Service manual
SAFETY
INSTRUCTIONS
ACCIDENTAL
STARTING
A
WARNING:
Accidental
starting
can
cause
Injury
01
death!
• Disconnect the battery cables before servicing the engine!
generator.
Remove the negative lead first and reconnect
it last.
• Make certain
all
personnel are clear of the engine before
starting.
• Make certain
all
covers, guards,
and
hatches
are
re-
installed before starting the engine.
BATTERY
EXPLOSION
A
WARNING:
Battery
explosion
can
cause
Injury
01
death!
•
Do
not smoke or allow
an
open
flame
near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas,
which can
be
ignited
by
electrical
arcing
or
by
lit tobacco products. Shut off all electrical
equipment in
the
vicinity
to
prevent electrical arcing
dur-
ing
servicing.
• Never connect
the
negative
(-)
battery cable
to
the posi-
tive
(+) connection terminal of
the
starter solenoid.
Do
not
test the battery condition by shorting the terminals
together.
Sparks could ignite battery gases or
fuel
vapors.
Ventilate
any
compartment containing batteries
to
prevent
accumulation of explosive gases.
To
avoid sparks,
do
not
disturb the battery charger connections while the battery
is
being charged.
•
Avoid
contacting the terminals with tools, etc.,
to
prevent
burns
or
sparks that could cause
an
explosion. Remove
wristwatch, rings, and any other jewelry before handling
the
battery.
•
Always
turn the battery charger off before disconnecting
the
battery connections. Remove the negative lead
first
and reconnect it last when disconnecting the
battery.
BATTERY
ACID
A
WARNING:
Sulfuric
acid
In
battelles
can
cause
severe
Injury
01
death!
•
When
servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion.
Batteries contain sulfuric acid which is destructive.
If
it comes in contact with your
skin,
wash
it off at
once
with
water.
Acid may splash
on
the skin or into
the
eyes
inadvertently
when
removing electrolyte
caps.
TOXIC
EXHAUST
GASES
A
WARNING:
carbon
monoxide
(CO)
Is
a
deadly
gas!
• Ensure that the exhaust system is adequate
to
expel
gases
discharged from the engine. Check the exhaust system
regularly for leaks and make
sure
the exhaust manifolds
are
securely attached and no warping exists.
Pay
close
attention
to
the manifold, water injection
elbow,
and
exhaust pipe
nipple.
• Be sure the unit and its surroundings
are
well ventilated.
• In addition to routine inspection of the exhaust
system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation
of
approved detectors.
• For additional information refer to
ABYC
T-22
(educa-
tional information
on
Carbon Monoxide).
A
WARNING:
ca,
bon
monoxide
(CO)
Is
an
Inlllsible
odorless
gas.
Inhalation
ploduces
Du-lIke
symptoms,
nausea
01
death!
•
Do
not use copper tubing in diesel exhaust
systems.
Diesel
fumes
can
rapidly
destroy
copper
tubing
in exhaust
sys-
tems.
Exhaust sulfur causes rapid deterioration of copper
tubing resulting in exhaust/water leakage.
•
Do
not install exhaust outlet where exhaust can
be
drawn
through portholes, vents, or
air conditioners.
If
the engine
exhaust discharge outlet
is
near the waterline, water could
enter the exhaust discharge outlet and
close
or
restrict the
flow
of exhaust.
Avoid
overloading the craft.
• Although diesel engine exhaust gases are not
as
toxic
as
exhaust fumes
from
gasoline engines, carbon monoxide
gas
is
present in diesel exhaust fumes. Some of the
symp-
toms or signs of carbon monoxide inhalation
or
poisoning
are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness
and sleepiness
AVOID
MOVING
PARTS
A
WARNING:
Rotating
parts
can
cause
Injury
01
death!
• Do not service the engine while it
is
running.
If
a situation
arises in which it
is
absolutely necessary to make operat-
ing adjustments, use extreme care
to
avoid touching mov-
ing parts and hot exhaust system components.
Engines
&
Generators
ii