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Application &
Installation Guide
Lubrication Systems
LEBW4957-03
Contents
G3300/G3400
C-10/C-12
C-15/C-16
l Standard C11/C13
C27/C32
C15/C18
G3500
G3600
m Optional
3126B
3412E
3500
3600
- Not Available
C-9
C7
C9
Filter Differential
Pressure Gauge - - - - - - - - - - m l - m m
Duplex Filter - - - - - - - - m - m m - m m
Centrifugal Bypass
Filter - - - - m m - - m - m m m m m
Pressure Regulator
Valve l l l l l l l l - l l - l l -
Priority Valve - - - - - - - - l - - l - - l
Temperature
Regulator - - - - - - - - - - m - - m l
Prelube System - - - - - - - - - - m m - m l
Postlube System - - - - - - - - - - - l - - l
Remote Filter - - m m m m m m - - - - - - -
Oil Heating System - - - - - - - - - - - m - - -
Makeup System - - - - - - - - - - m - - m m
Monitoring System - - - - - - - - l - - l - m l
Programmable
Monitoring System l l l l l l l l - l l - - - -
Turbocharger Oil
Accumulator - - - - - - - - - - - - - m -
Remote Sump - - - - - - - - - - - m - - -
Emergency
Systems - - - - - - - - - - - m - - -
Sample Points m l m l m l m l l l l l l l -
.
Lubrication Systems
SECTION CONTENTS
General Description ................ 2 Additional Considerations .... 24
Lubricating Oil Flow Marine/Offshore
Lubricating Oil Components Requirements
Sample System Diagrams Lubricating Oil Centrifuges
Optional Systems .................... 15 Lubricating Oil Storage
Optional Lubrication Lubricating Oil Transfer
Systems and Components Systems
Sample Sump Configurations
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General Description
The following is a brief description
Flow
of common lubrication system
A typical engine lubricating oil flow
components.
schematic is shown in Figure 1.
Figure 2 and Figure 3 show the Engine Sump
lubricating oil flow for 3600/G3600 The engine sump serves as the
engines. engines main oil reservoir and
The basic flow of the lubricating oil contains the bulk of the engine oil.
begins with an engine mounted, gear Typically part of the engine package,
driven, fixed displacement gear the sump is located below the
pump. The pump pulls oil from the crankcase to collect the oil as it
sump through a coarse strainer on drains from the engine.
the suction bell. The oil is then Sumps can differ in capacity,
pumped toward the oil cooler. Oil configuration and tilt capability to
cooler flow can differ depending on accommodate various engines and
engine design. Engines designed applications.
with an oil cooler bypass valve can Tilt capability requires additional
divert some of the oil flow around consideration for the oil sump to
the cooler under certain conditions. ensure proper lubricating oil system
The valve operates based on oil function. Marine and offshore
viscosity (measured by pressure- engines may be installed and put
drop across the oil cooler). In into continuous use while in a tilted
engines without a bypass valve, position. Other mobile applications
the oil flows through the oil cooler. may require temporary operation in a
Next, the oil flows to the oil filters. tilted position.
All oil flow is filtered before entering
Caterpillar can provide engines that
the engine unless the filter becomes
meet or exceed specific tilt angle
plugged. If the filter is plugged, a
requirements. Refer to the Caterpillar
valve allows the oil to bypass the
TMI for specific information.
filter to help prevent lubricating oil
starvation. Oil flow proceeds to oil Main Oil Pump
galleries in the engine block where it The main oil pump is a gear driven,
is distributed to all the components fixed displacement pump. The pump
requiring oil flow and pressure. output depends on engine speed and
Gravity returns the oil to the sump the effects of changing system
via drain tubes and passages in the restrictions are minimized by the use
cylinder head and engine block. of pressure regulating valves.
Lubricating oil systems may be
equipped with additional or optional Oil Coolers
components. Some components are The oil coolers are typically shell-
not available for all engine models, and-tube type, with series water
applications and duty cycles. flow and parallel oil flow. Some
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larger engines, however, may use the oil cooler becomes plugged or
plate-and-frame type for remote if the oil viscosity is high. In this
cooler applications. Specific cooler situation, viscosity is determined by
designs will vary with engine model the pressure differential across the
and rating. oil cooler. If the pressure differential
exceeds a preset limit, the valve
Oil Cooler Bypass Valve opens allowing oil to bypass the
The oil cooler bypass valve allows cooler. Cold starts often cause the
oil to flow directly to the oil filters if lubricating oil to bypass the cooler.
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Figure 1
1. Sump lube oil is drawn from the sump through a type with a bypass valve to provide adequate
strainer into the inlet of the lube oil pump. lubrication should the filter become plugged. The filter
system may have the replaceable element type or the
2. Lube Oil Pump the quantity of lube oil delivered by
spin-on type. The oil filter bypass valve is protection
the lube oil pump exceeds the engine's needs when
against lube oil starvation if the oil filter clogs.
the engine is new. As the engine clearances increase
through normal w ear, the flow required to properly 7. Engine O il Passages the m ain oil flow is distributed
lubricate the engine w ill remain adequate. through passages to internal engine components. The
oil flow carries away heat and wear particles and
3. Oil Pressure Regulating Valve this valve
returns to the sump by gravity.
regulates oil pressure in the engine and routes
excess oil back to the sump. 8. Prelubrication Pump used only during starting
cycle.
4. Lube Oil Cooler the oil to the engine is cooled by
jacket water or external water source in the engine 9. Check Valve prevents oil back flow through
oil cooler . prelubrication pump w hen the pump is inactive.
5. Oil Cooler Bypass Valve when the viscosity of the
oil causes a substantial pressure drop in the oil
cooler, the bypass valve will open, causing the
oil to bypass the cooler until the oil is warm enough
to require full oil flow through the cooler.
6. Lube Oil Filter Cat lube oil filters are the full-flow
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3600 Lubricating Oil System Model 3608
Figure 2
1. Oil Pump 10. Oil Manifold (Oil To Piston Cooling Jets)
2. Prelube Pump 11. Oil Manifold (Oil To Bearings)
3. Oil Coolers 12. Oil To Main Bearings
4. Oil Filters 13. Oil To Camshafts
5. Oil Thermostat Housing 14. Centrifugal Filters (3600 Only)
6. Oil Filter Duplex Valve Handle 15. Turbocharger
7. Priority V alve 16. Bypass Oil
8. Oil To Centrifugal Filters (3600 Only) 17. Check Valve
9. Emergency O il Locations * Flow in Opposite D irection During Prelube
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1. Oil Pump 11. Oil Manifold (2) (Oil To Piston Cooling Jets)
2. Prelube Pump 12. Oil To Main Bearings
3. Oil Coolers 13. Oil To Camshafts
4. Oil Filters 14. Centrifugal Filters (3600 Only)
5. Oil Thermostat Housing 15. Turbocharger
6. Oil Filter Duplex Valve Handle 16. Bypass Oil
7. Priority V alve 17. Check Valve
8. Oil To Centrifugal Filters (3600 Only) 18. Piston Cooling Jets
9. Emergency O il Locations 19. Check Valve
10. Oil Manifold (Oil To Piston Cooling Jets) * Flow in Opposite D irection During Prelube
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engine protection and lubricating oil gearbox uses a shaft driven oil pump
management. that pulls oil from the gearbox oil pan,
through the pump, through the filter,
Temperature Regulators through the oil cooler, and then to
Oil temperature regulators direct the gears and bearings.
lubricating oil to the oil coolers and The gearbox has a sight oil level
then oil filters. While most Cat gauge as well as a port for sampling
engine models require full oil flow and comes with an oil heater with
through the cooler at all times, some thermostat.
of the larger engines, notably 3500 For oil temperature regulation, the
engines configured for high jacket gearbox utilizes a heat exchanger
water (JW) temperatures and all that is connected in parallel to the
3600 engines, utilize a temperature engines SCAC circuit. The oil
regulator in the oil circuit in order to temperature is regulated by using a
more closely control the oil thermostat in a mixing type
temperature. application.
The 3500 engines, configured for The gearbox has oil temperature
high JW temperatures, cool the oil and pressure sensors installed for
using the aftercooler circuit instead safety monitoring by the EMCP
of the JW circuit. These engines controller.
also use an oil temperature regulator
in place of the oil cooler bypass
Prelubrication
Used primarily on larger engines,
valve to avoid overcooling the oil.
prelubrication systems lubricate all
Temperature regulators in 3600 critical bearing journals before
engines also help maintain the oil at energizing the starting motors.
the optimum temperatures needed Prelubrication is mandatory
for tighter ring clearances and equipment for 3600/G3600
extended ring life associated with engines and especially important
the engine. after periods of idleness, oil changes
In either case, oil temperatures are and filter changes.
controlled within acceptable limits, Prelubrication systems are
provided the cooling system is available to operate with electric
adequately sized. starter or air starter motors.
Note: Oil life will be shortened, and The systems can be manual or
engine components may suffer automatic. An automatic system
damage, if excessive oil is shown in Figure 7.
temperatures are permitted during The manual system requires the
operation. engine operator to manually operate
a sump pump to fill the engine oil
Gearbox Oil System
passages before activating the
Some G3500 generator-sets utilize
starter motors.
speed increasing gearbox for uses in
60Hz applications. The gearbox uses Automatic systems significantly
the same oil as the gas engine. The reduce the amount of prelube time
prior to engine crank. The prelube
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Figure 6
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3600/G3600 Air Prelube
Figure 7
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Optional Systems
This section generally describes The system provides the means for
various lubrication system options changing either the main or auxiliary
available for Cat engines. filter elements with the engine
Please refer to the engine price lists running at any load or speed. A filter
for availability of these options on change indicator is included to tell
specific engine models. when to change the main filter
elements. A vent valve allows
Duplex Oil Filter System purging of air trapped in either the
Many marine and oilfield engines main or auxiliary system when
that require marine classification installing new elements.
society certification must be capable Note: Air must be purged from
of oil filter change while running. the changed section to eliminate
Changing the filters during operation possible turbocharger and bearing
may also be a customer requirement damage. Refer to the engine
on certain Electric Power Generation Operation and Maintenance Manual
and Industrial applications. for purging instructions.
Note: Changing oil filters during The auxiliary system is capable of
engine operation should not be providing adequate oil filtration for at
performed on engines equipped with least 100 hours under full load and
unit-mounted radiators and cooling speed operation. The same filter
fans. Oil can be blown onto hot elements are used in both systems.
engine surfaces and ignite.
The optional Cat duplex oil filter Remote Oil Filters
system (one example is shown in Some Cat engines have the
Figure 8 below) meets the capability for remote mounting the
requirements of the standard filter oil filter when space limitation or
system plus an auxiliary filter system serviceability is a problem, such as
with the necessary valves and mobile type land drill rigs. However,
piping. to protect warranty coverage,
authorization from Caterpillar Inc.
must be obtained before making any
modification to the engine lubrication
system.
While remote filters have more
potential for oil leaks, they seldom
cause problems when the following
recommendations are followed:
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Locations for Low Oil Level Alarm, Shutdown and Makeup Gauge
Figure 9
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Figure 10
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Additional Considerations
This section generally describes and the ship to reach port for engine
additional systems and components repairs.
that are not part of Caterpillar Guidelines for emergency
standard or optional lubrication lubricating oil system operation:
systems. However, these systems
may be required for successful Keep pressure drops to a
engine or package application and minimum by using short, low
installation. restriction lines.
Use a line size at least as
Supplemental Bypass Filter large as the engine connection
Systems point.
If supplemental centrifugal or Install a low restriction
absorptive bypass filters are used, strainer in front of the
the system must have a non- emergency oil pump.
drainback feature in place for engine
Install a low restriction check
shutdown. A 3.175 mm (0.125 in.)
valve between the emergency
maximum diameter orifice, limiting
pump discharge and the
flow to 7.57 lpm (2 gpm), must also
engine inlet connection.
be used. Refer to engine general
dimension drawings for Use a pressure limiting valve
recommended bypass filter supply in the emergency system set
location and oil return to the at the maximum oil pressure
crankcase. limit of the engine.
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Figure 13
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Figure 14
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3600/G3600 Lube Oil System - Dry Sump Diagram
Figure 15
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SECTION CONTENTS
Properties ............................... 34 Monitoring Quality ................ 38
Characteristics of SOS
Lubricating Oil Oil Analysis
Components of Lubricating Contamination ..................... 39
Oil Contaminants and
Caterpillar Line of Oils Indications
Understanding TBN
Consumption .............................. 37
Consumption Estimate
Formula
Consumption as an Overhaul
Indicator
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Properties
Viscosity may be low, operating engines
Viscosity is the property of can be subjected to normal oil
resistance to flow in a fluid. Oil temperatures because of
viscosity is its thickness or temperature regulated components.
resistance to flow. Viscosity is The higher viscosity fluids will
directly related to how well an oil provide better protection to all
will lubricate and protect surfaces components during the full day
that contact one another. Oil must work cycle.
provide adequate supply to all
moving parts, regardless of the Additives
temperature. The more viscous Lubricating oil consists of a
(thicker) an oil is, the stronger the oil mixture of base oil fortified with
film it will provide. The thicker the certain additives. Depending on the
oil film, the more resistant it will be type of base, paraffinic, asphaltic,
to being wiped or rubbed from naphthenic or intermediate (which
lubricated surfaces. Conversely, oil has some of the properties of the
that is too thick will have excessive former), different additive
resistance to flow at low chemistries are used to strengthen
temperatures and so may not flow or modify certain characteristics of
quickly enough to those parts the base oil.
requiring lubrication. It is therefore The most common additives are
vital that the oil has the correct detergents, oxidation inhibitors,
viscosity at both the highest and the dispersants, alkalinity agents, anti-
lowest temperatures at which the wear agents, pour-point dispersants
engine is expected to operate. and viscosity improvers.
Oil thins out as temperature Detergents help clean the
increases. The measurement of the engine by reacting with
rate at which it thins out is called oxidation products to stop the
the oils viscosity index (VI). New formation of insoluble
refining techniques and the compounds.
development of special additives Oxidation inhibitors help
which improve the oils viscosity prevent increases in viscosity,
index help retard the thinning organic acids and
process. carbonaceous matter.
The minimum temperature for the Dispersants help prevent
viscosity grade provides guidelines sludge formation by keeping
for the lowest starting temperature contaminants in suspension.
with a cold soaked engine.
Alkalinity agents help
Caterpillar recommends using the
neutralize acids.
highest viscosity oil possible. Even
though the ambient temperature
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The Caterpillar line of oils include multi-grade oils are not appropriate.
Diesel Engine Oils (DEO), Natural For instance, SAEO is recommended
Gas Engine Oils (NGEO) and Special for engines equipped with
Application Engine Oils (SAEO). DEO mechanical unit injection. Additional
and NGEO are available in various reference on lubricating oil is
viscosity grades to cover a broad available in the sources listed at the
range of operating temperatures. end of this guide.
SAEO is used for products where
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Consumption
Oil consumption is a consequence Consumption as an Overhaul
of normal engine operation. This oil Guide
needs to be replenished between
maintenance intervals. Typical oil Oil consumption increases over
consumption figures are provided in time due to normal wear. Therefore,
the Technical Information Appendix oil consumption rate can serve as an
for the purpose of predicting the indicator of wear and used to predict
quantity and cost of make up oil, the need for an overhaul. Caterpillar,
as a part of total operating costs. however, recommends taking a more
In practice, many factors will affect comprehensive approach. Trending
oil consumption including load, oil engine output, measuring specific
density, oil additive packages and fuel consumption and measuring
maintenance practices. cylinder pressure are better tools
for determining the need for an
The rate of oil consumption is overhaul.
typically reported as brake-specific
oil consumption (BSOC) so it is Oil Change Interval
independent of operating load. To Caterpillar recommendations for
convert to a volume per hour basis, oil change periods are published in
the engine load and oil density must Operation and Maintenance Manuals
also be known. for each engine. As an alternative,
The following formula may be used change intervals can be established
to estimate oil consumption. by a comprehensive maintenance
management program that includes
oil condition analysis. Caterpillar
BSOC
offers such a program. It is the
SOS services program.
BSOC
gal/hr = Engine b hp x Load Factor (%) x (lb/bhp-hr)
Density of
Oil**
**Typical engine oil has a density of 899
g/L (7.5 lb/gal).
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Monitoring Quality
Monitoring lubrication quality can the various wear elements can be
maximize the life of engine oil and established for the particular engine.
provide optimum protection for the Impending failures can be identified
internal engine components. when trend lines deviate from the
established norm.
SOS
Wear analysis is limited to
The Caterpillar tool for oil analysis
detecting component wear and
is SOS, which is part of the
gradual dirt contamination. Failures
SOS services program. This
due to component fatigue, sudden
program determines oil change
loss of lubrication or sudden
intervals based on condemning limits
ingestion of dirt occur too rapidly
and trend analysis established for
to be predicted by this type of test.
the engine. It also looks for the
presence of oil contaminants, which Oil Condition Analysis
are used to analyze the condition of Oil condition analysis determines
the engine, indicate shortcomings in the amount of contaminants, such
engine maintenance and detect the as soot and sulfur, oxidation and
first signs of excessive wear. nitration products. Results can be
Sampling intervals differ for used to customize (reduce, maintain,
various engines and applications. or extend) oil change intervals for
Refer to the Operation and particular conditions and
Maintenance Manual for appropriate applications.
intervals or contact your Cat
dealer. Additional Tests
Chemical and physical tests detect
The SOS testing includes wear
water, fuel and antifreeze in the oil
analysis, oil condition analysis and
and determine whether or not their
additional chemical and physical
concentrations exceed established
tests. Contact your Cat dealer for
limits.
complete information and
assistance on the SOS services
program.
Wear Analysis
Wear analysis monitors component
wear rate by identifying and
measuring concentrations of wear
elements in oil. Based on known
normal concentration data,
maximum limits of wear elements
are established. After three oil
samples are taken, trend lines for
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Contamination
The following are examples of
Silicon, Lead, Aluminum, Tin
typical contaminants and the affect
This combination indicates dirt in
they have on the condition of your
the lower portion of the engine,
engine. Engine operating conditions
possibly leading to crankshaft and
can also play a major role in the type
bearing wear.
and degree of oil contamination. For
a more thorough discussion of this Chromium, Molybdenum,
topic, refer to Applied Failure
Aluminum
Analysis Oil and Your Engine,
This combination can lead to ring
Media Number SEBD0640.
and piston wear, resulting in blow-
Copper by, increased oil consumption and
A high concentration of copper oil degradation.
indicates thrust washer or bushing Aluminum
wear.
This can be a critical concern.
Silicon Concentrations of aluminum suggest
Above normal readings of silicon bearing wear. Relatively small
can indicate a major problem. Oil increases in the levels of this
loaded with silicon becomes, in element should receive immediate
effect, a grinding compound which attention because, once rapid wear
can remove metal from any number begins, the crankshaft may produce
of parts during operation. large metal particles which will
become trapped in the oil filters.
Sodium, Silicates, Carboxylic
Iron
Acid Base
Iron can come from any number
A sudden increase in sodium,
of sources. It can also appear as
silicates, or carboxylic acid base
rust after engine storage. Frequently,
readings indicate inhibitor leaking
when accompanied by a loss of
from the cooling system. Inhibitor
oil control, increases in iron
may indicate antifreeze in the
contamination indicate severe liner
system which can cause oil to
wear.
thicken and become like sludge,
leading to piston ring sticking and Soot
filter plugging. A high soot content is not usually
the direct cause of failure. Solid
Silicon, Chromium, Iron,
particles do not dissolve in the oil,
Aluminum causing the filters to become
A combination such as this signals plugged and depleting dispersant
dirt entry through the air induction additives. Soot indicates a dirty air
system, possibly causing ring and cleaner, engine lug, excessive fuel
liner wear. delivery, or repeated acceleration in
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Water
Water combined with oil will
create an emulsion which will plug
the filter. Water and oil can also
form a dangerous metal corroding
acid. Most instances of water
contamination are the result of
condensation within the crankcase.
More serious contamination occurs
when a leak in the cooling system
allows water to enter from outside
the engine oil system.
Fuel
Fuel contamination decreases the
oils lubricating properties. The oil
no longer has the necessary film
strength to prevent metal-to-metal
contact. This can lead to bearing
failure and piston seizure.
Sulfur
The presence of sulfur signals
danger to all engine parts. The type
of corrosive wear attributed to high
sulfur content can also cause
accelerated oil consumption. The
more fuel consumed during an oil
change interval, the more sulfur
oxides are available to form acids.
Therefore, an engine working under
heavy loads should have its oil
checked more often, including its
TBN, which relates directly to an
oils ability to neutralize sulfur by-
products. Fuel sulfur damage can
cause piston ring sticking and
corrosive wear of the metal surfaces
of valve guides, piston rings and
liners.
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Reference Material
The following information is
provided as additional reference to
subjects discussed in this manual.
The following service publications
provide comprehensive information
on lubricating oil, as well as other
fluids used in Cat engines.
Although Cat brand oil is the
only oil Caterpillar endorses, these
guides also provide minimum
requirements for commercially
available oils.
SEBD0640
Oil And Your Engine
LEBW4958
Application and Installation Guide,
Crankcase Ventilation
SEBU6251
Caterpillar Commercial Diesel
Engine Fluids Recommendations
SEBU6400
Caterpillar Gas Engine Lubricant,
Fuel and Coolant
Recommendations
SEBU7003
3600 Diesel Engine Fluids
Recommendations for Lubricants,
Fuels and Coolants
PEDP7036
SOS Fluid Analysis
WECAP
Web Engineering Cataloging and
Procuring website
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LEBW4957-03
Information contained in this publication may be considered confidential. Discretion is recommended when distributing.
Materials and specifications are subject to change without notice.
2015 Caterpillar. All rights reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, SOS, HEUI,
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of Caterpillar and may not be used without permission.