SAFETY Operation and Maintenance Manual Excerpt 2010 Caterpillar All Rights Reserved
SEBU7572-06 July 2010 Operation and Maintenance Manual G3406 and G3412 Generator Sets GNA1-Up (Generator Set) R7A1-Up (Generator Set) R7E1-Up (Generator Set) KAP1-Up (GeneratorSet) KAR1-Up (Generator Set) SAFETY.CAT.COM
6 SEBU7572-06 Safety Messages Safety Messages i02536861 SMCS Code: 1000; 7405 There may be several specific safety messages on the package. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiar with all safety 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 pictures are not visible. When the safety messages are cleaned, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety messages. The safety messages that are loosened coulddropoffofthepackage. Replace any damaged safety messages or missing safety messages. If a safety message is attached to a part of the package that is replaced, install a new safety message on the replacement part. Any Caterpillar dealer can provide new safety messages. Do not operate or work on this engine 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 could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. The safety messages that may be attached on the package are illustrated and described below.
SEBU7572-06 7 Safety Messages Illustration 1 g01269716
8 SEBU7572-06 Safety Messages Read the Manual Before Operating (1) The safety message for reading the manual before operating the unit is located on the outside of the door of the control panel. Improper Jumper Cable Connections (2) The safety message for the connections for the jumper cables is located near the electric starting motor. This motor can be located on either side of the engine. g00306265 g00897261 Do not operate or work on this engine or generator set unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the warnings and instructions could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. IMPROPER JUMPER CABLE CONNECTIONS CAN CAUSE EXPLOSION RESULTING IN PERSONAL INJURY. BATTERIES MAY BE LOCATED IN SEPARATE COMPARTMENTS. WHEN USING JUMPER CA- BLES, ALWAYS CONNECT POSITIVE (+) CABLE TO POSITIVE (+) TERMINAL OF BATTERY CON- NECTED TO STARTER SOLENOID AND NEGA- TIVE (-) CABLE FROM EXTERNAL SOURCE TO STARTER NEGATIVE (-) TERMINAL (IF MACHINE NOT EQUIPPED WITH STARTER NEGATIVE TER- MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW PROCEDURE IN THE OPERATION MANUAL.
SEBU7572-06 9 Safety Messages Electrical Shock (3) The safety message for electrical shock is located on the valve cover bases. Open Vandal Door (4) The safety message for keeping the vandal door open during operation is located on the outside of the door of the control panel. g00305892 g00305896 Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. Always operate this unit with the vandal door open. Operating the unit with the vandal door closed restricts access to the emergency stop button and could result in injury or death. No Step (5) The safety message for no step is located on the crossbeams for the radiator. g00327774 Do not climb on the crossbeams for the radiator. Personal injury may result. Use an adequate ladder or use an appropriate work platform for climbing.
10 SEBU7572-06 Safety Messages Electrical Distribution (6) The safety message for electrical distribution (generator) is located on the covers of the generator. High Voltage (7) The safety message for high voltage is located on the following components: the terminal box, the connection box, and the circuit breaker box. g00296980 g00308803 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 injury 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. 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. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged.
SEBU7572-06 11 Safety Messages Automatic Starting (8) The safety message for automatic starting is located on the following components: the terminal box, the connection box, and the circuit breaker box. Read the Manual Before Operating (9) The safety message for servicing the engine is located on the following components: the terminal box, the connection box, and the circuit breaker box. g00327883 g00308764 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. Do not operate or work on this engine 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 could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.
12 SEBU7572-06 Safety Messages Coolant Pressure and Hot Surface (10) The safety messages for the coolant pressure and the hot surface are located near the top of the radiator on the front and on the rear. CSA Hazardous Atmosphere (11) The warning label for the Canadian Standards Association (CSA) hazardous atmosphere is located on the left side of the engine on a flat surface. g00524055 g00107971 The coolant is hot and the coolant is under pressure. Do not touch the hot surfaces. Refer to the Operation and Maintenance Manual for the procedure to follow when you check the radiator. Do not disconnect equipment unless power has been disconnected or the area is known to be nonhazardous Approval by the CSA is a requirement for engines that operate in hazardous locations. Volatile flammable gases are present in these locations. The gases are normally confined within closed systems. The gases can only escape if the system accidentally breaks down. The CSA warning is intended to prevent a hazardous atmosphere from igniting. Volatile flammable gas that is contacted by a spark will cause an explosion. This could result in personal injury or death. Also, property could be damaged. Do not disconnect electrical equipment unless the power has been disconnected. Otherwise, ensure that the atmosphere is not hazardous.
SEBU7572-06 13 General Hazard Information Generator Set Lifting (12) The safety message for lifting the generator set is located on the engine mounting rails. 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. 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. g01270324 Improper lift rigging can allow unit to tumble causing injury and damage. Before lifting the generator set, read this Operation and Maintenance Manual, Generator Set Lifting topic in the Operation Section. If improper equipment is used to lift the generator set, injury and damage can occur. Use cables that are properly rated for the weight. Use a spreader bar and attach the cables according to the information on the safety message. i02602865 General Hazard Information 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. SMCS Code: 1000; 4450; 7405 Illustration 3 g00702020 Illustration 2 g00104545 Wear a hard hat, protective glasses, and other protective equipment, as required. When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing.
14 SEBU7572-06 General Hazard Information Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. Fluid Penetration Ensure that all protective guards and all covers are securedinplaceontheengine. 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. California Proposition 65 Warning Some engine exhaust constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Pressurized Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury. 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. The maximum air pressure for cleaning purposes must be below 205 kpa (30 psi) when the air nozzle is deadheaded. The maximum water pressure for cleaning purposes must be below 275 kpa (40 psi). Illustration 4 g00687600 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. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tools Catalog for the following items: Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids.
SEBU7572-06 15 Burn Prevention Asbestos Information 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 Illustration 5 g00702022 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 boundinaresinorsealedinsomeway.normal handling is not hazardous unless airborne dust that contains asbestos is generated. If dust that may contain asbestos is present, there are several guidelines that should be followed: Illustration 6 g00706404 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. Never use compressed air for cleaning. Avoid brushing materials that contain asbestos. Avoid grinding materials that contain asbestos. Burn Prevention SMCS Code: 1000; 4450; 7405 i01480768 Useawetmethodinordertocleanupasbestos 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. Wear an approved respirator if there is no other way to control the dust. 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. 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.
16 SEBU7572-06 Fire Prevention and Explosion Prevention 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 withabarehand. 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. i01372262 Fire Prevention and Explosion Prevention SMCS Code: 1000; 4450; 7405 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 fifteen 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 Caterpillar 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. 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 case of a line, a hose, 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 that contain flammable fluid. Clean any such lines thoroughly with a nonflammable solvent prior to welding or flame cutting. Wiring must be kept in good condition. All electrical wires must be properly routed and securely attached. 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. Illustration 7 g00704000 All fuels, most lubricants, and some coolant mixtures are flammable. Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking.
SEBU7572-06 17 Crushing Prevention and Cutting Prevention Inspect all lines and hoses for wear or for deterioration. The hoses must be properly routed. The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires. Oil filters and fuel filters must be properly installed. The filter housings must be tightened to the proper torque. Lines, Tubes and Hoses Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Caterpillar dealer for repair or for replacement parts. 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: End fittings are damaged or leaking. Outer coverings are chafed or cut. Wires are exposed. Outer coverings are ballooning. Flexible part of the hoses are kinked. Outer covers have embedded armoring. Illustration 8 g00704135 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 ahydrometer. Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions. Do not charge a frozen battery. This may cause 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. Fire Extinguisher 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. End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, and excessive heat. Crushing Prevention and Cutting Prevention SMCS Code: 1000; 4450; 7405 i01359666 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. Keep objects away from moving fan blades. The fan blades will throw objects or cut objects. When objects are struck, wear protective glasses in order to avoid injury to the eyes.
18 SEBU7572-06 Mounting and Dismounting 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. i01372247 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. 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. 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. 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. Ignition Systems SMCS Code: 1550 i02526919 Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring. Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers. When the ignition harness is reconnected, ensure that the Engine Control Switch (ECS) is in the STOP position or the OFF/RESET position so that the ignition system is immediately discharged. If the wiring harness is reconnected with the ECS in the AUTOMATIC position or the MANUAL START position, the storage capacitor of the ignition system may discharge. If the wiring harness is reconnected with the ECS in the AUTOMATIC position or the MANUAL START position, the storage capacitor of the ignition system may fire a spark plug. The spark plug will ignite any gas which is in the cylinder. The crankshaft can rotate and the crankshaft can be damaged. The drivenequipmentcanalsorotateand the driven equipment can also be damaged. Personal injury or damage to the equipment may be a result. Gas that has accumulated in the exhaust system mayalsobeignited. Magneto (If Equipped) The storage capacitor in a breakerless magneto can be charged by turning the magneto by hand. The storage capacitor can be charged even when the wiring harness is disconnected from the magneto. Before connecting the wiring harness to a breakerless magneto, discharge the storage capacitor to the ground. Use the following procedure to discharge the storage capacitor: 1. Attach one end of a wire to the magneto housing. 2. Contact the other end of the wire to the connector pins for the wiring harness that is on the magneto. You will hear a snap when the storage capacitor discharges. 3. Ground all of the connector pins. This will ensure that no charge is in the magneto. Some breakerless magnetos have more than one storage capacitor. TurntheignitionswitchtotheOFFpositionbefore connecting the wiring harness. If the ignition switch is in the OFF position, the storage capacitor is immediately discharged to the ground when the wiring harness is connected to the magneto. Caterpillar Digital Ignition System (CDIS) The Caterpillar Digital Ignition System (CDIS) replaces mechanical parts that are prone to wear. The system provides more precise control of ignition timing.
SEBU7572-06 19 Before Starting Engine The digital ignition system includes a timing disc, a speed sensor (timing), a timing control, and wiring harnesses. There is no magneto. The sensor monitors the rotation of the timing disc in order to sense a reference position of the crankshaft. The sensor sends a signal to the timing control for each cylinder. The timingcontrolinitiatestheignitionby providing a pulse to the transformer of the proper cylinder. There are two options for providing the electrical power for the timing control: The customer provides a source of 12 VDC or 24 VDC. (The customer can order a belt driven alternator and a battery from the factory.) An alternator enables self-powered ignition. The optional alternator is installed onto the magneto drive. A wiring harness connects the alternator to a voltage regulator in order to provide the correct voltage to the digital ignition system. Voltage for the timing control is regulated to 27 ± 3 VDC. For further information, consult your Caterpillar dealer. Before Starting Engine SMCS Code: 1000 Inspect the engine for potential hazards. i02453806 Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel. Ensure that the engine is equipped with a lighting system that is suitable for the conditions. Ensure that all lights work properly. 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. The initial start-up of a new engine or a engine that has been serviced make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the fuel supply to the engine, or shutting off the ignition system. Engine Starting SMCS Code: 1000 i02136012 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. 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. If there is a possibility that unburned gas remains in the exhaust system, refer to the purge procedure in this Operation and Maintenance Manual, Engine Starting topic in the Operation Section. Start the engine from the operator's 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 the correct procedure will help to prevent major damage to the engine components. Knowing 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 properly, check the water temperature and the oil temperature during 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 well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside. Engine Stopping SMCS Code: 1000 i00659907 To avoid overheating of the engine and accelerated wear of the engine components, stop the engine according to the instructions in this Operation and Maintenance Manual, Engine Stopping topic (Operation Section).
20 SEBU7572-06 Electrical System Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal 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 occurs. This may be accomplished by shutting off the fuel supply to the engine, or shutting off the ignition system. Electrical System SMCS Code: 1000; 1400 i00887114 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. Rubber couplings may connect the steel piping of the cooling system and the radiator. This causes the piping and the radiator to be electrically isolated. Ensure that the piping and the radiator is continuously grounded to the engine. Use ground straps that bypass the rubber couplings. Ensure that all grounds are secure and free of corrosion. Generator Isolating for Maintenance SMCS Code: 4450 i01489970 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. Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is operated. Repair all frayed electrical wires before the engine is started. Grounding Practices Proper grounding is necessary for optimum engine performance and reliability. Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths. Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft journal surfaces, and to aluminum components. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the engine electronics and communications. For the starting motor, do not attach the battery negative terminal to the engine block. Use a ground strap to ground the case of all control panels to the engine block. Ground the engine block with a ground strap that is furnished by the customer. Connect this ground strap tothegroundplane. Use a separate ground strap to ground the battery negative terminal for the control system to the ground plane. Illustration 9 g00104545 2. Attach a DO NOT OPERATE or similar warning tagtotheengineprimemoverstartingcircuit. Disconnect the engine starting circuit. 3. Disconnect the generator from the distribution system. 4. Lock out the circuit breaker. Attach a 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. 5. For the following circuitry, remove the transformer's fuses: power sensing control
SEBU7572-06 21 Generator Isolating for Maintenance 6. Attach a DO NOT OPERATE or similar warning tag to the generator excitation controls. 7. Remove the cover of the generator's terminal box. 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.
22 SEBU7572-06 Product Information Section Model Views and Specifications Product Information Section Model Views and Specifications Model View Illustrations i02536228 SMCS Code: 1000; 4450 The illustrations show various typical features of G3400 Generator Sets. The illustrations do not show all of the options that are available. Because of individual applications, your package may appear different from the illustrations.
SEBU7572-06 23 Product Information Section Model Views and Specifications Illustration 10 Naturally aspirated G3406 Generator Set (1) Control panel (2) Circuit breaker (3) Battery charger (4) Oil filler (5) Crankcase breather (6) Oil level gauge (7) Oil filter (8) Radiator filler cap (9) Lifting eye (10) Air cleaner (11) Battery (12) Starting motor (13) Exhaust (14) Water drain (15) Oil Drain (16) Gas pressure regulator (17) Customer connection (18) Gas Shutoff Valve (GSOV) (19) Generator g01269190
24 SEBU7572-06 Product Information Section Model Views and Specifications Product Description SMCS Code: 1000; 4450 i01536004 The G3400 Generator Set consists of an engine, a generator, and a control system. Engine Description Ignition System G3406 Engines use the CAT Digital Ignition System. G3412 Engines use the CAT Digital Ignition System or the Electronic Ignition System. Digital Ignition System The digital ignition system includes a timing disc, a speed sensor (timing), a timing control, and wiring harnesses. The sensor monitors the rotation of the timing disc in order to sense a reference position of the crankshaft. The sensor sends a signal to the timing control. The timing control calculates the correct ignition timing. The timing control initiates the ignition by providing a pulse to the transformer of the proper cylinder. Electronic Ignition System The system provides dependable firing and low maintenance. The system provides precise control of the duration of the spark and the ignition timing. The system also provides diagnostic capability that enhances troubleshooting. The primary ignition wiring is routed internally through the engine. The engines are equipped with protection from detonation. A detonation sensor is located on each side of the cylinder block. The ignition timing is retarded when excessive detonation is sensed. If the maximum retarded position is attained and detonation continues to occur, the ECM shuts down the engine. Inlet Air and Fuel System G3406 Engines are available with natural aspiration or turbocharged with separate circuit aftercooling. G3412 Engines are turbocharged with separate circuit aftercooling. Inlet air is filtered by an air cleaner. For turbocharged engines, the inlet air is compressed by the turbocharger. The turbocharger is driven by the engine exhaust. The air is cooled in an aftercooler before the air enters the carburetor. The air becomes more dense from compression and cooling. This provides more oxygen for combustion. Air is mixed with fuel in the carburetor before combustion. The throttle is controlled by a governor. The governor efficiently maintains the engine rpm that is selected by the operator. The valves and the valve mechanism control the flow of air and exhaust gases in the cylinder during engine operation. Each cylinder has two inlet valves and exhaust valves. The camshaft actuates the rocker arms and valves through mechanical lifters and pushrods. Lubrication System The engine lubrication oil is supplied by a gear-driven pump. The oil is cooled and the oil is filtered. A bypass valve provides unrestricted flow of lubrication oil to the engine parts if the oil filter elements become plugged. Cooling System The jacket water coolant is circulated by a gear-driven centrifugal pump. G3406 Engines have one temperature regulator. G3412 Engines have two temperature regulators. The 90 C (194 F) temperature regulators regulate the temperature of the coolant. Heat can be removed from the coolant by a radiator or a heat exchanger. For engines with a Separate Circuit Aftercooler (SCAC), the air is cooled by a heat exchanger. The water that cools the air in the heat exchanger is in a circuit that is separate from the jacket water. The aftercooler coolant is pumped by an auxiliary water pump. The SCAC is required to operate at 32 C (90 F) or 54 C (130 F). The operation temperature depends on the engine rating and the application. Generator Description The SR4B brushless generator can be used with the following loads: mixed loads of motors and lights, SCR-controlled equipment, computer centers, installations of communications, and petroleum drilling applications. The generator set packages can be utilized for prime power generation or standby power generation.
SEBU7572-06 25 Product Information Section Model Views and Specifications SR4B generators are utilized in three-phase full-wave excitation and regulation. The generators are either four pole or six pole design with six lead configuration or twelve lead configuration depending on frame size. The generators are capable of producing electrical powerineither50hzor60hzapplications. Specifications SMCS Code: 1000 S/N: R7E1-Up; CRE1-Up S/N: KAR1-Up; CTS1-Up Table 1 Cylinders and Arrangement Aspiration Bore Stroke Total displacement G3406 Engine Specifications 6 In-Line Naturally aspirated Turbocharged with separate circuit aftercooling 137 mm (5.4 inch) 165 mm (6.5 inch) 14.6L(893cuin) Firing order 1-5-3-6-2-4 Rotation (flywheel end) Counterclockwise i02518380 Specifications SMCS Code: 1000 S/N: GNA1-Up; J1E1-Up S/N: R7A1-Up; CRF1-Up S/N: KAP1-Up; CTP1-Up Table 2 G3412 Engine Specifications Cylinders and arrangement 65 degree V-12 Aspiration Bore Stroke Naturally Aspirated Turbocharged with separate circuit aftercooling 137 mm (5.4 inch) 152mm(6inch) Total displacement 27 L (1648 in 3 ) i04003047 Firing order 1-4-9-8-5-2-11-10-3-6-7-12 Rotation (flywheel end) Counterclockwise Illustration 12 G3412C Engine design (A) Inlet valve (B) Exhaust valve (C) Flywheel g01376793 Illustration 11 G3406 Engine design (A) Inlet valve (B) Exhaust valve (C) Flywheel g00762505
26 SEBU7572-06 Product Information Section Product Identification Information Product Identification Information Plate Locations and Film Locations i01536239 SMCS Code: 1000; 4450 Engine Identification Caterpillar engines are identified with serial numbers, with performance specification numbers, and with arrangement numbers. In some of the cases, modification numbers are used. These numbers are shown on the Serial Number Plate and the Information Plate that are mounted on the engine. Caterpillar dealers need these numbers in order to determine the components that were included with the engine. This permits accurate identification of replacement part numbers. g00708544 Illustration 14 Location of the Serial Number Plate on G3412 Engines For G3412 Engines, the Serial Number Plate is on the left side of the cylinder block near the front of the engine. Serial Number Plate Illustration 15 Typical Serial Number Plate g00123229 Illustration 13 Location of the Serial Number Plate on G3406 Engines g00797865 The following information is stamped on the Serial Number Plate: engine serial number, model, and arrangement number. Information Plate For G3406 Engines, the Serial Number Plate is on the right side of the cylinder block near the rear of the engine. Illustration 16 Location of the Information Plate on G3406 Engines g00797866
SEBU7572-06 27 Product Information Section Product Identification Information For G3406 Engines, the Information Plate is located on the top surface of the flywheel housing above the timing window. Illustration 17 Location of the Information Plate on G3412 Engines g00708556 For G3412 Engines, the Information Plate is located on the top surface of the right side of the aftercooler. Illustration 19 Generator Identification Plate g00572840 Illustration 18 Typical Information Plate g00361974 Illustration 20 Serial Number Plate g00601027 The following information is stamped on the Information Plate: maximum altitude, high idle, horsepower, full load rpm, and other information. Generator Identification The generator identification and information plate is located on the left side of the generator. When service is required, the information that is given on this plate should be used. The generator identification and information plate includes the following information: serial number, model number, and the rating of the generator set. The generator set consists of the engine and generator. All pertinent generator data is also included on the plate in order to provide the information that is necessary to order parts. Output Lead Wiring All generator lead wiring information can be found on a decal that is located on the side panel of the generator's terminal box. If the generator is equipped with a circuit breaker, the decal may be found on the sheet metal of the circuit breaker panel. i03649244 Emissions Certification Film SMCS Code: 1000; 7405 Note: This information is pertinent in the United States, in Canada and in Europe. Consult your Caterpillar dealer for an Emission Control Warranty Statement.
28 SEBU7572-06 Product Information Section Product Identification Information This label is located on the engine. Reference Information SMCS Code: 1000; 4450 i02135788 Identification of the items in Table 3 may be needed in order to obtain parts and service. Some of the numbers are on the engine Serial Number Plate and/or Information Plate. Locate the information for your engine. Record the information on the appropriate space in Table 3. Make a copy of this list for a record. Retain the information for future reference. The top level part numbers in the Parts Manual for theenginearelistedwiththeenginearrangement number. The packaging arrangement may also be called a pricing arrangement or a customer arrangement. This is the total package with attachments and options that are not included in the engine arrangement. The performance specification can be used by your Caterpillar dealer with the Technical Marketing Information system. Before the engine leaves the factory, the engine performance is tested. Detailed performance data is recorded. The performance specification number can be used for obtaining the data. Table 3 Engine Model Serial Number Arrangement Number Packaging Arrangement Turbocharger Fuel Filter Element Lubrication Oil Filter Element Auxiliary Oil Filter Element Air Cleaner Element Fan Drive Belt Alternator Belt Capacity of the Lubrication System Oil type Capacity of the Cooling System Performance Specification Number Low Idle rpm High Idle rpm Full Load rpm Power Rating Reference Numbers i01460946 Generator Lead Connections SMCS Code: 4450 Lead Numbering The Wye (Star) configurations and the Delta configurations are the most common generator lead connections. The following three-phase connection diagrams illustrate the proper connection and lead identification. The leads are numbered clockwise from the top and from the outside inward. The diagrams show lead numbering for the six and twelve lead generators.
SEBU7572-06 29 Product Information Section Product Identification Information Wye Configuration Diagrams 6Lead g00611486 Illustration 21 6 Lead Wye Configuration Terminals T4, T5 and T6 become neutral connection when the terminals are tied together. 12 Lead g00611608 Illustration 23 12 Lead Wye Configuration - Low Voltage Terminals T10, T11 and T12 become neutral connection when the terminals are tied together. Delta Configuration Diagrams 6 Lead g00661863 Illustration 22 12 Lead Wye Configuration - High Voltage Terminals T10, T11 and T12 become neutral connection when the terminals are tied together. Illustration 24 6 Lead Delta Configuration g00669319
30 SEBU7572-06 Product Information Section Product Identification Information 12 Lead g00669312 Illustration 25 12 Lead Delta Configuration Terminals T6 and T9 become the neutral connection when the terminals are tied together and grounded. This reflects the terminal T2 and T10 connection as the high phase. Grounding the Frame In any generator set installation, the frame of the generator must be positively connected to an earth ground. This connection is the first one that is made at the installation. This connection is the last one that should be removed. 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). Silver soldered and bolted joints are electrically and mechanically sound. Neutral Connections The generators with grounded configuration usually have the neutral grounded when the generator is installed. However, there are some cases when definite measures can be taken in order to prevent ground faults on the load side. The purpose of the grounding of the neutral is to prevent load side equipment damage. The purpose of the grounding of the neutral is also to prevent harm to personnel. If the neutral wire is grounded and one of the phase leads becomes grounded, the excessive current will open a load circuit breaker in order to isolate the fault. The excessive current will collapse the generator voltage, if the circuit breaker does not trip first. The result depends on the particular generator electrical characteristics, 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. There are some instances in which it is undesirable to ground the neutral wire. An ungrounded generator neutral lead is acceptable in the applications in which definite measures have been taken in order to prevent grounds to the phase leads. An example of such measures are ground fault protective circuits. Ground fault protection requires that the entire group of distribution circuits should be studied and treated as a system. The owner should engage a certified and registered consultant if a new distribution system is being developed. The owner should also engage acertified and registered consultant if an existing system should be modified for the ground fault protection. Neutral resistors and reactors may be added to the system for two reasons: to provide protection during faults and to limit neutral currents. Single Units In a three-phase, four-wire system, the neutral wire should be grounded according to local wiring codes. In applications, in which definite measures are taken in order to prevent grounds to the load leads, an ungrounded neutral can be used. Be sure to check your local wiring codes. Multiple Units Operation of multiple generators in parallel, having all neutrals grounded, may result in the circulating current through the neutral connections. In order to eliminate the possibility of circulating currents, ground the neutral of only one generator. If multiple generators are alternated on line, a switch should be installed in the neutral ground circuit of each generator. In this case all neutral ground circuits except one can be opened. Be sure that one of the neutral ground circuits is closed.
SEBU7572-06 31 Product Information Section Product Identification Information Parallel to Utility When a Wye (Star) connected generator is going to operate in parallel with a utility system (infinite bus) and when the secondary of the step-down transformer in theutilitysystemisalsoawye connection, the following may happen. The grounding of both Wye neutrals may result in circulating currents through the neutrals. Also, the coordination of ground fault protection requires an entire system study. A study should be done by a certified and registered consultant who is familiar with generator systems. The study will determine which grounding method should be used. Wye (Star) Configuration Diagrams 6 Lead Generators Voltage Connections i01460960 SMCS Code: 4450 Three-Phase Voltage Connections The Wye (Star) Configuration for a 480 V generator and the Delta Configuration for a 240 V generator are given in the following diagrams. The terminals must be connected securely. The terminals must also be insulated with a good quality electrical tape. If a Delta Configuration is used, a two-thirds winding pitch is recommended and is required with 590 frame size generators and above. If the generator winding pitch is not two-thirds, third harmonics will cause a high circulating current. The generator will need to be derated. This current can exceed the winding current rating causing generator overheating and damage which may pose a fire hazard. A Wye (Star) connected generator may require a two-thirds pitch winding if the neutral is solidly grounded. Refer to the Specifications, LEBX6693, Generator Set Installation Drawings for more information. A floating neutral does not require a two-thirds pitch winding. Illustration 26 Typical Wye (Star) Configuration (60 Hz, 6 Lead) 12 Lead Generators g00626053 g00637319 Illustration 27 Typical Series Wye (Star) Configuration (60 Hz, 12 Lead) This is a typical high voltage connection.
32 SEBU7572-06 Product Information Section Product Identification Information 12 Lead Generators g00637320 Illustration 28 Typical Parallel Wye (Star) Configuration (60 Hz, 12 Lead) This is a typical low voltage connection. Illustration 30 Typical Delta Configuration (60 Hz, 12 Lead) g00626130 Delta Configuration Diagrams 6 Lead Generators Single-Phase Current From a Three-Phase Generator Three-phase current and single-phase current can be taken simultaneously from a generator that is connected for three-phase service. In the Wye (Star) Configuration, connect the load to the three-phase leads (any two of the three leads). In the Delta Configuration, connect the load to the three-phase leads (any two of the three leads). In both configurations, this will provide single-phase voltage at the same voltage as three-phase voltage. Illustration 29 Typical Delta Configuration (60 Hz, 6 Lead) g00626129 Connect the load to any phase lead and neutral lead of the Wye (Star) Configuration. This will produce voltage at 58% of three-phase voltage. Refer to Operation Section, Generator Operation for allowable single-phase loading unbalance. Single-phase power that is taken from a three-phase source can be a problem. Ensure that the single-phase loading is equally distributed. Do not exceed the nameplate current rating for any one phase.
SEBU7572-06 33 Product Information Section Product Identification Information Wye (Star) Configuration Diagrams 6 Lead Generators Delta Configuration Diagrams 6 Lead Generators g00626132 Illustration 31 Single-Phase Voltage Diagram with 6 Lead Wye (Star) Configuration 12 Lead Generators g00626135 Illustration 33 Single-Phase Voltage Diagram with 6 Lead Delta Configuration 12 Lead Generators g00637321 Illustration 32 Single-Phase Voltage Diagram with 12 Lead Wye (Star) Configuration g00626136 Illustration 34 Single-Phase Voltage Diagram with 12 Lead Delta Configuration