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ISSUE DATE: February 17, 2005 PROGRAM INFORMATION BULLETIN NO. P05-04 FROM: MARK E. SKILES  Director of Technical Support JOHN F. LANGTON Melinda Pon for Acting Administrator for Coal Mine Safety and Health ROBERT M. FRIEND  Administrator for Metal and Nonmetal for Mine Safety and Health SUBJECT: Retrofit Program for Permissible Diesel-Powered Equipment Manufactured before November 25, 1999, and equipped with Caterpillar Model 3306 PCNA Diesel Engines Who needs this information? Mine Safety and Health Administration (MSHA) personnel, underground coal mine operators, underground metal and nonmetal operators, miner's representatives, and Repair Shop Facilities should have this information. Why is MSHA issuing this Bulletin? This Program Information Bulletin (PIB) is to inform mine operators of a Permissible Diesel-Powered Equipment retrofit program and of the importance of maintaining diesel engines in approved condition. What permissible diesel-powered equipment does this Program Information Bulletin address? This PIB addresses permissible diesel-powered equipment that was manufactured before November 25, 1999, under Title 30 Code of Federal Regulations (30 CFR), Part 36 and equipped with a Caterpillar 3306 PCNA diesel engine. PIB No. P04-3, issued January 13, 2004, addressed Caterpillar Model 3306 PCNA diesel engines installed in permissible machines that were manufactured on or after November 25, 1999, or installed in nonpermissible machines. Permissible diesel-powered equipment manufactured before November 25, 1999, was required to be identified with an MSHA approval label but was not required to have the diesel engines identified with an MSHA approval label. Although these diesel engines do not require an MSHA approval label, the engines must be properly derated for altitudes (elevations above sea level) above 1000 feet when installed in the approved permissible machine. Why does this permissible diesel-powered equipment require retrofit? Correct fuel rate settings are critical to minimize exhaust emissions of diesel engines. MSHA specifies a maximum fuel setting and an altitude fuel deration curve for each engine during the approval process. The fuel deration curve is intended to ensure that the fuel rate does not exceed the maximum allowable fuel at any altitude. MSHA has found Caterpillar Model 3306 PCNA diesel engines that were not properly derated for altitudes above 1000 feet and as a result were over-fueled. Over-fueling will not significantly increase the power output of the engine since engines can only utilize fuel in relation to the air available. Excess fuel is not efficiently burned in the combustion chambers of the engine; thus the exhaust will have an excessive amount of diesel particulate matter and carbon monoxide. Proper engine fuel settings convert fuel to power more efficiently, resulting in less fuel usage and creating about the same amount of power. In addition, engines with excessive fuel-to-air ratios operate at higher temperatures shortening their useful life. Most importantly, proper fuel settings result in cleaner exhaust emissions. How can Caterpillar Model 3306 PCNA diesel engines be properly adjusted? The proper fuel setting on diesel engines must be checked and adjusted for the intended altitude for operation of the machine. The work must be performed by either a Caterpillar authorized representative or a Caterpillar dealer. The mine operator is responsible to provide written documentation that the diesel engines are set to the proper fuel setting. The mine operator should be prepared to provide the following information to an MSHA inspector as evidence that the engine is properly adjusted for altitude:
2) sea level fuel setting (at 1000 feet and below) (Caterpillar can provide this information.), 3) altitude of mine, and 4) engine's current fuel setting (This must be based on a 3% per 1000 feet fuel deration starting above 1000 feet. Which permissible diesel-powered equipment requires retrofit? The permissible diesel-powered equipment labeled with a MSHA Approval Number beginning with "31-" and equipped with a Caterpillar Model 3306 PCNA diesel engine are affected. The injection fuel pump must be set properly for the intended altitude for operation of the machine in order to comply with the requirements of 30 CFR 36.22, and 30 CFR 36.44 (c). The correct altitude deration schedule for the Model 3306 PCNA is a fuel deration of 3% per 1000 feet starting above 1000 feet. What happens to permissible diesel-powered equipment that is not retrofitted? At the conclusion of the retrofit program, permissible diesel-powered equipment equipped with a Caterpillar Model 3306 PCNA diesel engine that DOES NOT have the fuel pump properly set for altitude WILL NOT be considered as MSHA approved. The retrofit program will conclude on April 30, 2005. What is the background for this bulletin? MSHA's Approval and Certification Center audits revealed that the fuel injection pumps may not be properly adjusted on these engines for operation at altitudes above 1000 feet. Section 36.44 (c) requires all diesel-powered equipment operating at elevations exceeding 1,000 feet above sea level be derated. The correct altitude deration schedule for the Model 3306 PCNA is a fuel deration of 3% per 1000 feet starting above 1000 feet to maintain the fuel:air ratio for the engine. What is MSHA's authority for this PIB? The Federal Mine Safety and Health Act of 1977; 30 CFR 36.22; 30 CFR 36.44 (c) Internet Availability This information bulletin may be viewed on the Internet by accessing MSHA's home page at http://www.MSHA.gov and then choosing Compliance Information and Program Information Bulletins. Who are the MSHA contact persons for this bulletin? Coal Mine Safety and Health, Safety Division Robert L. Phillips, (202) 693-9532 E-mail: Phillips.Robert@dol.gov Metal and Nonmetal Mine Safety and Health, Health Division Doris Cash, (202) 693-9631 E-mail: Cash.Doris@dol.gov Technical Support, Approval and Certification Center George Saseen, (304) 547-2072 E-mail: Saseen.George@dol.gov or Steve Cole, (304) 547-2304 E-mail: Cole.Stephen@dol.gov Who will receive this bulletin? MSHA Program Policy Manual Holders Miners' Representatives Underground Mine Operators Manufacturers of Mine Equipment and Mining Products Owners of Caterpillar Diesel Engines Special Interest Groups  |
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