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SERVICE MANUAL BCGB G.-. ..~ PUBLICATION NO.44898 JUNE 2000 1ST EDITION WESTERBEKE CORPORA TION· 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780 WEBSITE: www.WESTERBEKE.COM m ••••N~A Member National MariM Manufacturers Association Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators A WARNING Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death. Symptoms of Carbon Monoxide exposure can include: - Dizziness - Throbbing in Temples -Nausea - Muscular Twitching -Headache - Vomiting - Weakness and Sleepiness -Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not restart until it has been inspected and repaired. This WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the living/sleeping quarters of your vessel. They are inexpensive and easily obtainable at your local marine store. SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety 11UZRual carefully. Most accidents are caused by failure to follow fundamental rules and precau­ A WARNING: Fire can cause injury 01 death! tions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personne~ • Prevent flash fires. Do not smoke or permit flames or and your TIUlChinery. sparks to occur near the carburetor, fuel line, filter, fuel The following safety instructions are in complitmce with pump, or other potential sources of spilled fuel or fuel the American Boat and Yacht Council (ABYC) standards. vapors. Use a suitable container to catch all fuel when removing the fuel line, carburetor, or fuel filters. PREVENT ELECTRIC SHOCK • Do not operate with a Coast Guard Approved flame arrester removed. Backfire can cause severe injury or death. WARNING: Do not touch AC electrical connectlons A • Do not operate with the air cleaner/silencer removed. while engine is mnnlng, 01 when connected to shore Backfire can cause severe injury or death. power. Lethal voltage is present at these connections! • Do not smoke or permit flames or sparks to occur near the fuel system. Keep the compartment and the • Do not operate this machinery without electrical engine/generator clean and free of debris to minimize the enclosures and covers in place. chances of fire. Wipe up all spilled fuel and engine oil. • Shut off electrical power before accessing electrical • Be aware - diesel fuel will bum. equipment • Use insulated mats whenever working on electrical PREVENT BURNS - EXPLOSION equipment • Make sure your clothing and skin are dry, not damp WARNING: Explosions from fuel vapOIS can cause (particularly shoes) when handling electrical equipment A Injury 01 death! • Remove wristwatch and all jewelry when working on electrical equipment • Follow re-fueling safety instructions. Keep the vessel's • Do not connect utility shore power to vessel's AC hatches closed when fueling. Open and ventilate cabin circuits, except through a ship-ta-shore double throw after fueling. Check below for fumes/vapor before run­ transfer switch. Damage to vessel's AC generator may ning the blower. Run the blower for four minutes before result if this procedure is not followed. starting your engine. • Electrical shock results from handling a charged capaci­ • All fuel vapors are highly explosive. Use extreme care tor. Discharge capacitor by shorting terminals together. when handling and storing fuels. Store fuel in a well-ven­ tilated area away from spark-producing equipment and PREVENT BURNS - HOT ENGINE out of the reach of children. • Do not fill the fuel tank(s) while the engine is running. • Shut off the fuel service valve at the engine when servicing WARNING: Do not touch hot engine parts 01 A the fuel system. Take care in catching any fuel that might exhaust system components. A mnnlng engine gets spill. DO NOT allow any smoking, open flames, or other very hot! sources of fire near the fuel system or engine when servic­ ing. Ensure proper ventilation exists when servicing the • Always check the engine coolant level at the coolant fuel system. recovery tank. • Do not alter or modify the fuel system. • Be sure all fuel supplies have a positive shutoff valve. IA WARNING: -.." _1D/tII11lf_ • Be certain fuel line fittings are adequately tightened and free of leaks. • In case of an engine overheat, allow the engine to cool • Make sure a fire extinguisher is installed nearby and is before touching the engine or checking the coolant. properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment. Engines & Generators i SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES A WARNING: Accidental starting can cause Injury A WARNING: carbon mDnDxlde (CO) Is a deadly gas! or death! • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine! discharged from the engine. Check the exhaust system generator. Remove the negative lead first and reconnect regularly for leaks and make sure the exhaust manifolds it last are securely attached and no warping exists. Pay close • Make certain all personnel are clear of the engine before attention to the manifold, water injection elbow, and starting. exhaust pipe nipple. • Make certain all covers, guards, and hatches are re­ • Be sure the unit and its surroundings are well ventilated. installed before starting the engine. • In addition to routine inspection of the exhaust system, install a carbon monoxide detector. Consult your boat BAmRY EXPLOSION builder or dealer for installati~n of approved detectors. • For additional infonnation refer to ABYC T-22 (educa­ A WARNING: Battery explosion can cause Injury tional infonnation on Carbon Monoxide). or death! • Do not smoke or allow an open flame near the battery A WARNING: carbon mDnDxlde (CO) Is an Invisible being serviced. Lead acid batteries emit hydrogen, a Ddorless gas. InhalatlDn produces flu-like symptDms, highly explosive gas. which can be ignited by electrical nausea Df death! arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing dur­ • Do not use copper tubing in diesel exhaust systems. Diesel ing servicing. fumes can rapidly destroy copper tubing in exhaust sys­ • Never connect the negative (-) battery cable to the posi­ tems. Exhaust sulfur causes rapid deterioration of copper tive (+) connection terminal of the starter solenoid. Do tubing resulting in exhaust/water leakage. not test the battery condition by shorting the terminals • Do not install exhaust outlet where exhaust can be drawn together. Sparks could ignite battery gases or fuel vapors. through portholes, vents, or air conditioners. If the engine Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline, water could accumulation of explosive gases. To avoid sparks, do not enter the exhaust discharge outlet and close or restrict the disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft. is being charged. • Although diesel engine exhaust gases are not as toxic as • Avoid contacting the terminals with tools, etc., to prevent exhaust fumes from gasoline engines, carbon monoxide burns or sparks that could cause an explosion. Remove gas is present in diesel exhaust fumes. Some of the symp­ wristwatch, rings, and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning the battery. are: • Always tum the battery charger off before disconnecting Vomiting the battery connections. Remove the negative lead first and reconnect it last when disconnecting the battery. Dizziness Throbbing in temples BATTERY ACID Muscular twitching Intense headache A WARNING: Sulfuric acid In batteries can cause Weakness and sleepiness severe Injury or death! AVOID MOVING PARTS • When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protec­ RDtatlng parts can cause Injury tion. Batteries contain sulfuric acid which is destructive. A WARNING: If it comes in contact with your skin, wash it off at once Dr death! with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps. • Do not service the engine while it is running. If a situa­ tion arises in which it is absolutely necessary to make operating adjustments, use extreme care to avoid touch­ ing moving parts and hot exhaust system components. Engines & Generators ii SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBUCATIONS FOR equipment; tie back long hair and avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that INSTALLING DIESEL ENGINES could be caught in moving parts. Read the following ABYC, NFPA and USCG publications • Make sure all attaching hardware is properly tightened. for safety codes and standards. Follow their recommenda­ Keep protective shields and guards in their respective tions when installing your engine. places at all times. ABYC (American Boat and Yacht Council) • Do not check fluid levels or the drive belt's tension while "Safety Standards for Small Craft" the engine is operating. Order from: • stay clear of the drive shaft and the transmission coupling ABYC when the engine is running; hair and clothing can easily 15 East 26th Street be caught in these rotating parts. New York, NY 10010 NFPA (National Fire Protection Association) HAZARDOUS NOISE "Fire Protection Standard for Motor Craft" Order from: High noise levels can caUSll hearing A WARNING: National Fire Protection Association loss! 11 Tracy Drive Avon Industrial Park • Never operate an engine without its muffler installed. Avon, MA 02322 • Do not run an engine with the air intake (silencer) USCG (United States Coast Guard) removed.
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