CAT + Caterpillar D349 Industrial Engine Operation & Maintenance Manual by Heavy Equipment Manual

Product:INDUSTRIALENGINE

Model:D349INDUSTRIALENGINE61P

Configuration:D349ENGINE61P00001-UP

OperationandMaintenanceManual D346,D348ANDD349INDUSTRIALENGINES

MediaNumber-SEBU5405-02PublicationDate-01/05/1983DateUpdated-11/10/2001

AutomaticStart-Stop

Anautomaticstart-stopsystemisusedwhenanenginemuststartwhenaspecificconditionoccurs andwithnooneinattendance.Theenginewillstart,increasespeed,pick-uptheload,operatethe loaduntilasecondconditionoccurs,removetheload,coolandstop.Thefollowingconditions mustexistfortheenginetostartunattended:

1.Eithertheambient(engineroom)temperaturemustbeatleast70°F(20°C);or,theengine jacketwatertemperaturemustbeatleast90°F(32°C).Ajacketwaterheatercanmaintain thistemperature.

2.Ifaprelubeoilpumpisused(largeboreengines),thepumpmustoperatebeforethe startingmotor(s)areenergized,andstopwhentheenginestartsandoilpressureincreases.

ProtectionDevices

Theengine'scontrolpanelmaybeequippedwithprotectiondevicestoprotecttheenginewhile cranking,

Batteries:

Lightscanindicateifafaulthasoccurredinthebatterychargingsystemcausingthebatterytobe eitherunderchargedorovercharged.

Overcranking:

Atimerallowstheenginetocrankeitheroncefor30seconds,ortocrankthrough5ten-second crankingcycles(dependinguponthedeviceused)whileunattended.Iftheenginedoesnotstart beforethetimeelapsed,thefuelsystemwillbeshutoffandalightwillindicateastartingfailure.

EngineOperation:

Prealarmsystemsprovideanaudibleand/oravisualindicationforlowoilpressure,highwater temperature,lowfuelsupplyorlowjacketwatertemperaturebeforetheconditionbecomes critical.Thesealarmsareselfresettingwhentheconditioniscorrected.

Theenginemayalsobeequippedwithshutdowndevices.Iflowoilpressure,highjacketwater temperatureoranengineoverspeedconditionoccurs,theenginewillbeshutdownanda correspondinglightwillindicatethecauseoftheshutdown.Thesedevicesmustberesetafter repairshavebeenmadeandbeforestarting.Seethetopic,EMERGENCYSHUTOFFDEVICES ANDALARMS.

Iftheengineisequippedwithanelectricset,thecontrolpanelshouldbeequippedwithan ammeter,afrequencymeterandavoltmeter.Dependinguponthetypeofoperation,thepanelmay alsobeequippedwithothermetersandlights.Knowtheseinstrumentsandtheirnormalreadings. Theywillindicatehowtheengineisperforming.

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ShuttingDown:

Atimerallowstheenginetoremoveortransfertheload,andtocontinuerunningforupto2 minutesforcoolingpurposesbeforestopping.

EngineExerciser:

Atpresenttimes,theexerciserwillstart,runandstoptheengineinordertoensurebothproper lubricationofallenginepartsandproperequipmentoperationifandwhenthestandbyunitis needed.

Becomefamiliarwithallinstructionsincludedwiththeequipment.

MonApr823:01:57UTC+05302024

Product:INDUSTRIALENGINE

Model:D349INDUSTRIALENGINE61P

Configuration:D349ENGINE61P00001-UP

OperationandMaintenanceManual

D346,D348ANDD349INDUSTRIALENGINES

MediaNumber-SEBU5405-02PublicationDate-01/05/1983DateUpdated-11/10/2001

DeterminingCauseOfShutdown

NOTICE

Iftheenginehasbeenshutdownbyasafetydevice,donotstartthe engineandplaceitintoservicewithouthavingthecauseofthe shutdowninvestigatedandcorrected.

LowOilPressureChecks:

Ifthelowoilpressureshutoffcontrolhasstoppedtheengine,makethefollowingchecks:

1.Checkthewatertemperaturegauge.Determineiftheenginewasoverheated.Checkforexternal waterleaks.

Bewareofsteamorscaldingwater.Donotattempttoloosenthe radiatorcapuntilthetemperaturegaugeindicatesthecoolanthas sufficientlycooled.Then,loosenthecapslowly.

2.Checktheoillevel.OillevelmustbebetweentheADDandFULLmarksonthesideofthe dipstickstampedCHECKWITHENGINESTOPPED.

3.IftheoillevelisbelowtheADDmark,checkforoilsprayand/oroilaccumulations.Ifanyare found,havethenecessaryrepairsmade.Beforestarting,addoiltotheFULLmark.

4.Resettheshutoffcontrol.

5.Removetheloadandstarttheengineatitsslowestspeed.Bepreparedtoshuttheenginedown manually.

6.Bealertforunusualsoundsornoises.Iftheengineknocks,stoptheengineimmediatelyand callyourCaterpillardealer.

7.Iftheengineblowsexcessiveblackexhaustorhasexcessivecrankcaseblow-by,theengine mayneedreconditioning.StoptheengineandcallyourCaterpillardealer.

8.Iftheenginerunssatisfactorily,observetheoilpressuregauge.Ifsatisfactorypressureisnot indicated,shuttheenginedown;callyourCaterpillardealer.

9.Ifproperoilpressureisregistered,checktoseeiftheresetknobhasmovedtotherunposition. Iftheknobdoesnotmove,stoptheengine.Checktheshutoffcontrol,theoilline,andtheoil pressuregauge.Havenecessaryrepairsmade.

10.Iftheoilpressuregaugeregistersnormaloilpressure,iftheknobontheshutoffcontrolmoves totherunposition,andiftheengineoperationisotherwisesatisfactory,determineifthehigh watertemperatureshutoffmayhaveshutdowntheengine.

HighWaterTemperatureChecks-EngineRunning:

1.Determineiftheloadwastoogreatfortheengine:Reducetheloadandallowtheenginetocool whilerunning.

2.Ifpressuresteamorwaterleaksarevisible,removetheloadandstoptheengine.Have necessaryrepairsmade.

3.Checkforcollapsingordeterioratedwaterhoses.Haverepairsmade.

4.Checkfornoisywaterpumpoperation.Havenecessaryrepairsmade.

5.Refillthecoolingsystemwithasolutionofwaterandpermanenttypeantifreezeifbelow freezingtemperaturesareexpected;orwithasolutionofapprovedwaterandCaterpillarCorrosion Inhibitor.Followtheinstructionsonthecontainer.

DONOTremovethepressurecaponanoverheatedengine.Thecoolant isunderpressureandrelievingthepressurewillcausethecoolantto flashintosteam.Seriousflashburnsandenginedamagecanresult.If necessary,reducepressureinasurgetankbypouringwarmwateron topofthetank.Neveraddcoldwatertoahotengine.

NOTE:Ifthereisadequatecoolantinthecoolingsystem,gradualcoolingispreferredbyrunning theengineathalfspeed.Thiseliminateshotspotsintheengine,andpossiblefailure.

HighWaterTemperatureChecks-EngineStoppedandCold:

1.Checkcoolantlevel.Determineifthecoolanthasproperantifreezeprotection.A50-50solution ofpermanenttypeantifreezeandapprovedwaterwillgiveprotectionbelow-20°F(-29°C).

2.Checktobesuretherawwatervalvehasbeenopened.

3.Checkwaterpumpdrivebeltsforpropertension;seetheLUBRICATIONAND MAINTENANCEPROCEDUREStopic,FanBelts.

4.Checkengineroomventsand/orlouvers.Besuretheengineisreceivingsufficientair.

5.Besuretemperatureregulatorsareoperatingatpropertemperaturerange.

6.Inspectallwaterhosescarefullyforcollapsing,externalandinternalfailures.Replacehosesas required.

7.Havethecoolingsystemcleaned.

NOTICE

Ifsevereorprolongedoverheatinghasoccured,contactyour Caterpillardealertohaveyourenginecheckedforpossibledamage.

MonApr823:03:57UTC+05302024

Product:INDUSTRIALENGINE

Model:D349INDUSTRIALENGINE61P

Configuration:D349ENGINE61P00001-UP

OperationandMaintenanceManual D346,D348ANDD349INDUSTRIALENGINES

MediaNumber-SEBU5405-02PublicationDate-01/05/1983DateUpdated-11/10/2001

EmergencyShutoffDevicesAndAlarms

Emergencyshutoffdevicesareeitherelectrically,mechanicallyorhydraulicallyoperated. Familiarizeyourselfwiththetypesandlocationsoftheshutoffdevices,theconditionswhich causeeachcontroltofunction,andtheresettingprocedurerequiredtostartyourengine.

NOTICE

Alwaysdeterminethecauseoftheshutdown,andhavethenecessary repairsmadebeforerestartingtheengine.

Emergencyshutoffcontrolsareforemergencyuseonly.Donotusean emergencyshutoffdeviceforanormalstoppingprocedure.

ElectricShutoffControls

Theoperationofallelectricshutoffcontrolsissimilar:Acriticaloperatingconditionactuatesa switchinthesensingunit.Theswitchclosesthecircuittotheshutoffsolenoidwhichmoves linkagetobypassthefueltothecylinders;thusstoppingtheengine.Theshutoffcontrolmay requireresettingbeforetheenginecanstart.

HighWaterTemperatureShutoff:

Theshutoffswitchislocatedinthewatertemperatureregulatorhousing.Excessivewater temperatureclosestheswitch.Noresettingprocedureisrequired:Asthecoolantcools,theswitch opens.

NOTICE

Thesensingelementmustbesubmergedinthecoolanttooperate.A lowcoolantlevelcannotactuatetheshutoff.

LowOilPressureShutoffSwitch:

Thisdeviceisusuallymountedonthesideoftheenginewithoillinesconnectedtotheswitch. Lowoilpressureclosestheswitch.

Manuallyoperatedsystemsrequireresettingofthisswitchbeforestarting.Automaticstart-stop systemsuseapressureswitchwhichresetsitself.

Toresettheswitch,pushthebuttonuntilitlatches.Aftertheenginestartsanddevelopsoil pressure,theoilpressurewillpushthebuttontotheextendedrunningposition.

NOTICE

Theenginewillnotbeprotectediftheengineisoperatedwiththe buttonlatchedintheSTARTposition.

Ifthebuttonremainsintheresetposition,theengineoilpumpisnotdevelopingnormaloil pressureandacheckshouldbemade.

OverspeedShutoffSwitch(Electro-Mechanical):

Thisswitchismountedeitheronthetachometerdriveoronthegovernor.Excessiveenginespeed closesaswitchbycentrifugalforce.

TWOINSTALLATIONSOFOVERSPEEDSWITCH

Toresettheswitch,pushthebuttonmarkedRESET.Theknobwillremaindownuntiltheengine overspeeds.

OverspeedShutoffSwitch(Electronic):

Thisswitchisamagneticpick-upwhichismountedontheflywheelhousingandsensesengine speed.Thecontrolboxismountedontheengineblock.Excessiveenginespeedclosesacircuit breaker.Toresettheswitch,pusharmofbreakertotherunposition.

NOTICE

Thisswitchwillnotprovideoverspeedprotectionifthereisnopower tothecontrolbox.

Thisswitchismountedinthefuelmanifoldbetweenthecleansideofthefuelfilterandthefuel injectionpumphousing.Lowfuelpressure(below3psi)openstheswitchandtheelectricalcircuit toeithertheshutoffsolenoidorthecircuitbetweenthealternatorandthealternatorregulator. Openingofthesecircuitspreventsthebatteryfrombecomingdischargedwhiletheengineis stopped.

Thisswitchcanalsobeusedwithanelectricgovernor.Inthisapplication,oilpressureclosesthe switchtoallowtheelectricgovernortocontrolenginespeed.

Thisswitchdoesnotrequireresetting.

MechanicalSafetyShutoffControl

Themechanicalsafetyshutoffisbothalowoilpressureandanoverspeedshutoffdevice.Ahigh watertemperatureshutoffcanbeinstalledwhichusesthelowoilpressureshutoffdevicetostop theengine.

On6cylinderengines,themechanicalshutoffismountedonthesideoftheengine.Onvee engines,theshutoffismountedintheveeoftheenginebetweenthetwobanksofcylinders.

Thehighwatertemperatureshutoffisinstalledinthetemperatureregulatorhousingofallengines.

Ifanoverspeed,lowoilpressure,orhighwaterconditionoccurs,aspringloadedrodis mechanicallytrippedinternally,whichmovesandholdstherackintheshutoffposition.

Difficultstartingwithlongperiodsofcrankingcantripthelowoilpressureshutoff.Thereset levermustbemovedandlatchedintherunpositionbeforestartingcanbeaccomplished.Normal stoppingoftheenginewillnottriptheshutoffdevice.

Thebasiccausefortheshutdowncanbedeterminedbythemannerinwhichtheshutoffmustbe reset:

1.Pushtheresetlever(orhandle).

Iftherodlatches,anoverspeedconditionstoppedtheengine.Investigatethecauseforoverspeed condition.

Iftheroddoesnotlatch,theenginewasstoppedbecauseofalowoilsupplytotheshutoff control.Thiscouldbecausedbyeitherlowengineoilpressure,orbythehighwatertemperature shutoffbypassingtheoiltothemechanicalshutoff.Therefore,performchecksforbothlowoil supplyandhighwatertemperature.Resetthecontrolbythefollowingsteps:

1.Pushtheresetbuttonfirmly.

2.Pushtheresetlever(orhandle)untiltherodlatches.

Iftheresetleverdoesnotmovefreely,checktheresetcableforkinks,binds,orlackof lubrication.Makeneededrepairsoradjustments.

AirSafetyShutoffControl

Theairshutoffcontrolisanattachmenttothemechanicalsafetyshutoffdeviceinstalledonlarge boreveetypeengines.Whenanemergencyconditionoccurs,themechanicalshutoffpushesthe rackintotheshutoffpositionandpullsabutterflyvalve,locatedineachinletmanifold,tothe closedposition.Theairsafetyshutoffcontrolmustberesetbeforestarting.

Ifanoverspeedconditionshuttheenginedown:

1.PulltheairshutoffresetleverontheairinletmanifoldtotheRESETposition.

2.Releasethelever.ThelevershouldmoveslightlyandthenlatchintheRUNposition.

3.Pushthemechanicalshutoffresetleveruntiltherodlatches.

Ifalowoilpressureorhighwatertemperatureconditionshuttheenginedown:

1.Firmlypushtheresetbuttonintheveeoftheengine.

2.PulltheairshutoffresethandleontheairinletmanifoldtotheRESETposition.

3.Releasethelever.ThelevershouldmoveslightlyandlatchintheRUNposition.

4.Pushthemechanicalshutoffresetleveruntiltherodlatches.

HydraulicShutoffControls

Thehydraulicshutoffcontrolismountedon(ornear)thegovernor.Whenoilpressuredrops below8PSI,thefuelinjectionpumpsbypassthefueltothecylinders.

Tostarttheengine,moveandholdtheresetleveragainstthestopwhilecrankingtheengine.After theenginestarts,theleverwillstayintherunningposition.Manuallyresetthecontroleachtime theengineisstopped.

Ahighwatertemperatureshutoffcanbeusedwiththisshutoffcontrol.Excessivecoolant temperaturecausesthetemperaturesensortoopenadumpvalvewhichemptiesthepressureoil fromthelowoilpressureshutoffdevice.Thelowoilpressureshutoffcontrolshutsdownthe engine.

Resettheoilpressurecontrolasinstructedabove.Allowthewatersensortocool:Noresettingof thewatertemperatureshutoffswitchisrequired.

NOTICE

Thewatertemperaturesensormustbesubmergedinthecoolantto operate.Alowcoolantlevel,orafailedwaterpumpcannotactuatethe shutoff.

AlarmSwitches

Alarmswitchesaresetatalesscriticaltemperature,pressure,orlevellimitthanthecomparable shutoffcontrol.Thepurposeofthealarmswitchistowarntheoperatoranunsafeoperating conditionisstartingtooccur,andthatcorrectivemeasuresshouldbetakentoavoidpossible damagetotheengineand/orapossibleshutdownoftheengine.

LOWOILPRESSUREALARMSWITCH

NOTICE

Itcouldbehazardoustohavetheenginestopunexpectantlywhen enginepowerisneeded.However,iftheengineoverspeeds,theengine shouldbestoppedimmediately.

Whenthepresettemperature,pressureorfluidleveloccurs,thesensorofthealarmswitchwill moveandcloseanelectricalcircuit.Eitheralightoranaudiblealarmwillbeenergized.Thelight oralarmwillcontinuetooperateuntiltheconditioniscorrected.Whentheconditioniscorrected thealarmwillautomaticallyresetandthelightwillturnoff.

NOTICE

Thecauseoftheshutdownmustbeinvestigatedandcorrectedbefore startingandoperatingtheengine.

Aswitchmaybeinstalledinthealarmcircuitforsilencingthealarmwhiletheengineisstopped forrepairs.Besuretheswitchismovedtotheclosed(ON)positionandthewarninglightsarelit beforestarting.

NOTICE

Iftheswitchisleftintheopen(OFF)positionwhentheengineis started,theenginewillnotbeprotected.

TestingIndicatorLights:

Mostcontrolpanelsareequippedwithatestswitch.ByturningtheswitchON,alloftheindicator lightscanbecheckedforproperoperation.Testtheindicatorlightsperiodically,replaceburned outlightbulbsimmediately.

MonApr823:03:24UTC+05302024

Product:INDUSTRIALENGINE

Model:D349INDUSTRIALENGINE61P

Configuration:D349ENGINE61P00001-UP

OperationandMaintenanceManual D346,D348ANDD349INDUSTRIALENGINES

MediaNumber-SEBU5405-02PublicationDate-01/05/1983DateUpdated-11/10/2001

EmergencyStopping

Tostopinanemergency:

MechanicalGovernorControl:

Pullupwardonthehandgrip,andmovethecontroltotheshutoffposition.

ManualShutoffControl:

Pushandholdthecontrolhandleuntiltheenginestops.

WoodwardUG8Governor: Turntheloadlimitknobto"0".

WoodwardPSGGovernor:

Movetheleverforwardagainstthestop;holdtheleveruntiltheengineisstopped.

MechanicalSafetyShutoffControl:

Pushandholdtheemergencystopbuttonmomentarilytoallowtheoverspeedmechanismtotrip andstartslowingtheengine.

NOTICE

Thisbuttonhasaskirt.Donotconfuseitwiththeresetbuttonwhichis flat.Usethismechanicalshutoffbuttonforemergenciesonly.Donot useitfornormalstopping.

ElectricShutoffSolenoid:

PushandholdtheON-OFF-STOPswitchintheSTOPpositionuntiltheenginestops.

AirControls:

PushandholdtheON-OFF-STOPswitchintheSTOPpositionuntiltheenginestops.

MonApr823:03:03UTC+05302024

Product:INDUSTRIALENGINE

Model:D349INDUSTRIALENGINE61P

Configuration:D349ENGINE61P00001-UP

OperationandMaintenanceManual

D346,D348ANDD349INDUSTRIALENGINES

MediaNumber-SEBU5405-02PublicationDate-01/05/1983DateUpdated-11/10/2001

EngineOperation

Pre-StartChecksAndProcedures

1.Makea"walk-around"checkoftheengineandcomponents.Correctminoradjustmentsbefore theydevelopintomajorrepairjobs.

2.Checkthecrankcaseoillevel.MaintaintheoillevelbetweentheADDandFULLmarksonthe dipstick.SeetheLUBRICATIONANDMAINTENANCECHARTforpropertypeandviscosity ofoiltouse.

D346,D348,D379andD398Enginesareequippedwithacombinationsumppumpandprelube handpump.Afteralongshutdownorafterafilterandoilchange,operatethehandpumptofill theoilpassagesinthelubesystembeforestarting.SeetheLUBRICATIONAND

MAINTENANCEPROCEDUREStopic,OilFilterElements,beforestartinganyoneofthese modelsofengines.

3.Checkoillevel(s)ondrivenequipment.

4.Checkthefueltanklevel,SeetheLUBRICATIONANDMAINTENANCECHARTforproper fueltouse.

5.Checktheenginejacketcoolantlevel.Maintaincoolantleveltothebaseofthefillpipe.Seethe LUBRICATIONANDMAINTENANCECHARTforpropermake-upcoolanttouse.

6.Opentherawwatervalve(ifsoequipped)ontheenginejacketheatexchangersystem.

7.Resetshutoffdevices.Seethetopic,ATTACHMENTS,EmergencyShutoffDevicesand Alarms.

8.Openthefuelsupplyvalve.

NOTICE

Thefuelreturnlinemustbeopentopreventenginedamage.

9.Ifairhasenteredthefuelsystem,primethefuelsystem.SeetheLUBRICATIONAND MAINTENANCEPROCEDUREStopic,PrimingtheFuelSystem.

PRIMINGPUMPON6CYLINDERENGINE

PRIMINGPUMPONV-ENGINE

10.Disconnectanybatterychargerwhichisnotprotectedagainststartingmotordrain.

11.Disengagetheclutch,oropenthecircuitbreakeronanelectricset.

Donotstartanengineunderload.

12.Movethegovernorcontrollevertohalfenginespeedpositionortospeedlimiterstop.

13.Primetherawwaterpumpifnecessary.(Onlywaterpumpsequippedwithawaterreservoir andfillplugrequirepriming.)

Iftherawwaterpumpisofthetypeshownbelow,thepumpisaselfprimingpump.Thispump doesnothaveaprimingchamberorfillplug.

NOTICE

Theprimingchambermustbefilledwithwaterbeforestartingthe enginetopreventpumporenginedamage.Aftertheengineisstarted, increaseenginespeedimmediatelytoobtainandmaintainsystemflow.

1.Carefullyloosenthefillplug.Ifwaterispresentimmediatelytightentheplug;thepumpisfull.

2.Ifwaterisnotpresent,pourapproximatelytwogallons(7.5liters)(1.5Imp.Gals.),oruntil overflo7`/ccurs,intothefillhole.

3.Installthefillplug.

4.Starttheengineatfastenoughspeedtoobtainthenormalwaterflowfromtheoverboardraw waterdischargeorwatercooledexhaustpipe.

Iftheproperflowisnotobserved,stoptheengineandrepeatthisprocedure.Ifthepumpdoesnot holdwaterintheprimingchamber,thewaterpumpsealsshouldbereplaced.

StartingTheEngine

NOTICE

Donotengagethestarterwhentheflywheelismoving.

ElectricStarting:

1.Usestartingaidsifrequired.Seethetopic,GENERAL,ColdWeatherStarting.

NOTE:D349andD399Engines:

FILLPLUG

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