Operation and Maintenance Manual - Holt Ca

1 SEBU8598-09. December 2014. Operation and Maintenance Manual C15 and C18 Engines BDN 1-Up (C15 Engine). LDN 1-Up (C18 Engine). 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.

2 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.

3 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.

4 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.

5 SEBU8598 3. Table of Contents Table of Contents Refill .. 45.. 4 Maintenance .. 51. Maintenance Interval Schedule (C15 Engines) 54. Safety Section Maintenance Interval Schedule (C15 Engines Safety .. 5. With Ratings Greater Than 579 hp) .. 55. General Hazard Information .. 7. Maintenance Interval Schedule (C18 Engines Burn .. 10 With Ratings Greater Than 760 HP) .. 56. Fire Prevention and Explosion Prevention ..11 Maintenance Interval Schedule (C18 Engines) 58. Crushing Prevention and Cutting Prevention . 13 Warranty Section Mounting and .. 13 Warranty Information .. 94. Before Starting Engine .. 13 Reference Information Section Engine Starting .. 14 Engine Ratings .. 95. Engine Stopping .. 14 Customer Service .. 96. Electrical System .. 14 Reference Materials.

6 98. Engine .. 15 Index Section Product Information Section .. 102. General .. 16. Product Identification .. 20. Operation Section Lifting and .. 23. Features and Controls .. 27. Engine .. 32. Engine Starting .. 33. Engine .. 37. Cold Weather .. 42. Engine Stopping .. 44. Maintenance Section 4 SEBU8598. Foreword Foreword Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment Literature Information of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, This Manual contains safety, Operation instructions, wet or freezing cold operating conditions, more lubrication and Maintenance information. This Manual frequent lubrication and Maintenance than is should be stored in or near the engine area in a specified in the Maintenance Interval Schedule may literature holder or literature storage area.

7 Read, be necessary. study and keep it with the literature and engine information. The Maintenance schedule items are organized for a preventive Maintenance management program. If the English is the primary language for all Cat preventive Maintenance program is followed, a publications. The English used facilitates translation periodic tune-up is not required. The implementation and consistency in electronic media delivery. of a preventive Maintenance management program should minimize operating costs through cost Some photographs or illustrations in this Manual avoidances resulting from reductions in unscheduled show details or attachments that may be different downtime and failures. from your engine. Guards and covers may have been removed for illustrative purposes.

8 Continuing Maintenance Intervals improvement and advancement of product design may have caused changes to your engine which are Perform Maintenance on items at multiples of the not included in this Manual . Whenever a question original requirement. Each level and/or individual arises regarding your engine, or this Manual , please items in each level should be shifted ahead or back consult with your Cat dealer for the latest available depending upon your specific Maintenance practices, information. Operation and application. We recommend that the Maintenance schedules be reproduced and displayed Safety near the engine as a convenient reminder . We also recommend that a Maintenance record be maintained This safety section lists basic safety precautions. In as part of the engine's permanent record.

9 Addition, this section identifies hazardous, warning situations. Read and understand the basic See the section in the Operation and Maintenance precautions listed in the safety section before Manual , Maintenance Records for information operating or performing lubrication, Maintenance and regarding documents that are generally accepted as repair on this product. proof of Maintenance or repair. Your authorized Cat dealer can assist you in adjusting your Maintenance schedule to meet the needs of your operating Operation environment. Operating techniques outlined in this Manual are basic. They assist with developing the skills and Overhaul techniques required to operate the engine more Major engine overhaul details are not covered in the efficiently and economically.

10 Skill and techniques Operation and Maintenance Manual except for the develop as the operator gains knowledge of the interval and the Maintenance items in that interval. engine and its capabilities. Major repairs are best left to trained personnel or an authorized Cat dealer. Your Cat dealer offers a variety The Operation section is a reference for operators. of options regarding overhaul programs. If you Photographs and illustrations guide the operator experience a major engine failure, there are also through procedures of inspecting, starting, operating numerous after failure overhaul options available and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for discussion of electronic diagnostic information. information regarding these options.