Tips and Advice
Information, operation and maintenance tips and advice on all things fluid analysis. Our "Ask the Expert" section, features answers to frequently asked questions about fluids and fluid analysis.
Information Section:
Ask the Expert
How To Take A Good Oil Sample
General Recommended Cleanliness Levels
Cold Weather Recommendations
Operation Section:
Starting Recommendations
Engine Starting Recommendations
Operation Recommendations
Parking Recommendations
Maintenance Section:
Fluid Recommendations
Battery Recommendations
Tire Inflation Recommendations
Ask the Expert
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"Ask the Expert" section, features answers to frequently asked questions about fluids and fluid analysis. The comprehensive answers to these questions have been developed by Finning fluid analysis experts and categorized into the following sections:
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How To Take A Good Oil Sample
Developed by Caterpillar, our S·O·SSM program helps you detect problems
before they lead to costly repairs and downtime. We recommend sampling fluid compartments
every 250 hours and at each oil change. We recommend you check your OEM requirements for recommended sampling intervals.
Using oil valve probe
This sampling method requires a Brass Probe (8T9208) and approximately 15 cm (6 in) of
tubing. If you are sampling several compartments, begin with the cleaner
systems—usually the hydraulic system, then the transmission or steering system, and
finally the engine system.
Use a new piece of tubing for each machine or engine. It is especially important to
discard the tubing after sampling engine oil because soot and oil additives may remain in
the tubing and contaminate other samples.
Step A
Set the engine at low idle and remove the dust cap from the valve of the compartment you
are sampling.
Step B
Insert the probe into the valve and collect about 100 ml (4 fl oz) of oil into a waste
container. If the oil flow is slow at low idle, it may be necessary to have someone
accelerate the engine to high idle while extracting the sample. Dispose of the waste oil
properly. (This process cleans the valve and helps ensure a representative sample
Step C
Insert the probe into the valve again and fill the sample bottle three-quarters
full—do not fill to the top. Do not allow any dirt to enter the bottle or bottle cap.
Developed by Caterpillar, our S·O·SSM program helps you detect problems
before they lead to costly repairs and downtime. We recommend sampling fluid compartments
every 250 hours and at each oil change. We recommend sampling on-highway truck engines
every 15,000 miles (25,000 km) and at each oil change.
Step D
Withdraw the probe from the valve and secure the bottle cap. Then place the bottle with
the completed label into the shipping cylinder.
Ensuring accurate S·O·S results
Fill out sample label completely
To ensure accurate sample results, supply all of the information requested for each
machine compartment. Model, serial number, and service meter units on both equipment and
oil are very important. If necessary, you can obtain oil type and classification
information and the meter reading of your last oil change from shop records. It is also
critical to indicate whether or not you changed the oil when you took the sample.
New oil samples are necessary for oil condition analysis. When you receive a new brand
or shipment of bulk oil, submit a sample and indicate on the label the brand, type, and
classification of the oil.
Fill out the sample label information before you begin taking samples to keep the label
oil-free and easy to read. Use Equipment Commander – Oil Commander to register your samples online. For more information Link.
Avoiding contamination
To avoid contamination, do not take samples from the drain stream, a waste oil container,
or a used filter.
Caterpillar
PREVENTIVE MAINTENANCE PRODUCTS
Using vacuum extraction
This sampling method requires a Vacuum Pump (1U5718 or equivalent). Use this method for
pressurized systems not equipped with sampling valves.
Again, it is important to use a new piece of tubing after sampling engine oil because
soot and oil additives may remain in the tubing and contaminate other samples.
Step A
Turn the engine off. Measure and cut new tubing to the length of the dipstick. If the
compartment you are sampling does not have a dipstick, cut the tubing so that it reaches
about halfway into the oil depth.
Step B
Insert the tubing through the head of the vacuum pump and tighten the retaining nut. The
tubing should extend about 4 cm (1 in) beyond the base of the vacuum pump head.
Step C
Install a new sampling bottle onto the vacuum pump and insert the end of the tubing into
the oil—do not allow the tubing to touch the bottom of the compartment.
Step D
Pump the vacuum pump handle to create a vacuum. Hold the pump upright—if you turn it
over, oil may contaminate the pump. If oil enters the pump, disassemble and clean it
before taking the sample.
Fill the bottle three-quarters full—do not fill to the top.
Step E
Withdraw the tubing from the compartment. Remove the bottle from the vacuum pump and
secure the cap on the bottle. Then place the bottle with the completed label into the
shipping cylinder.
Using a separate pump for coolant samples
Do not use the vacuum pump used to extract oil samples to take engine coolant samples.
Although the fluid does not enter the barrel of the pump, glycol residue from a coolant
sample can cause a “false positive” in oil samples taken later with the same
pump. Designate a separate pump for coolant samples.
Making S·O·S sampling easier
Install oil sampling valves
All current Cat ® engines and machine models are equipped with sample valves for
pressurized oil compartments. Some engines and machines may not have these valves, but it
is easy and inexpensive to add them.
It is important to install valves in the correct location in each system and to avoid
contaminating the system during installation. We can help you with specific installation
procedures.
Use a tube cutting device
Cutting tubing with a pocket knife is difficult—and it allows particles that can
contaminate your sample into the tubing. To avoid these problems, we recommend the Tube
Cutter (1U7648), which allows you to make a quick, clean cut with just one hand.
Replacement blades (1U8589) for the Tube Cutter are also available.
Keep sampling supplies clean
Keep new, empty oil bottles capped and store bottles and tubing in dust-free plastic bags or containers.
The vacuum pump and brass valve probe should also be protected from dust. If you feel a
sample is contaminated, discard it and take another.
See Form No. PEGJ0047.pdf
General Recommended Cleanliness Levels
| PSI |
Target Level |
Industrial Hydraulic (Most Systems) |
|
| Less than 2000 |
16/14 |
| 3000 - 3000 |
15/13 |
| Greater than 3000 |
14/12 |
* 18/15 is recommended maximum level for most systems under 2000 PSI
* 16/14 is recommended maximum level for most 2000-4000 PSI systems |
* If servo values present
Less than 3000 PSI
Greater than 3000 PSI |
14/11
13/10
|
|
Bearing Lube Systems |
19/15 |
|
Industrial Gearboxes |
19/15 |
|
Turbines |
15/13 |
|
Hydraulic Systems (Implement & Steering) |
18/15 |
| Vehicles with Electronic Transmissions |
18/15 |
| Vehicles with Mechanical Transmissions |
21/17 |
| (777-797) OHT Filtered differentials & wheel groups |
18/15 |
|
Hydrostatic Transmissions |
|
| 2000+ |
16/14 |
| 3000+ |
15/13 |
| 4000+ |
14/12 |
|
Allison Transmissions |
18/15 |
| Fuel (Under Review) |
18/16/13 |
| Fill Oil |
18/15 |
| New and Rebuilt Engine (In process) |
18/15 |
| Component Rebuild Transmission, Pumps, Governors |
16/13 |
| Injector Testing Equipment Calibration Fluid |
15/13 |
| Pressurized, Non-filtered compartments |
To be established |
Note: Individual system requirements may vary. Customers should consult
manufacturers recommendations for exact cleanliness requirements.
Cold Weather Recommendations
Cold Weather Information
SMC Code: 1000; 7000
The information that is contained in this document is an aid to the operation and
maintenance of your Caterpillar machine in cold weather. This information will cover
operating your machine in temperatures from 0°C (32°F) to -55°C
(-67°F).
When you operate the machine in temperatures above 0°C (32°F),
refer to the Operation and Maintenance Manual for your machine.
The operation and maintenance of a machine in freezing
temperatures is difficult to outline in a general publication. The difficulty in outlining
the requirements is caused by the following conditions: the unlimited differences in
weather conditions, applications, and the supplies that are available in your area. In
order to provide the best possible guidelines, use the information in this document and
the following criteria: varying factors, recommendations form you Caterpillar dealer, and
past proven practices.
Hits for Cold Weather
NOTICE
Fluids contained in new machines permit operation to the temperature limits given in the
following table. If a new machine is shipped to an area outside of the temperatures below
these limits all fluids must be changed, the engine should not be started unless the
fluids have been warmed.
Make sure that you read the information for selecting the
lubricants to use in cold weather.
Limits For Oil Temperature For Machines With Factory Fill
| Compartment or System |
Oil Viscosities |
Min (°C) |
Max (°C) |
Min (°F) |
Max (°F) |
| Engine |
SAE 10W30 |
-20°C |
+40°C |
-4°F |
+104°F |
| Hydraulic |
SAE 10W |
-20°C |
+40°C |
-4°F |
+104°F |
| Transmission(1) |
SAE 30 |
0°C |
+35°C |
+32°F |
+95°F |
| Transmission(1) |
SAE 10W |
-20°C |
+10°C |
-4°F |
+50°F |
| Final Drives |
SAE 50 |
-15°C |
+50°C |
+5°F |
+122°F |
(1) The values are correct except for the power shift transmission that is installed in
the following trucks: 768C, 769C, and 771C
Prepare the machine for the weather conditions. Use the following options to keep the
machine warm: heaters, enclosures for compartments, and storage facilities.
- To assist in warm-up, block the radiator. Blocking the radiator will restrict air from
the fan.
- Before the beginning of cold weather, install the correct lubricant in each compartment.
- Keep all starting fluid at room temperature. Inject starting fluid only while the engine
is cranking.
- Provide cooling system protection for the lowest expected outside temperature.
Premix the antifreeze solution for the cooling system. At least, the freeze protection
that is provided by the solution should be equal to the system protection requirements.
- Check all rubber parts weekly: hoses, tires, and fan belts.
- Check all electrical wiring and connections for any fraying or for damaged insulation.
- Keep all batteries fully charged and warm.
- Fill the fuel tank at the end of each shift.
- Check the air cleaners and the air intake daily. If snow is present, check the air
intake more frequently.
Steering response on equipment with hydraulic steering may become very slow at very low
temperatures. This can happen even if the correct oils are used.
If the engine is started, run the engine until the engine reaches operating
temperature. Achieving operating temperature will help prevent the intake valves and
exhaust valves from sticking.
WARNING
Personal injury or property damage can result from alcohol or starting fluids
Alcohol or starting fluids are highly flammable and toxic and if improperly
stored could result in injury or property damage.
Do not store starting fluid or store alcohol in the operator's compartment.
Inject alcohol into air compressors in order to prevent moisture from freezing in the
air system.
The cooling system and the lubrication system for the engine do not lose heat
immediately upon shutdown. The transmission and the hydraulic system lose heat more
rapidly because of more exposed areas. Gear cases cool rapidly, since the gear cases do
not operate as warm as other compartments.
This means that an engine can maintain the ability to start readily after being shut
down for a few hours. The other systems will lose heat more rapidly. The equipment will
require exercising upon starting. If the engine is shut down for at least sixteen hours,
the engine will cool down to the outside temperature.
Running the engine at idle will keep the engine compartment warm. The compartment for
the transmission will also be kept warm. However, running the engine will not keep
hydraulic systems warm.
The outer wrapper on hydraulic hoses can crack when flexing occurs in cold
temperatures. This does not mean that the hoses have failed. The hoses will still carry
oil under pressure.
Condition the hydraulic hoses on the equipment before the temperatures decrease below -
40°C (-40°F).
Perform the following steps in order to condition the hoses with
the hoses on the machine: Operate at 66°C (150°F) hydraulic oil temperature for at least
one hour. Use an oil that has a pour point of -54°C (-65°F).
Normal machine operation will condition the hoses if arctic
fluids have been put into the system. However, the arctic fluid must be put into the
system before cold weather begins.
Condition the hoses before installation if the ambient
temperature is lower than =40°C (-40°F).
Perform the following steps in order to condition a hose before
installation:
- Fill the hose assembly with kerosene or with a winter blend of
diesel fuel. Leave the couplings attached.
- Keep the hoses filled for a minimum of eight hours at a
temperature of 22°C (72°F).
- Hose assemblies should be installed within thirty days of
conditioning.
Check the machine in order to be sure that the voltage of the
electric heaters matches the power source.
Do not get the cab too warm. In order to keep the operator from
sweating, keep the temperature below 0°C (32°F). If the operator is sweating, the
chances for the survival of the operator will decrease.
Correct track tension is especially important during cold weather
operation in snow. For adjustment procedures, refer to the Operation and Maintenance
Manual for the machine.
Starting Recommendations
Before Starting Engine
SMCS Code: 1000; 7000
NOTICE
Do not remove the air cleaner element when snow packing occurs. This could cause severe
engine damage. Instead, rework the air intake so air is taken in under the hood.
Do not use a torch to heat a compartment. This causes fires,
burns wiring, gaskets and seals, or melts the battery case.
When using canvas covers, do not install them near exhaust
systems. This helps to prevent fires.
Check the air cleaner daily before starting the machine. If you operate the machine in
heavy snow, attach a burlap sack loosely to the precleaner. By moving freely, the sack
will prevent the snow from accumulating around the precleaner. Keep the burlap sack away
from heated parts. The hot exhaust piping may ignite the burlap sack. Also, make sure that
the burlap sack does not touch any moving parts.
Keep starting fluid at room temperature.
In order to assist in warm-up, block the radiator. Blocking the
radiator will restrict air from the fan. Additional items may be needed to assist in
warm-up. The use of the following items may be required: coolant heaters, block heaters,
tents, and additional batteries.
Before entering the operator's station, inspect the condition of
the following parts: hydraulic hoses, tires, and fan belts. Carefully inspect these
components for any of these conditions: cuts, cracks, and worn spots. Check all electrical
wiring and check electrical connections for any fraying or for damaged insulation.
If the machine is equipped with a gasoline starting engine, check
the gasoline tank and check the sediment bowl. At every fifty service hours, check for
moisture and check for dirt.
Starting Information
SMCS Code: 1000, 7000
Categories of Cold Weather
| Category |
Temperature Range |
| Category 1 |
0 to -12°C (32 to 10°F) |
| Category 2 |
-12 to -26 (10 to -15°F) |
| Category 3 |
-26 to -40°C (-15 to -40°F) |
| Category 4 |
Lower than -40°C(-40°F) |
The fluids in all compartments must have a pour point below the outside starting
temperature.
Category 1
0 to -12°C (32 to 10°F)
The use of glow plugs on engines with electric start is required, if equipped.
Normally, a Caterpillar direct injection diesel engine will not require any starting
aids in this temperature range.
Note: If your machine is equipped with a Caterpillar 3500 Series
Engine that has an automatic ether injection system, leave the ether start switch in the
AUTOMATIC position. Ether will be injected automatically whenever the jacket water
temperature is below 13°C (55°F).
Machines that are equipped with Caterpillar 3500 Series Engines
without an ether starting aid should use an alternate system. A jacket water heater would
be a reasonable alternate system.
Category 2
-12 to -26 (10 to -15°F)
The use of glow plugs and the use of coolant heaters is required. Starting fluid may
also be required for engines that have an electric starter. An external power source for
starting will be required if the battery is not fully charged. Glow plugs or starting
fluid are required for engines that are equipped with a gasoline engine for starting.
Operate the equipment for fifteen minutes with no machine loading. Then, resume normal
operation.
Category 3
-26 to -40°C (-15 to -40°F)
When the outside temperatures are below -23°C (-9°F), run the
engine at IDLE. The following items are necessary for starting the engine at this
temperature: starting fluid, glow plugs (if equipped), and preheating of coolant.
An external power source or a heated battery compartment will be
required, if the battery is not fully charged. In applications that use an external power
source, provide permanent jumper cables in order to prevent arcing at the battery
terminals. Before starting normal operation, operate the equipment with no load for thirty
minutes.
Category 4
-40°C (-40°F)
Because starting cannot be ensured at these temperatures, run the engine at IDLE
position r park the machine in a heated area. If this recommendation is not followed,
preheat the oil and the coolant for four to eight hours. Heat the oil and coolant before
trying to start. Heat the oil and coolant in order to provide a minimum temperature of -18°C (0°F) from the following systems: water outlet, battery cell, and
oil. A heated battery compartment or an external power source will be required.
Ether may not be required if the engine is preheated adequately.
Even though the engine may start, all other compartments are cold. The compartments must
have fluids which can be pumped at starting temperature. Otherwise, the machine must be
sheltered or the machine must be heated.
Before starting normal operation, operate the equipment at no
load for one hour.
This recommendation is applicable, only if the engine compartment
and the battery compartment are closed and heated. If the machine is unprotected, the wind
will chill the compartments. In extreme situations, retention of heat is very low. The
compartments will gradually cool. Heat cannot be generated at a fast enough rate in order
to maintain the temperature of the compartments. Close and apply heat to the compartments
in order to maintain heat.
Engine Starting Recommendations
Starting Aid
SMCS Code: 1000; 1090; 1456; 7000
Diesel Engines That Are Equipped With Gasoline Starting Engines
- Place he lever that is used to release compression into the START position.
- Move the engine governor control to the SHUTOFF position.
- Shift the transmission for the gasoline starting engine into the LOW speed position.
Start cranking the diesel engine with the gasoline starting engine.
- After the diesel engine cranks freely, disengage the clutch for the gasoline starting
engine. Shift the transmission for the gasoline starting engine to HIGH speed. Engage the
clutch for the gasoline starting engine. Crank the diesel engine for several minutes in
order to warm the engine. As a result of cranking the diesel engine, the oil pressure
should attain the NORMAL range on the gauge. Also, the pressure of the diesel fuel should
register NORMAL.
- Place the lever that is used to release compression into the RUN position. Move the
diesel engine's governor control lever to the HIGH IDLE position.
NOTICE
Start the diesel engine with the starting engine transmission in High only.
- After the diesel engine starts, reduce the rpm of the diesel engine. Disengage the
clutch for the gasoline starting engine. Turn off the fuel to the gasoline starting
engine. Continue to run the gasoline starting engine until the gasoline starting engine's
carburetor bowl is dry.
Diesel Engines That Are Equipped With Gasoline Starting Engines and Glow Plugs
- Place the lever that is used to release compression into the START position.
- Move the governor control lever to the SHUTOFF position.
- Start cranking the diesel engine with the gasoline starting engine's transmission in LOW
speed.
- After the diesel engine cranks freely, disengage the clutch for the gasoline starting
engine. Shift the transmission for the gasoline starting engine to HIGH speed. Engage the
clutch for the gasoline starting engine. Crank the diesel engine for several minutes in
order to warm the engine. Cranking the diesel engine will also bring the oil pressure to
the NORMAL range on the gauges. Also, the pressure for the diesel fuel should register
NORMAL.
- Disengage the clutch for the gasoline starting engine, but allow the gasoline starting
engine to run.
- Turn the heat switch for the glow plug to the HEAT position. Allow the glow plug to
operate for two to five minutes. Do not crank the diesel engine.
- After warming the engine with the glow plug, move the lever that is used to release
compression into the RUN position. Engage the clutch in order to crank the diesel engine.
- With the heat switch in the ON position, allow the gasoline starting engine to crank the
diesel engine. Continue cranking the diesel engine until normal cranking rpm is achieved.
NOTICE
Start the diesel engine with the starting engine transmission in High only.
- While you crank the engine with the heat switch in the ON position, move the governor
control lever to the HIGH IDLE position.
- Keep the heat switch in the ON position until the engine starts and the engine runs
smoothly. After the engine starts, reduce the rpm of the engine.
NOTICE
Do not turn the heat switch to the Heat position if the engine is warm and running. Engine
damage could result.
- Disengage the clutch for the gasoline starting engine. Turn off the fuel for the
gasoline starting engine. Continue to run the gasoline starting engine until the engine's
carburetor bowl is dry.
Diesel Engines That Are Equipped With Ether Starting Aid or Manual Metered Ether Injection System warnings:
- Ether is poisonous and flammable.
- Breathing ether vapors or repeated contact of ether with skin can cause personal injury.
- Use ether only in well ventilated areas.
- Do not smoke while changing ether cylinders.
- Use ether with care to avoid fires.
- Do not store replacement ether cylinders in living areas or in the operator's compartment.
- Do not store ether cylinders in direct sunlight or at temperatures above 39°C (102°F).
- Discard cylinders in a safe place. Do not puncture or burn cylinders.
- Keep ether cylinders out of the reach of unauthorized personnel.
- To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
At temperatures above 0°C (32°F), the use of ether is not
normally necessary. At temperatures between 0°C (32°F) and -18°C (0°F), one to six
injections of ether may be required. The amount of ether that s required will depend on
the type of engine and the cranking rpm.
When you start the engine below -18°C (0°F), use a new
container of ether to make sure that there is adequate delivery pressure.
NOTICE
Inject starting aid (ether),only while cranking the engine.
At temperatures below -18°C (0°F), three to six injections of
ether will be required to start the engine. After the engine starts, and cranking is
stopped, continue to inject ether until the engine runs smoothly and/or the white smoke
stops. This may require as many as ten to twelve injections of ether.
Automatic Metered Ether Injection System
Start the engine with the ether starting aid in the AUTOMATIC
position.
After the engine starts, move the ether starting aid switch to
the MANUAL position. Hold the switch in the MANUAL position until the engine runs smoothly
and/or the white exhaust smoke stops.
Note: Regardless of the switch position, if the
jacket water temperature is at least 13°C (56°F), ether will not be injected.
Allow the engine to warm up at low idle for a minimum of five
minutes before operating machine.
Diesel Engines That Are Equipped With Glow Plugs
- Move the engine governor control to the FULL THROTTLE position.
- Turn the heat-start switch the the HEAT position. Maintain heat to
the engine for the time that is indicated in table below.
- Turn the heat-start switch to the START position. Spray ether starting fluid into the
air intake while you crank the engine.
| Times For Glow Plug Starting Aid |
| Starting Temperature |
Glow Plug Heating Time |
| Above 16°C (60°F) |
Zero minute |
| 16 to 0°C (60 to 32°F) |
One minute |
| 0 to -18°C (32 to 0°F) |
Two minutes |
| Lower Than -18°C (0°F) |
Three minutes |
Note: Ether starting fluid may not be requested in all instances.
NOTICE
Never operate the starter for more than twenty seconds at a time without allowing two
minutes for the engine to cool before attempting to start again.
Do not turn the heat start switch to the Heat position or the Start position with the
engine warm or running. Engine damage could result.
Use ether sparingly. Spray ether into the air intake for approximately one second. Wait
approximately two seconds before spraying again. Spray ether only while cranking the
engine. Follow instructions on the container.
- When the engine starts, return the engine governor control to the LOW IDLE position. Run
the engine at the rpm that allows the engine to run smoothly. If necessary, return the
heat-start switch to the HEAT position until the engine runs smoothly.
- When the engine is stopped, turn the disconnect switch to the OFF position in order to
prevent battery discharge.
Diesel Engines That Are Equipped With An Air Inlet Heater
WARNING
If equipped with an air inlet heater (AIH) for cold weather starting, do not
use types of starting aids such as ether Such use could result in an explosion and injury.
- Engage the parking brake
- Unlock the steering column and the steering wheel. Adjust the steering column and the
steering wheel to the desired position. Lock the steering column and the steering wheel.
- Move the control levers to the HOLD position.
- Push in the starting aid switch for the air inlet heater and release the starting aid
switch.
- The indicator light for the air inlet heater will come on during start-up. When the
indicator light goes off, turn the engine start switch to the START position.
- Depress the throttle pedal by 1/3 of the full pedal travel during engine cranking.
- When the engine starts, release the engine start switch key and the throttle pedal. The
throttle pedal will return to the low idle position.
After engine start-up, the air inlet heater can be activated for an extended postheat
cycles. The air inlet heater will operate for an additional 30 seconds in order to smooth
a rough running engine.
When your are starting the engine at temperatures below -18°C
(-0°F), the use of additional cold weather starting aids is recommended. A coolant
heater, a fuel heater, or extra battery capacity may be required.
Starting with Jump Start Cables
SMCS Code: 1000; 7000
WARNING
- Batteries give off flammable fumes that can explode resulting in personal injury.
- Prevent sparks near the batteries. They could cause vapors to explode. Do not allow the jump start cable ends to contact each other or the machine.
- Do not smoke when checking battery electrolyte levels.
- Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.
- Always wear eye protection when starting a machine with jump start cables.
- Improper jump start procedures can cause an explosion resulting in personal injury.
- Always connect the battery positive (+) to battery positive (+) and the battery negative (-) to battery negative (-).
- Jump start only with an energy source with the same voltage as the stalled machine.
- Turn off all lights and accessories on the stalled machine. Otherwise, they will operate when the energy source is connected.
NOTICE
When starting from another machine, make sure that the machines do not touch. This could
prevent damage to engine bearings and electrical circuits.
Turn on (close) the battery disconnected switch prior to the boost connection to
prevent damage to electrical components on the stalled machine.
Severely discharged maintenance free batteries do not fully recharge from the
alternator after jump starting. The batteries must be charged to proper voltage with a
battery charger. Many batteries though to be unusable are still rechargeable.
Use only equal voltage for starting. Check the battery and starter voltage rating of
your machine. Use only the same voltage for jump starting . Use of a welder or higher
voltage damages the electrical system.
Refer to Special Instruction, Battery Test Procedure, SEHS7633, available from your
Caterpillar dealer, for complete testing and charging information.
Severely discharge maintenance free batteries will not fully recharge from the
alternator alone after you jump start the machine. The batteries must be charged to the
proper voltage with a battery charger. Many batteries that are considered to be unusable
can still be recharged by this method.
Refer to Special Instruction, SEHS7633, "Battery Test Procedure" for complete
information about testing and about charging. This document is available from your
Caterpillar dealer.
When auxiliary start receptacles are not available, use the following procedure.
- Determine the reason that the engine will not crank. See Special Instruction, SEHS7768
for instructions about the use of a 6V-2150 Analyzer Group. This is still a valid
procedure if the machine does not have a diagnostic connector.
- Engage the parking brae on the stalled machine. Place the transmission into neutral.
Lower the equipment to the ground. Move all controls to the HOLD position.
- Turn the start switch on the stalled machine to the OFF position. Turn off all
accessories.
- Turn the battery disconnect switch on the stalled machine to the ON position.
- Move the machine that is being used as an electrical source near the stalled machine so
that the jump start cables reach the stalled machine. Do not allow the machines to
contact each other.
- Stop the engine of the machine that is being used as an electrical source. If you are
using an auxiliary power source, turn off the charging system.
- Ensure that battery caps on both machines are tight and correctly placed. Ensure that
batteries in the stalled machine are not frozen. Make sure that the batteries have enough
electrolyte.
- The positive ends of the jump start cable are red. Connect one positive end of the jump
start cable to the positive cable terminal of the discharged battery. Some machines have
battery sets.
Note: Batteries that are in series may be in separate compartments.
Use the terminal that is connected to the starter solenoid. This battery or battery set is
normally on the same side of the machine as the starter. The positive ends of the jump
start cable are red. Connect one positive end of the jump start cable to the positive
cable terminal of the discharged battery. Do not allow the positive cable clamps to
contact any metal except for the battery terminals.
- Connect the other positive end of the jump start cable to the positive cable terminal of
the electrical source.
- Connect one negative end of the jump start cable to the negative cable terminal of the
electrical source.
Note: In 24 volt battery systems, the negative cable terminal of the
electrical source is connected to the battery disconnected switch in the same battery set
that is used in Step 9.
- Finally, connect the other negative end of the jump start cable to the frame of the
installed machine. Do not connect the jump start cable to the battery post. Do not allow
the jump start cables to contact the battery cables, the fuel lines, the hydraulic lines,
or any moving parts.
- Start the engine of the machine that is being used as an electrical source or energize
the charging system on the auxiliary power source.
- Wait at least two minutes before you attempt to start the stalled machine. This will
allow the batteries in the stalled machine to partially charge.
- Attempt to start the stalled engine. See your machine's Operation and Maintenance
Manual, "Starting Above 0°C (+32°F) for the correct starting
procedure.
- Immediately after you start the stalled engine, disconnect the
jump start cables in reverse order.
- Conclude the failure analysis on the starting system of the
stalled machine and/or on the charging system of the stalled machine.
Starting with Auxiliary Start Receptacle
SMCS Code: 1000; 7000
Some Caterpillar products may be equipped with auxiliary start receptacles as standard
equipment. All other machines can e equipped with a receptacle from parts service. The
installation of an auxiliary starting receptacle will provide a permanent receptacle for
jump starting.
Two cable assemblies are also available in order to jump start the stalled machine from
another machine that is also equipped with this receptacle or with an auxiliary power
pack. Your Caterpillar dealer can provide the correct cables for your application.
- Make the initial determination of the machine's failure to crank. Refer to Special
Instruction, SEHS7768, "Use of 6V-2150 Starting Charging Analyzer Group". The
procedure is applicable, even if the machine does not have a diagnostic connector.
- Move the transmission control of the stalled machine into the NEUTRAL position. Engage
the parking brake. Lower the attachment to the ground. Move all controls to the HOLD
position.
- Turn the engine start switch of the stalled machine to the OFF position. Turn off all
accessories.
- Turn the battery disconnect switch of the stalled machine to the ON position.
- Move the machine that is being used as a power source so that the jump start cables can
reach the stalled machine. Do not allow the machines to contact each other.
- Stop the engine on the machine that is being used as a power source. If you are using an
auxiliary power source, turn off the charging system.
- On the stalled machine, connect the appropriate jump start cable to the auxiliary start
receptacle.
- Connect the other end of the jump start cable to the auxiliary start receptacle that is
on the power source.
- Start the engine on the machine that is being used as a power source. If you are using
an auxiliary power source, energize the charging system on the auxiliary power source.
- Wait for a minimum of two minutes while the batteries in the stalled machine partially
charge.
- Attempt to start the stalled engine. Refer to Operation and Maintenance Manual, Starting
Above 0°C.
- Immediately after you start the stalled engine, disconnect the
jump start cable from the machine that is being used as a power source.
- Disconnect the other end of the jump start cable from the stalled
machine.
- When the engine is running and the charging system is in
operation, conclude the failure analysis on the starting charging system of the stalled
machine, as required.
Operation Recommendations
After Starting Engine
SMCS Code: 1000; 7000
Whenever a machine as been parked for a long period of time, some of the systems will
cool to below normal operating temperatures. Always warm the machine systems before
operating the machine at full operation.
Damage to engine valve control components can result from engine operation for short
intervals during operation in very cold weather conditions. If the engine is not allowed
to warm completely, the engine can be damaged by repeated starting and stopping.
During engine operation below normal operating temperature, fuel and oil are not
completely burned in the combustion chambers. This fuel and oil causes soft carbon
deposits on the valve stems. Generally, these deposits do not cause problems because these
deposits are burned off during operating at normal engine temperatures.
Carbon deposits will interfere with valve operation. When the engine is started and
stopped at short intervals, carbon deposits will form. The short operating times do not
allow the engine to reach normal operating temperature. The carbon deposits will continue
to build up. Valve operation is affected by carbon deposits. Carbon deposits can cause the
following problems: burned valves, bent pushrods, and other damage to valve mechanism
components.
To avoid valve damage, always run the engine until the coolant temperature is at least
82°C (180°F). This will keep carbon deposits on the valve stems at
a minimum.
Thoroughly warming the engine will keep the other engine parts in
better condition. This could also extend the service life of the engine. With less acid
and less sludge in the oil, lubrication will be improved. This will give longer service
life for engine bearings, piston rings, and other parts.
White smoke is generated when you start the engine in cold
weather. In order to minimize white smoke, owners of 3208 Diesel Engines can install a
9N-3771 Cetane Injection Group. See your Caterpillar dealer for more information.
After the engine is warm, warm up the other systems. Start with
the hydraulics. Run the engine at less than one-third throttle, and slowly move the
control lever in order to lift the attachment. Initially, lift the control lever for a few
centimeters (inches). Lower the attachment slowly. Continue the sequence: raising,
lowering, extending, and retracting. Extend the travel during each cycle. Perform this
operation for all hydraulic circuits. Alternate between all of the attachments.
Exercise the transmission and the power train. If you cannot move
the control for the transmission, perform the following steps:
- Engage the parking brake or apply the brake pedal.
- Run the engine slightly above LOW IDLE.
- Shift the transmission several times from FIRST FORWARD to FIRST
REVERSE.
Release the brake. Move the equipment forward and backward for
several meters (feet). Exercise the machine for several minutes.
In order to reduce the total warm up time, start exercising the
entire machine before you complete the hydraulic warm up time.
Operate under light load until the systems reach normal operating
temperatures.
If the engine temperature is not high enough, enclose the engine
and block the radiator. A thermostat that opens at a higher temperature will not increase
the engine temperature if the engine is not under load.
In order to prevent seal damage and gasket damage, keep the
engine crankcase breather pipe clear of blockage.
In extreme conditions, use a canvas over the engine compartment.
Heat the engine area with a space heater. This will aid in starting the engine. Extending
the canvas over the hydraulic components will provide initial warming of the components.
Multigrade lubricants (10W30) may be used successfully at ambient
temperatures below the pour point of the oil. However, in order to use this oil, you must
leave the engine running at low idle. This helps keep lubricants and compartments warm for
the engine and for the transmission. Running the engine at low idle will not keep the
hydraulic systems warm.
Cold weather operations require more time for completion than
other operations. The extra time that is spent in properly caring for the equipment can
prolong the life of the equipment. Longer equipment life will decrease overall cost.This
is especially true in extreme conditions.
Parking Recommendations
Machine Parking
SMCS Code: 7000
Always park the machine in the proper area. Park the machine on wooden planks. The
planks will keep the machine from freezing to the ground.
Before parking a track-type machine, operate the machine in forward and in reverse, on
hard, dry material. Travel in second speed and in third speed. Move the machine 15 to 20
meters (40 to 60 feet) in each direction. This procedure ensures that the track parts are
free.
Clean all debris from the roller frames and from the track. Support the attachments on
wooden blocks. The wooden blocks will keep the attachments from freezing to the ground.
Follow the recommendations for stopping and for parking that are in the Operation and
Maintenance Manual for your machine.
Fluid Recommendations
SMCS Code: 1000; 1250;1280; 1350; 1395; 7000; 7581
For all coolant, lubricant, and fuel information, refer to Special Publication,
SEBU6250, "Caterpillar Machine Fluids Recommendations".
The information that is contained in this publication is the latest information that is
available for your Caterpillar machine.
Continuous improvements are being made to coolants, fuels, and lubricants. Check with
your Caterpillar dealer on a regular basis for updated information on fluid
recommendations.
Battery Recommendations
SMCS Code: 1401
WARNING
Personal injury can result from battery fumes or explosion.
Batteries give off flammable fumes that can explode. Electrolyte is an acid and
can cause personal injury if it contacts the skin or eyes.
Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not
allow jumper cable ends to contact each other or the engine. Improper jumper cable
connections can cause an explosion.
Always wear protective glasses when working with batteries.
The 1U-7297 Coolant/Battery Tester (Fahrenheit) or the 1U-7298 Coolant/Battery Tester
(Celsius) are available for testing the condition of the battery fluid and for checking
the freezing point of the coolant. These testers are optical refractometers. The optical
refractometer will automatically compensate for temperature. The readings are correct
without adjustment for temperature.
The temperature of the battery affects the battery's cranking power. When battery is
too cold, the battery will no crank the engine, even though the engine is warm. Keeping
the battery warm will maintain at least 70 percent of the battery's cranking power. When
possible, keep the batteries warm. Batteries may be stored in a warm environment or the
battery compartment can be heated.
Whenever the engine operates below the normal rpm, the batteries may no be charged.
Whenever an engine is not being operated in cold weather, use a battery charger to keep
the battery charged. A full charge prevents the battery from freezing.
All batteries should be kept charged to a corrected specific gravity of 1.250 or above.
If a hydrometer is used in place of the recommended refractormeter, use the following
table or follow the procedure to correct the reading.
In order to achieve the corrected reading use the following procedure.
At the temperature of 27°C (81°F), the specific gravity should
be 1.220. Subtract .004 from the reading for each increment of 6°C (10°F) below 27°C
(81°F). The result should be 1.220.
| Corrected Specific Gravity for the Battery at the
Specified Temperatures |
| Temperature |
Actual Readings of the Hydrometer That Wear Taken
at Specific Temperatures(1) |
| 27°C (80°F) |
1.300 |
1.280 |
1.250 |
1.220 |
1.190 |
1.160 |
| -18°C (0°F) |
1.332 |
1.312 |
1.282 |
1.252 |
1.222 |
1.192 |
| -23°C (-10°F) |
1.336 |
1.316 |
1.286 |
1.256 |
1.226 |
1.196 |
| -29°C (-20°F) |
1.340 |
1.320 |
1.290 |
1.260 |
1.230 |
1.200 |
| -34°C (-30°F) |
1.344 |
1.324 |
1.294 |
1.264 |
1.234 |
1.204 |
| -43°C (-45°F) |
1.350 |
1.330 |
1.300 |
1.270 |
1.240 |
1.210 |
| -54°C (-65°F) |
1.358 |
1.338 |
1.308 |
1.278 |
1.248 |
1.218 |
Approximate State
of Charge Shown
as a percent of
Full charge |
100 |
90 |
75 |
50 |
25 |
0 |
(1) Scales of the hydrometer do not usually show decimal readings. A reading
of 1280 is equivalent to a specific gravity of 1.280.
Tire Inflation Recommendations
SMCS Code: 4203
Tires that are inflated below the recommended pressure will have shortened life. A tire
that is inflated to the correct pressure in a 18 to 21°C (64 to
70°F) warm shop area will have an incorrect tire pressure in freezing temperatures.
Use dry nirogen gas to inflate the tires. Nitrogen gas is N2.
Dry nitrogen is recommended in order to eliminate ice crystals. Ice crystals could hold
the valve stem open in the tire.
The table shows the correct pressures for tires that are inflated
in an area with a temperature of 18 to 21°C (64 to 70°F). These pressures are adjusted
for the environmental working temperature of the machine.
Tire inflation should be done in aheated area. The tire bead will
seat beter when the tire bead is warm. The intial tire pressure should be fifteen to
twenty percent higher than the operating pressure in order to seat the tire bead against
the rim. Deflate the tires to operating pressure beforeoperating the machine. The contact
surface of tires will become flat incold weather when a machine is parked. To return the
tire to a normal shape, move the machine gradually.
some tractors and some wheel tractor-scrapers are equipped with
wheel coolant in orde to prevent overheating of therims and overheating of the tires
during the braking operation. This coolant consists of a mixture of twenty percent
ethylene glycol andeight percent water. Even though freezing may begin at -12°C (10°F),
these coolant solutions can be used in temperatures of approximately -51°C (-6°F).
Recommended
Inflation Pressure |
Recommended Inflation Pressure that is
Adjusted for a Specific Ambient Temperature |
| -1°C (30°F) |
-18°C (0°F) |
-29°C (-20°F) |
-40°C(-40°F) |
| 205 kPa (30 psi) |
230 kPa (33 psi) |
250 kPa (36 psi) |
270 kPa (39 psi) |
285 kPa (41 psi) |
| 240 kPa (35 psi) |
260 kPa (38 psi) |
290 kPa (42 psi) |
310 kPa (45 psi) |
325 kPa (47 psi) |
| 280 kPa (41 psi) |
305 kPa (44 psi) |
330 kPa (48 psi) |
350 kPa (51 psi) |
370 kPa (54 psi) |
| 310 kPa (45 psi) |
340 kPa (49 psi) |
365 kPa (53 psi) |
395 kPa (57 psi) |
415 kPa (60 psi) |
| 345 kPa (50 psi) |
380 kPa (55 psi) |
405 kPa (59 psi) |
430 kPa (62 psi) |
460 kPa (67 psi) |
| 380 kPa (55 psi) |
415 kPa (60 psi) |
450 kPa (65 psi) |
470 kPa (68 psi) |
500 kPa (73 psi) |
| 415 kPa (60 psi) |
450 kPa (65 psi) |
490 kPa (71 psi) |
510 kPa (74 psi) |
550 kPa (80 psi) |
| 450 kPa (65 psi) |
490 kPa (71 psi) |
520 kPa (75 psi) |
550 kPa (80 psi) |
590 kPa (86 psi) |
| 480 kPa (70 psi) |
520 kPa (75 psi) |
570 kPa (83 psi) |
590 kPa (86 psi) |
630 kPa (91 psi) |
| 520 kPa (75 psi) |
560 kPa (81 psi) |
610 kPa (88 psi) |
630 kPa (91 psi) |
670 kPa (97 psi) |
| 550 kPa (80 psi) |
600 kPa (87 psi) |
640 kPa (93 psi) |
680 kPa (99 psi) |
720 kPa (104 psi) |
| 590 kPa (86 psi) |
630 kPa (91 psi) |
680 kPa 99 psi) |
720 kPa (104 psi) |
760 kPa (110 psi) |
| 620 kPa (90 psi) |
670 kPa (97 psi) |
725 kPa (105 psi) |
760 kPa (110 psi) |
800 kPa (116 psi) |
| 660 kPa (96 psi) |
710 kPa (103 psi) |
760 kPa (110 psi) |
800 kPa (116 psi) |
840 kPa (122 psi) |
| 690 kPa (100 psi) |
745 kPa (108 psi) |
800 kPa (116 psi) |
840 kPa (122 psi) |
890 kPa (129 psi) |
| 725 kPa (105 psi) |
780 kPa (113 psi) |
840 kPa (122 psi) |
885 kPa (128 psi) |
930 kPa (135 psi) |
| 760 kPa (110 psi) |
820 kPa (119 psi) |
885 kPa (128 psi) |
925 kPa (34 psi) |
980 kPa (142 psi) |
| 795 kPa (115 psi) |
855 kPa (124 psi) |
925 kPa (134 psi) |
965 kPa (140 psi) |
1030 kPa (149 psi) |
| 830 kPa (120 psi) |
890 kPa (129 psi) |
965 kPa (140 psi) |
1005 kPa (146 psi) |
1060 kPa (154psi) |