2820A_311_B.pdf

Individual Manual Application Sheet

Technical Publications Number

2820A

Secton Applicability

SWBS Number 311 SWBS Element Title SHIP SERVICE POWER GENERATION

Section Identifier B

Equipment Functional Description SERVICE MANUAL - SSDG (SEBR0511)

CI Functional Description ESWBS Code Remarks

Planset Hulls

905-WMEC 905, 906, 907, 908, 909, 910, 911, 912, 913

SEBRO511

CATIIRPILA.AR

0 0

A

T.: LIM I

EJ

( 71 cl� -

7241 Marine Transmission, REGO0953 7251 Marine Transmission, REGO0917 7261 Marine Transmission, REGO0789 7271 Marine Transmission, SENR7476 See your Caterpillar Dealer.

03799 0398 & D399

INDUSTRIAL AND

MARINE ENGINES

SERIAL NUMBERS

D379: 68B2540-UP AND 69131 227-UP

D398:66B3561-UP AND 67131391-UP

D399: 3513688-UP AND 91 B387-UP

SPECIFICATIONS (Section 1D., SYSTEMS OPERATION (Section 21..

TESTING AND ADJUSTING (Section 3)..

ATTACHMENT SPECIFICATIONS (Section 4)..

ATTACHMENTS (Section W., GENERAL INSTRUCTIONS (O & A) (Section 61

DISASSEMBLY AND ASSEMBLY (Section 7)

Individual Service Manuals are available for the following MARINE TRANS-

MISSIONS:

INDEX

When the word "Permissible" is in the description, the spe 'cification given is the "maximum or mini-mum" tolerance permitted before adjustment, repair and/or new parts are needed.

A comparison can be made between the measure-ments of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the re-mainder of its service life is good. If a short service life is expected, replace the part.

The specifications given in this book are on the basis of information available at the time the book was written. These specifications give the torques, operating pressure, measurements of new parts, adjustments and other items that will affect the service of the product.

When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification given, use the part again.

NOTE: The specifications given for "use again" and "permissible" are in-tended for guidance only and Caterpillar Tractor Co. hereby expressly denies and excludes any representation, warranty or implied warranty of the reuse of any component.

SPECIFICATIONS (Section 1)

A ftercooler ......................................................................... : ........ 1-10 Air-�uel Ratio Control ............................................................... - 1-7 Air Starting Motor ....................... .............................................. 1-42 Alternator Regulators ................................................................. 1-39 Alternators and Regulators ........................................................ 1-38

Bearing Surface (Journal) for Connecting Rods ........................ 1-28 Bearing Surface (Journal) for Main Bearings ............................ 1-29

Camshaft and Timing Gears ........................................................ 1-8 Charging Pump for Hydraulic Starter ......................................... 1-43 Connecting Rod ................................................. ....................... 1-25 Connecting Rod Bearings ......................................................... 1-26 Cooling System Pressure Cap .................................................. 1-19 Crankshaft .................................................................................. 1-24 Cylinder Block ........................................................................... 1-21 C ylinder H ead .............................................................................. 1-9 C ylinder Liner ............................................................................. 1-22 Cylinder Liner Projection ............................................................ 1-22

E ngine D esign ............................ I ................. I.......I ....................... 1-2 Engine Oil Pressure .......................... . ...................................... 1-17 Exhaust M anifold . ....................................................................... 1-10

Flyw heel ............ m............................................................... ......... 1-33 Flywheel Runout ........................................................................ 1-34 Flywheel Housing .............................. ...................................... 1-33 Flywheel Housing Bore ............. -. 1 ............................................. 1-36 Flywheel Housing Runout ........................................................ 1-35 Fresh and Auxiliary Water Pumps ........................................... 1-20 Front Accessory Drive . ............................................................... 1-32 Fuel Control Valve .................... ................................................. 1-4 Fuel Injection Equipment .................................. .......................... 1-3 Fuel Pump and Governor Drive ................................................... 1-5 Fuel Transfer Pump .......................................................... ........... 1-4

General Tightening Torques Generator Regulator .................. ............................................ 1-39 G overnor .................................. .............................................. _ 1-6

Hand Pump for Hydraulic Starter ............................................... 1-43 Hydraulic Starting Motor ............................................................ 1-43

Intake Manifold ............................................................ ............ 1-10

Magnetic Switch .. ....................................................................... 1-39 Main Bearings ................................... ...................................... 1-27

O il F ilter ............................................................. ........................ 1-18 O il P um p .................................................................................... 1-16 Oil Pump Relief Valve ....................................... ....... ................ 1-17

Pistons and Rings ..................................................................... 1-23 Prelube Pump ............................ ............................................... 1-18 Pressure Accumulator for Hydraulic Starter .............................. 1-43 Pressure Regulating Valve for Air Starting Motor ..................... 1-42

Sea W ater Pump ............................................... ........................ 1-20 Service Meter and Tachometer Drive .......................................... 1-7 S tarter M otor .............................................................................. 1-40 Starter Solenoids ....................................... ............................... � 1-41

Torque for Flared and O-Ring Fittings T urbocharger .............................................................................. 1-11 Turbocharger Lubrication Valve ................................................. 1-18

V-Belt Tension Chart .................................................................. 1-37 V alves ....................................................................................... 1-14 Valve Rocker Arms and Lifters .................................................... 1-8 Vibration Damper ...................................................................... 1-30

W ater Level Switch ........... ........................................................ 1-19 Water Temperature Regulators ................................................ 1-19

SYSTEMS OPERATION (Section 2) Air Inlet and Exhaust System ...................................................... 2-7 Cooling System ............................................................. 2-12

Aftercooler .............................................................................. 2-7 Coolant Level .......................... I............................... 1. 2-14 Turbocharger .......................................................................... 2-8 Engine Jacket W ater Cooling System .................................. 2-12 Valves and Valve Mechanism ................................................ 2-7 Sea Water and Separate Circuit Aftercooler

Air Starting System .......................................................... ......... 2-20 W ater Systems ......................................... I.......I.......I......... 2-15

Basic Block ............................... ................................................. 2-18 Crankshaft ............................................................... e- ......... 2-18 Cylinder Block, Heads and Liners ...... ................................. 2-18 Front Accessory Drive .......................................................... 2-19 Pistons, Rings and Connecting Rods ................................... 2-18 Timing Gears ....................................................................... 2-18 Vibration Damper ................................................................. 2-19

Electrical System Charging System Components Other Components Starting Components W iring Diagrams

2-23 2-23 2-24 2-23 2-25

D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

INTRODUCTION

D379, D398, D399, INDUSTRIAL AND MARINE ENGINES INDEX

SYSTEMS OPERATION Cont. (Section 2)

Engine Protection Devices ......................................................... 2-33 Fuel Ratio Control ................................................................... 2-6 Setting the Shutoff Control ................................................... 2�36 Hydra-maLtanical Governor ................................................... 2-S Shutoff Control ...................................................................... 2-33 Shutoff Control Operation ..................................................... 2-33 Hydraulic Starting System .......................................................... 2-21

Hydraulic Starting Motor ....................................................... 2-22 Fuel System .............. ................................................................. 2-2

Duplex Fuel Filter System ...................................................... 2-3 Fuel Injection Pumps ............................................................. 2-4 Lubrication System ....................................................................... 2-9 Fuel Injection Valve ................................................................ 2-4 Duplex Oil Filter System ....................................................... 2-10

Prefutirication System ........................................................... 2-10

TESTING AND ADJUSTING (Section 3)

Air Inlet and Exhaust System Compression Crankcase (Crankshaft Compartment) Pressure Cylinder Head Measurement of Pressure In Inlet Manifold Precombustion Chamber Restriction of Air Inlet and Exhaust Valves Valve Guides Valve Lash Adjustment and Check Valve Seat Inserts Water Directors

,Basic Block Checking Crankshaft Deflection (Bend) Connecting Rod and Main Bearings Connecting Rods and Pistons Cylinder Block Cylinder Liner Projection Flywheel and Flywheel Housing Piston Ring Groove Gauge Vibration Damper

3-35 3-36 3,36 3-37 3-35 3-36 3-35 3�37 3-37 3-38 3-37 3,36

3-46 3-50 3-46 3-46 3-47 3-47 3-46 3-51

Fuel System ............................................................................... 3-15 Alr-Fuel Ratio Control Adjustment ........................................ 3-30 Camshaft Cluster Gear Installation ...................................... 3-33 Checking Engine Cylinders Separately ................................ 3-15 Checking Fuel Injection Pump Timing with Timing Pin ................................................................. 3-22 Checking Timing by the Fuel Flow Method ........................ 3-24 Checking Timing by Measuring Timing Dimension -

(Depth Micrometer) ............................................................ 3-22 Checking Timing by Measuring riming Dimension

(Dial Indicator) .................................................................... 3-23 Finding Top Center Compression Position

For No. I Piston ................................................................. 3-21 Fuel Injection Service ........................................................... 3-19 Fuel Nozzle Test Sequence ................................................. 3-17 Fuel Rack Adjustment ......................................................... 3-29 Fuel System Inspection ........................................................ 3-15 Governor Adjustments .......................................................... 3,31 Measuring Engine Speed ..................................................... 3-32 Setting Fuel Injection Pump Timing Dimension:

Off Engine .......................................................................... 3-27 Start Up Procedure .............................................................. 3-20 Testing Capsule-Type Fuel Injection Nozzles for PC Engines ................................................................... 3-15 Timing Balancer Gear in Accessory Drive

(V-8 Only) ........................................................................... 3-33 Timing Camshaft for Fuel Injection Pumps ......................... 3-26

Cooling System .......................................................................... 3-43 Testing the Cooling System ................................................. 3-43 Visual Inspection of the Cooling System

Lubrication Systern Measuring Engine Oil Pressure Oil Pressure is High Oil Pressure is Low Too Much BearingW ear Too Much Oil Consumption Turbocharger Lubrication Valve

3-40 3-40 3-42 3-41 3-42 3-40 3-42

Electrical System Battery Charging System Prelube System Starting System

3-52 3-52 3-52 3-54 3-53

Engine Shutolf Control .............................................................. 3-56 Overspeed Control Adjustment ........................................... 3-56 T roubleshooting .......................................................................... 3-2

Air Actuator Group (UG8-L Governor) ................... 4-5

Cable Adjustment (Air Inlet Shutoff) ..................... 4-1 Contactor Switch for Oil Pressure ..................... 4-16 Conlactor Switch (or Overspeed ....................... 4-15 Contactor Switch (or Temperature ..................... 4-16

Enclosed Clutches .................................... 4-11

Flexible Coupling ...... ...................... I ....... 4-11

Gauges, Electrical ........................ ........... 4-13 Gauges, Mechanical .................................. 4-12 General Tightening Torques Governors .............................................. 4-2 Governor Air Actuators .................................. 4-4 Governor Upper Drive ................................... 4-3

Magnetic Pickup ........................................ 4-5

Pressure Switches .................................... 4.14

Sending Units for Electrical Gauges ................... 4-14 Shut-off, Air Inlet ....................................... 4-7 Shut-off, Hydra-mechanical ............................. 4-8 Shut-off, Mechanical Overspeed ....................... 4-10 Shut-off, Rack Cylinder ................................. 4-7 Shut-off Solenoids ...................................... 4-6 Shut-off Valve for Water Temperature .................... 4-6

Tachometer, Electric .................................. 4.15 Torque for Flared and O-ring Fittings

ATTACHMENT SPECIFICATIONS (Section 4)

Pierce Output Shaft Governor ..................................................... 5-6

Power Take-off Clutches ............ ....I.......................................... 5-10

Automatic Start/Stop System .................................................... 5-34 Attachments For Cranking Panel ......................................... 5-40 Automatic Transfer Switch ........................................... ... 5-34 2301 Control System Application ........................... ............. 5-38 Cranking Panel ........................................... 6 ......................... 5-35 Electric Set ....... ...................................................... ............. 5-36 Hydraulic Governor Application ........................ .................. 5-36

Governor Air Actuators ................................................................ 5-9

Hydra-Mechanical Shutoff ......................................................... 5-14 Hydra-Mechanical Shutoff (5N5993 and 5N5994) ............... 5-14 Hydra-Mechanical Shutoff (3N5760 and 5NI 978) ............... 5-22

2301 Nonparallel Control System ................ ............................. 5-32

2301 Parallel Control System ...................... .............. I....I .... 5-30

Shutoff And Alarm System Components Circuit Breaker Contactor Switch .

Oil Pressure Swii�� ..................................................... i , , , , Pressure Switch Shutoff Solenoid

Shutoff Valve For Water Temperature Water Temperature Contactor Switch ............ I

5-11 5-12 5-13 5-11 5-11 5-12 5-13 5-12

Woodward SGT Governor .......................................................... � 5-8

Woodward UGS Governors ............................................... ......... � 5-2 Woodward UGB Dial and Lever Governors .......................... 5-2

Power Take-off Clutches ............................................................ 5-90 Assembly Adjustments .......................................................... 5-90 Clutch Adjustment ................................................................. 5-90

2301 Control Systems ........................................... .................... 5-77 Magnetic Pickup ........... ....................................................... 5-77 Potentiometer Adjustment

(Parallel or Nonparallel Control) ........................ ............... 5-77 Woodward EG-3P Governor Actuator .................................. 5-77

Shuloff and Alarm System Components Contactor Switch for Oil Pressure Contactor Switch for Overspeed .... I Contactor Switch for Water Temperature

Rack Shutoff Solenoid Shutoff Valve (Water Temperature)

5-83 5-83 5-86 "4 5-85

5-85

Electronic Overspeed Switch Procedure A Overspeed Setting Calibration

Procedure B Magnetic Pickup Adjustment

Procedure C � Crank Terminate Speed Adjustment

Procedure D Overspeed Verify Test

Speed Specification Chart Troubleshooting Procedure (CrankTerminate) Troubleshooting Procedure (Overspeed) Wiring Diagram

5-91 5-94 S-94 5-94 5-94 5-95 5-95 5-96 5-96 5-96 5-93 5-92 5-91

Troubleshooting ......................................................................... 5-42

Woodward EG-SP Actuator .......................... ......... .............. 5-75 Actuator Linkage Adjustment .................. ............................. 5-76 Fuel Rack Adjustment ......................................................... 5-75

W oodward SGT Governor ........................................................ 5-62 Engine Governor Low and High Idle Adjustment ... .............. 5-62 Engine Governor Speed Droop ............................................ 5-63 Fuel Rack Adjustm ent .................................................... .... 5-62 Governor Linkage Adjustment ...... ....................................... 5-64 Torque Converter Governor High Idle

Speed Adjustm ent .............................................................. 5-64 Torque Converter Governor Speed

Droop Adjustm ent ............................................................. 5-34 W oodward UG8 Dial Governor .................................................. 5-66

Com pensating Adjustm ent .................................................... 5-66 Fuel Rack Adjustm ent ......................................................... 5-67 Governor Linkage Adjustment .............................................. 5-69 High Idle Speed Adjustm ent ................................................. 5-67

Woodward UG8 Lever Governor ............................................... 5-70 Com pensating Adjustm ent .................................................... 5-70 Fuel Rack Adjustm ent .. ........................ ......... ................... .5-71 Governor Linkage Adjustment .............................................. 5-73 Low and High Idle Speed Adjustment .................................. 5-71 Speed Droop Adjustm ent .................................................... 5-72

Governor Air Actuators ............................................................. " O 2N6006 Actuator .................................................................. 5-80 I N9318 and 71-1135 Actuators .............................................. 5-81 3N9125 Actuator .................................................................. 5-82 instruments and Gauges Electric Gauges � Mechanical Gauges for Oil Pressure Mechanical Gauges for Temperature oil Pressure Sending Units Water Temperature Sending Unit

5-87 5-87 5-89 5-89 5-87 5-87

M easuring Engine Speed ........................................................... 5-59

Pierce Output Shaft Governor ................................................... 5-60

0379, D398, D399, INDUSTRIAL AND MARINE ENGINES

ATTACHMENT SYSTEMS OPERATION (Section 5)

ATrACHMENT TESTING AND ADJUSTING (Section 5)

B atte ries ............................................ .......................................... 6-8 B ea rings ....................................................................................... 6-7

A nti-F riction ......... ........................ ........................ 1.11.1 ............ 6 -7 Double Row, Tapered Roller .................................................. 6-7 Heating Bearings .................................................................... 6-7 Installation ..................................................................... ......... 6-7 P re load ..... :'1111 ... 11-1 ...... "I ..... 11 ................................................. 6-7 Sleeve Bearings ............................................................ i......... 6-7

Bolls and Bolt Torque ...... ........................................................... 6-5 Torque Wrench Extension ..................................................... 6-6 T-T-T Procedure ........................................................... ......... 6-S

C leanliness ................................................................................... 6-2 Conversion Chart (Inches to mm) ................................................ 6-8

Disassembly and Assembly .... ................................................... 6-2

G askets ........................................................................................ 6-7

Initial Operation After Engine Reconditioning ............................. 6-3

Lines a nd W ires ........................................................................... 6 -6 Locks ............................................................................................ 6-6 Lubrication ............................ ....................................................... 6-7 Lubrication For a Rebuilt Engine ................................................ 6-2

Procedure For Pressure Lubrication ...................................... 6-3

P ressing P a rts .............................................................................. 6 -5

Removal and Installation .............................................................. 6-2 Rules for Use of Tools ................................................................. 6-5 Rust Preventive Compounds ....................................................... 6-7

Seals (Lip-Type) .......................................................................... 6-8 S ervice T ools ............................................................................... 6-3

Bearing Cup Pulling Attachment ............................................ 6-5 Bearing Pulling Attachment .................................................... 6-5 Puller Assembly (2 or 3 arm) ................................................ 6-3 P ush P ullers ............................................................................ 6 -4

S him s ........................................................................................... 6 -7

Accessory Drive Gears .............................................................. 7-26 Accessory Drive Housing ........................................................... 7-24 Aftercooler Cores ..................................................................... 7-134 Aftercooler Housing ............................................. . ................... 7-132 Air Cleaner ............................................................................... 7-124 Air Starter ................................................................................. 7-136 Air Starter, Assemble .............................................................. 7-144 Air Starter, Disassembly ......................................................... 7-138

Camshaft ....... :� ......... 11 ...... I....................... 11 .............................. 7-160 Camshaft Bearings ................................................................... 7-163 Connecting Rod Bearings ......................................................... 7-48 Crankshaft ................................................................................ 7-164 Crankshaft Front Seal (Lip Type) and Wear Sleeve ................ 7-20 Crankshaft Front Seal Ring and Thrower .................................. 7-18 Crankshaft Main Bearings ................................ I............ 7-105 Crankshaft Rear Seal Ring and Thrower ................................ 7-154 Cylinder Liners ......................................................... ............... 7-119 Cylinder Heads ....... ................................................................. 7-110

Electric Starting Motors ............................................................ 7-13,5 Engine Oil Cooler ....................................................................... 7-38 Exhaust Manifold (Industrial Engines) ....................................... 7-72 Exhaust Manifolds (Marine Engines) ......................................... 7-75 Expansion Tank (Marine Engines) ........................................... 7-10

Flywheel ........ .................................................. ........................ 7-152 Flywheel Housing ............................................ ........................ 7-156 Fresh W ater Pump ..................................................................... 7-40 Fresh Water Pump, Assemble .. ................................................. 7-44 Fresh W ater Pump, Disassemble ............................................- 7-42 Fuel Filter Housing .......................................... .......................... 7-11 Fuel Injection Pumps ................................................................. 7-70 Fuel Injection Liner ..................................................................... 7-71 Fuel Injection Valves .................................................................. 7-97 Fuel Injection Pump Housing ..................................................... 7-79 Fuel Injection Pump Housing, Shutalf Control, Governor and Governor Drive .................. ........................ 7-77 Fuel Priming Pump ........................ I................I............................ 7-7 Fuel Priming Pump. Disassemble & Assemble .......................... 7-8 Fuel Ratio Control W ith Override ............................................... 7-51 Fuel Ratio Control With Override, Disassemble & Assemble ................. ........................ .......... 7-52 Fuel Transfer Pump ..................................................................... 7-3 Fuel Transfer Pump, Assemble .................................................... 7-6 Fuel Transfer Pump, Disassemble ................. I............................ 7-5

General Tightening Torques Generator ........................ See Special Instruction Form SMHS7259 Governor Drive Housing ............................................................ 7-88 Governor .................................................................................... 7.53 Governor, Assemble .................................................................. 7-59 Governor, Disassemble .............................................................. 7-55

Intake Manifolds ....................................................................... 7-104

Marine Gear .................... See Special Instruction Form GEGO0969

O il Filter H ousing O il P an B ass Oil Pressure Relief Valve Oil Pressure Relief Valve, Disassemble & Assemble O il P um p Oil Pump, Assemble Oil Pump, Disassemble

7-12 7-50 7-30 7-30 7-31 7-36 7-36

Pistons .................................................................................... 7-116 Pistons, Disassemble & Assemble .......................................... 7-118 Piston Cooling Tubes .............................................................. 7-108 Precombustion Chambers .......................................................... 7-98 Prelubircation Oil Pump (13399) ................................................ 7-46 Prelubrication Oil Pump (13399), Disassemble

& Assemble ........................................................................... 7-47

Rear Timing Gears ................................................................... 7-158 Rocker Shafts and Push Rods ..... ............................................ 7-99 Rocker Shafts and Push Rods, Disassemble

& Assemble ......................................................................... 7-100

Torque for Flared and O-Ring Fittings Turbocharger ............................................................................ 7-126 Turbocharger. Assemble ......................................................... 7-130 Turbocharger, Disassemble ..................................................... 7-126 Turbocharger Lubrication Valve ............................................... 7-121 Turbocharger Lubrication Valve, Disassemblo

& Assemble ......................................................................... 7-122 Turbocharger Heat Shield ..................... I..............................I... 7-125

Sea Water Pump ........................................................................ 7-13 Sea Water Pump, Assemble .................................................... 7-16 Sea Water Pump, Disassemble ................................................. 7-15 Service Meter and Tachometer Drive ....................................... 7-22 Shutoff Control ........................................................................... 7-63 Shutoff Control, Assemble ......................................................... 7-67 Shutolf Control, Disassemble .................................................... 7-64 Shutoff Control Group ................................................................ 7-90 Shutoff Control Group, Assemble .......... I......I......................I..... 7-94 Shutoff Control Group, Disassemble ......................................... 7-91 Sump Pump ............................................................................. 7-123

Valves ...................................................................................... 7-112 Valve Covers ........................................................................... 7-109 Vibration Damper (13398 and D399) .......................................... 7-17 Valve Guides ........................................................................... 7-114 Valve Lifters ............................................................................. 7-102 Valve Seat Inserts .................................................................... 7-115

Water Directors ....................................................................... 7-115 Water Temperature Regulators ................................................... 7-9

D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

GENERAL INSTRUCTIONS

DISASSEMBLY AND ASSEMBLY (Section 6)

DISASSEMBLY AND ASSEMBLY (Section 7)

GENERAL TIGHTENING TORQUE FOR

BOLTS, NUTS AND TAPERLOCK STUDS

The following charts give the standard torque values for bolts, nuts and taperlock studs of SAE Grade 5 or better quality. Exceptions are given in other sections of the Service Manual where needed.

THREAD DIAMETER STANDARD TORQUE

inches' millimeters lb. ft. N.m*

SUndard thmad Use these torques for bolts and nuts with stan-dard threads (conversions are approximate).

1/4 6.35 9 ± 3 12 ± 4 5/16 7.94 18 ±5 25 ± 7 3/8 9.53 32 ±5 45 ± 7 7116 11.11 50 ±10 70 ± 15 112 12.70 75 ±10 100 ±15 9/16 14.29' 110 ±15 150 ± 20 5/8 15.88 150 + 20 200 ± 25 3/4 19.05 265 35 360 ± 50 718 22.23 420 60 570 ± 80

1 25AO 640 80 875 ± 100

1 118 28.58 800 100 1 10D ± 150 1 114 31.75 1000 ±120 1350± 175 1 318 34.93 1200 ±150 1600 ± 200 1112 38.10 1500 ± 200 2000± 275

Use these torques for bolts and nuts on hydraulic valve bodies.

5/16 7.94 13 ±2 20 ± 3 318 9.53 24 ± 2 35 ± 3 7/16 11.11 39 ±2 50 ± 3 1/2 12.70 60 ± 3 80 ± 4 5/8 15.88 118 ±4 160 ± 6

Tapeflack3tud

C:Effm Use these torques for studs with Taperlock threads.

1/4 6.35 5 ± 2 7 3 5/16 7.94 10 ± 3 15 5 318 9.53 20 ± 3 30 5 7/16 11.11 30 5 40 10 112 12.70 40 5 65 10 9/16 14.29 60 10 80 15 5/8 15.88 75 ±10 100 ± is 3/4 ig.os 1101±15 150 ± 20 7/8 22.23 170 ± 20 230 ± 30

1 25.40 260 ± 30 '350 ± 40 1 1/8 28.58 320 ± 30 400 ± 40 11/4 31.75 400 ± 40 550 ± so 1 3/8 34.93 480 ± 40 650 ± 50 1 1/2 38.10 550 ± 50 750 ± 70

13379, D398, D399 INDUSTRIAL AND MARINE ENGINES SPECIFICATIONS

* 1 newton meter (N m) is approximately the same as 0.1 mkg- T95416-7

L-L4LLJ uu- q--Lj

FRTED O-RING45 ARE 370"VF L D -LARED 450 FLARED FITTING - PLUG SWIVEL N.UTS

TUBE mm 3.1 81 4.781 6.35 7.92 9.52 TUBE mm 12.70 15.88 19.05 22.22 25AO 31.75 38.10 1 50.80

SIZE SIZE

(O.D) � in. .125 .188 .250 .312 .375 (O.O.) n. .500 .625 .750 .875 1.000 i.250 1.5001 2.000

,THREAD 9116 THREAD 1 3116

SIZE (in.) 5116 3/8 7116 112 5/8 SIZE (in.) 314 7/8 1 1116 1 114 1 5/16 1 5/8 1 718 1 2 112

JORQUE 5 9 16 Is 21 TORQUE 40 55 75 90 110 135 160 310 N-rn I I, ±2 ±2 ±2 N-rn ±7 i7 ±7 ±7 ±7 +15 ±15 ±30

TORQUE 45 145 155 190 TORQUE

1b.in, ±10 ±10 ±20 ±20 ±20 IbJt. 30 ±5 40 ±5 55 ±5 65 ±5 80 ±5 100 ±10 120 ±10 230 ±20

D379, D398. D399 INDUSTRIAL & MARINE ENGINES SPECIFICATIONS

1. Put lock-nut (3), back-up washer (4) and O-ring seal (5) as far back on fitting body (2) as possible.

Hold these components in this position. Turn the fitting into the part it is used on, until backup washer (4) just makes contact with the face of the part it is used on.

NOTE: If the fitting is a connector (straight fitting) or plug, the hex on the body takes the place of the locknut.

To install this type fitting tighten the Iiex against the face of the part it goes into.

2. To put the fitting assembly in its correct position turn the fitting body (2) out (counterclockwise) a maximum of 359'. Tighten lock-nut (3) to the torque shown in the chart.

A71009XI

ELBOW BODY ASSEMBLY

1. End of fitting body (connects to tube). 2. Fitting body. 3. Locknut. 4. Backup washer. S. 0-ring seal. 6.

End of fitting that goes Into other part.

TORQUE FOR FLARED AND O-RING FITTINGS

I The torques shown in the chart that follows are to be used on the part of 37' Flared, 45' Flared and

Inverted Flared fittings (when used with steel tubing), O-ring plugs and O-ring fittings.

ASSEMBLY OF FITTINGS WITH

STRAIGHT THREADS AND O-RING SEALS

Operations that may result only in mechanical damage are identified by labels on the product and in the Service Manual by the word CAUTION.

Caterpillar can not anticipate every possible circumstance that might involve a potential hazard. The warnings in this Manual are therefore not all inclusive. If a procedure, tool device or work method not specifically recommended by Caterpil-lar is used, you must saftisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the procedures you choose.

IMPORTANT

The information, specifications and illustrations in this book are on the basis of information available at the time it was written. The specifications, torque, pres-sures of operation, measurements, adjustments, illustrations and other items can change at any titne. These changes can affect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current infortnation available. For a list of the most current modules and forni numbers available for each Service Manual, see the SERVICE

MANUAL CONTENTS MICROFICHE REG I 139F.

A83264X1

N Li [hl

IMPORTANT SAFETY NOTICE

Proper repair is important to the safe and reliable operation of this product. This Service Manual outlines basic recommended procedures, some of which require special tools, devices or work methods. Although not necessarily all inclusive, a list of additional skills, precautions and knowledge required to safely perform repairs is provided in the SAFETY section of this Manual.

Improper repair procedures can be dangerous and could result in injury or death.

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS

AND WARNINGS BEFORE PERFORMING REPAIRS

Basic safety precautions, skills and knowledge are listed in the SAFETY section of this Manual and in the descriptions of operations where hazards exist. Warning labels have also been put on to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons.

These labels identify hazards which may not be apparent to a trained mechanic.

There are many potential hazards during repair for a untrained mechanic and there is no way to label the product against all such hazards. These warnings in the Service Manual and on the product are identified by this symbol:

I 1-1 1. I Li I I 11 I

II-11A

Improper performance of lubrication or main-tenance procedures is dangerous and could result in injury or death. Read and understand the lubrication and maintenance procedures, recommended by Caterpillar, that are outlined in the OPERATION GUIDE and/or OWNER'S MANUAL for this product before performing any lubrication or maintenance.

Do not operate this product unless you have read and understood the instructions. Improp-er operation is dangerous and could result in injury or death.

- N""6

4. If an engine must be started to make pressure or speed checks, be sure all guards and shields are installed. To help prevent an accident caused by parts in rotation, work carefully around machinery that has been put into operation.

5 . If an engine has been running and the coolant is hot, loosen the filler cap slowly and let the pres-sure out of the cooling system, before any caps, plugs or lines are removed or disconnected.

6. Corrosion inhibitor contains alkali. Avoid contact with eyes. Avoid prolonged or repeated contact with skin. Do not take internally. In case of con-tact, immediately wash skin with soap, and water.

For eyes, flush with large amounts of water for at least 15 minutes. CALL PHYSICIAN. KEEP

OUT OF REACH OF CHILDREN.

7. Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not let electrolyte solution make con-tact with skin or eyes. Electrolyte solution is an acid. In case of contact, immediately wash skin with soapand Water. For eyes, flush with large amounts of water for at least 15 minutes. CALL

PHYSICIAN. KEEP OUT OF REACH OF

CHILDREN.

8. Disconnect battery and discharge any capacitors before starting any repair work-, Hang "Do Not Operate" tag in the Operator's compartment or on the controls.

9. Do not work on anything that is supported only by lift jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work.

10. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are dis-connected or removed. Be alert for possible pres-sure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can pierce the skin.

The servicemen or mechanic may be unfamiliar with many of the components and systems of this product.

This makes it important to use caution when perform-ing service work. A knowledge of the system and/or components is important before the removal or disas-sembly of any component.

Because of the size of some components, the service-man or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components.

Following is a list of basic precautions that should always be observed.

Read and understand all Warning plates and de-cals before operating, lubricating or repairing this product.

2. Make sure the work- area around the product is made safe and be aware of hazardous conditions that may exist.

3 . Always wear protective glasses and protective shoes when working. In particular, wear protec-tive glasses when a hammer or sledge is used for pounding to make repairs. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed.

Do not wear loose-fitting or torn clothing. Re-move all rings from fingers when working on machinery.

A83265XI

SAFETY

11. Never bend a fuel injection line, or install a line which has been bent. Keep the fuel injection lines and connections clean. Be sure to install caps and covers any time a line is removed or disconnected.

12.. During service work-, do not hit the fuel injection lines with wrenches or other tools. When lines are installed, use the correct torque to tighten connec-tions and be sure all clamps and dampers are correctly installed.

13. Make sure all fuel injection lines and pressure oil lines have enough clearance to prevent contact with any other component. Do not put any fuel or oil lines close to a hot component.

14. To avoid back injury use a hoist or get help when lifting components which weigh 50.1b. (23 kg) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capac-ity. Be sure hooks are positioned correctly. Lift-ing eyes are not to be side loaded during a lifting operation.

15. To avoid bums, be alert for hot parts on products which have just been stopped and hot fluids in lines, tubes and compartments.

16. Be careful when removing cover plates. Gradual-ly back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, be-fore removing them completely.

17. Be careful when removing filler caps, breathers and plugs on the product. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the product has recently been stopped because fluids can be hot.

18. Always use tools that are in good condition and be sure you understand how to use them before per-forming any service work. Use only Caterpillar replacement parts.

19. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary.

20. Repairs which require welding should be per-formed only with the benefit of the appropriate reference information and by personnel adequate-ly trained and knowledgeable in welding proce-dures. Make reference to "Techniques of Struc-tural Repair Course" form number JEG03719.

Detennine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

21. Before doing electrical work, disconnect battery.

Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp cor-ners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

22. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perforrn the repair work-, use extra caution. After the repair is com-pleted, reinstall any guard or shield that was re-moved.

A83266X2

D379. D398, D399 INDUSTRIAL AND MARINE ENGINES INDEX

A lteroooler .................................................................................. 1-10 Air-Fuel Ratio Control ............................... ................................. 1-7 Air Starting Motor ......... ............................................................ 1-42 Alternator Regulators .. ............... ................................... I'll ........ 1-39 Alternators and Regulators ........................................................ 1-38

Bearing Surface (Journal) for Connecting Rods ........................ 1-28 Bearing Surface (Journal) for Main Bearings ............................ 1-29

Camshaft and liming Gears ........................................................ 1-8 Charging Pump for Hydraulic Starter ......................................... 1-43 Connecting Rod ......................................................................... 1-25 Connecting Rod Bearings ......................................................... 1-26 Cooling System Pressure Cap .................................................. 1-19 C rankshaft .................................................................................. 1-24 C ylinder B lock ........................................................................... 1-2 1 C ylinder H ead ........................................... .................................. 1-9 C ylinder Liner ............................................................................. 1-22 Cylinder Liner Projection .............................. ............................. 1-22

E ngine D esign .............................................................................. 1-2 Engine Oil Pressure .................................................................. 1-17 Exhaust Manifold ....... .................................. ............................. 1-10

Flywheel .... ................................................................. .............. 1-33 Flywheel Runout ........................................................................ 1-34 Flywheel Housing ...................................................................... 1-33 Flywheel Housing Bore ............................................................. 1-36 Flywheel Housing Runout ....................................... I ................. 1-35 Fresh and Auxiliary Water Pumps ............................................. 1-20 Front Accessory Drive ................................................................ 1-32 Fuel Control Valve ...................................................................... 1-4 Fuel Injection Equipment ............................................................. 1-3 Fuel Pump and Govemor Drive ................................................... 1-5 Fuel Transfer Pump ..................................................................... 1-4

General Tightening Torques Generator Regulator .................................................................. 1-39 G overnor ...................................................................................... 1-6

Hand Pump for Hydraulic Starter ............................................... 1-43 Hydraulic Starting Motor ............................................................ 1-43

Intake M anifold .......................................................................... 1-10

M agnetic S w itch ......................................................................... 1-39 M ain B earings ........................................................................... 1-27

O il Filter ...................................................................................... 1-18 O il P um p .................................................................................... 1-16 Oil Pump Relief Valve ................................................................ 1-17

Pistons and Rings ............ ........................................................ 1-23 P relube P um p ............................................................................ 1-18 Pressure Accumulator for Hydraulic Starter .............................. 1-43 Pressure RegulaVng Valve for Air Starting Motor ..................... 1-42

Sea W ater Pump ........................................................................ 1-20 Service Meter and Tachometer Drive .......................................... 1-7 S tarter M otor .............................................................................. 1-40 S tarter S olenoids ........................................................................ 1-4 1

Torque for Flared and O-Ring Fiftings T u rbocharg er .............................................................................. 1-11 Turbocharger Lubrication Valve ................................................. 1-18

V-Beft Tension Chart .................................................................. 1-37 V alves ....................................................................................... 1-14 Valve Rocker Arms and Litters .................................................... 1-6 Vibration Damper ...................................................................... 1-30

W ater Level Switch .................................................................... 1-19 Water Temperature Regulators ................................................ 1-19

1-1

SPECIFICATIONS (Section 1)

ENGINE DESIGN

0 Q W W

000 0000 D379 Engine ................. ....................... Vs

U.

Bore .................................... 6.25 in. (158.8 mm)

Stroke ................................. 8.00 in. (203.2 mm)

Direction of Rotation (when seen from flywheel…