SAFETY.CAT.

COM

3408C, 3412, 3412C and

3412D HIGH PERFORMANCE
MARINE ENGINES
Engine Safety

Excerpted from Operation & Maintenance Manual (SEBU6497-07-01)

© 2007 Caterpillar
All Rights Reserved
 i01658146

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.

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.
6 SEBU6497-07
Safety Section
Safety Messages

Safety Section Battery

The safety message for the battery is located on the
i01976189 side of the engine or near the batteries.
Safety Messages
SMCS Code: 1000; 7405

There may be several specific safety messages on

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

Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if the words cannot be read or if the
pictures are not visible. When the safety messages
g00294510
are cleaned, 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 messages. The safety messages that are Improper jumper cable connections can cause an
loosened could drop off of the engine. explosion resulting in personal injury.

Replace any damaged safety messages or missing

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

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
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

The safety messages that may be found on the

engine are illustrated and described below.
SEBU6497-07 7
Safety Section
General Hazard Information

Clutch

g00104545
Illustration 2
g00107406
Illustration 1
Do not allow unauthorized personnel on the engine
The safety message for the clutch is located on the or around the engine when the engine is serviced.
clutch housing (if equipped).
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:

Note: To help prevent spraying or splashing of

pressurized fluids, hold a rag over the part that is
being removed.

• Filler caps

g00107407 • Grease fittings

Rotating gears can cause entanglement of the • Pressure taps

fingers. Rotating gears can cause entanglement of
the hands. Do not service this component without • Breathers
first reading the operator manual.
• Drain plugs
i02345910 Use caution when cover plates are removed.
Gradually loosen but do not remove the last two bolts
General Hazard Information or nuts that are located at opposite ends of the cover
plate or the device. Before removing the last two
SMCS Code: 1000; 7405 bolts or nuts, pry the cover loose in order to relieve
any spring pressure or other pressure.
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls • Wear a hard hat, protective glasses, and other
before the engine is serviced or before the engine is protective equipment, as required.
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar • When work is performed around an engine that is
dealer. Attach the warning tags to the engine and to operating, wear protective devices for ears in order
each operator control station. When it is appropriate, to help prevent damage to hearing.
disconnect the starting controls.
• 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.
8 SEBU6497-07
Safety Section
General Hazard Information

• Never put maintenance fluids into glass containers. Refer to Catalog, NENG2500, “Caterpillar Dealer
Glass containers can break. Service Tool Catalog” for the following items:

• Use all cleaning solutions with care. • Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Report all necessary repairs.
• Tools that are suitable for containing fluids and
Unless other instructions are provided, perform equipment that is suitable for containing fluids
the maintenance under the following conditions:
Obey all local regulations for the disposal of liquids.
• The engine is stopped. Ensure that the engine
cannot be started.
Asbestos Information
• Disconnect the batteries when maintenance
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. g00702022
Illustration 3
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective Caterpillar equipment and replacement parts that are
shoes, and eye protection. Eye protection includes shipped from Caterpillar are asbestos free. Caterpillar
goggles or a protective face shield. recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
The maximum air pressure for cleaning purposes when you handle any replacement parts that contain
must be below 205 kPa (30 psi). The maximum asbestos or when you handle asbestos debris.
water pressure for cleaning purposes must be below
275 kPa (40 psi). Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
Fluid Penetration to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
Always use a board or cardboard when the engine material, clutch plates, and some gaskets. The
components are checked for leaks. Leaking fluid asbestos that is used in these components is usually
that is under pressure can cause serious injury or bound in a resin or sealed in some way. Normal
possible death. This includes leaks that are the size handling is not hazardous unless airborne dust that
of a pin hole. contains asbestos is generated.
If fluid is injected into the skin, seek treatment If dust that may contain asbestos is present, there
immediately. Seek treatment from a doctor that is are several guidelines that should be followed:
familiar with this type of injury.
• Never use compressed air for cleaning.
Containing Fluid Spillage
• Avoid brushing materials that contain asbestos.
Care must be used in order to ensure that the fluids
are contained during the inspection, the maintenance, • Avoid grinding materials that contain asbestos.
the testing, the adjusting, and the repair of the engine.
Prepare to collect the fluid with suitable containers • Use a wet method in order to clean up asbestos
before any compartment is opened or before any materials.
component is disassembled.
SEBU6497-07 9
Safety Section
Burn Prevention

• A vacuum cleaner that is equipped with a high Always use leakproof containers when you drain
efficiency particulate air filter (HEPA) can also be fluids. Do not pour waste onto the ground, down a
used. drain, or into any source of water.

• Use exhaust ventilation on permanent machining

i01480768
jobs.
Burn Prevention
• Wear an approved respirator if there is no other
way to control the dust. SMCS Code: 1000; 7405
• Comply with applicable rules and regulations Do not touch any part of an operating engine.
for the work place. In the United States, use Allow the engine to cool before any maintenance
Occupational Safety and Health Administration is performed on the engine. Relieve all pressure
(OSHA) requirements. These OSHA requirements in the air system, in the hydraulic system, in the
can be found in “29 CFR 1910.1001”. lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
• Obey environmental regulations for the disposal items are disconnected.
of asbestos.

• Stay away from areas that might have asbestos Coolant

particles in the air.
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
Lines, Tubes, and Hoses pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Do not bend or strike high pressure lines. Do not
install lines, tubes, or hoses that are damaged. Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
Repair any fuel lines, oil lines, tubes, or hoses that cool before the cooling system is drained.
are loose or damaged. Leaks can cause fires.
Check the coolant level after the engine has stopped
Inspect all lines, tubes and hoses carefully. Do and the engine has been allowed to cool.
not use bare hands to check for leaks. Always
use a board or cardboard for checking engine Ensure that the filler cap is cool before removing the
components for leaks. Tighten all connections to the filler cap. The filler cap must be cool enough to touch
recommended torque. with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Check for the following conditions:
Cooling system conditioner contains alkali. Alkali can
• End fittings that are damaged or leaking cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
• Outer covering that is chafed or cut
• 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
Batteries
Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. This will help to Electrolyte is an acid. Electrolyte can cause personal
prevent these effects: vibration, rubbing against other injury. Do not allow electrolyte to contact the skin or
parts, and excessive heat during operation. 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
disposed of according to local regulations.
10 SEBU6497-07
Safety Section
Fire Prevention and Explosion Prevention

i01372262 Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines that contain flammable
Fire Prevention and Explosion fluid. Clean any such lines thoroughly with a
Prevention nonflammable solvent prior to welding or flame
cutting.
SMCS Code: 1000; 7405
Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
Illustration 4
g00704000 or sparking.

All fuels, most lubricants, and some coolant mixtures Inspect all lines and hoses for wear or for
are flammable. deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
Flammable fluids that are leaking or spilled onto hot and secure clamps. Tighten all connections to the
surfaces or onto electrical components can cause recommended torque. Leaks can cause fires.
a fire. Fire may cause personal injury and property
damage. Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
A flash fire may result if the covers for the engine torque.
crankcase are removed within fifteen minutes after
an emergency shutdown.

Determine whether the engine will be operated in an

environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.

If the application involves the presence of combustible

gases, consult your Caterpillar dealer for additional
information about suitable protection devices.

Remove all flammable materials such as fuel, oil, and

debris from the engine. Do not allow any flammable
materials to accumulate on the engine.

Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials. Illustration 5
g00704135

Do not expose the engine to any flame. Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
Exhaust shields (if equipped) protect hot exhaust not smoke in battery charging areas.
components from oil or fuel spray in case of a line,
a hose, or a seal failure. Exhaust shields must be
installed correctly.
SEBU6497-07 11
Safety Section
Crushing Prevention and Cutting Prevention

Never check the battery charge by placing a metal i01359666

object across the terminal posts. Use a voltmeter or
a hydrometer. Crushing Prevention and
Improper jumper cable connections can cause
Cutting Prevention
an explosion that can result in injury. Refer to SMCS Code: 1000; 7405
the Operation Section of this manual for specific
instructions. Support the component properly when work beneath
the component is performed.
Do not charge a frozen battery. This may cause an
explosion. Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
The batteries must be kept clean. The covers running.
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box Stay clear of all rotating parts and of all moving
covers when the engine is operated. parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
Fire Extinguisher reinstall the guards.

Make sure that a fire extinguisher is available. Be Keep objects away from moving fan blades. The fan
familiar with the operation of the fire extinguisher. blades will throw objects or cut objects.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations When objects are struck, wear protective glasses in
on the instruction plate. order to avoid injury to the eyes.

Chips or other debris may fly off objects when objects

Lines, Tubes and Hoses are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged. i01372247

Repair any lines that are loose or damaged. Leaks Mounting and Dismounting
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts. SMCS Code: 1000; 7405

Check lines, tubes and hoses carefully. Do not use Inspect the steps, the handholds, and the work area
your bare hand to check for leaks. Use a board or before mounting the engine. Keep these items clean
cardboard to check for leaks. Tighten all connections and keep these items in good repair.
to the recommended torque.
Mount the engine and dismount the engine only at
Replace the parts if any of the following conditions locations that have steps and/or handholds. Do not
are present: climb on the engine, and do not jump off the engine.

• End fittings are damaged or leaking. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
• Outer coverings are chafed or cut. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• Wires are exposed. controls as handholds.

• Outer coverings are ballooning. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Flexible part of the hoses are kinked. platform. Secure the climbing equipment so that the
equipment will not move.
• Outer covers have embedded armoring.
Do not carry tools or supplies when you mount the
• End fittings are displaced. engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
12 SEBU6497-07
Safety Section
Before Starting Engine

i01805780 Start the engine from the operator’s compartment or

from the engine start switch.
Before Starting Engine
Always start the engine according to the procedure
SMCS Code: 1000 that is described in this Operation and Maintenance
Manual, “Engine Starting” topic (Operation Section).
NOTICE Knowing the correct procedure will help to prevent
For initial start-up of a new or rebuilt engine, and for major damage to the engine components. Knowing
start-up of an engine that has been serviced, make the procedure will also help to prevent personal injury.
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the To ensure that the jacket water heater (if equipped)
air and/or fuel supply to the engine. 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.
Overspeed shutdown should occur automatically.
If automatic shutdown does not occur, press the Engine exhaust contains products of combustion
emergency stop button in order to cut the fuel and/or that can be harmful to your health. Always start the
air to the engine. engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
Inspect the engine for potential hazards. vent the engine exhaust to the outside.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the Ether
area is free of personnel.
Ether is poisonous and flammable.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all Do not inhale ether, and do not allow ether to contact
lights work properly, if equipped. the skin. Personal injury could result.

All protective guards and all protective covers must Do not smoke while ether cylinders are changed.
be installed if the engine must be started in order
to perform service procedures. To help prevent an Use ether in well ventilated areas.
accident that is caused by parts in rotation, work
around the parts carefully. Use ether with care in order to avoid fires.

Do not bypass the automatic shutoff circuits. Do not Keep ether cylinders out of the reach of unauthorized
disable the automatic shutoff circuits. The circuits are persons.
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent Store ether cylinders in authorized storage areas
engine damage. only.

See the Service Manual for repairs and for Do not store ether cylinders in direct sunlight or at
adjustments. temperatures above 49 °C (120 °F).

Discard the ether cylinders in a safe place. Do not

i01103904 puncture the ether cylinders. Do not burn the ether
cylinders.
Engine Starting
SMCS Code: 1000 i01462046

If a warning tag is attached to the engine start switch Engine Stopping

or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached SMCS Code: 1000
the warning tag before the engine is started.
Stop the engine according to the procedure in
All protective guards and all protective covers must the Operation and Maintenance Manual, “Engine
be installed if the engine must be started in order Stopping (Operation Section)” in order to avoid
to perform service procedures. To help prevent an overheating of the engine and accelerated wear of
accident that is caused by parts in rotation, work the engine components.
around the parts carefully.
SEBU6497-07 13
Safety Section
Electrical System

Use the Emergency Stop Button (if equipped) ONLY Uncontrolled electrical circuit paths can result in
in an emergency situation. Do not use the Emergency damage to the following components:
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the • main bearings
problem that caused the emergency stop has been
corrected. • crankshaft journal surfaces
Stop the engine if an overspeed condition occurs • aluminum components
during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished Uncontrolled electrical circuit paths can also cause
by shutting off the fuel supply to the engine and/or electrical noise. Uncontrolled electrical circuit paths
shutting off the air supply to the engine. may degrade the performance of the vessel and of
the radio.
To stop an electronically controlled engine, cut the
power to the engine. The following systems MUST be grounded to the
negative “-” battery terminal:
i00692613
• the alternator
Electrical System
• the starting motor
SMCS Code: 1000; 1400
• all other electrical systems
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit These components and these electrical systems can
is operating. A spark can cause the combustible be grounded to the negative “-” terminal in one of two
gases that are produced by some batteries to ignite. ways:

One way to keep these sparks from igniting can • direct

be accomplished in the last step for the following
connection. As a last step, connect the negative “−” • indirect
jump start cable from the external power source to
the negative “−” terminal of the starting motor. Note: The alternator and the starting motor must also
meet marine requirements for isolation.
If the starting motor is not equipped with a negative
“−” terminal, connect the jump start cable to the There is a direct method for grounding systems and
engine block. for components. This method involves running a
ground wire between the component to the negative
Check the electrical wires daily for wires that are “-” terminal.
loose or frayed. If either of these problems are
discovered, complete the following procedures before The indirect method accomplishes the same result.
starting the engine and before operating the engine, For engines with an alternator that is grounded to an
as required: engine component, two conditions must be met:

• Tighten all loose electrical wires. • A ground strap MUST connect that component to
the negative “-” battery terminal.
• Repair all frayed electrical wires.
• The component MUST be electrically isolated from
Note: See the Operation and Maintenance Manual, the engine.
“Engine Starting” in the Operation Sectionfor specific
starting instructions. A bus bar with a direct path to the negative “-” battery
terminal is permissible. This is also recommended for
use with all common ground connections.
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.