Safety: Operation and Maintenance Manual Excerpt
Safety: Operation and Maintenance Manual Excerpt
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 (Generator Set)
KAR1-Up (Generator Set)
SAFETY.CAT.COM
6 SEBU7572-06
Safety Section
Safety Messages
Safety Section
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Safety Messages
SMCS Code: 1000; 7405
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Illustration 1
8 SEBU7572-06
Safety Section
Safety Messages
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Failure to follow the warnings and instructions BATTERIES MAY BE LOCATED IN SEPARATE
could result in injury or death. Contact any COMPARTMENTS. WHEN USING JUMPER CA-
Caterpillar dealer for replacement manuals. Prop- BLES, ALWAYS CONNECT POSITIVE (+) CABLE
er care is your responsibility. 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 Section
Safety Messages
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Generator Set Lifting (12) Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
The safety message for lifting the generator set is before the engine is serviced or before the engine is
located on the engine mounting rails. 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.
Improper lift rigging can allow unit to tumble caus- • Filler caps
ing injury and damage.
• Grease fittings
Before lifting the generator set, read this Operation
and Maintenance Manual, “Generator Set Lifting” • Pressure taps
topic in the Operation Section.
• Breathers
If improper equipment is used to lift the generator
set, injury and damage can occur. Use cables that • Drain plugs
are properly rated for the weight. Use a spreader bar
and attach the cables according to the information Use caution when cover plates are removed.
on the safety message. 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
i02602865 last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
General Hazard Information
SMCS Code: 1000; 4450; 7405
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Illustration 3
• Do not wear loose clothing or jewelry that can snag Fluid Penetration
on controls or on other parts of the engine.
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Illustration 5
• Use a wet method in order to clean up asbestos Do not touch any part of an operating engine.
materials. Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
• A vacuum cleaner that is equipped with a high in the air system, in the hydraulic system, in the
efficiency particulate air filter (HEPA) can also be lubrication system, in the fuel system, or in the
used. cooling system before any lines, fittings or related
items are disconnected.
• Use exhaust ventilation on permanent machining
jobs.
Coolant
• Wear an approved respirator if there is no other When the engine is at operating temperature, the
way to control the dust.
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
Safety Section
Fire Prevention and Explosion Prevention
Any contact with hot coolant or with steam can cause Flammable fluids that are leaking or spilled onto hot
severe burns. Allow cooling system components to surfaces or onto electrical components can cause
cool before the cooling system is drained. a fire. Fire may cause personal injury and property
damage.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool. A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
Ensure that the filler cap is cool before removing the an emergency shutdown.
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in Determine whether the engine will be operated in an
order to relieve pressure. environment that allows combustible gases to be
drawn into the air inlet system. These gases could
Cooling system conditioner contains alkali. Alkali can cause the engine to overspeed. Personal injury,
cause personal injury. Do not allow alkali to contact property damage, or engine damage could result.
the skin, the eyes, or the mouth.
If the application involves the presence of combustible
gases, consult your Caterpillar dealer for additional
Oils information about suitable protection devices.
Hot oil and hot lubricating components can cause
Remove all flammable materials such as fuel, oil, and
personal injury. Do not allow hot oil to contact the
debris from the engine. Do not allow any flammable
skin. Also, do not allow hot components to contact
the skin. materials to accumulate on the engine.
Inspect all lines and hoses for wear or for Lines, Tubes and Hoses
deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support Do not bend high pressure lines. Do not strike high
and secure clamps. Tighten all connections to the pressure lines. Do not install any lines that are bent
recommended torque. Leaks can cause fires. or damaged.
Oil filters and fuel filters must be properly installed. Repair any lines that are loose or damaged. Leaks
The filter housings must be tightened to the proper can cause fires. Consult your Caterpillar dealer for
torque. repair or for replacement parts.
Illustration 8
g00704135 • End fittings are displaced.
Make sure that all clamps, guards, and heat shields
Gases from a battery can explode. Keep any open
are installed correctly. During engine operation, this
flames or sparks away from the top of a battery. Do
will help to prevent vibration, rubbing against other
not smoke in battery charging areas.
parts, and excessive heat.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or i01359666
a hydrometer.
Crushing Prevention and
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
Cutting Prevention
the Operation Section of this manual for specific SMCS Code: 1000; 4450; 7405
instructions.
Support the component properly when work beneath
Do not charge a frozen battery. This may cause an the component is performed.
explosion.
Unless other maintenance instructions are provided,
The batteries must be kept clean. The covers never attempt adjustments while the engine is
(if equipped) must be kept on the cells. Use the running.
recommended cables, connections, and battery box
covers when the engine is operated. Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
Fire Extinguisher is performed. After the maintenance is performed,
reinstall the guards.
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher. Keep objects away from moving fan blades. The fan
Inspect the fire extinguisher and service the fire blades will throw objects or cut objects.
extinguisher regularly. Obey the recommendations
on the instruction plate. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
18 SEBU7572-06
Safety Section
Mounting and Dismounting
Chips or other debris may fly off objects when objects If the wiring harness is reconnected with the ECS in
are struck. Before objects are struck, ensure that no the AUTOMATIC position or the MANUAL START
one will be injured by flying debris. 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
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MANUAL START position, the storage capacitor of
Mounting and Dismounting the ignition system may fire a spark plug. The spark
plug will ignite any gas which is in the cylinder. The
SMCS Code: 1000; 4450; 7405 crankshaft can rotate and the crankshaft can be
damaged. The driven equipment can also rotate and
Inspect the steps, the handholds, and the work area the driven equipment can also be damaged. Personal
before mounting the engine. Keep these items clean injury or damage to the equipment may be a result.
and keep these items in good repair.
Gas that has accumulated in the exhaust system
Mount the engine and dismount the engine only at may also be ignited.
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine. Magneto (If Equipped)
Face the engine in order to mount the engine or The storage capacitor in a breakerless magneto can
dismount the engine. Maintain a three-point contact be charged by turning the magneto by hand. The
with the steps and handholds. Use two feet and one storage capacitor can be charged even when the
hand or use one foot and two hands. Do not use any wiring harness is disconnected from the magneto.
controls as handholds.
Before connecting the wiring harness to a breakerless
Do not stand on components which cannot support magneto, discharge the storage capacitor to the
your weight. Use an adequate ladder or use a work ground. Use the following procedure to discharge the
platform. Secure the climbing equipment so that the storage capacitor:
equipment will not move.
1. Attach one end of a wire to the magneto housing.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand 2. Contact the other end of the wire to the connector
line to raise and lower tools or supplies. pins for the wiring harness that is on the magneto.
Ensure that the engine is equipped with a lighting Engine exhaust contains products of combustion
system that is suitable for the conditions. Ensure that which can be harmful to your health. Always start the
all lights work properly. engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
All protective guards and all protective covers must vent the engine exhaust to the outside.
be installed if the engine must be started in order
to perform service procedures. To help prevent an
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accident that is caused by parts in rotation, work
around the parts carefully. Engine Stopping
Do not bypass the automatic shutoff circuits. Do not SMCS Code: 1000
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The To avoid overheating of the engine and accelerated
circuits are also provided in order to help prevent wear of the engine components, stop the engine
engine damage. according to the instructions in this Operation and
Maintenance Manual, “Engine Stopping” topic
The initial start-up of a new engine or a engine that (Operation Section).
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.
20 SEBU7572-06
Safety Section
Electrical System
Use the Emergency Stop Button (if equipped) ONLY Rubber couplings may connect the steel piping of
in an emergency situation. Do not use the Emergency the cooling system and the radiator. This causes the
Stop Button for normal engine stopping. After an piping and the radiator to be electrically isolated.
emergency stop, DO NOT start the engine until the Ensure that the piping and the radiator is continuously
problem that caused the emergency stop has been grounded to the engine. Use ground straps that
corrected. bypass the rubber couplings.
On the initial start-up of a new engine or an engine Ensure that all grounds are secure and free of
that has been serviced, make provisions to stop corrosion.
the engine if an overspeed occurs. This may be
accomplished by shutting off the fuel supply to the
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engine, or shutting off the ignition system.
Generator Isolating for
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Electrical System SMCS Code: 4450
SMCS Code: 1000; 1400
When you service an electric power generation set
or when you repair an electric power generation set,
Never disconnect any charging unit circuit or battery
follow the procedure below:
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
1. Stop the engine.
gases that are produced by some batteries to ignite.
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.
For the starting motor, do not attach the battery 3. Disconnect the generator from the distribution
negative terminal to the engine block. system.
Use a ground strap to ground the case of all control 4. Lock out the circuit breaker. Attach a “DO NOT
panels to the engine block. OPERATE” or similar warning tag to the circuit
breaker. Refer to the electrical diagram. Verify that
Ground the engine block with a ground strap that is all points of possible reverse power flow have
furnished by the customer. Connect this ground strap been locked out.
to the ground plane.
5. For the following circuitry, remove the transformer's
Use a separate ground strap to ground the battery fuses:
negative terminal for the control system to the ground
plane. • power
• sensing
• control
SEBU7572-06 21
Safety Section
Generator Isolating for Maintenance
Product Information
Section
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Illustration 10
Naturally aspirated G3406 Generator Set
(1) Control panel (8) Radiator filler cap (15) Oil Drain
(2) Circuit breaker (9) Lifting eye (16) Gas pressure regulator
(3) Battery charger (10) Air cleaner (17) Customer connection
(4) Oil filler (11) Battery (18) Gas Shutoff Valve (GSOV)
(5) Crankcase breather (12) Starting motor (19) Generator
(6) Oil level gauge (13) Exhaust
(7) Oil filter (14) Water drain
24 SEBU7572-06
Product Information Section
Model Views and Specifications
Table 2
SMCS Code: 1000
G3412 Engine Specifications
S/N: R7E1-Up; CRE1-Up
Cylinders and arrangement 65 degree V-12
S/N: KAR1-Up; CTS1-Up Naturally Aspirated
Table 1 Aspiration Turbocharged with
separate circuit
G3406 Engine Specifications aftercooling
Cylinders and 6 Bore 137 mm (5.4 inch)
Arrangement In-Line
Naturally aspirated Stroke 152 mm (6 inch)
Aspiration Turbocharged with Total displacement 27 L (1648 in3)
separate circuit
aftercooling Firing order 1-4-9-8-5-2-11-10-3-6-7-12
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Illustration 12
G3412C Engine design
(A) Inlet valve
(B) Exhaust valve
(C) Flywheel
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Illustration 11
G3406 Engine design
(A) Inlet valve
(B) Exhaust valve
(C) Flywheel
26 SEBU7572-06
Product Information Section
Product Identification Information
Product Identification
Information
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Engine Identification
Caterpillar engines are identified with serial numbers, Illustration 14
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with performance specification numbers, and with Location of the Serial Number Plate on G3412 Engines
arrangement numbers. In some of the cases,
modification numbers are used. These numbers For G3412 Engines, the Serial Number Plate is on
are shown on the Serial Number Plate and the the left side of the cylinder block near the front of
Information Plate that are mounted on the engine. 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.
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Illustration 15
Typical Serial Number Plate
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Illustration 16
Location of the Information Plate on G3406 Engines
SEBU7572-06 27
Product Information Section
Product Identification Information
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Illustration 17
Location of the Information Plate on G3412 Engines
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Illustration 18 Illustration 20
Typical Information Plate Serial Number Plate
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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.
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Illustration 23
12 Lead Wye Configuration - Low Voltage
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Terminals T10, T11 and T12 become neutral connection when
Illustration 21 the terminals are tied together.
6 Lead Wye Configuration
Terminals T4, T5 and T6 become neutral connection when the Delta Configuration Diagrams
terminals are tied together.
6 Lead
12 Lead
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Illustration 24
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Illustration 22
6 Lead Delta Configuration
12 Lead Wye Configuration - High Voltage
Terminals T10, T11 and T12 become neutral connection when
the terminals are tied together.
30 SEBU7572-06
Product Information Section
Product Identification Information
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Voltage Connections
SMCS Code: 4450
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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
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Illustration 28
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Typical Parallel Wye (Star) Configuration (60 Hz, 12 Lead) Illustration 30
This is a typical low voltage connection. Typical Delta Configuration (60 Hz, 12 Lead)
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Illustration 31 Illustration 33
Single-Phase Voltage Diagram with 6 Lead Wye (Star) Single-Phase Voltage Diagram with 6 Lead Delta Configuration
Configuration
12 Lead Generators
12 Lead Generators
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Illustration 34
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Illustration 32
Single-Phase Voltage Diagram with 12 Lead Delta Configuration
Single-Phase Voltage Diagram with 12 Lead Wye (Star)
Configuration