Cooling Air Filter Installation For 680 And 800 Frame Generators{7263} Caterpillar

Introduction

In order to have proper operation of the air cooling system, the End Mounted Terminal Box (EMTB) must be sealed so that the incoming generator cooling air is channeled through the air filter elements. This air filter system provides protection against airborne abrasive dust and sand. This instruction will identify the proper installation of the sealing materials for the 680 and 800 frame generator sets.

NOTE: These filters will not protect against salt related damage.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

Safety

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When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE. Remove all fuses. * Make sure the generator engine is stopped. * Make sure all batteries are disconnected. * Make sure all capacitors are discharged. * Failure to do so could result in personal injury or death. * Make sure residual voltage in the rotor, stator and the generator is discharged.

Attach a "DO NOT OPERATE" or similar warning tag to start switch or controls before performing any service or repairs.

NOTE: "DO NOT OPERATE" tags are available from Caterpillar. Order Form SEHS7332.

680 Frame Generator Sets

The following procedure gives step by step instructions for the installation of the air filter assembly kit hardware.

Installation Procedure For 680 Frame Generator

Remove the side panels, top cover, grounding strap, and louver assembly to provide access to the EMTB frame assembly (see illustration 1).

Illustration 1 (EMTB frame assembly with covers removed).

Front Face Installation Procedure

Cut the foam sealing strips for the front face to the following lengths:

NOTE: Mounting surfaces must be free of all dirt, oil and foreign material before foam sealing strips are installed.

NOTE: Each foam strip installed should be touching the foam strip next to it.

See Illustration 2 for locations of foam strips on the front face.

Illustration 2

* Install one Item 1 strip at each (A) location.

* Install one Item 2 strip at each (B) location.

* Install one Item 3 strip at each (C) location.

* Install one Item 4 strip at each (D) location.

* Install one Item 5 strip at each (E) location.

* Install one Item 6 strip at each (F) location.

Top Face Installation Procedure

Cut the foam sealing strips for the top face to the following lengths:

NOTE: Mounting surfaces must be free of all dirt, oil and foreign material before foam sealing strips are installed.

NOTE: Each foam strip installed should be touching the foam strip next to it.

The locations where the foam strips are to be installed to the top face are shown in illustration 3. The first ten locations require two foam strips, one stacked on the other, to obtain the proper height. The foam strips should be installed to the EMTB top face in the following order:

Illustration 3

1. Stack two Item 11 strips and install at location (A).

2. Stack two Item 9 strips and install at location (B).

3. Stack two Item 7 strips and install at location (C).

4. Stack two Item 8 strips and install at location (D).

5. Stack two Item 10 strips and install at location (E).

6. Stack two Item 11 strips and install at location (F).

7. Stack two Item 9 strips and install at location (G).

8. Stack two Item 7 strips and install at location (H).

9. Stack two Item 8 strips and install at location (J).

10. Stack two Item 10 strips and install at location (K).

11. Install one Item 16 strip at location (L).

12. Install one Item 15 strip at location (M).

13. Install one Item 12 strip at location (N).

14. Install one Item 16 strip at location (P).

15. Install one Item 14 strip at location (R).

16. Install one Item 14 strip at location (S).

17. Install one Item 13 strip at location (T).

After all foam sealing strips are in place, cut four 12.7 mm (0.5 in) diagonal slots in the 50.8 mm × 25.4 mm (2.0 in × 1.0 in) foam installed on the top face. See illustration 4.

Place the top cover in normal assembly position and press down firmly. The top cover will act as a template for locating where to cut the diagonal slots.

Illustration 4
(1) Diagonal slot locations.

Top Cover Installation Procedure

The foam strips used for the top cover will be 25.4 mm × 25.4 mm (1.0 in × 1.0 in). These strips can be made from the 50.8 mm × 25.4 mm (2.0 in × 1.0) material.

Cut eight strips 109.2 mm (4.3 in) in length. Install one strip at each location A to H between the shock mount standoffs and the top cover. Locations are shown in Illustration 5.

Illustration 5

Pressure Switch Installation

To mount the 4P-8767 Differential Pressure Switch, four holes with a diameter of 4.8mm (.19 in) will need to be put in the EMTB back face. The 4P-9481 Mounting Bracket can be used as a template for hole placement.

The 7W-1380 Terminal Strip should be mounted on the EMTB back face beside the pressure switch. Four holes with a diameter of 4.8mm (.19 in) will need to put in the back face. The terminal stripe can be used as a template for hole placement.

The 6I-4938 Fitting mounts in the EMTB bottom face. A 9.0mm (0.35 in) diameter hole will have to be put in the bottom face to accommodate the fitting.

The 4P-8767 Differential Pressure Switch is a three contact switch. One contact is the common contact, one is for normally open (N.O.) contact position and the other is for the normally closed (N.C.) contact position. The switch should be wired according to the application that it is being used in.

Seal Holes In EMTB Bottom Face

Using the hardware that is provided, seal all the holes in the bottom face of the EMTB that are not being used.

Reassembly

Reassemble the top face cover and the grounding strap to the EMTB.

NOTE: A hole 4.3mm (.17 in) will have to be added to the EMTB front "C" channel for routing of the ground strap.

Before installing the filter elements spray a thin layer (1.5 - 2 oz) of light machine oil on the filter elements. Allow any excess oil to drain from the filter elements before installing in the generator.

Reassemble the side panels and mount the filter assembly to the EMTB front face.

Filter Maintenance

Remove the filter elements. Soak the filter elements in hot water and detergent. Rinse the filter elements and recharge with a thin layer of light weight machine oil before reinstalling.

800 Frame Generator Sets

The following procedure gives step by step instructions for the installation of the air filter assembly kit hardware.

Installation Procedure For 800 Frame Generator

Remove the side panels, top cover, grounding strap, and louver assembly to provide access to the EMTB frame assembly (see illustration 1).

Illustration 1 (EMTB frame assembly with covers removed).

Front Face Installation Procedure

Cut the foam sealing strips for the front face to the following lengths:

NOTE: Mounting surfaces must be free of all dirt, oil and foreign material before foam sealing strips are installed.

NOTE: Each foam strip installed should be touching the foam strip next to it.

See Illustration 2 for locations of foam strips on the front face.

Illustration 2

* Install one Item 1 strip at each (A) location.

* Install one Item 2 strip at each (B) location.

* Install one Item 3 strip at each (C) location.

* Install one Item 4 strip at each (D) location.

* Install one Item 5 strip at each (E) location.

* Install one Item 6 strip at each (F) location.

Top Face Installation Procedure

Cut the foam sealing strips for the top face to the following lengths:

NOTE: Mounting surfaces must be free of all dirt, oil and foreign material before foam sealing strips are installed.

NOTE: Each foam strip installed should be touching the foam strip next to it.

Illustration 3

The locations where the foam strips are to be installed to the top face are shown in illustration 3. The first ten locations require two foam strips, one stacked on the other, to obtain the proper height. The foam strips should be installed to the EMTB top face in the following order:

1. Stack two Item 11 strips and install at location (A).

2. Stack two Item 9 strips and install at location (B).

3. Stack two Item 7 strips and install at location (C).

4. Stack two Item 8 strips and install at location (D).

5. Stack two Item 10 strips and install at location (E).

6. Stack two Item 11 strips and install at location (F).

7. Stack two Item 9 strips and install at location (G).

8. Stack two Item 7 strips and install at location (H).

9. Stack two Item 8 strips and install at location (J).

10. Stack two Item 10 strips and install at location (K).

11. Install one Item 16 strip at location (L).

12. Install one Item 15 strip at location (M).

13. Install one Item 12 strip at location (N).

14. Install one Item 16 strip at location (P).

15. Install one Item 14 strip at location (R).

16. Install one Item 14 strip at location (S).

17. Install one Item 13 strip at location (T).

After all foam sealing strips are in place, cut four 12.7 mm (0.5 in) diagonal slots in the 50.8 mm × 25.4 mm (2.0 in × 1.0 in) foam installed on the top face. See illustration 4.

Place the top cover in normal assembly position and press down firmly. The top cover will act as a template for locating where to cut the diagonal slots.

Illustration 4
(1) Diagonal slot locations

Top Cover Installation Procedure

The foam strips used for the top cover will be 25.4 mm × 25.4 mm (1.0 in × 1.0 in). These strips can be made from the 50.8 mm × 25.4 mm (2.0 in × 1.0) material.

Cut eight strips 109.2 mm (4.3 in) in length. Install one strip at each location A to H between the shock mount standoffs and the top cover. Locations are shown in Illustration 5.

Illustration 5

Pressure Switch Installation

To mount the 4P-8767 Differential Pressure Switch, four holes with a diameter of 4.8mm (.19 in) will need to be put in the EMTB back face. The 4P-9481 Mounting Bracket can be used as a template for hole placement.

The 7W-1380 Terminal Strip should be mounted on the EMTB back face beside the pressure switch. Four holes with a diameter of 4.8mm (.19 in) will need to put in the back face. The terminal stripe can be used as a template for hole placement.

The 6I-4938 Fitting mounts in the EMTB bottom face. A 9.0 mm (0.35 in) diameter hole will have to be put in the bottom face to accommodate the fitting.

The 4P-8767 Differential Pressure Switch is a three contact switch. One contact is the common contact, one is for normally open (N.O.) contact position and the other is for the normally closed (N.C.) contact position. The switch should be wired according to the application that it is being used in.

Seal Holes In EMTB Bottom Face

Using the hardware that is provided, seal all the holes in the bottom face of the EMTB that are not being used.

Reassembly

Reassemble the top face cover and the grounding strap to the EMTB.

NOTE: A hole 4.3mm (.17 in) will have to be added to the EMTB front "C" channel for routing of the ground strap.

Before installing the filter elements spray a thin layer (1.5 - 2 oz) of light machine oil on the filter elements. Allow any excess oil to drain from the filter elements before installing in the generator.

Reassemble the side panels and mount the filter assembly to the EMTB front face.

Filter Maintenance

Remove the filter elements. Soak the filter elements in hot water and detergent. Rinse the filter elements and recharge with a thin layer of light weight machine oil before reinstalling.