Usage:
Pre-Start Checks And Procedures
- 1. Make a "walk-around" check of the engine and components. Correct minor adjustments before they develop into major repair jobs.
- 2. Check the crankcase oil level. Maintain the oil level between the ADD and FULL marks on the dipstick. See the LUBRICATION AND MAINTENANCE CHART for proper type and viscosity of oil to use.
D346, D348, D379 and D398 Engines are equipped with a combination sump pump and prelube hand pump. After a long shut down or after a filter and oil change, operate the hand pump to fill the oil passages in the lube system before starting. See the LUBRICATION AND MAINTENANCE PROCEDURES topic, Oil Filter Elements, before starting any one of these models of engines.
- 3. Check oil level(s) on driven equipment.
- 4. Check the fuel tank level, See the LUBRICATION AND MAINTENANCE CHART for proper fuel to use.
- 5. Check the engine jacket coolant level. Maintain coolant level to the base of the fill pipe. See the LUBRICATION AND MAINTENANCE CHART for proper make-up coolant to use.
- 6. Open the raw water valve (if so equipped) on the engine jacket heat exchanger system.
- 7. Reset shutoff devices. See the topic, ATTACHMENTS, Emergency Shutoff Devices and Alarms.
- 8. Open the fuel supply valve.
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The fuel return line must be open to prevent engine damage. |
- 9. If air has entered the fuel system, prime the fuel system. See the LUBRICATION AND MAINTENANCE PROCEDURES topic, Priming the Fuel System.
PRIMING PUMP ON 6 CYLINDER ENGINE
PRIMING PUMP ON V-ENGINE
- 10. Disconnect any battery charger which is not protected against starting motor drain.
- 11. Disengage the clutch, or open the circuit breaker on an electric set.
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Do not start an engine under load. |
- 12. Move the governor control lever to half engine speed position or to speed limiter stop.
- 13. Prime the raw water pump if necessary. (Only water pumps equipped with a water reservoir and fill plug require priming.)
If the raw water pump is of the type shown below, the pump is a self priming pump. This pump does not have a priming chamber or fill plug.
SELF PRIMING RAW WATER PUMP
Priming The Raw Water Pump:
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The priming chamber must be filled with water before starting the engine to prevent pump or engine damage. After the engine is started, increase engine speed immediately to obtain and maintain system flow. |
- 1. Carefully loosen the fill plug. If water is present immediately tighten the plug; the pump is full.
- 2. If water is not present, pour approximately two gallons (7.5 liters) (1.5 Imp. Gals.), or until overflow occurs, into the fill hole.
- 3. Install the fill plug.
FILL PLUG
- 4. Start the engine at fast enough speed to obtain the normal water flow from the overboard raw water discharge or water cooled exhaust pipe.
If the proper flow is not observed, stop the engine and repeat this procedure. If the pump does not hold water in the priming chamber, the water pump seals should be replaced.
Starting The Engine
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Do not engage the starter when the flywheel is moving. |
Electric Starting:
- 1. Use starting aids if required. See the topic, GENERAL, Cold Weather Starting.
NOTE: D349 and D399 Engines:
When the START switch is turned to the START position, a prelube pump driven by an electric motor will pressurize the engine lubrication system with oil. The crankcase oil will develop sufficient pressure before closing a switch which will energize the starting motor(s). The starting motor(s) will then crank the engine. After the engine starts, the starter switch is released, the prelube pump stops and the engine oil pump continues lubricating the lube system.
Prelube time will vary with the temperature of the oil. Hot oil will require more time to attain oil pressure before the engine can crank than will cold oil.
- 2. Push the START button; or turn the HEAT-START switch to the START position, depending upon the control the engine has. Release the control as soon as the engine starts.
For electric sets, place the AUTO-MAN switch in the MAN position; place the ON-OFF-STOP switch in the ON position to crank the engine. As soon as the engine starts, move the switch to the OFF position. (The STOP position is used to stop the diesel engine.)
If the engine fails to start in a few 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 starter to cool for 2 minutes before repeating the starting procedure.
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Prolonged cranking at low oil pressure can energize the mechanical safety shutoff which is used on 5.4" bore and larger engines. If the reset lever is in the shutoff position, reset the mechanical shutoff control. |
RESETTING MECHANICAL SHUTOFF CONTROL
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NEVER use starting aids when the engine is warm and running. |
If the engine is equipped with either a Woodward PSG or UG8 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. Check the oil level in the oiler jar. Keep jar at least half full. Add oil if necessary. See the LUBRICATION AND MAINTENANCE CHART for the proper oil to use.
- 4. Pull the air valve upward to crank the engine. As soon as the engine starts, release the valve.
The engine governor may be controlled by an air regulator valve. One control panel can regulate several synchronous operating engines.
GOVERNOR AIR REGULATOR VALVES
After Engine Starts
- 1. Observe the oil pressure gauge immediately after starting.
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If oil pressure is not indicated, stop the engine and have necessary repairs made. |
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Stop the engine if any repairs or adjustments are required. Do not work on machinery while the engine is running. |
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- 2. Move the governor control to low idle, allow the engine to warm (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.
- 3. Check the engine gauges and equipment.
- 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. Check the engine gauges.
- 2. Move the governor control to high idle (full load) position.
- 3. Engage the load.
Engine Operation
Instrument Panel Gauges
After the engine starts, and at frequent intervals while the engine is operating, the gauges should be observed. Determine the normal reading for each gauge. Investigate the cause whenever there is a significant change in the reading.
Your engine may be equipped with calibrated gauges. Periodic monitoring and recording of the gauge readings will provide a history of the engine's performance. As certain conditions develop, a change in the readings will indicate a problem is developing. The necessary repairs can be scheduled before the failure and the resulting unexpected downtime occurs.
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If a large quantity of oil or water is lost in a short period of time - as when the line ruptures - manually shut down the engine immediately. If the oil or water levels are allowed to go below the ADD levels, the safety shutoff devices will not protect your engine. |
Tachometer:
The tachometer indicates engine RPM. When the governor control lever is moved to the full speed position without load, the engine is running at high idle. When the governor control lever is moved to the full speed position and load is applied, the engine will slow slightly to full load speed. The high idle RPM and the full load RPM are stamped on the engine's altitude information plate. The engine can be operated between these two speed limits for long periods of time without shortening engine life.
If the engine speed drops below full load speed with the governor control lever positioned in the full load position, the engine will be operating in a lug condition; see the topic, LUGGING.
Engine Oil Pressure:
Oil pressure will be greatest after starting a cold engine. Oil pressure will decrease as the engine warms while idling. As the engine speed is increased to full load speed, oil pressure will increase into the NORMAL range and stabilize.
If the gauge reading fluctuates:
- 1. Remove the load.
- 2. Reduce engine speed to low idle.
- 3. Check the oil level. Maintain the oil level between the ADD and FULL mark on the dipstick. If the reading continues to fluctuate, call your Caterpillar dealer.
Engine Jacket Water Temperature:
The water temperature reading may vary according to load, but should never exceed the boiling temperature for the pressurized system being used.
If the engine operates with the indicator in the HOT range and steam becomes apparent:
- 1. Reduce the load and speed.
- 2. Inspect for pressure steam or water leaks. Determine if the engine must be shut down immediately; or if the engine can be safely cooled by reducing the load.
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Do not add cold water to a hot engine: Cracking of engine components may occur. Allow the engine to cool, then add coolant. |
The engine operating temperature should be approximately 200°F (95°C). If the temperature gauge reading registers in, or near, the cold range - approximately 170°F (75°C):
- 1. Check the temperature regulators for proper temperature range; and replace if necessary.
- 2. Check the water temperature gauge for accuracy.
- 3. Determine if the radiator is overcooled, and if radiator louvers are required.
Fuel Pressure:
The fuel filter gauge indicates pressure of the filtered fuel. If the fuel filter gauge registers in the OUT range, clean the primary fuel filter if so equipped, and install new fuel filter elements. See the LUBRICATION AND MAINTENANCE PROCEDURES topic, Fuel Filters.
In cold weather, paraffin crystals can form in the fuel and plug the fuel filter. If this occurs, a fuel that has a lower CLOUD POINT must be used. See your fuel distributor.
Ammeter:
The ammeter should indicate just to the right of zero (in the "+" range) when the engine is warm and running at rated speed. If the gauge registers to the left (in the "-" range) as the engine speed is increased, determine and correct the cause.
Engine Oil Temperature:
The purpose of the oil is to lubricate all moving parts inside the engine, and to cool (remove the heat from) the pistons, liners and bearings. The lube oil cooler transfers the heat in the oil to the engine water. If the radiator cannot expel the necessary heat from the water, the engine oil cannot be properly cooled. Above normal oil temperature indicates a heat problem has occurred with the cooling system and/or engine, and a problem can occur with cylinder heads, liners, pistons or bearings.
Exhaust Temperature Gauge:
This gauge measures exhaust gas temperature. On V-engines, temperature readings are taken from both the left and right banks. If the exhaust temperature increases:
- 1. Check the load on the engine. Running the engine below rated full speed RPM at full load causes excessive exhaust temperatures, overheating of the engine's cooling system, and possible engine damage. See the topic, LUGGING. Reduce the load if necessary.
- 2. Check the air cleaner service indicator or air cleaner pressure gauge; the air cleaner element may be plugged. Stop the engine and service the air cleaner if necessary.
- 3. After the engine has been stopped, check the tightness of the inlet and exhaust manifold bolts. These bolts must be tight to prevent air leakage.
Inlet Air Temperature Gauge:
As the inlet air increases in temperature, the inlet air expands. As the air expands, less fuel is burned in the cylinders; and less horsepower is developed. As a result, at full load position with a normal load, the engine may be overloaded.
If excessive air inlet temperature occurs:
- 1. Check the water temperature gauge. Determine if the engine jacket water system is able to cool the engine properly.
- 2. Listen for unusual water pump noises. Be sure the V-belts are properly operating the water pump. Check belt adjustment when the engine is stopped.
- 3. Reduce the load if necessary.
- 4. Determine if there is an adequate supply of cool air to the engine air inlet. Be sure hot air from another engine or exhaust system isn't being drawn into the air cleaner or radiator.
Air Cleaner Service Indicator:
This gauge measures the difference of air pressure between the inlet side (dirty side) and the engine side (clean side) of the air filter element. As the element becomes plugged, the gauge indicator reading will increase when the gauge indicates the filter element is dirty, service the air cleaner when the engine is stopped; see the LUBRICATION AND MAINTENANCE PROCEDURES topic, Air Cleaner Service Indicator.
Oil Filter Service Indicator:
This gauge measures the difference of oil pressure between the inlet side (dirty outer side) and the outlet side (inner diameter side) of the oil filter elements. As the element becomes plugged, the difference of pressure between the inner and outer sides of the element will increase. Then the gauge reading indicates the filter element is almost plugged, change filter elements when the engine is stopped. See the LUBRICATION AND MAINTENANCE PROCEDURES topic, Oil Filter Service Indicator.
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Shut the engine down if work on, or around, the engine is required. |
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Observe all gauge readings periodically. Know the normal indication of each gauge. If there is a sudden change, investigate the cause immediately, and make repairs if needed.
Indicators
Air Cleaner Service Indicator:
Periodically check the air cleaner service indicator. If the red piston remains in the visible position, the air cleaner element requires servicing. See the LUBRICATION AND MAINTENANCE PROCEDURES topic, Air Cleaner Service Indicator.
Oil Filter Change Indicator:
On Vee engines, periodically check the oil filter change indicator. When the red piston has raised half way in the clear plastic window, change the oil filter elements.
NOTE: The engine is shipped with an opaque covering over the clear plastic window. Be sure this covering is removed.
Engine Horsepower Ratings
There are two general horsepower ratings for industrial engines and two for electric set engines. They are: intermittent or continuous; standby or prime. These ratings are the recommended engine horsepower settings based upon load requirements and type of operation.
Continuous and Prime Ratings:
Horsepower settings for these two ratings allow the engine to operate a constant load at full speed for long periods of time without shortening engine life.
Intermittent Rating:
Horsepower settings for this rating requires the engine to be operated at full load and speed for periods up to an hour, followed by an equal time of operation at reduced load and speed.
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If an engine is set for an intermittent rating and is operated for long periods of time at constant full load, the engine life will be shortened. |
Standby Rating:
Horsepower settings for this rating allows the electric set to supply rated power for a period of time, after which the engine is stopped.
Contact your Caterpillar dealer if there is doubt as to which rating the engine has.
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Horsepower settings should only be done by authorized personnel. |
Full Load Operation:
The governor control lever should remain in the full governed position while powering full load.
Reduced Load Operation:
If the load varies, or is cyclic, the governor usually will adjust the engine speed as required. If a slower constant speed is desired, move the governor control lever to desired speed position.
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Be sure to increase engine speed before increasing the load. |
No Load Operation:
If the load is temporarily removed, engine speed may be reduced by manually moving the governor control. However, the engine may be operated at high idle without causing shortened engine life.
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Never operate an electric set below 2/3 full load RPM: Overheating and possible damage could occur to the generator below this RPM. |
Lugging:
Lugging can occur at any engine speed and with most applications. Lugging occurs whenever engine speed decreases below full load speed with the governor control at full load speed position; or when an increase in governor control setting will not increase engine speed.
Lugging can damage an engine: Maximum fuel is injected at reduced engine speed; and the water pump, oil pump and fan run slower than required to cool the engine. Certain engine areas will become extremely hot and failure of parts could occur.
Because maximum engine torque is developed, lugging - if properly used - can be useful. Lugging will not cause damage if the lugging period is short in duration, and if the engine is allowed to cool.
An example of lugging could be a shovel digging through rock and clay. As the bucket is raised, the governor increases engine speed. If the bucket becomes lodged on a rock, the engine speed will drop, but the fuel consumption rate, exhaust temperatures and torque will increase. The operator must determine if either the rock can be loosened in a short period of time, or the bucket should be repositioned and the load reduced. If the rock is to be loosened while in lug condition, the engine must be able to cool in the time it takes to finish the cut, swing and dump the load, and return to the next load.
The temperature gauges for the engine should be closely watched during periods of lugging. If the temperature readings increase, the load must be reduced.
Output Shaft Governor Operation:
When the load can overspeed the torque converter output shaft, an output shaft governor should be installed. The output shaft governor is a speed limiting device which eliminates having to frequently change engine speed by using the engine governor control lever.
The output shaft governor is installed on the torque converter output shaft and is connected to the engine governor through a hydraulic servo mechanism. When under load, the engine governor regulates engine speed. If the load is removed and the torque converter output shaft governor will operate the engine governor so as to reduce the speed of the engine. When the output shaft speed returns to normal operating speed, the engine governor maintains full load engine speed.
Electric Set Operation
See the ELECTRIC SET OPERATION INSTRUCTIONS.
Stopping
- 1. Flywheel clutch operation: Quickly pull the clutch lever to the released position. For electric set operation, see the ELECTRIC SET OPERATION instructions. For Woodward Governor operation, see the topic, WOODWARD GOVERNORS, Stopping the Engine.
- 2. Reduce engine speed to half speed. Run for 5 minutes to cool engine.
- 3. Reduce engine speed to low idle.
- 4. Check the crankcase oil level while the engine is idling. Maintain the oil level between the ADD and FULL marks on the side of the dipstick stamped CHECK WITH ENGINE RUNNING. See the LUBRICATION AND MAINTENANCE PROCEDURES topic, Diesel Engine Lube Oil.
- 5. Stop the engine by either moving the engine governor control to the shutoff position, or by pushing and holding the ON-OFF-STOP switch until the engine stops; depending upon how your engine is equipped.
After Stopping Checks And Procedures
- 1. Fill the fuel tank. See the LUBRICATION AND MAINTENANCE PROCEDURES topic, Fuel Tank.
- 2. Drain the raw water system if below freezing temperatures are expected; see Section D: Draining Raw Water System.
- 3. If below freezing temperatures are expected, allow the engine jacket water expansion tank to cool; then check the coolant for proper antifreeze protection. Add permanent type antifreeze if required. See the LUBRICATION AND MAINTENANCE PROCEDURES topic, Cooling System.
- 4. Repair any leaks, correct major adjustments, tighten loose bolts, etc.
- 5. Observe the Service Meter reading. Perform the periodic maintenance as instructed in the LUBRICATION AND MAINTENANCE CHART.
SERVICE METER ON 6 CYLINDER ENGINE
SERVICE METER ON V-ENGINE
- 6. Perform the required maintenance on all other equipment; see the equipment manufacturer's instructions.