SAFETY.CAT.

COM

3412E and C30

MARINE ENGINES
Engine Safety

Excerpted from Operation & Maintenance Manual (SEBU7178-06)

2009 Caterpillar
All Rights Reserved

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 i03602780

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.
A non-exhaustive list of 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. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. 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 become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
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.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications 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 or
death.

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 6 SEBU7178-06
Safety Section
Safety Messages

Safety Section
i02553902

Safety Messages
SMCS Code: 1000; 7405

There are several specific safety messages on

this engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.

Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace
the illustrations if the illustrations are not visible.
When you clean the safety messages, use a cloth,
water and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.

Replace any safety message that is damaged, or

missing. If a safety message is attached to a part
that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.

The safety messages that may be found on the

engine are illustrated and described below.

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 SEBU7178-06 7
Safety Section
Safety Messages

g01278236
Illustration 1

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 8 SEBU7178-06
Safety Section
Safety Messages

Universal Warning (1) Hot Fluid Under Pressure (2)

The universal safety message is located on each The safety message for hot fluid under pressure is
side of the valve covers. located on the expansion tank in front of the filler
neck.

g00934493
g00930639

Do not operate or work on this equipment unless

you have read and understand the instructions Pressurized system! Hot coolant can cause seri-
and warnings in the Operation and Maintenance ous burns, injury or death. To open the cooling
Manuals. Failure to follow the instructions or system filler cap, stop the engine and wait until
heed the warnings could result in serious injury the cooling system components are cool. Loosen
or death. the cooling system pressure cap slowly in order to
relieve the pressure. Read and understand the Op-
eration and Maintenance Manual before perform-
ing any cooling system maintenance.

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 SEBU7178-06 9
Safety Section
General Hazard Information

Clutch (If Equipped) Engine Lifting

g00367054
Illustration 3
Typical Example

The safety message for lifting the engine with a fuel

tank is located on the fuel tank (if equipped).

g00107406
Illustration 2
Typical Example

The safety message for the clutch is located on the

clutch housing (if equipped).

g00100728

Lift eyes or tank can fail when lifting tank con-

taining fluids resulting in possible personal injury.
g00107407 Drain tank of all fluids before lifting.

Rotating gears can cause entanglement of fingers

or entanglement of hands. Do not service this i02965953
component without first reading the operator manual.
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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 10 SEBU7178-06
Safety Section
General Hazard Information

Ensure that all protective guards and all covers are

secured in place on the engine.

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

g00104545
cannot be started.
Illustration 4

The protective locks or the controls are in the

Do not allow unauthorized personnel on the engine applied position.
or around the engine when the engine is serviced.
Disconnect the batteries when maintenance
Engine exhaust contains products of combustion is performed or when the electrical system is
which may be harmful to your health. Always start the serviced. Disconnect the battery ground leads.
engine and operate the engine in a well ventilated Tape the leads in order to help prevent sparks.
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside. For initial start-up of a new engine or for starting an
engine that has been serviced, make provisions to
Cautiously remove the following parts: stop the engine if an overspeed occurs. This may
be accomplished by shutting off the fuel supply
Note: To help prevent spraying or splashing of and/or the air supply to the engine.
pressurized fluids, hold a rag over the part that is
being removed. Start the engine with the operator controls. Never
short across the starting motor terminals or the
Filler caps batteries. This could bypass the engine neutral
start system and/or the electrical system could be
Grease fittings damaged.
Pressure taps
Pressurized Air and Water
Breathers
Pressurized air and/or water can cause debris
Drain plugs and/or hot water to be blown out. This could result in
personal injury.
Use caution when cover plates are removed.
Gradually loosen but do not remove the last two bolts When pressurized air and/or pressurized water is
or nuts that are located at opposite ends of the cover used for cleaning, wear protective clothing, protective
plate or the device. Before removing the last two shoes, and eye protection. Eye protection includes
bolts or nuts, pry the cover loose in order to relieve goggles or a protective face shield.
any spring pressure or other pressure.
The maximum air pressure for cleaning purposes
Wear a hard hat, protective glasses, and other must be reduced to 205 kPa (30 psi) when the air
protective equipment, as required. nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
Do not attempt any repairs that are not understood. equipment. The maximum water pressure for
Use the proper tools. Replace any equipment that cleaning purposes must be below 275 kPa (40 psi).
is damaged or repair the equipment. Always wear eye protection for cleaning the cooling
system.
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.

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 SEBU7178-06 11
Safety Section
General Hazard Information

Fluid Penetration Use caution. Avoid inhaling dust that might be

generated when you handle components that contain
Always use a board or cardboard when the engine asbestos fibers. Inhaling this dust can be hazardous
components are checked for leaks. Leaking fluid to your health. The components that may contain
that is under pressure can cause serious injury or asbestos fibers are brake pads, brake bands, lining
possible death. This includes leaks that are the size material, clutch plates, and some gaskets. The
of a pin hole. asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
If fluid is injected into the skin, seek treatment handling is not hazardous unless airborne dust that
immediately. Seek treatment from a doctor that is contains asbestos is generated.
familiar with this type of injury.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
Containing Fluid Spillage
Care must be used in order to ensure that the fluids Never use compressed air for cleaning.
are contained during the inspection, the maintenance,
the testing, the adjusting, and the repair of the engine. Avoid brushing materials that contain asbestos.
Prepare to collect the fluid with suitable containers
before any compartment is opened or before any Avoid grinding materials that contain asbestos.
component is disassembled.
Use a wet method in order to clean up asbestos
materials.
Refer to Catalog, NENG2500, Caterpillar Dealer
Service Tool Catalog for the following items:
A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
Tools that are suitable for collecting fluids and used.
equipment that is suitable for collecting fluids

Obey all local regulations for the disposal of liquids. Use exhaust ventilation on permanent machining
jobs.

Asbestos Information 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 United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in 29 CFR 1910.1001.

Obey environmental regulations for the disposal

of asbestos.

Stay away from areas that might have asbestos

particles in the air.

Illustration 5
g00702022 Lines, Tubes, and Hoses
Caterpillar equipment and replacement parts that are Do not bend or strike high pressure lines. Do not
shipped from Caterpillar are asbestos free. Caterpillar install lines, tubes, or hoses that are damaged.
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines Repair any fuel lines, oil lines, tubes, or hoses that
when you handle any replacement parts that contain are loose or damaged. Leaks can cause fires.
asbestos or when you handle asbestos debris.
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:

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 12 SEBU7178-06
Safety Section
Burn Prevention

End fittings that are damaged or leaking Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
Outer covering that is chafed or cut the skin, the eyes, or the mouth.

Wire that is exposed in reinforced hose Oils

Outer covering that is ballooning locally Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
Flexible part of the hose that is kinked or crushed skin. Also, do not allow hot components to contact
the skin.
Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and the Batteries
heat shields are installed correctly. This will help to
prevent these effects: vibration, rubbing against other Electrolyte is an acid. Electrolyte can cause personal
parts, and excessive heat during operation. 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
Dispose of Waste Properly and connectors. Use of gloves is recommended.
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be i01028355
disposed of according to local regulations.
Fire Prevention and Explosion
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
Prevention
drain, or into any source of water. SMCS Code: 1000; 7405

i01480768 Fire may result from lubricating oil or from fuel that
is sprayed on hot surfaces. Fire may cause personal
Burn Prevention injury and property damage. Inspect all lines and
tubes for wear or for deterioration. The lines must
SMCS Code: 1000; 7405 be properly routed. The lines must have adequate
support and secure clamps. Tighten all connections
Do not touch any part of an operating engine. to the recommended torque. Leaks can cause fires.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure Determine whether the engine will be operated in an
in the air system, in the hydraulic system, in the environment that allows combustible gases to be
lubrication system, in the fuel system, or in the drawn in through the air inlet system. These gases
cooling system before any lines, fittings or related could cause the engine to overspeed. This could
items are disconnected. result in bodily injury, property damage, or damage
to the engine.
Coolant If the application involves the presence of combustible
gases, consult your Caterpillar dealer in order to
When the engine is at operating temperature, the
obtain additional information concerning suitable
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or protection devices.
to the engine contain hot coolant.
Leaking fuel or fuel that is spilled onto hot surfaces or
Any contact with hot coolant or with steam can cause onto electrical components can cause a fire.
severe burns. Allow cooling system components to
All fuels, most lubricants, and some coolant mixtures
cool before the cooling system is drained.
are flammable. Diesel fuel is flammable. Gasoline is
flammable. The mixture of diesel fumes and gasoline
Check the coolant level after the engine has stopped
fumes is extremely explosive.
and the engine has been allowed to cool.
Do not smoke while the engine is refueled. Do not
Ensure that the filler cap is cool before removing the
smoke in the refueling area.
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
Store all fuels and all lubricants in properly marked
order to relieve pressure.
containers. Store the protective containers in a safe
place.

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 SEBU7178-06 13
Safety Section
Crushing Prevention and Cutting Prevention

Do not smoke in battery charging areas. Batteries Wiring must be kept in good condition. Wires must
give off flammable fumes which can explode. be properly routed and securely attached. Routinely
inspect the wiring for wear or for deterioration. Loose
Do not smoke in areas that contain flammable wiring, unattached wiring, or unnecessary wiring
material. must be eliminated. All wires and all cables must be
of the recommended gauge. The wires and cables
Store oily rags and other flammable material in must be connected to a fuse or to a circuit breaker, as
protective containers. required. Do not bypass fuses and/or circuit breakers.
Do not use a wire of a smaller gauge. Arcing or
Do not weld on pipes or tubes that contain flammable sparking could cause a fire. Secure connections,
fluids. Do not flame cut pipes or tubes that contain recommended wiring, and properly maintained
flammable fluids. Before pipes or tubes are welded battery cables will help to prevent arcing or sparking.
or flame cut, clean the inside and clean the outside
of the pipes or tubes thoroughly with nonflammable
solvent.
Fire Extinguisher
Ensure that a fire extinguisher is available. Be familiar
Do not allow flammable materials to accumulate on
with the operation of the fire extinguisher. Inspect
the engine.
the fire extinguisher and service the fire extinguisher
regularly. Service the fire extinguisher according to
Do not expose the engine to flames.
the recommendations on the instruction plate.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line, i01359666
a tube, or a seal failure. Exhaust shields must be
installed correctly. Crushing Prevention and
Dispose of oil according to local regulations. Oil
Cutting Prevention
filters and fuel filters must be properly installed. The SMCS Code: 1000; 7405
housing covers must be tightened to the proper
torque when the housing covers are reinstalled. Support the component properly when work beneath
the component is performed.
Batteries must be kept clean. The covers (if equipped)
must be kept on the cells. Use the recommended Unless other maintenance instructions are provided,
cables, connections, and battery box covers when never attempt adjustments while the engine is
the engine is operated. running.
When the engine is started from an external source, Stay clear of all rotating parts and of all moving
always connect the positive + jump start cable to parts. Leave the guards in place until maintenance
the positive + terminal of the battery of the engine is performed. After the maintenance is performed,
that is being started. Make this connection before the reinstall the guards.
negative jump start cable is connected.
Keep objects away from moving fan blades. The fan
To help prevent sparks from igniting combustible blades will throw objects or cut objects.
gases that are produced by some batteries, the
negative jump start cable should be connected When objects are struck, wear protective glasses in
last from the external power source to the negative order to avoid injury to the eyes.
terminal of the starting motor. If the starting motor
is not equipped with a negative terminal, connect Chips or other debris may fly off objects when objects
the jump start cable to the engine block. are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
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 i01372247
electrical wires.
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.

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 14 SEBU7178-06
Safety Section
Before Starting Engine

Mount the engine and dismount the engine only at All protective guards and all protective covers must
locations that have steps and/or handholds. Do not be installed if the engine must be started in order
climb on the engine, and do not jump off the engine. to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
Face the engine in order to mount the engine or around the parts carefully.
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one Do not bypass the automatic shutoff circuits. Do not
hand or use one foot and two hands. Do not use any disable the automatic shutoff circuits. The circuits are
controls as handholds. provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
Do not stand on components which cannot support engine damage.
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the See the Service Manual for repairs and for
equipment will not move. adjustments.

Do not carry tools or supplies when you mount the

i01103904
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies. Engine Starting
i03560601 SMCS Code: 1000

Before Starting Engine If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
SMCS Code: 1000 the controls. Consult with the person that attached
the warning tag before the engine is started.
NOTICE
For initial start-up of a new or rebuilt engine, and for All protective guards and all protective covers must
start-up of an engine that has been serviced, make be installed if the engine must be started in order
provision to shut the engine off should an overspeed to perform service procedures. To help prevent an
occur. This may be accomplished by shutting off the accident that is caused by parts in rotation, work
air and/or fuel supply to the engine. around the parts carefully.

Start the engine from the operator's compartment or

from the engine start switch.

Engine exhaust contains products of combustion Always start the engine according to the procedure
which may be harmful to your health. Always start that is described in this Operation and Maintenance
and operate the engine in a well ventilated area Manual, Engine Starting topic (Operation Section).
and, if in an enclosed area, vent the exhaust to the Knowing the correct procedure will help to prevent
outside. major damage to the engine components. Knowing
the procedure will also help to prevent personal injury.
Inspect the engine for potential hazards. To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Do not start the engine or move any of the controls properly, check the water temperature gauge and the
if there is a DO NOT OPERATE warning tag or oil temperature gauge during the heater operation.
similar warning tag attached to the start switch or to
the controls. Engine exhaust contains products of combustion
that can be harmful to your health. Always start the
Before starting the engine, ensure that no one is on, engine and operate the engine in a well ventilated
underneath, or close to the engine. Ensure that the area. If the engine is started in an enclosed area,
area is free of personnel. vent the engine exhaust to the outside.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all Ether
lights work properly, if equipped.
Ether is poisonous and flammable.

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.

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 SEBU7178-06 15
Safety Section
Engine Stopping

Use ether in well ventilated areas. To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
Use ether with care in order to avoid fires. negative jump start cable should be connected
last from the external power source to the negative
Keep ether cylinders out of the reach of unauthorized terminal of the starting motor. If the starting motor
persons. is not equipped with a negative terminal, connect
the jump start cable to the engine block.
Store ether cylinders in authorized storage areas
only. Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
Do not store ether cylinders in direct sunlight or at before the engine is operated. Repair all frayed
temperatures above 49 C (120 F). electrical wires before the engine is started. See
the Operation and Maintenance Manual, Engine
Discard the ether cylinders in a safe place. Do not Starting for specific starting instructions.
puncture the ether cylinders. Do not burn the ether
cylinders. Grounding Practices
i01462046 The electrical system for the vessel and the engine
must be properly grounded. Proper grounding
Engine Stopping is necessary for optimum engine performance
and reliability. Improper grounding will result in
SMCS Code: 1000 uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Stop the engine according to the procedure in
the Operation and Maintenance Manual, Engine Uncontrolled electrical circuit paths can result in
Stopping (Operation Section) in order to avoid damage to main bearings, to crankshaft bearing
overheating of the engine and accelerated wear of journal surfaces, and to aluminum components.
the engine components. Uncontrolled electrical circuit paths can also cause
electrical noise. Electrical noise may degrade the
Use the Emergency Stop Button (if equipped) ONLY performance of the vessel and of the radio.
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an The alternator, the starting motor, and all of the
emergency stop, DO NOT start the engine until the electrical systems MUST be grounded to the negative
problem that caused the emergency stop has been battery terminal. The alternator must meet marine
corrected. isolation requirements. The starting motor must also
meet marine isolation requirements.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine For engines which have an alternator that is grounded
that has been overhauled. This may be accomplished to an engine component, a ground strap MUST
by shutting off the fuel supply to the engine and/or connect that component to the negative battery
shutting off the air supply to the engine. terminal and the component MUST be electrically
isolated from the engine.
To stop an electronically controlled engine, cut the
power to 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
i02456933
connection. The bus bar should be directly connected
Electrical System to the negative - battery terminal. A bonding cable
should also be connected from the cylinder block to
SMCS Code: 1000; 1400 the bus bar on the negative - battery connection.

Never disconnect any charging unit circuit or battery Use of a bus bar ensures that the Electronic Control
circuit cable from the battery when the charging unit Module (ECM) and all of the components that are
is operating. A spark can cause the combustible connected to the ECM have a common reference
gases that are produced by some batteries to ignite. point.

Refer to Special Instruction, REHS1187, Marine

Engine Electronic Installation Guide for additional
information on grounding procedures.

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