C-15+Petroleum+Engine-Engine+Safety

8/12/2019 C-15+Petroleum+Engine-Engine+Safety

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SAFETY.CAT.COM

C-10

PETROLEUM ENGINEEngine Safety

Excerpted from Operation & Maintenance Manual (SEBU7894-01-01)

2007 CaterpillarAll Rights Reserved


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i01658146

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.

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 warningsin 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.


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6 SEBU7895-02Safety SectionInstallation Environment

Safety Section

i02520801

Installation Environment

SMCS Code: 1000

This engine is for use as a component in ATEXDirective (94/9/EC) Group II, 3G environments withGas Group IIB, Temperature Class T3 (200 Deg. Cmaximum surface temperature). This environmentalclassification is described as an area that is not likelyto experience an explosive atmosphere. Gases,which couldmake the atmosphere explosive, areconfined in a closed system. The gas can escape withunexpected conditions and abnormal conditions only.This can create an atmosphere that is explosive. Thepotential hazards that are associated with this engine

and used in these environments are noted in thisOperationand Maintenance Manual. The InstallationGuide, LEGW3354 for Petroleum ATEX Engines asa component, and the following publications for thisengine should also be read and understood.

Specifications Manual, SENR9952

Systems Operation/Testing and Adjusting,SENR9953

Troubleshooting Guide, RENR5061

Disassembly and Assembly, RENR8626,

Specifications Manual

i02038308

Safety Messages

SMCS Code: 1000; 7405

There may be several specific warning signs onan engine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiar with all warningsigns.

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 pictures are notvisible. When the warning signs are cleaned, use acloth, water, and soap. Do not use solvent, gasoline,or other harsh chemicals to clean the warning signs.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the warning signs. Thewarning signs that are loosened could drop off ofthe engine.

Replace any damaged warning signs or missingwarning signs. If a warning sign is attached to a partof the engine that is replaced, install a new warningsign on the replacement part. Any Caterpillar dealercan provide new warning signs.

The warning labels that may be found on the engineare illustrated and described below.

Universal Warning

g00418478Illustration 1

The universal warning label is located on each sideof the valve cover base.

g00934493

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.


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SEBU7895-02 7Safety Section

General Hazard Information

i02520038

General Hazard Information

SMCS Code: 1000; 7405

g00104545

Illustration 2

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 ornuts 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 torelieveany 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.

Electrostatic Phenomena

The operator, the installer and other personnel shouldbe aware of excessive polishing or buffing of plasticparts which could result in an energy potential thatcould cause a spark that could possibly ignite anexplosive atmosphere.


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8 SEBU7895-02Safety SectionGeneral Hazard Information

This petroleumengine is for use as a component inATEX Directive (94/9/EC) Group II, 3G environmentswith Gas Group IIB, Temperature Class T3 (200 Deg.C maximum surface temperature). The OEM mustensure that Non Static belts are used. Failure to useNon Static belts could result in an energy potential

that could cause a spark that could possibly ignitean explosive atmosphere.

Pressure Air and Water

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

When pressure air and/or pressure water is used forcleaning, wear protective clothing, protective shoes,and eye protection. Eye protection includes gogglesor a protective face shield.

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

Fluid Penetration


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 can

cause 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 Spillage

Care 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 any compartment is opened orbefore the disassembly of any component containsfluids.

Refer to Special Publication, NENG2500, Tools andShop Products Guide for the following items:

Tools that aresuitable for collecting fluids andequipment that is suitable for collecting fluids

Tools that aresuitable for containing fluids andequipment that is suitable for containing fluids

Obey all localregulations 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.


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Burn Prevention

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 asbestos

particles in the air.

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 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 can

cause 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 personal

injury. 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.

i02038504

Fire Prevention and ExplosionPrevention

SMCS Code: 1000; 7405



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10 SEBU7895-02Safety SectionFire Prevention and Explosion Prevention

All fuels, mostlubricants, 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 property

damage.

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 additional

information about suitable protection devices.

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerialsto 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, ora seal failure. Exhaust shields must beinstalled correctly.

Non Static belts must be used. Failure to use NonStatic belts could result in an energy potential thatcould create a spark which could ignite an explosiveatmosphere.

Excessive polishing or buffing of plastic parts canresult in an energy potential that could create a sparkwhich could ignite an explosive atmosphere.

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.

Wiringmust 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. Secure

connections, 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 andhoses 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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Crushing Prevention and Cutting 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.

Do not connect or disconnect the battery cables in anexplosive atmosphere. This could cause a spark thatcould ignite the explosive atmosphere.

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

Lines, Tubes and Hoses

Do not bend highpressure 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, this

will help to prevent vibration, rubbing against otherparts, and excessive heat.

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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.


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12 SEBU7895-02Safety SectionMounting and Dismounting

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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Mounting and DismountingSMCS 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 anycontrols 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.

i01805780

Before Starting Engine

SMCS 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.

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

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

See the Service Manual for repairs and foradjustments.

i02136012

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 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 in

the exhaust system, refer to the purge procedure inthis Operation and Maintenance Manual, EngineStarting topic in the Operation Section.

Start the engine from the operators 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 Stopping

i01462046

Engine Stopping

SMCS Code: 1000

Stop the engineaccording 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 occurs

during 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.

i02046999

Electrical System

SMCS Code: 1000; 1400

The connection of battery cables to a battery andthe disconnection of battery cables from a batterymay cause an explosion which may result in injuryor death. The connection and the disconnectionof other electrical equipment may also cause anexplosion which may result in injury or death. Theprocedures for the connection and the disconnec-tion of battery cables and other electrical equip-ment should only be performed in a nonexplosiveatmosphere.

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 engineblock or to the frame.

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. Seethe Operation and Maintenance Manual for specificstarting instructions.

Grounding Practices


Typical example

Alternate Grounding Stud To Battery Ground

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 in

damage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.

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

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 direct engineground to the frame.


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14 SEBU7895-02Safety SectionEngine Electronics

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.

i02038528

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.

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 the

ECM 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

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