Usage:
D398 (66B, 67B, 75B, 35Z);
D399 (35B, 91B, 36Z)
Reference: Service Manual; Operation And Maintenance Guides: Know Your Cooling System Form SEBD0518
This kit will make it easier to do the correct preventive maintenance operations on the above engines. Careful use of this instruction and a thorough visual inspection of your engine will give added performance, reliability, economy and service life. Due to the various service intervals needed to do each of the steps in this instruction, it will not be necessary to do all the steps at each service interval. Use this instruction along with the correct Operation and Maintenance Guide and the Service Manual for additional preventive maintenance information and service procedures.
Scheduled Oil Sampling (SOS)
Operate the engine until it is at the normal operating temperature. When an oil sample gun is used, fill the sample bottle approximately 75% full. If a sample is taken from the oil drain stream, do not get the sample from the first part or last part of the oil drain. Use caution to prevent burns or injuries caused by hot oil. Fill out the sample and shipment labels and send the sample container to your Caterpillar Dealer for the SOS test. Make sure engine serial number, hours on oil, and unit number are indicated.
NOTE: If the engine is equipped with a DUPLEX OIL AND/OR FUEL FILTER SYSTEM, consult Operation and Maintenance Guide to follow the correct procedures when switching from main to auxiliary filter systems.
Main Oil Filter Elements (Standard System)
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Use caution when draining oil or changing filters. Hot oil or components can cause burns if they contact skin. |
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Remove the oil cooler drain plugs and oil filter housing vent plug. Open the main filter drain valve and allow filter housing to drain. Remove the right-hand cover from the filter housing. Remove all filter elements. Wipe the inside of the filter housing with a clean rag. Install new filter elements. Install new housing cover gasket, if necessary, and install the cover. Close the drain valve and install all drain plugs. Fill the oil filter housing and oil cooler with oil through the vent openings. Install vent plugs. Inspect for leaks.
Main Oil Filter Elements (Duplex System)
(1) Push down and hold the fill valve to ensure auxiliary oil filter housing is filled with oil. When filter pressure stops rising, release fill valve. Move selector 90° (clockwise) to auxiliary filter position. Crankcase oil is now being filtered through the auxiliary oil filter elements. Remove oil filter housing vent plug from right-hand end cover.
(2) Open the main filter drain valve and allow the filter housing to drain. Remove the right-hand cover from the filter housing. Remove the oil filter elements. Install the new housing cover gasket, if needed, and install the cover. Close the drain valve and install the vent plug. Push down and hold the fill valve until the filter pressure stops rising, then release the fill valve.
| NOTICE |
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The oil must force the air out of the main filter housing to prevent air from later entering the oil lines and the engine bearings. |
(3) Move the selector lever 90° (counterclockwise) to the main filter position. Crankcase oil is now being filtered through the main oil filter elements. Inspect for leaks.
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For long periods of running, the selector lever must be turned so it is parallel with the crankshaft. If the selector lever remains positioned at right angle to the engine, only two filter elements will be filtering the engine crankcase oil instead of five. Early plugging of these two elements will result, and dirty oil will be bypassed through the engine. |
Auxiliary Oil Filter Elements (Duplex System)
(1) The auxiliary oil filter elements should be changed after each main oil filter change. The selector lever should be pointed forward. Remove the filter housing drain plugs to allow oil to drain from the housings. Remove each housing and element. Clean the inside of the housings. Remove the gasket from each filter housing base. Install new gaskets. Install new element in each housing. Install filter housings and drain plugs. Push down and hold fill valve until filter pressure stops using; then release the fill valve.
| NOTICE |
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The air must be removed from the auxiliary filter housings to prevent air from later entering the oil lines and engine bearings. |
(2) Move the selector lever 90° (clockwise) to the auxiliary filter position. Inspect for leaks. After determining the auxiliary filter system is ready for use, move the selector lever 90° (counterclockwise) motion to the main filter position.
Main Fuel Filter Elements (Standard System)
Close the fuel supply line valve. Remove the drain plug from each fuel filter end cover. Drain the filter housing. Remove the end covers and filter elements. Wipe the inside of the filter housing with a clean rag. Install the new filter elements. Install the new cover gaskets, if needed, and the end covers. Install the drain plugs. Open the fuel supply line valve. Prime the fuel system. Inspect for leaks.
Main Fuel Filter Elements (Duplex System)
(1) Move the selector lever to the AUX. VENT-MAIN RUN position. When air bubbles are no longer visible in the fuel tank sight gauge, move the selector lever to the AUX. FILTER RUN-MAIN OFF position. Remove the drain plug from the right-hand filter housing and vent plug from the right-hand cover. Drain the filter housing.
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Be sure you are removing the drain plug from the right-hand filter cover. As soon as the drain plug is loosened, fuel will spray out under high pressure for a short time until pressure drops in the housing. If the fuel continues to spray, you are removing the wrong drain plug and preparing to remove the wrong cover. |
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(2) Remove the end cover and filter elements. Wipe the inside of the housing with a clean rag. Install new filter elements. Install the end cover and a new gasket, if needed, the drain plug and the vent plug. Move selector lever to MAIN VENT-AUX. RUN position.
NOTE: If the fuel filter elements are changed while the engine is stopped, prime the fuel system by pumping the fuel priming pump until bubbles are no longer visible in bleed window. After air bubbles are no longer visible in the bleed window, move selector lever to MAIN FILTER RUN-AUX. OFF position. Inspect for leaks.
Auxiliary Fuel Filter Elements (Duplex System)
(1) Make sure selector lever is in the MAIN FILTER RUN-AUX. OFF position. Remove drain plug from left-hand housing and vent plug from left-hand cover.
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Be sure the drain plug from the left-hand cover is removed. As soon as the drain plug is loosened, fuel will spray out under high pressure for a short time. If spraying of fuel continues, you are removing the wrong cover. |
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(2) Remove the left-hand cover. Remove the filter elements. Wipe the inside of the housing with a clean rag. Install the new filter elements. Install the end cover and a new gasket, if needed, the drain plug and the vent plug. Move selector lever to AUX. VENT-MAIN RUN position.
NOTE: If the fuel filter elements were changed while the engine is stopped, prime the fuel system with the fuel priming pump until bubbles are no longer visible in bleed window. After air bubbles are no longer visible in the bleed window, move selector lever to AUX. FILTER RUN-MAIN OFF position. Check for fuel leaks. Move selector lever to MAIN FILTER RUN-AUX. OFF position.
Governor (Woodward)
Remove the Woodward UG8 Governor, if so equipped, from the engine. Remove the top cover and tip the governor over to drain the oil. Wash the inside of the governor with non-flammable solvent. Install the governor and fill the governor with oil; bleed the governor. See the Operation and Maintenance Guide for more detailed instructions.
Cooling System Conditioner
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Check the coolant ONLY when the engine is stopped and the filler cap is cool enough to touch with your hand. A serious burn can be the result from hot engine coolant. Slowly loosen the filler cap to release pressure in the cooling system. Add Caterpillar cooling system conditioner. The cooling system conditioner must be maintained at a concentration of 3% to 6%. |
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| NOTICE |
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Too much conditioner in a coolant mixture will form insoluble salts which can cause wear on water pump seal surfaces. See the Caterpillar service publications "Know Your Cooling System" for more detailed information about cooling system maintenance. |
Primary Fuel Filter (If so equipped)
Turn the fuel supply valve off, remove the element, wash the element in clean non-flammable solvent. Install the element, turn on the supply valve and check for leaks. Remove air from the fuel system, if necessary.
Soot Filter And Air Cleaner
Remove the soot filters (if so equipped). Remove and inspect the elements. Install new elements, if damaged. Clean the filter housings. Do not let any foreign material into the engine air intake. Clean the filter elements with air pressure [205 kPa (30 psi)], water [280 kPa (40 psi)] or wash in warm water and a non-sudsing household detergent. Dry the element and check for damage. Install new or clean elements. Install new soot filters, if needed.
Crankcase Breathers
Remove the breather element(s) and clean it in a non-flammable solvent. Use air pressure to dry the element. Install new gaskets, if needed. Install breather elements.
Valve Adjustment
Adjust the intake and exhaust valves on the engine when the engine is cold; see the Service Manual.
Water Pump(s)
Remove the water pump(s) (main and/or auxiliary) and install new seals in them or install exchange water pump(s); see the Service Manual.
Preventive Maintenance Checklist
Driven Equipment
