XQ230 and XQ300 Rental Generator Sets - Safety
Contents
1.2. g01120247 WARNING Shock Electrocution Hazard Read and understand the instructions and warnings in the Operation and Maintenance Manual Failure to fol low the instructions or heed the warnings could cause serious injury or death SEBU7911 02 13 Safety Section Safety Messages Jumper Cables 8 This safety message is located above the batteries in the battery compartment WARNING g01067366 Explosion Hazard Improper jumper cable connec tions can cause an explosion resulting in serious injury or death Batteries may be located in sep arate compartments When using jump start ca bles always connect the positive cable from the source to the positive terminal of the bat tery that is connected to the starter solenoid Con nect the negative cable from the source to the negative terminal of the starter If the machine is not equipped with a starter negative terminal connect the negative cable to the engine block Follow the procedure in the
3. TON A DANGER j Ba 8 re een ey Siaj Illustration 5 g01193865 Rear view of the enclosure A WARNING E y g01193964 Illustration 6 Front view of the enclosure 10 Safety Section Safety Messages SEBU7911 02 l Se Illustration 7 Top view of the generator set Hot Surface 1 This safety message for hot surfaces is located on the sides of the enclosure pa A WARNING g00943659 Hot parts or hot components can cause burns or personal injury Do not allow hot parts or compo nents to contact your skin Use protective clothing or protective equipment to protect your skin g01194068 Lifting the Generator Set 2 This safety message for lifting the generator set is located on the sides of the enclosure 225 3232 g00928085 Crushing Hazard Improper lifting could cause se
4. Illustration 9 g01200744 Left side view of the generator set with the doors open 16 Safety Section Additional Messages SEBU7911 02 N O 1 RESTIS Illustration 10 Rear view of the generator set Engine coolant drain 1 This message is located on the side of the generator set toward the bottom of the generator set Vv Illustration 11 g01151053 This is the location of the engine coolant drain Refer to this Operation and Maintenance Manual Cooling System Coolant ELC Change g01200914 Personal injury can result from 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 Engine oil drain 2 This message is located on the side of the generator set toward the bottom of the generator set Illustration 12 g01151083 SEBU7911 02 17 Safety Section Additional Messages This is the location of the engine oil drain Refer to this Operation and Maintenance Manual Engine Oil and Filter Change Hot oil and components can cause personal in jury Do not all
5. 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 101377941 Mounting and Dismounting SMCS Code 1000 7405 Generator sets in permanent installations may require the use of a ladder or a work platform in order to provide access for normal maintenance The owner and or the user is responsible for providing safe access that conforms to SAE J185 and or local building codes Inspect the steps the handholds and the work area before mounting the generator set Keep these items clean and keep these items in good repair Mount the generator set and dismount the generator set only at locations that have steps and or handholds Do not climb on the generator set and do not jump off the generator set Face the generator set in order to mount the generator set or dismount the generator set 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 jump from an elevated platform Do not jump from a ladder or stairs 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
6. Operation and Main tenance Manual Chock Wheels 9 This safety message is located on the tongue of the trailer P A WARNING A g01194172 Do not uncouple the trailer from the towing vehicle until the wheels are securely blocked or chocked Failure to do so could result in injury 14 Safety Section Additional Messages SEBU7911 02 Towing the Trailer 10 The safety message for towing the trailer is located on the tongue of the trailer 16 550 LBS 8000 Kg 13 690 LBS 6210 Kg F 2 300 LBS 1043 kg R 1 900 LBS 862 Kg RA LH 278 1101 g01194185 Failure to utilize an appropriate and properly sized tow vehicle with a level horizontal hitch connec tion could lead to excessive towing sway resulting in personal injury or death For trailer with adjustable hitch inspect the torque on the hitch bolts Required torque is 370 50 N m 273 37 Ib ft The capacities of the tow vehicle are given for towing the generator set with a full fuel tank and the capacities are given for towing the generator set with an empty fuel tank For towing the generator set with a full fuel tank the tow vehicle must be rated for towing a trailer of at least 8000 kg 16 550 Ib For towing the generator set with an empty fuel tank the tow vehicle must be rated for towing a trailer of at least 6210 kg 13 690 Ib For towing the generator set with a full fuel tank the rating
7. bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged SEBU7911 02 23 Safety Section Crushing Prevention and Cutting Prevention 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 e Outer coverings are ballooning Flexible part of the hoses are kinked e Outer covers have embedded armoring e End fittings are displaced 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 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
8. for the tongue weight of the hitch of the tow vehicle must be at least 1043 kg 2 300 Ib For towing the generator set with an empty fuel tank the rating for the tongue weight of the hitch of the tow vehicle must be at least 862 kg 1 900 Ib 102402356 Additional Messages SMCS Code 1000 7405 There are several specific messages on these machines The exact location of the messages and the description of the messages are reviewed in this section Please become familiarized with all messages Make sure that all of the messages are legible Clean the messages or replace the messages if the words or images are unreadable When you clean the messages use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the messages Solvents gasoline or harsh chemicals could loosen the adhesive that secures the messages Loose adhesive will allow the messages to fall 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 Any Caterpillar dealer can provide new messages SEBU7911 02 15 Safety Section Additional Messages Illustration 8 g01200854 Right side view of the generator set
9. 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 101372262 Fire Prevention and Explosion Prevention SMCS Code 1000 7405 I Illustration 24 g00704000 All fuels most lubricants and some coolant mixtures are flammable Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire Fire may cause personal injury and property damage 22 Safety Section Fire Prevention and Explosion Prevention SEBU7911 02 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 a
10. rious injury or death Follow the lifting instruc tions in the Operation and Maintenance Manual for safe lifting procedures SEBU7911 02 11 Safety Section Safety Messages Automatic Starting 3 This safety message is located on the side of the enclosure on enclosed generator sets This safety message is located on the side of the generator on open generator sets This safety message is also located on the enclosure for the breakers on open generator sets and enclosed generator sets A WARNING AUTO g01154070 When the engine is in the AUTOMATIC mode the engine can start at any moment To avoid personal injury always remain clear of the the engine when the engine is in the AUTOMATIC mode Electrocution 4 This safety message is located on the top of the generator This safety message is also located on the enclosure for the control panel and the load panel A DANGER 229 5047 Xo A g00928349 DANGER DANGER Shock Electrocution Hazard Do not op erate this equipment or work on this equipment unless you have read and understand the instruc tions and warnings in the Operation and Mainte nance Manual Failure to follow the instructions or heed the warnings will result in serious injury or death Do not connect generator to a utility electrical dis tribution system unless it is isolated from the sys tem Electrical feedback into the distribution sys tem can occur and cou
11. the equipment will not move Do not carry tools or supplies when you mount the generator set or when you dismount the generator set Use a hand line to raise and lower tools or supplies 102404480 Before Starting Engine SMCS Code 1000 NOTICE For initial start up of a new or rebuilt engine and for start up of an engine that has been serviced make provision to shut the engine off should an overspeed occur This may be accomplished by shutting off the air and or fuel supply to the engine Overspeed shutdown should occur automatically If automatic shutdown does not occur press the emergency stop button in order to cut the fuel and or air to the engine Inspect the engine for potential hazards 24 Safety Section Engine Starting SEBU7911 02 Before starting the engine ensure that no one is on underneath or close to the engine Ensure that the area is free of personnel If equipped ensure that the lighting system for the engine is suitable for the conditions Ensure that all lights work properly if equipped Ensure that the exhaust system is properly clamped Ensure that the connections are tight Check for leaks Check the condition of all connections and components of the exhaust system 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 t
12. SAFETY Operation and Maintenance Manual Excerpt 2010 Caterpillar All Rights Reserved CATERPILLAR CATERPILLAR apt 2008 Operation and Maintenance Manual XQ230 and XQ300 Rental Generator Sets X3R1 Up Generator Set 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 The meaning of this safety alert symbol is as follows Attention Become Alert Your Safe
13. 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 OO Illustration 25 g00704135 Gases from a battery can explode 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 Lines Tubes and Hoses Do not
14. al dimensions type strength and material Failure to heed this warning can lead to prema ture failures product damage personal injury or death 6 Safety Section Safety Messages SEBU7911 02 Safety Section 102386525 Safety Messages SMCS Code 1000 7405 There may be several specific safety messages on your generator set package The exact location and a description of the safety messages are reviewed in this section Please become familiar with all safety messages Ensure that all of the safety messages are legible Clean the safety messages or replace the safety messages if the words cannot be read or if the illustrations are not visible Use a cloth water and soap to clean the safety messages Do not use solvents gasoline or other harsh chemicals Solvents gasoline or harsh chemicals could loosen the adhesive that secures the safety messages The safety messages that are loosened could drop off of the generator set package Replace any safety message that is damaged or missing If a safety message is attached to a part of the generator set package that is replaced install a new safety message on the replacement part Your Caterpillar dealer can provide new safety messages 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 deat
15. an up asbestos materials A vacuum cleaner that is equipped with a high efficiency particulate air filter HEPA can also be used Use exhaust ventilation on permanent machining jobs Wear an approved respirator if there is no other way to control the dust Comply with applicable rules and regulations for the work place In the United States use Occupational Safety and Health Administration OSHA requirements These OSHA requirements can be found in 29 CFR 1910 1001 Obey environmental regulations for the disposal of asbestos Stay away from areas that might have asbestos particles in the air Lines Tubes and Hoses Do not bend or strike high pressure lines Do not install lines tubes or hoses that are damaged Repair any fuel lines oil lines tubes or hoses that are loose or damaged Leaks can cause fires SEBU7911 02 21 Safety Section Burn Prevention Inspect all lines tubes and hoses carefully Do not use bare hands to check for leaks Always use a board or cardboard for checking engine components for leaks Tighten all connections to the recommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Wire that is exposed in reinforced hose e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering Ensure that all of the
16. ar a hard hat protective glasses and other protective equipment as required Do not attempt any repairs that are not understood Use the proper tools Replace any equipment that is damaged or repair the equipment 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 Never put maintenance fluids into glass containers Glass containers can break Use all cleaning solutions with care Report all necessary repairs Unless other instructions are provided perform the maintenance under the following conditions The engine is stopped Ensure that the engine cannot be started The protective locks or the controls are in the applied position Disconnect the batteries when maintenance is performed or when the electrical system is serviced Disconnect the battery ground leads Tape the leads in order to help prevent sparks 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 Start the engine with the operator controls Never short across the starting motor terminals or the batterie
17. clamps the guards and the heat shields are installed correctly This will help to prevent these effects vibration rubbing against other parts and excessive heat during operation Dispose of Waste Properly Improperly disposing of waste can threaten the environment Potentially harmful fluids should be disposed of according to local regulations Always use leakproof containers when you drain fluids Do not pour waste onto the ground down a drain or into any source of water 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 radiator 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
18. erature 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 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 102353436 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
19. from igniting combustible gases that are produced by some batteries the negative jump start cable should be connected last from the external 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 SEBU7911 02 25 Safety Section Electrical System Check the electrical wires for wires that are loose or frayed Tighten all loose electrical wires before the engine is operated Repair all frayed electrical wires before the engine is started See the Operation and Maintenance Manual Engine Starting for specific starting instructions Grounding Practices The electrical system for the engine must be properly grounded Proper grounding 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 Uncontrolled electrical circuit paths can also cause electrical noise The alternator the starting motor and all of the electrical systems MUST be grounded to the negative battery terminal For engines which have an alternator that is grounded to an engine component a ground strap MUST connect that component to the negative batte
20. h Contact any Caterpillar dealer for replacement manuals Proper care is your responsibility The warning labels that may be found on the generator set package are illustrated and described SEBU7911 02 7 Safety Section Safety Messages WARNING A WARNING 3 Illustration 1 g01190681 Side view of the enclosure for the generator set A A g01199904 Illustration 2 View of the electrical bulkhead that is located inside of the enclosure 8 SEBU7911 02 Safety Section Safety Messages QO Illustration 3 g01199939 View of radiator from the inside of the enclosure E AR e 10 Oj o cil lt g01193922 Illustration 4 Rear of the enclosure SEBU7911 02 9 Safety Section Safety Messages
21. he 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 See the Service Manual for repairs and for adjustments 102404509 Engine Starting SMCS Code 1000 Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move the controls 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 accident that is caused by parts in rotation work around the parts carefully Start the engine from the operator s compartment or from the engine start switch Always start the engine according to the procedure that is described in this 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 temp
22. ld cause personal injury or death Open and secure main distribution system switch or if the connection is permanent install a double throw transfer switch to prevent electrical feed back Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required Always check with your utility as to the applicable circum stances 12 Safety Section Safety Messages SEBU7911 02 Hot Fluid Under Pressure 5 The safety message for hot fluid under pressure is located toward the top of the radiator by the filler neck A WARNING g00930639 Pressurized system Hot coolant can cause seri ous burns injury or death To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pressure Read and understand the Op eration and Maintenance Manual before perform ing any cooling system maintenance Universal Warning 6 This safety message is located on the rear of the enclosure WARNING 228 3581 g00934493 Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in serious injury or death Electrical Shock 7 The safety message for electrical sh
23. ock is located on the control panel
24. od when the doors are closed Torque for the bolts 7 that fasten the eye to the trailer This message is located on the tongue of the trailer 18 Safety Section Additional Messages SEBU7911 02 Illustration 17 g01200452 Tighten the bolts that fasten the eye to the tongue of the trailer to a torque of 370 50 N m 273 37 Ib ft Parking brake 8 This message is located above the lever for the parking brake at the rear of the trailer Illustration 18 g01200437 To apply the parking brake pull the lever outward and pull the lever to the right Adjust the tension for the parking brake by turning the lever To disengage the parking brake pull the lever to the left and push the lever inward Single point lifting eye 9 This message is located on the side of the enclosure near the top of the enclosure 8 000 Kg 16 550 LBS LEI Illustration 19 g01200730 The single point lifting eye is rated at 8000 kg 16 550 Ib Lifting point 10 This message is located by the single point lifting eye Illustration 20 g01034418 Lift the package from this point Refer to the following topic e Operation and Maintenance Manual Product Lifting Tie down point 11 This message is located on the bottom of the generator set and on the trailer Illustration 21 g01200450 Use these points to tie down the generator set for various shipping c
25. onfigurations SEBU7911 02 19 Safety Section General Hazard Information 102965953 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 22 g00104545 Do not allow unauthorized personnel on the engine or around the engine when the engine is serviced 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 Cautiously remove the following parts Note To help prevent spraying or splashing of pressurized fluids hold a rag over the part that is being removed e Filler caps e Grease fittings e Pressure taps e Breathers e Drain plugs Use caution when cover plates are removed Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device Before removing the last two bolts or nuts pry the cover loose in order to relieve any spring pressure or other pressure e We
26. ow hot oil or components to contact skin Cat ELC Extended Life Coolant 3 This message is located near the radiator filler cap Illustration 13 g01132922 Air cleaner 4 This message is located on the cover of the air cleaner The air cleaner is located inside the engine compartment on the right side of the machine Illustration 14 g01169444 To avoid engine damage use only Caterpillar radial seal air filters as replacement filters Refer to the following topics for correct replacement instructions e Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace e Operation and Maintenance Manual Engine Air Filter Secondary Element Replace Ground 5 Illustration 15 g01200346 This message is located on the control panel by the connection for grounding the generator set This connection is the ground for the generator frame This connection must be connected to a suitable earth ground with a resistance of no more than 25 ohms Refer to the following topic e Operation and Maintenance Manual Setup Prop rod for the doors 6 This message is located at the bottom of the opening for the doors on the enclosure Illustration 16 g01200429 Use the prop rod in order to secure the doors of the generator set in the open position The prop rod is stored on the bottom of the door Use the clip on the bottom of the door to store the prop r
27. pplication 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 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 hose 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 that contain flammable fluid Clean any such lines thoroughly with a nonflammable solvent prior 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
28. ry terminal and the component MUST be electrically isolated from the engine A bus bar with a direct path to the negative battery terminal is permissible and recommended for use for all components that require a negative battery connection The bus bar should be directly connected to the negative battery terminal A bonding cable should also be connected from the cylinder block to the bus bar on the negative battery connection Use of a bus bar ensures that the Electronic Control Module ECM and all of the components that are connected to the ECM have a common reference point
29. s This could bypass the engine neutral start system and or the electrical system could be damaged Pressurized 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 pressurized air and or pressurized water is used for cleaning wear protective clothing protective shoes and eye protection Eye protection includes goggles or a protective face shield 20 Safety Section General Hazard Information SEBU7911 02 The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded and used with effective chip guarding if applicable and personal protective equipment 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 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 Containing 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 Prepare to collect the fluid with sui
30. table containers before any compartment is opened or before any component is disassembled Refer to Catalog NENG2500 Caterpillar Dealer Service Tool Catalog for the following items e Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Obey all local regulations for the disposal of liquids Asbestos Information Illustration 23 g00702022 Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free Caterpillar recommends the use of only genuine Caterpillar replacement parts Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris Use caution Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers Inhaling this dust can be hazardous to your health The components that may contain asbestos fibers are brake pads brake bands lining material clutch plates and some gaskets The asbestos that is used in these components is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dust that contains asbestos is generated If dust that may contain asbestos is present there are 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 cle
31. ty is Involved The message that appears under the warning 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 When replacement parts are required for this product Caterpillar recommends using Caterpil lar replacement parts or parts with equivalent specifications including but not limited to phys ic
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