Westerbeke 4.5BCG User manual

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~~lt·t.~5~~~,.,
· OPERATORS MANUAL
4.5 BCG(A) - 60Hz
3.5 BCG(A)·~ 50Hz
MARINE GASOLINE GENE·RATOR
L
SINGLE PHASE
---·,,",' " . - ~
PUBLICATION NO. 037491
NOVEMBER 2018
REVISION 3
•• WESTERBEKE CORPORATION• MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
.. ~ .. , TEL: [phone] •FAX: [phone] • WEBSITE:.wytw.WESTERBEKE.COM

£WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is,paisonous and can cause
unconsciousness and death. Sy,;,ptOIJIS~of Carbon Monoxide
exposure can Include:
•Dizziness
• Throbbing in Temples
•Muscular Twitching
•Vomiting
•Nausea
•Headache
• Weakness and Sleepiness
•Inability to Think Coherently
IF YOU DR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. H symptoms persist,
· $t1Bk medical attention. Shut dawn the unit and do not restart
until It ha$ been inspected and repaired.
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommemlsinstalllng
CARBON MONOXIDE DETECTORS in the
•------llllL··. /Iring/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Kno.w when dangerous conditions exist and
take the necessary precautions to pr()tect yourself, your
persDnne~ andyour machinery.
As the owntr or operator, always observe the following
safety rules and adviSories p1',ovU!edfor yourconvenience.
'this sajetJ .. infotlllatiOn is• in tzlignnient:With ·the American
B6Q!aiul·.YachtCotl1UJil(AJ'JYCJs'tantlards;.howeverso/ety
rl!Jks are .nOt limited to the infdrination in thefollowing
pages;. T~e.respom!/Jtlityjor the U!entifi,ctitioti•ofpotential
and acflltd risks for compliance with :all safety•advisories,
iriaintinance activities; o:nd Other conditions belong
exclzisivelj to the ownef/operator.
PREVENTELECTRIC·SHOCK
•·WARNING:· Do not tilllch AC Blllt:trlcal caet:tions
while snglne is running, or when oannsctsd to shore
· powsr. Lethal riiJ/tage.is present at these connections!
I Do not operate this rtl.a.Chinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
I Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not daIIip
(particulatly shoes) when handling electrical equipment.
• Remove. wristwatch and all jewelry When working on
electrical equipment.
PREVENT BURNS - HOT ENGINE ;
a\':tlARNlRG: Do not. tlJut:b htft lnlJ!lie Pans or •·
eibailst·Syst;,m·ooinpallents •.. A ·'iilnitlng·englilegets
veryhatl · · · ·
;,..,;.
,• Monitor engine antifreeze coolant level at the plastic
coolant recovery tank and periodically at the filler cap
location on the waterjacketed exhaust manifold, but only
when the engine is COLD.
• ln case of an engine overheat, allow the engine to cool
before touching the engine orchecking the coolant.
PREVENT BURNS - FIRE
A WARNING: Firs t:an cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
.. eump, or other potential sources ofspilled fuel or fuel
vapors. Use a suit.able container to catch all fuel when'
reinoVing the fuel line, carburetor, or fuel filters·
• ·. D() notoperate with the air cleaner/silencer removed.
· Backfu,e ean cause severe injury or death.
• bo not smoke or permit flames or sparks to occur near
the fuelsysteni. Keep the compartment and the
engitie/generator clean and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware - diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions tram fuel vapors can cause
injury or death!
I Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for 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 of the reach of children.
• Do not fill the fuel tank(s) while the engine is runni?g.
• Shutoff 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.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff vruve. ·
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
I 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.
. ,Engtn~:'.& Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can oaUStl ln/UfY
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.
BAnERY EXPLOSION
A WARNING: Battsry t1xploslon oan caUSB 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 ofexplosive 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 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 oan cause
seveTB 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 offat 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 ofthe exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation of.approved detectors.
• For additional information refer toABYC T-22 (educa-
tional information
on Carbon Monoxide).
A WARNING: Carbon monoxidt1 (CO) Is an Invisible
odor/BSS gas. lnllalatlon prodllaes t/u-llkt1 symptoms,
nausea or dsath!
• 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 orrestrict 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 ofthe 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 oauss injury
or d1111th!
• 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.
l'W'IWESTERBEICE
f Engines & Generators
ii

SAFETY INSTRUCTIONS
II Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loosejackets, shirts, sleeves,
rings, necklaces or bracelets that could be caught in
moving parts.
II Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
II Do not check fluid levels or the drive belt's tension while
the engine is operating.
II Do not allow any swimming or activity around or near
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning
or
death can occur.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
II Never operate an engine without its muffler installed.
II Do not run an engine with the air intake (silencer) or
flame arrested removed.
II Do not run engines for long periods with their enclosures
open (when installed).
A WARNING: Do not work on machinery when you
are mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, andfollow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination
of the American Boat and
Yacht Council's (ABYC) standards. These standards are a
combination
of sources including the USCG and the NFPA.
Sections
of the ABYC standards of particular interest are:
H-2 Ventilation for Boats using Gasoline
H-24 Gasoline Fuel Systems
P-1 Installation of Exhaust systems
for Propulsion and Auxiliary Engines
P-4 Marine Inboard engines and Transmissions
E-11
AC and DC Electrical systems On Boats
All installations must comply with the Federal Code
of
Regulations (FCR).
www.abycinc.org
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow
their
recommendations when installing yourengine
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
ABYC
613 Third Street, Suite 10
Annapolis, MD 21403
www.abycinc.org
NFPA -(National Fire Protection Association)
"Pleasure and Commercial Motor Craft"
OrderFrom:
National Fire ProtectionAssociation
Battery March Park
Quincy, MA 02269
USCG (United States Coast Guard)
Regulations are under titles CFR33 and
CFR46 of the "Code
of Regulations"
Order From:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be
paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied 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 of20" above the vessel's waterline. Failure to use a siphon-break when ·
the exhaust manifokl injection port is at or below the load waterline will result in
raw water damage to the engine andpossibleflooding of the boat. ·
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer for proper maintenance.
EXHAUST SYSTEM
AVAILA9LE FROM
YOUR WESTERBEKE
DEALER .
SIPHON-BREAK WITH STAINLESS
LOOP
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust Hose is recommended. The use of this type of hose allows for extreme bends
and turns without the need ofadditiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length of corrugated exhaust hose can be used. The
system MUST be designed to prevent the entry of water into the exhaust system
under any sea conditions and at any angle of vessels heal.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification ............................................. 2 Remote Oil Filter ............................................... 21
Introduction ......................................................... 3 Starter Motor ..................................................... 22
Fuel, Engine Oil and Coolant .............................. 5 Testing .........................................................22
Control Panels .................................................... 6 Disassembly................................................. 23
Preparations for Initial Start-Up ......................... 7 Battery Charging Circuit ................................... 24
Operating Instructions ........................................ 8 Integral Controller.......................................25
Overspeed Shutdown.....................................9 Testing .........................................................25
Break·ln Procedure (Daily Operation) ................. 10 Engine Troubleshooting .............................. : ...... 26
Checklist.................................. ...................10 Engine Adjustments ........................................... 28
Safety Shutdown Switches ................................ 11
Govemor...................................................... 28
Exhaust Temperature Switch....................... 11 Spark Plugs..................................................29
Low Oil Pressure Switch............................. 11 Choke Solenoid ...........................................29
Engine Circuit Breaker................................
11 Ignition Wires ..............................................29
High RPM Shutdown Switch ......................
11 Valve Clearance Adjustment .......................30
High Water Temperature Switch ................. 11 Ignition Timing............................................30
. Maintenance Schedule ..................................... 12 Torquing Cylinder Head Bolts ....................30
Catalytic Converter...................................... 13 Wiring Diagram .................................................. 31
Cooling System .................................................. 14
Wiring Schematic ............................................. .32
Raw .Water Intake........................................ 15 Remote Start Panel ........................................... 33
·Raw Water Pump......................................... 15
Remote lnstrumentPanel ................................. 33
Changing Coolant........................................16 Generator Information ....................................... 34
Drive·Belt Adjustment.................................16 BC Generator ..................................................... 35
Heat Exchanger ........................................... 17 Internal Wiring Diagram ............................. 35
Thermostat................................................... 17 Circuit Breaker ............................................ 35
Fuel System ....................................................... 18 BCAWiring Diagram................................. .36
Fuel Lift Pump............................................. 18
No-Load Voltage Adjustment......................37
Carburetor Filter Screen..............................
18
Resistance Figures ...................................... .38
Gasoline/Water Filter................................... 18
Shore Power Transfer Switch......................39
Gasdenser.....................................................
18
Carburetor....................................................19
Lay-up and Recommissioning .......................... .40
BCG Generator Specifications ........................... 42
Engine Oil Change ............................................. 20 Torque Specifications ...................................... 44
Spm on Oil Filter......................................... 20 Suggested Spare Parts ...................................... 45
Engines &Generators
1

20AmpDC
Circuit
Breaker ·
LubeOI
Dipstick
Oil Pressure
Switch
PARTS IDENTIFICATION
Fresh WaterCoolant FBI
Medel Data TaQ
4JbeOU Fill.
Heat Exchanger/
ExhaustTemperature Switch
Distributor
45° Exhaust Elbow
E>C Battery Ground
Connection
REAR
Air Intake Flame ~ester
Carburetorwith Choke
Control. Panel'-
SA &15AFUSES ...........
FRONT
Governor
--e--water Temperature
switch
AC Connections---
Outlet
Sea Water Pump
Gasdenser
·Lube Oil Drain Hose
IW"IWESTERBEKB
(Engines &Generators
2

INTRODUCTION
This WESTERBEKE Generator is a product of
WESIBRBEKE'S long years ofexperience and advanced
technology. We take great pride in the superior durability
and dependable performance ofour 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 WESIBRBEKE dealer for
assistance.
·· This is your Operators Manual. AParts Catalog is also
provided and a Technical Manual is available from your
WESIBRBEKE dealer. If you are planning to install this
equipment yourself, contact your WESTERBEKE dealer
for WESIBRBEKE'S Installation Manual.
WARRANTY PROCEDURES
Your WESIBRBEKE Warranty is included in a separate
folder. If you have not received a customer identification
card registering
your warranty 60 days after submitting the
warranty registration form, , please contact the
factory in
writing with model infonnation, including the unit's serial
number and commission date
Engines &.Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model BCG - Ser. # ---- - ---
.Expires ____ _
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures and
catalogs) provided from sources other than WESTERBEKE
are not within WESTERBEKE'S CONTROL.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES
OR REPRESENTATIONS WITH RESPECT THERETO,
. INCLUDING ACCURACY, TIMELINESS OR COMPLETE-
NESS, THEREOF
AND WILL IN NO EVENT BE LIABLE
FOR'A'NYTYPE OF DAMAGE OR INJURY INCURRED IN
CONNECTION WITH OR ARISING OUT OF THE
FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the time
span between printings ofWESTERBEKE product software
and the unavoidable existence ofearlier WESTERBEKE
manuals. In summation, product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product. It
not only makes good sense but is imperative that appropriate
representatives ofWESIBRBEKE or the supplier in question
be consulted to determine the accuracy and currentness of the
product software being consulted by the customer.
SERIAL NUMBER LOCATION
The engine's model and serial number can be found on l.D.
· sticRers affixed to either side of the generator housing. The
.engine's serial number can also be found stamped into the
engine block on a flat surface just above and inboard of the
· lube oil filter. Take the time to enter this information on the
illustration of the I.D. sticker below, as this will provide a
quick reference when seeking tec.hnical information and/or
· ordering service/repair parts.
SPECIFICATlON
MODEL _______ _
RPM __________ _
KW ___________ _
· KVA -~---------
VOLTS ________ _
AMPS---------
ENG. HP-------
ENG. SER. NO.
GEN. SER. NO.
PF/PHASE ___ _
WIRES ________ _
RATING _______ _
INSUL CLASS __
TEMP. RISE----
BATIERY ------
C.1.0. ----------
50 HZ.
60, HZ.
I
Fill. in the information for your reference. tl:JJ
IE~!?i!•t =t=t~j
Engine l.D. Plate
Engines & Generators
3

INTRODUCTION
. ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine model and serial numbers. In addition,
include a complete part description and part number for each
part needed (see the separately furnished Parts Catalog).
Also insist upon WESTERBEKE packaged parts because
willfit or generic parts are frequently not made to the same
specifications as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your
generator,, critical infonnation will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Pracsdures, which if not strictly
observed, can result in the damage or destruction of your
engine.
A WARNING: Procedures, which If not properly
fallowed, can result in personal injury or loss of life.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visable location in
the engine room.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator or engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filters can be difficult to obtain along the
way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
on-board inventory of the proper WESTERBEKE parts.
NOTE: Also available are Spare Parts Kits (last page in this
manual). These provide basic service spares needed in maintaining
the drive engine. Visit our website: www.westerbeke.com to learn
about these ldts.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters. Carbon monoxide,
even insmall amounts, is deadly.
The presence ofcarbon monoxide could indicate
an exhaust
leak
from the main engine or the generator's engine or
from the exhaust elbow/exhaust hose system the engine is
connected
to. Even possibly from a neighboring vessel's
exhaust.
If carbon monoxide is present, ventilate the area with clean
air
and correct the problem immediately!
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE generator capable of
many thousands of hours of dependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner in which the unit is
operated and serviced in the field. this is up to the
buyer/owner operator.
NOTE: Six important steps to ensure long generator life:
• Proper engine and generator installation.
• An efficient well-designed exhaust system that includes an
anti-siphon break to prevent water from entering the
engine.
• Changing the engine oll andollfilters every JOO operating
hours.
• Proper maintenance of all engine and generator
components according to the maintenance schedule in
this manual.
• Use clean, filtered unleaded fuel
• Winterize your engine according to the JAY-UP AND
RECOMMISSIONING section in this manual.
UNDERSTANDING THE GASOLINE ENGINE
The gasoline engine driving an AC generator is in many
ways similar to a gasoline automobile engine. The cylinders
are vertical in-line, and the engine's cylinder head has an
overhead camshaft which is chain-driven. The engine utilizes
a solid-state distributor which is horizontally mounted and
camshaft-driven. The engine incorporates a pressure type
lubrication system, and a fresh water-cooled engine block
which is thennostatically controlled. To a large degree, the
generator's engine requires the same preventative
maintenance that is required ofa gasoline automobile engine.
The most important factors to the generator's longevity are
proper ventilation, maintenance of the fuel system, ignition
system, cooling system and the generator back-end.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: U,;, unl1111d~d 89 Octane gasoline or
· hlgller. Ethanol gasoline must not excesd E10 {100/a}.
Gfiiolln_e wi~h hlgh_srpercentagBS of·Bthanalare, not
, acc,pta#Jls iar11Se !n·thesemodels and can void the
warranty.
Gaisoline With an ETHANOL content .
higher than 10% IE10l is not iillowed'
and m.Y void wi11TJlnty. ·
Care Of The Fuel Supply
Use only clean properly filtered fuel! The clearance of some
components in the unit's fuel system are very critical; dirt
particles which might pass through the filter can damage
these finely finished parts. It is important to buy clean fuel,
and keep it clean. The best fuel can be rendered
unsatisfactory by careless handling or improper storage
facilities. To assure that the fuel going into the tank for your
engine's daily use is clean and pure, the following practice is
advisable:
Purchase a well-known brand of fuel.
Install and regularly service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel tank
and the engine.
ENGINE OIL
Use a good brand ofengine oil with an API and SAE
designations as listed in the SPECIF1CATION Section of
this manual.
Change the engine oil and filter after an initial 50 hours of
engine break-in operation.
Then follow the oil and filter
changeintervals 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 in this manual and not to be extended
if synthetic oils are used.
NOTE: The information above supercedes all previous
statements
regarding synthetic oil usage.
5
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 It also lubricates and prote.cts the
cooling circuit from rust and corrosion. Look for a good
quality antifreCze 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
antifreeze that is now available.
A proper 50/50 mixture as recommended will protect the
engine coolant temperature to temperatures of -40°F.
COOLANT RECOVERY TJ\NK
A coolant recovery tank kit is supplied with each generator.
The pwpose ofthis recovery tank is to allow for engine
coolant expansion and contraction during engine. operation,
without the loss ofcoolant and without introducing air into
the cooling system.
~"""""-.;;"'-"'
NOTE: This tank, with its short run of plastic hose, is best
located at or above the level of the engines exhaust
manifold.

CONTROL PANELS
DESCRIPTION
The generator mounted control panelis equipped with an
ON switch (black), a START switch(white) and aSTOP
switch (red).
The ONswitch provides powerto the start circuit. nus
switch by-passes the pr;otective oil pressure shutdown switch
until the oil pressure reaches S -
10 psi.
The START
switch energizes the start solenoid/starter which
cranks the engine. 1bis switch will not operate unless
the on
switch is depressed
and held at the same time.
The STOP switch will tum offthe engine/generator. nus
switch must be depressed until the stop sequence is complete.
The panel also
has two fuses !O protect the DC circuit:
•·A Slow-blo 15Amp Fuse to protect f;tle start: c;ireuit.
•An 8 Amp Fuse to protect the engine operating circuit and
any optitmal ref!iote. _paf!elS.
15AMPFUSE
HOURMETER
RECORDING HOURS
FOR MAINTENANCE
8AMPFUSE
REMOTE START/STOP PANEL (OPTIONAL)
An optional remote start/stop panel is available for
controlling the generator frOm a remote location.
This panel has
the same ON, START, and STOPfunctions
previously described. Also included
is a green LED light
which glows
once the engine/generator has reached 600
rpm's. The purpose of the LED is to alert the operator to
release the START switch. It is also an indication that the
engine/generator is running. ()
/
o~ ~
,~~
~
REMOTE INSTRUMENT PANEL (OPTIONAL)
An optional remote instrument panel is available which
includes awater temperature gauge, oil pressure gauge, ·
DC charging voltmeter, operating hounneter.!. IU!.d start/stop
switches.
REMOTE INSTRUMENT PANEL INSTAllATION
The remote instrument panel has two sending units to be
installed
on the engine block, a water temperature sender and
an oil pressure gauge sender. Plugged ports for each are
locate<i on the engine. The water temperature sender is
installed in the thermostat housing
and the oil pressure sender
is adjacent to the oil pressure switch. Use sealing compound
on the threads of both senders. Electrical connections for
each sender are tied off next to the senders location ( in the
wiring harness).
Theblue wire is for the oil pressure sender and the tan wire
is for the water temperature sender. If there is ajumper
between terminal board connections T-1 and T-2, it should be
removed. Refer to the REMOTE INSTRUMENT WIRING
DIAGRAM in this manual.
NOTE: When installing the optional remote panels, itis the
installers responsibility to comply with the U.S. Coast Guard
standards 33 CFR part 183.
Engines & Generators
6 .

PREPARATIONS FOR INITIAL START ·UP
PRESTART INSPECTION
.COOLANT
:FILL
Before starting your generator for the first time or after a pro·
longed layoff, check the following items:
a Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
a Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
a Check the DC electric.al system. Inspect wire connections
and battery cable connections.
a 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 coaling system will be purged ta the coolant
recovery tank. Open the air bleedpetcock to ensure that
the cooling system is purged of air. Aftershutdown and
after the engine has cooled, the coolant from 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
manifoldshoukl be tapped off, and the coolant recovery
tank may need to be filled to the MAX level.
a Visually exalnine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
OIL FILL
/
..(-MAX. FULL
a Check load leads for correct ~onnections as specified in
thewiring diagrams.
a Examine the airinlet and outlet for air flow obstructions.
a Be sure no other generator or utility power is connected to
the load lines.
a Be sure that in powersystems with a neutral line that the
neutral is properly grounded (or ungrounded) as the system
requires, and.that generator neutral is properly connected
to theload neutral. In single phase systems an incomplete
or open neutral can supply the wrong line-to-neutral volt-
age on unbalanced loads.
A CAUTION: Whenstart!ng the generator, it is
recommended thatal/ACloads,npecial/y/arge
motors, be switched OFF until the engine has come up
to speed and, in cold climates, stat1s to warm up. This
precaution will prevent damage caused by unantici-
pated operation of the AC machinery and will prevent a
cold engine from stalling.
Enginll!s & Generators
7·

OPERATING INSTRUCTIONS
STARTING tHE GENERATOR
A WARNING:·. Ventilate·fhe generator campanment
for a minimum of nvs minutes prior to starting. Tbs
ventilating blowers remove any sxploslve gasoline
fumes from thegeneratorcompartment aad bilges.
1. Depress the ON· switch and hOid it down (5-15 seconds),
this primes carburetor. Contiµue to depress ON.
2. Depress the STAltT (white), when the gepyrator
· starts, release the START switch: Continue to
en.gage
the ON switch a few seconds longer. ·· ·
NOTE: Keeping the ON switch depressed /;>y-passes
the oil pressure shutdown <;ircuit allowing the oil
pressure to rise enough to close the switch and
maintain the ignition. circuit
3. Release the ON switch.
·A CAUTION: Al/AC loads must be switched off
when starting. Thlspr11caution will prevent damage
caused by unanticipated operation of AC machinery
and wlllprwenta cold engine tmm Stalling.
Once The engine is running apply aJi~t foad to the gener-
atot and allow the engine to warm up to qperatingtemper-
ature (130°-150° Fl 55°-56°C) before appl)lin:g heavy loads.
If
an optional instrument panel is installed, m6nitorthe
gauges for nonnalreadings. : < ... · •. · ..... ·. ·
NOTE: Some unstable running. may oq€ur: "~·if. ,cof4<~~g~ne,.
This condition should smooth out anli.e. engine wdtins up
and wlitn the geMratorloadsare applied ... ..
A CAUTION: Prolonged t;ranklng Intervals wlthoat
the engine 'starting can result In fl/ling the engine
11Xhaust With raw water. This may bappen because the
pump Is pu/llping raw water through tile raw water
collllng system during cranking. This law water can
. enter the eiiglae's cylinders by way of t/NJ,exhaust
m.anifold once the. exhaust system nils. l'rwent this
ftom happening /Jyi:Josing thfJ raw water supply
throtlgb•htill Shulog, draining the exhaust muffler, and
commtlng thrl t:lluse 11f the Bx't:e$S/ve engine cranking.
Engine damage:resultingfrom raw water entry is not a
warrantable iS$11e: the (Jwner/operator should keep this
In mind.
STOPPING THE. GENERATOR
1. Remoye the AC loads frontthe generator and allow the
generator to run for an added 3 to 5 minutes (this stabilizes
its operating temperature).
.
2. Depress· the STOP (red) switch.
~. When the generator stops, release the STOP switch.
NOTE: In an emergency, if the generator will not stop using
the stop switch, remove the 8 amp fuse in the control
panel
· ··Engines & ·Generators
8

OPERATING .INSTRUCTIONS
ABNORMAL STOP
An abnormal stop is one in which the generator ceases to nm
and comes to a stop as a result of an operating fault which
may cause damage to the engine, the generator, or create an
unsafe operating condition. The fault stop conditions are:
1. Overspeed condition!.
2. High engine temperature.
3. Low oilpressure.
4. High exhaust temperature.
Should a fault condition occur, the engine will shut down,
and the green LED light on the remote panel will go off
indicating that a fault has occurred. Once detected, the fault
should
be located (see ENGINE TROUBLESHOOTING).
OVERSPEED SHUTDOWN
In the case of an overspeed shutdown, the overspeed circuit
must be reset before re-starting the generator. Simply depress
the Stop switch mtarily then proceed with the normal start
sequence.
If the overspeed switch itself is faulty and re-setting it by
depressing the SIDPswitch will not reset the circuit, lift the
T-1 coil connection from the overspeed switch and tape the
end of the T-1 wire with electrical tape. By-pass this circuit
only as a test Re-start the generator, if this by-pass is
successful, replace the faulty oversi:ieed switch.
Do not run the generator with out replacing the ov~peed
switch.
A WARNING: Do not operate the generator with ·
the overspeed sWitch by-p8S$ed.
Refer to the CONTROL PANEL WIRING DIAGRAM in this
manual.
NOTE: Overspeed switches draw a smallamount of
amperage (25 milliamps) atall times once the generator is
connected to its starting battery. This amounts to approxi-
mately 18 ainp-hours in a month. It is not necessary to be
concerned with this slight amperage draw during normal
seasonal operation.
However, ifthe generator set is to be
unusedfor many months, it is best to either remove the 8
amp ignitionfuse
from the control panel on the generator or
turn off the generator's starting battery switch.. ·
A CAUTION: It is very Important that the overspeed
shutdown always be installed and tunc,;oning. Any
tampering with the ov,,,S,eed shutdown madule. which
would cause it,to ma/function. could bea cause of
Injury shQuld the.gsnerator's belt-driven governor fail
and.~use the generator to run away.
REMOTE PANELS
The remote start-pqnel and the remt>te inStrumentpanel
operate the same as the generator mounted control panel
exceptthat they have green LED lights for starting at a,
remote location{where the soun(i of the generator may not
be audible). The green LED lights indica,te when the
generatods running at about 6QO rpms. Tuai is when the stm
switch should be released. For the remote start/stop sequence
refer to STARTING THE GENERATOR on the previous pag~.
l'W'IWESTERBEICE
) Engines &Generators
9

. BREAK~IN PROCEDURE/DAILY OPERATION
BREAK-IN PROCEDURE
After the generator has been started, check for proper operation
and then encourage a fast warm-up.Run the generator between
20% to 60% of full load for the first 10 hours.
'-"-
A CAUTION: · Do.notattempt to brsa/c-ln YDllT gsnera-
tor by running without a /tfad~
After the first I0 hours of the generators' operation, the load
can be increased to the full'-load·rated output;then periodically
vary the foad; · · · ·
Avoid qverl()~ ~:all tllJ1~, An 9~6~ ~s signaledpy _a·
smoky eXhaust withrc:do~ o~tput vol~ge.and rreqtiency.
Monitor the current beingdrawn·frc)tritb.e generator and keep
it within the:genetattifS'tatirig. Since the generator opetates
at 1800 rpm to produce 60 h~, or atJ500to produce 50
hertz, control of the generator's engine break~inis governed
by the current drawn. from the generator.
To protect against unintentional overloading dfthe generator, .
the generator's output leads should be routed through a circuit
breaker that is
rated at the rated output of the ge11erat0r.
NOTE: Be aware of motorstaningloads <»Z(j the high
current drawn required for starling fnf)tors'. This starting
amperage drawn can be $to 5 tim¢s.normgl riin,ning amper-
age. See GENERATOR INFOR°MA:Tl()_N in. this manual
CHECKLIST
Follow this checklist each day before starting your generator.
a R_ecord the hourmeter readifig in yoi.Jr log (engine hours
relate to the maintenance schedule)~
a VISually inspect the engine for fuel, oil, orwater leaks.
II Check the oil level {dipstick).
a Check the coolant level in the coolant recovery tank.
a. Check your fuel supply.
a Check the starting batteries·(weekly).
a Check the drive belts for wear and proper tension (weekly).
a Check for abnormal noise such as knocking, vibration and
blow-by sounds.
a Confirm exhaust smoke:
When the engine is cold -White Smoke.
When the engine is wann -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.
A CAUTION: Do not operate the gsnerator for long
periods of time without a load being placed on the
gsnerator.
STOPPING THE GENERATOR
Remove the major AC loads from the generator one at a time.
Allow the:generatortb.run for a few minutes.to stabilize the
operating temperature and press the STOP switch down, (see
CONTROL PANELS).
NOTE: Afterthefirst50hours of generator operation check
. the »14interuzn,ce schedule for the 50hourservice check.
. GENEllA.TOR· ADJUsTIVJENTS
Once the generator has been placed in operation, there may
be governor adjustments requiredfor engine speed (hertz)
during the engine's break-in period (first SO hours) or after
this period (see ENGINE SPEED (HER1Z) ADJUSTMENT
under ENGINEADJUSTMENTS. A ne>-Ioad voltage adjust-
ment rnay also be required in conjunction with the engine's
speed adjustment (see GENERATIOR INFORMATION).
EngiMs & .GenilratOts
10

SAFETY SHUTDOWN SWITCHES
. SAFETY SHUTDOWN SWITCHES
The engine is protected by a variety of shutdown switches.
Should a shutdown
occur, do notattempt to restart without
finding and correcting tlie cause. Refer
to the heading ·
Engine starts, nms and then shuts down in the ENGINE
TROUBLESHOOTING section of this manual. .
The following is a description
of these automatic shutdown
switches:
EXHAUST
TEMPERATURE
SWITCH
Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. This switch will open and interrupt the
DC voltage to
the ignition coil (which turns OFF the engine), should the
switch's sensor indicate an excessive exhaust temperature
(an
inadequate supply· of raw water coolant causes high exhaust
temperatures). This switch opens at 260° -270° F
(
127° -132° C) and resets at approximately 225°F (107° C).
High Water Temperature SWitch
A high water temperature switch is located on the thermostat
housing. This switch will open and intenupt the
DC voltage
to the ignition coil (which turns OFF the engine), should
the
fresh water coolant's operating temperature reach
approximately 205° F (96° C).
This switch resets at
195° F (1 OT C).
low Oil Pressure Switch
Alow oil pressure shutdown switch is located off the
engine's
oil gallery. The switch is·kept closed by engine oil
pressure. Should the engine's oil pressure fall
to 10 - 15 psi,
the switch will open interrupting the DC vo!cage to the
ignition coil (which turns OFF the engine).
LOW Oil PRESSURE SWITCH
Oil FILTER.
High RPM Shutdown SWitch
An overspeed shutdown switch shuts OFF the generator set.
by grounding out the ignition system should the engine's
speed reach approximately 2175 rpm. Reset
the switch by
momentarily depressing the STOP switch. (Make sure the
cause of the engine overspeed shutdown is corrected).
Engine Circuit Breaker
The. generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere in the instrument panel
wiring or engine wiring
will cause the breaker to trip. In this
event the generator will shut down because the opened
breaker interrupts the DC circuit
to the K2-run relay. If this
should occur, check and repair the source of the problem.
After repairing the fault, reset the breaker and restart the
generator.
Overspeed PC Board
Inside the Control Box on the generator is a solid state
Overspeed PC Board. It monitors engine rpm via ignition
coil pulses.
If these pulses reach a preset point. The PC
Board grounds the ignition and shuts the generator down.
Press the STOP switch to re-set the PC Board.
(For test purpose ONLY to determine a faulty PC Board
that will not re-set. Lift the
Tl connection off the board
and attempt to start the generator).
. Engines"& Generators
11

MAINTENANCE SCHEDULE
WARNING: Never attempt to perform any service while the engln fS tunning. Wear the propet safety equipment Sllch as goggles and
gloves, and use the correct tools tor each jab. When servicing/replacing DC components, tum oft the DC circuit break8r on the control
panel or tum off the battery SWltch.
SCHEDULED MAINTENANCE
Maintenance procedures are all detailed in this manual.
I DAILY CHECK BEFORE START-UP
Coolant level
Engine Oil Level
Fuel/Water Separator (owner installed)
Fuel Supply
Visual Inspection ol Engine
I INITIAL 50 HOURS OF OPERATION
•spark Plugs
Engine Oil and Fitter
*Exhaust System
"Valve Adjustment
Air Screen/flame Arrester
carburetor Filler Screen
Mechanical Govemor
I EVERY 50 OPERATING HOURS OR MONTHLY
Drive Belt (water pump)
Starting Batteries
Electric Fuel Pump and Gasdenser
Zinc Anode
I EVERY 100 OPERATING HOURS OR YEARLY
Engine Oil and Filter
Air Screen/Flame Arrester
I EVERY 250 OPERATING HOURS OR YEARLY
*Exhaust Elbow/Exhaust System
NOTE: Some models have catalytic converters
See data below.
Carburetor Filter Screen
•Generator
EXPLARATION 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
Fresh unleaded gasottne with an octane rating of 89 or higher. Lower octane wm affect engine
ner1iom1anr~e 10"4 ethanol maximum.
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 wiring and electrical
connections. Look for loose bolts/hardware and correct as needed.
Clean/regap.
Initial engine oil and filter change at 50 hours. then change both every 100 hours.
Initial check at 50 hours, then every 250 hours or once a year. carefully inspect tor leaks.
Check that the exhaust hoses are properly attached and !hat the securing clams are tight
Check the integrity/mounting security o1 the water injected exhaust elbow.
Check adjustment of valve. Check again at 500 hours. Torque head bolts first.
Remove, clean and re-install screen pack. Inspect rubber sealing ring and replace if
necessary, then every once a year.
Clean screen at 50 hours !hen every 250 hours.
Initial oil change, then every 250 hours or once a year.
Inspect for proper tension (318" to 112" 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 sctiedule.
Change engine oil and filter.
Remove. clean and re-install screen pack. Inspect rubber sealing ring and replace if
necessary.
Check the structural integrity of the water injected exhaust elbow casting. 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 teak will cause exposure to diesel exhaust!
Clean. replace fuel inlet screen.
Check that AC connections are clean and secure. Ensure wires have no chafing.
See GENERATOR INFORMATION.

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your engine hours running time.
SCHEDULED MAINTENANCE
EXPLANATION OF SCHEDULED MAINTENANCE
I EVERY 250 OPERATING HOURS OR YEARLY
Hoses
•1gnltlon Timing
-------
•spark Plugs
Engine hoses should be firm and tight. Replace if hoses become spongy, brittle or
delaminated. Check and tighten all hose clamps as needed.
Check timing and adjust as needed.
·~-----------
1 nspect, clean, re-gap or replace.
•Vibration lsolalorsJEngine Mounts
----------------------------~-~~-.
Check vibration isolators, brackets and mounting hardware. Replace as needed.
Heat Exchanger
Mechanical Governor
Open heat exchanger and cap(s) and clean out debris. Replace gasket and 0-rings if needed.
-~--------~·- .
Change governor oil.
I EVERY 500 OPERATING HOURS OR YEARLY
Raw Water Pump
Remove the pump cover and inspect the pump assembly for wear, especially cam and wear
plates. Replace the impeller and gasket. Lubricate the impener at re-assembly.
•Exhaust System catalyst
I EVERY 500 OPERATING HOURS OR EVERY TWO YEARS
Ignition Wires
•Coolant System
Inspect and/or replace. See Data below. *
Inspect for deterioration. Inspect resistance.
Drain, flush and re-fill the cooling system with appropriate antifreeze mix. Replace the
thermostat and coolant pressure cap.
·-------------~·
•valve Clearances
Adjust valves. (Incorrect varve clearance wiH result in poor engine performance.
*starter Motor
Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the
starter motor pinion drive.
EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS
•Engine Timing Belt
Inspect timing belt. Replace as needed. Failure to replace belt can result in severe engine
damage.
Heat Exchanger
Cylinder Head Bolts
Remove the heat exchanger for professional cleaning and pressure testing.
Re-torque bolts (engine cold). Adjust valves after re-torque.
NOTE: Keep the engine surface clean. Dirt and oil will inhibit the engine's ability to remain cool.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
*CATALYIC CONVERTER
ADDED TO PRODUCTION MODELS .... ( Date Code 0608 )
ACatalvtic Converter has been installed on the engine's
exhaust to reduce exhaustemissions and to conform with EXHl\U~r MANIFOLO
the current U$. Environmental ProtectionAgency and the "
California Air Resources Board exhaust emission standards. , ;-"Ip"'
~>o not operate the engine without the Catalyst assembly / 1~
mstaJled. ~. ''-...
Every 500 operating hours a visual inspection of the ~
convertershould be performed. Remove the converter '§ - _
assembly from the exhaust manifold and inspect the internal
part for damage, carbon build-up, or sootdeposits. If light
is not "tisible through the element,replace the converter.
The complete assembly with housing must be replaced. The
, internal pai1 is not available separately.
NOTE: Signs that the Cataly.~t may 1ieed replacing are high exhaust backpressure
arul a sooty exhaust. Do not allow sea water to contact the internal part.
lwlWESTERBEKE
(Engines & Generators
13
(CONT.)

COOLING SYSTEM
DESCRIPTION
Westerbeke marine engines are designed and equipped for
fresh watercooling. Heat produced in the engine by combus-
tion and friction is transferred to fresh water coolant which
circulates throughout the engine. This circulating fresh water
coolant cools
the engine block, its internal moving parts, and
the engine oil.
The heat is transferred externally from the
fresh water coolant to raw
water by means of a heat
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes of the heat exchanger while
fresh water coolant flows around
th~ 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 indepen-
dent
of each other. Using only fresh water coolant within the
engine allows the cooling water passages to stay clean and
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 be located at or above the
engine manifold level and should
be easily accessible.
jTO COOLANT RECOVERY
TANK ·
COOLANT EXPANSION
KEEP THESE PASSAGES CLEAR TO ENSURE
A 'FULL FLOW OF COOLANT TO AND FROM
THE COOLANT RECOVERY TANK (A PIPE
CLEANER WORKS WELL)
free from harmful deposits. ,,..·--.._'-......_ ENGINE COOLING DIAGRAM (TYPICAL)
WATER ---.. - -- FIRESSURE CAP
INJECTED ELBOW ----
FRESH WATER¢
RAWWATER ....
MANIFOLD
·PRESSURE
CAP
INCOMING
RAW WATER
NOTE: Periodically check the condition of the manifoldpres-
sure
cap. Ensure that the upper and lower rubber seals are in
good condition
and check that the vacuum vplve.opens and
closes tightly. Carry a
spare cap.
14
RAW WATER DRAIN