SAFETY

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU7899-05
January 2012

Operation and
Maintenance
Manual
C18 Industrial Engine
JDA1-Up (Engine)
GJE1-Up (Engine)
EJG1-Up (Engine)
WJH1-Up (Engine)
WRH1-Up (Engine)

SAFETY.CAT.COM
6 SEBU7899-05
Safety Section
Safety Messages

Safety Section
i04331780

Safety Messages
SMCS Code: 1000; 7405

g01416712
Illustration 1
View of the right side of a typical C18 Diesel Engine

There may be several specific safety messages on Universal Warning

your engine. The exact location and a description of
the safety messages are reviewed in this section.
Become familiar with all safety messages.

Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off
the engine.
g01370904
Replace any safety message that is damaged or Illustration 2
missing. If a safety message is attached to a part The safety messages for the universal warning are located toward
of the engine that is replaced, install a new safety the front of the engine on both sides of the valve cover base.
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
SEBU7899-05 7
Safety Section
General Hazard Information

Use caution when cover plates are removed.

Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
Do not operate or work on this engine unless you
the cover plate or the device. Before removing the
have read and understand the instructions and
last two bolts or nuts, pry the cover loose in order to
warnings in the Operation and Maintenance Man-
relieve any spring pressure or other pressure.
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

i04074884

General Hazard Information

SMCS Code: 1000; 4450; 7405

g00702020
Illustration 4

• Wear a hard hat, protective glasses, and other

protective equipment, as required.

• When work is performed around an engine that is

operating, wear protective devices for ears in order
to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snag

Illustration 3
g00104545 on controls or on other parts of the engine.

Attach a “Do Not Operate” warning tag to the start • Ensure that all protective guards and all covers are
switch or controls before the engine is serviced or secured in place on the engine.
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer. • Never put maintenance fluids into glass containers.
Attach the warning tags to the engine and to Glass containers can break.
each operator control station. When appropriate,
disconnect the starting controls. • Use all cleaning solutions with care.

Do not allow unauthorized personnel on the engine, • Report all necessary repairs.
or around the engine when the engine is being
serviced. Unless other instructions are provided, perform
the maintenance under the following conditions:
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids, • The engine is stopped. Ensure that the engine
hold a rag over the part that is being removed. cannot be started.

• Filler caps • The protective locks or the controls are in the

applied position.
• Grease fittings
• Disconnect the batteries when maintenance
• Pressure taps is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Breathers
• Drain plugs
8 SEBU7899-05
Safety Section
General Hazard Information

• When starting a new engine or an engine which Always use a board or cardboard when you check
has not been started since service has been for a leak. Leaking fluid that is under pressure can
performed, make provisions to stop the engine if an penetrate body tissue. Fluid penetration can cause
overspeed occurs. Shutting down the engine may serious injury and possible death. A pin hole leak can
be accomplished by shutting off the fuel supply cause severe injury. If fluid is injected into your skin,
and/or the air supply to the engine. you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
• Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
Containing Fluid Spillage

• Start the engine with the operator controls. Never NOTICE

short across the starting motor terminals or the Care must be taken to ensure that fluids are contained
batteries. This method of starting the engine could during performance of inspection, maintenance, test-
bypass the engine neutral start system and/or the ing, adjusting and repair of the product. Be prepared to
electrical system could be damaged. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Pressurized Air and Water
Refer to Special Publication, NENG2500, “Caterpillar
Pressurized air and/or water can cause debris and/or
Dealer Service Tool Catalog” or refer to Special Pub-
hot water to be blown out which could result in
lication, PECJ0003, “Caterpillar Shop Supplies and
personal injury.
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
Dispose of all fluids according to local regulations and
shoes, and eye protection. Eye protection includes
mandates.
goggles or a protective face shield.

The maximum air pressure for cleaning purposes Lines, Tubes, and Hoses
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip Do not bend or strike high-pressure lines. Do not
guarding (if applicable) and personal protective install lines, tubes, or hoses that are damaged.
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi). Repair any fuel lines, oil lines, tubes, or hoses that
Always wear eye protection for cleaning the cooling are loose or damaged. Leaks can cause fires.
system.
Inspect all lines, tubes, and hoses carefully. Do
Fluid Penetration not use bare hands to check for leaks. Always
use a board or cardboard for checking engine
components for leaks. Tighten all connections to the
recommended 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

g00687600
• Flexible part of the hose that is kinked or crushed
Illustration 5
• Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and
the heat shields are installed correctly. Correct
installation of these components will help to prevent
these effects: vibration, rubbing against other parts,
and excessive heat during operation.
SEBU7899-05 9
Safety Section
General Hazard Information

Inhalation • Use exhaust ventilation on permanent machining

jobs.

• Wear an approved respirator if there is no other

way to control the dust.

• Comply with applicable rules and regulations

for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal

of asbestos.

g02159053 • Stay away from areas that might have asbestos

Illustration 6 particles in the air.

Exhaust Softwrap
Use caution. Exhaust fumes can be hazardous to Keep the engine room ventilation operating at full
your health. If you operate the equipment in an capacity. Wear a particulate respirator that has been
enclosed area, adequate ventilation is necessary. approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
Asbestos Information protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands
Caterpillar equipment and replacement parts that thoroughly after handling Softwrapmaterial. Do not
are shipped from Caterpillar are asbestos free. smoke until washing hands thoroughly after handling
Caterpillar recommends the use of only genuine Softwrap material. Clean up debris with a vacuum
Cat replacement parts. Use the following guidelines or by wet sweeping. Do not use pressurized air to
when you handle any replacement parts that contain clean up debris.
asbestos or when you handle asbestos debris.
Reference: The applicable material safety data
Use caution. Avoid inhaling dust that might be sheets can be found at the following web site by
generated when you handle components that contain searching by the part number or the name of the
asbestos fibers. Inhaling this dust can be hazardous product:
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining http://dsf2ws.cat.com/msds/servlet/
material, clutch plates, and some gaskets. The cat.cis.ecs.msdsSearch.controller.
asbestos that is used in these components is usually UserIdentificationDisplayServlet
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated. Dispose of Waste Properly
If dust that may contain asbestos is present, there
are 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 asbestos
materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be g00706404
Illustration 7
used.
10 SEBU7899-05
Safety Section
Burn Prevention

Improperly disposing of waste can threaten the Always wear protective glasses when you work with
environment. Potentially harmful fluids should be batteries. Wash hands after touching batteries. The
disposed of according to local regulations. use of gloves is recommended.

Always use leakproof containers when you drain

i04090689
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water. Fire Prevention and Explosion
i02088921
Prevention
Burn Prevention SMCS Code: 1000; 4450; 7405

SMCS Code: 1000; 4450; 7405

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
g00704000
to the engine contain hot coolant. Any contact with Illustration 8
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the Use of personal protection equipment (PPE) may be
cooling system is drained. needed.

Check the coolant level after the engine has stopped All fuels, most lubricants, and some coolant mixtures
and the engine has been allowed to cool. Ensure are flammable.
that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with Always perform a Walk-Around Inspection, which
a bare hand. Remove the filler cap slowly in order may help you identify a fire hazard. Do not operate a
to relieve pressure. product when a fire hazard exists. Contact your Cat
dealer for service.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact Flammable fluids that are leaking or spilled onto hot
the skin, the eyes, or the mouth. surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
Oils
A flash fire may result if the covers for the engine
Hot oil and hot lubricating components can cause
crankcase are removed within 15 minutes after an
personal injury. Do not allow hot oil or hot components
emergency shutdown.
to contact the skin.
Determine whether the engine will be operated in an
If the application has a makeup tank, remove the cap
environment that allows combustible gases to be
for the makeup tank after the engine has stopped.
drawn into the air inlet system. These gases could
The filler cap must be cool to the touch.
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Batteries
If the application involves the presence of
The liquid in a battery is an electrolyte. Electrolyte is combustible gases, consult your Cat dealer for
an acid that can cause personal injury. Do not allow additional information about suitable protection
electrolyte to contact the skin or the eyes. devices.

Do not smoke while checking the battery electrolyte Remove all flammable materials such as fuel, oil, and
levels. Batteries give off flammable fumes which can debris from the engine. Do not allow any flammable
explode. materials to accumulate on the engine.
SEBU7899-05 11
Safety Section
Fire Prevention and Explosion Prevention

All fluids that are captured in the fluid spill

containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire
may cause personal injury and property damage.

Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaust

components from oil or fuel spray in a line, a tube,
or a seal failure. Exhaust shields must be installed
correctly.

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to Illustration 9
g00704059
welding or flame cutting.
Use caution when you are refueling an engine. Do
Wiring must be kept in good condition. Properly route not smoke while you are refueling an engine. Do not
and attach all electrical wires. Check all electrical refuel an engine near open flames or sparks. Always
wires daily. Repair any wires that are loose or frayed stop the engine before refueling.
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.

Inspect all lines and hoses for wear or for

deterioration. Properly route all hoses. The lines
and hoses must have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.

Properly install all oil filters and fuel filters. The filter
housings must be tightened to the proper torque.
g02298225
Illustration 10

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

Never check the battery charge by placing a metal

object across the terminal posts. Use a voltmeter or
a hydrometer.
12 SEBU7899-05
Safety Section
Crushing Prevention and Cutting Prevention

Improper jumper cable connections can cause • End fittings are damaged or leaking.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific • Outer coverings are chafed or cut.
instructions.
• Wires are exposed.
Do not charge a frozen battery. Charging a frozen
battery may result in an explosion. • Outer coverings are ballooning.
The batteries must be kept clean. The covers • Flexible parts of the hoses are kinked.
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box • Outer covers have embedded armoring.
covers when the engine is operated.
• End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
Make sure that a fire extinguisher is available. Be are installed correctly in order to prevent vibration,
rubbing against other parts, and excessive heat.
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations i01359666
on the instruction plate.
Crushing Prevention and
Ether Cutting Prevention
Ether is flammable and poisonous. SMCS Code: 1000; 4450; 7405

Use ether in well ventilated areas. Do not smoke Support the component properly when work beneath
while you are replacing an ether cylinder or while you the component is performed.
are using an ether spray.
Unless other maintenance instructions are provided,
Do not store ether cylinders in living areas or in the never attempt adjustments while the engine is
engine compartment. Do not store ether cylinders running.
in direct sunlight or in temperatures above 49 °C
(120 °F). Keep ether cylinders away from open Stay clear of all rotating parts and of all moving
flames or sparks. parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
Dispose of used ether cylinders properly. Do not reinstall the guards.
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel. Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather When objects are struck, wear protective glasses in
starting. order to avoid injury to the eyes.

Lines, Tubes, and Hoses Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
Do not bend high-pressure lines. Do not strike one will be injured by flying debris.
high-pressure lines. Do not install any lines that are
bent or damaged. i01372247

Repair any lines that are loose or damaged. Leaks Mounting and Dismounting
can cause fires. Consult your Cat dealer for repair
or for replacement parts. SMCS Code: 1000; 4450; 7405

Check lines, tubes, and hoses carefully. Do not use Inspect the steps, the handholds, and the work area
your bare hand to check for leaks. Use a board or before mounting the engine. Keep these items clean
cardboard to check for leaks. Tighten all connections and keep these items in good repair.
to the recommended torque.
Mount the engine and dismount the engine only at
Replace the parts if any of the following conditions locations that have steps and/or handholds. Do not
are present: climb on the engine, and do not jump off the engine.
SEBU7899-05 13
Safety Section
Before Starting Engine

Face the engine in order to mount the engine or Do not bypass the automatic shutoff circuits. Do not
dismount the engine. Maintain a three-point contact disable the automatic shutoff circuits. The circuits are
with the steps and handholds. Use two feet and one provided in order to help prevent personal injury. The
hand or use one foot and two hands. Do not use any circuits are also provided in order to help prevent
controls as handholds. engine damage.

Do not stand on components which cannot support See the Service Manual for repairs and for
your weight. Use an adequate ladder or use a work adjustments.
platform. Secure the climbing equipment so that the
equipment will not move.
i01103904

Do not carry tools or supplies when you mount the

engine or when you dismount the engine. Use a hand
Engine Starting
line to raise and lower tools or supplies. SMCS Code: 1000

i03560601 If a warning tag is attached to the engine start switch

or to the controls, DO NOT start the engine or move
Before Starting Engine the controls. Consult with the person that attached
the warning tag before the engine is started.
SMCS Code: 1000
All protective guards and all protective covers must
NOTICE be installed if the engine must be started in order
For initial start-up of a new or rebuilt engine, and for to perform service procedures. To help prevent an
start-up of an engine that has been serviced, make accident that is caused by parts in rotation, work
provision to shut the engine off should an overspeed around the parts carefully.
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine. Start the engine from the operator's compartment or
from the engine start switch.

Always start the engine according to the procedure

that is described in this Operation and Maintenance
Engine exhaust contains products of combustion Manual, “Engine Starting” topic (Operation Section).
which may be harmful to your health. Always start Knowing the correct procedure will help to prevent
and operate the engine in a well ventilated area major damage to the engine components. Knowing
and, if in an enclosed area, vent the exhaust to the the procedure will also help to prevent personal injury.
outside.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Inspect the engine for potential hazards. properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.
Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or Engine exhaust contains products of combustion
similar warning tag attached to the start switch or to that can be harmful to your health. Always start the
the controls. engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
Before starting the engine, ensure that no one is on, vent the engine exhaust to the outside.
underneath, or close to the engine. Ensure that the
area is free of personnel.
Ether
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all Ether is poisonous and flammable.
lights work properly, if equipped.
Do not inhale ether, and do not allow ether to contact
All protective guards and all protective covers must the skin. Personal injury could result.
be installed if the engine must be started in order
to perform service procedures. To help prevent an Do not smoke while ether cylinders are changed.
accident that is caused by parts in rotation, work
around the parts carefully. Use ether in well ventilated areas.

Use ether with care in order to avoid fires.

14 SEBU7899-05
Safety Section
Engine Stopping

Keep ether cylinders out of the reach of unauthorized Check the electrical wires daily for wires that are
persons. loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
Store ether cylinders in authorized storage areas electrical wires before the engine is started. Refer to
only. the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.
Do not store ether cylinders in direct sunlight or at
temperatures above 49 °C (120 °F).
Grounding Practices
Discard the ether cylinders in a safe place. Do not
puncture the ether cylinders. Do not burn the ether
cylinders.

i01462046

Engine Stopping
SMCS Code: 1000

Stop the engine according to the procedure in

the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.

Use the Emergency Stop Button (if equipped) ONLY

in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.

Stop the engine if an overspeed condition occurs

during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine. Illustration 11
g00771448

Typical example
To stop an electronically controlled engine, cut the
Grounding Stud To Battery Ground
power to the engine.

i02469632

Electrical System
SMCS Code: 1000; 1400

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
SEBU7899-05 15
Safety Section
Engine Electronics

i02784356

Engine Electronics
SMCS Code: 1000; 1900

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.

This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.

The following actions are available for engine

monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.

Many of the parameters that are monitored by the

g00771487
Illustration 12 ECM can be programmed for the engine monitoring
Typical example functions. The following parameters can be monitored
Alternate Grounding Stud To Battery Ground
as a part of the Engine Monitoring System:

Proper grounding for the engine electrical system • Operating Altitude

is necessary for optimum engine performance
and reliability. Improper grounding will result in • Engine Coolant Level
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths. • Engine Coolant Temperature

Uncontrolled electrical circuit paths can result in • Engine Oil Pressure

damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components. • Engine Speed

Engines that are installed without engine-to-frame • Fuel Temperature

ground straps can be damaged by electrical
discharge. • Intake Manifold Air Temperature

To ensure that the engine and the engine electrical • System Voltage
systems function properly, an engine-to-frame ground
strap with a direct path to the battery must be used. The Engine Monitoring package can vary for different
This path may be provided by way of a starting motor engine models and different engine applications.
ground, a starting motor ground to the frame, or a However, the monitoring system and the engine
direct engine ground to the frame. monitoring control will be similar for all engines.

All grounds should be tight and free of corrosion. The Note: Many of the engine control systems and display
engine alternator must be grounded to the negative modules that are available for Caterpillar Engines
“-” battery terminal with a wire that is adequate to will work in unison with the Engine Monitoring
handle the full charging current of the alternator. System. Together, the two controls will provide the
engine monitoring function for the specific engine
application. Refer to the Troubleshooting Manual for
more information.