Safety: Operation and Maintenance Manual Excerpt

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SAFETY

Operation and Maintenance


Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
SEBU7828-10
August 2010

Operation and
Maintenance
Manual
3406C Generator Set
ZKC1-Up (Generator Set)
C2G1-Up (Generator Set)
C5G1-Up (Generator Set)
C8G1-Up (Generator Set)
NKM1-Up (Generator Set)
C2Y1-Up (Generator Set)

SAFETY.CAT.COM
6 SEBU7828-10
Safety Section
Safety Messages

Safety Section
i01914689

Safety Messages
SMCS Code: 1000; 7405

There may be several specific safety messages


on your generator set. The exact location and a
description of the 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 safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off
of the engine.

Replace any safety message that is damaged or


missing. If a safety message is attached to a part
of the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
SEBU7828-10 7
Safety Section
Safety Messages

g00997405
Illustration 1
8 SEBU7828-10
Safety Section
Safety Messages

g01024480
Illustration 2
SEBU7828-10 9
Safety Section
Safety Messages

g01024694
Illustration 3
10 SEBU7828-10
Safety Section
Safety Messages

g01024708
Illustration 4

Hot Surface (1)


This safety message for hot surfaces is located on
top of the enclosure, on the sides of the radiator and
on the engine.

g01023637

Hot surface! Do not touch!


SEBU7828-10 11
Safety Section
Safety Messages

Automatic Starting (2) Lifting the Genset (4)


This safety message for automatic starting is located This safety message for lifting the genset is located
on the side of the enclosure and the control panel. on the side of the enclosure for enclosed gensets.

g01023635

When the engine is in the AUTOMATIC mode, the


engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.

Do Not Operate (3)


This safety message is located on the rear of the
enclosure and the control panel.

g01023710

Crushing Hazard! Improper lifting could cause se-


rious injury or death. Follow the lifting instruc-
tions in the Operation and Maintenance Manual for
safe lifting procedures.
g00920070

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.

Failure to follow the warnings and instructions


could result in injury or death. Contact any
Caterpillar dealer for replacement manuals. Prop-
er care is your responsibility.
12 SEBU7828-10
Safety Section
Safety Messages

Electrical Shock (5) Lifting the Genset (7)


This safety message is located on the sides of the This safety message for lifting the genset is located
generator. on the frame rails for open gensets.

g01018792

WARNING! Shock/Electrocution Hazard! Read and


understand the instructions and warnings in the
Operation and Maintenance Manual. Failure to fol- g01024607
low the instructions or heed the warnings could
cause serious injury or death.

Electrocution (6) Crushing Hazard! Improper lifting could cause se-


rious injury or death. Follow the lifting instruc-
This safety message for electrocution is located on tions in the Operation and Maintenance Manual for
the sides and the rear of the generator. safe lifting procedures.

Do Not Climb (8)


This safety message is located on the starting motor.

g00920549

WARNING: Shock/Electrocution Hazard-Read the g00327774


Operation and Maintenance Manual. Could cause
serious injury or death. Do not climb on the generator set. Personal injury
may result. Use an adequate ladder or use an
appropriate work platform for climbing.
SEBU7828-10 13
Safety Section
General Hazard Information

Hot Coolant Under Pressure (9) Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
This safety message is located near the top of the serviced.
radiator on the front.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.

Cautiously remove the following parts. To help


prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.

• Filler caps
• Grease fittings

g00107971 • Pressure taps


• Breathers
• Drain plugs
The coolant is hot and the coolant is under pres-
sure. Do not touch the hot surfaces. Refer to the Use caution when cover plates are removed.
Operation and Maintenance Manual for the proce- Gradually loosen, but do not remove the last two
dure to follow when you check the radiator. bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
i03704500 relieve any spring pressure or other pressure.
General Hazard Information
SMCS Code: 1000; 7405

g00702020
Illustration 6

• Wear a hard hat, protective glasses, and other


g00104545
protective equipment, as required.
Illustration 5
• When work is performed around an engine that is
Attach a “Do Not Operate” warning tag or a similar operating, wear protective devices for ears in order
warning tag to the start switch or to the controls to help prevent damage to hearing.
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction, • Do not wear loose clothing or jewelry that can snag
SEHS7332) are available from your Caterpillar on controls or on other parts of the engine.
dealer. Attach the warning tags to the engine and to
each operator control station. When it is appropriate, • Ensure that all protective guards and all covers are
disconnect the starting controls. secured in place on the engine.

• Never put maintenance fluids into glass containers.


Glass containers can break.
14 SEBU7828-10
Safety Section
General Hazard Information

• Use all cleaning solutions with care. Fluid Penetration


• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:

• The engine is stopped. Ensure that the engine


cannot be started.

• The protective locks or the controls are in the


applied position.

• Disconnect the batteries when maintenance


is performed or when the electrical system is
serviced. Disconnect the battery ground leads. g00687600
Tape the leads in order to help prevent sparks. Illustration 7

• For initial start-up of a new engine or for starting an Always use a board or cardboard when you check
engine that has been serviced, make provisions to for a leak. Leaking fluid that is under pressure can
stop the engine if an overspeed occurs. This may penetrate body tissue. Fluid penetration can cause
be accomplished by shutting off the fuel supply serious injury and possible death. A pin hole leak can
and/or the air supply to the engine. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
• Start the engine with the operator controls. Never from a doctor that is familiar with this type of injury.
short across the starting motor terminals or the
batteries. This could bypass the engine neutral Containing Fluid Spillage
start system and/or the electrical system could be
damaged.
NOTICE
Care must be taken to ensure that fluids are contained
Pressurized Air and Water during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Pressurized air and/or water can cause debris collect the fluid with suitable containers before open-
and/or hot water to be blown out. This could result in ing any compartment or disassembling any compo-
personal injury. nent containing fluids.
When pressurized air and/or pressurized water is Refer to Special Publication, NENG2500, “Caterpillar
used for cleaning, wear protective clothing, protective Dealer Service Tool Catalog” or refer to Special Pub-
shoes, and eye protection. Eye protection includes lication, PECJ0003, “Caterpillar Shop Supplies and
goggles or a protective face shield. Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi) when the air nozzle Dispose of all fluids according to local regulations and
is deadheaded. The maximum water pressure for mandates.
cleaning purposes must be below 275 kPa (40 psi).
SEBU7828-10 15
Safety Section
General Hazard Information

Asbestos Information • Comply with applicable rules and regulations


for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal


of asbestos.

• Stay away from areas that might have asbestos


particles in the air.

Lines, Tubes, and Hoses


Do not bend or strike high pressure lines. Do not
Illustration 8
g00702022 install lines, tubes, or hoses that are damaged.

Caterpillar equipment and replacement parts that are Repair any fuel lines, oil lines, tubes, or hoses that
shipped from Caterpillar are asbestos free. Caterpillar are loose or damaged. Leaks can cause fires.
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines Inspect all lines, tubes and hoses carefully. Do
when you handle any replacement parts that contain not use bare hands to check for leaks. Always
asbestos or when you handle asbestos debris. use a board or cardboard for checking engine
components for leaks. Tighten all connections to the
Use caution. Avoid inhaling dust that might be recommended torque.
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous Check for the following conditions:
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining • End fittings that are damaged or leaking
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually • Outer covering that is chafed or cut
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that • Wire that is exposed in reinforced hose
contains asbestos is generated.
• Outer covering that is ballooning locally
If dust that may contain asbestos is present, there
are several guidelines that should be followed: • Flexible part of the hose that is kinked or crushed

• Never use compressed air for cleaning. • Armoring that is embedded in the outer covering

• Avoid brushing materials that contain asbestos. Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. This will help to
• Avoid grinding materials that contain asbestos. prevent these effects: vibration, rubbing against other
parts, and excessive heat during operation.
• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high


efficiency particulate air filter (HEPA) can also be
used.

• Use exhaust ventilation on permanent machining


jobs.

• Wear an approved respirator if there is no other


way to control the dust.
16 SEBU7828-10
Safety Section
Burn Prevention

Dispose of Waste Properly 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 lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.

Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
Illustration 9
g00706404 the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
Improperly disposing of waste can threaten the and connectors. Use of gloves is recommended.
environment. Potentially harmful fluids should be
disposed of according to local regulations.
i03649377

Always use leakproof containers when you drain Fire Prevention and Explosion
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water. Prevention
SMCS Code: 1000; 7405
i01480768

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 air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.

Coolant g00704000
Illustration 10
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under Use of personal protection equipment (PPE) may be
pressure. The radiator and all lines to the heaters or needed.
to the engine contain hot coolant.
All fuels, most lubricants, and some coolant mixtures
Any contact with hot coolant or with steam can cause are flammable.
severe burns. Allow cooling system components to
cool before the cooling system is drained. Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate
Check the coolant level after the engine has stopped a product when a fire hazard exists. Contact your
and the engine has been allowed to cool. Caterpillar dealer for service.

Ensure that the filler cap is cool before removing the Flammable fluids that are leaking or spilled onto hot
filler cap. The filler cap must be cool enough to touch surfaces or onto electrical components can cause
with a bare hand. Remove the filler cap slowly in a fire. Fire may cause personal injury and property
order to relieve pressure. damage.
SEBU7828-10 17
Safety Section
Fire Prevention and Explosion Prevention

A flash fire may result if the covers for the engine Inspect all lines and hoses for wear or for
crankcase are removed within fifteen minutes after deterioration. The hoses must be properly routed.
an emergency shutdown. The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
Determine whether the engine will be operated in an recommended torque. Leaks can cause fires.
environment that allows combustible gases to be
drawn into the air inlet system. These gases could Oil filters and fuel filters must be properly installed.
cause the engine to overspeed. Personal injury, The filter housings must be tightened to the proper
property damage, or engine damage could result. torque.

If the application involves the presence of combustible


gases, consult your Caterpillar dealer for additional
information about suitable protection devices.

Remove all flammable materials such as fuel, oil, and


debris from the engine. Do not allow any flammable
materials to accumulate on the engine.

All fluids that are captured in the fluid spill


containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire
may cause personal injury and property damage.

Store fuels and lubricants in properly marked


containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.

Do not expose the engine to any flame.


g00704059
Illustration 11
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
Use caution when you are refueling an engine. Do
a tube, or a seal failure. Exhaust shields must be
not smoke while you are refueling an engine. Do not
installed correctly.
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.

Wiring must be kept in good condition. All electrical


wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.

Eliminate all wiring that is unattached or unnecessary.


Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure


connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
g00704135
Illustration 12
18 SEBU7828-10
Safety Section
Crushing Prevention and Cutting Prevention

Gases from a battery can explode. Keep any open Check lines, tubes and hoses carefully. Do not use
flames or sparks away from the top of a battery. Do your bare hand to check for leaks. Use a board or
not smoke in battery charging areas. cardboard to check for leaks. Tighten all connections
to the recommended torque.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or Replace the parts if any of the following conditions
a hydrometer. are present:

Improper jumper cable connections can cause • End fittings are damaged or leaking.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific • Outer coverings are chafed or cut.
instructions.
• Wires are exposed.
Do not charge a frozen battery. This may cause an
explosion. • Outer coverings are ballooning.
The batteries must be kept clean. The covers • Flexible part of the hoses are kinked.
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box • Outer covers have embedded armoring.
covers when the engine is operated.
• End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher. will help to prevent vibration, rubbing against other
parts, and excessive heat.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate. i01359666

Ether Crushing Prevention and


Cutting Prevention
Ether is flammable and poisonous.
SMCS Code: 1000; 7405
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while you Support the component properly when work beneath
are using an ether spray. the component is performed.

Do not store ether cylinders in living areas or in the Unless other maintenance instructions are provided,
engine compartment. Do not store ether cylinders never attempt adjustments while the engine is
in direct sunlight or in temperatures above 49 °C running.
(120 °F). Keep ether cylinders away from open
flames or sparks. Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
Dispose of used ether cylinders properly. Do not is performed. After the maintenance is performed,
puncture an ether cylinder. Keep ether cylinders reinstall the guards.
away from unauthorized personnel.
Keep objects away from moving fan blades. The fan
Do not spray ether into an engine if the engine is blades will throw objects or cut objects.
equipped with a thermal starting aid for cold weather
starting. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Lines, Tubes and Hoses Chips or other debris may fly off objects when objects
Do not bend high pressure lines. Do not strike high are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
pressure lines. Do not install any lines that are bent
or damaged.

Repair any lines that are loose or damaged. Leaks


can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
SEBU7828-10 19
Safety Section
Mounting and Dismounting

i01909770 • The sound pressure level of a complete generator


set (including the radiator) at 1 meter is 101
Mounting and Dismounting dB(A) for the noisiest configuration when “ISO
8528-10:1998(E) clause 14” is used at 75 percent
SMCS Code: 1000; 7405 of the rated power.
Inspect the steps, the handholds, and the work area • The sound power level of a complete generator
before mounting the unit. Keep these items clean set (including the radiator) that is not covered by
and keep these items in good repair. the “European Union Directive 2000/14/EC” is 115
dB(A) for the noisiest configuration when “ISO
Mount the unit and dismount the unit only at locations 8528-10:1998(E) clause 13” is used at 75 per cent
that have steps and/or handholds. Do not climb on of the rated power.
the engine, and do not jump off the engine.
Note: The preceding sound levels are emission
Face the unit in order to mount the unit or dismount levels. The preceding sound levels are not
the unit. Maintain a three-point contact with the steps necessarily safe sound levels. There is a correlation
and handholds. Use two feet and one hand or use between the emission levels and the level of
one foot and two hands. Do not use any controls as exposure. The correlation between emission levels
handholds. and the level of exposure can not be used to
determine if further precautions are required.
Some units require access to the roof of the
enclosure to perform maintenance. Do not stand on Refer to the following for factors that influence the
components which cannot support your weight. Use level of exposure:
an adequate ladder or use a work platform. Secure
the climbing equipment so that the equipment will • The characteristics of the area around the
not move. generator set
Do not carry tools or supplies when you mount the • Other sources of noise
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies. • The number of machines and other adjacent
processes
Strong winds may lift the doors for generator
enclosures off the hinge pins. If strong winds threaten • The length of time of exposure to the noise
to lift the doors for generator enclosures, the doors
should be removed from the hinges in order to help This information will enable the user of the machine
prevent damage. to evaluate the hazard and the risk.

i03877943 i03560601

Sound Information Before Starting Engine


SMCS Code: 1000 SMCS Code: 1000
Note: Information of the sound level is for machines
NOTICE
in European Union countries and in countries that
For initial start-up of a new or rebuilt engine, and for
adopt the directives of the European Union.
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
NOTICE occur. This may be accomplished by shutting off the
Hearing protection may be needed when working near air and/or fuel supply to the engine.
an operating generator set.

Sound levels will vary depending on the configuration


of the generator set and the final installation of the
Engine exhaust contains products of combustion
generator set.
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
Refer to the following for sound levels:
and, if in an enclosed area, vent the exhaust to the
outside.

Inspect the engine for potential hazards.


20 SEBU7828-10
Safety Section
Engine Starting

Do not start the engine or move any of the controls Engine exhaust contains products of combustion
if there is a “DO NOT OPERATE” warning tag or that can be harmful to your health. Always start the
similar warning tag attached to the start switch or to engine and operate the engine in a well ventilated
the controls. area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the Ether
area is free of personnel.
Ether is poisonous and flammable.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
Do not inhale ether, and do not allow ether to contact
lights work properly, if equipped.
the skin. Personal injury could result.
All protective guards and all protective covers must
Do not smoke while ether cylinders are changed.
be installed if the engine must be started in order
to perform service procedures. To help prevent an Use ether in well ventilated areas.
accident that is caused by parts in rotation, work
around the parts carefully.
Use ether with care in order to avoid fires.
Do not bypass the automatic shutoff circuits. Do not
Keep ether cylinders out of the reach of unauthorized
disable the automatic shutoff circuits. The circuits are
persons.
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
Store ether cylinders in authorized storage areas
engine damage.
only.
See the Service Manual for repairs and for
Do not store ether cylinders in direct sunlight or at
adjustments.
temperatures above 49 °C (120 °F).

i01103904 Discard the ether cylinders in a safe place. Do not


puncture the ether cylinders. Do not burn the ether
Engine Starting cylinders.

SMCS Code: 1000


i01462046

If a warning tag is attached to the engine start switch


or to the controls, DO NOT start the engine or move
Engine Stopping
the controls. Consult with the person that attached
SMCS Code: 1000
the warning tag before the engine is started.
Stop the engine according to the procedure in
All protective guards and all protective covers must
the Operation and Maintenance Manual, “Engine
be installed if the engine must be started in order Stopping (Operation Section)” in order to avoid
to perform service procedures. To help prevent an
overheating of the engine and accelerated wear of
accident that is caused by parts in rotation, work
the engine components.
around the parts carefully.
Use the Emergency Stop Button (if equipped) ONLY
Start the engine from the operator's compartment or
in an emergency situation. Do not use the Emergency
from the engine start switch. Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
Always start the engine according to the procedure
problem that caused the emergency stop has been
that is described in this Operation and Maintenance corrected.
Manual, “Engine Starting” topic (Operation Section).
Knowing the correct procedure will help to prevent
Stop the engine if an overspeed condition occurs
major damage to the engine components. Knowing during the initial start-up of a new engine or an engine
the procedure will also help to prevent personal injury.
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
To ensure that the jacket water heater (if equipped) shutting off the air supply to the engine.
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the
To stop an electronically controlled engine, cut the
oil temperature gauge during the heater operation. power to the engine.
SEBU7828-10 21
Safety Section
Electrical System

i01054945 i01226491

Electrical System Generator Isolating for


SMCS Code: 1000; 1400 Maintenance
SMCS Code: 4450
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
When you service an electric power generation set
is operating. A spark can cause the combustible
or when you repair an electric power generation set,
gases that are produced by some batteries to ignite.
follow the procedure below:
If the engine must be started by an external electrical
1. Stop the engine.
source, then always connect the positive jump start
cable “+” to the positive terminal “+” of the battery.

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 “−” terminal, connect
the jump start cable to the engine block.

Grounding Practices
Proper grounding for the engine electrical system
is necessary for proper engine performance
g00104545
and reliability. Improper grounding will result in Illustration 13
uncontrolled electrical circuit paths and unreliable
electrical circuit paths. 2. Attach a “DO NOT OPERATE” or similar warning
tag to the engine prime mover starting circuit.
Uncontrolled engine electrical circuit paths can Disconnect the engine starting circuit.
result in damage to the following components: main
bearings, crankshaft bearing journal surfaces, and 3. Disconnect the generator from the distribution
aluminum components. All grounds should be tight system.
and free of corrosion.
4. Lock out the circuit breaker. Attach a “DO NOT
The alternator and the starting motor must be OPERATE” or similar warning tag to the circuit
grounded to the negative “-” battery terminal. breaker. Refer to the electrical diagram. Verify that
all points of possible reverse power flow have
For engines that have an alternator that is grounded been locked out.
to an engine component, a ground strap must be
used. The ground strap must be connected to the 5. Remove the fuses for the transformers for the
component and to the negative “-” battery terminal. following circuitry:
The component must be electrically isolated from
the engine. • power
A ground plate with a direct path to the negative • sensing
battery terminal “-” can be used as a common ground
point for the components of one engine system. • control
The wire size that is used for the ground plate must 6. Attach a “DO NOT OPERATE” or similar warning
be large enough to handle the full charging current of tag to the generator excitation controls.
the alternator.
7. Remove the cover of the generator's terminal box.

8. Use an audio/visual proximity tester in order to


verify that the generator is de-energized. This
tester must be insulated for the proper voltage
rating. Follow all guidelines in order to verify that
the tester is operational.
22 SEBU7828-10
Safety Section
Generator Isolating for Maintenance

9. Determine that the generator is in a de-energized


condition. Add ground straps to the conductors
or terminals. During the entire work period, these
ground straps must remain connected to the
conductors and to the terminals.

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