C15 & C18 Engines

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SEBU8598-04

July 2012

Operation andMaintenance

ManualC15 and C18 Industrial Engines

BDN1-Up(C18 Industrial Engine)LDN1-Up (C15 Industrial Engine)

SAFETY.CAT.COM

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i03991620

Important Safety InformationMost accidentsthat involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 asDANGER, 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 pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by NOTICE labelson 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 mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand forothers. You should also ensure that the product will not be damaged or become unsafe bythe 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 thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstartany job. Cat dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Cat re-placement parts or parts with equivalent speci-fications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

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

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SEBU8598-04 3Table of Contents

Table of Contents

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

Safety Section

Safety Messages .................................................... 6

General Hazard Information ................................... 8

Burn Prevention ..................................................... 11

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

Crushing Prevention and Cutting Prevention ........ 13

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

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

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

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

Electrical System .................................................. 15

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

Product Information Section

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

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

Operation Section

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

Features and Controls .......................................... 26

Engine Diagnostics ............................................... 31

Engine Starting ..................................................... 40

Engine Operation .................................................. 45

Cold Weather Operation ....................................... 50

Engine Stopping ................................................... 52

Maintenance Section

Refill Capacities .................................................... 53

Maintenance Recommendations .......................... 59

Maintenance Interval Schedule ((Engines WithRatings Greater Than 579 hp)) ........................... 62

Maintenance Interval Schedule ............................ 64

Maintenance Interval Schedule ((Engines WithRatings Greater Than 699 hp)) ........................... 65

Maintenance Interval Schedule ............................ 67

Warranty Section

Warranty Information .......................................... 104

Reference Information Section

Engine Ratings ................................................... 106

Customer Service ............................................... 108

Reference Materials ............................................. 110

Index SectionIndex .................................................................... 114

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4 SEBU8598-04Foreword

Foreword

Literature Information

This manual contains safety, operation instructions,

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

English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuing

improvement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

Safety

This safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance and

repairon this product.

Operation

Operating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operator

through procedures of inspecting, starting, operatingandstopping the engine. This section also includes adiscussion of electronic diagnostic information.

Maintenance

The maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby fuel consumption, service hours and/or calendartime maintenance intervals. Items in the maintenanceschedule are referenced to detailed instructions thatfollow.

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

Recommendedservice should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementation

of a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems ineach level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced and

displayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engine's permanent record.

See the section in the Operation and MaintenanceManual, Maintenance Records for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

Overhaul

Major engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsavailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.

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SEBU8598-04 5Foreword

California Proposition 65 Warning

Diesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

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6 SEBU8598-04Safety SectionSafety Messages

Safety Section

i04085252

Safety Messages

SMCS Code: 1000; 7405

There may beseveral specific safety messages onyour engine. The exact location and a description ofthe 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 safetymessages if the words cannot be read or if theillustrations are not visible. Use a cloth, water,and soap to clean the safety messages. Do notuse solvents, gasoline, or other harsh chemicals.

Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety messages. Thesafety messages that are loosened could drop offthe engine.

Replace any safety message that is damaged ormissing. If a safety message is attached to a partof the engine that is replaced, install a new safetymessage on the replacement part. Your Caterpillardealer can provide new safety messages.

g02295113Illustration 1

View of the right side of a typical C15 or C18Industrial Engine

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SEBU8598-04 7Safety Section

Safety Messages

Universal Warning (1)


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

right side of the valve cover.

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManual. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

Sulfuric Acid Burn (2)


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

Sulfuric Acid Burn Hazard may cause serious per-sonal injury or death.

The exhaust gas cooler may contain a smallamount of sulfuric acid. The use of fuel with sul-fur levels greater than 15 ppm may increase theamount of sulfuric acid formed. The sulfuric acidmay spill from the cooler during service of theengine. The sulfuric acid will burn the eyes, skinand clothing on contact. Always wear the appro-priate personal protective equipment (PPE) thatis noted on a material safety data sheet (MSDS)for sulfuric acid. Always follow the directions forfirst aid that are noted on a material safety datasheet (MSDS) for sulfuric acid.

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8 SEBU8598-04Safety SectionGeneral Hazard Information

i04074884

General Hazard Information

SMCS Code:1000; 4450; 7405

g00104545

Illustration 4

Attach a Do Not Operate warning tag to the startswitch or controls before the engine is serviced orrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Cat dealer.

Attach the warning tags to the engine and toeach 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 beingserviced.

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold arag over the part that is being removed.

Filler caps

Grease fittings

Pressure taps

Breathers

Drain plugs

Usecaution when cover plates are removed.Gradually loosen, but do not remove the last twobolts or nuts that are located at opposite ends ofthecover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in order torelieve any spring pressure or other pressure.


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

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

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

Ensure that all protective guards and all covers aresecured in place on the engine.

Never put maintenancefluids into glass containers.Glass containers can break.

Use all cleaning solutions with care.

Report all necessary repairs.

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

The engine is stopped. Ensure that the enginecannot be started.

The protective locks or the controls are in theapplied position.

Disconnect the batteries when maintenanceis 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 or an engine whichhas not been started since service has beenperformed, make provisions to stop the engine if anoverspeed occurs. Shutting down the engine maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine.

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

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General Hazard Information

Start the engine with the operator controls. Nevershort across the starting motor terminals or thebatteries. This method of starting the engine couldbypass the engine neutral start system and/or theelectrical system could be damaged.

Pressurized Air and Water

Pressurizedair and/or water can cause debris and/orhot water to be blown out which could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the air

nozzle is deadheaded and used with effective chipguarding(if applicable) and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Always wear eye protection for cleaning the coolingsystem.

Fluid Penetration


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can cause

serious injury and possible death. A pin hole leak cancause severe injury. Iffluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog or refer to Special Pub-lication, PECJ0003, Caterpillar Shop Supplies andTools Catalog for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

Lines, Tubes, and Hoses

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

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

Inspect all lines, tubes, and hoses carefully. Donot use bare hands to check for leaks. Alwaysuse a board or cardboard for checking enginecomponents for leaks. Tighten all connections to therecommended torque.

Check for the following conditions:

End fittings that are damaged or leaking

Outer covering that is chafed or cut

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

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

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10 SEBU8598-04Safety SectionGeneral Hazard Information

Inhalation


Exhaust

Use caution. Exhaust fumes can be hazardous toyour health. If you operate the equipment in anenclosed area, adequate ventilation is necessary.

Asbestos Information

Caterpillar equipment and replacement parts thatare shipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCat replacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

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

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 asbestosmaterials.

A vacuum cleaner that is equipped with a highefficiency particulate airfilter (HEPA) can also beused.

Use exhaust ventilation on permanent machiningjobs.

Wear an approved respirator if there is no otherway to control the dust.

Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in 29 CFR 1910.1001.

Obey environmental regulations for the disposalof asbestos.

Stay away from areas that might have asbestosparticles in the air.

Softwrap

Keep the engine room ventilation operating at fullcapacity. Wear a particulate respirator that has beenapproved by the National Institute of OccupationalSafety and Health (NIOSH). Wear appropriateprotective clothing in order to minimize direct contact.Use good hygiene practices and wash handsthoroughly after handling Softwrapmaterial. Do notsmoke until washing hands thoroughly after handlingSoftwrap material. Clean up debris with a vacuumor by wetsweeping. Do not use pressurized air toclean up debris.

Reference: The applicable material safety data

sheets can be found at the following web site bysearching by the part number or the name of theproduct:

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

Dispose of Waste Properly


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Burn Prevention

Improperly disposing of waste can threaten theenvironment. Potentially harmfulfluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. 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 orengine aftertreatment system. Allow the engine orthe engine aftertreatment system to cool beforeany maintenance is performed on the engine or theengine aftertreatment system. Relieve all pressure inthe appropriate system before any lines, fittings orrelated items are disconnected.

Coolant

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

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

Check the coolant level after the engine has stopped

and the engine has been allowed to cool. Ensurethat the filler cap is cool before removing the fillercap. The filler cap must be cool enough to touch witha bare hand. Remove the filler cap slowly in orderto relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can cause

personal injury. Do not allow hot oil or hot componentsto contact the skin.

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

Batteries

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

Do not smoke while checking the battery electrolytelevels. Batteries give offflammable fumes which canexplode.

Always wear protective glasses when you work withbatteries. Wash hands after touching batteries. The

use of glovesis recommended.

i04090689

Fire Prevention and ExplosionPrevention

SMCS Code: 1000; 4450; 7405


Use of personal protection equipment (PPE) may beneeded.

All fuels, most lubricants, and some coolant mixturesare flammable.

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operate aproduct when a fire hazard exists. Contact your Catdealer for service.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within 15 minutes after anemergency shutdown.

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

If the application involves the presence ofcombustible gases, consult your Cat dealer foradditional information about suitable protectiondevices.

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12 SEBU8598-04Safety SectionFire Prevention and Explosion Prevention

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerials to accumulate on the engine.

All fluids that are captured in the fluid spillcontainment basin should be cleaned up immediately.

Failure to clean up spilledfluids can cause a fire. Firemay cause personal injury and property damage.

Store fuelsand lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

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

correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding orflame cutting.

Wiring must be kept in good condition. Properly routeand attach all electrical wires. Check all electricalwires daily. Repair any wires that are loose or frayedbefore you operate the engine. Clean all electricalconnections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or fordeterioration. Properly route all hoses. The linesand hoses must have adequate support and secureclamps. Tighten all connections to the recommended

torque. Leaks can cause fires.

Properly install all oil fi lters and fuel filters. The fi lterhousings must be tightened to the proper torque.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

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Crushing Prevention and Cutting Prevention

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

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 therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendations

on the instruction plate.

Ether

Ether is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin 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 notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the engine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike

high-pressure lines. Do not install any lines that arebent or damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Cat dealer for repairor for replacement parts.

Check lines, tubes, and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

End fittings aredamaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are ballooning.

Flexible parts of the hoses are kinked.

Outer covers have embedded armoring.

End fittings are displaced.

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

i01359666

Crushing Prevention andCutting Prevention

SMCS Code: 1000; 4450; 7405

Support the component properly when work beneaththe component is performed.

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

Stay clear of all rotating parts and of all moving

parts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

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

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

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

i01372247

Mounting and Dismounting

SMCS Code: 1000; 4450; 7405

Inspect the steps, the handholds, and the work areabefore mounting the engine. Keep these items cleanand keep these items in good repair.

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

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14 SEBU8598-04Safety SectionBefore Starting Engine

Face the enginein order to mount the engine ordismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use onefoot and two hands. Do not use anycontrols as handholds.

Do not stand on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

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

i03560601

Before Starting Engine

SMCS Code: 1000

NOTICEFor initial start-up of a new or rebuilt engine, and forstart-up of an engine that has been serviced, makeprovision to shut the engine off should an overspeedoccur. This may be accomplished by shutting off theair and/or fuel supply to the engine.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always start

and operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controlsif there is a DO NOT OPERATE warning tag orsimilar warning tag attached to the start switch or tothe controls.

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

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work properly, if equipped.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

See the Service Manual for repairs and foradjustments.

i03941639

Engine Starting

SMCS Code: 1000

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

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine with the engine start switch.

Always start the engine according to the procedurethat is described in this Operation and MaintenanceManual, Starting the Engine for information aboutstarting the engine. Know the correct procedure toprevent major damage to the engine components.

Know the correct procedure to prevent personalinjury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingproperly, check the water temperature gauge and theoil temperature gauge during the heater operation.

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

i01462046

Engine Stopping

SMCS Code: 1000

Stop the engine according to the procedure inthe Operation and Maintenance Manual, EngineStopping (Operation Section) in order to avoidoverheating of the engine and accelerated wear ofthe engine components.

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Electrical System

Use the Emergency Stop Button (if equipped) ONLYin an emergency situation. Do not use the EmergencyStop Button for normal engine stopping. After anemergency stop, DO NOT start the engine until theproblem that caused the emergency stop has beencorrected.

Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or an enginethat has been overhauled. This may be accomplishedby shutting off the fuel supply to the engine and/orshutting off the air supply to the engine.

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

i03896010

Electrical System

SMCS Code: 1000; 1400

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

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative jump start cable should be connectedlast from the external power source to the negative terminal of the starting motor. If the starting motoris not equipped with a negative terminal, connect

the jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Refer tothe Engine Starting section of this Operation andMaintenance Manual for specific starting instructions.

Grounding Practices

Proper grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Improper grounding will result in

uncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearing

journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

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

All grounds should be tight and free of corrosion. Theengine alternator must be grounded to the negative- batteryterminal with a wire that is adequate tohandle the full charging current of the alternator.

i04021529

Engine Electronics

SMCS Code: 1000; 1900

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

The Electronic Control Module (ECM) provides acomprehensive, programmable engine monitoringsystem for this engine. The ECM monitors specificengine operating parameters in order to detectabnormal conditions that may develop. The ECM willgenerate an event code if a specific engine parameterexceeds an acceptable range that is defined by the

engine monitoring system. The ECM will react withan action that is dependent on the severity of thecondition. For information on event codes, refer tothis Operation and Maintenance Manual, EventCodes topic (Operation Section) The followingactions may be initiated by the ECM. These actionsare dependent on the severity of the condition:

Illumination of a warning lamp or warning alarm

Engine derate

Engine protection shutdown

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

Note:Many of the engine control systems and displaymodules that are available for Caterpillar Engineswill work in unison with the Engine MonitoringSystem. Together, the two controls will provide theengine monitoring function for the specific engineapplication. Refer to the Troubleshooting Manual formore information.

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16 SEBU8598-04Product Information SectionGeneral Information

Product InformationSection

General Informationi04060965

Model View Illustrations

SMCS Code: 1000


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 fi lter base(12) Oil filler(13) Fuel temperature sensor

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SEBU8598-04 17Product Information Section

General Information


Right side view of a typical C15 or C18 Industrial Engine

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

i04061067

Product DescriptionSMCS Code:1000; 4450; 4491

Engine Description

The Caterpillar C15 and C18 Industrial Engineprovides the following features:

Four stroke cycle

Mechanically actuated electronically controlled fuelinjection system

Turbocharged

Engine Specifications

Note: The front end of the engine is opposite theflywheel end of the engine. The left and the rightsides of the engine are determined from the flywheelend. The number 1 cylinder is the front cylinder.

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18 SEBU8598-04Product Information SectionGeneral Information


Cylinder and valve location

(A) Exhaust valve(B) Inlet valve

Table 1

C15 Engine Specifications

Arrangement andCylinders

In-line six cylinder

Bore 137 mm (5.4 inch)

Stroke 171 mm (6.7 inch)

Aspiration ATAAC(1)

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 andCylinders

In-Line six cylinder

Bore 145 mm (5.7 inch)

Stroke 183 mm (7.2 inch)

Aspiration ATAAC(1)

Displacement 18.1 L (1105 cubic inch)

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

Rotation (flywheel end) Counterclockwise

(1) Air-to-air aftercooled

Electronic Engine Features

The Caterpillar C15 and C18 Engine are designed forelectronic controls. The integral on board computercontrols the operation of the engine. Currentoperating conditions are monitored. The Electronic

Control Module (ECM) controls the response of theengine to these conditions and to the demands of theoperator. These conditions and operator demandsdetermine the precise control of fuel injection by theECM. The electronic engine control system providesthe following features:

Engine speed governor

Automaticair/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 increasedengine fuel economy and serviceability:

Cold starting capability

Tampering detection

Diagnostics

Engine Diagnostics

The engine has built-in diagnostics in order to ensurethat all of the components are functioning properly.Under certain conditions, the engine horsepowerand the vehicle speed may be limited. A Caterpillarelectronic service tool may be used to display thediagnostic code.

There are two categories of codes: diagnostic code

andevent code. These two categories of codes maybe in two different states: active and logged.

Most of the diagnostic codes are logged and storedin the ECM. For additional information, refer tothe Operation and Maintenance Manual, EngineDiagnostics topic (Operation Section).

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General Information

Engine ServiceLife

Engine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants, and

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

Expected engine life is predicted by the averagepower that is demanded. The average power thatis demanded is based on fuel consumption of theengine overa time. Reduced hours of operationat full throttle and/or operating at reduced throttlesettings result in a lower average power demand.Reduced hours of operation will increase the lengthof operating time before an engine overhaul isrequired. For more information, refer to the Operationand Maintenance Manual, Overhaul Considerationstopic (Maintenance Section).

Aftermarket Products and CaterpillarEngines

NOTICEIn order to maximize fuel system life and preventpremature wear out from abrasive particles in the fuel,a four micron[c] absolute high efficiency fuel filter isrequired for all Caterpillar common rail fuel systems.Caterpillar High Efficiency Fuel Filters meet theserequirements. Consult your Caterpillar dealer for theproper part numbers.

When auxiliary devices, accessories, or consumables(filters, additives, catalysts, etc.) which are madeby other manufacturers are used on Caterpillarproducts, the Caterpillar warranty is not affectedsimply because of such use.

However, failures that result from the installationor use of devices, accessories, or consumablesfrom other manufacturers are NOT Caterpillardefects. Therefore, the defects are NOT coveredunder the Caterpillar warranty.

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20 SEBU8598-04Product Information SectionProduct Identification Information

Product IdentificationInformation

i04092302

Plate Locations and FilmLocations

SMCS Code: 1000; 4450


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

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


Serial number plate

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


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

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


Engine information plate

The following information is on the informationplate: engine serial number, engine model, enginearrangement number, maximum altitude of theengine that is necessary to achieve the rated power,horsepower, high idle, full load rpm, fuel settings, andother information

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Product Identification Information


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


CEM plate

The Clean Emission Module (CEM) identificationplate contains the following information: part number,serial number, change level, and configuration IDcode. This information may be needed by the Catdealer when inquiries are being made on the CEM.

i04019095

Emissions Certification Film

SMCS Code: 1000; 7405

Note: This information is pertinent in the UnitedStates, in Canada and in Europe.

Consult your Cat dealer for an Emission ControlWarranty Statement.

This label is located on the engine.

i00844066

Emissions Certification Film

SMCS Code: 1000; 7405

S/N: BDN1-Up


EPA Emissions Certification Film


European Emissions Certification Film

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

i01382270

Reference Information

SMCS Code: 1000; 4450

Identification of the items in Table 3 may be neededin order to obtain parts and service. Some of the

information is on the engine Serial Number Plateand/or Information Plate. Locate the informationfor your engine. Record the information on theappropriate space in Table 3. Make a copy of thislist for a record. Retain the information for futurereference.

The top level part numbers in the Parts Manual forthe engine are listed with the engine arrangementnumber. Occasionally, an arrangement may beslightly modified before the product is shipped fromthe factory. In these cases, a modification numberindicates that the arrangement has been modified.

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22 SEBU8598-04Product Information SectionProduct Identification Information

The packaging arrangement may also be called apricing arrangement or a customer arrangement. Thisis the total package with attachments and optionsthat are not included in the engine arrangement.

The performance specification can be used by

your Caterpillar dealer with the Technical MarketingInformation system. Before the engine leaves thefactory, the engine performance is tested. Detailedperformance data is recorded. The performancespecification number can be used for obtaining thedata.

Table 3

Reference Information

Engine Model

Serial Number

Arrangement Number

Modification Number

Packaging Arrangement

Turbocharger

Fuel Filter Element

Lubrication Oil FilterElement

Auxiliary Oil Filter Element

Air Cleaner Element

Fan Drive Belt

Alternator Belt

Capacity of the LubricationSystem

Capacity of the CoolingSystem

Performance SpecificationNumber

Personality Module

Low Idle rpm

High Idle rpm

Full Load rpm

Power Rating

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SEBU8598-04 23Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i04037083

Product Lifting

SMCS Code: 7000; 7002


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-

comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

Some removals require lifting thefi

xtures in order toobtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for the specificengine arrangement. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat proper lifting devices are provided. Consult yourCaterpillar dealer for information regarding fixturesfor proper engine lifting.

Engine Lifting with a Fuel Tank

Lift eyes or tank can fail when lifting tank con-

tainingfl

uids resulting in possible personal injury.Drain tank of all fluids before lifting.

Lifting the engine with a fuel tank that is mountedto the engine requires special equipment andprocedures. Do not lift the unit with fuel in the fueltank. Consult your Caterpillar dealer for informationregarding fixtures for proper lifting of your completepackage.

Clean Emission Module Lifting


The Clean Emission Module (CEM) should only belifted by the designated lifting eyes (1). Lifting eyelocations will be different depending on the CEMarrangement. Do not attempt to lift the CEM usingstraps around the diesel particulate filter.

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24 SEBU8598-04Operation SectionLifting and Storage

i04137650

Product Storage

SMCS Code: 7002

Storage (Less Than One Year)

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

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

When the engine is started again, metal to metalcontact will cause wear before the surfaces receiveoil. 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 paintdamage with a good quality paint.

2. Remove dirt from the air cleaners. Check all seals,gaskets, and the fi lter element for damage.

3. Apply lubricant to all points in this Operationand Maintenance Manual, Maintenance IntervalSchedule.

4. Drainthe crankcase oil. Replace the crankcase oiland change the oilfilters. For the proper procedure,refer to this Operation and Maintenance Manual.

5. If the engine is equipped with an air startingmotor, fill the reservoir with the followingmixture: 50 percent volatile corrosion inhibitoroil (VCI oil) and 50 percentengine oil.

6. Add VCI oil to the crankcase oil. The volumeof VCI oil in the crankcase oil should be 3 to 4percent.

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

7. Remove the airfi lter elements. Turn the engine atcranking speed with the throttle control in FUELOFF position. Use a sprayer to add a mixture of50 percent VCI oil and 50 percent engine oil intothe air inlet or turbocharger inlet.

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

8. Use a sprayerto apply a mixture of 50 percent VCIoil and 50 percent crankcase oil into the exhaustopenings. The minimum application rate for the oilmixture is 5.5 mL per L (3 oz per 1000 cu in) ofengine displacement. Seal the exhaust pipe andseal any drain holes in the muffler.

9. Remove the fuel from the secondary fuel filterhousing. Alternately, empty and reinstall thespin-on fuel filter element in order to remove anydirt and water. Drain any sleeve metering fuelpump.

Clean the primary fuel filter. Fill with calibration

fluid or kerosene. Install the primary fuel filterand operate the priming pump. This procedurewill send clean oil to the secondary filter and theengine.

Open the fuel tank drain valve in order to drainany water and dirt from the fuel tank. Apply aspray ofcalibration fluid or kerosene at the rateof 30 mL per 30 L (1 oz per 7.50 gal US) of fueltank capacity in order to prevent rust in the fueltank. Add 0.15 mL per L (.02 oz per 1 gal US) ofcommercial biocide such as Biobor JF to the fuel.

Apply asmall amount of oil to the threads on

the fuel tank filler neck and install the cap. Sealall openings to the tank in order to preventevaporation of the fuel and as a preservative.

10. Remove the fuel nozzles or spark plugs. Apply30 mL (1 oz) of the mixture of oils (50 percent VCIoil and 50 percent engine oil) into each cylinder.

Use abar or a turning tool in order to turn overthe engine slowly. This procedure puts the oil onthe cylinder walls. Install all fuel nozzles or sparkplugs and tighten to the correct torque.

11. Spray a thin amount of a mixture of 50 percent

VCIoil and 50 percent engine oil onto the followingcomponents: flywheel, ring gear teeth, and starterpinion. Install the covers in order to preventevaporation of the vapors from the VCI oil.

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

Note: Install all covers. Ensure that tape has beeninstalled over all openings, air inlets, exhaustopenings, the flywheel housing, the crankcasebreathers, the dipstick tubes.

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Lifting and Storage

Ensure that all covers are airtight andweatherproof. Use a waterproof weather resistanttape such as Kendall No. 231 or an equivalent. Donot use duct tape. Duct tape will only seal for ashort time.

13. Under most conditions, removing the batteriesis the best procedure. As an alternative, placethe batteries in storage. As needed, periodicallycharge the batteries while the batteries are instorage.

If the batteries are not removed, wash the topsof the batteries until the tops are clean. Apply anelectrical charge to the batteries in order to obtaina specific gravity of 1.225.

Disconnect the battery terminals. Place a plasticcover overthe batteries.

Note: For additional information, refer to SpecialInstruction, SEHS7633, Battery Test Procedure.

14. Loosen all belts.

15. Place a waterproof cover over the engine. Ensurethat the engine cover is secure. The cover shouldbe looseenough to allow air to circulate aroundthe engine in order to prevent damage fromcondensation.

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

17. Removethe waterproof cover at 2 month or 3

month intervals in order to check the engine forcorrosion. 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 aboutcoolants.

Removal from Storage

1. Remove all outside protective covers.

2. Change the oil and filters.

3. Check the condition of the fan and alternatorbelts. Replace the belts, if necessary. Refer tothis 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 cleanerelements.

6. Use a bar or a turning tool in order to turn theengine in the normal direction of rotation. Theprocedure ensures that no hydraulic locks orresistance exist.

7. Before starting the engine, remove the valve cover

or covers. Put a large amount of engine oil on thecamshaft, cam followers, and valve mechanism inorder to prevent damage to the mechanism.

8. Pressure-lubricate the engine before starting theengine. Pressure lubricating the engine ensuresimmediate lubrication and prevents damage tothe engine during the first few minutes of engineoperation. If the engine is not equipped witha prelube pump, contact your Cat dealer forinformation about lubrication of the engine beforestarting 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 3percent ro a 6 percent concentration of coolantconditioner. Add liquid coolant conditioner or acoolant conditioner element, if equipped.

Test thecoolant mixture for proper nitrite level. Ifnecessary, adjust the coolant mixture.

Prime the engine with clean diesel fuel beforestarting.

11. Ensurethat the cooling system is clean. Ensure

that the system is full. Ensure that the systemhas the correct amount of supplemental coolingsystem conditioner.

12. On the first day of operation, check the entireengine several times for leaks and correctoperation.

13. If the engine was removed from storage in whichtemperatures of less than -12C (10F) wereencountered, refer to Service Manual, SEBU5898,Cold Weather Recommendations Operation andMaintenance.

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26 SEBU8598-04Operation SectionFeatures and Controls

Features and Controls

i03646563

Battery Disconnect Switch

(If Equipped)SMCS Code: 1411

The battery disconnect switch and the engine startswitch perform different functions. Turn off the batterydisconnect switch in order to disable the entireelectrical system. The battery remains connected tothe electrical system when you turn off the enginestart switch.

Turn the battery disconnect switch to the OFFposition and remove the key when you service theelectrical system or any other components.

Also turn the battery disconnect switch to the OFFposition and remove the key when the engine will notbe used for an extended period of a month or more.This will prevent drainage of the battery.

NOTICENever move the battery disconnect switch to the OFFposition while the engine is operating. Serious dam-age to the electrical system could result.

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

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

1. With the battery disconnect switch in the ONposition, verify that electrical components arefunctioning. Verify that the hour meter is displayinginformation. Verify that the engine will crank.

2. Turn the battery disconnect switch to the OFFposition.

3. Verify that the following items are not functioning:electrical components, hour meter, and enginecranking. If any of the items continue to functionwith the battery disconnect switch in the OFFposition, consult your Caterpillar dealer.

i04129351

Monitoring System

SMCS Code: 1900; 7400; 7450; 7451

The monitoring system is designed to alert theoperator to an immediate problem with any of theengine systems that are monitored. The MonitoringSystem is also designed to alert the operator to animpending problem with any of the engine systemsthat are monitored.

The monitoring system parameters can be accessedvia the Cat ET service tool. Many of the parameterswithin themonitoring system can be tailored to suitthe operation of the engine.

An exampleof adjustments that may be made withinthe monitoring system is changing the setpoint of the

engine overspeed indicator from the factory defaultsetting.

Indicators and Gauges

The instrument panel may look like the instrumentpanel that is pictured in illustration 25 or theinstrument panel may look like the instrument panelthat is pictured in illustration 26. The instrument panelmay not include all of the instruments that are shownin the illustration.


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Circuit Breaker (1) Reset the circuitbreaker if a circuit breaker trips. Press thebutton in order to reset the circuit breaker. If

the electrical system is working properly, the buttonwill remain pressed. If the button does not remainpressed or if the circuit breaker trips soon after beingreset, check the appropriate electrical circuit. Repairthe electrical circuit, if necessary.

Resetting the circuit breakers in a flammable at-mosphere or a combustible atmosphere may leadto fire hazards or explosion hazards which may re-sult in personal injury or death. DO NOT reset thecircuit breaker when a flammable atmosphere or acombustible atmosphere is present and the pow-er has not been removed from the equipment.

Diesel Particulate Filter Lamp (2) The DPF lamp will illuminate when aregeneration of the DPF is needed. Refer

to this Operation and Maintenance Manual, Diesel

Particulate Filter Regeneration for more informationon this lamp.

High Exhaust Temperature Lamp (3) This lamp is illuminated when a DPFregeneration is active.

Regeneration Disabled (4) This lampwill be illuminated if the regeneration ismanually disabled through the regeneration

switch or through the Cat (ET) service tool.

Start Switch (5) The start switch hasthree positions: OFF, RUN, and START.When the startswitch is turned clockwise to

the RUN position, the lamps will flash for 5 secondsduring the system test. The lamps will then shut off.

In the RUN position, the ECM and electronic systemsare powered up.

Diagnostic Lamp (6) The diagnosticlamp will illuminate when an active faultcode is present.

Shutdown Lamp (7) The shutdownlamp will illuminate when a critical engineevent occurs which requires that the engine

be shut down. The event should be addressed asquickly aspossible.

Shutdown Switch (8) Use the engineshutdown switch in order to stop the engine.Push the shutdown switch in order to put

the switch in the OFF position. Moving the switch tothe OFF position will stop the engine. After the enginestops, turn the knob clockwise. Turning the knob willreset the engine shutdown switch to the ON position.

Service Hour Meter (9) This gaugeindicates the total number of clock hoursof engine operation. Hours of operation

are logged in the ECM. A service tool is needed toretrieve the hours from the ECM. A Service Hour

Meter may be installed on the engine.

Idle Speed Switch (10) When the switchis in the up position, the engine speedincreases to HIGH IDLE. When the switch

is in the down position, the engine speed decreasesto LOWIDLE.

Regeneration Switch (11) Usedto activate a forced regeneration ormanually disable regeneration. Refer to

this Operation and Maintenance Manual, DieselParticulate Filter Regeneration for more informationon this switch.

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High Speed Regeneration Enable Switch(12) Pressing in and locking the HIGH SPEEDREGENERATION ENABLE switch enables an

automatic regeneration during normal engineoperation or normal engine working speed and load.If this switch is not in the IN and LOCKED position,an automatic regeneration may only occur when theengine is at the programmed low idle speed (lessthan 1500 rpm).

Tachometer (13) This gauge indicatesengine speed (rpm). When the throttlecontrol lever is moved to the full throttle

position without load, the engine is running at highidle. The engine is running at the full load rpm whenthe throttle control lever is at the full throttle positionwith maximum rated load.

Voltmeter (14) This gauge indicates thevoltage of the electrical system. The needlein the red range indicates low voltage or

high voltage.

Fuel Pressure (15) This gauge indicatesfuel pressure to the fuel injection pump fromthe fuel fi lter. A decrease in fuel pressure

usually indicates a dirty fuel filter or a plugged fuelfilter. As the fuel filter becomes plugged, there willbe a noticeable reduction in the performance of theengine.

Engine Oil Pressure (16) The oilpressure should be greatest after acold engine is started. The pressure will

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

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

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

NOTICETo help prevent engine damage, never exceed the

high idle rpm. An overspeed can result in serious dam-age to the engine. The engine can be operated at highidle without damage, but the engine should never beallowed to exceed the high idle rpm.

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

Jacket Water Coolant Temperature (17) Typical temperature range is 87 to 98C(189 to 208F). Higher temperatures

may occurunder certain conditions. The watertemperature reading may vary according to load. The

reading should never exceed the boiling point for thepressurized system that is being used.

Coolant Temperature (18) When thecoolant temperature is above the normaloperating value, the coolant temperature

gauge will be in the red zone. Refer to the Messengerpanel for any additional information that may beavailable.

Warning Lamp (19) There is a generalfault in the engine. Refer to the Messengerdisplay for any additional information that

may be available.

Service Tool Connector (20) For more informationaboutthe use of Cat ET and the PC requirements forCat ET, refer to the documentation that accompaniesyour Cat ET software.

Mini Industrial Power Display(MIPD)

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

below.

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OK/Select button (1) The OK/Selectbutton isused to confirm the selections that were made withthe scroll left/right buttons.

Backlight button (2) This button is used to turnthe backlight of the display on or off.

Scroll left/right button (3) This button is usedto advance through the various screens of the MIPD.

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 variousengine, aftertreatment, and transmission informationover 14 screens. Diagnostic and system information

is also included. The information in Operator_1 isdisplayed via ISO symbols and metric display units.

Operator_2 user interface is preset with variousengine, aftertreatment, and transmission informationover 12 screens. Diagnostic and system informationis also included. The information is displayed inanalog style gauges and English display units.

Operator_3 user interface is preset with variousengine, aftertreatment, and transmission informationover 12 screens. Diagnostic and system informationis also included. The information is displayed inanalog style gauges and English display units.

Note: Only use Operator_1 and Operator_2interfaces on Tier 4 engines. The addedaftertreatment parameters in these interfaces arenecessary to ensure proper operation.

Parameters

Below are a list of all the parameters that areviewable through the three user interfaces usedwithin the MIPD.

Engine Speed Displays the current engine speedin RPM.

Coolant Temperature Displays the current coolanttemperature of the engine.

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

Regen Disable Status Displays whether theregeneration is manually disabled.

DPF Lamp Displays when a DPF regeneration isneeded.

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

Air Inlet Temperature Displays the temperature ofthe air entering the engine through the airfi lter.

Intake Manifold Air Temperature Displays thetemperature of the air entering the engine at the

intake manifold.

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

Crankcase Pressure Displays the amount ofpressure within the crankcase of the engine.

Atmospheric Pressure Displays the amount ofatmospheric pressure that the engine is operating in.

Fuel Temp Displays the temperature of the fuelentering the engine.

Fuel Rate Displays the amount of fuel being usedby the engine.

Filtered Fuel Delta Pressure Displays thepressure across the fuel filter.

Low Idle RPM Displays the low idle speed setpointin RPM.

Hi Idle Speed Displays the high idle speedsetpoint in RPM.

Desired Speed Displays the desired engine speedin RPM.

Primary Throttle Displays the primary throttleposition as a percentage.

Secondary Throttle Displays the secondarythrottle position as a percentage.

Auxiliary Pressure Sensor 1 Displays thepressure being measured by the #1 auxiliary sensorifone is being used.

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Auxiliary Temperature Sensor 1 Displays thetemperature being measured by the #1 auxiliarysensor if one is being used.

Battery Voltage Displays the battery voltage.

Aftertreatment 1 Regeneration Status Displaysthe status of the regeneration system as manual orautomatic.

HEST Lamp Illuminates when a DPF regenerationis active.

DPF Intake Temperature Displays thetemperature of the exhaust gas entering the DPF.

DPF Outlet Temperature Displays thetemperature of the exhaust gas leaving the DPF.

Transmission Selected Gear Displays the

transmission gear being requested.

Transmission Requested Gear Displays thetransmission gear being requested.

Transmission Oil Pressure Displays the oilpressure inside the transmission.

Transmission Oil Temperature Displays the oiltemperature of the transmission.

Transmission Torque Limit Displays the limit oftorque allowed by the transmission.

System Information

User Name Displays the preset user name thatis selected.

Software Version Displays the version of softwarethat is programmed in the MIPD.

Serial Number Displays the serial number of theMIPD.

Display Units Displays the units of measurementthat is selected for the given user.

Engine Location Displays which engine data isbeing reported if more than one engine is connectedto the MIPD.

Language Displays the selected language.

Alarm Indicates whether audible alarm is set toON or OFF when an audible alarm is connected tothe MIPD.

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Engine Diagnostics

Engine Diagnostics

i00863835

Self-Diagnostics

SMCS Code: 1000; 1900; 1901; 1902

The electronic control module has someself-diagnostic ability. When an electronic problemwith an input or an output is detected, a diagnosticcode is generated. This indicates the specific problemwith the circuitry.

Diagnostic codes are also generated when anabnormal engine operating condition is detected. Forexample, a diagnostic code will be generated if thelow oil pressure alarm is activated. In this case, thediagnostic code indicates the symptom of a problem.

This type of diagnostic code is called an event. Anevent is triggered by the detection of an abnormalengine operating condition.

A diagnostic code which represents a problem thatcurrently exists is called an active code.

A diagnostic code that is stored in memory is calleda logged code. Always service active codes prior toservicing logged codes. Logged codes may includethe following categories:

Intermittent problems

Recorded events

Performance history

Logged codes may not indicate that a repair isneeded. The problems may have been repaired sincethe logging of the code. Logged codes may be helpfulto troubleshoot intermittent problems.

i04129429

Diagnostic Flash CodeRetrieval

SMCS Code: 1000; 1900; 1901; 1902

In order to read the diagnostic flash codes throughthe diagnostic lamp, cycle the key switch from off toon twice within 3 seconds.

The codes will be flashing in sequence. For exampleif the flash code equals 133, the diagnostic lamp willflash once, pause, flash three times, pause, and flashthree times.

After the complete code has flashed, a 3 secondpause will take place before the next code will beginto flash (if another code is present).

Note: Always refer to the Troubleshooting guidefor the latest information related to engine

diagnosticsand troubleshooting. Contact yourlocal Cat dealer for more information.

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32 SEBU8598-04Operation SectionEngine Diagnostics

Table 4

Cross Reference for Diagnostic Codes and Event Codes

FlashCode

SPN(1)/FMI CodeDiagnostic Code

orEvent Code

Description of Code

651-5 1-5 Engine Injector Cylinder #1 : Current Below Normal651-6 1-6 Engine Injector Cylinder #1 : Current Above Normal

3959-5 2602-5 Engine Injector Cylinder #1 Actuator #2: Current Below Normal111/139

3959-6 2602-6 Engine Injector Cylinder #1 Actuator #2: Current Above Normal

2950-5 1901-5 Engine Intake Valve Actuator #1: Current Below Normal

2950-6 1901-6 Engine Intake Valve Actuator #1: Current Above Normal111/179

2950-7 1901-7 Engine Intake Valve Actuator #1: Not Responding Properly

652-5 2-5 Engine Injector Cylinder #2 : Current Below Normal

652-6 2-6 Engine Injector Cylinder #2 : Current Above Normal


3660-6 2604-6 Engine Injector Cylinder #2 Actuator #2: Current Above Normal2951-5 1902-5 Engine Intake Valve Actuator #2: Current Below Normal

2951-6 1902-6 Engine Intake Valve Actuator #2: Current Above Normal112-179



























(continued)

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Engine Diagnostics

(Table 4, contd)


FlashCode


orEvent Code

Description of Code

2955-5 1906-5 Engine Intake Valve Actuator #6: Current Below Normal2955-6 1906-6 Engine Intake Valve Actuator #6: Current Above Normal116-179


105-15 539 (1) Engine Intake Manifold #1 Temperature : High - least severe (1)

105-16 539 (2) Engine Intake Manifold #1 Temperature : High -

moderate severity (2)

110-3 110-3 Engine Coolant Temperature : Voltage Above Normal

110-4 110-4 Engine Coolant Temperature : Voltage Below Normal

172-3 2526-3 Engine Air Inlet Temperature : Voltage Above Normal

133

172-4 2526-4 Engine Air Inlet Temperature : Voltage Below Normal

135 102-18 1045 (2) Engine Intake Manifold #1 Pressure : Low - moderate severity (2)

190-8 190-8 Engine Speed : Abnormal Frequency, Pulse Width, or Period

190-0 362 (3) Engine Speed : High - most severe (3)141

190-15 362 (1) Engine Speed : High - least severe (1)

142 723-8 342-8 Engine Speed Sensor #2 : Abnormal Frequency,

Pulse Width, or Period

637-11 261-11 Engine Timing Sensor : Other Failure Mode143

637-13 261-13 Engine Timing Sensor : Calibration Required

100-3 100-3 Engine Oil Pressure : Voltage Above Normal

100-4 100-4 Engine Oil Pressure : Voltage Below Normal

108-3 274-3 Barometric Pressure : Voltage Above Normal152

108-4 274-4 Barometric Pressure : Voltage Below Normal100-1 360 (3) Engine Oil Pressure : Low - most severe (3)

100-17 360 (1) Engine Oil Pressure : Low - least severe (1)157

100-18 360 (2) Engine Oil Pressure : Low - moderate severity (2)

174-3 174-3 Engine Fuel Temperature 1 : Voltage Above Normal

174-4 174-4 Engine Fuel Temperature 1 : Voltage Below Normal165

174-15 363 (1) Engine Fuel Temperature 1 : High - least severe (1)

110-15 361 (1) Engine Coolant Temperature : High - least severe (1)168

110-16 361 (2) Engine Coolant Temperature : High - moderate severity (2)

2949-5 1922-5 Engine Intake Valve Actuation System Oil Pressure Control

Valve: Current Below Normal

2949-6 1922-6 Engine Intake Valve Actuation System Oil Pressure ControlValve - Current Above Normal

181

2949-7 1922-7 Engine Intake Valve Actuation System Oil Pressure Control

Valve - Not Responding Properly

(continued)

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34 SEBU8598-04Operation SectionEngine Diagnostics

(Table 4, contd)


FlashCode


orEvent Code

Description of Code

2948-3 1924-3 Engine Intake Valve Actuation System Oil Pressure:Voltage Above Normal

2948-4 1924-4 Engine Intake Valve Actuation System Oil Pressure:

Voltage Below Normal

2948-7 1101 (1) Engine Intake Valve Actuation System Oil Pressure:

Not Responding Properly

182

2948-17 488 (1) Engine Intake Valve Actuation System Oil Pressure:Low

- least severe (1)

3241-4 3485-4 Exhaust Gas Temperature 1 : Voltage Below Normal

1863241-3 3485-3 Exhaust Gas Temperature 1 : Voltage Above Normal

100-13 100-13 Engine Oil Pressure : Calibration Required

108-13 274-13 Barometric Pressure : Calibration Required

3358-13 3385-13 Engine Exhaust Gas Recirculation Inlet Pressure :

Calibration Required

3563-3 1785-3 Engine Intake Manifold #1 Absolute Pressure : Voltage

Above Normal

3563-4 1785-4 Engine Intake Manifold #1 Absolute Pressure : Voltage

Below Normal

197

3563-13 1785-13 Engine Intake Manifold #1 Absolute Pressure : Calibration Required

168-2 168-2 Battery Potential / Power Input 1 : Erratic, Intermittent, or Incorrect

168-3 168-3 Battery Potential / Power Input 1 : Voltage Above Normal422

168-4 168-4 Battery Potential / Power Input 1 : Voltage Below Normal

439 158-2 1834-2 Keyswitch Battery Potential : Erratic, Intermittent, or Incorrect

3509-3 262-3 Sensor Supply Voltage 1 : Voltage Above Normal

3509-4 262-4 Sensor Supply Voltage 1 : Voltage Below Normal

3510-3 2131-3 Sensor Supply Voltage 2 : Voltage Above Normal516

3510-4 2131-4 Sensor Supply Voltage 2 : Voltage Below Normal

527 630-2 268-2 Calibration Memory : Erratic, Intermittent, or Incorrect

NA 94-16 1218 (2) Engine Fuel Delivery Pressure : High - moderate severity (2)

NA 101-3 101-3 Engine Crankcase Pressure : Voltage Above Normal

NA 101-4 101-4 Engine Crankcase Pressure : Voltage Below Normal

NA 101-13 101-13 Engine Crankcase Pressure : Calibration Required

NA 101-15 1036 (1) Engine Crankcase Pressure : High - least severe (1)

NA 101-16 1036 (2) Engine Crankcase Pressure : High - moderate severity (2)

NA 105-0 539 (3) Engine Intake Manifold #1 Temperature : High - most severe (3)

NA 108-21 274-21 Barometric Pressure : Data Drifted Low

NA 110-0 361 (3) Engine Coolant Temperature : High - most severe (3)

NA 152-0 254-0 Number Of ECU Resets : High - most severe (3)

NA 152-1 254-1 Number Of ECU Resets : Low - most severe (3)

NA 152-2 254-2 Number Of ECU Resets : Erratic, Intermittent, or Incorrect

NA 152-3 254-3 Number Of ECU Resets : Voltage Above Normal

NA 152-4 254-4 Number Of ECU Resets : Voltage Below Normal

(continued)

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Engine Diagnostics

(Table 4, contd)


FlashCode


orEvent Code

Description of Code

NA 152-5 254-5 Number Of ECU Resets : Current Below NormalNA 152-6 254-6 Number Of ECU Resets : Current Above Normal

NA 152-7 254-7 Number Of ECU Resets : Not Responding Properly

NA 152-8 254-8 Number Of ECU Resets : Abnormal Frequency,

Pulse Width, or Period

NA 152-9 254-9 Number Of ECU Resets : Abnormal Update Rate

NA 152-10 254-10 Number Of ECU Resets : Abnormal Rate of Change

NA 152-11 254-11 Number Of ECU Resets : Other Failure Mode

NA 152-12 254-12 Number Of ECU Resets : Failure

NA 152-13 152-13 Number Of ECU Resets : Calibration Required

NA 173-15 E194(2) High Exhaust Temperature

NA 174-0 363 (3) Engine Fuel Temperature 1 : High - most severe (3)

NA 174-16 363 (2) Engine Fuel Temperature 1 : High - moderate severity (2)

NA 411-3 3387-3 Engine Exhaust Gas Recirculation Differential Pressure

: Voltage Above Normal


: Voltage Below Normal


: Calibration Required

NA 411-15 1094 (1) Engine Exhaust Gas Recirculation Differential Pressure

: High - least severe (1)

NA 411-17 1093 (1) Engine Exhaust Gas Recirculation Differential Pressure

: Low - least severe (1)

NA 412-3 3386-3 Engine Exhaust Gas Recirculation Temperature :

Voltage Above Normal

NA 412-4 3386-4 Engine Exhaust Gas Recirculation Temperature :

Voltage Below Normal

NA 412-15 1092 (1) Engine Exhaust Gas Recirculation Temperature :

High - least severe (1)

NA 412-16 1092 (2) Engine Exhaust Gas Recirculation Temperature : High

- moderate severity (2)

NA 626-5 2417-5 Engine Start Enable Device 1 : Current Below Normal

NA 626-6 2417-6 Engine Start Enable Device

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