SAFETY.CAT.COM

3116 and 3126 MARINE ENGINESEngine Safety

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

© 2007 CaterpillarAll Rights Reserved

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Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazardwarnings are not heeded, 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”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written orpictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Thewarnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,work method or operating technique that is not specifically recommended by Caterpillar is used,you must satisfy yourself that it is safe for you and for others. You should also ensure that theproduct will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information beforeyou start any job. Caterpillar dealers have the most current information available. For a list of the mostcurrent publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

6Safety SectionSafety Signs and Labels

Safety Section

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Safety Signs and LabelsSMCS Code: 1000; 7405

There may be several specific safety signs on anengine. The exact location of the hazards and thedescription of the hazards are reviewed in thissection. Please become familiar with all safety signs.

Ensure that all of the safety signs are legible. Cleanthe safety signs or replace the safety signs if thewords cannot be read or if the pictures are notvisible. When the safety signs are cleaned, use acloth, water, and soap. Do not use solvent, gasoline,or other harsh chemicals to clean the safety signs.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety signs. Thesafety signs that are loosened could drop off ofthe engine.

Replace any damaged safety signs or missingsafety signs. If a safety sign is attached to a part ofthe engine that is replaced, install a new safety signon the replacement part. Any Caterpillar dealer canprovide new safety signs.

Do not work on the engine and do not operate theengine unless the instructions and the warningsin the Operation and Maintenance Manual areunderstood. Proper care is your responsibility.Failure to follow the instructions or failure to heedthe warnings could result in injury or in death.

The following section illustrates and the followingsection describes the safety labels which may befound on the engine.

Starting Aid

g00513124Illustration 1

The safety label for the starting aid is located onthe valve cover.

g00283559

If the engine is equipped with an air inlet heaterfor cold weather starting, do not use starting aidsthat contain an aerosol such as ether. Using suchtypes of starting aids could result in an explosionand personal injury.

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General Hazard InformationSMCS Code: 1000; 7405

Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controlsbefore the engine is serviced or before the engineis repaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engineand to each operator control station. When it isappropriate, disconnect the starting controls.

7Safety Section

General Hazard Information

g00104545Illustration 2

Do not allow unauthorized personnel on the engineor around the engine when the engine is serviced.

Engine exhaust contains products of combustionwhich may be harmful to your health. Alwaysstart the engine and operate the engine in a wellventilated area. If the engine is in an enclosed area,vent the engine exhaust to the outside.

Cautiously remove the following parts:

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

To help prevent spraying or splashing of pressurizedfluids, hold a rag over the part that is beingremoved.

Use caution when cover plates are removed.Gradually loosen but do not remove the last twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in orderto relieve any spring pressure or other pressure.

• Wear a hard hat, protective glasses, and otherprotective equipment, as required.

• When work is performed around an engine thatis operating, wear protective devices for ears inorder to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that cansnag on controls or on other parts of the engine.

• Ensure that all protective guards and all coversare secured in place on the engine.

• Never put maintenance fluids into glasscontainers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, performthe maintenance under the following conditions:

• The engine is stopped. Ensure that the enginecannot be started.

• Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are notunderstood. Use the proper tools. Replaceany equipment that is damaged or repair theequipment.

Pressurized Air and Water

Pressurized air and/or water can cause debrisand/or hot water to be blown out. This could resultin personal injury.

When pressurized air is used for cleaning, weara protective face shield, protective clothing, andprotective shoes.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must bebelow 275 kPa (40 psi).

Always wear eye protection for cleaning the coolingsystem.

Fluid Penetration

Always use a board or cardboard when the enginecomponents are checked for leaks. Leaking fluidthat is under pressure can cause serious injury orpossible death. This includes leaks that are the sizeof a pin hole.

If fluid is injected into the skin, seek treatmentimmediately. Seek treatment from a doctor that isfamiliar with this type of injury.

8Safety SectionBurn Prevention

Fluid Spillage

Care must be used in order to ensure that thefluids are contained during the inspection, themaintenance, the testing, the adjusting, and therepair of the engine. Make provision to collectthe fluid with a suitable container before anycompartment is opened or before any componentis disassembled. Refer to the Special Publication,NENG2500. This publication explains the items thatare needed for collecting and for containing fluidsthat are used in Caterpillar engines. Dispose offluids according to local regulations.

Asbestos Information

Caterpillar equipment and replacement parts thatare shipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCaterpillar replacement parts. Use the followingguidelines when any replacement parts that containasbestos or debris that contains asbestos arehandled.

The asbestos in these components is usually sealedor bonded in a resin. Handling these materialsnormally is not hazardous unless airborne dust thatcontains asbestos is generated.

Do not inhale dust that might be generated whencomponents that contain asbestos fibers arehandled. Inhaling this dust can be hazardous toyour 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 highefficiency particulate air filter can also be used.

• Use exhaust ventilation when parts that containasbestos are machined.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulations forthe work place. In the USA, use the OccupationalSafety and Health Administration requirements.These OSHA requirements can be found in “29CFR 1910.1001”.

• Obey environmental regulations for disposal ofasbestos.

• Stay away from areas that might have asbestosparticles in the air.

Lines, Tubes, and Hoses

Do not bend or strike high pressure lines. Do notinstall lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses thatare loose or damaged. Leaks can cause fires.

Inspect all lines, tubes and hoses carefully. Donot use bare hands to check for leaks. Alwaysuse a board or cardboard for checking enginecomponents for leaks. Tighten all connections tothe 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 theheat shields are installed correctly. This will helpto prevent these effects: vibration, rubbing againstother parts, and excessive heat during operation.

i00910250

Burn PreventionSMCS Code: 1000; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenance isperformed on the engine. Relieve all pressure inthe lubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

Coolant

When the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant. When pressure isrelieved rapidly, the hot coolant can turn into steam.

Any contact with hot coolant or with steamcan cause severe burns. Allow cooling systemcomponents to cool before the cooling system isdrained.

9Safety Section

Fire Prevention and Explosion Prevention

Check the coolant level only after the engine hasbeen stopped.

Do not step on the engine in order to remove thefiller cap. Use a ladder, if necessary. Ensure thatthe filler cap is cool before removing the filler cap.Remove the filler cap slowly in order to relievepressure.

Cooling system conditioner contains alkali. Alkalican cause personal injury. Do not allow alkali tocontact the skin, the eyes, or the mouth.

Oils

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

Keep all of the exhaust manifold and turbochargershields in place in order to protect componentsfrom oil spray if there is a failure of a line, a tube,or a seal.

Batteries

Electrolyte is an acid. Electrolyte can causepersonal injury. Do not allow electrolyte to contactthe skin or the eyes. Always wear protective glassesfor servicing batteries. Wash hands after touchingthe batteries and connectors. Use of gloves isrecommended.

Batteries give off combustible gases which canexplode. Ensure proper ventilation for batteries thatare in an enclosure. Never disconnect any chargingunit circuit or battery circuit cable from the batterywhen the charging unit is operating. A spark cancause the combustible gases to ignite. Do notsmoke when batteries are serviced.

Always thaw a frozen battery before jump startingthe battery. Frozen batteries can explode.

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Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405

Fire may result from lubricating oil or from fuel that issprayed on hot surfaces. Fire may cause personalinjury and property damage. Inspect all lines andtubes for wear or for deterioration. The lines mustbe properly routed. The lines must have adequatesupport and secure clamps. Tighten all connectionsto the recommended torque. Leaks can cause fires.

Determine whether the engine will be operated inan environment that allows combustible gases to bedrawn in through the air inlet system. These gasescould cause the engine to overspeed. This couldresult in bodily injury, property damage, or damageto the engine.

If the application involves the presence ofcombustible gases, consult your Caterpillar dealerin order to obtain additional information concerningsuitable protection devices.

Leaking fuel or fuel that is spilled onto hot surfacesor onto electrical components can cause a fire.

All fuels, most lubricants, and some coolant mixturesare flammable. Diesel fuel is flammable. Gasolineis flammable. The mixture of diesel fumes andgasoline fumes is extremely explosive.

Do not smoke while the engine is refueled. Do notsmoke in the refueling area.

Store all fuels and all lubricants in properly markedcontainers. Store the protective containers in a safeplace.

Do not smoke in battery charging areas. Batteriesgive off flammable fumes which can explode.

Do not smoke in areas that contain flammablematerial.

Store oily rags and other flammable material inprotective containers.

Do not weld on pipes or tubes that containflammable fluids. Do not flame cut pipes or tubesthat contain flammable fluids. Before pipes or tubesare welded or flame cut, clean the inside and cleanthe outside of the pipes or tubes thoroughly withnonflammable solvent.

Do not allow flammable materials to accumulate onthe engine.

Do not expose the engine to flames.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a tube, or a seal failure. Exhaust shields must beinstalled correctly.

Dispose of oil according to local regulations. Oilfilters and fuel filters must be properly installed. Thehousing covers must be tightened to the propertorque when the housing covers are reinstalled.

Batteries must be kept clean. The covers (ifequipped) must be kept on the cells. Use therecommended cables, connections, and batterybox covers when the engine is operated.

10Safety SectionCrushing Prevention and Cutting Prevention

When the engine is started from an external source,always connect the positive “+” jump start cable tothe positive “+” terminal of the battery of the enginethat is being started. Make this connection beforethe negative “−” jump start cable is connected.

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative “−” jump start cable should be connectedlast from the external power source to the negative“−” terminal of the starting motor. If the startingmotor is not equipped with a negative “−” terminal,connect the jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Before the engine is operated,tighten all loose electrical wires. Repair all frayedelectrical wires.

Wiring must be kept in good condition. Wires mustbe properly routed and securely attached. Routinelyinspect the wiring for wear or for deterioration.Loose wiring, unattached wiring, or unnecessarywiring must be eliminated. All wires and all cablesmust be of the recommended gauge. The wiresand cables must be connected to a fuse or to acircuit breaker, as required. Do not bypass fusesand/or circuit breakers. Do not use a wire of asmaller gauge. Arcing or sparking could cause afire. Secure connections, recommended wiring,and properly maintained battery cables will help toprevent arcing or sparking.

Fire Extinguisher

Ensure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Service the fire extinguisheraccording to the recommendations on the instructionplate.

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Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when workbeneath the component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades (ifequipped). The fan blades will throw objects andthe fan blades can cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects whenobjects are struck. Before objects are struck, ensurethat no one will be injured by flying debris.

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Mounting and DismountingSMCS Code: 1000; 7405

Inspect the steps, the handholds, and the workarea before mounting the engine. Keep these itemsclean and keep these items in good repair.

Mount the engine and dismount the engine only atlocations that have steps and/or handholds. Do notclimb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine ordismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use one foot and two hands. Do not useany controls as handholds.

Do not stand on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

Do not carry tools or supplies when you areclimbing. Use a hand line or other means forcarrying equipment up to the work area.

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Before Starting EngineSMCS Code: 1000

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel.

Ensure that the engine is equipped with a lightingsystem that is suitable for the conditions. Ensurethat all lights work properly.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

11Safety Section

Engine Starting

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuitsare provided in order to help prevent personalinjury. The circuits are also provided in order to helpprevent engine damage.

For the initial start-up of a new engine and forstart-up of an engine that has been serviced,prepare to stop the engine if an overspeed occurs.This may be accomplished by shutting off the fueland the air supply to the engine.

See the Service Manual for repairs and foradjustments.

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Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine startswitch or to the controls, DO NOT start the engineor move the controls. Consult with the person thatattached the warning tag before the engine isstarted.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator’s compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in this Operation and MaintenanceManual, “Engine Starting” topic (Operation Section).Knowing the correct procedure will help to preventmajor damage to the engine components. Knowingthe procedure will also help to prevent personalinjury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingproperly, check the water temperature gaugeand the oil temperature gauge during the heateroperation.

Engine exhaust contains products of combustionthat can be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.

Ether

Ether is poisonous and flammable.

Do not inhale ether, and do not allow ether tocontact the skin. Personal injury could result.

Do not smoke while ether cylinders are changed.

Use ether in well ventilated areas.

Use ether with care in order to avoid fires.

Keep ether cylinders out of the reach ofunauthorized persons.

Store ether cylinders in authorized storage areasonly.

Do not store ether cylinders in direct sunlight or attemperatures above 49 �C (120 �F).

Discard the ether cylinders in a safe place. Do notpuncture the ether cylinders. Do not burn the ethercylinders.

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Engine StoppingSMCS Code: 1000

To avoid overheating of the engine and acceleratedwear of the engine components, stop the engineaccording to this Operation and MaintenanceManual, “Engine Stopping” topic (OperationSection).

Use the Emergency Stop Button (if equipped)ONLY in an emergency situation. DO NOT use theEmergency Stop Button for normal engine stopping.After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.

On the initial start-up of a new engine or an enginethat has been serviced, make provisions to stop theengine if an overspeed condition occurs. This maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine.

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Electrical SystemSMCS Code: 1000; 1400

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

12Safety SectionElectrical System

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative “−” jump start cable should be connectedlast from the external power source to the negative“−” terminal of the starting motor. If the startingmotor is not equipped with a negative “−” terminal,connect the jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is operated. Repair all frayedelectrical wires before the engine is started. Seethe Operation and Maintenance Manual for specificstarting instructions.

Grounding Practices

The electrical system for the vessel and the enginemust be properly grounded. Proper groundingis necessary for optimum engine performanceand reliability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.Uncontrolled electrical circuit paths can also causeelectrical noise. Electrical noise may degrade theperformance of the vessel and of the radio.

The alternator, the starting motor, and all of theelectrical systems MUST be grounded to thenegative battery terminal. The alternator must meetmarine isolation requirements. The starting motormust also meet marine isolation requirements.

For engines which have an alternator that isgrounded to an engine component, a ground strapMUST connect that component to the negativebattery terminal and the component MUST beelectrically isolated from the engine.

A bus bar with a direct path to the negative “-”battery terminal is permissible and recommendedfor use for all components that require a negative “-”battery connection. The bus bar should be directlyconnected to the negative “-” battery terminal. Abonding cable should also be connected from thecylinder block to the bus bar on the negative “-”battery connection.

Use of a bus bar ensures that the Electronic ControlModule (ECM) and all of the components that areconnected to the ECM have a common referencepoint.

Refer to the Installation Guide, “Power SupplyConnections To The Starting System” for additionalinformation on grounding procedures.