Westerbeke 8.0 KW BCGTC - 50 Hz User manual

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OPERATORS MANUAL
MARINE DIESEL GENERATORS
8.0KW • 60Hz ......... 6.0KW • 50Hz BTDA
10.0KW • 60Hz ......... 7.5KW • 50Hz BTDA
11.5KW • 60Hz ........ ,9.2KW • 50Hz BTD
12.5KW • 60Hz ......... 9.4KW • 50Hz BTDB
12.6KW • 60Hz ...... 10.4KW • 50Hz BTD
15.0KW - 60Hz ..... 12.0KW • 50Hz BTDC
Single an hase
PUBLICATION NO.44800
THIRD EDITION
JUNE 2008
WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAD
MYLES STANDISH INDf.lSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
---.-.
.J,YJJ!.ttfIJ Member NaJil>nal Marine Manu/aCIJITwAssociafiqn

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, 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,
6ET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
untilIt has been inspected and repaired.
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine Dr generator.
WfSTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefully. Mostaccidents are
caused byfailure to follow fundamentalrules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions toprotectyourself, your personnel,
and your machinery.
Thefollowing safety instructions are in compliance with
theAmerican Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC elsctrical connections
whIle engIne Is runnIng, or when connected to shore
power. Lethal voltage Is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers 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 dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessel's AC generator may
result
if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: DD nDt touch hot engine parts Dr
exhaust system components. A runnIng engIne gets
very hot!
• Always check the engine coolant level at the coolant
recovery
tank.
A WARNING: Steam can cause Injury Dr death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury Of death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, 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 line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• 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. Keep the compartment and the
engine/generator clean and free ofdebris 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 from fuel vapors can cause
injury Of death!
• 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 run-
ning 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-ven-
tilated area away from spark-producing equipment and
out of the reach ofchildren.
• Do not fill the fuel tank(s) while the engine 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 servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have apositive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
• 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.
BAnERY EXPLOSION
A WARNING: Banery 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 offall 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 orfuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any 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 banerles 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 ofapproved 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 nu-like symptoms,
nausea Dr death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
sys-
terns. 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 of carbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause Injury
or death!
• Do not service the engine while it is running. If a situa-
tion arises
in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment;
tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure aU attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is opemting.
• Stay clear ofthe drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High nol$8 levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally Dr 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. and follow all safety
procedures.
ENGINE INSTALlATIONS
Preparations to install an engine should begin with a thor-
ough 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 ofparticular interest are:
H- 2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions
when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order
from:
ABYC
15 East 26th Street
New York, NY 10010
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order
from:
National Fire Protection Association
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order
from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WES1ERBEKE 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 ~ 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 20" above the vessel's waterline. Failure to use a siplwn-break when
the exhaustmanifold injection port is at or below the load waterline willresult in
raw water damage to the engine
and possibleflooding 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, installa
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 manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gaSOline and
diesel, engines and generators, is available from Jour WESTERBEKE
dealer.
/w-/WESTERBEKE
I En9ines & Generators
iv

TABLE OF CONTENTS
Parts Identification . ............................................ 2
Glow Plugs ......................................................... 24
Introduction ......................................................... 3
Generator Wiring Diagram ................................. 25
Warranty Procedures......................................3
Generator Wiring Schematic ............................. 26
Serial Number Location ................................4
Generator Wiring Diagram
Diesel Fuel,. Engine Oil and Coolant.. ................. 5 (with Electronic Governng).........................27
Generator Control- Panels .................................... 6
Generator Wiring Schematic
Description of Switches.................................6 (with Electronic Schematic)........................28
Description
of Gauges...................................6
Remote Instrument Panel ................................. 29
Remote Panel.................................................6
Engine Troubleshooting (Chart) ....................... 30
Preparations for Initial Start·Up ......................... 7
Control Panel Troubleshooting ......................... 32
Pre-Start Inspection .......................................7
Engine Adjustments .. ........................................ .33
Generator Voltage ..........................................7 Drive BeltAdjustment.................................33
Starting/Stopping Procedure . .............................. 8 Electronic Governor (Optional)...................33
Safety Shutdown Switches ............................9 Engine Speed/Engine Shutdown.................33
Generator Break·ln Procedure ......................... .1 0 Valve Clearance..........................................
.34
The Daily Operation ......................... .................. 11
Testing Engine Compression.......................35
Maintenance Schedule ..................................... 12 Fuel Injectors...............................................35
Cooling System .................................................. 14 Generator Information .............. ......................... 36
Changing Coolant........................................14 BT Generator ..................................................... 37
Thermostat...................................................15 Internal Wiring
(6 Stud) .............................. 38
Raw Water Cooling Pump...........................15
Generator Voltage Adjustment ......................... 39
Changing the Raw Water Impeller..............16 Automatic Voltage Regulator ......................40
Heat Exchanger ...........................................16 Voltage Regulator Adjustments...................40
Air IntakelSilencer ............................................ 17
Generator Internal Wiring ............. ................... .41
Air Filter...................................................... 17
Regulator Sensing 3 Phase ............................. .42
Fuel System ....................................................... 18 Shore Power Transfer Switch ........................... .43
Fuel LiftlWater Separator............................18
Generator Troubleshooting (Chart) .................. .44
Fuel Lift Pump............................................. 18 Lay·Up and Recommissioning .......................... .45
Fuel Lift Pump Filter...................................
18
Specifications (3 Cylinder Engine) ................... .47
Fuel Filter ....................................................
18
8.0/6.0Kw . 10.0n .5Kw ................................... .48
Engine Lubricating Oil ....................................... 19
11.5/9.2Kw .. 12.6/10.4Kw .............................. ..49
Engine Oil Change ......................................19
Specifications (4 Cylinder Engine) ............... : .... 50
Oil Pressure ....................................................... 20 12.5/9.4Kw· 15.0/12.0Kw ................................ 51
Testing Oil Pressure.....................................20 Engine Torque Specifications ........................... 52
Remote Oil Filter ............. .................................. 21
Standard Hardware ............................................ 53
DC Electrical System ......................................... 22
Metric Conversion Data .................................... 55
Alternator Troubleshooting .........................22
Raw Water Discharge Hose ............................... 56
Battery Care.................................................
23
Power Take Off System ...... ............................... 57
Suggested Spare Parts ...................................... 58
Engines & Generators
1

DC
20 AMP
CIRCUIT
BREAKER
BREAKER
OIL FI
FRONT
PREHEAT
REAR MOUNT
PARTS IDENTIFICATION
OIL PAN
LEFT SIDE
GENERATOR EMERGENCY
STOP SWITCH
CONNECTION TO
BREAK
to.PlATE
'--"~-I----+---EXHAUST ELBOW
SOLENOID
STARTER MOTOR
REAR
MANIFOLD PRESSURE CAP
.FILL
RIGHT SIDE
Engines & Generators
2
'FILL
THERMOSTAT
ASSEMBLY
AIR INTAKE
SILENCER & FILTER
_---INJECTION
PUMP
ENGINE BLOCK DRAIN PLUG
FILTER
FRONT

INTRODUCTION
lhis WESTERBEKE Diesel Generator is a product of
WESTERBEKE's long years ofexperience 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. lhis
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. A parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer. If you are planning to install this
equipment contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days ofsubmitting the Warranty Registry
form you have not received a customer identification card
registering your
warranty, please contact the factory in
writing with model information, including the unit's serial
number
and commission date.
Customer Identification Card
,....".",WESTERBEKE
, Engines & Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model 15 BTC Ser. #
Expires
The WESTERBEKE serial number is an alphanumeric
number that can assist in determining the date of manufac-
ture ofyour WESTERBEKE engine or generator. The manu-
facturer's date code is placed at the end of the engine serial
number and consists ofa character followed by three
numbers. The character indicates the decade.
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 TIlE
CONTENTOF SUCH
SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS THEREOFAND WILL IN NO EVENT
BEUABLE
FOR ANYTYPE OFDAMAGE 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 exclusively as the definitive authority on
the respective product. It not only makes good sense
but
is imperative that appropriate representatives of
WESTERBEKE or the supplier in question be consulted
to determine the accuracy and currentness of the
product software being consulted by the customer.
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: Procedures, which if not stTictly
observed, can result In the damage Dr destruction of
your engine.
A WARNING: Procedures, which if not properly fol-
lowed, can rssult in personal Injury or lOss of me.
Engines &Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on a decal on~the generator housing. Take the
time to enter the information on the blank decal provided
below as this will provide a quick reference when seeking
technical information andlor ordering repair parts.
~
The engine serial number can also be found stamped into the
engine block just above the injection
pump. The generator
serial
number is stamped into the generator housing on the
flat surface on the left side of the generator. Il:n
: R!!i!i.!:2!)
~,~ .. -,
An identification plate on the engine manifold also displays
the engine model and serial number.
SERIAL
NUMBER
GENERATOR
ID DECAL
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 ofa 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 of the
fuel, lubricating and cooling systems.
Replacement of fuel and lubricating filter elements at the
time periods specified is a must, and frequent checking for
contamination (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 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 (sec the separately furnished
Partl! List): Also insist upon WESTERBEKE packaged parts
because willfit 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 loeal WESTERBEKE
dealer
will assist you in preparing an inventory ofspare parts.
See the SPARE PARTS page in this manual. For Engine and
GeneratorAccessories,
see the ACCESSORIES brochure.
Engines & Generators
4

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or speeification of Class
2-D (AS1M), and has a cetane rating
of #45 or better.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance ofthe components
in your fuel injeetion pump
is very critical; invisible dirt par-
ticles 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, visual-type fuel
filter/water separator between the
fuel tank and the engine.
The Rayeor 225 or
500MA are good examples of such filters.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF
or CG-4 or better. Change the engine oil after an initial 50
hours ofbreak-in operation, and every 100 hours of operation
thereafter. For reeommended oil viscosity, see the following
chart:
Operating TemperabJre 011 Viscosity
Above 68°F (20°C) SAE 30, 10W-30 or 15W-40
41 °- 68°F (5 - 20°C) SAE 20, 10W-30 or 1SW-40
Below 41°F (SOC)
SAE 10W-30 or 15W-40
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains Its own additives;
additives of diffefent brands could feact in the mixture
to produce properties harmful to your engine.
OIL PRESSURE
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
nonnal operation, the oil pressure will range between
35 and
55 psi (2.5 and 3.9 kg/cm2 ).
NOTE: A newly started, cold engine can have an oil pressure
reading up to 60 psi (4.2 kg!cm2). A wanned engine can have
an oil pressure reading as low as 25 psi (1.8 kglcm
2
). These
readings will vary depending upon the temperature of the
engine, the load placed on the engine, and the RPM's.
ENGINE COOLANT
WESTERBEKE reeommends a mixture of50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze perfonns 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 for a good quality
antifreeze that contains Supplemental Cooling Additives
(SCAs) that keep the antifreeze chemically balanced, crucial
to long tenn protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
NOTE: Lookfor the new environmentally-friendly long lasting
antifreeze that is now available.
Antifreeze mixtures will protect against an unexpected freeze
and they are beneficial
to the engine's cooling system. They
retard rust and
add to the life ofthe circulating pump seal.
ANTIFREEZE PROTECTION
Antifreeze Concentration 23% 30% 35% 50%
Freezing Temperature 14·F 8·F -4°F
(-10°C) (-13·C) (-20·C)
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each
WESTERBEKE diesel engine. The purpose
of this recovery
tank is to allow for engine coolant expansion and contraction
during engine operation, without the loss
of coolant and
without introducing air into the cooling system. This kit
is
provided and must be installed before operating the engine.
NOTE: This tank, with its slwrt run of plastic hose, is best
located at orabove
the level of the engine's manifold, but it
can be located below the level of the engine's manifold if the
particular installation makes this necessary.
Engines & Generators
5

GENERATOR CONTROL PANELS
DESCRIPTION OF SWITCHES
This manually controlled series ofWESTERBEKE marine
diesel generators is equipped with toggle switches on the
engine control panel and, optionally, at remote panels.
All three switches are momentary contact type and serve the
following functions:
PREHEAT: The PREHEAT toggle switch serves two purposes:
preheating the engine for easy starting and defeating of
bypassing the engine oil pressure switch. The defeat function
turns on the fuel solenoid, instrument power and alternator
excitation.
When the PREHEATswitch is depresseq, the voltmeter,
panel lights, gauges and meters and fuel solenoid will
activate.
START: The START toggle switch closes the Kl relay that
energizes the starter solenoid and activates the starter
..
While the PREHEAT switch is still depressed, depressing the
START switch engages the start solenoid. When the engine
begins to
fire, the START switch should be released. The
PREHEAT switch should not be released until the oil
pressure reaches 5 -10 psi.
STOP: The STOP toggle switch is a normally closed switch.
providing power to the fuel solenoid, instrument cluster and
alternator excitation, after the oil pressure switch has closed
upon starting. Opening of this switch opens the power circuit
to the fuel solenoid, stopping the flow
of fuel to the engine
and shuts down the engine.
To stop the engine, depress the STOP switch. When the
STOP switch is depressed, the power feed to the fuel
solenoid is opened, and the fuel flow to the engine is
stopped. The STOPswitch should be depressed until the
generator stops rotating.
NOTE: When the engine is shut down, the water temperature
gauge and the oil pressure gauge will continue to register the
last temperature and oil pressure readings displayed. They
will return to zero once electrical power is restored.
EMERGENCY STOP: The EMERGENCY
stop switch on the side
of the control box,
is normally closed. When depressed, it
will open the DC circuit to the control
panel and shut the engine down. As the
switch is not toggled
it can-be used when
performing maintenance.
DESCRIPTION OF GAUGES
Coolant Temperature
Engine coolant (water) temperature should normally indicate
175
0 to
195
0 F (800 to 90° C).
Engine 011 Pressure
Oil pressure (psi) may fluctuate depending on the generator
load but should range between between
30 to 60 psi.
DC Voltm8t8r
Indicates the amount the battery is being charged should show
13Vto 14V.
Hourmeter
Registers elapsed time and is used as a guide for when to
perform scheduled maintenance.
REMOTE PANEL
For remote operation of the generator system, the same three
switches are used.
The PREHEAT and START switches are
connected
in parallel with the gauge panel's switches and
serve the same functions as in the gauge panel.
The STOP
switch is in series with the gauge panel's STOP switch and
serves the same function. There is a REMOTE START/STOP
WIRING DIAGRAM in this manual.
GENERATOR
RELEASE
STARTER
PREHEAT
MUST ~
PRESS t:t)~
1ST ==
CI'
STOP
START
1ft!). PRESS
\' '1/ 2 ND
WESTERSEKE
NOTE: For additional infOnnalion on Control Panels. Refer to:
STARTING/STOPPING PROCEDURE, DC WIRING
DIAGRAMS and TROUBLESHOOTING GAUGES.
Engines & Generators
6

I PREPARATIONS FOR INITIAL START-UP
PRESTARTINSPECTIO~
This section of the manua provides the operator with prepa-
ration, initial starting, bre -in, starting (warm
or cold) and
stopping procedures. Foil w the procedures as presented for
the conditions indic your WESTERBEKE generator
set will give reliable pem ance and long service life.
Before starting your generator set for the first time or after a
prolonged layoff, check
th~ following items:
D Check the engine oil level.
Add oil to maintain the level
at the high mark on
thf dipstick.
Check the fuel supply
Md examine the fuel filter/separa-
tor bowls for contarnil1ants.
Check the DC electric~l system. Inspect wire connections
and battery cable connbctions.
Make certain the (+) bat-
tery cable is connecteq to the starter solenoid and the
negative
(-) cable iS~' nnected to the engine ground stud
(this location is tagg . .
Check the coolant lev 1 in both the plastic recovery tank
and
at the manifold. '
D Visually examine the lll1it. Look for loose ormissing
parts, disconnected
w+' ies, unattached hoses, and check
threaded connections.
Check load leads for c rrect connection as specified in
the wiring diagrams.
D Examine air inlet and 'l}Utlet for air flow obstructions.
D Be sure no other gene~ator or utility power is connected
to load lines. I
D Be sure that in power hstems with a neutral line that
the neutral is
properltOUnded (or ungrounded) as the
system requires, and at the generator neutral is properly
connected to the load eutral. In single phase and some
3-phase systems an indomplete or open neutral can sup-
ply the wrong line-to-qeutral voltage on unbalanced
loads. '
Make sure the mounting installation is secure.
Make sure that the generator is properly grounded.
---\
A CAUTION: When starling the generator, it is
recommended that aI/ 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 prevenl a cold engine from
slalling.
GENERATOR VOLTAGE
The speed of the generator engine is adjusted at the factory,
however, it is advisable to verify.
60 Hz The engine no-load speed is set at 61.5 -62 Hz.
50Hz
At rated amperage hertz output may decrease to
48.6 -59.0 Hz.
The engine no-load speed is set at 61.5 Hz. At
rated amperage hertz output may decrease to
48.5 -49.0 Hz.
The speed
of the generator engine is adjusted at the factory,
however it is advisable to verify. The voltages are easily
adjusted to optimum values no-load and full load (refer to
VOLTAGE ADJUSTMENTin this manual). If possible, apply
actual service or test load
of the same power factor as the
load to be used in service. If the voltage cannot be adjusted
to suitable values and fault seems evident, contact your
authorized .
GLOW
CONNECTION
rm:.'''''Ulru: CAP
Oil FILL CAP
~
DIPSTICK~
~ \\ \\ APPROXIMATELY
\ ONE QUART
SIDE OIL FILL CAP
OIL LEVEL \ ~.
Engines & Generators
7

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
Westerbeke diesel generators use electric starters assisted by
glow plugs for both normal and cold weather starting. The
illustration below shows a cross-sectional view
of one cylin-
der. The glow plug is located in the combustion chamber so
that its tip is in the injector nozzle's spray path. When the
glow plug is energized by the PREHEAT button, the plug
glows red at the tip and assists in igniting the fuel. The result
is a rapid start with less wear on the starter.
This system is common to WESTERBEKE diesels. The start
circuitry is designed so that the PREHEAT button must be
depressed
fOf the time specified in the preheat chart. Then,
while keeping the PREHEAT button engaged, the START
button is depressed to crank the engine.
NOTE: The START switch will not energize unless the PRE-
HEATswitch is depressed. Depressing the PREHEATswitch
activates
the glow plugs in the cylinder head so use the PRE-
HEAT intermittently to avoid overheating the glow plugs.
GLOW PLUG
PREHEAT: Depress the PREHEAT switch. The voltmeter and
panel lights, gauges and meters will be activated. The PRE-
HEAT switch should be depressed in accordance with the
following chart:
TemperatureJPreheat
Abnospheric Temperature
Preheating Time
+41 °F( +5°C) or higher
Approx. 10 seconds
+41°F(+5°C) to 23°F (-5°C)
Approx. 15 seconds
+23°F( -5°C) or lower
Approx. 20 seconds
Limit of continuous use
30 seconds before cranking
START: While still depressing the PREHEAT switch, depress
the START switch. This will engage the starter solenoid.
Upon engine starting, release the START switch. Do not
release the PREHEAT switch until the oil pressure reaches.
5 - 10 psi. Then as long as the high water temperature and
low oil pressure protective circuits do not activate. the engine
will remain energized and continue to run.
NOTE: When starting:
A voltage drop will occur
when the prelfleat switch
is depressed:
Should the engine not start when the START switch is
depressed for 10 to
20 seconds, release both switches and
wait 30 seconds; repeat the procedure above and preheat
longer. Never run the starterfor more than 30 seconds.
A CAUTION: Prolonged cranking intervals without the
engine stanlng can result In the engine exhaust system
filling with raw water. This may happen because the
pump is pumping raw water through the raw water CODl-
ing system during cranking. This raw water can enter the
engine's cylinders by way of the exhaust manifold once
the exhaust system nils. Prevent this from happening by
closing the raw water supply through-hull shut-off,
draining the exhaust muffler. and correcting the cause
of the excessive engine cranking. Engine damage result-
ing from raw water entry is not a warrantablelssuej the
owner/operator should keep this In mind. .
Remote Starting Procedure
The remote start panel is the same as the engine-mounted
start panel except that it has a green LED light and no
gauges. When starting at a remote location, the green LED
lights when the generator is running at approximately 600
rpm. This indicates when the START switch can be released
since the starting
of the generator may not be audible.
A. When the PREHEATswitch is depressed at the remote
start/stop panel the LED light will illuminate. When the
START switch is depressed and the starter cranks the
engine this
LED light will dim. When the engine starts
the LED light will brighten signaling to release the
START switch. Continue to hold the PREHEAT
depressed for a few seconds to allow oil pressure to build
up which closes the oil pressure safety switch that is in
the series path for I2V
B+ to the fuel run solenoid. The
green
LED will remain brightly illuminated while the
engine is running.
B. After the generator is started and the START switch is
released, the generator's starter will not crank unless the
PREHEAT switch is operated first because this switch
supplies voltage to the START switch.
Once the engine starts, check the engine's instruments for
proper oil pressure and battery charging voltage. Apply a
light'Ioad to the generator and allow the engine's operating
temperature to come up to 140-150° (60-66° C) before
applying heavy loads.
NOTE: Some unstable running may occur in a cold engine.
Depressing the PREHEATswitch/or10-15 second intervals
will help stabilize
the engine rpm until the operating
temperature
reaches 140 -1500 Fanda load is applied to
the engine.
lW-IWESTERBEKE
I Engines & Generators
\// 8

STARTING/STOPPING PROCEDURE
STARTING UNDER COLD CONDITIONS
Make sure the lubricating oil confonns with the ratings for
the prevailing temperature. Check the table in the ENGINE
OIL section in this manuaL
The battery should be fully charged to minimize voltage
drop.
Use a sufficient amount
of preheat to aid in starting. See the
TemperaturelPreheat chart on the previous page.
STOPPING PROCEDURE
1. Remove the AC electrical load from the generator and
allow the generator to run for three to five minutes to
stabilize its operating temperatures.
2. Depress the STOP switch and hold it until the generator
is completely stopped.
3. Now release the STOP switch.
Remote Stopping Procedure
To stop the generator, depress the STOPswitch which opens
the nonnally closed
B+ path for voltage to the engine's run
-circuit. The STOPswitch must be held open until the
generator comes to a complete stop and the green LED light
goes out. .
SAFETY SHUmOWN SWITCHES
The engine is protected by three automatic shutdown
switches. Should shutdown occur, do
not attemptto restart
withoutfinding and correcting the cause. Referto the
heading "Engine Stops"in the TROUBLESHOOTING
section
of this manual.
The following is a description of these automatic shutdown
switches:
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Nonnally closed, this switch will open and interrupt
the DC voltage to the K2 relay (shutting
OFF the engine)
should the switch's sensor indicate an excessive exhaust tem-
perature (an inadequate supply
of raw water causes high
exhaust temperatures). This switch opens at 260-270°F (127-
132°C). This switch resets at approximately 225°F (l07°C).
EXHAUST ELBOW
HIGH EXHAUST ~ I' ~tra.::=~
TEMPERATURE r
SWITCH
Coolant Temperature Switch
A high coolant temperature switch is located on the thennostat
housing. Nonnally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C), will open and interrupt the
DC voltage to the K2
relay, thereby shutting
off the engine. This switch resets at
195°F (107°C).
COOLANT
TEMPERATURE
SWITCH
Low Oil Pressure Switch
A low oil pressure shutdown switch is located off the engine's
oil gallery. Nonnally open in a static state, this switch's sensor
monitors the engine's oil pressure. Should the engine's oil
pressure fall to 5-10 psi, this switch will open interrupting the
DC voltage to the K2 relay, thereby shutting offthe engine.
OIL PRESSURE SWITCH
OIL PRESSURE /
SENDOR /
Engine Circuit Breaker
The generator's engine is protected by an engine moun~
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 and the voltage to the K2
relay is terminated.
If this should occur, check and repair the
source
of the problem.After repairing the fault, reset the
breaker and restart the generator.
Engines & Generators
9

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 oper-
ated 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
scored, which is caused by overloading the generator during
the break-in period.
Your new engine requires approximately
50 hours of initial
conditioning operation to break in each moving part in order
to maximize the performance 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 opera-
tion and then encourage a fast warm-up. Run the generator
between 20% and 60% of fun-load for the first 10 hours.
A CAUTION: 00 not attempt to bl'flak-in your
generator by running without a load.
After the first 10 hours of the generator's operation, the load
can be increased to the full-load rated output, then periodi-
cally 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
it within 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.
CHECK THE FOLLOWING
oMonitor the control panel gauges.
Check for leaks
of fuel and engine oiL
Check for abnormal noise such as knocking, friction,
vibration and blow-back sounds.
o 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.
To protect against unintentional overloading
of the generator,
the generator's output leads should be routed through a cir-
cuit breaker that is rated at the rated output
of the generator.
NOTE: Be aware of motorstarting 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, there may
be adjustments required for engine speed (hertz) during the
engine's break-in period (first 50 hours) or after this period.
A no-load voltage adjustment may also be required in con-
junction with the engine's speed adjustment. Sec
GENERATOR INFORMATION in this manual.
Engines &Generators
10

THE DAILY OPERATION
CHECK LIST
Follow this check list each day before starting your generator.
o Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
Visually inspect the generator for fuel, oil, or water leaks.
Check the
oil level (dipstick).
o Check the coolant level in the coolant recovery tank.
o Check: your diesel fuel supply.
Look for clean fuel in the fueUseparator transparent bowL
Check for loose wires at the alternator.
o Check the starting batteries (weekly).
o Check drive belts for wear and proper tension (weekly).
START THE GENERATOR
(See STARTING PROCEDURES on previous pages).
Allow
the engine to wann up for S to 10 minutes to reach an
operating temperature of 140° to 1S0°F (60°-66°C) before
applying AC loads. Apply loads systematically allowing the
generator to adjust to each load before applying the next.
Check the gauges for proper oil pressure, operating tempera-
ture, and DC voltage.
NOTE: Some unstable running may occur in a cold engine.
This condition should lessen as normal operating tempera-
ture is reached and loads are applied.
A CAUTION: Do not operate the generator for long
periods of time without a load being placed on the
STOPPING THE GENERATOR
Remove the major AC loads from the generator one at a
time. Allow the generator to run for a few minutes to stabi-
lize
the operating temperature and depress the stop switch.
(See STOPPING PROCEDURES on previous pages.)
Engines & Generators
11

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: NBvel attBmpt to pBrfDlm any SBIV/CS wh/Is ths sngins Is
lunnlng. Wsal ths PfOPSI safBty squlpmsnt such as gogglss and glOVBS
1
and
USB ths COfrsct tools fOf Bach Job. Dlsconnsct ths battsry tsrmlnals whsn
sSIV/clng any of the snglns's DC slsctrlcal squ/pmsnt.
NOTE: Many of the following maintenance jobs are simple but others are more
difficult andmay require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY 50 100
~50
500 750
1000 1250 MAINTENANCE
0
Diesel No.2 rating of 45 cetane or higher.
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
Oil level should indicate between MAX. and LOW on
dipstick.
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
0
Inspect for proper tension (3/8' to 1/2" deflection)
weekly and adjust if needed. Check belt edges for wear.
Visuallnspectlon of Engine
NOTE: Please keep engine surface clean. Dirt
Check for fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engine's ability to
and electrical connections. Keep bolts & nuts tight.
remain cool.
Check for loose belt tenSion.
Fuel Filter
0 0 0 0 0
Initial change at 50 hrs, then change every 250 hrs.
Starting Batteries
0
Every 50 operating hours check electrolyte levels
(and House Batteries) weekly and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil (and filter)
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
Generator
0 0 0 0 0 0 0
Check that AC connections are clean and secure
with no chafing. See GENERATOR SECTION
for additional information.
Heat Exchanger Zinc Anode
0 0 0 0 0 0 0
Inspect zinc anode, replace if needed, clear the heat
exchanger end of zinc anode debris.
Fuel/Water Separator
0 o
TOT 0 0 0
Change every 200 hours.
Electronic Governor Control
0 0
Check and or adjust the no-load speed in the panel,
(if applicable) req uired (hertz) and the regulator board adjustment
as needed.
NOTE: These adjustment are not a warrantable
adjustment during or after the unit's break-in.
Exhaust System
0 0 D 0
Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check anti-siphon valve operation. Check
the exhaust elbow for carbon and/or corrosion
buildup on inside passages; clean and replace as
necessary. Check that all connections are tight.
Engine Hoses
0 0 0 0 0 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
EngInes & Generators
12

MAINTENANCE SCHEDULE
NOTE: Use the engine Iwur meter gauge to log your engine hours or record your
engine Iwurs by running time.
CHECK
HOURS OF OPERATION
SCHEDULED
EACH
EXPLANATION OF SCHEDULED
MAINTENANCE
DAY
50 100
250
500 750
1000 1250
MAINTENANCE
Raw Water Pump
0 0 0
Remove the pump cover and inspect the impeller,
gasket, cam and cover for wear. Check the bearings
and seals (the shaft can turn, but not wobble).
Lubricate both when reassembled.
Coolant System
0 0
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
Electric Fuel Lift
0 0 0 0 0 0
Periodically check the wiring connections.
Pump Filter (If applicable)
Replace in-line filter filter every 200 hours.
DC Alternator
0 0 0
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
*Fuellnjectors
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
*Starter Motor
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
*Preheat Circuit
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (4-6 ohms).
Reinstall with anti seize compound on threads.
*Englne Cylinder
0 0
Check compression pressure and timing (see Engine
Compression
Adjustments).
*Torque Cylinder Head
0 0 0
At first 50 hours, then every 500 hours (see
Hold-down bolts
ENGINE ADJUSTMENTS).
*Adjust the Valve Clearances
0 0 0
Adjust Valve Clearances (see ENGINE
ADJUSTMENTS).
"Heat Exchanger
0
Remove, have professionally cleaned and pressure
tested.
Air Intake Filter
0 0 0 0 0
Clean every 100 operating hours. Replace as
needed. Refer to page 17 of this manual.
"WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
13

COOLING SYSTEM
DESCRIPTION
Westerbeke marine diesel engines are designed and equipped
for
fresh water cooling. Heat produced in the engine by com-
bustion 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 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
w~rds, 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
systetp.. The
fresh water co?lant and raw water circuits are independent of
each other. Usmg only fresh water coolant within the engine
allows
the cooling water passages to stay clean and free from
harmful deposits.
FRESH WATER COOLING CIRCUIT
NOTE: Refer to the ENGINE COOLANTsectionfor the rec-
ommendedantifreeze andwater mixture to be usedas the
fresh water coolant.
F~h water coolant .is pumped through the engine by a circu-
latmg pump, absorbmg heat from the engine. The coolant
then passes through the thermostat into the manifold, to the
heat ex:hanger w~ere ~t is cooled,. and returned to the engine
block Vla the suctIon SIde ofthe CIrculating pump.
ENGINE BLOCK COOLANT DRAIN
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.
Coolant Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi-
cant loss ofcoolant
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.
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 systllllJ maintenance is
critical; a substantial number of engine failures can be
traced back to cooling system Co"os/on.
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 the refill process.
NOTE: The drain petcock on the heat exchanger should also
be used to help drain engine coolant.
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.
Engines &Generators
14