190 US gal) of Fuel or 12 000 Service Hours
“Engine Air Cleaner Element (Dual Element) Inspect/Clean/Replace”........................................109
“Overhaul Considerations” ................................... 140
“Engine Air Cleaner Element (Single Element) Inspect/Clean/Replace”.........................................112 “Engine Crankcase Breather Element - Replace” .113 “Engine Mounts - Inspect” .....................................114 “Engine Oil Sample - Obtain”.................................115
94
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Maintenance Recommendations Maintenance Interval Schedule
i05277669
Maintenance Interval Schedule (Turbocharged Aftercooled Marine Generator Sets Rated at 50 Hz 86 ekW and 60 Hz 93 ekW)
“Generator Load - Check”..................................... 133 “Power Factor - Check”......................................... 143 “Walk-Around Inspection”..................................... 148
Every Week “Automatic Start/Stop - Inspect” ..............................97
SMCS Code: 1000; 4450; 7500
“Standby Generator Set Maintenance Recommendations” .............................................. 146
S/N: S1M1–Up
Every 250 Service Hours
Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.
“Coolant Sample (Level 1) - Obtain”..................... 105
The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance.
Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems) “Coolant Sample (Level 2) - Obtain”..................... 106
Every 500 Service Hours or 1 Year “Cooling System Supplemental Coolant Additive (SCA) - Test/Add”.................................................. 107
Every 1000 Service Hours “Engine Speed/Timing Sensor - Clean/Inspect”... 123
Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.
Every 1000 Service Hours or 1 Year
When Required
Every Year
“Battery - Replace”............. ......................................98
“Coolant Sample (Level 2) - Obtain”..................... 106
“Battery or Battery Cable - Disconnect”................ 100 “Engine - Clean”.................................................... 108
Every 3000 Service Hours or 3 Years
“Fuel System - Prime”...........................................123
“Engine Protective Devices - Check”.................... 122
“Generator - Dry”................................................... 129 “Generator Set - Test” ........................................... 133
Every 6000 Service Hours or 3 Years
“Generator Winding Insulation - Test”................... 134
“Coolant Extender (ELC) - Add” ....................... .... 103
“Rotating Rectifier - Inspect/Test” ......................... 143
Every 12 000 Service Hours or 6 Years
Daily “Belts - Inspect/Adjust/Replace” ........................... 100 “Coolant Level - Check” ........................................104 “Electrical Connections - Check” .......................... 108 “Engine Air Cleaner Service Indicator - Inspect” ...112 “Engine Oil Level - Check”.....................................115
“Battery Charger - Check”........................................99
“Coolant (ELC) - Change”..................................... 101
Every 10 350 L (2730 US gal) of Fuel or 500 Service Hours or 1 Year “Auxiliary Water Pump - Inspect”.............................97 “Auxiliary Water Pump - Inspect”.............................98
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95 Maintenance Recommendations Maintenance Interval Schedule
“Battery Electrolyte Level - Check” ..........................99 “Engine Air Cleaner Element (Dual Element) Inspect/Clean/Replace”........................................109 “Engine Air Cleaner Element (Single Element) Inspect/Clean/Replace”.........................................112 “Engine Crankcase Breather Element - Replace” .113 “Engine Mounts - Inspect” .....................................114 “Engine Oil Sample - Obtain”.................................115 “Engine Oil and Filter - Change” ............................116 “Engine Oil and Filter - Change”........................... 120 “Fuel System Primary Filter (Water Separator) Element - Replace” ............................................... 126 “Fuel System Secondary Filter - Replace” ........... 127 “Fuel Tank Water and Sediment - Drain” .............. 129 “Heat Exchanger - Inspect/Clean”........................ 139 “Hoses and Clamps - Inspect/Replace”.............. .. 139 “Sea Water Strainer - Clean/Inspect” ................... 144
Every 20 700 L (5470 US gal) of Fuel or 1000 Service Hours or 1 Year “Engine Valve Lash - Check” ................................ 123
Every 41 400 L (10 940 US gal) of Fuel or 2000 Service Hours or 2 Years “Alternator - Inspect” ................................................97 “Coolant Temperature Regulator - Replace” ........ 106 “Generator - Inspect” ............................................ 131 “Generator Set Vibration - Inspect”.......................134 “Rotating Rectifier - Check” ..................................143 “Starting Motor - Inspect”...................................... 147 “Turbocharger - Inspect” .......................................147 “Water Pump - Inspect”......................................... 149
Every 110 400 L (29 160 US gal) of Fuel or 8000 Service Hours
i05277409
Maintenance Interval Schedule (Turbocharged Aftercooled Marine Generator Set Rated at 50 Hz 69 ekW and 60 Hz 76 ekW) SMCS Code: 1000; 4450; 7500 S/N: S1M1–Up Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.
When Required “Battery - Replace”.............. .....................................98 “Battery or Battery Cable - Disconnect”................ 100 “Engine - Clean”.................................................... 108 “Fuel System - Prime”........................................... 123 “Generator - Dry”..................... .............................. 129 “Generator Set - Test” ...........................................133 “Generator Winding Insulation - Test”...................134 “Rotating Rectifier - Inspect/Test” ......................... 143
Daily “Belts - Inspect/Adjust/Replace”........................... 100
“Engine Crankcase Breather - Replace” ...............113
“Coolant Level - Check” ........................................ 104
Every 165 600 L (43 750 US gal) of Fuel or 12 000 Service Hours
“Electrical Connections - Check” .......................... 108
“Overhaul Considerations” ................................... 140
“Engine Oil Level - Check”.....................................115
“Engine Air Cleaner Service Indicator - Inspect” ...112
96
SEBU8607
Maintenance Recommendations Maintenance Interval Schedule
“Generator Load - Check”.....................................133
“Battery Electrolyte Level - Check” ..........................99
“Power Factor - Check”................................ ......... 143
“Engine Air Cleaner Element (Dual Element) Inspect/Clean/Replace”........................................ 109
“Walk-Around Inspection”.....................................148
Every Week
“Engine Air Cleaner Element (Single Element) Inspect/Clean/Replace”.........................................112
“Automatic Start/Stop - Inspect” ..............................97
“Engine Crankcase Breather Element - Replace” .113
“Standby Generator Set Maintenance Recommendations” .............................................. 146
“Engine Mounts - Inspect” .....................................114
Every 250 Service Hours “Coolant Sample (Level 1) - Obtain”..................... 105
Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)
“Engine Oil Sample - Obtain”.................................115 “Engine Oil and Filter - Change”............................116 “Engine Oil and Filter - Change”........................... 120 “Fuel System Primary Filter (Water Separator) Element - Replace”............................................... 126 “Fuel System Secondary Filter - Replace” ........... 127
“Coolant Sample (Level 2) - Obtain”..................... 106
“Fuel Tank Water and Sediment - Drain” .............. 129
Every 500 Service Hours or 1 Year
“Heat Exchanger - Inspect/Clean” ........................139
“Cooling System Supplemental Coolant Additive (SCA) - Test/Add”............. ..................................... 107
Every 1000 Service Hours “Engine Speed/Timing Sensor - Clean/Inspect”... 123
“Hoses and Clamps - Inspect/Replace”................ 139 “Sea Water Strainer - Clean/Inspect” ...................144
Every 13 800 L (3650 US gal) of Fuel or 1000 Service Hours or 1 Year
Every 1000 Service Hours or 1 Year
“Engine Valve Lash - Check”................................ 123
“Battery Charger - Check”........................................99
Every 27 600 L (7290 US gal) of Fuel or 2000 Service Hours or 2 Years
Every Year “Coolant Sample (Level 2) - Obtain”..................... 106
Every 3000 Service Hours or 3 Years “Engine Protective Devices - Check”....................122
Every 6000 Service Hours or 3 Years “Coolant Extender (ELC) - Add” ........................... 103
Every 12 000 Service Hours or 6 Years “Coolant (ELC) - Change”.....................................101
Every 6900 L (1820 US gal) of Fuel or 500 Service Hours or 1 Year “Auxiliary Water Pump - Inspect” .............................97 “Auxiliary Water Pump - Inspect” .............................98
“Alternator - Inspect” ................................................97 “Coolant Temperature Regulator - Replace” ........ 106 “Generator - Inspect” ............................................131 “Generator Set Vibration - Inspect”....................... 134 “Rotating Rectifier - Check” .................................. 143 “Starting Motor - Inspect”......................................147 “Turbocharger - Inspect” .......................................147 “Water Pump - Inspect”.........................................149
Every 110 400 L (29 160 US gal) of Fuel or 8000 Service Hours “Engine Crankcase Breather - Replace” ...............113
Every 165 600 L (43 750 US gal) of Fuel or 12 000 Service Hours “Overhaul Considerations” ................................... 140
SEBU8607
97 Maintenance Recommendations Alternator - Inspect
i03903113
Alternator - Inspect SMCS Code: 1405-040 Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required. Check the alternator and the battery charger for proper operation. If the batteries are properly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power of the battery. If the battery is too cold, the battery will not crank the engine. When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge. i03903115
Automatic Start/Stop - Inspect SMCS Code: 4462 The generator set must be ready to operate under a load at any time. After performing maintenance on the generator set, inspect the position of the control switches. Ensure the following conditions: • The starting system is enabled. • The control switches are in the correct position for automatic starting. • The switchgear and the automatic transfer switches that are associated with the generator are enabled. i03903117
Auxiliary Water Pump - Inspect SMCS Code: 1371-040; 1371 Impellers require periodic inspection and seals require periodic inspection. Impellers have a service life that is limited. The service life depends on the engine operating conditions. Inspect the components of the pump more frequently when the pump is exposed to debris, sand, or other abrasive materials. Inspect the components if the pump is operating at a differential pressure of more than 103 kPa (15 psi).
Check the following components for wear and check the following components for damage:
98
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Maintenance Recommendations Auxiliary Water Pump - Inspect
Illustration 70
(1)Seal (2)Seal (3) Wear Plate (4)Cam
g01740513
(5) Impeller (6) Seal (7) O Ring Seal (8) End Cover
(9) Screw that holds cam (10) O Ring Seal
• Cam
i03903118
• Impeller
Battery - Replace
• Seals
SMCS Code: 1401-510
• Wear plate If wear is found or if damage is found, replace the components which are worn or replace the components which are damaged. Use the proper repair kit for the pump. Refer to the Disassembly and Assembly for more information on servicing the auxiliary water pump. i03975610
Auxiliary Water Pump - Inspect (Bronze Auxiliary Water Pump)
Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death. Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.
SMCS Code: 1371-040; 1371 The service life depends on the engine operating conditions of the bronze auxiliary water pump. Check the components for wear and check the components for damage. If wear is found or if damage is found, replace the components which are worn or replace the components which are damaged.
The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury. 1. Switch the engine to the OFF position. Remove all electrical loads.
SEBU8607
99 Maintenance Recommendations Battery Charger - Check
2. Turn off any battery chargers. Disconnect any battery chargers. 3. The NEGATIVE - cable connects the NEGATIVE - battery terminal to the NEGATIVE - terminal on the starting motor. Disconnect the cable from the NEGATIVE - battery terminal. “
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4. The POSITIVE + cable connects the POSITIVE + battery terminal to the POSITIVE + terminal on the starting motor. Disconnect the cable from the POSITIVE + battery terminal. “
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Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate recycling facility. 5. Remove the used battery. 6. Install the new battery. Note: Before the cables are connected, ensure that the engine start switch is OFF. 7. Connect the cable from the starting motor to the POSITIVE + battery terminal. “
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8. Connect the NEGATIVE - cable to the NEGATIVE - battery terminal. “
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i03903122
Battery Electrolyte Level Check SMCS Code: 1401-535-FLV When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are properly charged, ammeter reading should be very near zero,when the engine is in operation.
All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries. 1. Remove the filler caps. Maintain the electrolyte level to the FULL mark on the battery. “
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If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artificially softened water.
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i03903120
Battery Charger - Check
2. Check the condition of the electrolyte with the 245-5829 Coolant Battery Tester Refractometer. 3. Keep the batteries clean. Clean the battery case with one of the following cleaning solutions:
SMCS Code: 1401-535 Check the battery charger for proper operation. If the batteries are properly charged, the needle of the ammeter will register near 0 (zero). “
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The batteries should be kept warm, when possible. The temperature of the battery will affect cranking power. A battery that is too cold will not crank the engine, even if the engine is warm. The batteries may not fully recharge when the engine is not run for long periods of time. The batteries may not fully recharge if the engine only runs for short periods. Ensure a full charge in order to help prevent the battery from freezing.
• Use a solution of 0.1 kg (0.2 lb) baking soda and 1 L (1 qt) of clean water. • Use a solution of ammonium hydroxide . Thoroughly rinse the battery case with clean water. Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not fit properly. Coat the clamps and the terminals with 5N-5561 Silicone Lubricant, petroleum jelly or MPGM.
100
SEBU8607
Maintenance Recommendations Battery or Battery Cable - Disconnect
i03903124
Inspection
Battery or Battery Cable Disconnect
To maximize the engine performance, inspect the belt for wear and for cracking. Replace a belt that is worn or damaged.
SMCS Code: 1401; 1402-029
If the belt is too loose, vibration causes unnecessary wear on the belt and the pulley.
The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury. 1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads. 2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When four 12 V batteries are involved, 2 negative connection must be disconnected. 3. Remove the positive connection. Illustration 71
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4. Clean all disconnected connection and battery terminals.
Typical example
5. Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not fit correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly.
1. Remove the bolts (1) and remove the guard (2). After inspection of the belt or adjustment of the belt, install the guard.
6. Tape the cable connections in order to help prevent accidental starting. 7. Proceed with necessary system repairs. 8. In order to connect the battery, connect the positive connection before the negative connector. i03903126
Belts - Inspect/Adjust/Replace (Single Belt) SMCS Code: 1357-025; 1357-040; 1357-510 Note: The engine may auto start. Ensure that the power supply is isolated before any service or repair is performed.
Illustration 72
Typical example
g01626059
SEBU8607
101 Maintenance Recommendations Coolant (ELC) - Change
2. To check the belt tension, install 144-0235 Belt Tension Gauge. Install the gauge (3) at the center of the longest free length and check the tension. The correct tension for a used belt is 355 N (79.8 lb). If the tension of the belt is below 250 N (56 lb) adjust the belt to 355 N (79.8 lb). The correct tension for a new belt or new belts is 535 N (120 lb). A higher tension is required in order to compensate for the stretch that is in a new belt. Only use the higher tension on a belt that has not been used. A used belt is a belt that has been in operation for 30 minutes or a longer time period. 3. Align the guard (2) to the engine. Install the bolts (1). Tighten the bolts securely.
Adjustment
Illustration 74
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2. Loosen bolt (3) and adjust the alternator in order to alter the belt tension. Tighten all bolts for the adjustment of the alternator to 22 N·m (16 lb ft). 3. Install the cover. Refer to “Inspection” for more information.
Replace Refer to Disassembly and Assembly manual, “V belt Remove and Install” for more information. i03903771
Coolant (ELC) - Change SMCS Code: 1350-070; 1395-044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. Illustration 73
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1. Loosen the nut and bolt (1). Then loosen the nut and bolt (2).
• Foaming is observed. • The oil has entered the cooling system and the coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated. Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.
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SEBU8607
Maintenance Recommendations Coolant (ELC) - Change
Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator, and the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
2. Close the drain valve. Clean the drain plugs. Install the drain plugs. Refer to Torque Specifications, SENR3130 for more information on the correct torques. NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks. Cooling system air locks may result in engine damage.
Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. 1. Stop the engine and allow the engine to cool. Turn isolator keyswitch to the OFF position. 2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. 3. Open the cooling system drain valve . If the cooling system is not equipped with a drain valve, remove the cooling system drain plugs. Note: Drain the engine coolant from the following positions. Rear of the engine block, Bottom of the heat exchanger and the underside of the exhaust manifold. The exhaust manifold may have two drains. The exhaust manifold that is installed on an engine that has a MCS control panel will only have one drain. Allow the coolant to drain. NOTICE Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Dealer Service Tools .
Flush 1. Flush the cooling system with clean water in order to remove any debris.
Illustration 75
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Typical example 3. Open the vent screw (1) enough to allow the air that is trapped to be purged from the system. Fill the cooling system with clean water. 4. Tighten the vent screw securely. Ensure that the coolant level is 25 mm (0.9843 inch) below filler neck (2) on the header tank or the radiator. 5. Install the cooling system filler cap. Operate the engine without load for approximately 30 minutes, in order to allow circulation. The coolant temperature should be at least 82 °C (180 °F).
SEBU8607
103 Maintenance Recommendations Coolant Extender (ELC) - Add
6. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the drain valve or remove the cooling system drain plugs. Allow the coolant to drain. Flush the cooling system with clean water. Close the drain valve. Clean the drain plugs. Install the drain plugs. Refer to Torque Specifications, SENR3130 for more information on the correct torques.
Fill NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks. Cooling system air locks may result in engine damage. 1. Open the vent screw (1) enough to allow the air that is trapped to be purged from the system. 2. Fill the cooling system with Extended Life Coolant (ELC). Refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section) for more information on cooling system specifications. 3. Tighten the vent screw securely. Ensure that the coolant level is 25 mm (0.9843 inch) below filler neck (2) on the header tank or the radiator. 4. Install the cooling system filler cap. Operate the engine without load for approximately 30 minutes, in order to allow circulation. The coolant temperature should be at least 82 °C (180 °F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Check the coolant level. If necessary, add coolant to the system. 6. Clean the cooling system filler cap. Inspect the gasket that is on the cooling system filler cap. If the gasket that is on the cooling system filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gasket that is on the cooling system filler cap is not damaged, perform a pressure test. A 9S-8140 Pressurizing Pump is used to perform the pressure test. The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap.
7. Operate the engine without load. Inspect the cooling system for leaks and for the correct operating temperature. i03903772
Coolant Extender (ELC) - Add SMCS Code: 1352-544-NL Cat ELC (Extended Life Coolant) does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants. NOTICE Use only Cat Extended Life Coolant (ELC) Extender with Cat ELC . Do NOT use conventional supplemental coolant additive (SCA) with Cat ELC. Mixing Cat ELC with conventional coolants and/or conventional SCA reduces the Cat ELC service life. Check the cooling system only when the engine is stopped and cool.
Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
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SEBU8607
Maintenance Recommendations Coolant Level - Check
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. 1. Stop the engine and allow the engine to cool. Turn isolator keyswitch to the OFF position. 2. Loosen the cooling system filler cap slowly in order to relieve pressure. Remove the cooling system filler cap. 3. It may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC Extender . 4. Add Cat ELC Extender according to the requirements for your engines cooling system capacity. Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations” article for more information. 5. Clean the cooling system filler cap. Inspect the gaskets on the cooling system filler cap. Replace the cooling system filler cap if the gaskets are damaged. Install the cooling system filler cap. i03903773
Coolant Level - Check SMCS Code: 1395-082 Check the coolant level when the engine is stopped and cool.
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
Illustration 76
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Typical example
Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. 1. Stop the engine and allow the engine to cool. Turn isolator keyswitch to the OFF position. 2. Remove the cooling system filler cap (1) slowly in order to relieve pressure. 3. Ensure that the coolant level is 25 mm (0.9843 inch) below filler neck (2) on the header tank or the radiator.
SEBU8607
105 Maintenance Recommendations Coolant Sample (Level 1) - Obtain
• Commercial long life coolants that meet the Caterpillar Engine Coolant Specification -1 (Caterpillar EC-1) • Cat DEAC (Diesel Engine Antifreeze/Coolant) • Commercial heavy-duty coolant/antifreeze Table 23
Recommended Interval Type of Coolant
Level 1
Level 2
Cat DEAC
Every 250 Hours(1)
Yearly(1) (2)
Optional(2)
Yearly(2)
Cat ELC (1)
(2)
Illustration 77
This is the recommended interval for coolant samples for all conventional heavy-duty coolant/antifreeze. This is also the recommended interval for coolantsamples of commercial coolants that meet the Cat EC-1 specification for engine coolant. The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified.
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Typical filler cap gaskets Note: Gasket (4) is not installed on radiator filler caps. 4. Clean the cooling system filler cap and check the condition of the filler cap gaskets (3) and (4). Replace the cooling system filler cap if the filler cap gaskets are damaged. Reinstall the cooling system filler cap.
NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Note: Level 1 results may indicate a need for Level 2 Analysis.
5. Inspect the cooling system for leaks. i03903775
Coolant Sample (Level 1) Obtain SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling system is filled with Cat ELC (Extended Life Coolant).Cooling systems that are filled with Cat ELC should have a Coolant Sample (Level 2). The Coolant Sample (Level 2) is obtained at the recommended interval that is stated in the Maintenance Interval Schedule. Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant instead of Cat ELC .This includes the following types of coolants:
Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, a consistent trend of data must be established. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for a proper sample of the coolant:
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SEBU8607
Maintenance Recommendations Coolant Sample (Level 2) - Obtain
• Complete the information on the label for the sampling bottle before you begin to take the samples. • Keep the unused sampling bottles stored in plastic bags. • Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location. • Keep the lids on empty sampling bottles until you are ready to collect the sample. • Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination. • Never collect samples from expansion bottles. • Never collect samples from the drain for a system. Submit the sample for Level 1 analysis. For additional information about coolant analysis, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” or consult your Caterpillar dealer. i03903779
Coolant Sample (Level 2) Obtain SMCS Code: 1350-008; 1395-008; 1395-554; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” for the guidelines for a proper sampling of the coolant.
i03903781
Coolant Temperature Regulator - Replace SMCS Code: 1355-510 Replace the water temperature regulator before the water temperature regulator fails. This is a recommended preventive maintenance practice. Replacing the water temperature regulator reduces the chances for unscheduled downtime. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for the proper maintenance interval. A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine. A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive overheating could result in the cracking of the cylinder head or piston seizure problems. A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner. NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage. Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed. If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that the water temperature regulator vent hole is open. Do not use liquid gasket material on the gasket or cylinder head surface.
Submit the sample for Level 2 analysis. For additional information about coolant analysis, see Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engines Fluids Recommendations” or consult your Caterpillar dealer.
Refer to two articles in the Disassembly and Assembly Manual, “Water Temperature Regulators Remove and Water Temperature Regulators - Install” for the replacement procedure of the water temperature regulator, or consult your Caterpillar dealer. Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing.
SEBU8607
107 Maintenance Recommendations Cooling System Supplemental Coolant Additive (SCA) - Test/Add
i03903780
Cooling System Supplemental Coolant Additive (SCA) - Test/ Add SMCS Code: 1352-045; 1395-081
5. Add one drop of NITRITE TEST SOLUTION A to the mixing bottle. Move the bottle in a circular motion in order to mix the solution. “
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6. Repeat 5 until the solution changes color from red to light gray, green, or blue. Record the number of drops of NITRITE TEST SOLUTION A that were required to cause the color change. “
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7. Use Table 24 to interpret the results. Table 24
Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and eyes. Do not drink cooling system coolant additive.
Number of Drops Concentration of Maintenance SCA Required Less than 25
Less than the recom- Add SCA. mended concentra- Retest the coolant. tion of SCA
Note: Caterpillar recommends an S·O·S coolant analysis (Level 1).
25 to 30
None The recommended concentrationof SCA
Test the Concentration of the SCA
Morethan 30
More than the recom- Remove the coolant. mended concentra- Replace with water tion of SCA only Retest the coolant.
Coolant/Antifreeze and SCA NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration. Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Follow the instructions that are provided in the kit.
Water and SCA NOTICE Do not exceed the recommended eight percent supplemental coolant additive concentration. Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Use the instructions that follow: 1. Fill the syringe to the 1.0 ml mark with the coolant. “
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2. Dispense the 1.0 mL coolant sample from the syringe into the empty mixing bottle. 3. Add tap water to the mixing bottle in order to bring the level up to the 10 ml mark. Place the cap on the bottle and shake the bottle. “
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4. Add 2 to 3 drops of NITRITE INDICATOR SOLUTION B to the mixing bottle. Move the bottle in a circular motion in order to mix the solution. “
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Add the SCA, If Necessary
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Remove the cooling system filler cap slowly. Note: Always dispose of fluids according to local regulations. 2. If necessary, drain some coolant in order to allow space for the addition of the SCA.
108
SEBU8607
Maintenance Recommendations Electrical Connections - Check
NOTICE Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water pump seal. Do not exceed the recommended amount of supplemental coolant additive concentration. 3. Add the proper amount of SCA. The concentration of the SCA depends on the type of coolant that is used. To determine the proper amount, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic. 4. Clean the cooling system filler cap. Install the cooling system filler cap. i01595880
Electrical Connections - Check
i03903782
Engine - Clean SMCS Code: 1000-070
Personal injury or death can result from high voltage. Moisture could conductivity.
create
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electrical
Make sure the unit is off line (disconnected from utility and/or other generators), locked out and tagged "Do Not Operate".
NOTICE Water or condensation can cause damage to generator components. Protect all electrical components from exposure to water.
NOTICE Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on the engine.
SMCS Code: 4459-535 Check all exposed electrical connections for tightness.
Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following benefits:
Check the following devices for loose mounting or for physical damage:
• Easy detection of fluid leaks
• transformers
• Maximum heat transfer characteristics
• fuses
• Ease of maintenance
• capacitors
Note: For more information on cleaning and drying electric generators, refer to Special Instruction, SEHS9124, Cleaning and Drying of Electric Set Generators.
• lightning arrestors Check all lead wires and electrical connections for proper clearance.
SEBU8607
109 Maintenance Recommendations Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
i03975470
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/ Replace SMCS Code: 1051; 1054-040; 1054-070; 1054-510 NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element. The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. The secondary air cleaner element is not serviceable or washable. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element. When the engine is operating in environments that are dusty or dirty, air cleaner elements may require more frequent replacement.
NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements If the air cleaner element becomes plugged, the air can split the material of the air cleaner element. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has the proper air cleaner elements for your application. Consult your Caterpillar dealer for the correct air cleaner element. Illustration 78
• Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any dirt and debris, as needed.
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(1) Cover (2) Primary air cleaner element (3) Secondary air cleaner element (4) Turbocharger air inlet
• Operating conditions (dust, dirt, and debris) may require more frequent service of the air cleaner element.
1. Remove the cover. Remove the primary air cleaner element.
• The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected.
2. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element.
• The air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.
Note: Refer to “Cleaning the Primary Air Cleaner Elements”.
Replace the dirty paper air cleaner elements with clean air cleaner elements. Before installation, the air cleaner elements should be thoroughly checked for tears and/or holes in the filter material. Inspect the gasket or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner elements for replacement purposes.
3. Cover the turbocharger air inlet with tape in order to keep out dirt. 4. Clean the inside of the air cleaner cover and body with a clean, dry cloth. 5. Remove the tape for the turbocharger air inlet. Install the secondary air cleaner element. Install a primary air cleaner element that is new or cleaned. 6. Install the air cleaner cover. 7. Reset the air cleaner service indicator.
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SEBU8607
Maintenance Recommendations Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Cleaning the Primary Air Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning services that are available at Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life.
Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use filtered, dry air with a maximum pressure of 207 kPa (30 psi).
Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to remove dust. Do not wash the filter element. Use low pressure compressed air in order to remove the dust from the filter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air flow up the pleats and down the pleats from the inside of the filter element. Take extreme care in order to avoid damage to the pleats. Do not use air filters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components. The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. When the primary air cleaner element is cleaned, check for rips or tears in the filter material. The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. Use clean primary air cleaner elements while dirty elements are being cleaned. NOTICE Do not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result. Visually inspect the primary air cleaner elements before cleaning. Inspect the air cleaner elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged air cleaner elements. There are two common methods that are used to clean primary air cleaner elements: • Pressurized air • Vacuum cleaning
Illustration 79
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Note: When the primary air cleaner elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the primary air cleaner element. Dirt could be forced further into the pleats. Note: Refer to “Inspecting the Primary Air Cleaner Elements”.
Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil. Note: Refer to “Inspecting the Primary Air Cleaner Elements”.
SEBU8607
111 Maintenance Recommendations Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Inspecting the Primary Air Cleaner Elements
Illustration 81
Illustration 80
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Inspect the clean, dry primary air cleaner element. Use a 60 Watt blue light in a dark room or in a similar facility. Place the blue light in the primary air cleaner element. Rotate the primary air cleaner element. Inspect the primary air cleaner element for tears and/ or holes. Inspect the primary air cleaner element for light that may show through the filter material. If it is necessary in order to confirm the result, compare the primary air cleaner element to a new primary air cleaner element that has the same part number. Do not use a primary air cleaner element that has any tears and/or holes in the filter material. Do not use a primary air cleaner element with damaged pleats, gaskets, or seals. Discard damaged primary air cleaner elements.
Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used, the primary air cleaner element can be stored for future use.
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Do not use paint, a waterproof cover, or plastic as a protective covering for storage. An airflow restriction may result. To protect against dirt and damage, wrap the primary air cleaner elements in Volatile Corrosion Inhibited (VCI) paper. Place the primary air cleaner element into a box for storage. For identification, mark the outside of the box and mark the primary air cleaner element. Include the following information: • Date of cleaning • Number of cleanings Store the box in a dry location.
112
SEBU8607
Maintenance Recommendations Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace
i03903854
Engine Air Cleaner Element (Single Element) - Inspect/ Clean/Replace SMCS Code: 1051; 1054-040; 1054-070; 1054-510
Some engines are equipped with a differential gauge for inlet air pressure. The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element. As the air cleaner element becomes dirty, the pressure differential rises. If your engine is equipped with a different type of service indicator, follow the OEM recommendations in order to service the air cleaner service indicator. The service indicator may be mounted on the air cleaner element or in a remote location.
Illustration 83
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Typical service indicator Illustration 82
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Typical example
Observe the service indicator. The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur:
Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. 1. Release the clips (3) and remove the cover (2).
• The yellow diaphragm enters the red zone.
2. Remove the element (1) and discard the element.
Service indicators are important instruments.
3. Ensure that all parts are clean and free from dirt. Install a new element.
• Check for ease of resetting. The service indicator should reset in less than three pushes.
4. Align the cover to the body of the air cleaner. Ensure that the cover is oriented correctly and install the cover.
• Check the movement of the yellow core when the engine is accelerated to the engine rated speed. The yellow core should latch at the greatest vacuum that is attained.
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Engine Air Cleaner Service Indicator - Inspect SMCS Code: 7452-040 Some engines may be equipped with a different service indicator.
• The red piston locks in the visible position.
Test the Service Indicator
If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, the service indicator should be replaced. If the new service indicator will not reset, the hole for the service indicator may be restricted. The service indicator may be replaced frequently in environments that are severely dusty.
SEBU8607
113 Maintenance Recommendations Engine Crankcase Breather - Replace
i03975253
SMCS Code: 1317-510
Engine Crankcase Breather Replace (Turbocharged Engines and Naturally Aspirated Engines)
S/N: S1M1–Up
SMCS Code: 1317-510
Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed.
Note: The housing for the crankcase ventilator filter must also be replaced on engines that are turbocharged. Refer to Operation and Maintenance Manual, “Engine Crankcase Breather - Replace (Turbocharged Engines)” for the correct procedure.
NOTICE Perform this maintenance with the engine stopped.
Illustration 85
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Typical example Illustration 84
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Typical example
1. Remove all dirt and oil from the outside of the breather assembly (1). 2. Remove the breather assembly. Refer to Disassembly and Assembly, “Crankcase Breather Remove and Install”.
1. Remove dust cover (1). 2. Remove screws (2) and cover (3). 3. Remove diaphragm (4) and spring (5). Discard diaphragm (4) and spring (5).
3. Install a new breather assembly. Refer to Disassembly and Assembly, “Crankcase Breather Remove and Install”.
4. Install new diaphragm (4) and a new spring (5). i05256770
5. Install cover (3) and screws (2). Tighten screws (2) to a torque of 1.3 N·m (11.5 lb in). 6. Install dust cover (1). i05257281
Engine Crankcase Breather Replace (Turbocharged Engines)
Engine Crankcase Breather Element - Replace (Turbocharged Engines) SMCS Code: 1317-510-FQ S/N: S1M1–Up
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Maintenance Recommendations Engine Mounts - Inspect
NOTICE Perform this maintenance with the engine stopped. Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed.
Illustration 87 Illustration 86
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Typical example 1. Remove all dirt and oil from the outside of the breather assembly (1).
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Typical example 2. Turn lid (2) in a counterclockwise direction for approximately 15 degrees. Remove the Lid. 3. Remove O-ring (3). 4. Remove crankcase ventilator filter (4). 5. Remove O-ring (5). 6. Install a new O-ring (5). 7. Install a new crankcase ventilator filter (4). 8. Install a new O-ring (3). 9. Install lid (2). i03903843
Engine Mounts - Inspect SMCS Code: 1152-040; 1152 Inspect the engine mounts for deterioration and for proper bolt torque. Engine vibration can be caused by the following conditions: • Improper mounting of the engine • Deterioration of the engine mounts
SEBU8607
115 Maintenance Recommendations Engine Oil Level - Check
Any engine mount that shows deterioration should be replaced. Refer to Special Publication, SENR3130, Torque Specifications for the recommended torques. Refer to the OEM recommendations for more information. i03903840
Engine Oil Level - Check
NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil's lubricating characteristics and could result in the loss of power. “
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2. Remove the oil filler cap and add oil, if necessary. Clean the oil filler cap. Install the oil filler cap.
SMCS Code: 1348-535-FLV
i03903839
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Engine Oil Sample - Obtain SMCS Code: 1348-554-SM In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. S·O·S oil analysis provides infrared analysis, which is required for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Illustration 88
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(Y) Min mark. (X) Max mark. “
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NOTICE Perform this maintenance with the engine stopped. Note: Ensure that the engine is either level or that the engine is in the normal operating position in order to obtain a true level indication. Note: After the engine has been switched OFF, wait for 10 minutes in order to allow the engine oil to drain to the oil pan before checking the oil level. Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. 1. Maintain the oil level between the ADD mark (Y) and the FULL mark (X) on the engine oil dipstick. Do not fill the crankcase above the FULL mark (X). “
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Before you take the oil sample, complete the Label, PEEP5031 for identification of the sample. In order to help obtain the most accurate analysis, provide the following information: • Engine model • Service hours on the engine • The number of hours that have accumulated since the last oil change • The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean. Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when the sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation.
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Maintenance Recommendations Engine Engine Oil and Filter - Change
The 169-8373 Fluid Sampling Bottle is recommended recommended for use with the sampling valve. valve. The fluid sampling sampling bottle includes includes the parts that are needed needed for obtaining obtaining oil samples. samples. Instructions Instructions are also provided. NOTICE Always use a designated pump for oil sampling, and use a separa separate te design designate ated d pump pump for coolan coolantt samsampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. If the engine is not equipped equipped with a sampling valve, valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must must be attached attached to the pump for insertion insertion into the sump. For instructions, instructions, see Special Publication, Publication, PEgj0047, PEgj0047, “How To To Take Take A Good S·O·S Oil Sample”. Consult your Caterpi Caterpillar llar dealer for complete complete information information and assistance assistance in establishing establishing an S·O·S program for your engine. i03906144
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component component life. Do not drain the engine lubricatin lubricating g oil when the engine is cold. As the engine lubricating lubricating oil cools, suspended suspended waste waste particles particles settle on the bottom bottom of the oil pan. The waste particles particles are not removed with with draining draining cold oil. Drain the oil pan with the engine engine stopped. stopped. Drain the oil pan with the oil warm. This draining draining method allows the waste waste particles particles that are are suspended in the oil to be drained properly. Ensure that all all adjustments, maintenance, and and repairs are performed performed by authorize authorized d personnel personnel that have the correct correct training. training. Ensure that the vessel that will be used is large enough to collect the waste oil. Failure to follow this recommende recommended d procedure will cause the waste waste particles particles to be recirculated recirculated through through the engine lubrication lubrication system with the new oil. 1. The 1. The engine can auto start. start. Ensure that that the power supply is is isolated isolated before any service service or repair repair is performed.
Engine Engine Oil and and Filte Filterr - Change Change (Duplex (Duplex Oil Filters) Filters) SMCS Code: 1318-510
Repl Replace ace Engi Engine ne Oil Oil
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact contact the skin. skin.
NOTICE Care Care must must be taken taken to ensure ensure that fluids are contained tained during during perfor performan mance ce of inspec inspection tion,, mainte mainte-nance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartmen compartmentt or disassembli disassembling ng any component component containing containing fluids. fluids. Illustration 89
Dispose Dispose of all fluids according according to local regulations regulations and mandates.
Typical example 2. Open 2. Open the drain valve (1).
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SEBU8607
117 Maintenance Recommendations Engine Oil Oil and Filter - Change
4. Stop 4. Stop the engine and allow the oil to drain back to the oil pan for a minimum of 10 minutes.
Illustration 91
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Typical example 5. Remove 5. Remove the engine engine oil level gauge in order to check the oil level. Maintain Maintain the oil level between between MIN and MAX marks on the engine oil level gauge. “
Illustration 90
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Typical example 3. Connect 3. Connect a drain line to the pump (2). Unlock the pump pump and operat operate e the pump pump in order order to remove remove the engine oil. oil. After the oil has been been removed, removed, lock the pump and remove the drain line. 4. After 4. After the oil has drained, close the drain valve valve (1).
Fill Fill the Oil Oil Pan 1. Remove 1. Remove the oil filler cap. Refer to the Operation Operation and Maintenance Maintenance Manual, Manual, “Fluid Recommenda Recommendations” tions” for more information information on suitable suitable oils. Fill the oil pan with the correct amount amount of new engine lubricating lubricating oil. Refer to this Operation Operation and Maintenance Maintenance Manual, Manual, “Refill Capacities” Capacities” for more information information on refill capacities. 2. Refer 2. Refer to “Commission “Commissioning ing Procedure Procedure for Duplex Duplex Oil Filters” Filters” before the engine engine is started. started. 3. Start 3. Start the engine and operate operate the engine at no load for 2 minut minutes. es. Perform Perform this proc procedu edure re in order to ensure that the lubrication lubrication system system has oil and that the oil filters are filled. Inspect Inspect the oil filter for oil leaks. “
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Maintenance Recommendations Engine Engine Oil and Filter - Change
Commission Commissioning ing Procedure Procedure for Duplex Duplex Oil Filters Filters
Illustration 92
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Typical example • (A) The The oil oil flow flow is to the the left-hand left-hand oil filter filter..
2. Apply 2. Apply clean engine oil to both O ring seals (1) for the new oil filters.
• (B) The The oil flow is is to both both oil oil filters. filters. • (C) The The oil flow is is to the the right-han right-hand d oil filter filter.. 1. The 1. The engine can auto start. start. Ensure that that the power supply is isolated before before any service or repair is performed.
3. Install 3. Install the engine engine oil filters. filters. Spin on the oil filter until the O ring seal contacts the oil filter base. Rotate Rotate the oil filter filter ¾ of a full turn. turn. 4. Ensure 4. Ensure that the control lever is in position B. Refer to illustration illustration 92 . 5. Ensure 5. Ensure that that the engine engine has the the correct correct amount amount of clean engine lubricating lubricating oil. Refer to “Replace “Replace Engine Oil” for more information. 6. Operate 6. Operate the engine with no load in order to fill both oil filters. 7. Check 7. Check the engine oil pressure. Stop the engine and allow time for the engine oil to drain into the oil pan. Check the engine engine oil, refer to the Operation and Maintenance Maintenance Manual, Manual, “Engine “Engine Oil Level Check”. 8. Rotate 8. Rotate the the lever in the the direction direction of the oil filter filter that is intended to be used and operate operate the engine. engine.
Replac Replaceme ement nt of Duplex Duplex Filter Filter with with the Engine Engine in Operatio Operation n An engine can be operated during the replacement of the filters, filters, if duplex filters filters are installed. installed. Illustration 93
Typical example
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SEBU8607
119 Maintenance Recommendations Engine Oil and Filter - Change
Note: With the control lever in position A, the flow of oil is to the left-hand oil filter. With the control lever in position C, the flow of oil is to the right-hand oil filter. Refer to illustration 91 . 1. Clean the area around the oil filters.
Illustration 95
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Element with debris 6. Cut the oil filter open with a 175-7546 Oil Filter Cutter. Break apart the pleats and inspect the oil filter for metal debris. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure. Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element. Ferrous metals may indicate wear on the steel and cast iron parts of the engine. Nonferrous metals may indicate wear on the aluminum parts, brass parts, or bronze parts of the engine. Parts that may be affected include the following items: main bearings, rod bearings, turbocharger bearings and cylinder heads. Illustration 94
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Typical example Note: The control lever is in position A. The righthand oil filter has been isolated from the oil flow. 2. Rotate the control lever (1) slowly in the direction of the oil filter that is intended to be used. Allow time for the oil filter to fill and check for leaks on the oil filter. Check that the engine oil pressure is correct. 3. Place a soft cloth over the vent screw (4) and open the vent screw. This will allow any pressure that is in the isolated oil filter to be released. 4. Tighten the vent screw securely. 5. Remove the oil filter with a 1U-8760 Chain Wrench. Note: The following actions can be carried out as part of the preventive maintenance program.
Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter. 7. Clean the sealing surface of the oil filter base (2). 8. Apply clean engine oil to the O ring seal (3) for the new oil filter. NOTICE Do not fill the oil filters with oil before installing them. This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to engine components. 9. Install the engine oil filter. Spin on the oil filter until the O ring seal contacts the oil filter base. Rotate the oil filter ¾ of a full turn. 10. Drain the tray below the filter.
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Maintenance Recommendations Engine Oil and Filter - Change
i03906141
Engine Oil and Filter - Change (Single Oil Filter) SMCS Code: 1318-510
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 96
Dispose of all fluids according to local regulations and mandates.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ensure that all adjustments, maintenance, and repairs are performed by authorized personnel that have had the correct training. Do not drain the engine lubricating oil when the engine is cold. As the engine lubricating oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with draining cold oil. Drain the oil pan with the engine stopped. Drain the oil pan with the oil warm. This draining method allows the waste particles that are suspended in the oil to be drained properly. Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil.
Drain the Engine Lubricating Oil Ensure that the vessel that will be used is large enough to collect the waste oil.
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Typical example 1. The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. 2. Open the drain valve (1).
SEBU8607
121 Maintenance Recommendations Engine Oil and Filter - Change
Illustration 98
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Element with debris 3. Cut the oil filter open with a 175-7546 Oil Filter Cutter. Break apart the pleats and inspect the oil filter for metal debris. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure. Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element. Ferrous metals may indicate wear on the steel and cast iron parts of the engine. Illustration 97
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Typical example 3. Connect a drain line to the pump (2). Unlock the pump and operate the pump in order to remove the engine oil. After the oil has been removed, lock the pump and remove the drain line. 4. After the oil has drained, close the drain valve (1).
Single Oil Filter Note: Change the oil filter with the engine stopped. Caterpillar oil filters are manufactured to Caterpillar specifications. Use of an oil filter that is not recommended by Caterpillar could result in severe damage to the engine bearings, and the crankshaft. This is a result of the larger waste particles from unfiltered oil that can enter the engine lubricating system. Only use oil filters that are recommended by Caterpillar . 1. Clear the area around the oil filter. 2. Remove the oil filter with a 1U-8760 Chain Wrench. Note: The following actions can be carried out as part of the preventive maintenance program.
Nonferrous metals may indicate wear on the aluminum parts, brass parts, or bronze parts of the engine. Parts that may be affected include the following items: main bearings, rod bearings, turbocharger bearings and cylinder heads. Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter.
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Maintenance Recommendations Engine Protective Devices - Check
Illustration 100
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Typical example
Illustration 99
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Typical example
4. Remove the engine oil level gauge in order to check the oil level. Maintain the oil level between MIN and MAX marks on the engine oil level gauge. “
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4. Clean the sealing surface of the oil filter base (3).
i03903838
5. Apply clean engine oil to the O ring seal for the new oil filter.
Engine Protective Devices Check
NOTICE Do not fill the oil filters with oil before installing them. This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to engine components.
SMCS Code: 7400-535
6. Install the engine oil filter. Spin on the oil filter until the O ring seal contacts the oil filter base. Rotate the oil filter ¾ of a full turn.
Fill the Oil Pan 1. Remove the oil filler cap. Refer to Operation and Maintenance Manual, “Refill Capacities and Recommendations” for more information on suitable oils. Fill the oil pan with the correct amount of new engine lubricating oil. Refer to Operation and Maintenance Manual, “Refill Capacities and Recommendations” for more information on refill capacities.
Visual Inspection Visually check the condition of all gauges, sensors, and wiring. Look for wiring and components that are loose, broken, or damaged. Damaged wiring or components should be repaired or replaced immediately.
Calibration Check NOTICE During testing, abnormal operating conditions must be simulated. The tests must be performed correctly in order to prevent possible damage to the engine.
2. Start the engine and operate the engine at no load for 2 minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled. Inspect the oil filter for oil leaks.
Alarms and shutoffs must function properly. Alarms provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation. Malfunctions must be simulated in order to test the engine protective devices. To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer should perform the tests.
3. Stop the engine and allow the oil to drain back to the oil pan for a minimum of 10 minutes.
Consult your Caterpillar dealer or refer to the Service Manual for more information.
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SEBU8607
123 Maintenance Recommendations Engine Speed/Timing Sensor - Clean/Inspect
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i03903837
Engine Speed/Timing Sensor Clean/Inspect
Engine Valve Lash - Check
SMCS Code: 1905-040; 1905-070; 1907-040; 1907070
This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life.
SMCS Code: 1105-535
NOTICE Only qualified service personnel should perform this maintenance. Refer to the Systems Operation/Testing and Adjusting Manual, “Valve Lash and Valve Bridge Adjustment” article or consult your Caterpillar dealer for the complete valve lash adjustment procedure. Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.
Ensure that the engine cannot be started while this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn the flywheel. Illustration 101
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Typical example
Note: The engine can auto start. Ensure that the power supply is isolated before any service or repair is performed. 1. Remove the sensor (3) from the flywheel housing. Check the condition of the end of the sensor. Check for signs of wear and contaminants. 2. Clean the metal shavings and other debris from the face of the magnet. 3. Install the sensor until the magnet comes in contact with a tooth on the flywheel ring gear (1).
Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance. Ensure that the engine is stopped before measuring the valve lash. To obtain an accurate measurement, allow the valves to cool before this maintenance is performed. Refer to the Service Manual for more information. i03906146
Fuel System - Prime (Duplex Fuel Filter if Equipped) SMCS Code: 1250-548; 1258-548
4. Back out 180 degrees and tighten the locknut (2) to 45 ± 7 N·m (33 ± 5 lb ft). Note: Ensure that the sensor cannot rotate when the locknut is tightened. Refer to the Service Manual for more information on the sensor.
Ensure that all adjustments, maintenance, and repairs are performed by authorized personnel that have had the correct training. NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
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Maintenance Recommendations Fuel System - Prime
If air enters the fuel system, the air must be purged from the fuel system system before the engine engine can be started. started. Air can enter the fuel system system when the following following events occur: occur: • The fuel fuel tank is empty or the fuel tank tank has been partially partially drained. drained. • The low-pressure low-pressure fuel lines are disconnecte disconnected. d. • A leak exists exists in the low-pre low-pressur ssure e fuel system system.. • The fuel fuel filter filter has been been repla replaced ced..
Primin Priming g the Dupl Duplex ex Fuel Fuel Filte Filters rs with with the Engine Engine Stopped Stopped Note: The engine can can auto start. Ensure that that the power supply supply is isolated before any service service or repair is performed. Use the following procedures procedures in order to remove air from the fuel fuel system: system:
Illustration 102
Typical example • (A) The The fuel fuel flow is to the the left-hand left-hand fuel filter filter.. • (B) The The fuel fuel flow is to both both fuel fuel filters. filters. • (C) The The fuel flow is to the the right-han right-hand d fuel filter. filter.
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SEBU8607
125 Maintenance Recommendations Fuel System - Prime
Illustration 103
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Typical example • (A) The The fuel fuel flow is to the the left-hand left-hand fuel filter filter.. • (B) The The fuel fuel flow is to both both fuel fuel filters. filters. • (C) The The fuel flow is to the the right-han right-hand d fuel filter. filter.
Commissio Commissioning ning procedure procedure Use the following procedure procedure in order to remove air from both fuel fuel filters. filters.
Duplex Duplex Fuel Filters Filters 1. The 1. The engine can auto start. start. Ensure that that the power supply is isolated before before any service or repair is performed.
Illustration 104
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Typical example 2. Ensure 2. Ensure that the fuel system is in working order. Check that the fuel supply supply valve (if equipped) equipped) is in the ON position. “
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3. Ensure 3. Ensure that the control levers are in position B. Refer to illustratio illustration n 102 and illustrat illustration ion 103 . 4. Start 4. Start the engine. Refer Refer to Operation and Maintenance Maintenance Manual, Manual, “Starting “Starting the Engine” Engine” for the the correct correct procedure. procedure. The electric electric fuel priming priming pump will operate.
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Maintenance Recommendations Fuel System System Primary Filter (Water (Water Separator) Separator) Element Element - Replace
5. After 5. After the engine engine has started, started, operate operate the engine engine for a minimum minimum of 5 minutes minutes without without load. load. Note: Operating Operating the engine for this time period will help ensure that the fuel system is free of air. 6. Select 6. Select the required required position position for the control control levers on the secondary filters.
Primin Priming g a Dupl Duplex ex Fuel Fuel Filter Filter with with the Engine Engine in Operation Operation Priming Priming the Secondary Secondary Filters Filters Illustration 105
1. Both 1. Both the secondary secondary fuel fuel filter and the primary primary fuel filter (if equipped equipped)) must be replaced replaced at the same time. 2. Slowly 2. Slowly rotate the control lever lever on the secondary secondary fuel filters toward position position B.
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Typical example (1) Cap (2) Locking Locking ring (3) Element Element (4) Water Water separatorbowl separatorbowl (5) Drain Drain
1. Close 1. Close the fuel supply valve. Note: Position Position B will allow the flow of fuel to both filters. 3. Rotate 3. Rotate the control control lever to the required required position. position. 4. Drain 4. Drain the tray below the filters. i03906212
Fuel Fuel Syst System em Prim Primar ary y Filt Filter er (Water (Water Separator Separator)) Element Element Replace (if Equipped) SMCS Code: 1260-510-FQ; 1260-510-FQ; 1263-510-FQ 1263-510-FQ
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possib possible le injury injury,, turn turn the start start switch switch off when when changing changing fuel filters or water separator separator elements. elements. Clean up fuel spills immediately immediately..
NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. Turn the fuel supply valve to the OFF position before performing performing this maintenance maintenance.. Place a tray under the fuel filter filter in order to catch any any fuel that might might spill. spill. Clean up any spilled fuel immediately.
2. Clean 2. Clean the outside of the fuel filter assembly assembly.. Drain the fuel into a suitable container container by using the fuel drain drain on the bottom bottom of element element (3). Drain Drain the water water from water separator separator (4) into a suitable containe container. r. Not all engines are equipped with a water separator. Note: The fuel level in element element (3) should be reduced reduced before before removal removal of the element. element. Remove Remove cap (1) if the element element is not equipped equipped with a drain on the bottom. Remove the nylon nylon insert in order to reduce the level level of fuel in the element element.. A reduction reduction in the level level of fuel in the element element will help help prevent prevent fuel from from being spilled spilled when the element element is removed. removed. NOTICE Do not use a tool in order to remove the fuel filter. Attempting to remove the fuel filter with a filter wrench or a filter strap could could damage damage the locking locking ring. 3. Hold 3. Hold element element (3) and rotate rotate locking locking ring (2) counterclockwise. Remove locking ring (2). The used element element should be removed removed and discarded. discarded. equipped with a sediment Note: If the element is equipped bowl, remove remove the sediment sediment bowl bowl from the element. element. Thoroughly Thoroughly clean the sediment bowl. Inspect Inspect the Oring seals for wear or damage. damage. Install new O-ring seals, if necessary. Install the sediment bowl onto the new element. element. Hand tighten the sedimen sedimentt bowl. Hand tightening tightening is the only method method that should should be used. used.
SEBU8607
127 Maintenance Recommendations Fuel System Secondary Filter - Replace
NOTICE Do not fill fuel filters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts. 4. Ensure that the filter head is clean. Push a new element fully into the filter head. 5. Hold the element in place. Install locking ring (2) into position. Rotate the locking ring clockwise in order to fasten the element to the filter head. Note: If the nylon insert was removed, install the nylon insert and install cap (1). 6. Prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information. i03906236
Fuel System Secondary Filter Replace SMCS Code: 1261-510-SE
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. Ensure that all adjustments, maintenance, and repairs are performed by authorized personnel that have had the correct training.
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Maintenance Recommendations Fuel System Secondary Filter - Replace
Duplex Filters
Illustration 106
(A) The fuel flow is to the left-handfuel filter.
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(B) The fuel flow is to both fuel filters.
(C)The fuel flow is to the right-hand fuel filter.
2. Isolate the contaminated filter by rotating the control lever into position A or position C. 3. Place a soft cloth over the vent of the filter that has been isolated, before opening the vent screw. 4. Open the vent screw and then close the vent screw on the filter that has been isolated. This will relieve any pressure that is still in the filter. 5. Clean the outside of the fuel filter. Use 1U-8760 Chain Wrench in order to remove canister (2) from the engine and dispose of the canister in a safe place. 6. Lubricate O ring seal (1) with clean engine oil. Do not fill the new canister with fuel before the canister is installed. 7. Do not use a tool in order to install the canister. Tighten the canister by hand. Illustration 107
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Typical example 1. The control lever will point in the direction of the fuel filter that is active. With the control lever in position A, the right-hand fuel filter can be replaced. With the control lever in position C, the left-hand fuel filter can be replaced. Refer to illustration 106 .
8. Install the new canister. Spin on the canister until the O ring seal contacts the filter base. Then rotate the canister 360 degree in order to tighten the canister correctly. 9. Prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime”.
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129 Maintenance Recommendations Fuel Tank Water and Sediment - Drain
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Fuel Tank Water and Sediment - Drain SMCS Code: 1273-543-M&S
Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important.
Fuel Storage Tanks NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
Fuel Tank Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.
Drain the water and the sediment from the fuel storage tank during the following conditions: • Weekly • Oil change • Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. A four micron(c) absolute filter for the breather vent on the fuel tank is also recommended. Refer to Special Publication, SENR9620, “Improving Fuel System Durability”. If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to settle before filling the engine fuel tank. Internal baffles in the bulk storage tank will also help trap sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel. When possible, water separators should be used. i03997990
Generator - Dry SMCS Code: 4450-569
Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve. Note: Failure to close the drain can allow air into the system, which could have detrimental results to performance. Check the fuel daily. Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled. Allow 5 to 10 minutes before performing this procedure. Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not fill the tank to the top. The fuel expands as the fuel gets warm. The tank may overflow.
Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment. Refer to this Operation and Maintenance Manual, “Generator Isolating for Maintenance” for information regarding the procedure to isolate the generator in a safe manner. Refer to Special Instruction, REHS9124, Cleaning and Drying of the Generator for further necessary information. Of the following methods for drying the generator, the use of external heat is preferred.
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Maintenance Recommendations Generator - Dry
• External heat
If the windings or insulation are wet during the resistance measurement, use a 5 megohm resistor for protection in series with red positive lead. This procedure limits the voltage across the circuit under the test. Use this method until drying is well in progress and the resistance has reached an acceptable level.
• Internal heat • Combination of external and internal heat • Circulating current External heat is the most preferable method. Insulation drying time can vary from a few hours to several days. The drying time depends on the moisture content and the process for drying that is used. Note: Drying sometimes does not produce the required results. The use of a qualified rebuild shop may be necessary for dipping and drying the generator.
Check the windings after every 4 hours when either external or internal heat is used to dry the generator. Check the windings very hour when circulating current is used to dry the generator. Refer to Special Instruction, REHS9124, Cleaning and Drying of the Generator for more information. Drying is complete when the tests show no increase in resistance and the resistance is above the minimum. Record these readings and compare these readings. Keep these records for future reference.
Illustration 109
g01696934
Curve of insulation resistance for windings in good condition (1) Resistance after 30 seconds (2) Resistance after 60 seconds Illustration 108
g02175752
Typical curves of the resistance in the insulation that is drying (1) Curve of the temperature in the windings (2)Heat turnedoff. (3) Drying time in hours (4) Temperature in degrees celsius (5) Curve of insulation resistance during drying process (6) Insulation resistance in megohms
Note: When new insulation or very damp insulation is being dried, the resistance will probably fall rapidly. The rapid fall in resistance is the result of the temperature being raised to a value for drying. After reaching a minimum for a given temperature, the resistance will again rise as moisture is driven out of the insulation. The actual values will vary with each situation. Refer to Illustration 109 .
Illustration 109 indicates the curve of the resistance of a normal high resistance in the windings over a period of 60 seconds. The resistance after 60 seconds will be greater than the resistance or equal to the resistance after 30 seconds . Note: If the insulation resistance after 60 seconds is not higher than the resistance after 30 seconds , the insulation may be weak.
SEBU8607
131 Maintenance Recommendations Generator - Inspect
Note: Many electrical shops are equipped with baking ovens. Heat the generator to approximately 75° C (167° F). Never exceed 75° C (167° F) until the insulation tester tests correctly for insulation resistance (at least 4 hours).
Alternate Method A tent formed by a tarp or a canvas with heated lamps or a portable space heater may be used as an alternate method.
Illustration 110
g01697074
Curve of insulation resistance for windings that are wet or dirty (1) Resistance after 30 seconds (2) Resistance after 60 seconds
Illustration 110 indicates the curve of the resistance that is decaying over a period of 60 seconds. If the insulation resistance after 60 seconds is not higher than the resistance after 30 seconds , clean the windings and thoroughly dry the windings. Refer to Special Instruction, REHS9124, Cleaning and Drying of the Generator for more information. Note: Caterpillar recommends a minimum acceptable insulation resistance of 1 megohm for generators which operate with less than 1000 V of operating or rated voltage. Generators which operate at 1000 V of operating or rated voltage should have a minimum insulation resistance as determined by the following equation: R = (V/1000) + M R is the minimum insulation resistance.
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V is the rated voltage.
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A hole should be left in the top of the tarp for ensuring proper circulation through the generator and for permitting the moisture to exhaust. Heat the generator to approximately 75° C (167° F). Never exceed 75° C (167° F) until the insulation tester tests correctly for insulation resistance (at least 4 hours).
Internal Heating If generators operate under one of the following conditions, the electric space heaters should be installed as part of the generator: • Generators are in damp environments and go for long periods of time without operation. • Generators operate regularly in an environment with moisture laden air.
Circulating Current Drying can be accomplished by circulating low voltage current through the windings. Since the voltage is low, the breakdown of the insulation will not occur as the breakdown might have occurred with normal operation and wet insulation. Refer to Special Instruction, REHS9124, Cleaning and Drying of the Generator for this procedure.
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M is 1 megohm.
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These values are approximate. It may be possible to operate a generator with less resistance.
External Heat
Generator - Inspect SMCS Code: 4450-040
Ovens The best oven is a forced air drying oven for drying electrical equipment. Radiant ovens sometimes cause localized overheating. NOTICE Do not heat the generator too quickly. Try to limit the rise in temperature of the insulation and windings to 11.11° C (20° F) per hour. Failure to do so may cause equipment damage.
Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.
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Maintenance Recommendations Generator - Inspect
• The extent of the cleaning procedure that is being attempted The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start. Place the engine control switch in the OFF position. Attach DO NOT OPERATE tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator. “ “
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• The type of enclosure of the generator • The voltage rating of the generator • The type of dirt that is being removed
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Refer to Safety Section, “Generator Isolating for Maintenance” for information regarding the procedure to safely isolate the generator. Proper maintenance of electrical equipment requires periodic visual examination of the generator and periodic visual examination of the windings. Proper maintenance of electrical equipment also requires appropriate electrical checks and appropriate thermal checks. Insulation material should be examined for cracks. The insulation material should be examined for accumulations of dirt and dust. If there is an insulation resistance value that is below normal, a conductive path may be present. This conductive path may be made of one of the following materials: • Carbon • Salt • Metal dust • Dirt that is saturated with moisture
Cleaning (Assembled Generators) Cleaning may be required at the point of installation. At this point, complete disassembly of the generator may not be necessary or feasible. In this case, a vacuum cleaner should be used to pick up the following items: dry dirt, dust and carbon. This will prevent the spreading of these contaminants. A small nonconductive tube may need to be connected to the vacuum cleaner. This will allow the vacuum cleaner to clean the surfaces that are not exposed. After most of the dust has been removed, a small brush may be attached to the vacuum hose in order to loosen dirt that is more firmly attached to the surface. After the initial cleaning with a vacuum, compressed air may be used to remove the remaining dust and dirt. Compressed air that is used for cleaning should be free of moisture and free of oil. Air pressure should be a maximum of 210 kPa (30 psi) in order to prevent mechanical damage to the insulation. If the above cleaning procedures are not effective, consult a Caterpillar dealer.
Cleaning (Disassembled Generators)
These contaminants will develop a conductive path which may produce shorts. Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be seen. If excess dirt is the cause of a restriction in the ventilation, cleaning is also advisable. Restricted ventilation will cause excessive heating.
An initial insulation resistance check should be made on the generator in order to confirm electrical integrity. A minimum reading of one megohm would be expected with severely contaminated generators. A zero megohm reading may indicate an insulation breakdown. An insulation breakdown requires more than cleaning. An insulation breakdown requires repair.
NOTICE To avoid the possibility of deterioration to the generator windings, do not clean the generator unless there is visual, electrical, or thermal evidence that dirt is present.
A high pressure wash is normally an effective way to clean windings. This includes windings that have been exposed to flooding or windings that have been contaminated by salt. A solution of hot water and detergent is used for this method of cleaning.
If harmful dirt accumulations are present, a variety of cleaning techniques are available. The cleaning procedure that is used may be determined by one of the items on the following list:
A high pressure wash sprays a high velocity fluid stream of this solution over the generator that is being cleaned. This detergent washing is followed by multiple sprays of clean water. The clean water is used in order to remove the detergent or the clean water is used in order to dilute the detergent.
SEBU8607
133 Maintenance Recommendations Generator Load - Check
Allow the generator to dry at room temperature. Check the insulation resistance. The insulation resistance should now be normal. If the insulation resistance is not normal, repeat the procedure. It may be necessary to use solvents if the generator is contaminated with oil or if the generator is contaminated with grease. Note: For more information on drying methods, refer to Special Instructions, SEHS9124, “Cleaning and Drying of Electric Set Generators”. i01878834
Generator Load - Check
i02377583
Generator Set - Test SMCS Code: 4450-081
DANGER: Shock/Electrocution Hazard-Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death.
SMCS Code: 4450-535-LA
Personal injury or death can result from high voltage.
Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
During normal operation, monitor the power factor and monitor generator loading. When a three-phase generator is installed or when a three-phase generator is reconnected, ensure that the total current in any one phase does not exceed the nameplate rating. Each phase should carry the same load. This allows the three-phase generator to work at the rated capacity. If one phase current exceeds the nameplate amperage, an electrical imbalance will occur. An electrical imbalance can result in an electrical overload and an electrical imbalance can result in overheating on three-phase generators. This is not applicable to single-phase generators. The power factor can be referred to as the efficiency of the load. This can be expressed as the ratio of kVA to actual kW. The power factor can be calculated by dividing kW by kVA. Power factor is expressed as a decimal. Power factor is used to mean the portion of current that is supplied to a system that is doing useful work. The portion of the current that is not doing useful work is absorbed in maintaining the magnetic field in motors. This current (reactive load) can be maintained without engine power.
When servicing or repairing electric power generation equipment: •
Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE.
• Make sure the generator engine is stopped. • Make sure all batteries are disconnected. • Make sure all capacitors are discharged. Table 25 Tools Needed
Quantity
Part Number
Part
237-5130
Digital Multimeter
1
12 VDC battery
1
Potential Transformer
1
The generator set functional test is a simplified test that can be performed in order to determine if the generator is functional. The generator set functional test should be performed on a generator set that is under load.
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Maintenance Recommendations Generator Set Vibration - Inspect
The generator set functional test determines if the following statements happen:
• loose fittings • loose bolts
• A phase voltage is being generated. • excessive noise • The phase voltages are balanced. • cracked insulation • The phase voltages change relative to engine speed.
The following areas are susceptible to vibration damage:
The generator set functional test consists of the following steps:
• stator output leads
1. Stop the generator. Connect the potential transformer's high voltage winding to the generator terminals (T1) and (T2). Connect the voltmeter to the low voltage winding. If two transformers are available, connect the high voltage winding of the second transformer to the generator terminals (T1) and (T3). Connect the secondary terminals that correspond to generator terminal (T2) of both transformers together.
• protective sleeving
2. Disconnect wires E+ and E- from the voltage regulator. Disconnect the generator from the load.
Check the generator set's vibration level by using a broad spectrum analyzer.
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3. Connect a 12 VDC automotive battery to wires E + and E- .
• insulation • exposed electrical connections • transformers • fuses • capacitors
i03904021
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4. Measure the AC voltage across the low voltage terminals of the transformer that correspond to the following generator terminals: T1 and T2 , T2 and T3 and T3 and T1 . Record the voltages. “
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i02291365
Generator Winding Insulation Test SMCS Code: 4453-081; 4454-081; 4457-081; 4470081
Recommended Periodic Insulation Tests
Generator Set Vibration Inspect SMCS Code: 4450-040-VI Excessive vibration will indicate a problem with the generator set. The vibration may be caused by the following:
The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start. Place the engine control switch in the OFF position. Attach DO NOT OPERATE tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator. “ “
• Misalignment of the coupling between the engine and the generator • Faulty mounting or play in the coupling • Incorrect balancing of the generator shaft or engine crankshaft • A three-phase generator has too much load on a single phase. • There is a short circuit in the stator. Check for vibration damage. Vibration may cause the following problems:
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Table 26 Tools Needed 142-5055 Insulation Testing Gp 9U-6003 Insulation Testing
Gp
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SEBU8607
135 Maintenance Recommendations Generator Winding Insulation - Test
Periodically, use an insulation tester to check the insulation resistance of the generators main stator winding. The frequency of this test is determined by the generators environment. Previous insulation tester readings will also determine the frequency of this test.
2. Visually inspect the generator for moisture. If moisture exists, do not perform this insulation test. Dry the unit first. Refer to Special Instruction, SEHS9124, “Cleaning and Drying of Electric Set Generators”.
Test the main stator windings with an insulation tester in the following situations:
3. Inspect the installation. Determine the equipment that will be tested by the insulation tester.
• The generator set is started for the first time.
4. Discharge the capacitance of the windings.
• The generator set is removed from storage.
5. Isolate the stator windings of the generator by disconnecting all other leads and cables from the generator terminals. This includes connections to the voltage regulator, the control panel, the switchgear, or other devices.
• The generator set is operating in a humid environment. Test every 3 months. • The generator set is not protected from the elements in an enclosed area. Test every 3 months.
6. Connect the insulation testers RED lead to ground.
• The generator set is installed in an enclosed area. This area needs to be low in humidity and this area needs to have steady temperatures. Test every 12 months (minimum). • The generator set has not been run under load for 3 months. Test the generator set weekly. Use space heaters around the generator set if the generator is exposed to a sea water environment or if the humidity is above 75 percent. Also use space heaters if a test result was below 3 megohms. Space heaters must be used whenever the generator set is not under load. Space heaters must also be used whenever salt is present or whenever high humidity is present. Using a space heater in this fashion is the only way to maintain insulation tester readings above 1 megohm. Use space heaters only when the generator is not running. For additional information, refer to Special Instruction, SEHS9124, “Cleaning and Drying of Electric Set Generators”.
Recommended Procedure for A Periodic Insulation Test
Personal injury electrocution.
or
death
can
result
from
The megohmmeter is applying a high voltage to the circuit. To avoid electrocution, do not touch the instrument leads without first discharging them. When finished testing also discharge the generator windings. 1. Take the generator out of service.
7. Connect the insulation testers BLACK lead to the wye point or star point of the generators windings. 8. For units that are 600 V or less, set the voltage to 500 V. For units that are more than 600 V, set the voltage to 1000 V. 9. Use the 30/60 Time Resistance Method: a.
Apply voltage.
b.
Observe the readings at 30 seconds. Observe the readings at 60 seconds.
c.
Record the 60 second reading. This reading must be corrected for temperature.
d.
Record temperature.
e.
Record humidity.
f.
Remove voltage.
10. Evaluate the readings. The actual value of the resistance may vary greatly between generators. For this reason, the insulations condition must be evaluated. Base this evaluation on the comparison between the 60 second resistance readings and the readings that were taken on previous dates. These two readings must be taken under similar conditions. If a 60 second resistance reading has a 50 percent reduction from the previous reading, the insulation may have absorbed too much moisture. Switch the insulation tester to the OFF position. This will discharge the insulation testers leads. Disconnect the insulation testers leads. “
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136 Maintenance Recommendations Generator Winding Insulation - Test
Note: The results from the insulation resistance checks indicate when cleaning and/or repairing is becoming critical. Generally, insulation resistance will vary greatly with temperature. Therefore, always test at the same temperature and humidity. Refer to Illustration 111 . Serial Number (Engine) Serial Number (Generator)
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SEBU8607
137 Maintenance Recommendations Generator Winding Insulation - Test
138
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Maintenance Recommendations Generator Winding Insulation - Test
Illustration 111
g00633226
SEBU8607
139 Maintenance Recommendations Heat Exchanger - Inspect/Clean
i03903805
Heat Exchanger - Inspect/ Clean
Table 27 Hydrosolv Liquid Cleaners(1) Part Number 1U-5490
SMCS Code: 1379-040; 1379-070
174-6854
The interval for the maintenance of the tube type heat exchanger depends on the operating environment of the vessel and on the operating time. The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items: • Cleanliness of the tubes for the heat exchanger
(1)
Description
Hydrosolv 4165 Hydrosolv 1 00
Size 19 L (5 US gallon) 19 L (5 US gallon)
Use a 2 to 5 percent concentration of the cleaner at temperatures up to 93°C (200°F). Refer to Application Guide, NEHS0526 or consult your Caterpillar dealer for more information.
4. Steam clean the core in order to remove any residue. Flush the tubes of the heat exchanger core. Remove any other trapped debris.
• Effectiveness of the heat exchanger system Operating in water that contains silt, sediment, salt, algae, and so on, will adversely affect the heat exchanger system. In addition, intermittent use of the vessel will adversely affect the heat exchanger system.
5. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.
The following items indicate that the heat exchanger may require cleaning:
Personal injury can result from air pressure.
• Increased coolant temperature
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
• Engine overheating • Excessive pressure drop between the water inlet and the water outlet An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range. Inspection and maintenance of the heat exchanger are required if the engine is overheating.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. 6. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.
Cleaning the Heat Exchanger
7. Inspect the core in order to ensure cleanliness. Pressure test the core. Many shops that service radiators are equipped to perform pressure tests. If necessary, repair the core.
1. Remove the heat exchanger. Refer to the Service Manual for the procedure.
8. Install the heat exchanger. Refer to the Service Manual for the procedure.
2. Turn the heat exchanger core upside-down in order to remove debris.
For more information on cleaning the core, consult your Caterpillar dealer. i03903802
NOTICE Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner. 3. Back flush the core with cleaner. Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 27 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer.
Hoses and Clamps - Inspect/ Replace SMCS Code: 7554-040; 7554-510 Inspect all hoses for leaks that are caused by the following conditions: • Cracking • Softness • Loose clamps
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Maintenance Recommendations Overhaul Considerations
Replace hoses that are cracked or soft. Tighten any loose clamps. NOTICE Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Note: Drain the coolant into a suitable, clean container. The coolant can be reused. 3. Drain the coolant from the cooling system to a level that is below the hose that is being replaced. 4. Remove the hose clamps.
Check for the following conditions:
5. Disconnect the old hose.
• End fittings that are damaged or leaking
6. Replace the old hose with a new hose.
• Outer covering that is chafed or cut
7. Install the hose clamps with a torque wrench.
• Exposed wire that is used for reinforcement • Outer covering that is ballooning locally • Flexible part of the hose that is kinked or crushed • Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen. This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps. Each installation application can be different. The differences depend on the following factors: • Type of hose
Note: Refer to the Specifications, SENR3130, “Torque Specifications” in order to locate the proper torques. 8. Refill the cooling system. 9. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. Replace the cooling system filler cap if the gaskets are damaged. Install the cooling system filler cap. 10. Start the engine. Inspect the cooling system for leaks. i03903800
Overhaul Considerations SMCS Code: 7595-043
• Anticipated expansion and contraction of the hose
Reduced hours of operation at full load will result in a lower average power demand. A decreased average power demand should increase both the engine service life and the overhaul interval.
• Anticipated expansion and contraction of the fittings
The need for an overhaul is generally indicated by increased fuel consumption and by reduced power.
Replace the Hoses and the Clamps
The following factors are important when a decision is being made on the proper time for an engine overhaul:
• Type of fitting material
• The need for preventive maintenance Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine. Allow the engine to cool.
• The quality of the fuel that is being used • The operating conditions • The results of the S·O·S analysis
SEBU8607
141 Maintenance Recommendations Overhaul Considerations
Oil Consumption as an Overhaul Indicator Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals. Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases. The oil consumption rate (brake-specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake-specific oil consumption (BSOC) depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine. When an engines oil consumption has risen to three times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled. There may be a corresponding increase in blowby and a slight increase in fuel consumption.
Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons: • Costly unplanned downtime can be avoided. • Many original parts can be reused according to the standards for reusable parts. • The engines service life can be extended without the risk of a major catastrophe due to engine failure. • The best cost/value relationship per hour of extended life can be attained.
After Failure Overhaul If a major engine failure occurs and the engine must be removed, many options are available. An overhaul should be performed if the engine block or the crankshaft needs to be repaired. If the engine block is repairable and/or the crankshaft is repairable, the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core. This lower cost can be attributed to three aspects:
• Specially designed Caterpillar engine features • Caterpillar dealer exchange components • Caterpillar Inc. remanufactured exchange components
Overhaul Recommendation To minimize downtime, Caterpillar Inc. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. This will provide you with the best cost/value relationship. Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life. If an overhaul is performed without overhaul service from your Caterpillar dealer, be aware of the following maintenance recommendations.
Rebuild or Exchange Cylinder Head Assembly, Oil Pump, and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications. The Special Publication, SEBF8029 lists the reusability publications that are needed for inspecting the engine parts. If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline, the parts should be reused. Parts that are not within the established inspection specifications should be dealt with in one of the following manners: • Salvaging • Repairing • Replacing Using out-of-spec parts can result in the following problems: • Unscheduled downtime • Costly repairs • Damage to other engine parts • Reduced engine efficiency • Increased fuel consumption
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Maintenance Recommendations Overhaul Considerations
Reduced engine efficiency and increased fuel consumption translates into higher operating costs. Therefore, Caterpillar Inc. recommends repairing outof-spec parts or replacing out-of-spec parts.
Inspection and/or Replacement Crankshaft Bearings and Crankshaft Seals The following components may not last until the second overhaul. • Thrust bearings • Main bearings • Rod bearings • Crankshaft seals Caterpillar Inc. recommends the installation of new parts at each overhaul period. Inspect these parts while the engine is disassembled for an overhaul. Inspect the crankshaft for any of the following conditions: • Deflection
Oil Cooler Core During an overhaul, Caterpillar Inc. recommends the removal of the oil cooler core. Clean the oil cooler core. Then, pressure test the oil cooler core. NOTICE Do not use caustic cleaners to clean the core. Caustic cleaners can attack the internal metals of the core and cause leakage. Note: Use this cleaning procedure to clean the oil cooler core. 1. Remove the oil cooler core. 2. Remove any debris from the oil cooler core. To remove debris from the oil cooler core, turn the oil cooler core onto one end. 3. Flush the oil cooler core internally with cleaner in order to loosen foreign substances. This will also help to remove oil from the oil cooler core. Note: Caterpillar Inc. recommends the use of Hydrosolv Liquid Cleaners. Table 28 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer. Table 28 Hydrosolv Liquid Cleaners
• Damage to the journals • Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components: • Rod bearing • Main bearings Inspect the camshaft for damage to the journals and to the lobes. Note: If the camshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the camshaft. Inspect the following components for signs of wear or for signs of scuffing: • Camshaft bearings
Part Number
Description
Size
1U-5490
Hydrosolv 4165
19 L (5 US gal)
1U-5492
Hydrosolv 100
19 L (5 US gallon)
4. Use steam to clean the oil cooler core. This removes any remaining residue from the cleaner. Flush the fins of the oil cooler core. Remove any other trapped debris. 5. Wash the oil cooler core with hot, soapy water. Rinse the oil cooler core thoroughly with clean water.
Personal injury can result from air pressure.
• Lifters
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Caterpillar Inc. recommends replacing the crankshaft vibration damper.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. 6. Dry the oil cooler core with compressed air. Direct the air in the reverse direction of the normal flow.
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143 Maintenance Recommendations Power Factor - Check
7. Inspect the components in order to ensure cleanliness. The oil cooler core should be pressure tested. Repair the oil cooler core, if necessary. Install the oil cooler core. For more information about cleaning the cores, consult your Caterpillar dealer.
Obtain Coolant Analysis The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits or with S·O·S Coolant Analysis (Level 1). Further coolant analysis is recommended when the engine is overhauled. For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals that were deposited on the engine over time. A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. Private laboratories are also available for water analysis. Caterpillar Inc. recommends an S·O·S Coolant Analysis (Level 2).
S·O·S Coolant Analysis (Level 2) An S·O·S Coolant Analysis (Level 2) is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system. An S·O·S Coolant Analysis (Level 2) provides the following information: • Complete S·O·S Coolant Analysis (Level 1) • Visual inspection of properties • Identification of metal corrosion
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Power Factor - Check SMCS Code: 4450-535-PWR The power factor of a system can be determined by a power factor meter or by calculations. The power factor can be calculated by dividing kW by kVA. Power factor is expressed as a decimal. i03903799
Rotating Rectifier - Check SMCS Code: 4465-535
The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start. Place the engine control switch in the OFF position. Attach DO NOT OPERATE tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator. “ “
“ “
”
” ”
Check the exciter armature. Ensure that the rotating rectifier is tight. If a failure of a rectifier is suspected, refer to Operation and Maintenance Manual, “Rotating Rectifier - Inspect/Test”. i03903798
Rotating Rectifier - Inspect/ Test SMCS Code: 4465-040; 4465-081
• Identification of contaminants • Identification of built up impurities (corrosion and scale) S·O·S Coolant Analysis (Level 2) provides a report of the results of both the analysis and the maintenance recommendations. For more information about coolant analysis, see your Caterpillar dealer.
The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start. Place the engine control switch in the OFF position. Attach DO NOT OPERATE tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator. “ “
“ “
” ”
Use the following procedure in order to test the rotating rectifier.
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Maintenance Recommendations Sea Water Strainer - Clean/Inspect
1. Stop the generator set. Disconnect the wires for the AVR and isolate the wires for the AVR. 2. Make an assembly for separate excitation. The assembly can use a 12 V battery or a variable DC power supply as a power source. Refer to Step 3 for an assembly that uses a 12 V battery. Refer to Step 4 for an assembly that uses a variable DC power supply.
5. The assembly should have characteristics that are compatible with the power for the field excitation of the generator. 6. Operate the generator set at rated speed. 7. Gradually increase the current of the exciter field by adjusting the rheostat or the variable power supply. Measure the output voltage and the current at no load. Measure the output voltage and measure the current at no load. 8. The generator is operating properly when the output voltage is at the rated value and the output voltage is balanced within 1 percent for the rated level of excitation. i03903797
Sea Water Strainer - Clean/ Inspect SMCS Code: 1371-040; 1371-070 Illustration 112
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(A) Exciter Field (B) Diode (one Amp) (C) Rheostat (50 Ohms 300 W)
3. Connect a 12 V battery in series with a rheostat (C) of 50 Ohms 300 Watts and a diode (B) on both wires for the exciter field (5+ and 6-). Go to step 5. “
”
S/N: S1M1–Up The sea water strainer must be clean in order to allow proper engine cooling. Check the sea water strainer for plugging. Inspect the sea water strainer more frequently if the vessel is being operated in water which is shallow or dirty. The sea water strainer protects the aftercooler from debris. The sea water strainer will catch pieces of the rubber impeller from the raw water pump due to a failure from debris. The sea water strainer is installed on turbocharged engines only.
Drain the Sea Water Cooling System Turbocharged Engines 1. Close the valve for the sea water.
Illustration 113
g01015808
(D) AC supply (E) Variable power supply (F) Exciter field (G) Diode bridge
4. Connect a variable power supply and a diode bridge to both of the wires for the exciter field (5+) and (6-).
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145 Maintenance Recommendations Sea Water Strainer - Clean/Inspect
5. Use the turning tool on the front of the crankshaft in order to rotate the engine. This will ensure that all of the water has drained from the sea water pump.
Clean the Sea Water Strainer Turbocharged Engines 1. Ensure that the sea water cooling system is drained. Refer to “Drain the Sea Water Cooling System” for the procedure.
Illustration 114
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Typical example 2. Disconnect both hoses (2) from the sea water pump (1). 3. Open the valve for the sea water.
Illustration 116
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Typical example 2. Remove the hose clamp (2) for the sea water strainer. Remove the sea water strainer (1) and clean the screen. Use clean water to clean the screen. Remove any dirt and debris. 3. Install the sea water strainer (1). Install the hose and the hose clamp (2). Fill the sea water strainer and the suction line for the auxiliary water pump with water.
Filling the Sea Water Cooling System Turbocharged Engines
Illustration 115
g00751786
Typical example 4. Remove the drain plug (3) from the front cover of the heat exchanger (4). Ensure that the drain hole is not plugged.
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Maintenance Recommendations Standby Generator Set Maintenance Recommendations
i03903795
Standby Generator Set Maintenance Recommendations SMCS Code: 4450-041 A standby generator set may not be used often. However, the generator set is needed for operation in an emergency situation. Maintenance of the standby generator set is important for the following reasons: • The generator set must always be in excellent operating condition. • The generator set must be ready to work under load at any time. Establishing a Preventive Maintenance Program will provide these benefits: Illustration 117
g00751785
• Maximum availability of the standby generator set
Typical example
• Longer service life for the generator set
1. Connect the hoses (2) at the sea water pump (1).
• Minimum of expensive repairs Your Caterpillar dealer can help you to establish an effective Preventive Maintenance Program for your generator set. Consult your Caterpillar dealer for details.
Maintenance and Operation Procedures
The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start. Place the engine control switch in the OFF position. Attach DO NOT OPERATE tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator. “ “
“ “
Illustration 118
g00751786
Typical example 2. Install the drain plug (3) in the front cover of the heat exchanger (4). 3. Open the valve for the sea water.
”
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The recommended maintenance for the generator set is listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule (Standby Generator Sets)” (Maintenance Section).
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147 Maintenance Recommendations Starting Motor - Inspect
Maintenance and Repair The maintenance that is recommended for Every Week can be performed by an authorized operator. The maintenance that is recommended for the subsequent maintenance intervals must be performed by an authorized service technician or by your Caterpillar dealer. Unless other instructions are provided, perform maintenance and repairs under the following conditions: • The engine is stopped. • The starting system is disabled.
i03903794
Starting Motor - Inspect SMCS Code: 1451-040; 1453-040 Caterpillar recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine may not start in an emergency situation. Check the starting motor for correct operation. Check the electrical connections and clean the electrical connections. Refer to the Systems Operation, Testing, and Adjusting Manual, “Electric Starting System - Test” for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance.
• The generator does not pose an electrical shock hazard.
i03903793
• The generator is disconnected from the load.
Turbocharger - Inspect
Operation
SMCS Code: 1052-040
To ensure proper operation, the generator set must be exercised regularly. For instructions on operating the generator set, see the Operation and Maintenance Manual for the generator set control panel.
S/N: S1M1–Up
For these operation procedures, follow the instructions that are provided in this Operation and Maintenance Manual, “Operation Section”: starting the engine, engine operation and stopping the engine.
Record Keeping Maintain a record in order to document these items: gauge readings, maintenance that is performed, problems and repairs.
Space Heaters Moisture causes damage to generators and other electrical equipment. Make every effort to keep the generator set as dry as possible. Generators can operate without problems in humid environments. However, problems can occur when the generator is inactive. Moisture can condense on the windings. This can result in poor performance. Also, damage to the windings can occur. Use space heaters in order to help keep the windings dry. When the generator is not active, ensure that the space heaters are operating. When the generator is operating, turn OFF the space heaters.
A regular visual inspection of the turbocharger is recommended. If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder head. NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage. Minor leakage of oil into a turbocharger under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occured. When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is renewed. A visual inspection of the turbocharger can minimize unscheduled downtime. A visual inspection of the turbocharger can also reduce the chance for potential damage to other engine parts.
Removal and Installation Note: The turbochargers that are supplied are nonserviceable. For options regarding the removal, installation, and replacement, consult your Carerpillar dealer. Refer to the Disassembly and Assembly Manual, “Turbocharger - Remove and Turbocharger - Install” for further information.
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Maintenance Recommendations Walk-Around Inspection
Inspecting
• The guards must be in the correct place. Repair damaged guards or replace missing guards.
NOTICE The compressor housing for the turbocharger must not be removed from the turbocharger for inspection or removed for the cleaning of the compressor.
• Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination.
1. Remove the pipe from the turbocharger exhaust outlet and remove the air intake pipe to the turbocharger. Visually inspect the piping for the presence of oil. Clean the interior of the pipes in order to prevent dirt from entering during reassembly.
NOTICE For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.
2. Check for obvious heat discoloration of the turbocharger. Check for any loose bolts or any missing bolts. Check for damage to the oil supply line and the oil drain line. Check for cracks in the housing of the turbocharger. Ensure that the compressor wheel can rotate freely. 3. Check for the presence of oil. If oil is leaking from the back side of the compressor wheel, there is a possibility of a failed turbocharger oil seal. The presence of oil may be the result of a restriction of the line for the intake air (clogged air filters), which causes the turbocharger to slobber. 4. Inspect the bore of the housing of the turbine outlet for corrosion. 5. Fasten the air intake pipe and the exhaust outlet pipe to the turbocharger housing. Ensure that all clamps are installed correctly and that all clamps are tightened securely. i03903792
Walk-Around Inspection SMCS Code: 1000-040
NOTICE Accumulated grease and/or oil on an engine is a fire hazard. Remove the accumulated grease and oil. Refer to this Operation and Maintenance Manual, “Engine - Clean” for more information. • Ensure that the cooling system hoses are correctly clamped and that the cooling system hoses are tight. Check for leaks. Check the condition of all pipes. • Inspect the water pump for coolant leaks. Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract. Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of the water pump and the installation of water pump and/or seal, refer to the Disassembly and Assembly Manual, “Water Pump - Remove and Install” for more information or consult your Caterpillar dealer. • Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters, and the rocker cover.
Inspect the Engine for Leaks and for Loose Connections
• Inspect the fuel system for leaks. Look for loose fuel line clamps and/or tie-wraps.
A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided.
• Inspect the piping for the air intake system and the elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other hoses, tubes, wiring harnesses, and so on.
For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections, and trash buildup. Make repairs, as needed:
• Inspect the alternator belts and any accessory drive belts for cracks, breaks, or other damage. Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break.
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149 Maintenance Recommendations Water Pump - Inspect
• Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system. • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires. • Inspect the ground strap for a good connection and for good condition. • Disconnect any battery chargers that are not protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery. • Check the condition of the gauges. Replace any gauges that are cracked. Replace any gauge that cannot be calibrated. i03903791
Water Pump - Inspect SMCS Code: 1361-040 A failed water pump might cause severe engine overheating problems that could result in the following conditions: • Cracks in the cylinder head • A piston seizure • Other potential damage to the engine Note: The water pump seal is lubricated by the coolant in the cooling system. A small amount of leakage normally occurs as the engine cools down and parts contract. Visually inspect the water pump for leaks. Note: If engine coolant enters the engine lubricating system the lubricating oil and the engine oil filter must be replaced. Replacing the oil filter will remove any contamination that is caused by the coolant and will prevent any irregular oil samples. The water pump is not a serviceable item. In order to install a new water pump, refer to the Disassembly and Assembly Manual, “Water Pump - Remove and Install” or contact your Caterpillar dealer.
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Warranty Section Emissions Warranty Information
Warranty Section Warranty Information i05264237
Emissions Warranty Information SMCS Code: 1000 This engine may be certified to comply with exhaust emission standards and gaseous emission standards. Standards are prescribed by law at the time of manufacture, and this engine may be covered by an Emissions Warranty. A detailed explanation of the Emissions Warranty that is applicable to emissions certified engines is found in Supplement, SEBU6981, Federal Emissions Control Warranty Information. Consult your authorized Cat dealer to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty.
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151 Reference Information Section Engine Rating Conditions
Reference Information Section
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Engine Rating Definitions SMCS Code: 1000
Engine Ratings
Ratings for Generator Set Engines i02719419
Engine Rating Conditions
The engine ratings that are listed below have a manufacturing tolerance of plus three percent or minus three percent.
SMCS Code: 1000
Standby Rating
All engine ratings are in compliance with the following standard ambient air conditions of SAE J1349:
• Typical load factor of 60 percent or less
• 100 kPa (29.3 Inches Hg)
• 100 typical operating hours per year
• 30 percent relative humidity
• Typical applications with standby service for building services with an enclosed environment
• A temperature of 25 °C (77 °F) Ratings relate to the standard condition of ISO14396:2002. The engine ratings are based on the following fuel specifications: • The Low Heat Value (LHV) of the fuel at 29 °C (84.2 °F) at 42780 kJ/kg (18390 Btu/lb) • Gravity (API) of 35 degrees at 15 °C (60 °F) • Specific gravity of .849 at 15 °C (60 °F) The engine ratings are gross output ratings. Gross Output Ratings – The total output capability of the engine that is equipped with standard accessories. Standard accessories include the following components:
• 80 percent typical peak demand of the standby rated kW • 100 percent of the rated kW for the duration of an emergency outage
Prime Rating • Typical load factor of 60 percent to 70 percent • No limit to typical operating hours • Typical peak demand at 100 percent of the continuous rated kW for less than 10 percent of the total operating hours Some typical applications include the following operations: • industrial • pumping
• Oil pumps
• construction
• Fuel pumps
• peak shaving
• Water pumps
• cogeneration
Subtract the power that is required to drive auxiliary components from the gross output. This will produce the net power that is available for the external load (flywheel).
NOTICE Operating a generator set engine above the rating definitions will result in a shorter engine service life before overhaul.
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Customer Service Customer Assistance
Customer Service i03910803
Customer Assistance SMCS Code: 1000; 4450
USA and Canada When a problem arises concerning the operation or the service of an engine, the problem will normally be managed by the dealer in your area. Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. If you have a problem that has not been handled to your complete satisfaction, follow these steps: 1. Discuss your problem with a manager from the dealership. 2. If your problem cannot be resolved at the dealer level, use the phone number that is listed below to talk with a Field Service Coordinator: 1-800-447-4986 The normal hours are from 8:00 to 4:30 Monday through Friday Central Standard Time. 3. If your needs have not been met still, submit the matter in writing to the following address: Caterpillar Inc. Marine Center of Excellence Manager, Customer Service 111 Southchase Blvd Fountain Inn, SC 29644 Please keep in mind: probably, your problem will ultimately be solved at the dealership, using the dealership facilities, equipment, and personnel. Therefore, follow the steps in sequence when a problem is experienced.
Outside of the USA and of Canada If a problem arises outside the USA and outside Canada , and if the problem cannot be resolved at the dealer level, consult the appropriate Caterpillar office. Latin America, Mexico, Carribean Caterpillar Americas Co. 701 Waterford Way, Suite 200 Miami, FL 33126-4670 USA Phone: 305-476-6800 Fax: 305-476-6801
Europe, Africa, and Middle East Caterpillar Overseas S.A. 76 Route de Frontenex P.O. Box 6000 CH-1211 Geneva 6 Switzerland Phone: 22-849-4444 Fax: 22-849-4544 Far East Caterpillar Asia Pte. Ltd. 7 Tractor Road Jurong, Singapore 627968 Republic of Singapore Phone: 65-662-8333 Fax: 65-662-8302 China Caterpillar China Ltd. 37/F., The Lee Gardens 33 Hysan Avenue Causeway Bay G.P.O. Box 3069 Hong Kong Phone: 852-2848-0333 Fax: 852-2848-0440 Japan Shin Caterpillar Mitsubishi Ltd. SBS Tower 10-1, Yoga 4-Chome Setagaya-Ku, Tokyo 158-8530 Japan Phone: 81-3-5717-1150 Fax: 81-3-5717-1177 Japan Caterpillar Power Systems, Inc. SBS Tower (14th floor) 4-10-1, Yoga Setagaya-Ku, Tokyo 158-0097 Phone: 81-3-5797-4300 Fax: 81-3-5797-4359 Australia and New Zealand Caterpillar of Australia Ltd. 1 Caterpillar Drive Private Mail Bag 4 Tullamarine, Victoria 3043 Australia Phone: 03-9953-9333 Fax: 03-9335-3366
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153 Customer Service Ordering Replacement Parts
i01028392
Ordering Replacement Parts SMCS Code: 4450; 7567
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world. Caterpillar dealers' parts inventories are up-to-date. The parts stocks include all of the parts that are normally needed to protect your Caterpillar engine investment. When you order parts, please specify the following information: • Part number • Part name • Quantity If there is a question concerning the part number, please provide your dealer with a complete description of the needed item. When a Caterpillar engine requires maintenance and/or repair, provide the dealer with all the information that is stamped on the Information Plate. This information is described in this Operation and Maintenance Manual (Product Information Section). Discuss the problem with the dealer. Inform the dealer about the conditions of the problem and the nature of the problem. Inform the dealer about when the problem occurs. This will help the dealer in troubleshooting the problem and solving the problem faster.
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Reference Materials Maintenance Records
Reference Materials i05264255
Maintenance Records SMCS Code: 1000; 4450 Caterpillar Inc. recommends the retention of accurate maintenance records. Accurate maintenance records can be used for the following purposes: • Determine operating costs. • Establish maintenance schedules for other engines that are operated in the same environment. • Show compliance with the required maintenance practices and maintenance intervals. Maintenance records can be used for various other business decisions that are related to engine maintenance. Maintenance records are a key element of a maintenance program that is managed. Accurate maintenance records can help your Cat dealer to fine-tune the recommended maintenance intervals in order to meet the specific operating situation. This should result in a lower engine operating cost. Records should be kept for the following items: Fuel Consumption – A record of fuel consumption is essential in order to determine when the load sensitive components should be inspected or repaired. Fuel consumption also determines overhaul intervals. Service Hours – A record of service hours is essential to determine when the speed sensitive components should be inspected or repaired. Documents – These items should be easy to obtain, and these items should be kept in the engine history file. All of the documents should show this information: date, service hours, fuel consumption, unit number and engine serial number. The following types of documents should be kept as proof of maintenance or repair for warranty: Keep the following types of documents as proof of maintenance for warranty. Also, keep these types of documents as proof of repair for warranty: • Dealer work orders and itemized bills • Owner repair costs • Owner receipts • Maintenance log
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155 Reference Materials Maintenance Log
i01176304
Maintenance Log SMCS Code: 1000; 4450 Table 29 Engine Model
Customer Identifier
Serial Number
Arrangement Number
Service Hours
Quantity Of Fuel
Service Item
Date
Authorization
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Reference Materials Reference Material
i03901129
Reference Material SMCS Code: 1000; 4450 The following literature can be obtained through any Caterpillar dealer.
Miscellaneous • Service Manual, REG1139F, “Service Manual Contents Microfiche” • Specifications, SENR3130, “Torque Specifications”
Lubricants
• Special Publication, PECP9067, “One Safe Source” English language for use in NACD
• Special Publication, PEHP8038, “Data Sheet Caterpillar Diesel Engine Oils (DEO) (CH-4) (North America)”
• Special Publication, LEDM5615, “Caterpillar Marine Parts and Service Locations Directory”
• Special Publication, PEHP9536, “Data Sheet Caterpillar Diesel Engine Oil (DEO) (CF-4) (International only)” • Special Publication, NEDG6022, “Cat Lubricating Grease” • Special Publication, PEHP0002, “Data Sheet Molybdenum (MPGM) Grease” • Special Publication, NEHP6015, “Data Sheet Caterpillar Special Purpose Grease (SPG)”
• Special Publication, SEBF8029, “Index to Guidelines for Reusable Parts and Salvage Operations” • Special Publication, SEBF8062, “Procedure to Inspect and Clean Air Filters” • Special Instruction, SEHS9031, “Storage Procedure for Caterpillar Products” • Special Publication, NEHS0526, “Service Technician Application Guide”
• Special Publication, SEBD0640, “Oil and Your Engine”
• Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations”
• Operation and Maintenance Manual, SEBU5898, “Cold Weather Recommendations”
• Special Instruction, SEHS7633, “Battery Test Procedure”
• Operation and Maintenance Manual, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations”
• Label, SEHS7332, “Danger Do Not Operate”
• Special Publication, PEHP6001, “How To Take A Good Oil Sample”
This engine may be Certified and this engine may be covered by an Emissions Warranty. A detailed explanation of the Emissions Warranty that is applicable to Certified engines is found in Supplement, SMBU6981, “Emissions Control Warranty Information”. The engine is Certified if the engine has a special label that verifies the certification. A Caterpillar dealer can also inform you if the engine is certified.
Fuels • Special Publication, SEBD0717, “Diesel Fuels and Your Engine”
Coolants • Special Publication, PEHP4036, “Data Sheet Extended Life Coolant” • Special Publication, PEHP7057, “Data Sheet S·O·S Coolant Analysis” • Special Publication, SEBD0518, “Know Your Cooling System” • Special Publication, SEBD0970, “Coolant and Your Engine” • Label, PEEP5027, “Extended Life Coolant/ Antifreeze”
Emissions Warranty
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157 Index Section
Index A After Starting Engine........................................ 52 After Stopping Engine...................................... 76 Alarms and Shutoffs ........................................ 36 Alarms.......................................................... 36 Prevention of Start-up .................................. 36 Shutoffs........................................................ 36 Testing Alarms and Shutoffs ........................ 36 Alternator - Inspect .......................................... 97 Automatic Start/Stop - Inspect ......................... 97 Auxiliary Water Pump - Inspect ....................... 97 Auxiliary Water Pump - Inspect (Bronze Auxiliary Water Pump) ................................... 98
B Battery - Replace ............................................. 98 Battery Charger - Check .................................. 99 Battery Electrolyte Level - Check .................... 99 Battery or Battery Cable - Disconnect ........... 100 Before Starting Engine ...............................16, 48 Belts - Inspect/Adjust/Replace (Single Belt).. 100 Adjustment ................................................. 101 Inspection................................................... 100 Replace...................................................... 101 Burn Prevention............................................... 13 Batteries....................................................... 13 Coolant......................................................... 13 Oils............................................................... 13
C Cold Weather Operation.................................. 71 Cold Weather Starting ..................................... 48 Configuration Parameters (Customer Specified Parameters)................................... 46 Configurable Inputs...................................... 46 ECM Identification Parameter...................... 46 Engine Rating Parameter............................. 46 Miscellaneous.............................................. 46 Control Panel................................................... 37 Marine Classification Society (MCS) Control Panel.......................................................... 37 Coolant (ELC) - Change ................................ 101 Drain .......................................................... 102 Fill............................................................... 103 Flush .......................................................... 102
Coolant Extender (ELC) - Add....................... 103 Coolant Level - Check ................................... 104 Coolant Sample (Level 1) - Obtain ................ 105 Coolant Sample (Level 2) - Obtain ................ 106 Coolant Temperature Regulator - Replace.... 106 Cooling System Supplemental Coolant Additive (SCA) - Test/Add............................ 107 Add the SCA, If Necessary ........................ 107 Test the Concentration of the SCA............. 107 Crushing Prevention and Cutting Prevention .. 15 Customer Assistance..................................... 152 Outside of the USA and of Canada ........... 152 USA and Canada ...................................... 152 Customer Service .......................................... 152
D Declaration of Conformity................................ 28 Diagnostic Lamp.............................................. 46
E Electrical Connections - Check...................... 108 Electrical System............................................. 17 Grounding Practices .................................... 17 Emergency Stopping ....................................... 73 Emergency Stop Button............................... 73 Emissions Certification Film ............................ 29 Emissions Warranty Information.................... 150 Engine - Clean............................................... 108 Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace .............................. 109 Cleaning the Primary Air Cleaner Elements ..................................................................110 Servicing the Air Cleaner Elements ........... 109 Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace................112 Engine Air Cleaner Service Indicator Inspect .......................................................... 112 Test the Service Indicator............................112 Engine Crankcase Breather - Replace (Turbocharged Engines and Naturally Aspirated Engines) .......................................113 Engine Crankcase Breather - Replace (Turbocharged Engines) ...............................113 Engine Crankcase Breather Element Replace (Turbocharged Engines).................113 Engine Diagnostics.......................................... 46
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Index Section
Engine Mounts - Inspect.................................114 Engine Oil and Filter - Change (Duplex Oil Filters)...........................................................116 Commissioning Procedure for Duplex Oil Filters ........................................................118 Replace Engine Oil .....................................116 Engine Oil and Filter - Change (Single Oil Filter)............................................................ 120 Drain the Engine Lubricating Oil ................ 120 Fill the Oil Pan............................................ 122 Single Oil Filter........................................... 121 Engine Oil Level - Check ................................115 Engine Oil Sample - Obtain............................115 Obtain the Sample and the Analysis...........115 Engine Operation............................................. 53 Engine Operation with Active Diagnostic Codes ............................................................ 46 Control Panel for MCS ................................. 46 Engine Operation with Intermittent Diagnostic Codes........................................... 46 Control Panel for MCS ................................. 46 Engine Protective Devices - Check ............... 122 Calibration Check....................................... 122 Visual Inspection........................................ 122 Engine Rating Conditions.............................. 151 Engine Rating Definitions .............................. 151 Ratings for Generator Set Engines ............ 151 Engine Ratings .............................................. 151 Engine Speed/Timing Sensor - Clean/ Inspect ......................................................... 123 Engine Starting ...........................................16, 48 Engine Stopping .........................................17, 73 Engine Valve Lash - Check............................ 123
F Features and Controls ..................................... 36 Fire Prevention and Explosion Prevention ...... 13 Ether ............................................................ 15 Fire Extinguisher.......................................... 15 Lines, Tubes, and Hoses ............................. 15 Foreword............................................................ 4 California Proposition 65 Warning ................. 4 Literature Information..................................... 4 Maintenance .................................................. 4 Maintenance Intervals.................................... 4 Operation ....................................................... 4 Overhaul ........................................................ 4 Safety............................................................. 4 Fuel and the Effect from Cold Weather............ 71 Fuel Conservation Practices............................ 53
Fuel Related Components in Cold Weather.... 71 Fuel Filters ................................................... 71 Fuel Heaters ................................................ 72 Fuel Tanks.................................................... 71 Fuel System - Prime (Duplex Fuel Filter if Equipped) .................................................... 123 Priming a Duplex Fuel Filter with the Engine in Operation ................................................. 126 Priming the Duplex Fuel Filters with the Engine Stopped........................................ 124 Fuel System Primary Filter (Water Separator) Element - Replace (if Equipped ).................................................................... 126 Fuel System Secondary Filter - Replace ....... 127 Duplex Filters ............................................. 128 Fuel Tank Water and Sediment - Drain.......... 129 Drain the Water and the Sediment............. 129 Fuel Storage Tanks .................................... 129 Fuel Tank ................................................... 129
G Gauges and Indicators .................................... 42 General Hazard Information ............................ 10 Asbestos Information ................................... 12 Containing Fluid Spillage ..............................11 Dispose of Waste Properly........................... 12 Fluid Penetration...........................................11 Pressurized Air and Water ............................11 General Information......................................... 19 General Maintenance Information................... 84 Generator - Dry.............................................. 129 Circulating Current..................................... 131 External Heat ............................................. 131 Internal Heating.......................................... 131 Generator - Inspect........................................ 131 Cleaning (Assembled Generators) ............ 132 Cleaning (Disassembled Generators)........ 132 Generator Isolating for Maintenance ............... 17 Generator Lead Connections .......................... 65 Connection Diagrams .................................. 66 Grounding the Frame................................... 65 Neutral Connections .................................... 65 Single Units.................................................. 66 Generator Load - Check ................................ 133 Generator Operation........................................ 54 Block Loading .............................................. 54 Excitation Systems....................................... 55 Loading of the Generator............................. 54 Options for the Generator ............................ 55 Power Factor................................................ 54
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159 Index Section
Standby Generator Sets .............................. 55 Generator Set - Test ...................................... 133 Generator Set Intended for Stationary Use Only ............................................................... 29 Generator Set Vibration - Inspect .................. 134 Generator Start-up Checklist ........................... 87 Generator Winding Insulation - Test .............. 134 Recommended Periodic Insulation Tests... 134 Recommended Procedure for A Periodic Insulation Test .......................................... 135
H Heat Exchanger - Inspect/Clean.................... 139 Cleaning the Heat Exchanger.................... 139 Hoses and Clamps - Inspect/Replace........... 139 Replace the Hoses and the Clamps .......... 140
I Important Safety Information ............................. 2 Installation ....................................................... 35
L Lifting and Storage........................................... 31
M Maintenance Interval Schedule (Naturally Aspirated Marine Generator Sets) ................. 91 Daily............................................................. 91 Every 1000 Service Hours ........................... 91 Every 1000 Service Hours or 1 Year............ 91 Every 12 000 Service Hours or 6 Years ....... 91 Every 16 600 L (4390 US gal) of Fuel or 2000 Service Hours or 2 Years ........................... 92 Every 250 Service Hours ............................. 91 Every 3000 Service Hours or 3 Years.......... 91 Every 4150 L (1100 US gal) of Fuel or 500 Service Hours or 1 Year ............................. 91 Every 500 Service Hours or 1 Year.............. 91 Every 6000 Service Hours or 3 Years.......... 91 Every 8000 Service Hours ........................... 91 Every 8300 L (2190 US gal) of Fuel or 1000 Service Hours or 1 Year ............................. 92 Every 99 600 L (26 310 US gal) of Fuel or 12 000 Service Hours...................................... 92 Every Week.................................................. 91 Every Year.................................................... 91
Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)............ 91 When Required............................................ 91 Maintenance Interval Schedule (Turbocharged Aftercooled Marine Generator Set Rated at 50 Hz 69 ekW and 60 Hz 76 ekW) ............................................... 95 Daily ............................................................. 95 Every 1000 Service Hours ........................... 96 Every 1000 Service Hours or 1 Year............ 96 Every 110 400 L (29 160 US gal) of Fuel or 8000 Service Hours.................................... 96 Every 12 000 Service Hours or 6 Years....... 96 Every 13 800 L (3650 US gal) of Fuel or 1000 Service Hours or 1 Year ............................. 96 Every 165 600 L (43 750 US gal) of Fuel or 12 000 Service Hours...................................... 96 Every 250 Service Hours ............................. 96 Every 27 600 L (7290 US gal) of Fuel or 2000 Service Hours or 2 Years ........................... 96 Every 3000 Service Hours or 3 Years.......... 96 Every 500 Service Hours or 1 Year.............. 96 Every 6000 Service Hours or 3 Years.......... 96 Every 6900 L (1820 US gal) of Fuel or 500 Service Hours or 1 Year ............................. 96 Every Week.................................................. 96 Every Year.................................................... 96 Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)............ 96 When Required............................................ 95 Maintenance Interval Schedule (Turbocharged Aftercooled Marine Generator Sets Rated at 50 Hz 86 ekW and 60 Hz 93 ekW) ........................................ 94 Daily ............................................................. 94 Every 10 350 L (2730 US gal) of Fuel or 500 Service Hours or 1 Year ............................. 94 Every 1000 Service Hours ........................... 94 Every 1000 Service Hours or 1 Year............ 94 Every 110 400 L (29 160 US gal) of Fuel or 8000 Service Hours.................................... 95 Every 12 000 Service Hours or 6 Years....... 94 Every 165 600 L (43 750 US gal) of Fuel or 12 000 Service Hours...................................... 95 Every 20 700 L (5470 US gal) of Fuel or 1000 Service Hours or 1 Year ............................. 95 Every 250 Service Hours ............................. 94 Every 3000 Service Hours or 3 Years.......... 94 Every 41 400 L (10 940 US gal) of Fuel or 2000 Service Hours or 2 Years .................. 95 Every 500 Service Hours or 1 Year.............. 94
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Index Section
Every 6000 Service Hours or 3 Years.......... 94 Every Week.................................................. 94 Every Year.................................................... 94 Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)............ 94 When Required............................................ 94 Maintenance Interval Schedule (Turbocharged Marine Generator Set Without Aftercooler)....................................... 92 Daily............................................................. 92 Every 1000 Service Hours ........................... 93 Every 1000 Service Hours or 1 Year............ 93 Every 11 100 L (2930 US gal) of Fuel or 1000 Service Hours or 1 Year ............................. 93 Every 12 000 Service Hours or 6 Years ....... 93 Every 133 200 L (35 190 US gal) of Fuel or 12 000 Service Hours...................................... 93 Every 22 200 L (5860 US gal) of Fuel or 2000 Service Hours or 2 Years ........................... 93 Every 250 Service Hours ............................. 93 Every 3000 Service Hours or 3 Years.......... 93 Every 500 Service Hours or 1 Year.............. 93 Every 5550 L (1470 US gal) of Fuel or 500 Service Hours or 1 Year ............................. 93 Every 6000 Service Hours or 3 Years.......... 93 Every 8300 L (2190 US gal) of Fuel or 1000 Service Hours or 1 Year ............................. 93 Every 88 800 L (23 460 US gal) of Fuel or 8000 Service Hours.................................... 93 Every Week.................................................. 92 Every Year.................................................... 93 Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)............ 93 When Required............................................ 92 Maintenance Log ........................................... 155 Maintenance Recommendations..................... 84 Maintenance Records.................................... 154 Maintenance Section....................................... 77 Manual Stop Procedure................................... 74 Stopping Procedure for the MCS Control Panel.......................................................... 74 Model View Illustrations................................... 19 A Keel Cooled System ................................. 21 Radiator Cooled System .............................. 23 Sea Water Cooled........................................ 19 Mounting and Dismounting.............................. 15
Overhaul Considerations............................... 140 Oil Consumption as an Overhaul Indicator ................................................................. 141 Overhaul Recommendation ....................... 141 Overspeed....................................................... 43
O
Reference Information..................................... 30 Record for Reference................................... 30 Reference Information Section ...................... 151 Reference Material ........................................ 156
Operation Section............................................ 31 Ordering Replacement Parts......................... 153
P Parallel Operation............................................ 56 Circulating Currents ..................................... 59 Initial Start-Up .............................................. 56 Load Division and Speed Droop (If Equipped) ................................................................... 58 Parallel Operation Of Governors.................. 58 Paralleling Multiple Units.............................. 58 Starting Multiple Units .................................. 57 Stopping....................................................... 59 Plate Locations and Film Locations................. 26 Engine Information Plate 1 ........................... 27 Generator Identification Plate 3 ................... 27 Serial Number Plate 2 .................................. 27 Power Factor - Check.................................... 143 Product Description ......................................... 24 Engine Cooling and Lubrication................... 25 Engine Service Life ...................................... 25 Engine Specifications .................................. 24 Product Identification Information.................... 26 Product Information Section ............................ 19 Product Installation.......................................... 35 Electrical Measurements ............................. 35 Location ....................................................... 35 Protective Devices....................................... 35 Receiving Inspection.................................... 35 Unpacking.................................................... 35 Product Lifting....................... ........................... 31 Engine Views ............................................... 31 Lifting the Engine Only................................. 33 Lifting the Entire Package............................ 33 Lifting the Generator Only............................ 33 Product Storage............................................... 33 Bearing Inspection ....................................... 34 Electrical Measurements ............................. 34 Long Time Storage....................................... 33 Short Time Storage...................................... 33
R
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161 Index Section
Coolants..................................................... 156 Emissions Warranty................................... 156 Fuels .......................................................... 156 Lubricants .................................................. 156 Miscellaneous............................................ 156 Reference Materials ...................................... 154 Refill Capacities............................................... 77 Refill Capacities and Recommendations......... 77 Coolant Recommendations ......................... 82 Engine Oil .................................................... 77 General Coolant Information........................ 80 General Fuel Information ............................. 80 Lubricating Grease....................................... 79 Refill Capacity of the Cooling System.......... 83 S·O·S Coolant Analysis ............................... 82 Rotating Rectifier - Check.............................. 143 Rotating Rectifier - Inspect/Test..................... 143
S Safety Messages ............................................... 5 (1) Universal Warning .................................... 8 Automatic Starting (5) .................................... 9 Do Not Use Ether (3)...................................... 8 Electrocution (4)............................................. 9 Hot Fluid Under Pressure (2) ......................... 8 Lifting the Generator Set (6)........................... 9 Safety Section ................................................... 5 Sea Water Strainer - Clean/Inspect............... 144 Clean the Sea Water Strainer .................... 145 Drain the Sea Water Cooling System ........ 144 Filling the Sea Water Cooling System........ 145 Sensors and Electrical Components (MCS Switches and Alarms).................................... 43 Locations of Electrical Components ............ 43 Severe Service Application.............................. 89 Environmental Factors................................. 89 Incorrect Maintenance Procedures.............. 90 Incorrect Operating Procedures................... 90 Single Unit Operation....................................... 55 Adjust the Voltage........................................ 55 Initial Start-Up .............................................. 55 Starting......................................................... 55 Stopping....................................................... 56 Standby Generator Set Maintenance Recommendations....................................... 146 Maintenance and Operation Procedures... 146 Starting Motor - Inspect ................................. 147 Starting the Engine.......................................... 48 Marine Certification Society (MCS) Control Panel.......................................................... 48
Starting with Jump Start Cables ...................... 51 Stopping the Engine ........................................ 73 System Pressure Release ............................... 84 Coolant System............................................ 84 Engine Oil .................................................... 84 Fuel System................................................. 84
T Table of Contents............................................... 3 Turbocharger - Inspect .................................. 147 Inspecting................................................... 148 Removal and Installation............................ 147
V Voltage Regulators .......................................... 60 R448 Adjustment for Maximum Excitation... 64 R448 Adjustments........................................ 62 Special Use.................................................. 64
W Walk-Around Inspection ................................ 148 Inspect the Engine for Leaks and for Loose Connections............................................. 148 Warranty Information..................................... 150 Warranty Section........................................... 150 Water Pump - Inspect.................................... 149 Welding on Engines with Electronic Controls .. 84
162 Index Section
SEBU8607
Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date:
Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:
Dealer Information Name:
Branch:
Address:
Dealer Contact Sales: Parts: Service:
Phone Number
Hours
