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CAT 3412C Service Manual

CAT 3412C
162 pages
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SAFETY.CAT.COM
Operation and
Maintenance
Manual
3412C Generator Set
4BZ 1-UP (Generator Set)
9EP 1-UP (Generator Set)
BCW 1-UP (Generator Set)
TGC 1-UP (Generator Set)
DJN 1-UP (Generator Set)
TFT 1-UP (Generator Set)
RTY 1-UP (Generator Set)
XJ5 1-UP (Generator)
SEBU7125-13 (en-us)
March 2016
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CAT 3412C Specifications

General IconGeneral
BrandCAT
Model3412C
CategoryPortable Generator
LanguageEnglish

Summary

Important Safety Information

Foreword

Literature Information

Discusses manual content, language, and illustrations.

Safety Precautions

Lists basic safety precautions and hazardous situations.

Operating Techniques

Outlines basic operating techniques and operator guidance.

Engine Care Guide

Guides engine care with step-by-step instructions and schedules.

Safety Section

Safety Messages Explained

Explains specific safety messages on the engine and their locations.

General Hazard Information

Burn Prevention

Coolant Hazards

Discusses hazards of hot coolant and pressure.

Oil and Component Hazards

Warns about hot oil and components.

Battery Hazards

Discusses hazards related to battery electrolyte and gases.

Fire Prevention and Explosion Prevention

Crushing and Cutting Prevention

Details precautions for moving parts and debris.

Mounting and Dismounting

Sound Information

Provides sound level information for EU countries and related directives.

Engine Stopping

Electrical System Safety

Discusses electrical system safety precautions and grounding.

Engine Electronics

Generator Isolating for Maintenance

Outlines the procedure for safely isolating the generator for maintenance.

Product Information Section

Model Views Illustrations

Shows illustrations of the 3412C generator set engine components.

Product Description

Engine Description and Specifications

Details engine type, stroke cycle, and key specifications.

Product Identification Information

Engine Identification Plates

Describes the location and purpose of serial and information plates.

Generator Lead Connections

Wye Configuration Diagrams

Illustrates Wye configurations for 4, 6, 10, and 12 lead generators.

Voltage Connections

Three-Phase Voltage Connections

Details Wye and Delta configuration connections for 480V and 240V generators.

Operation Section

Lifting and Storage Procedures

Provides instructions and precautions for lifting and storing the generator set.

Installation

Generator Installation Procedures

Covers receiving, unpacking, moving, location, protective devices, and storage.

Gauges and Indicators

Features and Controls

EMCP II Control Panel Overview

Describes the EMCP II control panel, its modules, and main components.

Generator Set Control (GSC)

GSC Functions and Features

Details the GSC's functions like starting, stopping, fault monitoring, and programmable features.

Fault Indicators

Display Area Overview

Keypad Operation

Alarm Module

Custom Alarm Module Functionality

Describes the optional custom alarm module for customer-supplied inputs.

EMCP II+ Control Panel Overview

Generator Set Control + (GSC+)

GSC+ Fault Indicators

GSC+ Display Area Overview

GSC+ Keypad Functions

Alarm Module Functionality

Describes the optional alarm module for visual and audible warnings.

EMCP II+P Control Panel Overview

Generator Set Control + (GSC+)

GSC+ Fault Indicators

GSC+ Display Area Overview

GSC+ Keypad Functions

Alarm Module Functionality

EMCP 3 Control Panel Overview

Annunciator Module Details

Details the EMCP 3 annunciator module for system events and conditions.

Electronic Control Module (Generator Set)

Digital Inputs

Annunciator Module

EMCP 4 Control Panel Overview

EMCP 4 Electronic Control Module

Describes the EMCP 4 control module and its navigation keys.

Control Panel Keys and Functions

Control Panel Components

Battery Disconnect Switch

Engine Shutoffs and Alarms

Shutoff and Alarm Systems Operation

Explains operation of electric and mechanical shutoffs and alarms.

Overspeed Shutoffs

Air Shutoff System

Voltage Regulators

VR6 Voltage Regulator

Discusses the VR6 voltage regulator, its types, and adjustments.

VR3F Voltage Regulator

VR3F Regulator Adjustment Procedure

Voltage Regulator Adjustment Procedure

Details procedures for adjusting VR3F voltage droop and level.

Cat Digital Voltage Regulator (DVR)

DVR Features and Configuration

Describes the Cat DVR, its features, and configuration parameters.

Engine Starting Procedures

Before Starting Engine Checks

Lists daily and periodic maintenance checks before starting the engine.

Starting the Engine (EMCP II/II+)

Automatic and Manual Starting

Explains automatic and manual engine starting procedures and precautions.

Cold Weather Starting

Starting Aid Switch Operation

Details using the starting aid switch for cold weather starting.

After Starting Engine Procedures

Engine Operation

Engine Warm-up Procedure

Describes the procedure for warming up the engine before operation.

Full Load Operation

Engine Stopping

Emergency Stopping Procedures

Explains the use of emergency stop buttons and their function.

After Stopping Engine Checks

Details checks and procedures after stopping the engine.

Cold Weather Operation

Fuel Effects in Cold Weather

Discusses fuel grades and their properties affecting cold weather performance.

Cold Weather Fuel Components

Covers fuel tanks, fuel filters, and their importance in cold weather.

Generator Operation

Loading the Generator

Explains how to load the generator, covering balanced and unbalanced loads.

Block Loading Capability

Defines block loading and factors influencing its capability.

Power Factor and Excitation Systems

Power Factor Explanation

Explains power factor and its relation to generator efficiency.

Excitation Systems Explained

Explains self-excited and permanent magnet pilot excited generator systems.

Generator Options

Generator Options Overview

Discusses space heaters, temperature detectors, and oilfield generators.

Maintenance Section

Refill Capacities and Lubrication

Lists refill capacities for engine crankcase and lubrication system.

Refill Capacities and Recommendations

Cooling System Capacities and Coolant

Lists capacities and recommends coolant types and mixtures.

Fuel System

Fuel Recommendations

Details preferred and permissible fuel types for diesel engines.

Maintenance Recommendations

General Maintenance Information

Covers stresses on rotating machines and the importance of inspection programs.

System Pressure Release Procedures

Details procedures for releasing pressure from coolant and fuel systems.

Welding on Engines with Electronic Controls

Generator Start-up Checklist

Maintenance Interval Schedule

Key Maintenance Intervals

Lists critical maintenance tasks at daily, weekly, 250hr, 2000hr, annual, and overhaul intervals.

Aftercooler Core - Clean/Test

Alternator and Fan Belts - Inspect/Adjust/Replace

Belt Inspection and Adjustment

Details belt tension checks, inspection for wear, and adjustment procedures.

Battery Replacement

Battery or Battery Cable Disconnect

Cooling System Coolant (DEAC) - Change

Coolant Draining Procedures

Provides steps to drain the cooling system coolant safely.

Cooling System Coolant (ELC) - Change

Coolant Filling and Draining

Provides instructions for filling and draining the cooling system with ELC coolant.

Cooling System Coolant Extender (ELC) - Add

Cooling System Coolant Level Check

Cooling System Coolant Sample (Level 1) Obtain

Cooling System Coolant Sample (Level 2) Obtain

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

SCA Concentration Testing

Explains testing SCA concentration using test kits or S·O·S analysis.

Cooling System Water Temperature Regulator - Replace

Crankshaft Vibration Damper - Inspect

Damper Inspection and Replacement

Details checks for damper damage, leaks, wear, and bolt fit.

Electrical Connections Check

Engine Cleaning and Air Cleaner Servicing

Servicing Air Cleaner Elements

Guides on servicing air cleaner elements, including cleaning and replacement.

Engine Air Cleaner Element - Clean/Replace

Cleaning Primary Air Cleaner Elements

Describes cleaning methods for primary air cleaner elements like water, air, vacuum, and washing.

Engine Air Cleaner Service Indicator - Inspect (If Equipped)

Testing the Service Indicator

Explains how to test the service indicator for proper function and resetting.

Engine Crankcase Breather - Clean

Engine Mounts - Inspect

Engine Oil Level Check

Engine Oil Sample Obtain

Engine Oil and Filter Change

Engine Oil and Filter Replacement

Details procedures for draining oil, replacing the filter, and filling crankcase.

Engine Protective Devices Check

Engine Valve Lash - Inspect/Adjust

Engine Valve Rotators - Inspect

Fan Drive Bearing Lubrication

Fuel Control Linkage Check/Lubricate

Fuel Injection Nozzles - Test/Exchange

Fuel System Prime

Fuel System Primary Filter - Replace

Fuel System Primary Filter/Water Separator - Drain

Fuel System Secondary Filter - Replace

Fuel Tank Water and Sediment Drain

Fuel Tank Draining Procedures

Details draining water and sediment from fuel tanks and storage.

Generator Drying Procedures

Generator Drying Methods

Explains self-circulating air, oven, and controlled current methods for drying generators.

Generator Inspection and Cleaning

Cleaning Assembled Generators

Guides on cleaning assembled generators using vacuum or brush.

Generator Bearing Temperature Measurement

Generator Lead (Flat Braided Cable) Check

Generator Lead (Round Cable) Check

Generator Load Check

Generator Set Test Procedures

Generator Set Vibration Inspection

Hoses and Clamps Inspection/Replacement

Hose and Clamp Inspection

Details inspection of hoses and clamps for wear, leaks, and damage.

Replace Hoses and Clamps by System

Cooling System Hose Replacement

Provides steps for replacing cooling system hoses and clamps safely.

Fuel System Hose Replacement

Warns about personal injury from removing fuel hoses under pressure.

Lubrication and Air System Hose Replacement

Instrument Panel Inspection

Insulation Test Procedures

Recommended Periodic Insulation Tests

Outlines periodic tests for generator insulation resistance.

Jacket Water Heater Check

Magnetic Pickups - Clean/Inspect

Overhaul Considerations

Oil Consumption as Overhaul Indicator

Overhaul Options

Planned vs. After-Failure Overhaul

Highlights benefits of planned overhauls and options after failure.

Inspection and/or Replacement During Overhaul

Crankshaft Bearings and Seals

Lists components that may need inspection/replacement during overhaul.

Oil Cooler and Aftercooler Core Cleaning

Recommends cleaning and pressure testing oil cooler and aftercooler cores during overhaul.

Power Factor Check

Radiator Cleaning Procedures

Rotating Rectifier Check and Test

Rotating Rectifier Testing Procedure

Guides testing the rotating rectifier using an ohmmeter.

Rectifier Block Test

Severe Service Application Check

Starting Motor Inspection

Turbocharger Inspection

Walk-Around Inspection

Engine Leak and Connection Inspection

Details walk-around inspection for leaks, loose connections, guards, and fluid levels.

Water Pump Inspection

Engine Ratings

Engine Rating Conditions and Definitions

Lists standard conditions and defines standby/prime ratings for generator engines.

Customer Service and Assistance

Customer Assistance Procedures

Provides contact information and steps for resolving problems with dealers.

Ordering Replacement Parts

Reference Materials

Reference Material and Disposal

Guides on purchasing literature and decommissioning/disposal procedures.

Maintenance Records Importance

Emphasizes the importance of accurate maintenance records for cost and scheduling.

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