Operation And Maintenance Manual - Altorfer - Free Download PDF

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SEBU8088-07January 2009Operation andMaintenanceManualC27 and C32 Generator SetsDWB1-Up (Generator Set)SXC1-Up (Generator Set)SAFETY.CAT.COM

i01658146Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.The meaning of this safety alert symbol is as follows:Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.When replacement parts are required for thisproduct Caterpillar recommends using Caterpillar replacement parts or parts with equivalentspecifications 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 ordeath.

SEBU8088-07Table of Contents3Table of ContentsMaintenance Interval Schedule (Standby) . 73Maintenance Interval Schedule (Standard) . 75Foreword . 4Safety SectionSafety Messages . 6General Hazard Information . 12Burn Prevention . 14Fire Prevention and Explosion Prevention . 15Crushing Prevention and Cutting Prevention . 17Mounting and Dismounting . 17Before Starting Engine . 17Engine Starting . 17Engine Stopping . 18Electrical System . 18Generator Isolating for Maintenance . 19Product Information SectionModel Views and Specifications . 20Product Identification Information . 25Operation SectionLifting and Storage . 34Installation . 36Features and Controls . 38Engine Starting . 52Engine Operation . 55Engine Stopping . 56Cold Weather Operation . 57Generator Operation . 59Voltage Regulators . 64Maintenance SectionRefill Capacities . 66Maintenance Recommendations . 68Reference Information SectionEngine Ratings . 129Customer Service . 131Reference Materials . 133Index SectionIndex . 142

4ForewordForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby fuel consumption, service hours and/or calendartime maintenance intervals. Items in the maintenanceschedule are referenced to detailed instructions thatfollow.SEBU8088-07Use fuel consumption or service hours to determineintervals. Calendar intervals shown (daily, annually,etc.) may be used instead of service meter intervalsif they provide more convenient schedules andapproximate the indicated service meter reading.Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.Maintenance IntervalsPerform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems in each level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced anddisplayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engine's permanent record.See the section in the Operation and MaintenanceManual, “Maintenance Records” for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.OverhaulMajor engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsavailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.

SEBU8088-07California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.5Foreword

6Safety SectionSafety MessagesSEBU8088-07Safety Sectioni02879636Safety MessagesSMCS Code: 1000; 7405Illustration 1C27 Generator Set right side viewg01433816

SEBU8088-07Illustration 2C27 Generator Set left side view7Safety SectionSafety Messagesg01433804

8Safety SectionSafety MessagesIllustration 3C32 Generator Set right side viewSEBU8088-07g01433818

SEBU8088-07Illustration 4C32 Generator Set left side view9Safety SectionSafety Messagesg01433805

10Safety SectionSafety MessagesSEBU8088-07Universal Warning (1)Hot Surface (3)The universal safety message is located on eachside of the generator enclosure and on each side ofthe terminal box.These safety messages are located on each sideof the radiator and on each side of the barrel of thegenerator.g01370904Do not operate or work on this product unless youhave read and understand the instructions andwarnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed thewarnings could result in injury or death. Contactany Caterpillar dealer for replacement manuals.Proper care is your responsibility.Automatic Starting (2)The safety message for automatic starting is locatedon each side of the enclosure.g01392484When the engine is in the AUTOMATIC mode, theengine can start at any moment. To avoid personalinjury, always remain clear of the the engine whenthe engine is in the AUTOMATIC mode.g01384734Hot parts or hot components can cause burns orpersonal injury. Do not allow hot parts or components to contact your skin. Use protective clothingor protective equipment to protect your skin.

SEBU8088-0711Safety SectionSafety MessagesLifting the Genset (4)Hot Fluid Under Pressure (5)This safety message for lifting the genset is locatedon right, left, and rear panels of the generatorenclosure.The safety message for hot fluid under pressure islocated on top of the radiator near the radiator cap.g01371640g01433231Crushing Hazard! Improper lifting could cause serious injury or death. Follow the lifting instructions in the Operation and Maintenance Manual forsafe lifting procedures.Pressurized system! Hot coolant can cause serious burns, injury or death. To open the coolingsystem filler cap, stop the engine and wait untilthe cooling system components are cool. Loosenthe cooling system pressure cap slowly in order torelieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.Electrical Shock (6)The safety message for electrical shock is located onthe sides of the terminal box.g01372247WARNING! Shock/Electrocution Hazard! Read andunderstand the instructions and warnings in theOperation and Maintenance Manual. Failure to follow the instructions or heed the warnings couldcause serious injury or death.

12Safety SectionGeneral Hazard InformationSEBU8088-07i02574315General Hazard InformationSMCS Code: 1000; 4450; 7405Illustration 6g00702020 Wear a hard hat, protective glasses, and otherprotective equipment, as required.Illustration 5g00104545Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controlsbefore the engine is serviced or before the engine isrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engine and toeach 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 beingserviced.Engine exhaust contains products of combustionwhich may be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine exhaust to the outside.Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being removed. Filler caps Grease fittings Pressure taps Breathers Drain plugsUse caution when cover plates are removed.Gradually loosen, but do not remove the last twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in order torelieve any spring pressure or other pressure. When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing. Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine. Ensure that all protective guards and all covers aresecured 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, performthe maintenance under the following conditions: The engine is stopped. Ensure that the enginecannot be started. Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks. Disconnect the connector for the unit injector thatis located on the valve cover base. This will helpprevent personal injury from the high voltage to theunit injectors. Do not come in contact with the unitinjector terminals while the engine is operating. Do not attempt any repairs that are not understood.Use the proper tools. Replace any equipment thatis damaged or repair the equipment.

SEBU8088-0713Safety SectionGeneral Hazard InformationPressurized Air and WaterAsbestos InformationPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).Illustration 8Fluid Penetrationg00702022Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.Illustration 7g00687600Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.If dust that may contain asbestos is present, thereare several guidelines that should be followed: Never use compressed air for cleaning. Avoid brushing materials that contain asbestos.Containing Fluid Spillage Avoid grinding materials that contain asbestos.Care must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids. Use a wet method in order to clean up asbestosRefer to Special Publication, NENG2500, “CaterpillarDealer Service Tools Catalog” for the following items: Use exhaust ventilation on permanent machining Tools that are suitable for collecting fluids and Wear an approved respirator if there is no otherequipment that is suitable for collecting fluids Tools that are suitable for containing fluids andequipment that is suitable for containing fluidsObey all local regulations for the disposal of liquids.materials. A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.jobs.way to control the dust.

14Safety SectionBurn PreventionSEBU8088-07 Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”. Obey environmental regulations for the disposalof asbestos. Stay away from areas that might have asbestosparticles in the air.SoftwrapKeep the engine room ventilation operating at fullcapacity. Wear a particulate respirator that has beenapproved by the National Institute of OccupationalSafety and Health (NIOSH). Wear appropriateprotective clothing in order to minimize direct contact.Use good hygiene practices and wash handsthoroughly after handling softwrapmaterial. Do notsmoke until washing hands thoroughly after handlingsoftwrap material. Clean up debris with a vacuumor by wet sweeping. Do not use pressurized air toclean up debris.Reference: The applicable material safety datasheets can be found at the following web site bysearching by the part number or the name of splayServleti01480768Burn PreventionSMCS Code: 1000; 4450; 7405Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.