Westerbeke 10.0 EGTD User manual

OPERATO S MANUAL ·
MARINE D.IESEL GENERATORS .
8.0 EGTD • 60Hz
10.0 EGTD ·• 60Hz
11.0 EGTD ·60Hz
11.5 EGTD ·60Hz
12.5 EGTD ·60Hz.
-15.0 EGTD ·60Hz
6.0
EGTD • 50Hz
7.5 EGTD ·50Hz
8.8 EGTD ·50Hz
9.2 EGTD • 50Hz
9.4 EGTD • 50Hz
12.0 E·GTD ·50Hz ·.
-· . . .
Electronically Governed
Singl·e a T . e Phase ·
PUBLICATION NO: 056272 f REVISION0 I 'DE~EMBER 2016
WESTERBEKE
Af'if'Af"f WESTERBEKE GORPORATION • I 50 JOHN HANCOCK ROAD
.-.-- MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE:: WWW. WE'STERBE;'KE:.COM

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,
SET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been Inspected and repaired.
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.

SAFETY INSTRUCTIONS
INTRODUCTION
.Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions existand
take the necessary precautions to protectyourself, your
personne~ and your machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running. Lethal voltage is present at
these connections!
II Do not operate this machinery without electrical
enclosures and covers in place.
11 Shut offelectrical power before accessing electrical
equipment
11 Use insulated mats whenever working on electrical
equipment
11 Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
11 Remove wristwatch and all jewelry when working on
electrical equipment
PREVENT BURNS -HOT ENGINE
A WARNING: Do not touch hot engine palfs or
exhaust system components. A nrnuing engine gets
. very hot!
iii Monitor engiile ·an~ze coolant ievei at the plastic
coolant recovery tank and periodicaly at the filler cap
location on the water jacketed exhaust manifold, but only
when the engine is COLD.
A WARNING: Steam can cause injury or death!
11 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 or death!
II Prevent flash fires. Do not smoke or pennit flames or
sparks to occur near the fuel injector, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel orfuel
vapors. Use a suitable container to catch all fuel when
removing the fuel lines or fuel filters.
II Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
II Do not smoke or permit flames or sparks to occur near
the fuel sysfem. ~eep the compartment and the
engine
dean and free ofdebris to minimize the
chances of
fire. Wipe up all spilled fuel and engine oil.
1111 Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
Injury or detftll!
llill Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate the cabin
after fueling. Check below for fumes/vapor before running
the blower. Run the blower per four minutes before starting
your engine.
111 All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area
away from spark-producing
equipment and out ofthe reach ofchildren.
Ill Do not fill the fuel tank(s) while the .engine while it is running.
1111 Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servici.1g
the fuel system.
iii Qo not alter or modify the fuel system.
llill ~~ sure all fuel supplies have a positive shutoff valve.
Ill Be certain fuel line fittings are adequately tightened and
free ofleaks.
Ill 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.

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
11 Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it
last. ·
11 Make certain all personnel are clear of the engine before
starting.
11 Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BAnERY EXPLOSION
A WARNING: Battery explosion can cause Injury
or death!
11 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.
11 Never connect the negative(-) battery cable to the posi-
tive (+) connection terminal ofthe 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.
11 Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings,
and any other jewelry before handling
the battery.
1!11 Always turn the battery charger off before disconnecting .
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BAnERYACID
A WARNING: Sulfuric acid In batteries can cause
severe injury or death!
111 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!
11!1 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.
II Be sure the unit and its surroundings are well ventilated.
111 In addition to routine inspection of the exhaust system,
install a carbon monoxide
detector. Consult your boat
builder or dealer for installation of approved detectors.
11 For additional information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO} Is an invisible
odorless gas. Inhalation produces flu·like symptoms,
nausea or death!
11 Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration ofcopper
tubing resulting in exhaust/water leakage.
111 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 dose or restrict the
flow of exhaust. Avoid overloading the craft.
11 Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the symp-
toms or signs ofcarbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
11 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
II Do not wear loose clothing orjewelry when servicing
equipment; avoid wearing loosejackets, shirts, sleeves,
rings, necklaces or bracelets that could be caught in
. moving parts ..
11 Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
111 Do not check fluid levels or the drive belt's tension while
.the engine is operating.
11 Stay clear of the 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 noise levels can cause hearing
loss/
II Never operate an engine without its muffier installed.
11 Do not run an engine with the airintake (silencer)
removed.
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 arerepeated
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 AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standar:ds. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion ofExhaust Systems for Propulsion
and Auxilliary Engines
P-4 Marine Inboard Engines and Transmissions
E-ll AC & DC Electrical Systems on Boats
TA Batteries and Battery Chargers
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
. INSTALLING MARINE ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda~
tions when installing your UNIVERSAL engine
ABYC (American Boat and Yacht Council)
"Safety Standartls for Small Craft'' ·
Order From:
ABYC
613 Third Dtreet, Suite 10
Annapolis, MD 21403
[phone]
www.abycinc.o_rg
NFPA (National Frre ProtectionAssociation)
''Fire Protection Standard for Motor Craft''
Order From:
NFPA
1 Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9101
USCG (United States Coast Guard)
"CPR 33 AND CFR46"
Code ofFederal Regulations
Order From:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

.INSTALLATION
When installing WBSTERBEKE 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 exlumst manifold injection port is at or beluw the load waterline will result in
raw water damage to the engine and po~rible flooding of the boat.
If you have any doubt about" the positii;>n of th~. w.ater-injected exhaust elbow relative •
to· the vessel's waterline :under the vessel's various operating oonditions, install a
siphon-break. , ....
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
op_eration. Failure to properly maintain a siphon-break can· result in catastrophic
enq.ine damage. Consult the siphon-break manufacturer for proper maintenance.
EXHAUST SYSTEM
Tiie exhaus't system's hose MD~T:~ certified for marine use. Conugated MaJ:ine
Exhaust Hose is recommended. The use of this type of hose a,llows for extreme bends
and turns without the ne~d of additiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length of conugated exhaust hose can be used. The
system MUST be designed to prevent the entry of wa~·into the exhaust syste$'·
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 ev!lry unit sold. This manual
.is also available in pdf format on our website to download
Website: www.westerbeke.com
Engines & Generators
iv
AVAILABLE FROM
YOUR. WESTERBEKE
DEALER
SIPHON-BREAK WITH~- fAINLES,
LOOP FOR 1" HOSE
PART NO. 044010

TABLE OF CONTENTS
Parts Identification ................................................ 2 Engine Adjustments ............................................. 28
Introduction ............................................................. 3 Glow Plugs .....................................................
28
Diesel Fuel, Engine Oil and Coolant.. ................. 5
Preparations for Initial Start-Up .......................... 6
Generator Control Panel ........................................ ?
Operating Instructions ......................................7
Remote Control Panels .......................................... 8
Operating Instructions ......................................8
Safety Shutdown Switches .................................... 9
Generator Break-In Procedures .......................... Io
Daily Operation ................................... : .................. 10
Maintenance Schedule (Chart) ........................... 11
Fuel Injectors................:................................. 28
Valve Clearance.............................................. 29
Injection Timing .............................................29
Generator Information ......................................... 30
Maintenance.................................................... 30
. BT Generator Description .................................... 31
Circuit Breaker............................................... 31
BTGenerator ·Single Phase .............................. .32
Wiring Schematic .................... ..- .................... .32
Generator Voltage Adjustment ........................... 34
No-Load Adjustment.....·................................. 34
Cooling System ..................................................... 13
Full-Load Adjustment..................................... 35
Changing Coolant........................................... 13
Thermostat......................................................14
BT Generator Internal Wiring ............................. 35
Three Phase/Twelve Wire............................... 35
Raw Water Cooling ........................................14
Raw Water Pump............................................
l5
Intake Strainer ................................................ 15
Heat Exchanger .............................................. 15
Zinc Anode ..................................................... 16
Air Intake/Silencer.......................................... l6
Filter Cartridge ...............................................16
Fuel System ........................................................... 17
Fuel Water Separator...................................... 17
Fuel Filter ....................................................... 17
BT Generator Internal Wiring ............................. 35
Three Phase/Twelve Wire............................... 35
Generator AC Voltage Connections ................... 36
BE Three Phase .............................................. 36
BT Generator Single Phase ............................. : .. .37
Troubleshooting Chart...............................,... .37
Optional Voltage Regulator........................... .37
Shore Power Transfer Switch .............................. 38
Lay-Up and Recommissioning ............................. 39
Fuel Lift Pump................................................ 17 Specifications (Engine) ..................................... .41
Engine Lubrication System ................................. 18
Oil Change...................................................... 18
8.0 EGTD, 10.0 EGTD.................................. .42
11.5 EGTD, 11.0 EGTD............................... ..43
Oil Filter ......................................................... 18 Specifications (Engine) ........................................ ~4
Oil Pressure ........................................................... 19
12.5 EGTD, 15.0 EGTD................................ .45
Testing Oil Pressure........................................ 19 Wiring Diagram #56225 ....................................... 46
Remote Oil Filter .................................................. 20 Wiring Schematic #56225 .................................. .47
DC Electrical System ........................................... 21
Wiring Diagram #56321 ...................................... .48
Alternator........................................................ 21 Remote Start/Stop Panel.................................48
Alternator Troubleshooting ............................
21
Battery Care.................................................... 22
Starter Motor ........................................................ 23
Troubleshooting..............................................24
Engine Troubleshooting ....................................... 25
LED/Shutdown (Chart) ................................... 25
Water Heater (Optional) ...................................... .49
Power Take-Off (Optional) ................................... 50
Raw Water Discharge Hose ................................ .51
Engine Torque Specifications ............................. 52
Suggested Spare Parts ........................................ 52
Engine Troubleshooting (Chart) .......................... 26
Water and Oil Pressure Gauges ..................... 27
Engines & Generators
1

INTRODUCTION
This WESTBRBEKE Diesel Generator is a product of
WESTBRBEKE's long years of experience and advanced .
technology. We take great pride in the superior durability and
dependable perfonnance of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator it
is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please, read this
manual carefully and observe all the safety precautions
throughout Should your generator require servicing, contact
your nearest WESTBRBEKE dealer for assistance.
This is your operators manual. Along wi!}i ~ manual, .there
is an Installation Manual and Parts Infonnation. A Servtee
Manual is available in pdf form. on our website or can be
ordered in book fonn from a WESTERBEKEfUNIVERSAL
Dealer
WARRANTY PROCEDURES
Your WESTERBEKE Warranty Statement is included inthe
product documentation package. There is a Warranty
Registration Card you can fillout and mail to Westerbeke ·
Corporation or go to ourwebsite:www.westerbeke.com :met
register your products warranty on line. You should recewe a
Customer Identification card in the mail within 60 days of
registering. I{you do not, please contact the factory and have
your protiuct mociei numoer, seriai number and in service
date available.
Customer Identification .Card
1-..v-IWESIERSEKE
j Engines &Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model _____ _
Serial#-----
E~~-------------
NOTES, CAUTIONS AND WARNIN~S
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procet/uress which if not strictly
observed, can result In the damage or destruction of
your engine.
A ·WARNING: Procedures, which If not property
followed, can result In personal injury or loss of life.
PRODUCT SOFTWARE
Pioduct software, (tech d$l. pans, lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are riot withinWESTERBEKE's control.
WESTERBEKE CANNOT BERESPONSIBLE FOR THE
CONI'ENT OFSUCH SOFIWARE, MAKES NO .
· WARRANIIES OR REPRESENTATIONS WITH RESPECT
THEREI'O, INCLUDING ACCURACY; TIMEliNESS OR
COMPLETENESS THEREOFAND WII..L IN NO EVENr ·
BE IJAB.LE FOR ANYTYPE OF DAMAGE OR INJURY
INCURRED INCONNECTION WITH OR ARISING OUT
.. OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers shouldalso keep in mind the
time span between printi:rigs ofWESTERBEKE product
software and the tinavoidable existence ofearlier ·
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE orother suppliers, must not and cannot
be relied upon· exclusiVely as the definitive authority on
the respective product Itnot .only makes good sense
but is inlperative that appropriate representatives of
WESlERBEKE orthe supplier in question be consulted
to determine the accuracy and current:ness ofthe
product software being consulted by the cuStomer.
PROTECTING YOUR. INVESTMENT·
care atthe factory: during assembly and tt,orough testing
have~ in aWES'IERBEKE generat9f capable of
Ill8.ey tt,.ousands of hours of dependable ~cerHowever the
manu.fiicturer cannot control how orwhere the generator is
inStall~ inthe vessel or· the mannerinwhich the unit is
opemt~ iind serviced inthe field. This isup to the
buyer/owner.:operator. ·
NOTE: Sa imp~rtant steps to ensure long generator life:
• Proper engine and generator insttziiLziion t1114.alignment.
• An ejJi.ci.ent well-designed exluiu.st 8.Y*m thal iltcltides
an antf.&iphon brea'K to preventwaterfrom entenng the
engine. . .
• Changing .the engine oil and oil filters! tzccordiitg .. to tlie
mainterurnce scl1edrde.
• .Proper mlzinte'iti.rftbe o/ all engine tuid 'generfztDT conq,o- ·
tts1its aieordjng to the '11111itt.tenane schedule in this
1lti.rn1liit; . . . .
• Use cletfii;~d #2 dieselfoel.
' '
• Winterize yourengine ciccOrilmg to the ~'lay-lip mul
Reco,mmissiotting" section in this manual.
Engines &Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model and serial number are Iqcatedon
a
nameplate mounted on the side of the waterjacketed
exhaust
manifold.
The engine's serial number is also found stamped in
the engine block on a flat surface just above the
the
side oil fill opening. Take time to enterthis inform-
~tion below on the illustrated nameplate.
An identification plate on the top ofthe engine air intake also
displays the engine model and serial number.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters. Carbonmonoxide,
even in small amounts, is deacny.
The presence of carbon monoxide indicates an exhaust leak
from the engine' or generator or from the exhaust
elbow/exhaust hose, or the fumes from a nearby vessel are
entering your boat.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine, .
since the mechanism is essentially the same. The cylinders
are arranged above aclosed crankcase; the crankshaftis of
the same general type as that ofa gasoline engine; and the
diesel engine bas the same types of valves, camshaft, pistons,
cbnnecting rods and lubricating system.
therefore, to a great extent, a diesel engine requires the
same preventive maintenance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance ofthe fuel, lubricating and cooling systems.
Replacement of fuel and lubricating filter elements at the
time periods specifi~ is a must, and frequent checking for
contanlination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of the same brand of high detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method of handling 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 of both.
ORDERING PARTS
Whenever replacement/service parts are needed, always
provide the generator model number, engine serial number,
and generator serial number as they appear on the silver and
·black name plate located on the generator end. You must
provide us with this information so we may properly identify
your generator set. In addition, include a complete part
description and part number for each part needed (see the
separately furnished Parts Ust). Also insist upon
WESTERBEKE packaged parts becavse 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 local WES'IERBEKE
· dealer willassist you in preparing an inventory of spare parts.
See the SPARE PARTS page in this manual. For Engine and
Generator Accessories, see the ACCESSORIES brochure.
. . .
INSTALLATION MANUAL
The Westerbeke Installation Manual publication #043268 is
supplied with this unit.
GENERATOR
ID DECAL
Engines & Generators
4

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use a diesel fuel that meets the requirements of No. 2-D
SAE J 313 and has a Cetane rating of #45 or higher grade of
diesel
fuel according to ASTM D975.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your engines fuel injection pump is very critical; invisible
dirt particles
which might pass through the primary and
secondary filters can damage these finely machined 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. The use of additives to
combat BACTERIAL growth on the fuel tank is recqm-
mended such as Bio-Bor and an additive such as Diesel
.Kleen + Cetane Boost to help restore lubricjty back into the
diesel
fuel when an Ultra Low Sulfur diesel is being used.
Install and regularly service a good, visual-type fuel
filter/water separator between the fuel tank and the engine.
The Raycor 500 MA or 230 RMAM are good examples of
such
filters. A 10 micron filter element is recommended.
E~&GINE OIL
Use a good brand ofengine oil having an API and SAE
specification as stated in the SPECIFICATIONS section in
this· manual. Change the engine oil and oil filter after the
initial 50 hours ofengine break-in operation and then every
100 hours ofoperation thereafter.
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 ofthis
manual and not be extended if
synthetic
oils are used.
NOTE: The infonnation above. supersedes all previous
statements regarding synthetic oil.
SAE OIL VISCOSITY GRADES
For all temperatures ranges: SAE lOW-40 or 15W-40.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze performs
double duty. It allows the engine to
run at proper temperatures by transferring heat away from the
engine
to the coolant, and lubricates and protects the cooling
circuit from rust and corrosion. Look for a good quality
antifreeze that contains Supplemental Cooling Additives
(SCAs) that keep the antifreeze chemically balanced, crucial
to long term protection.
The distilled water
and antifreeze should be premixed before
being poured into the cooling circuit.
NOTE: Lookfor the new environmentally-friendly long lasting
antifreeze that is now available.
PURCHASING ANTIFREEZE
Select a brand ofantifreeze specified for diesel engines.
Antifreeze specified for diesel engines contains a special
additive to protect against cavitation erosion ofthe engine's
cylinder
walls. Prestone and Zerex are two nationally known
brands that offer antifreeze specifically for use in diesel
engines. Select the pre-mixed variety so that the correct
mixture will always be added to the cooling system when
needed. Change the antifreeze mixture according to the
MAINTENANCE SCHEDULE in this manual.
MAINTENANCE
Change the engine coolant every five years regardless of the
number of operating hours as the chemical additives that
protect and lubricate the engine have a limited life.
COOLANT RECOVERY TANK
The coolant recovery allows for the expansion and
contraction of the engines coolant during engine operation
withoutintroducing air into the system. This recovery tank is
provided
with fresh water cooled models and with the fresh
water coolant conversion kit and must be installed before
operating the engine.
NOTE: This tank, with its short run of plastic hose, is best
located at or
above 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

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Befor~ starting your generator setfor the first time or after a
prolonged layoff,
check the following items:
• Make certain the cooling water thru-hull is open.
• Check the engine oil level. Add oil to maintain the level at
the fullmark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
•
Check the DC electrical system. Inspect wire connections
and battery cable connections.
R Check load leads for correct connection as specified in the
wiring diagrams.
• Examine air inlet and outlet for air flow obstructions
(SoundGuards ).
• Be sure no other generator orutility power is connected to
load lines.
• Be sure that in power systems with a neutral line that
the neutral is properly grounded (or ungrounded) as the
system requires, and that the generator neutral is properly
connected to the load neutral. In single phase systems an ·
incomplete or open neutral can supply the wrong line-to-
neutral voltage on unbalanced loads.
• Visually examine the unit. Look for loose or.missing_
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any fuel line leaks.
WAIT FOR THE ENGINE W COOL
BEFORE REMOVING THE RADfATOR
CAP .
MAWFOLD PRESSURE CAP,-~=,.,_~,
PRESS DOWN AND TURN
TOUFTOFF
FROM COOLANT
RECOVERY TANK
Olll)IPSTICK
LOW
A CAUTION: When starting the generator. it is
recommended that all AC loads, especially large
motors, be switched OFF until the engine has come
up to speed and,. in cold climates, starts to warm up.
This precaution will prevent damage caused by
unanticipated operation of the AC machinery and will
prevent a cold engine from stalling.
II Check the coolant level inboth the plastic recovery tank
and at the manifold.
NOTE: After the initial running of the generator, the air in
the engine's cooling system will be purged to the coolant
recovery tank. Open the air bleedpetcock to ensure that the
cooling system is purged of air. Aftershutdown and cifter the
engine has cooled, the coolantfrom the recovery tank will be
drawn into the engine's cooling system to replace the purged
air.
Before subsequent operation of the generator, the engine's
manifold should
be toppedoff, a:nd the coolant recovery tank
may need to be filled to the MAX level.
TO NIPPLE At
MANIFOLD PRESSURE CAP
ELECTRONIC CONlROLLER jJ_) __
THE ECU JS FACTORY PROGRAMMED
. TO CONTROL ALL ASPECTS J.
OF THE DRIVE ENGINE. .()) .
Engines & Generators
6

GENERATOR INSTRUMENT CONTROL PANEL
OPERATING INSTRUCTIONS
DESCRIPTION
The Generators Instrument Control contains a compact
gauge package, control rocker switches, circuit fuses, check
engine light, emergency stop toggle switch and a recording
hourmeter. These components are described below.
The 8 pin connector that is on the back
of the Control Box
is used to connect an optional remote start/stop panel or a
second instrument panel.
When
an optional panel is connected, the 8 pin connector
with jumper should be kept for future needs when
troubleshooting. Secure it to the lifting eye.
FUSES: The control box has two automotive type fuses. A
5 amp fuse protects the ECU and a 7.5 amp fuse to protect
the control circuit and instrument panel.
CHECK ENGINE LIGHT: The CHECK ENGINE LIGHT will
illuminate
if the engine shuts down. (Refer to the Safety
Shutdown in this manual).
EMERGENCY STOP: The EMERGENCY stop toggle switch
(Normally Closed)
is located at the side of the control box.
When depressed, it will open the DC circuit to the control
box. This switch can be used when servicing the unit to
prevent an unwanted start.
REMOTE PANEL PLUG-IN: A plug on the side on the control
box will allow for the remote mounting of the remote
instrument panel or the remote panel start/stop.
COOLANT TEMPERATURE: Engine coolant (water)
temperature should normally indicate: 175° to 195°F
(80o to 90°C).
ENGINE OIL PRESSURE: Oil Pressure (psi) may fluctuate
depending on the generator load but should range between
35 to 55 psi.
DC VOLTS: Indicates the amount the battery is being charged
and should show
13 V to 14 V.
HOURMETER: Registers elapsed time and is used as a guide
for when to perform scheduled maintenance.
PREHEAT: The PREHEAT rocker switch serves two purposes:
activates the preheat circuit and activates the K2 Run Relay.
This supplies power to the DC altemator R, fuel pump, ECU,
Instrument panel,
K3 Fault Relay pin #87 and Start toggle
switch.
START: The START rocker switch when pressed activates the
Kl Start Relay which activates the starter motor.
STOP: The STOP rocker switch when pressed and held,
opens the DC circuit supplying power to the K2 Run relay.
De-activating it and shutting down the engine drive.
7
THIS PANEL CAN ALSO BE
REMOTELY LOCATED, -REFER
TO THE FOLLOWING PAGE
NOTE: It is important to
closely monitorthe panel
gauges. Become aware
of
the nonnal engine readings
and take immediate action
if these readings start to Val)'·
STARTING/STOPPING INSTRUCTIONS
Depress the PREHEAT rocker switch for approximately 5-10
seconds. Then with the PREHEAT rocker still depressed,
depress the START rocker. When the engine starts, release
the START rocker.
Remote Control Panel: When the oil and voltmeter start to
register, release the Start rocker.
Continue to hold the PREHEAT rocker depressed until the
oil pressure reaches
10 psi. Then release the PREHEAT
rocker.
Once the generator has started, observe the meter readings
on the instrument panel. Ensure that raw water
is being
discharged with the exhaust. Apply a light amperage load on
the generator and allow it to warm up
to 140oF, then apply
your higher amperage loads as needed.
FAILURE TO START: Should the engine not start after the
START rocker has been depressed for
5-l 0 seconds, release
both rocker switches and wait 30 seconds and repeat the
above start procedure. Preheat a few seconds longer. Never
run the starter continually for more than 20-25 seconds.
STOPPING: To stop the generator, depress the STOP rocker
and hold it depressed, Release the STOP rocker when the
generator comes to a complete stop.
REMOTE CONTROL PANEL: Release the STOP rocker when
the oil and voltmeter stop registering.

OPTIONAL REMOTE CONTROL PANELS
OPERATING INSTRUCTIONS ,
DESCRIPTION
There are several options available when selecting remote
operation ofyour
generator.
1. Mount a second (repeating) Instrument Control Panel in a
remote location.
2. Simply remove_ the Instrument Control Panel from the
control box and mount it as a remote panel.
NOTE: The Instrument Control Panel can be replaced by
installing a basic start~~top panel in the control box.
3. Mount aremote start/stop control panel ina remote
location.
Remote panels connect to the 8pin plug on the back of
the control box using the extension harnesses listed below.
EXTENSION HARNESS
PNit056236 EG DIESEL (8 PIN) 15FT
PN1t056235 EG DIESEL (8 PIN) 30FT
INSTRUMENT ·.
CONTROL PANEL(AS A REMOTE PANEL)
PN56246
NOTE: When connecting aremote panel to the plug connector
on the back of the control box. DO NOT discard the plug with
jumper
found in this plug connector. Keep it with the ~it. Attach
itto
the rear lifting eye. It will be useful in troubleshootmg a DC/
running issue by eliminating the remote panel and returning this
plug with jumperto the connector.
REMOTE START/STOP PANEL • DESCRIPTION
The Remote Start/Stop Panel has the same three rocker
switches as the Instrument Control Panel. Their function is
the same. This panel has a RELEASE STARTER LED. This
LED will illuminate when the PREHEAT is depressed. When
this panel is remote mounted, this LED will indicate when
the generator has started. When depressing the START
rocker switch, this LED will dim. When the generator starts,
the
LED will brighten. This indicates to release the START
rocker switch. The PREHEAT rocker switch is held
depressed
for about 4-5 seconds to allow the oil pressure to
reach 10 psi, then release it.
For the REMOTE START/STOP PANEL wiring diagram
and wiring harness, refer to the Table ofContents.
REMOTE START/STOP PANEL
PN56320
Engines & Generators
8

SAFETY SHUTDOWN SWITCHES
DESCRIPTION
The engine is protected by a number of safety shutdown
features as described below. Should a shutdown occur, as a
result
of one of these features, the Check Engine LED will
illuminate. The cause should be determined using the
troubleshooting Diagnostic Software. Once corrected, the
ECU mustbe cleared of this fault by turning OFF the 20 amp
DC breaker and then back
ON in order to start the engine.
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Normally 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 tern-
perature (an inadequate supply ofraw water causes hjgh
exhaust temperatures). l'his switch opens at 260-270°F (127-
l320C}. This switch resets at approximately 225°F (l07°C).
·:;;::·-~:-
.~~'::---- .. EXHAUST ElBOW
//
Coolant Temperature Switch
h high coolant temperature switch is located on the thermostat
housing. Normally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C}, will open and intermpt the DC voltage to the K2
relay, thereby shutting offthe engine. This switch re&ets at
195°F (107°C).
THERMOSTAT
ASSEMBLY
9
low Oil Pressure Switcn
A low oil pressure shutdown switch is located off the engine's
oil gallery. Normally open.in a static state, this switch's sensor
monitors the engine's oil pre§sure. 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 off the engine.
fROM ENGINE
BLOCK
'(""".
OIL PRESSURE
SEtl!JOR
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
w~ng orengine wiring will cause the breaker to trip. In this
event the generator will shutdown and the voltage to the K2
relay is terminated. If this should occur, check and repair the
source ofthe problem. After repairing the fault; reset the
breaker and restart the generator.
Overspeed/Underspeed Shutdown
The unit's ECU is monitoring the engine speed via a signal
from the MPU (magnetic pick-up) positioned over the
fly
wheel's ring gear teeth. Should the engine speed reach a
programmed high rpm or low rpm, the ECU will shut the
engine down and the Check Engine LED will illuminate.

GENERATOR BREAK-IN PROCEDURE
DESCRIPnON
Although your engine has experienced aminimum of one
hour oftest 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 ofyour 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 ofinitial
conditioning operation
to break in each moving part in order
to maximize the performance and service life ofthe engine.
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% offull-load for the first 10 hours.
A CAUTION: Do not attempt to break·ln your
generator by running without a load.
After the first 10 hours ofthe 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 witll 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.
GENERATOR ADJUSTMENTS
Once the generator has l:!een placed in operation, there may
be adjdstments required for engine speed (hertz) during the
engine's break-in period (first 50 hours) or after this period.
A no-load voltage adjusunent may also be required in con-
junction with the engine's speed adjustmeqt See
GENERATOR INFORMATION in this mariual.
THE DAILY OPERATION
CHECKUST
·Follow this cheek listeach daY' before starting your generator.
0 Check th,at alJ...generator circuitbreakerS (power panel) are
in the offposition before starting.
0 Record the liourmeter reading inyour log (engine hours
relate to th~ maintenance schedule.)
0 VISually inspect the engine for fuel, oil, or water leaks.
0 Check the oil level (dipstick).
0 Checkthe coolant level in the coolant recovery tank.
0 eheckyour fuel supply.
0 Check the·starting.batteries (weekly).
0 Check drive belts for wear and proper tension (weekly).
CHECK WITH THE ENGINE RUNNING.
0 Checkfor abnormal noise such as knocking, vibrating and
blow-back sounds.
0 Confirm exhaust_ smoke:
When the engine is cold- Whlte Smoke. .
When the engine is warm- almost Smokeless.
When the engine is overloaded- some Black Smoke.
START THE GENERATOR
(See STARTING PROCEDURES on previous pages).
Allow the engine to wann up for 5 to 10 minutes to rea~h an
operating temperature of 140° to 150°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
temperature, and DC voltage. ·
. .
NOTE: Some unstable runn,ing may occur in !1 cold engine.
This condition should lessen as nonnal operating
temperature is reached and loads are applied.
A CAUTION: Oo not operate the generator for long
periods of time without a load being placed on the
generator. ·
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
10

MAINTENANCE SCHEDULE
WARNING: Nev8f attempt to perform any service while the engine is running. Wear the proper safety equipment such as goggles and
gloves, and use the correct tools for each job. When servicing/replacing DC components, tum off the Emergency Stop Switch on the
Control Box or tum off the DC battery.
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 of Engine
NOTE: Please keep engine suiface clean. Dirtandoil
will inhibit the engine's ability to remain cool.
Drive Belts
'INITIAL 50 HOURS OF OPERATION
Engine Oil and Filter
*Exhaust System
*Valve Adjustment
*Re-Torque Cylinderhead Hold Down Bolls
Inlet Fuel Filter
Fuel Filter
Generator
AC No-Load
I EVERY 50 OPERATING HOURS OR MONTHLY
Drive Bell
Starting Batteries
Electric Fuel Pump
Zinc Anode
I EVERY 100 OPERATING HOURS OR YEARLY
Engine Oil and Filler
Air Intake and Filter
EXPLANATION OF SCHEDULED MAINTENANCE
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Check for water and dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Use properly filtered #2 diesel with a Cetane rating of #45 or higher. Check that
. there is adeqilate fuel for the vessel's needs.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wiring and electrical
connections. Look for loose bolts/hardware and correct as needed.
Inspect for frayed edges. Belts must be properly tensioned.
Initial engine oil and filter change at 50 hours.
Check security of water injected exhaust elbow to exhaust manifold.
Ensure there are no leaks.
Check adjustment of valves.
Re-torque bolts, engine cold then check/adjust valve clearances.
Remove and replace inlet fuel filter.
Remove and replace fuel filter and all sealing O·rings.
Check that AC connections are secure with no chafing.
Check and adjust the no-toad AC output voltage as needed.
Inspect for proper tension (3/8" to 1/2' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte lev'els Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
your own inspection schedule.
Change engine oil and filter at 100 operating hours or yearly ..
Keep air intake clear of obstructions. Clean air filter and replace if needed.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
Engines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your engune hours running time.
SCHEDULED MAINTENANCE
I EVERY 250 OPERATING HOURS OR YEARLY
*Exhaust Elbow/Exhaust System
Fuel Filler and O·Rings
Inlet Fuel Filter
*Generator
Hoses
Fuel Water Separator Filter
DC Alternator
Impeller
EVERY 500 OPERATING HOURS OR FIVE YEARS
Raw Water Pump
Coolant System
*Valve Clearances
*Starter Motor
*Re· Torque Cylinderhead Hold Down Bolts
Pre-Heal Circuli
Fuellnjeclors
EXPLANATION OF SCHEDULED MAINTENANCE
Check the structual 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 leak will cause exposure to diesel exhaust!
Remove and replace fuel filter and all sealing 0-rings.
Remove and replace inlet fuel filter.
Check that AC connections are clean and secure. Ensure wires have no chafing.
See GENERATOR INFORMATION.
Engine heses should be firm and tight. Replace if hoses become spongy, brittle or
delaminated. Check and tighten all hose clamps as needed.
Inspect bowl for dirt or water in fuel. Drain and replace filter. .
Inspect wiring, connections should be tight. Alternator should be clean and free of corrision.
Check mounting bracket and alternator bolt. All should be tight.
Inspect the condition of the impeller, replace as needed.
Remove and disassemble the pump and inspect all parts: drive gear, pump shaft, wear plate
and cover for wear and corrosion. Replace the impeller and gasket. Lubricate the impeller
at re-assembly.
Drain, flush and re-fill the cooling system with appropriate antifreeze mil<. Inspect the
condition of the sealing gaskets of the pressure cap. Clean out coolant recovery tank
and connecting hose.
Adjust valves. (Incorrect valve clearance will result in poor engine performance.)
Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the starter
motor pinion drive.
Re-torque bolts, engine cold then check/adjust valve clearances.
Check operation of preheat solenoid. Remove glow plugs, clean tips and check operation.
Check and adjust injection opening pressure and spray conditions.
EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS
Heat Exchanger
Remove the heat exchanger for professional cleaning and pressure testing.
*MPU (Magnetic Pick-Up)
Remove, check and clean any metal debris from the tip of the MPU.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.

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 ofa heat
exchanger, similar in function to an automotive radiator. Raw
water
flows through the tubes ofthe heat exchanger while
fresh water coolant flows around the tubes; engine heat trans-
ferred to the fresh water coolant is conducted through the
tube walls to the raw water which is then pumped into the
exhaust system where finally it is discharged overboard. In
other words, the engine is cooled by fresh water coolant, this
coolant
is cooled by raw water, and the raw water carries the
transferred heat overboard through the exhaust systep:t. The
fresh water coolant and raw water circuits are independent of
each
other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.
FRESH WATER COOLING CIRCUIT
NOTE: Refer to the ENGINE COOIANI' section for the rec-
ommended antifreeze and water mixture to be used as the
fresh water coolant.
F~sh water coolant!spumped 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 exchanger
wheJ;e it is cooled, and returned to the en!rine
block via the suction side ofthe circulating pump. o
ENGINE BLOCK COOLANT DRAIH
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
Acoolant 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.
13
A CAUTION: Proper cooling system maintenance Is
critical; a substantial number of engine failures can be
traced back to cooling system corrosion.
Drain the engine coolant by loosening the drain plug on the
engine block and opening the manifold pressure cap. Flush
the system with fresh water, then start 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.

COOLING SYSTEM
Refilling the Coolant
After replacing the engine block drain plug, close the heat
exchanger's coolant petcock. Then pour clean, premixed
coolant and when the coolant
is visible in the manifold, start
the engine.
NOTE: When present, open the air-bleed petcock on the heat
exchanger. When a steadyflow
of coolant appears at the
petcock, close it
and continue to fill the cooling system.
Monitor the coolant in the manifold and add as needed. Fill
the manifold to the filler neck and install the manifold pres-
sure cap.
Remove the cap on the coolant recovery tank and fill with
coolant mix to halfway between LOW and MAX and replace
the cap. Run the engine and observe the coolant expansion
flow into the recovery tank.
After checking for leaks, stop the engine and allow it to cool.
Coolant should draw back into the cooling system as the
engine cools down. Add coolant to the recovery tank if
needed. Clean up any spilled coolant.
TO COOLANT
RECOVERY TANk
COOLANT RETRACTION
NOTE: Periodically check the condition of the manifold pres-
sure cap. Ensure that the upper and lower rubber seals are in
good condition and check that the vacuum valve opens and
closes tightly. Carry a spare cap.
SEALS
THERMOSTAT
A thermostat, located near the manifold at the front of the
engine, controls the coolant temperature as the coolant contin-
uously flows through the closed cooling circuit. When the
engine is first started, the closed thermostat prevents coolant
from flowing (some coolant is by-passed through a hole in the
thermostat to prevent the exhaust manifold from overheating).
As the engine warms up, the thermostat gradually opens. The
thermostat is accessible and can be checked, cleaned, or
replaced easily. Carry a spare thermostat and gasket.
Replacing the Thermostat
Remove the cap screws and disassemble the thermostat hous-
ing as shown. When installing the new thermostat and gas-
ket, apply a thin coat of sealant on both sides of the gasket
before pressing it into place. Do not over-tighten the cap
screws.
Run the engine and check for normal temperatures and that
there are no leaks at the thermostat housing.
THERMOSTAT
ASSEMBLY
RAW WATER COOLING CIRCUIT
BLEED
PET COCK
The raw water flow is created by a positive displacement
impeller
pump. This pump draws water directly from the raw
water source (ocean, lake, or river) through a hose to the
water strainer. The raw water passes from the strainer
through
the raw water pump to the heat exchanger (through
the heat exchanger tubes) where it cools the engine circulat-
ing fresh water coolant. The raw water is then discharged
into the water-injected exhaust elbow, mixing with and cool-
ing the exhaust gasses. This mixture ofexhaust gas and raw
water is discharged overboard by the engine's exhaust gas
discharge pressure.
Raw Water Pump
The raw water pump is a self-priming, rotary pump with a
non-ferrous housing and a neoprene impeller. The impeller
has flexible vanes which wipe against a curved cam plate
within the impeller housing, producing the pumping action.
On no account should this pump be run dry as water acts as a
lubricant
for the impeller. There should always be a spare
impeller and impeller cover gasket (an impeller kit) aboard.
Raw water pump impeller failures occur when lubricant (raw
water) is not present during engine operation. Such failures
are not warrantable, and operators are cautioned to make sure
raw water flow is present at start-up.
NOTE: Should afailure occur with the pumps internal parts
(seals and bearings), it may be more cost efficient to pur-
chase a new pump and rebuild the original pump as a spare.
14