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Do not allow unauthorized personnel on the engine, or around the engine when the engine is being 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. To help prevent 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 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.
- Wear a hard hat, protective glasses, and other protective equipment, as required.
- 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.
- 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.
- Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.
California Proposition 65 Warning
Some engine exhaust constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
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 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. Use the following guidelines when any replacement parts that contain asbestos or debris that contains asbestos are handled.
The asbestos in these components is usually sealed or bonded in a resin. Handling these materials normally is not hazardous unless airborne dust that contains asbestos is generated.
Do not inhale dust that might be generated when components that contain asbestos fibers are handled. Inhaling this dust can be hazardous to your health.
If dust which may contain asbestos is present, follow these guidelines:
- Never use compressed air for cleaning.
- Avoid abrasion of materials that contain asbestos.
- Use a wet method to clean up asbestos debris. A vacuum cleaner that is equipped with a high efficiency particulate air filter can also be used.
- Use exhaust ventilation when parts that contain asbestos are machined.
- 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 USA, use the Occupational Safety and Health Administration requirements. These OSHA requirements can be found in "29 CFR 1910.1001" .
- Obey environmental regulations for 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.
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:
- End fittings that are damaged or leaking
- Outer covering that is chafed or cut
- Wire that is exposed in reinforced hose
- Outer covering that is ballooning locally
- Flexible part of the hose that is kinked or crushed
- Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and the heat shields are installed correctly. This will help to prevent these effects: vibration, rubbing together of parts and excessive heat during operation .