Page 1 of 13 Shutdown SIS Previous Screen Product: TRUCK ENGINE Model: C7 TRUCK ENGINE WAX Configuration: C7 On-highway Engine WAX00001-UP Operation and Maintenance Manual C7 On-highway Engine Media Number -SEBU7766-07 Publication Date -01/04/2010 Date Updated -27/04/2010 Refill Capacities and Recommendations SMCS - 1348; 1395; 7560 i03903590 Every attempt is made to provide accurate, up to date information. By use of this document, you agree that Caterpillar Inc. is not responsible for errors or omissions. These recommendations are subject to change without prior notice. Contact your Caterpillar dealer for the most up to date recommendations. Note: Note: Refer to the latest edition of Special Publication, SEBU6385, "Caterpillar On-highway Diesel Engine Fluids Recommendations" for additional information. Contact your Caterpillar dealer in order to confirm that you have the newest recommendations for fluids. Note: Instructions for the installation of the filter are printed on the side of each Caterpillar spin-on filter. For filters that are not Caterpillar filters, refer to the installation instructions that are provided by the supplier of the filter. Engine Oil
Page 2 of 13 Cat DEO (Diesel Engine Oil) Cat oils have been developed and tested in order to provide the full performance and service life that has been designed and built into Cat engines. Due to significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations: Cat DEO (Diesel Engine Oil) (10W-30) Cat DEO (Diesel Engine Oil) (15W-40) Cat DEO-ULS (Diesel Engine Oil - Ultralow Sulfur) (15W-40) (SAE 10W-30 is only available in bulk quantities) Note: Cat DEO-ULS and Cat DEO multigrade oils are the preferred oils for use in all Cat on-highway engines. Note: For optimum engine system performance of DPF equipped Cat diesel engines, the use of Cat DEO-ULS is strongly recommended. For optimum engine system performance of DPF equipped Cat diesel engines, the use of ultralow sulfur diesel fuel (ULSD) is required. Commercial Oils Caterpillar does not warrant the quality or performance of non- Caterpillar fluids. Note: Non-Caterpillar commercial oils are, as a group, second choice oils. Within this grouping of second choice oils there are tiered levels of performance. Caterpillar developed the Engine Crankcase Fluid (ECF) specifications to ensure the availability of high performance commercial diesel engine oils in order to provide satisfactory life and performance in Cat diesel engines where recommended for use. There are three current Cat ECF specifications: Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each higher Cat ECF specification provides increased performance over lower Cat ECF specifications. For example, Cat ECF-3 provides higher performance than Cat ECF-2 and Cat ECF-3 provides much higher performance than Cat ECF-1-a. After Cat DEO-ULS and Cat DEO, commercial oils that meet the Cat ECF-3 specification are preferred oils for use in Cat On-highway Engines. Oils that meet the API CJ-4 oil category requirements are compliant with the Cat ECF-3 specification. Commercial oils that meet the requirements of the Cat ECF-1-a specification and commercial oils that meet the requirements of the Cat ECF-2 specification are acceptable for use in thecaterpillar On-
Page 3 of 13 highway Engines that are covered by this publication. API category oils that have not met the requirements of at least one Cat ECF specification may cause reduced engine life. Use of oil that does not meet the Cat ECF-3 specification and the API CJ-4 oil category may require more frequent DPF cleaning cycles and may contribute to DPF plugging. When the recommended and preferred Cat DEO-ULS is not used, it is strongly recommended that DPF equipped engines use oil that meets the Cat ECF-3 specification and the API CJ-4 oil category. In selecting oil for any engine application, both the oil viscosity and oil performance category/specification as specified by the engine manufacturer must be defined and satisfied. Using only one of these parameters will not sufficiently define oil for an engine application. Lubricant Viscosity Recommendations 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 1 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine. Refer to Table 1 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated. In selecting oil for any engine application, both the oil viscosity and oil performance category/specification as specified by the engine manufacturer must be defined and satisfied. Using only one of these parameters will not sufficiently define oil for an engine application. Table 1 Engine Oil Viscosities for Ambient Temperatures Ambient Temperature Viscosity Grade Minimum Maximum SAE 0W-30-40 C (-40 F) 30 C (86 F) SAE 0W-40 SAE 5W-30-40 C (-40 F) 40 C (104 F) -30 C (-22 F) 30 C (86 F)
Page 4 of 13 SAE 5W-40 SAE 10W-30 SAE 10W-40 SAE 15W-40-30 C (-22 F) 50 C (122 F) -18 C (0 F) 40 C (104 F) -18 C (0 F) 50 C (122 F) -9.5 C (15 F) 50 C (122 F) Note: Supplemental heat is recommended below the minimum recommended ambient temperature. S O S Oil Analysis Caterpillar has developed a maintenance tool that evaluates oil degradation. The maintenance management also detects the early signs of wear on internal components. The Caterpillar tool for oil analysis is called S O S oil analysis and the tool is part of the S O S Services program. S O S oil analysis divides oil analysis into four categories: Component wear rate Oil condition Oil contamination Identification of oil These four types of analysis are used to monitor the condition of your equipment. The four types of analysis will also help you identify potential problems. A properly administered S O S oil analysis program will reduce repair costs and the program will lessen the impact of downtime. The S O S oil analysis program uses a wide range of tests to determine the condition of the oil and the condition of the lubricated compartment. Guidelines that are based on experience and a correlation to failures have been established for these tests. Exceeding one or more of these guidelines could indicate serious fluid degradation or a pending component failure. A trained person at your Caterpillar dealership should make the final analysis. Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
Page 5 of 13 Refer to this Operation and Maintenance Manual, "Engine Oil Sample - Obtain" in order to ascertain the correct interval for obtaining an oil sample. Refer to Special Publication, SEBU6385, "Caterpillar On-highway Diesel Engine Fluids Recommendations" in order to obtain additional information about S O S Services oil analysis. You can also contact your local Caterpillar dealer in order to obtain additional information about the S O S Services oil analysis program. Refill Capacities (Engine Oil) The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter. Illustration 1 g01142908 (1) Shallow oil sump (2) Deep oil sump Table 2
Page 6 of 13 Compartment or System (1) Oil Sump Capacity (Shallow Sump) 180 mm (7.1 inch) deep Oil Sump Capacity (Deep Sump) (1) 245 mm (9.6 inch) deep C7 On-highway Engine Approximate Refill Capacities Refill with filter change (L) (Qts) 18 (L) 19 (Qts) 25.5 (L) 27 (Qts) Refill without filter change (L) (Qts) 16 (L) 17 (Qts) 23.7 (L) 25(Qts) ( 1 ) These values are the approximate capacities for the crankcase oil sump which include the standard oil filters that are installed at the factory. Engines with auxiliary oil filters will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter. Fuel Caterpillar is not in the position to continuously evaluate and monitor all of the many worldwide distillate diesel fuel specifications and the ongoing revisions that are published by governments and technological societies. Caterpillar recommends the filtration of distillate fuel through a fuel filter with a rating of four microns(c) absolute or less as the fuel is dispensed to the fuel tank for the engine. Note: Caterpillar requires the filtration of all fuel through a primary fuel filter with a rating of ten microns(c) absolute to 15 microns(c) absolute. In order to meet expected fuel system component life, 4 micron(c) absolute or less secondary fuel filtration is required for all Caterpillar Diesel Engines that are equipped with unit injected fuel systems. Note that all current Caterpillar Diesel Engines are factory equipped with Caterpillar Advanced Efficiency 4 micron(c) absolute fuel filters. Caterpillar does not warrant the quality or performance of non- Caterpillar fluids and filters.
Page 7 of 13 All fuel must meet the Caterpillar specifications for distillate diesel fuel found in Special Publication, SEBU6385, "Caterpillar On-highway Diesel Engine Fluids Recommendations", "Distillate Diesel Fuels". In the United States (U.S.), burning fuel with greater than 500 ppm sulfur in model year 2006 and older on-highway diesel engines is illegal and punishable with civil penalties. Note: The owner and the operator of the engine has the responsibility of using the correct fuel that is recommended by the manufacturer and allowed by the US EPA and, as appropriate, other regulatory agencies. The preferred fuels provide maximum engine service life and performance. The preferred fuels are distillate fuels. These fuels are commonly called diesel fuel, furnace oil, gas oil, or kerosene. Note: Fuel with 15 ppm sulfur or fuel with less than 15 ppm sulfur is required for use in every Caterpillar On-highway Engine that is equipped with a DPF. The permissible fuels include some biodiesel fuels. Use of permissable fuels can result in higher maintenance costs and reduced engine service life. Biodiesel Biodiesel that meets the requirements that are listed in the Caterpillar specification for biodiesel, ASTM D6751, or EN 14214 are acceptable for use in any Cat On-highway Engine that is covered by this publication. The biodiesel blend must meet the Caterpillar specifications for distillate diesel fuel found in Special Publication, SEBU6385, "Caterpillar On-highway Diesel Engine Fluids Recommendations", "Distillate Diesel Fuels". Biodiesel may be blended in amounts up to a maximum of 30 percent with an acceptable diesel fuel. Note: The user of the engine has the responsibility of using the correct fuel that is recommended by the manufacturer and allowed by the U.S. EPA and other appropriate regulatory agencies. Note: Refer to Special Publication, SEBU6385, "Caterpillar On-highway Diesel Engine Fluids Recommendations", "Fuel Specifications" for specific information about types of biodiesel that are recommended for use in Caterpillar On-highway Engines. Note: A complete Caterpillar S O S Services oil analysis program is strongly recommended when using biodiesel blends above 5 percent. Aftermarket Fuel Additives Note: Caterpillar strongly recommends that a fuel additive with 15 ppm sulfur or greater NOT be used with an engine that is equipped with a DPF.
Page 8 of 13 There are many different types of fuel additives that are available to use. Caterpillar does not generally recommend the use of fuel additives. In special circumstances, Caterpillar recognizes the need for fuel additives. Fuel additives need to be used with caution. Some additives may damage emission control systems. Some additives may raise fuel sulfur levels above the maximum allowed by the US Environmental Protection Agency (EPA) or, as appropriate, other regulatory agencies. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can make recommendations for additives to use and for the proper level of treatment. Note: The U.S. EPA bans the use of metallic fuel additives in on-highway applications. Note: For best results, your fuel supplier should treat the fuel when additives are needed. Cat Diesel Fuel Conditioner Cat Diesel Fuel Conditioner is the only fuel conditioner/additive that is tested and approved by Caterpillar for use in Caterpillar diesel engines. Cat Diesel Fuel Conditioner is a proven high performance, multipurpose diesel fuel conditioner that is designed to improve: Fuel economy (through cleanup of the fuel system) Lubricity Oxidative stability Detergency/dispersancy Dispersancy of moisture Corrosion protection Cetane Note: When used as directed, Cat Diesel Fuel Conditioner will not raise fuel sulfur levels measurably in the final fuel/additive blend. In the U.S. the current formulation of Cat Diesel Fuel Conditioner must be blended in at the recommended treat-rate at the fuel supplier/distributor level for use in onhighway or other applications where use of ULSD fuel is mandated (15 ppm or less fuel sulfur). Follow all applicable national, regional, and local laws, mandates, and regulations concerning the use of diesel fuel conditioners/additives. Lubricating Grease Caterpillar provides various greases that vary in performance from a moderate performance to an extremely high performance. These greases service the entire line of Caterpillar products in the wide variety of climates throughout the world. From this variety of Caterpillar grease products, you can find a Caterpillar grease that will meet or exceed the performance requirements of most on-highway trucks.
Page 9 of 13 The performance requirements of your engine must be determined before you select any Caterpillar grease. Consult the recommendations for greases that are made by the OEM for the equipment. Then, consult with your Caterpillar dealer for a list of greases that have the performance specifications and the available sizes of containers. Note: Always choose grease that meets or exceeds the recommendations that are specified by the equipment manufacturer for the application. If it is necessary to choose a single grease to use for all of the equipment at one site, always choose a grease that meets or exceeds the requirements of the most demanding application. Remember that the products which barely meet the minimum performance requirements can be expected to barely produce the minimum lives of your parts. False economy is being used if a grease is purchased with the lowest cost as the only consideration. Instead, use the grease that yields the lowest total operating cost. This cost should be based on an analysis that includes the costs of parts, labor, downtime, and the cost of the amount of grease that is required. Some greases are not chemically compatible with other greases. Consult your supplier in order to determine if the greases are compatible. Purge all of the old grease from a joint in the following circumstances: Before you change from one type of grease to another type of grease Before you change from one brand of grease to another brand of grease All Caterpillar greases are chemically compatable but may be formulated for different levels of performance. Mixing Caterpillar greases can affect the performance of the greases. Do not mix Caterpillar greases. If you are not certain that the old grease is compatible with the new grease, purge the old grease from the system before applying the new grease. Coolant Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first. If the truck 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 caused by freezing coolant.
Page 10 of 13 Frequently check the specific gravity of the coolant for proper freeze protection or for anti-boil protection. 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. The following two coolants are used in Caterpillar diesel engines: Preferred - Cat ELC (Extended Life Coolant) or a commercial extended life coolant that meets the Caterpillar EC-1 specification Acceptable - Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial heavy-duty coolant that meets "ASTM D4985", or "ASTM D6210" specifications Note: Cat DEAC does not require a treatment with an Supplemental Coolant Additive (SCA) at the initial fill. However, a commercial heavy-duty coolant that only meets the "ASTM D4985" specification WILL require a treatment with an SCA at the initial fill. A commercial heavy-duty coolant that meets the "ASTM D6210" specification will NOT require a treatment with an SCA at the initial fill. Read the label or the instructions that are provided by the manufacturer of the commercial heavy-duty coolant. Note: Coolants that meet only the "ASTM D4985" specification WILL require a treatment with a supplemental coolant additive on a maintenance basis. Coolants that meet only the "ASTM D6210" specification WILL require a treatment with a supplemental coolant additive on a maintenance basis. Table 3 Service Life Before Flushing and Before Refilling Coolant Service Life (1) (2) (3) Cat ELC 965,606 kilometers (600,000 miles), 12,000 hours, or 6 years (4)
Page 11 of 13 Commercial coolant that meets the Caterpillar EC-1 specification 482,803 kilometers (300,000 miles), 6000 hours, or 6 years (5) Cat DEAC 321,869 kilometers (200,000 miles), 3000 hours, or 3 years (6) Commercial Heavy-Duty Coolant that meets "ASTM D4985" (7) or "ASTM D6210" 241,402 kilometers (150,000 miles), 3000 hours, or 1 year (6) ( 1 ) Use the interval that occurs first. ( 2 ) Refer to this Operation and Maintenance Manual, "Maintenance Interval Schedule" for the interval for servicing the water temperature regulator. ( 3 ) Caterpillar On-highway Engines that have excessive idle time must reduce the coolant change intervals to one-half of the kilometers (miles) that are allowed or Caterpillar On-highway Engines that have excessive idle time must base the coolant service life on the hours that are stated. Engine hours of operation are reported in the ECM (Electronic Control Module). ( 4 ) Cat ELC Extender must be added at 6000 service hours or one half of the service life of the Cat ELC. ( 5 ) An extender must be added at 3000 service hours or one half of the service life of the coolant. ( 6 ) Requires treatment with a supplemental coolant additive on a maintenance basis. ( 7 ) Requires pre-charge of a supplemental coolant additive. Note: These coolant change intervals are only possible with annual S O S Services Level 2 coolant sampling and analysis. S O S Services Coolant Analysis 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 Services Coolant Analysis can be performed 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. 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 pump that is designated only for oil sampling and a pump that is designated only for coolant sampling. Failure to do so may cause a false analysis which could lead to customer and dealer concerns.
Page 12 of 13 Recommended Interval for S O S Services Coolant Sample Table 4 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC Every (1) (2) 24140 kilometers (15000 miles) Yearly (2) (3) Cat ELC Optional (3) Yearly (3) ( 1 ) This is also the recommended sampling interval for all commercial coolants that meet Cat EC-1 (Engine Coolant specification - 1) ( 2 ) The recommended sampling interval for all other conventional heavy-duty coolant/antifreeze is 20120 kilometers (12500 miles). ( 3 ) The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified. Note: Check the SCA (Supplemental Coolant Additive) of the conventional coolant at every oil change or at every 250 hours. Perform this check at the interval that occurs first. New Systems, Refilled Systems, and Converted Systems Perform an S O S coolant analysis (Level 2) at the following maintenance intervals. Every Year Initial 500 service hours Perform this analysis at the interval that occurs first for new systems, for refilled systems, or for converted systems that use Cat ELC (Extended Life Coolant) or use Cat DEAC (Diesel Engine Antifreeze/Coolant). This 500 hour check will also check for any residual cleaner that may have contaminated the system. Refill Capacity (Coolant System) The total cooling system capacity will vary depending on the radiator that is provided by the vehicle manufacturer. The table for the capacity of the cooling system is blank. The customer should fill in the table. Approximate Capacity of the Cooling System Compartment or System Liters Quarts Total Cooling System (1) Table 5
Page 13 of 13 ( 1 ) The total cooling system capacity includes the following components:the engine block, the radiator and all coolant hoses and lines. Note: Refer to Special Publication, SEBU6385, "Caterpillar On-highway Diesel Truck Engine Fluids Recommendations" for additional information that relates to coolant for your engine. Copyright 1993-2011 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Feb 20 12:01:07 PST 2011