3406E, C-10, C-12, C-15, and C-16 ON-HIGHWAY ENGINES
Contents
1. 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 protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully Do not bypass the automatic shutoff circuits Do not disable the automatic shutoff circuits The circuits are provided in order to help prevent personal injury The circuits are also provided in order to help prevent engine damage On the initial start up of a new engine or an engine that has been serviced prepare to stop the engine if an overspeed condition occurs This may be accomplished by shutting off the fuel supply to the engine and or shutting off the air supply to the engine See the Service Manual for repairs and for adjustments SEBU7186 08 21 Safety Section Engine Starting 100910470 Engine Starting SMCS Code 1000 If a warning tag is attached to the engine start switch or to the controls do not start the engine or move the controls Also do not disengage the parking brakes Consult with the person that attached the warning tag before the engine is started All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an ac2. If any of the engine parameters extend outside an allowable range the ECM will initiate an immediate action The following actions are available for engine monitoring control WARNING DERATE and SHUTDOWN These engine monitoring modes have the ability to limit engine speed and or the engine power Many of the parameters that are monitored by the ECM can be programmed for the engine monitoring functions The following parameters can be monitored as a part of the Engine Monitoring System e Operating Altitude e Engine Coolant Level e Engine Coolant Temperature e Engine Oil Pressure 26 SEBU7186 08 Safety Section Engine Electronics e Engine Speed e Fuel Temperature e Intake Manifold Air Temperature e System Voltage The Engine Monitoring package can vary for different engine models and different engine applications However the monitoring system and the engine monitoring control will be similar for all engines Note Many of the engine control systems and display modules that are available for Caterpillar Engines will work in unison with the Engine Monitoring System Together the two controls will provide the engine monitoring function for the specific engine application Refer to the Electronic Troubleshooting Manual for more information on the Engine Monitoring System
3. Safety Messages Unit Injectors oo o loo Illustration 1 900467451 The warning label for the electronic unit injector is typically located on the valve cover base Z AIR KAR Wi WARNING L A E au M y ELECTRICAL SHOCK HAZARD UNIT INJECTOR SYSTEM 9 90 120 VOLTS Illustration 2 900467452 Electrical shock hazard The electronic unit injec tor system uses 90 120 volts This engine uses high voltage to the unit injectors Disconnect the unit injector enable circuit connector in order to prevent personal injury Do not come into contact with the unit injector terminals while the engine is operating 10 SEBU7186 08 Safety Section General Hazard Information i00909638 General Hazard Information SMCS Code 1000 7405 Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired These warning tags Special Instruction SEHS7332 are available from your Caterpillar dealer Attach the warning tags to the engine and to each operator control station When it is appropriate disconnect the starting controls Illustration 3 900104545 Do not allow unauthorized personnel on the engine or around the engine when the engine is serviced Tampering with the engine installation or tampering with the truck OEM wiri
4. of all rotating parts and of all moving parts Leave the guards in place until maintenance is performed After the maintenance is performed reinstall the guards Keep objects away from moving fan blades The fan blades will throw objects or cut objects When objects are struck wear protective glasses in order to avoid injury to the eyes Chips or other debris may fly off objects when objects are struck Before objects are struck ensure that no one will be injured by flying debris 101372247 Mounting and Dismounting SMCS Code 1000 7405 Inspect the steps the handholds and the work area before mounting the engine Keep these items clean and keep these items in good repair Mount the engine and dismount the engine only at locations that have steps and or handholds Do not climb on the engine and do not jump off the engine 20 SEBU7186 08 Safety Section Before Starting Engine Face the engine in order to mount the engine or dismount the engine Maintain a three point contact with the steps and handholds Use two feet and one hand or use one foot and two hands Do not use any controls as handholds Do not stand on components which cannot support your weight Use an adequate ladder or use a work platform Secure the climbing equipment so that the equipment will not move Do not carry tools or supplies when you mount the engine or when you dismount the engine Use a hand line to raise and lower tools or supplies 100911989
5. 3406E C 10 C 12 C 15 and C 16 ON HIGHWAY ENGINES Engine Safety Excerpted from Operation amp Maintenance Manual SEBU7186 08 01 2007 Caterpillar CATERPILLAR All Rights Reserved 101658146 Important Safety Information Most accidents that involve product operation maintenance and repair are caused by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs A person must be alert to potential hazards This person should also have the necessary training skills and tools to perform these functions properly Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read 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 warnings are 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 A WARNING The meaning of this safety alert symbol is as follows Attention Become Alert Your Safety is Involved The message that appears under the w
6. ailure to heed this warning can lead to premature failures product damage personal injury or death 8 SEBU7186 08 Safety Section Safety Messages Safety Section 101828962 Safety Messages SMCS Code 1000 7405 There may be several specific warning signs on your engine The exact location and a description of the warning signs are reviewed in this section Please become familiar with all warning signs Ensure that all of the warning signs are legible Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible Use a cloth water and soap to clean the warning signs Do not use solvents gasoline or other harsh chemicals Solvents gasoline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off of the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the replacement part Your Caterpillar dealer can provide new warning signs Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Man ual Failure to follow the instructions or heed the warnings could result in injury or death Contact any Caterpillar dealer for replacement manuals Proper care is your responsibility SEBU7 186 08 9 Safety Section
7. al power source to the negative terminal of the starting motor If the starting motor is not equipped with a negative terminal connect the jump start cable to the engine block SEBU7 186 08 23 Safety Section Electrical System Check the electrical wires daily for wires that are loose or frayed Tighten all loose electrical wires before the engine is started Repair all frayed electrical wires before the engine is started Refer to the Engine Starting section of this Operation and Maintenance Manual for specific starting instructions Grounding Practices s o0 zH s n Li 4 o T o 0 a o EE 8 a E Ed o lo ci Illustration 7 g00771448 Typical example Grounding Stud To Battery Ground 24 SEBU7186 08 Safety Section Electrical System oo 3 A nl O 5 o T o o a 9 HE g g fa A a BS 9 4e o D dej BEP Ie Illustration 8 g00771487 Typical example Alternate Grounding St
8. arning explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on 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 If a tool procedure work method or operating technique that is not specifically recommended by Caterpillar is used you must satisfy yourself that it is safe for you and for others You should also ensure that the product will not be damaged or be made unsafe by the operation lubrication maintenance or repair procedures that you choose The information specifications and illustrations in this publication are on the basis of information that was 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 can affect the service that is given to the product Obtain the complete and most current information before you start any job Caterpillar dealers have the most current information available A WARNING When replacement parts are required for this product Caterpillar rec ommends using Caterpillar replacement parts or parts with equivalent specifications including but not limited to physical dimensions type strength and material F
9. cident that is caused by parts in rotation work around the parts carefully Start the engine from the operator s station cab Never short across the starting motor terminals or the batteries This could bypass the engine neutral start system and or the electrical system could be damaged Always start the engine according to the procedure that is described in the Operation and Maintenance Manual Engine Starting topic Operation Section Knowing the correct procedure will help to prevent major damage to the engine components Knowing the procedure will also help to prevent personal injury To ensure that the jacket water heater if equipped and or the lube oil heater if equipped is working properly check the water temperature gauge and the oil temperature gauge during the heater operation Engine exhaust contains products of combustion that can be harmful to your health Always start the engine and operate the engine in a well ventilated area If the engine is started in an enclosed area vent the engine exhaust to the outside Ether Ether is poisonous and flammable Do not inhale ether and do not allow ether to contact the skin Personal injury could result Do not smoke while ether cylinders are changed Use ether in well ventilated areas 22 SEBU7186 08 Safety Section Engine Stopping Keep ether cylinders out of the reach of unauthorized persons Store ether cylinders in authorized storage areas only Do not store ether
10. cylinders in direct sunlight or at temperatures above 39 C 102 F Discard the ether cylinders in a safe place Do not puncture the ether cylinders Do not burn the ether cylinders 101462046 Engine Stopping SMCS Code 1000 Stop the engine according to the procedure in the Operation and Maintenance Manual Engine Stopping Operation Section in order to avoid overheating of the engine and accelerated wear of the engine components Use the Emergency Stop Button if equipped ONLY in an emergency situation Do not use the Emergency Stop Button for normal engine stopping After an emergency stop DO NOT start the engine until the problem that caused the emergency stop has been corrected Stop the engine if an overspeed condition occurs during the initial start up of a new engine or an engine that has been overhauled This may be accomplished by shutting off the fuel supply to the engine and or shutting off the air supply to the engine To stop an electronically controlled engine cut the power to the engine 102469632 Electrical System SMCS Code 1000 1400 Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating A spark can cause the combustible gases that are produced by some batteries to ignite To help prevent sparks from igniting combustible gases that are produced by some batteries the negative jump start cable should be connected last from the extern
11. er to help prevent sparks Do not attempt any repairs or any adjustments to the engine while the engine is operating e Do not attempt any repairs that are not understood Use the proper tools Replace any equipment that is damaged or repair the equipment For initial start up of a new engine or for starting an engine that has been serviced make provisions to stop the engine if an overspeed occurs This may be accomplished by shutting off the fuel supply and or the air supply to the engine 12 SEBU7186 08 Safety Section General Hazard Information Start the engine from the operator s station cab Never short across the starting motor terminals or the batteries This could bypass the engine neutral start system and or the electrical system could be damaged Pressure Air and Water Pressurized air and or water can cause debris and or hot water to be blown out This could result in personal injury When pressure air is used for cleaning wear a protective face shield protective clothing and protective shoes The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Always wear eye protection for cleaning the cooling system Fluid Penetration Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death This includes leaks
12. n cause a fire Fire may cause personal injury and property damage A flash fire may result if the covers for the engine crankcase are removed within fifteen minutes after an emergency shutdown Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system These gases could cause the engine to overspeed Personal injury property damage or engine damage could result If the application involves the presence of combustible gases consult your Caterpillar dealer for additional information about suitable protection devices Remove all flammable materials such as fuel oil and debris from the engine Do not allow any flammable materials to accumulate on the engine SEBU7186 08 15 Safety Section Fire Prevention and Explosion Prevention Store fuels and lubricants in properly marked containers away from unauthorized persons Store oily rags and any flammable materials in protective containers Do not smoke in areas that are used for storing flammable materials Do not expose the engine to any flame Exhaust shields if equipped protect hot exhaust components from oil or fuel spray in case of a line a tube or a seal failure Exhaust shields must be installed correctly Do not weld on lines or tanks that contain flammable fluids Do not flame cut lines or tanks that contain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prio
13. ng installation can be dangerous Personal injury death and or engine damage could result Vent the engine exhaust to the outside when the engine is operated in an enclosed area If the engine is not running do not release the secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained Wear a hard hat protective glasses and other protective equipment as required SEBU7186 08 11 Safety Section General Hazard Information e When work is performed around an engine that is operating wear protective devices for ears in order to help prevent damage to hearing Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine Ensure that all protective guards and all covers are secured in place on the engine e Never put maintenance fluids into glass containers Glass containers can break Use all cleaning solutions with care e Report all necessary repairs Unless other instructions are provided perform the maintenance under the following conditions e The engine is stopped e The protective locks or the controls are in the applied position e Engage the secondary brakes or parking brakes e Block the vehicle or restrain the vehicle before maintenance or repairs are performed Disconnect the batteries when maintenance is performed or when the electrical system is serviced Disconnect the battery ground leads Tape the leads in ord
14. ode Keep any open flames or sparks away from the top of a battery Do not smoke in battery charging areas Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Improper jumper cable connections can cause an explosion that can result in injury Refer to the Operation Section of this manual for specific instructions Do not charge a frozen battery This may cause an explosion The batteries must be kept clean The covers if equipped must be kept on the cells Use the recommended cables connections and battery box covers 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 fire extinguisher regularly Obey the recommendations on the instruction plate 18 SEBU7186 08 Safety Section Fire Prevention and Explosion Prevention Ether Ether is flammable and poisonous Use ether in well ventilated areas Do not smoke while you are replacing an ether cylinder or while you are using an ether spray Do not store ether cylinders in living areas or in the engine compartment Do not store ether cylinders in direct sunlight or in temperatures above 49 C 120 F Keep ether cylinders away from open flames or sparks Dispose of used ether cylinders properly Do not puncture an ether cylinder Keep ether cylinders away from unautho
15. r and all lines to the heaters or to the engine contain hot coolant Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained Check the coolant level after the engine has stopped and the engine has been allowed to cool Ensure that the filler cap is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly in order to relieve pressure 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 the eyes Always wear protective glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended 14 SEBU7186 08 Safety Section Fire Prevention and Explosion Prevention 101372254 Fire Prevention and Explosion Prevention SMCS Code 1000 7405 I Illustration 4 900704000 All fuels most lubricants and some coolant mixtures are flammable Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components ca
16. r to welding or flame cutting Wiring must be kept in good condition All electrical wires must be properly routed and securely attached Check all electrical wires daily Repair any wires that are loose or frayed before you operate the engine Clean all electrical connections and tighten all electrical connections Eliminate all wiring that is unattached or unnecessary Do not use any wires or cables that are smaller than the recommended gauge Do not bypass any fuses and or circuit breakers Arcing or sparking could cause a fire Secure connections recommended wiring and properly maintained battery cables will help to prevent arcing or sparking Inspect all lines and hoses for wear or for deterioration The hoses must be properly routed The lines and hoses must have adequate support and secure clamps Tighten all connections to the recommended torque Leaks can cause fires Oil filters and fuel filters must be properly installed The filter housings must be tightened to the proper torque 16 SEBU7186 08 Safety Section Fire Prevention and Explosion Prevention Illustration 5 g00704059 Use caution when you are refueling an engine Do not smoke while you are refueling an engine Do not refuel an engine near open flames or sparks Always stop the engine before refueling SEBU7 186 08 17 Safety Section Fire Prevention and Explosion Prevention OQO Illustration 6 g00704135 Gases from a battery can expl
17. rized personnel Do not spray ether into an engine if the engine is equipped with a thermal starting aid for cold weather starting Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged Repair any lines that are loose or damaged Leaks can cause fires Consult your Caterpillar dealer for repair or for replacement parts Check lines tubes and hoses carefully Do not use your bare hand to check for leaks Use a board or cardboard to check for leaks Tighten all connections to the recommended torque Replace the parts if any of the following conditions are present e End fittings are damaged or leaking e Outer coverings are chafed or cut e Wires are exposed Outer coverings are ballooning Flexible part of the hoses are kinked e Outer covers have embedded armoring End fittings are displaced SEBU7186 08 19 Safety Section Crushing Prevention and Cutting Prevention Make sure that all clamps guards and heat shields are installed correctly During engine operation this will help to prevent vibration rubbing against other parts and excessive heat 101359666 Crushing Prevention and Cutting Prevention SMCS Code 1000 7405 Support the component properly when work beneath the component is performed Unless other maintenance instructions are provided never attempt adjustments while the engine is running Stay clear
18. that are the size of a pin hole If fluid is injected into the skin seek treatment immediately Seek treatment from a doctor that is familiar with this type of injury Fluid Spillage Care must be used in order to ensure that the fluids are contained during the inspection the maintenance the testing the adjusting and the repair of the engine Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is disassembled Refer to the Special Publication NENG2500 This publication explains the items that are needed for collecting and for containing fluids that are used in Caterpillar engines Dispose of fluids according to local regulations Asbestos Information Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free Caterpillar recommends the use of only genuine Caterpillar replacement parts SEBU7186 08 13 Safety Section Burn Prevention 101480768 Burn Prevention SMCS Code 1000 7405 Do not touch any part of an operating engine Allow the engine to cool before any maintenance is performed on the engine Relieve all pressure in the air system in the hydraulic system in the lubrication system in the fuel system or in the cooling system before any lines fittings or related items are disconnected Coolant When the engine is at operating temperature the engine coolant is hot The coolant is also under pressure The radiato
19. ud To Battery Ground Proper grounding for the engine electrical system is necessary for optimum engine performance and reliability Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths Uncontrolled electrical circuit paths can result in damage to main bearings to crankshaft bearing journal surfaces and to aluminum components Engines that are installed without engine to frame ground straps can be damaged by electrical discharge SEBU7 186 08 25 Safety Section Engine Electronics To ensure that the engine and the engine electrical systems function properly an engine to frame ground strap with a direct path to the battery must be used This path may be provided by way of a starting motor ground a starting motor ground to the frame or a direct engine ground to the frame All grounds should be tight and free of corrosion The engine alternator must be grounded to the negative battery terminal with a wire that is adequate to handle the full charging current of the alternator 101563743 Engine Electronics SMCS Code 1000 1400 1900 Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and or engine damage This engine has a comprehensive programmable Engine Monitoring System The Engine Control Module ECM has the ability to monitor the engine operating conditions
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