Operating media A4

CAT"
•

Operating media

,e
en / 13.03.2006 AA020105 1/1
 Table of contents M.01
CAT'
•
Operating media A4.

Table of contents A4.01

Introduction M.02
Safety instructions M.03
Regulations and recommendations
Engine M.OS.OO
Regulations and recommendations
Engine Oil A4.0S.08.00
Regulations and recommendations
Cooling Water A4.0S.09.00

•
Regulations and care
Treatment of cooling water M.OS.09.01
Regulations and care
Treatment of cooling water A4.0S.09.02
Regulations and care
Diagramm I M.OS.09.03
Regulations and care
Diagram 11+111 A4.0S.09.04

• en /13.03.2006 AA020032 1/1

 Safety instructions A4.03

GCM34

Safety instructions
• No <>penfire during work at the fuel system!

No smoking!

Lube oil and fuel vapours may ignite on contact with ignition sources!

Caution! Buming and scalding h hen handling hot process materials!

• During all work or

stem disconnect allvoltagesl

~ fuel

.0
• dete

• coolant (C02• N2)

the safety instructions/safety specification sheets of the pro-

duct manufacturer are to be observed!

• en I 29.05.2002 AA021844 1/1

 CAT Regulations and recommendations A4.05.00

• I Engine

Regulations and recommendations

• en / 21.02.2001 BAO00158 1/1

 Regulations and recommendations A4.05.08.00

• GCM34

Engine oil
Engine Oil

The quality of the engine oil has a significant influence on the service life and performance, and
therefore on the economic operation of the engine A5.05.0B.25.01.nn.

For this reason, the lubricants to be used are subject to high requirements.

The oil used should cause as little deposits in the engine and in the heat exchangers as possible,
allow for long oil change intervais and low oil consumption and should prevent wear to the greatest
extent possible.
The sulfur ash content should be between 0.4 and 0.6 % by weight.

Base oil

The base oil should be a high-quality solvent raffinate from a source suitable for use as an engine
iubricant, should be highly resistant to oxidation and nitration, should be highly pressure resistant
and have a high thermal stability.

Regenerated oils may not be used.

Additives

The additives in the engine oil must fulfill the following requirements in Caterpillar engines at all
temperatures that can occur in normal operations between the setting point and 220 .C and must
remain effective and evenly fluid in bearings:

• Good cleaning (detergent) effect and dispersing power to prevent combustion product depos-

•
its and to dissolve and carry these products .

• Sufficient alkalinity to neutralize the acidic sulfur compounds produced during combustion .

• Good wear and corrosion protection.

• Low ash deposit formation tendency .

• en / 23.11.2005 BA021185 1/5

 Regulations and recommendations A4.05.08.00
CAT'
• GCM34

Lube oil treatment

Engine Oil

Only mechanical filters suitable for the filtering of doped oils may be used. Chemically active filters
may not be used.

• Oil filtering (full now)

Manually switchable double filters are sufficient for diesel engines.

Exception: automatic filters .

• Engine oil recommendations - Guarantee limitations

The name of the company is normally part of the name of the oil and should be indicated before the
oil designation in all orders in order to prevent confusion. Caterpillar-Kiel has not been able to
gather sufficient experience on the oil brands listed in column II. For this reason, the planned use of
any of these oils must be coordinated with the engine manufacturer in order to ensure that the guar-
antee is not voided.

Caterpillar has no experience with any oils not listed here. Caterpillar-Kiel can provide no guarantee
on the oil used, as the mixture and production cannot be influenced by Caterpillar. No guarantee can
be provided in the event of poor engine oil maintenance or the use of non-approved fuels. The oper-
ator is responsible for proving that any damage to the engine cannot be traced back to the oil used .

• en / 23.11.2005 BA021185 2/5

 Regulations and recommendations A4.05.08.00
CAT'
• GCM34
Engine Oil

Index of brands for use with gas fuel

Viscosity SAE 40 is required for all Caterpillar engines.

Engine oil Company Oil brand I II

Caterpillar CAT NGEO 40 X

CAT NGEO EL 350 X

CHEVRON CHEVRON HDAX

Low Ash Engine Oil X

EXXONMOBIL ESSO ESTOR HPC 40 X

EXXONMOBIL MOBIL PEGASUS 805 X

• EXXONMOBIL

EXXONMOBIL

SHELL
.
MOBIL PEGASUS 905

MOBIL PEGASUS 705

SHELL MYSELLA LA 40
X

I Proven in operation

II Approved for monitored use. Caterpillar must be informed if these oils are used, as there is
currently no information on the use of these oils in Caterpillar engines. Failure to inform
Caterpillar / Kiel of the use of these oils will void the guarantee .

• en / 23.11.2005 BA021185 3/5

 Regulations and recommendations A4.05.08.00

• CAT"
GCM34

Changing engine oil

Engine Oil

,
The oil change interval is significantly influenced by the circulating oil vcilume in the engine lubrica-
tion system, the operating conditions, the oil consumption of the engine' and the maintenance of the
engine.

The minimum oil circulating volume is 0.5 l/kW.

It is recommended that the oil level be checked daily (24 h) (the oil level may not fall below the min-
imum alarm limit). The oil should be topped off once per week, in any case no later than when 20%
of the circulating volume is used.

• The recommended. oil change interval for a system with a circulating oil volume of 0.5 I/kW is
7500 h.

The actual time of the oil change is dependent on compliance with the following limiting values.
This requires the continual monitoring of the engine oil by means of oil analyses.
These analyses are completed by the technical service department ofthe oil manufacturer or by Cat-
erpillar/ Kiel for a nominal fee. The oil for the analysis must be drawn during operation, ahead of the
engine.

Approximately 0.5 to 1 liter is required for the analysis.

The oil should be analyzed every 100 h for the first 500 hours of operation, after which an analysis
interval of 150 h is sufficient.

•
Value Interpretation Umitina value
Viscosity /40. C Increase as a result of oxidation/nitration +50 mm</ s
.
(Minimum level: 120 mm2/s)
Base number BN Reduction due to high acidity < 2.5 mg KOH Ig
I otal aCid number I AN Increase due to oil oxidation and acidity > ;j.U mg I'.UH Ig
pH value Presence of acids <4.0
Water Condensation, leaks > 0.2 Vol.% (vlv)
n-neptane InSOlubles l,;ontamlnatlon Trom 2:1 VOL'? Im/ml
combustion residue
IR WN 1710 Oil oxidation > 20 AJcm
IR WN1630 Oil nitration 2:20 AJcm

• en / 23.11.2005 BA021185 4/5

 Regulations and recommendations A4.05.08.00

• CAT'
GCM34

Hydraulic oil for the hydraulic system

Engine Oil

A turbine or hydraulic oil with very good anti-oxidation properties of between 68 and 90 mm2ls (cSt)
at 40 .C should be selected.

The standard value for changing the hydraulic oil is 7,500 h or annually.

Note:
Every time the hydraulic oil is changed also the filter needs to be
replaced (B1.05.06.346740 nn).

•
Lubricating oil firm Lubricating oil brand

AGIP OSO 68
OTE 68

BP ENERGOL HLP 68
ENERGOL THB 68

CALTEX RANDO HD68

REGAL R &0 68

CASTROL PERFECTO T 68
HYSPIN AWH-M 68

CEPSA HD TURBINAS 68

CHEVRON I
EP HYDRAULIK OIL 68
OC TURBINE OIL 68

ELF LUBMARINE TURBINET68

ESSO TERESSa 68

•
TROMART)

MOBIL D.T.E OIL HEAVY

SHELL TELLUS OIL T 68

TURBO OIL T 68

TEXACO RANDO HD 68
REGAL R & a 68)
.
TOTAL FINAELF PRESLIA 68
AZOLLAZS68

• en /23.11.2005 BA021185 5/5

 Regulations and recommendations A4.05.09.00
CAT'
• GCM34

Recirculating Cooling Water

Cooling Water

The cooling system consists of a closed cooling water circuit with a cooling water volume which must
be kept constant by topping up, depending on the evaporation loss. The checking of the recirculating
cooling water level has to occur at the expansion tank.

Our engines put particular requirements on the recirculating cooling water due to the increased po-
wer desity and the consequently increased heat to be dissipated.

These requirements can only be met by proper prepared, monitored and maintained cooling water.
If the the preperation, monitoring and maintenance work are not carried out properly, even a short
period of operation may result in damages due to corrosion.

• Three decisive facts are to be considerd for a proper treatment:

•
Suitable fresh water
effective corrosion inhibiting agent
- corrosion inhibiting oil, soluble
• chemical corrosion inhibiting agent (chemicals)
exact dosing of the corrosion inhibiting agent

Requirements for the cooling water

Always use clear, clean water. Suitable are:

Natural water (deep well-, well water)
condensate and
fully de-ionized water.

• The values for the fresh water analysis must be within the following limits:

corrosion-
inhibiting oil
Chemicals

total - alkaline earths mmolll 0,5 - 2,2 0 - 1,8

- Hardness' ° dGH 3 - 12 0 - 10***

pH value •• at 20 °C 6,5 - 8

Chloride ion content mg II max. 100

total chloride + max. 200

sulphate ions mg II

• en I 29.05.2002 BA020100 1/2

 Regulations and recommendations M.05.09.00

• GCM34

*) Water hardness:
Cooling Water

Water which does not fulfil the above requirements must be hardened or softened.
Water with a hardness of < 12° (10°) dGH must be brought within the specified range by
mixing with condensate or fully de-ionized water (by ion exchangel, see Diagram I
(M.05.09.03) .
Condensate and fully de-ionized water should be hardened up to 3° dPH. Magnesium
sulfate (Mg 5041 should be used for this purpose, if corrosion inhibiting oils are used.

Dosing:
For 1. dPH 21.4 g Mg SO. per ton of water are required .

• German total
dGH
=
=
Permanent hardness
dPH

Comparison with other values:

1° dGH = 0,18° mmol/l
1° dGH = 1,79° French hardness
+ Carbonate hardness
+ dKH

1° dGH = 1,25° British hardness

1° dGH = 17,9 USA hardness

**) pH value:

Concentration of hydrogen ions

< 7 = acid, 7 = neutral, > 7 = alkaline.

***) In general, the corrosion inhibiting effect of chemicals shows the best results with low

• water hardness values (- 0). At higher hardness values and with missing hardness
stabilization the chemicals may react with water contents, what may result in
precipitations and in reduction of the inhibiting effect .

• en I 29.05.2002 BA020100 212

 Regulations and care M.05.09.01

• CJJ'
GCM34

1.
Treatment of cooling water

Treatment of cooling water with corrosion inhibitors

Anticorrosive agents to be used in Caterpillar engines must have been tested for their effectiveness
according to the rules of the "Forschungsvereinigung Verbrennungskraftmaschinen e. V." (Research
Association for Internal Combustion Engines Inc).

Caterpillar will issue a recommendation on the basis of the results of the test. No liability for the
anticorrosive agent used will be accepted because Caterpillar is unable to control the recipe and
treatment.

Caterpillar has received positive test results for the agents mentioned in 1.1 and 1.2 or they have
proven effective over a long period of operation .

• 1.1 Anti-corrosion oil

The fresh water is mixed outside the engine with anti-corrosion oil to form a stable emulsion.

Forthe initial filling or after cleaning the coolant circuit a

1.5 % emulsion

should be used and for the subsequent filling a

1.0 % emulsion
should be used.

The following anti-corrosion oils are known to us to be effective (alphabetical order, not
complete):

• BP:
Castrol:
Esso:
Shell:
FEDARO-M
SOLVEXWT3
Kutwell40
Dromus B
Shell Oil 9156

The preparation of the emulsion can generally be carried out as follows:

Add oil to the water (15 - 25 .C) and stir vigorously. For initial fillings take so much water that
a 10 % emulsion can be prepared with the required amount of anti-corrosion oil.
This 10 % emulsion is added to the cooling circuit which is already filled with 75 % of the
necessary cooling water amount, via the expansion tank. Topping up can be done with the
engine running.

en / 07.04.2004 BA021161 1/3

 Regulations and care
CAT' A4.05.09.01

• GCM34

1.2 Chemical corrosion inhibitors

Treatment of cooling water

The chemical corrosion inhibitors have some advantages over the anti-corrosion oils e. g. no
danger of sludge formation due to breaking down of the emulsion and are simplier to prepare
and control.

Attention:
It is important to avoid too low concentration, because this may result in crevice corrosion!

The following materials are being used in Caterpillar engines at the moment:

Manufacturer Additive Limit value of

nitrite content as
N02 in mg II
Bedia Bedia Liquid BL1 1200 - 1500
Rohm + Haas Dia-Prosim RD 11 1400 - 2100
Dia-Prosim RD 25 -
Ashland DEWT-NC (Schiff) 1500 - 2250
(Drew Ameroid) CWT-11 0 (Land)

Maxigard 800 - 1100

Liqui dew1 500 - 700
Maritech Marisol CW 1000 - 2000
Nalfleet 9-108 750 - 1000
9-111 750 - 1000
Nalcool 2000 750 - 1000
Unitor Dieselguard NB 1500 - 2500
- Rocor NB LiquidO 1500 - 2500
Vecom CWT Diesel I OC2 (D99) 1500 - 2500
Arteco Havoline XLC -

&. Safety note!

Chromates are not recommended despite of their good properties due to their
poisonous nature!

Using and checking procedures must be obtained from the manufacturers, taking particular
care not to use any poisonous substance .

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 Regulations and care M.05.09.01

• GCM34

2.
Treatment of cooling water

Checking and care of the treated water

2.1 Anti-corrosion oil

A daily check (24 h) of the coolant level in the sight glass on the expansion tank is just as
important as checking the anti-corrosion oil contents every 1500 operating hours. During
prolonged operating breaks, a monthly check should be made.

Take the emulsion sample out of the supply line from expansion tank to pump and let it stand
for 1 h. Pour off oil which rises to the surface.

Carry out emulsion test e.g. with hand refractometer (specialist shop laboratory equipment) .

0% Cooling water change and cleaning necessary, see A4.05.09.02

<0,5% - Emulsion freshening required
0,5 - 1 % - Emulsion in order
>1% Concentration too high, possibly incorrect measurement

In case the measured values are higher than 1.5 %, test again with fresh sample water. If the
result is confirmed, a correction of the emulsion is necessary.

Emulsion freshening in case of concentration too low

Mix required amount of oil according to diagram II (A4.05.09.04) with conditioning water to a
highly concentrated emulsion.

Always add oil to water

Fill in the mixed emulsion via the compensator reservoir, also possible with engine running.

Emulsion correction in case of concentration too high

•
Drain cooling water emulsion according to diagram II (A4.05.09.04) and refill the circuit with
conditioning water .

Observe the manufacturer's instructions for use and all safety and disposal instructions!

2.2 Chemical corrosion inhibitors.

The maintaining of the determined concentration is of decisive importance for a proper

corrosion protection.

A concentration check of the chemical corrosion inhibitors under consideration of the limit
values (see 1.2) is to be carried out with the relevant testing equipment every 1500 h in
accordance with the instructions of the supplying companies.

After a freshening up of the concentration mix well with engine running!

• en 1 07.04.2004 BA021161 3/3

 Regulations and care A4.05.09.02

• GCM34

1. Changing the cooling water

Treatment of cooling water

Observe the manufacturer's instructions for use and all safety and disposal instructions!

1.1 Anti-corrosion oil emulsion

The anti-corrosion emulsion must be changed at the latest every 7500 operating hours, at least
annually ifthe 7500 operating hours are spread over a period of more than one year due to long
breaks in operation.

1.1.1 Cleaning the cooling water chambers before changing the emulsion

•
Stop engine and let cooling water cool down to 30 .C. First drain expansion tank with floating
oil then drain the entire system.

Remove water inlets on the crankcase and flush out any sludge which may have formed.

Fill engine with an alkali solution (e. g. P3T 308 from Messrs. Henkel 0.5 % solution) and run it
for approximately 12 hours. Stop engine and let it cool down to 30 .C.

Drain the cleaning solution and flush engine thoroughly with fresh water.

Then put in 90 % of the required amount of water. With the remaining 10 % and the required
amount of anti-corrosion oil (according to diagram II: A4.05.09.04) prepare a highly
concentrated emulsion.

Attention:
Always add oil to water!

•. Add the emulsion to system via the expansion tank.

1.2 Chemical corrosion inhibitors

When recirculating cooling water has chemical corrosion protection the cooling water does not
need changing .

• en 129.05.2002 BA020104 1/2

 Regulations and care A4.05.09.02
CAT"
• GCM34

2.
Treatment of cooling water

Cooling water with anti.freeze agent

In case of temperatures at or below the freezing point of the cooling water an anti-freeze agent
must be added to the coolant.

Only an anti-freeze agent with a corrosion protective effect may be used.

To obtain adequate corrosion protection, a 30 % concentration is necessary. The highest

concentration is 50%.
This agent must be changed annually (7.500 h).

•
When an anti-freeze agent is used, a reduction in cooling efficiency must be expected. In cases
of doubt MaK should be contacted .

For summer operation, it is advisable to drain off the cooling water with anti-freeze in it and
replace it with cooling water with chemical corrosion protection in order to guarantee adequate
radiator performance at higher am bienttemperatures.

3. Cleaning the cooling water chambers

Before badly scaled cooling water cha.mbers can be cleaned, they must be precleaned as
described and flushed well with water under pressure. This will remove loose foreign matter
such as sand and sludge which may have been deposited at places where the water flow speed
islow.
The firm which supplies the anti-corrosion material will usually be able to offer a good cleaning
agent for scale, such as:

Drew Chemical: SAF-ACID

•
Rohm + Haas: RD 13 M

Attention:
Keep to the manufacturer's instructions!
Improper use of the cleaning agents may cause damages to your health!

Flush cooling water chambers or cooling system with a 1 % sodium carbonate solution after
draining off the cleaning agent. Afterwards flush the water chambers with fresh water .

• en /29,05.2002 BA020104 2/2

•
Regulations and care A4.05.09.03
Diagramm I

GCM34

Diagram I
Determining the cooling water mixture for 10° dGH

5000 10'

4S00

12°
4000
13°

• 3500

3000
14'
15'
16°
17"
18'
19°
2500 20°
'iii' 21°
••~
.1: 22°
24'
"" 2000
"•:I•
VI
26'
28'
•..c 1500
30'
:I
0
E
co :t
1000 Cl
""
SOO
~
c
'E

• :t ••
500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Cooling system capacity (Iitres)

Note:
Calculation example:
Piant-specific filling quantities are to be determined on site

Cooling system capacity: 2300 I

Hardness of available fresh water: 19° dGH

To determine the fresh water mixture, proceed from the abscissa "Cooling system capacity" (2300 I)
via the intersection of the 19° dGH line to the ordinate" Amount used" and read off the amount of
water with 19' dGH which is to be used and which is to be mixed with the difference of 2300 - 1200 =

•
1100 litres of condensate or fully de-ionized water .

en /24.01.2001 BA020106 1/1

 Regulations and care A4.05.09.04

• GCM34

Diagram II
Diagram II +111

Emulsion freshening for weak concentration

measured oil concentration in vol. % 0.6 0.5 0,4 0,3 0,2 0,1 0
5

4
/
3
/

1/ /

,,
1
~E

•
0,8 I
.~ 0,7 1/
.5 0,6
.: 0,5
1/ V /
I 0,4
-;
17

1/ ;
C) 0,3
o
"i5
/ 1/ T

8 0,2 V / T
'0
E
o
, ,
E
co 0,1
0,1 0,2 0,3 0,4 0,6 0,8 1,0 2 3 45678910 20 30 40

amount of oil to be added in litres to obtain a 0.7 % oil concentration ••

Diagram III
Emulsion freshening for excessive concentration

measured oil concentration in vol. % __ --.l~- 1,1 1,2 1,3 1,4 1.5 1,6 1,82.0
5

•
4

1/ 1/1/
'$IH

."~ O,B
"u 0,7 T7
l: 0,6
V '/'
! 0,5
; 0,4
1

:E'"
g
0,3
17
,- ;
1
17/ I I I
b
,
E
0,2
!j! ~
o ,
E
~ , , I
0,1
0,01 0.02 0,03 0,04 0,05 0,06 0.08 0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 2 3 •

•
amount of cooling em~lsion to be drained off
water to be added in m ••

en / 20.02.2001 BA020108 1/1