Caterpillar® Product Information

Salesgram
July 2001

Cat® Oil Renewal Oil Degradation versus Time

System (ORS)

0 1000 2000 3000 4000 5000

Hours

The Caterpillar® Oil Renewal System (ORS) is a new on-board

engine oil management system designed to increase the availability
and productivity of Caterpillar machines by extending oil change
intervals and reducing oil disposal labor and costs.

This oil management system is designed, manufactured by

Caterpillar, for Caterpillar 3500 Series Engines.

ORS meters and injects used engine oil from the crankcase into
the engine’s fuel return line. The quantity of oil injected varies
as fuel consumption (load factor) varies. The ratio of oil to fuel
injected can also be adjusted to specific job site conditions and
applications with the Cat Electronic Technician (ET) service tool.

Unlike some competitive oil burn systems, Caterpillar’s ORS

system is linked directly to the engine Electronic Control Module
(ECM). The ORS electronic control strategy ensures that fuel oil
concentration levels remain within recommended parameters.

For Dealer Sales Personnel

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 “Make-up” oil is added as part of the regular fuel service interval.
This continuous addition of new oil maintains a high level of
engine oil quality. In fact, the oil quality (additive content and
soot content) of an engine with ORS is often significantly better
than engines without an ORS system.

ORS will extend oil change intervals significantly. This interval,

for both U.S. Environmental Protection Agency (EPA) certified
engines and non-EPA certified engines, is dependent on oil
quality as measured through S•O•STM oil analysis.

The recommended oil filter change interval remains at 500 hours.

The separate ORS oil filter recommended change interval is also
500 hours. The extension of engine oil change intervals, from
500 hours until the point when S•O•S indicates a change is needed,
will result in a significant increase in machine availability and
productivity. In most cases oil changes can be eliminated entirely.
Additionally, the amount of time and effort in disposing of oil
represents additional productivity gains.

Oil added to fuel tank

Oil filter

Oil metering
valve

Oil supply

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The Oil Renewal System hardware is installed into the fuel How Does ORS Work?
system between the return fuel regulator and the fuel tank.
Mounted on the left side of the engine, and utilizing existing fuel
system pressure, return fuel passes through a return fuel regulator.
At this point the ORS metering unit injects a precise amount of
used oil coming directly from the crankcase. A two-micron ORS
filter cleans the used oil to fuel quality standards prior to adding it
into the fuel system. The ORS fuel-metering unit will only inject
engine oil into the fuel return line when the following electronic
control system activating conditions are met.

• ORS is turned on.

• Engine fuel setting > 10 mm.
• Engine in operating range (1100-1850 rpm).
• Engine is warm; Jacket water temp (63-107 degrees C).
• Oil filter working properly (pressure differential < 70 kPa).
• Fuel filter working properly (pressure differential < 140 kPa).
• Engine oil above low level.
• Engine fuel level above 10%.
• Engine running for more than five minutes.

Once all the ORS activating conditions are met, the system
will calculate the average fuel rate for the last five-minute
interval, and based on this fuel rate, identify oil injection volume
requirements. This oil volume will then be injected into the fuel
return line during the next five-minute interval period. The cycle
then repeats itself.
Measure/Calculate

Five
Inject

Minutes

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 The system is designed to maintain an oil concentration level of
approximately 0.5%. Typically the amount of oil burned equates
to about five gallons per 1000 gallons of fuel. To replenish oil
consumed during normal operation, the engine oil level should
be “topped up” with each refueling. ORS is also monitored and
integrated within Caterpillar’s Vital Information Management
System (VIMS) – thus an operator is automatically alerted if
engine oil drops below recommended levels or the system
develops an operating fault.

With the Oil Renewal System, the quantity of oil injected varies
as operating conditions and fuel consumption varies. This means
that oil is burned at the selected rate whether the engine is idling
or working hard.

The ratio of oil injected to fuel consumption can be adjusted

with the ET service tool. This means the user can adjust to local
conditions at the job site and customize the system for specific
applications.

ORS System Requirements For efficient and reliable performance ORS does require the
following product arrangement and maintenance practices:
• Use Caterpillar Diesel Engine Oil (API CG-4) or a commercially
available, high quality, multi-viscosity oil with an API specification
of CF-4 or higher.
• Use Caterpillar S•O•S oil analysis and Infrared (IR) analysis
a minimum of every 500 hours.
• On both EPA emissions certified engines and non-EPA certified
engines, oil should be changed as indicated by S•O•S analysis
results. It is important that customers utilize S•O•S to get the
most from their ORS investment while maintaining good service
and maintenance predictability. Failure to implement an
appropriate engine maintenance program may result in
shortened engine life or a catastrophic engine failure.
• Daily oil check and log of all engine oil additions.
• Change the engine oil filters, the secondary fuel filters and
the ORS filter every 500 hours or sooner if indicated by the
monitoring system.

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• Higher machine availability. ORS Benefits
• Less handling and disposal time for used engine oil.
• Higher engine oil quality and life.

New Machines ORS Availability

ORS has been approved by the EPA for use on the 793C, 789C
and 785C. It is currently available for all three trucks. ORS will
be available for the 797 by January 2002.

Retrofits
Retrofitting ORS on existing C-Series trucks is possible, if the
appropriate system requirements are met (ORS requirements
listed below). Retrofit installations are relatively simple for
C-Series trucks. Install the appropriate Oil Metering Group and
required Engine Software and use the ET Service Tool to turn
ORS “ON” at the “configuration tool” screen.

Retrofit System Requirements:

• 3500B series heads (45 degree exhaust valve face, and 20 degree
intake valve face) and valve stem seals.
• Engines must be equipped with the appropriate engine electric
harness breakout and ORS control software. 793C’s with engine
S/N from 7TR00527 to 7TR01037 have this breakout, but
requires updated software. 793C’s with engine S/N 7TR01038
or later, 789C’s with engine S/N 7TR00527 or later and 785C’s
with engine S/N 8BR00518 or later are all equipped with both
the breakout harness and software as a part of the standard
shipping configuration. For installation of ORS on earlier
model engines refer to Service Instructions released 6/2000
(Media # SEPD0529).

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ORS Parts Consist Oil Metering Group (135-3101) Consist for 793C/789C:

Item Qty Part No. Name

1 1 1R-0750 FILTER AS-FUEL
2 1 1W-8129 SUPPORT
3 3 3B-4589* STUD
4 1 4P-7581 CLIP-LADDER
5 2 4P-8134 CLIP-LADDER
6 1 4V-3263 HOSE AS
7 1 7K-3377 PIPE
8 3 9X-6772 STRAP-CABLE
9 1 108-7615 HOSE AS
10 1 141-7156 BASE AS
11 1 141-7157 BRACKET AS
12 1 142-7363 VALVE GP
13 1 149-0196 HOSE AS
14 1 153-7477 PLATE
15 1 030-7941 ELBOW
16 1 030-7946 ELBOW
17 3 033-6042 SEAL-O-RING
18 1 115-3069 CLIP AS
19 1 3A-3692 CLIP
20 4 3J-7354 SEAL-O-RING
21 3 3K-0360 SEAL
22 2 4J-5477 SEAL-O-RING
23 1 4K-8302 CLIP
24 5 4L-6454 BOLT-HEX
25 2 4L-9337 BOLT-HEX
26 2 5P-1075 WASHER-HARD
27 1 5P-9299 CLIP
28 2 5P-9617 ADAPTER
29 1 6D-7109** STUD
30 2 6V-8397 SEAL-O-RING
31 2 6V-8628 ELBOW-90 DEGS ORFS
32 1 6V-8723 ELBOW-90 DEGS ORFS
33 1 6V-8724 ELBOW-90 DEGS ORFS
34 6 6V-8801 NUT-FULL
35 15 8T-4896 WASHER-HARD
36 1 8T-9377 BOLT-HEX
37 2 8T-9379 BOLT-HEX
38 2 9S-4185 PLUG
39 1 158-7601** SOFTWARE, LOW ALT.
Or 168-8606** SOFTWARE, HIGH ALT.
** Note: Required for 789C only
** Note: Required for 793C only
40 1 209-0021* SOFTWARE

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Oil Metering Group (209-5285) Consist for 785C:

Item Qty Part No. Name

1 1 1R-0750 FILTER AS-FUEL
2 1 1W-8129 SUPPORT
3 1 3A-3692 CLIP
4 2 3B-4589 STUD
5 4 3J-7354 SEAL-O-RING
6 3 3K-0360 SEAL-O-RING
7 2 4J-5477 SEAL-O-RING
8 1 4K-8302 CLIP
9 5 4L-6454 BOLT
10 2 4L-9337 BOLT
11 1 4P-7581 CLIP-LADDER
12 2 4P-8134 CLIP-LADDER
13 1 4V-3263 HOSE AS
14 2 5P-1075 WASHER-HARD
15 1 5P-9299 CLIP
16 2 5P-9617 ADAPTER-STR THD
17 1 6D-7109 STUD
18 2 6V-8397 SEAL-O-RING
19 2 6V-8628 ELBOW-FACE SEAL
20 1 6V-8723 ELBOW-FACE SEAL
21 1 6V-8724 ELBOW-FACE SEAL
22 6 6V-8801 NUT
23 1 7K-3377 PIPE
24 15 8T-4896 WASHER-HARD
25 1 8T-9377 BOLT
26 2 8T-9379 BOLT
27 2 9S-4185 PLUG-O-RING
28 3 9X-6772 STRAP-CABLE
29 1 030-7941 ELBOW
30 1 030-7946 ELBOW
31 3 033-6042 SEAL-O-RING
32 1 108-7615 HOSE AS
33 1 115-3069 CLIP AS-CONNECT
34 1 141-7156 BASE AS
35 1 141-7157 BRACKET AS
36 1 142-7363 VALVE GP
37 1 149-0196 HOSE AS
38 1 153-7477 PLATE
39 1 211-0587 SOFTWARE, LOW ALT.
Or 206-2524 SOFTWARE, HIGH ALT.

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Additional Information Requests for additional information can be directed to the
Mining Truck Marketing Support Group in Decatur, IL
by calling: Dave Faber at (217) 475-4723 or
John Chambers at (217) 475-5636.

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and is
intended exclusively for their information and training. It may contain unverified analysis and facts observed by various Caterpillar or dealer employees. However,
effort has been made to provide reliable results regarding any information comparing Caterpillar built and competitive machines. Effort has been made to use the
latest available spec sheet and other material in the full understanding that these are subject to change without notice. Any reproduction of this release without
the foregoing explanation is prohibited.

TELQ3764
July 2001
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© 2001 Caterpillar
Printed in U.S.A.