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C15 INDUSTRIAL
ENGINE
Machine Safety
2007 Caterpillar
All Rights Reserved
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Safety Section
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Safety Messages
SMCS Code: 1000; 7405
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Illustration 1
Breathers
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Illustration 4
Grease fittings Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
Pressure taps
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Safety Section
General Hazard Information
Refer to Special Publication, NENG2500, Caterpillar Use exhaust ventilation on permanent machining
Dealer Service Tools Catalog for the following items: jobs.
Tools that are suitable for collecting fluids and Wear an approved respirator if there is no other
equipment that is suitable for collecting fluids way to control the dust.
Comply with applicable rules and regulations Check the coolant level after the engine has stopped
for the work place. In the United States, use and the engine has been allowed to cool. Ensure
Occupational Safety and Health Administration that the filler cap is cool before removing the filler
(OSHA) requirements. These OSHA requirements cap. The filler cap must be cool enough to touch with
can be found in 29 CFR 1910.1001. a bare hand. Remove the filler cap slowly in order
to relieve pressure.
Obey environmental regulations for the disposal
of asbestos. Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
Stay away from areas that might have asbestos the skin, the eyes, or the mouth.
particles in the air.
Oils
Dispose of Waste Properly
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot components
to contact the skin.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Burn Prevention
SMCS Code: 1000; 7405
SMCS Code: 1000; 7405
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. Illustration 8
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Allow cooling system components to cool before the
cooling system is drained. All fuels, most lubricants, and some coolant mixtures
are flammable.
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Safety Section
Fire Prevention and Explosion Prevention
Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause deterioration. The hoses must be properly routed.
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after Oil filters and fuel filters must be properly installed.
an emergency shutdown. The filter housings must be tightened to the proper
torque.
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.
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.
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Inspect the steps, the handholds, and the work area If a warning tag is attached to the engine start switch
before mounting the engine. Keep these items clean or to the controls, DO NOT start the engine or move
and keep these items in good repair. the controls. Consult with the person that attached
the warning tag before the engine is started.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not All protective guards and all protective covers must
climb on the engine, and do not jump off the engine. be installed if the engine must be started in order
to perform service procedures. To help prevent an
Face the engine in order to mount the engine or accident that is caused by parts in rotation, work
dismount the engine. Maintain a three-point contact around the parts carefully.
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any If there is a possibility that unburned gas remains in
controls as handholds. the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, Engine
Do not stand on components which cannot support Starting topic in the Operation Section.
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the Start the engine from the operators compartment or
equipment will not move. from the engine start switch.
Do not carry tools or supplies when you mount the Always start the engine according to the procedure
engine or when you dismount the engine. Use a hand that is described in the Operation and Maintenance
line to raise and lower tools or supplies. Manual, Engine Starting topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
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Knowing the procedure will also help to prevent
Before Starting Engine personal injury.
SMCS Code: 1000 To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Inspect the engine for potential hazards. properly, check the water temperature and the oil
temperature during heater operation.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. All protective Engine exhaust contains products of combustion
guards and all protective covers must be installed which can be harmful to your health. Always start the
if the engine must be started in order to perform engine and operate the engine in a well ventilated
service procedures. To help prevent an accident that area. If the engine is started in an enclosed area,
is caused by parts in rotation, work around the parts vent the engine exhaust to the outside.
carefully.
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Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are Engine Stopping
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent SMCS Code: 1000
engine damage.
Stop the engine according to the procedure in
On the initial start-up of a new engine or an engine the Operation and Maintenance Manual, Engine
that has been serviced, prepare to stop the engine Stopping (Operation Section) in order to avoid
if an overspeed condition occurs. This may be overheating of the engine and accelerated wear of
accomplished by shutting off the fuel supply to the the engine components.
engine and/or shutting off the air supply to the engine.
Use the Emergency Stop Button (if equipped) ONLY Grounding Practices
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.
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Electrical System
SMCS Code: 1000; 1400
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Engine Electronics
SMCS Code: 1000; 1400; 1900
To ensure that the engine and the engine electrical System Voltage
systems function properly, an engine-to-frame ground
strap with a direct path to the battery must be used. The Engine Monitoring package can vary for different
This path may be provided by way of a starting motor engine models and different engine applications.
ground, a starting motor ground to the frame, or a However, the monitoring system and the engine
direct engine ground to the frame. monitoring control will be similar for all engines.
All grounds should be tight and free of corrosion. The Note: Many of the engine control systems and display
engine alternator must be grounded to the negative modules that are available for Caterpillar Engines
- battery terminal with a wire that is adequate to will work in unison with the Engine Monitoring
handle the full charging current of the alternator. System. Together, the two controls will provide the
engine monitoring function for the specific engine
application. Refer to the Troubleshooting Manual for
more information.