0211440 JOHNSON OWNERS MANUAL

Illustration 1 g00704000All 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.A flash fire may result if the covers for the engine crankcase are removed within 15 minutes after an emergency shutdown.Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result.If the application involves the presence of combustible gases, consult your Caterpillar dealer for additional information about suitable protection devices.Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any flammable combustible materials or conductive 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 a case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly.Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting.Wiring must be kept in good condition. Ensure that all electrical wires are properly routed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections.Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
After the engine has stopped, you must wait for 15 minutes to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. The 15 minute wait will also allow static charge to dissipate from the low-pressure fuel system.Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration. Ensure that the hoses are correctly routed. The lines and hoses must have adequate support and secure clamps.Oil filters and fuel filters must be correctly installed. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly for more information.
Illustration 2 g00704059Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.Avoid static electricity risk when fueling. Ultra-low Sulfur Diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur content. Avoid death or serious injury from fire or explosion. Consult your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
Illustration 3 g00704135Gases 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. A frozen battery 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.Ether
Ether is flammable and poisonous.Do not smoke while you are replacing an ether cylinder.Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49 °C (120 °F). Keep ether cylinders away from open flames or sparks.Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install any lines that are bent or damaged.Leaks can cause fires. Consult your Caterpillar dealer for repair or for replacement parts.Replace the parts if any of the following conditions are present:
High-pressure fuel line or lines are removed.
End fittings are damaged or leaking.
Outer coverings are chafed or cut.
Wires are exposed.
Outer coverings are ballooning.
Flexible parts of the hoses are kinked.
Outer covers have embedded armoring.
End fittings are displaced.Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, correct installation will help to prevent vibration, rubbing against other parts, and excessive heat.