C15 Generator Sets Caterpillar

Note: Many of the following recommendations and requirements are interrelated. Read all of the information which is provided. Refer to the latest edition of Special Publication, SEBU6251, "Caterpillar Commercial Diesel Engine Fluids Recommendations" for additional information. Contact your Caterpillar dealer in order to confirm that you have the latest recommendations for fluids.

Lubrication System

A Caterpillar Engine which is covered by this Operation and Maintenance Manual may be equipped with a Caterpillar Engine Aftertreatment System. The engine with the engine aftertreatment system meets United States Environmental Protection Agency (US EPA) Tier 4 emissions requirements.

Caterpillar requires that Caterpillar Engines which meet US EPA Tier 4 emissions requirements use one of the following engine oils:

• Cat DEO-ULS (Diesel Engine Oil - Ultralow Sulfur)

• Cat DEO-ULS SYN (Diesel Engine Oil - Ultralow Sulfur Synthetic)

• Cat Cold Weather DEO-ULS

• Commercial oil which meets the Caterpillar ECF-3 (Engine Crankcase Fluid - 3) specification or which meets the requirements of the American Petroleum Institute (API) CJ-4 oil category

Engine Oil Viscosity

In selecting oil for any engine application, both of the following must be satisfied: the oil viscosity and the category of oil performance or the specification for oil performance . Using only one of these parameters will not sufficiently define oil for an engine application.

The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.

Refer to Table 1 (minimum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Refer to Table 1 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Note: Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.

Caterpillar S·O·S Services Oil Analysis

The Caterpillar tool for oil analysis is called S·O·S Oil Analysis and the tool is part of the S·O·S Services program. S·O·S Oil Analysis evaluates oil degradation and S·O·S Oil Analysis detects early signs of wear on internal components.S·O·S Oil Analysis divides oil analysis into four categories: component wear rate, condition of the oil, oil contamination and identification of the oil.

The S·O·S Oil Analysis program uses a wide range of tests to determine the condition of the oil and the condition of the lubricated compartment. Exceeding one or more of these guidelines could indicate serious fluid degradation or a pending component failure. A trained person at your Caterpillar dealership should make the final analysis.

In order to help protect your engine and in order to help optimize oil drain intervals, use S·O·S Oil Analysis as follows:

• Recommended as a matter of course

• Strongly recommended in order to determine oil drain intervals when operating with fuel which has sulfur levels of between 0.05 percent (500 ppm) and 0.5 percent (5000 ppm)

• Required in order to determine oil drain intervals when operating with fuel which has sulfur levels that are above 0.5 percent (5000 ppm)

Refer to Special Publication, SEBU6251, "Caterpillar Commercial Diesel Engine Fluids Recommendations" in order to obtain additional information about S·O·S Services oil analysis. You can also contact your local Caterpillar dealer.

The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter.

Refill Capacities (Engine Oil)

The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter.

Fuel System

Filter the fuel entering the bulk storage fuel tank through a filter with a rating of 20 micron (c) absolute or less. Filter the fuel at the last dispensing stage into the engine fuel tank through a filter with a rating of 4 microns (c) absolute or less. The use of a series of filters is recommended. The use of filters which are made from wire mesh is not recommended unless filters with cellulose media or synthetic media are downstream of the wire mesh filters. The use of water separators is also recommended with the fuel filters.

Use Caterpillar Advanced Efficiency Fuel Filters on diesel engines which burn distillate fuels in order to provide maximum life to the fuel system.

Fuel Recommendations

Diesel engines can burn a wide variety of fuels. These fuels are divided into two general groups. The two groups are called the preferred fuels and the permissible fuels.

The preferred fuels provide maximum engine service life and performance. The preferred fuels are distillate fuels. These fuels must meet the "Caterpillar Specification for Distillate Diesel Fuel for Off-Highway Diesel Engines" which is found in Special Publication, SEBU6251, "Caterpillar Commercial Diesel Engines Fluids Recommendations".

The permissible fuels are some crude oils, some blends of crude oil with distillate fuel, and some biodiesel. These fuels are not suitable for use in all engine applications. A complete fuel analysis is required. Consult your Caterpillar dealer for further information. For information which concerns biodiesel or biodiesel blends, refer to Special Publication, SEBU6251, "Caterpillar Commercial Diesel Engines Fluids Recommendations".

Note: Use lubricating oils which are compatible with the certification of the engine, the engine aftertreatment system, and the sulfur levels of the fuel.

Ultralow sulfur diesel fuel (ULSD) contains no more than 15 ppm (mg/kg) of sulfur. ULSD is required by regulation for engines which are certified to nonroad Tier 4 standards (U.S. EPA Tier 4 certified) and which are equipped with engine aftertreatment systems. Other governments may require the use of ULSD fuel. Consult local officials for guidance on fuel requirements.

Aftermarket Fuel Additives

Note: For the best results, fuel which is treated with fuel additives should be treated by the fuel supplier.

Cat Diesel Fuel Conditioner is the only fuel conditioner/additive available that is tested and approved by Caterpillar for use in Caterpillar Diesel Engines. Cat Diesel Fuel Conditioner is a proprietary metal and ash free formulation that has been extensively tested for use with distillate diesel fuels for use in Caterpillar diesel engines. Cat Diesel Fuel Conditioner helps address many of the challenges that various fuels present in regards to fuel life/stability, engine startability, injector deposits, fuel system life, and long-term engine performance.

Aftermarket Fuel Cleaners

Cat Diesel Fuel System Cleaner is the only fuel system cleaner available that is tested and approved by Caterpillar for use in Caterpillar Diesel Fuel Conditioner.

Cat Diesel Fuel System Cleaner is a proven high performance cleaner that is designed to perform the following:

• Clean performance-robbing fuel system deposits

• Restore fuel economy losses resulting from injector deposits

• Restore power losses resulting from injector deposits

• Eliminate visible black exhaust smoke resulting from injector deposits

• Prevent the formation of new fuel-related deposits

Refer to Special Publication, SEBU6251, "Caterpillar Commercial Diesel Engines Fluids Recommendations" for instructions on the use of Cat Diesel Fuel System Cleaner.

Cooling System

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The cooling system operates under pressure which is controlled by the radiator pressure cap. Removing the cap while the system is hot may allow the escape of hot coolant and steam, causing serious burns. Before you remove the radiator cap, allow the system to cool. Use a thick cloth and turn the radiator cap slowly to the first stop to allow pressure to escape before fully removing the cap. Avoid contact with coolant.

Water

Distilled water or deionized water is recommended for use in engine cooling systems. If distilled water or deionized water is not available, use water that meets or water that exceeds the Caterpillar minimum acceptable water requirements. For these requirements, refer to Special Publication, SEBU6251, "Caterpillar Commercial Diesel Engine Fluids Recommendations", "General Coolant Information".

Additives

Caterpillar strongly recommends a minimum of 50 percent glycol in diesel engine cooling systems. For optimum performance, Caterpillar recommends a 1:1 mixture of properly inhibited distilled or deionized water and glycol.

Use the following table to determine the concentration of glycol required for protection from freezing and boiling conditions:

Coolants

The following two types of coolants may be used in Caterpillar Diesel Engines:

Preferred - Cat ELC (Extended Life Coolant)

Acceptable - (listed in order of most recommended to least recommended)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial extended life coolant that meets the Caterpillar EC-1 (Engine Coolant -1) specification and the additional requirements for EC-1 specification coolants as stated in the coolant section of this Special Publication.

• Commercial heavy-duty antifreeze/coolant that meets the "ASTM D6210-06" specifications

• Commercial heavy-duty antifreeze/coolant that meets "ASTM D4985-05" specifications

Note: Cat DEAC does not require a treatment with a supplemental coolant additive (SCA) at the initial fill. However, a commercial heavy-duty coolant/antifreeze that only meets "ASTM D4985", by specification, WILL require a treatment with an SCA at the initial fill. A commercial heavy-duty coolant/antifreeze that meets the "ASTM D6210" specification WILL NOT require a treatment with an SCA at the initial fill. Read the label or the instructions that are provided by the manufacturer of the commercial heavy-duty coolant/antifreeze.

Note: When adding SCA at initial fill to a coolant/antifreeze which only meets the "ASTM D4985" requirements, ensure the SCA is compatible with the antifreeze/coolant. Providing sources of compatible SCAs is the responsibility of the coolant manufacturer.

Note: These coolants WILL require a treatment with a supplemental coolant additive on a maintenance basis.

Service Life of Coolants

Note: These coolant change intervals are only achievable with annual S·O·S Services Level 2 coolant sampling and analysis.

S·O·S Services Coolant Analysis

Testing of the engine coolant is important in order to ensure that the engine is protected from internal cavitation and corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling and freezing. S·O·S coolant analysis can be done at your Caterpillar dealer. Caterpillar S·O·S coolant analysis is a program that is based on periodic samples.

Refer to this Operation and Maintenance Manual, "Maintenance Interval schedule" for information about the correct maintenance intervals for coolant sampling.

S·O·S Services Coolant Analysis (Level 1)

A coolant analysis (Level 1) is a test of the properties of the coolant.

The following properties of the coolant are tested:

• Glycol concentration for freeze protection and boil protection

• Ability to protect from erosion and corrosion

• pH

• Conductivity

• Visual analysis

• Odor analysis

The results are reported, and appropriate recommendations are made.

S·O·S Services Coolant Analysis (Level 2)

A coolant analysis ( Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the cooling system.

The S·O·S coolant analysis ( Level 2) has the following features:

• Full coolant analysis (Level 1)

• Identification of metal corrosion and of contaminants

• Identification of buildup of the impurities that cause corrosion

• Identification of buildup of the impurities that cause scaling

• Determination of the possibility of electrolysis within the cooling system of the engine

The results are reported, and appropriate recommendations are made.

Refill Capacity (Coolant System)

To maintain the cooling system, the total cooling system capacity must be known. The capacity of the total cooling system will vary. The capacity will depend on the size of the radiator (capacity). Table 5 should be completed by the customer for the maintenance of the cooling system.

Greases

If it is necessary to choose a single grease to use for all of the equipment at one site, always choose a grease that meets or exceeds the requirements of the most demanding application. Remember that the products which barely meet the minimum performance requirements can be expected to barely produce the minimum lives of your parts. False economy is being used if a grease is purchased with the lowest cost as the only consideration. Instead, use the grease that yields the lowest total operating cost. This cost should be based on an analysis that includes the costs of parts, labor, downtime, and the cost of the amount of grease that is required.

Caterpillar Greases

Caterpillar provides various greases that vary in performance from a moderate performance to an extremely high performance. These greases service the entire line of Caterpillar products in the wide variety of climates throughout the world.

Most Caterpillar greases are chemically compatible but may be formulated for different levels of performance. Mixing Caterpillar greases can affect the performance of the greases. Do not mix Caterpillar greases.

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Commercial Greases

Some greases are not chemically compatible with other greases. Consult your supplier in order to determine if the greases are compatible. Purge all of the old grease from a joint in the following circumstances:

• Before you change from one type of grease to another type of grease

• Before you change from one brand of grease to another brand of grease

If you are not certain that the old grease is compatible with the new grease, purge the old grease from the system before applying the new grease.