SAFETY.CAT.COM

3176C and 3196MARINE ENGINESEngine Safety

Excerpted from Operation & Maintenance Manual (SEBU7040-04-01)

© 2007 CaterpillarAll Rights Reserved

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Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave 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 hazard warningsare 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 pictoriallypresented.

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.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 Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product 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 before youstart any job. Caterpillar dealers have the most current information available.

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.

6 SEBU7040-04Safety SectionSafety Messages

Safety Sectioni02507467

Safety MessagesSMCS Code: 1000; 7405

There may be several specific safety messages onan engine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all safetymessages.

Ensure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if the words cannot be read or if thepictures are not visible. When the safety messagesare cleaned, use a cloth, water, and soap. Do not usesolvent, gasoline, or other harsh chemicals to cleanthe safety messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that securesthe safety messages. The safety messages that areloosened could drop off of the engine.

Replace any damaged safety messages or missingsafety messages. If a safety message is attachedto a part of the engine that is replaced, install anew safety message on the replacement part. AnyCaterpillar dealer can provide new safety messages.

Do not operate or work on this engine unless youhave read and understand the instructions andwarnings in the Operation and Maintenance Man-ual. Failure to follow the instructions or heed thewarnings could result in injury or death. Contactany Caterpillar dealer for replacement manuals.Proper care is your responsibility.

The safety messages that are on the engine areillustrated and described below.

g00887196Illustration 1

(1) Electrical Shock HazardA safety message for the electronic unit injector islocated on each side of the valve cover base near thefront end of the engine.

Electrical shock hazard. The electronic unit injec-tor system uses 90-120 volts.

The ECM sends a high voltage signal to the injectorsolenoid. To help prevent personal injury, disconnectthe electronic unit injector enable circuit connector.Do not come in contact with the electronic unitinjector terminals while the engine is running.

SEBU7040-04 7Safety Section

General Hazard Information

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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 engine isrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engine and toeach operator control station. When it is appropriate,disconnect the starting controls.

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. Always start theengine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine exhaust to the outside.

Cautiously remove the following parts:

Note: To help prevent spraying or splashing ofpressurized fluids, hold a rag over the part that isbeing removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.Gradually loosen but do not remove the last two boltsor nuts that are located at opposite ends of the coverplate or the device. Before removing the last twobolts or nuts, pry the cover loose in order to relieveany spring pressure or other pressure.

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

• When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing.

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

• Ensure that all protective guards and all covers aresecured 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, 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 not understood.Use the proper tools. Replace any equipment thatis damaged or repair the equipment.

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).

Fluid PenetrationAlways 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.

8 SEBU7040-04Safety SectionGeneral Hazard Information

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

Containing Fluid SpillageCare must be used in order to ensure that the fluidsare contained during the inspection, the maintenance,the testing, the adjusting, and the repair of the engine.Prepare to collect the fluid with suitable containersbefore any compartment is opened or before anycomponent is disassembled.

Refer to Catalog, NENG2500, “Caterpillar DealerService Tool Catalog” for the following items:

• Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Asbestos Information

g00702022Illustration 3

Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machiningjobs.

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

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

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

Lines, Tubes, and HosesDo 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 to therecommended 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

SEBU7040-04 9Safety Section

Burn Prevention

Ensure that all of the clamps, the guards, and theheat shields are installed correctly. This will help toprevent these effects: vibration, rubbing against otherparts, and excessive heat during operation.

Dispose of Waste ProperlyImproperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

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Burn PreventionSMCS Code: 1000; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed 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.

CoolantWhen 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 steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level only after the engine hasbeen stopped.

Do not step on the engine in order to remove the fillercap. Use a ladder, if necessary. Ensure that the fillercap is cool before removing the filler cap. Removethe filler cap slowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot 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 components fromoil spray if there is a failure of a line, a tube, or a seal.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

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 not smokewhen batteries are serviced.

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

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Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405

Fire may result from lubricating oil or from fuel thatis sprayed 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 in anenvironment 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 of combustiblegases, consult your Caterpillar dealer in order toobtain additional information concerning suitableprotection devices.

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

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

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

10 SEBU7040-04Safety SectionCrushing Prevention and Cutting Prevention

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 contain flammablefluids. Do not flame cut pipes or tubes that containflammable fluids. Before pipes or tubes are weldedor flame cut, clean the inside and clean the outsideof the pipes or tubes thoroughly with nonflammablesolvent.

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 (if equipped)must be kept on the cells. Use the recommendedcables, connections, and battery box covers whenthe engine is operated.

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 before thenegative “−” 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 starting motoris not equipped with a negative “−” terminal, connectthe 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. Loosewiring, unattached wiring, or unnecessary wiringmust be eliminated. All wires and all cables must beof the recommended gauge. The wires and cablesmust be connected to a fuse or to a circuit breaker, asrequired. Do not bypass fuses and/or circuit breakers.Do not use a wire of a smaller gauge. Arcing orsparking could cause a fire. Secure connections,recommended wiring, and properly maintainedbattery cables will help to prevent arcing or sparking.

Fire ExtinguisherEnsure that a fire extinguisher is available. Be familiarwith the operation of the fire extinguisher. Inspectthe fire extinguisher and service the fire extinguisherregularly. Service the fire extinguisher according tothe recommendations on the instruction plate.

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Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when work beneaththe 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. The fanblades will throw objects or cut objects.

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

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

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Mounting and DismountingSMCS Code: 1000; 7405

Inspect the steps, the handholds, and the work areabefore mounting the engine. Keep these items cleanand keep these items in good repair.

SEBU7040-04 11Safety Section

Before Starting Engine

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 use anycontrols 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 mount theengine or when you dismount the engine. Use a handline to raise and lower tools or supplies.

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Before Starting EngineSMCS Code: 1000

Inspect the engine for potential hazards.

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.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

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

To stop an electrically controlled engine, cut thepower 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 start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

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 personal injury.

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

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.

EtherEther is poisonous and flammable.

Do not inhale ether, and do not allow ether to contactthe 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 of unauthorizedpersons.

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.

12 SEBU7040-04Safety SectionEngine Stopping

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Engine StoppingSMCS Code: 1000

Stop the engine according to the procedure inthe Operation and Maintenance Manual, “EngineStopping (Operation Section)” in order to avoidoverheating of the engine and accelerated wear ofthe engine components.

Use the Emergency Stop Button (if equipped) ONLYin an emergency situation. Do not use the EmergencyStop Button for normal engine stopping. After anemergency stop, DO NOT start the engine until theproblem that caused the emergency stop has beencorrected.

Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or an enginethat has been overhauled. This may be accomplishedby shutting off the fuel supply to the engine and/orshutting off the air supply to the engine.

To stop an electronically controlled engine, cut thepower 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.

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 starting motoris not equipped with a negative “−” terminal, connectthe 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, “EngineStarting” for specific starting instructions.

Grounding PracticesThe 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 the negativebattery terminal. The alternator must meet marineisolation requirements. The starting motor must alsomeet marine isolation requirements.

For engines which have an alternator that is groundedto an engine component, a ground strap MUSTconnect that component to the negative batteryterminal and the component MUST be electricallyisolated from the engine.

A bus bar with a direct path to the negative “-” batteryterminal is permissible and recommended for usefor all components that require a negative “-” batteryconnection. The bus bar should be directly connectedto the negative “-” battery terminal. A bonding cableshould also be connected from the cylinder block tothe 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 Special Instruction, REHS1187, “MarineEngine Electronic Installation Guide” for additionalinformation on grounding procedures.

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Engine ElectronicsSMCS Code: 1000; 1400; 1900

Tampering with the electronic system installationor the OEM wiring installation can be dangerousand could result in personal injury or death and/orengine damage.

SEBU7040-04 13Safety Section

Engine Electronics

This engine has a comprehensive, programmableEngine Monitoring System. The Engine ControlModule (ECM) has the ability to monitor the engineoperating conditions. If any of the engine parametersextend outside an allowable range, the ECM willinitiate an immediate action.

The following actions are available for enginemonitoring control: WARNING, DERATE, andSHUTDOWN. These engine monitoring modes havethe ability to limit engine speed and/or the enginepower.

Many of the parameters that are monitored by theECM can be programmed for the engine monitoringfunctions. The following parameters can be monitoredas a part of the Engine Monitoring System:

• Operating Altitude

• Engine Coolant Level

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Fuel Temperature

• Intake Manifold Air Temperature

• System Voltage

The Engine Monitoring package can vary for differentengine models and different engine applications.However, the monitoring system and the enginemonitoring control will be similar for all engines.

Note:Many of the engine control systems and displaymodules that are available for Caterpillar Engines willwork in unison with the Engine Monitoring System.Together, the two controls will provide the enginemonitoring function for the specific engine application.Refer to the Electronic Troubleshooting Manual formore information on the Engine Monitoring System.