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SAFETY.CAT.

COM

3116 and 3126 MARINE ENGINES
Engine Safety

Excerpted from Operation & Maintenance Manual (SEBU6100-02-01)

© 2007 Caterpillar All Rights Reserved

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. strength and material. illustrations. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. skills and tools to perform these functions properly. you must satisfy yourself that it is safe for you and for others. bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”. personal injury or death. A person must be alert to potential hazards. If these hazard warnings are not heeded. maintenance or repair of this product can be dangerous and could result in injury or death. procedure. The message that appears under the warning explains the hazard and can be either written or pictorially presented. maintenance and repair information. pressures. The specifications. torques. specifications. but not limited to. “WARNING” or “CAUTION”. not all inclusive. If a tool. and illustrations in this publication are on the basis of information that was available at the time that the publication was written. Improper operation. When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including. lubrication. work method or operating technique that is not specifically recommended by Caterpillar is used. lubrication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. maintenance or repair procedures that you choose. adjustments. The warnings in this publication and on the product are. These changes can affect the service that is given to the product. and other items can change at any time. For a list of the most current publication form numbers available. lubrication. You should also ensure that the product will not be damaged or be made unsafe by the operation. see the Service Manual Contents Microfiche.i01097883 Important Safety Information Most accidents that involve product operation. . Caterpillar dealers have the most current information available. The information. This person should also have the necessary training. physical dimensions. Do not operate or perform any lubrication. until you have read and understood the operation. REG1139F. maintenance or repair on this product. therefore. Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Obtain the complete and most current information before you start any job. The Safety Alert “WARNING” label is shown below. measurements. Failure to heed this warning can lead to premature failures. Safety precautions and warnings are provided in this manual and on the product. maintenance and repair are caused by failure to observe basic safety rules or precautions. product damage. type.

. Proper care is your responsibility. gasoline. or other harsh chemicals to clean the safety signs. If a safety sign is attached to a part of the engine that is replaced. Illustration 1 g00513124 The safety label for the starting aid is located on the valve cover. i01038557 General Hazard Information SMCS Code: 1000. The following section illustrates and the following section describes the safety labels which may be found on the engine. or harsh chemicals could loosen the adhesive that secures the safety signs. disconnect the starting controls. The exact location of the hazards and the description of the hazards are reviewed in this section. 7405 Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. water. Do not use solvent. Solvents. do not use starting aids that contain an aerosol such as ether. use a cloth. Any Caterpillar dealer can provide new safety signs. The safety signs that are loosened could drop off of the engine. Clean the safety signs or replace the safety signs if the words cannot be read or if the pictures are not visible. Failure to follow the instructions or failure to heed the warnings could result in injury or in death. Using such types of starting aids could result in an explosion and personal injury. g00283559 If the engine is equipped with an air inlet heater for cold weather starting. Replace any damaged safety signs or missing safety signs. gasoline. and soap. Do not work on the engine and do not operate the engine unless the instructions and the warnings in the Operation and Maintenance Manual are understood. SEHS7332) are available from your Caterpillar dealer. Please become familiar with all safety signs. These warning tags (Special Instruction. 7405 There may be several specific safety signs on an engine. When the safety signs are cleaned. Ensure that all of the safety signs are legible. Attach the warning tags to the engine and to each operator control station.6 Safety Section Safety Signs and Labels Safety Section i01001241 Starting Aid Safety Signs and Labels SMCS Code: 1000. When it is appropriate. install a new safety sign on the replacement part.

This could result in personal injury. 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. If fluid is injected into the skin. • Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. • Report all necessary repairs. Ensure that the engine cannot be started. as required. perform the maintenance under the following conditions: • The engine is stopped. protective clothing. • Do not attempt any repairs that are not understood. Use the proper tools. Engine exhaust contains products of combustion which may be harmful to your health. • When work is performed around an engine that is operating. seek treatment immediately. hold a rag over the part that is being removed. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). Cautiously remove the following parts: is performed or when the electrical system is serviced. and other protective equipment. Leaking fluid that is under pressure can cause serious injury or possible death. • Filler caps • Grease fittings • Pressure taps • Breathers • Drain plugs To help prevent spraying or splashing of pressurized fluids. If the engine is in an enclosed area. wear a protective face shield. • Disconnect the batteries when maintenance Illustration 2 g00104545 Do not allow unauthorized personnel on the engine or around the engine when the engine is serviced. • Ensure that all protective guards and all covers are secured in place on the engine. wear protective devices for ears in order to help prevent damage to hearing. Glass containers can break. Replace any equipment that is damaged or repair the equipment. Always start the engine and operate the engine in a well ventilated area. • Wear a hard hat. Fluid Penetration Always use a board or cardboard when the engine components are checked for leaks. Unless other instructions are provided. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). • Use all cleaning solutions with care. Before removing the last two bolts or nuts. pry the cover loose in order to relieve any spring pressure or other pressure. protective glasses. and protective shoes. Always wear eye protection for cleaning the cooling system. Disconnect the battery ground leads.7 Safety Section General Hazard Information • Never put maintenance fluids into glass containers. Seek treatment from a doctor that is familiar with this type of injury. Pressurized Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out. When pressurized air is used for cleaning. Tape the leads in order to help prevent sparks. vent the engine exhaust to the outside. This includes leaks that are the size of a pin hole. .

Inspect all lines. NENG2500. way to control the dust. Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is disassembled. The coolant is also under pressure. . Do not install lines. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the lubrication system. the hot coolant can turn into steam. the guards. Repair any fuel lines. • Wear an approved respirator if there is no other • Comply with applicable rules and regulations for the work place. and the repair of the engine. or hoses that are loose or damaged. Inhaling this dust can be hazardous to your health. The asbestos in these components is usually sealed or bonded in a resin. use the Occupational Safety and Health Administration requirements. The radiator and all lines to the heaters or to the engine contain hot coolant. and Hoses Do not bend or strike high pressure lines. Lines. or hoses that are damaged. follow these guidelines: • 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. Any contact with hot coolant or with steam can cause severe burns. Always use a board or cardboard for checking engine components for leaks. the maintenance. • Use exhaust ventilation when parts that contain asbestos are machined. Refer to the Special Publication. oil lines. Burn Prevention SMCS Code: 1000.1001”. tubes. tubes and hoses carefully. In the USA. Handling these materials normally is not hazardous unless airborne dust that contains asbestos is generated. This publication explains the items that are needed for collecting and for containing fluids that are used in Caterpillar engines. the adjusting. A vacuum cleaner that is equipped with a high efficiency particulate air filter can also be used. • Avoid abrasion of materials that contain asbestos. If dust which may contain asbestos is present. This will help to prevent these effects: vibration. Do not inhale dust that might be generated when components that contain asbestos fibers are handled. i00910250 • Never use compressed air for cleaning.8 Safety Section Burn Prevention Fluid Spillage Care must be used in order to ensure that the fluids are contained during the inspection. Check for the following conditions: Asbestos Information Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free. tubes. Dispose of fluids according to local regulations. Leaks can cause fires. • Use a wet method to clean up asbestos debris. Coolant When the engine is at operating temperature. the testing. Tighten all connections to the recommended torque. and the heat shields are installed correctly. fittings or related items are disconnected. 7405 Do not touch any part of an operating engine. Do not use bare hands to check for leaks. These OSHA requirements can be found in “29 CFR 1910. Tubes. • Stay away from areas that might have asbestos particles in the air. • Obey environmental regulations for disposal of asbestos. or in the cooling system before any lines. and excessive heat during operation. When pressure is relieved rapidly. Allow cooling system components to cool before the cooling system is drained. 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. rubbing against other parts. the engine coolant is hot. in the fuel system.

Gasoline is flammable. A spark can cause the combustible gases to ignite. Use the recommended cables. or a seal. or damage to the engine. a tube. Alkali can cause personal injury. The covers (if equipped) must be kept on the cells. Exhaust shields must be installed correctly. Batteries Electrolyte is an acid. Frozen batteries can explode. Fire may cause personal injury and property damage. If the application involves the presence of combustible gases. Store all fuels and all lubricants in properly marked containers. or a seal failure. Tighten all connections to the recommended torque. a tube. The mixture of diesel fumes and gasoline fumes is extremely explosive. Leaks can cause fires. The lines must be properly routed. Wash hands after touching the batteries and connectors. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. Oils Hot oil and hot components can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. 7405 Fire may result from lubricating oil or from fuel that is sprayed on hot surfaces. Use of gloves is recommended. Do not smoke when batteries are serviced. Do not smoke in the refueling area. or the mouth. Batteries give off flammable fumes which can explode. Ensure proper ventilation for batteries that are in an enclosure. These gases could cause the engine to overspeed. This could result in bodily injury. if necessary. The housing covers must be tightened to the proper torque when the housing covers are reinstalled. consult your Caterpillar dealer in order to obtain additional information concerning suitable protection devices. Do not smoke while the engine is refueled. Batteries must be kept clean. Do not expose the engine to flames. and some coolant mixtures are flammable. All fuels. Cooling system conditioner contains alkali. Determine whether the engine will be operated in an environment that allows combustible gases to be drawn in through the air inlet system. Use a ladder. Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line.9 Safety Section Fire Prevention and Explosion Prevention Check the coolant level only after the engine has been stopped. Oil filters and fuel filters must be properly installed. Store oily rags and other flammable material in protective containers. Do not step on the engine in order to remove the filler cap. Do not allow alkali to contact the skin. Ensure that the filler cap is cool before removing the filler cap. connections. Store the protective containers in a safe place. Batteries give off combustible gases which can explode. and battery box covers when the engine is operated. The lines must have adequate support and secure clamps. the eyes. Always wear protective glasses for servicing batteries. Always thaw a frozen battery before jump starting the battery. Before pipes or tubes are welded or flame cut. Do not weld on pipes or tubes that contain flammable fluids. Dispose of oil according to local regulations. Do not allow flammable materials to accumulate on the engine. Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire. Keep all of the exhaust manifold and turbocharger shields in place in order to protect components from oil spray if there is a failure of a line. Do not smoke in areas that contain flammable material. clean the inside and clean the outside of the pipes or tubes thoroughly with nonflammable solvent. . Diesel fuel is flammable. i01028355 Fire Prevention and Explosion Prevention SMCS Code: 1000. Electrolyte can cause personal injury. Do not flame cut pipes or tubes that contain flammable fluids. property damage. Do not smoke in battery charging areas. Inspect all lines and tubes for wear or for deterioration. Remove the filler cap slowly in order to relieve pressure. Do not allow hot oil or hot components to contact the skin. most lubricants.

The fan blades will throw objects and the fan blades can cut objects. ensure that no one will be injured by flying debris. Use two feet and one hand or use one foot and two hands. Service the fire extinguisher according to the recommendations on the instruction plate. Ensure that the area is free of personnel. the handholds. always connect the positive “+” jump start cable to the positive “+” terminal of the battery of the engine that is being started. Crushing Prevention and Cutting Prevention SMCS Code: 1000. and properly maintained battery cables will help to prevent arcing or sparking. When objects are struck. Ensure that all lights work properly. Unless other maintenance instructions are provided. Be familiar with the operation of the fire extinguisher. If the starting motor is not equipped with a negative “−” terminal. Maintain a three-point contact with the steps and handholds. i00776840 Mounting and Dismounting SMCS Code: 1000. Check the electrical wires daily for wires that are loose or frayed. ensure that no one is on. Use a hand line or other means for carrying equipment up to the work area. never attempt adjustments while the engine is running. Arcing or sparking could cause a fire. Loose wiring. 7405 Inspect the steps. 7405 Support the component properly when work beneath the component is performed. Keep objects away from moving fan blades (if equipped). Chips or other debris may fly off objects when objects are struck. and the work area before mounting the engine. Before objects are struck. Before the engine is operated. underneath. Before starting the engine. connect the jump start cable to the engine block. Do not carry tools or supplies when you are climbing. Repair all frayed electrical wires. work around the parts carefully. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. or close to the engine. and do not jump off the engine. To help prevent sparks from igniting combustible gases that are produced by some batteries. After the maintenance is performed. Do not bypass fuses and/or circuit breakers. Inspect the fire extinguisher and service the fire extinguisher regularly. Stay clear of all rotating parts and of all moving parts. Do not use a wire of a smaller gauge. reinstall the guards. Wiring must be kept in good condition. Do not stand on components which cannot support your weight. recommended wiring. i00061952 Before Starting Engine SMCS Code: 1000 Inspect the engine for potential hazards. Keep these items clean and keep these items in good repair. the negative “−” jump start cable should be connected last from the external power source to the negative “−” terminal of the starting motor. Do not climb on the engine. Use an adequate ladder or use a work platform.10 Safety Section Crushing Prevention and Cutting Prevention When the engine is started from an external source. . Wires must be properly routed and securely attached. i01072501 Fire Extinguisher Ensure that a fire extinguisher is available. Make this connection before the negative “−” jump start cable is connected. Routinely inspect the wiring for wear or for deterioration. tighten all loose electrical wires. or unnecessary wiring must be eliminated. Leave the guards in place until maintenance is performed. Do not use any controls as handholds. Face the engine in order to mount the engine or dismount the engine. as required. All wires and all cables must be of the recommended gauge. unattached wiring. Secure connections. Ensure that the engine is equipped with a lighting system that is suitable for the conditions. To help prevent an accident that is caused by parts in rotation. The wires and cables must be connected to a fuse or to a circuit breaker. Secure the climbing equipment so that the equipment will not move. Mount the engine and dismount the engine only at locations that have steps and/or handholds. wear protective glasses in order to avoid injury to the eyes.

Do not store ether cylinders in direct sunlight or at temperatures above 49 C (120 F). After an emergency stop. DO NOT start the engine or move the controls. Personal injury could result. “Engine Stopping” topic (Operation Section). Ether Ether is poisonous and flammable. Keep ether cylinders out of the reach of unauthorized persons. Always start the engine and operate the engine in a well ventilated area. Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not burn the ether cylinders. “Engine Starting” topic (Operation Section). Use ether with care in order to avoid fires. A spark can cause the combustible gases that are produced by some batteries to ignite. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. Do not puncture the ether cylinders. Use ether in well ventilated areas. DO NOT use the Emergency Stop Button for normal engine stopping. Knowing the correct procedure will help to prevent major damage to the engine components. On the initial start-up of a new engine or an engine that has been serviced. make provisions to stop the engine if an overspeed condition occurs. i01103904 Do not inhale ether. work around the parts carefully. To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working properly. Engine Stopping SMCS Code: 1000 To avoid overheating of the engine and accelerated wear of the engine components. Store ether cylinders in authorized storage areas only. Consult with the person that attached the warning tag before the engine is started. Start the engine from the operator’s compartment or from the engine start switch. . vent the engine exhaust to the outside. prepare to stop the engine if an overspeed occurs. Do not smoke while ether cylinders are changed. i01080974 Electrical System SMCS Code: 1000. Do not disable the automatic shutoff circuits. Always start the engine according to the procedure that is described in this Operation and Maintenance Manual. This may be accomplished by shutting off the fuel and the air supply to the engine. Engine exhaust contains products of combustion that can be harmful to your health. and do not allow ether to contact the skin. If the engine is started in an enclosed area. See the Service Manual for repairs and for adjustments. Knowing the procedure will also help to prevent personal injury. DO NOT start the engine until the problem that caused the emergency stop has been corrected. 1400 Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. This may be accomplished by shutting off the fuel supply and/or the air supply to the engine. The circuits are also provided in order to help prevent engine damage. For the initial start-up of a new engine and for start-up of an engine that has been serviced. i01032808 Engine Starting SMCS Code: 1000 If a warning tag is attached to the engine start switch or to the controls. stop the engine according to this Operation and Maintenance Manual. The circuits are provided in order to help prevent personal injury. check the water temperature gauge and the oil temperature gauge during the heater operation.11 Safety Section Engine Starting Do not bypass the automatic shutoff circuits. To help prevent an accident that is caused by parts in rotation. Discard the ether cylinders in a safe place.

Proper grounding is necessary for optimum engine performance and reliability. Electrical noise may degrade the performance of the vessel and of the radio. The bus bar should be directly connected to the negative “-” battery terminal. a ground strap MUST connect that component to the negative battery terminal and the component MUST be electrically isolated from the engine. Refer to the Installation Guide. The alternator must meet marine isolation requirements.12 Safety Section Electrical System To help prevent sparks from igniting combustible gases that are produced by some batteries. A bus bar with a direct path to the negative “-” battery terminal is permissible and recommended for use for all components that require a negative “-” battery connection. Grounding Practices The electrical system for the vessel and the engine must be properly grounded. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions. the starting motor. The alternator. The starting motor must also meet marine isolation requirements. If the starting motor is not equipped with a negative “−” terminal. Tighten all loose electrical wires before the engine is operated. For engines which have an alternator that is grounded to an engine component. and to aluminum components. Uncontrolled electrical circuit paths can result in damage to main bearings. the negative “−” jump start cable should be connected last from the external power source to the negative “−” terminal of the starting motor. and all of the electrical systems MUST be grounded to the negative battery terminal. connect the jump start cable to the engine block. “Power Supply Connections To The Starting System” for additional information on grounding procedures. to crankshaft bearing journal surfaces. A bonding cable should also be connected from the cylinder block to the bus bar on the negative “-” battery connection. Uncontrolled electrical circuit paths can also cause electrical noise. . Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths. Check the electrical wires daily for wires that are loose or frayed. Use of a bus bar ensures that the Electronic Control Module (ECM) and all of the components that are connected to the ECM have a common reference point.