Usage:
Customers sometimes want to convert on-highway truck and on-highway vehicle engines to improve fuel economy, change horsepower output or change operating speed. It is imperative that the conversion be done properly to attain proper performance and adequate life, as well as maintain emission certification.
Caterpillar truck engines sold in the United States, Canada, and certain other countries are certified as meeting U.S. EPA emission standards. The Environmental Protection Agency (EPA) sets these standards under the provisions of the Clean Air Act. The law expressly prohibits a manufacturer, dealer, or fleet operator from changing an engine to a non-certified setting or configuration. In the United States, neither Caterpillar, the Original Equipment Manufacturer (OEM), a Caterpillar dealer, an OEM serviceman, nor a fleet serviceman can legally make changes to a Caterpillar engine that would alter its emission characteristics. This includes not only fuel and speed settings, but also the torque control group, air-fuel ratio control setting, engine timing, and other parts defined as emission related under the law.
The prohibition also includes recommending or informing people how to make such illegal changes. Violation of this law carries fines and/or penalties of up to $10,000 for each change.
Although tampering is strictly prohibited, persons MAY convert a certified heavy-duty engine to a different certified configuration. In order to avoid violating the Federal tampering prohibition, however, the conversion performed must result in an engine that is IDENTICAL to a CERTIFIED CONFIGURATION of the SAME MODEL YEAR or LATER MODEL YEARS. The converted engine must be identical to the certified configuration with regard to all emission-related parts, and engine calibrations. Emission control labels on the engine must also be changed to accurately describe the converted engine.
While Caterpillar can not be responsible for the actions of its independent dealers or customers, it provides accurate and complete information concerning conversions or modifications for motor vehicle engines.
Example of SIMS report form.
Information on frequently requested conversions will be published as it becomes available. The general procedure to convert from one certified configuration to another is:
1. The customer requests a change to the power setting and/or configuration of his certified engine.
2. Refer to Caterpillar published information on engine conversions. Follow the instructions contained in the published information to convert the customer's engine.
3. If the engine change requested by the customer is not contained in any Caterpillar published information: In the United States and Canada contact a Service Engineering G.O. Engine Product Analyst. In Caterpillar subsidiaries contact the appropriate Service/Service Engineering group. Describe the changes which the customer has requested, along with engine serial number and arrangement number.
4. The Engine Product Analyst determines if the configuration requested was built in the same model year or later (calendar year for Caterpillar engines) as the engine which is in the vehicle.
5. If the configuration and/or horsepower requested were not certified, the Engine Product Analyst shall instruct the dealer that the conversion can not be made as requested by the customer.
6. If the configuration and/or horsepower requested were certified, then the Engine Product Analyst shall instruct the dealer how to correctly convert the engine. The dealer shall make a SIMS report (see the illustration) any time an approved conversion is made, to be included in the engine history. When an approved change is made, the engine data plate should be restamped with the proper new information (i.e. arrangement number, rack setting, high idle, fuel setting, horsepower, and full load RPM). If no room is available, obtain a new plate from Caterpillar Engine Division Service and stamp accordingly. This is an important reference for future service work to assure correct replacement parts and settings are used to keep the engine in its certified configuration.
7. If the conversion affects the Caterpillar EPA engine family, EPA engine code, or model year, the Engine Product Analyst will inform the dealer how to correctly convert the engine and obtain a new Engine Exhaust Emission Control Information (EEECI) label. After completing the modifications, remove the old EEECI label and discard. Install the new EEECI label. Be sure to stamp the engine data plate with the proper new information and complete a SIMS report (see the illustration).
Servicemen who work on governors must always seal the governor to assure against incorrect resetting. Use the 5P1660 or 8S8157 Governor Sealing Tool Group and the seals for fastening the seals on governors.
The complete conversion to the new arrangement must be made. Partial conversion results in an uncertified engine.
If a change to a setting is made that does not have a factory approval, engine damage, performance problems and/or emission violations resulting from the use of non-approved settings are the responsibility of the user or dealer making the change.