Cummins_Marine_Engine_Manual.pdf

Operation and Maintenance Manual QSC8.3 and QSL9 Marine Engines

Cummins Inc.

Box 3005 Columbus, Indiana, U.S.A., 47202 www.cummins.com

Copyright© 2021 Cummins Inc.

Bulletin 4021571 Printed in U.S.A. 02-MARCH-2021

O p eratio n an d

M ain ten an ce M anu al Q S

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CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

CALIFORNIA

Proposition 65

WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

• If in an enclosed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to www.P65warnings.ca.gov/diesel.

Off-Road Equipment

Master_PROP_65_COMP.indd 1 5/5/17 7:03 AM

PRODUCT REGISTRATION DEPT

M/C 60203

CUMMINS INC

PO BOX 3005

COLUMBUS IN 47202-9982

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED STATES

BUSINESS REPLY MAIL

FIRST-CLASS MAIL COLUMBUS INPERMIT NO. 15

POSTAGE WILL BE PAID BY ADDRESSEE

Artwork for User Defined (4" x 6") Layout: sample BRM Env with IMB2.lyt February 9, 2016

Produced by DAZzle, Version 12.2.02

(c) 1993-2012, DYMO Endicia, www.Endicia.com Authorized User, Serial #

IMPORTANT: DO NOT ENLARGE, REDUCE OR MOVE the FIM and barcodes. They are only valid as printed!

Special care must be taken to ensure FIM and barcode are actual size AND placed properly on the mail piece to meet both USPS regulations and automation compatibility standards.

Cummins Product Registration

361584_Cummins_Digital.indd 1 7/22/16 12:34 PM

First Name Last Name

Customer Name

Address

City State Zip Code

Phone Number

Email Address

Engine Serial Number (Must be 8 digits)

VIN

Date of Purchase (MM-DD-YYYY)

In order to serve you better it is important to register your product.

Use one of the following options to register your product:

• Scan the QR code and complete the registration online.

• Complete the registration online at prodreg.cummins.com

• Fill out and return this card.

Cummins Product Registration

361584_Cummins_Digital.indd 2 7/22/16 12:34 PM

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Operation and Maintenance Manual QSC8.3 and QSL9 Marine Engines

Copyright© 2021 Bulletin 4021571 Cummins Inc. Printed 02-MARCH-2021 All rights reserved

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com

Foreword Thank you for depending on Cummins® products. If you have any questions about this product, please contact your Cummins® Authorized Repair Location. You can also visit cumminsengines.com or quickserve.cummins.com for more information, or go to locator.cummins.com for Cummins® distributor and dealer locations and contact information.

Read and follow all safety instructions. See the General Safety instructions in Section i - Introduction.

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com

Table of Contents Section

Introduction ........................................................................................................................................................ i

Engine and System Identification .................................................................................................................... E

Operating Instructions

Maintenance Guidelines

Maintenance Procedures at Daily Interval

Maintenance Procedures at 250 Hours or 6 Months

Maintenance Procedures at 250 Hours or 1 Year

Maintenance Procedures at 500 Hours or 1 Year

Maintenance Procedures at 1500 Hours

Maintenance Procedures at 3 Years

Maintenance Procedures at 2000 Hours or 4 Years

Adjustment, Repair, and Replacement ............................................................................................................ A

System Diagrams .............................................................................................................................................. D

Service Literature .............................................................................................................................................. L

Service Assistance ............................................................................................................................................ S

Seasonal Storage (Marine Only) ....................................................................................................................... SS

Troubleshooting Symptoms ............................................................................................................................. TS

Maintenance Specifications .............................................................................................................................. V

Warranty ............................................................................................................................................................. W

Back .................................................................................................................................................................... back

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Important Reference Numbers Fill in the blank spaces provided below. This will provide a reference whenever service or maintenance is required.

Description Number Comments/Additional Information Engine

Engine Model Engine Serial Number (ESN) Control Parts List (CPL) Electronic Control Module (ECM) Part Number(s)

Electronic Control Module (ECM) Serial Number(s)

Governor Control Module (GCM) (if applicable)

Belt Part Number(s) Filter Part Numbers:

Air Lubricating Oil

Fuel* Fuel (Water Separator) Coolant (if equipped)

Crankcase/Breather (if equipped) Eliminator™ Filter Centrifuge (if equipped)

*The number of fuel filters may vary by application. Record all fuel filters.

Aftertreatment (if applicable):

Aftertreatment Diesel Particulate Filter (if equipped)

Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter (if equipped)

Aftertreatment Diesel Exhaust Fluid Dosing Air Oil Separator (if equipped)

Clutch or Marine Gear (if applicable):

Model

Serial Number Part Number

Oil Type Sea Water Pump:

Model Part Number

QSC8.3 and QSL9 Section i - Introduction Page i-a

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Section i - Introduction Section Contents

Page About the Manual ......................................................................................................................................................... i-2

About............................................................................................................................................................................i-2 General Information..................................................................................................................................................... i-2

Acronyms and Abbreviations ................................................................................................................................... i-28 General Information................................................................................................................................................... i-28

General Cleaning Instructions .................................................................................................................................. i-23 Abrasive Pads and Abrasive Paper........................................................................................................................... i-23 Definition of Clean......................................................................................................................................................i-23 Fuel System............................................................................................................................................................... i-26 Gasket Surfaces........................................................................................................................................................ i-24 Plastic Bead Cleaning................................................................................................................................................i-25 Solvent and Acid Cleaning.........................................................................................................................................i-24 Steam Cleaning......................................................................................................................................................... i-25

General Repair Instructions ...................................................................................................................................... i-21 General Information................................................................................................................................................... i-21 Welding on a Vehicle with an Electronic Controlled Fuel System.............................................................................. i-22

General Safety Instructions ........................................................................................................................................ i-9 Aftertreatment............................................................................................................................................................ i-14 Best Practices.............................................................................................................................................................. i-9 Common Hazards...................................................................................................................................................... i-17 Common Substances.................................................................................................................................................i-15 Electrical Components............................................................................................................................................... i-17 Fuels...........................................................................................................................................................................i-11 Hazardous Substances..............................................................................................................................................i-16 Important Safety Notice............................................................................................................................................... i-9 Job Safety Assessment............................................................................................................................................. i-18 Personal Protective Equipment (PPE)....................................................................................................................... i-10 Power Generation Applications..................................................................................................................................i-14 Work Environment........................................................................................................................................................i-9

How to Use the Manual ................................................................................................................................................i-3 General Information..................................................................................................................................................... i-3

Illustrations ...................................................................................................................................................................i-8 General Information..................................................................................................................................................... i-8

Symbols ........................................................................................................................................................................ i-4 General Information..................................................................................................................................................... i-4

To the Owner and Operator .........................................................................................................................................i-1 General Information..................................................................................................................................................... i-1

Page i-b Section i - Introduction

This Page Left Intentionally Blank

QSC8.3 and QSL9 To the Owner and Operator Section i - Introduction Page i-1

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To the Owner and Operator General Information This guide contains information for the correct operation and maintenance of your Cummins® product. This manual also includes important safety information which can be found in Section i - Introduction.

Thank you for depending on Cummins® products. If you have any questions about this product, please contact your local Cummins® Authorized Repair Location. To locate a Cummins® Authorized Repair Location, refer to Section S - Service Assistance in this manual.

About the Manual QSC8.3 and QSL9 Page i-2 Section i - Introduction

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About the Manual General Information Cummins Inc. manuals are created to support Cummins® products. For information on components or fault codes not supplied by Cummins Inc., contact the original equipment manufacturer or supplier.

The content of this manual is based on the information in effect at the time of publish. Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins® Authorized Repair Location.

About Cummins® manuals are divided into sections. Each section consists of procedures which are associated with the title of the section.

When viewing a manual online, the sections of the manual are displayed to the left of the procedure display. If a section is clicked, it will expand to show the procedures within that section. To view a procedure, click on the procedure title.

When viewing a printed manual, the table of contents provides the list of sections and their subsequent procedures, with page numbers located to the right.

QSC8.3 and QSL9 How to Use the Manual Section i - Introduction Page i-3

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How to Use the Manual General Information This manual is divided into the same group system used for previous manuals and the Cummins' filmcard system.

Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired information.

The disassemble/assemble sections of this manual is divided into the same group system used for previous manuals and the Cummins' filmcard system.

Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired information.

Each section contains the following in sequence:

• Table of Contents

• Required Service Tool Listings

• General Information containing the basic service, maintenance, design and revision information necessary to assist in the rebuild of an engine or a component

• Procedure instructions for the disassembly, inspection, maintenance, and assembly that can be required to rebuild an engine; additional procedures that are not necessary during every rebuild, but can be necessary, are included.

These procedures depend on the length of time an engine has been in service and the conditions of the parts.

All the procedures are identified with a name and a number. Each digit in the procedure number has a specific meaning.

The first three digits of the number refer to the specific section that the procedure can be found within the manual. In this example, “001” represents Section 01 - Cylinder Block. This number will range from 000 to 022.

The second three digits of the number are unique and refer to a specific subject. In this example, “028” represents Cylinder Liner. This number will range from 001 to 999.

Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications and torque values for each engine system are given in that section.

NOTE: Discharge of oil or oily water into or upon the water is a direct violation of today's laws. Violators are subject to a penalty of various monetary charges. Dispose of these substances in accordance with standards set by the EPA.

Symbols QSC8.3 and QSL9 Page i-4 Section i - Introduction

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Symbols General Information The symbols are used only in printed manuals to help communicate the intent of the instructions. Symbols will not appear in the online version of this procedure. When one of the symbols appears in the printed manual, it conveys the meaning defined below.

NOTE: It is possible to have four symbols for each text and graphic combination.

WARNING

Serious personal injury or extensive property damage can result if the warning instructions are not followed.

CAUTION

Minor personal injury can result or a part, and assembly, or the engine can be damaged if the caution instructions are not followed.

Indicates a REMOVAL or Dissassembly step.

QSC8.3 and QSL9 Symbols Section i - Introduction Page i-5

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Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

Symbols QSC8.3 and QSL9 Page i-6 Section i - Introduction

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LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

QSC8.3 and QSL9 Symbols Section i - Introduction Page i-7

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Refer to another location in this manual or another publication for additional information.

The component weighs 23kg [50 lbs] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.

Illustrations QSC8.3 and QSL9 Page i-8 Section i - Introduction

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Illustrations General Information Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition.

The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration can differ.

QSC8.3 and QSL9 General Safety Instructions Section i - Introduction Page i-9

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General Safety Instructions Important Safety Notice Read and understand the safety information and precautions before performing any repair or operating equipment.

This procedure contains general safety precautions that must be followed to provide personal safety. Always follow procedures to mitigate safety concerns.

Work Environment Follow these recommended practices when servicing products.

• Always follow on-site safety requirements.

• Always follow local training, certification, authorization, and specific customer requirements. Do not work on products unless proper training has been completed to allow safe repair completion. Do not operate equipment unless proper training has been completed to allow safe operation..

• Work in a well-ventilated area away from ignition sources.

• If adverse weather conditions are present, take appropriate safety precautions when performing work.

• Always be aware of hazardous conditions that may exist in the work environment.

Best Practices Follow these recommended practices when servicing or operating equipment.

• Always wear protective glasses and protective shoes.

• Remove rings, watches, long jewelry, or metallic items.

• Do not wear loose fitting or torn clothing, jewelry, long hair, etc.. These increase the risk for personal injury.

• Do not perform any repairs, or operate equipment, when fatigued or impaired due to drugs or alcohol.

• Always use tools that are in good condition.

• Do not work on equipment with the key switch ON or that is running unless otherwise directed by troubleshooting procedures.

• If any work must be performed while the key switch is ON or the unit is running, use extreme caution around hot components, moving parts, etc.

• Exercise caution when working on products that have just been turned off. Hot parts may cause burns or ignite or melt common materials.

• Do not bleed the fuel system of a hot engine. Contact with hot manifolds or other components can cause a fire.

• Do not attempt to rotate the crankshaft by pulling or prying on the fan. Only use proper engine barring techniques.

• Do not lift components that weigh 23 kg [ 50 lb ] or more. Use mechanical help or seek assistance.

• Exercise caution when working around rotating parts. Rotating parts can cause cuts, mutilation, or strangulation.

• Exercise caution when working on electrical components. High voltages can cause serious injury or death.

• Relieve system pressure as instructed before removing or disconnecting lines, fittings, or related items.

• Always test for pressure leaks as instructed.

• Always torque fittings and connections to the required specifications. Over or under tightening can damage threads and create leaks.

• Always use the same fastener part number, or equivalent, when replacing fasteners.

Perform the following prior to beginning work on any products.

• Shutdown the equipment unless otherwise directed by troubleshooting procedures.

• Always allow the product to cool.

• Always ensure the product is properly supported by blocks or stands. Do not work on a product supported only by lifting jacks or hoists.

• Disconnect the battery unless otherwise directed by troubleshooting procedures.

• Disconnect the starting motor, if equipped, unless otherwise directed by troubleshooting procedures.

General Safety Instructions QSC8.3 and QSL9 Page i-10 Section i - Introduction

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• Place a "Do NOT Operate" tag in the operator area or near the product controls.

• Become familiar with the tools required for performing the task at hand and how to use those tools correctly.

• Use only genuine Cummins or Cummins Recon replacement parts as instructed.

Personal Protective Equipment (PPE)

To reduce the possibility of personal injury, personal protective equipment (PPE) should be utilized. Various types of PPE are listed below. Use proper judgment to determine which types of PPE are required for a given task. Always meet on-site safety regulations for required PPE. Proper maintenance of safety equipment must be practiced. Integrity of safety equipment must be checked to ensure equipment functionality is maintained.

Eye Protection Eye protection must always be worn. Wear appropriate eye protection based on the task being completed. Types of eye protection to consider are listed below.

• Safety glasses. Exposure to flying particles or debris, chemicals or caustic liquids, gases or vapors.

• Polarized safety glasses. Working in outdoor or bright lighting environments.

• Over-the-glass safety glasses. Add protection to prescription glasses.

• Safety goggles. Handling caustic liquids or chemicals.

• Shade or arc rated eyewear. Exposure to welding. Use appropriate filter ratings.

Foot Protection Protective shoes must alwaysbe worn. Wear appropriate foot protection based on the task being completed. Types of protective footwear to consider are listed below.

• Steel toed shoes. Exposure to falling or rolling objects. Working with or around parts, tools, and equipment.

• Chemical resistant. Exposure to chemicals and other fluids.

• Overshoes and overboots. Add protection to everyday work shoes.

• Foot, toe, and metatarsal guards. Add protection to everyday work shoes.

• Electrical hazard safety toe shoes. Exposure to electrical hazards.

• Leather footwear or shoe protectors. Exposure to welding or arc flash.

• Cold protection. Exposure to cold weather.

Head and Face Protection Wear appropriate face protection based on the task being completed. Types of head and face protection to consider are listed below.

• Hard hats. Exposure varies. Consider welding, heat, or arc-rated.

• Visors. Exposure varies. Consider welding, heat, or arc-rated.

• Face liners. Exposure to cold weather.

• Face shields. Exposure to liquid splash. Handling caustic liquids or chemicals.

Hand Protection Wear appropriate type and fit of gloves based on the task being completed. Types of protective gloves to consider are listed below.

• Heat resistant or insulated. Exposure to hot items.

• Flame resistant. Exposure to welding or arc flash.

• Impact resistant. Performing repetitive impact and vibration work. Using pneumatic tools.

• Impervious. Exposure to high pressure fluids.

• Chemical resistant. Exposure to chemicals, fluids, or batteries.

• Cut resistant. Handling sharp objects or tools.

• Cold weather. Exposure to cold weather.

Hearing Protection

Section i - Introduction Page i-11

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When working around operating equipment, appropriately rated hearing protection should be worn. Types of hearing protection to consider are listed below.

• Single use ear plugs.

• Pre-formed ear plugs.

• Ear muffs.

Protective Clothing Wear appropriate protective clothing based on the task being completed. Types of protective clothing to consider are listed below.

• Flame resistant. Exposure to electrical hazards. Exposure to oil and gas or generator set applications. Performing welding.

• Chemical resistant. Exposure to chemicals.

• High visibility. Exposure to reduced visibility working environments. Working on mining, oil and gas, or sites with large equipment.

Respiratory Protection Wear appropriate respiratory protection based on the task being completed. Types of respiratory protection to consider are listed below.

• Disposable respirators. Exposure to dust and particles, welding fumes, nuisance odors, nuisance level acid gas.

• Reusable respirators. Exposure to cleaning, machining, welding, sanding, grinding, etc.

Fall Protection Utilize fall protection if a task is being completed more than 1.2 m [ 4 ft ] above a solid surface. Types of fall protection to consider are listed below.

• Fall harness and lanyard combinations.

• Safety nets.

• Guardrails.

Fuels

Follow these recommended practices when interacting with equipment that uses different fuel types. For information regarding proper handling of various substances, refer to the manufacturer's safety data sheet.

Diesel Fuel

• Protect eyes.

• Protect skin.

• Always test for fuel leaks as instructed.

• Do not dilute.

• Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition.

• Provide extra ventilation to the work area.

• Do not troubleshoot or repair fuel leaks while the engine is running.

• If material is spilled, avoid contact and dispersal with runoff, soil, waterways, drains, and sewers. Absorb with sand, clay, or commercial absorbent. Transfer to containers and neutralize the material. Flush spill area with soap and excess water.

• Report spills effecting water source contamination to local authorities immediately.

• Proper disposal is required. Dispose of in accordance with local and environmental regulations.

• Always torque fittings and connections to the required specifications. over or under tightening can damage threads and create leaks.

Gasoline

• Protect eyes.

• Protect skin.

• Always be alert for the smell of gas.

Page i-12 Section i - Introduction

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• Always test for fuel leaks as instructed.

• Do not dilute.

• Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition.

• Vapors accumulate near the floor. Check the work floor, sumps, and low lying areas for ignition sources before servicing equipment..

• Provide extra ventilation to the work area.

• Do not troubleshoot or repair fuel leaks while the engine is running.

• If material is spilled, avoid contact and dispersal with runoff, soil, waterways, drains, and sewers. Absorb with sand, clay, or commercial absorbent. Transfer to containers and neutralize the material. Flush spill area with soap and excess water.

• Report spills effecting water source contamination to local authorities immediately.

• Proper disposal is required. Dispose of in accordance with local and environmental regulations.

• Always torque fittings and connections to the required specifications. over or under tightening can damage threads and create leaks.

Biodiesel

• Protect eyes.

• Protect skin.

• Always test for fuel leaks as instructed.

• Do not dilute.

• Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition.

• Vapors accumulate near the floor. Check the work floor, sumps, and low lying areas for ignition sources before servicing equipment..

• Provide extra ventilation to the work area.

• Do not troubleshoot or repair fuel leaks while the engine is running.

• If material is spilled, avoid contact and dispersal with runoff, soil, waterways, drains, and sewers. Absorb with sand, clay, or commercial absorbent. Transfer to containers and neutralize the material. Flush spill area with soap and excess water.

• Report spills effecting water source contamination to local authorities immediately.

• Proper disposal is required. Dispose of in accordance with local and environmental regulations.

• Always torque fittings and connections to the required specifications. over or under tightening can damage threads and create leaks.

Compressed Natural Gas

• Protect eyes.

• Protect skin.

• Always be alert for the smell of gas. Compressed natural gas is typically treated with an odor producing chemical for leak detection. Non-refined sources of natural gas (landfill gas, biogas, coal bed gas, wellhead gas, etc.) can not always be detected by smell.

• Always test for fuel leaks as instructed. Odorant can fade.

• Upon entering a room or approaching a vehicle where the smell of gas is present, immediately shutoff all engines and ignition sources.

• Natural gas ignites when there is a 5% - 15% mixture in the air. Asphyxiation can occur when concentration reaches 21% or more.

• Do not start equipment or nearby equipment until a suspected gas leak is corrected and the area is ventilated.

• Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition.

• Work in areas that do not share common ventilation with areas containing ignition sources.

• Store and service natural gas fueled equipment in large, well-ventilated areas, or outside.

• Provide extra ventilation to the work area.

Section i - Introduction Page i-13

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• Natural gas accumulates near the ceiling. Check the ceiling of the work area for ignition sources before servicing equipment.

• Only disconnect gas lines in a well-ventilated area.

• Do not troubleshoot or repair gas leaks while the engine is running.

• Natural gas ignition systems produce high voltage during operation. Do not touch ignition wiring or components while the engine is operating. If necessary, use only insulated tools.

• Natural gas exhaust systems operate at higher temperatures than similar diesel exhaust systems. Do not touch exhaust components. Do not route lines or hoses which deteriorate from heat exposure near exhaust components or in the flow path of the exhaust.

• Always torque fittings and connections to the required specifications. over or under tightening can damage threads and create leaks.

Liquefied Natural Gas

• Protect eyes.

• Protect skin.

• Always be alert for the smell of gas. Liquefied natural gas may not have an odor. Non-refined sources of natural gas (landfill gas, biogas, coal bed gas, wellhead gas, etc.) can not always be detected by smell.

• Always test for fuel leaks as instructed. Odorant can fade.

• Upon entering a room or approaching a vehicle where the smell of gas is present, immediately shutoff all engines and ignition sources.

• Natural gas ignites when there is a 5% - 15% mixture in the air. Asphyxiation can occur when concentration reaches 21% or more.

• Do not start equipment or nearby equipment until a suspected gas leak is corrected and the area is ventilated.

• Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition.

• Work in areas that do not share common ventilation with areas containing ignition sources.

• Store and service natural gas fueled equipment in large, well-ventilated areas, or outside.

• Provide extra ventilation to the work area.

• Natural gas accumulates near the ceiling. Check the ceiling of the work area for ignition sources before servicing equipment.

• Only disconnect gas lines in a well-ventilated area.

• Do not troubleshoot or repair gas leaks while the engine is running.

• Natural gas ignition systems produce high voltage during operation. Do not touch ignition wiring or components while the engine is operating. If necessary, use only insulated tools.

• Natural gas exhaust systems operate at higher temperatures than similar diesel exhaust systems. Do not touch exhaust components. Do not route lines or hoses which deteriorate from heat exposure near exhaust components or in the flow path of the exhaust..

• Liquefied natural gas is stored in vehicle tanks at extremely cold temperatures. If there is a liquefied natural gas spill, evacuate the area immediately and do not attempt to make contact with the liquid.

• Always torque fittings and connections to the required specifications. over or under tightening can damage threads and create leaks.

• Vapors accumulate near the floor. Check the work floor, sumps, and low lying areas for ignition sources before servicing equipment.

Liquefied Petroleum Gas

• Protect eyes.

• Protect skin.

• Always be alert for the smell of gas. Liquefied petroleum gas is typically treated with an odor producing chemical for leak detection.

• Always test for fuel leaks as instructed. Odorant can fade.

• Upon entering a room or approaching a vehicle where the smell of gas is present, immediately shutoff all engines and ignition sources.

Page i-14 Section i - Introduction

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• Do not start equipment or nearby equipment until a suspected gas leak is corrected and the area is ventilated.

• Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition.

• Work in areas that do not share common ventilation with areas containing ignition sources.

• Store and service natural gas fueled equipment in large, well-ventilated areas, or outside.

• Provide extra ventilation to the work area.

• Liquefied petroluem gas accumulates near the floor. Check the work floor, sumps, and low lying areas for ignition sources before servicing equipment.

• Only disconnect gas lines in a well-ventilated area.

• Do not troubleshoot or repair gas leaks while the engine is running.

• Liquefied petroleum gas ignition systems produce high voltage during operation. Do not touch ignition wiring or components while the engine is operating. If necessary, use only insulated tools.

• Liquefied petroleum gas exhaust systems operate at higher temperatures than similar diesel exhaust systems. Do not touch exhaust components. Do not route lines or hoses which deteriorate from heat exposure near exhaust components or in the flow path of the exhaust..

• Liquefied natural gas is stored in vehicle tanks at extremely cold temperatures. If there is a liquefied natural gas spill, evacuate the area immediately and do not attempt to make contact with the liquid.

• Always torque fittings and connections to the required specifications. over or under tightening can damage threads and create leaks.

Power Generation Applications Follow these recommended practices when interacting with equipment in generator set applications.

Power generation applications produce high voltage during operation. When servicing a generator set, the following safety precautions must be taken.

• Remove any debris from the generator set.

• Keep the floor clean and dry throughout servicing

• Service access doors must be secured in the "open" position before working on enclosed generator sets.

• Use insulated or non-conducting tools.

• Prevent accidental or remote starting. Disconnect the starting battery cables. Disconnect the negative ( - ) terminal first.

• Isolate all auxiliary supplies.

• Switch the generator set control panel "off."

• Place a "Do Not Operate" tag on the control panel.

• Lock the generator set circuit breaker in the "Open" position.

• Activate the manual "Emergency Stop" device.

• Do not step on the generator set when servicing, entering, or leaving the generator room.

Aftertreatment

Follow these recommended practices when interacting with equipment that utilize aftertreatment systems. For information regarding proper handling of various substances, refer to the manufacturer's safety data sheet.

Diesel Exhaust Fluid

• Avoid breathing vapor or mist.

• Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes.

• Protect skin. In case of contact with skin, wash with soap and water.

• Do not ingest. If ingested, contact a physician immediately.

Diesel Particulate Filter

• Protect eyes.

• Protect skin.

Section i - Introduction Page i-15

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• Avoid stirring up exhaust particulate dust.

• Avoid inhalation of exhaust particulate dust. Wear a dust mask. If respiratory irritation or discomfort occurs, leave the dusty area. Utilize breathing assistance or oxygen if necessary.

• Elevated concentrations of metals in the form of dust, soot, and contaminants are contained in these filters.

Health regulations may exist for the materials found in these filters such as Zinc, Molybdenum, polynuclear aromatic hydrocarbons. Potentially toxic materials found in these filters are oxides of calcium, zinc, phosphorous, silicon, sulfur, and iron.

• Proper disposal of the exhaust dust and filter are required. Dispose of in accordance with local and environmental regulations.

• Diesel particulate filter maintenance must be completed by appropriately trained personnel.

Selective Catalytic Reduction (SCR) Catalyst

• Protect eyes.

• Protect skin.

• Avoid stirring up exhaust catalyst dust.

• Avoid inhalation of exhaust catalyst dust. Wear a dust mask. If respiratory irritation or discomfort occurs, leave the dusty area. Utilize breathing assistance or oxygen if necessary.

• Do not cut open exhaust catalyst assemblies.

• Proper disposal of the exhaust catalyst is required. Dispose of in accordance with local and environmental regulations.

Oxidation Catalysts Types of Oxidation Catalysts may include, but are not limited to the following.

• Diesel Oxidation Catalyst (DOC)

• 3-way Oxidation Catalyst

When working with oxidation catalysts, perform the following.

• Protect eyes.

• Protect skin.

• Avoid stirring up exhaust catalyst dust.

• Avoid inhalation of exhaust catalyst dust. Wear a dust mask. If respiratory irritation or discomfort occurs, leave the dusty area. Utilize breathing assistance or oxygen if necessary.

• Do not cut open exhaust catalyst assemblies.

Common Substances

Follow these recommended practices when interacting with the following substances. For information regarding proper handling of various substances, refer to the manufacturer's safety data sheet.

Coolant

• Coolant is also referred to as antifreeze.

• Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes. Receive medical attention immediately.

• Protect skin. In case of contact with skin, wash with soap and water. Remove contaminated clothing. If injection occurs, it is a medical emergency. Receive medical attention immediately.

• Do not ingest. If ingested, drink excess water for dilution and seek medical attention.

• Do not pour used antifreeze into containers that have been used to store other chemicals or products, such as oil or gasoline, unless they have been thoroughly cleaned.

• If material is spilled, avoid contact and dispersal with runoff, soil, waterways, drains, and sewers. Provide adequate ventilation to the area. Absorb with sand, clay, or commercial absorbent. Transfer to containers and neutralize the material. Flush spill area with soap and excess water.

• Report spills effecting water source contamination to local authorities immediately.

• Proper disposal is required. Dispose of in accordance with local and environmental regulations.

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Liquid Nitrogen

• Work in a well-ventilated area.

• Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes. Receive medical attention immediately.

• Protect skin. In case of contact with skin, receive medical attention immediately.

• Wear protective clothing and gloves that insulate.

• Handle items with tongs or wire hooks.

• Avoid prolonged breathing of liquid nitrogen vapors. Utilize breathing assistance or oxygen if necessary.

Lubricating Oil See Lubricating Oil in the "Hazardous Substances" step.

Refrigerant

• Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes. In case of frostbite, use lukewarm water, not hot. Seek medical attention if irritation continues.

• Protect skin. Wear leather or insulated gloves. In case of contact with skin, wash with soap and water. Seek medical attention if irritation continues.

• Proper disposal is required. Dispose of in accordance with local and environmental regulations.

• Only disconnect liquid refrigerant lines in a well-ventilated area. liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas into the atmosphere. Federal law requires capturing and recycling refrigerant in the United States of America.

Solvents

• Follow the manufacturer's instructions for safe handling practices.

• Follow the manufacturer's recommendations for use.

• Some solvents are flammable and toxic..

• Protect eyes. In case of contact with eyes, follow manufacturer's recommendations.

• Protect skin. In case of contact with skin, follow manufacturer's recommendations.

• Dispose of in accordance with manufacturer's recommendations.

Starting Aids (Starting Fluid)

• Do not use starting fluid if the intake air heater option is used.

• Do not use volatile cold starting aids in underground mine or tunnel operations. The local United States Bureau of

Mines inspector can provide more information and instructions.

• Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition.

• Work in a well-ventilated area.

• Avoid inhalation.

Hazardous Substances Hazardous substances are known to some state and federal agencies to be carcinogenic and cause reproductive harm. Hazardous substances that may be encountered during service events are listed below.

Diesel Engine Exhaust

• Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes.

• Protect skin. In case of contact with skin, wash with soap and water.

• Avoid inhalation.

Lubricating Oil

• Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes.

• Protect skin. In case of contact with skin, wash with soap and water.

• Do not ingest. If ingested, contact a physician immediately..

• Proper disposal is required. Dispose of in accordance with local and environmental regulations.

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• Do not allow water droplets to enter a container of hot oil. A violent reaction can result.

Mercury

• Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes.

• Protect skin. In case of contact with skin, wash with soap and water.

• Do not ingest. If ingested, contact a physician immediately.

• Proper disposal is required. Dispose of in accordance with local and environmental regulations.

Vanadium Pentoxide

• Can be found in some selective catalytic reduction (SCR) catalysts.

• Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes.

• Protect skin. In case of contact with skin, wash with soap and water.

• Do not ingest. If ingested, contact a physician immediately.

• Avoid inhalation of vapors or airborne particles.

• Proper disposal is required. Dispose of in accordance with local and environmental regulations.

Electrical Components Follow these recommended practices when interacting with electrical components.

Batteries

• Protect eyes. Wear safety glasses or goggles. In case of battery acid contact with eyes, flush with water for a minimum of 15 minutes. Receive medical attention immediately.

• Protect skin. Wear rubber gloves and a chemical apron. In case of battery acid contact with skin or clothing, rinse with water for several minutes. Avoid spreading the acid. Receive medical attention immediately.

• Do not open the battery caps with your face over or near the battery.

• Remove rings, watches, long jewelry, or metallic items when working with or near batteries.

• Ventilate the battery compartment before servicing the battery.

• Work in a well-ventilated area.

• Avoid sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition.

• Use insulated or non-conducting tools.

• Neutralize static buildup by contacting the nearest ground surface before working on a battery.

• Do not lift batteries by the posts.

• Do not touch both battery terminals with your bare hands at the same time.

• Disconnect the negative ( - ) battery cable first.

• Attach the negative ( - ) battery cable last.

Common Hazards

Follow these recommended practices when interacting with equipment as the following hazards may exist.

High Temperature Area Be alert for high temperature areas which may cause severe burns. High temperature areas may be encountered in the following situations.

• On products that have just been turned off.

• On or around exhaust related components (turbocharger, aftertreatment systems, etc).

• In exhaust gas flow paths.

• Contacting hot fluid lines, tubes, or compartments.

Recommended Practices:

• Allow components to cool before servicing. Verify the temperature of the component. Utilize an infrared gun, temperature sensor, temperature gauge, or other reliable method to determine component temperature. Take appropriate precautions before starting work.

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• Protect eyes.

• Protect skin. Wear insulated gloves.

• Ensure surrounding items do not come in contact with hot components or exhaust. Contact may ignite or melt those materials.

Heavy Objects Be alert when working with heavy objects.

• Do not lift components that weigh 23 kg [ 50 lb ] or more. Use mechanical help or seek assistance.

• Use mechanical help to move items whenever possible. Make sure the load is securely fastened to the equipment.

• Make sure lifting devices, like chains, hooks, slings, etc., are in good condition and are rated for the correct capacity before use.

• Make sure lifting devices are positioned correctly before use.

• Use a spreader bar when necessary.

• If the item can be lifted manually, squat to lift and lower the item. Do not bend at the waist.

• Maintain balance when lifting items by keeping feet apart or staggered if possible.

• If the item must be carried, make sure the path is clear when carrying the item to, and placing the item in, the desired location.

Pressurized Areas Be alert for pressurized areas. Pressurized areas may be encountered in the following situations.

• Air, Oil, Fuel, and Cooling systems.

• When disconnecting or removing lines, fittings, or related items.

• When disconnecting a device from a pressurized system.

• When removing or loosening caps on tanks or pressurized systems.

Injuries that may result when…