3408 TRUCK ENGINE Caterpillar

NOTE: INFORMATION IN THIS SECTION DOES NOT APPLY OUTSIDE THE UNITED STATES OF AMERICA

Foreword

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.

Emission Control

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.

Maintenance Recommendations

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 high and low idle RPM at the first oil change and every 50,000 miles (80 000 km) or 1,250 service hours thereafter. 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 thermostats, gaskets and seals 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 (322 000 km) check bearing condition and rebuild or replace as necessary.

Keep Maintenance Records

Keep records to show proof of compliance with the required maintenance practices and intervals.

The following types of documents are generally accepted as proof of maintenance or repair. All documents must show date, mileage, unit number, vehicle and/or engine serial number. If the vehicle is sold within the five year/100,000 mile (161 000 km) useful life, transfer the records with the vehicle.

1. Dealer work order or itemized bill

2. Owner's repair order

3. Owner's vehicle log

4. Receipts

Supplemental California Emission Warranty

EFFECTIVE WITH ENGINES DELIVERED TO THE INITIAL USER ON OR AFTER JANUARY 1, 1980

Caterpillar warrants to the initial user and each subsequent user of Diesel Truck Engines (powering on-highway trucks) that such engines sold by it for installation in vehicles to be registered in the State of California conform at the time of sale with regulations of the California Air Resources Board applicable at time of manufacture for the time periods and subject to the terms and conditions of the Caterpillar Warranty for Emission Related Components Form No. FEGO2590-00 set forth page 81 hereof. This supplemental warranty covers the following parts:

Fuel injection system

Air/fuel ratio controller

Intake manifold

Turbocharger

During the term of this supplemental warranty, Caterpillar will provide, through a Caterpillar dealer or other establishment authorized by it, diagnostic labor that leads to the determination that a Caterpillar engine emission part is defective and will repair or replace at its option all other engine components damaged as a result of the failure of such defective engine emission part. User is encouraged to keep adequate maintenance records but the absence of such, in and of itself, will not invalidate this warranty.

For information regarding an authorized service facility, call toll free 800-447-4986. If an authorized service facility is not available in the event of an emergency, warranty service may be performed by an individual or automotive repair establishment, and Caterpillar will reimburse the user for the cost of such service as is covered under this supplemental warranty up to an amount equal to Caterpillar's suggested list price for parts used and labor charged based on Caterpillar's recommended time allowance for the warranty repair at the customary hourly labor rate in that geographic area. As a condition of reimbursement, replaced parts and receipted invoices must be presented at a place of business of a Caterpillar dealer or other establishment authorized by Caterpillar.

Customer Assistance

Caterpillar wishes to ensure that the Emission Control Systems Warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Systems Warranty, call or write: