Westerbeke 29.0 EGED 60Hz User manual

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OPERATORS MANUAL
.· MARINE DIESEL GENERATORS
29.0 EGED 60Hz 23.0 EGED 50 Hz
Single and Three Phase .
PUBLICATION NO. 056402
REVISIONO
MARCH 2017
member' WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK
~--- 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780·7319 U.S.A.
§.J!H TEL: (508)823·7677 • FAX: {508)884-9688 • WEBSITE: WWW. WESTERBEKE.COM

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancerJ birth defectsJ and other
reproductive harm.
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
•Nausea
•Headache
• Throbbing in Temples
• Muscular Twitching
• 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
IRTRODUCnON
Read this safety 11Ullluol carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
toke the necessary precautions to protect yourself, your
personne4 and your machinery.
The foUowing sofety instruciions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELEcTRIC SHOCK
A WARNING: liD IIIII tout:h AC electrical t:llllllet:tiDifS
while IIIJine/s runlling. Lethal raltage is ptt~Sent at
tllese t:D111181:ti1111SI
• Do not oPerate tbis machinery without electrical
enclosures and co:vers in place.
• Shut off electrical power before accessing electrical
equipment ·
•
Use insulated mats whenever working on electrical
equipment
• Make sure your clothing and skin are dty, not damp
(particularly shoes) when handling electrical'equipment.
•
Remove wristwatch and all jewelry when working on
electrical equipment
PREVENT BURRS- HOT ENGINE
A WARNING: Do 11111 fDIIDb bill tlllg/ne patls or
8Xhstlst"""" comptlllllllls. A IIIIJIIIng engine gets
,. '
• Monitor EingiQe -~ cooiant ievei at the plastic
coolant recovery·tank and periodiCaly at the filler atp
location on the waterjacketed exhau.<tt manifold, but only
when the engineis COLD.
j AwA1818: ___ ,.,.,_
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS- FIRE
IA WARIIIIIG: Flnl""" ...... illjmp ... _, ]
• Prevent flash fires. Do not smoke or permit flames or
sparlcs to occur near the fuel injector, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel lines or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. J(eep ~compartment and the
engine 'clean imd free of debris to minimize the
chances of fire. wq,e up all spilled fuel and engine oil.
• Be aware- diesel fuel will bum.
PREVENT BURNS- EXPLOSION
A WARNING: Exp/llsiiiiiS frllm fuel V11J1D1S can t:aiiSI1
Injury D1 dlllf#'l
• . Follow re--fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate the cabin
after fueling. Check below for fumes/vapor refore running
the blower. Run the blower per four minutes before starting
your engine.
• All fuel vapors are highly explosive. Use extreme care .
when handling and storing fuels. Store fuel in a
well-ventilated area away from spark-producing
equipment and out ofthe ~h of children.
• Do notfill the fuel tank(s) while the ,engine while it is running.
• Shut off the fuel service Valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other .
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Qo not alter or modify the fuel system.
·• ~~ sure all fuel supplies have a positive shutoff valve.
• Becertain fuel line fittings are ?dequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
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
A WARNING: Accidental starting can cause injury
or 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.
BAmRY EXPLOSION
A WARNING: Battery explosion can cause injury
or 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
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting _
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BAnERYACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or 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: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or 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 ofcopper
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 ofexhaust. 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 ofcarbon 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
or death!
• Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to m'ake
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
a Do not wear loose clothing or jewehy when servicing
equipment: avoid wearing loose jackets, shirts, sleeves,
rings, necklaces or bmcelets that could be caught in
. maving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times. · ·
a Do not check fluid levels or the drive belt's tension while
.the engine is operating.
IIi Stay clear ofthe drive shaft and the transmission coupling
when the engine is running; h3ir and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High llt1ise IBvetsl:atl t:BIISfl bearing
IIISSI
~ Never operate an engine withoutits -muffler installed.
• Donot nm an engine with the airintake (sUencer)
removed.
A WARNING: Dollllf Pllltk Dll macblnety PJbell,. are
. mBIItally D1 physlally /muipat;llatstJ by fatl!lllel
OPERATORS MANUAL
·Many of the preceding safety tips and warnings ate-repeated
in yOur opemtors Manual along with other cautions and
notes to highlight critical inforination. Read your manual
carefully, m•tain your equipment. and follow all safety
procedures. .
ENGINE AID GENERATOR INSTALLATIONS .
Preparations to install an engine should begin with a thor-
ough examiDation of the American Boat and Yacht Council's
(ABYQ standat:ds. These standards ate a combination of
soun:es including the USCG and the NPPA.
Sections of the ABYC standards ofparticular interest are:
H-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion of Exhaust Systems for Propulsion
and Auxiliary Engines
P-4 Marine Jnbo$'d Engines and Transmissions
E-ll AC & DC Electrical Systems on Boats
TA Batteries and Battery Chargers
All installations must comply with the Federal Code of
Regulations (FCR.).
ABYC, NFPA AND USCG PUBUCAnONS FOR
.. INSTALLING MARINE ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for
safety codes and standards. Follow their recommenda-
tions when insialUng your UNIVERSAL engine
ABYC
(American Boat and Yacht Council)
"Safety Standaras for Small Craft'' .
Order From:
ABYC
613 Third Dtreet, Suite 10
Annapolis, MD 21403
[phone]
· www.abycinc.O!J
NFPA (National Fire Protection Association)
"Fue Protection Standard for Motor Craft"
Order From~
NFPA
1 Ba.tterymarch Park
P.O. Box 9101
Quincy, MA 02269--9101
USCG (United States Coast Guard)
"CFR 33 AND CFR46'•
Code.ofFedeml Regulations
Order From:
U.S. GovernmentPrinting Office
Washington, D.C. 20404
I""''V"IWESTERSEKB
(Engines & Generators
•••
Ill

.INSTALLATION
When installing WESTERBEKE engines and generators it isimportant that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must becomplied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 2ft' above the vessel's waterline. Failure to use a siphon-break' when
the exhaust manifold injection porl Ia at or below the loaJ1 waterline will result in
raw water damage to Ow engine and po~Bible Jlboding of the boat.
If you have any doubt abOut' the positii;>.n oft}w. water-injected exhaust elbow relative :
to· the vessel's watedirte.under the vessel's various operating cOnditions, install a
siphon-break. .. ,. .. . ......
AVAILABLE FROM
YOUR. WESTERBEKE
NOTE: A si.Phon~break requires periodic inspection ·and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can· result in catastrophic
en~ne damage. CoMllt the siphon-break manufacturer for proper maintenance.
. DEALER
EXHAUST SYSTEM
· Tlie exhauSt system's hose 'Mli~t:~ certified for marine use. Corrugated Marine
Exhaust Hose is recommen~~ The use ofthis type of hose; a,llows for extreme bends
and turns without the~ ofadditiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length of coxrugated 9xhaust hose can be used. 'The
system MUST be designed to prevent the entry ofwater·into the exhaust syste~ ·
under any sea conditions and at any angle of vessels heal.
A detailed Marine lnstaHation Manual covering gasoline and diesel
engines an~ generators is supplied wHb ~ unit sold. This manual
Js also available In pdf format on our website to download
We~lte: www.westerbeke.com
l"YYV'IWESTERBEKE
l Eng/,_ & Generators
iv
SIPHON-BREAK WfTH fifAINLES,
LOOP FOR 1" HOSE .
PART NO. 044010

TABLE OF CONTENTS
Parts Identification ............................................. 2 Glow Plugs ......................................................... 21
Introduction ......................................................... 3 Inspection and Testing.................................
21
Fuel, Engine Oil and Engine Coolant.. ................ 5
Alternators ......................................................... 22
Preparations for Initial Start·Up ......................... 6 Testing and Troubleshooting ....................... 22
Control Panel ....................................................... 7 Battery Care.................................................
24
Manual Engine Shut-Off...............................7
Starter Motor ..................................................... 25
Starting/Stopping Procedure ............................... 8
Remote Panels ...............................................8 .Testing withElectrical Jumper....................
25
Testing with Screwdriver............................. 26
Benerator Break-In Procedure ... : ........................ 9 Removing for Service.................................. 27
Daily Routine ....................................................... 9
Raw Water Pump (Exploded View) .................... 28
Maintenance Schedule ..................................... 1o
Fuel System ........................................... : ........... 12
Cooling System .................................................. t3',,
Raw Water Intake........................................ 13
Draining the Raw Water System ................. 13
Fresh Water Cooling Circuit......................... 14
Changing the Coolant.................................. 14
Thermostat................................................... 15
Raw Water Cooling Circuit ......................... 16
Heat Exchanger ........................................... 16
Raw Water Pump......................................... 16
Engine Lubricating Oil ....................................... 17
Engine Oil Change ...................................... 17
Water Heater Installation (Optional) ................. 29
Remote 011 Filter (Optional) .............................. 30
Block Heater (Optional) .................................... .30
Specifications .................................................... 31
Benerator Information ...................................... .33
Twelve Lead Winding Connections .................. .34
Electronic Regulation (AVR) ............................. 35
Internal Wiring Diagram .................................... 37
AC Outlet Configuration ..................................... 37
Shore Power Transfer Switch ........................... .38
Lay·Up and Recommissioning.' .......................... 39
Suggested Spares ............................................. .41
Engine Troubleshooting ..................................... 18
Wiring Diagrams and Schematics .................... .42
Engine AdJustments ........................................... 19
Drive BeltAdjustment................................. 19
Fuel Injectors............................................... 19
Troubleshooting Instrument Gauges ........... 19
Testing Oil Pressure.....................................20
Checking Valve Clearance........................... 20
Valve Adjustment.........................................20
r.viWE§I"ERBEKE
l Engines & Generators
1

PARTS IDENTIFICATION
CONNECTION FOR
SIPHON BREAK
REAR
FUEL LIFT
MANIFOLD PRESSURE CAP
COOLA~T FILL
DRIVE BELT
COVER
DC ALTERNATO
FRONT.
FLEXIBLE ISOLATED
MOUNTS
COOLANT FILL
RIGHT SIDE
CONTROl
LEFT.
SIDE
Engines & Generators
2
OIL FILL
I
PUMP
DC FIELD BREAKER
SYPHON BREAK
CONNECTION

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKE's long years of experience and advanced .
technology. We take great pride in the superior durability and
dependable performance of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator it
is important that you operate and maintain it correctly~ This
manual is designed to help you do this. Please, read this
manual carefully and observe all the safety precautions
throughout Should your generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This is your operators manual. Along wi~ ~ manual, .there
is an Installation Manual and Parts Information. A Semce
Manual is available in pdf form on our website or can be
ordered in book form from a WESTERBEKFJUNIVERSAL
Dealer
WARRANTY PROCEDURES
Your WESTERBEKE Warranty Statement is included in the
product documentation package. There is a Warranty
Registration Card you can fill out and mail to Westerbeke ·
Corporation or go to our website:www. westerbeke.com and
register your products warranty on line. You should receive a
Customer Identification card in the mail within 60 days of
registering. If.you do not, please contact the factory and have
your product model number, serial number and in service ·
date available.
Customer Identification Card
I,.,IWESTERSEKE
I Engines & Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires
Serihl #
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Proceduress which if not strictly
observed, can result In the damage or destruction of
your engine.
A ·WARNING: Procedures, which If not properly
followed, can result in personal injuryor loss oflife.
PRODUCT SOFTWARE
Pioduct software, (tech dlUa. pans, lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BERESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKEs NO .
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY; TIMELINESS OR
COMP'zErENESS THEREOFANDW1U IN NO EVENT ·
BE UABLE FOR ANYTYPE OF DAMAGE OR INJURY
iNCURRED INCONNECI10NWITH OR ARISING OUT
.. OF THE FURNISHING OR USE OF SUCH SOF1WARE.
WESTERBEKE customers should also keep in mind the
time span between printirigs ofWESTERBEKE product
software and the tinavoidable existence ofearlier ·
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE orother suppliers, must not and cannot
be relied upon· exclusively as the definitive authority on
the respective product It not only makes good sense
but is imperative that appropriate representatives of
WES'IERBEKE or the supplier in question be consnited
to detennine the accuracy and currentness ofthe
product software being consulted by the customer.
PROTECTING YOUR. INVESTMENT·
care at~ factory during assembly and tl)orough testing
have n$tdtedin a WESTERBEKE generat9r capable of
Ill8I).Y tbousands ofhours of dependable ~ce~ ·However the
manuflicturer cannot control how orwhere the generator is
install~ in the vessel orthe manner in which the unit is
operat6jl 'and serviced in the field. This is up to the
buyer/owner.:Operator. ·
;•
NOTE: SU: imp~rtant steps to ensure long generaJor life:
• Proper engine andgenerotor insttlllaiion and.alignment.
• An efficient weU-designed exhtiust system that irtt;,.ludes
an mzti:.siphon breafc to prevent water from entering the
engine.
. . . .
• Changingthe engine oilandoil filters' accordiit.g .. to tlie
maintenance scltedule.
•
.Proper niainte1tizliee of all engine a7ii1 generfdor compo- ·
ne1its accortli;ng to the maintenance schedule in this
mimuii! . .
·• Use clei:bi;:(ilierf!d #2 dieselfUel.
• Wznterize your engine ticcoriliitg to the ""Lay-up and
Reco;mmissioninlf'section in this manuaL
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model and serial number are lo,cate<i on
anameplate mounted on the side
of the waterjacketed
exhaust manifold.
The engine's serial number is also found stamped in
the engine block on a flat surfacejust above the
the side oil fill opening. Take time to enter this inform-
ation below on the illustrated nameplate.
50 HZ. 60HZ.
I
An identification plateon the top of the engine airintake also
displays the engine model and serial number.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters.
Carbon monoxide,
even in small amounts, is deadly.
The presence of carbon monoxide indicates an exhaust leak
from the engine
or generator or from the exhaust
elbow/exhaust
hose, or the fumes from a nearby vessel are
entering your boat.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visible position in the
engine
room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the
same. The cylinders
are arranged above a closed crankcase; the crankshaft is of
the same general type as that of a gasoline engine; and the
diesel engine has the same types ofvalves, camshaft, pistons,
connecting rods and lubricating system.
Therefore,
to a great extent, a diesel engine requires the
same preventive maintenance
as a gasoline engine. The
most important factors
are proper ventilation and proper
maintenance ofthe
fuel, lubricating and cooling systems.
Replacement of fuel and lubricating filter elements at the
time periods specified is a must, and frequent checking
for
contaillination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of the same brand ofhigh detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine
does differ from the gasoline engine,
however, in its method ofhandling and firing of fuel. The
carburetor and ignition systems are done away with
and in
their place is a single component -the
fuel injection pump -
which performs the function ofboth.
ORDERING PARTS
Whenever replacement/service parts are needed, always
provide the generator model
number, engine serial number,
and generator serial number as they appear on the silver and
black name plate located on the generator end. You must
provide
us with this information so we may properly identify
your generator
set. In addition, include a complete part
description and part number for each part needed
(see the
separately furnished Parts List). Also insist upon
WESTERBEKE packaged parts because will fit or generic
parts are frequently not made to the same specifications as
original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator.
Your local WESTERBEKE
dealer
will assist you in preparing an inventory of spare parts.
See the SPARE PARTS page inthis manual. For Engine and
Generator Acces8ories, see the ACCESSORIESbrochure.
INSTALLATION MANUAL
The Westerbeke Installation Manual publication #043268 is
supplied with this unit.
Engines & Generators
4

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use a diesel fuel that meets the requirements of No. 2-D
SAE J 313 and has a Cetane rating of #45 or higher grade of
diesel fuel according to ASTM 0975
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your engines fuel injection pump is very critical; invisible
dirt particles which might pass through the primary and sec-
ondary filters can damage these finely machined parts. It is
impm1ant to buy clean fuel, and keep it dean. The best fuel
can be rendered unsatisfactory by careless handling or
improper storage
facilities. To ensure that the fuel going into
the tank for your engine's daily use is clean and pure, the
f-ollowing practice is advisable:
Pin-chase a well-known brand of fuel. The use of additives
to combat BAC1ERIAL growth in the fuel tank is
recommended such as Bio-Bor and an additive such as
Diesel Kleen + Cetane Boost. to help restore lubricity back
into the diesel fuel when an Ultra Low Sulfur diesel is being
used.
Install and regularly service a good, visual-type fuel
filter/water separator between the fuel tank and the engine.
The Raycor 500 MA or 230 RMAM are good examples of
such filters. A 10 micron filter element is recommended.
ENGINE OIL
Use a heavy duty diesel oil with an API classification ofCF,
CG-4, CH-4 or CI-4. Change the engine oil and filter after an
initial 50 hours ofbreak-in operation.Then follow the oil and
filter change intervals as specified in the MAINTENANCE
SCHEDULE
in this manual. Westerbeke Corporation does
not approve or disapprove the use ofsynthetic oils. If
synthetic oils are used, engine break-in must be performed
using conventional oil. Oil change intervals must be as listed
in the MAINTENANCE SCHEDULE section of this
manual and not be extended ifsynthetic oils are used.
· NOTE: The infonnation above supersedes all previous
statements regarding synthetic oil.
SAE OIL VISCOSITY ..
For all temperature ranges: SAE 15W-40 or SAE lOW-40 ...
· ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze performs double duty. It allows the engine to
run at proper temperatures by transferring heat away from
the engine to the coolant, and lubricates and protects the
cooling circuit from rust and corrosion. Look fora good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs) that keep the antifreeze chemically
balanced, crucial to long term protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
NOTE: Look for the new environmentally-friendly long lasting
antifreezethat'is now available.
. PURCHASING ANTIFREEZE
Select abrand ofantifreeze specified for diesel engines.
Antifreeze specified for diesel engines contains a special
additive to protect againstcavitation erosion of the engine's
cylinder walls. Prestone and Zerex are two nationally known
brands that offer antifreeze specifically for use in diesel
engines. Select the pre-mixed variety so that the correct
mixture will always be added to the cooling system when
needed. Change the antifreeze mixture according to the
MA1NTENANCE SCHEJ?ULE in this manual.
MAINTEN.A8CE .
Change the eniirte coolant every five years regardless ~f the
number ofoperating hours as the chemical additives that
protect and lubricate the engine have a limited ll.fe.
COOLANT RECOVERY TANK
The coolant recovery tank allows for the expansion and
contraction ofthe engines coolant during engine operation
without iJ;ttroducing air into the system. This recovery tank is
provided with fresh water cooled models and with the fresh
water coolant conversion kit and must be installed before
operating the engine.
.. f
. I
NOTE: This tank, ;vith its short run of plastic hose, is best
located at or above the level of the engines tnanifold, but it
can be located below the level of the engines manifold if the
particular installation maJ:es this necessary.
Engines & Generators
.. 5

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your generator for the first time or after a
prolonged layoff, check
the following items:
• Make certain the cooling water thru-hull petcock is open.
• Check the engine oil level: add oil to maintain the level at
the
full mark on the dipstick.
• Check the fuel supply and examine the fuel fiiter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
• Check load leads for correct connections as specified in
the wiring diagrams.
• Examine the air inlet and outlet for air flow obstructions
(Soundguard).
.• Be sure no other generator or utility power is connected to
the load lines.
• Be sure that in power systems with a neutral line that the
neutral is properly grounded (or ungrounded) as the system
requires, and that generator neutral is properly connected
to the load neutral. In single phase systems an incomplete
or open neutral can supply the wrong line-to-neutral volt-
age on unbalanced loads.
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any fuel' leaks.
A CAUTION: When starting the generator, it is
recommended that all AC loads, especially large
motors, be switched OFF until the engine has come
up to speed and, in cold climates, starts to warm up.
This precaution will prevent damage caused by
unanticipated operation of the AC machinery and will
prevent a cold engine from stalling.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: After the initial running of the generator, the air in
the engine's cooling system will be purged to the coolant
recovery
tank. Open the air bleedpetcock to ensure that
the cooling system is purged of air. After shutdown and
after the engine
has cooled, the coolantfrom the recovery .
tank will be drawn into the engine 's cooling system to
replace the purged air.
Before subsequent operation of the generator, the engine's
manifold should
be topped off, and the coolant recovery
tank may need to be filled to the MAX level.
COOLANT
RECOVERY TANK
MAINTAIN
COOLANT LEVEL
AT 1/2 FULL

GENERATOR INSTRUMENT CONTROL PANELS
DESCRIPTION AND OPERATING INSTRUCTIONS
DESCRIPTION
The Generators Instrument Control contains a compact
gauge package, contrQl r9Cker switches, circuit fuses, check
engine light, emergency stop toggle switch and a recording ·
hourmeter. These comJ>9nents are descdbed below.
The 8pinconnector that is on the side of the Control Box
is used to connect an optional remote Start/Stop panel or
a second Control Panel.
When an optional panel is connected, the 8 pin connector
with jumpershould be kept for future needs when ·
troubleshoolin$· Secure it to the lifting eye.
OR alATION
STARTING/STOPPING INSTRUCTIONS
--· -
START: The START rocker switch, when depressed.
activates the starter motor. The starter M terminal then
supplies DC power ·to the pull coil of the fuel solenoid
.allowing fuel delivery to the injectors.
NOTE: It is importantto closely monitorthepanel
gauges, Become aware of the normal engine readings
and take immediate action if these readings start to vary.
-
--·---
-----~- .. -.
*STOP: The STOP rocker switch when pressed and held,
··opens the DC circuit supplying power to the·K2 Run Relay.
De-acti.vati.ng it and shutting down,th• engine drive.
THIS PANEL CANA~SO BE .,
REMOTFLYUJCATED; REFER.
TO THE FOLLOWING.PAGE
EMERGENCY STOP·
20A DC BREAKER
Fuse/DC Breaker: The control box has a 7.5 amp
automotive typefuse to protect the-run circuit and remote
panel: :A 20ampDC breaker is on the control box protecting
the unit's DC circuits and acts
as an Emergency Stop Switch.
20A DC Breaker/Emergency Stop Switcb : This
rocker switch on the front of the panel is Nonnally oH
When depressed, it will open the DC circuit to the Control
Box
and shut the engine down. When servicing. this switch
can be used as a breakerto prevent an accidental start.
Remote Panel Plug-In: A plug on the sideon the
90ntrol box will allow for the mount:in~ of the remote
instrument panel or the remote panel start/stop.
Coolalt Temperature: Engine coolant (water)
temperature should normally indicate: 175° to.195°F
(80° to 90°C).
*:MANUAL ENGINE SHUT·OFF
Engine Oil Pressure: Oil Pressure (psi) may fluctuate ·
depending on the generator load but should range between
• 35 to 55 psi. ·
DC Volts: Indicates the amount the battery isbeing charged
and show 13V to 14V.
Hourmeter: Registers elapsed time and is used as a guide
for when to perfonn scheduled maintenance.
Prebeat: The. PREHEAT rocker switch serves two
purposes:
1. It activates th~ preheat circuit.
2. lt activates the .. K2 Run Relay. This supplies DC power to
the Instrument.pahel.and HourMeterDC power to the fuel
pump. the Hold
cOilm the fuel sol6!loid and the R terminal
on the DC alternator.· .·
Should the engine fail: to stop when the fuel shut offsolenoid
is de~energised when the STOP button is depressed. The engine
is equiped with a manual shut-offlever. This is locatedjustbelow
the fixed throttle le.ver on the side of the engine block below
the fuel injection pmnp/Move this l~ver to the left and hold
itthere until the engine comes to a stop. Then release.
1-w"IWESTERB§KE
) EngineS &Generators
7 ... -

OPTIONAL REMOTE CONTROL PANELS
OPERATING INSTRUCTIONS
DESCRIPTION
There are several options available when selecting remote
operation of your generator.
1. Mo'unt a second (repeating) Instrument Control Panel in a
remote location.
2. Simply remove
the Instrument Control Panel from the
control box
and mount it as a remote panel.
NOTE: The Instrument Control Panel can be replaced by
installing a basic start/stop panel in the control box.
3. Mount a remote start/stop control panel ina remote
location.
The remote
)?anels connect to the 15 pin plug on the back of
the
control box using the extension harnesses listed below.
EXTENSION HARNESS
PN#056236 EG DIESEL (8 PIN) 15FT
PN#056235 EG DIESEL (8 PIN) 30FT
REMOTE START/STOP PANEL· DESCRIPTION
The Remote Start/Stop Panel has the same three rocker
switches
as the Instrument Control Panel. Their function is
the same. This panel has a RELEASE STARTER LED. This
LED will illuminate when the PREHEAT is depressed. When
this panel is remote mounted, this LED will indicate when
the generator has started. When depressing the START
rocker switch, this LED will dim. When the generator starts,
the
LED will brighten. This indicates to release the START
rocker switch. The PREHEAT rocker switch is held
depressed for about
4-5 seconds to allow the oil pressure to
reach 10 psi, then release it.
For the REMOTE START/STOP PANEL wiring diagram
and wiring harness, refer to the Table of Contents.
INSTRUMENT
CONTROL PANEL(AS A REMOTE PANEL)
PN56246
REMOTE START/STOP PANEL
PN56320
Engines & Generators
8

GENERATOR BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine
operated properly, a break-in time is required. The service
life of your engine is dependent upon how the engine is
operated and serviced during its initial hours of use.
Breaking in a new engine basically involves seating the
piston rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
glazed or scored, which is caused by overloading the engine
during the break-in period.
Your new engine requires approximately 50 hours ofinitial
conditioning operation to break in each moving pari in order
to maximize the perfonnance and service life of the engine.
Perform this conditioning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems (raw
water pump, oil pressure, battery charging) are functioning.
AFTER START·UP
Once the generator has been started, check for proper
operation and then encourage a fast warm-up. Run the
generator between 20% and 60% offull-load for the first
tO hours.
After the first 10 hours of the generator's operation, the load
can be increased to the full-load rated output, then
periodically vary the load.
Avoid overload at all times. An overload is signaled by
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
itwithin the generator's rating. Since the generator operates
at 1800 rpm to produce 60 hertz (or at 1500 rpm to produce
50 Hertz), control of the generator's break-in is governed by
the current drawn from the generator.
NOTE: Be aware of motor starting loads and the high current
draw required for starting motors. This starting amperage
draw can be 3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
GENERATOR' ADJUSTMENTS
Once the generator has been placed in operation and during
the initial 50 hours ofbreak.-in operation or after, the no-load
AC voltage output may need adjustment using the voltage
pod on the AVR found in the generators control box. Review
the GENERATOR section ofthis manual for infonnation.
THE DAILY ROUTINE
CHECK LIST
Follow this check list each day before starting your generator.
• Check that all generator circuit breakers (power panel) are
in the off position before starting.
• Record the hounnete:r reading in your log (engine hours
relate to the maintenance schedule).
Any deficiency or problems in the following items must
be corrected before start-up.
•
Visually inspect the engine for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolantlevel in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check drive belts for wear and proper tension (weekly).
CHECK WITH ENGINE RUNNING
• Check for abnormal noise such as knocking, vibration and
blow-back sounds. ·
•
Confirm exhaust smoke:
When the engine is cold -white smoke.
When the engine is warm- almost smokeless.
When the engine is overloaded -some black smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached and loads are applied.
CAUTION: Do not operate the generator for long
periods of time without a load being placed on the
=generator.
STOPPING THE GENERATOR
Remove the AC amperage loads from the generator one at a
time. Allow the generator to run for 3-5 minutes to stabilize
the operating temperatures. Then depress the STOP switch
and ·hold. depressed until the generator comes to a complete
STOP.
Engines &Generators
9

MAINTENANCE SCHEDULE
WARNING: Nevsr attempt to perform any SBtvice while the engine is running. Wear the proper safety equipment such as goggles and
gloves, and use the correct tools for each job. When SBtViclng/replacing DC components, turn off the DC circuit breaker on the Control
Box or tum off thti battery switch.
SCHEDULED MAINTENANCE
Maintenance procedures are all detailed in this manual.
I DAllY CHECK BEFORE START-UP
Coolant Level
Engine Oil Level
Fuel/Water Separator (owner installed}
Fuel Supply
Visual Inspection of Engine
Keep the engine surface clean, dirt and oil
wiHlnhibit the engines ability to dfsapate heat
Drive Belts
'INITIAl 50 HOURS OF':OPERATION
Engine Oil and Filter
*Exhaust System
•valve Adjustment
Inlet Fuel Filter
Fuel filler
Generator
I EVERY 50 OPERATING HOURS OR MONTHLY
Drive Belt
Starting Batteries
Electric Fuel Pump
Zinc Anode
I EVERY 100 OPERATING HOURS OR YEARLY
Air Intake and Filter {if applicable)
EXPLANATION OF SCHEDULED MAINTENANCE
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Check for water and dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Use properly filtered #2 diesel with a Cetane rating of #45 or higher. Check that
there is adequate fuel for the vessel's needs.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wifing and electrical
connections .. Look for loose bolts/hardware and correct as needed.
Inspect for frayed edges. Belts must be properly tensioned.
Initial engine oil and filter change at 50 hours, then every 250 hours.
Check security of water Injected exhaust elbow to exhaust manifold.
Ensure there are no leaks. ·
Check adjustment of valves at 50 hours, then every 500 hours.
Initial change.
Initial change.
Check that AC connections are secure with no chafing.
Inspect for proper tension (3/8" to 1/2" deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
your own inspection schedule.
Keep air intake clear of obstructions. Clean air fflter (if applicable).
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
l"fN'f'IIESIERBEICIE
· Engines & Generators
10

MAINTENANCE SCHEDULE
NOTE: Use the engine hourrneter gauge to log your engine hours or record your engune hours running time.
SCHEDULED MAINTENANCE
I EVERY 250 OPERATING HOURS OR YEARLY
Exhaust Elbow/Exhaust System
Fuel Filler and O·Rings
Inlet Fuel Filter
Generator
Hoses
Fuel Water Separator Filler
DC Alternator
Engine Oil and Filter
Raw Water Pump Impeller
EVERY 500 OPERATING HOURS OR FIVE YEARS
Raw Water Pump
Coolant System
*Valve Clearances
Cooling System Hoses
EXPLANATION OF SCHEDULED MAINTENANCE
Check the structual integrity of the water injected exhaust elbow {asting. Check the integrity
of the exhaust system attached to the elbow. All hose connections should be secure. No
chaffing. No exhaust leaks. Hoses and muffler are in good serviceable condition.
NOTE: An exhaust leak will cause exposure to diesel exhaust!
Remove and replace fuel filter and all sealing 0-rings.
Remove and replace inlet fuel filter.
Check that AC connections are clean and secure. Ensure wires have no chafing.
See GENERATOR INFORMATION.
Engine hoses should be firm and tight. Replace if hoses become spongy, brittle or
delaminated. Check and tighten all hose clamps as needed.
Inspect bowl for dirt or water in fuel. Drain and replace filter.
Inspect wiring, connections should be tight. Alternator should be clean and free of corrision.
Check mounting bracket and alternator bolt. All should be tight.
Change engine oil and filter every 250 hours or yearly.
Remove and inspect impeller. Replace if blades have cracks or missing.
Remove and disassemble the pump and inspect all parts: drive gear, pump shaft, wear plate
and cover for wear and corrosion. Replace the impeller and gasket. Lubricate the impeller
at re-assembly.
Drain, flush and re-fill the cooling system with appropriate antifreeze mix. Inspect the
condition of the sealing gaskets of the pressure cap. Clean out coolant recovery tank
and connecting hose.
Adjust valves. (Incorrect valve clearance will result in poor engine performance.)
Check hose condition and securing clamps, replace as needed.
EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS
Heat Exchanger
Starter Motor
Fuel Injectors
Position Crankcase Ventilation Valve
Remove the heat exchanger for professional cleaning and pressure testing.
Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the
starter motor pinion drive.
Pressure test the injectors, rebuild at 1500 hours.
Disassemble and clean. Replace as needed.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
Engines & Generators
11

FUEL SYSTEM
DIESEL FUEL
Use No.2-D (SAE J313) diesel fuel with a Cetane rating
of #45 or higher. A lower Cetane rating will result in
combustion deposits with the exhaust and poor engine
peiformance. Use an additive such as "Diesel Kleen+
· Cetane Boost to help restore lubricity with low sulfur diesel.
. ..
FUEL WATER SEPARATOR·
A primary fuel :filter of the water separating type must be
instailed between the fuel. tank and the engine to remove
water apd other contaminants from the fuel before they can
be carried to the fuel system on the engine.
A typical fuel :filter/water separator is illustrated in this
diagram. This is the Raycor Model 500 MA. Keep in mind
that "if a water separator type :filter is not installed between the
fuel supply tank and engine-mounted fuel system, any water
in the fuel. will affect the fuel pump, engine :filter, and injec-
tion equipment. The owner/operator is responsible for making
· certain the fuel reaching the engine's injection equipment is
free of impurities. This process is accomplished by installing
·and maintaining a proper filtration/separation system.
TYPICAl FUEl
FILTER/WATER
SEPARATOR
FUEL INJECTION PUMP
10 micron filter
element recommended.
The fuel injection pump is the most important component of
the diesel engine, requiring the utmost caution in handling.
The fuel injection pump has been thoroughly bench-tested
and
the owner-operator is cautioned not to attempt to service
it If it requires servicing, remove it and take it to an
authorizep fuel injection pump service facility. Do not
attempt to disassemble
and repair it. Do not send the timing
shims with the injection pump, leave on engine.
BLEED SCREW
The bleed ~re.w on the injection pump should be left in the
open position. This will then allow for ease in priming the
engine's fuel system and during engine operation allow for
air in the system to be delivered to the fuel tank through the
fuel return system.
ENGINE FUEL FILTER
Perioilically check the fuel connections and the filter bowl for
Ieakage. Change the filter element after the first 50 hours. See
the MAINTENANCE SCHEDULE. .
Changing the Filter Cartridge
1. Shut off the fuel supply.
'
NOTE: Slide a plastic bag up over thefuel filter cartridge
as it wiU be full of fuel.
2. l!nscrew the cartridge from its housing and remove the
cartridge and its gasket.
3. Wipe both the housing and the top of the new cartridge
with clean fuel.
4. To help reduce fuel system priming, fill the fuel filter
with diesel before installing. This will dramatically
reduce the priming time needed to purge air from the
engines fuel system before starting.
5. Install the new cartridge and spin on real tight by ha!!d.
6. Open the fuel supply. Run the engine to inspect for leaks.
FUEL LIFT PUMP
LIGHTLY WIPE
WITH CLEAN FUEL
WHEN INSTALLING
THE NEW FUEL
ALTER CARTRIDGE
iNCOMING FUEL
Periodically check the fuel connections to and out of the
pump and make sure that no leakage is present and that the
fittings are tight and secure. The DC ground connection at
.one ofthe pumps J.l10Unting bolts should be clean and well
secured by the mounting bolts to ensure proper pump
operations.
INLET FUEb,FILTER
To ensure clean fuel into the fuel lift pump, there is a small
in-line fuel filter connected to th~ fuel lift pump ell~ow. This
fil~r should be replaced every 250 hours of operation.
,..,..,.,WESJ!RBEKE
.Engines It Generators
12

COOLING SYSTEM
DESCRIPnDN
Westerbeke marine diesel engines are designed and equipped SEALING
for fresh water cooling. Heat produced in the engine by com- GASKET
bustion and friction is transferred to fresh water coolant·
which circulates throughout the engine. This circulating fresh
water coolant c.ools the engine block; its internal moving
parts, and the engine oil. The heat is transferred externally
from the fresq water coolant to raw water by means of aheat STRAINER --rJM""'
exchanger, similar in function to an automotive radiator. Raw 'FILTER
water flows through the tubes ofthe heat exchanger while
fresh water coolant flows around the tubes; engine heat trans-
ferred to the fresh water coolant is conducted through the
tube walls to the raw water which is then pumped into the
exhaust system
where finally it is discharged overboard. In
other words, the engine is cooled by fresh water coolant, this
coolant is cooled by raw water, and the raw water carries the
transferred heat overboard through the exhaust system. The
fresh water coolant and raw water circuits are independent of
each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.
RAW WATER INTAKE STRAINER
Amajor part ofthe raw water cooling system is a proper
boatyard/builder installed intake strainer.
NOTE: Always install the strainer at or below the waterline so
the strainer will always be self-priming.
A clean raw water intake strainer is a vital component of the
engine's cooling system. Include a visual inspection of this
strainer when making your periodic engine check The water
in the glass should be clear.
Perform the following maintenance after every 100 hours of
operation:
1. Close the raw waterseacock.
2. Remove and clean the strainer filter.
3. Clean the glass.
4. Replace the washer if necessary.
5. Reassemble and install the strainer.
6. Open the seacock.
7. Run the engine and check for leaks.
NOTE: Also follow the above procedure after having run hard
agroun4.
If the engine temperature gauge ever shows a higher than
· normal reading, the cause may be that silt, leaves or grass
may have been caught up in the strainer, slowing the flow of
·raw waterthrough the cooling system.
TYPICAL RAW WATER INTAKE STRAINER
(Owner Installed)
SEA COCK
~
DRAINING THE RAW WATER SYSTEM
INSPECT AND
' CLEAN EVERY
100HOURS
When freezing temperatures are expected, it is best to
protect the raw water cooling circuit and engine exhaust
· from damage.
This procedure is best accomplished by disconnecting the
water intake hose from the vessels thru-hull fitting. Close the
intake valve before disconnecting the hose. Insert the hose
end into a large container of fresh water.
Provide an external fresh water supply for the bucket to
maintain the water level in the bucket while the unit is being
operated during the flushing process.
Run the unit for 10 minutes or longer to adequately flush the
raw water system.
Once the raw water system has been flushed, replace the
buckets content with a 50/50 antifreeze mixture. Run the
engine and allow this mixture to be pumped through the raw
water circuit. Once this antifreeze mixture is visible being
discharged from the exhaust opening, shut the engine down.
This antifreeze mixture should protect the raw water cooling
system and exhaust from freezing.
Re-attach .the water intake valve and remember to open the
intake valve before starting the engine.
When recommissioning, make certain the valves and
seacocks are open so the engine will quickly receive fresh
water. If the engine is stowed where it is warm, the fresh
water can stay in the engine.
Engines & Generatol"$
13

COOLING SYSTEM
FRESH WATER COOLING CIRCUIT
NOTE: Referto the ENGINE COOLANT section for the rec-
ommendedantifreeze
and water mixture to be used as the
fresh water coolant.
Fresh water coolant is pumped through the engine by a circu-
lating pump, absorbing heat from the engine. The coolant
then passes through the thermostat into the manifold, to the
heat exchanger where it is cooled, and returned to the engine
block via the suction side
of the circulating pump.
When the engine is started cold, external coolant flow
is pre-
vented by the closed thermostat (although some coolant flow
is bypassed around the thermostat to prevent the exhaust
manifold from overheating). As the engine warms up, the
thermostat gradually opens, allowing full flow
of the engine's
coolant to flow unrestricted to the external portion
of the
cooling system.
TO COOLANT
RECOVERY TANK
KEEP THE
COOLANT PASSAGE
CLEAR
FROM COOLANT-
RECOVERY TANK
COOLANT EXPANSION
PRESSURE
/CAP
COOLANT RETRACTION
NOTE: Periodically check the condition of the manifold
pressure cap. Ensure the
upper and lower rubber seals are in
good condition. Check to ensure .
the vacuum valve opens and
closes tightly. Cany a spare
cap. Checkalso to ensure the
coolantpassage is
clear so
coolantwithin. the,system is
able to expand
and contract SEAL
to and from the coolant recove1y tank..
Coolant Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi-
cant loss
of coolant and without introducing air into the cool-
ing system. This tank should
9e located at or ~hove the
engine manifold level and should be
ea.Sily accessible.
NOTE: 11zis tank, with its short run of plastic hose, is best
located
at or above tlze level of the engine :S manifold.
CHANGING COOLANT
The engine's coolant must be changed according to the
MAINTENANCE SCHEDULE. If the coolant is allowed to
become contaminated, it can lead to overheating problems.
A CAUTION: Proper cooling system maintenance is
critical; a substantial number of engine failures can be
traced back to cooling system corrosion.
Drain the engine coolant by loosening the drain plug on the
engine block and opening the manifold pressure cap. Flush
the system with fresh water, then start th~ refill process.
NOTE: The drain on the heat exchanger shouldalso be us(td
to help drain engine coolant.
OIL GALLERY
Refilling the Coolant
After closing the engine block drain, pour clean, premixed
antifreeze coolant into the open filler neck. When coolant is
visible in the filler neck, start the engine. Open the air bleed
petcocks when present
on the thermostat housing and heat
exchanger.
Monitor the coolant in the filler neck and add
as needed to
keep
it filled. Monitor the airbleed petcocks and when clear
coolant is flowing from them close each. Top off the filler
neck with coolant and install the pressure cap.
Remove the cap
on the coolant recovery tank and fill with
coolant
mix to halfway between LOW and MAX and replace
the cap. Run the engine and observe the coolant expansion
flow into the recovery tank.
After checking for leaks, stop the engine and allow it to cool.
Coolant should draw
back into the cooling system as the
engine cools down.
Add coolant to the recovery tank if
needed. Clean up any spilled coolant.
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.
Engines & Generators
14