CAT + Caterpillar G342C Gas Engine Operation & Maintenance Manual by Heavy Equipment Manual

Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

Foreword

SMCS-1350;1352;1395;7542-008

Thisguidecontainsoperationinstructionsandlubricationandmaintenanceinformation.

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedone. Read-study-andkeepithandy.

Illustrationsguidetheoperatorthroughthecorrectproceduresofchecking,starting,operatingand stoppingtheengine.

Themaintenancesectionisaguidetoequipmentcare.Theillustrated,step-by-stepinstructionsare groupedbyservicingintervals.Topicswithoutspecificintervalsarelistedunder"WhenRequired." Topicsinthe"LubricationandMaintenanceChart"arereferencedtodetailedinstructionsthatfollow.

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)maybeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenient servicingschedulesandapproximatetheindicatedservcemeterreading.Recommendedservice shouldalwaysbeperformedattheintervalthatoccursfirst.

Underextremelysevere,dustyorwetoperatingcondition,morefrequentlubricationthanisspecified inthe"LubricationandMaintenanceChart"maybenecessary.

Performserviceontopicsatmultiplesoftheoriginalrequirement.Forexample,atEvery500Service Hoursor3Months,alsoservicethosetopicslistedunderEvery250ServiceHoursorMonthly,Every 125ServiceHoursor2Weeks,Every50ServiceHoursorWeekly,andEvery10ServiceHoursor Daily.

Somephotographsinthispublicationmayshowdetailsorattachmentsthatmaybedifferentfrom yourengine.Also,guardsandcoversmayhavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmayhavecausedchangestoyour enginewhichmaynotbecoveredinthispublication.

Wheneveraquestionarisesregardingyourengineorthispublication,pleaseconsultyourCaterpillar dealerforthelatestavailableinformation.

EngineIdentification

CaterpillarenginesareidentifiedwithSERIALNUMBERSandARRANGEMENTNUMBERS.In somecasesMODIFICATIONNUMBERSarealsoused.Thesenumbersareshownontheserial nuberplatemountedontheengine.

Caterpillardealersneedallofthesenumberstodeterminewhichcomponentswereincludedonthe enginewhenitwasassembledatthefactory.Thispermitsaccurateidentificationofreplacementpart numbers.

OrderingParts

QualityCaterpillarreplacementpartsareavailablefromCaterpillardealersthroughouttheworld. Theirpartsstocksareuptodateandincludeallpartsnormallyrequiredtoprotectyourinvestmentin Caterpillarengines.Whenorderingparts,yourordershouldspecifythequantity,partnumber,part nameandserialnumber,arrangementnumberandmodificationnumberoftheengineforwhichthe partsareneeded.Ifindoubtaboutthepartnumber,pleaseprovideyourdealerwithacomplete descriptionoftheneededitem.

WedDec402:28:20UTC+05302024

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Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

AltitudeOperation

SMCS-1350;1352;1395;7542-008

Turbochargerspeedisdeterminedbyenginehighidlespeed,turbochargernozzle,exhaustbypass valveregulatorassembly,andthealtitudeatwhichtheengineisoperating.Thealtitudelimitsare stampedontheengineinformationplate.Theregulatorassemblyissealedandanychangestothe regulatorassemblyshouldbemadeonlybyyourCaterpillardealer.

Theenginecanbeoperatedsafelyatloweraltitudesthanspecifiedontheengineinformationplate, butwillnotproduceratedhorsepower.

AlwaysconsultyourCaterpillardealerwheneverchangesinoperatingaltitudesareanticipatedwhich differfromthenameplatelimits.

ENGINEINFORMATIONPLATE

WedDec402:31:46UTC+05302024

Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

Attachments

SMCS-1350;1352;1395;7542-008

GovernorControls

Varioustypesofgovernorcontrolscanbeinstalledonenginesaccordingtotheapplication.Themost commoncontrolisdirectmechanical.Thecontrolmaybemountedeitherontheengineorona remotecontrolpanel.Enginemountedcontrolsnormallyconsistofapositivelockinghandle connecteddirectlytothegovernorshaft.Cablesandverniercontrolsmountontheengineorona controlpanel.

Shutdowncontrolsareusedonlytostoptheengine.Mechanicalorelectricalcontrolsarecommonly used.Thesedevicesstopthegasflow.Shutdowncontrolsallowtheenginetoberestartedafter shutdownwithoutreadjustingthespeedcontrols.ShutdowncontrolsareusuallyfoundonAutomatic Start-Stopinstallations.

Gauges

OILPRESSURE

WATERTEMPERATURE

Gaugesprovidea"look"insidetheengine.Besuretheyareingoodworkingorder.Youcan determinewhatis"normal"operatingrangebyobservingthegaugesoveraperiodoftime.Thecause ofanysuddenorsignificantchangeinthereadingsshouldbedeterminedandcorrected.

OILPRESSURE-Oilpressureisnormallygreatestwhenstartingacoldengine.Astheoilwarmsup itwillproducelesspressure.Oilpressureisgreateratoperatingspeedsthanatlowidle.Fluctuating readingscanmeanairintheoilorastickingpressurereliefvalve.Stoptheengineimmediatelyifa suddenlossofoilpressureoccurs.

WATERTEMPERATURE-Theoperatingtemperatureisdeterminedbythewatertemperature regulator.Highcoolanttemperaturesmeanthecoolingsystemisnotdissipatingenoughengineheat. Pressurizedcoolingsystemgaugesaremarkedwithrangesratherthantemperatures.Ifthegauge indicatesintheredrange,thecoolingsystemshouldbeinspected.

Theminimumoperatingtemperatureshouldnotbebelowtheopeningtemperatureofthewater temperatureregulator.

Incoldweatherthetemperaturegaugemayfluctuateinornearthecoldrange.Thisindicatesthe engineisbeingovercooled.Intheseinstancestheuseofradiatorlouversissuggested.

AMMETER-Theammetershouldregisterinthechargingrangewhentheengineisrunningabove lowidle.Ifthegaugeregistersadischargewhentheenginespeedisincreased,determinethecause.

AutomaticStart-Stop

Anautomaticstart-stopsystemensuresthatpowerissuppliedtoaloadwhenthenormalpowersource isinterrupted.Thecrankingpanelistheheartofthesystemandconsistsofthefailurewarningsystem andrelaystostartandstoptheengine.Whenapowerfailureoccursthesystemsensesthefailureand startstheenginetotransfertheloadtostandby.Whenpowerisrestored,itsensesandtransfersthe loadfromstandbyandstopstheengine.Themajoruseofautomaticstart-stopsystemsisstandby electricsetsandthisdiscussionislimitedtothatapplication.

Ifapowerfailureoccurs,acircuitbreakeropensandasetofcontactsinthetransferswitchcloses, completingthecircuittothestartermotor.Whentheenginestarts,thestartercircuitopens,protecting thestarterfromoverspeeddamage.

Sinceastandbyengineisusuallyunmanned,itisusuallyprotectedfrommechanicalmalfunctionbya seriesofelectricalsafetydevices:highwatertemperature,lowoilpressureandengineoverspeed.Ifa faultoccursitenergizesoneoftheshut-offcontrolsandgroundsthemagnetotostoptheengine.

NOTICE

DONOTuseanyemergencyshut-offcontrolfornormalshutdown. Theemergencyshut-offcontrolsareforemergenciesonly.

Iftheunithasastandardcrankingpanel,thebatteryandstarterareprotectedfromprolongedcranking byacrankingcycletimer.Atimerprovidingfiveten-secondcrankingcyclescanbeused.Bothunits havefaultlightswhichlightifthecrankingcycleiscompletedandtheenginedoesnotstart.

Automaticstart-stopunitsmayhaveatimedelayrelaytopreventthestandbycircuitbreakerfrom closinguntiltheenginehashadafewsecondswarmuptime.Ashutdowntimedelayprovidesupto twominutestocooloffaftertheloadhasbeentransferredbacktonormalpowersource.

Atimedelayrelayinthetransfercircuitcanbeadjustedfrom1to30minutes.Thisdelaysthetransfer fromstandbytonormalpoweruntilthenormalsourcehasbeenrestoredandremainedstableforthe presetperiod.

Unattendedunitsmayhaveanexerciser.Atapresettimetheengineautomaticallystartsandruns, underloadifpossible,andshutsitselfoff.Thishelpstoensuretheuntilwillstartandperformas requiredwhennecessary.

Ashutdowntimermayalsobeusedwithanautomaticstart-stopsystem.Thisprovidesatwominute cooloffperiodaftertheloadhasbeenremovedfromtheengine.Thisallowstheheatoffullload operationtobedissipatedgradually.

Manysafetycircuitshavefaultlightstoaidtheoperatorinlocatingthecauseofthemalfunction. Theselightsarelightedbythesafetycircuitthatisenergizedbyamechanicalfaulti.e.,highwater temperature,lowoilpressure,etc.

SafetyGauges

Safetyshut-offsprotecttheenginefromdamageifconditionsexceednormaloperatinglimits.The safetycircuitssenseoilpressureandwatertemperature.Thesendingunitsareapartofthegaugesin theinstrumentpanels.Ifafaultoccurs,thewatertemperatureoroilpressureindicatorwillmake contactwithaterminalandcompletestheshutdowncircuit.Amagneticswitchisenergizedand groundsthemagnetotostoptheengine.Beforerestartingtheengine,pushthemagneticswitchreset button,locatedontheinstrumentpanel.Theoilpressureswitchresetbutton,locatedontheoil pressuregauge,mustbeheldinduringstarting.

SAFETYGAUGES

Amanualstopbuttonlocatedontheinstrumentpanelshouldbeusedonlyinanemergency.The manualstopbuttongroundsthemagnetotostoptheengine.

Unburnedgasleftinthemanifoldcanignitewhentheengineis restarted.

Beforerestartinganygasenginewhichwasstoppedbygroundingthemagneto,cranktheenginewith thegasvalveturnedoffandthemagnetogroundedfor10-15seconds.Thiswillcleartheunburned gasfromtheexhaustsystem.

GasShut-OffValve

Agasshut-offvalveisavailable.Onanelectricalsignalfromeitherthesafetycircuitoraremote mountedswitch,thevalvecloses,stoppingthegasflowtotheengine.Thisvalvemustbereset manually.

OverspeedSwitch

Acontractoractuatedbyaflyweightgovernorprovidesoverspeedprotectionfortheengine.The overspeedswitchismountedonthetachometerdrive.Iftheengineoverspeeds,thegovernorcloses

thecontacts,energizingthemagneticswitch.Theswitchgroundsthemagnetotostoptheengine. Whenanoverspeedoccurs,theswitchmustberesetbeforetheenginecanbestarted.

RESETOVERSPEEDSWITCH

SafetyShut-Off

Asafetyshut-offsystemwhichisnotpartofthegaugesisavailable.Thesystemstopstheengineif theoilpressureorwatertemperatureexceedsafeoperatinglimits.Theoverspeedswitchcanbeused withthissystem.

Highwatertemperaturecausesaninternalelementtoexpandandoperateamicroswitch.The microswitchclosesandgroundsthemagneto,stoppingtheengine.Themagnetoisgroundedby contactsintheoilpressureswitchifoilpressurefallsbelowsafeoperatinglimits.Amagneticswitch, usedwiththesafetygauges,isnotrequiredwiththissafetyshut-offduetohighercapacitycontactors.

NOTE:Oilpressureshut-offisdesignedtoprotectenginefromsuddenoillossageorpressure,not againstlowoillevel.Likewise,thetemperatureshut-offprotectsagainstanincreasingwater temperaturebutoffersnoprotectionagainstsuddenwaterlossageorwhentemperatureelementisnot inthewater.Alowcoolantlevelwillnotactuatetheswitch.

Afteranemergencyshutdown,theoilpressureand/oroverspeedswitchmustbereset.

Theoilpressureswitchmustalwaysberesetbeforestartingtheengine.Toresettheswitch,pushthe buttontotheOFFposition.Asoilpressureincreasesthebuttonwillautomaticallypositionitselfto theRUNposition.

SafetyShut-OffTesting

Safetyshut-offsfunctiononlywhenanabnormalconditionexists.Becausetheshut-offsoperateonly intimeofamechanicalemergency,itisimpossibletotelliftheyareingoodworkingorderthrough normaloperation.Sinceitisimportanttheyareinworkingorder,havetheshut-offschecked periodicallybyyourCaterpillardealer.SeetheLubricationandMaintenanceChartforservice intervals.

AlarmSwitch

Alarmswitchesareavailabletonotifytheoperatorthatafaultconditionexists.Ifoilpressuredropsto adangerouslevelorwatertemperaturereachesahighlevelanalarmisactivated.Dependingonthe system,alightisturnedon,orabellorhornissoundedcallingtheoperator'sattentiontotheproblem.

Thewatertemperatureelementmustbeincontactwiththecoolantto operate.Alowcoolantlevelwillnotactuatetheswitch.

WedDec402:30:38UTC+05302024

Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

DeterminingCauseOfShutdown

SMCS-1350;1352;1395;7542-008

Anytimeanengineisshutdownbyitssafetycircuit,thecausemustbedetermined.Insomecasesthe causewillbeobviousbutoftenaninvestigationwillhavetobemade.Oninstallationswithfault lightsthefaultisindicated.Undernocircumstancesshouldtheenginebeputbackintoservice withoutdeterminingandcorrectingthecauseofshutdown.

HighWaterTemperature

Lookfortheobviousfirst.

1.Determineifthereiswateronthefloorfromspilledorleakingcoolant.

2.Checkthewatertemperaturegaugeforaccuracy.

DONOTremovetheradiatorcapofanoverheatedunit.Thecoolantis underpressureandrelievingthispressurewillcausethecoolanttoflash intosteam.Seriousburnsandenginedamagecanresultfromthe escapingcoolant.Pressureinaradiatormaybereducedbypouring warmwateronthetoptanktocondensethesteam.

NOTICE

NEVERaddcoldwatertoanoverheatedengine.

3.Checkairflowthroughtheradiatorandwaterflowthroughtheheatexchanger.

4.Checkairtemperaturetoradiator.Fewradiatorscanadequatelycoolafullyloadedenginewith 125°F(52°C)ambientair.

5.Checkforrecirculatingaircurrents.

6.Checkfanbeltsforpropertension.

7.Seethatengineroomventsandlouversareopen.

8.Checkwaterflow.

9.Checkwaterhosesforleaks.Checkforcollapsedhoses.Hoseshavebeenknowntopeeloff internallyandrestrictwaterflow.

10.Determineifflowvalvesareopen.

11.Checkwaterpumpdrivebelts.

12.Checkrawwaterflowtoheatexchanger.

13.Iftheengineisoverloaded,overheatingcanresult.

14.Checkenginetiming.

Overheatingcancausesealsandgasketstorelax.Ifsevereorprolongedoverheatinghasoccurred, havetheenginecheckedbyproperlytrainedpersonnel.

LowOilPressure

Lookfortheobviousfirst.

1.Checkthedipstick.

2.Checkfloorforoilfromleaks.

3.Todetermineiflowoilpressurewasthecauseoftheshutdown,cranktheenginewiththefueloff. Ifunusualnoisescomefromtheengine,discontinuecranking.Ifoilpressurefailstobuildup,andno externalleaksarefound,theproblemisprobablyinternal.

Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

General

SMCS-1350;1352;1395;7542-008

Properengineoperationandmaintenanceareessentialtolongenginelifeandmaximumperformance. Theessentialsforproperoperationandnormalperiodicmaintenanceareoutlinedinthisguide. However,yourCaterpillardealerisavailablefortroubleshootingand/orrepairswhenrequired.

Beforestartingtheengine,familiarizeyourselfwiththeseproceduresandapplytheprinciplestoyour particularinstallation.

WedDec402:28:36UTC+05302024

Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

InitialAdjustments

SMCS-1350;1352;1395;7542-008

Beforemakinginitialadjustments,checktheengineandinstallationasyouwouldduringnormal operation.Seepage4.

CarburetorAdjustment

CARBURETORADJUSTMENTS

1.IdleAdjustmentScrew2.PowerMistureScrew

1.Setthepowermixturescrew(2)midwaybetween"L"and"R".

2.Turntheidleadjustmentscrew(1)clockwiseallthewayin,thenoutfourturns.

3.Setlowidlespeedonacoldengine.Withtheenginerunning,turnthelowidlescrew(1)toobtain recommendedlowidlespeed(seetheEngineInformationPlate).

Changethegaspressuredeliveredbythelinepressureregulatortocompensateforanychangeinheat contentofthefuel.SeeyourCaterpillardealerforpressuresettings.

LinkageAdjustment

1.Disconnectlinkage(1).

2.Turnscrew(2)counterclockwiseuntilthethrottleplatewillclosewithouttouchingthescrew.

3.Turnscrew(2)untilittouchesstop(3)withthethrottleplateclosed.

LINKAGEADJUSTMENTS

1.GovernorLinkage2.ThrottleStopScrew3.Stop

4.WiththegovernorleverintheOFFpositionandthethrottleplateclosed,adjustthelinkagesand reconnectthem.(Ifadditionallinkageadjustmentisnecessary,seeyourCaterpillardealer.)

5.OnVeeenginesadjustlinkagesothatboththrottleplatesopensimultaneously.

GasLinePressure

Gaslinepressuremustberegulatedforuseinengines.Naturallyaspiratedengines,usingaline pressureregulator,requirelinepressureof3PSIto20PSI.Aturbochargedenginemusthavegreater workingpressureavailable-12PSIto20PSI.TwentyPSIisthemaximumlinepressurewhichis easilyreducedtoaworkingpressure.Ifgaspressureexceeds20PSI,asecondregulatorwillhaveto beused.

LinePressureRegulator

Thelinepressureregulatorrequiresadjustmentwhentheengineisinstalled,whentheregulatoris reworked,orwhentheheatcontentofthefuelischanged.Awatermanometerisusedtosetthe regulatoroutputgaspressure.

1.Removeplugs(1)and(2)fromthecarburetor.

CARBURETOR

1.AirPressureManometerPlug2.GasinletPlug3.PowerMixtureScrew

2.Connectawatermanometerbetweenthetwopressuretaps.

LINEPRESSUREREGULATOR

4.RegulatorAdjustmentPlug

NOTE:Avalveisusedbetweenthemanometerandthecarburetortopreventwaterfrombeing drawnintotheengineduringstartup.Closethevalveduringcrankingandstartup,thenopenthe valvewhenengineisrunning.

3.Openthemaingasvalve.

4.Adjustthegaspressuretosupporta51/2inch(14cm)columnofwater,ortocorrectdifferentialif fuelBTUisknown.

5Theregulatoradjustmentismadebyremovingplug(4)andturningtheslottedcapclockwiseto increaseoutputpressureandcounterclockwisetodecreasepressure.

6.Repeatthisprocedureforeachcarburetor.

7.Aftertheseinitialadjustmentstheenginecanbestarted.

AdjustingLinePressureRegualtorWithKnownBTUFuel

1.WithknownBTUfuel,refertoadifferentialandBTUcurve.SeeFormFE036044,orseeyour CaterpillarDealerforpressuresetting.

2.Usethecurvetofindproperdifferentialsettingwhichgivesthecorrectairfuelration.

3.Followprocedureunderlinepressureregulatoruntiladjustedgaspressurewillsupporttheproper differentialwithengineatidlecondition.

AdjustingLinePressureRegulatorWithUnknownBTUFuels

1.Followprocedureunderlinepressureregulatorforsettingwhichwillallowstartingofengine.

2.Installaccuratetachometeronengine.

3.Removelineregulatorplug(4)andinstalladjustingtool.

NOTE:Onturbochargedenginesaspecialtoolisnecessarytopreventboostpressurefromescaping whenregulatorcapisremoved.

4.Startengineandputunderconstantfixedload.Loadshouldbeasnearfullloadaspossiblewith enginerunningsteady.

5.Physicallylockcarburetorthrottleplateinpositionwhileengineisoperating.(OnVeeEngines lockboththrottleplates.)

6.Disconnectgovernorlinkage.

7.AdjustregulatorslottedcaptogetmaximumengineRPM.MaximumengineRPMcanbefound bestbystartingwithaleanmixtureandslowlyincreasingtoreachmaximumRPM.

8.ReducethemaximumobtainableRPMby3%.Thisisdonebyleaningmixture-turnslottedcap counterclockwiseinregulator.Thiswillgiveproperairfuelratio.

NOTE:OnVeeEngineseachsidehastobeadjustedseparately.

9.Reconnectgovernorlinkageandunlockthrottleplate.

10.Removespecialtoolfromregulatororinstallcap.

11.Ifdifferentialisdesired,amanometermaybeinstalledatcarburetorpoint1and2andread.

AdjustingPowerMixtureScrew-

1.Powermixturescrew(3)shouldbeadjustedwithengineoperatingatratedloadandRPMonly.

2.IncreaserichnessuntilenginereachesitsmaximumRPM.

3.TurnpowermixturescrewtoleanuntilenginelosesRPM.

4.TurnpowermixturescrewtorichuntilengineregainshighestRPM.

NOTE:PowermixturescrewisonlyeffectiveatratedloadandRPM.With905BTULHVfuel mixture,screwshouldbeset21/2notchesfromlean.

BalanceLine

Turbochargedengineshaveabalancelinefromthecarburetortothelinepressureregulator.The balancelinetransmitsmanifoldairpressuretotheuppersideoftheregulatordiaphragm.Thisforce, addedtothespringforce,ensuresthatgaspressuretothecarburetorwillalwaysbegreaterthaninlet airpressureregardlessofloadconditions.Aturbochargedenginewillnotdevelopfullpowerwithout abalanceline.

ThrottleSynchronization-VeeEngines

Besurebothlinkageshavebeenadjusted.

TwoturbochargersareusedonVeeengines.Theairinductionsystemiscrossblown,thatis,the turbochargerturbinewheelisdrivenbytheexhaustfromonebankandthecompressorwheelsupplies airtotheoppositebank.Thisreducestheamountofunbalancedloadpossibleandkeepsonebank fromoverworking.Themaximumamountofunbalancewithoutalossofpoweris.3inches(0,76cm) ofmercury.Unbalanceisdeterminedinthefollowingmanner.

MANOMETERCONNECTIONLOCATION

Withtheenginestopped:

1.Removetheplugfromeachmanifoldandconnectthemanometer.

2.Closethevalveonthemanometerandstarttheengine.Openthevalve.

3.Runtheengineat2/3ratedspeedandadjustthethrottlelinkageuntilthedifferenceinthetwo columnsiswithin.3inches(0,76cm)ofmercury.DONOTchangegaspressuretobalancethe output.

WedDec402:29:32UTC+05302024

Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

PeriodsOfLimitedUse

SMCS-1350;1352;1395;7542-008

Prolongedoperationatlowidleorreducedloadmaycauseoilconsumptionandcarboninginthe combustionchamberandresultinpoorperformanceandalossofpower.Everyfourhours,loadthe enginetoclearcarbonfromthecombustionchamber.

Iftheengineistobestoredorleftstandingforalongperiodoftime,thelubricatingoilmaydrain awayfromthecylinderwallsandpistonrings.Thislackoflubricantpermitsringstorust,andcauses unnecessarywearbymetal-to-metalcontactbetweenthepistonsandringswhentheengineisstarted. Thelackoflubricantmaynotcauseanynoticeablechangeinengineoperationafterithasbeen started,butitdoescontributetoshorterenginelife.

Ifanengineisnotgoingtobeusedforseveralweeks,renewtheoilfilmbyrunningtheengineoncea weekuntilitisthoroughlywarm.Thiswillcirculatetheoilandwillpreventrustfromforming. Lubricateallpointsmentionedinthelubricationchart.

Ifanengineisgoingtobeputinwinterstorage,seeyourCaterpillardealerforstorageinstructions.

WedDec402:29:12UTC+05302024

Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

SafetyPrecautions

SMCS-1350;1352;1395;7542-008

Safetyisbasicallycommonsense.Therearestandardsafetyrulesbuteachsituationhasitsown peculiaritieswhichcannotalwaysbecoveredbyrules.Therefore,yourexperienceandcommonsense willbeyourbestguidestosafety.Lackofattentiontosafetycanresultin:accidents,personalinjury, reductioninefficiencyandworstofall-lossoflife.Watchforsafetyhazards.Correctdeficiencies promptly.

Usethefollowingsafetyprecautionsasageneralguidetosafeoperation.

1.Neveradjustorrepairamachinewhileinoperation.

2.Removeallloosetoolsandelectricalcordsfromtheenginebeforestarting.

3.Keeptheengineroomandfloorareaclean.

4.Storeoilyragsincontainers.

5.Neverstoreflammableliquidsneartheengine.

6.Donotsmokearoundbatteries.Hydrogengasgeneratedbyachargingbatteryisexplosive.Keep batteriesinawellventilatedarea.

7.ObserveNOSMOKINGsigns.

8.Donotwearlooseclothingaroundmachinery.

9.Besuretheengineroomisproperlyventilated.

10.Alwaysdisconnectandtapethegroundbatteryleadbeforeworkingontheelectricalsystem.

11.Allelectricalequipmentmustbegroundedaccordingtolocalbuildingcodes.

12.Besureanautomaticstart-stopsystemisinoperativewhentheengineisbeingworkedon. Disconnectthestarterfromthestartswitch.

13.Usetheemergencystopbuttonforemergencyonly.(Thisprocedureshortsoutthemagneto,thus leavingunburnedgasinthemanifold.)

14.Anoverlyrichfuelmixturecancausecombustionintheexhaustsystem.

15.Allgaslinesandvalvesmustmeetlocalcodes.

16.Checkpipingperiodicallyforgasleaks.Remember,safetyiseveryone'sbusiness.

WedDec402:29:02UTC+05302024

INSTALLGUARDSONALLEXPOSEDROTATINGCOMPONENTS

Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

Starting

SMCS-1350;1352;1395;7542-008

Performrequiredperiodicmaintenancebeforestartingtheengine.Makea"walk-around"checkofthe installation.Itonlytakesafewminutestocorrectminordiscrepancies.Thiscanpreventmajorrepairs atalaterdate.

Pre-StartChecks

1.Checktheaircleanerserviceindicator.Iftheredpistonislockedintheraisedposition,servicethe aircleaner.

2.Correctanyleaks,looseboltsorcovers.Thefanandradiatormustbeclearofrestrictions.

3.Checkthecoolantlevel.Theradiatormustbefulltothebottomofthefillerneck.

4.ThecrankcaseoillevelmustbeabovetheADDmark.

5.Disconnectanybatterychargersthatarenotprotectedagainstthestartercurrentdrain.

6.Allguardsmustbeinplace.Ifguardsareinadequateorinneedofrepair,notifyyoursupervisor.

StartingProcedure

ElectricStart

1.Opentherawwatervalve-ifsoequipped.

2.Openthegasvalve.

3.Disengagetheclutchoropenthecircuitbreaker.Donotstartanengineunderload.

4.Movethecontrolstohalfenginespeedposition.

5.Resetanysafetydevices.

SafetyGauges-Pushresetbuttononthemagneticswitchandholdtheoilpressureresetbuttonin.

Electrical-turnoilpressureswitchOFF.

6.Starttheengine.

7.Iftheenginefailstostartafter30secondsofcranking,stop.Allowthestartertocoolfortwo minutes.TurnthegasvalveOFFandcranktheenginefor10to15secondstopurgeunburnedgas fromtheexhaustsystem.

8.TurnthegasvalveONandrepeatcrankingprocedure.

NOTICE

Donotengagethestarterwhentheflywheelismoving.

Clearancesandtolerancesaredesignedforoperatingconditions-includingoperatingtemperature. Whentheengineisstartedittakesseveralminutestoestablishthelubricatingoilfilmandallowthe movingpartstoheatupandexpand.Loadingacoldenginewillcauseshortenedservicelife,i.e., brokenrings,seizedpistons,etc.Thiswarmupperiodallowstimeforanother"walk-around"check forleaks,etc.

Ifoilpressurefailstoregister,stoptheengineanddeterminethecause.Ontheunitswithanoil pressureswitch,theresetknobwillmovefromONtoRUNautomaticallywhenoilpressurebuilds up.Iftheknobfailstomove,stoptheengineanddeterminethecause.

AirStart

Performallelectricstartingpreliminarychecks.

Checktheairsupply.Theairstartermusthave100PSIairpressureavailable.Thestandardreceiver stores10.5cubicft.(,3cubicm)ofairat250PSI.Pressureisreducedattheairstartermotor.

Openbleedvalve(onthebottomofthereceiver)weekly,todrainanycondensationandoilcarryover.

Thelubricatormustbefilledwithoil.SeetheLubricationandMaintenanceProcedures.

HydraulicStart

Performallelectricstartingpreliminarychecks.

Checkthehydraulicaccumulatorpressure-itmustbe3000PSI.

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Product:GASENGINE

Model:G342CGASENGINE71B

Configuration:G342ENGINE71B00001-UP

OperationandMaintenanceManual

G342CNATURALGASENGINE

MediaNumber-SEBU5560-01PublicationDate-01/11/1983DateUpdated-11/10/2001

Stopping

SMCS-1350;1352;1395;7542-008

1.Removetheloadfromtheengine.

2.Allowtheenginetorunatabouthalfspeedforfiveminutes.Thisreducesinternaltemperaturesand preventsthelossofcoolantby"afterboil".

3.Reducespeedtolowidleforabout30seconds.

4.DONOTracetheenginebeforeshutoff.Thiscausestheturbochargerto"coast"without lubrication.

5.Turngasvalveofftostoptheengine.Donotuseemergencystopbuttonexceptinemergencies.

This is the sample of the manual if you need complete manual Click Here to download