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Protection Devices
The Caterpillar generator mounted control panel is equipped with protection devices to protect the engine while cranking.Batteries
Lights or buttons may indicate if a fault has occurred in the battery charging system causing the battery to be either undercharged or overcharged.Overcranking
A timer allows the engine to crank either once for 30 seconds, or to crank through 5 ten-second cranking cycles (depending upon the device used) while unattended. If the engine does not start before the time elapsed, the fuel system will be shutoff and a light will indicate a starting failure. Engine Operation
Prealarm systems provide an audible and/or a visual indication for low oil pressure, high water temperature, low fuel supply or low jacket water temperature before the condition becomes critical. These alarms are self resetting when the condition is corrected. The engine may also be equipped with shutdown devices. If low oil pressure, high jacket water temperature or an engine overspeed condition occurs, the engine will be shutdown and a corresponding button or light will indicate the cause of the shutdown. These devices must be reset after repairs have been made and before starting. See the topic, EMERGENCY SHUTOFF DEVICES AND ALARMS.Generator set control panels should be equipped with an ammeter, a frequency meter and a voltmeter. Depending upon the type of operation, the panel may also be equipped with other meters and lights. Know these instruments and their normal readings. They will indicate how the generator set is performing.Shutting Down
A timer allows the transfer switch to transfer the load to another source and to continue engine running 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 order to ensure both proper lubrication of all engine parts and proper equipment operation if and when the standby unit is needed.Become familiar with all instructions included with the equipment.Woodward Governors
Woodward Governors are usually electrically operated from a control panel.Generator Set Control Panel
The generator set control panel is located on top of the generator and is equipped with the following controls and gauges:Panel lights (1) are controlled by an ON/OFF switch (7). An ammeter (2), frequency meter (3) and a voltmeter (4) show the output of the generator. Two gauges (5 and 6) show engine oil pressure and water temperature respectively. The ammeter selector switch (12) gives the operator a choice of which phase (T1, T2 or T3) of the generator output the ammeter (2) will show. Voltage level rheostat (9) takes the place of the voltage level rheostat in the generator regulator assembly.The engine control switch (8) has four positions; MANUAL, AUTOMATIC, STOP and OFF. Placing the control in the MANUAL position will start the engine and allow the operator to manually connect the generator to the load. If the unit is used for standby application with a remote transfer switch, the AUTOMATIC position is used. In this position the engine will automatically start and take up the load when commercial power has stopped. Placing the control in the STOP or OFF position will stop the engine. When in the AUTOMATIC or MANUAL position, the engine will automatically stop if the commercial power has started or if the engne has a fault.The PSG governor control switch allows the operator to control the engine rpm from the panel. If the engine is equipped with glow plugs, they are controlled by an ON/OFF heat switch (15).If the engine has a fault, engine failure light/reset switch (11) will operate. The light/switch (11) will activate a shutdown relay to stop the engine. A shutdown indicator (14) will also operate to show the cause of the fault. The shutdown indicators (14) give an indication that the fault was either oil pressure, water temperature or overspeed. A fourth shutdown indicator will show an overcrank condition. A D.C. ammeter and a governor control switch will take the place of buttons (10 and 13) respectively if ordered. The shutdown indicators have four auxiliary contacts; one for each time its shutdown indicator operates. The contacts are connected to a remote annunciator panel if ordered.The shutdown indicator lights can be checked for malfunction by depressing the shutdown indicators. Replace burned out bulbs immediately.
CONTROL PANEL
1. Panel lights. 2. Alternating current ammeter. 3. Frequency meter. 4. Alternating current voltmeter. 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 if ordered). 11. Engine failure light/reset switch. 12. Ammeter selector switch. 13. Button (governor control switch if engine is equipped with a PSG governor). 14. Shutdown indicator (oil pressure, water temperature, overspeed and overcrank). 15. Button; heat switch (if so equipped). 16. Panel; prealarm module (if so equipped).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 starts and engine rpm reaches 600 rpm and the oil pressure registers 22 psi (1.5 kg/cm2) the starting motor will automatically disconnect from the start circuit.4. Start the load.5. Regulate the engine speed with the RAISE-LOWER switch to the required instrument panel gauge readings.Stopping The Engine
1. Remove the load. See GENERATOR SET OPERATION instructions if equipped with an electric set generator.2. Reduce engine speed to low idle: Push down and hold the RAISE-LOWER switch until the engine low idle speed is reached.3. While the engine is idling, check the engine oil level. Oil level must be maintained between the ADD and FULL marks on the side of the dipstick marked "CHECK WITH ENGINE RUNNING".4. Stop the engine.Solenoid Shutoff
a. Move the control switch to the STOP or OFF positions. (Do not confuse this with the "RAISE-LOWER" switch.)
ON-OFF-STOP SWITCHPSG Governor:
b. Move the shutoff lever forward, or 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 expected.7. Observe the Service Meter reading. Perform the