Safety Summary
Installation and servicing of generator set equipment can be hazardous due to system belts, radiator fan, and electrical components. Only trained and qualified service personnel should install, repair, or service generator set equipment. When working on generator set equipment, observe all potential Danger, Warning and Caution hazards, including those shown below and on hazard labels attached to the unit.
The following general safety notices supplement specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.
Always wear safety glasses and hearing protection.
Keep hands, clothing and tools clear of the radiator fan and rotating belts.
No work should be performed on the unit until all circuit breakers and start-stop switches are turned off and the negative battery terminal has been disconnected.
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the unit and investigate.
Be sure power is turned off and the negative battery cable is disconnected before working on generator set.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.
In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).
Fuel Tanks present explosion, fire, and rupture hazards even if liquid fuel has been drained. Do not attempt any repairs, especially repairs using flame, welder or torch, unless you have been properly trained and the tank has been emptied of liquid fuel and fuel vapors and the tank is properly ventilated
To help identify the hazard labels on the unit and explain the level of awareness each one carries, explanations with appropriate consequences are provided below:
DANGER - Indicates an immediate hazard which WILL result in severe personal injury or death.
WARNING - Indicates hazards or unsafe conditions which COULD result in severe personal injury or death.
CAUTION - Indicates potential hazards or unsafe practices which COULD result in minor personal injury, product, or property damage.
The statements that follow are applicable to the generator set and appear elsewhere in this manual. These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein.
To prevent injury, the procedures provided for installation and removal of the generator set must be followed carefully.
Disconnect the power plug before removing the generator set.
Beware of moving poly V-belt, belt driven components and hot exhaust components.
Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the air intake heater.
Beware of pinch points.
Do not use gasoline to clean air cleaner parts.
Observe proper polarity when installing the battery or connecting a battery charger. The negative battery terminal must be grounded. Reverse polarity may damage the charging system. When charging the battery in unit, isolate the battery by disconnecting the negative battery terminal first, then the positive. Once the battery has been charged, connect the positive battery terminal first, then the negative.
Never pour cold water into a hot engine.
Use only ethylene glycol anti-freeze (with inhibitors) in system. Use of glycol by itself will damage the cooling system.
Always cover the engine inlet tube while the air cleaner is being serviced.
When reassembling the air cleaner, make sure the clamp bolt faces out, away from the fuel filter. If the clamp bolt is assembled facing in, it can contact the fuel filter and cause excessive wear.
Continued operation with failed shockmounts may result in engine or generator damage. When a shockmount has been cut, split, abraded or has flared due to normal deterioration, it must be replaced. Damage to the mounts may not be visible when installed and under load from the component. To correctly inspect shockmounts, they must be removed.
This generator set is equipped with special pins and mounting bolts and can be installed only on containers with matching installation points.
Piston rings in engines that have operated less than 100 hours may not be fully seated. This may lead to the possibility of oil seepage from the exhaust pipe. To properly seat the rings, operate the engine under full load for a period of 24 hours. If the condition persists, check valve clearance when the engine is cold. (Refer to engine workshop manual listed in Section 2.4).
If the generator set is equipped with the fuel filter bowl assembly, when replacing the fuel filter, a new fuel filter O-ring should be oiled and replaced, and then the clear bowl should also be tightened to 18 ft-lbs.
Do not attempt to adjust engine speed.
A frayed, cracked or worn poly V-belt must be replaced. After installing a new belt, check the adjustment after running the unit for three or four hours. This will allow for the initial stretch, which is common on new belts. Once this initial stretch has taken place, the belt should be checked at regular intervals.
The generator / engine must be slightly lifted off of the unit frame in order to provide enough clearance for the generator support plate to slide back, away from the engine.
Although the generator torsional dampener and flywheel adapter plate will normally keep the generator coupled to the engine, even without the bolts, it is safest to remove the lower generator bolts first, in case the generator shifts and falls during bolt removal.
Inspect the generator torsional dampener, bolt, and key as they are removed from the old generator and installed onto the new generator. Replace any components that are worn or damaged.
Align the torsional dampener and aluminum housing by rotating either one to seat correctly.
SST
is an abbreviation for 300 Series Corrosion Resistant Steel.
Loctite #242 or an equivalent product should be used on ALL hardware shown
in Figure
6.12.