Caterpillar Operation and Maintenance Manual (EN)

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 re- placement parts. Failure to follow this warning may lead to pre- mature failures, product damage, personal in- jury 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.

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SEBU8598 3 Table of Contents Table of Contents Refill Capacities....................... ....................... 45 Foreword.............................. ............................. 4 Maintenance Recommendations.......... .......... 51 Maintenance Interval Schedule (C15 Engines)54 Safety Section Maintenance Interval Schedule (C15 Engines With Ratings Greater Than 579 hp)....... ....... 55 Safety Messages....................... ....................... 5 General Hazard Information............... .............. 7 Maintenance Interval Schedule (C18 Engines With Ratings Greater Than 760 HP)....... ...... 56 Burn Prevention....................... .......................

10 Maintenance Interval Schedule (C18 Engines)58 Fire Prevention and Explosion Prevention ... ...11 Crushing Prevention and Cutting Prevention . 13 Warranty Section Mounting and Dismounting............... .............. 13 Warranty Information................... ................... 94 Before Starting Engine ................. .................. 13 Reference Information Section Engine Ratings ........................ ....................... 95 Engine Starting........................ ....................... 14 Engine Stopping ....................... ...................... 14 Customer Service...................... ..................... 96 Electrical System......................

...................... 14 Reference Materials ........................................ 98 Engine Electronics..................... ..................... 15 Index Section Product Information Section Index............................... .............................. 102 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 Engine Stopping ....................... ...................... 44 Maintenance Section

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4 SEBU8598 Foreword Foreword 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Maintenance California Proposition 65 Warning 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. 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. 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.

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SEBU8598 5 Safety Section Safety Messages 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. 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

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