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TP-6069 6/03IV Safety Precautions and Instructions
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiringharness,andengineelectronic
control module (ECM).
CAUTION
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Open the main circuit
breakers of all power sources before
servicingtheequipment. Configurethe
installation to electrically ground the
generator set, transfer switch, and
related equipment and electrical
circuitstocomplywithapplicablecodes
and standards. Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditionsincrease the
risk of electrocution.
Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect
the generator set from the load by
opening the line circuit breaker or by
disconnecting thegenerator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.
Welding the generator set. Can
cause severe electrical equipment
damage. Beforeweldingthegenerator
set perform the following steps:
(1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine battery-
charging alternator connections.
(5) Attach the weld ground connection
close to the weld location.
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Removealljewelrybeforeservicingthe
equipment.
Testing the voltage regulator.
Hazardous voltage can cause
severe injury or death. High voltage
is present atthe voltage regulator heat
sink. To preventelectrical shockdonot
touch the voltage regulator heat sink
when testing the voltage regulator.
(PowerBoostt, PowerBoostt III, and
PowerBoostt V voltage regulator
models only)
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death.
Connect the generator set to the
building/marina electrical system only
through an approved device and after
the building/marina main switch is
opened. Backfeed connections can
cause severe injury or death to utility
personnel working on power lines
and/or personnel near the work area.
Some states and localities prohibit
unauthorized connection to the utility
electrical system. Install a
ship-to-shoretransferswitchtoprevent
interconnection of the generator set
power and shore power.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probesandfollowtheinstructionsofthe
test equipment manufacturer when
performing voltage tests. Observe the
followingprecautions whenperforming
voltage tests: (1) Remove all jewelry.
(2)Standonadry,approvedelectrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
Hot Parts
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, stop
thegeneratorsetandallowittocool. Then
loosen the pressure cap to relieve
pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it
cools.
WARNING
Checking the coolant level. Hot
coolant can cause severe injury or
death. Allow the engine to cool.
Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressurecapwithathickclothandthen
slowlyturnthe capcounterclockwiseto
the first stop. Remove the cap after
pressure has been completely
released and the engine has cooled.
Checkthecoolantlevelatthetankifthe
generator set has a coolant recovery
tank.