SAFETY.CAT.

COM

3208
MARINE ENGINE
Engine Safety

Excerpted from Operation & Maintenance Manual (SEBU6090-03-01)

© 2007 Caterpillar
All Rights Reserved

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 i00056692

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
“WARNING” as 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.

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 6
Safety Section
Warning Signs and Labels

Safety Section Battery

i00890538

Warning Signs and Labels

SMCS Code: 1000; 7405

There may be several specific warning 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 warning
signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if Illustration 1
g00454398
the words cannot be read or if the pictures are not
visible. When the warning signs are cleaned, use a The warning label for the battery should be installed
cloth, water, and soap. Do not use solvent, gasoline, on the side of the engine or in a visible location near
or other harsh chemicals to clean the warning signs. the batteries. If the batteries are located on both
Solvents, gasoline, or harsh chemicals could loosen sides of the package, the warning label should be
the adhesive that secures the warning signs. The located on both sides of the engine.
warning signs that are loosened could drop off of
the engine.

Replace any damaged warning signs or missing

warning signs. If a warning sign is attached to a part
of the engine that is replaced, install a new warning
sign on the replacement part. Any Caterpillar dealer
can provide new warning signs.

Do not operate or work on this engine unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the g00455028
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
Improper jumper cable connections can cause an
The warning labels that may be found on the engine explosion resulting in personal injury.
are illustrated and described below.
Batteries may be located in separate compartments.
When you are using jump start cables, always
connect the positive “+” cable to the positive “+”
terminal of the battery that is connected to the starter
solenoid. Connect the negative “-” cable from the
external source to the negative “-” terminal of the
starter. If the engine is not equipped with a negative
“-” terminal on the starter, connect the negative
“-” cable from the external source to the engine
block. Follow the procedure in this Operation and
Maintenance Manual.

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 7
Safety Section
General Hazard Information

i00947640 • Wear a hard hat, protective glasses, and other

protective equipment, as required.
General Hazard Information
• When work is performed around an engine that is
SMCS Code: 1000; 7405 operating, wear protective devices for ears in order
to help prevent damage to hearing.
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls • Do not wear loose clothing or jewelry that can snag
before the engine is serviced or before the engine is on controls or on other parts of the engine.
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar • Ensure that all protective guards and all covers are
dealer. Attach the warning tags to the engine and to secured in place on the engine.
each operator control station. When it is appropriate,
disconnect the starting controls. • 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.

• The protective locks or the controls are in the
applied position.

g00104545 • Disconnect the batteries when maintenance

Illustration 2 is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Do not allow unauthorized personnel on the engine Tape the leads in order to help prevent sparks.
or around the engine when the engine is serviced.
• Do not attempt any repairs or any adjustments to
Engine exhaust contains products of combustion the engine while the engine is operating.
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
• Do not attempt any repairs that are not understood.
area. If the engine is in an enclosed area, vent the Use the proper tools. Replace any equipment that
engine exhaust to the outside. is damaged or repair the equipment.
Cautiously remove the following parts:
• For initial start-up of a new engine or for starting an
engine that has been serviced, make provisions to
• Filler caps stop the engine if an overspeed occurs. This may
be accomplished by shutting off the fuel supply
• Grease fittings and/or the air supply to the engine.
• Pressure taps • Start the engine from the operator’s position or
from the control panel that is in the local engine
• Breathers room.
• Drain plugs
Pressurized Air and Water
To help prevent spraying or splashing of pressurized
fluids, hold a rag over the part that is being removed. Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
Use caution when cover plates are removed. personal injury.
Gradually loosen but do not remove the last two bolts
or nuts that are located at opposite ends of the cover When pressurized air is used for cleaning, wear
plate or the device. Before removing the last two a protective face shield, protective clothing, and
bolts or nuts, pry the cover loose in order to relieve protective shoes.
any spring pressure or other pressure.

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 8
Safety Section
General Hazard Information

The maximum air pressure for cleaning purposes • Use a wet method to clean up asbestos debris.
must be below 205 kPa (30 psi). The maximum A vacuum cleaner that is equipped with a high
water pressure for cleaning purposes must be below efficiency particulate air filter can also be used.
275 kPa (40 psi).
• Use exhaust ventilation when parts that contain
Always wear eye protection for cleaning the cooling asbestos are machined.
system.
• Wear an approved respirator if there is no other
way to control the dust.
Fluid Penetration
Always use a board or cardboard when the engine • Comply with applicable rules and regulations for
the work place. In the USA, use the Occupational
components are checked for leaks. Leaking fluid
that is under pressure can cause serious injury or Safety and Health Administration requirements.
These OSHA requirements can be found in “29
possible death. This includes leaks that are the size
CFR 1910.1001”.
of a pin hole.

If fluid is injected into the skin, seek treatment • Obey environmental regulations for disposal of
asbestos.
immediately. Seek treatment from a doctor that is
familiar with this type of injury.
• Stay away from areas that might have asbestos
particles in the air.
Fluid Spillage
Care must be used in order to ensure that the
Lines, Tubes, and Hoses
fluids are contained during the inspection, the
Do not bend or strike high pressure lines. Do not
maintenance, the testing, the adjusting, and the
install lines, tubes, or hoses that are damaged.
repair of the engine. Make provision to collect the fluid
with a suitable container before any compartment is
Repair any fuel lines, oil lines, tubes, or hoses that
opened or before any component is disassembled.
are loose or damaged. Leaks can cause fires.
Refer to the Special Publication, NENG2500. This
publication explains the items that are needed for
Inspect all lines, tubes and hoses carefully. Do
collecting and for containing fluids that are used in
not use bare hands to check for leaks. Always
Caterpillar engines. Dispose of fluids according to
local regulations. use a board or cardboard for checking engine
components for leaks. Tighten all connections to the
recommended torque.
Asbestos Information
Check for the following conditions:
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar • End fittings that are damaged or leaking
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines • Outer covering that is chafed or cut
when any replacement parts that contain asbestos or
debris that contains asbestos are handled. • Wire that is exposed in reinforced hose
The asbestos in these components is usually sealed • Outer covering that is ballooning locally
or bonded in a resin. Handling these materials
normally is not hazardous unless airborne dust that • Flexible part of the hose that is kinked or crushed
contains asbestos is generated.
• Armoring that is embedded in the outer covering
Do not inhale dust that might be generated when
components that contain asbestos fibers are handled. Ensure that all of the clamps, the guards, and the
Inhaling this dust can be hazardous to your health. heat shields are installed correctly. This will help to
prevent the following items: vibration, rubbing against
If dust which may contain asbestos is present, follow other parts, and excessive heat during operation.
these guidelines:

• Never use compressed air for cleaning.

• Avoid abrasion of materials that contain asbestos.

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 9
Safety Section
Burn Prevention

i00910250 Batteries give off combustible gases which can

explode. Ensure proper ventilation for batteries that
Burn Prevention are in an enclosure. Never disconnect any charging
unit circuit or battery circuit cable from the battery
SMCS Code: 1000; 7405 when the charging unit is operating. A spark can
cause the combustible gases to ignite. Do not smoke
Do not touch any part of an operating engine. when batteries are serviced.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in Always thaw a frozen battery before jump starting the
the lubrication system, in the fuel system, or in the battery. Frozen batteries can explode.
cooling system before any lines, fittings or related
items are disconnected.
i00061925

Coolant Fire Prevention and Explosion

When the engine is at operating temperature, the Prevention
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or SMCS Code: 1000; 7405
to the engine contain hot coolant. When pressure is
relieved rapidly, the hot coolant can turn into steam. Fire may result from lubricating oil or from fuel that
is sprayed on hot surfaces. Fire may cause personal
Any contact with hot coolant or with steam can cause injury and property damage. Inspect all lines and
severe burns. Allow cooling system components to tubes for wear or for deterioration. The lines must
cool before the cooling system is drained. be routed, supported, or clamped securely. Tighten
all connections to the recommended torque. Leaks
Check the coolant level only after the engine has can cause fires.
been stopped.
Determine whether the engine will be operated in an
Do not step on the engine in order to remove the filler environment that allows combustible gases to be
cap. Use a ladder, if necessary. Ensure that the filler drawn in through the air inlet system. These gases
cap is cool before removing the filler cap. Remove could cause the engine to overspeed. This could
the filler cap slowly in order to relieve pressure. result in bodily injury, property damage, or damage
to the engine.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact If the application involves the presence of combustible
the skin, the eyes, or the mouth. gases, consult your Caterpillar dealer in order to
obtain additional information concerning suitable
protection devices.
Oils
Leaking fuel or fuel that is spilled onto hot surfaces or
Hot oil and hot components can cause personal onto electrical components can cause a fire.
injury. Do not allow hot oil or hot components to
contact the skin. All fuels, most lubricants, and some coolant mixtures
are flammable. Diesel fuel is flammable. Gasoline is
Keep all of the exhaust manifold and turbocharger flammable. The mixture of diesel fumes and gasoline
shields in place in order to protect components from fumes is extremely explosive.
oil spray if there is a failure of a line, a tube, or a seal.
Do not smoke while the engine is refueled. Do not
Batteries smoke in the refueling area.

Electrolyte is an acid. Electrolyte can cause personal Store all fuels and all lubricants in properly marked
injury. Do not allow electrolyte to contact the skin or containers. Store the protective containers in a safe
the eyes. Always wear protective glasses for servicing place.
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended. 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.

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 10
Safety Section
Crushing Prevention and Cutting Prevention

Do not weld on pipes or tubes that contain flammable Fire Extinguisher

fluids. Do not flame cut pipes or tubes that contain
flammable fluids. Before pipes or tubes are welded Ensure that a fire extinguisher is available. Be familiar
or flame cut, clean the inside and clean the outside with the operation of the fire extinguisher. Inspect
of the pipes or tubes thoroughly with nonflammable the fire extinguisher and service the fire extinguisher
solvent. regularly. Service the fire extinguisher according to
the recommendations on the instruction plate.
Do not allow flammable materials to accumulate on
the engine.
i00061952

Do not expose the engine to flames. Crushing Prevention and

Exhaust shields (if equipped) protect hot exhaust Cutting Prevention
components from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be SMCS Code: 1000; 7405
installed correctly.
Support the component properly when work beneath
Dispose of oil according to local regulations. Oil the component is performed.
filters and fuel filters must be properly installed. The
housing covers must be tightened to the proper Unless other maintenance instructions are provided,
torque when the housing covers are reinstalled. never attempt adjustments while the engine is
running.
Batteries must be kept clean. The covers (if equipped)
must be kept on the cells. Use the recommended Stay clear of all rotating parts and of all moving
cables, connections, and battery box covers when parts. Leave the guards in place until maintenance
the engine is operated. is performed. After the maintenance is performed,
reinstall the guards.
When the engine is started from an external source,
always connect the positive “+” jump start cable to Keep objects away from moving fan blades (if
the positive “+” terminal of the battery of the engine equipped). The fan blades will throw objects and the
that is being started. Make this connection before the fan blades can cut objects.
negative “−” jump start cable is connected.
When objects are struck, wear protective glasses in
To help prevent sparks from igniting combustible order to avoid injury to the eyes.
gases that are produced by some batteries, the
negative “−” jump start cable should be connected Chips or other debris may fly off objects when objects
last from the external power source to the negative are struck. Before objects are struck, ensure that no
“−” terminal of the starting motor. If the starting motor one will be injured by flying debris.
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
i00776840

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
Mounting and Dismounting
before the engine is operated. Repair all frayed SMCS Code: 1000; 7405
electrical wires before the engine is operated. See
the Operation and Maintenance Manual for specific Inspect the steps, the handholds, and the work area
starting instructions. before mounting the engine. Keep these items clean
and keep these items in good repair.
Wiring must be kept in good condition, properly
routed, and securely attached. Routinely inspect Mount the engine and dismount the engine only at
the wiring for wear or for deterioration. Loose locations that have steps and/or handholds. Do not
wiring, unattached wiring, or unnecessary wiring climb on the engine, and do not jump off the engine.
must be eliminated. All wires and all cables must
be of the recommended gauge. The wires and Face the engine in order to mount the engine or
cables must be connected to a fuse or to a circuit dismount the engine. Maintain a three-point contact
breaker, if necessary. Do not bypass fuses and/or with the steps and handholds. Use two feet and one
circuit breakers. Do not use a wire of a smaller hand or use one foot and two hands. Do not use any
gauge. Arcing or sparking could cause a fire. Secure controls as handholds.
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.

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 11
Safety Section
Before Starting Engine

Do not stand on components which cannot support All protective guards and all protective covers must
your weight. Use an adequate ladder or use a work be installed if the engine must be started in order
platform. Secure the climbing equipment so that the to perform service procedures. To help prevent an
equipment will not move. accident that is caused by parts in rotation, work
around the parts carefully.
Do not carry tools or supplies when you are
climbing. Use a hand line or other means for carrying Start the engine from the operator’s compartment or
equipment up to the work area. from the engine start switch.

Always start the engine according to the procedure

i00317208
that is described in this Operation and Maintenance
Before Starting Engine Manual, “Engine Starting” topic (Operation Section).
Knowing the correct procedure will help to prevent
SMCS Code: 1000 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)
Before starting the engine, ensure that no one is on, and/or the lube oil heater (if equipped) is working
underneath, or close to the engine. Ensure that the properly, check the water temperature gauge and the
area is free of personnel. oil temperature gauge during the heater operation.

Ensure that the engine is equipped with a lighting Engine exhaust contains products of combustion
system that is suitable for the conditions. Ensure that that can be harmful to your health. Always start the
all lights work properly. engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
All protective guards and all protective covers must vent the engine exhaust to the outside.
be installed if the engine must be started in order
to perform service procedures. To help prevent an Ether
accident that is caused by parts in rotation, work
around the parts carefully. Ether is poisonous and flammable.

Do not bypass the automatic shutoff circuits. Do not Do not inhale ether, and do not allow ether to contact
disable the automatic shutoff circuits. The circuits are the skin. Personal injury could result.
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent Do not smoke while ether cylinders are changed.
engine damage.
Use ether in well ventilated areas.
On the initial start-up of a new engine or an engine
that has been serviced, be prepared to stop the Use ether with care in order to avoid fires.
engine if an overspeed condition occurs. This may
be accomplished by shutting off the fuel supply to the Keep ether cylinders out of the reach of unauthorized
engine and/or shutting off the air supply to the engine. persons.

See the Service Manual for repairs and for Store ether cylinders in authorized storage areas
adjustments. only.

Do not store ether cylinders in direct sunlight or at

i00912327
temperatures above 39 °C (102 °F).
Engine Starting Discard the ether cylinders in a safe place. Do not
SMCS Code: 1000 puncture the ether cylinders. Do not burn the ether
cylinders.
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.

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 12
Safety Section
Engine Stopping

i00912338 Uncontrolled electrical circuit paths can result in

damage to main bearings, to crankshaft journal
Engine Stopping surfaces, and to aluminum components. Uncontrolled
electrical circuit paths can also cause electrical noise.
SMCS Code: 1000 Electrical noise may degrade the performance of the
vessel and of the radio.
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine The alternator, the starting motor, and all of the
according to this Operation and Maintenance Manual, electrical systems MUST be grounded to the negative
“Engine Stopping” topic (Operation Section). battery terminal. The alternator and the starting motor
must also meet marine isolation requirements.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency For engines which have an alternator that is grounded
Stop Button for normal engine stopping. After an to an engine component, a ground strap MUST
emergency stop, DO NOT start the engine until the connect that component to the negative battery
problem that caused the emergency stop has been terminal and the component MUST be electrically
corrected. isolated from the engine.
On the initial start-up of a new engine or an engine A bus bar with a direct path to the negative battery
that has been serviced, make provisions to stop the terminal is permissible and recommended for use for
engine if an overspeed condition occurs. This may be all common ground connections.
accomplished by shutting off the fuel supply and/or
the air supply to the engine.

i00061975

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.

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.

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