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APPLICATION AND INSTALLATION GUIDE LUBRICATION SYSTEMS



ContentsLubricating Oil Systems .......................................................... 1 General Description ............................................................ 2 Flow ............................................................................. 2 Engine Sump ................................................................. 2 Main Oil Pump ............................................................... 2 Oil Coolers .................................................................... 2 Oil Cooler Bypass Valve .................................................. 3 Oil Filters....................................................................... 7 Oil Filter Differential Pressure Gauge ................................ 7 Duplex Oil Filters............................................................ 7 Auxiliary Oil Filters ......................................................... 7 Supplemental Bypass Filters ............................................ 7 Centrifugal ................................................................ 7 Absorptive................................................................. 8 Oil Level Gauge (Dipstick) ............................................... 8 Crankcase Breather ........................................................ 8 Oil Pressure Regulation Valve .......................................... 8 Priority Valve ................................................................. 8 Temperature Regulators .................................................. 9 Prelubrication................................................................. 9 Intermittent Prelube System ...................................... 10 Continuous Prelube System....................................... 10 Redundant Prelube System........................................ 10

Quick Start Prelube System....................................... 11 Postlubrication ............................................................. 11Optional Systems ............................................................. 15 Duplex Oil Filter System................................................ 15 Remote Oil Filters......................................................... 15 Lubricating Oil Heating System ...................................... 16 Oil Makeup Systems..................................................... 17 Oil Pressure Monitoring ................................................. 19 Turbocharger Oil Accumulator ....................................... 19 Remote Sump Tanks .................................................... 19 Remote Sump with Gravity Drain ............................... 19 Remote Sump with Scavenging Pump ........................ 21 Piping ..................................................................... 21 Suction Strainer ....................................................... 22 Auxiliary Sump Tank ................................................ 22 Auxiliary Oil Sump System Considerations .................. 22Additional Considerations.................................................. 24 Supplemental Bypass Filter Systems .............................. 24 Emergency Systems ..................................................... 24 Transmissions.............................................................. 24 Piping Systems and Flexible Hoses................................. 24 Lubricating Oil Centrifuges ............................................ 25 Centrifuge Supply Pump ............................................... 26 PreHeater .................................................................... 26 Sample Points.............................................................. 26

Lube Oil Storage and Transfer Systems .......................... 26 Clean Oil ................................................................. 26 Dirty Oil .................................................................. 27 Renovated Oil .......................................................... 27 Transfer Pumps........................................................ 27 Storage Tanks ......................................................... 27Lubricating Oil Selection ....................................................... 33 Properties........................................................................ 34 Viscosity ..................................................................... 34 Additives..................................................................... 34 Total Base Number (TBN).............................................. 35 Total Acid Number (TAN).............................................. 35 Cleanliness .................................................................. 35 Engine Oil Selection...................................................... 35 Consumption ................................................................... 37 Oil Change Interval ....................................................... 37 Monitoring Quality............................................................ 38 S•O•SSM...................................................................... 38 Wear Analysis.............................................................. 38 Oil Condition Analysis................................................... 38 Additional Tests ........................................................... 38 Contamination ................................................................. 39 Copper........................................................................ 39 Silicon......................................................................... 39 Sodium, Silicates, Carboxylic Acid Base ......................... 39

Silicon, Chromium, Iron, Aluminum ................................ 39 Silicon, Lead, Aluminum, Tin ......................................... 39 Chromium, Molybdenum, Aluminum............................... 39 Aluminum.................................................................... 39 Iron ............................................................................ 39 Soot ........................................................................... 39 Water ......................................................................... 40 Fuel ............................................................................ 40 Sulfur ......................................................................... 40Reference Material ............................................................... 41

Foreword This section of the Application and Installation Guide generally describes wide-ranging requirements and options for the Lubrication System on Caterpillar® engineslisted on the cover of this section. Additional engine systems, components anddynamics are addressed in other sections of this Application and Installation Guide. Engine-specific information and data are available from a variety of sources. Referto the Introduction section of this guide for additional references. Systems and components described in this guide may not be available orapplicable for every engine. Below is a general listing of lubrication systems andcomponents for various Caterpillar engines. Refer to the Price List for specificoptions and compatibility. Standard 3126B Optional C7- Not Available C-9 C9 C-10/C-12 C11/C13 C-15/C-16 C15/C18 3412E C27/C32 3500 3600 G3300/G3400 G3500 G3600Filter Differential ---------- -Pressure GaugeDuplex Filter -------- - -Centrifugal Bypass - - - - -- -FilterPressure Regulator ---ValvePriority Valve -------- -- --Temperature ---------- --RegulatorPrelube System ---------- -Postlube System ----------- --Remote Filter -- -------Oil Heating System - - - - - - - - - - - ---Makeup System ---------- --Monitoring System - - - - - - - - -- -Programmable - ----Monitoring SystemTurbocharger Oil ------------- -AccumulatorRemote Sump ----------- ---Emergency ----------- ---SystemsSample Points -Caterpillar®All rights reserved.

Information contained in this publication may be considered confidential.Discretion is recommended when distributing. Materials and specificationsare subject to change without notice.CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and thePOWER EDGE trade dress, as well as corporate and product identity usedherein, are trademarks of Caterpillar and may not be used withoutpermission.

Application and Installation Guide Lubrication SystemsLubricating Oil Systems Proper lubrication is critical to successful engine operation. The lubricationsystem of a modern engine accomplishes three primary purposes: It lubricates surfaces to minimize friction losses. It cools internal engine parts that cannot be directly cooled by the engine’swater-cooling system. It cleans the engine by flushing away wear particles. Additionally, the lubricant itself performs other functions: • It cushions the engine’s bearings from the shocks of cylinder firing. • It neutralizes the corrosive elements created during combustion. • It seals the engine’s metal surfaces from rust. Lubricating oil systems require clean oil that is free from abrasive particlesand corrosive compounds. These systems require a lubricant with sufficientfilm strength to withstand bearing pressures and heat exposure to cylinderand piston walls. In addition, the lubricant must have a viscosity index that islow enough to flow properly when cold. The lubricant must also be capableof neutralizing harmful combustion products and holding them in suspensionfor the duration of the oil change period. Your local Caterpillar dealer shouldbe consulted to determine the best lubricant for your local fuels. The oil system provides a constant supply of filtered oil to the engine.Main bearings, piston cooling jets, camshafts, gear train, rocker arms, andturbocharger bearings are just a few of the components that require properlubrication for normal function. The oil system is not only for lubrication.Engines equipped with HEUI fuel systems use engine oil to drive and controlfuel delivery. This makes an effective lubricating oil system particularlyimportant on these engines. SECTION CONTENTSGeneral Description ............. 2 Additional Considerations .... 24• Lubricating Oil Flow • Marine/Offshore• Lubricating Oil Components Requirements• Sample System Diagrams • Lubricating Oil CentrifugesOptional Systems ...............15 • Lubricating Oil Storage• Optional Lubrication • Lubricating Oil Transfer Systems and Components Systems • Sample Sump ConfigurationsCaterpillar® Page 1All rights reserved.

Lubrication Systems Application and Installation GuideGeneral DescriptionFlow The following is a brief description of common lubrication system A typical engine lubricating oil flow components.schematic is shown in Figure 1. Engine Sump Figure 2 and Figure 3 show thelubricating oil flow for 3600/G3600 The engine sump serves as theengines. engine’s main oil reservoir and contains the bulk of the engine oil. The basic flow of the lubricating oil Typically part of the engine package,begins with an engine mounted, gear the sump is located below thedriven, fixed displacement gear crankcase to collect the oil as itpump. The pump pulls oil from the drains from the engine.sump through a coarse strainer onthe suction bell. The oil is then Sumps can differ in capacity,pumped toward the oil cooler. Oil configuration and tilt capability tocooler flow can differ depending on accommodate various engines andengine design. Engines designed applications.with an oil cooler bypass valve candivert some of the oil flow around Tilt capability requires additionalthe cooler under certain conditions. consideration for the oil sump toThe valve operates based on oil ensure proper lubricating oil systemviscosity (measured by pressure- function. Marine and offshoredrop across the oil cooler). In engines may be installed and putengines without a bypass valve, into continuous use while in a tiltedthe oil flows through the oil cooler. position. Other mobile applicationsNext, the oil flows to the oil filters. may require temporary operation inAll oil flow is filtered before entering a tilted position.the engine unless the filter becomesplugged. If the filter is plugged, a Caterpillar can provide engines thatvalve allows the oil to bypass the meet or exceed specific tilt anglefilter to help prevent lubricating oil requirements. Refer to the Caterpillarstarvation. Oil flow proceeds to oil TMI for specific information.galleries in the engine block where itis distributed to all the components Main Oil Pumprequiring oil flow and pressure.Gravity returns the oil to the sump The main oil pump is a gear driven,via drain tubes and passages in the fixed displacement pump. The pumpcylinder head and engine block. output depends on engine speed and the effects of changing system Lubricating oil systems may be restrictions are minimized by the useequipped with additional or optional of pressure regulating valves.components. Some components arenot available for all engine models, Oil Coolersapplications and duty cycles. The oil coolers are typically shell- and-tube type, with series water flow and parallel oil flow. SomePage 2 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systemslarger engines, however, may use the oil cooler becomes plugged orplate-and-frame type for remote if the oil viscosity is high. In thiscooler applications. Specific cooler situation, viscosity is determined bydesigns will vary with engine model the pressure differential across theand rating. oil cooler. If the pressure differential exceeds a preset limit, the valveOil Cooler Bypass Valve opens allowing oil to bypass the cooler. Cold starts often cause the The oil cooler bypass valve allows lubricating oil to bypass the cooler.oil to flow directly to the oil filters ifCaterpillar® Page 3All rights reserved.

Lubrication Systems Application and Installation GuideTypical Engine Lubricating Oil Flow Schematic Figure 1 oil to bypass the cooler until the oil is warm enough to require full oil flow through the cooler. 1. Sump – lube oil is drawn from the sump through a 6. Lube Oil Filter – Caterpillar lube oil filters are the strainer into the inlet of the lube oil pump. full-flow type with a bypass valve to provide adequate lubrication should the filter become 2. Lube Oil Pump – the quantity of lube oil delivered plugged. The filter system may have the by the lube oil pump exceeds the engine's needs replaceable element type or the spin-on type. The when the engine is new. As the engine clearances oil filter bypass valve is protection against lube oil increase through normal wear, the flow required starvation if the oil filter clogs. to properly lubricate the engine will remain adequate. 7. Engine Oil Passages – the main oil flow is distributed through passages to internal engine 3. Oil Pressure Regulating Valve – this valve components. The oil flow carries away heat and regulates oil pressure in the engine and routes wear particles and returns to the sump by gravity. excess oil back to the sump. 8. Prelubrication Pump – used only during starting 4. Lube Oil Cooler – the oil to the engine is cooled by cycle. jacket water or external water source in the engine oil cooler . 9. Check Valve – prevents oil back flow through prelubrication pump when the pump is inactive. 5. Oil Cooler Bypass Valve – when the viscosity of the oil causes a substantial pressure drop in the Caterpillar® oil cooler, the bypass valve will open, causing the All rights reserved.Page 4

Application and Installation Guide Lubrication Systems 3600 Lubricating Oil System – Model 36081. Oil Pump Figure 22. Prelube Pump3. Oil Coolers 10. Oil Manifold (Oil To Piston Cooling Jets)4. Oil Filters 11. Oil Manifold (Oil To Bearings)5. Oil Thermostat Housing 12. Oil To Main Bearings6. Oil Filter Duplex Valve Handle 13. Oil To Camshafts7. Priority Valve 14. Centrifugal Filters (3600 Only)8. Oil To Centrifugal Filters (3600 Only) 15. Turbocharger9. Emergency Oil Locations 16. Bypass Oil 17. Check Valve * Flow in Opposite Direction During PrelubeCaterpillar® Page 5All rights reserved.

Lubrication Systems Application and Installation Guide3600 Lubricating Oil System Schematic - Model 3612 Figure 3 11. Oil Manifold (2) (Oil To Piston Cooling Jets) 12. Oil To Main Bearings 1. Oil Pump 13. Oil To Camshafts 2. Prelube Pump 14. Centrifugal Filters (3600 Only) 3. Oil Coolers 15. Turbocharger 4. Oil Filters 16. Bypass Oil 5. Oil Thermostat Housing 17. Check Valve 6. Oil Filter Duplex Valve Handle 18. Piston Cooling Jets 7. Priority Valve 19. Check Valve 8. Oil To Centrifugal Filters (3600 Only) * Flow in Opposite Direction During Prelube 9. Emergency Oil Locations 10. Oil Manifold (Oil To Piston Cooling Jets) Caterpillar® All rights reserved.Page 6

Application and Installation Guide Lubrication SystemsOil Filters Auxiliary Oil Filters Caterpillar oil filters are designed to Some Caterpillar rich burnremove solid particles (large enough (stoichiometric) gas engines includeto cause noticeable abrasion) from an auxiliary oil filter. Wherethe oil by mechanical filtration. applicable, this auxiliary filter isStandard oil filter systems on shipped loose and provides addedCaterpillar engines meet particulate capacity and filtering to therequirements and are sized to lubricating oil system, providingprovide reasonable time intervals for longer oil change intervals.between element changes. If a deep sump oil pan option is Filter change intervals should be used, the auxiliary filter should bemaintained in line with published omitted from the system. Theservice data relating to particular auxiliary oil filter may be consideredengine models, application and duty optional on engines equipped withcycle. a standard sized oil pan if the oil change interval is reduced. In such The use of genuine Caterpillar circumstances, an oil analysis iselements is encouraged for optimum recommended to determine theprotection of your engine. correct oil change interval.Oil Filter Differential Pressure Auxiliary filter capacity varies byGauge engine model, application and duty cycle. Oil filter differential pressuregauges are available and Supplemental Bypass Filtersrecommended for many enginemodels. In most cases the gauges Caterpillar engines usually do notare not integrated into the engine require a supplemental bypass oilcontrols, but can be monitored by filter system. However, somethe operator to protect against unusual operating conditions mayengine operation with plugged cause users to install such a system.filters. Refer to the Special Considerations section for more information. Differential pressure gauges arestandard on 3600/G3600 lubricating Supplemental filters generally falloil systems. into two categories, centrifugal and absorptive. Centrifugal filters haveDuplex Oil Filters proved helpful in extending the primary filter life while absorptive Duplex oil filters can be used filters reduce acids andinstead of standard oil filters on contaminants in the oil.some engine models. In manyapplications, the use of duplex filters Centrifugalcan allow an oil filter change while Used primarily on the 3500 andthe engine is operating. Refer to theOptional Lube Oil Systems section 3600 diesel engines, engine-for more information. mounted centrifugal filters remove micron-size solids from the oil suchCaterpillar® Page 7All rights reserved.

Lubrication Systems Application and Installation Guideas sludge, wear materials, soot and checked for accuracy andcarbonous material. recalibrated if necessary. Centrifugal bypass filters are not Crankcase Breatherrecommended for gas engines. The crankcase breather benefits Centrifugal filters can increase the the oil system by equalizingnumber of operating hours before crankcase and ambient air pressures.the primary filters become restricted. Refer to the Crankcase Ventilation Application and Installation Guide, Additional information about Media Number LEBW4958-00 forcentrifugal bypass filters can be more information.found in the AdditionalConsiderations section of this guide. Oil Pressure Regulation ValveAbsorptive Most engine models utilize an oil Absorptive filters have an pressure regulation valve to regulate the oil pressure in the lubricating oilabsorbent media such as cotton or circuit. Excess oil is routed back tocellulose fibers which absorb acids, the sump.moisture and remove contaminantsfrom the oil. Priority Valve Supplemental bypass absorptive 3600/G3600 lubricating oilfilters increase oil capacity and may systems are regulated by an oilallow oil and filter change periods to priority valve. Refer to Figure 4.be extended. However, the drainintervals cannot be extended Figure 4arbitrarily. Oil and filter life must beverified by adequate monitoring The priority valve regulates oilsystems. pressure at the cylinder block main oil gallery rather than at the oilOil Level Gauge (Dipstick) pump. This makes the oil gallery pressure independent of the oil filter The oil level gauge, or dipstick, and oil cooler pressure drops.is marked with graduations thatindicate the engine oil level in the The valve also features advancedsump. Engines that are 32 liters or oil regulating capabilities for betterless must be stopped to check theoil level. On engines above 32 liters, thedipstick is marked to allow the oillevel to be checked while the engineis stopped or running. Marine and offshore engines arecommonly installed and operated ina tilted position. After installation,dipsticks on these engines should bePage 8 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systemsengine protection and lubricating oil energizing the starting motors.management. Prelubrication is mandatory equipment for 3600/G3600Temperature Regulators engines and especially important after periods of idleness, oil changes Oil temperature regulators direct and filter changes.lubricating oil to the oil coolers andthen oil filters. While most Caterpillar Prelubrication systems areengine models require full oil flow available to operate with electricthrough the cooler at all times, some starter or air starter motors.of the larger engines, notably 3500 The systems can be manual orengines configured for high jacket automatic. An automatic systemwater (JW) temperatures and all is shown in Figure 7.3600 engines, utilize a temperatureregulator in the oil circuit in order to The manual system requires themore closely control the oil engine operator to manually operatetemperature. a sump pump to fill the engine oil passages before activating the The 3500 engines, configured for starter motors.high JW temperatures, cool the oilusing the aftercooler circuit instead Automatic systems significantlyof the JW circuit. These engines reduce the amount of prelube timealso use an oil temperature regulator prior to engine crank. The prelubein place of the oil cooler bypass pumps may be driven by an electricvalve to avoid overcooling the oil. motor, a compressed air motor, or a compressed natural gas motor (gas Temperature regulators in 3600 engines only), but must be poweredengines also help maintain the oil at from a source independent of anythe optimum temperatures needed failure that could require the enginefor tighter ring clearances and to start. After oil is sensed at theextended ring life associated with upper portion of the lubricationthe engine. system, the starter motors are automatically energized. In either case, oil temperatures arecontrolled within acceptable limits, Automatic prelubrication systemsprovided the cooling system is supplied by Caterpillar includeadequately sized. starting controls, electric or air powered pumps, a check valve andNote: Oil life will be shortened, and engine piping. The check valve isengine components may suffer used to prevent pressurized oil fromdamage, if excessive oil flowing through the prelube pumptemperatures are permitted during during engine operation.operation. Refer to the engine model specificPrelubrication price lists for the various options available. Used primarily on larger engines,prelubrication systems lubricate allcritical bearing journals beforeCaterpillar® Page 9All rights reserved.

Lubrication Systems Application and Installation GuideNote: Remote mounted prelube is typically used in conjunction withpumps must be located and piped to jacket water and lube oil heating.prevent excessive inlet restriction. Used mostly on the 3600 family Several automatic prelubrication of engines, a continuous prelubesystems available for Caterpillar system eliminates the delay ofengines are: waiting for the completion of an intermittent prelube cycle. This • Intermittent Prelube System system is operating continuously when the engine is not running. This • Continuous Prelube System ensures that lube oil will be available at the bearings at all times, allowing • Redundant Prelube System immediate starting of the engine. The continuous prelube systems • Quick Start Prelube System utilize pumps with lower flow rates than intermittent prelube systems.Intermittent Prelube System This system relies on an engine oil The intermittent prelube system level start permissive, in lieu of the pressure switch permissive usedprovides suitable performance for with the intermittent prelubeapplications not requiring quick start system. A minimum level of oil incapability. the engine is required to fulfill the starting system interlock. The intermittent prelube systemuses an engine mounted pump and Redundant Prelube Systemis engaged immediately prior to The redundant prelube systemengine start-up. combines the continuous and Figure 5 is a schematic of a intermittent prelube systems,prelube system for a 3600/G3600 offering the benefits of both. Underengine. The type of prelube pump normal circumstances, thedetermines whether the system is continuous prelube pump keeps theintermittent or continuous. engine ready for immediate start-up by maintaining the level of oil in the Intermittent prelube time will vary engine. The intermittent prelubewith engine model as well as oil pump will only operate if thetemperature. A well-designed continuous pump fails. This systemsystem must include a prelube pump is typically selected for black start orshutdown capability to prevent the emergency generator applications,pump from operating too long. Since when it is critical that an engine isthe intermittent prelube pump able to start.operates at a higher flow rate andpressure than the continuous pump, When an engine equipped with aoperating the pump for extended continuous prelube system shutstime periods is not recommended. down, the intermittent pump willThis can result in excessive oil in postlubricate the engine. Afterthe cylinders and potentially cause postlubrication the oil pressurehydraulic lock at start-up.Continuous Prelube System Continuous prelubrication is forimmediate starting applications andPage 10 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systemsdecreases and the pilot controlled controlled spill valve opens and thespill valve opens and the prelube prelube pressure switch opens.pressure switch opens. When the When the pressure switch opens thepressure switch opens the continuous pump will energize andcontinuous pump will energize and maintain the oil level in the engine.maintain the oil level in the engine. Quick start prelube time will varyQuick Start Prelube System little with oil temperature. Typical The quick start prelube system quick start prelube times, measured from the start initiate signal toconsists of two electric prelube starter engagement, are 5 to 7pumps, a continuous pump and a seconds with 25°C (77°F) oil.booster pump. This system is similarto the redundant prelube system, Postlubricationexcept that the booster pump is notjust a back-up for the continuous 3600/G3600 engines have apump, it is an integral part of the standard postlubrication cycle.system. Postlubrication maintains oil flow after engine shutdown to protect Figure 6 and Figure 7 are the turbocharger bearings.schematic examples of quick startprelube systems. Engine postlubrication will not function if the Emergency Stop While the engine is not operating, (E-Stop) button is used to shutdownthe continuous pump maintains the the engine. Since an oil leak couldoil level near the top of the cylinder potentially require the use of theblock via the spill valve. When the E-Stop button, the postlubrication isengine is started, the continuous disabled to stop oil flow to apump will stop and the booster possible leak. An E-Stop button ispump will start in order to raise the located on the control panel,pressure to a sufficient level to junction box and the customerpermit cranking. terminal strip. Since no postlubrication occurs with the use When the engine shuts down, of the E-Stop button, the E-Stopthe booster pump will postlubricate. should only be used for emergencyAfter postlubrication, the oil shutdowns.pressure decreases and the pilotCaterpillar® Page 11All rights reserved.

Lubrication Systems Application and Installation Guide 3600/G3600 Engine Lubricating Oil System with Intermittent or Continuous Prelube Figure 5 Caterpillar® All rights reserved.Page 12

Application and Installation Guide Lubrication Systems G3600 Engine Lubricating Oil System with Optional Quick Start PrelubeCaterpillar® Figure 6All rights reserved. Page 13

Lubrication Systems Application and Installation Guide 3600/G3600 Air Prelube Figure 7 Caterpillar® All rights reserved.Page 14

Application and Installation Guide Lubrication SystemsOptional Systems The system provides the means for changing either the main or auxiliary This section generally describes filter elements with the enginevarious lubrication system options running at any load or speed. A filteravailable for Caterpillar engines. change indicator is included to tellPlease refer to the engine price lists when to change the main filterfor availability of these options on elements. A vent valve allowsspecific engine models. purging of air trapped in either the main or auxiliary system whenDuplex Oil Filter System installing new elements. Many marine and oilfield engines Note: Air must be purged fromthat require marine classification the changed section to eliminatesociety certification must be capable possible turbocharger and bearingof oil filter change while running. damage. Refer to the engineChanging the filters during operation Operation and Maintenance Manualmay also be a customer requirement for purging instructions.on certain Electric Power Generationand Industrial applications. The auxiliary system is capable of providing adequate oil filtration for atNote: Changing oil filters during least 100 hours under full load andengine operation should not be speed operation. The same filterperformed on engines equipped with elements are used in both systems.unit-mounted radiators and coolingfans. Oil can be blown onto hot Remote Oil Filtersengine surfaces and ignite. Some Caterpillar engines have the The optional Caterpillar duplex oil capability for remote mounting thefilter system (one example is shown oil filter when space limitation orin Figure 8 below) meets the serviceability is a problem, such asrequirements of the standard filter mobile type land drill rigs. However,system plus an auxiliary filter system to protect warranty coverage,with the necessary valves and authorization from Caterpillar Inc.piping. must be obtained before making any modification to the engine lubrication system. While remote filters have more potential for oil leaks, they seldom cause problems when the following recommendations are followed: Figure 8Caterpillar® Page 15All rights reserved.

Lubrication Systems Application and Installation Guide • Use procedures designed to Lube oil heating systems are often maintain oil system thermostatically controlled. When cleanliness during removal and the engine is shutdown and the installation of oil filters and oil drops below the desired lines. Keep all openings temperature, the heating system covered until final connections activates. The heating system stops are made. after the engine is started or the oil has reached the desired • Use quality pipe or medium temperature. pressure, high temperature 120°C (250°F) hose that is The Caterpillar lube oil heating equivalent to, or exceeds, the system is a prepackaged, shipped SAE 100R5 specification. loose unit, that may be used as a stand-alone lube oil heater or in • Keep oil lines as short as combination with a jacket water possible and at least as large heater. The typical package includes: as engine connections. • Circulating pump • Support hoses as necessary to keep from chafing or • Electric oil heater cutting on sharp corners. • Control panel, including • Use care in connecting oil controls for starting/stopping lines so the direction of oil pump, temperature control, flow is correct. etc.CAUTION: Engine damage will occur • Piping, valves and fittings onif the oil filter is improperly the unit (customer must makeconnected. piping connections to the engine).Lubricating Oil Heating System In some limited applications, jacket Cold oil has a higher viscosity and water heaters in conjunction withflows more slowly through oil continuous prelubrication maypassages, reducing its ability to satisfy lube oil heating requirements.quickly go where it is needed. Cold However, this method of heatingoil can also place a higher demand should be carefully calculated beforeon the starting system, requiring implementation.higher starting torque. Lubricatingoil heating systems address these Another solution that requiresissues. careful consideration is immersion heating. Heating elements in direct On some engines lube oil heating contact with lubricating oil are notsystems are recommended for recommended due to the dangerheating the lube oil to 10°C (50°F) of coking. To avoid coking whenwhen lube oil is below this heating oil, heater skin temperaturestemperature. They are also must not exceed 150°C (300°F)recommended when quick start and heater elements must havecapability is required.0 a maximum heat density ofPage 16 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systems1.24 w/cm2 (8w/in2). Marine activated. See Figure 9 for properapplications use a variation of an mount locations.immersion heater when steam ispiped though the engine oil sump. Most oil level switches and oil level makeup devices are vented. If Heating pads, designed for oil vented to the atmosphere, they willpreheating, may also be used. These regulate to some erroneous level duecan be used to bring the lubricating to the crankcase pressure. The ventoil up to the desired 10°C (50°F). line from these devices should go to the crankcase (well above the oilOil Makeup Systems line). There must be no low spots in the vent line that could allow oil to Some applications may require that collect and cause a blockage of thea fixed oil makeup system be vent line.installed to ensure that a constantlevel of lube oil is maintained in the For an oil makeup system toengine sump. In most cases, this is maintain a constant oil level in thea customer furnished system, but sump, the system should add oilCaterpillar offers oil makeup systems to the sump when the level dropsthat work with a customer supplied below the Running Full mark ongravity-fed oil supply to maintain a the oil level gauge (dipstick). Seesafe and constant oil level. The Figure 9 for proper mount location.Caterpillar lube oil makeup system This automatic system senses thetypically includes an oil level oil level and feeds oil into the sumpregulator and alarm & shutdown from a remote oil reservoir asswitches. required. Oil level alarm and shutdown The remote reservoir must be ableswitches alert the operator when to feed the oil into the sump at alllow oil levels are present. The oil operating conditions. Some makeuplevel alarm should sound when the systems are pump operated whileoil level in the sump drops below others are gravity fed. Depending onthe Add mark on the oil level gauge the height at which the makeup line(dipstick). An oil level shutdown enters the oil pan, pressure in the oiloccurs when the oil level in the pan can range from 0 kPa to 7 kPasump drops below an acceptable (0 psig to 1 psig), so it is importantlevel in the sump. that each system be inspected and tested to ensure proper operation It is important to mount the oil and positive oil flow.level regulator and shutdown switchgauges in the proper location. Failure A shutoff valve should also beto properly locate the gauges could installed between the remote oilresult in premature alarm/shutdown reservoir and the oil level regulatorconditions or allow the sump oil level to provide a means for serviceabilityto drop far below recommended and maintenancelevels before the alarm/shutdown is The Caterpillar oil makeup system offered on G3600 engines providesCaterpillar® Page 17All rights reserved.

Lubrication Systems Application and Installation Guidea floor-standing, gravity-fed oilmakeup system. The system isactivated by a float valve if the oillevel drops below full running level.A second float valve activates alow/high level alarm if the oil leveldrops below or exceeds a presetalarm level. A third float valveprovides an engine shutdowncontact if the oil level drops belowa preset shutdown level. Locations for Low Oil Level Alarm, Shutdown and Makeup Gauge Figure 9 Caterpillar® All rights reserved.Page 18

Application and Installation Guide Lubrication SystemsOil Pressure Monitoring engine shutdown. This is caused by high pressure intake air in the heat Maintaining sufficient oil pressure exchanger flowing back though theis critical to engine operation. A turbocharger compressor. Themeans of monitoring oil pressure turbocharger oil accumulatorshould be used. In some cases, this provides a supply of oil to lubricatewill be done by the use of oil and cool the turbocharger in such apressure gauges. Additionally, low circumstance. The oil accumulatoroil pressure contactors may be used protects and can extend the life ofto shutdown the engine if pressure turbocharger bearings.becomes too low. Turbocharger accumulators are Most engines have some level of optional equipment on G3500oil pressure monitoring; refer to the engines.Operation and Maintenance Manualfor each engine for available Remote Sump Tanksfeatures. Advanced features onsome Caterpillar engines include Engine room space, tiltuser-switchable options and user- requirements or the desire to extendprogrammable setpoints for oil change periods, may dictateWarning/Derate/Shutdown. using a remote oil sump tank. Figure 12 to Figure 15 are provided as The switchable options allow the examples of remote sump tanks.user to choose how the engineresponds to low oil pressure. A common external lube oil tank system for use during standard The programmable setpoints allow operation for a multiple enginethe user to choose when and how installation is NOT recommendedthe engine responds to low oil under any circumstances. While thepressure. economics of a common lube oil system can be appealing, the Default parameters and setpoint increased risks involved do notvalues for these functions are outweigh the benefits. In the eventavailable in the Caterpillar TIA, TMI, of the failure of one engine, all ofand Electronic Special Instructions the engines which share thefor each engine. common lube oil system will be compromised. For increased safety, automaticengine shutdown features may not Remote Sump with Gravity Drainbe available on single engine marine The suggested design of an remoteor mobile applications where anunexpected engine shutdown may sump tank is shown in Figure 15.create a hazardous situation. The following guidelines should beTurbocharger Oil Accumulator considered when remote sumps are installed in the engine mounting Engine models above 32 liters structure:equipped with air-to-air aftercooling(ATAAC) may experience reverse Page 19running of the turbocharger uponCaterpillar®All rights reserved.

Lubrication Systems Application and Installation Guide • The sump should occupy the • To provide adequate entire length of the engine to degassing of the remote ensure uniform thermal sump, a minimum distance of expansion. approximately 150 mm (6 in.) must be provided between the • Flanged, flexible, drain top of the tank and the connections should be used highest oil level expected in at each end of the engine the tank. mounted sump to prevent damage from vibration and • Transverse structures in the thermal growth. tank should be configured with air holes and oil passages • The connections must be in the structure must ensure compatible with engine lube adequate oil flow to the pump oil at a temperature up to suction piping. 130°C (266°F). • Two 100 mm (4 in) minimum • The connections should diameter air vent pipes should withstand exposure to fuel, be located on remote sump coolant and solutions used to tanks. On marine applications, wash the engine. install one vent tube at the forward end of the tank and • Drain pipes from the engine oil another at the aft end of the sump to the remote sump tank. should terminate below the minimum oil level. • Locate collecting sumps on marine applications at the aft • The engine sump drains end of the tank. When used, a should be located as far from lube oil centrifuge would take the oil pump suction area as oil from the collecting sump, possible. at a level below the main lube oil pump suction pipe, and • Each suction pipe should be discharge clean oil back to the fitted with a bell mouth to sump near the lube oil pump keep pressure losses to a suction piping. minimum. The maximum available suction lift to the • Prior to filling, the inner engine driven lube oil pump, surfaces of the remote sump including losses in the piping tank must be accessible for and strainer, must be kept cleaning, after initial below 1.3 m (51 in). construction or following repairs. • The oil should be in the tank for the longest possible time • Use flanged joints on the to maximize degassing. suction piping to the lube oil pumps to allow inspectionPage 20 before use. Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systems • The surfaces above the crankshaft during engine operation. minimum oil level must be Remote sumps with scavenging corrosion protection coated. pumps are normally used where the foundation structure height is small. • The tank requires a local sounding tube for determining Oil from the remote sump is oil volume as well as a low returned to the engine oil system by level alarm contactor. the engine driven main pressure pump. Due to the importance of the • On marine applications, a main engine lube oil system, marine cofferdam should be installed societies and/or the owner may to separate the remote sump require electric, motor-driven tank from the shell. standby pumps. This system can become very complex due to the • Marine sump tanks should additional pumps, piping and valves. also be fitted with a coil to Also, the oil level in the remote heat the oil to 38°C (100°F). sump must be kept below the engine The coil must be crankcase to prevent oil leak back manufactured from corrosion into the engine during shutdown. resistant material. Heating This system can also result in a long elements in direct contact narrow tank. The space required for with lubricating oil are not such a tank can be put to better use recommended due to the on marine applications. Incorporate danger of coking. To avoid the features recommended in the coking when heating oil, design of the remote sump tank with heater skin temperatures must gravity drain discussed above. not exceed 150°C (300°F) and heater elements must The scavenging pump can not be have a maximum heat density used on applications requiring the of 1.24 w/cm2 (8w/in2). engine driven auxiliary water pump, as it is driven off the same engineRemote Sump with Scavenging drive.Pump Piping An engine driven scavenging pump Remote sump tank piping must becan be provided for remote sumpapplications that do not permit short with minimum bends and havegravity drains. The scavenging pump a continual upward slope towardsis used to empty the oil from the the pump. This slope helps avoidengine collection pan into the remote pump cavitation and keeps suctionsump; Refer to Figure 12. The pressure drops to a minimum. Installengine collection pan typically has a non-return valve in the piping toa very low capacity and excess oil prevent the oil from flowingaccumulation will result in the backwards when the engine iscrankshaft throws splashing in the stopped. The pipes must beoil. This splashing contributes to supported and have flexibleexcessive foaming of the oil and connections at the engine andcan cause dynamic problems in theCaterpillar® Page 21All rights reserved.

Lubrication Systems Application and Installation Guideauxiliary connecting points. Provide Although the relationship betweenvent and drain connections at the lubricating oil volume and oil changehigh and low points in the system. interval is a reasonable guide, oil analysis should be used to determineSuction Strainer oil change intervals for the increased Install a suction strainer in the capacity.piping between the remote sump Auxiliary Oil Sump Systemand the lube oil circulating pumps. ConsiderationsThis protects the pumps from largeparticles that may collect in the • The oil source line should betank. It should have a stainless steel connected to the auxiliarybasket with 650 micron (0.025 in) tank as close to the engine oilperforations and magnetic inserts. pump as possible.A differential pressure gauge shouldbe used to indicate when manual • The auxiliary oil sump tankcleaning of the strainer is required. must be full prior to starting the engine and remain full atAuxiliary Sump Tank all times. If longer oil change periods are • Upon engine start, thedesired, consider the use of an auxiliary oil sump overflows,auxiliary oil sump tank. Refer to returning the oil to the engine;Figure 10. Unlike remote sump tanks exactly compensating for thewhich replace the engine oil sumps, oil removed through the oilauxiliary sump tanks supplement the source line to the auxiliaryengine oil sump. The auxiliary oil tank.sump is used in addition to theengine’s oil sump. • Use hoses and fittings as described in Remote Sump An engine’s oil change interval is Tanks. An orifice may bedirectly proportional to its total oil required in the line to achievequantity, all other factors remaining appropriate oil flow for theequal. The oil change interval can be system.doubled by adding an auxiliary sumpwith the same capacity as the • A check valve should beengine mounted oil sump. This installed in the oil pumpincreased capacity doubles the discharge line. Set the valveamount of oil available to be to open at 75% of thecontaminated, diluted, or neutralized measured pressure at the lineand allow proportionately longer connection point, when theperiods between oil changes. engine is at operating temperature and maximumNote: Auxiliary sump tanks can operating speed.increase the interval between oilchanges. They do not increase theinterval between filter changes.Page 22 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systems Auxiliary Oil Sump Connection Schematic Figure 10Caterpillar® Page 23All rights reserved.

Lubrication Systems Application and Installation GuideAdditional Considerations and the ship to reach port for engine repairs. This section generally describesadditional systems and components Guidelines for emergencythat are not part of Caterpillar lubricating oil system operation:standard or optional lubricationsystems. However, these systems • Keep pressure drops to amay be required for successful minimum by using short, lowengine or package application and restriction lines.installation. • Use a line size at least asSupplemental Bypass Filter large as the engine connectionSystems point. If supplemental centrifugal or • Install a low restrictionabsorptive bypass filters are used, strainer in front of thethe system must have a non- emergency oil pump.drainback feature in place for engineshutdown. A 3.175 mm (0.125 in.) • Install a low restriction checkmaximum diameter orifice, limiting valve between the emergencyflow to 7.57 lpm (2 gpm), must also pump discharge and thebe used. Refer to engine general engine inlet connection.dimension drawings forrecommended bypass filter supply • Use a pressure limiting valvelocation and oil return to the in the emergency system setcrankcase. at the maximum oil pressure limit of the engine.Emergency Systems Transmissions Many standby generators, firepump and marine applications Marine classification societies thatrequire the capability to connect an require emergency lubricating oilemergency lubricating oil pump into pumps for single propulsion enginethe engine’s lube oil system. Many applications also require emergencyCaterpillar engines can be provided lubricating oil pumps for thewith these optional connections associated marine transmissions towhen necessary. meet the unrestricted service classification. In these cases, refer This is a specific requirement of to the transmission manufacturer’smarine classification societies for operation manual for instructions, oilseagoing single propulsion engine flow and pressure requirements andapplications. The purpose is to follow the guidelines listed above.ensure lubricating oil pressure andcirculation in the event of an engine Piping Systems and Flexiblelubricating oil pump failure. The Hosesemergency oil pump allows thesingle propulsion engine to operate In addition to the emergency lubricating oil system requirementsPage 24 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systemsdescribed above, marine direct gravity feed from theclassification societies have specific centrifuge.requirements relating to thematerials used in the installation There are two basic methodsof these systems. Although these for configuring the lubricating oilsystems are not typically offered centrifuge system. The first methodby Caterpillar, they are still critical is to supply each engine with itsto the overall success of a given own centrifuge.installation. Therefore, piping systemand flexible hose material Figure 14 and Figure 15 includeconsiderations are discussed in the a typical lubricating oil centrifugePiping Systems section of this guide. system. The second method is to service up to four engines with aLubricating Oil Centrifuges single lube oil centrifuge. Certain requirements must be met in order Caterpillar engines are provided to use a single centrifuge forwith attached lubricating oil filters multiple engines. These requirementsand in some cases, centrifugal are:bypass filters. However, customer-supplied centrifuges or separators • All precautions must be takencan also be installed in certain to minimize sump cross-applications. Lubricating oil contamination. This includescentrifuges are commonly used in locating the changeovermarine and offshore applications, manifold at the centrifuge.where the availability of clean oilmay be limited. • Programmable Logic Controllers (PLC) and Caterpillar does not offer a automatic valves must becentrifuge as part of its standard used for the changeover ofpackage and recommends that a sumps.reputable centrifuge manufacturer beconsulted to ensure proper • No more than four oil sumpsequipment selection, application and per centrifuge may be used.installation. Centrifuge size istypically based on the power output • A redundant centrifuge andof the engine. Due to frequent the necessary piping andcleaning requirements, the centrifuge valves, must be incorporatedshould be self-cleaning. Solid bowl into the design of theseparators must not be used for lube application.oil service. The fresh water andcontrol air requirements for the • The centrifuges should becentrifuge should be specified by the oversized.manufacturer. The sludge dischargeprocess should be automatic, with • Consult Caterpillar for athe sludge tank arranged to accept specific project or application. The centrifuge should take oil from the rear of the engine and return it to the front of the engine, so that clean oil is as close to the engine oilCaterpillar® Page 25All rights reserved.

Lubrication Systems Application and Installation Guidepump suction as possible. Shutoff heating oil, heater skin temperaturesvalves can be provided for customer must not exceed 150°C (300°F)connection, but flexible connections and heater elements must have amust be provided by the customer. maximum heat density of 1.24 w/cm2 (8w/in2).Centrifuge Supply Pump Sample Points The centrifuge supply pump canbe either direct driven from the Check the centrifuge efficiencycentrifuge or electric motor driven, by drawing samples from pointsbut is typically part of the centrifuge upstream and downstream of thepackage and is sized accordingly. centrifuge. Figure 11 shows a typical sampling connection.PreHeater Figure 11 The centrifuge preheater is also apart of the centrifuge package and Lube Oil Storage and Transferits size is determined by pump Systemscapacity and required temperaturerise between the sump and the final Figure 13 and Figure 14, at thecentrifuge. The final outlet end of this section, show typicaltemperature is determined by the piping schematics for an operationalcentrifuge manufacturer, but will lubricating oil storage and transferrange between 80° and 90°C (176° system.and 194°F), depending on the gradeand type of oil used. Other heater The system consists of threesizing considerations are: storage tanks, a centrifuge system and a transfer pump arranged as • Oil temperature should be follows: 98°C (210°F) for engines Clean Oil centrifuging during engine operation. Clean oil from the storage tank is piped to supply the engine sump • If the centrifuges operate (or sumps), either by gravity, via the when the engines are not centrifuge, or by the transfer pump. running the heater must be oversized to account for the heat normally supplied by an operating engine. • The heater must be thermostatically controlled to maintain the oil temperature to the centrifuge within 2°C (±4°F).Note: Heating elements in directcontact with lubricating oil are notrecommended due to the danger ofcoking. To avoid coking whenPage 26 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication SystemsDirty Oil Storage Tanks Dirty lube oil is removed from the Each tank should be configuredengine sump (or sumps), by the with the following:transfer pump and discharged to thedirty lube oil storage and settling • Fill Porttank. • Vent LocationRenovated Oil Contaminated oil can be cleaned • Local Sounding Portusing the lubricating oil centrifuge • Gauge Glassand discharged to the renovated oiltank. • Heating CoilTransfer Pumps • Thermometer (with well) The lube oil transfer pump is used • Transfer Pump Suction Portto move oil from the engine sump(or sumps), the clean oil storage • Drain Porttank, the dirty oil storage andsettling tank and the renovated oil • Steam Blowout Porttank. The pump can discharge oil tothe dirty oil storage and settling • Manholetank, the sludge tank and the enginesump (or sumps). • Ladder (if required) The transfer pump should be a Heating coils should raise thegear-type pump and include a relief lubricating oil temperature tovalve. Transfer pump sizing is based approximately 38°C (100°F). Whenon project specific requirements. heating with steam or water, theThe following transfer pump heating coils must be manufacturedcharacteristics are provided only from corrosion resistant material.as a sample. Note: Heating elements in direct • Pump Flow Rate – 190 lpm contact with lubricating oil are not (50 gpm) recommended due to the danger of coking. To avoid coking when • Pump Pressure - 345 kPa heating oil, heater skin temperatures (50 psi) must not exceed 150°C (300°F) and heater elements must have a • Operating Fluid Temp. – maximum heat density of 1.24 130°C (266°F) w/cm2 (8w/in2). • Viscosity for sizing electric The engine can be filled with oil motor – 1000 cSt from the storage tank via the centrifuge, by the transfer pump (with a strainer), through the forward or aft simplex drain valves, or through the filling cap located on the engine crankcase cover.Caterpillar® Page 27All rights reserved.

Lubrication Systems Application and Installation Guide Many variables go into establishing Tank Volumes Liters Gallonstank capacity. The number of Lubricating Oil 7500 2000engines installed, sump volume and Storage Tank 3750 1000lubricating oil consumption are just a Dirty Oil Storage 3750 1000few. The lubricating oil storage tank and Settling Tankcapacity table is provided only as a Renovated Oilsample to show the size relationship Storage Tankbetween tanks.Page 28 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systems Remote Lube Oil Sump ArrangementCaterpillar® Figure 12All rights reserved. Page 29

Lubrication Systems Application and Installation Guide Remote Dry Sump SystemFigure 13 Caterpillar® All rights reserved.Page 30

Application and Installation Guide Lubrication Systems3600/G3600 Lube Oil System - Wet Sump DiagramCaterpillar® Figure 14All rights reserved. Page 31

Lubrication Systems Application and Installation Guide 3600/G3600 Lube Oil System - Dry Sump DiagramFigure 15 Caterpillar® All rights reserved.Page 32

Application and Installation Guide Lubrication SystemsLubricating Oil Selection Bearing failure, piston ring sticking and excessive oil consumption areclassic symptoms of oil-related engine failure. There are numerous ways toavoid them. Three of the most important are S•O•SSM, regular maintenanceof the lubrication system and the use of correct lubricants. Taking thesemeasures can mean the difference between experiencing repeated oil-relatedengine failure and benefiting from a productive and satisfactory engine life. The following information describes the properties of lubricating oil, as wellas the consequences of oil contamination and degradation. Also discussedare methods of identifying contamination and degradation and preventivemeasures to help you protect your engine against the devastating effectsof oil-related engine failure. Please note that this information is supplemental and in no way replacesspecific lubricating oil requirements for your application; nor does it precludethe need for oil analysis. For model-specific information, refer to the Operation and MaintenanceManual for each engine. SECTION CONTENTSProperties..........................34 Monitoring Quality ............. 38• Characteristics of • S•O•SSM Lubricating Oil • Oil Analysis• Components of Lubricating Contamination ................... 39 Oil • Contaminants and• Caterpillar Line of Oils Indications• Understanding TBNConsumption .....................37• Consumption Estimate Formula• Consumption as an Overhaul IndicatorCaterpillar® Page 33All rights reserved.

Lubrication Systems Application and Installation GuideProperties may be low, operating engines can be subjected to normal oilViscosity temperatures because of temperature regulated components. Viscosity is the property of The higher viscosity fluids willresistance to flow in a fluid. Oil provide better protection to allviscosity is its thickness or components during the full dayresistance to flow. Viscosity is work cycle.directly related to how well an oilwill lubricate and protect surfaces Additivesthat contact one another. Oil mustprovide adequate supply to all Lubricating oil consists of amoving parts, regardless of the mixture of base oil fortified withtemperature. The more viscous certain additives. Depending on the(thicker) an oil is, the stronger the oil type of base, paraffinic, asphaltic,film it will provide. The thicker the naphthenic or intermediate (whichoil film, the more resistant it will be has some of the properties of theto being wiped or rubbed from former), different additivelubricated surfaces. Conversely, oil chemistries are used to strengthenthat is too thick will have excessive or modify certain characteristics ofresistance to flow at low the base oil.temperatures and so may not flowquickly enough to those parts The most common additives arerequiring lubrication. It is therefore detergents, oxidation inhibitors,vital that the oil has the correct dispersants, alkalinity agents, anti-viscosity at both the highest and the wear agents, pour-point dispersantslowest temperatures at which the and viscosity improvers.engine is expected to operate. • Detergents help clean the Oil thins out as temperature engine by reacting withincreases. The measurement of the oxidation products to stop therate at which it thins out is called formation of insolublethe oil’s viscosity index (VI). New compounds.refining techniques and thedevelopment of special additives • Oxidation inhibitors helpwhich improve the oil’s viscosity prevent increases in viscosity,index help retard the thinning organic acids andprocess. carbonaceous matter. The minimum temperature for the • Dispersants help preventviscosity grade provides guidelines sludge formation by keepingfor the lowest starting temperature contaminants in suspension.with a cold soaked engine.Caterpillar recommends using the • Alkalinity agents helphighest viscosity oil possible. Even neutralize acids.though the ambient temperaturePage 34 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication Systems • Anti-wear agents reduce TAN monitoring is especially friction by forming a thin film important in engines using landfill on metal surfaces. gas. • Pour-point dispersants keep Cleanliness the oil fluid at low temperatures by preventing Normal engine operation generates the growth and agglomeration a variety of contamination, ranging of wax crystals. from microscopic metal particles to corrosive chemicals. If the engine oil • Viscosity improvers help is not kept clean through filtration, prevent the oil from becoming this contamination would be carried too thin at high temperatures. through the engine via the oil.Total Base Number (TBN) Oil filters are designed to remove these harmful debris particles from Understanding TBN requires some the lubrication system. Use of a filterknowledge of fuel sulfur content. beyond its intended life can result inMost diesel fuel contains some a plugged filter.degree of sulfur. One of lubricatingoils functions is to neutralize sulfur A plugged filter will cause theby-products, retarding corrosive bypass valve to open, releasingdamage to the engine. Additives in unfiltered oil. Any debris particlesthe oil contain alkaline compounds in the oil will flow directly to thewhich are formulated to neutralize engine. When a bypass valvethese acids. The measure of this remains open, the particles thatreserve alkalinity in an oil is known were previously trapped by the filteras its TBN. Generally, the higher may also be flushed from it and thenthe TBN value, the more reserve through the open bypass valve. Filteralkalinity or acid-neutralizing plugging can also cause distortion ofcapacity the oil contains. the element. This happens when there is an unacceptable increase in The TBN value of an oil degrades the pressure difference between theduring operation over time and can outside and inside of the filterbe used as a potential indicator of element. Distortion can progresswhen to change oil. to cracks or tears in the paper. This again allows debris to flow intoTotal Acid Number (TAN) the engine where it can damage components. High combustion temperatures innatural gas engines, especially lean- Engine Oil Selectionburn fuel systems, can rapidlydeplete TBN and raise acid content Due to significant variations inin the oil. A TAN value higher than quality and performance ofthat of new oil may indicate commercially available oils,oxidation or contamination. Caterpillar has developed its own line oil products for Caterpillar engines.Caterpillar® Page 35All rights reserved.

Lubrication Systems Application and Installation Guide The Caterpillar line of oils include multi-grade oils are not appropriate.Diesel Engine Oils (DEO), Natural For instance, SAEO is recommendedGas Engine Oils (NGEO) and Special for engines equipped withApplication Engine Oils (SAEO). DEO mechanical unit injection. Additionaland NGEO are available in various reference on lubricating oil isviscosity grades to cover a broad available in the sources listed at therange of operating temperatures. end of this guide.SAEO is used for products wherePage 36 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication SystemsConsumption Consumption as an Overhaul Guide Oil consumption is a consequenceof normal engine operation. This oil Oil consumption increases overneeds to be replenished between time due to normal wear. Therefore,maintenance intervals. Typical oil oil consumption rate can serve as anconsumption figures are provided in indicator of wear and used to predictthe Technical Information Appendix the need for an overhaul. Caterpillar,for the purpose of predicting the however, recommends taking a morequantity and cost of make up oil, comprehensive approach. Trendingas a part of total operating costs. engine output, measuring specificIn practice, many factors will affect fuel consumption and measuringoil consumption including load, oil cylinder pressure are better toolsdensity, oil additive packages and for determining the need for anmaintenance practices. overhaul. The rate of oil consumption is Oil Change Intervaltypically reported as brake-specificoil consumption (BSOC) so it is Caterpillar recommendations forindependent of operating load. To oil change periods are published inconvert to a volume per hour basis, Operation and Maintenance Manualsthe engine load and oil density must for each engine. As an alternative,also be known. change intervals can be established by a comprehensive maintenance The following formula may be used management program that includesto estimate oil consumption. oil condition analysis. Caterpillar offers such a program. It is theL/hr = Engine bkW x Load Factor (%) x BSOC S•O•SSM services program. (g/bkW-hr) Density of Oil** BSOCgal/hr = Engine bhp x Load Factor (%) x (lb/bhp-hr) Density of Oil****Typical engine oil has a density of 899g/L (7.5 lb/gal).Caterpillar® Page 37All rights reserved.

Lubrication Systems Application and Installation GuideMonitoring Quality the various wear elements can be established for the particular engine. Monitoring lubrication quality can Impending failures can be identifiedmaximize the life of engine oil and when trend lines deviate from theprovide optimum protection for the established norm.internal engine components. Wear analysis is limited toS•O•SSM detecting component wear and gradual dirt contamination. Failures The Caterpillar tool for oil analysis due to component fatigue, suddenis S•O•SSM, which is part of the loss of lubrication or suddenS•O•SSM services program. This ingestion of dirt occur too rapidlyprogram determines oil change to be predicted by this type of test.intervals based on condemning limitsand trend analysis established for Oil Condition Analysisthe engine. It also looks for thepresence of oil contaminants, which Oil condition analysis determinesare used to analyze the condition of the amount of contaminants, suchthe engine, indicate shortcomings in as soot and sulfur, oxidation andengine maintenance and detect the nitration products. Results can befirst signs of excessive wear. used to customize (reduce, maintain, or extend) oil change intervals for Sampling intervals differ for particular conditions andvarious engines and applications. applications.Refer to the Operation andMaintenance Manual for appropriate Additional Testsintervals or contact your Caterpillardealer. Chemical and physical tests detect water, fuel and antifreeze in the oil The S•O•SSM testing includes wear and determine whether or not theiranalysis, oil condition analysis and concentrations exceed establishedadditional chemical and physical limits.tests. Contact your Caterpillar dealerfor complete information andassistance on the S•O•SSM servicesprogram.Wear Analysis Wear analysis monitors componentwear rate by identifying andmeasuring concentrations of wearelements in oil. Based on knownnormal concentration data,maximum limits of wear elementsare established. After three oilsamples are taken, trend lines forPage 38 Caterpillar® All rights reserved.

Application and Installation Guide Lubrication SystemsContamination Silicon, Lead, Aluminum, Tin The following are examples of This combination indicates dirt intypical contaminants and the affect the lower portion of the engine,they have on the condition of your possibly leading to crankshaft andengine. Engine operating conditions bearing wear.can also play a major role in the typeand degree of oil contamination. For Chromium, Molybdenum,a more thorough discussion of this Aluminumtopic, refer to Applied FailureAnalysis – Oil and Your Engine, This combination can lead to ringMedia Number SEBD0640. and piston wear, resulting in blow- by, increased oil consumption andCopper oil degradation. A high concentration of copper Aluminumindicates thrust washer or bushingwear. This can be a critical concern. Concentrations of aluminum suggestSilicon bearing wear. Relatively small increases in the levels of this Above normal readings of silicon element should receive immediatecan indicate a major problem. Oil attention because, once rapid wearloaded with silicon becomes, in begins, the crankshaft may produceeffect, a grinding compound which large metal particles which willcan remove metal from any number become trapped in the oil filters.of parts during operation. IronSodium, Silicates, CarboxylicAcid Base Iron can come from any number of sources. It can also appear as A sudden increase in sodium, rust after engine storage. Frequently,silicates, or carboxylic acid base when accompanied by a loss ofreadings indicate inhibitor leaking oil control, increases in ironfrom the cooling system. Inhibitor contamination indicate severe linermay indicate antifreeze in the wear.system which can cause oil tothicken and become like sludge, Sootleading to piston ring sticking andfilter plugging. A high soot content is not usually the direct cause of failure. SolidSilicon, Chromium, Iron, particles do not dissolve in the oil,Aluminum causing the filters to become plugged and depleting dispersant A combination such as this signals additives. Soot indicates a dirty airdirt entry through the air induction cleaner, engine lug, excessive fuelsystem, possibly causing ring and delivery, or repeated acceleration inliner wear.Caterpillar® Page 39All rights reserved.

Lubrication Systems Application and Installation Guidethe improperly set rack limiter Caterpillar®(smoke limiter). It can also indicate All rights reserved.a poor quality fuel.Water Water combined with oil willcreate an emulsion which will plugthe filter. Water and oil can alsoform a dangerous metal corrodingacid. Most instances of watercontamination are the result ofcondensation within the crankcase.More serious contamination occurswhen a leak in the cooling systemallows water to enter from outsidethe engine oil system.Fuel Fuel contamination decreases theoil’s lubricating properties. The oilno longer has the necessary filmstrength to prevent metal-to-metalcontact. This can lead to bearingfailure and piston seizure.Sulfur The presence of sulfur signalsdanger to all engine parts. The typeof corrosive wear attributed to highsulfur content can also causeaccelerated oil consumption. Themore fuel consumed during an oilchange interval, the more sulfuroxides are available to form acids.Therefore, an engine working underheavy loads should have its oilchecked more often, including itsTBN, which relates directly to anoils ability to neutralize sulfur by-products. Fuel sulfur damage cancause piston ring sticking andcorrosive wear of the metal surfacesof valve guides, piston rings andliners.Page 40

Application and Installation Guide Lubrication Systems Page 41Reference Material The following information isprovided as additional reference tosubjects discussed in this manual. The following service publicationsprovide comprehensive informationon lubricating oil, as well as otherfluids used in Caterpillar engines. Although Caterpillar brand oil isthe only oil Caterpillar endorses,these guides also provide minimumrequirements for commerciallyavailable oils. SEBD0640 Oil And Your Engine LEBW4958 Application and Installation Guide, Crankcase Ventilation SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations SEBU6400 Caterpillar Gas Engine Lubricant, Fuel and Coolant Recommendations SEBU7003 3600 Diesel Engine Fluids Recommendations for Lubricants, Fuels and Coolants PEDP7036 S•O•SSM Fluid Analysis WECAP Web Engineering Cataloging and Procuring websiteCaterpillar®All rights reserved.

LEBW4957-01 ©2008 Caterpillar® Printed in U.S.A. All rights reserved.