c11, c13 and c15 on-highway engines-engine safety

7/27/2019 C11, C13 and C15 on-Highway Engines-Engine Safety

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SAFETY.CAT.COM

C11, C13 and C15

ON-HIGHWAY ENGINESEngine Safety

Excerpted from Operation & Maintenance Manual (SEBU7695-13)

2009 CaterpillarAll Rights Reserved


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i03602780

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 asDANGER, 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.

A non-exhaustive list of operations that may cause product damage are identified by NOTICE labelson the product and in this 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. You mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand forothers. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.

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.


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6 SEBU7695-13Safety SectionSafety Messages

Safety Section

i01956922

Safety Messages

SMCS Code: 1000; 7405

There may be several specific warning signs on yourengine. The exact location and a description of thewarning signs are reviewed in this section. Pleasebecome familiar with all warning signs.

Ensure that all of the warning signs are legible. Cleanthe warning signs or replace the warning signs ifthe words cannot be read or if the illustrations arenot visible. Use a cloth, water, and soap to cleanthe warning signs. Do not use solvents, gasoline, orother harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures thewarning signs. The warning signs that are loosenedcould drop off of the engine.

Replace any warning sign that is damaged ormissing. If a warning sign is attached to a part of theengine that is replaced, install a new warning signon the replacement part. Your Caterpillar dealer canprovide new warning signs.

g01017254Illustration 1

Typical example

C15 is shown.

(1) Universal Warning


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SEBU7695-13 7Safety Section

Safety Messages


Typical example

C15 is shown.



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.



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8 SEBU7695-13Safety SectionGeneral Hazard Information

One warning label for the Universal Warning islocated on the valve cover base on the left side of theengine. The label is on the fourth flat surface from therear of the engine.

The other warning label for the Universal Warning

is located on the vertical surface of the watertemperature regulator housing just below the roundboss that is cast into the housing.

i02966200

General Hazard Information

SMCS 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 theengine or around the engine when the engine isserviced.

Tampering with the engine installation or tamperingwith the OEM supplied wiring can be dangerous.

Personal injury, death and/or engine damage couldresult.

Vent the engine exhaust to the outside when theengine is operated in an enclosed area.

If the engine is not running, do not release thesecondary brake or the parking brake systemsunless the vehicle is blocked or unless the vehicleis restrained.

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.

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, perform themaintenance under the following conditions:

The engine is stopped. Ensure that the engine cannot be started.

The protective locks or the controls are in theapplied position.

Engage the secondary brakes or parking brakes.

Block the vehicle or restrain the vehicle beforemaintenance or repairs are performed.

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.

Disconnect the connector for the unit injector thatis located on the valve cover base. This will helpprevent personal injury from the high voltage to theunit injectors. Do not come in contact with the unitinjector terminals while the engine is operating.

Do not attempt any repairs or any adjustments tothe engine while the engine is operating.

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

For initial start-up of a new engine or for starting anengine that has been serviced, make provisions tostop the engine if an overspeed occurs. This maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine.

Start the engine from the operator's station (cab).Never short across the starting motor terminals orthe batteries. This could bypass the engine neutralstart system and/or the electrical system could bedamaged.


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General Hazard Information

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 two

bolts or nuts, pry the cover loose in order to relieveany spring pressure or other pressure.

Pressure Air and Water

Pressurized air and/or water can cause debrisand/or hot water to be blown out. This could resultin personal injury. When pressure air is used forcleaning, wear a protective face shield, protectiveclothing, and protective shoes. The maximum airpressure for cleaning purposes must be reduced to205 kPa (30 psi) when the air nozzle is deadheadedand used with effective chip guarding (if applicable)

and personal protective equipment. The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi). Always wear eye protection forcleaning the cooling system.

Fluid Penetration

Always 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. Iffluid is injected into the skin, seektreatment immediately. Seek treatment from a doctorthat is familiar with this type of injury.

Fluid Spillage

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog or refer to Special Pub-lication, PECJ0003, Caterpillar Shop Supplies andTools Catalog for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

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.


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10 SEBU7695-13Safety SectionBurn Prevention

Avoid brushing materials that contain asbestos.

Avoid grinding materials that contain asbestos.

Use a wet method in order to clean up asbestosmaterials.

A vacuum cleaner that is equipped with a highefficiency particulate airfilter (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 Hoses

Do 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.

i01480768

Burn Prevention

SMCS 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.

Coolant

When 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.

Oils

Hot 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.

Batteries

Electrolyte 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.


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Fire Prevention and Explosion Prevention

i01806909

Fire Prevention and ExplosionPrevention

SMCS 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 tube, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding orflame cutting.

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 properly

maintained 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.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


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12 SEBU7695-13Safety SectionFire Prevention and Explosion Prevention


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

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 Extinguisher

Make sure that a fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Ether (If Equipped)

Ether is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin direct sunlight or in temperatures above 49 C(120 F). Keep ether cylinders away from openflames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. If the engine isequipped with an Air Inlet Heater (electrically orfuel ignited manifold heater), DO NOT use ether(starting fluids) at any time. The use could resultin engine damage and/or personal injury.

Do not spray ether into an engine if the engine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes and Hoses

Do 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 and Cutting Prevention

i01359666

Crushing Prevention andCutting Prevention

SMCS 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.

i01372247

Mounting and Dismounting

SMCS 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 any

controls 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.

i00911989

Before Starting Engine

SMCS Code: 1000

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. All protectiveguards and all protective covers must be installedif the engine must be started in order to performservice procedures. To help prevent an accident thatis caused by parts in rotation, work around the partscarefully.

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 prevent

engine damage.

On the initial start-up of a new engine or an enginethat has been serviced, prepare to stop the engineif an overspeed condition occurs. This may beaccomplished by shutting off the fuel supply to theengine and/or shutting off the air supply to the engine.

See the Service Manual for repairs and foradjustments.

i01807173

Engine Starting

SMCS Code: 1000

If a warning tag is attached to the engine start switchor to the controls, do not start the engine or move thecontrols. Also, do not disengage the parking brakes.Consult with the person that attached the warning tagbefore 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 station (cab).Never short across the starting motor terminals orthe batteries. This could bypass the engine neutralstart system and/or the electrical system could bedamaged.

Always start the engine according to the procedurethat is described in the 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.


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14 SEBU7695-13Safety SectionEngine Stopping

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 combustion

that 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.

Ether (If Equipped)

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. If the engine isequipped with an Air Inlet Heater (electrically orfuel ignited manifold heater), DO NOT use ether

(starting fluids) at any time. The use could resultin engine damage and/or personal injury.

Ether is poisonous and flammable. Do not inhaleether, and do not allow ether to contact the skin.Personal injury could result. Do not smoke whileether cylinders are changed. Use ether in wellventilated areas.

Keep ether cylinders out of the reach of unauthorizedpersons. Store ether cylinders in authorized storageareas only. Do not store ether cylinders in directsunlight or at temperatures above 39 C (102 F).

Discard the ether cylinders in a safe place. Do notpuncture the ether cylinders. Do not burn the ethercylinders.

i01462046

Engine Stopping

SMCS 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.

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.

i02463889

Electrical System

SMCS 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 daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. See yourOperation and Maintenance Manual, Starting the

Engine for specifi

c starting instructions.


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Engine Electronics

Grounding Practices


Typical example

Engine ground

( 1) Re co mm en ded co nn ect io ns (2 ) A lte rn ate co nn ec tio ns


Typical example

Frame ground

(1) Recommended connections(2) Alternate connections

Proper grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearing

journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electrical

discharge.

To ensure that the engine and the engine electricalsystems function properly, an engine-to-frame groundstrap with a direct path to the battery must be used.This path may be provided by way of a starting motorground, a starting motor ground to the frame, or adirect engine ground to the frame.

All grounds should be tight and free of corrosion. Theengine alternator must be grounded to the negative- battery terminal with a wire that is adequate tohandle the full charging current of the alternator.

i02784356

Engine Electronics

SMCS 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.


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16 SEBU7695-13Safety SectionEngine Electronics

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

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 Engineswill work in unison with the Engine MonitoringSystem. Together, the two controls will provide theengine monitoring function for the specific engineapplication. Refer to the Troubleshooting Manual formore information.

c11, c13 and c15 on-highway engines-engine safety

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