3500B GENERATOR SET ENGINES

PBRi-UP, ZADi-UP, ZAHi-UP, ZA.Ji-UP, ZAP1-UP, ZARi-UP, YAM1-UP, YAN1-UP, YAT1-UP, YAW1-UP, YAY1-UP, YAZ1-UP, YAP1-UP, YAR1-UP

RENR5056-07 Contents for Service Manual RENR5055

Note: This form lists the contents of the complete Service Manual for this product. The items listed can be ordered separately. Section Binder Binder Label Safely Service Manual Contents Torque Specifications Engine Index Tab Spedfications Systems Operation, Testing & Adjusting Troubleshooting Index Tab Systems Operation, Testing & Adjusting Disassembly & Assembly Index Tab Disassembly and Assembly Maintenance Index Tab Operation & Maintenance Manual Schematic Index Tab Schematic Title Form No. SENR2910 RENR5054 SENR2995 RENR5056 SENR3130 SENR2870 RENR5057 RENR5058 SENR3987 RENR5059 SENR2875 RENR5060 SENR2874 SEBU7789 SENR2902 RENR7885

3500B Generator Set Engine 3500B Generator Set Engine 35008 and 3500C Generator Set Engines 3500B Engines 35008 Generator Sets 3500B and 3500B High Displacement Engine Electrical System 237-9000-01 35008 and 35008 High Displacement Generator Electrical System 233-6966-01

Schematic

RENR9845

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CAT-POD B.5X 11

P9STLOOSE
81W Color

.. 08876.003 3
Cvr: SELF 3 HOLE 5/16

2 P:

Q.Y!

3 P:

CAT BINDER/LABEL

06/09

11/10/09

we:

RENR5055

00

SENR3130-12 February 2009

Specifications
Torque Specifications

SAFETY.CAT.COM

iD1658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training. skills and tools to perform these functions properly. Improper operation, lubrication, could result in injury or death. maintenance or repair of this product can be dangerous and

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safely precautions and warnings are provided in this manual and on the product. If these hazard wamings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

A WARNING
The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by "NOTICF this publication. labels on the product and in

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

A WARNING
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

SENR3130-12

3 Table of Contents

Table of Contents
Specifications Section
Generallnformation .... _........................................ Metric (ISO) Fasteners ".................................. English (SAE) Fasteners ".......................... Ground Engaging Tool (GET.) Fasteners Installation of Fittings Straight Thread O-Ring Fittings Plugs : O-Ring Face Seal Fittings _ Bulkhead Nuts Flare Fittings Air Conditioning Fittings ,....................................... Air Brake Fittings Tapered Pipe Thread Fittings Miscellaneous Fittings '........ Hose Clamps

5
6

8
9 10 12 14 1:4

15
17 17

16 17 18

Index Section
Index , , 20

4
Specifications Section

SENR3130-12

Specifications Section
i02357647

General Information
SMCS Code: 7553

Note: Do not use sealants that are not specified in the Service Manual. Do not use compounds that are not specified in the Service Manual. Clean old compound from the bolt and from the hole before install ation.

Torque-Turn
The torque-turn method is used when precise control over clamping force is required. There is an initial torque and an additional turn. The initial torque is required to bring all parts of the joint into contact. The additional turn provides the desired damping force. Ensure that all fasteners have been torqued before you perform the additional turns. Turn the fastener according to the specified amount. The specified amount will normally be equal to or greater than 90°. The specified amount will normally be in 30° increments. Turns of 1200 or 1800 are preferred. Turns of 120 or 180° are easily measured by the points of the hex head of the fastener. Lubrication may be specified in order to reduce the effort that is required for the final turn. The use of the torque-turn method will allow the following:
0

A WARNING
Mismatched or incorrect fasteners can result in damage or malfunction, or personal injury. Take care to avoid mixing metric dimensioned teners and inch dimensioned fasteners. fas-

Introduction to Torque
"Torque" is measured in terms of force and distance. Force is the amount of pushing or pulling applied at the end of the lever. Distance is the length of the lever that is being used. Torque values are given in the following units: NEWTON meters (N·m), pound inches (Ib in). and pound feet (Ib ft) This manual is intended to provide the operator with a reference. This manual will provide the standard torque settings for the following: bolts, nuts, plugs, fittings, and clamps. Exceptions to these torques are given in the Service Manual, if necessary. Be sure to use a torque wrench that has the proper range. Torque wrenches must be used properly in order to ensure that the correct torque is applied. Always use a smooth pull for torque wrenches. Do not jerk a torque wrench. Do not use adapters that change the length of the torque wrench. For the correct use of your torque wrench. refer to the instructions that were packaged with your torque wrench. For more information on the correct use of torque wrenches. refer to Special Publication, SEBV0516, "An Introduction to Torque". Prior to installation of any hardware, ensure that components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of rust and corrosion. Clean reused fasteners with a noncorrosive cleaner. Lightly lubricate the threads of reused fasteners. Lightly lubricate the mating surface of the head of reused fasteners. Other applications for lubricating fasteners may also be specified in the Service Manual. The Service Manual may also specify the use of sealants and compounds.

• Increase the life of the fastener. • Maximize the potential clamping force of a fastener. Typical applications are the following: • Track bolts • Sprocket bolts • Connecting rod bolts • Engine Cylinder Heads • Drive Shaft bolts Note: Too much tension on the bolt will cause the bolt to be stretched beyond the point of yield. The bolt will be permanently stretched. The bolt will loosen the grip on the parts that are being fastened. If the bolt is tightened again, the bolt will break. Do not reuse bolts that have been permanently stretched.

Torque Sequence
Unless the bolt tightening sequence is specified by the Service Manual, the fasteners should be tightened in a cross pattern. Use Step 1 through Step 5 unless the tightening sequence is specified: 1. Hand tighten all fasteners. Larger fasteners may require the use of a small hand wrench. 2. Torque all fasteners to 40% of full torque. 3. Torque all fasteners to 70% of full torque.

SENR2995-04 December 1999

Product Safety

All Caterpillar Engines

in '175998

Important Safety Information

Proper maintenance and proper repair are important to the safe operation and the reliable operation of this product. This document outlines basic recommended procedures. Some of the procedures require special tools, devices, or work methods. Ensure that all safety messages and information messages are read and understood before any repairs are performed or before any maintenance is performed. The person who services the product may be unfamiliar with many of the systems on the product It is important to use caution when service work is performed. A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the product components, the service person should check the weights that are noted in the Service Manual and the Service Information System (SIS). Use the proper lifting procedures when any components are removed.

Note: Warning Labels are used to provide instructions and identify specific hazards which if not heeded could cause bodily injury or death to you or other persons. These labels identify hazards which may not be apparent to a trained mechanic. There are many potential hazards during the repair for an untrained mechanic and it is impossible to label the product against all such hazards. Improper repair procedures can be dangerous and could result in injury or death. Operations or conditions that may cause product damage are identified by "NOTICE" labels on the product and in the service information. An example of a "NOTICE" label is shown below. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety messages in this document, the Service Manual, the Service Information System (SIS), and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it Is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

Warnings and Notices

Safety messages and information messages are provided in this document, the Service Manual. the Service Information System (SIS), and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARN!NG" or "CAUTION". The Safety Alert "WARNING" label is shown below.

Current Information
The information, specifications, and illustrations in the service information are on the basis of information available at the time it was written. The specifications, torques, pressures of operation, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Get the complete and most current information before you start any job. The most current information is available on the Service Information System (SIS). Caterpillar dealers also have the most current information available.

A WARNING
Illustration 1
gOOOOl1fi(j(;

The meaning of this safety alert is as follows: Attentionl Become Alert! Your Safety is Involved.

The message that appears under the safety alert symbol explains the hazard and can be either written or pictorially presented.

Basic Precautions

Corrosion Inhibitor
Corrosion inhibitor contains alkali. 00 not allow alkali to contact the skin or the eyes. 00 not take alkali internally. In case of contact, immediately wash skin with soap and water. II alkali contacts the eyes, flush the eyes with large amounts of water for at least 15 minutes. Call a Physician. Keep toxic chemicals out of reach of children.

A WARNING
Improper operation, lubrication, maintenance or

repair of this product can be dangerous and could

result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. The following list contains basic precautions should always be observed. that

Batteries
00 not smoke or expose an open flame when an inspection o.f the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause combustible gases to ignite. 00 not allow electrolyte to contact the skin or the eyes. Electrolyte is an acid. In case of contact, immediately wash skin with soap and water. Flush the eyes with large amounts 01 water for at least 15 minutes. Call a Physician. Keep toxic chemicals out of reach of children.

1. Ensure that all of the "Safety" signs on the

product are read and understood before operating, lubricating or repairing this product. Replace any of the safety plates, signs or decals that are damaged, unreadable or missing. 2. II you start the engine to check the pressure or engine speed (rpm), ensure that all of the guards are installed. To help prevent an accident that is caused by parts in rotation, work carefully around an' engine that has been put into operation. 3. Ensure that the work area around the product is made safe and be aware of hazardous conditions that may exist. If an engine is started inside an enclosure, ensure that the engine exhaust is properly vented. 4. Mount the engine and dismount the engine only al locations that have steps and/or handholds. Clean any mud or debris from shoes, steps, walkways, or work platforms before mounting the engine or dismounting the engine. Face the engine in order 10 mount the engine or dismount the engine. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms in order to perform safe repair operations. 5. For initial start-up of a new engine, or for an engi;ne that has been serviced, make provisions te stop the engine if an overspeed occurs. This can be accomplished by shutting oft the fuel supply and/or the air supply to the engine. If the engine has not been assembled correctly or if the fuel settings are not correct, the engine can possibly overspeed. The result can be bodily injury, death or property damage.

Protective Equipment
Wear a hard hat, protective glasses with side shields, and other protective equipment, as required. In particular, wear protective glasses when you pound on any part 01 the product or the attachments with a hammer or a sledge hammer. Use welders gloves, hood/goggles, an apron and other protective clothing that is appropriate to the welding job that is being performed. 00 not wear loose clothing or jewelry that can snag on controls or on other parts of the product. Do not expose loose clothing, jewelry, or long hair near rotating parts.

Pressurized Items
1. Always use a board or a piece of cardboard
when you check for a leak. Leaking fluid under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatmentlrom a doctor that is familiar with this type of injury. 2. Relieve all pressure in air, oil or water systems before any lines, fitlings or related items are disconnected or removed. Always ensure that aU raised components are blocked correctly. Be alert for possible pressure when any device from a system that utilizes pressure is disconnected.

3. Do not bend or strike high pressure lines. Do not install lines, tubes or hoses that are damaged. Repair any fuel lines, oil lines, tubes, or hoses thai are loose or damaged. Leaks can cause fires. Inspect atl lines. lubes and hoses carefully. Do not use bare hands to check for leaks. Always use a board or cardboard for checking engine components lor leaks. Tighten all connections to the recommended torque.

4. Be careful when cover ptates are removed. Gradually back off the last two bolts or nuts thai are located at opposite ends ot the cover or the device. Then pry the cover toose in order to relieve any spring pressure or other pressure before Ihe last two bolts or nuts are completely removed. 5. Atways use tools that are in good condition. Ensure that you understand the usage of the tools before performing any service work. 6. Replace all fasteners with the same parI number. Do not use a lesser quality fastener if replacements are necessary.

4. Pressurized air or water can cause personal injury. When pressurized air or water is used
for cleaning, wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). When you use a pressure washer, keep in mind that nozzle pressures are very high. Generally, pressures are well above 13790 kPa (2000 psi). Follow all recommended practices thaI are provided by the manufacturer of the pressure washer.

7. Repairs which require welding should be

performed only with the benefit of the appropriate reference information. Repairs should only be performed by personnel that are adequately trained and knowledgeable in welding procedures. Refer to Instruction Manual, SEGV2549, "Techniques of Structural Repair Course". Determine the type of metal that is being welded. Select the correct wetding procedure, electrodes, rods or wire in order to provide a weld metal strength that is at least equivalent to the parent metal. B. Do not damage wiring during removal operations. Reinstall the wiring so that the wiring is not damaged. The wiring should not be damaged during operation through contact with sharp corners. The wiring shoutd not be damaged by being rubbed against an object or a hot surface. Do not connect wiring to a line that contains Iluid. 9. Ensure that all protective devices are properly installed and that all protective devices are functioning correctly before a repair is started. If a guard or a shield must be removed to perform the repair work, use extra caution, and ensure to reinstall the guard or shield after the repair work is completed.

Hot Fluids and Parts

1. To avoid burns, be alert for hot parts on engines which have just been stopped. Also, be alert for hot fluids in lines, tubes and compartments.

2. Be careful when you remove filler caps, breathers

and plugs on the engine. Hold a rag over the cap or the plug in order to prevent being sprayed by fluids under pressure. The danger is even greater if the engine has just been stopped. The flu·ids can be hot.

Lifting
Use a hoist when you lift components which weigh 23 kg (50 Ib) or more in order to avoid back injury. Also use a hoist when you lift components from an awkward position. Ensure that all chains, hooks, slings, etc are in good condition with the correct capacity. Ensure thai the hooks are positioned correctly. Also, ensure that the hooks are equipped with a spring latch. Lifting eyes should not be used for side loading during a lifting operation.

10. Tighten connections

Repair
1. Disconnect the battery and discharge any capacitors before you start to work on the product. Attach a "Do Not Operate" tag in the Operator's Compartment. 2.. When possible, make all repairs on a level, hard surface. 3. Do not work on any engine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the engine before performing any service or disassembly.

to the correct torque. Ensure that all clamps, guards, and shields are installed correctly This will help to prevent damage from: vibration. rubbing against other parts, and excessive heat during operation. Particular attention for correct installation should be given \0 shields that protect against oit or fuel spray onto hot exhaust components.

11. Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstaflthe gLiards. Any high speed rotating component that has been damaged or altered should be checked for batance before reusing.

A WARNING
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal Injury or death.

Stay away from areas that might have asbestos particles in the air.

Asbestos Information
Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Caterpillar replacement parts.

If replacement parts are obtained from another supplier, use the following guidelines when any replacement parts that contain asbestos or asbestos debris are handled.
Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually sealed or bonded in a resin. Handling these materials normally is not hazardous unless airborne dust that contains asbestos is generated, If dust which may contain asbestos is present, there are several guidelines that should be followed. Never use compressed air for cleaning. Avoid brushing materials that contain asbestos or grinding materials that contain asbestos. Use a wet method to clean up asbestos debris. A vacuum that is equipped with the high efficiency particulate air filter (HEPA filter) can also be used. Use exhaust ventilation on permanent machining jobs. Wear an approved respirator if there is no other way to control the dust. Comply with applicable rules and regulations for the work place. In the USA, use Occupational Safety and Health Administration requirements. These OSHA requirements can be found in "29 CFR 1910.1001". Obey environmental asbestos. regulations for disposal of

©1999 Caterpillar
All Rights Reserved

Printed in U.S.A.

SENR3130-12 Specifications

5 Section

4. Torque all fasteners to full torque by using a cross

pattern. Large flanges may require additional passes. 5. ~pply at least one final full torque to all fasteners In a clockwise direction until all torque is uniform. Large flanges may require additional passes. Note: Final torque may be a turn.
i03508884

Table 2

Torque
.f----_-----

Thread Size mm M6 M8
1--------

5 N-m (44 Ib in) 22 N·m (195 Ib in) 44 N-m (32 !b fI) 78 Nm (60 Ib ft) 124 Nm (90 Ib fI)
--

M10 M12

-_.

M14 M16
.-

Metric (150) Fasteners

SMCS Code: 7553

._-_.-

177 N-m (130 Ib fI) 200 N-m (150 Ib fI) 400 N-m (300 Ib ft)
-

._--------

M18 M20 M24

Metric (ISO) Nuts and Bolts

790 N-m (580 Ib ft)

-----

Note: The difference between Caterpillar standard torque values and Perkins standard torque values are due to different classes of fasteners. Caterpillar uses class 10.9 fasteners. Perkins uses class 8.8 fasteners. The different class of fasteners have different tensile strenqths.
g00909614

Illustration

Metric (ISO) Taperlock Studs

Note: The following table has the recommended standard torque values for metric taperlock studs for use on all Caterpillar equipment and Mitsubishi engines.
Table 3

Note: The following table has the recommended standard torque values for metric nuts and bolts for use on all Caterpillar equipment and Milsubishi engines.
Table 1

Thread Size
mm M6

Thread Size Torque

".~

mm
M6
----_._--

Torque
---

---

12 ± 3 N·m (105 ± 27 Ib in) 28 ± 7 N·m (250 ± 62 Ib in) 55 ± 10 N·m (41 ± 7 Ib ft)

---------------

M10
1-----

M8

M8

.-~~ I---

8 ± 3 N-m (71 ± 27 Ib in)

17 ± 5 N'm (150 ± 44 Ib in) 35 ± 5 N-m (26 ± 4 Ib ft) _. 65 ± 10 N-m (48 ± 7 Ib ft)

M10 M12 M16 M20 M24 M30 M36

M12 M14 M16

--

___

!~O ±_~O N-m (75 ± 15 Ib tt) 160 ± 30 N·m (120 ± 22 Ib fI) 240 ± 40 Nm (175 ± 30 Ib It)

-------------

..

110 ± 20 N·m (80 ± 151b ft) 170 ± 30 Nrn (125 ± 22 Ib __ 400!

ttl

--

1----------

M20

1-------

460 ± 60 N-m (340 ± 44 Ib ft)

60 N_:__~{300 ~4 Ib ft) ±

M24 M30 M36

1-----

800 ± 100 Nm (590 ± 75 lb

ttl

750 ± 80 N·m (550 ± 60 Ib ft) 1200 ± 150 N-m (880 ± 110 Ib ft)

1600

200 N-m (1180 ± 150 Ib ft)

2800 ± 350 N-m (2060

260 Ib tt)

Note: The following table has the recommended standard torque values for metric nuts and bolts for use on Perkins engines.

Note: The following table has the recommended standard torque values for Metric taperlock studs for use on Perkins engines_

6
Specifications Section

SENR3130-12

Table 4

Table 6

Thread Size mm
M6 M8 MiD M12

Torque
5 N-m (44 Ib in) 11 N'm (97 Ib in) 18 N'm (160 Ib in) 25 N'm (220 Ib in)

Thread Size

Torque
.6 ±.1 N'm (5 ± 0.91b in) 2 ±.3 N'm (18 ± 31b in) 4 ± .5 N'm (35 ± 4 Ib in) 6

mm

M3 M4 M5 M6 M8

1 N'm (55 ± 9 Ib in)

15 ± 2 N'm (135 ± 181b in) 30 ± 7 N'm (265 ± 62 Ib in) 50± 10 N'm (37 ± 7 Ib tt) 80 ± 15 N'm (60 ± 11 Ib ft) 125 ± 20 Nrn (90 ± 151b ft) 250 ± 40 N'm (1B5 ± 30 Ib ft) 425 ± 50 N'm (310 ± 37 Ib It) 850 ± 100 Nrn (620 ± 75 Ib tt) 1500 ± 200 N'm (1100 ± 150 Ib ft)

Metric (ISO) Machine Screws

Mi0 M12 M14 M16 M20 M24 M30

Illustration Table 5

g00908932

Thread Size

mm
M2

Torque
0.10 ± 0.01 N'm (0.9 ± 0.1 Ib in) 0.15 ± 0.Q1 N'm (13 ± 0.1 Ib in) 0.35 ± 0.05 N'm (3.1 ± 0.4 Ib in) 0.50 ± 0.05 N'm (4.4 ± 0.4 lb in) 1.70 ± 0.25 Nrn (15.0 ± 2.2 Ib in) 2.25.± 0.25 Nrn (19.9 ± 2.2 Ib in)

M36

M1.6

M2.5 M3 M4 M5

103517320

English (SAEl Fasteners

SMCS Code: 7553

English (SAE) Nuts and Bolts

Hex Button Head Screw and Set Screws

!!Iustraiion 4

g00908911

Illustration

gOl186742

SENR3130-12 Specifications

7
Section

Table 7
r---

--_.
Torque 12 ± 3 N'm (105

Table 9

Thread Size Inch

Thread Size No.

Torque -0.10 ± 0.01 Nrn (0.9 ± 0.1 Ib in)

.-

114
5/16

27 Ib in)

0-80 1-64 2-56 3-48 4-40 5-40 6-32

25 ± 6 N-m (220 ± 53 Ib in) 47

0.15 ± 0.01 Nrn (1.3 ± 0.1 Ib in) 0.25 ± 0.02 N'm (2.2 ± 0.2 Ib in) 0.35 ± 0.05 Nm (3.1 ± 0.4 Ib in) 0.50 ± 0.05 Nm (4.4 ± 0.4 Ib in)

3/8
7/16 1/2

9 N-m (35 ± 7 Ib ft)

---

70 ± 15 N'm (50 ± 11 Ib fI)

----~-

105 ± 20 N'm (75 ± 15fb ft)

9/16 ---_.5/8
3/4 7/8 1

._----------

160 ± 30 N'm (120 ± 22 Ib ft)

..

--.

215

± ±

40 N'm (160 ± 30 Ib fI) 50 Nm (275 ± 37 Ib ft)

---

._-

._--

0.70 ± 0.10 Nrn (6.2 ± 0.91b in)

----

370

620 ± 80 N'm (460± 60 Ib ftl 900 ± 100 N'm (660 ± 75 Ib ft)

-----

_----10-24 12-24
--

8-32

0.90 ± 0.10 Nrn (8.0 ± 0.91b in) -1.70 ± 0.25 N'm (15.0 ± 2.2 Ib in)

2.25 ± 0.25 Nrn (19.9 ± 2.2 Ib in) 3.40 ± 0.60 N'm (30.1 ± 53 Ib in)

.--

1 1/8
1 1/4 1 3/8 1 1/2
--

1300 ± 150 N-m (960 ± 110 Ib ft)

.-

1BOO ± 200 N'm (1320 ± 150 Ib It) 2400 ± 300 Nrn (1780 ± 220 Ib fI)

..

._-

Hex Button Head Screw and Set Screws

--

3100 ± 350 N'm (2280 ± 260 Ib ft)

English (SAE) Taperlock Studs

Table 8

.... Thread ~ Inch

s;-

\Q Y '--.:_.
IlIuslration 6

~#
gO 1186972

-----1/4

an ar

Torque

8 ± 3 N-m (70 ± 27 Ib in) 17 ± 5 N'm (150 ± 44 Ib in) 35 ± 5 N-m {2 6

5/16 3/B 7/16 1/2

1----

±4

Ib ft)

45 ± 10 Nm (3 3 ± 7 Ib ft) 65 ± 10 Nm (4 8 ± 7 Ib fl) ---I -110 ± 20 N'm (8 ± 15 Ib ft)

SIB

1----._------

3/4
7/8
--

1
1--.

----260 ± 40 -----

170±30Nm(1

25 ± 22 Ib tt)

Nm (1 90 ± 30 Ib ft)

400 ± 60 N'm (3 00 ± 44 Ib ft) 525 ± 60 N'm (3 90 ± 44 Ib fll 750 ± 80 Nrn (5 50 ± 60 Ib ft)

1 1/8

1 1/4
-_.

1 3/8
1 1/2

.. f---.

950 ± 125 N'm (7 00

± 90

Ib fI)

1200 ± 150 N'm (8 80 ± 110 Ib ft)

English (SAE) Machine Screws

Illustration 5

g009013932

8
Specifications Section

SENR3130-12

Table 10

Table 11

Thread Size
inch

Torque
.6 ±.1 N'm (5 ± 0.91b in) 2 ± .3 N'm (18 ± 3 Ib in) 4 ± .5 N'm (35 ± 4 Ib in) 6 ± 1 N'm (55 ± 9 Ib in) 13 ± 3 Nrn (115 ± 271b in) 25 ± 6 Nrn (220 ± 531b in) 40 ± 8 N'm (20 ± 6 Ib ft) 60 ± 12 Nrn {44 ± 91b ft} 85 ± 15 N'm {65 ± 11 Ib ft} 115 ± 20 N'm (85 ± 151b ft) 200 ± 40 N'm (150 ± 30 Ib ttl 325 ± 40 N'm (240 ± 30 Ib ft) 500 ± 65 Nm (370 ± 48 lb tt) 700 ± 90 N'm (520 ± 65 Ib tt) 1000 ± 125 N'm (740 ± 90 Ib ttl 1300 ± 150 N'm (960 ± 110 Ib ft) 1700 ± 200 N'm (1260 ± 150 Ib ft)

Thread Size
Inch 5/8 inch 3/4 inch 7/8 inch 1 inch 1 1/4 inch

Torque(1) N'm
270 Ib ft 200

# 4 & #5 #6 & #8
#10 & #12 1/4

40

30

475 ± 60 750 ± 90 1150 ± 150 2300 ± 300

350 ± 45 550 ± 65 850 ± 110 1700 ± 220

bolts for cutting edges.

5/16
3/8 7/16

(1) These values are only for Caterpillar

1/2 9/16
5/8

A WARNING
Personal injury can result when installing plow bolts. The appropriate safety equipment must be worn when striking the plow bolts. To avoid injury to your eyes and ears, wear protective glasses and hearing protection during this procedure.

3/4
718

1
1 1/8 1 1/4

1 3/8
1 1/2

Illustration

g00909058

View of a typical plow bolt

Plow bolts must be installed properly. Refer to the following procedure for the correct installation of plow bolts. 1. Clean all surfaces that contact the bolt. Remove all occurrences of the following conditions:rust, paint, nicks, and burrs 2. Tighten the nut to the correct torque, Refer to Table 11 for the correct torque. 3. Use a hammer to strike the head of the bolt. The bolt must be struck with significant force. Note: The head of the bolt may be recessed below the mounting surface. Use a suitable punch in order to transfer the hammer blow to the bolt head. 4. Tighten the nut to the correct torque. Refer to Table 11 for the correct torque.

;03518060

Ground Engaging Tool (G.E.T.) Fasteners

SMCS Code: 7553 Ground Engaging Tools (G.E.T.) are secured by many types of bolts. Refer to Table 11 for the correct torque for the following combinations of fasteners for G.E.T.: • Plow bolts and nuts • Hex head bolts and nuts

SENR3130-12 Specifications

9 Section

i03515062

Installation of Fittings
SMCS Code: 7553 Note: The tightening sequence of the fasteners that attach a tube assembly or hose assembly to the machine is very critical to the proper function of the machine. The sealing surfaces of the tube assembly or hose assembly should be secured squarely. The sealing surfaces of the tube assembly or hose assembly should be tightened to the serviced component (control valve, cylinder, hydraulic motor, etc). Perform this procedure prior to the final tightening of any clamps or clips that are used in order to fasten the tube assembly or the hose assembly to the machine. Fittings have different connections. Fittings may have two completely different ends. Be sure to use the proper torque for the end of the fitting that is used. The following list contains some common types of fittings. • Straight Thread O-Ring (STOR) • Adjustable Straight Thread O-Ring (STOR) • O-Ring Face Seal (ORFS) • Tapered Pipe Thread (NPT and NPTF) • 37 Degree Flare Filling • 45 Degree Flare Fitting • 45 Degree Inverted Flare Fitting • Split Flange Coupling

/'~~Q
illustration

/ »<. //

~--------._

<,

".~ I
8
g009OO528

4. Position the split flange parallel over Ihe port. Tighten the bolts on both connections to the proper torque. Follow the prescribed torque sequence for spilt flange connections. Refer to Illustration 8. Add the measurement of gap (A) to the measurement of gap (8). The total must not exceed 4.0 mm (0.16 inch). 5. Start the engine. 6. Move the implement conlrollevers positions. to all of the

7. Look at the hose during movement of the implement. Ensure that the hose is not in contact with the machine or with other hoses. Note: For hoses that cross an articulation hitch, check for contact during articulation. For hoses thai connect to the steering system, check for contact during steering. 8. Shut off the engine. 9. If the hose contacts other hoses or the machine during the test, loosen Ihe bolls and reposition the hose. Repeat steps 3 through 8 until there is no contact

Installation of Split Flange Couplings

1. For a metal tube to hose installation, install the tube and tighten all bolts finger tight at the rigid end. 2. Instalilhe hose and tighten all bolts finger Ught.

Installation of Adjustable STOR Fittings

This type of fitting is used in many applications. One end of the fitting will be an adjustable STOR fitting. The other end will be different. Always use the same installation procedure for the STOR end. Adjustable STOR fittings can be positioned before tightening.

3. Put the hose in a position so that the hose does not make contact with the machine or with another hose.

10
Specifications Section

SENR3130-12

Note: If the above conditions occur due to excessive tightening, the damaged fluid connector must be scrapped and the fluid connectors must be replaced.
i03513306

Straight Thread O..Ring Fittings

SMCS Code: 7553

1ifustration 9 Elbow body assembly (1) (2) (3) (4) (5) (6) End that connects to the tube or hose Fitting body locknut Backup washer O·ring seal End that is assembled to the mating part

g01848653

Illustration

10

g00911924

Note: For torques for plugs, refer to Specifications, "Plugs". Note: Straight Thread O-Ring fittings for medium pressure usage will have shorter threaded ends than high pressure fittings. The torque value for medium pressure Straight Thread O-Ring fittings will be lower than the torque values that are required for Straight Thread O-Ring fittings for high pressure fittings.

1. Put locknut (3), backup washer (4) and O-ring seal (5) as far away from the threads as possible, Hold these components in this position. Turn the fitting into the mating part, Turn the fitting until backup washer (4) contacts the surface of the mating part. Note: Excessive use of the wrench will distort the washer. Distortion of the washer will prevent proper sealing.

2. Put the fitting assembly in the correct position.

loosen fitting (2) until the correct assembly position is achieved. Do not loosen the fitting more than 360 degrees. Install the tube or hose hand tight in order to verify the orientation of the fitting. Tighten the fitting (2) to the torque that is shown in the correct chart for the fitting that is used. Tighten locknut (3) to the torque that is shown in the correct chart for the fitting that is used. Use a backup wrench, when the locknut is tightened. Note: Torque the fitting prior to the locknut. Note: If the fitting is not adjustable, the hex on the body replaces the locknut. To install this type of fitting, tighten the hex against the face of the mating part. Excessive tightening of the connectors can cause failure. Connectors that are under tightened can also cause failures. The following failures occur: • Excessive tightening can expand a loose ferrule into the nut. This will cause the ferrule to lock up in the nut and the nut will not function properly. • Excessive tightening can split the nut on the end of the tube or can split the ferrule. • Excessive tightening can gall or excessive tightening can strip the threads of the nut.

SENR3130-12
Specifications

11
Section

Table 12

Table 13

Ferrous Straight Thread O-Ring Fitting Torques for Mating with Ferrous Materials Medium Pressure use with 37' Flare FiUings

-.

Ferrous Straight Thread O·Ring Fittings Torques for Mating with Ferrous Materials High Pressure use with O·Ring Face Seal Fittings Nominal Outer Diameter of the Tube 4.76 mm (0.lB8 inch) 6.35 mm (0.250 inch) 7.94 mm (0.312 inch) 9.52 mm (0.375 inch) 12.7 mm (0.500 inch) 15.88 mm (0.625 inch)
1---

Nominal Outer Diameter of the Tube 3.18 mm (.125 inch) 4.76 mm (.188 inch) 6.35 mm

Thread Size Inch

Standard Torque Tolerance (+10% - 0%) 8 + 1 N·m (70 + 9 Ib in)

Thread Size Inch

Standard Torque Tolerance (+10% - 0%)

---

5/16

- 24

318 - 24 7/16 - 20

-3/8 - 24 7/16 - 20 1/2 - 20

9/16 - 18

---

12 + 2 N'm (105 + 18 Ib in) 22 + 3 N'm (195 + 27 Ib in)

---

13 + 2 N'm (115 + 181b in) 17 (150 -" 28 (250

+ 2 Nrn + 18 Ib in)

~250mch)

1/2 - 20
9116 - 18 3/4 - 16 7/8 - 14 11/16-12
.--

30 + 3 N'm (265 + 27 Ib in)

----

--

7.94 mm (.312 inch) mm inch) mm inch)

9.52 (375 _._. 12.70 (.500

--

+ 3 N'm + 27 lb in)

48 + 5 N'm (35 + 4 Ib fI) 82 + 9 N'm (60 + 7 Ib ft)

._---_.

-3/4 - 16
7/8 - 14 1 1116 - 12 1 3/16 - 12

35 + 4 N'm (26 + 3 Ib tt)

.--

_.

55 + 6 Nm (41 + 4 Ib ft) 80 + 8 Nm (60 + 6 tb tt) 100 + 10 Nrn (75 + 7 Ib ft)

--

-----------

140 + 14 N'm (i05 + 10 Ib fI)

15.88 mm (.625 inch) _. 19.05 mm (.750 inch)

._--

19.05 mm (0,750 inch) 22.22 mm (0.875 inch) 25.40 mm (1.000 inch) 31.75 mm (1.250 inch) 38.10 mm (1.500 inch) 63.50 mm (2.500 inch)

190 + 19 N'm (140 + 14 Ib ft) 250 + 25 N'm (185 + 18 Ib ft) 300 + 30 Nm (220 + 22 Ib ft) 350 + 36 N'm (260 + 27 Ib ft) 415 + 42 Nrn (305 + 31 Ib ft)

1 3/16 - 12 1 5/16 - 12 1 5/8 -12

-----

22.22 (.875 r-------25.40 (1.000

mm inch) mm inch)

.1 5/16 - 12 1 5/8 - 12

135 + 14 Nm (100 + 10 Ib ft) 150 + 15 N'm (110+ l1lbft) 290 + 29 N'm (215 + 21 tb tt) 325 + 33 Nrn (240 + 24 Ib ft)

--

31.75 mm (1 .250 inch) 38.10 mm (1.500 inch) 50.80 mm (2.000 inch)

-_
---

1 7/8 - 12 2112-12

_._.

1 7/8 - 12

21/2 - 12

c-------.

--

510 + 51 Nrn (375 + 38 Ib ft)

--

420 + 43 Nrn (310 + 321b ft)

Note: Use 50 percent of the torque values from Table 13 when the fitting or the port material is nonferrous.

Note: Use 50 percent of the torque values from Table

12 when the fitting or the pori material is nonferrous. Note: Straight Thread O-Ring fittings for high pressure usage will have longer threaded ends than medium pressure fittings. The torque value for high pressure Straight Thread O-Ring fittings will be higher than the torque values that are required for Straight Thread a-Ring fittings for medium pressure fittings.

12 Specifications

SENR3130-12 Section

Table 14

Table 15

Metric Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials Ref Nominal Outer Diameter of the Tube 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 16 mm 20 mm 22 mm 25 mm 30 mm 38 mm 50 mm Thread Size Standard Torque Tolerance (+10% -0%) 11 + 2 N-m (95 + 18 Ib in) 21 + 3 N-m (185 + 27 Ib in) 37 + 4 N-m (27 + 3 Ib tt) 47 + 5 Nrn (35 + 4 Ib ft) 58 + 6 N-m (43 + 4 Ib tt) 75 + 8 Nm (55 + 6 Ib tt) 105 + 11 N-m (75 + 8 Ib tt) 180 + 18 Nrn (130 + 13 Ib ft) 225 + 23 N'm (165 + 17 Ib ft) 325 + 33 N'rn (240 + 24 Ib tt) 350 + 36 N·m (260 + 27 Ib ft) 440 + 45 N'm (325 + 33 Ib tt) 525 + 53 Nm (390 + 39 Ib ft)

Thread Size Inch 5/16 318 7/16 1/2 9/16 3/4

Torque Tolerance (+10% - 0'%) 9 + 1 N'm (80 + 9 Ib in) 17 + 2 N'm (150 + 18 Ib in) 23 + 3 N'm (205 + 27 Ib in) 28 + 3 N'm (250 + 27 Ib in) 34 + 4 Nrn (25 + 3 Ib ft) 60 + 6 N'm (44 + 4 Ib ft) 115 + 12 N'm (85 + 9 Ib tt) 140 + 14 N·m (105 + 10 Ib tt) 190 + 19 N·m (140 + 141b ft) 210 + 21 N'm (155 + 151b ft) 290 + 29 Nrn (215 + 21 Ib ft) 325 + 33 N'm (240 + 24 Ib

M8 X 1 M10 Xl M12 X 1.5 M14 X 1_5 M16 X 1.5 M18Xl.5 M22Xl.5 M27 X 2 M30 X 2 M33 X 2 M42 X 2 M48 X 2 MBO X 2

7/8
1 1/16 1 3/16

1 5/16 1 518
1 7/8

ttl

2 1/2

420 + 43 N'm (310 + 32 Ib ft)

Note: Use 50 percent of the torque values from Table 15 when the fitting or the port material is nonferrous.

Straight Thread O-Ring Plugs (Socket Drive)

Illustration

12

g00912006

Note: Use 50 percent of the torque values from 14 when the filting or the port material is nonferrous.
103514960

Note: The socket may be hexagonal or a square recessed drive.

Plugs
SMCS Code: 7553

Straight Thread O-Ring Plugs (Hex Drive)

O~
Illustration 11

900911999

SENR3130-12 Specifications

13
Section

Table 16

Table 17

Thread Size

Inch ---_ .._-5/16

-,--.,-.~ - .~,-

Torque Tolerance (+10% - 0%) 5 + 1 N'm (44 + 9 Ib in)

Type of

Plug

Thread Size Inch

Torque Tolerance (+10'% - 0%)

----------

1/2 - 13

3/8

,---

20 + 5 N'm (175 + 441b in) 35 + 5 Nm (26 ...4 Ib f1) 50 + 5 N'm (37 + 4 Ib fI) 70 + 15 N-m (52 + 11 Ib ft)

11 + 2 N-m pOO + 181b in)

5/8 - 11 A 3/4 - 12 3/4 - 16 7/8 - 14 1 1/8 - 12 1 5/16 - 12 1 1/2 - 12 ,_

---------------

----

7/16

_.,----

1/2
9/16
-----

--

16 + 2 Nm (140 + 181b in)

20 + 2 N-m (180 + 18 Ib in) 35 + 4 Nom (26 + 3 Ib fI) 70 + 7 N'm (50 + 5 Ib ft)

---------~

------ -----.---'.~-------

314 7/8
1 1/16 1 3/16 1 5/16
1 5/8 1
---

90 + 15 N'm (66 + 11 Ib ft)

---

100 + 10 Nm (75 + 7 Ib ft)

----

----_._------

170 + 17 N'm (125 + 131b ft) C

2 - 12

12.5 + 15 N'm (92 + 111b ft) 70 + 15 N'm (52 + l11b fI) 90 + 15 N'm (66 + 11 Ib It) 11 + 4 Nom (97 + 35 Ib in)
._----

215 ... 22 Nom (160 + 16 fb fI)

--------

1 1/8 - 12
1 5/16 - 12
-----

270 + 27 N'm (200 + 20 Ib ft) 285 + 29 N-m (210 + 21 Ib ft)

718

----~-~.----.
370
---------

1/2 - 20
D
f----

+ 37 N-m (270 + 27 lb ft) c----

_ _--..

7/8 -14

55 + 7 N'm (41 + 5 Ib fI)

2 1/2

415 + 42 Nrn (305 +31 lb ft)

--

1 3/8 ·13
1 1/2 - 12

~~-~ _,_

90 + 15 Nrn (66 + 11 lb ft)

Drain Plugs with Straight Threads

110 + 15 Nom (81 + 11 Ib ft)

L____

_______

Note: Use 50% of the values in Table 17 when either the plug or the port material is nonferrous.

Straight Thread O..Ring Plugs (Mechanical Joint Tube Assemblies)

Illustration 13 g01848045

Note: Plug (A), plug (8) and plug (C) are used with a gasket. Conical seal plug (D) does not use a gasket.

Illustration

14

g00912010

Note: When you tighten the plug, the torque must not be transmitted to the joint between the tube and the elbow.

14
Specifications Section

SENR3130-12

Table 18

i03509587

Thread Size
Inch 7/8 1 1/16 1 3/16 1 1/4 1 5/16 1 5/8 1 7/8 2 1/2

Torque
150 ± 25 N'm (110 ± 181b ft) 200 ± 25 N'm (150 ± 181b ft) 275 ± 35 Nm (200 ± 26 Ib ft) 275 ± 35 N'm (200 ± 26 Ib ft) 300 ± 40 Nrn (220 ± 30 Ib ft) 450 ± 50 N'm (330 ± 37 Ib tt) 575 ± 75 N'm (425 ± 55 Ib ft) 1000 ± 100 Nrn (740 ± 741b ft)

Bulkhead Nuts
SMCS Code: 7553

1 ~'A

-~-::<~,~" ~

""1\'~))
(T-'
g01848733

i03509272

'--.,:=--'

O..Ring Face Seal Fittings

SMCS Code: 7553

Illustration

16

(1) Bulkhead connector (1Al Bulkhead nut

Note: The bulkhead connector may have different connections. The type of fluid connection does not affect the torque for nut (1A). Note: When you assemble the fluid connection, do not use the bulkhead nut (1A) as leverage for a backup wrench. Use the hex on the body (1) of the connector for leverage.

Illustration

15

g01848710

O-nng face seal fitting (ORFS fitting) (1) O-ring face seal connector (1A) O-ring groove (2) O-ring seal (3) Nul for the O-ring face seal Table 19

Ferrous Thread Size Inch 9/16 - 18 11/16 - 16 13/16 - 16 1 - 14 113/16-12 1 7/16 - 12 1 11/16 - 12 2 - 12

ORFS Fitting

Standard Torque for Nut (3) 26 ± 3 N'm (230 ± 27 Ib in) 43 ± 5 N'm (30 ± 4 Ib ft) 65 ± 7 N'm (50 ± 5 Ib ft) 109 ± 11 N'm (80 ± 8 Ib tt) 144 ± 15 N'm (105 ± 11 Ib tt) 216 ± 22 N'm (160 ± 16 Ib tt) 304 ± 31 N'm (220 ± 23 Ib f1) 360 ± 36 N'm (270 ± 27 Ib f1)

SENR3130-12 Specifications

15
Section

Table 20

---------------------

-_._---------------

37 Degree Flare Fittings

2

---_ ..,,-~--5/16
8± 1 N'm (70 ± 9 Ib in)
---- --------------_._------

Thread Size Inch

Torque

----

3/8 7/16 112

17

10 ± 1 N'm (90 ± 9 Ib in)

± 1 N'm

(150 ± 9 Ib in)
--

21 ± 2 N-m (185 ± 18 Ib in)

_.-._._.

9/16

27 ± 2 N'm (240 ± 18 Ib in) ... ~--_ .. -------~--- -----_._._---36 ± 2 N'm (27 ± 1.5 Ib tt) 45 t. 3 N'm {33 ± 2 Ib

11116 314

----_._--------

ttl

------

r-------------

13/16 -------_.7/8 1

_._- _,-----

48 ± 3 N'm (35 ± 2 Ib tt) 53 ± 3 N'm (39 ± 2 Ib f1) 72 ± 4 N'm (55 ± 3 Ib fI)

Illustration 17 g0184804B

---------_.

f--

1 1/16

1 3/16 1 5/16 1 7/16 r--'--1 5/8

84 ± 5 N'm (60 ± 4 lb ft) ------..--~ 108 ± 6 Nm (80 ± 4 Ib ft) 137 ± 7 N'm (100 ± 5 Ib ft)
--------_._---

-_

(1) 37 degree flare fitting. (2) Swivel nuts. Tab!e 21

149 ± 8 N'm (110 t 6 Ib ft) 179 ± 9 N'm (130 ± 7 Ib fI)

------

-------------

---_ .._
f--------~-

1 11/16 1 7/8
---

179 ± 9 N-m (130 ± 7 Ib It) 185 ± 10 N'm (135 ± 7 Ib

--~~~
fll

Nuts for 37 Degree Flare Fittings --_._--_._-----...~--.Standard Nominal Outer Torque Thread Size Diameter of Tolerance (+ Inch the Tube 10% - 0%)
--

-~-----~-~-

--.~~.-.-, 5116
-

-----

3.18 mm (.125 inch) 4.76 mm (.188 inch)

.._-----_.

5 ± 1 N'm (45 ± 9 Ib in) _ 11 ± 2 N'm (100 ± 18 Ib in) 16 ± 2 N'm (140 ± 18 Ib in)

,-~-.

----,.._--_._--------

203 ± 11 N'm (150 ± 81b fl) 262 ± 14 N'm (195 ± 10 Ib ft)

----

318
..

----_

- ----

~,-,---~-

2 1/2

6.35 mm (.250 inch) 7.94 mm (.312 inch)

7/16 1/2 9/16

_._-----

--

Note:
i03512924

.--~-

- -----------------

20 ± 2 N'm (180 ± 18 Ib in)

Flare Fittings
SMCS Code: 7553 The torques in Table 21 are for 37 degree flare fittings. The torques in Table 22 are for 45 degree flare fittings and 45 degree inverted flare fittings.

9.52 mm (.375 inch) 12.70 mm (.500 inch) 15.88 mm (.625 inch) 19.05 mm (_750 inch) 22..22 mm (.875 inch)

-------._------

3/4 718 1 1116

- -_ .. _--------

27 ± 3 N'm (240 ± 25 Ib in) -,..~-~ 58 + 6 Nrn (43 + 4 Ib ft) 74 ± 8 N-m (55 ± 6 !bll)

r--1 3/16
----

---~----135 ± 14 N-m (100 ± 10 Ib ft) 156 ± 16 N'm (11 5 ± 12 Ib ttl 217 ± 22 Nrn (160 ± 16 lb fI)

108 ± 11 N'm (80 ± 8 Ib ft)

~----

._-_.
_

_.

25.40 mm (1.000 inch) 31..75 mm (1.250 inch)

1 Sl16
_ ._---

1 5/8 1 7/8
------_
..

---_._--_ .. _----

---~-----.--

38.10 mm (1.500 inch) 50.80 mm (2.000 inch)

251 ± 26 N'm (185 ± 19 Ib ft) _ 339 ± 34 N·m (250 ± 25 !b ft)

2 1/2

--

-----------

Note: Use 50 percent of the torque values from Table 21 when the filting or the port material is nonferrous.

16
Specifications Section

SENR3130-12

45 Degree Flare and 45 Degree

i03514282

Inverted Flare Fittings

2

Air Conditioning Fittings

SMCS Code: 7553

Illustration

18

g01848049
illustration

(1) 45 Degree Inverted Flare Fittings, (2) 45 Degree Flare Fittings,

19

901848052

Table 22

(1) D-ring seal. (2) 45 degree Rare filling.

45 Degree Flare Fittings and 45 Degree Inverted Flare Fittings Nominal Outer Diameter of the Tube 3,18 mm (_125 inch) 4,76 mm (,188 inch) 6,35 mm (.250 inch) 7.94 mm (.312 inch) 9,52 mm (.375 inch) 11_11 mm (.438 inch) 12.70 mm (,SO~ inch} 15,88 mm (,625 inch) 19,05 mm (,750 inch) 22,22 mm (.875 inch) Thread Size Inch 5f16 Standard Torque 5 ± 1 N'm (45 ± 91b in) 8 ± 1 N'm (70 ± 9 lb in) 11 ± 1 N'm (100 ± 9 Ib in) 17 ± 1 N'm (150 ± 9 Ib in) 30 ± 2 Nm (265 ± 18 Ib in) 30 ± 2 N-m (265 ± 181b in) 38 ± 2 N'm (28 ± 2 Ib ft) 50 ± 3 Nrn (37 ± 2 Ib ft) 90 ± 5 Nm (65 ± 4 lb tt) 100 ± 6 N'm (75 ± 5 Ib ft)

Table 23

Air Conditioning O-Ring Fitting End Torque 14 ± 4 N'm (125 ± 35 Ib in) 27 ± 4 Nrn (240 ± 35 Ib in) 40 ± 4 N'm (30 ± 3 Ib ft) 45 ± 5 N'm (33 ± 4 Ib ft)

Fittings 45 Degree Flare Fitting End Torque for Steel Tubes Torque for Aluminum Tubes 23 ± 3 Nm (205 ± 27 Ib in) 33 ± 4 N-m (290 ± 35 Ib in) 38 ± 4 N'm (335 ± 35 Ib in) 50 ± 5 Nm (37 ± 4 Ib ft)

Thread Size Inch

3/8
7116 1/2

5/8 - 18

30 ± 3 N'm {265 ± 27 Ib in) 52 ± 5 N'm (38 ± 4 Ib ft) 60 ± 7 N'm (44 ± 51b ft) 75 ± 8 Nrn (55 ± 61b tt)

3/4 - 16 7/8 - 14 1 - 14
1 1/16 - 14

5/8 11/16 3/4

7f8 1 1/16 1 1f4

Table 24

Quick Disconnect Thread Size Inch 7/8 - 20

Air Conditioning

Fittings

Torque49 ± 3 Nm (36 ± 2 Ib fI) 62 ± 3 Nrn (46 ± 2 Ib fI)

1 1/4 - 18

---

SENR3130-12 Specifications

17 Section

i03517423

Air Brake Fittings

SMCS Code: 7553

Note: The following table has the recommended standard torque value for tapered pipe thread fitting for use on all Caterpillar equipment and Mitsubishi enqines, Use Table 26 as a general recommendation only. Actual values may vary due to variations in the material of [he connector. Actual values may vary due to variations in the characteristiCS of the threads.
Table 26
,------------

Tapered
.-

Pipe Thread

Fittings Torque

Illustration 20

gOlB48737

Diameter of the Pipe Thread (Inch)

Standard Threads with 5P-3413 Pipe Sealant ---_. 10 N'm (90 Ib in) 16 N'm (140 Ib in) 20 N'm (175 Ib in) 35 Nm (26 Ib ft)
--

..-----~-Threads without Pipe Sealant 10 N'm (90 Ib in) 16 N'm (140 Ib in) 25 Nom (220 Ib in) 45 N'm (33 Ib tt) 60 N-m (44 Ib ft) 75 N·m (55 Ib ft) 90 Nm (65 Ib ft)
-------

Put nut (1) and sleeve (2) over the tube. Push the tube into the counterbore of the fitting body as far as possible. There are two methods that may be used to lighten the nut. Tlghten the nut with one of two methods. • Tighten nut (1) to the torque that is specified in Table 25. • Tighten nut (1) by the number of turns that is specified in Table 25. The number of turns is for the turns after the nut is finger tight.
Table 25

1/16 1/8
1/4
f-----

3/8

112
3/4

45 N'm (33 Ib ft) 60 N'm (44 Ib ft)

-

1
1 1/4 1 1/2 2

75 N-m (55 Ib ft)

----

Nominal Outer Diameter of the Tube 6.35 mm (0.250 inch) 9.53 mm (0.375 inch)

..Torque Turn Tightening Nonmetallic Tubing 11 ± 3 N'm (97 ± 27 Ib in) 20 ± 3 Nm (175 ± 27 Ib in) 3
-

---

95 N-m (70 Ib tt)

110 N-m (80 Ib ft) 130 Nm (95 Ib tt) 160 N'm (120 Ib ff)

110 Nrn (80 Ib ft)

Copper Tubing 2
--

-_ .._,_

130 N'm (95 Ib £I)

Note: Use 50 percent of the torque values from Table 26 when the fitting, the plug, or the pori material is nonferrous. Note: Use 50 percent of the torque values from Table 26 when a tapered thread is mated with a straight thread.
i02387806

-1------

--_.

12.70 mm (0.500 inch)

35 ± 6 N-m (26 ± 4 Ib ft) 40 ± 6 Nom (30 ± 4 Ib ft) 50 ± 6 N'm (37 ± 4 Ib fI)

4 3 1/2 3 1/2

2 3

---

f----

15.88 mm W625 inch) 19.05 mm (0.750 inch)

Miscellaneous Fittings
3

--

SMCS Code: 7553

Note: Clean the connectors and the seals and lubricate the connectors and seals by using Refrigerant Mineral Oil. This is a special oil that is compatible with R-134a.
i03517443

Hi Duty Tube Fittings (Shear Sleeve)

Tapered Pipe Thread Fittings

SMCS Code: 7553 Torque is based on the diameter of the thread. The torque values are identical for coarse threads and fine threads.
Illustration 21
g00909648

Specifications

18

SENR3130-12 Section

Put nut (1 ) over the tube and push the tu be into the counterbore of the fitting body as far as possible. Turn the nut with a wrench until a small decrease in torque is felt. The small decrease in torque indicates that the sleeve (1A) has been broken off of the nut. Hold the tube in order to prevent the tube from turning. Tighten the nut for an additional 1 1/2 turns.

103515082

Hose Clamps
SMCS Code: 7553

Worm Drive Band Type Clamps

SAE Flareless Fittings

lllustratlon

22

g00909647

Installing a New Flareless Fitting

Pul nut (1) and sleeve (2) over the tube. The head end of the sleeve should be next to the nut. The head end has a shoulder. The nut will be seated against this shoulder when the nut is tightened. Push Ihe tube into the counlerbore of the fitting body as far as possible. Turn nut (1) clockwise until the sleeve grips the tube. The sleeve must prevent all movement of the tube. Tighten the nut for an additional 1 1/4 turns. The sleeve should be seated and the sleeve should give a locking action.
Illustration Table 27 24 g00910017

Width (A) of Clamp 7.9 mm (0.31 inch) 13.5 mm (0.53 inch) 15.9 mm (0.63 inch) Width (A) of Clamp 7.9 mm (0.31 inch) 13.5 mm (0.53 inch)

Torque for New Hose 1.4.± 0.3 N'm (12 ± 3 Ib in) 4.5 ± 0_7 N-m (40 ± 6 Ibin) 7.5 ± 1 N'm (66 ± 9 Ib in) Torque for Reused Hose(') 0.8 ± 0.3 N'm (7 ± 3 Ib in) 3_0 ± 0.5 N'm (27 ± 4 Ib in) 4.5 ± 0.7 N'm (40 ± 6 Ib in)

Installing a Used Flareless Fitting

Less turns are required for a used fitting. Put nut (1) and sleeve (2) over the lube. The head of the sleeve should be next to the nut. Push the tube into the counterbore of the fitting body as far as possible. Tighten the nut until a sudden increase in torque is felt Next, tighten the fitting for an additional 1/6 to 1/3 turn in order to seat the sleeve.

15.9 mm (0_63 inch)

(1)

Use this value when the hose is reused. The clamp may be new or reused.

Constant Torque Hose Clamps

Use a constant torque hose clamp in place of any worm drive band type clamp. Ensure that the constant torque hose clamp is the same size as the worm drive band type clamp. Due to extreme temperature changes, the hose will heat set. Heat setting can cause worm drive band type clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures that have been caused by worm drive band type clamps that have loosened. The constant torque hose clamp will help prevent these failures.

Flex Fittings

Illustration

23

g00909645

Put nut (1) and sleeve (2) over the tube and push the tube into the counterbore of the fitting body as far as possible. Tighten the nut until the nut is against the hex part of the fitting body

SENR3130-12 Specifications

19 Section

Illustration 25 (1) Constant Torque Hose Clamp (Belleville Washer) (2) Constant Torque Hose Clamp (Tee boll and Spring)

g01848056

Use a torque wrench for proper installation of all constant torque hose clamps. There are two types of constant torque hose clamps: Belleville washer (1) and Tee bolt and spring (2) When the constant torque hose clamp (Belleville washer) (1) is assembled correctly, the Belleville washers (1A) are nearly collapsed flat The proper torque for screw (18) is based on the diameter (B) of the clamp. Refer to the following table for the correct torque.
r---.---------------~-----------------Diameter (8) Standard Torque r------------.--------~---------1 Up to 50.8 mm (2 inch) 7.5 ± 1 N·m (65 ± 10 Ib in) Greater than 50.8 mm (2 inch) 11 ± 1 Nm (95 ± 10 Ib in)
Table 28

The correct torque for the constant torque hose clamp (tee bolt and spring) (2) is 7.5 ± 1 N·m (65 ± 10 Ib in).

Index
A Air Brake Fittings Air Conditioning Fittings 17 16

M
Metric (ISO) Fasteners Hex Button Head Screw and Set Screws.......... Metric (ISO) Machine Screws... Metric (ISO) Nuts and Bolts Metric (ISO) Taperlock Studs Miscellaneous Fittings Flex Fittings........................................................ Hi Duty Tube Fittings (Shear Sleeve) SAE Ffareless Fittings........................................ 5 6 6 5 5 17 18 17 18

8
Bulkhead Nuts 14

E
English (SAE) Fasteners English (SAE) Machine Screws English (SAE) Nuts and Bolts English (SAE) Taperlock Studs Hex Button Head Screw and Set Screws.......... 6 7 6 7 7

o
O-Ring Face Seal Fittings "" 14

p
Ptugs Drain Plugs with Straight Threads Straight Thread O-Ring Plugs (Hex Drive) Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies) Straight Thread O-Ring Plugs (Socket Drive) 12 13 12 13 12

F
Flare Fittings 15 37 Degree Flare Fittings 15 45 Degree Flare and 45 Degree Inverted Flare Fittings 16

G General Information............... Introduction to Torque Torque Sequence Torque-Turn Ground Engaging Tool (GET) 4 4 4 4 8

5
Specifications Section ..,....................................... Straight Thread O-Ring Fittings............................. 4 10

Fasteners

T
Table of Contents. Tapered Pipe Thread Fittings " 3 17

H Hose Clamps......................................................... Constant Torque Hose Clamps Worm Drive Band Type Clamps 18 18 18

Important Safety Information..... Installation of Fittings............................................. Installation of Adjustable STOR Fittings Installation of Split Flange Couplings.................

2 9 9 9

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