3408 AND 3412 INDUSTRIAL AND EPG DIESEL ENGINES Caterpillar

Electric Starting

1. Move the governor control lever to approximate half engine speed position.

2. Use starting aids if required. See the topic, STARTING AIDS.

3. Push the START button; or turn the HEATSTART switch to the START position, depending upon the control the engine has. Release the control as soon as the engine starts.

For generator sets, place the AUTO-MAN switch in the MAN position to crank the engine. As soon as the engine starts, and the engine speed reaches 600 rpm and oil pressure is approximately 22 psi (1.5 kg/cm²), the starter motor will disconnect from the circuit. (The STOP position is used to stop the diesel engine.)

If the engine fails to start in 10 seconds, move the governor control lever to the fuel off position, then continue to crank for 10 seconds. This will clear the cylinders of unburned fuel.

If the engine fails to start after 30 seconds of cranking, allow the engine to cool for 2 minutes before repeating the starting procedure.

If the engine is equipped with a Woodward PSG Governor, see the topic, WOODWARD GOVERNORS for the governor operation instructions.

Air Starting

1. Open and close the bleed valve on the bottom of the air tank to drain condensation and oil carryover.

2. Check the air supply pressure. The air start must have 100 PSI (7 kg/cm²) to operate properly.

3. Keep oil level, in the oiler jar, at least half full. Add oil if necessary. See the LUBRICATION AND MAINTENANCE PROCEDURES, Filling Motor Oiler.

4. Push the air valve control in to crank the engine. As soon as the engine starts, release the valve.

Starting Aids

Many variables can affect cold weather starting. Use the chart as a guide, but actual experience will determine when aids are necessary and how they should be used. Your engine may have one or more of the following starting aids:

Glow Plugs (Precombustion Chamber Engines Only)

1. Push in and turn the HEAT-START switch to the HEAT position and hold for the approximate heating time shown in the STARTING AID CHART.

2. Turn the HEAT-START switch to the START position.

3. If necessary, when the engine starts turn the HEAT-START switch to the HEAT position. Hold the switch in this position until the engine is running smoothly.

4. Release the switch.

Starting Fluid

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Starting fluid is volatile and must be stored away from heat and direct sunlight. If an aerosol container is used, follow the instructions on the container.

1. Heat the glow plugs (If equipped) for the approximate heating time shown in the STARTING AID CHART.

2. Turn the HEAT-START switch to START position. While cranking, spray starting fluid into the air inlet or air cleaner for approximately 1 second.

3. If necessary, repeat the procedure.

4. After the engine starts, it may be necessary to return the HEAT-START switch to the HEAT position until the engine runs smoothly.

Jacket Water Heater (Attachment)

In very low temperatures, the lubricating oil must be warmed to allow starting. A jacket water heater can maintain the water temperature at approximately 90°F (32°C). The warm water will keep the oil in the upper part of the engine block warm enough to flow when starting.

Dipstick Oil Heater

Generator

Starting Single Unit Operation

1. Make all preliminary engine starting checks.

2. Be sure the main or line circuit breaker is open.

3. Start the engine and allow it to warm up.

4. Close the main circuit breaker.

5. Apply the load. Do not try to apply full load in one move, rather apply the load in increments to maintain system frequency at a constant level.

Standby Generator Sets

Most standby units are automatic. They start, pickup the load, run and stop without an operator in attendance. Standby units can not change the governor control setting automatically. The throttle must be preset for the proper operation of that unit. Whenever the set is exercised or operated manually, be sure the throttle setting is correct for automatic operation. Check all switches to see they are properly set: Start Selector Switch in AUTOMATIC position and any Emergency Stop Switches in RUN position.

Paralleling

Units may be paralleled at no load or paralleled with units under load. To parallel two or more units the following conditions must be met:

1. Same phase rotation.

2. Same voltage level.

3. Same voltage droop.

4. Same frequency.

5. Voltages must be in phase.

The first condition is established by "phased" wiring connections of initial installation.

The second and third conditions are usually established by semi-permanent adjustments to the generator controls.

The fourth and fifth conditions are under control of the operation in manual paralleling systems (or under automatic control in automatic paralleling systems).

To Parallel

1. Start the unit to be paralleled.

2. Turn the synchronizer lights on.

3. After the engine has run long enough to warm up, bring it up to synchronous speed (the same frequency as the unit on the line). The synchronizing lights will begin to blink.

4. Using the governor control, adjust the speed until the lights blink 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.

NOTE: The frequency of the incoming unit should be slightly greater than the line frequency. This will allow the incoming unit to assume some of the load rather than add to the system load.

Load Division

Once two units have been paralleled, their share of the load is determined by the governor control setting. If two units of the same capacity and the same governor characteristics have the same governor control setting they will share the load equally.

To add load to one engine, slowly increase the governor control setting of that engine, or slowly decrease the governor control setting of the engine giving up load.

Load Transfer

At this point open the circuit breaker to remove any remaining load on the outgoing generator set.

NOTE: The total load must not exceed the capacity of the engine, or the engine will be overloaded.

1. Increase the governor speed control of the unit to the high idle position to assume the load.

2. Reduce the governor speed control of the outgoing unit until the generator amperage is at a minimum. (The amperage may never be zero due to circulating currents.) At this point transfer the load.

Stopping

To remove a generator from the line do the following:

1. Check the load. It must be less than the rated capacity of remaining units.

NOTE: If removing a generator from the line will cause overloading of the remaining units, remove some of the load first.

2. Be sure the NEUTRAL of one of the remaining units is grounded.

3. Remove the load from the outgoing unit as described in Load Division and Load Transfer.

4. Open the circuit breaker.

5. Run the engine for 5 minutes without a load, to allow it to cool. Stop the engine.

After Engine Starts

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Stop the engine if any repairs or adjustments are required. Do not work on machinery while the engine is running.

1. Observe the oil pressure gauge immediately after starting.

2. Move the governor control to low idle, allow the engine to reach normal operating range (usually several minutes). Make another "walk-around" inspection for leaks, etc.

Starting The Load

Driven Equipment without Load

To engage the driven equipment before applying load:

1. Move the governor control to 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 control to high idle (full load) 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 (full load) position.

3. Engage the load.