3126E COMMERCIAL and TRUCK ENGINES and 3126B ENGINE
Contents
1. Failure to heed this warning can lead to premature failures product damage personal injury or death 8 SEBU7011 17 Safety Section Safety Messages Safety Section i02005611 Safety Messages 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 the words cannot be read or if the pictures are not visible When the warning signs are cleaned use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the warning signs Solvents gasoline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off of the engine Replace any damaged safety signs or missing safety signs If a safety sign is attached to a part of the engine that is replaced install a new safety sign on the replacement part Any Caterpillar dealer can provide new safety 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 warnings could result in injury or death Contact any Caterpillar dealer for replacement manuals Proper care is your responsib2. for the HEUI injectors WARNING 4P 6422 3 900283559 If equipped with an air inlet heater for cold weather starting do not use aerosal types of start ing aids such as ether Such use could result in an explosion and personal injury 100909638 General Hazard Information SMCS Code 1000 7405 Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired These warning tags Special Instruction SEHS7332 are available from your Caterpillar dealer Attach the warning tags to the engine and to each operator control station When it is appropriate disconnect the starting controls 12 SEBU7011 17 Safety Section General Hazard Information Illustration 2 g00104545 Do not allow unauthorized personnel on the engine or around the engine when the engine is serviced Tampering with the engine installation or tampering with the truck OEM wiring installation can be dangerous Personal injury death and or engine damage could result Vent the engine exhaust to the outside when the engine is operated in an enclosed area If the engine is not running do not release the secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained Wear a hard hat protective glasses and other protective equipment as required When work is perfo
3. 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 A WARNING When replacement parts are required for this product Caterpillar rec ommends using Caterpillar replacement parts or parts with equivalent specifications including but not limited to physical dimensions type strength and material
4. 3126E COMMERCIAL and TRUCK ENGINES and 3126B ENGINE Engine Safety Excerpted from Operation amp Maintenance Manual SEBU701 1 17 01 O 2007 Caterpillar CATERPILLAR All Rights Reserved 101658146 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 A WARNING The meaning of this safety alert symbol is as follows Attention Become Alert Your Safety is Involved The message that appears under the
5. e filler cap slowly in order to relieve pressure Cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Oils Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Keep all of the exhaust manifold and turbocharger shields in place in order to protect components from oil spray if there is a failure of a line a tube or a seal Batteries Electrolyte is an acid Electrolyte can cause personal injury Do not allow electrolyte to contact the skin or the eyes Always wear protective glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended Batteries give off combustible gases which can explode Ensure proper ventilation for batteries that are in an enclosure 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 to ignite Do not smoke when batteries are serviced Always thaw a frozen battery before jump starting the battery Frozen batteries can explode 16 SEBU7011 17 Safety Section Fire Prevention and Explosion Prevention 101028355 Fire Prevention and Explosion Prevention SMCS Code 1000 7405 Fire may result from lubricating oil or from fuel that is sprayed on hot surfaces Fire may cause personal injury and pro
6. er an emergency stop DO NOT start the engine until the problem that caused the emergency stop has been corrected SEBU7011 17 21 Safety Section Electrical System Stop the engine if an overspeed condition occurs during the initial start up of a new engine or an engine that has been overhauled This may be accomplished by shutting off the fuel supply to the engine and or shutting off the air supply to the engine To stop an electronically controlled engine cut the power to the engine 102469632 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 7 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 started Repair all frayed electrical wires before the engine is started Refer to the Engine Starting section of this Operation and Maintenance Manual for specific starting instructions 22 SEBU7011 17 Safety Sectio
7. ever attempt adjustments while the engine is running Stay clear of all rotating parts and of all moving parts Leave the guards in place until maintenance is performed After the maintenance is performed reinstall the guards Keep objects away from moving fan blades The fan blades will throw objects or cut objects When objects are struck wear protective glasses in order to avoid injury to the eyes Chips or other debris may fly off objects when objects are struck Before objects are struck ensure that no one will be injured by flying debris 100910430 Mounting and Dismounting SMCS Code 1000 7405 Do not climb on the engine and do not jump off the engine Do not stand on components which cannot support your weight Use an adequate ladder Clean the steps the handholds and the areas of the vehicle that will be worked on SEBU7011 17 19 Safety Section Before Starting Engine 100911989 Before Starting Engine SMCS Code 1000 Inspect the engine for potential hazards Before starting the engine ensure that no one is on underneath or close to the engine All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully Do not bypass the automatic shutoff circuits Do not disable the automatic shutoff circuits The circuits are provided in order to hel
8. ility Do not work on the engine and do not operate the engine unless the instructions and the warnings in the Operation and Maintenance Manual are understood Proper care is your responsibility Failure to follow the instructions or failure to heed the warnings could result in injury or in death The following section illustrates and the following section describes the safety labels which may be found on the engine SEBU7011 17 9 Safety Section Safety Messages A WARNING Illustration 1 g01037410 10 SEBU7011 17 Safety Section Safety Messages Hydraulic Electronic Unit Injectors 1 The warning label for the hydraulic electronic unit injector is located on the top of the valve cover Ay WARNING 505 118 650 0090 7230 Explosion hazard do not spray ether the en gine Electrocution hazard Hydraulic fluid under pressure These hazards could cause personal injury or death Read the Operation and Mainte nance Manual before you service the engine The Electronic Control Module ECM sends a high voltage signal to the injector solenoid To help prevent personal injury disconnect the electronic unit injector enable circuit connector Do not come in contact with the electronic unit injector terminals while the engine is running SEBU7011 17 11 Safety Section General Hazard Information Starting Aid 2 The safety sign for the starting aid is located on the hydraulic pump
9. isassembled Refer to the Special Publication NENG2500 This publication explains the items that are needed for collecting and for containing fluids that are used in Caterpillar engines Dispose of fluids according to local regulations Asbestos Information Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free Caterpillar recommends the use of only genuine Caterpillar replacement parts 100910250 Burn Prevention SMCS Code 1000 7405 Do not touch any part of an operating engine Allow the engine to cool before any maintenance is performed on the engine Relieve all pressure in the lubrication system in the fuel system or in the cooling system before any lines fittings or related items are disconnected Coolant When the engine is at operating temperature the engine coolant is hot The coolant is also under pressure The radiator and all lines to the heaters or to the engine contain hot coolant When pressure is relieved rapidly the hot coolant can turn into steam SEBU7011 17 15 Safety Section Burn Prevention Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained Check the coolant level only after the engine has been stopped Do not step on the engine in order to remove the filler cap Use a ladder if necessary Ensure that the filler cap is cool before removing the filler cap Remove th
10. me cut pipes or tubes that contain flammable fluids Before pipes or tubes are welded or flame cut clean the inside and clean the outside of the pipes or tubes thoroughly with nonflammable solvent SEBU7011 17 17 Safety Section Fire Prevention and Explosion Prevention Do not allow flammable materials to accumulate on the engine Do not expose the engine to flames Exhaust shields if equipped protect hot exhaust components from oil or fuel spray in case of a line a tube or a seal failure Exhaust shields must be installed correctly Dispose of oil according to local regulations Oil filters and fuel filters must be properly installed The housing covers must be tightened to the proper torque when the housing covers are reinstalled Batteries must be kept clean The covers if equipped must be kept on the cells Use the recommended cables connections and battery box covers when the engine is operated When the engine is started from an external source always connect the positive jump start cable to the positive terminal of the battery of the engine that is being started Make this connection before the negative jump start cable is connected 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
11. n Electrical System Grounding Practices e 9 Illustration 3 900771448 Typical example Grounding Stud To Battery Ground SEBU7011 17 23 Safety Section Electrical System A nl T o o a 9 HE g g fa A a BS Fe D dej BEP Ie Illustration 4 g00771487 Typical example Alternate Grounding Stud To Battery Ground Proper grounding for the engine electrical system is necessary for optimum engine performance and reliability Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths Uncontrolled electrical circuit paths can result in damage to main bearings to crankshaft bearing journal surfaces and to aluminum components Engines that are installed without engine to frame ground straps can be damaged by electrical discharge 24 SEBU7011 17 Safety Section Engine Electronics To ensure that the engine and
12. 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 Before the engine is operated tighten all loose electrical wires Repair all frayed electrical wires Wiring must be kept in good condition Wires must be properly routed and securely attached Routinely inspect the wiring for wear or for deterioration Loose wiring unattached wiring or unnecessary wiring must be eliminated All wires and all cables must be of the recommended gauge The wires and cables must be connected to a fuse or to a circuit breaker as required Do not bypass fuses and or circuit breakers Do not use a wire of a smaller gauge Arcing or sparking could cause a fire Secure connections recommended wiring and properly maintained battery cables will help to prevent arcing or sparking 18 SEBU7011 17 Safety Section Crushing Prevention and Cutting Prevention Fire Extinguisher Ensure that a fire extinguisher is available Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Service the fire extinguisher according to the recommendations on the instruction plate 101359666 Crushing Prevention and Cutting Prevention SMCS Code 1000 7405 Support the component properly when work beneath the component is performed Unless other maintenance instructions are provided n
13. p prevent personal injury The circuits are also provided in order to help prevent engine damage On the initial start up of a new engine or an engine that has been serviced prepare to stop the engine if an overspeed condition occurs This may be accomplished by shutting off the fuel supply to the engine and or shutting off the air supply to the engine See the Service Manual for repairs and for adjustments 100910470 Engine Starting SMCS Code 1000 If a warning tag is attached to the engine start switch or to the controls do not start the engine or move the controls Also do not disengage the parking brakes Consult with the person that attached the warning tag before the engine is started All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully Start the engine from the operator s station cab Never short across the starting motor terminals or the batteries This could bypass the engine neutral start system and or the electrical system could be damaged 20 SEBU7011 17 Safety Section Engine Stopping Always start the engine according to the procedure that is described in the Operation and Maintenance Manual Engine Starting topic Operation Section Knowing the correct procedure will help to prevent major damage to the engine components Kno
14. perty damage Inspect all lines and tubes for wear or for deterioration The lines must be properly routed The lines must have adequate support and secure clamps Tighten all connections to the recommended torque Leaks can cause fires Determine whether the engine will be operated in an environment that allows combustible gases to be drawn in through the air inlet system These gases could cause the engine to overspeed This could result in bodily injury property damage or damage to the engine If the application involves the presence of combustible gases consult your Caterpillar dealer in order to obtain additional information concerning suitable protection devices Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire All fuels most lubricants and some coolant mixtures are flammable Diesel fuel is flammable Gasoline is flammable The mixture of diesel fumes and gasoline fumes is extremely explosive Do not smoke while the engine is refueled Do not smoke in the refueling area Store all fuels and all lubricants in properly marked containers Store the protective containers in a safe place 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 Do not weld on pipes or tubes that contain flammable fluids Do not fla
15. ressure SEBU7011 17 25 Safety Section Engine Electronics e Engine Speed e Fuel Temperature e Intake Manifold Air Temperature System Voltage The Engine Monitoring package can vary for different engine models and different engine applications However the monitoring system and the engine monitoring control will be similar for all engines Note Many of the engine control systems and display modules that are available for Caterpillar Engines will work in unison with the Engine Monitoring System Together the two controls will provide the engine monitoring function for the specific engine application Refer to the Electronic Troubleshooting Manual for more information on the Engine Monitoring System
16. rmed around an engine that is operating wear protective devices for ears in order to help prevent damage to hearing 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 Never put maintenance fluids into glass containers Glass containers can break SEBU7011 17 13 Safety Section General Hazard Information Use all cleaning solutions with care Report all necessary repairs Unless other instructions are provided perform the maintenance under the following conditions e The engine is stopped The protective locks or the controls are in the applied position Engage the secondary brakes or parking brakes Block the vehicle or restrain the vehicle before maintenance or repairs are performed 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 or any adjustments to the engine while the engine is operating Do not attempt any repairs that are not understood Use the proper tools Replace any equipment that is damaged or repair the equipment For initial start up of a new engine or for starting an engine that has been serviced make provisions to stop the engine if an overspeed occurs This may be accomplished by shutting off the fuel s
17. the engine electrical systems function properly an engine to frame ground strap with a direct path to the battery must be used This path may be provided by way of a starting motor ground a starting motor ground to the 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 the negative battery terminal with a wire that is adequate to handle the full charging current of the alternator 101563743 Engine Electronics SMCS Code 1000 1400 1900 Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and or engine damage This engine has a comprehensive programmable Engine Monitoring System The Engine Control Module ECM has the ability to monitor the engine operating conditions If any of the engine parameters extend outside an allowable range the ECM will initiate an immediate action The following actions are available for engine monitoring control WARNING DERATE and SHUTDOWN These engine monitoring modes have the ability to limit engine speed and or the engine power Many of the parameters that are monitored by the ECM can be programmed for the engine monitoring functions The following parameters can be monitored as a part of the Engine Monitoring System e Operating Altitude e Engine Coolant Level e Engine Coolant Temperature e Engine Oil P
18. upply and or the air supply to the engine Start the engine from the operator s station cab Never short across the starting motor terminals or the batteries This could bypass the engine neutral start system and or the electrical system could be damaged Pressure 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 When pressure air is used for cleaning wear a protective face shield protective clothing and protective shoes The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Always wear eye protection for cleaning the cooling system 14 SEBU7011 17 Safety Section Burn Prevention Fluid Penetration Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death This includes leaks that are the size of a pin hole If fluid is injected into the skin seek treatment immediately Seek treatment from a doctor that is familiar with this type of injury Fluid Spillage Care must be used in order to ensure that the fluids are contained during the inspection the maintenance the testing the adjusting and the repair of the engine Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is d
19. wing the procedure will also help to prevent personal injury To ensure that the jacket water heater if equipped and or the lube oil heater if equipped is working properly check the water temperature gauge and the oil temperature gauge during the heater operation Engine exhaust contains products of combustion that can be harmful to your health Always start the engine and operate the engine in a well ventilated area If the engine is started in an enclosed area vent the engine exhaust to the outside Ether Ether is poisonous and flammable Do not inhale ether and do not allow ether to contact the skin Personal injury could result Do not smoke while ether cylinders are changed Use ether in well ventilated areas Keep ether cylinders out of the reach of unauthorized persons Store ether cylinders in authorized storage areas only Do not store ether cylinders in direct sunlight or at temperatures above 39 C 102 F Discard the ether cylinders in a safe place Do not puncture the ether cylinders Do not burn the ether cylinders 101462046 Engine Stopping SMCS Code 1000 Stop the engine according to the procedure in the Operation and Maintenance Manual Engine Stopping Operation Section in order to avoid overheating of the engine and accelerated wear of the engine components Use the Emergency Stop Button if equipped ONLY in an emergency situation Do not use the Emergency Stop Button for normal engine stopping Aft
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