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Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Foreword

Literature Information

This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area Read, study and keep it with the literature and engine information.

English is the primary language for all Cat publications. The English used facilitates translation and consistency in electronic media delivery.

Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Cat dealer for the latest available information.

Safety

This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.

Operation

Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.

The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.

Maintenance

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The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by fuel consumption, service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.

Use fuel consumption or service hours to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading.

Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record.

See the section in the Operation and Maintenance Manual, "Maintenance Records" for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Cat dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

Overhaul

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs are best left to trained personnel or an authorized Cat dealer. Your Cat dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available from your Cat dealer. Consult with your dealer for information regarding these options.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Wed Jan 8 03:44:01 UTC+0530 2025

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Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Aftercooler Core - Clean/Test - Air-To-Air Aftercooler

SMCS - 1064-070; 1064-081

Note: Adjust the frequency of cleaning according to the effects of the operating environment.

Inspect the aftercooler for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the aftercooler, if necessary.

For air-to-air aftercoolers, use the same methods that are used for cleaning radiators.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the fan's air flow. Hold the nozzle approximately 6 mm (0.25 inch) away from the fins. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi) when the air nozzle is deadheaded. Slowly move the air nozzle in a direction that is parallel with the tubes. This will remove debris that is between the tubes.

Pressurized water may also be used for cleaning. The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides.

Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.

Inspect the fins for damage. Bent fins may be opened with a "comb".

Note: If parts of the aftercooler system are repaired or replaced, a leak test is highly recommended.

Inspect these items for good condition: welds, mounting brackets, air lines, connections, clamps and seals. Make repairs, if necessary.

For more detailed information on cleaning and inspection, see Special Publication, SEBD0518, "Know Your Cooling System".

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Aftercooler Core - Clean/Test

SMCS - 1064-070; 1064-081

1. Remove the core. Refer to the Service Manual for the procedure.

2. Turn the aftercooler core upside-down in order to remove debris.

NOTICE

Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 1 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer.

Table 1

Hydrosolv Liquid Cleaners(1)

Part

1U-5490

174-6854

Hydrosolv 4165 19 L (5 US gallon)

Hydrosolv 100 19 L (5 US gallon)

(1) Use a two to five percent concentration of the cleaner at temperatures up to 93°C (200°F). Refer to Application Guide, NEHS0526 or consult your Caterpillar dealer for more information.

4. Steam clean the core in order to remove any residue. Flush the fins of the aftercooler core. Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.

7. Inspect the core in order to ensure cleanliness. Pressure test the core. Many shops that service radiators are equipped to perform pressure tests. If necessary, repair the core.

8. Install the core. Refer to the Service Manual for the procedure.

For more information on cleaning the core, consult your Caterpillar dealer.

Wed Jan 8 04:08:09 UTC+0530 2025

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Aftermarket Oil Additives

SMCS - 1300; 1348; 7581

Caterpillar does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket additives in order to achieve the engine's maximum service life or rated performance. Fully formulated, finished oils consist of base oils and of commercial additive packages. These additive packages are blended into the base oils at precise percentages in order to help provide finished oils with performance characteristics that meet industry standards.

There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in finished oil. Aftermarket additives may not be compatible with the finished oil's additive package, which could lower the performance of the finished oil. The aftermarket additive could fail to mix with the finished oil. This could produce sludge in the crankcase. Caterpillar discourages the use of aftermarket additives in finished oils.

To achieve the best performance from a Caterpillar engine, conform to the following guidelines:

• Select the proper Caterpillar oil or a commercial oil that meets the Caterpillar recommendations.

• See the appropriate "Lubricant Viscosities" table in order to find the correct oil viscosity grade for your engine.

• At the specified interval, service the engine compartment. Use new oil and install a new oil filter.

• Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual, "Maintenance Interval Schedule".

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Air Compressor - Inspect

SMCS - 1803-040

Do not disconnect the air line from the air compressor governor without purging the air brake and the auxiliary air systems. Failure to purge the air brake and the auxiliary air systems before removing the air compressor and/or the air lines could cause personal injury. Illustration 1

i02113479

(1) Pressure relief valve

If the air compressor pressure relief valve that is mounted in the air compressor cylinder head is bypassing compressed air, there is a malfunction in the air system, possibly ice blockage. Under these conditions, your engine may have insufficient air for normal brake operation.

Do not operate the engine until the reason for the air bypass is identified and corrected. Failure to heed this warning could lead to property damage, personal injury, or death to the operator or bystanders.

The function of the pressure relief valve is to bypass air when there is a malfunction in the air compressor system.

The pressure relief valve releases air at 1723 kPa (250 psi). Do not stand near the pressure relief valve. Compressed air may be released without warning. All personnel should also stay clear of the air compressor when the engine is operating and the air compressor is exposed.

Refer to the Service Manual or refer to the OEM specifications in order to find information concerning the air compressor. Consult your Caterpillar dealer for assistance.

1993 - 2025 Caterpillar Inc.

Wed Jan 8 04:08:23 UTC+0530 2025

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Air Compressor Filter - Clean/Replace

SMCS - 1803-070; 1803-510

One of the single most important aspects of preventive maintenance for the air compressor is the induction of clean air. The type of maintenance that is required for the air compressor and the maintenance interval depends on the type of air induction system that is used. Operating conditions (dust, dirt and debris) may require more frequent service.

Refer to the Service Manual for the type of air compressor that is installed on the engine. Follow the maintenance recommendations that are provided by the OEM of the air compressor. Some engines use boost air pressure so the engine air cleaner will require servicing.

Wed Jan 8 04:08:36 UTC+0530 2025

i01491325

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines Media

Air Starting Motor Lubricator Oil Level - Check - If

Equipped

SMCS - 1451-535

NOTICE

Never allow the lubricator bowl to become empty. The air starting motor will be damaged by a lack of lubrication. Ensure that sufficient oil is in the lubricator bowl.

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(1) Air valve

(2) Lubricator bowl

(3) Adjustment knob

1. The vanes of the air starting motor are lubricated with a fine mist of oil from the air starting motor lubricator. Check the level of oil in lubricator bowl (2). If the oil level is less than 1/2, add oil to the lubricator bowl.

2. Ensure that the air supply to the lubricator is OFF.

3. Remove the plug. Pour oil into lubricator bowl (2). Use "10W" oil for temperatures that are greater than 0° C (32° F). Use air tool oil for temperatures that are below 0° C (32° F).

4. Install the plug.

Oiler Feed Adjustment

If necessary, adjust the lubricator in order to release approximately two drops of fluid per 30 seconds into the starting motor air stream.

1. Ensure that the fuel supply to the engine is OFF.

2. Turn adjustment knob (3) clockwise until the adjustment knob locks.

3. Turn adjustment knob (3) counterclockwise for 1/4 turns.

NOTICE

Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

4. Crank the starting motor for ten seconds and observe the exhaust air from the mufflers of the starting motor. Look for oil mist. A slight oil mist should be barely visible.

If no mist is observed, or if the mist is excessive, rotate adjustment knob (3) in increments of 1/16 in order to increase or decrease the oil mist. Repeat the starting motor cranking and observe until the mist is satisfactory.

Note: Drip rates should only be made under an average steady flow condition. Once a steady flow condition is established, the lubricator will automatically adjust the drip rate in proportion to the variations in air flow.

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Wed Jan 8 04:08:46 UTC+0530 2025

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Air Tank Moisture and Sediment - Drain - If Equipped

SMCS - 1466-543-M&S

Moisture and sediment in the air starting system can cause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

When opening the drain valve, wear protective gloves, a protective face shield, protective clothing, and protective shoes. Pressurized air could cause debris to be blown and result in personal injury.

1. Open the drain valve that is on the bottom of the air tank. Allow the moisture and sediment to drain.

2. Close the drain valve.

3. Check the air supply pressure. The air starting motor requires a minimum of 620 kPa (90 psi) of air pressure to operate properly. The maximum air pressure must not exceed 1550 kPa (225 psi). The normal air pressure will be 758 to 965 kPa (110 to 140 psi).

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Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Media Number -SEBU7517-01

Alternator - Inspect

SMCS - 1405-040

-01/08/2001

-09/10/2001

Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required.

Check the alternator and the battery charger for proper operation. If the batteries are properly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. The battery will not crank the engine, even if the engine is warm. When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge.

Wed Jan 8 04:09:07 UTC+0530 2025

i02676048

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Battery - Replace

SMCS - 1401-510

Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.

Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.

The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

Note: Always recycle a battery. Never discard a battery. Return used batteries to an appropriate recycling facility.

1. Turn the key start switch to the OFF position. Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect the charger.

i06738473

3. Turn battery isolator switch to OFF position.

4. The NEGATIVE "-" cable connects the NEGATIVE "-" battery terminal to the ground plane. Disconnect the cable from the NEGATIVE "-" battery terminal.

5. The POSITIVE "+" cable connects the POSITIVE "+" battery terminal to the starting motor. Disconnect the cable from the POSITIVE "+" battery terminal.

Note: Always recycle a battery. Never discard a battery. Return used batteries to an appropriate recycling facility.

6. Remove the used battery.

7. Install the new battery.

Note: Before the cables are connected, ensure that the key start switch is OFF.

8. Connect the cable from the starting motor to the POSITIVE "+" battery terminal.

9. Connect the cable from the ground plane to the NEGATIVE "-" battery terminal.

Wed Jan 8 04:09:25 UTC+0530 2025

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Battery Electrolyte Level - Check

SMCS - 1401-535

When the engine has not run for long or short periods of time, the batteries may not fully recharge. Ensure a full charge to help prevent the battery from freezing.

In warmer climates, check the electrolyte level more frequently.

Ensure that the electrolyte level is 13 mm (0.5 inch) above the top of the separators.

All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.

1. Remove the filler caps. Maintain the electrolyte level to the "FULL" mark on the battery.

If the addition of water is necessary, use distilled water. If distilled water is not available, use clean water that is low in minerals. Do not use artificially softened water.

2. Check the condition of the electrolyte with the 245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the following cleaning solutions:

A mixture of 0.1 kg (0.2 lb) of baking soda and 1 L (1 qt) of clean water

A mixture of 0.1 L (0.11 qt) of ammonia and 1 L (1 qt) of clean water

Thoroughly rinse the battery case with clean water.

i07185134

Use the 1U-9921 Battery Service Tool to clean the battery terminals. Use a wire brush to clean the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to fit improperly. Coat the clamps and the terminals with 5N-5561 Silicone Lubricant, petroleum jelly or MPGM.

Wed Jan 8 04:09:41 UTC+0530 2025

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Battery or Battery Cable - Disconnect

SMCS - 1402-029

The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.

2. Disconnect the negative battery terminal at the battery that goes to the start switch. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, the negative side of two batteries must be disconnected.

3. Tape the leads in order to help prevent accidental starting.

4. Proceed with necessary system repairs. Reverse the steps in order to reconnect all of the cables.

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Belt - Inspect

SMCS - 1357-040; 1357; 1397-040; 1397

Inspection

Belt tension should be checked initially between the first 20 to 40 hours of engine operation.

After the initial check, the belt tension should be checked at Every PM Level 1 or Three Months.

To maximize the engine performance, inspect the belts for wear and for cracking. Replace belts that are worn or damaged.

For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break.

If the belts are too loose, vibration causes unnecessary wear on the belts and pulleys. Loose belts may slip enough to cause overheating.

If the belts are too tight, unnecessary stresses are placed on the pulley bearings and on the belts. This may shorten the service life of the components.

Remove the belt guard. Inspect the condition and adjustment of the alternator belts and accessory drive belts (if equipped).

To check the belt tension, apply 110 N (25 lb ft) of force midway between the pulleys. A correctly adjusted belt will deflect 9 mm (0.35 inch) to 15 mm (0.59 inch).

If the belt does not require replacement or adjustment, install the belt guard. If the belt requires adjustment or replacement, perform the following procedure to adjust the belt tension.

• If the engine is equipped with a refrigerant compressor (air conditioner), the belt for the fan drive, the alternator, and the accessories will have an automatic belt tensioner.

• If the engine is not equipped with a refrigerant compressor, the alternator is used to adjust the belt tension.

i02126625

Adjustment

Alternator Belt

Illustration 1

Typical alternator mounting

(1) Adjusting nuts

(2) Mounting bolts

1. Slightly loosen mounting bolt (2) and adjusting nut (1) .

2. Move the pulley in order to adjust the belt tension.

g00485289

3. Tighten adjusting nuts (1) and mounting bolts (2). Refer to the Specifications, SENR3130 in order to locate the proper torques.

4. Install the belt guard.

Wed Jan 8 04:10:12 UTC+0530 2025

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Media Number -SEBU7517-01

Belt Tensioner - Inspect - If Equipped

SMCS - 1358-040

Illustration 1 g00426964 Belt tensioner

-09/10/2001 i01555583

Inspect the belt tensioner for unusual noise, excessive looseness and/or shaking of the bearings. If the belt tensioner should require disassembly, refer to the Service Manual for the procedure.

Wed Jan 8 04:10:21 UTC+0530 2025

Product: INDUSTRIAL ENGINE

Model: C-16 INDUSTRIAL ENGINE BFM

Configuration: C-16 Industrial Engine BFM00001-UP

Operation and Maintenance Manual

C-15 and C-16 Industrial Engines

Cold Weather Lubricants

SMCS - 1300; 1348; 7581

When an engine is started and an engine is operated in ambient temperatures below -20 °C (-4 °F), use multigrade oils that are capable of flowing in low temperatures.

These oils have lubricant viscosity grades of SAE 0W or SAE 5W.

When an engine is started and operated in ambient temperatures below -30 °C (-22 °F), use a synthetic base stock multigrade oil with a 0W viscosity grade or with a 5W viscosity grade. Use an oil with a pour point that is lower than -50 °C (-58 °F).

The number of acceptable lubricants is limited in cold weather conditions. Caterpillar recommends the following lubricants for use in cold weather conditions:

First Choice - use an oil with an EMA LRG-1 Recommended Guideline or use a CH-4 oil that is API licensed with an SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade. A CG-4 oil that is API licensed with an SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade may also be used. A CF-4 oil that is API licensed with an SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade may also be used.

Second Choice - use an oil that contains the CH-4, CG-4, or CF-4 additive package although the oil has not been tested for the requirements of the API license. The oil must have an SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade.