3608 Engine Caterpillar

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Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside.

Do not start the engine or move any of the controls if there is a "DO NOT OPERATE" warning tag or similar warning tag attached to the start switch or to the controls.

Ensure that no one will be endangered before the engine is started and when the engine is started.

Perform the procedures that are described in this Operation and Maintenance Manual, "Before Starting Engine" topic (Operation Section).

1. Ensure that the driven equipment is disengaged.
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   Illustration 1	g00748458
   (1) "OFF/RESET, LOCAL, and REMOTE" switch (2) "PRELUBE/START" switch (3) "FUEL ON/OFF" switch (4) "PRELUBE" indicator

2. Turn "OFF/RESET, LOCAL, and REMOTE" switch (1) to the "LOCAL" position.
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   NOTICE
   The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing surfaces.

3. Turn "PRELUBE/START" switch (2) to the "PRELUBE" position. Allow the prelube pump to operate.

4. Turn "FUEL ON/OFF" switch (3) to the "ON" position.
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   Illustration 2	g00275016
   Fuel priming pump

5. Turn the handle of the fuel priming pump clockwise in order to prime the fuel system. Turn the handle until a resistance to the fuel flow is felt. If the engine is equipped with an electric fuel priming pump, activate the electric fuel priming pump. Operate the electric fuel priming pump until fuel pressure is indicated on the fuel pressure gauge.

6. When "PRELUBE" indicator lamp (4) illuminates, start the engine at low idle rpm with no load. Turn "PRELUBE/START" switch (2) to the "START" position. When 180 to 200 rpm is achieved, release the "PRELUBE/START" switch. The starting motors will disengage when the engine reaches 170 rpm.

   Note: If the engine does not start after ten seconds, turn the "FUEL ON/OFF" switch to the "OFF"position. Purge the cylinders. See this Operation and Maintenance Manual, "Before Starting Engine" topic (Operation Section).

7. Immediately after engine start-up, ensure that oil pressure and fuel pressure are indicated on the gauges. Allow the engine to idle for three to five minutes. The engine speed should stabilize at low idle rpm. Check all of the pressure gauges. Inspect the engine for leaks and listen for unusual noises. When all systems are normal, the rpm may be increased.

Ensure that the oil pressure and the fuel pressure are in the normal ranges. After the engine has started and the warm-up is complete, the engine can be operated at low rpm and low load. The engine will reach normal operating temperature faster if the engine is operated at low rpm and with a low power demand. This procedure is more effective than idling the engine with no load. The engine should reach normal operating temperature in a few minutes.

Starting the Engine After an Overhaul or Major Repair

Use the following guidelines for operation and maintenance after an overhaul or a major repair. This will ensure that the engine is functioning correctly. The procedure for start-up requires approximately one hour and 45 minutes.

1. Perform the procedures that are described in this Operation and Maintenance Manual, "Before Starting Engine" topic (Operation Section).

2. Operate the jacket water heaters and the prelube pump. Allow the lubricating oil to circulate for 1/2 hour.

3. During prelube pump operation, use the barring device to rotate the crankshaft for a minimum of four revolutions.

4. Start the engine. Operate the engine at low idle rpm for 15 minutes. Allow the engine temperature to rise. Check for the correct temperatures and pressures. Inspect the installation for leaks.

5. Do not apply the load. Increase the engine rpm to high idle rpm for 5 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

6. Shut off the engine. Remove the side covers. Measure the temperature of the bearings with a 123-6700 Laser Infrared Thermometer. Ensure that the large end of the connecting rod bearings move freely. Visually inspect the piston skirts, cylinder liners, and bearings for any abnormal signs such as flaking and/or scuffing. If the appearance of the components is satisfactory, install the side covers.

7. Start the engine. Operate the engine at low idle rpm for five minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

8. The temperatures will not stabilize for some time because the engine will be operating without a load. To warm the engine up to “normal” operating temperature, increase the engine rpm to high idle rpm for 5 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

   Note: Monitor the cooling system temperatures in order to ensure that the water to the engine is being properly cooled. Observe the water temperature of the aftercooler and oil cooler system. The temperature should not exceed 50 °C (122 °F).

9. Apply 25 percent of the rated load. Operate the engine with this load for 15 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

10. Increase the load to 50 percent of the rated load. Operate the engine with this load for 15 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

11. Increase the load to the full rated load. Operate the engine with this load for 15 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

    If all of the temperatures and the pressures are acceptable, the engine can be returned service.

Maintenance Procedures After an Overhaul or Major Repair

After the initial start-up, perform the maintenance that is listed in Table 1. See the maintenance procedures that are in this Operation and Maintenance Manual (Maintenance Section).