63600 Engines RENR5906-10 BLB1-Up, BKE1-Up, BEN4-Up, 4781-Up Contents for Service Manual RENRS5905, Not This form lists the Service Manual modules available for this product. These items listed can also be ordered separately. When items are updated or supplements are added, they will be announced in PREVIEW and should be ordered as they become available Section Title Form No. Binder SENR2300 Binder Label RENR5904 Safety SENR2995 Service Manual Contents RENR5906 Torque Specifications SENR3130 Engine Index Tab SENR2870 Special Instruction Installation and Initial Start-Up Procedure for REHS1336 \ ‘63600 Engines Specifications 63600 Engines, RENRS907 Systems Operations, Testing & Adjusting G3600 Engines RENR5908 Disassembly & Assembly (G3606 and G3608 Engines ‘SENR4259 Disassembly & Assembly 63612 and G3616 Engines ‘SENRS535 Troubleshooting Index Tab ‘SENR3987 Troubleshooting 69600 Engines RENRSON Maintenance Index Tab SENR28ii4 Operation & Maintenance 63600 Engines ‘SEBU756) Schematic Index Tab SENR2902 ‘Schematic 63612 Electrical System RENKS911 Schematic, 63616 Electrical System RENR5912 Schematic 63606 Electrical System RENRS9K6 4 Schematic 63608 Electrical System RENRSSSF Note: The following forms are available for insertion into this manual. The forms are not a standard pet othe i manual Systems Operation Jacket Water Heater, Lube Oil Heater, REWRSO70 Combination Heaters for Gas and Diesel 3600 Engines TEMA DE GESTION SST AE CALIAD 10 ABR. 2014 oszs0 CATERPILLAR’1 A e SENR2995-04 C LL December 1999 Product Safety EEC All Caterpillar Engines |Sesor7eoon Important Safety Information Proper maintenance and proper repair are important to the safe operation and the reliable operation of this product, This document outlines basic recommended procedures, Some of the procedures require special tools, devices, or work methods, Ensuro that all safety messages and information messages are read and understood before any repairs are performed or bofore any maintenance is performed. The person who services the praduct may be unfamiliar with many of the systems an the product. It is important to use caution when service work is performed. A knowledge of the system and/or ‘components is important before the removal or disassembly of any component, Because of the size of some of the product ‘components, the service parson should check the weights that are noted in the Service Manual and the Service Information System (SIS). Use the proper lifting procedures when any components are removed. Warnings and Notices Safely messages and information messages aro provided in this document, the Service Manual, the Service Information System (SIS), and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons, The hazards aro identitied by the “Safely Alert Symbol" and followed by a "Signal Word” such as “DANGER", WARNING" or *CAUTION’. The Safety Alert “WARNING? label is shown below. WN) Iustration 1 en008Ers The meaning of this eafely alert Is as follows: Attention! Become Alert! Your Safety is Involved. ‘The message that anpears under the safety alert symbol explains the hazard and can be either written or pictorially prosonted. Note: Warning Labels are used to provide instructions and identity specific hazards which it not heeded could cause bodily injury or death to you or othar persons. These labels identify hazards Which may not be apparent to a trained mechanic. ‘There are many potential hazards during the repair for an untrained mechanic and itis impossible to label the product against all such hazards, Improper repair procedures can be dangerous and could result in injury or death, Operations or conditions that may cause product damage are identiied by *NOTIGE” labels an the produc! and in the service information. An example of @ *NOTICE” label is shown below. NOTICE Koop all parts clean from contaminants. Contaminants may cause rapid wear and shortened component ite. Caterpillar cannot anticipate every possiblo circumstance that might Involve a potential hazard. The safety messages in this document, the Sorvice Manual, the Service Information System (SIS), and on the product are, therefore, notall inclusive. Ifa tool, procedure, work method ‘or operating technique that is not specifically recommenced by Caterpiliar is used, you must satisfy yourself that it is safe for you and for others, You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. Current Information The information, specifications, and illustrations in the service information are on the basis of information available at the time ht was writon. The specifications, torques, pressures of operation, measurements, adjustments, ilustralions, and other iterns can change at any time, These changes can affect the service given lo the product, Get the complete and most current information betore you start any job. The mast current information is available on the Service information System (SiS). Caterpillar dealers also have the most current information available,Basic Precautions Improper operation, lubrication, maintenance or ropair of this product can be dangerous and could rosult in Injury or death, Do not operate or perform any lubrication, main- tenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair Information. The following list contains basic precautions that should always be observed. 41. Ensure that all of the "Safety" signs on the product are read and understood before operating, lubricating or repairing this product. Replace any of the safety plates, signs or decals thal are damaged, unreadable or missing. If you start the engine to check the pressure or ‘ongine speed (rpm), ensure that all of the guards are inctalled, To help provent an accident that is caused by parts in fotation, work carefully around arvongino that has bsen put into operation. 3, Ensure that the work aroa around the product is, made safe and be avvare of hazardous conditions that may exist, If an engine is started inside an enclosure, ensure that the engine exhaust is properly vented. 4, Mount the engine and dismount the engine only al locations that have steps endfor hancholds. Clean any mud or debris from shoas, stops, walkways, or work platforms before mounting the engine or dismounting the engine. Face the engine in order to mount the engine or dismount the engine. When it 18 not poasible to use the designed access system, provide ladders, scaifalds, or work plates in order to perform safe repair operations. 5, For initial start-up of a new engine or for an engine that has been serviced, make provisions to stop the engine if an overspeed ogcurs, This can be accomplished by shulting off the fuol supply andior the air supply to the engine. if the engine has not been assembled correotly or If the fuel settings are not correct, the engine can possibly overspeed. The result can be bodily injury, death or property damage. Corrosion Inhibitor Corrosion inhibitor contains alkali, Do not allow alkali to cortact the skin or the eyes. Do not take alkali internally. in case of contact, immediately wash skin with soap and water. If alkali contacts tha eyes, flush the eyes with large amounts of water for al least 15 minutes. Call a Physician. Keep toxic chemicals out of reach of children. Batteries Do not smoke or expose an open flame when. an ingpection of tho battery electrolyte level is, made. Never disconnect any charging unit circuit of battery circuit cable from the battery when the charging unit is operating. A spark can cause combustible gasos to ignite. Do not allow electrolyte to contact the skin or the eyes. Electrolyte is an acid. In case of contact, immediately wash skin wih soap and water. Flush the eyes with largo amounts, of water for at least 15 minutes. Call a Physician. Keep toxic chemicals out of reach of children. Protective Equipment Wear a hard hal, protective glasses with side shioids, and cthor protective equipment, as required. In particular, wear protective glasses when you pound on any part of the product or the attachments with a hammer or a sledge hammer. Use welders gloves, hoodigoggles, an apron and other protective clothing that fs appropriate to the welding job that is being performed. Do not wear loose clothing oF jewelry that can snag on controls or on other parts of the product, Do not expose loose clothing, jewelry, or long hair near rotating parts, Pressurized Items 1. Aiways use a board or a piece of cardboard when you check for a leak, Leaking fluid under pressure can penetrate body tissue. Fluid penetration can causo serious injury and possible deatn. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediatoly. Seek treatment from a doctor that is familiar with this type of Injury 2, Relieve all pressure in alt, oll or water systems before any lines, fitings or related items are disconnected or removed. Always ensure that ail raised components are blocked correctly. Be alert for possible pressure when any device trom. a system that ullizes pressure is disconnected.3. Do not bend or strike high pressure lines. Do not install ines, tubes or hoses that are damaged. Repair any fuel lines, oil lines, {ubes, or hoses. thal are loosa or damaged. Leaks can cause fires. Inspect all fines, tubes and hoses carelully Do rot use bare hands to check for leaks. Always use @ board or cardboard for chocking engine ‘components for leaks. Tighten ali connections to the recommendad torquo. Pressutized air or water can cause personal injury. When pressurized air or water is used for cleaning, wear a protective face shisld, protective clothing, and protective shoes. the maximum air pressure for cieaning purposes: must be below 205 kPa (30 psi. When you use pressure washer, keep in mind thet nozzle pressures are very high. Generally, pressures are well above 13790 kPa (2000 psi). Follow all recommended practices that are provided by Ihe manufacturer of the pressure washer. Hot Fluids and Parts 1. To avoid burns, be alert for hot parts on ony which have just been stopped. Also, be alert for hot iluids in lines, tubes and compartments, 2, Be careful when you remove filer caps, breathers and plugs on the engine. Hold a rag over the cap, cr the plug in order to prevent being sprayed by fluids under pressure. The danger is even greater if the engine has just been stopped. The fluids can be hot. Lifting Use a hoist when you lift components which weigh 23 kg (50 Ib) of more in order to avoid back injury. ‘Aiso use a hoist when you lft components from an awkward position. Eneure that all chains, hooks, slings, ete are in good! condition with the correct capacity. Ensure that the hooks are positioned correctly. Also, ensure that the hooks are equipped with a spring latch. Lilting eyes should not be used for side loading during a lifting operation Repair 1. Disconnect the battery and discharge any pavilors before you start to work on tho product. Attach a "Do Not Operate” tag in the Operator's Compariment. 2. When possible, make all repairs on a level, hard surtace, 3. Do not work on any engine that is supported only by lift jacks or a hoist. Aways use blocks or jack slands fo support the engino before performing any service or disassembly. 4. Bo care{ul when cover plates are removed. Gradually back off the last two bolts or nuts that are located at opposite ends of the cover or the device. Then pry the cover loose in order to relieve any spring pressure or other pressure betore the last two bolts or nuts are completely removed. 5. Always use tools that are in good condition, Ensure that you understand the usage of the tools before performing any service work. 6. Replace all fasteners with the same part number. Do not use a lesser quality fastener if replacements ate necessary. 7. Repairs which require welding should be perlormed only wih the benefit of the apprapriate reference information, Repairs should only be performed by personne! that are adequately trained and knowledgeable in welding procedures. Refer to Instruction Manual, SEGV2549, "Techniquos of Structural Repair Course”. Determine the type of metal {hat is being welded. Select the correct welding procedute, electrodes, rods or wire in order to provide a Weld metal strength that is at least equivalent to the parent retal. 8. Do not damage wiring during removal operations, Reinstall the wiring so that the wiring Is net damaged, The wiring should not be damaged during operation through contact with sharp comers. The wiring should not be damaged by being rubbed against an object or a hot surface, Do not connect wiring to a fine that contains fluid, 9. Ensure that ail protective devices aro properly installed and that all protective devices are functioning correctly before a repair is started, If a guard or a shiold must be removed to perform the repair work, use extra caution, and ensure to reinstall the guard or shield alter the repair work is completed. 10. Tighten connections to tho correct torque, isure thal all clamps, guards, and shiolds are installed correctly. This will help to prevent damage from: vibration, rubbing against other parts, and excessive heal during operation, Particular attention for correct installation should be given to shields that protect against oll or fuel spray onto hot exhaust compononts, 11.Stay clear of all rotating parts and of all moving parts. Leave the quards in place Until maintenance is performed, After the maintenance is porformed, reinstall the guards, Any high speed rotating component that has, been damaged or altered should be checked for balance before reusing.Siay away from areas thal might have a Paid particles in the ai, When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent spec- iffeations including, but not limited to, physical dimensions, type, strength and material. Fallure to heed this warning can lead to prema- ture folures, product damage, personal injury or leath. Asbestos Information Caterpillar equipment and replacement parts thet are shipped from Caterpillar aro asbestos freo. Caterpillar recommends the use of only genuine Caterpillar replacement parts. If replacement parts are obtained from another supplier, use the following guidelines when any replacement parts that contain asbestos or asbestos, debris are handled. Use caution, Avoid inhaling dust thal right be generated when you handle components that Contain asbestos fibers. Inhaling this dust can be hazarcous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining ratorial, clutch plates, and some gaskets, The asbestos thal is used in these components is usually sealed or bonded in a resin. Handling these materials normally is not hazardous unless airborne dust that contains asbestos is. generated. Hf dust which may contain asbestos is present, there are several guidelines that should be followed. Never use compressed air for cleaning, Avoid brushing materials that contain asbestos or grinding materials that contain asbestos. Use a wet method to clean up asbestos debris, A vacuum that Is equinped with the high efficiency particulate air fiter (HEPA fiter) can also be used, Use exhaust ventilation on permanent machin jobs. Weer an approved respirator if ther to control the dust. Comply with applicable rules and regulations for the work place. In the USA, use Occupational Salely and Health Admiristration requirements These OSHA requirements can be found in “28 CFR, 1910.1001". Obey environmental regulations for disposal of asbestos,(©1999 Ceterpillar Printed in U.S.A. AAI Rights Reservede SENR3130-12, CATERPILLAR eects Specifications Torque Specifications Paar ry]lovosstas Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safely rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs, A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance of repair of this product can be dangerous and could result in injury or death, Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and wamings are provided in this manual and on the product. if these hazard warnings are not heeded, bodily injury of death could accur to you or to other persons. ‘The hazards are Identified by the "Safety Alert Symbol" and followed by a “Signal Word” such as "DANGER’, "WARNING" or “CAUTION”. The Safaty Alert “WARNING label is shown below. 7 eA ‘The meaning of this safety alert symbol Is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented, Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. ‘The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that itis safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available af the ime thal the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service thal is given to the product, Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications inctuding, but not limited to, phys- Ical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death.SENR3130-12 3 Table of Contents Table of Contents Specifications Section General information Metric (ISO) Fasteners .. English (SAE) Fasteners .. Ground Engaging Tool (G.E.T.) Fasteners . Installation of Fittings ... : Sralght Treed O-Ring Fitings Plugs, O-Ring Face Seal Bulkhead NUS srnnnnnn Flare Fittings ... ‘Air Conditioning Fitings ‘Air Brake Fittings . ‘Tapered Pipe Thread Fitings .. Miscellaneous Fitings. 0. Hose Clamps «nn Index Section Index 204 Specifications Section Specifications Section vorssres7 General Information SMCS Code: 7553 A Warninc ‘Mismatched or incorrect fasteners can result in damage or malfunction, or personal injury. ‘Take care to avoid mixing motric dimensioned fas- teners and inch dimensioned fasteners. Introduction to Torque “Torque” is measured in terms of force and distance. Force is the amount of pushing of pulling applied at the end of the lever. Distanca is the length of the lever that is being used. Torque values are given in the following units: NEWTON meters (N'm), pound inches (Ib in), and pound feet (Ib ft) This manual is intended to provide the operator with a reference. This manual will provide the standard torque settings for the following: bolts, nuts, plugs, filings, and clamps. Exceptions to these torques are given in the Service Manual, if necessary. Be sure to use a torque wrench that has the proper range. Torque wrenches must be used properly in ‘order to ensure that the correct torque is applied. Always use a smooth pull for torque wrenches. ‘Do not jerk a torque wrench. Do not use adapters that change the fength of the torque wrench. For the correct use of your torque wrench, refer to the instructions that were packaged with your torque ‘wrench, For more information on the correct use ‘of torque wrenches, refer to Special Publication, SEBV0616, “An introduction to Torque” Prior to installation of any hardware, ensure that ‘components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks, Hardware must be free of rust and corrosion. Clean reused fasteners with a noncorrosive cleaner. Lightly lubricate the threads of reused fasteners. Lightly lubricate the mating surface of the head of reused fasteners. Other applications {or lubricating fasteners may also be specified in the Service Manual. The Service Manual may also specify the use of sealants and compounds. SENR3130-12 Note: Do not use sealants that are not specified the Service Manual. Do not use compounds that are not specified in the Service Manual. Clean old ‘compound from the bolt and from the hole before installation. Torque-Turn ‘The torque-turm method Is used when procise control over clamping force is required, There is an initial torque and an additional turn. The initial torque 18 required fo bring all parts of the joint into contact. The adltional turn provides the desired clamping force. Ensure that all fasteners have been torqued before you perform the additional tums. Turn the fastener according to the specified amount. The specified amount will normally be equal to or greater than 80°. The specified amount will normally be in 30° increments. Turns of 120° or 180° are preferred. ‘Tums of 120° or 180° are easily measured by the points of the hex head of the fastener. Lubrication may be specified in order to reduce the effort that is. required for the final tum. The use of the torque-tum method will allow the following: + Increase the life of the fastener. ‘+ Maximize the potential clamping force of a fastener. ‘Typical applications are the following: + Track bolts + Sprocket bolts + Connecting rod bolts + Engine Cylinder Hoads + Drive Shaft bolts Note: Too much tension on the bolt wil! cause the bolt to be stretched beyond the point of yield. The bolt will ‘be permanently stretched. The bolt will loosen the ‘rip on the parts that are being fastened. If the bolt Is tightened again, the bolt will break. Do not reuse bolls that have been permanently stretched. Torque Sequence Unless the bolt tightening sequence is specified by the Service Manual, the fasteners should be tightened in a cross pattem. Use Step 1 through Step 5 unioss the tightening sequence is specified: 1. Hand tighten all fasteners. Larger fasteners may require the use of a small hand wrench. 2, Torque all fasteners to 40% of fll torque. 3. Torque all fasteners to 70% of full torque.SENR3130-12 4. Torque all fasteners to full torque by using a cross pattem. Large flanges may require additional passes, 5. Apply al feast one final full torque to all fasteners ina clockwise direction until all forque is uniform. Large flanges may require additional passes. Note: Final torque may be a tum, vasonaes Metric (ISO) Fasteners SMCS Code: 7553 Metric (ISO) Nuts and Bolts 000% 4 ustration ¢ Note: The following table has the recommended standard torque values for metric nuts and bolts for use on all Caterpillar equipment and Mitsubishi engines, Tate Thread Sizo Torque M6 12:8 3 Nem (105 £ 27 Ib in) MB 28 8 7 Nem (250 + 6216 i) M10, 55 £10 Nm (4147 1b fl) M12 100 + 20 Nom (75 & 15 tb ft) 4 Mid 4160 * 90 Nim (120 # 22 Ib ft) Mi6 pe 240 & 40 Nem (175 2 30 Ib ft) | _mz0 “480 + 60 Nem (340 # 44 Ib Nt) M24 {800 # 100 Nim (6002 751 ft) “M30 41600 # 200 Nm (1180 2 150 1b ft) M6 £2800 + 350 Nm (2080 260 f N) Note: The following table has the recommended standard torque values for metric nuts and bolts for use on Perkins engines. 5 Specifications Section “Tablo2 i Thread Size Torque [ . “5 Nm (44 fb in) MB 2Nm (185 in) Mo 44 Nim (62 Ib f) ia 78Nm GOI) Mid 124 Nm (90 A) Mie TT Nm (30M MiB 200 Nem (160 fo Mt) [mao [M00 Nm GOO A) M24 790 Nim (680 Io f) Note: The difference between Caterpillar standard torque values and Perkins standard torque values ‘are due to cifforont classes of fasteners. Caterpilar uses class 10.9 fasteners, Perkins uses class 8.8 fasteners, The different class of fasteners have ifforont tensile strengths. Metric (ISO) Taperlock Studs Note: The following table has tho recommended standard torque values for metric tapertock studs for use on ali Caterpillar equipment and Mitsubishi engines, Torque BL3NMT1 227 bin) {THE Nm (150244 10m) | 3625Nm (2644 1b i) 652 1ONM(B47 bi) 1104 20Nm (0% 151M) | 170 # 80 Nm (125 4 22 M) 400 £ 60 Nm (3004446) | 7502 80Nm (6502608) | 41200 + 150 Nm (880 # 110 b A) Note: The following table has the recommended standard torque values for Motric taperlock studs for use on Perkins enginos,6 Specifications Section SENR3130-12 mate ia Thro Sizo an Twread seo [Torque Me z 5 Nem (44 Ib in) M3 1 Nem (5 # 0.9 fb In) 7 HN 671) Was hm 1023 | ieee ‘Bun tU A v5 Ta BRM OSEABH) m2 25 in 0 FY We [82 tm gseomy —_ — M8 15 £2.N-m (135 + 18 Ib in) Metric (ISO) Machine Screws M10 ‘30 2 7 Nem (265 + 62 Ib in) We SEGe) a oem G0E NBA D SD at = M6 125 2 20 Nm (0 18 1b A) or ww Smee i (185 * 30 Ib ft) \ tus 2 oer we (oar bt) ‘eble § M30 ‘850 + 100 Nem Thread Size (620 + 75 tb ft) _ Torque M36 4500 = 200 Nm eee wees tive | oso Wee GOUT BR) td [osm 001 Waid 20am) was | abs 00s Nefts04 bm) : conn [ie esr ooswmatroapm | English (SAE) Fasteners ie a7esaasm(i50 2201) | SMCS Code: 7550 [ws 2.25 £0.25 Nm (19.9 # 2.2 Ibin) Hex Button Head Screw and Set Screws yy hy { © Oy stron 3 English (SAE) Nuts and Bolts 200006077 Mustation 4SENR3130-12 7 ‘Specifications Section Tobie 7 ice Toblo 9 Thread Size rae Thread Size Goan a 12 £3 Nim (105 2 27 Ib in) 080 (0.10 £ 0.01 Nm (0.9 £ 0.4 Ib In) siN6 25. 6 Nm (220 ¥ 53 [b in) 164 0.15 0.01 Nm (1.3 0.1 15 in) 318 47 £9 Nm (852 715%) 266 0.25 £ 0.02NNm (22 £0215 in) 716 TO415Nn GOs HIM | 348 0.35 # 0.05 Nm (3.1 £04 Ib in) We 105 # 20 Nm (75 #1516 M) 440 10.50 + 0.05 Nem (4.4 40.4 Ib in) 916 160 + 30 Nim (120 2 22 16) 50 0.70 + 0.10 Nm (62 0. Ib in) 58 215 & 40 Nim (160 2 30 fbf) a2 (0.90 # 0.40 Nm (6.0 #09 Ib in) Ez 370 # 50 Nem (275 # 37 1b) e92 4.70 2 0.25 Nim (15.0 # 22 Ibn) 78 20 £ 80 Nm (460 + 60 fo f) 10-24 2.254025 Nim (19.9 # 22 bin) 1 200 3 100 Nim (660 75 b F) 1224 3.40: 0.60 Nm (20.1 2 5.3 bin) 118 41900 #150 Nm (980 + 110 tb fy 144 1800 200 Nem (1320 # 160 Ib ft) Hex Button Head Screw and Set 13/8 ‘2400 + 300 Nm (1780 + 220 Ib ft) Screws 112 3400-4 350 Nim (2280 # 260 Ib f) English (SAE) Taperlock Studs Tate 8 ee ‘Standard Torque va 82 3Nm (70227 bin) | ene 17 = 5 Nm (180 4 44 In) 38 2525Nm 2624 bf) 7H 454 10Nm (39 #71 f) [12 854 10Nm (48 #716 A) 58 410 4 20 Nim (80 # 16 1b ft) aM 170 30 Nim (125 4 22 tM) [7 280-4 40 Nm (19090161) | 1 4400 + 60 Nim (300 + 44 1b A) 18 525 2 60 Nm (090 444 Ib) 114 [_750280Nm (65026011) | 950 « 125 Nim (700 # 80 Ib) 200 & 150 N: £10 English (SAE) Machine Screws FAP KF ‘ev0905859 ustraon 5 Mustotion 6 orraoar28 Specifications Section ‘SENR3130-12 roto 10 get i Tread Size Torque Then Sts Torqua “och inch wa aaais | 824nmosoom | [ann | aro’ | _mooes0 {iets 983 24.3¥m (1823 bH) aitinch | a78 «60 360 445 Ho8H2 | 42. 6NMOSEA DIN) a woes 7 82 1Wm 549m) tinch | 1160150 | aso HO | He 2 i HEE GCC [ead em (been) 1 1/4inch | 2300 # 300 1700 £ 220 38 2546Nm(220.469'bir)| Thos yton aro or Gore ba et 08 716 4028 Nm(@02sbA) 12 602 12.Nm (4429 6M) WN Sieeeeetase le ae Te Rime eb RD Personal injury can result when installing plow 58 5 + 20 Nm (85 + 15 Ib ft) bolts. The appropriate safety equipment must be aan Sean worn when striking the plow bolts. To avoid injury eek toyour eyes and ears, wear protective glasses and [erin Eta #40 hearing protection during ths procede. 7 225 + 40 Nin 0490.1) 1 500 65 Nm (04 480) 18 700 © 90 Nm (20 080) 118 4000 #125 Nin Cee sie Mustration 7 738 1200 # 160. Nem oars (960 + 110 Ih ft) ba pea Pee ees 412 1700 + 200 Nm Plow bolts must be installed properly. Refer to the is (ia 130 following procedure fort camect talon of plow eee to9512000 4. Clean alll surfaces that contact the bolt. Remove Ground Engaging Tool (G.E.T.) Fasteners SMCS Code: 7553 Ground Engaging Tools (G.E.T.) are secured by many types of bats, Refer fo Table 11 forthe correct torque for the folowing combinations of fasteners for G.E- + Plow bolts and nuts + Hox head bolts and nuts all occurrences of the following conditions:tust, paint, nicks, and burrs 2. Tighten the nut fo the correct torque. Refer to Table 11 for the correct torque. 3. Use a hammer to strike the head of the bolt, The bolt must be struck with significant force. Note: The head of the bolt may be recessed below the mounting surface. Use a suitable punch in order to transfer the hammer blow to the bolt head. 4, Tighten the nut to the correct torque. Refer to Table 11 for the correct torque.SENR3130-12 xstsone Installation of Fittings SMCS Code: 7553 Note: The tightening sequence of the fasteners that attach a tube assembly or hose assembly to the machine is very critical to the proper function of the machine. The sealing surfaces of the tube assembly or hose assembly should be sacured squarely. The sealing surfaces of the tube assembly or hose assembly should be tightened to the serviced ‘component (control valve, cylinder, hydraulle motor, etc). Perform this procedure prior to the final tightening of any clamps or clips that are used in order to fasten the tube assembly or tho hose assembly to the machine. Fittings have different connections. Fittings may have two completely different ends. Bo sure to use the proper torque for the end of the fitting that is used. The following list contains some common typos of fittings. + Straight Thread O-Ring (STOR) + Adjustable Straight Thread O-Ring (STOR) + O-Ring Face Seal (ORFS) + Taporod Pipe Thread (NPT and NPTF) + 37 Degree Flare Fitting + 45 Degree Flare Fitting + 45 Degree Inverted Flare Fitting + Split Flange Coupling Installation of Split Flange Couplings 4. For @ metal tube to hose insiallation, install the tube and tighten all bolts finger light'al the rigid end, 2. Install the hose and tighten all bolts finger tight 3. Put the hose in a position so that the hose does not make contact with the machine or with another hose. 9 Specifications Section Muetration 8 aooonns 4. Position the split lange parallel over the port Tighten the bolts on both connections to the proper torque. Follow the prescribed torque sequence for split flange connections. Refer to Iilustration 8. Add the measurement of gap (A) to the measurement of gap (B). The total must nat exceed 4.0 mm (0.16 inch). 5. Siart the engine. 6. Move the implement control levers fo all of the positions. x Look at the hose during movement of the implement, Ensure that the hose is not in contact, with the machine or with other hoses, Note: For hoses that cross an articulation hitch, check for contact during articulation. For hoses that connect fo the steering system, check for contact during steering 8. Shut off the engine. 9. If the hose contacts other hoses or the machine during the test, loosen the bolts and reposition the hose, Repeat steps 3 through 8 until there is no contact. Installation of Adjustable STOR Fittings ‘This type of fitting is used in many applications. One end of the fitting will be an adjustable STOR fitting, ‘The other end will be difforont, Always use the same installation procedure for the STOR end. Adjustable STOR fitings oan be positioned before tightening,40 Specifications Section AU Mustain 9 Elbow body assombly (1) End that eonneets to the tube oc hos (2) Fig boay (3) Lockrut (4) Backup washer (5) O-ring soa (6) End that is assembled to the meting pot oTa7aecs 1, Put locknut (3), backup washer (4) and O-ring seal (6) as far away from the threads as possible. Hold these components in this position. Tum the fitting Info the mating part. Turn the fiting until backup ‘washer (4) contacts the surface of the mating part, Note: Excessive use of the wrench will distort the washer, Distortion of the washer will prevent propor sealing 2. Put the fitting assembly in the correct position. loosen fitting (2) until the correct assembly position is achieved. Do not loosen the fitting more than 360 degrees. Install the tube or hose hand tight in order to verify the orientation of the fitting. Tighten the fitting (2) to the torque that is shown in the correct chat for the fitting that is used Tighten locknut (3) to the torque that is shown in the correct charl for the fiting that is used. Use a backup wrench, when the locknut is tightened. Note: Torque the fitting prior to the locknut. Note: I the fing is not adjustable, the hex on the ody replaces the locknut. To instal this type of fiting, lighten the hex against the face of the mating part. Excessive tightening of the connectors can cause {allure, Connectors that are under tightened can also cause failures. The following fallures occur: + Excessive tightening can expand a loose ferrule into the nut. This will cause the ferrule to lock up in ‘the nut and the nut will not function property. + Excessive tightening can split the nut on the end of the tube or can split the ferrule. + Excessive tightening can gail or excessive {tightening can strip the threads of the nut. SENR3130-12 Note: If the above conditions occur due to excessive tightening, the damaged fluid connector must be scrapped and the fluid connectors must be replaced. 2013900 Straight Thread O-Ring Fittings ‘SMCS Code: 7553 Se ‘entvo28 . (aie HY stration 10 Note: For torques for plugs, refer to Specifications, “Plugs’, Note: Straight Thread O-Ring fittings for medium pressure usage will have shorter threaded ends than high pressure fittings. The torque value for medium pressure Straight Thread O-Ring fittings will be lower than the forque values that are required for Straight Thread O-Ring fitings for high pressure fittings.SENR3130-12 “ Specifications Section “abie 12 Table 19 Ferrous Straight Thread O-Ring Fitting Ferrous Straight Thread O-Ring Fittings ‘Torques for Mating with Ferrous Materials Torques for Mating with Ferrous Materials Medium Pressure use with 37° Flare Fittings High Pressure use with O-Ring Face Seal Fittings Standard Standard Nominal Outer Nominal Outer ‘orminal Outer | Thread Size Torque Sante et | Thread Size Torque aad Inch Tolerance nee Inch Tolerance (10% ~ 0%) (10% ~ 0%) 3.18 mm acs a+ tNm 4.76 mm 124 2Nm (425 inch) 816-24 | (70+ 9 Ib in) (0.188 inch) 8-24 | (105+ 18 1b In) 4.76 min 19 +2Nm 6.35 mm 22+ 3Nm (188 inch) 3-24 | 15+ 18 In) (0.250 inch) TH6=20 | (105 +27 tb In) 6.35 mm 17 +2Nm | 7.94 mam 30+ 3 Nm (250 inch) THB ~20 | (150+ 18 1bin) | | @312 inch) W220 | (265427 ibm) 7.94 mm 28 +3.Nm 9.52 mm 48+ 6 Nm (312 inch) 12-20 | _(250# 27 1b in) (0.375 inch) eae G54 Ib) 9.52 mm 36+ 4.Nm 12.7 mm 2 9Nm (375 inch) eae (26 +30 f) {6.500 inch) eabnl) (60+71b A) 42.70 mm 55 +6 Nm 45.88 mm 140 + 14 Nm (500 inch ee @144 bn) (0.625 inch) 7®- "4 | (105+ 10 6A) 15.88 mm 80 + 8 Nm 419.05 mm ; i00+ 191 (625 inch) eee (60 +6 bf) | (0.750 inch) | 1 MI8-12 | (140+ 14 1) 419.05 mm 100 + 10 Nin 22.22 mm 250 + 25 Nm (750 inch) Vane 12 | @5+7 In) 0.676 inch) | 1986-12 | (105+ 18 mm) 22.22 mm 135 + 14Nm 25.40 mm ‘300 + 30 Nem (878 inch) 136-12 | 00+ 10 A) (000 inch) | 181" 12 | a0 22M) 25.40 mm 150 + 15 Nm 31.75 mm 360+ 36 Nm (000 inch) | 188-12) tos 1 A) (1250 inch) Vee-12 | (260+27 bf) 31.75 mm giz | 200+20Nm 38.10 mm 15+ 42m (1.250 inch) 18-12 | 15+ 21 1) (800 inch) 178-12 | 05 +31 A) 38.10 mm 2 | 325+33Nm 63.50 mm 510 4 51 Nm 4.500 inch 118-12 | (240 +24 1) (2.500 inch) 2-12 | (375 +38 IdM) 60.80 mm pin. | 120+43Nm 2.000, G10 + 32 0} Note: Use 50 percent of the torque values from Table Note: Use 50 percent of the torque values from Table 42 when the fitting or the port material is nonferrous, Note: Straight Thread O-Ring fitings for high pressure usage vill have longer threaded ends than mecium pressure fitings. The torque value for high pressure Straight Thread O-Ring fitings will be higher than the torque values that are required for Straight Throad O-Ring fitings for medium pressure tings 13 when the fiting or the port material is nonferrous.12 Specifications Section SENR3130-12 rate Talo 8 faeces Hote Ferrous Siaighi Thread O-Ring Fittings Thvead Size Torave “eques for Noting with Parous Waters Thc Tolerance (10% ~ 0%) RetNominal | thread | Standard Eo @=1Nm (60+ 81H) Cuter Diameter | Sze cae, 38 7 #2 Nm (160+ 10 (#40% -0%) 716 23 +3 Nem (205 + 27 Ib in} | 4mm Me x4 4+2Nm Tiereeeeerea gpa et eorE Rail rake, 12 72 +3Nm @50+77ibin | 1 ; +36) | 5mm M10 Xt 21+3Nm sie eed Nea eee (foo 37 8h) a for Nm(de 4ib%) sam | Mioxis | are anm 5 = 12Nm@5+0 iar 3168) “0 +16 Nm (105% 101) tam [RTS [arog ToIHEN (M+ aBA 10 mm M16 X 1.5 58 +6 Nim 210 + 21 Nem (155 + 15 Ib ft) (43 + 4 Ib ft) 290 + 29 N-m (215 +24 tof) | im | MOXIE | 7+ 8Ne ee aanate S| Bieey (825 + 33 Nim (240 +24 bf) team) Mee x15 | 108 + 11 Nm #20 -48Nm 8107321) fateew ose - Note: Use 50 porootf th torque values from Table 20 mm warx2 | (90 18h 1 whon tho fing or he por matenals nonferrous. = ) Zam waoxe | 22525 Him i ai ena Straight Thread O-Ring Plugs 2emm | MOaX2 | 9254 99.Nhm (Socket Drive) | ob} 30m wax2 | 350+36 Hm (260 + 27 Ib ft) oe mm) ORD | 440+ 45 Nim (O (325 + 33 Ib ft) XX sorm | W8OK2 | $25 591m ora aa Note: Use 50 percent of the torque values from 14 when the fiting or the port material is nonferrous. Plugs SMCS Code: 7553 Straight Thread O-Ring Plugs (Hex Drive) IMuetation 14 0 OF Note: The socket may be hexagonal or a square recessed drive,SENR3130-12 13, Specifications Section “eble 10 Tobi 17 Thread Size Torque Typo of | Throad Size Torque Inch Tolerance (+10% ~ 0%) Plug Inch Tolorance (+10% ~ 0%) 56 +1 Nem (44 + 9b in) 112-13 | 20+ 5 Nem (175+ 44 Ib in) : [41+ 2.Nem (100 + 18 1b Iny 58-11 35+ 5Nm (26+ 411) 16 2Nm (140 +16 bin a | 4-2) sorENmereabm | 1 20> 2 Nem (180 + 18 tb in) | Se et ace cECECE (a seas cea ( as awe ence | {Bei | TOs thm 62 11H) (ee er) 1ore-12 | 00+ 15Nm(65+ 11151) | 78 _ 100 + 10 Nim (75 + 7 Ib th) B 1112-12 Te | 170+ 17 Nem (125 + 13 1b A 2-12 | 125+15NmO2+ 11 bf) [+316 215 + 22.Nemn (180 + 16 Ib Fae 12 | 70+ SNm(52+11 Ay | 156 270+ 27 Nim (200 + 20 Ib ft) . 1516-12 | 90+ 15Nm(66+ HM) 15/8 285 + 29 Nim (210 + 24 Ib f) i 2-20 | 1+4Nm(@7 36 bin) 1778 370 + 87 Nem (270 + 27 bf) 7-14 | 65+ TNme@I+SwH | _ 22 415+ 42Nm (08 + 31161) | [ Tae 43 | 90415Nm 8+ 11 BA) 112-12 | HO+tENm@r+ bf Drain Plugs with Straight Threads ytration 13 oats Note: Plug (A), plug (B) and plug (C) are used with a gasket. Conical seal plug (D) does not use @ gasket Note: Use 50% of the values in Table 17 when either the plug or the port material is nonferrous. Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies) Mustaton 14 0092010 Note: When you tighten the plug, the torque must not be transmitted to the joint between the tube and the elbow.14 Specifications Section Totle 19 Thread Size Torque Teh 78 150 #25 Nm (1104 181b A) | 116 (200425 Nim (180 18 6 &) 7 ar6 275 + 35 Nm (200.4 26 6 f) 114 275 + 95 Nm (200 + 26 fof) 1 o6 300 #40 Nem (2204 30/6 ft) 4 56 450 + 50 Nm (830-2 37 Ib f) 718 ‘575 £ 75 Nem (426 4 65 lb t) 212 1000 # 100 Nam (740 #74 lb) tnxsonar2 O-Ring Face Seal Fittings ~ax§ ~\ . A : 1A 3 “ i< tustation 16 ‘ntng face set ating (ORFS srg) (1) O-ing face sea! connector (1A) Oring groove (2) 0+ing seal (3) Nut forthe Ovrng taco wieere Table 19 Ferrous ORFS Fitting Thread Size ‘Standard Torque for Nut (3) 96 - 18 26 + 3 Nem (230 * 27 Mb in) 1116 = 16 43 £5 Nem (30 # 4 tb fh) 13/16 - 16 65 #7 Nim (50 # 5 tb fl) 414 108 «11 Nem (80-8 ib A) 113/16 - 12 144 £15 Nem (105 = 11 Ib Mt) 17/16 - 12 216 + 22 Nem (160 # 16 Ib M) 1116-12 304 + 31 Nem (220 # 23 Ib Rt) 2-12 360 + 36 Nem (270 + 27 hh) SENR3130-12 Bulkhead Nuts ‘SMCS Code: 7553 steal Poros (1) Bulkhead connector (1A) Bulkhoad nt Note: The bulkhead connector may have different connections. The type of fluid connection does not affect the torque for nut (1A). Note: When you assemble the fluid connection, do not use the bulkhead nut (1A) as leverage for a backup wrench. Use the hex on the body (1) of the connector for leverage.SENR3130-12 45. Specifications Section Table 20 37 Degree Flare Fittings Thread Size Torque Inch 56 84 1Nm (7029 bin) 38 10.£ 1 Nm (90+ 91 In) 7H6 47-41 Nim (150 + 9b in) We 21 #2 Nem (185 # 18 Bb in} 916 27 2 Nam (240 + 18 tb in) 116 96 £2.Nm (27 1.516 A) ala 45 43 Nem (33420) ‘a6 48£3Nm (522M) 718 53 £9 Nem (99.4 21 A) station 17 1 2e4Nm (543A) (1)37 dogroe Rar fing. 2) Snivel nus. 116 84 #5 Nm (60 +4 f) Table 24 136 408 4 6 Nim (00 # 4b fi) Nuts for 37 Degree Flare Fittings 766 197 £7 Nm (100 # 5b A) Nomina! Outer | veeg se | tendo! 176 149+ 8Nm(11026bq) | Blanton of mas ron 186 179 £9 Nm (1002 716M) i | 10% 0%) 41016 179 & 9 Nim (130 + 7 Io ft) ae enh sit uefa 178 185 4 10.Nm (195 ¢ 7 ff) = ——| Een 4.76 ram aa 14 2Nm 2 203 2 11 Nim (150 £8 1b M) (488 inch) (100 + 18 fin) 210 282.4 14 Nim (195 + 10 Ib ft) 6.35 mm 76 1622Nm — 7 ~ (250 ine) i (140 #18 Ibn) Noto: 7.94 rn 2 20+ 2Nm (312 inen) (180 #18 Ibn) wom ae [we | deeSiy Flare Fittings 12.70 mm a 58+ 68Nm gee gas |__(500 inch) | (3 +aron 1888 mm 7 428 Nm The torques in Table 21 are for 37 degree flare (625 inch) (854611) fillings. The torques in Table 22 are for 45 degree 49.05 mm 08 + 11 Nm fiare fittings and 45 degree inverted flare fitings. (750'neh) | TAS (60481 n) 22.22 mm 195 = 14Nm (875 inch) sae (100 # 10 A} 25.40 mm 166 = 16 Nm (41000 inch dete (18 £ 121m) 34,75 mm 4 217 + 22 Nm (1.280 inch (160 #16 b A} 38.10 mm aa 251 = 26 Nm (1.500 inch) (185 4419 1 6) 330 = 94 Nm ad (250 #25 1b Nh Use 60 percent of the torque values from Table 24 when the fitting or the port matorial is nonferrous.16 Specifications Section 45 Degree Flare and 45 Degree Inverted Flare Fittings SENR3130-12 Air Condi SMCS Code: 7553 \ \ ning Fittings Mustration 18 eee (48 Dero kets Fie tgs 348 Ospeo Fae Pings. aaa slo 72 ‘es (1) ong sel @) 45 dogo tae tn, {5 Degree Flare Fltings and 46 Degree Inverted Flare Fittings ‘Table 23, ‘ie Conditioning Fitings ominal Outer: ‘Thread Size ‘Standard +H Diameter of mad a O-Ring | 48 Degree Fare iting the Tbe thread | Filing End End 3.18 mm i SE tNem size Fariatal roma ror {_ (425 lnety bh (4549 Io) inch | Torque | for'steo! | Alurannn 4.76 mm 38 BL1Nm a. Tubes eo) (702910 T4a4nm | 043Nm | 223Nm - - se-18 | Gaswos | (aes22r | (200227 €.35 mn thet Nm m6 teen ony | “ein | “tiny 7.94 ram i741 Nm 224m | soasnm | B24hm mm |e | dosh anese | OOS? | Bateg | ess 9.5 rm | 302 2.Nm Geim | 9 | capt etlty Tan [sosanm | oostin | BEANe a Ul oo ane Pot | oleh | ash | BS, (48 2852 180) crea) 525m | Beem | es Wm 4270 mmm aa 98 #2 Win Baswn | Goeobe | Grea! (500 ine) (42 iM) _—__— Leeeeee| 4 15.88 mm 718. 5043.Nm Table 24 (625 inch) G7 £200) ‘Quick Disconnect Air Conditioning Fittings 48,05 tm 904 6 Nm Fesceaccaa easter (750 inch tae | eoedim toh Torque zag2. mm 100 + 6 Nin . ere +14 tree 718-20 a29Nm@zZER) 14-18 @223Nm 4642 bf)SENR3130-12 7 ‘Specifications Section 103547423 Note: The following table has the recommended ‘ fe standard torque value for tapered pipe thread fiting Air Brake Fittings for use on all Caterpiiar equipment and Nilsubishi engines. Use Table 26 as a general recommendation SMCS Code: 7553 ‘only. Actual values may vary due to veriations in the — material of the connector. Actual values may vary due to variations in the characteristics of the threads, “abe 26 Tapered Pipe Thread Fittings z Standard Torque Sai ppissr of the Pipe | Threads with sara an ° Toni | PSE Bs | Myo new Put nut (‘!) and sleeve (2) over the tube. Push the ts tube into the counterbore ofthe fiting body as far as 148 | 40N-m@01b in) | 10 Nm (G0 bin) | possible, There are two methods that may be used 716 Nm - to tighten the nut. Tighten the nut with one of two a (140 1b ny | 76N (140 lb iny methods. 20 W- ma CR, | 25 Nm (220 w wy + Tighten nut (1) to the torque that is specified in - a aie Table 28. 38 35Nm 26 A) | 48 Nm (33 bA) * Tighten nut (1) by the number of turns that is ae 45 Nem (33 fbf) | 60 Nem (44 Toft) specttiod in Table 25. The number of tums is for 34 | 6ONm (Ab A) |_75Nen (55M the tums after the nut is finger tight. 1 75 Nem (55 Ib ft) | 90 Nm (85 Ib ft) Table 25 114 95 Nem (70 fb ft) | 110 N-m (80 Ib ft) Nominal | Torque Tum Tightening | 142 | 410N-m (B0ib A) | 130 Nem (06 16 8) Diameter Copper 2 130 Nom (95 tb ft) | 160 N-m (120 th ft) of the Tube Tubing - Ht 635 mm | 143Na 3 2 Note: Use 50 porcent of tho torque values from Table (0.250 inch) | (87 & 27 26 when the fitting, the plug, or the port material is “| tein) nonferrous. 4 953 mm | 2023N. 2 (os7binch) | (17527 Note: Use 50 percent of the torque values from Table tb in) 26 when a tapered thread is mated with a straight 12.70 mm | 3526Nm 4 2 bikes (01500 inch) | (20 4 of) 15.88 mm | 4046Nm 312 } 3 | eee gidtues nei Ces 9 Rh ee i Miscellaneous Fittings 19.05 mm | s026Nm | 3 472 3 {0.750 inch) | (37 44 Ib ft) SMCS Code: 7553. Note: Clean the connectors and the seals and lubricate the connectors and seals by using Refrigerant Mineral Oil. This is @ special of thai compatible with R-134a asia Tapered Pipe Thread Fittings SMCS Code: 7553 ‘Torque is based on the diameter of the thread. The torque values are identical for coarse threads and fine threads. Hi Duty Tube Fittings (Shear Sleeve) Iystraon 2418 Sposifications Section Put nut (1) over the tube and push the tube into the counterbore of the fitting body as far as possibie. Turn the nut with a wrench until a small decrease in torque is fell. The small decrease in torque indicates that the sleeve (1A) has been broken off of the nut. Hold the tube in order to prevent the tube from turning. Tighten the nut for an additional 1 4/2 tums. SAE Flareless Fittings Mustain 22 Installing a New Flareless Fitting Put nut (1) and sleeve (2) over the tube. The head end of the sleave should be next to the nut. The head end has a shoulder. The nut will be seated against this shoulder when the nut is tightened. Push the tube inio the counterbore of the fiting body as far as possible, Tum nut (1) clockwise until the steeve grips the tube. The sleeve must prevent all movement of the tube, Tighten the nut for an additional 4 1/4 tums. ‘The sleeve should be seated and the sleeve should give a locking action. Installing a Used Flareless Fitting Less (ums are required for a used fiting. Put nut (1) and sleeve (2) over the tube. The head of the sleeve should be next to the nut. Push the tube into the countervore of the filling body as far as possible, Tighten the nut until a sudden increase in torque is fell. Next, tighten the fitting for an additional 1/6 to 4/3 tuin in order to seat the sleeve. Flex Fittings stration 23 spose Put nut (1) and sleeve (2) over the tube and push the {ube into the counterbore of the fiting body 2s far as possible, Tighten the nut until the nut is against the hex part of the fiting body, SENR3130-12 sossson2 Hose Clamps ‘SMCS Code: 7553 Worm Drive Band Type Clamps Wustration 24 eo00T0017 abl 27 ‘Width (A) of Clamp | Torque for New Hose: 44203Nm (1223 1bin) | 4.5 £ 0.7 Nem (40 4 6 fo in) 7544Nm(68291bin) | Torque for Roused Hose) | 08£0.3Nm (7+ bin) 3.00.5 Nm (27 44 Ib in) 45 £0.7 Nem (40 £6 th in) 1086 is Feusod. Tho clamp may bo [7.9 mm (0.31 inch) 18.5 rn (0.63 inch) 15.9 mm (0.68 inch) | with (4) of Clamp | 7.9 mm (0.31 Inch) 49.5 av (0.53 inch) 16.9 mm (0.63 inch) (> Use this vate when the Rose new or reused Constant Torque Hose Clamps Use a constant torque hose clamp in place of any worm drive band type clamp. Ensure that the constant torque hose clamp is the same size as the worm drive band type clamp. Due to extreme: temperature changes, the hose will heat set. Heat setting can cause worm drive band type clamps to loosen, Loose hose clamps can result in leaks, There have been reports of component fallures that have been caused by worm drive band type clamps that have loosened. The constant torque hose clamp will help prevent these failures.SENR3130-12 stration 25 otters (1) Constant Torque Hose Clamp (Botivite Whee) (2) Constant Toreua Hose Clamp (Tes bolt and Spring) Use a torque wrench for proper installation of all ‘constant torque hose clamps. There are two types of ‘constant torque hose clamps: Belleville washer (1) and Tee bolt and spring (2) When the constant torque hose clamp (Belloville washer) (1) is assembled correctly, the Belleville washers (1A) are nearly collapsed fiat. The proper torque for sorew (1B) is based on the diameter (B) of the clamp. Refer to the following table for the correct torque. Yablo 28 Diameter (B) i Standard Torque Up 0 50.8 mm (2 inch) | 7.541 Nem (65+ 101 in) Greater than 60.8 mm (954 10 Ibn) inch) The correct torque for the constant torque hose clamp (lee bolt and spring) (2)is 7.5 4 1 Nem (65 + 10 tb in). 19 Specifications SectionIndex A u Air Brake Fittings Air Conditioning Fittings. Metric (ISO) Fasteners... . 16 Hex Button Head Screw and Set Screws Moiric (ISO) Machine Screws. a Motric (ISO) Nuts and Bolts B Metric (ISO) Taperlock Studs: Miscellaneous Fittings ... Flox Fittings.. eta Hi Duty Tube Fittings (Shear Sleeve) SAE Flareless Fittings.. Bulkhead Nuts. E English (SAE) Fasteners. 6 ° English (SAE) Machine Screws a English (SAE) Nuts and Bolts 6 O-Ring Face Seal Fittings 4 English (SAE) Tapertock Studs 7 Hox Bution Head Screw and Sel Screws tf Pp F Plugs... 12 Drain Plugs with Straight Threads... 8 Flare Fittings 15 Straight Thread O-Ring Plugs (Hox Di 12 37 Degros Flara Fittings EEA: Straight Thread O-Ring Plugs (Vechanical Joint 45 Degree Flare and 45 Beares| inverted Flare Tube Assemblies) 0.0 13 Fritings... 16 Straight Thread O-Ring Plugs (Socket Drive)... 12 6 s General Information.. Specifications Section aera Introduction to Torque Straight Thread O-Ring Fitlings...0.-0n 10 Torque Sequence... Torque-Tum Ground Engagi T Table of Contents... 3 H Tapered Pipe Thread Fittings 17 Hose Clamps. oe 18 ‘Constant Torque Hose Clamps eat 1g: Worm Drive Band Type Clamps... 218 ' Important Safely Information 2 Installation of Fitings 2. 9 installation of Adjustable STOR Fittings 8 Installation of Split Flange Couplings. 8 {©2008 Caterpillar Cat, Caterpllar, thelr respective logos, “Caterpillar Yellow’ and the Power edge Printed nUS.A. AI Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks Cf Caterpilar and may not be used without permission,