D398a, D398b Caterillar Marine Engine Operation and Maintenance by quality service repair manual

Product: MARINE ENGINE

Model: D398A MARINE ENGINE 67B

Configuration: D398 MARINE ENGINE 67B00001-00919

Operation and Maintenance Manual

D379B, D398B, D399 MARINE ENGINES

Media Number -SEBU5561-01

Publication Date -01/09/1984

Date Updated -11/10/2001

D379 - D398 - D399 Marine Engines(69B824-UP - 67B920-UP91B1-UP)

This LUBRICATION AND MAINTENANCE SCHEDULE lists those items commonly ordered on this engine which require servicing.

The time intervals are based upon the numbers showing on the engine's service meter. Use the daily readings of the Service Meter to determine maintenance intervals. Perform required maintenance at multiples of each unit. "EVERY 10" means perform that maintenance at 10, 20, 30, etc., service meter units. For those areas which require periodic maintenance which cannot be given a definite service hour, see the column "WHEN TO SERVICE".

For items marked (*) see "KEY TO FUELS, LUBRICANTS AND WATER" in this chart. "Page" refers to the page number in the LUBRICATION AND MAINTENANCE PROCEDURES where the service procedure is detailed for that item.

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Product: MARINE ENGINE

Model: D398A MARINE ENGINE 67B

Configuration: D398 MARINE ENGINE 67B00001-00919

Operation and Maintenance Manual

D379B, D398B, D399 MARINE ENGINES

Media Number -SEBU5561-01

Publication Date -01/09/1984

Air Induction And Exhaust System

Air Cleaner Service Indicator

Checking Air Cleaner Service Indicator

Date Updated -11/10/2001

Before starting, check the window of the indicator. If the red piston is locked in the raised position, service the air cleaner as outlined.

NOTE: Have spare elements on hand to install while cleaning used elements.

NOTICE

Service the air cleaner with the engine STOPPED.

PISTON LOCKED IN RAISED POSITION

Single Stage Air Cleaner

Servicing

1. Remove the air cleaner cover and filter element. On some engines, a soot filter may cover the filter element.

REMOVING COVER, SOOT FILTER AND FILTER ELEMENT

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

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

CLEANING INSIDE OF AIR CLEANER

1. Air Inlet Cover

4. Inspect the replacement element for damage and dirt.

5. Remove the covering from the turbocharger inlet opening.

6. Install the element.

INSTALLING AIR CLEANER ELEMENT

NOTICE

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

7. If a soot filter is used, place a new soot filter over the air cleaner element.

8. Install the air cleaner cover.

9. Reset the service indicator piston by pushing the reset button. See the instructions for cleaning the used air cleaner element.

RESETTING AIR INDICATOR PISTON

Cleaning Used Air Cleaner

Elements

Cleaning With Pressure Air

1. Use clean, dry air- 40 PSI maximum. Hold the nozzle at least one inch from the element and at a slight angle. (A direct blast can rip the pleating.)

CLEANING ELEMENT WITH AIR

2. Direct the air stream along the complete length of each pleat on the CLEANEST side of the element. (This will loosen the dirt from the dirtier side.)

3. Blow the loosened dirt from the DIRTY side.

4. Direct the air from the CLEAN side through to the DIRTY side to remove dirt blown into the pleating.

Cleaning With Water

1. Use clean water at no more than 40 PSI. Do not use a nozzle.

2. Direct the water stream along the complete length of each pleat on the CLEAN side of the element.

CLEANING ELEMENT WITH WATER

3. Direct water along the complete length of each pleat on the DIRTY side of the element.

4. Rinse the CLEAN side of the element.

5. Allow the cleaned element to dry thoroughly.

Cleaning With Detergent

1. Wash both sides of the element in a solution of warm water and non-sudsing household detergent.

2. Rinse the CLEANEST side of the element with clean water (40 PSI maximum) along the complete length of each pleat.

WASHING ELEMENT WITH DETERGENT

3. Rinse the opposite side of the element along the complete length of each pleat.

4. Rinse the first side again to remove all loosened dirt.

5. Allow the cleaned element to dry thoroughly.

Storing Cleaned Elements

1. Hold the dried element in front of a lighted electric bulb. Carefully inspect the element for tiny, pinpoints of light. Any light showing indicates a pleat has ruptured and will tear with further use. Discard the element.

INSPECTING ELEMENT

2. Wrap usable elements in heavy paper.

WRAPPING ELEMENT FOR STORAGE

3. Store the wrapped element in a dry, clean place.

Two Stage Air Cleaner

Emptying Dust Collector Cup

1. Loosen the clamping bolt on the lower body.

2. Remove and empty the dust collector cup.

3. Inspect and install the seal; install a new seal if necessary.

REMOVING DUST CUP

1. Seal

4. Inspect the tubes in the lower body. If dirty, clean the tubes with a round bottle brush.

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5. Install the dust collector cup.

Cleaning The Lower Body

1. Remove the dust collector cup.

2. Loosen the clamping bolt on the upper body.

REMOVING LOWER BODY

1. Seal

3. Remove the lower body. Clean the tubes from both ends.

4. Inspect and install the upper body seal. Install a new seal if it is damaged.

Installing Replacement Filter Element

1. Remove the cover.

REMOVING COVER AND INNER COVER

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

REMOVE ELEMENT

3. Clean all parts of the air cleaner.

4. Inspect the replacement element for damage and cleanliness.

5. Install the element, inner cover, and wing nut. Tighten the wing nut to prevent dust from bypassing the filter element.

6. Install the cover.

If, after servicing the air cleaner, the exhaust smoke and/or loss of power continues; or the service indicator locks in the raised position, discard that element and install a new element. Install a new element at least once a year.

Cleaning Used Air Cleaner Elements

Cleaning With Pressure Air

1. Use clean, dry air- 40 PSI maximum. Hold the nozzle at least one inch from the element and at a slight angle. (A direct blast can rip the pleating.)

CLEANING ELEMENT WITH AIR

2. Direct the air stream along the complete length of each pleat on the CLEANEST side of the element. (This will loosen the dirt from the dirtier side.)

3. Blow the loosened dirt from the DIRTY side.

4. Direct the air from the CLEAN side through to the DIRTY side to remove dirt blown into the pleating.

Cleaning With Water

1. Use clean water at no more than 40 PSI. Do not use a nozzle.

2. Direct the water stream along the complete length of each pleat on the CLEAN side of the element.

CLEANING ELEMENT WITH WATER

3. Direct water along the complete length of each pleat on the DIRTY side of the element.

4. Rinse the CLEAN side of the element.

5. Allow the cleaned element to dry thoroughly.

Cleaning With Detergent

1. Wash both sides of the element in a solution of warm water and non-sudsing household detergent.

2. Rinse the CLEANEST side of the element with clean water (40 PSI maximum) along the complete length of each pleat.

WASHING ELEMENT WITH DETERGENT

3. Rinse the opposite side of the element along the complete length of each pleat.

4. Rinse the first side again to remove all loosened dirt.

5. Allow the cleaned element to dry thoroughly.

Storing Cleaned Elements

INSPECTING ELEMENT

2. Wrap usable elements in heavy paper.

3. Store the wrapped element in a dry, clean place.

Precleaner

Servicing

When the precleaner body is 3/4 full, remove and empty the precleaner.

1. Remove the dust collector cover.

2. Remove and empty the dust collector body.

3. If necessary, wash the dust collector in water.

Engine Valve Lash

Valve Lash

1. Stop the engine.

2. Remove the flywheel housing timing cover.

REMOVING TIMING COVER

3. Determine the direction of flywheel rotation. See the decal above the flywheel housing.

FLYWHEEL ROTATION DECAL

4. Wipe dirt from the base of the valve covers.

5. Remove the valve covers.

6. Bar the flywheel in the direction of normal rotation. Align the "TDC 1" timing mark for your engine, ("TDC 1-7", "TDC 1"11", or "TDC 1-15"), with the timing pointer on the flywheel housing.

BARRING FLYWHEEL

Checking Adjustment

1. Observe the rocker arms for cylinder No. 1. Determine if the piston is on compression or exhaust stroke.

Compression stroke: Both intake and exhaust valves are closed.

Exhaust stroke: Intake valve is closed, exhaust valve is opened.

I - Intake Valves

E - Exhaust Valves

LOOSENING LOCKNUT

2. With NO 1 CYLINDER ON COMPRESSION STROKE, check the lash of the following valves: Adjust if necessary. See the Lubrication and Maintenance Chart for correct valve lash.

CHECKING VALVE LASH

ADJUSTING VALVE LASH

Adjusting Valve Lash

1. Loosen the locknut on the adjusting screw.

2. Hold the locknut and turn the adjusting screw to obtain the proper lash.

3. Hold the adjusting screw and tighten the locknut.

4. Recheck the lash.

3. Bar the flywheel one revolution in the direction of normal rotation. Align the "TDC 1" timing mark for your engine, ("TDC 1-7", "TDC 1-11" or "TDC 1-15"), with the timing pointer on the flywheel housing.

4. With NO. 1 CYLINDER ON EXHAUST STROKE, check the lash for the following valves. Adjust if necessary. See the Lubrication and Maintenance Chart for correct valve lash.

Valve Rotators

Checking Rotation

After checking all valve clearances, and before installing the valve covers:

1. Start the engine.

2. Move the governor control to low idle position.

3. Watch the serrations on each valve retainer. Each valve retainer should turn slightly each time the valve closes.

If a valve retainer fails to rotate, contact your Caterpillar dealer. Repairs must be made to prevent burning the valve.

If all valves rotate, proceed as follows:

4. Stop the engine.

5. Inspect and install valve cover gaskets. Install new gaskets if necessary.

6. Install the valve covers.

7. Install the flywheel housing timing cover.

Product: MARINE ENGINE

Model: D398A MARINE ENGINE 67B

Configuration: D398 MARINE ENGINE 67B00001-00919

Operation and Maintenance Manual

D379B, D398B, D399 MARINE ENGINES

Media Number -SEBU5561-01

Cooling System

Engine Jacket Water

Publication Date -01/09/1984

Checking Coolant Level - Using Coolant Sight Level Gauge

Date Updated -11/10/2001

If the engine is equipped with a sight level gauge on either the radiator, expansion tank, or heat exchanger system, the coolant level can be checked with the engine either running or stopped.

Add coolant whenever the coolant level is in the LOW level range. A warning device will be actuated when the level is lowered to the unsafe operating level.

SIGHT LEVEL GAUGE

Checking Coolant Level

With the engine stopped:

1. Slowly turn the filler cap to the first stop and release pressure.

Be careful. If the engine is warm-steam may spray outward under high pressure.

2. Push the cap down; turn until the cap is released.

3. Maintain level to base of fill pipe. The coolant requires expansion space as it is heated.

4. Make-up coolant should be one of the following, in the order of preference:

a. Permanent anti-freeze and fresh water solution.

b. Rust inhibitor and fresh water solution.

c. Drinkable water.

d. Any available untreated raw water-never salt water.

(a) Must be used if engine is to be shut down in below freezing weather without draining the coolant (b) Can only be used when the coolant temperature is above freezing, or if the coolant will be immediately drained after shut down during below freezing temperatures.

Checking Water Temperature Gauge Reading

The water temperature gauge should normally register in the NORMAL range when operating. However, with some systems, as long as the coolant does not boil the cooling system is functioning properly.

1. If the water temperature gauge continually registers near-or in the "HOT" range-without boiling, have the system checked to determine if the cooling system is functioning properly.

2. Frequently check the water temperature gauge while operating. Be sure to note any deviation from the normal reading.

3. Whenever the reading changes, investigate the cause and have necessary repairs made.

Draining Radiator Or Expansion Tank

Whenever it is necessary to drain the cooling system for repairs:

1. Shut the engine off.

2. Slowly turn the pressure cap to the first stop and release pressure.

Be careful. If the engine is warm-steam may spray outward under high pressure.

3. Push the cap down and turn until the cap is released.

4. Open the drain valve for the radiator, or expansion tank.

Draining Complete Cooling System (D379, D398, D399 Engines)

1. Drain the radiator or expansion tank.

2. Remove the water pump drain plug.

3. Remove the engine block right rear drain cover.

COOLANT DRAIN

4. Remove the drain plug from the elbow of the oil cooler.

COOLANT DRAIN

5. Remove the drain plugs from the front of the left and right water shields.

COOLANT DRAINS

6. Remove the front and rear drain covers from the left side of the engine block.

7. Remove the drain plug from the elbow on the left side of the flywheel housing.

COOLANT DRAIN

COOLANT DRAINS

8. Remove the aftercooler drain plugs.

COOLANT DRAIN

9. If equipped with a marine gear oil cooler, remove the oil cooler bonnet drain plug.

COOLANT DRAIN

10. Allow the coolant to drain.

11. Install all drain covers and plugs. Close the radiator or expansion tank drain valve.

Draining Complete Cooling System (D346, D348, D349 Engines)

1. Open the radiator or expansion tank drain.

2. Remove the left front elbow drain plug.

ELBOW DRAIN

3. Remove the oil cooler bonnet drain plug.

4. Remove the engine jacket water pump drain plug.

5. Remove the auxiliary water pump drain plug if so equipped.

OIL COOLER WATER DRAIN

WATER PUMP DRAIN PLUG

This is the sample of the manual Click on the download link for complete Manual