CATERPILLAR” ss ‘September 1988 = Operation & Maintenances. : So 3408 and 3412 nee ee and EPG Diesel Engines 81Z1-UPQ\ IMPORTANT SAFETY NOTICE Most accidents involving engine opers jatety rules of precautions. An accident can ing potentially hazardous situations: Improper operation is dangerous and could result in injury or death. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE OPERATING THIS ENGINE. @ outlined in the “Safety” Section of jon of operations where hazards exist. Warning decals have also been put on the engine to provide instructions and to identity specific hazards which, it ot heeded, could cause bodily injury or death to you or other persons. These warnings in the Guide and on the engine ns that may result only in engine damage are identified by CAUTION decals on the engine and in the Guide. pillar cannot anticipate every possible circumstance that ht involve a potential hazard. The warnings in this Guide and fon the engine are therefore not all inclusive. if an operation is not performed as specitically recommended by Caterpillar, you must satisty yourselt that it is safe for you and others. You ‘should also ensure that the engine will not be damaged or made tunsate by the method of operation you choose. ‘The proper and safe lubrication and maintenance procedures for this engine, recommended by Caterpillar, are outlined in the "Lubrication & Maintenance” Section of this Guide. Improper performance of lubrication ot maintenance procedures is dar erous and could result in injury or death. Read and understand the “Lubrication & Maintenance” Section before performing any lubrication (oF maintenance.FOREWORD ‘This guide contains operation insttuctons and bce tion and maintenance information, ‘The operation sectonis a reterence for the new oper: stor and a retrosher for the experienced one. Read — ‘Staty — and Keep It handy. lustrations guide the operator through correct proce ‘ures of checking, staring, operating ané stopping the engine ‘The maintenance sections a guide to equipment care ‘Te tustrated, step-by-step natructions are grouped by servicing intervals. ems inthe Lubiction and Manto nance Chart” are raferanced to the detased instructions that folow Use the service meter to determine servicing ite: vals, Calendar inervais shown may be used stead of Service meter intervals f they provide mare convenient Servicing schedules and approximate the indicated ser- vce meter reading. Recommended service should al ways be performed at the terval thal occurs f Under extremely severe, dusty of wet operating com tions, mere requent ication than spectied inthe ‘Laincation and Maintenance Chart” may be neces Perform service on items at mutes of the original ‘equrement. For example, at Every 500 Service Meter Unis, alza service those items bsted under Every 250 Service Moter Uns, Every 80 Service Moter Units and Every 10 Service Meter Unis ‘Some photographs in this publication show details or attachmants that may Be diferent fam your engine ‘Also, guards and covers may have boon removod for Iustrative purposes. Cominuing improvement and advancement of product design may have caused changes fo you engine which fire not Included nthe pubieaton Each publication I reviewed and revised, as euied to update and include these changes in lator edions Whenever a question arises regarding your engine or this pubteation. please consult your Caterpilar dealer for the latest avaiable information, Engine Identification Caterpilar engines are dentiied with SERIAL NUM. BERS and ARRANGEMENT NUMBERS. in some cases MODIFICATION NUMBERS are also used. These nur bors are shown on the serial number plate mounted on the engine CCaterpilar dealers needa these numbers to deter rine wich componente ware included on te engine when ft wag assembled at the factory. Ths permits ‘accurate Identification of replacement part numbers Ordering Parts Qualty Caterpiar replacement parts are avaiable from Caterpilar dealers throughout the worl. Thee parts stocks are upto date and clude al pars normally Fequirod 0 protect your vvestment In Caterpilar er fines. When ordering parts, your order should specity the quant, part number part name and sal nomber frrangement number and modiication number of the fengne for which te parts are needed Fin doubt about {he part azmber, please provi your dealer wth com plete description ofthe nooded item,TABLE OF CONTENTS Mooel. VIEWS SAFETY PRECAUTIONS OPERATING INSTRUCTIONS PRE-START INSPECTION AND PROCEDURES STARTING THE ENGINE AIR STARTING STARTING AIDS GENERATOR AFTER ENGINE STARTS. [STARTING THE LOAD ENGINE OPERATION ALTITUDE OPERATION STOPPING AFTER STOPPING CHECKS AND PROCEDURES [ATTACHMENTS AUTOMATIC START-STOP WOODWARD GOVERNORS EMERGENCY SHUTOFF DEVICES. "AND ALARWS. EMERGENCY STOPPING MAINTENANCE RECOMMENDATIONS SPECIFICATIONS. LUBRICATION FUEL (COOLANT LUBRICATION AND MAINTENANCE INSTAUCTIONS LUBRICATION AND MAINTENANCE ‘CHART LUBRICATION INSTRUCTIONS ‘COOLING SYSTEM FusL SYSTEM AIRINDUCTION AND EXHAUST ‘SYSTEMS, ELECTRICAL SYSTEM POWER COUPLINGS ENGINE STORAGE GENERATOR STORAGE PREVENTIVE MAINTENANCE RECOMMEND: IRVONS FON STANDBY GENERATOR SETS (GENERATOR MAINTENANCE ‘TROUBLESHOOTING MAINTENANCE RECORD Ey ea 32 99 «a 58 56 580 560 ss 87 63408 GENERATOR SET ENGINE GAUGE PANEL COOLANT FILL CAP GeneRaron | expansion ranx FUEL. PRIMING. ; at FAN DRIVE, see FUEL, FILTER on COOLER + CRANKCASE DRAIN lL FILTER‘TEMPERATURE REGULATOR Goo “-/ water PUMP % y one on cOoLeR” 3408 INDUSTRIAL ENGINE GOVERNOR AFTERCOOLER aim cLeANER — I oneurers CRANKCASE ORAINTEMPERATURE REGULATORS . a ’ GovenNgn AFTERGOOLER OIL FILL CaP 3412 INDUSTRIAL ENGINE CONTROL PANEL, AIR CLEANER OW FILTERS ™/™ celenron —--PUELFILTERSSAFETY PRECAUTIONS Safety is everyone's business ands basicaly th use of good common sense. A general quide of ‘Safety precautions ara given below. but each instal- iatonfas tgown peculiarities which cannot always be predicted and covered by established ules. Past Sxpenience and common sense are neoded for the ecessary safety measures. Attention to safety will Relp avotd senius accidents. Be alert, Watch for haraids, Use preventive measures. Correct de fieieneies immediately ‘The fallowing safety precautions are # general ‘guide to sate operation “To prevent personal injury, install guards over all exposed rotating parts. 2.To prevent hearing damage, woar ear protec- tive devices vf working Insida an enclosed en bine room with engine running 3. To prevent head injury, wear safety hat when lnorking in the area of overhead equipment. 4. Wear safety glasses and shoes as requited. Do not wear loose clothing whenever working around engines er machinery. Wipe up spilled ol, fuel or coolant. Keep batteries in a well ventilated area. Do not Smoke aroundatierles. Hydrogen gas, whichis, present nthe area of the batteries, is highly explosive. Provide adequate and sate waste oll disposal ‘store oily rags in fireproof containers, Don't leave rags on engine. A WARNING When using pressure air, woar safety and provective clothi Surer used for cleaning 2ikgiem®, 10. Remove all tools, Toase items fram the engine before starting, 11, Disconnect and tape the battery ground lead Detore working on an engine topreventacciden: {al starting. Be sure an automatic startstop sys tem cannot operate and start tho engine while working on 6 12, Do not attempt repairs you do not understand. Follow instructions. 13, Stop engine before adjusting or repairing en gine or driven equipment. 14. Remove radiator cap slowly. Cooling systems Ean be pressurized and hot fluid wil flash to Stoam as pressure is removed 46: Never start an engine with the governor linkage disconnected 16. Replace or repair broken or damaged equip ment. Use proper tools 47. Do not smoke while retueling. Observe NO SMOKING sighs. 18, Never store flammable liquids near the engine 19. All electrical equipment must be grounded ac- cording to local Building codes, 20. Check all connections periodically for tightness ‘and insulation 21. Insulate all connections and disconnected 22. Do not use carbon tetrachloride tire extin uishers, Fumes are toxic and the liquid has @ Seteriorating effect on Insulation. £28, Do not touch the heat sink on the generator Fegulstor when the generater Is running. Its tlectrically "nat 24. Do not work on electrically “hot” equipment 25. Always disconnect the engine starter circuit when working on the goneratcr. 26. Hot engine oil can cause burns when drained. ‘Allow the ol to €00! below I40"F or provide pro- fection whon draining the hot oi 27. Never remove a plug to chock pressure withthe gine running, Shut down the engine and as Sure there is ne pressure before removing plug 28. Whon starting an engine after repair, make pro Vistons for shutting of aie supply in case theres fan overepeed on start up. 29. Never look into an open cylinder port and turn over the engine. Oil or water in the cylinder wil be ejected violently.OPERATION INSTRUCTIONS PRE-START INSPECTION AND PROCEDURES 1. Make a "walk-arouna'” ingpection ofthe engine and components for the all, water oF fuel leaks and general appearance. Correct minor adjust iments betore they develop nto major repair jobs. 2. Check the erankease oil love). Maintain the oil level Between the ADD and FULL marks on the lipstick. See OIL SPECIFICATIONS for typo of wannine hac oe cana ee anh tn pind roy eutwara unr igh pressure ond euuse eaeecne 4. Check the engine jacket coolant level. Slowly turn the pressure cap unt the cap is removed Maintaincoolantloveltothe base at the ilipipe. 5. Chock the fuel supply. Keep fuel tanks full, as partially tiles tanks will collect moisture. See {he FUEL SPECIFICATIONS for type of Tue! KEEP THE FUEL SUPPLY CLEAN 6. Open the raw water valve on the engine jacket heat exchanger system (i so equipped). Prime the raw water pump the raw water system has boen draine 7. Reset shutolt devices. See the topic, AT. TACHMENTS, Emorgency Shutolf Devices and Raarms OVERSPEED RESETtthe engine is equipped with an ar saety shutoff antral. ang nas inpped to the shutot! position Foset the latch fo the run position Oe AIR SHUTOFF RESET £8, Open theusl supply valve. the engine has not fun for some time it may be necessary to arime the system. See the topic, PRIMING THE FUEL System 9. Disconnect any battery charger which is not protected against starting motor drain, 10. Disengage the clutoh, or open the circuit breaker on a generator sat. STARTING THE ENGINE CAUTION Do not engage the starter when the flywheel Is moving. Electric Starting 1. Move the govarnor control lever to approximate half engine speed position 2. Use starting aids if required. See the topic, STARTING AIDS. 43, Push the START button: or turn the HEAT- START switch fo the START position. depend- ‘ngupon the control he engine has. Release the ‘control's soon a8 the angine starts. For generator sole, place the AUTO-MAN switch Inthe MAN position tocrank the engine. As soon as the engine starts, and the engine spoed reac! {600 rpm and oil prossure ts approximately 22 psi (1 Skovem), the starter motor will disconnect from the elreut. (The STOP position is used f0 stop the iesel engine.) Ifthe engine fails to startin 10 seconds, move the ‘governor control lever to the fuel off position, then ontinue to crank for 10 seconds. This wll clear the ylinders of unburned Tush. It the engine falls to start after 80 seconds of cranking, allow the engine to cool for 2 minutes botore repeating the starting procedure, CAUTION Prolonged cranking at low oil pressure can actl- wate the mechanical safety shut-off. If the reset ever isin the shut-off position, reset the mechanical shut-off controlcaution NEVER use starting aids when the engine is ‘warm and running. It the engine is equipped with a Woodward PSG Governor. see the topie, WOODWARD GOVER- NORS Yor the governor operation instructions. Air Starting 1, Open and close the blood valve onthe bottom of the alr tank to drain condensation and ail car ryover 2. Check the air supply pressure. The air start ‘must have 100 PSI (7 xg/em) to operate prop erly. 8. Keep ol level, in the oiler jar. at least halt fll ‘Add’ necessary. See the LUBRICATION AND MAINTENANCE PROCEDURES, Filing Motor Oiler 4. Push the ar valve controlin to crank the engine. ‘As soon as ho angine starts, release the valve. Starting Aids Many variables can affect cold weather starting Use the chart as a guide, but actual experience wil determine when aids are necessary and how they ‘Should be used. Your engine may have one or more fof the following starting aids: Glow Plugs (Precombustion Chamber Engines Only) 1. Push in an turn the HEAT-START switch tothe HEAT position and nold for the approximate heating time shawn in the STARTING AID CHART Orr o starr e SX 2. Turn the HEAT-STAAT switch to the START position HEATA, oF o HEAT A ASTART £ 3. I necessary, when the engine starts turn the HEAT-START switch tothe HEAT position. Hold the switen in this position until the engine is Funning smoothly 4, Release the switch s weata: Xa start s CAUTION NEVER use glow plugs when the engine is warm ‘and running,‘STARTING AID CHART ‘STARTING TEMPERATURE ‘STARTING AID HEATING TIME Above 60 (15°C) None None aor 030 : Teal Gscwoo Giow Pug i apr oor, ae ec eemel Glow Pgs 2 Minute Below OF (-2007 Gow Plugs antes Heating of jacket water/and or crankcase ol; and/or use of extra battery capacity may be required Starting Fluid A warninc tions on the container. CAUTION Spray starting fluid only while cranking the gine. 1. Heatthe glow plugs (If equipped) forthe approx imate neating me shown inthe STARTING AID CHART. OFF HEATA_— ASTART Tuen the HEAT-STAAT switch to START posi CAUTION Wait at least 2 seconds before spraying starting fuld again. 3. If necessary, repeat the procedure. 4. Alter the engine starts, it may be necessary to feturn the HEAT-STAAT switch to the HEAT position until the engine runs smoothly Jacket Water Heater (attachment) Invery low temperatures, the lubricating oll must be marmad to allow starting. A jacket water heater an maintain the water temperature. at approx mately 90°F (32°C). The warm water willkeep the ol inthe upper partol the engine block warm enough to tow wnen starting, Dipstick Oil Heater CAUTION Contact your Caterpillar dealer before installing 4 dipstick crankcase ol heater tion While cranking, spray starting uid into the Siriniet or sircleaner for approximately 1 9ec na 10 GENERATOR Starting Single Unit Operation iminary engine starting checks. Be sure the main or line circuit broaker is open. Start the engine and allow it to warm up. Close the main circuit breaker Apply the load. Donat try to apply full/oadin one. ‘move, rather apply the load in increments to ‘maintain system frequency ata constant level Make all pe 1 2 3 4 5.‘Standby Generator Sets Most standby units are automatic. They start pickup the load, run and stop without an operatorin dance. Standby units ean not change the gov mor control selting automatically. The throtile ‘must be preset forthe proper operation ofthat unit Whenever the set's exorcised oF operated manu ally. bo sure the throttle setting is correct for au- omatie operation. Check all switches to seo thoy 2a properly set: Start Selector Switch in AUTOMA- ‘Tie'postion ane any Emergency Stop Switches in RUN position Paralteling Units may be paralleleg at no load or paralleled with units undertoad. To parallel two or more units the folowing conditions must be met 1. Same phase rotation 2. Same voltage level 3, Same voltage droop. 4. Same frequency 5. Voltagos must be in phaso. The fist condition is established by “phased wiring connections of initial Installation The second and third conditions are usually es- tablished by semi-permanent adjustments to tho generator contrels ‘The fourth and fifth conditions ate under contro! of the operation in manual paralleling systems (or Under automatic contrl in automatic parallling systems). To Parallel 1, Start the unit to be paralleled 2. Turn the synchronizer lights on 3. Alter the engine has tun long enough to warm up, bring Itup to synchronous speed (the same frequency as the unit on the line). The sy hronizinglignts wil Bogin to link 4, Using the governor contol, adjust the speed Until the lights Bink very slowly, ‘5 The lights are off when the voltages of the two units are in phase. At this point, very quickly Close the breaker while the lights are out Ths trguaney of eineomign Load Division ‘Once two units have been paralleled, their share of the load is determines by the governor control setting. If two units of the same capacity and the ‘Same governor characteristics have the same gov: ‘ernor control setting they wil share the load equal Wy ‘To add load ta one engine, slowly increase the governor control setting of that engine, oF slowly Socrease the governor contra setting of the engine ‘iving up load. Load Transfer [At this point open the circuit breaker to remove ‘any remaining ioag on tho outgoing generator sot 1. Increase the governor speed contro! ofthe unit 1 the high idle position to assume the load. 2. Reduce the governor speed control of the out {going unit until the generator amperage Is at a minimum. (The amperage may never be zero due ocireulaling currents) Atthis point transter the load Stopping ‘Toremove a generator Irom the line do the follow: ing: 1. Check the load. it must be loss than the rated Capacity of ramaining units 2. Be sure the NEUTRAL of one of the remaining units 18 grounded, 3, Remove the load from the outgoing unit as de Seribed in Load Division and Load Transter 4 Open the eireult breaker 5 lun the engine for § minutes without a load, to low it to e001 Stop the engine After Engine Starts A, warning 3 oF adjustments, ‘work on machinery wl 1, Observe the oil pressure gauge immediately alter starting CAUTION Pressure is not indicated within seconds, ‘stop the engine and have necessary repairs made. u2. Move the governor control to low idle allow the {gine foreach normal operating range (usvally Soveral minutes). Make another "walk-around Inspection for leaks, etc STARTING THE LOAD Driven Equipment without Load To engage the stiven equipment before applying toad 1. Move the governor control half engine speed, 2. Engage the driven equipment without load on the equipment 3, Make sure the engine and equipment gauges register In the operating range. 4, Move the governor contralto high ile ulload) position. 5. Apply the load to the driven equipment. Driven Equipment With Load 1, Move the governor control to half engine speed. Make sure the engine gauges register in the normal operating range: 2, Move the governor control to high idle (ull load) position. 2. Engage the load ENGINE OPERATION After the engine starts, and at frequent intervals, while the engine is operating, the gauges should be Observed. Determine the normal reading for each {auge. Investigate the cause whenever there is @ Signficant change inthe reading, Gauges ‘Tachometer “Ihe tachometer indicates engine RPM. The high lle RPM and the (ull load APM are stamped on the tengine’s information plate. The engine can be op- erated between these two speed limits for long periods of fme without shortening engine lite, Pro: fonged operation at high ide with lite or no load can cause adverse engine operation Engine Oll Pressure It the gauge reading fluctuates after the load is stable: 1, Remove the load 2. Reduce engine speed to low idle 3, Observe the oil eval. Maintain the oll evel b ween the ADD and FULL mark onthe dipstick It the reading continues to fluctuate when the olf levels correct stop engine and call your Cate pillar dealer. Engine Jacket Water Temperature The engine should operate within the NORMAL (green) range. I the engine is operating inthe (red) ange and steam becomes apparent4, Reduce the load and engine RPM. 2, Inspect for coolant leaks, 3, Determine if the engine must be shut down im- ‘mediately: orif the engine can be safely cooled By reducing the loa See COOLING SYSTEM MAINTENANCE IN- STRUCTIONS, CAUTION Do not add cold water to ahot engine: Cracking af engine components may secur. Aliow the en- Sine fo.cool, then add cool Iv the temperature gauge reading registers in or rear the cold range {white) while operating under Toad 1. Check the water temperature gauge for accu ray. 2. Check the temperature regulators for proper temperature range. Replace regulators. If necessary See COOLING SYSTEM MAINTENANCE for DETAUS. Fuel pressure If the fue iter gauge registers in the OUT range, clean the primary fue! filer, so equipped. install few secondary or final us! fiter elements H gauge Siill registers OUT. See the FUEL MAINTENANCE INSTRUCTIONS ang FUEL SPECIFICATIONS. Amme The ammeter reading is normal when the ingi- ceatoris at or on the (2) side of 2er0, when the fengine is running at rated speed. It indicator isto the lolt(-) sido of zero, investigate and correct Air Cleaner Service Indicator ‘When the gauge Indicator locks inthe red range, service the air cleaner. With the engine stopped: See AIR INDUCTION AND EXHAUST SYSTEM MAINTENANCE INSTRUCTIONS Calibrated Gauges Calibrated gauges are used on some engines to ‘monitor tho engine systoms. Ifan abnormal engine Condition develops, determine ane analyze and Correct the cause before a failure and downtime The operating limits gon in the “OPERATING. RANGES FOR ENGINES" chart are based on the tengine running at continuous rated speed and load, afer warm-up, using SAE 30, oll. It any of the gauges rogister st oF outside the operating limits, Investigate and correct any malfunction, See TROUBLESHOOTING GUIDE tor guidance. WaRNING ‘Shut the engine down if work on or around the ‘engine ie requir DO_NOT OPERATE THE ENGINE WITH THE GAUGES REGISTERING AT OR OUTSIDE THE tinarrs B(a eee I ‘Tachometer. ‘Left Inlet manifold temperature Right inlet manifold temperature. {Left and right exhaust manifold temepratures. 5. Engine oll temperature 6. Engine jacket water lemperature. 7. Engine oll pressure. 8. Fuel pressure. OPERATING RANGES FOR ENGINES WITH CALIBRATED GAUGES (Engine running at continuous rating and load.) (OPERATING RANGE GAUGE iu MAXIMUM Teckel Walr Temperature (Ould Wer (70) 2IOF (OO) Inet Mario Ar Temperature Mercooled (0) 00°F (149°0) Newateroooed (OD 200°F (149°0) Bihaust Temperature ‘Atocooled Po) eo 4270) Non-atteroookd (OD BO0F 4270), Oi Temperature ‘atoreooles (eo) 200 (N00) Non-atiercaled (OD W2F (770), BOF (100) Tene 20 PSI(ia8 KPa) | 62 PSI(A27 KPa) i (15 halen?) (¢kgfom?) Fuel Pressure 17 PSI(117 KPa) | 90PSI(207 Pa) inigion’) fryerAltitude Operation ‘The fuel system settings and altitude limits aro stamped on the engine information plate. When an fengine 's moved to a higher altitude, these settings must be changes by your Caterpillar dealer in order te provent damaging tho turbocharger, and to pro Vide maximum engine efficiency a It the engine is moves to lower alttuce than that which is stampad on the angine information plate, the engine can be operated safely; however, tl oliver less than rated horsepower, ang the fol Setungs should be changed by your Calerpliar ealer to obtain rated horsepower Stopping 1. Flywheel clutch operation: Quickly pull the Clutch ever tothe released position. For electic Set operation, sec the GENERATOR SET OP- ERATION instructions. For Woodward Gover for operation, see the topic, WOODWARD GOVERNORS: Stopping the Engine 2. Reduce engine speed to hall speed. Aun for 5 minutes to e201 engine 3. Reduce engine speed to low isle 4. Observe the crankcase oll level while the on: {gine is ing, Maintain the oll evel between the ADD and FULL marks on the side of the cipstick Stamped, CHECK WITH ENGINE RUNNING, See the LUBRICATION AND MAINTENANCE SECTION, 5. Stop the engine. After Stopping Checks ‘And Procedures 1. Fill the fual tank, See the LUBRICATION AND MAINTENANCE SECTION: Fuel Tank Maint Drain the raw water system it below freezing mperatures aro expected: see: Draining Raw ater System 1 below freezing temperatures are expected, allow the engine jacket water expansion tank 0 foe; then check the coolant for proper anti: ze protection. Add pormanent-type anti reeze, i roquired 4 Repair any leaks, make major adjustments, tignten loose bolts, ete 5. Odserve the Service Meter reading. Pertorm the periodic maintenance as instructed in the LUBRICATION AND MAINTENANCE CHART SERVICE METERATTACHMENTS, Automatic Start-Stop {An automatic start-stop system is used when an ‘ongine must star! when a specific condition occurs with no one invattendance. The engine will start Increase speed, pick-up te load, operate the load Unt a second gondition occurs, remove the load, feoel and stop. The folowing conditions must exist for the engine to start unattended: Either the ambient (engine room) temperature must be al least 70°F (20°C): oF, the engine jacket Water temperature must be at least 80°F (92°C) ‘Gne or two 3 kw jacket water heaters can maintain this temperature. Protection Devices The Caterpillar generator mounted control pane! {is equipped with protection devices to protect the fongine wile cranking. Batteries. Lights or buttons may indicate itafaulthas occur red inthe battery charging system causing the bat tery to be elther undercharges or overcharged Overcranking ‘Atimer allows the engine to crank either once for 0seconds, orto crank inrough ston second erank- ing eyeles (depending upon the device used) while Unattended. ittne engine doos not start before the time elapsed, the fuel system will be shutot! and a light will naicate a starting failure Engine Operation Prealarm systems provide an audible and/or a visual indication for fow cil pressure, high water temperature, low tue! supply or low jacket water temperature before the condition becomes ertical hose alarms are self resetting when the condition is corrected, ‘The engine may also be equipped with shutdown, devices. low oll pressure, high jacket water temp- feralure of an engine overspeed condition occurs, the engine wil be shutdown and a corresponding button or light wil indicate the cause of the shut Gown, These devices must Oe reset alter repairs have been made ang betore starting. See the topic, EMERGENCY SHUTOFF DEVICES AND ALARMS. Generator set control panels should be equipped with-an ammeter. a lrequeney moter and a voltme- Ter" Depending upon the type of operation, the panel may alse be oquipped with other meters ang fights. Know these instruments and their normal readings. They will indicate how the generator setis performing Shutting Down timer allows tho transter switch to transter the fad to another source and to cantinue engine run- ring for up to 2 minutes for cooling purposes before stopping, Engine Exerciser At preset times, the exerciser will start run and stop the engine in atder to ensure both proper lub tation of all engine paris and proper equipment ‘operation if and when the standby unit is needed Become familiar with all instructions included withthe equipmentWoodward Governors Woodward Governors are usually electrically op erated trom a contro! panel Generator Set Control Panel ‘The generator set control panel is located on top of the generator andis equipped withthe following Controls and gauges Panel lights (1) are controlled by an ON/OFF switen (7)-An ammeter (2) requency meter (3) anc a voltmeter (8) show the output of the generator. ‘Two gauges (5 and) show engine oll pressure and water tomporature respectively. Tho am’ Selector switch (12) gives the operator a choice of whieh phase (71. T2.6r T3) of the generator output the ammeter (2) wil show. Voltage level rheostat {@) takes the place of the voltage level rheostat in the generator regulator assembly Tho engine control switch (8) has four positions MANUAL. AUTOMATIC, STOP and OFF Placing the control in the MANUAL position will start the tengine and allow the operator io manually connect the ganerator to the load. the unit Is used for standby application with a remate transfer switch the AUTOMATIC position 1 Used. In this position the engine will automatically start and take up the load when commercial power has stopped. Placing the control inthe STOP or OFF position will stop the engine. Whenin the AUTOMATIC or MANUAL posi- tian, the engine will automatically stop if the com- mercial power nas started or the engne has afault ‘The PSG governor control switch allows the ‘operator to contra the engine rpm trom the panel. the engine 's equipped with glow plugs. they are Controliad by an ON/OFF heat switch (15). Ifthe engine has a fault, engine talurelight/roset sswiteh (11) wilh operate. ‘The lgat/switen (11) wil activate a shutdown relay to stop the engine. A Shutdown indicator (14) will also operate to show the cause ofthe fault. The shutdown indicators (14) {ive an indication that the fault was either oll pres Sure, water temperature or overspeed. A four shutdown indicator will show an overerank cond. tion. AD.C. ammeter and a governor contrel switch Will take the place of buttons (10 and 13) respec. tively itordered. The shutdown indicators have four ‘auxiliary contacts: one for each time ts shutown indicator operates. The contacts are connected toa emote annunciator panel orderea ‘The shutdown indicator lights can be checked for malfunction by depressing he shutdown indicators Replace burned ut bulbs immediately CONTROL PANEL 4. Panel lights. 2. Alternating current ammeter. 3. Frequency meter. 4. Alternating current voltme: ter. 5. Oil pressure gauge. 6. Water temperature ‘gauge. 7. ON/OFF toggle switch for panel lights. 8. Engine control switch. 9 Voltage level rheostat. 10. Button (direct current ammeter # ordered). 11. Ene ‘ine failure light/reset switch, 12. Ammeter selector Switch. 13.Button (governor control switch fengine is equipped with a PSG governor). 14. Shutdown indicator (oll pressure, wator temperature, ov speed and overcrank). 15. Button; heat switch (iso ‘equipped). 16. Panel; prealarm module (i 0 equip. ped).Starting The Engine 1 Perform all prestart checks outlined previously. 2, Place the CONTROL switch in the MANUAL. position to crank the engine. ‘3, When the engine staris and engine rpm reaches {600 rpm and the ol pressure registers 22 pst (1.5 kg/m) the Starting motor will automati- cally disconect from the start circuit 4. Stat the load. Regulate the engine speed with the RAISE- LOWER ewiteh tothe requited instrument pane! gauge readings. ‘Stopping The Engine 1 Remove the load. See GENERATOR SET OP. ERATION inetructions ifequipped with an elec inie set generator. 2, Reduce engine speed to low idle: Push down and hold the RAISE-LOWER switch until the en- {ine low idle speed Is reached 43. While the engine is idling, check the engine oi level Oi level must be maintained between the ‘ADO and FULL marks on the side of tha dipstick marked "CHECK WITH ENGINE RUNNING 4. Stop the engine. Solenoid Shutoft ‘a. Move the control switch to the STOP or OFF positions. (Do not confuse this with the PRAISE-LOWER™ switch) ON-OFF-STOP SWITCH is PSG Governor: . Move the shutotf lover forward, oF hold the lever up. depending upon Installation. Hold the lever in this position until the engine stops, 5. Fill the fuel tank. See the LUBRICATION AND MAINTENANCE section. 6. Drain the raw water system if below freezing temperatures are expecte 7. Observe the Service Meter reading. Perform the periodic maintenance as instructed in the LUBRICATION AND MAINTENANCE CHART. Emergency Shutoff Devices And Alarms Pails the shulelf devices, the conditions which cause ‘each control to function, and the resetting proce- ‘ure required to start your engine. CAUTION Always determine the cause of the shutdown, fand have the necessary repairs made before Starting the engine. See TROUBLESHOOTING GUIDE: Do not use an emergency shutoff device for @ normal stopping procedure, The operation of all electric shutoff controls is, similar: A critical operating condition actuates Switch which closes the citeult to the shutoff sol ‘enotd, whion stops the engine. The shutoff control may require resetting betore the engine can start High Water Temperature Shutoff “The shutott switch is located in the water temper- ature regulator housing, Excessive water tempera- ture closes the switch. No resetting procedure is required: As the coolant cools, the switch opens, CAUTION ‘The sensing element must be submerged in the ‘Coolant to operate. Coolant level must be main- tained in order for the shutoff to operate. Low Oil Pressure Shutoff Switch ‘CAUTION Does not protect system from rapid oll loss, such as line breakage.‘This device is usually mounted on the side ofthe ‘engine, and oil lines ave connected to the switch {Low ail pressure closes the switch Manually operated systems require resetting of this switch before starting. Automatic. starl-stop Systems vse a pressure switch which resets sel! To reset the switch. push the button until it latches. Alter the engine starts and develops oll pressure. the bution wil move tothe extended run hing posivon CAUTION ‘The button must be in the RUN position to pro- tect the engine, It the button remains in the reset position, the engine oll pump may not be developing normal ollipressure and checks shoul Overspeed Shutoff Switch (Electronic) ‘This switen senses engine speod. The contro! box is mounted on the engine block. Excessive on ine speed closes a circu! broaker. To reset tho Switch, push the reset button, CAUTION To provide overspeed protection there must be Fuel/Oil Pressure Switch ‘This switch is mounted in the tual manifold bet ‘naen the outlet side of the fuel Miter and the fuel injection pump. Low fuel pressure opens the switch and the electrical cireuit to either the shutoff so fold or the cirult between the alternator and the faternator regulator While the engine Is stopped ‘pen these circuits to prevent the battery trom De- ‘coming discharged, This switch can also be used with an electric gov ‘ernor, In this application, 01 pressure closes the ‘Switch o allow the electric governor fo control en- sine speed, ‘This switch does not require resetting Air Safety Shutoff Control The air shutotf control is an attachment to the safety shutolt devices, When an emergency condi tions occurs, the solenoid pushes the rack into the shutoff posiiion and a solenoid trips a butterfly Yalve, located in the inlet manifolg, o the closed position. The alr safoty shutot" contral mustboreset Before starting, ‘Alarm Switches: Alarm switches are set a a lass critical tempera ture, pressure, or level limit than the comparable shutoff eantrol. The purpose of the alarm switch is to warn the operator'an unsafe operating condition is starting to oceur, and that corrective measures Should be taken (o avoid possible damage to the tengine and/or a possible Shutdown of me engine caution Even though it could be hazardous to have the ‘engine stop unexpectantly, t the engine over- Speeds, it should be stopped Immediately 19When the preset temperature, prossure or fluid level occurs, eltheralightor an audible alarm willbe ‘energized. The light of alarm will continue to oper- fate unt the condition is corrected. When the condi- tion is corrected tne alarm will automatically rest fand tho ight will ture of. ‘CAUTION ‘The cause of the shutdown must be investigated and corrected before starling and operating the engine, Testing Indicator Lights Most control panels are equipped with a test switen. By turning the switch ON. al ofthe Indicator lights can be checked for proper operation. Test tho Indicator lights periogically, replace burned out light bults immediatly ‘Alarm Shutoff Switch {A switch may be installed in the alarm circuit for silencing the alarm while the engine is stopped for fepairs. Be sure the switch Is moved to the closed (Gn) position and the warning lights are lit before starting CAUTION Place switch in the closed (ON) position when the engine Is started, so the engine will be pro- tected Output Shaft Governor Operation When the load can overspeed the torque convor- tor output shatt, an output shaft governar should be installed. The output shalt govornor sa speediimit- Ing device which automatically adjusts engine gov- ‘omor setting according to toad requirement. Determining Cause Of ‘Shutdown CAUTION HW the engine has been shutdown by a safety device, da not start the engine and place it into Service without having the cause of the shut- down investigated and corrected. Low Oil Pressure Checks Ifthe iow oil pressure shutotf controlhas stopped the engine, make the following checks: 1. Check the water temperature gauge. Determine iftme engine was overneated. Check forexternal water leaks 20 A warninc jing water. Do not the hi cap 2. Check the oil level, Oil level must be between the ADD and FULL marks on the side of the Uipstick stamped CHECK WITH ENGINE STOPPED. 2.11 the oil level is below the AOD mark, check for oil spray and/or oll accumulations. it any fare found, have the necessary repairs made. Betore starting, add oll to the FULL mark 4, Reset the shutotl contro 5, Remove the load and start the engine at its slowest spec. Be prepared to shut the en fine down manually. 6. Be alert for unusual sounds or noises. If the fengine knocks, stop the engine immediately ‘and call your Caterpilar deaier 7.1f the engine blows excessive black exhaust for has excessive crankcase blow-by, the en- fine may need recanaiioning. Stop the en- ine and call your Caterpillar dealer 8.1f the engine runs satistactorily, observe the ‘oll pressure gauge. if satisfactory pressure is hot indicated, shut the engine down: call your Caterpillar dealer 9.1 proper oil pressure Is registered, check to see if the reset knob has moved to the un position. If the knob does not move, stop the Engine. Check the shutoff control, the ol line ‘nd ihe oll pressure gauge. Have necessary Fopairs mado. 10.1f the oll pressure gauge registers normal oll pressure, it the knob on the shutot! control moves t0 the run position, and if the engine operation is otherwise satisfactory, determine ifthe high water temperatura shutott may have shut down the engine High Water Temperature Checks—Engine Running +, Detormine if the load was too great for the engine! Reduce the load ang allow the engine to coo! while running 2.1 pressure steam or water leaks are visible, temove the load and stop the engine. Have ‘necessary repairs made. 3. Check for collapsing or deteriorated water hoses, Have repairs mado,4. Check for noisy water pump operation. Have nocessary repairs made 5. Refill the cooling system with a solution of water and permanent-lype antifreeze if below freezing temperatures are expected: or with a solution of approved water and Caterpillar Corrosion Inhibitor or equivalent, Foliow the Instructions on the container A wanninc High Water Temperature ‘Checks—Engine Stopped and Cold 1. Check coolant level. Determine if the cootant has proper anifreeze protection. A $0-50 solu- tion 6 permanent-type antireeze and approved ‘water willgive protection below 20°F (29°C) 2. Check tobe sure the raw water valve has been ‘opened. 3. Check engine room vents and/or louvers. Be sure the angina is receiving sulficient air 4. Be sure temperature regulators are operating at proper temperature range. 5. Inspect all water noses caretully for collapsing, external andinternal failures. Replace hoses as required, 6. Have the cooling system cleaned CAUTION If severe or prolonged 0 red, contact your fengine checked for po: ible damage. Emergency Stopping To stop in an emergency: Mechanical Governor Control Pll upward on the hand grip, and move the con: trol to the shutott position Woodward PSG Governor Move the lever forward against the stop; hold the lover unt the engine is stopped. Electric Shutoff Solenoid Push and hold the ON-OFF-STOP switch in the ‘STOP position unt the engine stops Air Controls Push and hold the ON:OFF-STOP switch in the ‘STOP position untirthe engine stops.MAINTENANCE RECOMMENDATIONS Cooling CAUTION Never add coolant to an overheated engine; allow the engine fo coal Hest. Check specie gravity of antifreeze solution tre- {quently in cold weather fo assure adequate protec- tion Coolant should be drained and replaced “Every 2000 Service Meter Units.” With additions of Caterpillar Cooling System inhibitor or the use of Coolant Conc- tioner Elemente a8 recommended, the drain period ‘canbe extended o""Every 4000 Service Meter Units.” All water is corrosive at engine operating tempers = The cooling system should be protected with Inhibitor at ll mes regardless of concentration of ‘nlilreeze. This can be done by maintaining 2 3% Concentration of guid Caterpilar Cooling System Inmbitor or by using Coolant Conaltioner Element Never use both the liquid cooling system inhib land coolant elements at the same time. Do not use Caterpillar Cooling System Inhibitor or Coolant Concitioner Elements with Dowtherm 208 Full-Fill Coolant Whenever ctaning and rafiing cooling system, a ways recheck the coolant level when he engine reaches ‘Normal operating tempersture Filing at over U.S. gallos (19 Mors) per minute can cause ar pockets inthe cooing system Premix antifreeze solution to provide protection to the lowest expected ambient temperature, Pure unciutes fnttroeze wil freeze a1 10"F (28°C). Operate with a thermostat in the cooing system all year-round. Cooing System problems can arise without 2 ihermastat. Electrical caurion When using jumper cables to start the engine, b Sure to connect in parallel POSITIVE (-) to POS! ive (/) and NEGATIVE (~) to NEGATIVE (~ ) ‘Scheduled Oil Sampling Use Scheduled Ol Sampling to monitor the engine's condition and maintenance requrements. Each of sample should be taken when the ois hot and well mived, to insure @ sample whichis representa tive ofthe ol nthe compartment CConsutt your Caterpilar dealer for complete informa: tion endassistance mestablehing a Scheudied Ol Sav ping program for your equipment Fuel CAUTION Fil tue! tank atthe end of each day of oper Grive out moisture laden air and to prevent conden- Sation: Do not fil the tank tothe brim. The fuel @x- ands when it gets warm and may overflow: ‘Water and sediment shoud be drained from the fue tank atthe start of]each shit or after the ful tank has been tiled and alowed to stand for 5 to 10 minutes Drain ful tank of moisture and sediment as required by prevaling conditions ‘ter changing fue titers, always bleas tel system to remove air bsobes fom system. Air intake Service air cleaners when RED band in indicator locks in vise positonSPECIFICATIONS LUBRICATION SPECIFICATIONS Crankcase Lubricating Oils Use ols which meet Engine Service Classification CD (MIL-L-2104) oF CD/TO-2. Tose are agdiive-ype ols that have been approved for use in Caterpllar Dose Engines. Consut the "EMA Lubreating Oils Data Book,” Form 'SEBUS939, for listing of CD ol brand. ‘The proper SAE grade of oo seletis determined by the ambien! temperature at which the engine is started and the maximum ambient temperature in which the engine wil be operating, See chert for recommended viscosity and temperature range To determine i the olin the crankeaso wil tow in cold weather. remove tol dipstick before staring! the ol ‘wil Tow aff the is fhid enough to eeulate propery Lubricating Grease Uso Multipurpose- ps 1¢ Grease (MPGM) which Contains 3-88 molybdenum disulfide contorming to MIL:M-7866, and a suitable corrosion inhibitor NLGINo. 2 Gradels eutable formost temperatures Use NUGI No. 0 of No. 1 Grade for extremely low temperature Recommended Lubricant Viscosities "Wer spetng tion SP [277 er oe Cal Wey Reason Gian avd Maviaranos Gace, Fors SED, Air Starting Motor Oiler: Use SAE 10W in all temperatures. Flywheel Clutch Bearing Reservoir: Use SAE 30 ‘nal temperatures, REFILL CAPACITIES WODEL | US.GAL | LITRE | IMP. GAL. 3406 72 | 455. 10 ae 6 305. 13FUEL SPECIFICATIONS. No, 2 tue! oil and No. 20 diesel fuel are recom: mended tor use In Caterpilar Diesel Engines, In Extreme caid tomporatures use No.1 fuel cil or No, 1D iasel fuel In selecting a fuel, note that distilate fuels are especially desirable because the {uel is heated toa Vaporous stale and condensed, thus eliminating all Sediment and residue, “There is considerable variation in the composi- tion of fuels aistabuted under the No.2 grade clas- Sieations, For desirable engine service its most important to give special attention to cetane no. later and sediment pour point. cloud point and Sulphur content USE THE LOWEST PRICE OIS- TIWUATE FUEL WHICH MEETS THE FOLLOWING REQUIREMENTS. Water ang Sediment 0.1% sogimont Cotane No. (PC Enaine) ‘35 minimum {Orengine) 40 minimum Pour Point {G'F (6°0) below ‘ambient temperature Cloud Point ‘No higher tran ‘biient temper ‘Adjust oll change period Gravity 33:40 AP. at 60'F (15.6°C) *See the topic SULPHUR CONTENT. Catane No: This s an indication of a fuet's igni- tion quality and should notbe loss than 35 or the PC tengine and 40 for the DI engine, For high altitude operation or cold weather starting, anigher cotano number fs required Water and Sediment: A good clean fue! will con: tain no more than 0 1% sediment and water. Dirty {els lead to early filter plugging and in aoaition can {esultin the formation of gums and resins reducing fter and engine ite Sulphur Content” Pour Point: The pour point of the fuel has no effect on engine performance, as tong as the fuel is fiuid enough to flow from the fuel tank the engine, ‘The pour point of the fuel should be al loast 10°F (G:C) Below tno lowest almospherle temperature at finich the engine must start and operate. Ine tremely cold temperatures it may be necessary to Use No. t fuel gilor No. 1D diesel fuel Cloud Point: Cloud point is the temperature at which wax crystals become visible and is general ‘above the pour point of the fuel. The cloud por Should be ho higher than the Towest atmospheric {emporatore at which the engine must start 1o keep the fuel iter elements from plugging with wax crys tals Sulfur Content: The percentage of sur inthe tut ‘wifatect he engine of recommendations. H the fel has ‘ver 0.5 sulfur content, he CD engine oil must have a “TBN of 20 mes the percentage of fuel sultur TEN as, Tneasuted by the ASTAID 2856 method). Your o supp shoul be able to furnish te corect ol Gravity: Gravity isthe measurement of heat units inacortainamount of fuel The heavier the fuel (the lower the number) the morefeat units per volume. fa fuel with ahigher A P.. gravity is used the power, roduced will be lower. Select fucis with the lower Keil gravity reacing ‘Some fuel specifications that meet the above re urements are ASTM—D396--No. 1 & No. 2fusle (burner fuels) ASTM 0975 -No. 1D &No.20 diese! vel ails BS2a69—Class At to Class A2 engine fuels Bs2869—Ciass C & Class D burner fuels DINS1601—Diesel fuel DINS1603—EL heating oil Authorizes dealers are familiar with fuels that have given good results in Caterpillar Diesel En- {ines and should be consulted regarding fuel use ‘then abnormal conditions occur COOLANT SPECIFICATIONS Water used in the jacket water cooling system should be clean, ang as free as possible trom scale {forming minerals or earrasive chemicals. Artificially Softened water should not be used. Treating the water with Caterpillar Coolant Inhibitor. or equiva- Tent will help prevent the formation of rust and pit- ting. It will also retard, and in some cases com- pletely siminate, mineral depasits in the engine. ‘The mast efficient and satislactory corrosion pro toction for the cooling systam is to maintain proper level of coolant innibter and antilteeze solution {ine use of auxiliary water filters Is rot recom mended. During freezing weather use the proper perma: rent type antireeze and water solution to prevent freezing Before placing the engine in operation, make sure a 3% concentration of Caterpillar Corrosion Inhibitor or equivalent hae been added to the coo! Ing system. This 3% concentration must be main: tained in cooling systems which ae filled with water land systems protected with etfiiene glycol anti feeze mixture, regardless of anlireeze concentra- ton WARNING ‘void contact with