3516C Generator Sets Caterpillar

Refer to Special Publication, SEBU6251, "Cat Commercial Diesel Engine Fluids Recommendations" for additional information.

Refer to this Operation and Maintenance Manual, "Severe Service Application" for information about operating an engine in a severe service application.

Note: Instructions for the installation of the filter are printed on the side of each Cat spin-on filter. For filters that are not Cat filters, refer to the installation instructions that are provided by the supplier of the filter.

Diesel Engine Oil

Cat DEO (Diesel Engine Oil)

Due to significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations:

• Cat DEO-ULS (Diesel Engine Oil Ultra Low Sulfur) (SAE 5W-40)

• Cat DEO-ULS (Diesel Engine Oil Ultra Low Sulfur) (SAE 10W-30)

• Cat DEO-ULS (Diesel Engine Oil Ultra Low Sulfur) (SAE 15W-40)

Engine Oil

Cat oils have been developed and tested in order to provide the full performance and life that has been designed and built into Cat engines.

Cat DEO-ULS or oils that meet the Cat ECF-3 specification and the API CJ-4 are required for use in the applications listed below. Cat DEO-ULS and oils meeting Cat ECF-3 specification and the API CJ-4 and ACEA E9 oil categories have been developed with limited sulfated ash, phosphorus, and sulfur. These chemical limits are designed to maintain the expected aftertreatment devices life, performance, and service interval. If oils meeting the Cat ECF-3 specification and the API CJ-4 specifications are not available, oils meeting ACEA E9 may be used. ACEA E9 oils meet the chemical limits designed to maintain aftertreatment device life. ACEA E9 oils are validated using some but not all ECF-3 and API CJ-4 standard engine performance tests. Consult your oil supplier when considering use of an oil that is not Cat ECF-3 or API CJ-4 qualified.

Failure to meet the listed requirements will damage aftertreatment-equipped engines and can negatively impact the performance of the aftertreatment devices. The Diesel Particulate Filter (DPF) will plug sooner and require more frequent DPF ash service intervals.

Typical aftertreatment systems include the following:

• Diesel Particulate Filters (DPF)

• Diesel Oxidation Catalysts (DOC)

• Selective Catalytic Reduction (SCR)

• Lean NOx Traps (LNT)

Other systems may apply.

S·O·S Services Oil Analysis

Caterpillar has developed a maintenance tool that evaluates oil degradation. the maintenance management also detects the early signs of wear on internal components. The Cat tool for oil analysis is called S·O·S Oil Analysis and the tool is part of the S·O·S Services program. S·O·S Oil Analysis divides oil analysis into four categories:

• Component wear rate

• Oil condition

• Oil contamination

• Identification of oil

These four types of analysis are used to monitor the condition of your equipment. The four types of analysis will also help you identify potential problems. A properly administered S·O·S Oil Analysis program will reduce repair costs and the program will lessen the impact of downtime.

The S·O·S Oil Analysis program uses a wide range of tests to determine the condition of the oil and the lubricated compartment. Guidelines that are based on experience and a correlation to failures have been established for these tests. Exceeding one or more of these guidelines could indicate serious fluid degradation or a pending component failure. A trained person at your Cat dealer should make the final analysis.

Refer to Special Publication, SEBU6251, "Cat Commercial Diesel Engine Fluids Recommendations" in order to obtain additional information about S·O·S Services oil analysis. You can also contact your local Cat dealer in order to obtain additional information about the S·O·S Services Oil Analysis program.

Diesel Fuel Recommendations

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NACD Film

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EAME Film

Diesel fuel must meet “Cat Specification for Distillate Fuel” and the latest versions of "ASTM D975" or "EN 590" in order to ensure optimum engine performance. Refer to Special Publication, SEBU6251, "Cat Commercial Diesel Engine Fluids Recommendations" for the latest fuel information and for Cat fuel specification. This manual may be found on the Web at Safety.Cat.com.

Misfueling with fuels of higher sulfur level can have the following negative effects:

• Shorten the time interval between aftertreatment device service intervals (cause the need for more frequent service intervals)

• Adversely impact the performance and life of aftertreatment devices (cause loss of performance)

• Reduce regeneration intervals of aftertreatment devices

• Reduce engine efficiency and durability.

• Increase the wear.

• Increase the corrosion.

• Increase the deposits.

• Lower fuel economy

• Shorten the time period between oil drain intervals (more frequent oil drain intervals).

• Increase overall operating costs.

Failures that result from the use of improper fuels are not Cat factory defects. Therefore the cost of repairs would not be covered by a Cat warranty.

Cat does not require the use of ULSD in off road and machine applications that are not Tier 4/Stage IIIB certified engines. ULSD is not required in engines that are not equipped with after treatment devices. For Tier 4/Stage IIIB/Stage IV certified engines always follow operating instructions. Fuel tank inlet labels are installed in order to ensure that the correct fuels are used.

Refer to Special Publication, SEBU6251, "Cat Commercial Diesel Engine Fluids Recommendations" for more details about fuels, lubricants, and Tier four requirements. This manual may be found on the Web at Safety.Cat.com.

Lubricating Grease

Cat provides various greases that vary in performance from a moderate performance to high performance. Cat greases service the entire line of Caterpillar products in the wide variety of climates throughout the world. From this variety of Cat grease products, you can find a Cat grease that will meet or exceed the performance requirements of most engines.

The performance requirements of your engine must be determined before you select any Cat grease. Consult the recommendations for greases that are made by the OEM for the equipment. Then, consult with your Cat dealer for a list of greases that have the performance specifications and the available sizes of containers.

Note: Always choose grease that meets or exceeds the recommendations that are specified by the equipment manufacturer for the application.

If necessary, choose a single grease to use for all of the equipment at one site. Always choose a grease that meets or exceeds the requirements of the most demanding application. Remember that the products which barely meet the minimum performance requirements can be expected to produce the minimum lives of your parts. False economy is being used if a grease is purchased with the lowest cost as the only consideration. Instead, use the grease that yields the lowest total operating cost. This cost should be based on an analysis that includes the costs of parts, labor, downtime, and the grease that is required.

Note: Purge all of the old grease from a joint before you change from one type of grease to another type of grease. Some greases are not chemically compatible with other greases. Consult your supplier in order to determine if the greases are compatible.

If you are not certain that the old grease is compatible with the new grease, purge the old grease from the system. Install the new grease.

Note: All Cat greases are chemically compatible with each other. Mixing of Cat greases does not result in an adverse chemical reaction. However, mixing of Cat greases may result in reduced performance.

Non-Cat commercial greases are as a group second choice greases. Within this grouping of second choice greases, there are tiered levels of performance. For more information, refer to Special Publication, SEBU6251, "Cat Commercial Diesel Engines Fluids Recommendations".

Coolant

The following two coolants are used in Cat Diesel Engines:

Preferred - Cat ELC (Extended Life Coolant) or a commercial extended life coolant that meets the Cat Engine Coolant -1 (EC-1) specification.

Acceptable - Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial heavy-duty coolant that meets "ASTM D4985", or "ASTM D6210" specifications

Note: Cat DEAC does not require a treatment with a Supplemental Coolant Additive (SCA) at the initial fill. However, a commercial heavy-duty coolant that only meets the "ASTM D4985" specification will require a treatment with an SCA at the initial fill. A commercial heavy-duty coolant that meets the "ASTM D6210" specification will not require a treatment with an SCA at the initial fill. Read the label or the instructions that are provided by the manufacturer of the commercial heavy-duty coolant.

Note: These coolants will require a treatment with a supplemental coolant additive on a maintenance basis.

Note: Add the Cat ELC Extender at the halfway point of the coolant change interval.

Note: These coolant change intervals are only possible with annual S·O·S Services Level 2 coolant sampling and analysis.

S·O·S Services Coolant Analysis

Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and from corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling and from freezing. The S·O·S Coolant Analysis can be performed at your Cat dealer. Cat S·O·S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system. S·O·S Coolant Analysis is a program that is based on periodic samples.

For more information, refer to Special Publication, SEBU6251, "Cat Commercial Diesel Engines Fluids Recommendations"

Diesel Exhaust Fluid (DEF) Recommendations

For use in Cat engines, DEF concentration must be 32.5 percent, meeting all requirements defined by "ISO 22241-1".

Caterpillar recommends the use of DEF available through the Cat parts ordering system for use in Cat engines equipped with SCR systems. Refer to Table 5 for part number information:

In North America, commercial DEF that is API approved and meets all the requirements defined in "ISO 22241-1" may be used in Cat engines that are equipped with SCR systems.

Outside of North America, commercial DEF that meets all requirements defined in "ISO 22241-1" may be used in Cat engines that are equipped with SCR systems.

The supplier should provide documentation to prove the DEF is compliant with the requirements of "ISO 22241-1".

To obtain locations of DEF suppliers, call (888)-598-8186 or (309)-494-7532.

DEF is a solution of solid urea that is dissolved in demineralized water to produce a final concentration of 32.5 percent urea. DEF concentration of 32.5 percent is optimal for use in SCR systems. DEF solution of 32.5 percent urea has the lowest attainable freeze point of −11.5° C (11.3° F). DEF dosing systems and "ISO 22241-1" specifications are designed for a solution that is 32.5 percent.

Caterpillar offers a refractometer, Cat part number 360-0774, that can be used to measure DEF concentration. Follow the instructions provided with the instrument. Appropriate commercial portable refractometers can be used to determine urea concentration. Follow the instructions from the manufacturer.

DEF Guidelines

Quality of DEF can degrade when stored and handled inappropriately or if DEF is not protected from contamination. Details are provided below.

If quality issues are suspected or a DEF quality fault is active, testing of DEF should focus on urea concentration, alkalinity as NH₃ and biuret content. DEF that does not pass all these tests should not be used.

Note: Caterpillar strongly recommends that customers purchase the pre-mixed DEF urea solution from a reputable supplier. The DEF must satisfy all the specifications of quality. Refer to Special Publication, SEBU6251, "Exhaust Aftertreatment Fluids Specifications". Urea solutions that are not made of urea and water of the appropriate quality and cleanliness may damage the SCR system. Poor or questionable quality DEF can lead to additional repair and maintenance costs to the customer. Cat warranties do not cover failures caused by or related to use of out of specification urea solutions in Tier 4 Stage IIIB MLIT Step 4 products equipped with SCR systems.

Materials compatibility

DEF is corrosive. Due to the corrosion caused, DEF must be stored in tanks constructed of approved materials. Recommended storage materials:

Stainless Steels:

• 304 (S30400)

• 304L (S30403)

• 316 (S31600)

• 316L (S31603)

• 409 (S40900)

• 439 (S43035)

Alloys and metals:

• Chromium Nickel (CrNi)

• Chromium Nickel Molybdenum (CrNiMo)

• Titanium

Non-metallic materials:

• Polyethylene

• Polypropylene

• Polyisobutylene

• Teflon (PFA)

• Polyfluoroethylene (PFE)

• Polyvinylidene fluoride (PVDF)

• Polytetrafluoroethylene (PTFE)

Materials NOT compatible with DEF solutions include Aluminum, Magnesium, Zinc, Nickel coatings, Silver and Carbon steel and Solders containing any of the above. Unexpected reactions may occur if DEF solutions come in contact with any non-compatible material or unknown materials.

Bulk storage

Follow all local regulations covering bulk storage tanks. Follow proper tank construction guidelines. Tank volume typically should be 110% of planned capacity. Appropriately vent indoor tanks. Plan for control of overflow of the tank. Heat tanks that dispense DEF in cold climates.

Bulk tank breathers should be fitted with filtration to keep airborne debris from entering the tank. Desiccant breathers should not be used because water will be absorbed, which potentially can alter DEF concentration.

Handling

Follow all local regulations covering transport and handling. DEF transport temperature is recommended to be −5° C (23° F) to 25° C (77° F). All transfer equipment and intermediate containers should be used exclusively for DEF. Containers should not be reused for any other fluids. Ensure that transfer equipment is made from DEF compatible materials. Recommended material for hoses and other non-metallic transfer equipment include:

• Nitrile Rubber (NBR)

• Fluoroelastomer (FKM)

• Ethylene Propylene Diene Monomer (EPDM)

The condition of hoses and other nonmetallic that are used with DEF should be monitored for signs of degradation. DEF leaks are easily recognizable by white urea crystals that accumulate at the site of the leak. Solid urea can be corrosive to galvanized or unalloyed steel, aluminum, copper, and brass. Leaks should be repaired immediately to avoid damage to surrounding hardware.

Cleanliness

Contaminants can degrade the quality and life of DEF. Filtering DEF is required when dispensed into the DEF tank. Filters should be compatible with DEF and should be used exclusively with DEF. Check with the filter supplier to confirm compatibility with DEF before using. Mesh-type filters using compatible metals, such as stainless steel, are recommended. Paper (cellulose) media and some synthetic filter media are not recommended because of degradation during use.

Care should be taken when dispensing DEF. Spills should be cleaned immediately. Machine or engine surfaces should be wiped clean and rinsed with water. Caution should be used when dispensing DEF near an engine that has recently been running.

Note: Spilling DEF onto hot components may cause the release of ammonia vapors. Do not breathe ammonia vapors. Do not clean up any spills with bleach.

Stability

DEF fluid is stable when stored and handled properly. The quality of DEF rapidly degrades when stored at high temperatures. The ideal storage temperature for DEF is between −9° C (15.8° F) and 25° C (77° F). DEF that is stored above 35° C (95° F) for longer than 1 month must be tested before use. Testing should evaluate Urea Percentage, Alkalinity as NH₃ and Biuret content.

The length of storage of DEF is listed in the following table:

Refer to "ISO 22241" document series for more information about DEF quality control.

Note: Dispose of all fluids according to applicable regulations and mandates.

General Characteristics of DEF

DEF with a concentration of 32.5 percent has a freezing point of −11° C (12° F). For detailed information on the requirements and other characteristics of DEF, refer to Operation and Maintenance Manual, SEBU6251, "Exhaust Aftertreatment Fluids Specifications".