Westerbeke 20.0 BEDA User manual

OPERATORS MANUAL
.MARINE DIESEL GENERATORS
20.0 BEDA 60 Hz 16.0 BEDA 50 Hz
25.0 BED 60Hz; 20· .. 0· BED 50 Hz
32.0 BEDA 60 Hz 25.0 BEDA 50 Hz
· Single and Three Phase ·
PUBLICATION. N0.039685
REVISIONS
AUGUST 2017
WcSTERBEKECORPORATiON •1SOJ0HNHANCOCK ROAD
MYLES STAND{.S,f! INDUSTRIAL PARK • TAUNTON MA 02780
'WEBSITE; WWW.WESTERBEKE.COM '
,«"""' .....
.....,'A(1f.A Member National Marine Manufacturers Association

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 poif¥Jnous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
•Dizziness
•Nausea
•Headache
• Weakness and Sleepiness
• Throbbing in Temples
• Muscular Twitching
• Vomiting
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit _and do not restart
until it has been inspected and repaired.

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis sqfety manual carefully. Most accidents are
caused by failure to foUow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protect yourself, your .
personne~ andyour machinery.
The following safety instructions are in compliance with
theAmerican Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine Is running. or when connected to shore
power. Lethal voltage Is present at these connections/
11 Do not operate this machinery without electrical
enclosures and covers in place.
11 Shut offelectrical power before accessing electrical
equipment.
II Use insulated mats whenever working on electrical
equipment.·
II 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 parts or
exhaust system components. A running engine gets very
hot/
11 Monitor engine antifreeze coolant level at the plastic
coolant
recovery tank and periodically 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/
Ill! In case ofan 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!
11 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 of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
m Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
II!! Do not smoke or pennit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
l!il Be aware- diesel fuel will burn.
PREVENT BURNS -EXPLOSION
A WARNING: Explosions from fuel vapors can cause
Injury or death/
I!Rl Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
II!! All fuel vapors are highly explosive: Use extreme care
when handling and storing fuels. Store fuel in a well-
ventilated area away from spark-pr9ducing equipment
and out of the reach of children.
!FJ Do not fill the fuel tank(s) while the engine is runnir!g.
~ Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO Nar allow any smoking;· open flames, or other
sources of fire near the fuel system qr engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
l1ll Do not alter or modify the fuel system.
mBe sure all fuel supplies have a positive shutoff valve.
rm Be certain fuel line fittings are adequately tightened and
free ofleaks.
~ Make sure a fire extlDguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the Nf.PA are appropriate
for all applications encountered in this environmen~.
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
111 1\Jrn OFF the DC breaker on the control panel or turn the
unit's battery selector switch to OFF before servicing the
engine.
111 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.
BATTERY 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, ~
highly explosive gas, which can be ignited by elec~cal
arcing or by lit tobacco products. Shut o~ all ele~tncal
equipment in the vicinity to prevent electrical arcmg
during servicing.
a Never connect the negative(-) battery cable to the
positive (
+) connection terminal of the starter solenoi~.
Do not test the battery condition by shorting the temunals
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.
a Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the
battery.
111 Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when servicing the battery.
BATTERY ACID
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
protection. 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!
IB 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 manifold/
water-injected elbow is securely attached.
a Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
a Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder or dealer for installation of approved
detectors.
IB For additional information, refer to ABYC lli-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) Is an Invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
a Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water leakage.
11 Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. Avoid overloading the craft.
1111 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
symptoms or signs of carbon monoxide inhalation or
poisoning are:
Vomiting
Dizziness
Headache
Inability to think coherently
Throbbing in temples
Muscular twitching
Nausea
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death/
111 Do not service the engine while it is running. If a
situation arises
in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
ii

SAFETY·INSTRUCTIONS
1111 Do not wear loose clothing orjewelry when servicing
~quipment; avoid wearing loose jackets, shirts, sleeves,
nngs, necklaces or bracelets that could be caught in
. moving parts.
Ill Make sure all attl:!-ching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times. ·
II Do not check ~uid levels or the drive belt's tension while
. the engine is operating.
1111 Stay clear of the drive shaft and the transmission coupling
when the engine is running; nair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High nolsel~vels can caus11 hearing
loss/
1111 Never operate an engine without its ·muffler installed.
111 Do not run an engine with the air intake (silencer)
removed
A WARNING: Do not work on machinery when you are
mentally or physically Incapacitated by fatigue!
I!IIPE~TORS MANUAL
·Many of the preceding safety tips and warnings are1"epeated
in your Operators Manual along withother cautions and
notes to highlight critical information. Read your manual
carefully, m~ntain your equipment, and follow all safety
procedures.
ENGINE AND GENERATOR BNSTALII.ATDONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) stanclar.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).
AIBYC, NFIP'A ANIDl USCG IP'UBH.HCATIONS !FOR
.. DNSTAB.I!.ING MARINE !ENGINES AND GIENERA'II'ORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your UNlVBRSAL engine
ABYC (American Boat and Yacht Council)
"Safety Standari:ls for Small Craft" ·
Order From:
ABYC
613 Third Dtreet, Suite 10
Annapolis, MD 21403
( 41 0) 990-4460
· www.abycinc.~rg
NFPA (National Fire Protection Association)
"Fire Protection Standardfor Motor Craft"
Order From:
NFPA
1 Battecymarch 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
•••
HD

INSTALLATION
When installing WESTERBEKEengines and generators it is important that strict
attention be paid
to the following information:
CODES AND REGULATIONS
Strictfederal 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 exhaustelbow. This hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection porl is at or below the load waterline wiU result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative '
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation.
Failure to properly maintain a siphon-break can result in catastrophic
engine
damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
. AVAILABLE FROM
YOUR WESTERBEKE
·'DEALER
\"sJPHON~MEAKWlTHSTAINLESS
LOOP'
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust Hose is recommended. The use
of this type of hose allows for extreme bends
and turns without the need
of additional fitting and clamps to accomplish these bends
and turns. In this regard, a single length
of corrugated exhaust hose can be used. The
system
MUST be designed to prevent the entry of water into the exhaust system
under any sea conditions and at any angle
of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Introduction ...................................................................... .2 Fuel Filters .................................................................17
Warranty Procedures ....................................................2
Customer Identification Card.......................................2 Changing the Fuel Filters....................................17
Feed Pump Strainer (32 KW) ....................................17
Product Software..........................................................2 Bleeding the Fuel System ..........................................18
Notes, Cautions and Warnings .....................................2
Serial Number Location..............................................
.3
Fuel Pressure Gauge...................................................18
Fuel Additives ............................................................18
Understanding the Diesel Engine................................
.3
Ordering Parts ..............................................................3 Spares.........................................................................
l8
Engine Oil Change .......................................................... 19
Spares and Accessories ................................................3 Engine Oil Change.....................................................19
Control Panels ................................................................. .4 Oil Pressure................................................................19
Main Panel ...................................................................4
Remote Oil Filter ............................................................ 2o
Remote Panel ...............................................................4 Installation..................................................................20
Diesel Fuel, Engine Oil and Engine Coolant ............... 5 DC Electrical System ..................................................... 21
Diesel Fuel ...................................................................5 Engine 12 Volt
DC Control Circuit............................ 21
Care Of The Fuel Supply .............................................5 Battery Specification ..................................................
21
Engine Oil ................................................................... .5 Battery Care ............................................................... 21
Oil Pressure .......................................................,..........5 Glow Plugs .................................................................
21
Engine Coolant.............................................................5
Coolant Recovery Tank................................................5
Preparations for Initial Start-Up ................................... 6
DC Electrical System/Aiternator .................................. 22
Troubleshooting..........................................................22
Testing the Alternator.................................................22
Prestart Inspection........................................................6
Generator Voltage.........................................................6
Starting/Stopping Procedure .......................................... 7
DC Electrical System Wiring Diagram ........................ 24
DC Electrical System Wiring Schematic .................... 25
Remote Start/Stop Panel ............................................... 25
The Starting System.....................................................7
Electronic Governor ....................................................... 26
Remote Starting Procedure ..........................................7
Troubleshooting the Electronic Governor .................. 27
Starting Under Cold Conditions...................................8
Stopping Procedure ......................................................8
Remote Stopping Procedure.........................................8
Safety Shut down Switches..........................................8
High Exhaust Temperature Switch .......................8
High Water Temperature Switch...........................8
Low Oil Pressure Switch ......................................8
Engine Circuit Breaker .........................................8
Generator Break-In Procedure ....................................... 9
Description ...................................................................9
After Start-up ...............................................................9
Check List ....................................................................9
Generator Adjustments.................................................9
The Daily Routine ........................................................... 10
Check List ..................................................................10
Start the Generator .....................................................
10
Maintenance Schedule .................................................. ll
Engine Cooling Circuit. .................................................. 13
Description .................................................................13
Fresh Water Circuit ....................................................14
Coolant Recovery Tank.......................................14
Engine Adjustments ....................................................... 28
Valve Clearance Adjustment ......................................28
Drive Belt Adjustment ...............................................28
Torquing Cylinder Head Bolts ...................................29
Engine Compression ..................................................29
Testing the Fuel Injectors...........................................29
Inspecting the Spray Pattern ......................................30
Engine Troubleshooting ............................................... ..31
Troubleshooting Water Temp. and Oil Gauges..........32
Generator Information .................................................. .33
Use of Electric Motors ...............................................33
The BE Generator .......................................................... .34
Internal Wiring Schematics........................................35
Generator AC Voltage Connections ........................... .36
BE Three Phase (Six Wire) ........................................37
BE Three Phase (Twelve Wire)..................................37
Voltage Regulator Adjustments ................................... 38
BE Troubleshooting ...................................................39
Shore Power Transfer Switch ...................................... .40
Lay-Up and Recommissioning ..................................... .41
Changing Coolant.......................................................14
Specifications 20 KW BEDA Generator ...................... 43
To Refill the Coolant...........................................14
Thermostat..................................................................14
To Replace The Thermostat................................14
Raw Water Cooling Circuit........................................14
Raw Water
Pump ................................................14
Specifications 25 KW BED Generator ........................ .45
Specifications 32 KW BEDA Generator ..................... .47
Photo Identification 20 KW ......................................... .49
Photo Identification 25 KW ......................................... .so
Changing the Raw Water Pump Impeller...........14
Heat Exchanger ..........................................................14
Zinc Anode..........................................................14
Heat Exchanger Service......................................14
Fuel System ..................................................................... 16
Photo Identification 32 KW ......................................... .51
Torque Specifications ..................................................... 52
Standard Hardware Torques ......................................... 53
Metric Conversions ........................................................ 54
Diesel Fuel .................................................................16
Suggested Spare Parts .................................................. 55
Fuel Water Separator..................................................16
Fuel Lift Pumps..........................................................16
Fuel Injection Pump...................................................16
Engines & Generators
1

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKE's long years of experience and advanced
technology. We take great pride in the superior durability and
dependable performance
of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator it
is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout. Should your generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This is your operators manual. 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 of submitting 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
/-.rAT/ WESTERBEKE
I
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model 32 BEDA Ser. #UOOOO-D702
Expires 4/4/98
The WESTERBEKE serial number is
an alphanumeric
number that can assist in determining the date
of manufac-
ture
of your WESTERBEKE engine or generator. The manu-
facturer's date code
is placed at the end of the engine serial
number and consists
of a character followed by three
numbers. The character indicates the decade.
(A= 1960s,
B = 1970s, C = 1980s, D = 1990s, the first number represents
the year in the decade and the second and third numbers the
month
of manufacture.
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDINGACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings
of WESTERBEKE product
software and the unavoidable existence
of earlier
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
of your marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operatingprocedure essential to note.
A CAUTION: Procedures, which It not strictly
observed, can result In the damage or destruction of
your engine.
A WARNING: Procedures, which If not properly to/·
lowed, can result In persona/Injury or loss of lite.
Engines &Generators
2

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 and/or ordering repair parts.
SPECIFICATION
MODEL _______ _
RPM __________ _
KW ___________ _
KVA -----------
VOLTS---------
AMPS ---------
ENG. HP -------
ENG. SER. NO.
GEN. SEA. NO.
PF/PHASE ----
WIRES ________ _
RATING _______ _
INSUL ClASS __
TEMP. RISE ----
BATTERY------
C.t.D. ----------
50 HZ.
60HZ.
I
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.
An identification plate on the engine manifold also displays
the engine model and 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 of a gasoline engine; and the
diesel engine has the same types
of valves, 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 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 parts are needed, always provide the
generator model number, engine serial number, and generator
serial number as they appear on the silver and black name
plate located on the generator end.
You must provide us with
this information so we may properly identify your generator
set. In addition, include a complete part description and part
number for each part needed (see the separately furnished
Parts List). Also insist upon WESTERBEKE packaged parts
because 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 WESTERBEKE
dealer will assist you in preparing an inventory
of spare parts.
See the
SPARE B4RTS page in this manual. For Engine and
Generator Accessories, see the ACCESSORIES brochure.
Engines & Generators
3

CONTROL PANELS
MAIN PANEL
This manually-controlled WESTERBEKE diesel generator is
equipped with toggle switches
on the engine's control panel
and, optionally, at a remote panel. All three switches are
momentary contact type and serve the following functions:
1. PREHEAT: The PREHEAT toggle switch is a double-pole,
single-throw switch.
The switch serves two purposes: pre-
heating the engine for easy starting and defeating or bypass-
ing the engine's protective oil pressure switch. The defeat
function activates the fuel solenoid, instrument power, alter-
nator excitation, electronic governor and provides power to
the STARTswitch.
2. START: The START toggle switch is a double-pole, single-
throw switch. The switch, when activated, energizes the
starter solenoid for starting the engine.
This switch will not
operate electrically unless the PREHEAT switch is depressed
and held at the same
time.
3. STOP: The STOPtoggle switch is a single-pole, single-
throw, normally closed switch. This switch provides power to
the fuel solenoid, and the instrument cluster, after the oil
pressure switqh hasclosed upon engine starting. Opening
of
this switch opens the power circuit to the fuel solenoid,
thereby stopping the fuel flow
to the injection pump and
stopping the engine.
WATER TEMPERATURE GAUGE: ENGINE
COOLANT. TEMPERATURE. SHOULD INDICATE
1W.T0·1-95°F (80° TO 91°C).
NOTE: When the engine is shiP down, the water temperature
gauge and the oilpressure gauge will continue
to register the
last temperature and oilpressure readings displayed. They
will return to zero once electricalpower is restored.
4. EMERGENCY STOP: The EMERGENCY stop switch at the
rear
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.
REMOTE START/STOP 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 STOPswitch and
serves the same function.
0
@
RELEASE
STARTER
MUST~
PRESS.
FIRST
t'W'JMi' .......
0
STOP
~
START
A PRESS
~2ND
GENERAToR
o·
REMOTE PANEL (OPTIONAL)
CONTROL PANEL
1
2
DC VOLTMETER: INDICATES THE AMOUNT THE.
BATIERY IS BEING CHARGED. SHOULD SHOW
13VTO 14V.
Engines &Generators
4
0
mL PRESSURE: ENGINE LUBRICATION OIL
PRESSURE- THE NEEDLE WILL FLUCTUATE
DEPENDING ON LOAD, BUT SHOULD INDICATE
50 TO 57 PSI (3.5 TO 4.5 KG/CM).
. HOURMETER: REGISTERS ELAPSED TIME, AND
SHOULD BE USED AS A GUIDE FOR THE
MAINTENANCE SCHEDULE.

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 pruticles which might pass through the primary and sec-
ondary filters can damage these finely machined pm1s. 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 ensure 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 gro\Yth in the fuel tank is
recommended such as Bio-Bor and an additive such as
Diesel Kleen +· Cetane Boost. to help restore lubricity back
into the diesel fuel when an Ultra Low Sulfur diesel is being
used.
Install and regulru·Iy service a good, visual-type fuel
filter/water separator between the fuel tank and the engine.
The Raycor 500 MA or 230 RMAM are good examples of
such filters. A 10 micron filter element is recommended.
ENGINE OIL
Use a heavy duty diesel oil with an API classification of CF,
CG-4, CH-4 or Cl-4. Change the engine oil and filter after an
initial 50 itours ofbreak-in operation.Then follow the oil and
filter change intervals as specified in the MAINTENANCE
SCHEDULE in this manual. Westerbeke Corporation does
not approve or disapprove the use ofsynthetic oils. If
synthetic
oils are used, engine break-in must be performed
using conventional oil. Oil change intervals must be as listed
in the MAINTENANCE SCHEDULE section of this
manual and not be extended if synthetic oils are used.
NOTE: The information above supersedes all previous
statements regarding synthetic oil.
SAE OIL VISCOSITY
For all temperature ranges: SAE lSW-40 or SAE lOW-40.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze performs double duty. It allows the engine to
run at proper temperatures by transferring heat away from
the engine to the coolant, and lubricates and protects the
cooling circuit from rust and corrosion. Look 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: Look for the new environmentally-friendly long lasting
antifreeze that is now available.
. PURCHASING ANTIFREEZE
. Select abrand ofantifreeze specified for diesel engines.
Antifreeze specified for diesel engines contains a special
additive to protect against cavitation erosion of the engine's
cylinder walls. Prestone andZerex are two nationally known
brands that offer antifreeze specifically for use indiesel
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 SCHEJ?ULE 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 iife.
COOLANT RECOVERY TANK
The coolant recovery tank allows for the expansion and
contraction of the engines coolant during engine operation
without introducing 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.
r
NOTE: 771is tank, •vith its short run of plastic hose, is best
located at or above the level of the engines manifold, but it
can be located below the level of the engines manifold if the
particular installation makes this necessary.
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
This section of the manual provides the operator with prepa-
ration, initial starting, break-in, starting (warm
or cold) and
stopping procedures. Follow the procedures as presented for
the conditions indicated and your WESTERBEKE generator
set will give reliable performance and long service life.
Before starting your generator set for the first time
or after a
prolonged layoff, check the following items:
0 Check the engine oil level. Add oil to maintain the level
at the high mark
on the dipstick.
0 Check the fuel supply and examine the fuel filter/separa-
tor bowls for contaminants.
0 Check the DC electrical system. Inspect wire connections
and battery cable connections. Make certain the (+) bat-
tery cable is connected to the starter solenoid and the
negative(-) cable is connected to the engine ground stud
(this location is tagged).
0 Check the coolant level in both the plastic recovery tank
and at the manifold.
0 Visually e_~ine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections.
0 Check load leads for correct connection as specified in
the wiring diagrams.
0 Examine air inlet and outlet for air flow obstructions.
0 Be sure no other generator or utility power is connected
to load lines.
0 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 and some
3-phase systems an incomplete
or open neutral can sup-
ply the wrong line-to-neutral voltage
on unbalanced
loads.
0 Make sure the mounting installation is secure.
0 Make sure that the generator is properly grounded.
MANIFOLD PRESSURE CAP
ENGINE OIL FILL
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.
GENERATOR VOLTAGE
The speed of the generator engine is adjusted at the factory,
however, it is advisable to verify.
To supply 60 hertz, the speed should be 1800 rpm at no-
load, and should not fall below 1800 rpm by more than .005
percent .3 Hz at full-load.
To supply
50 hertz, the speed should be 1500 rpm at full-
load. Generator voltage should build to its rated value within
5 seconds after rated speed is attained. Record orobserve the
voltage
of the generator at no-load and at full-load (hot). The
voltages are easily adjusted to optimum values no-load and
full-load (refer to
VOLTAGE ADJUSTMENTin this manual).
If possible, apply actual service load or test load of the same
powerfactor
as the load to be used in service. If the voltage
ca011ot be adjusted to suitable values and a fault seems evi-
dent, contact your authorized WESTERBEKE service dealer.
DIPSTICK
2DKW
•DIPSTICK
32KW
DIPSTICK
25KW
j...,.,IWESTERBEKE
) Engines & Generators
6

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
Westerbeke diesel generators use electric starters assisted by
glow plugs for both nonnal and cold weather starting. The
illustration
below shows a cross-sectional view ofone 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 WES1ERBEKE diesels. The start
circuitry
is designed so that the PREHEAT button must be
depressed for 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 STARTswitch will not energize unless the PRE-
HEAT switch is depressed. Depressing the PREHEAT switch
activates
the glow plugs in the cylinder head so use the PRE-
HEAT intermittently to avoid overheating the glow plugs.
• GLOW
An air intake heater is used in place of glow pings on the
32 KW generator. The preheat sequence described is the
same.
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: :
Temperature/Preheat
Atmospheric Temperature Preheating Tillie
+41 •f( +5"C). or higher
Approx. 10 seconds
+41"F( +5.C) to 23~f ( -s·c)
Approx. 15 seconds
+23.F(-5"Cf 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
15 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 preheat switch
is depressed.
Should the engine not start when the START switch is
depressed for 10 to 20 seconds, release both switches and
wait 30seconds; repeat the procedure above and preheat
longer. Never run the starterfor more than 30 seconds.
A CAUTION: Prolonged cranking Intervals without the
engine starting 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 cool-
Ing system during cranking. This raw water can enter the
engine's cylinders by way of the exhaust manifold once
the exhaust system fills. Prevent this from happening by
closing the raw water supply through-hull shut-off,
f/ralnlng the exhaust muffler, and correcting the cause
of the excessive engine cranking. Engine damage result-
Ing from raw water entry Is not a warrantable Issue; the
owner/operator should keep this In mind.
Remote Starting Procedure
The remote start panel is the same ~s 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 ofthe generator may not be audible.
A. When the PREHEAT switch 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 12V 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 load
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 PREHEATswitchfor 10-15 second intervals
will help stabilize the engine rpm until the operating
temperature reaches 140- 150° F and a load is applied to
the engine.
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.
Engines & Generators
7

STARTING/STOPPING PROCEDURE
STARTING UNDER COLD CONDITIONS
Make sure the lubricating oil conforms 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
Temperature/Preheat 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 sta-
bilize 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 normally closed
~+ path for
voltage to the engine's run circuit. The STOP
switch must be held open until the generator
comes to a complete stop.
NOTE: The generator is stopped when the electric
solenoid mounted on
the injection pump is
de-energized shutting off
the flow of fuel (Models 20 KW
and 25
/Gl1). The 32 KWGenerator is
shutdown by an electric fuel solenoid that is
attached to a lever on the fuel injection pump.
SAFETY SHUTDOWN SWITCHES
The engine is protected by three automatic shut-
down switches. Should shutdown occur, do not
attempt
to restarl withoutfinding and correcting
the cause. Refer to 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. Normally closed, this switch will open and interrupt _
the DC voltage to the fuel solenoid on the injection pump ·
(shutting OFF the engine) should the switch's sensor indicate
an excessive exhaust temperature (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 (107°C).
HIGH EXHAUST
TEMPERATURE
SWITCH
High Water Temperature Switch
A high water 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 interrupt the
DC voltage to the fuel
solenoid
on the-injection pump, thereby shutting off the
engine. This switch resets at 195°F (107°C).
HIGH WATER
TEMPERATURE SWITCH
Low Oil Pressure Switch
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 pressure. Should the
engine's oil pressure fall to 5-10 psi;: this switch will open
interrupting the
DC voltage to the fuel solenoid on the injec-
tion pump, thereby shutting off the engine.
OIL
PRESSURE
'SWITCH -· --s;;::og.
LOW OIL PRESSURE SWITCH
[20 KW SHOWN]
Engine Circuit Breaker
. OIL PRESSURE
SENDER
The generator's engine is proiected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw
or electrical overload anywhere in the instrument panel
wiring
or engine wiring will cause the breaker to trip. In this
event most generators will shut down because the opened
breaker disconnects the fuel supply.
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
8

GENERATOR BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour
of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-
ated properly, a break-in time is required. The service life of
your engine is dependent upon how the engine is operated
and serviced during its initial hours
of use.
Breaking-in a new engine basically involves seating the pis-
ton 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 full-load for the first 10 hours.
A CAUTION: Do not attempt to break-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 1500rpm to produce
50 Hertz), control of the generator's break-in is governed by
the current drawn from the generator.
CHECK THE FOLLOWING
D Monitor the control panel gauges.
D Check for leaks of fuel and engine oil.
D Check for abnormal noise such as knocking, friction,
vibration and blow-back sounds.
D 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 motor starting loads and the high current
draw requiredfor 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. See
GENERATOR INFORMATIONin this manual.
Engines & Generators
9

THE DAILY OPERATION
CHECK LIST
Follow this check list each day before starting your generator.
0 Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
0 Visually inspect the generator for fuel, oil, or water leaks.
0 Check the oil level (dipstick).
0 Check the coolant level in the coolant recovery tank.
0 Check your diesel fuel supply.
0 Look for clean fuel in the fueVseparator transparent bowl.
0 Check for loose wires at the alternator.
0 Check the starting batteries (weekly).
0 Check drive belts for wear and proper tension (weekly).
START THE GENERATOR
(See STARTING PROCEDURES on previous pages).
Allow the engine to warm up for 5 to 10 minutes to reach
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 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 SWPPING PROCEDURES on previous pages.)
Engines & Generators
10

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the co«ect tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenance jobs are simple but others are more
difficult and may require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH EXPLANATION OF SCHEDULED
DAY
50 100 250 500 750 1000 1250 MAINTENANCE
D
Diesel No. 2 rating of 45 cetane or higher.
D
Check for water and dirt in fuel (drain/replace filter
if necessary).
D
Oil level should indicate between MAX. and LOW on
dipstick.
D
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
D
Inspect for proper tension (3/8" to 1/2" deflection)
weekly
and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine
D
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
D D D 0 D D
Initial change at 50 hrs, then change every 250 hrs.
Starting BaHeries
D
Every 50 operating hours check electrolyte levels
(and House BaHeries) weekly
and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil (and filter)
D D D D D D D
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 0 0 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)
required (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 D
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 D D 0 D 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Engines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hour meter gauge to log your engine hours or record your
engine hours
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 when reassembling.
Coolant System
0 0
Drain, flush, and refill cooling system with appro-
priate antifreeze mix.
Electric Fuel lift 0 0 0 0 0 0
Initial filter change at 50 hours, then change
Pump Filter (if applicable)
filter every 250 hours.
DC Alternator
0 0 0
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
Feed Pump Strainer
0 0 0 0 0
Clean every 250 operating hours.
(if applicable)
*Fuel Injectors
0
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.
*Engine Cylinder
0 0
Check compression pressure and timing (see
Compression
ENGINE 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.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
12

ENGINE COOLING CIRCUIT
DESCRIPTION
Westerbeke marine diesel generators are designed and
equipped for fresh water cooling. Heat produced in the
engine by combustion and friction is transferred
to fresh
water coolant which circulates throughout the engine. This
circulating fresh water coolant cools the engine block and its
internal moving parts. 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 system. The
fresh water coolant and raw water circuits are independent
of
each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.
Fresh Water Circuit
NOTE: Refer to ENGINE COOLANT section for the recom-
mended antifreeze and water mixture to be used as the fresh
water coolant.
Fresh water coolant is pumped through the engine by a circu-
lating pump, absorbing heat from the engine. The coolant
then passes through the thermostat into the manifold, to the
heat exchanger where it
is cooled and returned to the engine
block via the suction side of the circulating pump.
COOLANT RECOVERY TANK
TYPICAL ENGINE
COOLING CIRCUIT
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
of coolant and without introducing air into the cool-
' ing system. This tank should be located at
or above the
engine manifold level and should be easily accessible.
,CHANGING COOLANT
The engine's coolant must be changed according to the
MAINTENANCE SCHEDULE. Ifthe coolant is allowed to
become contaminated,
it can lead to overheating problems.
A CAUTION: Proper cooling system maintenance is
critical; a substantial number of engine failures can be
traced back to cooling system corrosion.
Drain the engine coolant by loosening the drain plug on the
engine block and opening the manifold pressure cap. Flush
the system with fresh water, then start the refill process.
NOTE: The drain plug on the heat exchanger can also be used
to drain engine coolant.
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.
THERMOSTAT
·HOUSIN.G
COOLANT Q
Engines & Generators
..
13

ENGINE COOLING CIRCUIT
Refilling the Coolant
After replacing the manifold drain plug, run the engine at
idle and slowly pour clean, premixed coolant into the mani-
fold.
NOTE: When a steady flow of coolant appears at the heat
exchanger drain plug opening, close the drain
plug andfill
the system until the manifold remainsfull.
Monitor the coolant
in the manifold and add as needed. Fill
the !llanifold 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 imd 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.
COOLANT RETRACTION
TO COOLANT
RECOVERY
TANK
INSPECT AND CLEAN
THE COOLANT RECOVERY
TANK AND ITS CONNECTING
HOSE EVERY 3 MONTHS
----- MANIFOLD PRESSURE CAP
COOLANT EXPANSION
NOTE: Periodically check the condition of the manifoldpres-
sure cap. Ensure that the upper and lower rubber seals are in
good condition and check that the vacuum valve opens and
closes tightly. Carry a spare cap.
THERMOSTAT
A thermostat, located near the manifold at the front of the
engine, controls the coolant temperature, as it continuously
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 overheat-
ing); 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 gasket
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.
TO MANIFOLD
RAW WATER COOLING CIRCUIT
/ AIR BLEED PETCOCK
\~'----COOLANT
TEMPERATURE
SWITCH
The raw water flow is created by a positive displacement
impeller pump. This pump draws water directly from the
ocean, lake, or river through a hose to the water strainer. The
raw water passes from the strainer through the heat
exchanger (through the heat exchanger tubes) where
it cools
the engine circulating fresh water cqolant. The raw water
is
then discharged into the water injected exhaust elbow, mix-
ing with and cooling the exhaust gasses. This mixture
of
exhaust gas and raw water is discharged overboard.
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 aboard (an impeller kit).
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 a failure occur with the pump's internalparts
(seals and bearings) it may be more cost efficient to purchase
a new
pump and rebuild the original pump as a spare.
Engines & Generators
14