0306803 JOHNSON SCREW, Retainer

Note: When electric power is cycled, the electronic thermostat will cycle, which will make a unique sound that is a normal sound for a start-up.Note: To operate the engine at different speeds, refer to this Operation and Maintenance Manual, "Engine Operation".Manual Starting
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 the controls if there is a lock out tag attached. Do not start the engine or operate controls if a "DO NOT OPERATE" or similar warning tag is attached.Ensure that no one will be endangered when the engine is started.
Perform all the procedures that are described in this Operation and Maintenance Manual, "Before Starting Engine" (Operation Section).
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.
Refer to Locomotive OEM publications on starting the engine.Starting the Engine After an Overhaul or Major Repair
Use the following guidelines for operation and maintenance after an overhaul or a major repair. Using the guidelines will ensure that the engine is functioning correctly. The procedure for start-up requires approximately 1 hour and 30 minutes.
Perform the procedures that are described in this Operation and Maintenance Manual, "Before Starting Engine" topic (Operation Section).
Operate the jacket water heaters, if installed. Run the prelube pump and allow the lubricating oil to circulate for 10 minutes or less. To operate the prelube pump without starting the engine when the starting oil pressure is reached, perform the following: Access the service override file in Cat electronic technician (ET), override the prelube pump to ON.Note: Running the prelube pump for more than 10 minutes at a time risks overheating the pump electrical motor.To operate the prelube pump without starting the engine when the starting oil pressure is reached, perform the following:
Access the override tile in Cat electronic technician (ET)
Override the prelube pump to ON
During prelube pump operation, use the barring device to rotate the crankshaft for a minimum of two revolutions.
Start the engine. Operate the engine at low idle rpm for 15 minutes. Refer to this Operation and Maintenance Manual, "Engine Operation" for the procedure on starting and running the engine at low idle. 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 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 the temperatures and the pressures are acceptable, the engine can be returned service.Note: Monitor the engine oil pressure while the pre-lube pump is on. If the engine oil pressure does not increase after several minutes, the engine oil pre-lube pump is not self-priming. To manually prime the pre-lube pump, loosen a fitting in the pump discharge line near the pump. Loosening a fitting allows air to vent from the line. The pump is primed once oil is detected at the loosened fitting. Tighten the fitting to prevent leaks. Monitor the engine oil pressure to ensure that the pressure increases.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).
Table 1
Maintenance Procedures After an Overhaul or Major Repair
Interval Maintenance Procedure
Following the start-up procedure Obtain an oil sample and analysis.
Remove at least one oil filter element from each oil filter housing. Inspect the filter material for debris.
100 operating hours Obtain an oil sample and analysis.
500 operating hours Replace all the oil filter elements. Inspect the filter material for debris.
Starting the Engine After a System Generated Shutdown
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction provides a procedure for inspecting the engine after a system generated shutdown.The cause of a system generated shutdown must be corrected prior to an engine restart. Severe engine damage may occur if the problem is not corrected. Sometimes, the cause of the shutdown may be obvious and easily corrected. Sometimes, a visual inspection may not reveal the