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.
•Wear proper service attire when performing work. Do not wear loose clothing as they could get caught on machine components.
•Wear the proper protective equipment when working around the machine, including 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.
•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 an electrical fire, open the circuit switch and extinguish with CO2 (never use water).
•This unit is equipped with a lead-acid type battery. The battery normally vents small amounts of flammable hydrogen gas. Do not smoke when checking the battery. A battery explosion can cause serious physical harm and/or blindness.
•Be sure power is turned off and the negative battery cable is disconnected before working on a generator set.
•Keep the electrolyte away from your eyes, hands, and clothes. Sulfuric acid in the battery electrolyte is poisonous: it can cause blindness and is strong enough to burn your skin and clothing. If you spill electrolyte on yourself, clean yourself with water and get medical aid immediately.
•Exhaust gas and components are extremely hot during operation. Avoid skin exposure and contact with hot exhaust gas or components.
•Do not work immediately after stopping the engine. The engine, muffler, radiator, and hydraulic components are extremely hot.
•The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pressure without spray.
•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.
•Keep fire (welding sparks, grinding sparks, cigarettes) away from the fuel.
•Wipe off the fuel when spilled.
•Keep away from high pressure fluids bursting from a hose or pipe. The fluid can penetrate your skin and cause serious injuries.
•Release residual pressure in the hydraulic circuit before removing the hydraulic components. Pay attention because the machine or attachment may move unexpectedly.
•Do not remove caps and plugs soon after stopping the engine. The temperature and pressure of the coolant, hydraulic oil, and fuel are still high.
•Protective goggles must be worn when checking for fuel discharge from the supply pump outlet, as fuel may be discharged.
•Prior to disconnecting a high pressure pipe, stop the engine and wait at least 5 minutes.
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 fan 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.
Make sure the engine is cooled down enough before removing the oil pressure switch. Be careful when removing the oil pressure switch as engine oil will flow out.
Prior to first use of the genset, ensure all shipping packaging and debris is removed and discarded.
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.
Do not pre-fill a new replaced fuel filter prior to installation. This can damage the engine’s fuel injectors.
Never pour cold water into a hot engine.
Use only ethylene glycol anti-freeze (with inhibitors) in system. Using glycol by itself will damage the cooling system.
Always cover the engine inlet tube while the air cleaner is being serviced.
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.