D379, D398, D399 LOCOMOTIVE ENGINES-Lubrication And Maintenance Chart

Lubrication And Maintenance Chart

This LUBRICATION AND MAINTENANCE CHART lists the serviceable items usually installed on locomotive engines. The items are listed according to their interval of servicing.
The intervals are based on readings of the engine's service meter which is mounted on the front of the engine. Every day the service meter should be observed. The servicing of each item in the chart should be performed at multiples of the readings. For example, "EVERY 10 SERVICE METER UNITS" means to perform that maintenance at every 10, 20, 30, etc., service meter units. For those items which cannot be serviced at a definite interval, see the section: "NON-SCHEDULED ITEMS, WHEN TO SERVICE ITEMS".
For items marked "*", see the "SPECTIFCATIONS" on page 12. "PAGE" refers to the LUBRICATION AND MAINTENANCE PROCEDURES page number where detailed instructions can be found for that item.

D379, D398, D399 LOCOMOTIVE ENGINES-Attachments

Attachments

Gauges And Indicators

Oil Pressure Gauge

Oil pressure is normally greater after starting. As the oil warms, oil pressure decreases. As engine speed decreases, oil pressure decreases. At low idle, hot oil should register near the middle range of the gauge scale. Stop the engine and determine the cause if there is no oil pressure, or if the indicator fluctuates.
If the gauge reading fluctuates after the load is stable:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Observe the oil level. Maintain the oil level between the ADD and FULL mark on the dipstick. If the reading continues to fluctuate when the oil level is correct, stop engine and call your Caterpillar dealer.

Engine Jacket Water Temperature Gauge

Operating temperature is maintained by water temperature regulators and radiator shutters. High coolant temperatures results when the cooling system does not dissipate engine heat properly. If overheating occurs, have the cooling system and radiators inspected.
If the operating temperature is below the opening temperature of the water temperature regulators, have the regulators checked.
The engine should operate within the NORMAL (green) range. If the engine is operating in the (red) range and steam becomes apparent:

1. Reduce the load and engine RPM.

2. Inspect for coolant leaks.

3. Determine if the engine must be shut down immediately; or if the engine can be safely cooled by reducing the load.

See COOLING SYSTEM MAINTENANCE INSTRUCTIONS.

NOTICE
Do not add cold water to a hot engine: Cracking of engine components may occur. Allow the engine to cool, then add coolant.

If the temperature gauge reading continuously registers in or near the cold range (white) while operating under load, have the following checks made:

1. Have the water temperature gauge checked for accuracy.

2. Have the temperature regulators removed and checked for proper temperature range. Replace regulators if necessary.

See COOLING SYSTEM MAINTENANCE INSTRUCTIONS.

Fuel Pressure Gauge

The fuel pressure gauge indicates pressure of the fuel pumped to the engine injection pumps. As the filters collect dirt, the fuel pressure drops until the gauge registers in the OUT range and engine performance decreases. When this occurs, clean the primary fuel filter. If low fuel pressure is still indicated, replace the fuel filter elements.

See the FUEL SYSTEM MAINTENANCE INSTRUCTIONS.

Ammeter

The ammeter should register in the charging range when the engine is running above low idle. If the gauge registers a discharge with an increase in engine speed, shut off the engine and determine the cause.

Air Cleaner Service Indicator
When the gauge indicator locks in the red range, service the air cleaner. With the engine stopped; see AIR INDUCTION AND EXHAUST SYSTEM MAINTENANCE INSTRUCTIONS.

Shut the engine down if work on or around the engine is required.

Safety Alarms And Shutoff Devices

Electric Safety Alarm Operation

When a fault condition occurs-either high water temperature or low oil pressure-a microswitch in the sensing unit is actuated and completes a circuit to either a light, a bell or a horn. The light or sound warns the operator the engine must be stopped to prevent damage to the engine.
The high water temperature alarm switch is located in the regulator housing. The sensor must be in contact with the coolant in order to operate. A low coolant level will not actuate the switch.
The oil pressure alarm is energized when the oil pressure falls below the safe operating limits. For this reason, it may be desirable to turn the alarm to the OFF position when stopping the engine. The alarm must be turned to the OFF position before starting in order to allow the engine to start. The knob will move by itself to the RUN position after normal oil pressure is reached.

Mechanical Safety Shutoff

The mechanical safety shutoff device is mechanically driven and shuts off the fuel when either an overspeed or a low oil pressure condition exists. The shutoff mounts in the vee of the engine to the rear of the governor.

To protect the engine against operating with insufficient oil pressure, a gear driven slide is held from the engine driven worm shaft by normal oil pressure. If oil pressure drops below safe limits, the slide engages the revolving worm shaft and is propelled against a latching mechanism. The latch disengages, a spring-loaded rod strikes against the fuel rack and moves the fuel rack to the fuel off position. The engine will stop.
If sufficient oil pressure does not develop after starting, the engine will run approximately 7 seconds at operating speed and then will shut down. Therefore, check the oil pressure gauge reading immediately after starting.

MECHANICAL SHUTOFF CROSS SECTION1. Slide
2. Overspeed Carrier
3. Worm Shaft
4. Latch5. Spring-loaded Rod
To protect the engine against overspeeding, a spring-loaded weight, rotated by an engine gear train, is forced outward by centrifugal force. The weight strikes the latch mechanism discussed above. The latch disengages, the spring-loaded rod strikes against the rack and moves it to the fuel off position. The engine will stop.
By pressing the emergency stop button, the overspeed weight is released, the weight strikes the latch mechanism, and the spring-loaded rod strikes the rack, and moves it to the fuel off position; stopping the engine.

Safety Shutoff Reset Controls

After either mechanical shutoff device has stopped the engine, the shutoff controls must be reset before the fuel rack can be moved from the shutoff position and the engine started. First, push down on the reset button, then push the reset lever until the safety mechanism latches.

PUSHING RESET BUTTON

PUSHING RESET LEVERIf the reset lever does not return to its original position after latching the safety mechanism, check the cable for kinks or other internal resistance. The cable must move freely.

NOTICE
DO NOT use any emergency shutoff control for normal shut down. The emergency shutoff controls are for emergencies only.

Safety Shutoff Testing

Shutoff devices operate only when an abnormal condition exists, therefore, it is impossible to know if they are in working condition during normal operation. Since it is important that they will operate when necessary, have the shutoff devices checked every 6 months by your Caterpillar dealer or authorized personnel.
Do not use these shutoff devices for normal engine stopping. Such use may cause failure of these parts.

Determining Cause For A Shutdown

Anytime the engine is shut down by the safety circuit, the cause must be determined and corrective measures must be taken before starting the engine.

High Water Temperature

1. Determine if the locomotive is overloaded in relation to tonnage being pulled. High altitude or hot air entering the radiator can create an over-heated engine condition for an otherwise normal load.

2. Check the radiator fan drive.

3. Check the water level. Low water level will not shut the engine down, but may contribute to other failures.

4. Check shutter operation. Dirt or objects may prevent the shutters from properly opening.

5. Check the objects obstructing air flow through the radiator.

6. Check for faulty water pump operation, collapsed hoses, failed shut temperature regulators, or dirty cooling system.

Low Oil Pressure

1. Check the oil level. With the engine stopped, the oil level must be between the ADD and FULL mark. If oil level is low, determine the cause.

2. Check for new, wet oil accumulations at all gasketed joints. Check for leaks.

3. If visual checks cannot determine the cause, crank the engine with fuel off. If hard cranking or unusual noises are heard, immediately stop cranking. Have internal checks made on the engine.

4. Check for excessive smoke in the exhaust gasses.

5. Check for excessive blow-by.

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D379, D398, D399 LOCOMOTIVE ENGINES-Operating Instructions

Operating Instructions

Altitude Operation

The fuel system settings and altitude limits are stamped on the engine information plate. When an engine is moved to a higher altitude, these settings must be changed by your Caterpillar dealer in order to prevent damaging the turbocharger, and to provide maximum engine efficiency.

If the engine is moved to a lower altitude than that which is stamped on the engine information plate, the engine can be operated safely; however, it will deliver less than rated horsepower, and the fuel settings should be changed by your Caterpillar dealer to obtain rated horsepower.

Pre-Start Inspection And Procedures

1. Make a "Walk-around" inspection of the engine and components for the oil, water or fuel leaks and general appearance. Correct minor adjustments before they develop into major repairs.

2. Check for dragging brake rods or equipment. Check air hoses and electric jumper cables for proper connections.

3. Check the crankcase oil level. Maintain the oil level between the ADD and FULL marks on the dipstick. See OIL SPECIFICATIONS for type of oil to use.

4. Check the oil level in the governor sight glass. Oil must be at, but not over, the FULL mark on the sight gauge.

NOTICE
Do not fill above full mark. This may cause aeration of the oil which will cause surging of the engine.

5. Check oil level(s) on driven equipment.

6. Check the engine jacket coolant glass guage. Never operate the engine if water level is below the low mark. Fill the cooling system as required. The filler pipe may be either outside above the water tank, or inside the carbody connected into the jacket coolant system.

7. Check for restrictions to the fan or radiator.

8. Check the fuel supply. Keep fuel tanks full. See the FUEL SPECIFICATIONS for type of fuel.

Prime the fuel system if the engine has not been started for several weeks. See the LUBRICATION AND MAINTENANCE PROCEDURES.

9. Check each air cleaner service indicator. If the red piston is visible with the engine stopped, or remains visible while the engine is running, have the air cleaner serviced.

10. Reset shutoff devices. See the topic, ATTACHMENTS, Emergency Shutoff Devices and Alarms.

OIL PRESSURE RESET

RESETTING SHUTOFF LEVER

11. Check the air brake system as instructed by the manufacturer's instructions.

12. Disconnect the battery chargers or the train's service connections.

13. Perform all other checks required by the other equipment manufacturers.

Starting The Engine

Electric Starting (If air starting is used, see topic, Air Start.)

1. Perform all cab starting procedures as per locomotive instructions.

2. Prepare the locomotive for starting as recommended by the manufacturer.

3. Move the control handle to approximately half engine speed position.

4. Turn the master electrical control switch to ON position, if so equipped.

5. Push the start button to motor the diesel engine either using the generator or the starting motor. If the engine fails to start within 30 seconds, release the start button and allow the starter motors to cool 2 minutes before repeating the starting procedure.

6. As soon as the engine starts, release the button.

7. Check the oil pressure gauge or the oil pressure light. If no oil pressure is indicated and immediate stopping action has not been taken, the oil pressure safety shutoff control should stop the engine in approximately 7 seconds.

8. Reduce engine speed to low idle and allow the engine to warm.

Air Starting

1. Fill the oiler. See the LUBRICATION AND MAINTENANCE CHART for proper oil to use.

2. Check the air supply. The air starter must have 100 PSI available for starting.

3. Perform all cab starting procedures as per locomotive instructions.

4. Prepare the locomotive for starting as recommended by other manufacturers.

5. Move the control handle to approximate half engine speed position.

6. Turn the master electrical control switch to ON position, if so equipped.

7. Pull upward on the air starter valve lever located on the engine, or operate the air starter control provided in the cab.

8. As soon as the engine starts:

a. Release the air starter valve lever.

b. Check the low oil pressure gauge or the oil pressure light. If no oil pressure is indicated and immediate stopping action has not been taken, the oil pressure safety shutoff control should stop the engine in approximately 7 seconds.

c. Reduce engine speed to low idle and allow the engine to warm.

Starting D399 Engines

The D399 Engine uses a prelube pump to lubricate all moving engine parts prior to starting the engine. To start a D399 Engine, follow the Electric or Air Starting instructions as required. When the starter motor is actuated, the prelube pump motor starts running and pumps oil throughout all oil passages. When oil pressure is achieved, a pressure switch closes, and the engine then begins to crank. When the engine starts, and the starter switch or lever is released, the prelube pump stops and the engine oil pump provides the lubrication. Prelube time varies with oil temperature. More time is required to achieve oil pressure with hot oil than with cold oil.

After Engine Starts

NOTICE
If oil pressure is not indicated within 5 seconds, stop the engine and have necessary repairs made.

1. Check the operation of the headlights, marker lights, running lights and rear warning lights.

2. Check the operation of the bell.

3. Observe all guages for proper readings as explained in the topic, GAUGES.

4. In the engine room, check the engine crankcase oil level with the engine running. Oil level should be between the ADD mark and the FULL mark. Add oil if required.

5. Check for water leaks. Observe the water level gauge.

6. Perform all checks and operations required by the manufacturers of the locomotive and running gear.

Starting The Locomotive Or Train

Because this engine may be powering the locomotive through one of several available drive mechanisms, see the locomotive manufacturer's recommendations for starting, operating and stopping the train.
When accelerating, operate the controller to obtain a smooth rate of acceleration and travel. Allow the engine to pickup the load before notching to the next position.

Stopping The Engine

1. Stop the train or locomotive as per the locomotive manufacturer's instructions.

2. Place the operating control lever in neutral with brakes applied.

3. Move the throttle control lever to half engine speed position, and allow the engine to idle five minutes.

4. While the engine is running, do the shutdown inspections required by the other manufacturers.

5. Reduce engine speed to low idle.

6. Check engine oil level while oil is hot. Add oil if necessary.

7. Stop the engine by pushing the engine fuel control to shutoff position. Hold the control until the engine stops.

8. Follow the locomotive instructions and your Mechanical Department Instructions for leaving the locomotive.

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