cat sebu7656-02 s

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SAFETYOperation and Maintenance Manual Excerpt

SEBU7656-02December 2005

Operation andMaintenanceManualC1.5 and C2.2 Marine Generator SetsTAF1-Up (Generator)TAG1-Up (Generator Set)JAW1-Up (Generator Set)

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Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

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

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

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

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

6 SEBU7656-02Safety SectionSafety Messages

Safety Sectioni02006579

Safety MessagesSMCS Code: 1000; 7405

g00947421Illustration 1

Typical example

C2.2 is shown.Safety messages on the enclosure

SEBU7656-02 7Safety Section

Safety Messages

g00949565Illustration 2Typical exampleC2.2 is shown.



Typical exampleC2.2 is shown.


Safety Messages


Typical exampleC2.2 is shown.


Control panel

There may be several specific safety messageson an engine. The exact location of the hazardsand the description of the hazards are reviewed inthis section. Please become familiar with all safetymessages.

Ensure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if the words cannot be read or if thepictures are not visible. When the safety messagesare cleaned, use a cloth, water, and soap. Do not usesolvent, gasoline, or other harsh chemicals to cleanthe safety messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that securesthe safety messages. The safety messages that areloosened could drop off of the engine.

Replace any damaged safety messages or missingsafety messages. If a safety message is attached toa part that is replaced, install a new safety messageon the replacement part. Any Caterpillar dealer canprovide new safety messages.


Do Not Operate Before Reading theManual (1)This message is located on the enclosure by thecontrol panel.

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Do not operate or work on this engine unless youhave read and understand the instructions andwarnings in the Operation and Maintenance Man-ual. Failure to follow the instructions or heed thewarnings could result in injury or death. Contactany Caterpillar dealer for replacement manuals.Proper care is your responsibility.

Automatic Starting (2)This message is located on the enclosure on thelarge panel.

g00950254

Generator on Standby! When the generator is onstandby, the engine can start automatically at anytime. Stay clear of the engine when the generatoris on standby to prevent personal injury or death.

Improper Lifting (3)This message is located on top of the enclosure.

g00950274

Crushing Hazard! Improper lifting could cause se-rious injury or death. Follow the lifting instruc-tions in the Operation andMaintenanceManual forsafe lifting procedures.


Safety Messages

Fire (4)This safety message is positioned on the side of theenclosure.

g00950811

Fire Hazard! Stop the Engine. Do not open theservice doors if a fire exists. Opening the servicedoors if a fire exists could result in personal injuryor death. Read and understand the instructions inthe Operation and Maintenance Manual.

Refer to Operation and Maintenance Manual, “FirePrevention and Explosion Prevention” for moreinformation.

Ether (5)This safety message is positioned on the intake forthe air cleaner.

g00931562

Do not use ether. This machine is equipped withglow plugs. Using ether can create explosions orfires that can cause personal injury or death. Readand follow the engine starting procedure in theOperation and Maintenance Manual.

Refer to Operation and Maintenance Manual, “FirePrevention and Explosion Prevention” for moreinformation.

12 SEBU7656-02Safety SectionAdditional Messages

Electrocution (6)This safety message is positioned on both sides ofthe generator.

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

Engine Coolant (7)This safety message is positioned on top of theenclosure and on the water cooled exhaust manifold.

g00931247

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

Refer to Operation and Maintenance Manual,“Cooling System Coolant (ELC) - Change” for thecorrect procedure to remove the pressure cap.

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Additional MessagesSMCS Code: 1000; 7405

There are several specific messages on thismachine. The exact location of the messages andthe description of the messages are reviewed inthis section. Please become familiarized with allmessages.

Make sure that all of the messages are legible.Clean the messages or replace the messages ifyou cannot read the words. Replace the illustrationsif the illustrations are not legible. When you cleanthe messages, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures themessages. Loose adhesive will allow the messagesto fall.


General Hazard Information

Replace any message that is damaged, or missing.If a message is attached to a part that is replaced,install a message on the replacement part. AnyCaterpillar dealer can provide new messages.

g00955623Illustration 6Typical example

C2.2 is shown.

Port for Fire Extinguisher (1)

This message is located on the side of the enclosure.


In case of fire, break through the hole with the spraynozzle of the fire extinguisher.

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General Hazard InformationSMCS Code: 1000; 7405


14 SEBU7656-02Safety SectionGeneral Hazard Information

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

Do not allow unauthorized personnel on the engine,or around the engine when the engine is beingserviced.

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

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being 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 twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in order torelieve any spring pressure or other pressure.


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

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

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

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

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

• Use all cleaning solutions with care.

• Report all necessary repairs.

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

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

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

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

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

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

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

Fluid Penetration



General Hazard Information

Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids.

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

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

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

Obey all local regulations for the disposal of liquids.

Asbestos Information


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

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

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

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

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

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

• Use exhaust ventilation on permanent machiningjobs.

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

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

• Obey environmental regulations for the disposalof asbestos.

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

16 SEBU7656-02Safety SectionBurn Prevention

Dispose of Waste Properly


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

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

i01480768

Burn PreventionSMCS Code: 1000; 7405

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

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

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

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

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

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

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

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

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Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405


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

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

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.


Fire Prevention and Explosion Prevention

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 or flame 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 properlymaintained battery cables will help to prevent arcingor sparking.

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

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


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.


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.

18 SEBU7656-02Safety SectionCrushing Prevention and Cutting Prevention

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

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

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

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

Ether

Do not use ether. This machine is equipped withglow plugs. Using ether can create explosions orfires that can cause personal injury or death. Readand follow the engine starting procedure in theOperation and Maintenance Manual.

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

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

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

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

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

i01359666

Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when work beneaththe component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. The fanblades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

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Before Starting EngineSMCS Code: 1000

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

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

Inspect the engine for potential hazards.

SEBU7656-02 19Safety SectionEngine Starting

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

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

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

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

See the Service Manual for repairs and foradjustments.

i02136012

Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

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

If there is a possibility that unburned gas remains inthe exhaust system, refer to the purge procedure inthis Operation and Maintenance Manual, “EngineStarting” topic in the Operation Section.

Start the engine from the operator’s compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, “Engine Starting” topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingproperly, check the water temperature and the oiltemperature during heater operation.

Engine exhaust contains products of combustionwhich 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.

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Engine StoppingSMCS Code: 1000

To avoid overheating of the engine and acceleratedwear of the engine components, stop the engineaccording to this Operation and Maintenance Manual,“Engine Stopping” topic (Operation Section).

Use the Emergency Stop Button (if equipped)ONLY in an emergency situation. DO NOT use theEmergency Stop Button for normal engine stopping.After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.

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

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Electrical SystemSMCS Code: 1000; 1400

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

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

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is operated. Repair all frayedelectrical wires before the engine is started. Seethe Operation and Maintenance Manual for specificstarting instructions.

20 SEBU7656-02Safety SectionGenerator Isolating for Maintenance

Grounding PracticesThe electrical system for the vessel and the enginemust be properly grounded. Proper groundingis 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 bearingjournal surfaces, and to aluminum components.Uncontrolled electrical circuit paths can also causeelectrical noise. Electrical noise may degrade theperformance of the vessel and of the radio.

The alternator, the starting motor, and all of theelectrical systems MUST be grounded to the negativebattery terminal. The alternator must meet marineisolation requirements. The starting motor must alsomeet marine isolation requirements.

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

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

Refer to the Installation Guide for additionalinformation on grounding procedures.

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Generator Isolating forMaintenanceSMCS Code: 4450

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

1. Stop the engine.


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

3. Disconnect the generator from the distributionsystem.

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

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

• power

• sensing

• control

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

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

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

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

cat sebu7656-02 s

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