CATERPILLAR” ss
‘September 1988
=
Operation &
Maintenances. :
So
3408 and 3412 nee ee
and EPG Diesel Engines
81Z1-UPQ\ 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
63408 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 ORAINTEMPERATURE
REGULATORS
.
a ’
GovenNgn AFTERGOOLER OIL FILL CaP
3412
INDUSTRIAL
ENGINE
CONTROL PANEL, AIR CLEANER
OW FILTERS
™/™ celenron —--PUELFILTERSSAFETY 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 RESETtthe 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 controlcaution
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.
u2. 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 apparent4, 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’) fryerAltitude 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 METERATTACHMENTS,
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 equipmentWoodward 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
19When 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 positonSPECIFICATIONS
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. 13FUEL 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