Note: Prior to starting the engine, ensure that the urea dosing system power is turned on.
Perform the required daily maintenance and other periodic maintenance before starting the engine. This maintenance can prevent major repairs at a later date. See this Operation and Maintenance Manual, "Maintenance Interval Schedule" (Maintenance Section).
For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.
To obtain maximum service life for your engine, make a thorough inspection before starting the engine. Make a walk-around inspection of the installation. Look for items such as oil or coolant leaks, loose bolts, and trash buildup. Remove any trash. Make repairs, if necessary.
- The guards must be in the proper place. Repair damaged guards or replace missing guards.
- Ensure that the areas around the rotating parts are clear.
Ensure the following conditions:
- The air inlet piping and the air filters are in place.
- All clamps and connections are secure.
- Inspect the cooling system for leaks or loose connections. Inspect the condition of all the pipes for the cooling system. Ensure that the connections are properly clamped.
- Inspect the water pumps for evidence of leaks.
- Check the coolant level. Add coolant, if necessary. For information on the proper coolant to use, see this Operation and Maintenance Manual, "Refill Capacities and Recommendations" (Maintenance Section).
Perform a lamp test for the alarm system.
Reset all of the devices that may prevent the engine from starting:
- Air shutoff
- Control panel
- Overspeed switch
Pumping air into the pneumatic linkage of the fuel rack shutoff may be necessary.
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.
- Open all fuel supply lines and fuel return lines.
- Inspect the fuel lines for loose fittings and leaks. Ensure that the fuel lines are properly clamped.
- Check the fuel supply. Keep fuel tanks nearly full. Partially filled tanks will collect moisture. Do not overfill the fuel tank. When fuel is warm, fuel expands and the fuel may overflow.
- Drain water and sediment from the fuel tank.
- Drain water and sediment from the primary filter/water separators.
Oil level gauge|
(1) "ADD" mark
(2) (FULL) "mark"
- Check the engine crankcase oil level. Maintain the oil level between the "ADD" and "FULL " marks on the "ENGINE STOPPED WITH OIL COLD" side of the oil level gauge. For information on the proper oil to use, see the Operation and Maintenance Manual, "Refill Capacities and Recommendations" (Maintenance Section).
- Check for leaks at the following components: crankshaft seals, crankcase, oil filters, oil gallery plugs, sensors and valve covers.
- Inspect the tubes, tee pieces, and clamps on the crankcase breathers.
- Ensure that the engine control system allows the engine to be started from the local position.
- Ensure that the engine will be started at low idle rpm.
- Ensure that the barring device is fully disengaged.
- Drain moisture and sediment from the air tank and from any other air piping.
- Check the air pressure for starting. Open the air supply valve.
Note: If the engine is equipped with a system for external support, prepare the system before starting the engine. Ensure that all of the systems for engine support are enabled. Perform all prestart checks for the control system.
Cylinder pressure valve (Kiene valve)|
(1) Cap nut
(2) Valve cock
Fluids may escape from the cylinder pressure valves at high velocity during this procedure and cause personal injury. Always stay clear and keep personnel away from the cylinder pressure valves during this procedure.
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.
For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the air and/or fuel supply to the engine.
Do not start the engine or move any controls while a "DO NOT OPERATE" warning tag is attached to the start switch or other controls. Do not start the engine or move any controls if a similar warning tag is attached to the start switch or 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).
- Ensure that the driven equipment is disengaged.
Note: Two typical control panels are illustrated. If the engine is equipped with a different control panel, follow the instructions that are provided by the OEM of the control panel.
Illustration 3 g03404144 (1) "ENGINE CONTROL" switch Illustration 4 g03404149 (2) "LOCAL THROTTLE" switch
(3) "STARTING MOTOR" switch
(4) "CRANK OVERRIDE" switch
(5) "RUN/STOP" switch
(6) "LOW IDLE" switch
(7) "ENGINE PROTECTION OVERRIDE" switch
(8) "RAPID START/STOP" switch
(9) "MANUAL PRELUBE" switch
(10) "OIL MIST OVERRIDE" switch
- Turn "OFF/RESET, LOCAL, and REMOTE" switch (1) to the "LOCAL" position.
The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing surfaces.
- Turn "MANUAL PRELUBE" switch (9) to the "ON (I)" position. Allow the prelube pump to operate. When the prelube indicator illuminates, the engine has sufficient prelube to start.
Illustration 5 g00275016 Fuel priming pump
- 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.
- Immediately after engine start-up, ensure that oil pressure and fuel pressure are indicated on the gauges. Allow the engine to idle for 3 to 5 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.
Use the following guidelines for operation and maintenance after an overhaul or a major repair. This procedure will ensure that the engine is functioning correctly. The procedure for start-up requires approximately 1hour and 45 minutes.
- Perform the procedures that are described in this Operation and Maintenance Manual, "Before Starting Engine" topic (Operation Section).
- Operate the jacket water heaters and the prelube pump. Allow the lubricating oil to circulate for 30 minutes.
- During prelube pump operation, use the barring device to rotate the crankshaft for a minimum of four revolutions.
- 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.
- 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.
- 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 ends 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.
- Start the engine. Operate the engine at low idle rpm for 5 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.
- 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).
- 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.
- 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.
- 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.
After the initial start-up, See the maintenance procedures that are in this Operation and Maintenance Manual (Maintenance Section).
|Maintenance Procedures After an Overhaul or Major Repair|
|After the start-up procedure||Obtain an oil sample and analysis.|
|Remove at least one oil filter element from each oil filter housing. Cut the element open. Inspect the filter material for debris.|
|100 operating hours||Obtain an oil sample and analysis.|
|500 operating hours||Replace all of the oil filter elements. Cut the used elements open. Inspect the filter material for debris.|
|Perform the procedures that are described in this Operation and Maintenance Manual, "Engine Valve Lash - Check/Adjust" topic (Maintenance Section).|
- Ensure that area around SCR system is clear of flammable materials.
- Inspect access panels.
- Inspect injector.
- Inspect bulkhead fittings.
- Ensure that urea and air lines are connected.
- Inspect sensors.
- Inspect wiring harness.
- Ensure that filter screens are in place.
- Ensure that drains are closed.
- Ensure that all lines are connected.
- Check for leaking fluids. Ensure all fluids that have leaked are cleaned up and properly disposed of.
- Check the A/C power supply.
Turn on both breakers that are located on the dosing cabinet. The control program should automatically boot up on the Touch Panel Screen.
Once properly commissioned, the dosing cabinet is designed to operate automatically without operator intervention. The system uses inputs from the following: turbo boost pressure, boost temperature, Pre NOx level and percent desired reductions to determine start-up, shut down, and the precise amount of DEF to deliver to the injection system. The controller software measures operating conditions and adjusts the amount of DEF injection to achieve the desired reductions.