CAT C15, C18 Maintenance Manual

Operation and
Maintenance
Manual

SEBU8598-09

December 2014

C15 and C18 Engines

BDN 1-Up (C15 Engine)
LDN 1-Up (C18 Engine)

SAFETY.CAT.COM

i05296198

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety 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, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.

Improper operation, lubrication, maintenance or 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 verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur 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 Safety Alert “WARNING” label is shown below.

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.

A non-exhaustive list of 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. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that 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 that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this
product Caterpillar recommends using Cat re­placement parts.

Failure to follow this warning may lead to pre­mature failures, product damage, personal in­jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.

SEBU8598 3

Table of Contents

Table of Contents

Foreword.............................. ............................. 4

Safety Section

Safety Messages ....................... ....................... 5

General Hazard Information ............... .............. 7

Burn Prevention....................... ....................... 10

Fire Prevention and Explosion Prevention ... ...11

Crushing Prevention and Cutting Prevention . 13

Mounting and Dismounting............... .............. 13

Before Starting Engine ................. .................. 13

Engine Starting ........................ ....................... 14

Engine Stopping ....................... ...................... 14

Refill Capacities....................... ....................... 45

Maintenance Recommendations.......... .......... 51

Maintenance Interval Schedule (C15 Engines)54

Maintenance Interval Schedule (C15 Engines

With Ratings Greater Than 579 hp)....... ....... 55

Maintenance Interval Schedule (C18 Engines

With Ratings Greater Than 760 HP)....... ...... 56

Maintenance Interval Schedule (C18 Engines)58

Warranty Section

Warranty Information ................... ................... 94

Reference Information Section

Engine Ratings ........................ ....................... 95

Customer Service ...................... ..................... 96

Electrical System ...................... ...................... 14

Engine Electronics..................... ..................... 15

Product Information Section

General Information.................... .................... 16

Product Identification Information.......... ......... 20

Operation Section

Lifting and Storage..................... ..................... 23

Features and Controls .................. .................. 27

Engine Diagnostics..................... .................... 32

Engine Starting ........................ ....................... 33

Engine Operation...................... ...................... 37

Cold Weather Operation................. ................ 42

Reference Materials ........................................ 98

Index Section

Index............................... .............................. 102

Engine Stopping ....................... ...................... 44

Maintenance Section

4

Foreword

SEBU8598

Foreword

Literature Information

This manual contains safety, operation instructions,
lubrication and maintenance information. This manual

should be stored in or near the engine area in a
literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.

English is the primary language for all Cat
publications. The English used facilitates translation
and consistency in electronic media delivery.

Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Cat dealer for the latest available
information.

Safety

This safety section lists basic safety precautions. In
addition, this section identifies hazardous, warning
situations. Read and understand the basic

precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.

Operation

Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.

The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.

Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
wet or freezing cold operating conditions, more
frequent lubrication and maintenance than is
specified in the Maintenance Interval Schedule may
be necessary.

The maintenance schedule items are organized for a
preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back

depending upon your specific maintenance practices,
operation and application. We recommend that the
maintenance schedules be reproduced and displayed
near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained

as part of the engine's permanent record.

See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information

regarding documents that are generally accepted as
proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
environment.

Overhaul

Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.

Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers a variety
of options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available
from your Cat dealer. Consult with your dealer for
information regarding these options.

Maintenance

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance

schedule are referenced to detailed instructions that
follow.

Use fuel consumption or service hours to determine
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,

birth defects, and other reproductive harm.

Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after

handling.

SEBU8598

Safety Section

i04085252

Safety Messages

SMCS Code: 1000; 7405

There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Become familiar with all safety messages.

Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and

soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off the
engine.

5

Safety Section

Safety Messages

Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.

Illustration 1 g02295113

View of the right side of a typical C15 or C18 Industrial Engine

6 SEBU8598

Safety Section
Safety Messages

Universal Warning (1)

Illustration 2 g01370904

One safety message is located on the left side of the
valve cover. One safety message is located on the
right side of the valve cover.

Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con­tact any Caterpillar dealer for replacement man­uals. Proper care is your responsibility.

Sulfuric Acid Burn (2)

Illustration 3 g01382725

One safety message for sulfuric acid burn is located
on top of the exhaust cooler. One safety message for
sulfuric acid burn is located on the right side of the
exhaust cooler.

Sulfuric Acid Burn Hazard may cause serious per­sonal injury or death.

The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sulfur

levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid

may spill from the cooler during service of the en­gine. The sulfuric acid will burn the eyes, skin and
clothing on contact. Always wear the appropriate
personal protective equipment (PPE) that is noted
on a material safety data sheet (MSDS) for sulfuric
acid. Always follow the directions for first aid that
are noted on a material safety data sheet (MSDS)
for sulfuric acid.

SEBU8598

General Hazard Information

SMCS Code: 1000; 4450; 7405

7

Safety Section

General Hazard Information

i05334609

Illustration 5 g00702020

• Wear a hard hat, protective glasses, and other
protective equipment, as required.

Illustration 4 g00104545

Attach a “Do Not Operate” warning tag to the start
switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each
operator control station. When appropriate,
disconnect the starting controls.

Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.

Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two bolts
or nuts that are located at opposite ends of the cover
plate or the device. Before removing the last two bolts
or nuts, pry the cover loose in order to relieve any
spring pressure or other pressure.

• When work is performed around an engine that is
operating, wear protective devices for ears in order
to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are
secured in place on the engine.

• Never put maintenance fluids into glass
containers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform
the maintenance under the following conditions:

8 SEBU8598

Safety Section
General Hazard Information

• The engine is stopped. Ensure that the engine
cannot be started.

• The protective locks or the controls are in the
applied position.

• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

• When starting a new engine, make provisions to
stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.

• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.

• Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.

The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).

When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield. Always wear eye
protection for cleaning the cooling system.

Fluid Penetration

Illustration 6 g00687600

Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICE
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte­nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain­ers before opening any compartment or disassem­bling any component containing fluids.

Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.

Dispose of all fluids according to local regulations and
mandates.

Avoid direct spraying of water on electrical
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when
redeposited on hot surfaces.

SEBU8598 9

Safety Section

General Hazard Information

Static Electricity Hazard when
Fueling with Ultra-low Sulfur Diesel
Fuel

The removal of sulfur and other compounds in ultra­low sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.

Avoid static electricity risk when fueling. Ultra-low
sulfur diesel fuel (ULSD fuel) poses a greater stat­ic ignition hazard than earlier diesel formulations
with a higher sulfur contents. Avoid death or seri­ous injury from fire or explosion. Consult with
your fuel or fuel system supplier to ensure the de­livery system is in compliance with fueling stand­ards for proper grounding and bonding practices.

Lines, Tubes, and Hoses

Do not bend or strike high-pressure lines. Do not
install lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses that
are loose or damaged. Leaks can cause fires.

Inspect all lines, tubes, and hoses carefully. Do not
use bare hands to check for leaks. Always use a
board or cardboard for checking engine components
for leaks. Tighten all connections to the
recommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct installation
of these components will help to prevent these
effects: vibration, rubbing against other parts and
excessive heat during operation.

Inhalation

Illustration 7 g02159053

Exhaust

Use caution. Exhaust fumes can be hazardous to
your health. If you operate the equipment in an

enclosed area, adequate ventilation is necessary.

Asbestos Information

Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains

asbestos is generated.

If dust that may contain asbestos is present, there are
several guidelines that should be followed:

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

10 SEBU8598

Safety Section
Burn Prevention

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.

• Use exhaust ventilation on permanent machining
jobs.

• Wear an approved respirator if there is no other
way to control the dust.

• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal of
asbestos.

• Stay away from areas that might have asbestos
particles in the air.

Softwrap

Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands
thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
up debris.

Reference: The applicable material safety data
sheets can be found at the following web site by
searching using part number or the name:

http://dsf2ws.cat.com/msds/servlet/
cat.cis.ecs.msdsSearch.controller.
UserIdentificationDisplayServlet

Dispose of Waste Properly

Illustration 8 g00706404

Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.

Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.

i03895768

Burn Prevention

SMCS Code: 1000; 4450; 7405

Do not touch any part of an operating engine or
engine aftertreatment system. Allow the engine or the
engine aftertreatment system to cool before any
maintenance is performed on the engine or the
engine aftertreatment system. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.

Coolant

When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.

Allow cooling system components to cool before the
cooling system is drained.

Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Ensure that
the filler cap is cool before removing the filler cap.
The filler cap must be cool enough to touch with a
bare hand. Remove the filler cap slowly in order to
relieve pressure.

Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.

SEBU8598 11

Safety Section

Fire Prevention and Explosion Prevention

Oils

Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot
components to contact the skin.

If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.

Batteries

The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.

Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.

Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.

i05626649

Fire Prevention and Explosion
Prevention

SMCS Code: 1000; 4450; 7405

A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an

emergency shutdown.

Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.

If the application involves the presence of
combustible gases, consult your Cat dealer for
additional information about suitable protection
devices.

Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable

materials to accumulate on the engine.

All fluids that are captured in the fluid spill
containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire
may cause personal injury and property damage.

Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for

storing flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or
a seal failure. Exhaust shields must be installed

correctly.

Illustration 9 g00704000

Use of personal protection equipment (PPE) may be
needed.

All fuels, most lubricants, and some coolant mixtures
are flammable.

Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
product when a fire hazard exists. Contact your Cat
dealer for service.

Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
damage.

Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to
welding or flame cutting.

Wiring must be kept in good condition. Properly route
and attach all electrical wires. Check all electrical

wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.

Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.

Properly install all oil filters and fuel filters. The filter
housings must be tightened to the proper torque.

12 SEBU8598

Safety Section
Fire Prevention and Explosion Prevention

Illustration 10 g00704059

Use caution when you are refueling an engine. Do not
smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.

Avoid static electricity risk when fueling. Ultra Low
Sulfur Diesel (ULSD) poses a greater static ignition
hazard than earlier diesel formulations with a higher
Sulfur content. Avoid death or serious injury from fire
or explosion. Consult with your fuel or fuel system
supplier to ensure that the delivery system is in
compliance with fueling standards for proper
grounding and bonding practices.

Illustration 11 g02298225

Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.

Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. Charging a frozen
battery may result in an explosion.

The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations on
the instruction plate.

Ether

Ether is flammable and poisonous.

Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder or while you are

using an ether spray.

SEBU8598 13

Safety Section

Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49 °C
(120 °F). Keep ether cylinders away from open
flames or sparks.

Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders away
from unauthorized personnel.

Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather
starting.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high­pressure lines. Do not install any lines that are bent or
damaged.

Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or
for replacement parts.

Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.

Replace the parts if any of the following conditions
are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.

Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.

When objects are struck, wear protective glasses in
order to avoid injury to the eyes.

Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.

i01372247

Mounting and Dismounting

SMCS Code: 1000; 4450; 7405

Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.

Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.

Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields
are installed correctly in order to prevent vibration,
rubbing against other parts, and excessive heat.

i01359666

Crushing Prevention and
Cutting Prevention

SMCS Code: 1000; 4450; 7405

Support the component properly when work beneath
the component is performed.

Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.

Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.

i03560601

Before Starting Engine

SMCS Code: 1000

NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.

14 SEBU8598

Safety Section
Engine Starting

To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working

Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or to
the controls.

Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.

If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.

All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.

See the Service Manual for repairs and for
adjustments.

properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.

Engine exhaust contains products of combustion that
can be harmful to your health. Always start the engine
and operate the engine in a ventilated area. If the
engine is started in an enclosed area, vent the engine
exhaust to the outside.

i01462046

Engine Stopping

SMCS Code: 1000

Stop the engine according to the procedure in the
Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.

Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.

Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.

To stop an electronically controlled engine, cut the
power to the engine.

i03941639

Engine Starting

SMCS Code: 1000

If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.

All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.

Start the engine with the engine start switch.

Always start the engine according to the procedure
that is described in this Operation and Maintenance
Manual, “Starting the Engine” for information about
starting the engine. Know the correct procedure to
prevent major damage to the engine components.
Know the correct procedure to prevent personal
injury.

i03896010

Electrical System

SMCS Code: 1000; 1400

Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit is
operating. A spark can cause the combustible gases
that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.

Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.

SEBU8598 15

Safety Section

Engine Electronics

Grounding Practices

Proper grounding for the engine electrical system is
necessary for optimum engine performance and
reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.

Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.

To ensure that the engine and the engine electrical
systems function properly, an engine-to-frame ground
strap with a direct path to the battery must be used.
This path may be provided by way of a starting motor
ground, a starting motor ground to the frame, or a
direct engine ground to the frame.

All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.

i04021529

The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.

Note: Many of the engine control systems and
display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
Manual for more information.

Engine Electronics

SMCS Code: 1000; 1900

Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.

The Electronic Control Module (ECM) provides a
comprehensive, programmable engine monitoring
system for this engine. The ECM monitors specific
engine operating parameters in order to detect
abnormal conditions that may develop. The ECM will
generate an event code if a specific engine parameter
exceeds an acceptable range that is defined by the
engine monitoring system. The ECM will react with an
action that is dependent on the severity of the
condition. For information on event codes, refer to

this Operation and Maintenance Manual, “Event
Codes” topic (Operation Section) The following
actions may be initiated by the ECM. These actions
are dependent on the severity of the condition:

• Illumination of a warning lamp or warning alarm

• Engine derate

• Engine protection shutdown

16 SEBU8598

Product Information Section
Model View Illustrations

Product Information
Section

Model View Illustrations

SMCS Code: 1000

General Information

i04060965

Illustration 12 g02272773

Left side view of a typical C15 or C18 Industrial Engine

(1) Fuel pressure sensor pre-filter
(2) Fuel pressure sensor post-filter
(3) Charge air cooler outlet sensor
(4) Open crankcase ventilation breather
(5) NRS temperature sensor

(6) NRS valve
(7) Engine control module (ECM)
(8) Crankcase pressure sensor
(9) Engine speed sensor
(10) Fuel pump

(11) Secondary fuel filter base
(12) Oil filler
(13) Fuel temperature sensor

SEBU8598 17

General Information

Product Description

Illustration 13 g02272613

Right side view of a typical C15 or C18 Industrial Engine

(14) NRS cooler (15) Turbocharger (16) Oil filter base

i04061067

Product Description

SMCS Code: 1000; 4450; 4491

• Four stroke cycle

• Mechanically actuated electronically controlled fuel

injection system

• Turbocharged

Engine Description

Engine Specifications

The Caterpillar C15 and C18 Industrial Engine
provides the following features:

Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.

18 SEBU8598

General Information
Product Description

Electronic Engine Features

The Caterpillar C15 and C18 Engine are designed
for electronic controls. The integral on board
computer controls the operation of the engine.
Current operating conditions are monitored. The
Electronic Control Module (ECM) controls the
response of the engine to these conditions and to the
demands of the operator. These conditions and
operator demands determine the precise control of
fuel injection by the ECM. The electronic engine
control system provides the following features:

• Engine speed governor

Illustration 14 g01387009

Cylinder and valve location

(A) Exhaust valve
(B) Inlet valve

Table 1

C15 Engine Specifications

Arrangement and Cylinders In-line six cylinder

Bore 137 mm (5.4 inch)

Stroke 171 mm (6.7 inch)

Aspiration ATAAC

Displacement 15.2 L (928 cubic inch)

Firing Order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise

(1)

Air-to-air aftercooled

Table 2

C18 Engine Specifications

Arrangement and Cylinders In-Line six cylinder

Bore 145 mm (5.7 inch)

Stroke 183 mm (7.2 inch)

Aspiration ATAAC

Displacement 18.1 L (1105 cubic inch)

Firing Order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise

(1)

Air-to-air aftercooled

(1)

(1)

• Automatic air/fuel ratio control

• Torque rise shaping

• Injection timing control

• System diagnostics

• Aftertreatment regeneration control

• NOx reduction system control

Additional Features

The following additional features provide increased
engine fuel economy and serviceability:

• Cold starting capability

• Tampering detection

• Diagnostics

Engine Diagnostics

The engine has built-in diagnostics in order to ensure
that all of the components are functioning properly.
Under certain conditions, the engine horsepower and
the vehicle speed may be limited. A Caterpillar
electronic service tool may be used to display the
diagnostic code.

There are two categories of codes: diagnostic code
and event code. These two categories of codes may
be in two different states: active and logged.

Most of the diagnostic codes are logged and stored in
the ECM. For additional information, refer to the

Operation and Maintenance Manual, “Engine
Diagnostics” topic (Operation Section).

Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and

lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.

SEBU8598 19

General Information

Product Description

Expected engine life is predicted by the average
power that is demanded. The average power that is
demanded is based on fuel consumption of the
engine over a time. Reduced hours of operation at full
throttle and/or operating at reduced throttle settings
result in a lower average power demand. Reduced
hours of operation will increase the length of
operating time before an engine overhaul is required.
For more information, refer to the Operation and
Maintenance Manual, “Overhaul Considerations”

topic (Maintenance Section).

Aftermarket Products and Caterpillar
Engines

NOTICE
In order to maximize fuel system life and prevent pre­mature wear out from abrasive particles in the fuel, a
four micron[c] absolute high efficiency fuel filter is re­quired for all Caterpillar common rail fuel systems.
Caterpillar High Efficiency Fuel Filters meet these re­quirements. Consult your Caterpillar dealer for the
proper part numbers.

When auxiliary devices, accessories, or consumables
(filters, additives, catalysts, etc.) which are made by
other manufacturers are used on Caterpillar
products, the Caterpillar warranty is not affected
simply because of such use.

However, failures that result from the installation
or use of devices, accessories, or consumables
from other manufacturers are NOT Caterpillar

defects. Therefore, the defects are NOT covered
under the Caterpillar warranty.

20 SEBU8598

Product Identification Information
Plate Locations and Film Locations

Product Identification
Information

i04092302

Plate Locations and Film
Locations

SMCS Code: 1000; 4450

Illustration 15 g02273593

View of the left side of a typical C15 or C18 Industrial
Engine

The serial number plate is located on the left side of
the cylinder block. The engine control module will
obstruct the view of the serial number plate.

Illustration 17 g02272993

View of the top of a typical C15 or C18 Industrial
Engine

The engine information plate is located toward the
rear of the valve cover. The engine information plate
may be read from the right side of the engine.

Illustration 18 g01347963

Engine information plate

The following information is on the information plate:
engine serial number, engine model, engine
arrangement number, maximum altitude of the engine
that is necessary to achieve the rated power,
horsepower, high idle, full load rpm, fuel settings and
other information

Illustration 16 g00123229

Serial number plate

The following information is stamped on the serial
number plate: engine serial number, engine model
and arrangement number.

SEBU8598 21

Product Identification Information

Emissions Certification Film

This label is located on the engine.

i00844066

Emissions Certification Film

SMCS Code: 1000; 7405

S/N: BDN1–Up

Illustration 21 g00284658

EPA Emissions Certification Film

Illustration 19 g02236893

View of the exhaust system of a C15 or C18 Industrial
Engine

Illustration 20 g02236574

CEM plate

The Clean Emission Module (CEM) identification
plate contains the following information: part number,
serial number, change level and configuration ID
code. This information may be needed by the Cat
dealer when inquiries are being made on the CEM.

i04019095

Emissions Certification Film

SMCS Code: 1000; 7405

Note: This information is pertinent in the United

States, in Canada and in Europe.

Illustration 22 g00415538

European Emissions Certification Film

The EPA Emissions Certification Film (if equipped)
and/or the European Emissions Certification Film (if
equipped) is located on the side of the engine.

i01382270

Reference Information

SMCS Code: 1000; 4450

Identification of the items in Table 3 may be needed
in order to obtain parts and service. Some of the
information is on the engine Serial Number Plate and/
or Information Plate. Locate the information for your
engine. Record the information on the appropriate
space in Table 3 . Make a copy of this list for a record.
Retain the information for future reference.

Consult your Cat dealer for an Emission Control
Warranty Statement.

22 SEBU8598

Product Identification Information
Reference Information

The top level part numbers in the Parts Manual for the
engine are listed with the engine arrangement
number. Occasionally, an arrangement may be
slightly modified before the product is shipped from
the factory. In these cases, a modification number
indicates that the arrangement has been modified.

The packaging arrangement may also be called a
pricing arrangement or a customer arrangement. This
is the total package with attachments and options that
are not included in the engine arrangement.

The performance specification can be used by your
Caterpillar dealer with the Technical Marketing
Information system. Before the engine leaves the
factory, the engine performance is tested. Detailed
performance data is recorded. The performance
specification number can be used for obtaining the
data.

Table 3

Reference Information

Engine Model

Serial Number

Arrangement Number

Modification Number

Packaging Arrangement

Turbocharger

Fuel Filter Element

Lubrication Oil Filter Element

Auxiliary Oil Filter Element

Air Cleaner Element

Fan Drive Belt

Alternator Belt

Capacity of the Lubrication
System

Capacity of the Cooling System

Performance Specification
Number

Personality Module

Low Idle rpm

High Idle rpm

Full Load rpm

Power Rating

SEBU8598 23

Operation Section

Product Lifting

Operation Section

Lifting and Storage

Product Lifting

SMCS Code: 7000; 7002

i04037083

Engine Lifting with a Fuel Tank

Lift eyes or tank can fail when lifting tank contain­ing fluids resulting in possible personal injury.
Drain tank of all fluids before lifting.

Lifting the engine with a fuel tank that is mounted to
the engine requires special equipment and
procedures. Do not lift the unit with fuel in the fuel
tank. Consult your Caterpillar dealer for information
regarding fixtures for proper lifting of your complete
package.

Clean Emission Module Lifting

Illustration 23 g00103219

NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem­ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be­comes less than 90 degrees.

When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.

Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.

Some removals require lifting the fixtures in order to
obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that
are on the engine.

Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure that

proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.

Illustration 24 g02240095

The Clean Emission Module (CEM) should only be
lifted by the designated lifting eyes (1). Lifting eye
locations will be different depending on the CEM
arrangement. Do not attempt to lift the CEM using
straps around the diesel particulate filter.

24 SEBU8598

Lifting and Storage
Product Storage

i05242858

Product Storage

SMCS Code: 7002

Storage (Less Than One Year)

If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft and gears.

This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas
of high humidity.

When the engine is started again, metal to metal
contact will cause wear before the surfaces receive

oil. To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.

When oil pressure is shown on the pressure gauge,
start the engine.

1. Clean the engine of any dirt, rust, grease, and oil.

Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.

2. Remove dirt from the air cleaners. Check all seals,

gaskets, and the filter element for damage.

3. Apply lubricant to all points in this Operation and

Maintenance Manual, “Maintenance Interval
Schedule”.

4. Drain the crankcase oil. Replace the crankcase oil

and change the oil filters. For the proper
procedure, refer to this Operation and
Maintenance Manual.

5. If the engine is equipped with an air starting motor,

fill the reservoir with the following mixture: 50
percent volatile corrosion inhibitor oil
(<nomen>VCI oil</nomen>) and 50 percent
engine oil.

6. Add VCI oil to the crankcase oil. The volume of VCI

oil in the crankcase oil should be 3 to 4 percent.

Note: If the engine crankcase is full, drain enough
engine oil so the mixture can be added.

Note: The mixture of VCI oil can be added to the inlet
by removing the plug for checking turbocharger boost
pressure. The minimum application rate for the VCI
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement.

8. Use a sprayer to apply a mixture of 50 percent VCI
oil and 50 percent crankcase oil into the exhaust
openings. The minimum application rate for the oil
mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement. Seal the exhaust pipe and
seal any drain holes in the muffler.

9. Remove the fuel from the secondary fuel filter
housing. Alternately, empty and reinstall the spin­on fuel filter element in order to remove any dirt
and water. Drain any sleeve metering fuel pump.

Clean the primary fuel filter. Fill with calibration
fluid or kerosene. Install the primary fuel filter and
operate the priming pump. This procedure will
send clean oil to the secondary filter and the
engine.

Open the fuel tank drain valve in order to drain any
water and dirt from the fuel tank. Apply a spray of
calibration fluid or kerosene at the rate of

30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
capacity in order to prevent rust in the fuel tank.
Add 0.15 mL per L (.02 oz per 1 gal US) of
commercial biocide such as Biobor JF to the fuel.

Apply a small amount of oil to the threads on the
fuel tank filler neck and install the cap. Seal all
openings to the tank in order to prevent
evaporation of the fuel and as a preservative.

10. Remove the fuel nozzles or spark plugs. Apply
30 mL (1 oz) of the mixture of oils (50 percent VCI
oil and 50 percent engine oil) into each cylinder.

Use a bar or a turning tool in order to turn over the
engine slowly. This procedure puts the oil on the
cylinder walls. Install all fuel nozzles or spark plugs
and tighten to the correct torque.

11. Spray a thin amount of a mixture of 50 percent
VCI oil and 50 percent engine oil onto the following
components: flywheel, ring gear teeth and starter
pinion. Install the covers in order to prevent
evaporation of the vapors from the VCI oil.

7. Remove the air filter elements. Turn the engine at
cranking speed with the throttle control in FUEL
OFF position. Use a sprayer to add a mixture of 50
percent VCI oil and 50 percent engine oil into the
air inlet or turbocharger inlet.

12. Apply a heavy amount of Cat Multipurpose
Grease (MPGM) to all outside parts that move,
such as rod threads, ball joints, linkage.

Note: Install all covers. Ensure that tape has been
installed over all openings, air inlets, exhaust
openings, the flywheel housing, the crankcase
breathers, the dipstick tubes.

SEBU8598 25

Lifting and Storage

Product Storage

Ensure that all covers are airtight and
weatherproof. Use a waterproof weather resistant
tape such as Kendall No. 231 or an equivalent.
Do not use duct tape. Duct tape will only seal for a
short time.

13. Under most conditions, removing the batteries is
the best procedure. As an alternative, place the
batteries in storage. As needed, periodically
charge the batteries while the batteries are in
storage.

If the batteries are not removed, wash the tops of
the batteries until the tops are clean. Apply an
electrical charge to the batteries in order to obtain
a specific gravity of 1.225.

Disconnect the battery terminals. Place a plastic
cover over the batteries.

Note: For additional information, refer to Special
Instruction, SEHS7633, “Battery Test Procedure”.

14. Loosen all belts.

15. Place a waterproof cover over the engine. Ensure

that the engine cover is secure. The cover should
be loose enough to allow air to circulate around the
engine in order to prevent damage from
condensation.

16. Attach a tag with the storage date to the engine.

17. Remove the waterproof cover at 2 month or 3

month intervals in order to check the engine for
corrosion. If the engine has signs of corrosion,
repeat the protection procedure.

Coolant System

Completely fill the cooling system before storage.

Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for more information about

coolants.

Removal from Storage

1. Remove all outside protective covers.

6. Use a bar or a turning tool in order to turn the

engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.

7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.

8. Pressure-lubricate the engine before starting the
engine. Pressure lubricating the engine ensures
immediate lubrication and prevents damage to the
engine during the first few minutes of engine
operation. If the engine is not equipped with a
prelube pump, contact your Cat dealer for
information about lubrication of the engine before
starting the engine.

9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.

10. Before start-up, test the cooling system for a 3
percent ro a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or a
coolant conditioner element, if equipped.

Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.

Prime the engine with clean diesel fuel before
starting.

11. Ensure that the cooling system is clean. Ensure
that the system is full. Ensure that the system has
the correct amount of supplemental cooling system
conditioner.

12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.

13. If the engine was removed from storage in which
temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898,
“Cold Weather Recommendations Operation and
Maintenance”.

2. Change the oil and filters.

3. Check the condition of the fan and alternator belts.

Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual, “Belts ­Inspect/Adjust/Replace” for the correct procedure.

4. Replace the fuel filter elements.

5. Remove the plastic covers from the air cleaner

elements.

Engines with 2 year preservation group
from the factory

Note: Engines that are stored more than 6 months

must be prelubed and rotated in 6 month intervals.

For engines purchased with a factory applied, 2 year
preservation group, follow the instructions from this
Operation and Maintenance Manual, “Removal From
Storage”, step 8 and in this Operation and
Maintenance Manual, “Storage (less than 1 year)”
section.

26 SEBU8598

Lifting and Storage
Product Storage

For engine CEM's stored for more than one year, use
fuel system cleaner (part no. 343-6210) or equivalent
as recommenced in PEHJ0237, for 80 hours of

operation.

SEBU8598 27

Features and Controls

Battery Disconnect Switch

Features and Controls

i03646563

Battery Disconnect Switch

(If Equipped)

SMCS Code: 1411

The battery disconnect switch and the engine start
switch perform different functions. Turn off the battery
disconnect switch in order to disable the entire

electrical system. The battery remains connected to
the electrical system when you turn off the engine
start switch.

Turn the battery disconnect switch to the OFF
position and remove the key when you service the
electrical system or any other components.

Also turn the battery disconnect switch to the OFF
position and remove the key when the engine will not
be used for an extended period of a month or more.
This will prevent drainage of the battery.

NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam­age to the electrical system could result.

i05316709

Monitoring System

SMCS Code: 1900; 7400; 7450; 7451

The monitoring system is designed to alert the
operator to an immediate problem with any of the
engine systems that are monitored. The Monitoring
System is also designed to alert the operator to an
impending problem with any of the engine systems
that are monitored.

The monitoring system parameters can be accessed
via the Cat ET service tool. Many of the parameters
within the monitoring system can be tailored to suit
the operation of the engine.

An example of adjustments that may be made within
the monitoring system is changing the setpoint of the
engine overspeed indicator from the factory default
setting.

Indicators and Gauges

The instrument panel may look like the instrument
panel that is pictured in illustration 25 or the
instrument panel may look like the instrument panel
that is pictured in illustration 26 . The instrument
panel may not include all of the instruments that are
shown in the illustration.

To ensure that no damage to the engine occurs, verify
that the engine is fully operational before cranking the
engine. Do not crank an engine that is not fully
operational.

Perform the following procedure in order to check the
battery disconnect switch for proper operation:

1. With the battery disconnect switch in the ON

position, verify that electrical components are
functioning. Verify that the hour meter is displaying
information. Verify that the engine will crank.

2. Turn the battery disconnect switch to the OFF

position.

3. Verify that the following items are not functioning:

electrical components, hour meter and engine
cranking. If any of the items continue to function
with the battery disconnect switch in the OFF
position, consult your Caterpillar dealer.

28 SEBU8598

Features and Controls
Monitoring System

Diesel Particulate Filter (DPF) Lamp (2) –
The DPF lamp will illuminate when a

regeneration of the DPF is needed. Refer
to this Operation and Maintenance Manual,
“Diesel Particulate Filter Regeneration” for more
information on this lamp.

High Exhaust Temperature Lamp (3) –

This lamp is illuminated when a DPF

regeneration is active.

Regeneration Disabled (4) – This lamp

will be illuminated if the regeneration is

manually disabled through the
regeneration switch or through the Cat (ET)

Illustration 25 g02212133

service tool.

Start Switch (5) – The start switch has

three positions: OFF, RUN and START.

When the start switch is turned
clockwise to the RUN position, the lamps will
flash for 5 seconds during the system test. The
lamps will then shut off. In the RUN position, the
Electronic Control Module (ECM) and electronic
systems are powered up.

Illustration 26 g02215293

Circuit Breaker (1) – Reset the circuit
breaker if a circuit breaker trips. Press

the button in order to reset the circuit
breaker. If the electrical system is working
properly, the button will remain pressed. If the
button does not remain pressed or if the circuit
breaker trips soon after being reset, check the
appropriate electrical circuit. Repair the electrical
circuit, if necessary.

Resetting the circuit breakers in a flammable at­mosphere or a combustible atmosphere may lead
to fire hazards or explosion hazards which may
result in personal injury or death. DO NOT reset
the circuit breaker when a flammable atmosphere
or a combustible atmosphere is present and the
power has not been removed from the equipment.

Diagnostic Lamp (6) – The diagnostic
lamp will illuminate when an active fault
code is present.

Shutdown Lamp (7) – The shutdown
lamp will illuminate when a critical

engine event occurs which requires that
the engine be shut down. The event should be
addressed as quickly as possible.

Shutdown Switch (8) – Use the engine

shutdown switch in order to stop the

engine. Push the shutdown switch in
order to put the switch in the OFF position.
Moving the switch to the OFF position will stop
the engine. After the engine stops, turn the knob
clockwise. Turning the knob will reset the engine
shutdown switch to the ON position.

Service Hour Meter (9) – This gauge

indicates the total number of clock hours

of engine operation. Hours of operation
are logged in the ECM. A service tool is needed to
retrieve the hours from the ECM. A Service Hour
Meter may be installed on the engine.

Idle Speed Switch (10) – When the switch

is in the up position, the engine speed

increases to HIGH IDLE. When the
switch is in the down position, the engine speed
decreases to LOW IDLE.

SEBU8598 29

Features and Controls

Monitoring System

Regeneration Switch (11) – Used to
activate a forced regeneration or

manually disable regeneration. Refer to
this Operation and Maintenance Manual, “Diesel
Particulate Filter Regeneration” for more
information on this switch.

Illustration 27 g02333673

OK to Elevate Idle Switch (12) – Pressing in and
locking the “OK to Elevate Idle” switch enables the
engine ECM to elevate engine speed automatically
when needed. For example, if the engine is running at
low idle and a DPF regeneration is activated, having
the “OK to Elevate Idle” switch in the LOCKED

position will allow the engine speed to increase in
order for the DPF regeneration to occur.

Tachometer (13) – This gauge indicates

engine speed (rpm). When the throttle

control lever is moved to the full throttle
position without load, the engine is running at
high idle. The engine is running at the full load
rpm when the throttle control lever is at the full
throttle position with maximum rated load.

Voltmeter (14) – This gauge indicates the

voltage of the electrical system. The

needle in the red range indicates low
voltage or high voltage.

Fuel Pressure (15) – This gauge

indicates fuel pressure to the fuel

injection pump from the fuel filter. A
decrease in fuel pressure usually indicates a dirty
fuel filter or a plugged fuel filter. As the fuel filter
becomes plugged, there will be a noticeable
reduction in the performance of the engine.

Engine Oil Pressure (16) – The oil

pressure should be greatest after a cold

engine is started. The pressure will
decrease as the engine warms up. The pressure
will increase when the engine rpm is increased.
The pressure will stabilize when the engine rpm is
stable.

A lower oil pressure is normal at low idle. If the load is
stable and the gauge reading changes, perform the
following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

NOTICE
To help prevent engine damage, never exceed the
high idle rpm. An overspeed can result in serious
damage to the engine. The engine can be operated at
high idle without damage, but the engine should
never be allowed to exceed the high idle rpm.

Note: The high idle rpm and the full load rpm are
stamped on the Information Plate.

Jacket Water Coolant Temperature (17) –
Typical temperature range is 87 to 98°C

(189 to 208°F). Higher temperatures may
occur under certain conditions. The water
temperature reading may vary according to load.
The reading should never exceed the boiling
point for the pressurized system that is being
used.

Coolant Temperature (18) – When the

coolant temperature is above the normal

operating value, the coolant temperature
gauge will be in the red zone. Refer to the
Messenger panel for any additional information
that may be available.

Warning Lamp (19) – There is a general

fault in the engine. Refer to the

Messenger display for any additional
information that may be available.

Service Tool Connector (20) – For more information

about the use of Cat ET and the PC requirements for
Cat ET, refer to the documentation that

accompanies your Cat ET software.

Mini Industrial Power Display
(MIPD)

The mini industrial power display provides for a
means to view various types of engine information.
The information that can be viewed is described

below.

30 SEBU8598

Features and Controls
Monitoring System

Engine Load – Displays the amount of load on the
engine as a percentage.

Regen Disable Status – Displays whether the
regeneration is manually disabled.

DPF Lamp – Displays when a DPF regeneration is
needed.

Soot Loading – Displays the amount of soot within
the DPF as a percentage.

Air Inlet Temperature – Displays the temperature of
the air entering the engine through the air filter.

Intake Manifold Air Temperature – Displays the

Illustration 28 g02216234

““OK/Select”” button (1) – The “OK/Select” button is

used to confirm the selections that were made with
the “scroll left/right” buttons.

““Backlight”” button (2) – This button is used to turn

the backlight of the display on or off.

““Scroll left/right button”” (3) – This button is used to

advance through the various screens of the MIPD.

temperature of the air entering the engine at the
intake manifold.

Boost Pressure – Displays the amount of pressure
of the air entering the intake manifold of the engine.

Crankcase Pressure – Displays the amount of
pressure within the crankcase of the engine.

Atmospheric Pressure – Displays the amount of
atmospheric pressure that the engine is operating in.

Fuel Temp – Displays the temperature of the fuel

The MIPD comes with three preset user interfaces.
The interfaces are labeled as “Operator_1” ,

“Operator_2” , and “Operator_3” .

“Operator_1” user interface is preset with various

engine, aftertreatment, and transmission information
over 14 screens. Diagnostic and system information
is also included. The information in “Operator_1” is
displayed via ISO symbols and metric display units.

entering the engine.

Fuel Rate – Displays the amount of fuel being used
by the engine.

Filtered Fuel Delta Pressure – Displays the
pressure across the fuel filter.

Low Idle RPM – Displays the low idle speed setpoint
in RPM.

“Operator_2” user interface is preset with various

engine, aftertreatment, and transmission information
over 12 screens. Diagnostic and system information
is also included. The information is displayed in
analog style gauges and English display units.

“Operator_3” user interface is preset with various

engine, aftertreatment, and transmission information
over 12 screens. Diagnostic and system information
is also included. The information is displayed in
analog style gauges and English display units.

Note: Only use “Operator_1” and “Operator_2”
interfaces on Tier 4 engines. The added
aftertreatment parameters in these interfaces are
necessary to ensure proper operation.

Parameters

Below are a list of all the parameters that are
viewable through the three user interfaces used
within the MIPD.

Engine Speed – Displays the current engine speed
in RPM.

Coolant Temperature – Displays the current coolant
temperature of the engine.

Hi Idle Speed – Displays the high idle speed setpoint
in RPM.

Desired Speed – Displays the desired engine speed
in RPM.

Primary Throttle – Displays the primary throttle
position as a percentage.

Secondary Throttle – Displays the secondary
throttle position as a percentage.

Auxiliary Pressure Sensor 1 – Displays the
pressure being measured by the #1 auxiliary sensor if
one is being used.

Auxiliary Temperature Sensor 1 – Displays the
temperature being measured by the #1 auxiliary
sensor if one is being used.

Battery Voltage – Displays the battery voltage.

Aftertreatment 1 Regeneration Status – Displays

the status of the regeneration system as manual or
automatic.

HEST Lamp – Illuminates when a DPF regeneration
is active.