3COM SEBU6251-06 User Manual

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Operation and Maintenance Manual

SEBU6251-06

April 1999

Caterpillar Commercial Diesel Engine Fluids Recommendations

For All Commercial Diesel Engines Except 3600 Series Engines

i01097883

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Table of Contents

Foreword ............................................................... 4

Maintenance Section

Lubricant Specifications ........................................ 5

Fuel Specifications ................................................ 17

Cooling System Specifications ............................. 24

Reference Information Section

Reference Materials .............................................. 37

Index Section

Index ..................................................................... 39

Table of Contents

4 Foreword

Foreword

Literature Information

This manual should be stored in the literature storage area.

The information contained in this document is the most current information available for coolants, fuels, and lubricants. Refer to the Operation and Maintenance Manual for any special lubrication requirements for your engine.

Whenever a question arises regarding the engine, this publication, or the Operation and Maintenance Manual, please consult any Caterpillar dealer for the latest available information.

Safety

Refer to the Operation and Maintenance Manual for your engine for all safety information. Read and understand the basic safety precautions listed in the Safety Section. In addition to safety precautions, this section identifies the text and locations of safety signs used on the engine.

Read and understand the basic precautions listed in the Safety Section before operating or performing lubrication, maintenance and repair on this engine.

Maintenance

Refer to the Operation and Maintenance Manual for your engine to determine all maintenance requirements.

Maintenance Intervals

Use the Maintenance Interval Schedule in the Operation and Maintenance Manual for your engine to determine servicing intervals. The actual operating environment of the engine also governs the maintenance interval schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.

Maintenance Section

Lubricant Specifications

Maintenance Section

Lubricant Specifications

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Lubricant Information

SMCS Code: 1000; 1300; 7581

General Information

Because of government regulations regarding the certification of engine exhaust emissions, the lubricant recommendations must be followed.

Engine Manufacturers Association (EMA) Oils

The “Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil” is recognized by Caterpillar. For detailed information about this guideline, see the latest edition of EMA publication, “EMA LRG-1”.

API Oils

The Engine Oil Licensing and Certification System by the American Petroleum Institute (API) is recognized by Caterpillar. For detailed information about this system, see the latest edition of the “API publication No. 1509”. Engine oils that bear the API symbol are authorized by API.

Ta bl e 1

API Classifications

Current Obsolete

CF-4, CG-4, CH-4 CE

CF CC, CD

(1)

CF-2

(1)

CD-2 and API CF-2 are classifications for two-cycle diesel engines. Caterpillar does not sell engines that utilize CD-2 and API CF-2 oils.

Note: API CF is not the same classification as

API CF-4. API CF oils are only recommended for Caterpillar 3600 Series Diesel Engines and Caterpillar engines with precombustion chamber (PC) fuel systems.

CD-2

(1)

Grease

The classifications of grease are based on the “ASTM D217” worked penetration characteristics. These characteristics for grease are given a defined consistency number.

Terminology

Certain abbreviations follow the nomenclature of “SAE J754”. Some classifications follow “SAE J183” abbreviations, and some classifications follow the “EMA Recommended Guideline on Diesel Engine Oil”. In addition to Caterpillar definitions, there are other definitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, “Engine Oil” topic (Maintenance Section).

Illustration 1 Typical API symbol

Diesel engine oils CC, CD, CD-2, and CE have not been API authorized classifications since 1 January 1996. Table 1 summarizes the status of the classifications.

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Engine Oil

SMCS Code: 1348

Caterpillar Diesel Engine Oil

Caterpillar Oils have been developed and tested in order to provide the full performance and service life that has been designed and built into Caterpillar Engines. Caterpillar Oils are currently used to fill diesel engines at the factory. These oils are offered by Caterpillar dealers for continued use when the engine oil is changed. Consult your Caterpillar dealer for more information on these oils.

Due to significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations:

Caterpillar Diesel Engine Oil (10W30)

•

6 Maintenance Section Lubricant Specifications

Caterpillar Diesel Engine Oil (15W40)

•

Caterpillar multigrade Diesel Engine Oil is formulated with the correct amounts of detergents, dispersants, and alkalinity in order to provide superior performance in Caterpillar Diesel Engines.

Caterpillar multigrade Diesel Engine Oil is available in two viscosity grades (10W30 and 15W40). For direct injection engines, see Table 2 in order to choose the correct viscosity grade for the ambient temperature. Multigrade oils provide the correct viscosity for a broad range of operating temperatures.

Multigrade oils are effective in maintaining low oil consumption and low levels of piston deposits.

Caterpillar multigrade Diesel Engine Oil can be used in other diesel engines and in gasoline engines. See the engine manufacturer’s guide for the recommended specifications. Compare the specifications to the specifications of Caterpillar multigrade Diesel Engine Oil. The current industry standards for Caterpillar Diesel Engine Oil are listed on the product label and on the data sheets for the product.

Consult your Caterpillar dealer for part numbers and for available sizes of containers.

Commercial Oils

The performance of commercial diesel engine oils is based on American Petroleum Institute (API) classifications. These API classifications are developed in order to provide commercial lubricants for a broad range of diesel engines that operate at various conditions.

If Caterpillar multigrade Diesel Engine Oil is not used, only use commercial oils that meet the following classifications:

EMA LRG-1 multigrade oil (preferred oil)

•

API CH-4 multigrade oil (preferred oil)

•

API CG-4 multigrade oil (preferred oil)

•

API CF-4 multigrade oil (acceptable oil)

•

In order to make the proper choice of a commercial oil, refer to the following explanations:

EMA LRG-1 – The Engine Manufacturers Association (EMA) has developed lubricant recommendations as an alternative to the API oil classification system. LRG-1 is a Recommended Guideline that defines a level of oil performance for these types of diesel engines: high speed, four stroke cycle, heavy-duty, and light duty. LRG-1 oils may be used in Caterpillar engines when API CH-4, API CG-4, and API CF-4 oils are recommended. LRG-1 oils are intended to provide superior performance in comparison to API CG-4 and API CF-4.

LRG-1 oils will meet the needs of high performance Caterpillar diesel engines that are operating in many applications. The tests and the test limits that are used to define LRG-1 are similar to the new API CH-4 classification. Therefore, these oils will also meet the requirements of the low emissions diesel engines. LRG-1 oils are designed to control the harmful effects of soot with improved wear resistance and improved resistance to oil filter plugging. These oils will also provide superior piston deposit control for engines with either two-piece steel pistons or aluminum pistons.

All LRG-1 oils must complete a full test program with the base stock and with the viscosity grade of the finished commercial oil. The use of “API Base Oil Interchange Guidelines” are not appropriate for LRG-1 oils. This feature reduces the variation in performance that can occur when base stocks are changed in commercial oil formulations.

LRG-1 oils are recommended for use in extended oil change interval programs that optimize oil life. These oil change interval programs are based on oil analysis. LRG-1 oils are recommended for conditions that demand a premium oil. Your Caterpillar dealer has the specific guidelines for optimizing oil change intervals.

API CH-4 – API CH-4 oils were developed in order to meet the requirements of the new high performance diesel engines. Also, the oil was designed to meet the requirements of the low emissions diesel engines. API CH-4 oils are also acceptable for use in older diesel engines and in diesel engines that use high sulfur diesel fuel. API CH-4 oils may be used in Caterpillar engines that use API CG-4 and API CF-4 oils. API CH-4 oils will generally exceed the performance of API CG-4 oils in the following criteria: deposits on pistons, control of oil consumption, wear of piston rings, valve train wear, viscosity control, and corrosion.

Maintenance Section

Lubricant Specifications

Three new engine tests were developed for the API CH-4 oil. The first test specifically evaluates deposits on pistons for engines with the two-piece steel piston. This test (piston deposit) also measures the control of oil consumption. A second test is conducted with moderate oil soot. The second test measures the following criteria: wear of piston rings, wear of cylinder liners, and resistance to corrosion. A third new test measures the following characteristics with high levels of soot in the oil: wear of the valve train, resistance of the oil in plugging the oil filter, and control of sludge.

In addition to the new tests, API CH-4 oils have tougher limits for viscosity control in applications that generate high soot. The oils also have improved oxidation resistance. API CH-4 oils must pass an additional test (piston deposit) for engines that use aluminum pistons (single piece). Oil performance is also established for engines that operate in areas with high sulfur diesel fuel.

All of these improvements allow the API CH-4 oil to achieve optimum oil change intervals. API CH-4 oils are recommended for use in extended oil change intervals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Caterpillar dealer has specific guidelines for optimizing oil change intervals.

Some commercial oils that meet the API classifications may require reduced oil change intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear metal analysis. Caterpillar’sS·O·S oil analysis program is the preferred method.

NOTICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.

Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines

The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For direct injection engines that use distillate fuel, the minimum TBN of the new oil must be 10 times the fuel sulfur level. The TBN is defined by “ASTM D2896”. The minimum TBN of the oil is 5 regardless of fuel sulfur level. Illustration 2 demonstrates the TBN.

API CG-4 – API CG-4 oils were developed primarily for diesel engines that use a 0.05 percent level of fuel sulfur. However, API CG-4 oils can be used with higher sulfur fuels. The TBN of the new oil determines the maximum fuel sulfur level for API CG-4 and API CF-4 oils. See Illustration 2.

API CG-4 oils are the first oils that are required to pass industry standard tests for foam control and viscosity shear loss. API CG-4 oils must also pass tests that were developed for corrosion, wear and oxidation.

API CF-4 – These oils service a wide variety of modern diesel engines. API CF-4 oils provide more stable oil control and reduced piston deposits in comparison to API CF and the obsolete CE and CD classifications of oil. API CF-4 oils provide improved soot dispersancy in comparison to API CF and obsolete CD oils. The API CF-4 classification was developed with a 0.40 percent sulfur diesel fuel. This represents the type of diesel fuels that are commonly available worldwide.

Note: Do not use single grade API CF oils or multigrade API CF oils in Caterpillar Direct Injection (DI) Commercial Diesel Engines.

Illustration 2 (Y) TBN by “ASTM D2896”

(X) Percentage of fuel sulfur by weight (1) TBN of new oil (2) Change the oil when the TBN deteriorates to 50 percent of

the original TBN.

Use the following guidelines for fuel sulfur levels that exceed 1.5 percent:

Choose an oil with the highest TBN that meets

•

one of these classifications: EMA LRG-1, API CH-4, API CG-4, and API CF-4.

Reduce the oil change interval. Base the oil

•

change interval on the oil analysis. Ensure that the oil analysis includes the condition of the oil and a wear metal analysis.

g00104890

Excessive piston deposits can be produced by an oil with a high TBN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.

8 Maintenance Section Lubricant Specifications

NOTICE Operating Direct Injected (DI) diesel engines with fuel sulfur levels over 1.0 percent may require shortened oil change intervals in order to help maintain adequate wear protection.

i01111341

Engine Oil (3116 and 3126 Marine Engines)

SMCS Code: 1348

Lubricant Viscosity Recommendations for Direct Injection (DI) Diesel Engines

The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.

Refer to Table 2 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Refer to Table 2 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.

Ta bl e 2

Engine Oil Viscosity

Ambient TemperatureCaterpillar DEO

Multigrade

EMA LRG-1

API CH-4

API CG-4 and

API CF-4

Viscosity Grade

SAE 0W20

SAE 0W30

SAE 0W40 SAE 5W30 −30C(−22F) 30C (86F)

SAE 5W40 −30C(−22F) 40C (104F) SAE 10W30 −20C(−4F) 40C (104F) SAE 15W40 −15C(5

Minimum Maximum

−40C(−40



−40

C(−40F)

−40C(−40



C (50F)



C (86F)

40C (104

50C (122



Recommendations

Caterpillar does not recommend the use of multigrade oils in the 3116 and 3126 Marine Diesel Engines with mechanical unit injection.

Multigrade oils use high molecular weight polymers as viscosity index improvers.

When the crankcase blowby flows through the turbocharger and the aftercooler, the viscosity index improvers in the oil vapor can adhere to the turbocharger compressor and aftercooler core.

The fouling of the turbocharger and aftercooler can cause reduced air flow, loss of power, and increased black smoke. The emission of black smoke results in buildup of soot on the transom of the boat.

Note: Caterpillar recommends the use of single grade oils with the API CF-4 classification for all 3116 and 3126 Marine Engines unless crankcase blowby has been routed completely away from the air cleaner inlet.

Caterpillar Special Application Engine Oil (SAEO)

Note: Special Application Engine Oil is for use in Caterpillar 3116 and 3126 Marine Diesel Engines with mechanical unit injection. This includes all 3116 and 3126 Marine Diesel Engines that begin with the following serial number prefixes: (S/N: 4KG), (S/N: 1SK), (S/N: 8NM), and (S/N: 6SR).

The factory fill in 3116 and 3126 Marine Engines is Caterpillar Special Application Engine Oil (SAEO). The oil that is used for the factory fill has the following properties:

API CF-4 classification

•

Viscosity of SAE 30

•

For maximum performance in 3116 and 3126 Marine Diesel Engines with mechanical unit injection, Caterpillar recommends the following engine oil:

Caterpillar Special Application Engine Oil (SAEO)

•

with a viscosity of SAE 30

Caterpillar Special Application Engine Oil (SAEO)

•

with a viscosity of SAE 40

Maintenance Section

Lubricant Specifications

Commercial Oils (3116 and 3126 Marine Engines)

The performance of commercial diesel engine oil is based on American Petroleum Institute (API) classifications. These API classifications are developed in order to provide commercial lubricants for a broad range of diesel engines that operate at various conditions.

When a Caterpillar Special Application Engine Oil (SAEO) is not used, use the following commercial oils:

Single grade oil with a viscosity of SAE 30 or SAE

•

40 with an API CF-4 classification is preferred.

Single grade oil with a viscosity of SAE 30 or

•

SAE 40 with a CF-4 or CG-4 additive package that does NOT contain viscosity improvers is an acceptable oil.

For an acceptable commercial single grade oil, contact your oil supplier or Caterpillar Customer Service:

Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines (3116 and 3126 Marine Engines)

The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For direct injection engines that use distillate fuel, the minimum TBN must be 10 times the fuel sulfur level. The TBN is determined by the “ASTM D2896” procedure. The minimum TBN of the oil is 5 regardless of a low fuel sulfur level. Illustration 3 demonstrates the TBN.

1-800-447-4986

The following explanation of the API CF-4 classification can be used to make the proper choice when a commercial single grade oil with API CF-4 classification is chosen.

Some commercial oils that meet the API CF-4 classifications may require reduced oil change intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear metal analysis. Caterpillar’sS·O·S oil analysis program is the preferred method.

NOTICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.

Illustration 3 (Y) TBN by “ASTM D2896”

(X) Percentage of fuel sulfur by weight (1) TBN of new oil (2) Change the used oil when the TBN reaches this level.

Use the following guidelines for fuel sulfur levels that exceed 1.5 percent:

Choose an oil with the highest TBN within the

•

API CF-4 classification.

Reduce the oil change interval. Base the oil

•

change interval on the oil analysis. Ensure that the oil analysis includes the condition of the oil and a wear metal analysis.

Excessive piston deposits can be produced by an oil with a high TBN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.

NOTICE Operating Direct Injected (DI) diesel engines with fuel sulfur levels over 1.0 percent may require shortened oil change intervals in order to help maintain adequate wear protection.

g00104890

10 Maintenance Section Lubricant Specifications

Lubricant Viscosity Recommendations (3116 and 3126 Marine Engines)

The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.

Refer to Table 3 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Refer to Table 3 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is allowed for the ambient temperature at start-up.

Ta bl e 3

Engine Oil Viscosity

API CF-4 Oil

Viscosity Grade

SAE 30 0C (32F) 40C (104

SAE 40 5

Ambient Temperature

Minimum Maximum



C (41F)



C (122F)

i01123508



Caterpillar multigrade Diesel Engine Oil is available in two viscosity grades (10W30 and 15W40). For precombustion chamber engines, see Table 4 in order to choose the correct viscosity grade for the ambient temperature. Multigrade oils provide the correct viscosity for a broad range of operating temperatures.

Multigrade oils are effective in maintaining low oil consumption and low levels of piston deposits.

Consult your Caterpillar dealer for part numbers and for available sizes of containers.

Commercial Oils

Engine Oil for Precombustion Chamber (PC) Diesel Engines

SMCS Code: 1348

Caterpillar Diesel Engine Oil

Due to significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations:

Caterpillar Diesel Engine Oil (10W30)

•

Caterpillar Diesel Engine Oil (15W40)

•

Caterpillar multigrade Diesel Engine Oil is formulated with the correct amounts of detergents, dispersants, and alkalinity in order to provide superior performance in Caterpillar Diesel Engines.

If Caterpillar multigrade Diesel Engine Oil is not used, only use commercial oils that meet the following classifications:

EMA LRG-1 multigrade oil (preferred oil)

•

API CH-4 multigrade oil (preferred oil)

•

API CG-4 multigrade oil (preferred oil)

•

API CF-4 multigrade oil (acceptable oil)

•

API CF oil (acceptable oil for PC engines)

•

In order to make the proper choice of a commercial oil, refer to the following explanations:

Maintenance Section

Lubricant Specifications

EMA LRG-1 – The Engine Manufacturers

Association (EMA) has developed lubricant recommendations as an alternative to the API oil classification system. LRG-1 is a Recommended Guideline that defines a level of oil performance for these types of diesel engines: high speed, four stroke cycle, heavy-duty, and light duty. LRG-1 oils may be used in Caterpillar engines when API CH-4, API CG-4, and API CF-4 oils are recommended. LRG-1 oils are intended to provide superior performance in comparison to API CG-4 and API CF-4.

12 Maintenance Section Lubricant Specifications

NOTICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.

Total Base Number (TBN) and Fuel Sulfur Levels for Precombustion Chamber (PC) Diesel Engines

The TBN for a new oil depends on the fuel sulfur level of the fuel that is used. The minimum TBN of the oil that is used in PC engines must be 20 times the fuel sulfur level. The TBN is defined in “ASTM D2896”. Regardless of fuel sulfur level, the minimum TBN of new oil is five. Refer to illustration 4.

Lubricant Viscosity Recommendations for Precombustion Chamber (PC) Diesel Engines

The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.

Refer to Table 4 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Refer to Table 4 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.

Illustration 4 (Y) The TBN that is shown by “ASTM D2896”

(X) Percentages of fuel sulfur by weight (1) TBN of new oil (2) Change the oil when the TBN deteriorates to 50 percent of

the original TBN.

g00274867

Whenever the fuel sulfur exceeds 1.5 percent, do the following tasks.

Choose an oil with the highest TBN that meets

•

one of these classifications: EMA LRG-1, API CF, API CF-4, API CG-4, and API CH-4.

Shorten the oil change interval if the oil analysis

•

dictates.

Ta bl e 4

Engine Oil Viscosity

Caterpillar DEO

Multigrade

EMA LRG-1

API CH-4 API CG-4

API CF-4 and

API CF

Viscosity Grade

SAE 0W20 −40C(−40F) 10C (50F)

SAE 0W30

SAE 0W40

SAE 5W30

SAE 5W40

SAE 10W30 −20C(−4F) 40C (104F) SAE 15W40 −15C(5F) 50C (122F)

SAE 30 0C (32F) 40C (104F)

SAE 40 5C (41F) 50C (122F)

Ambient Temperature

Minimum Maximum

−40C(−40F) 30C (86F)

−40C(−40F) 40C (104F)

−30C(−22F) 30C (86F)

−30C(−22F) 40C (104F)

i01098470

Excessive piston deposits can be produced by an oil with a high TBN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.

NOTICE Operating PC engines at fuel sulfur levels over 1.0 percent may require shortened oil change intervals to maintain adequate wear protection.

Marine Transmission Oil

SMCS Code: 3080; 3300

Caterpillar Transmission/Drive Train Oil (TDTO) is balanced in order to give maximum frictional material service life in Caterpillar transmissions. TDTO exceeds the requirements for the Caterpillar TO-4 oil specification which includes the frictional requirements and gear wear requirements. TDTO is offered in different lubricant viscosity grades for maximum service life of components at high ambient temperatures and heavy duty cycles.

For maximum transmission service life and performance, Caterpillar recommends Caterpillar Transmission/Drive Train Oil (TDTO).

Ta bl e 5

Lubricant Viscosities For Operating Temperatures

Cooling of

Transmission

Raw/Seawater

Jacket Water SAE 50 −5

Oil Viscosities

SAE 30

SAE 50

Caterpillar TDTO

Minimum

Temperature

−15C(5

−5C (23



C (23

Maintenance Section

Lubricant Specifications

Maximum

Temperature



C (176F)

95C (203



C (203



Contact your Caterpillar dealer for part numbers and for sizes of available containers.

NOTICE This oil is formulated for transmissions and drive trains only, and should not be used in engines. Shortened engine life will result.

NOTICE Caterpillar Gear Oil (GO) is not the same as Caterpillar Transmission/Drive Train Oil, and does not meet Caterpillar’s specifications for TO-4 oil. Caterpillar GO or commercial gear oils should not be used in compartments which specify TO-4 oil.

Caterpillar Transmission/Drive Train Oils

If Caterpillar Transmission/Drive Train Oil is not used, commercial oils meeting the Caterpillar TO-4 specification must be used in Caterpillar marine transmissions. Use TO-4 Specification Oils that are single grade only.

Commercial Marine Transmissions

For marine transmissions which are not manufactured by Caterpillar, refer to the lubrication recommendation of the OEM for the marine transmission or the vessel.

i01111406

Synthetic base oils generally perform better than conventional oils in the following two areas:

Synthetic base oils have improved flow at low

•

temperatures especially in arctic conditions.

Synthetic base oils have improved oxidation

•

stability especially at high operating temperatures.

Some synthetic base oils have performance characteristics that enhance the service life of the oil. However, Caterpillar does not recommend the automatic extension of oil change intervals for any type of oil. Oil change intervals for Caterpillar engines can only be adjusted after an oil analysis program that contains the following tests: oil condition and wear metal analysis (Caterpillar’s S·O·S oil analysis), trend analysis, fuel consumption, and oil consumption.

i01111412

Re-refined Base Stock Oils

SMCS Code: 1300; 1348; 7581

Re-refined base stock oils are acceptable for use in Caterpillar engines if these oils meet the performance requirements that are specified by Caterpillar. Re-refined base stock oils can be used exclusively in finished oil or in a combination with new base stock oils. The US military specifications and the specifications of other heavy equipment manufacturers also allow the use of re-refined base stock oils that meet the same criteria.

Synthetic Base Stock Oils

SMCS Code: 1300; 1348; 7581

Synthetic base oils are acceptable for use in Caterpillar engines if these oils meet the performance requirements that are specified for the engine compartment.

The process that is used to make re-refined base stock oil should adequately remove all wear metals that are in the used oil and all additives that are in the used oil. The process that is used to make re-refined base stock oil generally involves the processes of vacuum distillation and hydrotreating the used oil. Filtering is inadequate for the production of high quality re-refined base stock oils from used oil.

14 Maintenance Section Lubricant Specifications

i01123104

Aftermarket Oil Additives

SMCS Code: 1300; 1348; 7581

Caterpillar does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket additives in order to achieve the engine’s maximum service life or rated performance. Fully formulated, finished oils consist of base oils and of commercial additive packages. These additive packages are blended into the base oils at precise percentages in order to help provide finished oils with performance characteristics that meet industry standards.

There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in finished oil. Aftermarket additives may not be compatible with the finished oil’s additive package, which could lower the performance of the finished oil. The aftermarket additive could fail to mix with the finished oil. This could produce sludge in the crankcase. Caterpillar discourages the use of aftermarket additives in finished oils.

To achieve the best performance from a Caterpillar engine, conform to the following guidelines:

When an engine is started and operated in ambient temperatures below −30



C(−22



F), use a synthetic base stock multigrade oil with a 0W viscosity grade or with a 5W viscosity grade. Use an oil with a pour point that is lower than −50



C(−58



F).

The number of acceptable lubricants is limited in cold weather conditions. Caterpillar recommends the following lubricants for use in cold weather conditions:

First Choice – use an oil with an EMA LRG-1 Recommended Guideline or use a CH-4 oil that is API licensed with an SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade. A CG-4 oil that is API licensed with an SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade may also be used. A CF-4 oil that is API licensed with an SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade may also be used.

Second Choice – use an oil that contains the CH-4, CG-4, or CF-4 additive package although the oil has not been tested for the requirements of the API license. The oil must have an SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade.

Select the proper Caterpillar oil or a commercial

•

oil that meets the “EMA Recommended Guideline on Diesel Engine Oil” or the recommended API classification.

See the appropriate “Lubricant Viscosities” table

•

in order to find the correct oil viscosity grade for your engine.

At the specified interval, service the engine

•

compartment. Use new oil and install a new oil filter.

Perform maintenance at the intervals that are

•

specified in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.

i01113213

Cold Weather Lubricants

SMCS Code: 1300; 1348; 7581

When an engine is started and an engine is operated in ambient temperatures below −20



(−4

F), use multigrade oils that are capable of

flowing in low temperatures.

NOTICE Shortened engine service life could result if second choice oils are used.

i01111438

Lubricating Grease

SMCS Code: 1000; 7581

Caterpillar provides greases in order to cover a variety of applications and extreme temperature conditions. Consult your Caterpillar dealer for part numbers and for available sizes of containers.

Note: Some greases may not be used with other greases. When a commercial grease is used, ensure that the grease is compatible with the grease that is currently used in the system. If the commercial grease is not compatible, the system must be purged. If any questions arise concerning the compatibility of a grease, consult the supplier.



These oils have lubricant viscosity grades of SAE 0W or SAE 5W.

Maintenance Section

Lubricant Specifications

Multipurpose Greases

Multipurpose Lithium Complex Grease (MPGL)

Multipurpose Lithium Complex Grease (MPGL) is a general purpose lithium complex grease for medium-duty applications. This product has good characteristics at high temperatures such as a dropping point of 260 unleaded extreme pressure additives, antiwear inhibitors, and corrosion inhibitors that provide extra protection in the following applications:

Construction

•

Agricultural

•

Automotive

•

MPGL meets the requirements for extended service intervals of automotive chassis points. MPGL also meets the requirements for extended service intervals of wheel bearings with disc brakes in automobiles, in vans and in light trucks. This product meets the NLGI certification of “GC-LB”. MPGL is also available in a NGLI No. 2 grade. Normal operating temperatures for this product are

−28 to 149 available as a white lithium complex grease.



C(−18 to 300

Multipurpose Lithium Complex Grease with Molybdenum (MPGM)

Multipurpose Lithium Complex Grease with Molybdenum (MPGM) is a general purpose lithium complex grease that is used for light-duty applications and for medium-duty applications. The MPGM is available in the following grades: NLGI No. 2 and NLGI No. 0. The MPGM is strengthened with a molybdenum disulfide and a polymer for extra lubrication and protection. MPGM contains unleaded additives. MPGM also contains antiwear inhibitors, rust inhibitors, and corrosion inhibitors that are for protection and lubrication in many environments. The MPGM is formulated with a base fluid that has high viscosity.

The MPGM has the following features:

Increased protection against water washout

•

Increased retention

•

Resistance to heavy loads

•



C (500



F). MPGL contains



F). This product is also

This product is recommended for heavily loaded pin joints and for journal bearings. This product meets the certification of “GC-LB”. Normal operating temperatures for this product are −28 to 149 (−18 to 300 temperatures for this product are −18 to 149 (0 to 300

Note: If MPGM is not available, use a multipurpose type grease which contains three to five percent molybdenum.



F) for the NLGI No. 0. Normal operating



F) for the NLGI No. 2.



Special Purpose Grease (SPG)

Bearing Lubrication (SPG)

Bearing Lubricant (SPG) is available in a NLGI No. 2 grade with a polyurea thickener. This grease is recommended for high temperature antifriction bearings in the following applications: electric starting motors, alternators, fan drives, and generators. The Bearing Lubricant (SPG) has an effective operating range of −29 to 177 (−20 to 350



F).

Water and Temperature Resistant Grease (WTR)

The Water and Temperature Resistant Grease is designed for use whenever the following conditions are a concern: water washout, severe corrosion, and high operating temperatures. The Water and Temperature Resistant Grease provides extreme pressure protection, antiwear protection, rust protection and corrosion protection. The Water and Temperature Resistant Grease is an environmentally friendly grease which does not contain the following materials: antimony, sulfur, barium, zinc, lead, and phosphorous materials. The Water and Temperature Resistant Grease has excellent shear stability. Water and Temperature Resistant Grease can also resist breakdown in the presence of water. The Water and Temperature Resistant Grease works well in the following applications:

Construction

•

Agricultural

•

Automotive

•

Industrial

•

Marine

•

This product meets the NLGI certification of “GC-LB”. Normal operating temperatures for this product are −40 to 204



C(−40 to 400F).



16 Maintenance Section Lubricant Specifications

Caterpillar Premium Grease (CPG)

Desert Gold (CPG)

Desert Gold is a heavy-duty, premium synthetic grease that is developed for the most extreme operating environments. This grease is formulated with the following characteristics: high viscosity synthetic base fluid, polymers, molybdenum disulfide, high viscosity index, and high dropping point.

Desert Gold will protect equipment against heavy shock loads. Desert Gold protects against corrosion in extreme heat, in moist conditions, or in dusty conditions. This product has excellent characteristics of adhesion and of stability. Desert Gold provides longer protection than other greases. Desert Gold is an environmentally friendly grease which does not contain the following materials: antimony, sulfur, barium, zinc, lead, and phosphorous materials. Normal operating temperatures are

−6 to 230

Gold can operate at higher temperatures for short time periods. Desert Gold has additional extreme pressure protection for highly loaded pin joints.

Arctic Platinum (CPG)

Arctic Platinum is a super-premium extreme pressure lubricating grease that is developed for lubrication in temperatures that are below zero to moderate operating temperatures. Arctic Platinum is available in grades 000, 00, 0, 1, and 2. These grades ensure pumpability in central lube systems in a variety of ambient temperatures from −60 to 18 (−76 to 65 point. Arctic Platinum contains a five percent concentrate of molybdenum disulfide for protection against extra heavy loads. Arctic Platinum provides excellent corrosion protection and rust protection. Arctic Platinum is an environmentally friendly grease which does not contain the following materials: antimony, sulfur, barium, zinc, and phosphorous.

Arctic Platinum is designed for long life lubrication of the following components: horizontal pivot bearings, lower link bearings, steering cylinders, kingbolt bearings, upper hitch link bearings, and ejector carrier roller bearings. This grease is extra tacky for retention on excavator carbody bearings. Arctic Platinum has additional extreme pressure protection for highly loaded pin joints.



F). Arctic Platinum has a high dropping



C (21 to 450



F). Desert



i01065849

S·O·S Oil Analysis

SMCS Code: 1000; 7542

Caterpillar recommends the use of the S·O·S oil analysis program in order to monitor the condition and the maintenance requirements of the equipment. The S·O·S oil analysis program will complement the preventive maintenance program.

The S·O·S oil analysis is a diagnostic tool that is used to determine oil performance and component wear rates. Contamination can be identified and measured through the use of the S·O·S oil analysis. The S·O·S oil analysis includes the following tests:

The Wear Rate Analysis monitors the wear of the

•

engine’s metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase in the rate of engine wear metal in the oil is as important as the quantity of engine wear metal in the oil. For this reason, regular sampling at specified intervals is necessary in order to establish wear rates. Intermittent sampling does not allow wear rate trend lines to be established. Engine wear metals in the oil sample are compared to established Caterpillar norms in order to determine acceptability.

Tests are conducted in order to detect

•

contamination of the oil by water, glycol or fuel.

The Oil Condition Analysis determines the loss

•

of the oil’s lubricating properties. An infrared analysis is used to compare the properties of new oil to the properties of the used oil sample. This analysis allows technicians to determine the amount of deterioration of the oil during use. This analysis also allows technicians to verify the performance of the oil according to the specification during the entire oil change interval.

The test results of the oil samples will then be used as a basis for determining the oil change interval for the engine. The results of the S·O·S oil analysis may allow the engine to operate longer between oil changes without the risk of engine damage.

Ta bl e 6

S·O·S Oil Analysis Interval

Compartment

Engine crankcase Every 250 Service Hours

Interval

For more information, see Special Publication, PEDP7036, “S·O·S Fluid Analysis”. Consult your Caterpillar dealer for complete information and assistance about the program.

Maintenance Section

Fuel Specifications

i01060086

General Fuel Information

SMCS Code: 1250; 1280

Purchase fuel from a reputable supplier.

•

Use fuel that meets the minimum Caterpillar

•

specifications for diesel fuel. The specifications are included in the table Caterpillar Specifications for Distillate Fuel. This table is included in the recommendations for diesel fuel. These fuels have a minimum lubricity level of 3100 g. This result is obtained by conducting the Scuffing Load Wear Test (SBOCLE). If a High Frequency Reciprocating Rig (HFRR) is used for testing, the maximum allowable wear scar is .45 mm (0.018 inch) at 60 allowable wear scar is .38 mm (0.0150 inch) at



Keep the fuel storage tank clean of water, debris

•

and sediment.

Drain water and sediment from the fuel storage

•

tank weekly. Drain water and sediment before the tank is refilled.

C (77



F).



C (140F). The maximum

i01096371

Fuel Information for Diesel Engines

SMCS Code: 1250; 1280

The two basic types of diesel fuel are No. 2 diesel fuel and No. 1 diesel fuel. No. 2 diesel fuel is a heavier diesel fuel than No. 1 diesel fuel. Heavier fuels can cause problems with fuel filters, fuel lines, fuel tanks, and fuel storage in cold weather. Heavier diesel fuels such as No. 2 diesel fuel can be used in diesel engines that operate in cold temperatures with a minimum amount of pour point depressant additive. For more information on fuels which include blends of No. 1 and No. 2 diesel fuel, consult your fuel supplier.

When you use No. 2 diesel fuel or other heavier fuels, some of the fuel’s qualities may interfere with successful cold weather operation. Additional information about the characteristics of diesel fuel is available. This information contains a discussion on the modification to the characteristics of diesel fuel. There are several possible methods that can be used to compensate for the fuel qualities that may interfere with cold weather operation. These methods include the use of starting aids, engine coolant heaters, fuel heaters, and de-icers.

Keep the area around the fuel tank filler neck

•

clean of debris in order to prevent contamination of the fuel tank.

As required, clean the inside of the engine’s fuel

•

tank.

Drain water and sediment from the engine’s fuel

•

tank daily. Drain the tank at the start of a shift. After the fuel tank has been filled, allow the fuel to settle for ten minutes. This will allow the water and sediment to separate from the fuel. Then, drain the water and sediment from the tank.

Install water separators.

•

Drain the water from the water separator daily.

•

For some applications, Caterpillar high efficiency

•

fuel filters are required in order to provide maximum life to the fuel system.

Change fuel filters at the scheduled interval.

•

Never fill the new fuel filter with fuel before installation. Use the fuel priming pump to remove air from the system.

Install breather filters on the fuel tanks.

•

Starting Aids

The use of a starting aid is a conventional method of assistance for cold starts in low temperature conditions. A variety of starting aids are available for Caterpillar engines. Follow the recommendations that are provided by the manufacturer of the starting aid.

Engine Coolant Heaters

These heaters heat the engine coolant. The heated coolant flows through the cylinder block. The flow of heated coolant keeps the engine warm. A warm engine is easier to start in cold weather. Most coolant heaters use electrical power. A source of electricity is necessary for this type of heater. Other heaters that burn fuel are available as a source of heat. These heaters may be used in place of the electrical heaters.

With either type of heater, starting aids and/or fuels with higher cetane numbers are less important because the engine is warm. Problems with fuel cloud point can cause the plugging of fuel filters. Problems with fuel cloud point cannot be corrected by engine coolant heaters. This is especially true for fuel filters that are cooled by air flow during operation.

18 Maintenance Section Fuel Specifications

Fuel Heaters

The fuel cloud point is related to problems with fuel filters. The heater heats the fuel above the cloud point before the fuel enters the fuel filter. This prevents wax from blocking the filter. Fuel can flow through pumps and lines at temperatures below the cloud point. The cloud point is often above the pour point of a fuel. While the fuel can flow through these lines, the wax in the fuel can still plug the fuel filter.

In some engine installations, small modifications can prevent problems that are caused by the cloud point. One of the following changes can prevent problems in many conditions: a change in the location of fuel filters and/or supply lines and the addition of insulation. In extreme temperatures, heating of the fuel may be required to prevent the filters from plugging. There are several types of fuel heaters that are available. The heaters use either engine coolant or exhaust gas as a heat source. These systems may prevent filter waxing problems without the use of de-icers. These systems may be ineffective when the fuel contains a large amount of dirt or of water. Use of a fuel heater can help eliminate some cold weather problems. A fuel heater should be installed so that the fuel is heated before flowing into the fuel filter.

Note: Only use fuel heaters that are controlled by thermostats or use fuel heaters that are self-regulated. Do not use fuel heaters in warm temperatures.

Select a fuel heater that is mechanically simple, yet adequate for the application. The fuel heater should also prevent overheating of the fuel. Disconnect the fuel heater or deactivate the fuel heater in warm weather. An unacceptable loss of fuel viscosity and engine power will occur if the fuel supply temperature is allowed to become too hot.

For additional information on fuel heaters, see your Caterpillar dealer.

De-Icers

De-icers lower the freezing point of the moisture in the fuel. De-icers are not generally needed when fuel heaters are used. If you experience trouble, consult your fuel supplier for recommendations of a compatible commercial de-icer.

i01111474

Fuel Recommendations

SMCS Code: 1250; 1280

Diesel engines have the ability to burn a wide variety of fuels. These fuels are divided into two general groups. The two groups are called the preferred fuels and the permissible fuels.

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

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

Diesel fuels that meet the specifications in Table 7 will help to provide maximum engine service life and performance. In North America, diesel fuel that is identified as No. 1-D or No. 2-D in “ASTM D975” generally meet the specifications. Table 7 is for diesel fuels that are distilled from crude oil. Diesel fuels from other sources could exhibit detrimental properties that are not defined or controlled by this specification.

Ta bl e 7

Caterpillar Specifications for Distillate Diesel Fuel

Specifications

Aromatics 35% maximum “D1319” Ash 0.02% maximum (weight) “D482” Carbon Residue

on 10% Bottoms

Cetane Number

Cloud Point

Copper Strip Corrosion

Distillation

Flash Point legal limit “D93”

Requirements

0.35% maximum (weight) “D524”

40 minimum (DI engines) 35 minimum (PC engines) The cloud point must

not exceed the lowest expected ambient temperature.

No. 3 maximum “D130”

10% at 282C (540F) maximum

90% at 360C (680F) maximum

ASTM

Test

“D613”

“D86”

(continued)

Maintenance Section

Fuel Specifications

(Table 7, contd)

Caterpillar Specifications for Distillate Diesel Fuel

Specifications

Requirements

ASTM

Test

30 minimum

“D287”

API Gravity

45 maximum



Pour Point

F) minimum



C (10

below ambient

“D97”

temperature 3% maximum “D3605”

(1)

Sulfur

“D1552”

Kinematic Viscosity

Water and

1.4 cSt minimum and 20.0

(2)

cSt maximum at 40



(104



0.1% maximum “D1796”

“D445”

Sediment

Water 0.1% maximum “D1744” Sediment 0.05% maximum (weight) “D473” Gums and

(3)

Resins

10 mg per 100 mL maximum

“D381”

3100 g minimum “D6708”

Lubricity

(4)

0.45 mm (0.018 inch) maximum at 60



C (140



“D6079”

0.38 mm (0.015 inch) maximum at 25

(1)

Caterpillar fuel systems and engine components can operate on high sulfur fuels. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal components. Fuel sulfur levels above 1.0 percent may significantly shorten the oil change interval. For additional information, see this publication, “Engine Oil” topic (Maintenance Section).

(2)

The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to bring down the viscosity to a 20 cSt viscosity. For additional information, see Special Publication, SEBD0717, “Diesel Fuel and Your Engine”.

(3)

Follow the test conditions and procedures for gasoline (motor).

(4)

The lubricity of a fuel is a concern with low sulfur fuel. To determine the lubricity of the fuel, use either the “ASTM D6708 Scuffing Load Wear Test (SBOCLE)” or the “ASTM D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.



C (77



NOTICE Operating with fuels that do not meet Caterpillar’s recommendations can cause the following effects: starting difficulty, poor combustion, deposits in the fuel injectors, reduced service life of the fuel system, deposits in the combustion chamber, and reduced service life of the engine.

In the USA, 0.05 percent diesel fuels have been used in all on-highway truck engines since 1 January 1994. This low sulfur diesel fuel was mandated as a means of directly reducing particulate emissions from diesel truck engines. This low sulfur fuel will also be used in Caterpillar commercial diesel engines when low emissions are required or when the fuel supply sources provide this type of fuel. Caterpillar has not seen any detrimental effects with 0.05 percent sulfur fuel in Caterpillar diesel engines.

NOTICE Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel must NOT be used in Caterpillar diesel engines (except in 3600 Series HFOengines). Severe component wear and component failures will result if HFO type fuels are used in engines that are configured to use distillate fuel.

In extreme cold ambient conditions, you may use the distillate fuels that are specified in Table

8. However, the fuel that is selected must meet the requirements that are specified in Table 7. These fuels are intended to be used in operating temperatures that are down to

Ta bl e 8

Distillate Fuels

Specification Grade

“MIL-T-5624R” JP-5

“ASTM D1655” Jet-A-1

“MIL-T-83133D” JP-8

(1)

The fuels that are listed in this Table may not meet the requirements that are specified in the “Caterpillar Specifications for Distillate Diesel Fuel” Table. Consult the supplier for the recommended additives in order to maintain the proper fuel lubricity.

−54

(1)



C(−65



F).

These fuels are lighter than the No. 2 grades of fuel. The cetane number of the fuels in Table 8 must be at least 40. If the viscosity is below 1.4 cSt at 38



(100

F), use the fuel only in temperatures below



C (32F). Do not use any fuels with a viscosity

0 of less than 1.2 cSt at 38



C (100



F). Fuel cooling



may be required in order to maintain the minimum viscosity of 1.4 cSt at the fuel injection pump.

There are many other diesel fuel specifications that are published by governments and by technological societies. Usually, those specifications do not review all the requirements that are addressed in this specification. To ensure optimum engine performance, a complete fuel analysis should be obtained before engine operation. The fuel analysis should include all of the properties that are listed in Table 7.

20 Maintenance Section Fuel Specifications

i01111650

Characteristics of Diesel Fuel

SMCS Code: 1250; 1280

The primary characteristics that affect engine operation and performance in cold temperatures are the following characteristics: Lubricity, Viscosity, Cetane Number, Cloud Point, Pour Point, and Moisture Content.

Refer to Special Publication, SEBD0717, “Diesel Fuels and Your Engine” for information about the following fuel properties: ignition quality, gravity (density), viscosity, cloud point, pour point, and sulfur content.

Lubricity and Low Sulfur Fuel

Note: The fuel lubricity is important. You should consider the fuel’s lubricity whenever you operate the equipment in arctic weather. Also, you should consider the fuel’s lubricity whenever you use fuels that are lower in viscosity. There are many aftermarket additives that are available to treat fuel. If the fuel’s lubricity is an issue, consult your fuel supplier for proper recommendations regarding fuel additives.

In the USA, a 0.05 percent limit on the amount of fuel sulfur in diesel fuel was mandated in January of 1994 for on-highway trucks. The removal of sulfur from diesel fuel helps to reduce particulate emissions from diesel engines. While limits for fuel sulfur have not generally been mandated for off-highway use, some local governments have regulations that include off-highway use. There is frequently no difference in the fuel that is sold for different applications. The same fuel is often used for both on-highway applications and off-highway applications. Other areas of the world are mandating similar limits. Regulations continue to become more stringent. Lower sulfur limits can be expected in the future.

The fluid’s lubricity describes the ability of the fluid to reduce the friction between surfaces that are under load. This ability reduces the damage that is caused by friction. Fuel injection systems rely on the lubricating properties of the fuel. Until fuel sulfur limits were mandated, the fuel’s lubricity was generally believed to be a function of fuel viscosity.

The process that is most commonly used to remove sulfur from fuel is called hydro-treatment. This process is also the most economical process. Each source of crude oil contains different amounts of sulfur. Crude oils with low sulfur require little hydro-treatment to obtain the 0.05 percent limit. Crude oils with high sulfur require a more severe treatment.

The Hydro-treatment removes the fuel’s sulfur as well as other components. The treatment removes nitrogen compounds, polar materials, bicyclic aromatics, polycyclic aromatics, and oxygen compounds. While the removal of sulfur has shown no detrimental effects to the engine, the removal of other compounds have lowered the lubricity of the fuel. As a result of the lowered lubricity, the fuel is less tolerant of contamination by water and dirt. The lower fuel lubricity can be seen as abrasive wear of fuel system components. Fuels that have a low lubricity may not provide adequate lubrication to plungers, to barrels, and to injectors. This problem may be compounded in areas that require winter blends of fuel. The lighter winter fuel blend has the following characteristics: lower viscosity, lower cloud point, and lower pour point.

All low sulfur fuels do not have a low lubricity. The fuel’s lubricity may be enhanced with additives. Many fuel suppliers treat the fuel with these additives. Do not use a fuel lubricity additive before you consult the fuel’s supplier. Some aftermarket additives may not be compatible with the additives that are already in the fuel. Some additive packages that are supplied by the aftermarket manufacturer may not be compatible with the seals that are used in fuel systems of some diesel engines. Other additive packages that are supplied by aftermarket manufacturers cannot provide proper performance in high temperature conditions. These additives may leave deposits because of the high temperatures that exist in the fuel systems of diesel engines.

Maximum life of the fuel system can be achieved by performing the following tasks: using a reliable fuel supplier, performing proper maintenance of the fuel system, and installing Caterpillar high efficiency fuel filters in the fuel system.

Note: Lighter fuels are frequently used in arctic temperatures. Lighter fuels may include the following fuels: Jet A-1, JP-8, JP-5, and kerosene. The fuel lubricity is not a requirement of the specifications for these fuels. Do not assume that a fuel meets the minimum Caterpillar specification. Contact the fuel supplier for proper recommendations on fuel lubricity additives.

Viscosity

The viscosity of the fuel is significant because the fuel serves as a lubricant for fuel system components. Arctic fuels need to have sufficient viscosity. The fuel must lubricate the fuel system at a temperature of 0 kinematic viscosity of the fuel is lower than 1.4 cSt as supplied to the fuel injection pump or to the unit injectors, excessive scuffing and seizure can occur.



C (32F) or below freezing. If the

Maintenance Section

Fuel Specifications

Cetane Number

The cetane number of the fuel has an effect on the ability of the engine to start. Also, the cetane number has an effect on the interval of time before the engine runs smoothly. Generally, an increase of ten in the cetane number will allow the engine to be started at a lower temperature. The starting temperature can be improved approximately



7to8 the cetane number. After the engine reaches the normal operating temperature, a change in the cetane from 40 to 50 will have a minimal effect on engine performance.

Most fuels that have a cetane number above 40 will permit acceptable engine starts in warmer outside temperatures. The engine will start satisfactorily with this fuel when the engine is kept warm. The engine can be kept warm by using either a heated room or a coolant heater.

During average starting conditions, direct injection engines require a minimum cetane number of 40. A higher cetane value may be required for operation in high altitudes or for cold weather operation. The minimum fuel cetane number that is required for the precombustion engine is 35.

C (12 to 15

Modifying the Cetane Number

The cetane number of a fuel can be changed if the fuel is mixed with a fuel that has a different cetane number. Generally, the cetane number of the mixture will be in direct relation to the ratio of the fuels that were mixed. Your fuel supplier can provide the information about the cetane number of a particular fuel.

Additives can also be used to improve the cetane number of a fuel. Additives are evaluated through testing in special engines. However, the fuel characteristics of additives are not identical to a natural product. While both fuels may be rated as having the same cetane number, starting may be different.



F) for every increase of ten in

Cloud Point

It is important to understand that the cloud point of a fuel is different from the pour point. There is no relationship between cloud point and the pour point. The cloud point is the temperature that allows some of the heavier components in the wax to solidify in the fuel. This wax is not a contaminant in the fuel. The wax is an important element of No. 2 diesel fuel. The wax has a high fuel energy content and the wax has a very high cetane value. Removal of the heavier wax lowers the cloud point of the fuel. Removal of the wax also increases the cost because less fuel can be made from the same amount of crude oil. Basically, a No. 1 diesel fuel is formulated by removing the wax from a No. 2 diesel fuel.

The cloud point of the fuel is important because the cloud point can limit the performance of the fuel filter. The wax can alter the fuel characteristics in cold weather. Solid wax can fill the fuel filters. The solidified wax will stop the flow of fuel. Fuel filters are necessary in order to remove dirt from the fuel. The filters block foreign material, and the filters protect the parts for the fuel injection system. Since fuel must flow through the filters, installing a fuel heater is the most practical way to prevent the problem. A fuel heater will keep the fuel above the cloud point as the fuel flows through the fuel system. The fuel heater will permit the wax to flow through the filters with the fuel.

Modifying the Cloud Point

You can lower the cloud point of a diesel fuel by mixing the diesel fuel with a different fuel that has a lower cloud point. No. 1 diesel fuel or kerosene may be used to lower the cloud point of a diesel fuel. The efficiency of this method is not good, because the ratio of the mixture does not have a direct relation to the improvement in cloud point. The amount of fuel with low cloud point that is required makes the process less preferable to use.

The following illustration contains a table that can be used to find the necessary mixture for two fuels with different cloud points. In order to use the table, you must know the exact fuel cloud point of each fuel. This specification can change from one purchase of fuel to the next purchase of fuel. This specification is normally available from personnel at the source of the fuel supply. When fuels that have a lower cloud point are not available, this method cannot be used.

The manufacturer of the fuel can add cold flow improvers to the fuel. Cold flow improvers modify the wax crystals in the fuels. The cold flow improvers do not change the fuel’s cloud point. However, the cold flow improvers keep the wax crystals small enough to pass through standard fuel filters. For mixing precautions, see the topic “Pour Point”.

22 Maintenance Section Fuel Specifications

Modifying the Pour Point

You can lower the fuel’s pour point by using additives. You can also lower the pour point by mixing the fuel with a fuel that has a lower pour point. See the topic “Cloud Point” for the procedure. This procedure is not the best procedure to use.

The same table that was use for cloud point can be used for an estimate of pour points. This is true only if the fuels do not have additives which change the pour point.

Illustration 5 Cloud point of fuel mixtures Generally, the most practical method that is used to prevent

problems that are caused by fuel cloud point at low temperatures is the use of fuel heaters. In most applications, fuel heaters can be used at a lower cost than fuel mixtures.

g00592741

Pour Point

The fuel’s pour point is a temperature below the fuel’s cloud point. Fuel stops flowing below the pour point. The pour point is the temperature which limits movement of the fuel with pumps.

To measure the pour point, the fuel temperature is lowered below the cloud point in steps of 3



F) at a time. The temperature is lowered until the fuel does not flow. The pour point is the last temperature that is shown before the flow stops. At the pour point, the wax has solidified out of the fuel. This makes the fuel more solid than liquid. The pour point of the fuel can be improved. This does not require the removal of important elements. This process is the same process that is used to improve the cloud point of a fuel.

A fuel’s pour point should be at least 6 below the lowest ambient temperature that is required for engine start-up and for engine operation. To operate the engine in extremely cold weather, No. 1 fuel or No. 1-D fuel may be necessary because of these fuels’ lower pour points.



C (10F)



Illustration 6 Cloud point of fuel mixtures

g00592741

In order to calculate the amount of lighter fuel that is required to be blended with the heavier fuel, perform the following steps:

1. Obtain the specification for fuel cloud point of both fuels from your fuel supplier.

2. Locate the cloud point of the heavier fuel on the left side of the table. Mark the point on the table.

3. Locate the cloud point of the lighter fuel on the right side of the table. Mark the point on the table.

4. Draw a line between the two points that were established. Label this line “A”.

Maintenance Section

Fuel Specifications

5. Determine the lowest outside temperature for machine operation. Find this point on the left side of the table. Mark this point. Draw a horizontal line from this point. Stop the line at the intersection of line “A”. Label this new line “C”.

6. Line “C” and line “A” intersect. Mark this point. Draw a vertical line from this point. Stop the line at the bottom of the table. Label this line “B”. The point at the bottom of line “B” reveals the percentage of lighter fuel that is required to modify the pour point.

The above example shows that the blending will require a thirty percent mixture of lighter fuel.

Additives are a good method to use in order to lower the pour point of a fuel. These additives are known by the following names: pour depressants, cold flow improvers, and wax modifiers. When the additives are used in a low concentration, the fuel will flow through pumps, lines, and hoses. These additives must be thoroughly mixed into the fuel at temperatures that are above the cloud point. The fuel supplier should be contacted in order to blend the fuel with the additives. The blended fuel can be delivered to your fuel tanks.

Moisture Content

Problems with fuel filters can occur at any time. The cause of the problem can be water in the fuel or moisture in the fuel. At low temperatures, moisture causes special problems. There are three types of moisture in fuel: dissolved moisture (moisture in solution), free and dispersed moisture in the fuel, and free and settled at the bottom of the tank.

Most diesel fuels have some dissolved moisture. Just as the moisture in air, the fuel can only contain a specific maximum amount of moisture at any one temperature. The amount becomes less as the temperature is lowered. For example, a fuel could contain 100 ppm (0.010 percent) of water in solution



C (65F). This same fuel can possibly hold

at 18 only 30 ppm (0.003 percent) at 4



C (40F).

The small drops of water cause a cloudy appearance in the fuel. If the change in temperature is slow, the small drops of water can settle to the bottom of the tank. When the fuel temperature is lowered rapidly to freezing temperature, the moisture that comes out-of-solution changes to very fine particles of ice instead of small drops of water.

The particles of ice are lighter than the fuel, and the particles of ice will not settle to the bottom of the tank. When this type of moisture is mixed in the fuel, this moisture will fill the fuel filters. The ice crystals will plug the fuel filters in the same way as wax plugs the fuel filters.

If a filter is plugged and fuel flow is stopped, perform the following procedure to determine the cause:

1. Remove the fuel filters.

2. Cut the fuel filters open.

3. Inspect the fuel filter before the filter warms. This

inspection will show that the filter is filled with particles of either ice or wax.

The moisture which is free and settled at the bottom of the tank can become mixed with the fuel. The force of any pumping action will mix the moisture with the fuel whenever fuel is transferred. This moisture then becomes free and dispersed water. This moisture can cause ice in the filters. This moisture can cause other problems with filters at any temperature. Generally, the same force that mixes the water into the fuel will also mix dirt and rust from the bottom of the tank with the water. The result is a dirty mixture of fuel and water which can also fill the filters and stop fuel flow.

After the fuel has absorbed the maximum possible amount of water, the additional water will be free and dispersed. Free and dispersed moisture is fine droplets of water that is suspended in the fuel. Since the water is heavier than the fuel, the water will slowly become free and settled at the bottom of the tank. In the above example, when the fuel temperature was lowered from 18



(40

F), 70 ppm of water became free and dispersed



C (65F) to 4C

in the fuel.

24 Maintenance Section Cooling System Specifications

Cooling System Specifications

i01111669

General Coolant Information

SMCS Code: 1350; 1395

NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first.

NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature or drained completely to prevent damage.

NOTICE In cold weather, frequently check the specific gravity of the coolant solution to ensure adequate protection.

Clean the cooling system for the following reasons:

Contamination of the cooling system

•

Many engine failures are related to the cooling system. The following problems are related to cooling system failures: overheating, leakage of the water pump, plugged radiators or heat exchangers, and pitting of the cylinder liners.

These failures can be avoided with proper cooling system maintenance. Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system. Quality of the coolant is as important as the quality of the fuel and the lubricating oil.

Coolant is normally composed of three elements: water, additives, and glycol.

Water

NOTICE All Caterpillar diesel engines equipped with air-to-air aftercooling (ATAAC) require a minimum of 30 percent glycol to prevent water pump cavitation.

NOTICE Never use water alone without Supplemental Coolant Additives (SCA) or without inhibited coolant. Water alone is corrosive at engine operating temperatures. Water alone does not provide adequate protection against boiling or freezing.

Overheating of the engine

•

Foaming of the coolant

•

Note: Air pockets can form in the cooling system if the cooling system is filled at a rate that is greater than 20 L (5 US gal) per minute.

After you drain the cooling system and after you refill the cooling system, operate the engine. Operate the engine without the filler cap until the coolant reaches normal operating temperature and the coolant level stabilizes. Ensure that the coolant is maintained to the proper level.

NOTICE Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators.

Refer to Special Instruction, SEBD0518, “Know Your Cooling System” and Special Instruction, SEBD0970, “Coolant and Your Engine” for more detailed information.

Water is used in the cooling system in order to transfer heat.

Distilled water or deionized water is recommended for use in engine cooling systems.

DO NOT use the following types of water in cooling systems: hard water, softened water that has been conditioned with salt, and sea water.

If distilled water or deionized water is not available, use water with the properties that are listed in Table

Maintenance Section

Cooling System Specifications

Ta bl e 9

Caterpillar Minimum Acceptable Water Requirements

Property Maximum Limit ASTM Test

Chloride (Cl)

Sulfate (SO

Total Hardness

Total Solids

Acidity pH of 5.5 to 9.0 “D1293”

)

40 mg/L

(2.4 grains/US gal)

100 mg/L

(5.9 grains/US gal)

170 mg/L

(10 grains/US gal)

340 mg/L

(20 grain/US gal)

“D512”, “D4327”

“D516”

“D1126”

“D1888”

For a water analysis, consult one of the following sources:

Caterpillar dealer

•

Local water utility company

•

Agricultural agent

•

Independent laboratory

•

Reduction of heat transfer

•

Leakage of the water pump seal

•

Plugging of radiators, coolers, and small

•

passages

Glycol

Glycol in the coolant helps to provide protection against the following conditions:

Boiling

•

Freezing

•

Cavitation of the water pump and the cylinder liner

•

For optimum performance, Caterpillar recommends a 1:1 mixture of a water/glycol solution.

NOTICE All Caterpillar diesel engines equipped with air-to-air aftercooling (ATAAC) require a minimum of 30 percent glycol to prevent water pump cavitation.

Additives

Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives or insufficient amounts of additives enable the following conditions to occur:

Corrosion

•

Formation of mineral deposits

•

Rust

•

Scale

•

Pitting and erosion from cavitation of the cylinder

•

liner

Foaming of the coolant

•

Many additives are depleted during engine operation. These additives must be replaced periodically. This can be done by adding Supplemental Coolant Additives (SCA) to Diesel Engine Antifreeze/Coolant (DEAC) or by adding ELC Extender to Extended Life Coolant (ELC).

Additives must be added at the proper concentration. Overconcentration of additives can cause the inhibitors to drop out-of-solution. The deposits can enable the following problems to occur:

Note: Use a mixture that will provide protection against the lowest ambient temperature.

Note: 100 percent pure glycol will freeze at a temperature of −23



C(−9



F).

Most conventional heavy-duty coolant/antifreezes use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture with water, ethylene and propylene glycol provide similar protection against freezing and boiling. See Tables 10 and 11.

Ta bl e 1 0

Ethylene Glycol

Concentration

50 Percent

60 Percent

Freeze

Protection

−36C(−33F) 106C (223

−51C(−60



Boil

Protection

111C (232



NOTICE Do not use propylene glycol in concentrations that exceed 50 percent glycol because of propylene glycol’s reduced heat transfer capability. Use ethylene glycol in conditions that require additional protection against boiling or freezing.

Formation of gel compounds

•

26 Maintenance Section Cooling System Specifications

Ta bl e 1 1

Propylene Glycol

Concentration

50 Percent −29C(−20

Freeze

Protection



Anti-Boil

Protection



106

C (223F)

To check the concentration of glycol, use the 1U-7298 Coolant/Battery Tester (Celsius) or use the 1U-7297 Coolant/Battery Tester (Fahrenheit). The testers give readings that are immediate and accurate. The testers can be used with ethylene or propylene glycol.

i01096597

Coolant Recommendations

SMCS Code: 1350; 1352; 1395

The following two coolants are used in Caterpillar diesel engines:

Preferred – Caterpillar Extended Life Coolant (ELC) or a commercial extended life coolant that meets the Caterpillar EC-1 specification

NOTICE All Caterpillar diesel engines equipped with air-to-air aftercooling (ATAAC) require a minimum of 30 percent glycol to prevent water pump cavitation.

Ta bl e 1 2

Coolant Service Life

Coolant Type Service Life

Caterpillar ELC

Caterpillar DEAC

Commercial Heavy-Duty

Coolant/Antifreeze that

meets “ASTM D5345”

Commercial Heavy-Duty

Coolant/Antifreeze that

meets “ASTM D4985”

Caterpillar SCA and

Water

Commercial SCA and

Water

6000 Service Hours or

Six Years

3000 Service Hours or

Three Years

3000 Service Hours or

Two Years

3000 Service Hours or

One Year

3000 Service Hours or

Two Years

3000 Service Hours or

One Year

Acceptable – A Caterpillar Diesel Engine

Antifreeze/Coolant (DEAC) or a commercial heavy-duty coolant/antifreeze that meets “ASTM D4985” or “ASTM D5345” specifications

NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 or D4656 specification. This type of coolant/antifreeze is made for light duty automotive applications.

Caterpillar recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as a coolant/antifreeze.

Note: Caterpillar DEAC DOES NOT require a treatment with an SCA at the initial fill. Commercial heavy-duty coolant/antifreeze that meets “ASTM D4985” or “ASTM D5345” specifications MAY require a treatment with an SCA at the initial fill. Read the label or the instructions that are provided by the OEM of the product.

In stationary engine applications and marine engine applications that do not require anti-boil protection or freeze protection, a mixture of SCA and water is acceptable. Caterpillar recommends a six percent to eight percent concentration of SCA in those cooling systems. Distilled water or deionized water is preferred. Water which has the recommended properties may be used.

i01096605

Extended Life Coolant (ELC)

SMCS Code: 1350; 1352; 1395

Caterpillar provides Extended Life Coolant (ELC) for use in the following applications:

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Automotive applications

•

The anti-corrosion package for Caterpillar ELC is different from the anti-corrosion package for other coolants. Caterpillar ELC is an ethylene glycol base coolant. However, Caterpillar ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Caterpillar ELC has been formulated with the correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems.

ELC extends the service life of the coolant to 6000 service hours or six years. ELC does not require a frequent addition of a Supplemental Coolant Additive (SCA). An Extender is the only additional maintenance that is needed at 3000 service hours or one half of the ELC service life.

ELC is available in a 1:1 premixed cooling solution with distilled water. The Premixed ELC provides freeze protection to −36



C(−33



F). The Premixed ELC is recommended for the initial fill of the cooling system. The Premixed ELC is also recommended for topping off the cooling system.

ELC Concentrate is also available. ELC Concentrate can be used to lower the freezing point to −51



F) for arctic conditions.

(−60



Containers of several sizes are available. Consult your Caterpillar dealer for the part numbers.

Note: Caterpillar developed the EC-1 specification. The EC-1 specification is an industry standard. The EC-1 specification defines all of the performance requirements that are needed for an engine coolant to be sold as an extended life coolant for Caterpillar engines. ELC can be used in most OEM engines of the following types: diesel, gasoline, and natural gas. ELC meets the performance requirements of “ASTM D4985” and “ASTM D5345” for heavy-duty low silicate antifreeze/coolants. ELC also meets the performance requirements of “ASTM D3306” and “ASTM D4656” for automotive applications.

i01111712

Extended Life Coolant (ELC) Cooling System Maintenance

SMCS Code: 1350; 1352; 1395

Proper additions to the Extended Life Coolant

NOTICE Use only Caterpillar products or commercial products that have passed Caterpillar’s EC-1 specification for pre-mixed or concentrated coolants.

Use only Caterpillar Extender with Extended Life Coolant.

Mixing Extended Life Coolant with other products reduces the Extended LifeCoolant service life. Failure to follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.

Maintenance Section

Cooling System Specifications

NOTICE Do not use a conventional coolant to top-off a cooling system that is filled with Extended Life Coolant (ELC).

Do not use standard supplemental coolant additive (SCA). Only use ELC Extender in cooling systems that are filled with ELC.

Caterpillar ELC Extender

Caterpillar ELC Extender is added to the cooling system halfway through the ELC service life. Treat the cooling system with ELC Extender at 3000 hours or one half of the coolant service life. Use Table 13 in order to determine the proper amount of ELC Extender that is required.

Containers of several sizes are available. Consult your Caterpillar dealer for the part numbers.

Ta bl e 1 3

Caterpillar ELC Extender Additions by

Cooling System Capacity

22 to 30 L (6 to 8 US gal) 0.57 L (20 fl oz)

31 to 38 L (9 to 10 US gal) 0.71 L (24 fl oz) 39 to 49 L (11 to 13 US gal) 0.95 L (32 fl oz) 50 to 64 L (14 to 17 US gal) 1.18 L (40 fl oz) 65 to 83 L (18 to 22 US gal) 1.60 L (54 fl oz)

84 to 114 L (23 to 30 US gal) 2.15 L (72 fl oz) 115 to 163 L (31 to 43 US gal) 3.00 L (100 fl oz) 164 to 242 L (44 to 64 US gal) 4.40 L (148 fl oz)

For cooling system capacities that exceed the capacities that are specified in Table 13, use the equation that is in Table 14 in order to determine the proper amount of ELC Extender that is required.

Ta bl e 1 4

Equation For Adding ELC Extender To ELC

V × 0.02 = X

V is the total volume of the cooling system. X is the amount of ELC Extender that is required.

Addition of ELC

Extender

In order to maintain the correct balance between the antifreeze and the additives, you must maintain the recommended concentration of Extended Life Coolant (ELC). Lowering the proportion of antifreeze lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits.

Table 15 is an example for using the equation that is in Table 14.

28 Maintenance Section Cooling System Specifications

Ta bl e 1 5

Example Of The Equation For Adding ELC

Total Volume

of the Cooling

System (V)

946 L

(250 US gal)

Extender To ELC

Multiplication

Factor

× 0.02

Amount of ELC Extender that is

Required (X)

19 L

(5 US gal)

NOTICE When using Caterpillar ELC, do not use standard SCA’s or SCA filters. To avoid SCA contamination of an ELC system, remove the SCA filter base and plug off or by-pass the coolant lines.

NOTICE Care mustbe taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

ELC Cooling System Cleaning

Note: If the cooling system is already using ELC, cleaning agents are not required to be used at the specified coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage.

Clean water is the only cleaning agent that is required when ELC is drained from the cooling system.

ELC can be recycled. The drained coolant mixture can be distilled in order to remove the ethylene glycol and the water. The ethylene glycol and the water can be reused. Consult your Caterpillar dealer for more information.

After the cooling system is drained and after the cooling system is refilled, operate the engine while the cooling system filler cap is removed. Operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes. As needed, add the coolant mixture in order to fill the system to the proper level.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

regulations.

NOTICE Do not leave an empty SCA filter on an ELC system.

The filter housing may corrode and leak causing an engine failure.

Remove the SCA filter base and plug off or by-pass the coolant lines.

3. Remove the empty SCA filter and remove the

filter base. Plug the coolant lines or bypass the coolant lines.

4. Flush the system with clean water in order to

remove any debris.

5. Use Caterpillar cleaner to clean the system.

Follow the instruction on the label.

6. Drain the cleaner into a suitable container. Flush

the cooling system with clean water.

Changing to Caterpillar ELC

To change from heavy-duty coolant/antifreeze to the Caterpillar ELC, perform the following steps:

7. Fill the cooling system with clean water and

operate the engine until the engine is warmed to



to 66C (120to 150



F).

NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components.

To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

Maintenance Section

Cooling System Specifications

8. Drain the cooling system into a suitable container and flush the cooling system with clean water.

Note: The cooling system cleaner must be thoroughly flushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the coolant. The cleaner may also corrode the cooling system.

9. Repeat Steps 7 and 8 until the system is completely clean.

10. Fill the cooling system with the Caterpillar premixed ELC.

11. Attach the Special Publication, PEEP5027, “Label” to the cooling system filler for the engine in order to indicate the use of Caterpillar ELC.

ELC Cooling System Contamination

NOTICE Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specification for premixed or concentrate coolants. Use only Caterpillar ELC Extender with Caterpillar ELC. Failure to follow these recommendations can result in shortened cooling system component life.

Commercial ELC

If Caterpillar ELC is not used, then select a commercial ELC that meets the Caterpillar specification of EC-1 and either the “ASTM D5345” specification or the “ASTM D4985” specification. Do not use an extended life coolant that does not meet the EC-1 specification. Follow the maintenance guide for the coolant from the supplier of the commercial ELC. Follow the Caterpillar guidelines for the quality of water and the specified coolant change interval.

i01111753

Diesel Engine Antifreeze/ Coolant (DEAC)

SMCS Code: 1350; 1352; 1395

Caterpillar recommends using Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) for cooling systems that require a heavy-duty coolant/antifreeze. Caterpillar DEAC is an alkaline single-phase ethylene glycol type antifreeze that contains corrosion inhibitors and antifoam agents.

Caterpillar DEAC is formulated with the correct amount of Caterpillar Supplemental Coolant Additive (SCA). Do no use SCA at the initial fill when DEAC is used.

ELC cooling systems can withstand contamination to a maximum of ten percent of conventional heavy-duty coolant/antifreeze or SCA. If the contamination exceeds ten percent of the total system capacity, perform ONE of the following procedures:

Drain the cooling system into a suitable container.

•

Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the Caterpillar ELC.

Drain a portion of the cooling system into a

•

suitable container according to local regulations. Then, fill the cooling system with premixed ELC. This should lower the contamination to less than 10 percent.

Maintain the system as a conventional Diesel

•

Engine Antifreeze/Coolant (DEAC). Treat the system with an SCA. Change the coolant at the interval that is recommended for the conventional Diesel Engine Antifreeze/Coolant (DEAC).

Containers of several sizes are available. Consult your Caterpillar dealer for the part numbers.

If concentrated DEAC is used, Caterpillar recommends mixing the concentrate with distilled water or with deionized water. If distilled water is not available or deionized water is not available, use water which has the required properties. For the water properties, see this publication, “General Coolant Information” topic (Maintenance Section).

i01069295

Supplemental Coolant Additive (SCA)

SMCS Code: 1350; 1352; 1395

The use of SCA helps to prevent the following conditions from occurring:

Corrosion

•

Formation of mineral deposits

•

Cavitation erosion of the cylinder liners

•

Foaming of the coolant

•

30 Maintenance Section Cooling System Specifications

Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) is formulated with the correct level of Caterpillar SCA. When the cooling system is initially filled with DEAC, adding more SCA is not necessary until the concentration of SCA has been depleted. To ensure that the correct amount of SCA is in the cooling system, the concentration of SCA must be tested on a scheduled basis. Refer to the specific engine’s Operation and Maintenance Manual, “Maintenance Interval Schedule”.

Containers of SCA are available in several sizes. Consult your Caterpillar dealer for the part numbers.

i01111872

Conventional Coolant/ Antifreeze Cooling System Maintenance

SMCS Code: 1350; 1352; 1395

Table 16 also lists additions of SCA for liquid and for maintenance elements at 250 hours. The additions are required for Caterpillar DEAC and for commercial coolant/antifreezes.

Check the coolant/antifreeze (glycol concentration) in order to ensure adequate protection against boiling or freezing. Caterpillar recommends the use of a refractometer for checking the glycol concentration. Use the 1U-7298 Coolant/Battery Tester (Celsius) or use the 1U-7297 Coolant/Battery Tester (Fahrenheit). The testers give readings that are immediate and accurate. The testers can be used with ethylene or with propylene glycol.

Caterpillar engine cooling systems should be tested at 250 hour intervals for the concentration of Supplemental Coolant Additive (SCA). SCA test kits are available from your Caterpillar dealer. Test the concentration of SCA or submit a coolant sample to your Caterpillar dealer at 250 hour intervals. Refer to S·O·S Coolant Analysis for more information on this topic.

Additions of SCA are based on the results of the test or based on the results of the coolant analysis. An SCA that is liquid or a maintenance element for an SCA (if equipped) may be needed at 250 hour intervals.

Table 16 lists the amount of Caterpillar SCA that is needed at the initial fill in order to treat coolant/antifreeze. These amounts of SCA are for systems that use heavy-duty coolant/antifreeze.

Ta bl e 1 6

Caterpillar SCA Requirements for Heavy-Duty Coolant/Antifreeze

Cooling System

Capacity

22 to 30 L

(6 to 8 US gal)

31 to 38 L

(9 to 10 US gal)

39 to 49 L

(11 to 13 US gal)

50 to 64 L

(14 to 17 US gal)

65 to 83 L

(18 to 22 US gal)

84 to 114 L

(23 to 30 US gal)

115 to 163 L

(31 to 43 US gal)

164 to 242 L

(44 to 64 US gal)

(1)

When the coolant system is first filled, the SCA is not required to be used with Caterpillar DEAC.

(2)

Do not exceed the six percent maximum concentration. Check the concentration of SCA with a SCA test kit.

(3)

Do not use the maintenance element for the SCA and the liquid for the SCA at the same time.

Initial Fill

0.95 L (32 fl oz) 0.24 L (8 fl oz) 111-2370 (1)

1.18 L (40 fl oz) 0.36 L (12 fl oz) 111-2369 (1)

1.42 L (48 fl oz) 0.36 L (12 fl oz) 111-2369 (1)

1.90 L (64 fl oz) 0.47 L (16 fl oz) 9N-3368 (1)

2.37 L (80 fl oz) 0.60 L (20 fl oz) 111-2371 (1)

3.32 L (112 fl oz) 0.95 L (32 fl oz) 9N-3718 (1)

4.75 L (160 fl oz) 1.18 L (40 fl oz) 111-2371 (2)

7.60 L (256 fl oz) 1.90 L (64 fl oz) 9N-3718 (2)

(1)

250 Service

Hour

Maintenance

(2)

Spin-on

Element at 250

Service Hour

Maintenance

Maintenance Section

Cooling System Specifications

(3)

Note: Specific engine applications may require

maintenance practices to be periodically evaluated in order to properly maintain the engine’s cooling system.

Refer to Table 17 for part numbers and for quantities of SCA.

Ta bl e 1 7

Caterpillar Liquid SCA

Part Number

6V-3542 0.24 L (8 oz)

111-2372 0.36 L (12 oz)

8T-1589 0.47 L (16 oz) 3P-2044 0.94 L (32 oz)

8C-3680 19 L (5 US gal) 5P-2907 208 L (55 US gal)

Quantity

Cooling Systems with Larger Capacities

Adding the SCA to Conventional Coolant/Antifreeze at the Initial Fill

Note: Caterpillar DEAC DOES NOT require an addition of SCA when the cooling system is initially filled.

Commercial heavy duty coolant/antifreeze that meet “ASTM D4985” or “ASTM D5345” specifications MAY require an addition of SCA at the initial fill. Read the label or the instructions that are provided by the OEM of the product.

Use the equation that is in Table 18 to determine the amount of Caterpillar SCA that is required when the cooling system is initially filled with the following fluids:

“ASTM D4985”

•

“ASTM D5345”

•

32 Maintenance Section Cooling System Specifications

Ta bl e 1 8

Equation For Adding The SCA To Conventional

Coolant/Antifreeze At The Initial Fill

V × 0.045 = X

V is the total volume of the cooling system. X is the amount of SCA that is required.

Table 19 is an example for using the equation that is in Table 18.

Ta bl e 1 9

Example Of The Equation For Adding The SCA To

Conventional Coolant/Antifreeze At The Initial Fill

Total Volume

of the Cooling

System (V)

946 L

(250 US gal)

Multiplication

Factor

× 0.045

Amount of SCA

that is Required

(X)

43 L

(11 US gal)

Adding the SCA to Conventional Coolant/Antifreeze For Maintenance

Heavy duty coolant/antifreeze of all types REQUIRE periodic additions of an SCA.

Test the coolant/antifreeze periodically for the concentration of SCA. For the interval, see the Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section). SCA test kits are available from your Caterpillar dealer. Test the concentration of SCA or submit a coolant sample to your Caterpillar dealer. See this publication, “S·O·S Coolant Analysis” topic (Maintenance Section).

Ta bl e 2 1

Example Of The Equation For Adding The SCA To

Conventional Coolant/Antifreeze For Maintenance Total Volume

of the Cooling

System (V)

946 L

(250 US gal)

Multiplication

Factor

× 0.014

Amount of SCA

that is Required

(X)

(4 US gal)

Note: Specific engine applications may require

maintenance practices to be periodically evaluated in order to properly maintain the engine’s cooling system.

Table 17 lists part numbers and quantities of SCA that is available from your Caterpillar dealer.

Cleaning the System of Heavy-Duty Coolant/Antifreeze

Caterpillar cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Caterpillar cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination and sludge.

Clean the cooling system after used coolant is

•

drained or before the cooling system is filled with new coolant.

Clean the cooling system whenever the coolant is

•

contaminated or whenever the coolant is foaming.

For the recommended service interval, refer

•

to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for your engine.

Additions of SCA are based on the results of the test or based on the results of the coolant analysis. The size of the cooling system determines the amount of SCA that is needed.

Use the equation that is in Table 20 to determine the amount of Caterpillar SCA that is required, if necessary:

Ta bl e 2 0

Equation For Adding The SCA To Conventional

Coolant/Antifreeze For Maintenance

V × 0.014 = X

V is the total volume of the cooling system. X is the amount of SCA that is required.

Table 21 is an example for using the equation that is in Table 20.

i01111887

Commercial Heavy-Duty Coolant/Antifreeze and SCA

SMCS Code: 1350; 1352; 1395

If Caterpillar DEAC is not used, select a coolant/antifreeze with low silicate content for heavy-duty applications that meets “ASTM D5345” or “ASTM D4985” specifications.

Note: When you are not using Caterpillar DEAC the cooling system must be drained one time during every year. The cooling system must be flushed at this time as well.

Maintenance Section

Cooling System Specifications

When a heavy-duty coolant/antifreeze is used, treat the cooling system with three to six percent Caterpillar SCA by volume. For more information, see this publication, “Conventional Coolant/Antifreeze Cooling System Maintenance” topic (Maintenance Section).

If Caterpillar SCA is not used, select a commercial SCA. The commercial SCA must provide a minimum of 1200 mg/L or 1200 ppm (70 grains/US gal) of nitrates in the final coolant mixture.

Coolant/antifreeze that meets “ASTM D5345” or “ASTM D4985” specifications MAY require treatment with SCA at the initial fill. These coolants WILL require treatment with SCA on a maintenance basis.

When concentrated coolant/antifreeze is mixed, Caterpillar recommends mixing the concentrate with distilled water or with deionized water. If distilled water or deionized water is not available, water which has the required properties may be used. For the water properties, see this publication, “General Coolant Information” topic (Maintenance Section).

i01096747

Water/Supplemental Coolant

Cavitation erosion of the cylinder liner

•

Foaming of the coolant

•

If Caterpillar SCA is not used, select a commercial SCA. The commercial SCA must provide a minimum of 2400 mg/L or 2400 ppm (140 grains/US gal) of nitrates in the final coolant mixture.

The quality of the water is a very important factor in this type of cooling system. Distilled water or deionized water is recommended for use in cooling systems. If distilled water or deionized water is not available, use water that meets the minimum requirements that are listed in the table for recommended water properties in this publication, “General Coolant Information” topic (Maintenance Section).

A cooling system that uses a mixture of SCA and water only needs more SCA than a cooling system that uses a mixture of glycol and water. The SCA concentration in a cooling system that uses SCA and water should be six to eight percent by volume. Refer to Table 22 for the amount of SCA that is required for various capacities of the cooling system.

Additive (SCA)

SMCS Code: 1350; 1352; 1395

NOTICE All Caterpillar diesel engines equipped with air-to-air aftercooling (ATAAC) require a minimum of 30 percent glycol to prevent water pump cavitation.

Note: Premix the coolant solution in order to provide

protection to the lowest ambient temperature that is expected.



Note: Pure undiluted antifreeze freezes at −23



(−9

F).

In engine cooling systems that use Supplemental Coolant Additive (SCA) and water alone, Caterpillar recommends the use of SCA. SCA helps to prevent the following conditions from occurring:

Corrosion

•

Formation of mineral deposits

•

34 Maintenance Section Cooling System Specifications

Ta bl e 2 2

Caterpillar SCA Requirements for SCA and

Cooling System

Capacity

22 to 30 L

(6 to 8 US gal)

31 to 38 L

(9 to 10 US gal)

39 to 49 L

(11 to 13 US gal)

50 to 64 L

(14 to 17 US gal)

65 to 83 L

(18 to 22 US gal)

84 to 110 L

(23 to 29 US gal)

111 to 145 L

(30 to 38 US gal)

146 to 190 L

(39 to 50 US gal)

191 to 250 L

(51 to 66 US gal)

Water Cooling Systems

Caterpillar SCA

at Initial Fill

1.75 L (64 fl oz) 0.44 L (15 fl oz)

2.30 L (80 fl oz) 0.57 L (20 fl oz)

3.00 L (100 fl oz) 0.75 L (25 fl oz)

3.90 L (128 fl oz) 0.95 L (32 fl oz)

5.00 L (168 fl oz) 1.25 L (42 fl oz)

6.60 L (224 fl oz) 1.65 L (56 fl oz)

8.75 L (296 fl oz) 2.19 L (74 fl oz)

11.50 L

(392 fl oz)

15.00 L

(512 fl oz)

Caterpillar SCA

at 250 Hours

2.88 L (98 fl oz)

3.75 L (128 fl oz)

Refer to Table 23 for part numbers and for quantities of SCA.

Ta bl e 2 3

Caterpillar Liquid SCA

Part Number

6V-3542 0.24 L (8 oz)

111-2372 0.36 L (12 oz)

8T-1589 0.47 L (16 oz)

3P-2044 0.94 L (32 oz) 8C-3680 19 L (5 US gal) 5P-2907 208 L (55 US gal)

Quantity

Maintain the SCA in the same way as you would maintain a cooling system that uses heavy-duty coolant/antifreeze. Adjust the maintenance for the amount of SCA additions. See Table 22 for the amount of SCA that is required.

Cooling Systems with Larger Capacities

Adding the SCA to Water at the Initial Fill

Use the equation that is in Table 24 to determine the amount of Caterpillar SCA that is required at the initial fill. This equation is for a mixture of only SCA and water.

Ta bl e 2 4

Equation For Adding The SCA To Water

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table 25 is an example for using the equation that is in Table 24.

Ta bl e 2 5

Example Of The Equation For Adding The SCA

Total Volume

of the Cooling

System (V)

946 L

(250 US gal)

Adding the SCA to Water for Maintenance

For the recommended service interval, refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for your engine.

Use the 8T-5296 Coolant Conditioner Test Kit to test the concentration of SCA. Make the following modifications to Steps 3 and 5 of the 8T-5296 Coolant Conditioner Test Kit instructions:

STEP 3 – Add tap water to the vial up to the “20 ml” mark.

STEP 5 – When the defined procedure is used, a concentration of six to eight percent will yield between 20 drops and 27 drops. If the number of drops is below 20 drops, the concentration of SCA is low. If the number of drops is above 27 drops, the concentration of SCA is high. Make the appropriate adjustments to the concentration of SCA.

At The Initial Fill

V × 0.07 = X

To Water At The Initial Fill

Multiplication

Factor

× 0.07 66 L

Amount of SCA

that is Required

(X)

(18 US gal)

Test the concentration of SCA or submit a coolant sample to your Caterpillar dealer. See this publication, “S·O·S Coolant Analysis” topic (Maintenance Section).

Additions of SCA are based on the results of the test or based on the results of the coolant analysis. The size of the cooling system determines the amount of SCA that is required.

Use the equation that is in Table 24 to determine the amount of Caterpillar SCA that is required for maintenance, if necessary:

Ta bl e 2 6

SCA To Water Addition Equation For Maintenance

V × 0.023 = X

V is the total volume of the cooling system. X is the amount of SCA that is required.

Maintenance Section

Cooling System Specifications

NOTICE Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples.

A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken.

Always use a designated pump for oil sampling and a designated pump for coolant sampling.

Failure to do so may cause a false analysis which could lead to customer and dealer concerns.

Table 27 is an example for using the equation that is in Table 24.

Ta bl e 2 7

SCA To Water Addition Equation Example

Total Volume

of the Cooling

System (V)

946 L

(250 US gal)

Note: Specific engine applications may require

maintenance practices to be periodically evaluated in order to properly maintain the engine’s cooling system.

Table 23 lists part numbers and quantities of SCA that is available from your Caterpillar dealer.

For Maintenance

Multiplication

Factor

× 0.023

Amount of SCA

that is Required

(X)

22 L

(6 US gal)

i01053475

S·O·S Coolant Analysis

SMCS Code: 1350; 1352; 1395; 7542-008; 7542

Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and from corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling and from freezing. The S·O·S Coolant Analysis can be done at your Caterpillar dealer. Caterpillar S·O·S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system. S·O·S Coolant Analysis is a program that is based on periodic samples.

Recommended Interval for S·O·S Coolant Sample

Ta bl e 2 8

Recommended Interval

Type of Coolant Level 1 Level 2

DEAC Every 250 Hours Yearly

ELC Not Required Yearly

Converted Systems

Perform a coolant analysis (Level 2) at 500 service hours for new systems or for converted systems that use ELC or use DEAC. This 500 hour check will also check for any residual cleaner that may have contaminated the system.

S·O·S Coolant Analysis (Level 1)

A coolant analysis (Level 1) is a test of the properties of the coolant.

The following properties of the coolant are tested:

Glycol Concentration for freeze protection

•

Ability to protect from erosion and corrosion

•

Conductivity

•

Water hardness

•

Visual analysis

•

Odor analysis

•

The results are reported, and appropriate recommendations are made.

36 Maintenance Section Cooling System Specifications

S·O·S Coolant Analysis (Level 2)

Level 2 coolant analysis is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of the cooling system.

The S·O·S Coolant Analysis has the following five features:

Full analysis of Level 1

•

Identification of the source of metal corrosion and

•

of contaminants

Identification of buildup of the impurities that

•

cause corrosion

Identification of buildup of the impurities that

•

cause scaling

Determination of possible electrolysis within the

•

engines’ cooling system

The results are reported, and appropriate recommendations are made.

For more information on S·O·S Coolant Analysis, consult your Caterpillar dealer.

Reference Information Section

Reference Materials

i01123492

Reference Material

SMCS Code: 1000

The following literature can be obtained through any Caterpillar dealer.

Coolants

Special Publication, SEBD0970, “Coolant and

•

Your Engine”

Reference Information Section

Reference Materials

Special Publication, NEDG6022, “Data Sheet -

•

Multipurpose Lithium Complex Grease (MPG)”

Special Publication, PEHP0002, “Data Sheet

•

- Multipurpose Lithium Complex Grease with Molybdenum (MPGM)”

Special Publication, PEHP0017, “Data Sheet -

•

Special Purpose Grease (SPG) Bearing Lubricant”

Special Publication, NEHP5621, “How To Select

•

The Right Grease For Any Job”

Special Publication, PEHP6001, “How To Take A

•

Good Oil Sample”

Special Publication, SEBD0640, “Oil and Your

•

Engine”

Special Publications, PEDP7036, “S·O·S Fluids

•

Analysis Cornerstone”

Special Publication, PEHP4036, “Data Sheet-

•

Extended Life Coolant”

Special Publication, SEBD0518, “Know Your

•

Cooling System”

Special Publication, PEEP5027, “Label - ELC

•

Radiator Label”

Special Publication, PEHP7057, “S·O·S Coolant

•

Analysis”

Fuels

Special Publication, SEBD0717, “Diesel Fuels and

•

Your Engine”

Lubricants

Special Publication, PEHP8038, “Data Sheet -

•

Caterpillar Diesel Engine Oils (DEO) (CH-4, CG-4, CF-4) (North America and Australia)”

Special Publication, PEHP7041, “Product Data

•

Sheet for Caterpillar Diesel Engine Oils (DEO)” CG-4 engine oils (International markets)

Miscellaneous

Special Publication, PECP6026, “One Safe Source” English language for use in NACD

Special Publication, PECP6027, “One Safe Source” English language for use in COSA

Special Publication, PECP6028, “One Safe Source” English language for use in non NACD and non COSA

i01109461

Additional Reference Material

SMCS Code: 1000

The “EMA Lubricating Oils Data Book” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult EMA at the following address:

Engine Manufacturers Associaton 401 N. Michigan Ave. Chicago, IL, USA 60611 Telephone: (312) 644-6610 ext. 3626

Special Publication, PEHP9516, “Product Data

•

Sheet for Special Application Engine Oil For Caterpillar 3116 and 3126 Marine Diesel Engines with Mechanical Unit Injectors”

Special Publication, PEWP3014, “Cat Fluids

•

Selector Dial (International)”

Special Publication, PEWP9733, “Cat Fluids

•

Selector Dial (North America)”

The “Society of Automotive Engineers (SAE) Specifications” can be found in your SAE handbook. This publication can also be obtained from the following locations: local technological society, local library, and local college. If necessary, consult SAE at the following address:

SAE International 400 Commonwealth Drive Warrendale, PA, USA 15096-0001 Telephone: (724) 776-4841

38 Reference Information Section Reference Materials

The “American Petroleum Institute Publication No. 1509” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult API at the following address:

American Petroleum Institute 1220 L St. N.W. Washington, DC, USA 20005 Telephone: (202) 682-8000

The International Organization for Standardization (ISO) offers information and customer service regarding international standards and standardizing activities. ISO can also supply information on the following subjects that are not controlled by ISO: national standards, regional standards, regulations, certification, and related activities. Consult the member of ISO in your country.

International Organization for Standardization (ISO) 1, rue de Varembé Case postale 56 CH-1211 Genève 20 Switzerland Telephone: +41 22 749 01 11 Facsimile: +41 22 733 34 30 E-mail: central@iso.ch Web site: http://www.iso.ch

European classifications are established by the Counseil International Des Machines a Combustion (CIMAC) (International Council on Combustion Engines).

CIMAC Central Secretariat Lyoner Strasse 18 60528 Frankfurt Germany Telephone: +49 69 6603 1567 Facsimile: +49 69 6603 1566

Index

Index Section

Additional Reference Material ............................... 37

Aftermarket Oil Additives....................................... 14

Characteristics of Diesel Fuel................................ 20

Cetane Number.................................................. 21

Cloud Point ........................................................ 21

Lubricity and Low Sulfur Fuel............................. 20

Moisture Content................................................ 23

Pour Point .......................................................... 22

Viscosity............................................................. 20

Cold Weather Lubricants....................................... 14

Commercial Heavy-Duty Coolant/Antifreeze and

SCA ..................................................................... 32

Conventional Coolant/Antifreeze Cooling System

Maintenance ........................................................ 30

Cleaning the System of Heavy-Duty

Coolant/Antifreeze ........................................... 32

Cooling Systems with Larger Capacities ........... 31

Coolant Recommendations ................................... 26

Cooling System Specifications .............................. 24

Diesel Engine Antifreeze/Coolant (DEAC) ............ 29

Extended Life Coolant (ELC) Cooling System

Maintenance ........................................................ 27

Caterpillar ELC Extender .................................. 27

Changing to Caterpillar ELC .............................. 28

Commercial ELC................................................ 29

ELC Cooling System Cleaning........................... 28

ELC Cooling System Contamination.................. 29

Proper additions to the Extended Life Coolant .. 27

Foreword................................................................ 4

Literature Information......................................... 4

Maintenance ...................................................... 4

Safety................................................................. 4

Fuel Information for Diesel Engines ...................... 17

Starting Aids ...................................................... 17

Fuel Recommendations......................................... 18

Fuel Specifications ................................................ 17

General Coolant Information ................................. 24

Additives ............................................................ 25

Glycol................................................................. 25

Water ................................................................. 24

General Fuel Information....................................... 17

Engine Oil.............................................................. 5

Caterpillar Diesel Engine Oil.............................. 5

Commercial Oils................................................. 6

Total Base Number (TBN) and Fuel Sulfur Levels

for Direct Injection (DI) Diesel Engines ............ 7

Engine Oil (3116 and 3126 Marine Engines) ........ 8

Commercial Oils (3116 and 3126 Marine

Engines)........................................................... 9

Lubricant Viscosity Recommendations (3116 and

3126 Marine Engines)...................................... 10

Recommendations............................................. 8

Total Base Number (TBN) and Fuel Sulfur Levels

for Direct Injection (DI) Diesel Engines (3116 and

3126 Marine Engines)...................................... 9

Engine Oil for Precombustion Chamber (PC) Diesel

Engines................................................................ 10

Caterpillar Diesel Engine Oil.............................. 10

Commercial Oils................................................. 10

Total Base Number (TBN) and Fuel Sulfur

Levels for Precombustion Chamber (PC) Diesel

Engines ............................................................ 12

Extended Life Coolant (ELC)................................. 26

Important Safety Information ................................. 2

Lubricant Information............................................. 5

API Oils.............................................................. 5

Engine Manufacturers Association (EMA) Oils.. 5

General Information ........................................... 5

Lubricant Specifications ........................................ 5

Lubricating Grease ................................................ 14

Caterpillar Premium Grease (CPG) ................... 16

Multipurpose Greases........................................ 15

Special Purpose Grease (SPG)......................... 15

Maintenance Section............................................. 5

Marine Transmission Oil ........................................ 12

Caterpillar Transmission/Drive Train Oils ........... 13

Commercial Marine Transmissions.................... 13

40 Index Section

Re-refined Base Stock Oils ................................... 13

Reference Information Section.............................. 37

Reference Material ................................................ 37

Coolants............................................................. 37

Fuels .................................................................. 37

Lubricants .......................................................... 37

Miscellaneous .................................................... 37

Reference Materials .............................................. 37

S·O·S Coolant Analysis ......................................... 35

Recommended Interval for S·O·S Coolant

Sample............................................................. 35

S·O·S Coolant Analysis (Level 1)....................... 35

S·O·S Coolant Analysis (Level 2)....................... 36

S·O·S Oil Analysis ................................................. 16

Supplemental Coolant Additive (SCA)................... 29

Synthetic Base Stock Oils ..................................... 13

Table of Contents................................................... 3

Water/Supplemental Coolant Additive (SCA)........ 33

Cooling Systems with Larger Capacities ........... 34

Product and Dealer Information

Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

3COM SEBU6251-06 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual