SEBU7147-05+S

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SAFETYOperation and Maintenance Manual Excerpt

SEBU7147-05October 2009

Operation andMaintenanceManual3508, 3512 and 3516 Generator Sets5PW1-Up (Generator Set)6WW1-Up (Generator Set)8TW1-Up (Generator Set)

SAFETY.CAT.COM

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Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave 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 hazard warningsare 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 pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labelson 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. You mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.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 before youstart 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.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.

6 SEBU7147-05Safety SectionSafety Messages

Safety Sectioni03474101

Safety MessagesSMCS Code: 1000; 7405

There may be several specific safety messages onyour engine. The exact location and a description ofthe safety 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 safetymessages if the words cannot be read or if theillustrations are not visible. Use a cloth, water,and soap to clean the safety messages. Do notuse solvents, gasoline, or other harsh chemicals.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety messages. Thesafety messages that are loosened could drop offof the engine.

Replace any safety message that is damaged ormissing. If a safety message is attached to a partof the engine that is replaced, install a new safetymessage on the replacement part. Your Caterpillardealer can provide new safety messages.

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SEBU7147-05 7Safety Section

Safety Messages


Do not operate or work on this engine unless youhave read and understand the instructions andwarnings in the Operation and Maintenance Man-ual. Failure to follow the instructions or heed thewarnings could result in injury or death. Contactany Caterpillar dealer for replacement manuals.Proper care is your responsibility.


Universal Warning (1)This safety message is located on the rear of theterminal box.

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Do not operate or work on this engine or genera-tor set unless you have read and understand theinstructions and warnings in the Operation andMaintenance Manuals.

Failure to follow the warnings and instructionscould result in injury or death. Contact anyCaterpillar dealer for replacement manuals. Prop-er care is your responsibility.

Shock (2)One safety message is located on the control panel.One safety message may be located on the oil coolerand one safety message may be located on the leftside of the engine.

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WARNING! Shock/Electrocution Hazard! Read andunderstand the instructions and warnings in theOperation and Maintenance Manual. Failure to fol-low the instructions or heed the warnings couldcause serious injury or death.


Safety Messages

Electrocution (3)One safety message is located on the rear of theterminal box. One safety message is located on eachside of the terminal box.

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Do not connect the generator to a utility electricaldistribution system unless it is isolated from thesystem. Electrical feedback into the distributionsystem can occur and could cause personal injuryor death.

Open and secure the main distribution switch, orif the connection is permanent, install a doublethrow switch to prevent electrical feedback. Somegenerators are specifically approved by a utilityto run in parallel with the distribution system andisolation may not be required. Always check withyour utility for the applicable circumstances.

Automatic Starting (4)This safety message is located on the side of theterminal box and on the rear of the terminal box.

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When the engine is in the AUTOMATIC mode, theengine can start at anymoment. To avoid personalinjury, always remain clear of the the engine whenthe engine is in the AUTOMATIC mode.


Crushing (5)One safety message is located on each side of theterminal box.

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Crushing Hazard! Improper lifting could cause se-rious injury or death. Follow the lifting instruc-tions in the Operation andMaintenanceManual forsafe lifting procedures.

Hot Surface (6)One safety message is located on the oil cooler.One safety message is located on the left side of thecrankcase cover. One safety message is located oneach side of the barrel of the generator. One safetymessage is located on each side of the radiator.

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Hot parts or hot components can cause burns orpersonal injury. Do not allow hot parts or compo-nents to contact your skin. Use protective clothingor protective equipment to protect your skin.


Safety Messages

Vapor Explosion (Oil Filter) (7)One safety message is located on each side of theengine on the duplex oil filter.

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Warning: Vapor Explosion. May cause seriousinjury or death. Read the Operation and Main-tenance Manual before conducting any mainte-nance on the duplex oil filter.

Vapor Explosion (Fuel Filter) (8)One safety message is located on each side of theengine on the duplex fuel filter.

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Warning: Vapor Explosion. Could cause seri-ous injury or death. Read the Operation andMaintenance Manual before conducting any main-tenance on the duplex fuel filter.

Lifting the Product (Not Includingthe Radiator) (9)


One safety message is located on each side of theterminal box.

Before lifting the product, read this Operation andMaintenance Manual, “Product Lifting” in the Op-eration Section.

If improper equipment is used to lift the product,injury and damage can occur. Use cables whichare properly rated for the weight. Use a spreaderbar and attach the cables according to the infor-mation on the safety message.

12 SEBU7147-05Safety SectionAdditional Messages

Lifting the Product (Including theRadiator) (10)


One safety message is located on each side of theterminal box.

Before lifting the product, read this Operation andMaintenance Manual, “Product Lifting” in the Op-eration Section.

If improper equipment is used to lift the product,injury and damage can occur. Use cables whichare properly rated for the weight. Use a spreaderbar and attach the cables according to the infor-mation on the safety message.

Hot Fluid Under Pressure (11)One safety message is located next to the radiatorcap.

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Pressurized system! Hot coolant can cause seri-ous burns, injury or death. To open the coolingsystem filler cap, stop the engine and wait untilthe cooling system components are cool. Loosenthe cooling system pressure cap slowly in order torelieve the pressure. Read and understand the Op-eration and Maintenance Manual before perform-ing any cooling system maintenance.

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Additional MessagesSMCS Code: 1000; 7405

The exact location of the message and the descriptionof the message are reviewed in this section.

Make sure that the message is legible. Clean themessage or replace the message if images areunreadable. When you clean the message, use acloth, water and soap. Do not use solvent, gasoline,or other harsh chemicals to clean the message.Solvents, gasoline or other harsh chemicals couldloosen the adhesive that secures the message.

Replace the message if the message is damaged,or missing. If a message is attached to a part that isreplaced, install a message on the replacement part.Any Caterpillar dealer can provide a new message.


General Hazard Information


This film should be placed on a location that is nearthe unpainted surface of the earth ground connectionon the rear of the generator.

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General Hazard InformationSMCS Code: 1000; 4450; 7405


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 engine isrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engine and toeach operator control station. When it is appropriate,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. Always start theengine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine 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 order torelieve any spring pressure or other pressure.


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

• When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing.

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

• Ensure that all protective guards and all covers aresecured in place on the engine.

• 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, performthe maintenance under the following conditions:

• The engine is stopped. Ensure that the enginecannot be started.

14 SEBU7147-05Safety SectionGeneral Hazard Information

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

• 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.

• For initial start-up of a new engine or for starting anengine that has been serviced, make provisions tostop the engine if an overspeed occurs. This maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine.

• Start the engine with the operator controls. Nevershort across the starting motor terminals or thebatteries. This could bypass the engine neutralstart system and/or the electrical system could bedamaged.

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressurized air and/or pressurized water isused for 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) when the air nozzleis deadheaded. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Fluid Penetration


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 leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” or refer to Special Pub-lication, PECJ0003, “Caterpillar Shop Supplies andTools Catalog” for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.


Burn Prevention

• 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.

Lines, Tubes, and HosesDo not bend or strike high pressure lines. Do notinstall lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses thatare loose or damaged. Leaks can cause fires.

Inspect all lines, tubes and hoses carefully. Donot use bare hands to check for leaks. Alwaysuse a board or cardboard for checking enginecomponents for leaks. Tighten all connections to therecommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

Ensure that all of the clamps, the guards, and theheat shields are installed correctly. This will help toprevent these effects: vibration, rubbing against otherparts, and excessive heat during operation.

Dispose of Waste Properly


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; 4450; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressure inthe appropriate system before any lines, fittings orrelated items are disconnected.

CoolantWhen 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. Any contact withhot coolant or with steam can cause severe burns.Allow cooling system components to cool before thecooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool. Ensurethat the filler cap is cool before removing the fillercap. The filler cap must be cool enough to touch witha bare hand. Remove the filler cap slowly in orderto relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

16 SEBU7147-05Safety SectionFire Prevention and Explosion Prevention

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil or hot componentsto contact the skin.

If the application has a makeup tank, remove the capfor the makeup tank after the engine has stopped.The filler cap must be cool to the touch.

BatteriesThe liquid in a battery is an electrolyte. Electrolyte isan acid that can cause personal injury. Do not allowelectrolyte to contact the skin or the eyes.

Do not smoke while checking the battery electrolytelevels. Batteries give off flammable fumes which canexplode.

Always wear protective glasses when you work withbatteries. Wash hands after touching batteries. Theuse of gloves is recommended.

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Fire Prevention and ExplosionPreventionSMCS Code: 1000; 4450; 7405


Use of personal protection equipment (PPE) may beneeded.

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

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operatea product when a fire hazard exists. Contact yourCaterpillar dealer for service.

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 in anenvironment 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 of combustiblegases, consult your Caterpillar dealer for additionalinformation about suitable protection devices.

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerials to accumulate on the engine.

All fluids that are captured in the fluid spillcontainment basin should be cleaned up immediately.Failure to clean up spilled fluids can cause a fire. Firemay cause personal injury and property damage.

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 securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.


Fire Prevention and Explosion Prevention

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

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.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


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 cause anexplosion.

The batteries must be kept clean. The covers(if equipped) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire ExtinguisherMake 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.

EtherEther is flammable and poisonous.

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

18 SEBU7147-05Safety SectionCrushing Prevention and Cutting Prevention

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 engine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes and HosesDo 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.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto 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; 4450; 7405

Support the component properly when work beneaththe 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. The fanblades 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 when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

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Mounting and DismountingSMCS Code: 1000; 4450; 7405

Generator sets in permanent installations mayrequire the use of a ladder or a work platform inorder to provide access for normal maintenance. Theowner and/or the user is responsible for providingsafe access that conforms to SAE J185 and/or localbuilding codes.

Inspect the steps, the handholds, and the work areabefore mounting the generator set. Keep these itemsclean and keep these items in good repair.

Mount the generator set and dismount the generatorset only at locations that have steps and/orhandholds. Do not climb on the generator set, and donot jump off the generator set.

Face the generator set in order to mount thegenerator set or dismount the generator set. Maintaina three-point contact with the steps and handholds.Use two feet and one hand or use one foot and twohands. Do not use any controls as handholds.

Do not jump from an elevated platform. Do not jumpfrom a ladder or stairs.

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 thegenerator set or when you dismount the generatorset. Use a hand line to raise and lower tools orsupplies.


Sound Information

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Sound InformationSMCS Code: 1000

Note: Information of the sound level is for machinesin European Union countries and in countries thatadopt the directives of the European Union.

NOTICEHearing protection may be needed when working nearan operating generator set.

Sound levels will vary depending on the configurationof the generator set and the final installation of thegenerator set.

Refer to the following for sound levels:

• The sound pressure level of a complete generatorset (including the radiator) at 1 meter is 111dB(A) for the noisiest configuration when “ISO8528-10:1998(E) clause 14” is used at 75 percentof the rated power.

• The sound power level of a complete generator set(including the radiator) is 125 dB(A) for the noisiestconfiguration when “ISO 8528-10:1998(E) clause13” is used at 75 per cent of the rated power.

Note: The preceding sound levels are emissionlevels. The preceding sound levels are notnecessarily safe sound levels. There is a correlationbetween the emission levels and the level ofexposure. The correlation between emission levelsand the level of exposure can not be used todetermine if further precautions are required.

Refer to the following for factors that influence thelevel of exposure:

• The characteristics of the area around thegenerator set

• Other sources of noise

• The number of machines and other adjacentprocesses

• The length of time of exposure to the noise

This information will enable the user of the machineto evaluate the hazard and the risk.

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Before Starting EngineSMCS Code: 1000

NOTICEFor initial start-up of a new or rebuilt engine, and forstart-up of an engine that has been serviced, makeprovision to shut the engine off should an overspeedoccur. This may be accomplished by shutting off theair and/or fuel supply to the engine.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controlsif there is a “DO NOT OPERATE” warning tag orsimilar warning tag attached to the start switch or tothe controls.

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

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work properly, if equipped.

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 circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

See the Service Manual for repairs and foradjustments.

20 SEBU7147-05Safety SectionEngine Starting

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Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

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 this Operation and MaintenanceManual, “Engine Starting” topic (Operation Section).Knowing the correct procedure will help to preventmajor damage to the engine components. Knowingthe 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 workingproperly, check the water temperature gauge and theoil temperature gauge during the heater operation.

Engine exhaust contains products of combustionthat 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.

EtherEther is poisonous and flammable.

Do not inhale ether, and do not allow ether to contactthe skin. Personal injury could result.

Do not smoke while ether cylinders are changed.

Use ether in well ventilated areas.

Use ether with care in order to avoid fires.

Keep ether cylinders out of the reach of unauthorizedpersons.

Store ether cylinders in authorized storage areasonly.

Do not store ether cylinders in direct sunlight or attemperatures above 49 °C (120 °F).

Discard the ether cylinders in a safe place. Do notpuncture the ether cylinders. Do not burn the ethercylinders.

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Engine StoppingSMCS Code: 1000

To avoid overheating of the engine and acceleratedwear of the engine components, stop the engineaccording to this Operation and Maintenance Manual,“Engine Stopping” topic (Operation Section).

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.

On the initial start-up of a new engine or an enginethat has been serviced, make provisions to stop theengine if an overspeed condition occurs. This may beaccomplished by shutting off the fuel supply and/orthe air supply 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.

When the engine is started from an external source,follow this procedure: first, connect the positive “+”jump start cable from the external power source tothe positive “+” battery terminal of the engine that isbeing started. Then connect the negative “−” jumpstart cable from the external power source to thenegative “−” terminal of the starting motor. This willhelp to prevent sparks from igniting combustiblegases that are produced by some batteries.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is operated. Repair all frayedelectrical wires before the engine is started.


Generator Isolating for Maintenance

Grounding PracticesThe electrical systems for the generator, the engineand the control systems must be properly grounded.Proper grounding is necessary for optimumperformance and reliability. Improper grounding willresult in uncontrolled electrical circuit paths and inunreliable electrical circuit paths.

Uncontrolled electrical circuit paths can resultin damage to main bearings, to the surface ofcrankshaft journals, and to aluminum components.Uncontrolled electrical circuit paths can also causeelectrical activity that may degrade the performanceof the generator set's electronics.

The alternator and the starting motor must begrounded to the negative “−” battery terminal.

A ground plate with a direct path to the negative “−”battery terminal may be used as a common groundfor the components of one engine system.

For engines with an alternator that is grounded toan engine component, a ground strap must connectthat component to the negative “−” battery terminal.Also, that component must be electrically isolatedfrom the engine.

The ground strap for the alternator must be of a sizethat is adequate for carrying the full charging currentof the alternator.

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Generator Isolating forMaintenanceSMCS Code: 4450

When you service an electric power generation setor when you repair an electric power generation set,follow the procedure below:

1. Stop the engine.


2. Attach a “DO NOT OPERATE” or similar warningtag to the engine prime mover starting circuit.Disconnect the engine starting circuit.

3. Disconnect the generator from the distributionsystem.

4. Lock out the circuit breaker. Attach a “DO NOTOPERATE” or similar warning tag to the circuitbreaker. Refer to the electrical diagram. Verify thatall points of possible reverse power flow havebeen locked out.

5. Remove the fuses for the transformers for thefollowing circuitry:

• power

• sensing

• control

6. Attach a “DO NOT OPERATE” or similar warningtag to the generator excitation controls.

7. Remove the cover of the generator's terminal box.

8. Use an audio/visual proximity tester in order toverify that the generator is de-energized. Thistester must be insulated for the proper voltagerating. Follow all guidelines in order to verify thatthe tester is operational.

9. Determine that the generator is in a de-energizedcondition. Add ground straps to the conductorsor terminals. During the entire work period, theseground straps must remain connected to theconductors and to the terminals.