Operation and Maintenance Manual - Altorfer

1 SEBU8088-07 January 2009 Operation andMaintenanceManualC27andC32 GeneratorSetsDWB1-Up(Generator Set)SXC1-Up (Generator Set) Safety InformationMost accidentsthat 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 Operation , lubrication, Maintenance or repair of this product can be dangerous andcould result in injury or not operate or perform any lubrication, Maintenance or repair on this product, until you haveread and understood the Operation , lubrication, Maintenance and repair precautions and warnings are provided in this Manual and on the product.

2 If these hazard warningsare not heeded, bodily injury or death could occur to you or to other 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 meaning of this safety alert symbol is as follows:Attention! Become Alert! Your Safety is message that appears under the warning explains the hazard and can be either written or that may cause product damage are identified by NOTICE labels on the product and inthis cannot anticipate every possible circumstance that might involve a potential 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.

3 You should also ensure thatthe product will not be damaged or be made unsafe by the Operation , lubrication, Maintenance orrepair procedures that you 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 youstartany job. Caterpillar dealers have the most current information replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and to heed this warning can lead to prema-ture failures, product damage, personal injury of ContentsTable of ContentsForeword.

4 4 Safety SectionSafety Messages .. 6 General Hazard Information .. 12 Burn Prevention .. 14 Fire Prevention and Explosion Prevention .. 15 Crushing Prevention and Cutting Prevention .. 17 Mounting and Dismounting .. 17 Before Starting Engine .. 17 Engine Starting .. 17 Engine Stopping .. 18 Electrical System .. 18 Generator Isolating for Maintenance .. 19 Product Information SectionModel Views and Specifications .. 20 Product Identification Information .. 25 Operation SectionLifting and Storage .. 34 Installation .. 36 Features and Controls .. 38 Engine Starting .. 52 Engine Operation .. 55 Engine Stopping .. 56 Cold Weather Operation .. 57 Generator Operation .. 59 Voltage Regulators .. 64 Maintenance SectionRefill Capacities .. 66 Maintenance Recommendations .. 68 Maintenance Interval schedule (Standby) .. 73 Maintenance Interval schedule (Standard) .. 75 Reference Information SectionEngine Ratings.

5 129 Customer Service .. 131 Reference Materials .. 133 Index SectionIndex .. 1424 SEBU8088-07 ForewordForewordLiterature 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 is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media 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 safety section lists basic safety addition, this section identifies hazardous,warning situations.

6 Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, Maintenance andrepairon this 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 Operation section is a reference for and illustrations guide the operatorthrough procedures of inspecting, starting, operatingandstopping the engine. This section also includes adiscussion of electronic diagnostic Maintenance section is a guide to engine 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 fuel consumption or service hours to determineintervals.

7 Calendar intervals shown (daily, annually,etc.) may be used instead of service meter intervalsif they provide more convenient schedules andapproximate the indicated service meter 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 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 IntervalsPerform Maintenance on items at multiples of theoriginal requirement.

8 Each level and/or individualitems ineach 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 also recommend that a Maintenance record bemaintained as part of the engine's permanent 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 engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the Maintenance items in that repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms.

9 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 Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive posts, terminals and related accessoriescontain lead and lead handsafter SectionSafety MessagesSafety Sectioni02879636 Safety MessagesSMCS Code:1000; 7405g01433816 Illustration 1C27 Generator Set right side viewSEBU8088-077 Safety SectionSafety Messagesg01433804 Illustration 2C27 Generator Set left side view8 SEBU8088-07 Safety SectionSafety Messagesg01433818 Illustration 3C32 Generator Set right side viewSEBU8088-079 Safety SectionSafety Messagesg01433805 Illustration 4C32 Generator Set left side view10 SEBU8088-07 Safety SectionSafety MessagesUniversal Warning (1)The universal safety message is located on eachside of the generator enclosure and on each side ofthe terminal not operate or work on this product unless youhave read and understand the instructions andwarnings in the Operation and Maintenance Man-ual.

10 Failure to follow the instructions or heed thewarnings could result in injury or death. Contactany Caterpillar dealer for replacement care is your Starting (2)The safety message for automatic starting is locatedon each side of the 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 Surface (3)These safety messages are located on each sideof the radiator and on each side of the barrel of parts or hot components can cause burns orpersonal injury. Do not allow hot parts or compo-nentsto contact your skin. Use protective clothingor protective equipment to protect your SectionSafety MessagesLifting the Genset (4)This safety message for lifting the genset is locatedon right, left, and rear panels of the Hazard! Improper lifting could cause se-rious injury or death.