C15 Gen Set-Machine Safety

SAFETY.CAT.COM

C15 Generator SetMachine Safety

Excerpted from Operation & Maintenance Manual (SEBU7909-04-01)

© 2007 CaterpillarAll Rights Reserved

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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 necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such 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 pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis 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. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

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

6 SEBU7909-04Safety SectionSafety Messages

Safety Sectioni02373615

Safety MessagesSMCS Code: 1000; 7405

There may be several specific safety messageson your generator set. The exact location and adescription of the safety messages are reviewed inthis section. Please become familiar with all safetymessages.

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 offof the engine.

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

SEBU7909-04 7Safety Section

Safety Messages

g01184231Illustration 1

Side view of an open generator set



View of the control panel

g01184235Illustration 3Top view of the enclosure


Safety Messages


Side view of the generator set inside the enclosure



Side view of the enclosure


Safety Messages


Side view of the enclosure

Hot Surface (1)This safety message is located on each side of theradiator on open generator sets. This safety messageis located on the sides and the top of the enclosurefor enclosed generator sets.

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Hot parts or hot components can cause burns orpersonal injury. Do not allow hot parts or compo-nents to contact your skin. Use protective clothingor protective equipment to protect your skin.


Automatic Starting (2)This safety message is located on the sides of theenclosure on enclosed generator sets. This safetymessage is located on the sides of the generator foropen generator sets. This safety message is alsolocated on the enclosure for the control panel.

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When the engine is in the AUTOMATIC mode, theengine can start at anymoment. To avoid personalinjury, always remain clear of the the engine whenthe engine is in the AUTOMATIC mode.

Electrocution (3)This safety message is located on the side of thegenerator and on the enclosure for the circuit breaker.This safety message is also located on the side ofthe enclosure.

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DANGER: Shock/Electrocution Hazard-Do not op-erate this equipment or work on this equipmentunless you have read and understand the instruc-tions and warnings in the Operation and Mainte-nance Manual. Failure to follow the instructions orheed the warnings will result in serious injury ordeath.

Do not connect generator to a utility electrical dis-tribution system unless it is isolated from the sys-tem. Electrical feedback into the distribution sys-tem can occur and could cause personal injury ordeath.

Open and secure main distribution system switch,or if the connection is permanent, install a doublethrow transfer switch to prevent electrical feed-back. Some generators are specifically approvedby a utility to run in parallel with the distributionsystem and isolation may not be required. Alwayscheck with your utility as to the applicable circum-stances.


Safety Messages

Crush (4)This safety message is located on the sides ofenclosed generator sets. This safety message is alsolocated on the base for open generator sets.

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Crushing hazard! Read and understand the in-structions and warnings in the Operation andMaintenance manual. Failure to follow the in-structions or heed the warnings could causeserious injury or death.

Universal Warning (5)This safety message is located on the enclosure forthe control panel.

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Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.

Electrical Shock (6)The safety message for electrical shock is located onthe front and the rear of the enclosure for the controlpanel.

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WARNING! Shock/Electrocution Hazard! Read andunderstand the instructions and warnings in theOperation and Maintenance Manual. Failure to fol-low the instructions or heed the warnings couldcause serious injury or death.

14 SEBU7909-04Safety SectionGeneral Hazard Information

Hot Fluid Under Pressure (7)This safety message is located by the cooling systemfiller cap.

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Pressurized system! Hot coolant can cause seri-ous burns, injury or death. To open the coolingsystem filler cap, stop the engine and wait untilthe cooling system components are cool. Loosenthe cooling system pressure cap slowly in order torelieve the pressure. Read and understand the Op-eration and Maintenance Manual before perform-ing any cooling system maintenance.

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General Hazard InformationSMCS Code: 1000; 7405

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


Do not allow unauthorized personnel on the engineor around the engine when the engine is serviced.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine exhaust to the outside.

Cautiously remove the following parts:

Note: To help prevent spraying or splashing ofpressurized fluids, hold a rag over the part that isbeing removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

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

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

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

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

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


General Hazard Information

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

• Use all cleaning solutions with care.

• Report all necessary repairs.

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

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

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

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

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

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

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).

Fluid PenetrationAlways use a board or cardboard when the enginecomponents are checked for leaks. Leaking fluidthat is under pressure can cause serious injury orpossible death. This includes leaks that are the sizeof a pin hole.

If fluid is injected into the skin, seek treatmentimmediately. Seek treatment from a doctor that isfamiliar with this type of injury.

Containing Fluid SpillageCare must be used in order to ensure that the fluidsare contained during the inspection, the maintenance,the testing, the adjusting, and the repair of the engine.Prepare to collect the fluid with suitable containersbefore any compartment is opened or before anycomponent is disassembled.

Refer to Catalog, NENG2500, “Caterpillar DealerService Tool Catalog” for the following items:

• Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

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

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

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

16 SEBU7909-04Safety SectionBurn Prevention

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

• Use exhaust ventilation on permanent machiningjobs.

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

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

• Obey environmental regulations for the disposalof asbestos.

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

Lines, Tubes, and HosesDo not bend or strike high pressure lines. Do notinstall lines, tubes, or hoses that are damaged.

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

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

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

Ensure that all of the clamps, the guards, and theheat shields are installed correctly. This will help toprevent these effects: vibration, rubbing against otherparts, and excessive heat during operation.

Dispose of Waste ProperlyImproperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

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

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Burn PreventionSMCS Code: 1000; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

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

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.


Fire Prevention and Explosion Prevention

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Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405


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

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

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency 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 combustiblegases, consult your Caterpillar dealer for additionalinformation about suitable protection devices.

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

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

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a hose, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines that contain flammablefluid. Clean any such lines thoroughly with anonflammable solvent prior to welding or flamecutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

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

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

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.


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

18 SEBU7909-04Safety SectionCrushing Prevention and Cutting Prevention

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

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

Do not charge a frozen battery. This may cause anexplosion.

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

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

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

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

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

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Crushing Prevention andCutting PreventionSMCS Code: 1000; 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 fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

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Mounting and DismountingSMCS Code: 1000; 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.

Face the engine in order to mount the engine ordismount 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 on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

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


Before Starting Engine

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Before Starting EngineSMCS Code: 1000

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

Overspeed shutdown should occur automatically.If automatic shutdown does not occur, press theemergency stop button in order to cut the fuel and/orair to the engine.

Inspect the engine for potential hazards.

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

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

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

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

See the Service Manual for repairs and foradjustments.

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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 orderto 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 orfrom 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 preventmajor 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.

EtherEther is poisonous and flammable.

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 fires.

Keep ether cylinders out of the reach of unauthorizedpersons.

Store ether cylinders in authorized storage areasonly.

Do not store ether 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 ethercylinders.

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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 ofthe engine components.

20 SEBU7909-04Safety SectionElectrical System

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

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

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

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Electrical SystemSMCS Code: 1000; 1400

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

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

Check the electrical wires for wires that are loose orfrayed. Tighten all loose electrical wires before theengine is operated. Repair all frayed electrical wiresbefore the engine is started. See the Operation andMaintenance Manual, “Engine Starting” for specificstarting instructions.

Grounding PracticesThe electrical system for the engine must be properlygrounded. Proper grounding is necessary foroptimum engine performance and reliability. Impropergrounding will result in uncontrolled electrical circuitpaths and in unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.Uncontrolled electrical circuit paths can also causeelectrical noise.

The alternator, the starting motor, and all of theelectrical systems MUST be grounded to the negativebattery terminal.

For engines which have an alternator that is groundedto an engine component, a ground strap MUSTconnect that component to the negative batteryterminal and the component MUST be electricallyisolated from the engine.

A bus bar with a direct path to the negative “-” batteryterminal is permissible and recommended for usefor all components that require a negative “-” batteryconnection. The bus bar should be directly connectedto the negative “-” battery terminal. A bonding cableshould also be connected from the cylinder block tothe bus bar on the negative “-” battery connection.

Use of a bus bar ensures that the Electronic ControlModule (ECM) and all of the components that areconnected to the ECM have a common referencepoint.

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Engine ElectronicsSMCS Code: 1000; 1400; 1900

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


Generator Isolating for Maintenance

• 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 Engines willwork in unison with the Engine Monitoring System.Together, the two controls will provide the enginemonitoring function for the specific engine application.Refer to the Electronic Troubleshooting Manual formore information on the Engine Monitoring System.

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Generator Isolating forMaintenanceSMCS Code: 4450

When you service an electric power generation setor when you repair an electric power generation set,follow the procedure below:

1. Stop the engine.


2. Attach a “DO NOT OPERATE” or similar warningtag to the engine prime mover starting circuit.Disconnect the engine starting circuit.

3. Disconnect the generator from the distributionsystem.

4. Lock out the circuit breaker. Attach a “DO NOTOPERATE” or similar warning tag to the circuitbreaker. Refer to the electrical diagram. Verify thatall points of possible reverse power flow havebeen locked out.

5. For the following circuitry, remove thetransformer’s fuses:

• power

• sensing

• control

6. Attach a “DO NOT OPERATE” or similar warningtag to the generator excitation controls.

7. Remove the cover of the generator’s terminal box.

8. Use an audio/visual proximity tester in order toverify that the generator is de-energized. Thistester must be insulated for the proper voltagerating. Follow all guidelines in order to verify thatthe tester is operational.

9. Determine that the generator is in a de-energizedcondition. Add ground straps to the conductorsor terminals. During the entire work period, theseground straps must remain connected to theconductors and to the terminals.

22 SEBU7909-04Product Information SectionGeneral Information

Product InformationSection

General Informationi02668476

Welding on Engines withElectronic ControlsSMCS Code: 1000

NOTICEBecause the strength of the frame may decrease,some manufacturers do not recommend welding ontoa chassis frame or rail. Consult the OEM of the equip-ment or your Caterpillar dealer regarding welding ona chassis frame or rail.

Proper welding procedures are necessary in orderto avoid damage to the engine’s ECM, sensors,and associated components. When possible,remove the component from the unit and thenweld the component. If removal of the componentis not possible, the following procedure must befollowed when you weld on a unit that is equippedwith a Caterpillar Electronic Engine. The followingprocedure is considered to be the safest procedure toweld on a component. This procedure should providea minimum risk of damage to electronic components.

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

1. Stop the engine. Turn the switched power to theOFF position.

2. Disconnect the negative battery cable from thebattery. If a battery disconnect switch is provided,open the switch.

3. Disconnect the J1/P1 and J2/P2 connectors fromthe ECM. Move the harness to a position that willnot allow the harness to accidentally move backand make contact with any of the ECM pins.


Use the example above. The current flow from the welder tothe ground clamp of the welder will not cause damage to anyassociated components.

(1) Engine(2) Welding electrode(3) Keyswitch in the OFF position(4) Battery disconnect switch in the open position(5) Disconnected battery cables(6) Battery(7) Electrical/Electronic component(8) Minimum distance between the component that is being welded

and any electrical/electronic component(9) The component that is being welded(10) Current path of the welder(11) Ground clamp for the welder

4. Connect the welding ground cable directly to thepart that will be welded. Place the ground cable asclose as possible to the weld in order to reduce thepossibility of welding current damage to bearings,hydraulic components, electrical components, andground straps.

Note: If electrical/electronic components are usedas a ground for the welder, or electrical/electroniccomponents are located between the welder groundand the weld, current flow from the welder couldseverely damage the component.

5. Protect the wiring harness from welding debrisand spatter.

6. Use standard welding practices to weld thematerials.

SEBU7909-04 23Product Information Section

Model Views

Model Viewsi02386706

Model View IllustrationsSMCS Code: 1000

The following engine model views show typical C15Generator Set features. The operator should becomefamiliar with the locations of these items. Due toindividual applications, your engine may appeardifferent from the illustrations.


Right Hand Side View(1) Enclosure for the control panel(2) Terminal box for the generator(3) Air cleaner

(4) Radiator cap(5) Engine coolant drain(6) Engine oil drain

(7) Engine oil drain plug(8) Engine oil filters(9) Engine oil drain valve

24 SEBU7909-04Product Information SectionModel Views


Left Hand Side View(10) Engine lifting eye(11) Engine lifting eye(12) Lifting eye for generator(13) Lifting eye for generator

(14) Starting motor(15) Engine oil cooler(16) Fuel priming pump(17) Secondary fuel filter

(18) Fuel filter/water separator(19) Oil filler(20) Engine oil level gauge (dipstick)

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Product DescriptionSMCS Code: 1000; 4450; 4491; 7000

Engine InformationThese Caterpillar Engines provide the followingfeatures:

• Four stroke cycle

• Electronic engine control

• Direct injection fuel system

• Mechanically actuated electronic unit injectors

• Turbocharger

• Air-to-air aftercooler

Engine SpecificationsNote: The front end of the engine is opposite theflywheel end of the engine. The left side and the rightside of the engine are determined from the flywheelend. The number 1 cylinder is the front cylinder.


Model Views

g00284836Illustration 15Cylinder and valve locations(A) Inlet valves(B) Exhaust valves

Table 1

C15 Engine Specifications

Cylinders and Arrangement In-line six cylinder

Bore 140 mm (5.5 inch)

Stroke 171 mm (6.7 inch)

Displacement 15.8 L (964.2 in3)

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

Rotation (flywheel end) Counterclockwise

Electronic Engine FeaturesThese Caterpillar Engines are specifically designedfor electronic controls. These engines have anintegral on board computer that is called anElectronic Control Module (ECM). The ECM monitorscurrent engine conditions and power requirements.The optimum engine response is calculated andinstructions are sent to the engine control systems.The systems respond and the engine respondsaccordingly. Total engine control is realized throughthe control of the fuel system and the enginespeed/timing system. The electronic engine controlsystem provides the following features:

• Engine speed governing

• Injection timing control

• Automatic air/fuel ratio control

• Torque rise shaping

• Engine monitoring and protection

The ECM provides the electronic governing of fueldelivery in order to dictate the following enginecontrols: engine speed setpoint, engine timingaccuracy, air/fuel ratio control, and torque rise fuelsetting.

Electronically controlled, mechanically actuatedunit injectors combine the pumping, electronicfuel metering (duration and timing), and injectingelements of the fuel system into a single unit. Eachcylinder has an independent unit injector.

Fuel metering is controlled by an electrical signalthat is sent to the injector solenoid from the ECM.Very high fuel injection pressures are produced bythe unit injector pump. High injection pressures andaccurate fuel metering ensure good fuel atomizationand thorough combustion. This state-of-the-arttechnology provides the engine with the followingbenefits: reduced fuel consumption, controlled smokeemissions, and electronically controlled accelerationramp rates.

The engine timing control and speed control areprovided by the ECM. The speed/timing circuitconsists of two speed/timing sensors. During enginecranking, the ECM uses the timing signal from thesecondary speed/timing sensor. The timing signalfrom the primary speed/timing sensor is used bythe ECM while the engine speed is greater thancranking speed. Utilizing two sensors for this circuithas several advantages. Each of the speed/timingsensors is treated as a discrete component by theECM. If the signal from one of the sensors becomessuspect the ECM will use the signal from the othersensor in order to keep the engine operational.

Injection duration is also managed by the ECM. Theduration of the fuel injection cycle determines theengine speed. The placement of the injection cycle inrelation to the crankshaft position will determine thetiming advance. The speed/timing circuit providesinformation to the fuel cooled ECM for detectionof crankshaft position and engine speed. Thisinformation is utilized by the ECM in order to controldesired engine speed and engine timing.

The ECM changes injection timing according toengine operating conditions and demand. Improvedtiming control results in improved performance.Improvements in several aspects of engine operationwill be realized: better engine starting ability, shorterresponse times, reduced emissions, reduced noise,and optimized fuel consumption.

26 SEBU7909-04Product Information SectionModel Views

Engine monitoring and interactive diagnosticsare also provided by the ECM. Essential engineoperating conditions and diagnostic information aremonitored and recorded in the ECM memory. TheECM quantifies the information. The information isthen compared to an acceptable range of values.If the values are not within the acceptable range,then the diagnostic information is communicated tothe operator and the abnormal condition is stored inECM memory.

For more information on electronic engine features,refer to the Operation and Maintenance Manual,“Engine Features and Controls” topic (OperationSection).

Engine Cooling and LubricationThe cooling system consists of the followingcomponents:

• Self-priming centrifugal type pump that is drivenby gears

• Water temperature regulators which regulate theengine coolant temperature

• Engine oil cooler which is used to transfer excessheat from the engine oil to the cooling system

• Radiator

The engine lubricating oil is supplied by a highpressure oil pump. The engine lubricating oil is cooledand filtered. Bypass valves provide unrestricted flowof lubrication oil to the engine components duringthe following conditions:

• High oil viscosity

• Plugged oil cooler or plugged oil filter elements(paper cartridge)

Engine Service LifeEngine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.

Expected engine life is generally predicted by theaverage power that is demanded. The average powerthat is demanded is based on fuel consumption ofthe engine over a period of time. Reduced hours ofoperation at full throttle and/or operating at reducedthrottle settings result in a lower average powerdemand. Reduced hours of operation will increasethe length of operating time before an engineoverhaul is required. For more information, refer toOperation and Maintenance Manual, SEBU7902,“Overhaul Considerations”.

Generator DescriptionThese brushless generators are used with thefollowing loads: mixed loads of motors and lights,SCR-controlled equipment, computer centers,installations of communications, and petroleumdrilling applications. The elimination of the brushes inthe field circuit reduces maintenance. The eliminationof the brushes in the field circuit increases reliability.The elimination of brushes provides a higher degreeof protection in potentially hazardous atmospheres.

The generator set packages can be utilized for primepower generation or standby power generation. Thegenerator set packages can be used in land basedapplications or marine applications.

The generators have four poles. The generators havesix or twelve lead configurations. The configurationdepends on the frame size. The generators arecapable of producing electrical power in either 50 Hzor 60 Hz applications.

Aftermarket Products andCaterpillar Engines

NOTICEIn order to maximize fuel system life and prevent pre-mature wear out from abrasive particles in the fuel,a two micron absolute high efficiency fuel filter is re-quired for all Caterpillar Hydraulic Electronic Unit In-jectors. Caterpillar High Efficiency Fuel Filters meetthese requirements. Consult your Caterpillar dealerfor the proper part numbers.

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

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


Product Identification Information

Product IdentificationInformation

i02374529

Plate Locations and FilmLocationsSMCS Code: 1000

Generator Set Identification

g01185578Illustration 16(1) Location of the identification plate for the generator set

The generator set consists of the generator and theengine. The location of the identification plate for thegenerator set is shown in illustration 17.

28 SEBU7909-04Product Information SectionProduct Identification Information

Serial Number Plate

g01185411Illustration 17Right Side View of Engine Only(2) Location of serial number plate

The Engine Serial Number Plate contains thefollowing information:

• Engine serial number __________________________________

• Engine model number _________________________________

• Arrangement number __________________________________

Engine Information Plate

g01185515Illustration 18(3) Location of the engine information plate

The Engine Information Plate contains the followinginformation:

• Engine serial number __________________________________

• Arrangement number __________________________________

• Compression ratio ______________________________________

• Aftercooler temperature _______________________________

• Power _____________________________________________________

• Full load RPM ___________________________________________


Product Identification Information

Generator Identification Plate

g01185532Illustration 19Location of the generator identification plate

The generator identification is located on the side ofthe generator.

The generator identification film includes the followinginformation:

• Serial number for the generator _____________________

• Generator model number _____________________________

i02237440

Reference NumbersSMCS Code: 1000

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

Record for ReferenceEngine Model _______________________________________________

Engine Serial Number ____________________________________

Engine Arrangement Number ___________________________

Modification Number ______________________________________

Engine Low Idle Speed ___________________________________

Engine Full Load Speed __________________________________

Performance Specification Number ____________________

Primary Fuel Filter Element _____________________________

Secondary Fuel Filter Element __________________________

Engine Oil Filter Element _________________________________

Auxiliary Oil Filter Element _______________________________

Supplemental Coolant Additive Maintenance Element_________________________________________________________________

Engine Oil Capacity _______________________________________

Total Cooling System Capacity _________________________

Air Cleaner Element _______________________________________

Fan Drive Belt ______________________________________________

Alternator Belt ______________________________________________

Generator Arrangement Number _______________________

Generator Set Serial Number ___________________________

Generator Frame Size ____________________________________

Voltage Rating ______________________________________________

kW Rating ___________________________________________________

Excitation System

S.E. ________________

P.M. ________________

i01830750

Emissions Certification FilmSMCS Code: 1000; 7405

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

A typical example is shown.

Documents

C15 Gen Set-Machine Safety