Safety: Operation and Maintenance Manual Excerpt
Safety: Operation and Maintenance Manual Excerpt
Safety: Operation and Maintenance Manual Excerpt
® ®
© 2010 Caterpillar
All Rights Reserved
SEBU7828-10
August 2010
Operation and
Maintenance
Manual
3406C Generator Set
ZKC1-Up (Generator Set)
C2G1-Up (Generator Set)
C5G1-Up (Generator Set)
C8G1-Up (Generator Set)
NKM1-Up (Generator Set)
C2Y1-Up (Generator Set)
SAFETY.CAT.COM
6 SEBU7828-10
Safety Section
Safety Messages
Safety Section
i01914689
Safety Messages
SMCS Code: 1000; 7405
g00997405
Illustration 1
8 SEBU7828-10
Safety Section
Safety Messages
g01024480
Illustration 2
SEBU7828-10 9
Safety Section
Safety Messages
g01024694
Illustration 3
10 SEBU7828-10
Safety Section
Safety Messages
g01024708
Illustration 4
g01023637
g01023635
g01023710
g01018792
g00920549
Hot Coolant Under Pressure (9) Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
This safety message is located near the top of the serviced.
radiator on the front.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
• Filler caps
• Grease fittings
g00702020
Illustration 6
• For initial start-up of a new engine or for starting an Always use a board or cardboard when you check
engine that has been serviced, make provisions to for a leak. Leaking fluid that is under pressure can
stop the engine if an overspeed occurs. This may penetrate body tissue. Fluid penetration can cause
be accomplished by shutting off the fuel supply serious injury and possible death. A pin hole leak can
and/or the air supply to the engine. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
• Start the engine with the operator controls. Never from a doctor that is familiar with this type of injury.
short across the starting motor terminals or the
batteries. This could bypass the engine neutral Containing Fluid Spillage
start system and/or the electrical system could be
damaged.
NOTICE
Care must be taken to ensure that fluids are contained
Pressurized Air and Water during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Pressurized air and/or water can cause debris collect the fluid with suitable containers before open-
and/or hot water to be blown out. This could result in ing any compartment or disassembling any compo-
personal injury. nent containing fluids.
When pressurized air and/or pressurized water is Refer to Special Publication, NENG2500, “Caterpillar
used for cleaning, wear protective clothing, protective Dealer Service Tool Catalog” or refer to Special Pub-
shoes, and eye protection. Eye protection includes lication, PECJ0003, “Caterpillar Shop Supplies and
goggles or a protective face shield. Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi) when the air nozzle Dispose of all fluids according to local regulations and
is deadheaded. The maximum water pressure for mandates.
cleaning purposes must be below 275 kPa (40 psi).
SEBU7828-10 15
Safety Section
General Hazard Information
Caterpillar equipment and replacement parts that are Repair any fuel lines, oil lines, tubes, or hoses that
shipped from Caterpillar are asbestos free. Caterpillar are loose or damaged. Leaks can cause fires.
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines Inspect all lines, tubes and hoses carefully. Do
when you handle any replacement parts that contain not use bare hands to check for leaks. Always
asbestos or when you handle asbestos debris. use a board or cardboard for checking engine
components for leaks. Tighten all connections to the
Use caution. Avoid inhaling dust that might be recommended torque.
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous Check for the following conditions:
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining • End fittings that are damaged or leaking
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually • Outer covering that is chafed or cut
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that • Wire that is exposed in reinforced hose
contains asbestos is generated.
• Outer covering that is ballooning locally
If dust that may contain asbestos is present, there
are several guidelines that should be followed: • Flexible part of the hose that is kinked or crushed
• Never use compressed air for cleaning. • Armoring that is embedded in the outer covering
• Avoid brushing materials that contain asbestos. Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. This will help to
• Avoid grinding materials that contain asbestos. prevent these effects: vibration, rubbing against other
parts, and excessive heat during operation.
• Use a wet method in order to clean up asbestos
materials.
Dispose of Waste Properly Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
Illustration 9
g00706404 the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
Improperly disposing of waste can threaten the and connectors. Use of gloves is recommended.
environment. Potentially harmful fluids should be
disposed of according to local regulations.
i03649377
Always use leakproof containers when you drain Fire Prevention and Explosion
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water. Prevention
SMCS Code: 1000; 7405
i01480768
Burn Prevention
SMCS Code: 1000; 7405
Coolant g00704000
Illustration 10
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under Use of personal protection equipment (PPE) may be
pressure. The radiator and all lines to the heaters or needed.
to the engine contain hot coolant.
All fuels, most lubricants, and some coolant mixtures
Any contact with hot coolant or with steam can cause are flammable.
severe burns. Allow cooling system components to
cool before the cooling system is drained. Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate
Check the coolant level after the engine has stopped a product when a fire hazard exists. Contact your
and the engine has been allowed to cool. Caterpillar dealer for service.
Ensure that the filler cap is cool before removing the Flammable fluids that are leaking or spilled onto hot
filler cap. The filler cap must be cool enough to touch surfaces or onto electrical components can cause
with a bare hand. Remove the filler cap slowly in a fire. Fire may cause personal injury and property
order to relieve pressure. damage.
SEBU7828-10 17
Safety Section
Fire Prevention and Explosion Prevention
A flash fire may result if the covers for the engine Inspect all lines and hoses for wear or for
crankcase are removed within fifteen minutes after deterioration. The hoses must be properly routed.
an emergency shutdown. The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
Determine whether the engine will be operated in an recommended torque. Leaks can cause fires.
environment that allows combustible gases to be
drawn into the air inlet system. These gases could Oil filters and fuel filters must be properly installed.
cause the engine to overspeed. Personal injury, The filter housings must be tightened to the proper
property damage, or engine damage could result. torque.
Gases from a battery can explode. Keep any open Check lines, tubes and hoses carefully. Do not use
flames or sparks away from the top of a battery. Do your bare hand to check for leaks. Use a board or
not smoke in battery charging areas. cardboard to check for leaks. Tighten all connections
to the recommended torque.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or Replace the parts if any of the following conditions
a hydrometer. are present:
Improper jumper cable connections can cause • End fittings are damaged or leaking.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific • Outer coverings are chafed or cut.
instructions.
• Wires are exposed.
Do not charge a frozen battery. This may cause an
explosion. • Outer coverings are ballooning.
The batteries must be kept clean. The covers • Flexible part of the hoses are kinked.
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box • Outer covers have embedded armoring.
covers when the engine is operated.
• End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher. will help to prevent vibration, rubbing against other
parts, and excessive heat.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate. i01359666
Do not store ether cylinders in living areas or in the Unless other maintenance instructions are provided,
engine compartment. Do not store ether cylinders never attempt adjustments while the engine is
in direct sunlight or in temperatures above 49 °C running.
(120 °F). Keep ether cylinders away from open
flames or sparks. Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
Dispose of used ether cylinders properly. Do not is performed. After the maintenance is performed,
puncture an ether cylinder. Keep ether cylinders reinstall the guards.
away from unauthorized personnel.
Keep objects away from moving fan blades. The fan
Do not spray ether into an engine if the engine is blades will throw objects or cut objects.
equipped with a thermal starting aid for cold weather
starting. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Lines, Tubes and Hoses Chips or other debris may fly off objects when objects
Do not bend high pressure lines. Do not strike high are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
pressure lines. Do not install any lines that are bent
or damaged.
i03877943 i03560601
Do not start the engine or move any of the controls Engine exhaust contains products of combustion
if there is a “DO NOT OPERATE” warning tag or that can be harmful to your health. Always start the
similar warning tag attached to the start switch or to engine and operate the engine in a well ventilated
the controls. area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the Ether
area is free of personnel.
Ether is poisonous and flammable.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
Do not inhale ether, and do not allow ether to contact
lights work properly, if equipped.
the skin. Personal injury could result.
All protective guards and all protective covers must
Do not smoke while ether cylinders are changed.
be installed if the engine must be started in order
to perform service procedures. To help prevent an Use ether in well ventilated areas.
accident that is caused by parts in rotation, work
around the parts carefully.
Use ether with care in order to avoid fires.
Do not bypass the automatic shutoff circuits. Do not
Keep ether cylinders out of the reach of unauthorized
disable the automatic shutoff circuits. The circuits are
persons.
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
Store ether cylinders in authorized storage areas
engine damage.
only.
See the Service Manual for repairs and for
Do not store ether cylinders in direct sunlight or at
adjustments.
temperatures above 49 °C (120 °F).
i01054945 i01226491
Grounding Practices
Proper grounding for the engine electrical system
is necessary for proper engine performance
g00104545
and reliability. Improper grounding will result in Illustration 13
uncontrolled electrical circuit paths and unreliable
electrical circuit paths. 2. Attach a “DO NOT OPERATE” or similar warning
tag to the engine prime mover starting circuit.
Uncontrolled engine electrical circuit paths can Disconnect the engine starting circuit.
result in damage to the following components: main
bearings, crankshaft bearing journal surfaces, and 3. Disconnect the generator from the distribution
aluminum components. All grounds should be tight system.
and free of corrosion.
4. Lock out the circuit breaker. Attach a “DO NOT
The alternator and the starting motor must be OPERATE” or similar warning tag to the circuit
grounded to the negative “-” battery terminal. breaker. Refer to the electrical diagram. Verify that
all points of possible reverse power flow have
For engines that have an alternator that is grounded been locked out.
to an engine component, a ground strap must be
used. The ground strap must be connected to the 5. Remove the fuses for the transformers for the
component and to the negative “-” battery terminal. following circuitry:
The component must be electrically isolated from
the engine. • power
A ground plate with a direct path to the negative • sensing
battery terminal “-” can be used as a common ground
point for the components of one engine system. • control
The wire size that is used for the ground plate must 6. Attach a “DO NOT OPERATE” or similar warning
be large enough to handle the full charging current of tag to the generator excitation controls.
the alternator.
7. Remove the cover of the generator's terminal box.