2820A_311_C.pdf

Individual Manual Application Sheet

Technical Publications Number

2820A

Secton Applicability

SWBS Number 311 SWBS Element Title SHIP SERVICE POWER GENERATION

Section Identifier C

Equipment Functional Description

OPERATION AND MAINTENANCE

MANUAL - SSDG (SEBU5698-01)

CI Functional Description ESWBS Code Remarks

Planset Hulls

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

SEBU5698-01

CATORPILLAR

Cl

1:3

Li

B-B

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Table of Contents M o d e l V ie w s

S a fe ty

B e fo re S ta rting

S ta rting th e E n g ine

O perating the Engine

Stopping the Engine

A tta c h m e nts

Maintenance Recommendations

Lubricants, Fuels and Coolants

Lubrication and Maintenance Chart

R e fill C a p a c itie s ....................................................................................................... 3 3

Every 10 Service Hours

Every 50 Service Hours

Every 125 Service Hours

Every 250 Service Hours

Every 500 Service Hours ......................................... I

Maintenance Periods for Engine Filters, Oils and Breather(s)

Every 1000 Service Hours

Every 2000 Service Hours

W h e n R e q uire d .......................................................... ............................................... 5 8

Model Views

D379

D398

D399

M

Be sure engine room is properly ventilated.

Do not allow electrolyte solution to contact skin or eyes. Electrolyte solution is an acid.

Do not attempt repairs you do not understand. Follow instructions.

Replace or repair broken or damaged servicing equip-ment. Use proper tools.

Remove all tools, electrical cords and other loose items from the engine before starting.

Wipe up spilled oil, fuel or coolant.

To prevent personal injury, install guards over all ex-posed rotating parts.

Stop engine before adjusting or repairing engine or driven equipment.

Do not wear loose clothing whenever working around engines or machinery.

To prevent hearing damage, wear ear protective de-vices if working inside an enclosed engine room with engine running.

Wear protective glasses, clothing, hat, respirator or other protective items when necessary.

When using pressure air, wear protective face shield and clothing. Use 30 PSI (205 kPa) maximum air for cleaning purposes.

Always inspect cooling system with engine stopped.

If equipped with jacket water cooling system, remove filler cap slowly to relieve pressure. Steam may cause personal injury.

Cooling system inhibitor contains alkali, avoid contact with skin and eyes to prevent personal injury.

Do not smoke while refueling. Fumes from fuel are flammable.

Do not smoke when observing battery electrolyte lev-

el. Batteries give off flammable fumes.

Provide adequate and safe waste oil disposal.

Store oily rags in fireproof containers. DO NOT leave rags on engine.

Never store flammable liquids near the engine.

Disconnect and tape the battery ground lead before working on an engine to prevent accidental starting.

Never start an engine with the governor linkage disconnected.

When starting an engine after repair, make provisions for shutting off air supply, to stop engine, in case there is an overspeed on start up.

Safety VAF'J THIS SYMBOL WARNS OF POSSIBLE

PERSONAL INJURY

1. Inspect the air cleaner service indicator. If the red piston is locked in the raised position, service the air cleaner.

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3. Measure the crankcase oil level. The oil level must be between ADD and FULL marks on the dipstick.

2. Inspect the coolant level. The level must be to the bottom of the radiator filler neck.

4. Disconnect any battery chargers that are not pro-tected against the starter current drain.

5. All guards must be in place, Repair or replace all guards that are damaged.

Before Starting

Perform required periodic maintenance before starting the engine. Make a "walk-around" inspection of the in-stallation. It only takes a few minutes to correct.minor discrepancies. This can prevent major repairs at a I er date. F

Starting fluid is volatile and must be stared away from heat and direct sunlight. If an aerosol container is used, follow the instructions on the container.

8. Operate the engine at low load until all systems reach operating temperatures. Check all gauges dur-ing the warm-up period.

If the temperature is below 60"F (160C), a starting aid may be necessary and/or crankcase oil may need to be heated. Jacket water heaters are often used to as-sist starting in cold temperatures.

1. Place the transmission in NEUTRAL.

2. Move the throttle to half engine speed.

3. Turn the starter switch to START. If starting fluid is necessary, discharge the starting fluid capsule or spray starting fluid into the air cleaner inlet. (if the en-gine fails to start within 30 seconds, release the start-er switch and wait 2 minutes to allow the starter motor to cool before using it again.)

4. As soon as the engine starts, allow the engine to idle for 3 to 5 minutes, or until the water temperature gauge has begun to rise.

5. Do not apply load to the engine or increase engine speed until the oil pressure gauge indicates normal.

(Oil pressure should raise within 15 seconds after the engine starts.)

6. Operate the engine at low load until all systems reach operating temperatures. Check all gauges dur-ing the warm-up period.

1. Place the transmission in NEUTRAL.

2. Move throttle to half engine speed.

3. Turn the switch to the ON position.

4. Turn the HEAT-START switch to HEAT or START, as indicated by the chart.

S. After the indicated heat time, turn the switch to the START position, and if starting fluid is necessary, dis-charge the starting fluid capsule or spray starting fluid into the air cleaner inlet. (If the engine fails to start within 30 seconds, release the starter switch and wait 2 minutes to allow the starter motor to cool before us-ing it again.)

6. As soon as the engine starts, allow the engine to Idle 3 to 5 minutes or until the water temperature gauge has begun to rise. In cold temperature, turn the HEAT-START switch to the HEAT position until the engine runs smoothly at low idle.

7. Do not apply load to the engine or increase engine speed until the oil pressure registers on the gauge.

(Oil pressure should raise to normal within 15 seconds after the engine starts.)

1. Open and close the bleed valve on the bottom of the air tank to drain condensation and oil carryover.

2. Check the air supply pressure. The air start must have 100 PSI (7 kg/cm2) to operate properly.

3. Check the oil level in the oiler jar. Keep jar at least half full. Add oil if necessary. See the LUBRICATION AND MAINTENANCE CHART for the proper oil to use.

4. Pull the air valve upward to crank the engine. As soon as the engine starts, release the valve.

Starting the Engine Electric Starting

Engines Equipped With Glow Plug Starting Aid

Engines Not Equipped With Glow Plug Starting Aid

Air Starting

Starting Aid Chart Engines Equipped With Glow Plug Starting Aid

Starting Temperature Glow Plug Heating Time

Above 60OF (160C) As Required

Between 60OF and 32OF (1 &C and OOC) 1 Min.

I Between 32OF and OOF* (OOC and -1 80c) 2 Min.

I - Below OOF** (-180C) i 3 Min.

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PRESSURE

'Use starting fluid sparingly it required.

"Heating of coolant and crankcase oil, use of starting fluid and/or use of extra battery capacity may be required.

Gauges

Be sure they are in good working order. You can de-termine what is "normal" operating range by observing and recording the gauges over a period of time. The cause of any sudden or significant change in the read-ings should be determined and corrected.

Fuel

Indicates the level of fuel in the tank. Electrically oper-ated, it registers only when the key switch is ON. -

Indicator should register in the NORMAL (green) range. When the filter element becomes clogged, the indicator moves to the OUT (red) position. Wash the primary fuel filter and replace the secondary fuel filter element.

Starting the Engine

Fuel Pressure

Ammeter Tachometer Indicates the rate of battery charge or discharge. Indicates engine RPM.

Oil Pressure Water Temperature Registers between 45 and 70 psi (310 and 480 kPa) when the engine is running at rated engine speed, with SAE 30 oil, at operating temperature. A lower pressure is normal at low idling speeds. If no pressure is indicated, stop the engine immediately.

Normally registers between 170OF and 195OF (70'C and 900C). Somewhat higher temperatures may occur under certain conditions. Maximum allowable tempera-ture is 210'F (99'C) with the cooling system pressurized.

1. Move the governor control to half engine speed.

2. Engage the driven equipment.

4. Move the governor control to high idle (full load) position.

5. Apply the load to the driven equipment.

3. Check the engine gauges and equipment.

Operating the Engine

30 Seconds

Low Idle

Before stopping the engine, operate it at low load for 5 minutes, then at low idle for 30 seconds. (This proce-dure allows hot areas in the engine to cool gradually, lextending the engine life.)

1. Remove the load from the engine.

2. Move the governor control to the off position.

See "Attachment" section for type of shutoff your engine is equipped with, Stopping the Engine

The oil sight gauge Cl) shows the amount of oil in the Governor.

The speed droop control Cg) is used to adjust the amount of speed droop. Speed droop is the difference between no load high idle rpm and full load rpm.

The synchronizer knob (1) is used to change engine speed. The synchronizer motor, mounted on top of the governor, can also be used to change engine speed.

The synchronizer indicator � tells the amount of turns the synchronzier has moved.

Load limit knob � is used to control the maximum of travel of the output terminal shaft. The control can be used to stop the engine if the knob is turned to zero.

Starting the Engine With a Woodward UG-8 Governor

7. Turn the load limit knob � to "10."CAUTION

Do not move the governor linkage in the increase fuel direction until the load limit control is moved to the maximum position.

1. Perform all pre-start checks outlined previously.

2. Check the oil level in the sight level gauge with the engine stopped. Oil level should be near the top of the sight level gauge.

3. Turn the load limit knob � until the indicator is be-tween "5" and "T"

4. Turn the synchronizer knob � clockwise until the indicator (g) is at "8."

If the governor is equipped with an electric motor, op-erate synchronizer knob (5) by using the RAISE- LOWER switch on the control panel.

5. Move the START-STOP switch to the START posi-tion; start the engine.

6. Run the engine at low idle for 5 minutes.

S. Turn synchronizing knob (3) clockwise until the en-gine runs at full governed speed.

9. Turn speed droop knob (2) to obtain proper droop for the operation:

a. For single unit operation, set knob (k) at "O."

b. Speed droop can be adjusted as follows - all at no load.

(I.) Set speed droop knob at "O."

(2.) Adjust synchronizer to full load speed.

(3.) Use speed droop knob to raise engine to de-sired High Idle.

(4.) Verify by applying full load. Engine should re-turn to full load speed.

10. Apply the load. Readjust the synchronizer knob to obtain the desired load division. Load pointer indicates the relative load.

Attachments Woodward UG-8 Dial Governors

b. i.A-M�Vrk The UG-8 Lever governor is used when the rpm must be raised or lowered quickly.

The oil sight gauge 0 shows the amount of oil in the governor.

The lever � on the speed adjustment shaft is used to change the engine speed. It is normally remote controlled with air actuation.

This governor is equipped with speed droop, however, it must be adjusted inside the governor. See Service Manual for adjusting speed droop.

The 2301 Nonparallel Control gives exact engine speed control. The system measures engine speed constantly and makes necessary corrections to the en-gine fuel setting through an actuator connected to the fuel system.

The 2301 Parallel Control has two functions: exact en-gine speed and kilowatt load sharing. The system measures engine speed constantly and makes neces-sary corrections to the engine fuel setting through an actuator connected to the fuel system.

The actuator is connected to the fuel system by link-age. It changes the electrical input from the control box to mechanical output that changes the engine fuel setting. For example, if the engine speed was more than the speed setting, the control box will decrease fuel tothe engine.

1 1

Stopping the UG-8 Woodward Dial Governor

1. Move the synchronizer knob (2) until the synchro- 3. Turn the load limit knob �) to "O."

nizer indicator points to "B", or the low idle is reached.

2. Run the engine at low idle for 5 minutes to allow the engine to cool down before shutting the engine

OFF,

Woodward UG-8 Lever Governor

Woodward 2301 Electronic Governors

2301 Parallel and Nonparallel

Output-Shaft Governor and Hydraulic Servo Mechanism

1. Flexible drive cable. 2. Output shaft gover-nor. 3. Terminal lever. 4. Rocker shaft. S. Rate ad-justing screw. 6. Speed change lever. 7. Governor spring. 8. Bumper screw. 9. Link. 10. Lever. 11.

Lever. 12. Low speed adjusting screw. 13. High speed adjusting screw. 14. Bracket.

Thus, it acts as a speed-limiting device by preventing ,the output shaft and drive equipment from suddenly overspeeding. This also relieves the operator of mak-ing speed adjustments through the engine governor.

The output shaft governor acts as an "assistant opera-tor," automatically reducing engine speed, which, in turn, reduces converter output-shaft speed whenever the load on the converter output shaft decreases.

Attachments Pierce Output-Shaft Governor

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Woodward SGT Governor

1. Fuel control lever. 2. High idle screw for the torque converter governor. 3. Speed adjusting le-ver. 4. High Idle screw for the engine governor.

The SGT Governor for the torque converter has two speed-droop governors assembled in a single housing so that either governor can control fuel to the engine.

One governor is operated by the engine. The other governor is operated by a flexible cable from the torque converter.

The two governors use a single servo piston to move the fuel system linkage. The actions of the speeder springs in the governor, which are oper-ated by the speed droop can be made for control of engine and torque converter speed. Oil from the pilot valve of the engine governor is moved to and from the governor servo piston by going through the piston valve of the converter governor.

When the torque converter speed is less than the val-ue given in the specifications, the pilot valve for the converter governor gives a straight through oil pas-sage from the engine governor to the servo piston be-cause the force from the flyweights of the converter governor is not enough to lift the pilot valve. Under this condition the fuel is under control of the engine governor only. At an increase in the engine speed set-ting or a decrease in the load, the speed of the torque converter will go to the maximum speed adjustment for the converter governors At this point, the pilot valve for the converter governor will be lifted to close the passage between the engine governor and the servo piston and the converter governor will take control. A decrease in load or increase in engine speed setting will now cause no increase in torque converter speed because the pilot valve for the converter governor will be lifted to release oil from the servo piston and the converter governor will control fuel flow to the engine.

Woodward SGT Governor

1 N9318 and 71-1 35 Air Actuators

2. Hand control lever for the governor.

2N6006 Air Actuator

1. Linkage.

Three types of actuators are available. The 2N6006 Actuator connects directly to the governor control shaft through linkage (j). Inspection or replacement of the diaphragm without changing the adjustment of the high or low idle speeds or the spring preload is possi-ble. See REMOVE AND INSTALL DIAPHRAGM in DISASSEMBLY AND ASSEMBLY. The 1N9318 and 7LI35 Actuators control the governor through the hand control lever (g) and cross shaft linkage. These actuators have an adjustment for spring preload only.

3N9124 Air Actuator

3N9124 Air Actuator for UG8 Lever Governor is at-tached directly to the governor. One linkage rod con-nects the actuator to the governor speed control lever.

Attachments Governor Air Actuators

The governor air actuator gives remote control of vari-able speed for the engine. The actuator operates on air pressure. Air pressure on the cup in the actuator moves the plunger, spring and rod. This motion con-trols the governor through the linkage.

An automatic start-stop system is used when an en- speed, pick up the load, operate the load until a see-gine must start when a specific condition occurs. With ond condition occurs, remove the load, cool and stop.

no one In attendance, the engine will start, increase

Conditions Required for Starting

1. Either the ambient (engine room) temperature should be maintained at a minimum temperature of approximately 70OF (20110) or, the engine jacket water temperature must be maintained at a minimum tem-perature of 9011F (320C). A jacket water heater should be used to maintain this temperature.

2. If a prelube oil pump is used, the pump must oper-ate before the starting motor(s) are energized, and stop when the engine starts and oil pressure in-creases. In some applications, special prelube pumps run continuously when engine is shut down.

A timer allows the engine to crank either once for 30 seconds, or to crank through 5 ten-second cranking cycles (depending upon the device used) while unat-tended. If the engine does not start before the time elapsed, the fuel system will be shut off and a light will indicate a starting failure.

Audible prealarms provide an audible, and usually, a visual indication for low oil pressure, high water tem-perature, low fuel supply or low jacket water tempera-ture, before the condition becomes critical. These alarms are self resetting as soon as the condition is corrected.

The engine may also be equipped with shutoff devices so that if low oil pressure, high jacket water tempera-ture or an engine overspeed condition occurs, the en-gine will be shut down. A light will indicate the cause of the shutdown. These devices must be reset after repairs have been made and before starting.

Automatic Start-Stop

Protection Devices

Batteries

Lights can indicate it a fault has occurred in the bat-tery charging system, This would cause the battery to be either undercharged or overcharged.

Overcranking

Engine Operating

To silence the bell or horn while repairs are being made, a two-way switch and a red indicator light may be installed. When the alarm is turned OFFj the red indicator light will light.

CAUTION

If the switch is left in the OFF position after the re-pairs have been made, the red light will indicate the engine is not protected.

Industrial engines should be equipped with various alarm systems which will warn the operator when an abnormal engine operating condition is arising. When an alarm is activated, corrective measures should be taken before the situation becomes an emergency. If corrective measures are not taken in reasonable time, engine damage may result. If equipped, a correspond-ing shutoff device will stop the engine.

Each alarm switch is electrically connected to an indi-cating light, bell or horn. The alarm will continue until the condition is corrected and then the light, bell or horn will turn off.

Most control panels are equipped with a test switch.

By turning the switch ON, all of the indicator lights can be checked for proper operation. Test the indicator lights periodically. Replace burned out light bulbs immediately.

All alarms on the engine should be checked twice a year for proper operation by authorized dealer person-nel. Abnormal operating conditions must be simulated which could cause engine damage if the tests are in-correctly performed.

Attachments Shutting Down

A timer allows the engine to remove or to transfer the load, and to continue running for up to 2 minutes to allow the engine to cool before stopping.

Engine Exerciser

At preset times, the exerciser will start, run and stop the engine. This ensures both proper lubrication of all engine parts and proper equipment operation if, and when, the standby unit is needed.

Electrical Alarm Shutoff Switches

Operation

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Shutoff and Alarm System Components Oil Pressure Switch

Micro Switch Type

The oil pressure switch is used to give protection to the engine from damage because of low oil pressure.

When oil pressure lowers to the pressure specification of the switch, the switch closes and activates the rack shutoff solenoid.

On automatic start/stop installations, this switch closes to remove the starting system from the circuit when the engine is running with normal oil pressure.

This switch for oil pressure can be connected in a warning system for indication of low oil pressure with a light or horn..

As pressure on the oil in bellows � becomes higher, arm � is moved against the force of spring �.

When projection (jD of arm (a) makes contact with arm �, pressure in the bellows moves both arms.

This also moves button � of the micro switch to acti-vate the micro switch.

Some of these switches have a "Set For Start" button.

When the button is pushed in, the micro switch is in the START position. This is done because latch plate 0 holds arm � against button (A) of the micro switch and the switch operates as if the oil pressure was normal. When the engine is started, pressure oil flows into bellows �. The bellows move arm � into contact with latch plate �. The latch plate releases the "Set For Start" button and spring � moves it to the RUN position. This puts the switch in a ready to operate condition.

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Oil Pressure Switch

(Micro Switch Type)

1. Locknut. 2. Adjustment screw. 3. Spring. 4.

Arm. S. Spring. 6. Bellows. 7. Latch plate. 8. But-ton for micro switch. 9. Arm. 10. Projection of arm.

Earlier Type Switch

Early type switches for oil pressure have a con-trol knob (1). The knob must be turned (reset) every time the engine is stopped, Turn the knob counterclockwise to the OFF position before the engine is started. The knob will move to the RUN position when the oil pressure is normal.

This switch uses a flywheel housing mounted magnet-ic pickup to sense engine speed. The control box is mounted on the engine block. Excessive engine speed closes a circuit breaker. To reset switch, push arm of breaker to the run position.

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Attachments

Pressure Switch

These type pressure switches are used for several purposes and are available with different specifica-tions. They are used in the oil system and in the fuel system. One use of the switch is to open the circuit between the battery and the rack shutoff solenoid after the oil pressure is below the pressure specifications of the switch. It also closes when the engine starts.

Pressure Switch Another use of the switch is to close and acti-vate the battery charging circuit when the pressure is above the pressure specification of the switch. It also disconnects the circuit when the engine is stopped.

Overspeed Shutoff Switch (Electro-Mechanical)

This switch is mounted either on the tachometer drive WCE or on the governor. Excessive engine speed closes a Ecosm 1, switch by centrifugal force.

To reset the switch, push the button marked RESET.

The knob will remain down until the engine overspeeds.

Overspeed Shutoff Switch (Electronic) iI z �-�'_ �7'VM_' -

SPEED �jSWITCH PI AIRPM ELErTRONCS

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Emergency shutolf devices stop the engine, when op-erating conditions are such that engine damage may result if operation is continued. Authorized dealer per-sonnel should analyze major engine problems.

Familiarize yourself with the types and locations of the shutoff devices on your engine. Also, the conditions which can cause each control to function,. and the re-setting procedures required to start your engine.

Have all shutolf controls on the engine checked twice a year by your Caterpillar dealer. To test the devices, abnormal operating conditions must be simulated which could cause engine damage if the tests are in-correctly performed.

CAUTION

If severe or prolonged overheating of the engine has occurred, contact your Caterpillar dealer to have your engine checked for damage.

Always determine the cause of the shutdown, and have the necessary repairs made before restarting your engine.

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The shutoff switch is located in the water temperature regulator housing. Excessive water temperature closes the switch. No resetting procedure is required. As the coolant cools, the switch opens.

CAUTION

The sensing element must be submerged in the coolant to operate. A low coolant level cannot aL-tuate the shutoff.

16'11

Low Oil Pressure Shutoff Switch

This switch is usually mounted on the side of the en-gine with oil lines connected to the switch. Low oil pressure closes the switch.

Manually operated systems require resetting by push- Ing the button on the switch until it latches. After the engine Is started and oil pressure builds, the knob will return to the extended position.

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Electrical High Water Temperature Shutoff

Engine Jacket Water Temperature Switch Engine Oil Pressure and Oil Pressure Alarm Switch

Inlet Air Temperature Switch - Left Bank Inlet Air Temperature Switch - Right Bank

Engine Jacket Water Level Switch

Attachments

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This switch is mounted in the fuel manifold between the clean side of the fuel filter and the fuel injection pump housing. Low fuel pressure below 20 kPa (3 psi) opens the switch after the engine has been stopped by one of the shutoff controls. This switch prevents the battery from discharging after the engine is stopped.

The switch can be used to de-energize the shutoff so-lenoid after stopping the engine. Or, to open the circuit between the alternator regulator and the charging al-ternator, after the engine is stopped.

This switch is also used on automatic start-stop appli-cations equipped with an electric governor. In this ap-plication, when adequate oil pressure is reached, the switch closes to allow the electric governor to control engine speed.

This switch does not require resetting.

Fuel Pressure Switch

1. Push latches.

the reset lever until the rod in the cable

Attachments Engine Shutoffs

The Mechanical and Hydramechanical Shutoffs should be tested monthly to ensure proper operation protec-tion for your engine.

Manual Shutoff too, ------

Push the control handle knob in until the engine stops.

Emergency Mechanical Shutoff

CAUTION

This button has a skirt. Do not confuse it with the reset button which is flat.

Use this mechanical shutoff button for emergen-cles only. Do not use it for normal stopping.

Push the emergency stop button in, and hold in that position momentarily. This allows the overspeed mechanism to trip and stop the engine.

To Reset the Emergency Mechanical Shutoff:

j�';� ( I-- 2. Push the reset button firmly.

Air Shutoff

Attachment to the Emergency Mechanical Shutoff

When an emergency condition occurs, the mechanical shutoff pushes the rack into the shutoff position. This in turn pulls a butterfly valve, located in each inlet manifold, to the closed position.

The air shutoff must be reset before starting.

To Reset the Air Shutoff:

1. Pull the air shutoff reset lever to the RESET position,

2. Release the lever. The lever should move slightly, and then latch in the RUN position.

To Reset:

Attachments Hydra-mechanical Shutoff

The Hydra-mechanical Shutoff will automatically shut off the engine due to low oil pressure or an overspeed.

The Hydra-mechanical Shutoff may also be used as an emergency manual shutoff. This is done by pulling the red emergency knob out.

The Hydra-mechanical Shutoff should be tested "Every 500 Service Meter Units," to ensure proper operation and protection to the engine.

Check air inlet valves to make sure they are closed during testing.

Push the emergency shutoff knob in.

Turn both air shutoff knobs to the run position.

CAUTION

Never add coolant to an overheated engine; allow the engine to cool first.

Check specific gravity of antifreeze solution fre-quently In cold weather to assure adequate protection.

Coolant should be drained and replaced "Every 2000 Service Meter Units." With additions of Caterpillar Cooling System Conditioner or the use of Caterpillar Coolant Conditioner Elements as recommended, the drain period can be extended to Every 4000 Service Meter Units.

All water Is corrosive at engine operating tempera-ture. The cooling system should be protected with conditioner at all times regardless of concentra-tion of antifreeze. This can be done by maintaining a 3% concentration of liquid Caterpillar Cooling System Conditioner or by using Caterpillar Cool-ant Conditioner Elements.

Never use both the liquid cooling system condi-tioner and coolant conditioner elements at the same time.

Do not use Caterpillar Cooling System Conditioner or Coolant Conditioner Elements with Dowtherm 209 Full-Fill coolant.

Whenever draining and refilling cooling system, al-ways recheck the coolant level when the engine reaches normal operating temperature.

Filling at over 5 U.S. gallons (19 liters) per minute can cause air pockets in the cooling system.

CAUTION

When using jumper cables to start the engine, be sure to connect In parallel. POSITIVE (+) to POSI- TIVE (+) and NEGATIVE (-) to NEGATIVE I-).

When using external electrical source to start ma-chine, turn disconnect switch off and remove key before attaching jumper cables. Insert key and turn disconnect switch on, before starting.

Scheduled Oil Sampling Use Scheduled Oil Sampling to monitor the engines condition and maintenance requirements.

Each oil sample should be taken when the oil is hot, and well mixed, to insure a sample which is represen-tative of the oil in the compartment.

Consult your Caterpillar dealer for complete informa-tion, and assistance in establishing a Scheduled Oil Sampling program for your equipment.

Fuel

CAUTION

Fill fuel tank at the end of each day of operation to drive out moisture laden air and to prevent con-densation. Do not f III the tank to the brim. The fuel expands when It gets warm and may overflow.

Water and sediment should be drained from the fuel tank at the start of each shift or after the fuel tank has been filled and allowed to stand for 5 to 10 minutes.

Drain fuel tank of moisture and sediment as required by prevailing conditions.

Premix antifreeze solution to provide protection to the lowest expected ambient temperature. Pure undiluted antifreeze will freeze at -10"F (-230C).

Operate with a thermostat in the cooling system all year-round. Cooling system problems can arise with-out a thermostat.

After changing fuel filters, always bleed fuel system to .

remove air bubbles from system.

Air Intake Check precleaner screen daily for accumulation of dust and debris.

Service air cleaners when RED band in indicator locks in visible position.

Maintenance Recommendations

Cooling Electrical

GENERAL TIGHTENING TORQUE FOR

BOLTS AND NUTS

The following charts give the standard torque values for bolts and nuts of SAE Grade 5 or better quality.

Standard thread Use these torques for bolts and nuts with standard threads (conversions are approximate).

THREAD DIAMETER STANDARD TbRQUE inches millimeters lb. ft. N-m

1/4 6.35 9- 3 12 t 4

5/16 7.94 18 - 5 25 - 7

3/8 9.53 32 5 45 - 7

7/16 11.11 50 lo 70 ± 15

1/2 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

7/8 22.23 420 60 570 80

1 25.40 640 80 875 100

1-1/8 28.58 800 100 1000 ±150

1-1/4 31.75 1000 120 1350 175

1 3/8 34.93 1200 150 1600 200

1-1/2 38.10 1500 200 2000 ±275

Maintenance Recommendations

General

CAUTION

Accumulated grease and oil on the engine is a fire hazard. Remove this debris with steam cleaning or Wipe all fiftings, caps and plugs before servicing.

high pressure water, at least every 1000 hours or each time any significant quantity of oil is spilled on the engine.

SAE VISCOSITY RECOMMENDATIONS

Ambient Temperatures

OC -28 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +43 +49

'IF -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120

'bAE 1 OW

ZAE 15 W/40

SAE So

SAE 40

AirStarterOilerJar SAE 10W in all temperatures

Lubricating Grease (MPG) Use Multipurpose-type Grease (MPG). NLGI No. 2 Grade is suitable for most temperatures. Use NLGI No. 1 or No. 0 Grade for extremely low temperatures.

Lubricants W Fuels - Coolants

Lubricant specifications

The abbreviations listed below fillow S.A.E. J754 nomenclature. The classifications follow S.A.E. J183 classifica-tions. The MIL specifications are U.S.A. Military Specifications. These definitions are for purchasing assistance.

Engine Oils (CD) Use oils that meet Engine Service Classification CD (MIL-L-2104C), or CD/TO-2. See Caterpillar Form GEGO5044, EMA Lubricating Oil Data Book, for a listing of CD oil brands.

Lubricants - Fuels - Coolants

Fuel Specifications

Types of Fuel

Caterpillar Diesel Engines have the ability to burn a wide variety of fuels. These fuels are divided into two gen-eral groups, Preferred and Permissible.

The Preferred Fuels provide maximum engine service life and performance. These are distillate fuels. They are commonly called fuel oil, furnace oil, diesel fuel, or kerosene.

The Permissible Fuels are crude oils or blended fuels. Use of these fuels can result in higher maintenance costs and reduced engine service life.

See Caterpillar Form Number SEHS7067 for a detailed summary of Preferred and Permissible Fuels and their specifications.

Cetane Requirement The minimum cetaine recommended for this engine is 35 cetane.

Fuel Cloud Point

In cold weather, the cloud point of the fuel must be below the temperature of the surrounding air. If the cloud point is too high, wax will form in the fuel which will cause clogging of the fuel filters and loss of power.

Fuel Sulphur Content

The percent of fuel sulphur content will effect.the engine oil and filter change interval. See chart below:

CRANKCASE OIL CHANGE INTERVALS

Fuel Sulphur Content Oil and Filter Change interval 0.0% to 0.4% normal interval 0.4% to 1.0% Y2 normal interval 1.0% to 1.5% 1/4 normal interval

Water Contents 50% or More Antifreeze Less than 50% Antifreeze

Chlorides 100 ppm or less 50 ppm or less

Sulfates 100 ppm or less - 50 ppm or less

HardnessasCaCo:3 200 ppm or less 1 00 ppm or less

Dissolved Solids 500 ppm or less 250 ppm or less

PH 1 6.5 or higher 1 6.5 or higher

Acceptable Water ppm = parts per million

Antifreeze Use ethylene glycol-type antifreeze. Use the correct amount to provide freeze protection to the lowest expected temperature.

Conditioner

Use Caterpillar Cooling System Conditioner or equivalent. Add enough conditioner to provide a 3% to 6% concen-tration in the coolant. Caterpillar Cooling System Conditioner is available in 1 qt. containers (11 liter) Part Number 3132044.

3% = approximately 1 pint per 4 U.S. gal. (11 liter per 33 liters).

6% = approximately 1 pint per 2 U.S. gal. (I liter per 16 liters).

Coolant Specifications

Engine Coolant (EC)

Use a mixture of fill water, antifreeze and Cooling System Conditioner.

Caterpillar Form Number SEBDO518 entitled "Know Your Cooling System" can provide more detailed specifications.

Fill Water

Always add conditioner to water. Never use plain water.

Acceptable water for use in the ethylene glycol-type antifreze and water mixture is shown on the chart below:

Engine Crankcase Check the oil.],evel-add oil as required CD 34

(2) Air Cleaner indicator If the red piston locks in the "UP" position, 34 service the element

FuelTank Drain water and sediment 34

Woodward UG8 Governor Maintain oil level between marks on sight 35 gauge

Cooling System Inspect coolant level 35

Clutch Shift Collar Lubricate 1 fitting MPG 36

Main Shaft Bearing-13399 only Maintain oil level between the ADD and 36 FULL marks on the dipstick

Every 50 Service Hours Pre-Lube Pump-13399 with 32 volt pumps only Maintain oil level between the ADD and CD 37

FULL marks

Dust Collector Empty dust cap and clean tubes. May be 37 required more often in dusty conditions

(9 Zinc Rods Replace rods if they are deteriorated 38

(ID Batteries Observe electrolyte level 39

Every 125 Service Hours 0 Clutch Control Lever Lubricate 2 fittings MPG 40

(g Clutch Pilot Bearing Lubricate 1 fitting MPG 40

(R Clutch Main Shaft Bearing Lubricate 1 fitting MPG 40

$0 0I.Item I Procedure

Lubrication and Maintenance Chart

Everv 10 Service Hours

Every 500 Service Hours (5 Fan Drive Belts Check belt wear and adjustment 42 a Cooling System Add cooling system condifioner EC 45

(g Fan Bearing Lubricate I fitting MPG 45

Main Shaft Bearing-D399 only Drain and fill with clean oil CD 46 I

Maintenance Periods for Engine Filters, Oils and Breather (D Lubrication System and Breather(s) I Change Oil and Filters-Clean breather(s) CD 47

Clean Fuel Sulphur GontenUChange Periods Approx. Approx. Breather Capacity Capacity Elements 0.0-0.4% 0.4-1.0% Above 1.0%

(S.M.U.) (S.M.U.) (S.M.U.)Model (U.S. Gals.) (Liters) (S.M .U.)

D379 50 189 750 750 375 185 D379 92 348 1200 1200 600 300 D398 65 246 750 750 375 185 D398 110 416 1000 1000 500 250 D399 110 416 800 800 400 200 D399 160 606 low 1000 500 250

Every 1000 Service Hours Woodward UG8 Governor Change oil and fill to FULL on sight gauge. CD 49

Lubricate wick in oil cup

Fuel Priming Pump-early engines only Lubricate 2 fittings MPG 51

(9 Crankshaft Coupling-D399 only Lubricate I fitting MPG 52

(a Shut Off Control Lever Lubricate 1 fitting MPG 52

(&Tachometer Drive Lubricate 1 fitting MPG 52

Item

Every 250 Service Hours 0 Fuel System Drain water and sediment from filter hous-ing

(ID Alternator Belts Check belt wear and ac

Lubrication And Maintenance Chart

Procedure

(gD Engine Valve Lash Measure-Adjust if necessary

0 Engine Valve Rotators Observe rotation of valves with engine idling

(� Cooling system Change Antifreeze Solution

When Required (9 Cooling System Drain and clean when solution is dirty 58

(B Air induction system (i) install clean filter elements when air clean- 59 er indicator piston locks in the "UP" posi-tion. Clean precleaner

(P Fuel System Change filters when fuel gauge registers 64 Primary filter "OUT" with engine running. Prime the fuel Secondary filter-Priming the Fuel System system when required

(P Air Starter Fill motor oiler jar-Empty collector jar- CD 66 Adjust oiler feed

Batteries Clean batteries and electrical connections 68

Glow Plugs Inspectif adefectiveglowplug issuspected I 68

(9 Clutch inspect-Adjust if necessary I 69

Item

(1) Service intervals may be shortened in dusty operating conditions. If the exhaust smoke and/or loss of power continues after servicing the air cleaner, discard that element and install a new element.

Install a new element at least once a year.

IProcedure

Every 2000 Service Hours

Refill Capicities U.S. Gals. Liters Imp. Gals.

D379 Industrial Engine:

Engine Crankcase, Standard Pan 50 189 42

Engine Crankcase, Large Capacity 92 348 77

Coolant. Engine Only 28 105 23

Engine and Radiator 68 257 57

D398 Industrial Engine:

Engine Crankcas� Standard Pan 65 246 54

Engine Crankcase, Large Capacity 110 416 92

Coolant, Engine Only 64 240 53

Engine and Radiator 112 422 93

D399 Industrial Engine:

Engine Crankcase, Standard Pan 110 416 92

Engine Crankcase, Large Capacity 160 606 133

Pre-Lube Pump Reduction Gear Case .25 1 .2

Coolant, Engine Only 85 322 71

Coolant, Engine and Radiator 140 530 117

Flywheel Clutch, Main Shaft Bearing Reservoir .5 2 .4

Refill Capacities

0-11.") Engine Crankcase

2. Add oil if necessary.

1. Measure oil level. Oil should be between the FULL and ADD marks on the dipstick.

0-3" Air Cleaner Indicator

Inspect the air cleaner indicator. If the red piston is locked in the. raised position, service the air cleaner.

Drain water and sediment.

"I'D Fuel Tank

Every 10 Service Hours

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.

1J.'1011111

At Operating Temperature, engine coolant is hot and under pressure.

2. Add oil if necessary.

1. Check the oil level. Maintain oil level between the FULL and ADD marks on the sight gauge.

(1-2r") Cooling System

If it is necessary to add coolant daily, inspect the cool-ing system for leaks.Steam can cause personal injury.

1. Inspect coolant level with the engine cold. Remove the radiator cap slowly to sure. Observe the coolant level.

stopped and relieve pres-

2. Maintain coolant level within 1/2 inch (1 cm) below the top of the fill pipe. Inspect cap gasket and replace if necessary.

� Woodward UG8 Governor _� 19

� I 11

Every 10 Service Hours t Collar

Lubricate I fitting.

Bearing-13399 Only

2. Add oil if necessary. Do not overfill.1. Check oil level. Maintain oil between the ADD and FULL marks on the dipstick.

T Main Shaft ?� � ��6

/ � � �: �:e

1_11�1 Pre-Lube Pump-Early 399 Only

2. Add oil it necessary.

1, Check the oil level. Maintain the oil between the ADD and FULL marks on the dipstick.

(_10 Dust Collector Cup

2. Remove and clean the dust collector cup.1. Remove the retaining wing nut from the top of the dust collector cup.

3. Install the dust collector cup.

Every 50 Service Hours

2. Remove all the zinc plugs. They are painted red for easy identification.

- X�' �

� Z�� ��� � � ��� . , ' � �:

3. Tap the zinc rods lightly with a hammer. If the rod has deteriorated, or flakes when tapped, install a new zinc Tod.

1. Unscrew or drill the existing rod from the plug base.

2. Install a new rod in the plug base.

3. Install the plug.

Every 50 Service Hours

0 Zinc Rods � 9

- �t- A

1. Move the battery disconnect switch to the OFF position.

Installing New Zinc Rods

Do not smoke when observing battery electro-lyte level. Batteries give off fumes that can explode.

Electrolyte is an acid and can cause personal in-jury if it contacts skin or eyes.

1. Clean the tops of the batteries. Keep the terminals clean and covered with a light coat of grease.

2. Remove all fill caps. Observe the electrolyte level.

3. Maintain the electrolyte level to the bottom of the filler openings.

4. Install the fill caps.

If water is necessary, use distilled water if it is avail-able. Otherwise, use clean water that is low in miner-als, not artificailly softened water.

(ED Batteries

Every 125 Service Hours

Clutch Control Lever

Lubricate 2 fittings; 1 fitting on each side of the clutch housing.

(1� Clutch Pilot Bearing

Lubricate 1 fitting at the end of shaft.

(9 Clutch Main Shaft Bearing

Lubricate I fitting on top-rear of housing.

(B Fuel SysteM-Drain Fuel Filter Housir M

4. Remove the drain plug from the other cover of the fuel filter housing.

5. Drain water and sediment from that end.

6. Install the drain plug and vent plug.

7. Prime the fuel system.

1. Close the fuel supply valve if the fuel tank is locat-ed above the level of the fuel filters.

2. Remove the drain plug from one cover of the fuel filter housing. Drain water and sediment from the filter housing.

3. Install the drain plug.

1. Inspect the belts for wear.

When belt replacement is necessary, belts must be re-placed in complete matched sets. Never replace only one belt. The new belt will carry all the load and fail rapidly.

2. Apply a 25 pound (110 N) force perpendicular to the belt, midway between the driving and driven pul-ley. Measure the belt deflection.

Proper belt deflection is 9/16 to 13/16" (15 to 20 mm). Adjust the belt tension as required.

1. Remove the belt guard.

2. Loosen the locknut on the belt tightener rod.

3. Turn the adjustment nut until correct belt deflection is obtained.

4. Tighten the locknut.

5. Check the belt adjustment.

6. Install the belt guard.

To Adjust Alternator Belts L"'I . �t _I t - --- 4r N �*�W7

Every 250 Service Hours

0 Alternator Belts

Belt Deflection

Engine Belt Deflection

D379 9/16" to 13/16" (1 5 to 20 mm)

D398,D399 1 1 /8" to 1/38" (30 to 35 mm)

1. Inspect the condition and the adjustment of the fan drive belts.

2. Apply 25 lb. (110 N) force midway between the pulleys.

Replace belts in sets only, Every 500 Service Hours n17 Fan Drive Belts

0�

1. Loosen the four nuts holding the fan plate to the 2. Loosen the locknut (1).

engine block.

3. Turn the adjusting screw (g) until the belts are properly adjusted.

4. Tighten the four nuts on the fan plate. 5. Tighten the locknut (D.

To Adjust Fan Drive Belts - D398 9,111� �'Ivl 111111M

�4 1,--

IIIIIIIIIIIINW7X",

and D399 C ["

1. Loosen the pillow block mounting bolts. 2. Loosen the locknut on the pillow block positioning screw.

To Adjust Fan Drive Belts - D379

4. Tighten the pillow block mounting bolts.3. Turn the positioning screw until the belt is adjusted properly.

5. Tighten the locknut on the positioning screw.

6. Check the belt adjustment.

Every 250 Service Hours

�liklaJ I J'.10 110

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.

On a new or reconditioned engine: Add enough Caterpillar Cooling System Conditioner, or equi-valent, so that the cooling system will have a 3% concentration of conditioner. Add 1 qt. (I liter) of Caterpillar Cooling System Conditioner for each 8 gallons (30 liters) of coolant used.

CAUTION

All water Is corrosive at engine operating tempera-ture. Use either Caterpillar Cooling System Condl-tioner liquid, or the coolant conditioner element to treat either plain water or ethylene glycol anti-freeze solution. NEVER use both the liquid cooling system conditioner and the coolant conditioner element at the same time.

k*&-

Do not use Caterpillar Cooling System Conditioner or Coolant Conditioner Elements with Dowtherm 209 Full-Fill coolant.

It may be necessary to drain enough coolant to allow for the addition of cooling system conditioner.

2. Add Caterpillar Cooling System Conditioner.

See above for amount of conditioner to add.

3. Inspect filler cap gasket. Replace it damaged.

4. Install filler cap.

1. Loosen filler cap slowly to relieve pressure, and re-move filler cap, 1-1-61 Fan Bearing-D379

I i I

Lubricate 1 fitting.

(9 Cooling System-Add Cooling System Conditioners

0 Main Shaft Bearing

Hot oil or components can cause personal injury if they contact skin. Use caution when draining oil or changing filters.

nna.q-nnaa

1. Lubricate the�'2 fittings bearings.

2. Lubricate the 1 fitting bearing.

blockon the upper pillow

D399 only on the lower pillow block

3. Maintain the oil level between.the ADD and FULL marks on the dipstick. -. -

1. Remove the drain plug and allow the oil to drain.

2. Install the drain plug.

if A ZI III VI

Use caution when draining oil or changing filters.

Not oil or components can cause burns if they contact skin, L� -A,�-, W� ,

- 1*AdW -1.1 -

I

I

�7w- " -, "I'll, , �1-1 -, � � �� � �-,z

1. Remove the oil pan drain plug,Drain the crankcase with oil warm and the engine stopped.

..... -�; 1',AEW_4W�0

3. Remove the filter housing vent plug.2. Remove the oil cooler drain plugs.

4. Open the oil filter housing drain plug, 5. Remove the fight hand cover from the filter housing.

47.

Maintenance Periods for Engine Filters, Oils, and Breather(s)

0 Lubrication System

7. Wipe the oil filter housing with, a clean rag.

8. Install new filter elements, and the filter housing cover.

9. Close the filter housing drain valve.

10. Install all drain plugs.

1 1. Fill the oil filter housing and the oil cooler with oil, through the vent plug opening.

6. Remove the oil filter elements.

12. Install the vent plugs.

13. Fill the crankcase to the FULL mark on the oil lev-el gauge. See REFILL CAPACITIES,

14. Loosen the front hose clamp from the breather 15. Remove the breather(s) mounting bolts and lift off tube (D399 only). the breathers.

19. Install upper and lower hoses (D399 only).

20. Tighten all clamps.

21. Start and run the engine.

Inspect for leaks. Reduce engine speed to low idle.

22. Maintain the oil level to the FULL mark on EN- GINE RUNNING side of dipstick. Stop the engine.

16. Remove and inspect the upper and lower hoses from the breather(s) (13399 only).

17. Wash the breather(s) in clean nonflammable solvent.

18. Install the breather(s).

Maintenance Periods for Engine Filters, Oils, and Breather(s)

Be sure the engine cannot be started while work is being done. This is very important when the engine is equipped with an Automatia'Start-Stop System.

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

2. Shut off the fuel tank fuel supply valve.

3. Disconnect the ground cable from battery.

4. Disconnect the governor linkage from the governor.

5. Disconnect the governor synchronizing motor wires.

8. Turn the governor upside down and drain the oil.

9. Flush the governor with clean nonflammable solvent.

10, Install the governor on the engine.

1 1. Fill the governor, with clean oil, to the FULL mark on the sight gauge. See Lubrication and Maintenance Chart for proper oil.

Every 1000 Service Hours

(� Woodward UG8 Governor

6. Remove the governor from the engine.

7. Remove the governor cover.

12. Connect the governor linkage.

13. Connect the ground cable to the battery.

3. Manually move the pointer to the extreme upper po-sition and tighten the nut. This will allow the governor to be purged of air.

4. Remove the plug from the base of the governor.

6. Allow the engine to surge for approximately 30 seconds.

7. Loosen the nut and move the compensation adjust-ing pointer to the extreme downward position. Tighten the nut.

8. Slowly turn the needle valve (wide shallow slot) clockwise until the surging stops.

5. Using a wide blade screwdriver, engage the wide shallow screwdriverslot and turn the needle valve 3 or more turns counterclockwise.

9. It should now take less than one turn from this point to close the valve completely.

10. Open the valve to the same position where the surging had stopped.

1 1. Manually move the governor linkage to disturb the engine speed.

Every 1000 Service Hours

Bleeding the Governor

1. Start the engine and allow the engine to reach nor-mal operating temperature.

2. Loosen the nut on the side of the governor which holds the compensation adjusting pointer.

If the engine speed stabilizes, and the needle valve is…