APPLICATION AND INSTALLATION AUDIT FORMS

Page General . . . 126 Serviceability . . . 126 Application Approval Form . . . 127 Installation Audit Form . . . 129 Power Transmission System . . . 129 Mounting System. . . 129 Air Intake System . . . 129 Exhaust System . . . 130 Cooling System . . . 130 Lube System . . . 130 Fuel System, Governing, and Engine Control. . . 131 Starting and Charging System . . . 131 Monitoring System and Gauges . . . 131 Serviceability Checklist . . . 131 Photos Required . . . 132

GENERAL

The goal of all engine sales should be to provide an application which is within the capabilities of the engine and to assure that the engine is installed in a manner which will permit proper operation and maintenance. To assist in attaining that goal, the application approval form and the installation audit form, reproduced on the following pages, were created.

The application approval form is designed to be used where a new application is expected to generate repeat business. The form should be completely filled out and returned to the factory where an applica- tion engineer will approve or disapprove the engine for installation in a pilot model. Upon completion of the pilot model instal- lation, the installation audit form should be filled out in its entirety, as the engine pack- age is reviewed system by system. Any deficiencies should be corrected at that time, assuring the integrity of the installa- tion. Once the form is completed, it can be returned to the factory where, if accept- able; final approval for multiple production of identical units will be given.

It is felt that the information gained by com- pleting and retaining these forms is very useful in enabling both the factory and the engine installer to provide the customer with knowledgeable assistance when questions or problems arise.

It is considered good practice to use the installation audit form as a guide when reviewing any engine installation. It provides a logical approach to spotting potential prob- lems or areas that can be improved to achieve a more reliable engine installation. SERVICEABILITY

Good maintenance is a key factor affecting the life of an engine. Adherence to a good scheduled maintenance program depends, in part, on the ease with which that main- tenance can be performed. Included in the installation audit form is a serviceability checklist. The items on this list should be reviewed to determine if the maintenance or repairs can be performed easily or if they are difficult to the point where they will not receive the required attention.

Experienced machine builders have learned that it is economically advantageous to make any design changes that may be nec- essary as early as possible in a machine’s life in order to alleviate difficulty in perfor- mance of routine maintenance and repairs. It is equally important to correct any instal- lation deficiencies as soon as they are detected in order to avoid more costly problems at a later date.

General Information

1. Data submitted by ______________________________________ Address ______________________________________________ ______________________________________________________ 2. OEM customer name ____________________________________ Address ______________________________________________ ______________________________________________________ 3. OEM equipment model or designation ______________________ ______________________________________________________ ______________________________________________________

Factory Use Only

Pilot Model Application Approval

Reference Number ______________________________________

4. Engine model _____________

5. Engine rating __________ HP at ______________________ RPM *6. Provide specification sheet, drawing or photograph of equipment if

possible.

7. Potential annual sales ______________________________ units.

Date ________________________

Use additional paper to provide more complete data where required.

Application Approval Information

8. Describe application as completely as possible:________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ 9. Transmission make _____________________ Model __________ 10. Clutch make _____________Model__________ Size __________ 11. Torque converter make ______________ Model ______________ 12. PTO equipment make ____________ Model __________________ 13. Front power takeoff HP required ____________________________ How driven: in-line ________________ side load ______________ *Describe, or provide sketch of front driven equipment __________ ______________________________________________________ ______________________________________________________ ______________________________________________________ 14. Air compressor make ________________ Model ______________

HP required _________________

15. Alternator make ____________________ Model ______________ Volts ________________ Amps ____________

16. Muffler make _______________________ Model ______________ 17. Radiator make ______________________ Model ______________ *If radiator to be used is not a Caterpillar furnished radiator, supply a radiator blueprint with this application.

How are torque converter or auxiliary heat loads cooled? ________ ______________________________________________________ ______________________________________________________ 18. Radiator sized to _____________ btu full load cooling requirements. 19. Angle of engine installation ________________________________ 20. Percentage of time engine is operating at full load: ____________ 21. Percentage of time engine is idling to total daily operating time

______________________________________________________ 22. Expected maximum altitude of operation ____________________

feet (meters)

23. Expected maximum ambient air temperature for this application ______________ °F (°C)

Printed in U.S.A.

Industrial Data

24. HP required at flywheel end of engine ______________________ *25. Describe, or provide sketch of rear driven equipment __________ ______________________________________________________ ______________________________________________________ ______________________________________________________ 26. Distance from centerline of PTO drive to front face of crankshaft

pulley (in/cm) ________________ _____________(overhung load) Diameter of driver pulley __________________________ (in/cm) Diameter of driven pulley __________________________ (in/cm) 27. Maximum angle of engine operation ________________________ 28. Accessories not furnished by CTCo. driven by engine. How and

where driven, HP required ________________________________ ______________________________________________________ ______________________________________________________ 29. Operating hours per day _______________ per year __________ ______________________________________________________ ______________________________________________________ 30. Anticipated number hours to major overhaul __________________

Automotive Data

24. Vehicle or body frontal area ______________________________ 25. Type of trailer or body ____________________________________ 26. Rear axle ratio(s)________________________________________ 27. Overall gear reduction ____________________________________ 28. Single or tandem drive axle ______________________________ 29. Tire size ______________________________________________ 30. Maximum GCW or GVW __________________________________ 31. Average GCW or GVW __________________________________ 32. Top geared speed ______________________________ (mph/kph) 33. Normal top speed when fully loaded ________________ (mph/kph)

empty ________________ (mph/kph)

34. Anticipated miles (km) per day ____________________________ Per year ______________________________________________ 35. Air conditioning make ____________________________________ Model ____________ HP required __________________________ 36. Power steering make _________________ Model ____________

HP required ________________

Caterpillar OEM Pilot Model Application Approval Truck-Industrial Engines

If this application is currently being performed by another make gasoline or diesel engine, provide the following information, if possible. Engine make ____________ model _______________ gas _______________ diesel _______________ hp _______________ rpm ____________________________________fuel consumption rate _______________ mpg (Km/Liter) or gallons (liters) per hour _______________. Typical top engine overhaul miles/Km/hours __________________________. Other appropriate operation information ____________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________

Preliminary approval for a Pilot Model installation engine is requested for the application described. Final approval for multiple production of identical units will be based on an acceptable Pilot Model Installation Audit (Form 40-681-83188).

This information is correct to the best of my knowledge.

__________________________________________________________ Company Name __________________________________________________________ Individual’s Name __________________________________________________________ Title __________________________________________________________ Telephone ________________________________________________

*Blueprint, sketch, drawing, specifications, or photo required.

Caterpillar approves/disapproves this application as described. Remarks: __________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ Signed ___________________________________________ ____________ Title Date

Caterpillar Tractor Co. Marketing Department Engine Division

Copy returned to ____________________________________________ Company on __________________________________________(date).

Installation

Audit No. ____________

Equipment Mfgr. ________________________________________ Address ________________________________________________________________ Cat Dealer ______________________________________________ Location ________________________________________________________________ Cat Dealer Contact ____________________________________________ Position _____________________________________ Phone ________________

Equipment Model/Type ____________________________________________________________________________________________________________ Application ______________________________________________________________________________________________________________________

Engine Model ________________________ SN ____________________ Arrangement Number _________________________ Issue __________________

□DI □PC _______________ Aspiration

Rating: ____________________ HP, ____________________ RPM, ____________________ Hi Idle, ____________________ Low Idle Estimated annual sales __________ units

Audit Test Data and Installation Information Date of Audit __________________________________

1 Power Transmission System

1. Flywheel Driven Equipment: Type ____________________________________ Make ______________ Model __________________

□Clutch, □Coupling Size/Type ____________________________________ Make ______________ Model __________________ 2. Flywheel Housing is SAE # ______________________, □Dry, □Wet, SAE# ____________ to ____________ Adapter Req’d. 3. Auxiliary Equipment Driven from Engine:

__________________ HP____________________ Driven By ____________________________ At ________________ Times Engine speed __________________ HP____________________ Driven By ____________________________ At ________________ Times Engine speed __________________ HP____________________ Driven By ____________________________ At ________________ Times Engine speed 4.□Yes □No Torsional Analysis Performed? Clutch Side Load:

□Yes □No Flywheel Thrust Load Within Limits? Clutch pulley diameter __________ in (__________ mm)

□Yes □No Flywheel Side Load Within Limits? Distance from LC of side load to clutch output

□Yes □No Auxiliary Drives Within Torque Limits? shaft shoulder __________ in (__________ mm) 5. If This is a Self Propelled Machine, or Automotive:

Transmission Make ____________________________________________________________________Model__________________________________ ___________________ Speeds with Following Ratios: __________________________________________________________: Engine

Axle Make ____________________________________ Model ____________________________________ Ratio(s) ____________________________ Remarks:

6. If Electric Power Generator is Involved:

Rating: __________ kW, __________ Volts, __________ Hz, __________ Phase, Wired: □Y □

Generator Manufacturer ______________________________________________ □Single Bearing □Two Bearing Voltage Regulator Manufacturer ________________________________________ □Volts/Hz □Constant Voltage Series Boost: □Yes □No

Remarks:

2 Mounting System

1. Front: □Solid □Semi-Soft □Soft, Isolation Describe ____________________________________________ 2. Rear: □Solid □Semi-Soft □Soft, Isolation Describe ____________________________________________ 3. Bending Moment at Rear Face of Flywheel Housing _______________ lb-in (_______________ kg-m) caused

by Overhung Transmission or Other Equipment. Remarks:

3 Air Intake System

1. Air Cleaner Make _______________________________________ Model ________________________ Size/Type________________________________ 2. Inlet Pipe Size ___________________________ Length ____________________ Mat’l ____________________ Beaded Connections? ______________ 3. Restriction Gauge Used: □Yes □No, Setting ________________________________ Location __________________________________________ 4. Combustion Air is Taken from □Outside □Inside Engine Compartment.

5. ____________in-H2O (_____________ mm-H2O) Inlet Restriction At Full Load.

Remarks: