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G3500
ENGINES
Engine Safety
2007 Caterpillar
All Rights Reserved
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Safety Section
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Safety Messages
SMCS Code: 1000; 7405
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Illustration 1
Left side view of a typical engine
SEBU8099-02 7
Safety Section
Safety Messages
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Illustration 2
Right side view of a typical engine
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Illustration 3 Illustration 4
This safety message is located on the first valve On both sides of a 3508 Engine, this safety message
cover base on each side of the engine. is located on the third valve cover base. On both
sides of a 3512 Engine, this safety message is
located on the fourth valve cover base. On both sides
of a 3516 Engine, this safety message is located on
the sixth valve cover base.
Do not operate or work on this engine or genera-
tor set unless you have read and understand the
instructions and warnings in the Operation and
Maintenance Manuals.
WARNING! Shock/Electrocution Hazard! Read and
Failure to follow the warnings and instructions understand the instructions and warnings in the
could result in injury or death. Contact any Operation and Maintenance Manual. Failure to fol-
Caterpillar dealer for replacement manuals. Prop- low the instructions or heed the warnings could
er care is your responsibility. cause serious injury or death.
8 SEBU8099-02
Safety Section
Safety Messages
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Illustration 5
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Illustration 6
On both sides of a 3508 Engine, this safety message
is located on the third valve cover. On both sides of a
This safety message may be located on the engine
3512 Engine, this safety message is located on the interface module. This safety message may be
fifth valve cover. On both sides of a 3516 Engine,
located on a control panel that is mounted in a remote
this safety message is located on the seventh valve
location.
cover.
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Illustration 8
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Illustration 9
Do not wear loose clothing or jewelry that can snag Always use a board or cardboard when you check
on controls or on other parts of the engine. for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Ensure that all protective guards and all covers are serious injury and possible death. A pin hole leak can
secured in place on the engine. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
Never put maintenance fluids into glass containers. from a doctor that is familiar with this type of injury.
Glass containers can break.
Containing Fluid Spillage
Use all cleaning solutions with care.
Care must be taken in order to ensure that fluids
Report all necessary repairs. are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
Unless other instructions are provided, perform
engine. Prepare to collect the fluid with suitable
the maintenance under the following conditions:
containers before opening any compartment or
disassembling any component that contains fluids.
The engine is stopped. Ensure that the engine
cannot be started.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tools Catalog for the following items:
Disconnect the batteries when maintenance
is performed or when the electrical system is
serviced. Disconnect the battery ground leads. Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
Tape the leads in order to help prevent sparks.
Tools that are suitable for containing fluids and
Do not attempt any repairs that are not understood. equipment that is suitable for containing fluids
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
Obey all local regulations for the disposal of liquids.
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Fluid Penetration Illustration 11
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Illustration 10
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Safety Section
Burn Prevention
Use caution. Avoid inhaling dust that might be Dispose of Waste Properly
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
Avoid grinding materials that contain asbestos. Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
Use a wet method in order to clean up asbestos disposed of according to local regulations.
materials.
Always use leakproof containers when you drain
A vacuum cleaner that is equipped with a high fluids. Do not pour waste onto the ground, down a
efficiency particulate air filter (HEPA) can also be drain, or into any source of water.
used.
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Use exhaust ventilation on permanent machining
jobs. Burn Prevention
Wear an approved respirator if there is no other SMCS Code: 1000; 4450; 7405
way to control the dust.
Do not touch any part of an operating engine.
Comply with applicable rules and regulations Allow the engine to cool before any maintenance
for the work place. In the United States, use is performed on the engine. Relieve all pressure in
Occupational Safety and Health Administration the appropriate system before any lines, fittings or
(OSHA) requirements. These OSHA requirements related items are disconnected.
can be found in 29 CFR 1910.1001.
SMCS Code: 1000; 4450; 7405 Exhaust shields (if equipped) protect hot exhaust
components from oil spray or fuel spray in case of
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.
Inspect all lines and hoses for wear or for Lines, Tubes and Hoses
deterioration. The hoses must be properly routed.
The lines and the hoses must have adequate support Do not bend high pressure lines. Do not strike high
and secure clamps. Tighten all connections to the pressure lines. Do not install any lines that are bent
recommended torque. Leaks can cause fires. or damaged.
Oil filters and fuel filters must be properly installed. Repair any lines that are loose or damaged. Leaks
The filter housings must be tightened to the proper can cause fires. Consult your Caterpillar dealer for
torque. repair or for replacement parts.
Illustration 14
g00704135 End fittings are displaced.
Make sure that all clamps, guards, and heat shields
Gases from a battery can explode. Keep any open
are installed correctly. During equipment operation,
flames or sparks away from the top of a battery. Do
this will help to prevent vibration, rubbing against
not smoke in battery charging areas.
other parts, and excessive heat.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or i01359666
a hydrometer.
Crushing Prevention and
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
Cutting Prevention
the Operation Section of this manual for specific SMCS Code: 1000; 4450; 7405
instructions.
Support the component properly when work beneath
Do not charge a frozen battery. This may cause an the component is performed.
explosion.
Unless other maintenance instructions are provided,
The batteries must be kept clean. The covers never attempt adjustments while the engine is
(if equipped) must be kept on the cells. Use the running.
recommended cables, connections, and battery box
covers when the engine is operated. Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
Fire Extinguisher is performed. After the maintenance is performed,
reinstall the guards.
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher. Keep objects away from moving fan blades. The fan
Inspect the fire extinguisher and service the fire blades will throw objects or cut objects.
extinguisher regularly. Obey the recommendations
on the instruction plate. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
14 SEBU8099-02
Safety Section
Mounting and Dismounting
Chips or other debris may fly off objects when objects i01805780
are struck. Before objects are struck, ensure that no
one will be injured by flying debris. Before Starting Engine
SMCS Code: 1000
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To ensure that the jacket water heater (if equipped) Grounding Practices
and/or the lube oil heater (if equipped) is working
properly, check the water temperature and the oil Proper grounding is necessary for optimum engine
temperature during heater operation. performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in
Engine exhaust contains products of combustion unreliable electrical circuit paths.
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated Uncontrolled electrical circuit paths can result in
area. If the engine is started in an enclosed area, damage to main bearings, to crankshaft journal
vent the engine exhaust to the outside. surfaces, and to aluminum components. Uncontrolled
electrical circuit paths can also cause electrical
activity that may degrade the engine electronics and
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communications.
Engine Stopping
For the starting motor, do not attach the battery
SMCS Code: 1000 negative terminal to the engine block.
To avoid overheating of the engine and accelerated Use a ground strap to ground the case of all control
wear of the engine components, stop the engine panels to the engine block.
according to the instructions in this Operation and
Maintenance Manual, Engine Stopping topic Ground the engine block with a ground strap that is
(Operation Section). furnished by the customer. Connect this ground strap
to the ground plane.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency Use a separate ground strap to ground the battery
Stop Button for normal engine stopping. After an negative terminal for the control system to the ground
emergency stop, DO NOT start the engine until the plane.
problem that caused the emergency stop has been
corrected. Rubber couplings may connect the steel piping of
the cooling system and the radiator. This causes the
On the initial start-up of a new engine or an engine piping and the radiator to be electrically isolated.
that has been serviced, make provisions to stop Ensure that the piping and the radiator is continuously
the engine if an overspeed occurs. This may be grounded to the engine. Use ground straps that
accomplished by shutting off the fuel supply to the bypass the rubber couplings.
engine, or shutting off the ignition system.
Ensure that all grounds are secure and free of
corrosion.