D379, D398, D399 LOCOMOTIVE ENGINES Caterpillar

Air Cleaner Service Indicator

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.

Single Stage Air Cleaner

1. Remove the air cleaner cover and element.

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

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

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.

7. Install the air cleaner cover.

8. Reset the service indicator piston by pushing the reset button. (See the instructions for air cleaner element cleaning).

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.

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

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.

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.

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

3. Clean all parts of the air cleaner.

4. Inspect the replacement element for damage and 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-30 PSI, maximum. Hold the nozzle at least one inch from the element at a slight angle. (A direct blast can rip the pleating.)

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.

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.

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, pin points of light. Any light showing indicates a pleat has ruptured and will tear with further use. Discard the element.

2. Wrap usable elements in heavy paper.

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

Engine Valve Lash Adjustment

Preparing To Set Valve Lash

1. Stop the engine and allow it to cool at least 20 minutes.

2. Remove the flywheel housing timing cover.

3. Bar the flywheel in the direction of normal rotation. Align the "TC1" timing mark with the flywheel housing timing pointer.

4. Wipe the base of the valve covers to keep dirt from getting into the valve mechanism.

5. Remove both valve covers.

6. Observe the rockers for cylinder No. 1. Determine if the piston is on COMPRESSION or EXHAUST stroke.

Compression Stroke: Both inlet and exhaust valve rockers can be moved freely.

Exhaust Stroke: Only inlet valve rocker moves freely.

NUMBERING OF CYLINDERS
D379 ENGINE SHOWN (D398 AND D399 ENGINES VALVES AND CYLINDERS ARE SIMILARLY IDENTIFIED)

7. Using the chart that applies: "NO. 1 CYLINDER ON COMPRESSION STROKE" or "NO. 1 CYLINDER ON EXHAUST STROKE", set those valves listed under the columns "LEFT BANK" and "RIGHT BANK" for your engine.

8. Bar the flywheel in the direction of normal flywheel rotation. Align the TDC timing mark with the pointer on the flywheel housing.

9. Set those valves specified under the remaining heading: "NO. 1 CYLINDER ON EXHAUST STROKE" or "NO. 1 CYLINDER ON COMPRESSION STROKE".

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.

Checking Valve Rotators

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.