Usage:
Required Maintenance and Warranty Information
Information in This Section Does Not Apply Outside the United States of America
The United States Environmental Protection Agency has issued regulations to establish emission standards and ensure that new motor vehicle engines will perform within prescribed limits. These regulations require new motor vehicle and new motor vehicle engine manufacturers to furnish maintenance instructions necessary to ensure the proper functioning of the engine within these limits. This publication has been prepared for this purpose.
MAINTENANCE, REPLACEMENT, OR REPAIR OF THE EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY AUTOMOTIVE REPAIR ESTABLISHMENT OR INDIVIDUAL USING ANY AUTOMOTIVE PART WHICH HAS BEEN CERTIFIED PURSUANT TO EPA REGULATIONS.
Authorized dealers are recommended for major maintenance and repair work as they are staffed with trained servicemen, necessary tools and are aware of the latest service methods and procedures. Owners and others who desire to perform their own work should purchase a Service Manual and obtain current information from their Caterpillar dealer.
The combustion process of a diesel engine produces exhaust products such as smoke (visible), hydrocarbons and oxides of nitrogen (invisible). The dark smoke emitted by a diesel engine is soot or carbon particles and even in low concentration makes the diesel exhaust highly visible and offensive to most people. Every effort must be made to eliminate smoke through proper maintenance and operation.
Under certain conditions oxides of nitrogen react with certain hydrocarbons to form smog which can become irritating and toxic if large concentrations accumulate. Concentrations of this pollutant combined with pollution of other sources all contribute to the total air quality problem.
As an engine manufacturer, our goal is to see that environmental standards are met with a minimum additional complexity or cost to the product. Throughout the years, continuing research and design improvements have been directed at minimizing exhaust emissions. Caterpillar has incorporated items such as -
TURBOCHARGING: Reduces exhaust noise and provides more air per cylinder allowing the fuel to burn more efficiently. These engines are integrally designed for turbocharging.
FUEL-AIR RATIO CONTROL FOR TURBOCHARGED ENGINES: Limits the amount of fuel during acceleration to minimize smoke levels.
RECOMMEND FUELS, LUBRICATING OILS AND MAINTENANCE SCHEDULES: To assure minimum exhaust emissions.
Caterpillar Truck Engines are certified by the United States Environmental Protection Agency to comply with smoke and gaseous emission standards prescribed by Federal laws at the time of manufacture.
Efficiency of emission control and good engine performance depend on adherence to proper operation and maintenance recommendations, use of recommended fuels and lubricating oils. It is recommended that major adjustments and repair be entrusted to your authorized dealer.
Various chemical fuel additives are commercially available that claim to reduce visible smoke. Although additives have been used by individuals to solve some isolated smoke problems in the field, they are not recommended for general use. Federal smoke regulations require the certification of engines without a smoke depressant.
The corrective steps taken immediately on discovery of worn parts, which may affect emission levels, will help assure proper operation of emission control systems. The use of genuine Caterpillar parts is recommended. Suppliers of non-Caterpillar parts must assure the user that the use of such parts will not adversely affect emission levels.
Regular service intervals, along with special emphasis on the following items, are necessary to keep exhaust emissions within acceptable limits for the useful life of the engine. Refer to the Lubrication and Maintenance Section of this Operation Guide for details and maintenance schedule. If the engine is operating under severe conditions, adjust maintenance schedule accordingly. See your authorized dealer to help analyze your specific maintenance schedule.
NOTE: For flexibility in meeting various applications and emission requirements, these engines are offered either with a direct injection (DI) fuel system or with a precombustion chamber (PC) fuel system. Identification of the fuel system used on the engine is attached to the fuel injection pump housing.
The following explanation of required emission related component maintenance has been keyed by number to correspond with item number in the maintenance chart.
- 1. COOLANT - LEVEL AND PROTECTION: Check the engine coolant level daily with the engine stopped and cool. Release cooling system pressure before checking. Fill to proper level with permanent-type antifreeze and water as free as possible from scale forming minerals. DO NOT USE SOFTENED WATER.
- 2. CRANKCASE LUBRICATING OIL LEVEL: Check oil level before starting engine and when refueling. Check with the engine stopped. Add oil of proper classification and grade as to starting temperatures.
- 3. CRANKCASE LUBRICATING OIL: Change oil according to Lubrication and Maintenance Chart. After filling to proper level start engine and check for leaks.
- 4. CRANKCASE LUBRICATING OIL FILTER: Change filters at each oil change period. Check for leaks after engine is started.
- 5. AIR CLEANER: Excessive engine exhaust smoke or loss of power may indicate the need for servicing. Never service the air cleaner while the engine is running. Service as recommended in Lubrication and Maintenance Chart or at the interval recommended by the truck manufacturer. Inspect air inlet and exhaust piping for damage which may cause restriction or leaks.
- 6. CRANKCASE BREATHERS: Remove breather elements and wash with clean solvent every 30,000 miles (48 000 km). Inspect gaskets and replace if necessary.
- 7. GOVERNOR: Check the engine full load speed and low idle every 50,000 miles (80 000 km) or 1,250 service hours. The engines were tested for certification at the specified speeds and should be operated within these limits. It is recommended these adjustments be made by an authorized dealer.
- 8. FUEL-AIR RATIO CONTROL: The fuel-air ratio control is a device to control the smoke emission of an engine during its operation when low inlet manifold pressure exists. Low inlet manifold pressure occurs during operation at low power output due to low engine speed or low torque output. During this type of operation the fuel-air ratio control regulates the maximum fuel injected into each cylinder. If the controlling diaphragm within the fuel-air ratio control should rupture, the fuel system will be restricted and same as it would be with low inlet manifold pressure. Slow engine response and low power may indicate a need for adjustment or repair. Authorized dealers are equipped with the necessary tools, personnel and procedures to perform these services.
- 9. VALVE LASH: Check and adjust valve lash in accordance with procedures given in the topic VALVE ADJUSTMENT.
- 10. FUEL INJECTION NOZZLES: Defective fuel nozzles will normally cause the engine to misfire, run rough and smoke. Check and replace if necessary at interval given in the Required Maintenance Schedule. Fuel nozzles can be tested by an authorized dealer.
- 11. THERMOSTATS: Replace the thermostat, gasket and seal annually. It is preferable this be done when preparing for cold weather operation.
- 12. FUEL FILTER ELEMENT: Replace final fuel filter and clean primary fuel filter as instructed in the Lubrication and Maintenance Section of the Operation Guide.
- 13. TURBOCHARGER: Check for any unusual sound or vibration in the turbocharger. Inspect inlet and exhaust piping and connections. Every 200,000 miles (320 000 km) check bearing condition and rebuild or replace as necessary.