SAFETY.CAT.COM

3054E and 3056EINDUSTRIAL ENGINESEngine Safety

Excerpted from Operation & Maintenance Manual (SEBU7641-01-01)

© 2007 CaterpillarAll Rights Reserved

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Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson 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 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 hazardwarnings 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 orpictorially presented.

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. Thewarnings 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 theproduct 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 beforeyou start 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.

6Safety SectionSafety Signs and Labels

Safety Section

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Safety Signs and LabelsSMCS Code: 1000; 7405

There may be several specific warning signs onan engine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiar with all warningsigns.

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

Replace any damaged warning signs or missingwarning signs. If a warning sign is attached to a partof the engine that is replaced, install a new warningsign on the replacement part. Any Caterpillar dealercan provide new warning signs.

Do not work on the engine and do not operate theengine unless the instructions and warnings in theOperation and Maintenance Manual are understood.Proper care is your responsibility. Failure to followthe instructions or failure to heed the warningscould result in injury or in death.

The warning labels that may be found on the engineare illustrated and described.

Ether

The warning label for ether is located on the top,the front, the rear, or the side of the engine.

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Do not spray starting aids such as ether into theair inlet. Such use could result in an explosion andpersonal injury.

7Safety Section

General Hazard Information

Clutch

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The warning label for the clutch is located on theclutch housing (if equipped).

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Rotating gears can cause entanglement of fingersor entanglement of hands. Do not service thiscomponent without first reading the operatormanual.

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General Hazard InformationSMCS Code: 1000; 7405

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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 engineis repaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engineand to each operator control station. When it isappropriate, disconnect the starting controls.

Do not allow unauthorized personnel on the engine,or around the engine when the engine is beingserviced.

Engine exhaust contains products of combustionwhich may be harmful to your health. Alwaysstart the engine and operate the engine in a wellventilated area. If the engine is in an enclosed area,vent the engine exhaust to the outside.

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being 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 twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in orderto relieve any spring pressure or other pressure.

8Safety SectionGeneral Hazard Information

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

• When work is performed around an engine thatis operating, wear protective devices for ears inorder to help prevent damage to hearing.

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

• Ensure that all protective guards and all coversare secured in place on the engine.

• Never put maintenance fluids into glasscontainers. 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 notunderstood. Use the proper tools. Replaceany equipment that is damaged or repair theequipment.

Pressure Air and Water

Pressurized air and/or water can cause debrisand/or hot water to be blown out. This could resultin personal injury.

When pressure air and/or pressure water is usedfor 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 bebelow 275 kPa (40 psi).

Fluid Penetration

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Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leakcan cause severe injury. If fluid is injected into yourskin, you must get treatment immediately. Seektreatment from a doctor that is familiar with this typeof injury.

Containing Fluid Spillage

Care must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component containing fluids.

Refer to Special Publication, NENG2500, “Tools andShop Products Guide” 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.

9Safety Section

Burn Prevention

Asbestos Information

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Caterpillar equipment and replacement parts thatare shipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCaterpillar replacement parts. Use the followingguidelines when you handle any replacement partsthat contain asbestos or when you handle asbestosdebris.

Use caution. Avoid inhaling dust that might begenerated when you handle components thatcontain asbestos fibers. Inhaling this dust canbe hazardous to your health. The componentsthat may contain asbestos fibers are brake pads,brake bands, lining material, clutch plates, andsome gaskets. The asbestos that is used in thesecomponents is usually bound in a resin or sealed insome way. Normal handling is not hazardous unlessairborne dust that contains 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.

Dispose of Waste Properly

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Improperly 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 pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

Coolant

When 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.

10Safety SectionFire Prevention and Explosion Prevention

Any contact with hot coolant or with steamcan cause severe burns. Allow cooling systemcomponents to cool before the cooling system isdrained.

Check the coolant level after the engine hasstopped and the engine has been allowed to cool.

Ensure that the filler cap is cool before removingthe filler cap. The filler cap must be cool enoughto touch with a bare hand. Remove the filler capslowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkalican cause personal injury. Do not allow alkali tocontact the skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

Batteries

Electrolyte is an acid. Electrolyte can causepersonal injury. Do not allow electrolyte to contactthe skin or the eyes. Always wear protective glassesfor servicing batteries. Wash hands after touchingthe batteries and connectors. Use of gloves isrecommended.

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Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405

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All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated inan environment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

If the application involves the presence ofcombustible gases, consult your Caterpillar dealerfor additional information about suitable protectiondevices.

Remove all flammable materials such as fuel, oil,and debris from the engine. Do not allow anyflammable materials to accumulate on the engine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

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.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securelyattached. Check all electrical wires daily. Repair anywires that are loose or frayed before you operatethe engine. Clean all electrical connections andtighten all electrical connections.

Eliminate all wiring that is unattached orunnecessary. Do not use any wires or cables thatare smaller than the recommended gauge. Do notbypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

11Safety Section

Fire Prevention and Explosion Prevention

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.

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Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Donot refuel an engine near open flames or sparks.Always stop the engine before refueling.

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Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may causean explosion.

The batteries must be kept clean. The covers (ifequipped) must be kept on the cells. Use therecommended cables, connections, and batterybox covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Ether

Ether is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or whileyou are using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin direct sunlight or in temperatures above 49 C(120 F). Keep ether cylinders away from openflames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the engineis equipped with a thermal starting aid for coldweather starting.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

12Safety SectionCrushing Prevention and Cutting Prevention

Check lines, tubes and hoses carefully. Do notuse your bare hand to check for leaks. Use aboard or cardboard to check for leaks. Tighten allconnections to the recommended torque.

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

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Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when workbeneath the 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. Thefan blades 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 whenobjects are struck. Before objects are struck, ensurethat no one will be injured by flying debris.

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Mounting and DismountingSMCS Code: 1000; 7405

Inspect the steps, the handholds, and the workarea before mounting the engine. Keep these itemsclean and keep these items in good repair.

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 useany controls 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 ahand line to raise and lower tools or supplies.

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Before Starting EngineSMCS Code: 1000

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel.

Ensure that the engine is equipped with a lightingsystem that is suitable for the conditions. Ensurethat all lights work properly.

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 circuitsare provided in order to help prevent personalinjury. The circuits are also provided in order to helpprevent engine damage.

13Safety Section

Engine Starting

For the initial start-up of a new engine and forstart-up of an engine that has been serviced,prepare to stop the engine if an overspeed occurs.This may be accomplished by shutting off the fueland/or the air supply to the engine.

See the Service Manual for repairs and foradjustments.

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Engine StartingSMCS Code: 1000

Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.

If a warning tag is attached to the engine startswitch or to the controls, DO NOT start the engineor move the controls. Consult with the person thatattached the warning tag before the engine isstarted.

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 the Operation and MaintenanceManual, “Engine Starting” topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

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

Engine exhaust contains products of combustionwhich 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.

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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)ONLY in an emergency situation. Do not use theEmergency Stop Button for normal engine stopping.After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.

Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or anengine that has been overhauled. This may beaccomplished by shutting off the fuel supply tothe engine and/or shutting off the air supply to theengine.

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 startingmotor is not equipped with a negative “−” terminal,connect the 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 started. Repair all frayedelectrical wires before the engine is started. Seethe Operation and Maintenance Manual for specificstarting instructions.

14Safety SectionElectrical System

Grounding Practices

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Typical example

Grounding Stud To Battery Ground

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Typical example

Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical systemis 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.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

To ensure that the engine and the engine electricalsystems function properly, an engine-to-frameground strap with a direct path to the battery mustbe used. This path may be provided by way of astarting motor ground, a starting motor ground tothe frame, or a direct engine ground to the frame.

All grounds should be tight and free of corrosion.The engine alternator must be grounded to thenegative “-” battery terminal with a wire that isadequate to handle the full charging current of thealternator.

15Safety Section

Engine Electronics

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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.

This engine has a comprehensive, programmableEngine Monitoring System. The Engine ControlModule (ECM) has the ability to monitor theengine operating conditions. If any of the engineparameters extend outside an allowable range, theECM will initiate 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 bythe ECM can be programmed for the enginemonitoring functions. The following parameters canbe monitored as a part of the Engine MonitoringSystem:

• 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 fordifferent engine models and different engineapplications. However, the monitoring system andthe engine monitoring control will be similar for allengines.

Note: Many of the engine control systems anddisplay modules that are available for CaterpillarEngines will work in unison with the EngineMonitoring System. Together, the two controls willprovide the engine monitoring function for thespecific engine application. Refer to the ElectronicTroubleshooting Manual for more information on theEngine Monitoring System.