SAFETY.CAT.

COM

3116 and 3126

MARINE ENGINES
Engine Safety

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

2007 Caterpillar
All Rights Reserved

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i01097883

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person 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 and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings 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 or
pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings 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 the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was 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 can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for this

product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

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6
Safety Section
Safety Signs and Labels

Starting Aid

Safety Section
i01001241

Safety Signs and Labels

SMCS Code: 1000; 7405
There may be several specific safety signs on an
engine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiar with all safety signs.
Ensure that all of the safety signs are legible. Clean
the safety signs or replace the safety signs if the
words cannot be read or if the pictures are not
visible. When the safety signs are cleaned, use a
cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the safety signs.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety signs. The
safety signs that are loosened could drop off of
the engine.

Illustration 1

g00513124

The safety label for the starting aid is located on

the valve cover.

Replace any damaged safety signs or missing

safety signs. If a safety sign is attached to a part of
the engine that is replaced, install a new safety sign
on the replacement part. Any Caterpillar dealer can
provide new safety signs.
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. Proper care is your responsibility.
Failure to follow the instructions or failure to heed
the warnings could result in injury or in death.
The following section illustrates and the following
section describes the safety labels which may be
found on the engine.

g00283559

If the engine is equipped with an air inlet heater

for cold weather starting, do not use starting aids
that contain an aerosol such as ether. Using such
types of starting aids could result in an explosion
and personal injury.
i01038557

General Hazard Information

SMCS Code: 1000; 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. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine
and to each operator control station. When it is
appropriate, disconnect the starting controls.

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7
Safety Section
General Hazard Information

Never put maintenance fluids into glass

containers. Glass containers can break.

Use all cleaning solutions with care.

Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:

The engine is stopped. Ensure that the engine

cannot be started.

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.
Engine exhaust contains products of combustion
which may be harmful to your health. Always
start the engine and operate the engine in a well
ventilated 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 pressurized
fluids, hold a rag over the part that is being
removed.
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. Before removing the
last two bolts or nuts, pry the cover loose in order
to relieve any spring pressure or other pressure.

Wear a hard hat, protective glasses, and other

protective equipment, as required.

When work is performed around an engine that

is operating, wear protective devices for ears in
order to help prevent damage to hearing.

Do not wear loose clothing or jewelry that can

snag on controls or on other parts of the engine.

Ensure that all protective guards and all covers

are secured in place on the engine.

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is performed or when the electrical system is

serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

Do not attempt any repairs that are not

understood. Use the proper tools. Replace
any equipment that is damaged or repair the
equipment.

Pressurized Air and Water

Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result
in personal injury.
When pressurized air is used for cleaning, wear
a protective face shield, protective clothing, and
protective shoes.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be
below 275 kPa (40 psi).
Always wear eye protection for cleaning the cooling
system.

Fluid Penetration
Always use a board or cardboard when the engine
components are checked for leaks. Leaking fluid
that is under pressure can cause serious injury or
possible death. This includes leaks that are the size
of a pin hole.
If fluid is injected into the skin, seek treatment
immediately. Seek treatment from a doctor that is
familiar with this type of injury.

8
Safety Section
Burn Prevention

Fluid Spillage

Stay away from areas that might have asbestos

particles in the air.

Care must be used in order to ensure that the

fluids are contained during the inspection, the
maintenance, the testing, the adjusting, and the
repair of the engine. Make provision to collect
the fluid with a suitable container before any
compartment is opened or before any component
is disassembled. Refer to the Special Publication,
NENG2500. This publication explains the items that
are needed for collecting and for containing fluids
that are used in Caterpillar engines. Dispose of
fluids according to local regulations.

Asbestos Information
Caterpillar equipment and replacement parts that
are shipped from Caterpillar are asbestos free.
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.

Lines, Tubes, and Hoses

Do not bend or strike high pressure lines. Do not
install lines, tubes, or hoses that are damaged.
Repair any fuel lines, oil lines, tubes, or hoses that
are loose or damaged. Leaks can cause fires.
Inspect all lines, tubes and hoses carefully. Do
not use bare hands to check for leaks. Always
use a board or cardboard for checking engine
components for leaks. Tighten all connections to
the 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

The asbestos in these components is usually sealed

or bonded in a resin. Handling these materials
normally is not hazardous unless airborne dust that
contains asbestos is generated.
Do not inhale dust that might be generated when
components that contain asbestos fibers are
handled. Inhaling this dust can be hazardous to
your 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 high
efficiency particulate air filter can also be used.

Use exhaust ventilation when parts that contain

asbestos are machined.

Wear an approved respirator if there is no other

way to control the dust.

Comply with applicable rules and regulations for

the work place. In the USA, use the Occupational
Safety and Health Administration requirements.
These OSHA requirements can be found in 29
CFR 1910.1001.
Obey environmental regulations for disposal of
asbestos.

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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 the
heat shields are installed correctly. This will help
to prevent these effects: vibration, rubbing against
other parts, and excessive heat during operation.
i00910250

Burn Prevention
SMCS Code: 1000; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in
the lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. When pressure is
relieved rapidly, the hot coolant can turn into steam.
Any contact with hot coolant or with steam
can cause severe burns. Allow cooling system
components to cool before the cooling system is
drained.

9
Safety Section
Fire Prevention and Explosion Prevention

Check the coolant level only after the engine has

been stopped.
Do not step on the engine in order to remove the
filler cap. Use a ladder, if necessary. Ensure that
the filler cap is cool before removing the filler cap.
Remove the filler cap slowly in order to relieve
pressure.
Cooling system conditioner contains alkali. Alkali
can cause personal injury. Do not allow alkali to
contact the skin, the eyes, or the mouth.

If the application involves the presence of

combustible gases, consult your Caterpillar dealer
in order to obtain additional information concerning
suitable protection devices.
Leaking fuel or fuel that is spilled onto hot surfaces
or onto electrical components can cause a fire.

Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
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, a tube,
or a seal.

Batteries
Electrolyte is an acid. Electrolyte can cause
personal injury. Do not allow electrolyte to contact
the skin or the eyes. Always wear protective glasses
for servicing batteries. Wash hands after touching
the batteries and connectors. Use of gloves is
recommended.
Batteries give off combustible gases which can
explode. Ensure proper ventilation for batteries that
are in an enclosure. Never disconnect any charging
unit circuit or battery circuit cable from the battery
when the charging unit is operating. A spark can
cause the combustible gases to ignite. Do not
smoke when batteries are serviced.
Always thaw a frozen battery before jump starting
the battery. Frozen batteries can explode.
i01028355

Fire Prevention and Explosion

Prevention
SMCS Code: 1000; 7405
Fire may result from lubricating oil or from fuel that is
sprayed on hot surfaces. Fire may cause personal
injury and property damage. Inspect all lines and
tubes for wear or for deterioration. The lines must
be properly routed. The lines must have adequate
support and secure clamps. Tighten all connections
to the recommended torque. Leaks can cause fires.

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Determine whether the engine will be operated in

an environment that allows combustible gases to be
drawn in through the air inlet system. These gases
could cause the engine to overspeed. This could
result in bodily injury, property damage, or damage
to the engine.

All fuels, most lubricants, and some coolant mixtures

are flammable. Diesel fuel is flammable. Gasoline
is flammable. The mixture of diesel fumes and
gasoline fumes is extremely explosive.
Do not smoke while the engine is refueled. Do not
smoke in the refueling area.
Store all fuels and all lubricants in properly marked
containers. Store the protective containers in a safe
place.
Do not smoke in battery charging areas. Batteries
give off flammable fumes which can explode.
Do not smoke in areas that contain flammable
material.
Store oily rags and other flammable material in
protective containers.
Do not weld on pipes or tubes that contain
flammable fluids. Do not flame cut pipes or tubes
that contain flammable fluids. Before pipes or tubes
are welded or flame cut, clean the inside and clean
the outside of the pipes or tubes thoroughly with
nonflammable solvent.
Do not allow flammable materials to accumulate on
the engine.
Do not expose the engine to flames.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
Dispose of oil according to local regulations. Oil
filters and fuel filters must be properly installed. The
housing covers must be tightened to the proper
torque when the housing covers are reinstalled.
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.

10
Safety Section
Crushing Prevention and Cutting Prevention

When the engine is started from an external source,

always connect the positive + jump start cable to
the positive + terminal of the battery of the engine
that is being started. Make this connection before
the negative jump start cable is connected.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative jump start cable should be connected
last from the external power source to the negative
terminal of the starting motor. If the starting
motor is not equipped with a negative terminal,
connect the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Before the engine is operated,
tighten all loose electrical wires. Repair all frayed
electrical wires.
Wiring must be kept in good condition. Wires must
be properly routed and securely attached. Routinely
inspect the wiring for wear or for deterioration.
Loose wiring, unattached wiring, or unnecessary
wiring must be eliminated. All wires and all cables
must be of the recommended gauge. The wires
and cables must be connected to a fuse or to a
circuit breaker, as required. Do not bypass fuses
and/or circuit breakers. Do not use a wire of a
smaller gauge. Arcing or sparking could cause a
fire. Secure connections, recommended wiring,
and properly maintained battery cables will help to
prevent arcing or sparking.

Fire Extinguisher
Ensure 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. Service the fire extinguisher
according to the recommendations on the instruction
plate.
i00061952

Keep objects away from moving fan blades (if

equipped). The fan blades will throw objects and
the fan blades can cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when
objects are struck. Before objects are struck, ensure
that no one will be injured by flying debris.
i00776840

Mounting and Dismounting

SMCS Code: 1000; 7405
Inspect the steps, the handholds, and the work
area before mounting the engine. Keep these items
clean and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use
any controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you are
climbing. Use a hand line or other means for
carrying equipment up to the work area.
i01072501

Before Starting Engine

Crushing Prevention and

Cutting Prevention

SMCS Code: 1000

SMCS Code: 1000; 7405

Before starting the engine, ensure that no one is on,

underneath, or close to the engine. Ensure that the
area is free of personnel.

Support the component properly when work

beneath the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
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Inspect the engine for potential hazards.

Ensure that the engine is equipped with a lighting

system that is suitable for the conditions. Ensure
that all lights work properly.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.

11
Safety Section
Engine Starting

Do not bypass the automatic shutoff circuits. Do not

disable the automatic shutoff circuits. The circuits
are provided in order to help prevent personal
injury. The circuits are also provided in order to help
prevent engine damage.

Do not inhale ether, and do not allow ether to

contact the skin. Personal injury could result.
Do not smoke while ether cylinders are changed.
Use ether in well ventilated areas.

For the initial start-up of a new engine and for

start-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 fuel
and the air supply to the engine.

Use ether with care in order to avoid fires.

Keep ether cylinders out of the reach of
unauthorized persons.
Store ether cylinders in authorized storage areas
only.

See the Service Manual for repairs and for

adjustments.
i01103904

Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start
switch or to the controls, DO NOT start the engine
or move the controls. Consult with the person that
attached the warning tag before the engine is
started.

Do not store ether cylinders in direct sunlight or at

temperatures above 49 C (120 F).
Discard the ether cylinders in a safe place. Do not
puncture the ether cylinders. Do not burn the ether
cylinders.
i01032808

Engine Stopping
SMCS Code: 1000

All protective guards and all protective covers must

be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operators compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in this Operation and Maintenance
Manual, Engine Starting topic (Operation Section).
Knowing the correct procedure will help to prevent
major damage to the engine components. Knowing
the procedure will also help to prevent personal
injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge
and the oil temperature gauge during the heater
operation.
Engine exhaust contains products of combustion
that can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.

Ether
Ether is poisonous and flammable.

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To avoid overheating of the engine and accelerated

wear of the engine components, stop the engine
according to this Operation and Maintenance
Manual, Engine Stopping topic (Operation
Section).
Use the Emergency Stop Button (if equipped)
ONLY in an emergency situation. DO NOT use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
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. This may
be accomplished by shutting off the fuel supply
and/or the air supply to the engine.
i01080974

Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.

12
Safety Section
Electrical System

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the
negative jump start cable should be connected
last from the external power source to the negative
terminal of the starting motor. If the starting
motor is not equipped with a negative terminal,
connect the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual for specific
starting instructions.

Grounding Practices
The electrical system for the vessel and the engine
must be properly grounded. Proper grounding
is necessary for optimum engine performance
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Uncontrolled electrical circuit paths can also cause
electrical noise. Electrical noise may degrade the
performance of the vessel and of the radio.
The alternator, the starting motor, and all of the
electrical systems MUST be grounded to the
negative battery terminal. The alternator must meet
marine isolation requirements. The starting motor
must also meet marine isolation requirements.
For engines which have an alternator that is
grounded to an engine component, a ground strap
MUST connect that component to the negative
battery terminal and the component MUST be
electrically isolated from the engine.
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. The bus bar should be directly
connected to the negative - battery terminal. A
bonding cable should also be connected from the
cylinder block to the bus bar on the negative -
battery connection.
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.
Refer to the Installation Guide, Power Supply
Connections To The Starting System for additional
information on grounding procedures.

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