D379, D398, D399 INDUSTRIAL AND GENERATOR SET ENGINES Caterpillar

When Required

Usage:

(30)Cooling System-Cleaning

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At Operating Temperature, engine coolant is hot and under pressure.
Steam can cause personal injury.
Check coolant level ONLY when engine is stopped and radiator cap is cool enough to touch with your hand.
Remove filler cap slowly to relieve pressure.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.

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NOTICE

If engine is to be stored in, or shipped to, an area with below freezing temperatures, the cooling system must either be protected to the lowest expected ambient temperature, or drained completely. Never add coolant to an overheated engine, allow engine to cool first. Do not use Caterpillar Cooling System Conditioner or Coolant Conditioner Elements with Dowtherm 209 Full-Fill coolant.

1. Loosen radiator cap slowly to release pressure and remove filler cap.

2. Remove radiator drain plug.

3. Remove engine block drain plugs.

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Use all cleaning solutions with care.

4. Fill the cooling system with a cleaning solution. Use a commercially available cleaner or 2 lb. (1 kg) sodium bisulfate (NaHSO₄) per 10 gal. (38 liters) water as a cleaner.

5. Start and operate engine for 1/2 hour. Stop engine and drain the cleaning solution.

6. Flush the system, with engine off, with water until draining water is clear.

7. Close drain valve. Fill the system with a neutralizer. Use a commercially available neutralizer of 1/2 lb. (250 grams) sodium carbonate crystals (NaCO₃ · 10H₂O) per 10 gal. (38 liters) water.

8. Operate engine for ten minutes. Shut off engine and drain the neutralizer.

9. Flush the system, with engine off, with water until drain water is clear. Close drain valve.

10. Fill system with clean water and operate engine for 5 minutes. Drain the cooling system and close drain valve.

11. Repeat Step 10 until water drained is clear.

12. Mix a solution of water, antifreeze and Caterpillar Cooling System System Conditioner.

13. To avoid air locks, add solution slowly at 5 gal. (19 liters) or less per minute.

14. Start engine and operate engine with radiator cap off until thermostat opens and level stabilizes. Fill system to within 1/2 inch (13 mm) of bottom of fill tube.

15. Install radiator cap.

(31)Air Induction System

Single Stage Air Cleaner

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NOTICE

Service the air cleaner with the engine stopped.

Service the air cleaner when the red plunger in the indicator locks in the visible position.

1. Remove the air cleaner cover and element.

2. Cover the turbocharger air inlet opening to prevent dirt from entering the engine.

3. Clean the inside of the air cleaner cover and body.

4. Inspect the replacement element for damage and dirt. See the subject, "Cleaning Air Cleaner Elements."

5. Remove the covering from the turbocharger inlet opening.

6. Install the element.

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NOTICE

The reinforcing brace across the middle of panel type elements fits over the supporting bar of the turbocharger.

7. Install the air cleaner cover.

8. Reset the service indicator.

Two Stage Air Cleaner

1. Loosen the clamping bolt on the lower body.

2. Remove and empty the dust collector cup.

3. Loosen the clamping bolt on the upper body.

4. Remove the lower body and clean the tubes from both ends.

5. Inspect the seals between the lower body and the dust collector cup, and between the lower body and upper body. Install new seals if necessary.

6. Install the lower body to the upper body and tighten the retaining clamp.

7. Install the dust cup and tighten the retaining clamp.

Installing Replacement Filter Element For Two Stage Air Cleaner

1. Remove the cover.

2. Remove the inner cover and filter element. In cold weather, a stuck inner cover may be removed by warming the air cleaner cover to 70-75°F (21-24°C).

3. Clean all parts of the air cleaner.

4. Inspect the replacement element for damage and dirt. See the subject, "Cleaning Air Cleaner Elements."

5. Install the element, inner cover, and wing nut. Tighten the wing nut.

6. Install the cover.

Cleaning Air Cleaner Elements

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When using pressure air, wear face shield and protective clothing. Maximum air pressure for cleaning purposes must be 30 psi (205 kPa).

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NOTICE

When cleaning with pressure water, use 40 psi (280 kPa) maximum pressure to prevent element damage.

Panel type air cleaners can be cleaned in the same manner.

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NOTICE

Do not clean elements by bumping or tapping them on hard objects. Inspect an element after cleaning. Do not use an element with damaged pleats, gaskets or seals.

Have spare elements on hand to use when cleaning used ones.

Elements may be cleaned either with pressure air, water or detergent.

Pressure Air-30 psi (205 kPa) Maximum

1. Direct air inside along length of pleats.

2. Direct air outside along length of pleats. Direct air inside along length of pleats. Inspect.

Water-40 psi (280 kPa) Maximum

1. Direct water inside along length of pleats.

2. Direct water outside along length of pleats. Air dry and inspect the element.

Detergent

1. Wash in warm water and nonsudsing household detergent.

2. Rinse with clean water.

3. Air dry and inspect.

Inspecting Elements

1. Insert a light inside a clean and dry element. Discard element if rips or tears are found.

2. Wrap and store good elements in a clean dry place.

(32)Fuel System

Cleaning the Primary Filter

1. Stop the engine.

2. Close the fuel supply line valve.

3. Loosen the nut on the cover and remove the case.

4. Remove the filter element. Clean the element and case in clean nonflammable solvent.

5. Inspect and install the upper and lower cover gaskets. Install new gaskets if necessary.

6. Install the cleaned filter element and case.

7. Open fuel supply line valve.

8. Prime the fuel system.

Changing Final Fuel Filters

1. Close the fuel supply line valve.

2. Remove the drain plug in each cover. Drain the fuel filter housing.

3. Remove both end covers.

4. Push the used filter elements from left to right through the filter housing.

5. Wipe all sediment from inside the filter housing.

6. Inspect the cover gaskets. Install new gaskets if necessary.

7. Install the right cover. Install new filter elements.

8. Install the left cover.

9. Install the drain plugs in the covers.

10. Open the fuel supply line valve.

11. Prime the fuel system.

Priming the Fuel System

1. Open the fuel supply line valve.

2. Move the governor control lever to the shut-off position.

3. Turn the pump handle knob counterclockwise. Release the lock plate from the retainer on the fuel priming pump.

4. Operate the fuel priming pump until the air in the fuel system has been pumped through the fuel return line to the fuel tank.

If desired, the fuel return line connection may be loosened. When a solid stream of fuel flows from the connection, air has been expelled and the connection can be tightened.

5. Secure the pump handle. Turn the lock plate vertically, turn the pump handle knob clockwise until the lock plate contacts the plate retainer.

6. Start the engine. If the engine misfires or smokes, loosen a fuel injection line nut, and allow the fuel to flow until free of air bubbles. Tighten the line nut. Open the next line nut and continue venting each successive line.

(33)Air Starter

Filing Motor Oiler

The vanes of the starting motor are lubricated with a fine oil mist from the motor oiler while the motor is operating.

When the oiler jar becomes half empty, remove the oil filler plug and fill the jar with clean oil. Refer to the Lubrication and Maintenance Chart for proper oil.

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NOTICE

Never allow the jar to become empty. The starting motor will be damaged by lack of proper lubrication.

Emptying Oil Collector Jar

The collector jar collects both the oil after it has lubricated the starting motor vanes, and the moisture condensation from the compressed air.

Empty the collector jar whenever the jar becomes half full.

Adjusting Oiler Feed

If necessary, adjust the oiler to release approximately four drops of oil per minute into the starting motor air stream.

1. Be sure the fuel supply to the engine is turned OFF.

2. Pull up on the air start control lever and crank the engine.

3. Count the drops of oil released per minute into the air stream.

a. Turn the valve needle (the uppermost knob is the oiler) counterclockwise to increase the number of drops per minute.

b. Turn the valve needle clockwise to decrease the number of drops per minute.

(34)Batteries-Cleaning

1. Loosen and remove cable clamps from all battery terminals.

2. Clean all battery terminals.

3. Clean all cable clamps.

4. Install and tighten cable clamps to battery terminals.

5. Coat cable clamps and terminals with grease.

(35)Glow Plugs

Testing

1. Stop the engine.

2. Disconnect the lead harness wire from the magnetic switch.

3. Connect an ammeter of sufficient capacity between the magnetic switch terminal and the lead harness wire.

4. Push in, turn and hold the HEAT-START switch in the HEAT position.

5. The ammeter reading should be approximately equal to the number of low plugs multiplied by 5, the approximate amperage used by each glow plug.

A deviation of 5 or more amps from this reading may indicate one or more defective glow plugs.

Locating Defective Glow Plugs

1. Push in, turn and hold the HEAT-START switch in the HEAT position. Observe the ammeter reading.

2. Pull the lead from a glow plug. Observe the ammeter reading.

If the ammeter reading does not change, the glow plug was not drawing current when connected and can be assumed to be defective. If the ammeter reading decreases, the glow plug is working properly.

3. Release the HEAT-START switch.

4. Connect the lead to the glow plug.

5. Test each glow plug individually.