797F Off-Highway Truck Caterpillar

General Information for Lubricants

When the machine is operating in temperatures below −20°C (−4°F), refer to Special Publication, SEBU5898, "Cold-Weather Recommendations". This publication is available from your Cat dealer.

For cold-weather applications where transmission oil SAE 0W-20 is recommended, Cat Cold-Weather TDTO is recommended.

Refer to the “Lubricant Information” section in the latest revision of the Special Publication, SEBU6250, "Caterpillar Machine Fluids Recommendations" for a list of Cat engine oils and for detailed information. This manual may be found on the web at Safety.Cat.com. The footnotes are a key part of the tables. Read ALL footnotes that pertain to the machine compartment in question.

Selecting the Viscosity

To select the proper oil for each machine compartment, refer to the “Lubricant Viscosity for Ambient Temperature” table. Use the oil type AND oil viscosity for the specific compartment at the proper ambient temperature.

The proper oil viscosity grade is determined by the minimum ambient temperature (the air in the immediate vicinity of the machine). Measure the temperature when the machine is started and although the machine is operated. To determine the proper oil viscosity grade, refer to the “Min” column in the table. This information reflects the coldest ambient temperature condition for starting a cold machine and for operating a cold machine. Refer to the “Max” column in the table for operating the machine at the highest temperature that is anticipated. Unless specified otherwise in the “Lubricant Viscosities for Ambient Temperatures” tables, use the highest oil viscosity that is allowed for the ambient temperature.

Machines that are operated continuously should use oils that have the higher oil viscosity in the final drives and in the differentials. The oils that have the higher oil viscosity will maintain the highest possible oil film thickness.

Engine Oil

Cat oils have been developed and tested 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, API CJ-4, and the newer API CK-4, are required for use in the applications listed below. Cat DEO-ULS and oils meeting Cat ECF-3 specification, API CJ-4, the newer API CK-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, API CJ-4, the newer API CK-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, API CJ-4, or the newer API CK-4 qualified.

Failure to meet the listed requirements will damage aftertreatment-equipped engines and can negatively impact the performance of the aftertreatment devices.

Oils that are per API CI-4 or prior categories are not allowed. These oils have high ash and are not appropriate for use in engines with aftertreatment devices.

Off Highway Trucks

Cat FDAO SYN, CatFDAOSAE 60, or commercial oil that meets Cat FD-1 SAE 60 is preferred in most Differential, Front Wheels, and Final Drives, particularly continuous operation.

If the ambient temperature is below −10°C (14°F), warm up the oil prior to operation. The oil must be maintained to a temperature above −10°C (14°F) during operation. If the ambient temperature is below −10°C (14°F), prior to operation, perform the differential warmup procedure. Refer to Operation and Maintenance Manual, "Differential warmup and Break-in".

If the ambient temperature is below −25°C (−13°F) (below −35°C (−31°F) for Cat FDAO SYN), consult your Cat dealer for instructions. Failure to warmup the oil prior to operation will damage the machine.

For cold-weather applications where transmission oil SAE 0W-20 is recommended, Cat Cold-Weather TDTO is recommended.

Grease Recommendations

Grease for the Autolube System

The grease used with the automatic lubrication system must not contain any graphite or PTFE.

Note: Pumpability is based on "US Steel Mobility and Lincoln Ventmeter Tests". Performance may vary depending on lubrication equipment and the length of the lines.

Reference: Refer to Special Publication, SEBU6250, "Caterpillar Machine Fluids Recommendations" for additional information about grease. This manual may be found on the web at Safety.Cat.com.

Diesel Fuel Recommendations

Diesel fuel must meet “Caterpillar Specification for Distillate Fuel” and the latest versions of "ASTM D975" or "EN 590" to ensure optimum engine performance.

The preferred fuels are distillate fuels. These fuels are commonly called diesel fuel, furnace oil, gas oil, or kerosene. These fuels must meet the “Caterpillar Specification for Distillate Diesel Fuel for Off-Highway Diesel Engines”. Diesel Fuels that meet the Caterpillar specification will help provide maximum engine service life and performance.

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

• 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

• Negatively impact engine emissions

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

Caterpillar 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.

Follow operating instructions and fuel tank inlet labels, if available, to ensure that the correct fuels are used.

Fuel Additives

Cat Diesel Fuel Conditioner and Cat Fuel System Cleaner are available for use when needed. These products are applicable to diesel and biodiesel fuels. Consult your Cat dealer for availability.

Biodiesel

Biodiesel is a fuel that can be made from various renewable resources that include vegetable oils, animal fat, and waste cooking oil. Soybean oil and rapeseed oil are the primary vegetable oil sources. To use any of these oils or fats as fuel, the oils or fats are chemically processed (esterified). The water and contaminants are removed.

U.S. distillate diesel fuel specification "ASTM D975-09a" includes up to B5 (5 percent) biodiesel. Currently, any diesel fuel in the U.S. may contain up to B5 biodiesel fuel.

European distillate diesel fuel specification "EN 590" includes up to B5 (5 percent) and in some regions up to B7 (7 percent) biodiesel. Any diesel fuel in Europe may contain up to B5 or in some regions up to B7 biodiesel fuel.

Note: Up to B20 biodiesel blend level is acceptable for use in Medium Wheel Loader engines.

When biodiesel fuel is used, certain guidelines must be followed. Biodiesel fuel can influence the engine oil, aftertreatment devices, non-metallic, fuel system components, and others. Biodiesel fuel has limited storage life and has limited oxidation stability. Follow the guidelines and requirements for engines that are seasonally operated and for standby power generation engines.

To reduce the risks associated with the use of biodiesel, the final biodiesel blend and the biodiesel fuel used must meet specific blending requirements.

Reference: Refer to Special Publication, SEBU6250, "Caterpillar Machine Fluids Recommendations" for additional information about fuels. This manual may be found on the web at Safety.Cat.com.

Diesel Exhaust Fluid (DEF)

General Information

Diesel Exhaust Fluid (DEF) is a liquid that is injected into the exhaust system of engines equipped with Selective Catalytic Reduction (SCR) systems. SCR reduces emissions of nitrogen oxides (NOx) in diesel engine exhaust.

Diesel Exhaust Fluid (DEF) is also known under other names including Aqueous Urea Solution (AUS) 32, AdBlue, or generically referred to as urea.

In engines equipped with SCR emissions reduction system, DEF is injected in controlled amounts into the engine exhaust stream. At the elevated exhaust temperature, urea in DEF is converted to ammonia. The ammonia chemically reacts with NOx in diesel exhaust in the presence of the SCR catalyst. The reaction converts NOx into harmless nitrogen (N2) and water (H2O).

DEF Recommendations for Diesel Engines

For use in Cat engines, DEF must meet all the requirements defined by the "ISO 22241-1" standard.

The caps of DEF tanks are blue, as required by emissions regulations. Fill DEF only in clearly marked DEF tanks that have the blue cap.

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 that the DEF is compliant with the requirements of "ISO 22241-1".

DEF is a solution of solid urea that is dissolved in demineralized water to produce a final concentration of 32.5% urea. Most SCR systems are designed to operate only on DEF concentration of 32.5 percent. DEF solution of 32.5% urea has the lowest attainable freeze point of −11.5° C (11.3° F). DEF concentrations that are higher or lower than 32.5% have higher freeze points. DEF dosing systems and "ISO 22241-1" specifications are designed for a solution that is approximately 32.5%.

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.

Diesel Exhaust Fluid

General Information

Diesel Exhaust Fluid (DEF) is a liquid that is injected into the exhaust system of engines equipped with Selective Catalytic Reduction (SCR) systems. SCR reduces emissions of nitrogen oxides (NOx) in diesel engine exhaust.

Diesel Exhaust Fluid (DEF) is also known under other names including Aqueous Urea Solution (AUS) 32, AdBlue, or generically referred to as urea.

In engines equipped with SCR emissions reduction system, DEF is injected in controlled amounts into the engine exhaust stream. At the elevated exhaust temperature, urea in DEF is converted to ammonia. The ammonia chemically reacts with NOx in diesel exhaust in the presence of the SCR catalyst. The reaction converts NOx into harmless nitrogen (N2) and water (H2O).

DEF Recommendations

For use in Cat engines, DEF must meet all the requirements defined by "ISO 22241-1" Requirements.

Caterpillar recommends the use of DEF available through the Cat parts ordering system for use in Cat engines equipped with SCR systems.

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 that the DEF is compliant with the requirements of "ISO 22241-1".

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

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

DEF solution is typically colorless and clear. Changes to color or clarity are indicators of quality issues. 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, testing of DEF should focus on urea percentage, alkalinity as NH3 and biuret content. DEF that does not pass all these tests or that is no longer clear should not be used.

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)

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.

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.

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 includes:

• Nitrile Rubber (NBR)

• Fluoroelastomer (FKM)

• Ethylene Propylene Diene Monomer (EPDM)

The condition of hoses and other nonmetallics 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.

Contaminants can degrade the quality and life of DEF. Filtering DEF is recommended 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. Spilling DEF onto hot components will cause harmful vapors.

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.

Coolant Information

The following two types of coolants may be used in Cat diesel engines:

Preferred - Cat ELC (Extended Life Coolant)

Acceptable - Cat DEAC (Diesel Engine Antifreeze/Coolant)

Reference: Refer to Special Publication, SEBU6250, "Caterpillar Machine Fluids Recommendations" for additional information about coolant. This manual may be found on the web at Safety.Cat.com.