SAFETY Safety Precautions When welding is complete, reconnect the leads to the alternator and engine control unit prior to reconnecting the batteries. Sever Hazard NEVER wear jewelry, unbuttoned cuffs, ties or loose-fitting clothing and ALWAYS tie long hair back when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts. ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions and damaged or corroded connectors. The propeller may rotate during towing or if the engine is running at idle speed. NEVER service the engine while being towed or when the engine is running.
NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electrical system will result. Exhaust Hazard All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning. If the vessel has more than one engine, NEVER service an engine if either of the engines is running. In multi-engine configurations the propeller for an engine that is shut down may rotate if any of the other engines are running. NEVER block windows, vents or other means of ventilation if the engine is operating in an enclosed area. NEVER operate the engine without the guards in place.
ALWAYS ensure that all connections are tightened to specifications after repair is made to the exhaust system. NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals. Burn Hazard Some of the engine surfaces become very hot during operation and shortly after shutdown. Electrical Hazard Make welding repairs safely. ALWAYS turn off the battery switch (if equipped) or disconnect the negative (-) battery cable and the leads to the alternator when welding on the equipment. Keep hands and other body parts away from hot engine surfaces. Handle hot components with heat-resistant gloves.
Remove the multi-pin connector to the engine control unit. Connect the weld clamp to the component to be welded and as close as possible to the welding point. Sudden Movement Hazard To prevent accidental equipment movement, NEVER start the engine in gear. NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket. Shift the marine gear into the NEUTRAL position any time the engine is at idle. 2-4 BY Service Manual © 2009 Yanmar Marine International