Operation and Maintenance Manual - CS Diesel Generators

1 Set4BZ 1-UP(GeneratorSet)9EP 1-UP(GeneratorSet)BCW1-UP(GeneratorSet)T GC1-UP(GeneratorSet)DJN 1-UP(GeneratorSet)TFT 1-UP(GeneratorSet)RTY 1-UP(GeneratorSet)XJ5 1-UP(Generator)SEBU7125-13(en-us)March20 16i06558969 ImportantSafetyInformationMostaccidentst hat involveproductoperation,maintenanceand repairare causedby failureto observebasicsafetyrulesor accidentcan oftenbe avoidedby recognizingpotentiallyhazardoussituation sbeforean personmustbe alert to potentialhazards,includinghumanfactorsth at can affectsafety. This personshouldalso havethe necessarytraining,skillsand toolsto ,lubrication,maintenanceor repairof this productcan be dangerousand couldresultin injuryor not operateor performany lubrication,maintenanceor repairon this product,until you verifythat you are authorizedto performthis work, and have read and understoodthe Operation ,lubrication,maintenanceand warningsare providedin this manualand on the thesehazardwarningsare not heeded.

2 Bodilyinjuryor deathcouldoccurto you or to hazardsare identifiedby the SafetyAlert Symbol and followedby a SignalWord suchas DANGER , WARNING or CAUTION .The SafetyAlert WARNING labelis meaningof this safetyalert symbolis as follows:Attention!BecomeAlert! Your Safetyis messagethat appearsunderthe warningexplainsthe hazardand can be eitherwrittenor non-exhaustivelist of operationsthat may causeproductdamageare identifiedby NOTICE labelsonthe productand in this possiblecircumstancethat mightinvolvea warningsin this publicationand on the productare, therefore,not all must notuse this productin any mannerdifferentfrom that consideredby this manualwithoutfirstsatisfyingyourselfthat you have consideredall safetyrules and precautionsapplicableto theoperationof the productin the locationof use.

3 Includingsite-specificrules and precautionsapplicableto the a tool, procedure,work methodor operatingtechniquethat is notspecificallyrecommendedby Caterpillaris used, you must satisfyyourselfthat it is safe for youand for shouldalso ensurethat you are authorizedto performthis work, and that theproductwill not be damagedor becomeunsafeby the Operation ,lubrication,maintenanceor repairproceduresthat you intendto information,specifications,and illustrationsin this publicationare on the basisof informationthat wasavailableat the time that the publicationwas specifications,torques,pressures,measure ments,adjustments,illustrations,and otheritemscan changeat any the servicethat is givento the completeand mostcurrentinformationbeforeyoustart any job.

4 Cat dealershavethe requiredfor thisproductCaterpillarrecommendsusingCat followthis warningmay lead to pre-maturefailures,productdamage,persona lin-jury or the UnitedStates,the Maintenance ,replacement,or repairof the emissioncontroldevicesandsystemsmay be performedby any repairestablishmentor individualof the owner' of 12 Fire Preventionand 12 CrushingPreventionand 13 Mountingand 16 GeneratorIsolatingfor 21 OperationSectionLiftingand 34 Gaugesand 35 Featuresand 90 Cold 156 Index 157 SEBU7125-133 Table of ContentsForewordLiteratureInformationThi s manualcontainssafety, operationinstructions,lubricationand storedin or near the enginearea ina literatureholderor.

5 Studyand keepit with the literatureand the primarylanguagefor all Englishusedfacilitatestranslationand consistencyin illustrationsin this manualshowdetailsor attachmentsthat may be differentfrom your coversmay havebeenremovedfor advancementof productdesignmay havecausedchangesto your enginewhicharenot includedin this questionarisesregardingyour engine,or this Manual ,pleaseconsultwith your Cat dealerfor the safetysectionlists ,this sectionidentifieshazardous, understandthe basicprecautionslistedin the safetysectionbeforeoperatingor performinglubrication,maintenanceandrepa iron this this developingthe skillsandtechniquesrequiredto operatethe enginemoreefficientlyand economically.

6 Skill and techniquesdevelopas the operatorgainsknowledgeof theengineand its operationsectionis a referencefor illustrationsguidethe operatorthroughproceduresof inspecting,starting,operatingand stoppingthe sectionalso includesadiscussionof maintenancesectionis a guideto illustrated,step-by-stepinstructionsare groupedby fuel consumption,servicehoursand/orcalendarti me the maintenancescheduleare referencedto fuel consumptionor servicehoursto (daily, annually,etc.) may be usedinsteadof servicemeterintervalsifthey providemoreconvenientschedulesandapproxi matethe performedat theappropriateintervalsas indicatedin the actualoperatingenvironmentof the enginealso governsthe ,underextremelysevere,dusty,wet or freezingcold operatingconditions,morefrequentlubricat ionand maintenancethan isspecifiedin the MaintenanceIntervalSchedulemaybe maintenancescheduleitemsare organizedfor thepreventivemaintenanceprogramis followed.

7 Aperiodictune-upis not implementationof a preventivemaintenancemanagementprogramsh ouldminimizeoperatingcoststhroughcostavo idancesresultingfrom reductionsin unscheduleddowntimeand itemsat multiplesof and/orindividualitemsin eachlevel shouldbe shiftedaheador backdependinguponyour specificmaintenancepractices,operationan d recommendthat themaintenanceschedulesbe reproducedanddisplayednear the engineas a also recommendthat a maintenancerecordbemaintainedas part of the engine' the sectionin the Operationand MaintenanceManual, MaintenanceRecords for informationregardingdocumentsthat are generallyacceptedasproofof maintenanceor repair.

8 Your authorizedCatdealercan assistyou in adjustingyour maintenancescheduleto meetthe needsof your not coveredin theOperationand MaintenanceManualexceptfor theintervaland the maintenanceitemsin that best left to trainedpersonnelor anauthorizedCat dealer. Your Cat dealeroffersavarietyof youexperiencea majorenginefailure,thereare alsonumerousafter failureoverhauloptionsavailablefrom your Cat dealer. Consultwith your WarningDieselengineexhaustand someof its constituentsare knownto the Stateof Californiato causecancer,birth defects,and ,terminalsand relatedaccessoriescontainlead and lead handsafter :1000.

9 7405 Theremay be severalspecificsafetymessagesonyour exactlocationand a descriptionofthe safetymessagesare reviewedin this all all the safetymessagesare safetymessagesor replacethe safetymessagesif the wordscannotbe read or if theillustrationsare not a cloth,water, andsoapto cleanthe not usesolvents,gasoline,or ,gasoline,or harshchemicalscouldloosenthe adhesivethat securesthe are loosenedcoulddrop off safetymessagethat is a safetymessageis attachedto a part ofthe enginethat is replaced,installa new safetymessageon the replacementpart. Your Caterpillardealercan providenew not operateor work on this engineunlessyouhave read and understandthe instructionsandwarningsin the Operationand MaintenanceMan-ual.

10 Failureto followthe instructionsor heed thewarningscouldresultin injuryor Caterpillardealerfor is your Engineand Readingthe ManualIllustration1g00329090 Locationsof the safetymessagefor servicingtheengineand readingthe manualThe safetymessagefor servicingthe engineandreadingthe manualis locatedon the followingcomponents:terminalbox (1), customerconnectionbox (2) and circuitbreakerbox (3).Illustration2g00308764Do not operateor workon the engineunlesstheinstructionand warningsin the OperationandMaintenanceManualare instructionsor failureto heedthe warningscouldresultin personalinjuryor isyour Hot SurfaceIllustration3g00309883 Locationof the safetymessagefor coolantpressureand hot surfaceThe safetymessagefor coolantpressureis locatednear the top of the engineis at operatingtemperature,theenginecoolantis hot.