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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. |
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Initial Inspection
Perform the required daily maintenance and other periodic maintenance before you start the engine. Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the Operation and Maintenance Manual, "Walk-Around Inspection" topic (Maintenance Section) for more information.
- For the maximum service life of the engine, make a thorough inspection before you start the engine. Look for the following items: oil leaks, coolant leaks, loose bolts and trash buildup. Remove trash buildup and arrange for repairs, as needed.
- Inspect the cooling system hoses for cracks and for loose clamps.
- Inspect the alternator and accessory drive belts for cracks, breaks, and other damage.
- Inspect the wiring for loose connections and for worn wires or frayed wires.
- Check the fuel supply. Drain water from the water separator (if equipped). Open the fuel supply valve.
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All valves in the fuel return line must be open before and during engine operation to help prevent high fuel pressure. High fuel pressure may cause filter housing failure or other damage. |
- Do not start the engine or do not 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 the areas around the rotating parts are clear.
- All of the guards must be put in place. Check for damaged guards or for missing guards. Repair any damaged guards. Replace damaged guards and/or missing guards.
- Disconnect any battery chargers that are not protected against the high current drain that is created when the electric starting motor (if equipped) is engaged. Check electrical cables and check the battery for poor connections and for corrosion.
- Reset all of the shutoffs or alarm components.
- Check the engine lubrication oil level. Maintain the oil level between the "ADD" mark and the "FULL" mark on the oil level gauge.
- Check the coolant level. Observe the coolant level in the coolant recovery tank (if equipped). Maintain the coolant level to the "FULL" mark on the coolant recovery tank.
- If the engine is not equipped with a coolant recovery tank maintain the coolant level within 13 mm (.5 inch) of the bottom of the filler pipe. If the engine is equipped with a sight glass, maintain the coolant level in the sight glass.
- Observe the air cleaner service indicator (if equipped). Service the air cleaner when the yellow diaphragm enters the red zone, or when the red piston locks in the visible position.
- Ensure that any driven equipment has been disengaged. Remove any electrical loads.
Cold Weather Starting
Starting the engine and operation in cold weather is dependent on the type of fuel that is used, the oil viscosity, and other optional starting aids. For more information, refer to the Operation and Maintenance Manual, "Cold Weather Operation" topic (Operation Section).
Air Inlet Heater
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DO NOT USE ETHER (starting fluids) unless specifically instructed to do so. If the engine is equipped with an Air Inlet Heater (electrically or fuel ignited manifold heater), DO NOT use ether (starting fluids) at any time. The use could result in engine damage and/or personal injury. |
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Note: There will be an indicator lamp on the control panel that is marked "AIR INLET HEATER".
For detailed information on the operation of the Air Inlet Heater, refer to Troubleshooting Manual, "Air Inlet Heater Circuit - Test".
Refer to the Owner's Manual of the OEM for your type of controls. Use the following procedure to start the engine.
- Place the transmission in NEUTRAL. Disengage the flywheel clutch in order to allow the engine to start faster. This also reduces the draining of the battery.
- Turn the ignition switch to the ON position.
The "WARNING and DIAGNOSTIC" lamp (if equipped) will flash while the engine is cranking. The lamp should turn off after proper engine oil pressure is achieved. If the lamp fails to flash, notify your authorized Caterpillar dealer. If the lamp continues to flash, the Electronic Control Module (ECM) has detected a problem in the system. For more information, refer to the Operation and Maintenance Manual, "Diagnostic Flash Code Retrival" (Operation Section).
- Push the start button or turn the ignition switch to the START position in order to crank the engine.
Do not push down or hold the throttle down while the engine is cranked. The system will automatically provide the correct amount of fuel that is needed to start the engine.
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Do not engage the starting motor when flywheel is turning. Do not start the engine under load. If the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again. |
- If the engine fails to start within 30 seconds, release the start button, or the ignition switch. Wait for two minutes in order to allow the starting motor to cool before attempting to start the engine again.
Note: The "WARNING and DIAGNOSTIC" lamps (if equipped) may come on after the engine is started. If this occurs, the ECM has detected a problem with the system. For more information, refer to the Operation and Maintenance Manual, "Diagnostic Flash Code Retrival" (Operation Section) .
- Allow the engine to idle for approximately three minutes. Idle the engine until the water temperature gauge has begun to rise. Check all gauges during the warm-up period.
Note: Oil pressures and fuel pressures should be in the normal range on the instrument panel. Engines that are equipped with "WARNING" lamps do not have an operating range. The "WARNING and DIAGNOSTIC" lamp (if equipped) will flash while the engine is cranking. The lamp should turn off after proper engine oil pressure or fuel pressure is achieved. Do not apply a load to the engine or increase engine rpm until the oil pressure gauge indicates at least normal pressure. Inspect the engine for leaks and/or unusual noises.
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Oil pressure should rise within 15 seconds after the engine starts. Do not increase engine rpm until the oil pressure gauge indicates normal. If oil pressure is not indicated on the gauge within 15 seconds, DO NOT operate the engine. STOP the engine, investigate and correct the cause. |
After the engine has started, the air inlet heater may continue to operate in a "Continuous" mode and/or in an "Intermittent" mode. The air inlet heater will turn OFF when the sum of the coolant temperature and the air inlet temperature exceeds 35 °C or 127 °F.
If the engine is operated with a low load, the engine will reach normal operating temperature sooner than idling the engine with no load. When the engine is idled in cold weather, increase the engine rpm to approximately 1000 to 1200 rpm. This will warm up the engine more quickly. Do not exceed the recommended rpm in order to increase the speed of the warm-up. Limit unnecessary idle time to ten minutes.
Ether Injection System
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Personal injury or property damage can result from alcohol or starting fluids. Alcohol or starting fluids are highly flammable and toxic and if improperly stored could result in injury or property damage. |
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DO NOT USE ETHER (starting fluids) unless specifically instructed to do so. If the engine is equipped with an Air Inlet Heater (electrically or fuel ignited manifold heater), DO NOT use ether (starting fluids) at any time. The use could result in engine damage and/or personal injury. |
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The optional automatic ether injection system is the only starting fluid system that is recommended. Excessive starting fluid can cause piston and ring damage. Use starting fluid for cold starting purposes only. |
Startability will be improved at temperatures below 0 °C (32 °F) by the use of a continuous flow injection system and/or a jacket water heater. This will help alleviate white smoke and misfire during start-up in cold weather. Consult your Caterpillar dealer for other means of improving startability in cold temperatures.
The Continuous Flow Ether is an optional ether starting aid that is available for use with the engine. The system injects ether into the air inlet manifold after the air inlet heater. Extensive damage to the engine could occur if ether is directed at the air inlet heater during activation.
Continuous Flow Ether Control has two modes, the Manual Mode and the Automatic Mode.
Manual Mode:
In the manual mode, as the ether switch is depressed there is a predetermined amount of ether that is injected. The manual mode is disabled, if the engine speed is more than 200 rpm above the low idle, if the ambient air temperature is above 0° C (32° F), or if the coolant temperature is above 0° C 32° F.
If the engine is equipped with the ether injection system, perform the following procedure for the manual mode:
- Crank the engine.
- Depress the ether switch.
- Hold the ether switch for three seconds.
- Release the ether switch.
Automatic Mode:
When the ether switch is placed in the automatic mode, the ether injection system operates automatically, when the engine is cranking. The automatic mode is enabled if the engine has been idling for less than 10 seconds, if the engine speed is less than 200 rpm above low idle, if the ambient air temperature is below 0° C (32° F), and if the coolant temperature is below 0° (32° F).
Additional injections may be necessary in order to start the engine. Additional injections may be necessary in order to achieve the low idle speed. For additional information on the Ether Injection System refer to Troubleshooting Manual, "Air Inlet Heater Circuit - Test".
Starting Problems
An occasional starting problem may be caused by one of the following items:
- Low battery charge
- Lack of fuel
- Problem with the wiring harness
If the engine fuel system has been run dry, fill the fuel tank and prime the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System - Prime" topic (Maintenance Section).
If the other problems are suspected, perform the appropriate procedure in order to start the engine.
Problems with the Wiring Harness
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| Illustration 1 | g00772964 |
(1) ECM Connector J2/P2 (2) ECM Connector J1/P1 | |
Locate the ECM. Two harness connectors are attached to the ECM. One connector is ECM J2/P2 (1) and the other connector is ECM J1/P1. Check the connectors in order to ensure that the connectors are secure. Lightly pull each of the wires in the chassis harness.
- Pull each wire with approximately 4.5 kg (10 lb) of force. The wire should remain in the connector.
- If a wire is loose, push the wire back into the connector. Pull the wire again in order to ensure that the wire is secure.
- Start the engine. If the engine does not start, consult the nearest Caterpillar dealer for assistance.