c15 export engine

8/10/2019 C15 Export Engine

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SEBU7902-05February 2012

Operation andMaintenance

ManualC15 Industrial EnginesJRE1-Up (Engine)JKG1-Up (Engine)JAS1-Up (Engine)MCW1-U p (Engine)

SAFETY.CAT.COM


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i03991620

Important Safety InformationMost accidents that 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 neces sary 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 operat e 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 heed ed, bodily injury or death could occur to you or to other persons.

The hazards are identi ed 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-exh austive list of operations that may cause product damage are identi ed by NOTICE labelson the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warn ings 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 rstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperat ion of the product in the location of use, including site-speci c rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspeci cally recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. 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, speci cations, and illustrations in this publication are on the basis of information thatwas av ailable at the time that the publication was written. The speci cations, 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 youstart any job. Cat dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Cat re-pla cement parts or parts with equivalent speci- cations 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 or de ath.

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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SEBU7902-05 3Table of Contents

Table of Contents

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

Safety Section

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

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

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

Fire Prevention and Explosion Prevention ............ 10

Crushing Prevention and Cutting Prevention ........ 12

Mounting and Dismounting ................................... 12

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

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

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

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

Product Information Section

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

Product Identi cation Information ........................ 19

Operation Section

Lifting and Storage ................................................ 21

Features and Controls .......................................... 24

Engine Diagnostics ............................................... 28

Engine Starting ..................................................... 38

Engine Operation .................................................. 41

Cold Weather Operation ....................................... 43

Engine Stopping ................................................... 45

Maintenance Section

Re ll Capacities .................................................... 46

Maintenance Recommendations .......................... 56

Maintenance Interval Schedule (Engines Which HaveShallow Sumps) .................................................. 59

Maintenance In terval Schedule (Engines Which HaveDeep Sumps) ...................................................... 60

Warranty Section

Warranty Info rmation ............................................ 96

Reference In formation Section

Engine Ratings ..................................................... 98

Customer Service ............................................... 100

Reference M aterials ............................................ 102

Index Sect ion

Index ................................................................... 105


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4 SEBU7902-05Foreword

Foreword

Literature Information

This manual co ntains safety, operation instructions,

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

English is the primary language for all Caterpillar publications. The English used facilitates translationand consist ency in electronic media delivery.

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

improveme nt and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises re garding 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 identi es hazardous,warnin g situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.

Opera tion

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

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

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

Maintenance

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

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

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engin e also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more freque nt lubrication and maintenance than isspeci ed in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the preven tive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould mi nimize 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 in each level should be shifted ahead or backdepending upon your speci c maintenance practices,operation and application. We recommend thatthe mai ntenance schedules be reproduced and

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

See the section in the Operation and MaintenanceManua l, Maintenance Records for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCate rpillar 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 theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel or an authorized Caterpillar dealer. Your Caterpillar dea ler offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsav ailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.


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SEBU7902-05 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 SEBU7902-05Safety SectionSafety Messages

Safety Section

i02840190

Safety MessagesSMCS Code: 1000; 7405

g01416710Illustration 1

Do not operate or work on this engine unless youhave read and understand the instructions andwarnings in the Operation and Maintenance Man-ual. Failure to follow the instructions or heed thewarnings could result in injury or death. Contactany Caterpillar dealer for replacement manuals.Proper care is your responsibility.

There may be several speci c safety messages onyour engine. The exact location and a description of the safety messages are reviewed in this section.Please 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 off of the engine.

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

Universal Warning (1)

The safety messages for the universal warning arelocated toward the front of the engine on both sidesof the valve cover base.



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8 SEBU7902-05Safety SectionGeneral Hazard Information

When starting a new engine or an engine whichhas not been started since service has beenperformed, make provisions to stop the engine if anoverspeed occ urs. 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 o r repair the equipment.

Start the engine with the operator controls. Never short acros s the starting motor terminals or thebatteries. This method of starting the engine couldbypass the engine neutral start system and/or theelectrica l system could be damaged.

Pressuriz ed Air and Water

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

When pres surized 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 r educed to 205 kPa (30 psi) when the air nozzle is deadheaded and used with effective chipguarding (if applicable) and personal protectiveequipm ent. The maximum water pressure for

cleaning purposes must be below 275 kPa (40 psi). Always wear eye protection for cleaning the coolingsyste m.

Fluid Penetration


Always use a boa rd or cardboard when you checkfor a leak. Leaking uid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injur y and possible death. A pin hole leak cancause severe injury. If uid is injected into your skin,you must get treatment immediately. Seek treatment

from a doctor that is familiar with this type of injury.

Containing F luid Spillage

NOTICECare must be taken to ensure that uids are containedduring per formance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the uid with suitable containers before open-ing any com partment or disassembling any compo-nent containing uids.

Refer to S pecial Publication, NENG2500, Caterpillar Dealer Service Tool Catalog or refer to Special Pub-lication, PECJ0003, Caterpillar Shop Supplies andTools Cat alog for tools and supplies suitable to col-lect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations andmandates.

Lines, Tubes, and Hoses

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

Repair any fuel lines, oil lines, tubes, or hoses thatare lo ose or damaged. Leaks can cause res.

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

Check for the following conditions:

End ttings that are damaged or leaking

Out er 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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SEBU7902-05 9Safety Section

General 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 bers. Inhaling this dust can be hazardousto your health. The components that may containasbestos bers 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 highef ciency particulate air lter (HEPA) can also beused.

Use exhaust ven tilation on permanent machining jobs.

Wear an approv ed respirator if there is no other way to control the dust.

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

Obey enviro nmental regulations for the disposalof asbestos.

Stay away f rom areas that might have asbestosparticles in the air.

Softwrap

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

Refere nce: The applicable material safety data

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

http://dsf2ws.cat.com/msds/servlet/cat.c is.ecs.msdsSearch.controller.UserIdenti cationDisplayServlet

Dispose of Waste Properly



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10 SEBU7902-05Safety SectionBurn Prevention

Improperly dis posing of waste can threaten theenvironment. Potentially harmful uids should bedisposed of according to local regulations.

Always use leakproof containers when you drainuids. Do not pour waste onto the ground, down a

drain, or int o any source of water.

i02088921

Burn PreventionSMCS Code: 1000; 4450; 7405

Do not touch any part of an operating engine. Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressure inthe appropriate system before any lines, ttings or related items are disconnected.

Coolant

When the engine is at operating temperature, theengine 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 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 stoppedand the engine has been allowed to cool. Ensurethat the ller cap is cool before removing the ller cap. The ller cap must be cool enough to touch witha bare hand. Remove the ller cap slowly in order to 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 causepersonal 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 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 off ammable fumes which canexplode.

Always wear pro tective glasses when you work withbatteries. Wash hands after touching batteries. Theuse of gloves is recommended.

i04090689

Fire Prevention and ExplosionPreventionSMCS Code: 1000; 4450; 7405


Use of personal protection equipment (PPE) may beneeded.

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

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

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

A ash re 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 of combustible gases, consult your Cat dealer for additional information about suitable protectiondevices.

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


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Fire Prevention and Explosion Prevention

All uids that a re captured in the uid spillcontainment basin should be cleaned up immediately.Failure to clean up spilled uids can cause a re. Firemay cause pers onal injury and property damage.

Store fuels and lubricants in properly marked

containers a way from unauthorized persons. Storeoily rags and any ammable materials in protectivecontainers. Do not smoke in areas that are used for storing am mable materials.

Do not expose the engine to any ame.

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

Do not weld on lines or tanks that contain ammableuids. Do not ame cut lines or tanks that containammable uid. Clean any such lines or tanksthorough ly with a non ammable solvent prior towelding or ame cutting.

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

Elimina te 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 re. Secureconne ctions, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or for deterioration. Properly route all hoses. The linesand h oses must have adequate support and secureclamps. Tighten all connections to the recommendedtorque. Leaks can cause res.

Properly install all oil lters and fuel lters. The lter housings 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 ames or sparks. Alwaysstop the engine before refueling.


Gases from a battery can explode. Keep any openames 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 or a hydrometer.


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12 SEBU7902-05Safety SectionCrushing Prevention and Cutting Prevention

Improper jumpe r cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for speci cinstructions .

Do not charge a frozen battery. Charging a frozen

battery may r esult in an explosion.

The batteries must be kept clean. The covers(if equippe d) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire Extinguisher

Make sure that a re extinguisher is available. Befamiliar with the operation of the re extinguisher.Inspect th e re extinguisher and service the reextinguisher regularly. Obey the recommendations

on the instruction plate.

Ether

Ether is ammable and poisonous.

Use ethe r 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 dire ct sunlight or in temperatures above 49 C(120 F). Keep ether cylinders away from openames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway f rom unauthorized personnel.

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

Lines, Tubes, and Hoses

Do no t 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 res. Consult your Cat dealer for repair or f or replacement parts.

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

Replace the parts if any of the following conditionsare present:

End ttings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coveri ngs are ballooning.

Flexible parts of the hoses are kinked.

Outer covers have embedded armoring.

End ttings are displaced.

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

i01359666

Crushing Prevention andCutting PreventionSMCS 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 movingparts. 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 y off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by ying debris.

i01372247

Mounting and DismountingSM CS 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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Before Starting Engine

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use one foot and two hands. Do not use anycontrols as handholds.

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

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

i03560601

Before St arting EngineSMCS Code: 1000

NOTICEFor init ial start-up of a new or rebuilt engine, and for start-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 or similar 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 order to perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

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

See the Servi ce Manual for repairs and for adjustments.

i01103904

Engine StartingSMCS 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 order to perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator's compartment or from the engine start switch.

Always start the engine according to the procedurethat is described in this Operation and MaintenanceManual, Engine Starting topic (Operation Section).Knowing the correct procedure will help to prevent

major damage to the engine components. Knowingthe procedure will also help to prevent personal injury.

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 well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.

Ether Ether is poisonous and ammable.

Do not inhale ether, and do not allow ether to contactthe skin. Personal injury could result.

Do not smoke while ether cylinders are changed.

Use ether in well ventilated areas.

Use ether with care in order to avoid res.


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14 SEBU7902-05Safety SectionEngine Stopping

Keep ether cyli nders out of the reach of unauthorizedpersons.

Store ether cy linders in authorized storage areasonly.

Do not store e ther cylinders in direct sunlight or attemperatures above 49 C (120 F).

Discard the ether cylinders in a safe place. Do notpuncture the ether cylinders. Do not burn the ether cylinders.

i01462046

Engine StoppingSMCS 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 of the engine components.

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 occurs

during 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/or shutting off the air supply to the engine.

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

i02469632

Electrical SystemSMC S 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 motor is not equipped with a negative terminal, connectthe jump start cable to the engine block.

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

Grounding Practices

g0077 1448Illustration 11

Typical example

Groun ding Stud To Battery Ground


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Engine Electronics


Typical example

Alternate Grounding Stud To Batte ry Ground

Proper grounding for the engine electrical systemis necessary for optimum engine performanceand rel iability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearing journ al surfaces, and to aluminum components.

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

To en sure 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 motor ground, 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- battery terminal with a wire that is adequate tohandle the full charging current of the alternator.

i02784356

Engine ElectronicsSMCS Code: 1000; 1900

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

This engine has a comprehensive, programmableEngine Monitoring System. The Engine ControlModule (ECM) has the ability to monitor the engineoperating conditions. If any of the engine parametersextend outside an allowable range, the ECM willinitiate an immediate action.

The following actions are available for enginemonitoring control: WARNING, DERATE, andSHUTDOWN. These engine monitoring modes havethe ability to limit engine speed and/or the enginepower.

Many of the parameters that are monitored by theECM can be programmed for the engine monitoringfunctions. The following parameters can be monitoredas a part of the Engine Monitoring System:

Operating Altitude

Engine Coolant Level

Engine Coolant Temperature

Engine Oil Pressure

Engine Speed

Fuel Temperature

Intake Manifold Air Temperature

System Voltage

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 speci c engineapplication. Refer to the Troubleshooting Manual for more information.


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16 SEBU7902-05Product Information SectionGeneral Information

Product InformationSection

General Informationi02093819

Model View IllustrationsSMCS Code: 1000


(1) Inlet air manifold(2) Lifting eyes(3) E ngine crankcase breather (4) Water temperature regulator housing

(5) Low pressure turbocharger (6) H igh pressure turbocharger (7) C ooler (8) E ngine oil lter

(9) Water pump(10) Vibration damper


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SEBU7902-05 17Product Information Section

General Information


(11) Air compressor (12) Fuel transfer pump (13) Fuel lter

i04250469

Product DescriptionSMCS Code: 1000; 4450; 4491

Table 1

C15 Engine Speci cations

Cylinders and Arrangement In-line six cylinder Bore 137.2 mm (5.4 inch)

Stroke 171.5 mm (6.8 inch)

Displacement 15.2 L (928 in 3)

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

Rot ation ( ywheel end) Cou nterclockwise

The electronic engines that are covered by thismanual have the following characteristics: direct fuelinjection, electronic unit injection that is mechanicallyac tuated, turbocharged, and air-to-air aftercooled

(ATAAC).

Th e electronic engine control system provides thefollowing functions: electronic governing, automaticair to fuel ratio control, torque rise shaping, injectiontiming control, and system diagnostics.

An electronic governor controls the output of the unitinjectors in order to maintain the engine rpm thatis desired. The functions of the governor include aprogrammable low idle and a 20 rpm to 200 rpmgovernor overrun.

Very high injection pressures are produced byelectronically controlled, mechanically actuated unitinjectors. The injectors combine the pumping and theelectronic fuel metering (duration and timing) duringinjection. The unit injectors accurately control smokelimiting, white smoke, and engine acceleration rates.

There is one unit injector per cylinder. Individual unitinjectors meter the fuel. The individual unit injectorsalso pump the fuel. The metering and the pumping isdone under high pressure. High injection pressureshelp to reduce fuel consumption and emissions.The use of this type of unit injector provides totalelectronic control of injection timing. The injectiontiming varies with engine operating conditions. Theengine performance is optimized in the followingareas:

Starting

Emissions

Noise

Fuel consumption

The timing advance is achieved through precisecontrol of the injector ring. Engine speed iscontrolled by adjusting the ring duration. Theinformation is provided to the Electronic ControlModule (ECM) by an engine speed/timing sensor.The information is for detection of cylinder positionand engine speed.


18/110

18 SEBU7902-05Product Information SectionGeneral Information

The engines hav e built-in diagnostics in order toensure that all of the components are functioningand operating properly. In the event of a systemcomponent dev iation from the programmed limits, theoperator is alerted to the condition by a DIAGNOSTIClamp that is mounted on the control panel. An

electronic s ervice tool that is provided by Cat may beused to read the numerical code of the diagnosticash code. There are three types of diagnostic codes: ACTIVE, LOG GED, and EVENT. These codes arelogged and stored in the ECM. Refer to the Operationand Maintenance Manual, Engine Diagnostics for additional information.

The cooling system consists of the following items:a centrifu gal pump that is driven by a gear, water temperature regulator, an oil cooler, and a radiator that incorporates a shunt system.

The engine lubricating oil is supplied by a gear type pump. The engine lubricating oil is cooled and ltered. Bypass valves provide unrestricted ow of lubrication oil when the oil viscosity is high or if the oilcooler or oil lter elements become plugged.

Engine ef ciency, ef ciency of emission controls,and engine performance depend on adherence toproper o peration and maintenance recommendationsincluding the use of recommended fuels, coolants,and lubrication oils.

Aftermarket Products and CatEngines

NOTICEIn ord er to maximize fuel system life and preventpremature wear out from abrasive particles in thefuel, a two micron absolute high ef ciency fuel lter is re quired for all Caterpillar Electronic Unit Injectors.Caterpillar High Ef ciency Fuel Filters meet theserequirements. Consult your Caterpillar dealer for theprop er part numbers.

When auxiliary devices, accessories, or consumableswhich are made by other manufacturers are used onCat products, 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 Caterpillar defects. Therefore, the defects are NOT coveredunder the Caterpillar warranty.

Welding and Cat ElectronicEngines

NOTICEBecause the strength of the frame may decrease,

some manufacturers do not recommend weldingonto a chassis frame or rail. Consult the OEM of theequipment or your Cat dealer regarding welding on achassis frame or rail.

To help avoid damage to the electronic controls,proper welding procedures are necessary. Beforewelding on a vehicle that is equipped with anelectronic engine, observe the following precautions:

1. Turn off the engine. Place the key start switch inthe OFF position.

2. If the application has a battery disconnect switch,open the switch. Otherwise, disconnect thenegative - battery cable from the battery of thevehicle.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train bearings, hydrauliccomponents, electrical components, and other com-ponents.

Clamp the ground cable from the welder to the com-ponent that will be welded. Place the clamp as close

as possible to the weld. This will help reduce the pos-sibility of damage.

3. Clamp the ground cable from the welder to thecomponent that will be welded. Place the clampas close as possible to the weld.

4. Protect wiring harnesses from welding debris andfrom spatter. Use proper welding procedures.


19/110

SEBU7902-05 19Product Information Section

Product Identi cation Information

Product Identi cationInformation

i02093824

Plate Locations and FilmLocationsSMCS Code: 1000; 4450


(1) Serial number plate

(2) Information plate

Caterpillar engines are identi ed by serial numbersand by arrangement numbers. These numbers areshown on the engine serial number plate and on theengine information plate. Caterpillar dealers needthese numbers in order to determine the componentsthat were included with the engine. This permitsaccurate identi cation of replacement part numbers.

Serial Number Plate (1)

The engine serial number plate is located on theupper right side of the engine block.

Engine serial number _____________________________________

Engine model _______________________________________________

Arrangement number _____________________________________

Information Plate (2)

The engine information plate is located on the valvecover base near the front of the left side of the engine.

Engine Serial Number ____________________________________

Engine Arrangement Number ___________________________

Engine Modi cation Number ____________________________

The engine identi cation plate also contains other important information about the engine.

i00844066

Emissi ons Certi cation FilmSMCS Code: 1000; 7405


EPA Emissions Certi cation Film


European Emissions Certi cation Film


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20 SEBU7902-05Product Information SectionProduct Identi cation Information

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

i04128675

Reference InformationSMCS Code: 1000; 4450

Information for the following items may be needed toorder parts. Locate the information for your engine.Record the information on the appropriate space.Make a copy of this list for a record. Retain theinformation for future reference.

Record for ReferenceTable 2

System or Component Information

Chassis serial number

Engine model

Engine s erial number

Engine arrangement number

Modication number

Engine low idle rpm

Engine full load rpm

Performance speci cationnumber

Engine horsepower

Primary fuel lter part number

Wat er separator element partnumber

Secondary fuel lter elementpart number

Lubrication oil lter elementpart number

Auxiliary oil lter element partnumber

Supplemental coolant additivemaintenance element partnumber (if equipped)

Total lubrication systemcapacity

Total cooling system capacity

Engine air cleaner elementpart number

Fan drive belt part number

Alternator belt part number


21/110

SEBU7902-05 21Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i01988813

Product LiftingSMCS 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 for the 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 the

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 speci cengine arrangement. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingxtures obsolete. If alterations are made, ensurethat proper lifting devices are provided. Consult your Caterpillar dealer for information regarding xturesfor proper engine lifting.

i04137650

Product StorageSMCS Code: 7002

Storage (Less Than One Year)If an engine i s 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 th e metal. This condition is worse in areasof high humidity.

When the en gine is started again, metal to metalcontact will cause wear before the surfaces receiveoil. To minimize this wear, use the starter to turn theengine wi th 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 w ith a good quality paint.

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

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

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

5. If the engine is equipped with an air startingmotor, ll the reservoir with the followingmixture: 50 percent volatile corrosion inhibitor oil (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 4perc ent.

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

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


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22 SEBU7902-05Operation SectionLifting and Storage

Note: The mixtu re of VCI oil can be added to theinlet by removing the plug for checking turbocharger boost pressure. The minimum application rate for theVCI oil mixtur e 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 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) of engine displacement. Seal the exhaust pipe andseal any drain holes in the muf er.

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

Clean the primary fuel lter. Fill with calibrationuid or kerosene. Install the primary fuel lter and opera te the priming pump. This procedurewill send clean oil to the secondary lter and theengine.

Open the fuel tank drain valve in order to drainany water and dirt from the fuel tank. Apply aspray of calibration uid 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. Ad d 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 onthe fuel tank ller neck and install the cap. Sealall openings to the tank in order to preventevapo ration 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 a bar or a turning tool in order to turn over the engine slowly. This procedure puts the oil onthe cylinder walls. Install all fuel nozzles or sparkplug s and tighten to the correct torque.

11. Spray a thin amount of a mixture of 50 percentVCI oil and 50 percent engine oil onto the followingcomponents: ywheel, ring gear teeth, and starter pinion. Install the covers in order to preventeva poration of the vapors from the VCI oil.

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

No te: Install all covers. Ensure that tape has beeninstalled over all openings, air inlets, exhaustopenings, the ywheel housing, the crankcasebreathers, the dipstick tubes.

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

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

If the batte ries are not removed, wash the topsof the batteries until the tops are clean. Apply anelectrical charge to the batteries in order to obtaina speci c g ravity of 1.225.

Disconnect the battery terminals. Place a plasticcover over the batteries.

Note: For additional information, refer to SpecialInstruct ion, 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 loose enough 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. Remove the waterproof cover at 2 month or 3month intervals in order to check the engine for corrosion. If the engine has signs of corrosion,repea t the protection procedure.

Coolant System

Completely ll the cooling system before storage.

Refe r to this Operation and Maintenance Manual,Fluid Recommendations for more information aboutcoolants.

Removal from Storage

1. Remove all outside protective covers.

2. Cha nge the oil and lters.

3. Check the condition of the fan and alternator be lts. Replace the belts, if necessary. Refer tothis Operation and Maintenance Manual, Belts -Inspect/Adjust/Replace for the correct procedure.

4. Replace the fuel lter elements.

5. Remove the plastic covers from the air cleaner elements.


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Lifting and Storage

6. Use a bar or a tur ning tool in order to turn theengine in the normal direction of rotation. Theprocedure ensures that no hydraulic locks or resistance ex ist.

7. Before starting the engine, remove the valve cover

or covers. Pu t 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 l ubrication and prevents damage tothe engine during the rst few minutes of engineoperation. If the engine is not equipped witha prelube p ump, contact your Cat dealer for information about lubrication of the engine beforestarting the engine.

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

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

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

Prime th e engine with clean diesel fuel beforestarting.

11. Ensure that the cooling system is clean. Ensurethat the system is full. Ensure that the systemhas the correct amount of supplemental coolingsyste m conditioner.

12. On the rst day of operation, check the entireengin e 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.


24/110

24 SEBU7902-05Operation SectionFeatures and Controls

Features and Controls

i03953970

Monitoring System(If Equipped)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.

Indicators and Gauges


Gauge cluster and indicators

Diagnostic Lamp (1) The diagnosticlamp is used to indicate the existenceof a fault by ashing a fault code. For a

more detailed discussion of the diagnostic lamp,

please see this Operation and Maintenance Manual,Diagnostic Lamp topic.

Engine Oil Pressure (2) The oil pressureshould be greatest after a cold engine isstarted. The pressure will decrease as

the engine warms up. The pressure will increasewhen the engine rpm is increased. The pressure willstabilize 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.

Tachometer ( 3) This gauge indicatesengine speed (rpm). When the throttlecontrol lever is moved to the full throttle

position wi thout 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 maximu m rated load.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. Overspeeding can result in seriousdamage to the engine. The engine can be operatedat high idle without damage, but should never be

allowed to exceed high idle rpm.

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

Coolant Temperature (4) When thecoolant temperature is above the normaloperating value, the coolant temperature

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

Warning Lamp (5) There is a general

fault in the engine. Refer to the Messenger display for any additional information thatmay be available.

Fuel Pressure (6) This gauge indicatesfuel pressure to the fuel injection pump fromthe fuel lter. A decrease in fuel pressure

usually indicates a dirty fuel lter or a plugged fuel lter. As the fuel lter becomes plugged, there will bea noticeable reduction in engine performance.

System Voltage (7) This gauge indicatesthe voltage of the electrical system.

Circuit Breaker (8) Reset the circuit breaker if a circuit breaker trips. Press the button in order toreset the circuit breaker. If the electrical system isworking properly, the button will remain pressed. If the button does not remain pressed or if the circuitbreaker trips soon after being reset, check theappropriate electrical circuit. Repair the electricalcircuit, if necessary.


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Start Switch (9 ) The start switch has threepositions: OFF, RUN, and START. When the startswitch is turned clockwise to the RUN position, thelamps will as h for 5 seconds during the system test.The lamps will then shut off. In the RUN position, theECM and electronic systems are powered up.

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

is in the down position, the engine speed decreasesto LOW IDLE.

Maintenanc e Lamp (11) The ECMrecords data that is related to equipmentmaintenance. The ECM will activate

the mainte nance indicator lamp when scheduledmaintenance is due. The maintenance indicator lamp can be reset by actuating the maintenanceclear swit ch. The maintenance interval may bebased on operating hours or fuel consumption.The ECM provides information that pertains tomaintena nce intervals and the last maintenance thatwas performed.

Maintenance Clear Switch (12) Themainten ance clear switch is requiredto reset the maintenance lamp after

maintenance on the engine is performed.

Shutdo wn Switch (13) Use the engineshutdown switch in order to stop the engine.Push the shutdown switch in order to put

the swi tch in the OFF position. After the engine stops,turn the knob clockwise. Turning the knob clockwisewill reset the engine shutdown switch to the ONposit ion.

Service Tool Connector (14) For more informationregarding the use of Cat Electronic Technician (ET)and t he PC requirements for Cat ET, refer to thedocumentation.

Caterpillar Messenger Display


Digital displa y area (15) The Messenger systemshows information on the digital display area.

Previous butt on (16) Use the previous button toreturn to information that was previously shown onthe digital display area.

Scroll up/left button (17) This button is used toscroll up through information that is shown on thedisplay are a. The button can also be used to scrollto the left through information that is shown on thedisplay area.

Scroll down/right button (18) This button is usedto scroll down through information that is shown onthe displa y area. The button can also be used toscroll to the right through information that is shownon the display area.

OK button (19) Use this button to con rmselections that you have made with the scroll up/leftbutton an d the scroll down/right button.

Totals Display


Typical totals display

The f ollowing information is available through thedisplay:

CUM ULATIVE TOTALS

Service Hours When you scroll to this option, thedis play shows the total amount of service hours thatthe engine has accumulated.

To tal Time When you scroll to this option, thedisplay shows the total hours for the engine ECM.

To tal Fuel When you scroll to this option, thedisplay shows the total amount of fuel that has beenconsumed.


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26 SEBU7902-05Operation SectionFeatures and Controls

Settings Displ ay

g01054565Illustrat ion 22

Typical settings display

The following options are available through thepayload display:

MONITORING SYSTEM

Languag e Select this option to change thelanguage shown on the display.

Units S elect this option to choose the desiredmeasurement system. The choices are metric or English.

Adjust Contrast Select this option to adjust thecontrast of the display in order to improve the visibilityof the i nformation.

Adjust Backlight Select this option to adjust thebackl ighting of the display in order to improve thevisibility of the information.

ENGI NE

Equipment ID Select this option to view theequi pment identi cation number.

Product ID Select this option to view the productide ntication number.

Service Displa y

g01054566Illustrat ion 23

Typical service display

DIANOSTICS/EVENTS

The follo wing options are password protected. Enter a password to change the settings.

View Se lect this option to view events loggedby the monitoring system. If you use an authorizedpassword, you can clear individual events.

Clear All Diagnostics If you use an authorizedpassword, you can select this option to clear alllogged events.

SYSTEM PARAMETERS

MONITORING SYSTEM

Batte ry Voltage: When you scroll to this option,the battery voltage is displayed.

Fuel Level: When you scroll to this option, the fuellevel is displayed.

Alte rnator Status: When you scroll to this option,the alternator status is displayed.

Eng ine Speed: When you scroll to this option, theengine RPM is displayed.

Des ired Engine Speed: When you scroll to thisoption, the desired engine speed is displayed.This parameter is used by the Automatic Retarder Co ntrol to prevent the engine from overspeeding. If you have an approved password, you can changethis parameter.

Throttle Position: When you scroll to this option,the throttle position is displayed.

Coolant Temperature: When you scroll to thisoption, the coolant temperature is displayed.


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Coolant Flow: When you scroll to this option, theamount of coolant ow is displayed.

Boost Pressur e: When you scroll to this option,the boost pressure is displayed.

Atmospheric Pressure: When you scroll to thisoption, the atmospheric pressure is displayed.

Turbo Inlet Pressure: When you scroll to thisoption, the turbo inlet pressure is displayed.

Oil Pressur e (Antilock brake system): Whenyou scroll to this option, the absolute engine oilpressure is displayed.

Oil Pressure: When you scroll to this option, thegauge engine oil pressure is displayed.

Fuel Temperature: When you scroll to this option,the fuel temperature is displayed.

SYSTEMS TESTS

SYSTEM SE LF TEST

If you select this option, the monitoring system willinitiat e the self-test feature. The self test feature islike the functional test that occurs when you turn thestart switch from the OFF position to the ON position.

SYSTEM INFORMATION

MONITO RING SYSTEM

Software Part Number: When you scroll to thisoptio n, the software part number is displayed.

ECM Part Number: When you scroll to this option,the EC M part number is displayed.

Software Release Date: When you scroll to thisopti on, the software release date is displayed.

Software Description: When you scroll to thisopti on, the software description is displayed.

ENGINE

ECM Serial Number: When you scroll to thisoption, the ECM serial number is displayed.

Software Part Number: When you scroll to thisoption, the software part number is displayed.

Software Release Date: When you scroll to thisoption, the software release date is displayed.

Software Description: When you scroll to thisoption, the software description is displayed.

Engine Serial N umber: When you scroll to thisoption, the engine serial number is displayed.

TATTLETALE

Full Tattletale Readout: When you select thisoption, all i ndicators and gauges will display themaximum values reached during operation.

Engine Cool ant Temperature: When you selectthis option, all indicators and will display themaximum values reached during operation. Theengine cool ant temperature gauge will also showthe maximum value reached during operation.

Tachomete r: When you select this option, allindicators will display the maximum values reachedduring operation. The tachometer will also showthe maximu m value reached during operation.

Fuel Level: When you select this option, allindicato rs will display the maximum values reachedduring operation. The fuel level gauge will alsoshow the minimum value reached during operation.

Clear: If you have an approved password, you canclear the maximum values stored by the monitoringsystem.


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28 SEBU7902-05Operation SectionEngine Diagnostics

Engine Diagnostics

i00863835

Self-DiagnosticsSMCS 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 speci c problemwith the circuitry.

Diagnostic codes are also generated when anabnormal engine operating condition is detected. For example, 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.

i01463253

Diagnostic LampSMCS Code: 1000; 1900; 1901; 1902; 7451

The DIAGNOST IC lamp is used to indicate theexistence of an active fault by ashing codes.

When the igni tion switch is rst turned on, theDIAGNOSTIC lamp will go through the followingprocedure:

The DIAGNOSTIC lamp will come on andthe DIAGNOSTIC lamp will remain on for veseconds. T his checks the operation of the lamp.

The DIAGNOSTIC lamp will turn off.

The DIAGNOSTIC lamp will come on again andthe DIAGNOSTIC lamp will ash codes for anyactive di agnostic codes. Not all diagnostic codeshave a unique ash code.

The DIAG NOSTIC lamp will turn off for veseconds.

The DIAGNOSTIC lamp repeats all activediagnostic codes.

A fault d iagnostic code will remain active until theproblem is repaired. The electronic control modulewill continue ashing the ash code at ve secondinterv als until the problem is repaired.

i0249 6338

Diagnostic Flash CodeRetr ievalSMCS Code: 1000; 1900; 1901; 1902

Problems with the electronic control system arereported via these types of codes: ash codes,SPN /FMI codes, diagnostic codes, and event codes.


29/110


Engine Diagnostics

Table 3

Cross Reference for Diagnostic Codes

Flash Code SPN (1) /FMI CodeDiagnostic Code

or Event Code

Description of Code

1387-15 High Auxiliary Pressure Warning

1387-16 High Auxiliary Pressure Derate

1387-00

E443 (2)

High Auxiliary Pressure Shutdown

0441-15 High Auxiliary Temperature Warning

0441-16 High Auxiliary Temperature Derate

0441-00

E445 (2)

High Auxil iary Temperature Shutdown

545-05 Ether Start Relay open/short to +batt626-05

2417-05 Ether Injection Control Solenoid open/short to +batt

545-06 Ether Start Relay short to ground626-06

2417-06 Ether Injection Control Solenoid short to ground1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt

1835-04 1835-04 Auxiliary Pressure Sensor short to ground

1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt

1836-04 1836-04 Auxiliary Temperature Sensor short to ground

N/A

111-02 111-02 Engine Coolant Level Sensor Loss of Signal

174-03 174-03 Fuel Temperature open/short to +batt13

174-04 174-04 Fuel Temperature short to ground

678-03 41-03 8 Volt DC Supply short to +batt

678-04 41-04 8 Volt DC Supply short to ground

620-03

1079-03262-03 5 Volt Sensor DC Power Supply short to +batt

620-04

21

1079-04262-04 5 Volt Sensor DC Power Supply short to ground

100-03 100-03 Engine Oil Pressure open/short to +batt

100-04 100-04 Engine Oil Pressure short to ground24

100-10 100-10 Engine Oil Pressure abnormal rate of change

102-03 102-03 Boost Pressure Sensor short to +batt

102-04 102-04 Boost Pressure Sensor short to ground25

102-10 102-10 Boost Pressure Sensor abnormal rate of change

108-03 274-03 Atmospheric Pressure open/short to +batt26

108-04 274-04 Atmospheric Pressure short to ground

110-03 110-03 Engine Coolant Temperature open/short to +batt27

110-04 110-04 Engine Coolant Temperature short to ground

28 91-13 91-13 Throttle Position calibration required

32 91-08 91-08 Throttle Position signal abnormal

(continued)


30/110


(Table 3, contd)



or Event Code

Description of Code

190-08 190-08 Engine Speed signal abnormal34

723-08 342-08 Secondary Engine Speed signal abnormal

190-15 Engine Overspeed Warning35

190-00E362 (2)

Engine Overspeed Shutdown

94-03 94-03 Fuel Pressure open/short to +batt37

94-04 94-04 Fuel Pressure short to ground

105-03 172-03 Intake Ma nifold Air Temp open/short to +batt38

105-04 172-04 Intake Manifold Air Temp short to ground

42 637-13 261-13 Engine Timing calibration required

100-17 Low Engine Oil Pressure Warning100-18 Low Engine Oil Pressure Derate46

100-01

E360 (2)

Low Engine Oil Pressure Shutdown

168-00 168-00 System Voltage high

168-01 168-01 System Voltage low51

168-02 168-02 System Voltage intermittent/erratic

56 630-02 268-02 Che ck Programmable Parameters

58 639-09 247-09 J1939 Data Link communications

110-15 High Engine Coolant Temperature Warning

110-16 High Engine Coolant Temperature Derate61

110-00

E361 (2)

High Engine Coolant Temperature Shutdown

111-17 Low Engine Coolant Level Warning

111-18 Low Engine Coolant Level Derate62

111-01

E2143 (2)

Low Engine Coolant Level Shutdown

63 94-15 E096 High Fuel Pressure Warning

1636-15 High Inlet Air Temperature Warning64

1636-00E539 (2)

High Inlet Air Temperature Shutdown

174-15 High Fuel Temperature Warning

174-16 High Fuel Temperature Derate65

174-00

E363 (2)

High Fuel Temperature Shutdown

651-05 001-05 Injector Cylinder 1 open circuit

651-06 001-06 Injector Cylinder 1 short71

651-11 001-11 Injector Cylinder #1 fault




(continued)


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Engine Diagnostics

(Table 3, contd)



or Event Code

Description of Code








655-06 005-06 Injector Cylinder 5 short

75


656-05 006-05 Inject or Cylinder 6 open circuit656-06 006-06 Injector Cylinder 6 short76

656-11 006-11 Injector Cylinder #6 fault(1) Suspect Parameter Number (2) Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event code in order to designate a warning, a derate,

or a shutdown.

For further information, see the troubleshooting guidefor your engine.

i03840813

Fault LoggingSMC S Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault Logging.Wh en the Electronic Control Module (ECM)generates an active diagnostic code, the code will belogged in the memory of the ECM. The codes thatha ve been logged in the memory of the ECM canbe retrieved with Caterpillar electronic service tools.The codes that have been logged can be clearedwith Caterpillar electronic service tools. The codesthat have been logged in the memory of the ECMwill be automatically cleared from the memory after 100 hours. The following faults cannot be clearedfrom the memory of the ECM without using a factorypassword: overspeed, low engine oil pressure, andhigh engine coolant temperature.

i01797045

Engine Operation with ActiveDiagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If a diagnostic lamp illuminates during normal engineoperation, the system has identi ed a situation that isnot within the speci cation. Use Caterpillar electronicservice tools to check the active diagnostic codes.

Note: If the customer has selected DERATE and if there is a low oil pressure condition, the ElectronicControl Module (ECM) will limit the engine power until the problem is corrected. If the oil pressure iswithin the normal range, the engine may be operatedat the rated speed and load. However, maintenanceshould be performed as soon as possible.

The active diagnostic code should be investigated.The cause of the problem should be corrected assoon as possible. If the cause of the active diagnosticcode is repaired and there is only one activediagnostic code, the diagnostic lamp will turn off.

Operation of the engine and performance of theengine can be limited as a result of the activediagnostic code that is generated. Accelerationrates may be signi cantly slower. Refer to theTroubleshooting Guide for more information on therelationship between these active diagnostic codesand engine performance.


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i01456915

Engine Operation withIntermittent Diagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to ash codes duringnormal engine operation and the diagnostic lampshuts off, a n intermittent fault may have occurred. If a fault has occurred, the fault will be logged into thememory of the Electronic Control Module (ECM).

In most cases, it is not necessary to stop the enginebecause of an intermittent code. However, theoperator s hould retrieve the logged fault codesand the operator should reference the appropriateinformation in order to identify the nature of the event.The operat or should log any observation that couldhave caused the lamp to light.

Low power

Limits of the engine speed

Excessive smoke, etc

This inf ormation can be useful to help troubleshootthe situation. The information can also be used for future reference. For more information on diagnosticcodes, refer to the Troubleshooting Guide for thisengine.

i04250489

Con guration ParametersSMCS Code: 1000; 1900; 1901; 1902

System con guration parameters are parametersthat affect the emissions and the power of the engine.Default values for the parameters are programmedat the factory. Some parameters may be changed bythe customer in order to suit the needs of the speci capplication.

Parameter Descriptions

Equipment ID

EQUIPMENT ID allows the customer to enter a description into the Electronic Control Module(ECM) in order to identify the machine. A maximumof 17 characters may be entered in the eld. Thisparameter is only for reference by the customer. Thisparameter is not required.

Engine Serial Number

Program the ENGINE SERIAL NUMBER to matchthe engine ser ial number that is stamped on theengine information plate. If the ECM is replaced, theengine serial number from the engine information

plate must be programmed into the new ECM.

Note: When you are requesting factory passwords,always use t he engine serial number that isprogrammed in the ECM.

Rating Num ber

The RATING NUMBER corresponds to the selectedset of perf ormance maps for the application. Thisselected set of performance maps comes out of several unique sets of maps that are resident in theash le. T he dealer and/or the OEM will need toselect the appropriate rating tier, if more than onerating tier is present. The rating tiers are A throughE.

Note: Refer to this Operation and MaintenanceManual, Engine Rating De nitions for information.

Factory passwords are required in order to changethe rati ng number.

Top Engine Limit (TEL)


TEL is a customer programmable parameter thatde nes the maximum allowable engine speed for maximum power. TEL can be programmed up tothe maximum rated engine speed. TEL is de nedalong the lug curve.


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Engine Diagnostics

Engine Accel. Rate

The engine acceleration rate determines the rateof change of th e engine speed (acceleration or deceleration) during PTO operation. This rate of change is also used to achieve intermediate engine

speed.

Low Idle Speed

Low speed idle is the minimum allowable operatingspeed for the engine. This parameter can beprogrammed between 600 and 1400 rpm.

PTO Mode

PTO Mode allows the ECM to be programmed toeither one of the two PTO con gurations that areavailable .

Ramp Up/Ramp Down When PTO Mode isprogramm ed to RAMP UP/RAMP DOWN, the ECMallows PTO operation with traditional features.

Set/Re sume When PTO Mode is programmedto SET/RESUME, the ECM allows PTO operationwith enhanced features.

High Idle Speed


The high idle speed is the maximum no-load enginespeed when the throttle or the PTO switch is in themaximum position.

Note: HIGH IDLE SPEED cannot be programmedlower than TEL.

Intermediate Engine Speed

The intermediate engine speed de nes the speedfor the engine when the intermediate enginespeed switch is activated. This parameter can beprogrammed to any engine speed between Low Idle

Speed and T EL. Engine speed will increase or engine speed will decrease at the rate that is de nedby the programmed value for ENGINE ACCEL.RATE.

Maximum Engine Torque Limit


ENGINE TORQUE LIMIT can be used to limittorque output to the programmed value when thetorque limit switch is activated.

FLS (Full Load Setting)

FLS is a number representing the adjustment tothe fuel system made at the factory to ne-tune thefuel system. The correct value for this parameter isstamped on the engine information plate. Factorypasswords are required in order to change thisparameter.

FTS (Full Torque Setting)

FTS is similar to FLS. Factory passwords arerequired in order to change this parameter.

Ether Control

Program the ETHER CONTROL to ENABLED if an ether injection system is installed on the engineso the ECM can control ether injection. If the engineis not equipped with ether, program this parameter to DISABLED.


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Air Shutoff

AIR SHUTOFF allows the ECM to be programmedfor operation of an air shutoff system. If thisparameter is programmed to INSTALLED, the ECMwill activate the air shutoff solenoid in the event of an

engine overs peed condition.

Note: If an engine overspeed condition occurs andAIR SHUTOF F is programmed to ENABLED, theswitched power to the ECM must be cycled and theair shutoff solenoid must be manually reset beforethe engine w ill restart.

Maintenance Indicator Mode

The ECM records data that is related to equipmentmaintenance. The ECM will activate the maintenanceindicator lamp when scheduled maintenance isdue. The maintenance indicator lamp can be resetby actuating the maintenance clear switch. Themaintena nce interval may be based on operatinghours or on fuel consumption. The ECM providesinformation that pertains to maintenance intervalsand the l ast maintenance that was performed.

PM1 Interval

The PM1 interval allows the customer to de ne themaintenance interval if the MAINTENCE INTERVALMODE is programmed to one of the manual options.

Throttle Position Sensor

Program the throttle position sensor to INSTALLEDif a throttle position sensor is used for desired speedcontr ol. Otherwise program this parameter to NOTINSTALLED.

Cool ant Level Sensor

Program the coolant level sensor to INSTALLEDif a coolant level sensor is installed on the engine.Otherwise program this parameter to NOTINSTALLED.

Aux Press Sensor Installation StatusPro gram AUX PRESS ENABLE to INSTALLEDif an auxiliary pressure sensor is installed. This willallow the Cat Messenger Driver Information Displayto m onitor the pressure of another system. Programthis parameter to NOT INSTALLED if an auxiliarypressure sensor is not installed.

Aux Temp Senso r Installation Status

Program AUX TEMP ENABLE to INSTALLED if an auxiliary t emperature sensor is installed. This willallow the Cat Messenger Driver Information Displayto monitor the temperature of another system.

Program this parameter to NOT INSTALLED if anauxiliary temperature sensor is not installed.


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Engine Diagnostics

System Con guration ParametersTable 4

System Con guration Parameters

Parameter Available Range or Options Default Required

PasswordECM Identi cation Parameters

Equipment ID 17 alphanumeric characters NOT PROGRAMMED None

Engine Serial Number 0XX00000 or XXX00000 0XX00000 None

ECM Serial Number Read Only (1)

Software Gp Part Number Software Dependent Read Only (1)

Software Gp Release Date Software Dependent Read Only (1)

Selected Engine Rating

Rating Number Software Dependent Customer

Rated Power Software Dependent Read Only (1)

Rated Peak Torque Software Dependent Read Only (1)

Top Engine Speed Range Software Dependent Read Only (1)

Test Spec Software Dependent Read Only (1)

Top Engine Limit Soft ware Dependent Cust omer

Engine Governor PrimaryMode

Speed ControlMin/Max Speed Control None

Engine Accel. Rate 50 to 1000 50 None

Low Idle Speed 600 to 1400 700 None

PTO Mode Ramp Up/Ramp DownSet/Resume Ramp Up/Ramp Down None

High Idle Speed 1800 to 2310 2310 Customer

Intermediate Engine Speed Programmed Low Idle to TEL 1100 None

Maximum Engine Torque Limit Software Dependent None

Customer Password #1 8 alphanumeric characters Blank Customer

Customer Password #2 8 alphanumeric characters Blank Customer

FLS (Full Load Setting) - 128 to 127 0 Factory

FTS (Full Torque Setting) -128 to 127 0 Factory

Ether Control No EtherContinuous Flow No Ether None

Air Shutoff EnabledDisabled Disabled None

Maintenance Indicator Mode

OFFAuto FuelAuto HourMan FuelMan Hour

OFF None

PM1 Interval100 to 750 Hours

or 3785 to 28390 L (1000 to 7500 US gal)

250 Hoursor

9463 L (2500 US gal)None

Throttle Position Sensor InstalledNot Installed Not Installed None

(continued)


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(Table 4, contd)

System Con guration Parameters

Parameter Available Range or Options Default RequiredPassword

Coolant Level On Installed

Not Installed Not Installed None

Last Tool to change Customer Parameters Read Only

(1)

Last Tool t o change SystemParameters Read Only

(1)

Aux Temp Sensor InstallationStatus

OnOff Off None

Aux Press Sensor

c15 export engine

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