Caterpillar (CAT) 3406E Marine Engine OEM Service & Repair Manual

DIESEL GENERATOR SET STANDBY 240 ekW 300 kVA 50 Hz 1500 rpm 400 Volts Caterpillar is leading the power generation marketplace with Power Solutions engineered to deliver unmatched flexibility, expandability, reliability, and cost-effectiveness. Image shown may not reflect actual package. FEATURES Fuel Strategy • Low fuel consumption FULL RANGE OF ATTACHMENTS • Wide range of bolt-on system expansion attachments, factory designed and tested COMPLETE, READY-TO-RUN SYSTEM • Fully configured generator set • Full range of attachments and options available ENCLOSURES (optional) • Weather protective and sound attenuated SINGLE-SOURCE SUPPLIER • Factory-designed systems built at Cat ISO 9001:2000 certified facilities • Fully prototype tested with certified torsional vibration analysis available WORLDWIDE PRODUCT SUPPORT • Cat dealers provide extensive post sale support including maintenance and repair agreements • Cat dealers have over 1,800 dealer branch stores operating in 200 countries • The Cat® S•O•S SM program cost effectively detects internal engine component condition, even the presence of unwanted fluids and combustion by-products CAT® 3406C TA DIESEL ENGINE • High efficiency, four-stroke-cycle engine designed for thousands of trouble-free hours of operation • Field-proven in thousands of applications CAT GENERATOR • Matched to the performance and output characteristics of Cat engines • Load adjustment module provides engine relief upon load impact and improves load acceptance and recovery time • UL 1446 Recognized Class H insulation CAT EMCP 3 SERIES CONTROL • Simple user friendly interface and navigation • Scalable system to meet a wide range of customer needs • Integrated Control System and Communications Gateway

STANDBY 240 ekW 300 kVA 50 Hz 1500 rpm 400 Volts FACTORY INSTALLED STANDARD & OPTIONAL EQUIPMENT System Standard Optional Air Inlet • Light duty air cleaner [ ] Regular duty canister style, single stage with service indicator [ ] Dual element [ ] Heavy duty [ ] Heavy duty and Muffler [ ] Air Inlet Shutoff Cooling • Coolant drain line with valve • Fan and belt guards • Radiator with guard • Coolant drain line with valve • Fan and belt guards • Cat Extended Life Coolant • Coolant level sight gauge [ ] Low coolant level shutdown [ ] Duct flange Exhaust • Stainless steel exhaust flex • ANSI style outlet flange, gasket, bolts and mating weld flange; shipped loose [ ] 10 DBA Industrial muffler [ ] 25 DBA Residential muffler [ ] Critical muffler [ ] Flexible fitting [ ] Elbow kit [ ] Throughwall Installation kit [ ] Manifold and Turbo Guard Fuel • Fuel priming pump • Fuel pressure gauge • Primary and secondary fuel filters • Flexible fuel lines [ ] Water separator [ ] Fuel level switch [ ] Flexible fuel lines [ ] Manual or auto fuel pumps [ ] Single wall tank bases Generator • Three phase sensing • Class H insulation • VR6 3-phase sensing voltage regulator with load adjustment module • IP23 Protection • Circuit Breaker IEC, 3-pole • Segregated L.V. (AC/DC) wiring panel [ ] Anti-condensation space heater [ ] Permanent Magnet excitation [ ] RFI Filter [ ] Coastal Protection [ ] Terminal strip connection [ ] Oversize generator [ ] Circuit breaker, UL and IEC Listed, 3 & 4-pole with shunt trip [ ] Multiple breaker capability [ ] Digital Voltage Regulator Governor • Hydra-mechanical (3% speed regulation) [ ] Electronic isochronous governor [ ] Load sharing module Control Panels • EMCP 3.1 • User Interface panel (UIP) - rear mount (standard) • Emergency Stop Pushbutton [ ] EMCP 3.2 & EMCP 3.3 [ ] Local & remote annunciator modules [ ] Load share module [ ] Discrete I/O module [ ] Generator temperature monitoring & protection Lube • Lubricating oil and filter • Oil drain line with valve piped to edge of base • Fumes disposal piped to front of radiator [ ] Manual sump pump [ ] Oil temperature sensor Mounting • Narrow integral fuel tank base (950L) • Linear vibration isolators between base and engine-generator [ ] Narrow base [ ] Wide Base [ ] Lifting arch [ ] Oil field skid base Starting/Charging • 45 amp charging alternator • 24 volt starting motor • Batteries with rack and cables • Safety shutoff protection [ ] 5 and 10 amp battery charger [ ] Oversize batteries [ ] Battery disconnect switch [ ] Ether starting aid [ ] Jacket water heater General [ ] Enclosures - sound attenuated, weather protective [ ] EU Certificate of Conformance (CE) February 22 2011 10:55 AM 2

STANDBY 240 ekW 300 kVA 50 Hz 1500 rpm 400 Volts SPECIFICATIONS CAT GENERATOR Frame Size................................................................ LC5014J Excitation............................................................. Self Excited Pitch.............................................................................. 0.6667 Number of poles................................................................... 4 Number of bearings...................................... Single Bearing Insulation....................... UL 1446 Recognized Class H with tropicalization and antiabrasion IP Rating........................................................................... IP23 Overspeed capability - % of rated................................... 150 Wave form.................................................................... 002.00 Paralleling kit/Droop transformer........................... Optional Voltage regulator................................. Three phase sensing Voltage regulation.. Less than +/- 1/2% (steady state) Less than +/- 1% (no load to full load) Telephone Influence Factor.............................. Less than 50 Harmonic distortion......................................... Less than 5% CAT DIESEL ENGINE 3406C TA, I-6, 4-Stroke-Cycle Watercooled Diesel Bore - mm................................................ 137.20 mm (5.4 in) Stroke - mm............................................. 165.10 mm (6.5 in) Displacement - L..................................... 14.64 L (893.39 in 3 ) Compression ratio........................................................ 14.5:1 Aspiration........................................................................... TA Governor type.......................................... Hydra-mechanical CAT EMCP 3 CONTROL PANELS EMCP 3.1 (Standard) EMCP 3.2 / EMCP 3.3 (Option) • Single location customer connector point • True RMS metering, 3-phase • Controls - Run / Auto / Stop control - Speed Adjust - Voltage Adjust - Emergency Stop Pushbutton - Engine cycle crank • Digital Indication for: - RPM - Coolant temperature - Operating hours - Oil Pressure - Coolant temperature - System DC volts - L-L volts, L-N volts, phase amps, Hz - ekW, kVA, kVAR, kW-hr, % kW, PF (EMCP 3.2 / 3.3) • Shutdowns with common indicating light for: - Low oil pressure - High coolant temperature - Low coolant level - Overspeed - Emergency stop - Failure to start (overcrank) • Programmable protective relaying functions: (EMCP 3.2 & 3.3) - Under and over voltage - Under and over frequency - Overcurrent (time and inverse time) - Reverse power (EMCP 3.3) • MODBUS isolated data link (RS-485 half-duplex EMCP 3.2 & 3.3) • Options - Vandal door - Local annunciator module - Remote annunciator module - Input / Output module - RTD / Thermocouple Modules - Monitoring software February 22 2011 10:55 AM 3

STANDBY 240 ekW 300 kVA 50 Hz 1500 rpm 400 Volts TECHNICAL DATA Open Generator Set - - 1500 rpm/50 Hz/400 Volts DM7523 Low Fuel Consumption Generator Set Package Performance Genset Power rating @ 0.8 pf Genset Power rating with fan 300 kVA 240 ekW Fuel Consumption 100% load with fan 75% load with fan 50% load with fan 69.3 L/hr 18.3 Gal/hr 53.8 L/hr 14.2 Gal/hr 38.5 L/hr 10.2 Gal/hr Cooling System 1 Air flow restriction (system) Air flow (max @ rated speed for radiator arrangement) Engine Coolant capacity with radiator/exp. tank Engine coolant capacity Radiator coolant capacity 0.12 kPa 0.48 in. water 522 m³/min 18434 cfm 57.8 L 15.3 gal 20.8 L 5.5 gal 37.0 L 9.8 gal Inlet Air Combustion air inlet flow rate 17.7 m³/min 625.1 cfm Exhaust System Exhaust stack gas temperature Exhaust gas flow rate Exhaust flange size (internal diameter) Exhaust system backpressure (maximum allowable) 580.6 º C 1077.1 º F 52.9 m³/min 1868.1 cfm 152.4 mm 6.0 in 6.7 kPa 26.9 in. water Heat rejection Heat rejection to atmosphere from generator 18.6 kW 1057.8 Btu/min Alternator 2 Motor starting capability @ 30% voltage dip Frame Temperature Rise 585 skVA LC5014J 163 º C 293 º F Lube System Sump refill with filter 38.0 L 10.0 gal 1 For ambient and altitude capabilities consult your Cat dealer. Air flow restriction (system) is added to existing restriction from factory. 2 UL 2200 Listed packages may have oversized generators with a different temperature rise and motor starting characteristics. Generator temperature rise is based on a 40ºC ambient per NEMA MG1-32. February 22 2011 10:55 AM 4

STANDBY 240 ekW 300 kVA 50 Hz 1500 rpm 400 Volts RATING DEFINITIONS AND CONDITIONS Meets or Exceeds International Specifications: AS1359, CSA, IEC60034-1, ISO3046, ISO8528, NEMA MG 1-22, NEMA MG 1-33, UL508A, 72/23/EEC, 98/37/EC, 2004/108/EC Standby - Output available with varying load for the duration of the interruption of the normal source power. Average power output is 70% of the standby power rating. Typical operation is 200 hours per year, with maximum expected usage of 500 hours per year. Standby power in accordance with ISO8528. Fuel stop power in accordance with ISO3046. Standby ambients shown indicate ambient temperature at 100% load which results in a coolant top tank temperature just below the shutdown temperature. Ratings are based on SAE J1349 standard conditions. These ratings also apply at ISO3046 standard conditions. Fuel rates are based on fuel oil of 35º API [16º C (60º F)] gravity having an LHV of 42 780 kJ/kg (18,390 Btu/lb) when used at 29º C (85º F) and weighing 838.9 g/liter (7.001 lbs/U.S. gal.). Additional ratings may be available for specific customer requirements, contact your Cat representative for details. For information regarding Low Sulfur fuel and Biodiesel capability, please consult your Cat dealer. February 22 2011 10:55 AM 5

Caterpillar (CAT) 3406E Marine Engine OEM Service & Repair Manual

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