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SERIES 638 PREPARATION FOR A FIRST TIME START

Before starting an engine for the first time, carefully read and follow the instructions in this section. Also, refer to section of this manual. ‪

NOTICE:

Attempting to run the engine before studying these instructions may result in serious damage to the engine. ‪

NOTICE:

When preparing to start a new or overhauled engine or an engine that has been in storage, perform all of the operations listed below. Before a routine start (at each shift), see Daily Operations in the Preventive Maintenance Chart. Refer to section . Failure to perform required prestart operations may result in engine damage. ‪

Cooling System

Secure all drain plugs in the cooling system as instructed below: ‪

  1. Remove the radiator filler cap and fill the cooling system.
  2. Check system for leaks. Repair as necessary.

Lubrication System

The lubricating oil film on the rotating parts and bearings of a new or overhauled engine, or one which has been in storage, may be insufficient for proper lubrication when the engine is started for the first time. ‪

It is recommended that the engine lubricating system be charged with a pressure prelubricator, set to supply a minimum of 172 kPa (25 lb/in. 2 ) oil pressure, to ensure an immediate flow of oil to all bearings at the initial engine start-up. The oil supply line should be attached to the engine so that oil under pressure is supplied to the main oil gallery. ‪

With the oil pan dry, use the prelubricator to prime the engine with sufficient oil to reach all bearing surfaces. Use lubricating oil as specified. Then, remove the dipstick, wipe it with a clean cloth, insert and remove it again to check the oil level in the oil pan. Add sufficient oil, if necessary, to bring it to the full mark on the dipstick. Do not overfill. ‪

If a pressure prelubricator is not available, fill the crankcase to the proper level with lubricating oil. Then, prelubricate the upper engine parts by removing the valve rocker cover and pouring lubricating oil, of the same grade and viscosity as used in the crankcase, over the rocker arms, rocker arm shafts, camshaft lobes and camshaft follower rollers. ‪

Turbocharger

When a turbocharger is replaced, or if the engine has been in storage, the turbocharger must be prelubricated by pouring oil into the oil supply inlet before the engine is started. Rotate the shaft to coat the bearings with oil. ‪

Start and run the engine at idle until oil supply pressure has reached all the turbocharger moving parts. A good indicator that all the moving parts are getting lubrication is when the oil pressure gauge reaches normal operating pressure at idle speed. ‪

Air Cleaner

Check the air cleaner element for dirt, contamination, damage, and air restriction. Replace as required. ‪

It is recommended that the air cleaner assembly be replaced every 15,000 miles (24,000 km). ‪

Transmission

Check the oil level and fill the transmission case or torque converter to the proper level with the lubricant specified by the manufacturer. ‪

Fuel System

Fill the fuel tank with the fuel specified. Refer to section . ‪

If the unit is equipped with a fuel valve, it must be opened. To ensure prompt starting, the fuel system between the pump and fuel return line must be full of fuel. ‪

If the engine has been out of service for a considerable length of time, prime the fuel system between the fuel pump and the fuel return manifold. Before priming the fuel system, remove and fill both fuel filters with clean fuel oil and reinstall them. ‪

Note: The engine fuel system is filled with fuel before leaving the factory. If the fuel is still in the system when preparing to start the engine, priming should be unnecessary.

Drive Belts

Adjust all drive belts as recommended. Refer to section . ‪

Storage Battery

Check the battery. The top should be clean and dry, the terminals tight and protected with a coat of silicone spray or petroleum jelly and the electrolyte must be at the proper level. ‪

A hydrometer reading (corrected for the temperature of the electrolyte) should be 1.265 or higher. If necessary, charge the battery. ‪

Clutch

Disengage the clutch, if the unit is so equipped. ‪