Westerbeke 7.6 EGTD User manual

OPERATORS MANUAL
. .
7.6 E GTD 60HZ
5. 7E GTD 50HZ
MARINE DIESEL GENERATORS
· SIN E HASE
REVISIONO
JULY 2016
l..,_. rWESTERBEKE
j WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD
I MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE: WWW. WESTERBEKE.COM
..,_..,Air
NMMA Member NIJJional Marine Manufacturus 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 Monox/1111/s poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can Include:
• Dizziness
•NauSBa
• HtJadache
• Throbbing In Temples
• Muscular Twitching
• Vomiting
• Weakness and Sl1111plness •Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
Sllllk medical aflllllt/QII. Shut down the. unit and do not restart.
until It has been Inspected and repalflld.
This WARNING DECAL Is provided by
WESTERBEKE and should be nxed to a
bulkhead near your engine or generator.
WE_STERBEKE also recommends Installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quaders of your vessel.
They are Inexpensive and easily
obtainable at your local marine store.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefuUy. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protect yourself, your
personne4 and your machinery.
The foUowing safety instructions are in compliance with the
American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: liD not touch AC electrical t:Dilllet:tiiJIIS
while engine is runolng, or when connected tD shore
power. Lethal voltage Is preseot at these connections!
• Do not operate this machinery without electrical
enclosures and
covers in place.
• Shut offelectrical power before accessing electrical
equipment
• Use insulated mats whenever working on electrical
equipment
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
PREVENT BURNS- HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets very
hot!
• 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 t:aUse injury or death!
• In case of an engine overheat, allow the engine to cool
before touching
the engine orchecking the coolant.
PREVENT BURNS - FIRE
IA WARIIING: Rte- ..... hl/lltlllt _,
• Prevent flash fires. Do not smoke or permit flames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire
can cause severe injury or death.
• Do not smoke or permit flames or sp~ to occurnear
the fuel system. Keep the compartment ~d the
engine/generator clean and free ofdebris
tQ_ minimize the
chances of
fire. Wipe up all spilled fuel and~gine oil,
• Be aware- diesel fuel will burn.
PREVENT BURNS- EXPLOSION
A WARNING: Explosions from fuel vapors can ~;ause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open
and ventilate cabin
after fueling. Check below for fumes/vapor before
running the
blower. Run the engine compartment blow'f
prior to starting, following the recommendatiin ofthe
vessel
builder.
• All fuel vapors are highly explosive. Use extreme care
when handling and ~toring fuels. Store fuel ina well-
ventilated area away from spark-producing equipment
and out ofthe reach
of children. ·
•
Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Thke care in catching any fuel that might
spill.
DO NOT allow any smoking, open flames, orother
sources of fire near the fuel system or engine when ··
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter ormodify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA.are appropriate
for all applications encountered in this
environment.

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
a Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it
last.
a Make certain all personnel are clear of the engine before
starting.
a 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!
a 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 elect?cal
arcing or by lit tobacco products. Shut offall electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
a Never connect the negative(-) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation of explosive gases. To avoid sparks, do not
disturb
the battery charger connections while the battery
is
being charged.
a Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remo~e
wristwatch, rings, and any otherjewelry before handling
the
battery.
a Always turn the battery charger offbefore disconnecting
the battery connections.
Remove the negative lead first
and reconnect itlast when servicing the battery.
BATTERY ACID
A WARNING: Sultutic acid in batteries can cause
severe injury 01 death!
• When servicing the battery orchecking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid
whic~ is
destructive. If it comes in contact with your skin, wash
it off at once with water. Acid may splash on the skin or
into
the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO} is a deadly gas!
• Ensure that the exhaust system is adequate toexpel gases
discharged from the engine. Check the exhaust system
regularly
for leaks and make sure the exhaust manifold/
water-injected elbow is securely attached.
• 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 ofapproved
detectors.
• For additional information, refer to ABYC TH-22
(educational information on Carbon Monoxide).
A WARNING: carbon monoxide (CO} is an Invisible
odotless gas. Inhalation produces Bu·like symptoms,
nausea or death!
• Do not use coppertubing in diesel exhaust systems.
Diesel fumes can rapidly destroy coppertubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting
in exhaust/water leakage.
• Do not install exhaust outlet where emaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet
is near the waterline, water could
enter the exhaust discharge outlet and close orrestrict the
flow ofexhaust: Avoid overloading the craft.
a Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fume~. S~me o~the
symptoms orsigns ofcarbon 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
Otdeath!
• 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
• Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loose jackets, shirts, sleeves,
rings, necklaces or bracelets that could be caught in
moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• 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!
• · Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
·A WARNING: Do lUll work on machinery when you are
mentally or physically incapacitated by fatigue/
OPERATORS MANUAL
'
Many ofthe preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a thor~
ough examination of the American Boatand Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticularinterest are:
H~32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion of Exhaust 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
RegulatiQns (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 Standards for Small Craft"
Order From:
A)JYC
613 Third Dtreet, Suite 10
Annapolis, MD 21403
( 410) 990-4460
www.abycinc.org
NFPA (National Fire Protection Association)
"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)
"CFR 33 AND CFR46''
Code ofFederal Regrilations
Order From:
U.S. Government Printing Office
Washington, D.C. 20404
I "'ff'tiTlWESTERBEKE
) Engines &Generators
iii

INSTALLATION
When installing WES1ERBEKE engines and generators it is important that strict
attention be paid to the following information: ·
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterlirie, proVisions inlistbe made to irisfiill a: siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifqld injection port is ator below the load waterline will result in
raw water damage to the engine andpossibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions~ install a
siphon-break. ·
NOTE: A siphon-break reqidros periodic inspection and cleaning to ensure proper
operation. Failure to properly mairi.tain a siphon-break can result in catastrophic
engine damage.' Consult the siphon-break mamifacturer for proper maintenance.
EXHAUST SYSTEM
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
SIPHON·BREAI{ WITH STAINLESS
wop·
The exhaustsystem'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 ofwater·into the exhaust system
under any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gasQiine and diesel, ·
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification ................................................ 2
Engine troubleshooting (Charts) ....................... 26
Introduction ............................................................. 3
Fuel, Engine Oil and Engine Coolant .................. 5
Preparations for Initial Start·Up ......................... 6
Generator Control Panels .................................... 7
Remote Panels ..................................................7
Electronic Governor.......................................
26
Alternator Testing ............................................. 29
DC Battery Circuit ............................................ .31
Wiring Diagram .................................................. 32
Wiring Schematic ............................................. .33
Starting/Stopping Procedure ............................... 8
Remote Panels ..................................................8
Remote Panel Wiring Diagrams ......................... .34
Shore Power Connections ................................... 35
Generator Break-In Procedure ............................ 9
Engine/Generator Specifications ...................... 36
Dally Routine ....................................................... 9
Generator Information ....................................... 37
Safety Shutdown Switches ................................ 1o
Maintenance Schedule (Chart) ......................... 11
Fuel System ....................................................... 13
Cooling System ..................................................14
Fresh_ Water Cooling Circuit........................... 15
Changing the Coolant..................................... 15
Thermostat......................................................16
Generator Single Phase ..................................... 38
Circuit Breaker...............................................38
Internal Wiring Schematics ............................ .39
Component Resistant Data.............................39
BT Troubleshooting Se .. ence .......................... 40
BT Troubleshooting .......................................... .41
Measuring Residual Voltage...........................41
Raw Water Intake Strainer..............................16
Testing Exciter Rotor Windings ........................ 42
Raw Water Cooling Circuit............................17
Testing Diodes and Thermistor ......................... 43
Heat Exchanger ..............................................17
Raw Water Pump............................................
17
Engine Lubflcating 011 ....................................... 18
Engine Oil Change .........................................18
Remote Oil Filter (optional)...........................19
Starter Motor ..................................................... 20
Troubleshooting.............................................. 20
Engine AdJustments ............................................. 22
Drive
Belt Adjustment.................................... 22
Torquing the Cylinder Head Bolts .................22
Testing Stator Windings ................................... 44
Testing Bridge Rectifier.................................. 44
Testing Excitor Windings ................................. .45
Compound Transformers ................................ ,..45
Voltage Ad)ustment ........................................... 46
Terminal Block Connections ............................ .47
Hot Water Tank Connections ........................... .48
lay-up and Recommissioning ........................... 50
Power Take-Off Systems ................................... 52
Fuel Injectors .................................................22
Metric Conversion Data (Chart) ........................ 53
Valve Clearance Adjustment ..........................23
Spill Timing....................................................24
Suggested Spare Parts ..................................... 54
Testing Glow Plugs ........................................25
Testing Oil Pressure........................................25

GENERATOR BREAK·IN PROCEDURE
. DESCRIPTION
Although your engine bas experienced a minimum of one
houroftest operations at the factory to make sure accurate
assembly procedures were followed and thatthe engine
operated properly, a break-in time i& required. The service
life of your engine is dependent upon how the engine is
operated and serviced dming its initial hours of ~e.
Breaking-in a new engine basically involves seating the
piston rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate thatthe cylinder walls are
scored, which is caused by overloading the engine dming the
~in perl<?d-. . .
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.
Pexfonn this conditioning carefully, ~ing in mind the
following:
S~ the engine according to the STARTING PROCEDURE
section. Run the engine while checking thatall systems (raw
water pump, oil pressure, batterycharging) are functioning.
· AFTER START·UP
Once the generator bas 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 fi:tSt 10 hours.
After the first 10 hours of the generators operation, the
load can be increased to the full-load rated output, then
periodically
vary the load.
Avoid overload at all times. An overload is signaled by a
smoky exhaust with reduced output voltage and frequency.
Monitor the current
being drawn from the genemtor and keep
it within the generators' rating. Since the generatoroperates at
1800 xpm to produce 60 hertz, or at .1500 to produce 50 hertz,
control of the generato~ engine break-in 'govemed by the
current drawn from the generator.
NOTE: Be aware of motor starting loads and the high
currentdrawn required for starting motors. This starting
amperage draw can be 3 to 5 times normal ruruzing
amperage. See GENERATOR INFORMATION in this 11UJJ'JJJ.Oi..
GENERATOR ADJUSTMENTS
Once the generator hasbeen placed into operation, theremay be
the need for a
AC no-load voltage adjustment before oratthe
50 hour break-in service. (see GeneratorInformation).
THE DAILY ROUTINE
CHECKUST
•. Follow this checklisteach day before starting your generator.
a Cleekthat all generator circuit breakers (power panel) are in
the off position before starting.
a Record the hourmeter reading in your log (engine hours relate
to the maintenance sChedule).
a Visually inspectthe engine for fuel, oil,or water leaks.
a Cleekthe oil level (dipstick).
a Cleekthe coolant level in the coolant recovery tank.
a Cleek your fuel supply.
a Cleek the starting batteries (weekly).
a Cleekthe drive beltfor wear and proper tension (weekly)
CHECKWlfH 11IE ENGINE RUNNING.
• Cleek for abnormal noise such as lmocking, vibration and
blow-back SOUnds.
a Confirm exhaust smoke:
When the engine is cold- White Smoke.
When the engine is warm-almost Smokeless. .
When the engine ·is overloaded-some BIRck Smoke. ·
NOTE: Some unstable 17l1'117ing may occur in acold engine.
This condition should abate as nomli1l operating temperature
is reqched .and loads ai·e applied.
A CAUTION: Do 1101 operate the ge11erator tOr long
periotls of time witboot a load beiog placed· on the
geilerator. . .
:&J18!1N111R.hl\INER.AtOR;:
Remove the AC amperage loads from the generator one at a
time. Allow the generator to run for 3 - 5 minutes to stabilize
the operating temperatures. Then depress the STOP switch
and hold depressed until the generator
comes to a complete
STOP.
--- .
Nm: This engine is certified to operate at 1800 rpm (60 H(.)
in the United States. Operating this engine at 1500 rpm
(50 Hz) in the 'United States may be a' violation of
Federal Law. ·
1-.v-IWESTERBEKE
l Engines & Generators
g

SAFETY SHUTDOWN SWITCHES
CHECK ENGINE LED
SAFETY SHUTDOWN SWITCHES/SENSORS
The engine is protected by three safety shutdown switches.
Should a shutdown occur due to one· of these switches, the
Cbeck Engine LED will illuminate. The cause should be
detennined and corrected. The ECU must be cleared of tlns
fault by turning off the 20 amp DC breaker and turning it
back ON in order to start the engine.
High Water Temperature Switch
A high water temperature switch is located at the ~ermostat
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 thereby
shutting offthe engine. This switch resets at 1?5°F (107°C.
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-lOpsi, this switch will open
interrupting the DC voltage thereby shutting off the engine.
OIL PRESSURE
SEND OR
~
•mE\~~~
~~
~ ~ ~
-. .
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 (shutting offthe 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).
1).lls switch resets at approximately 225°F (1 O?"C).
EXHAUST
TEMPERATURE
SWITCH
Engine Circuit Breaker
EXHAUST ELBOW
The generator's engine is protected by an engine mounted
manual reset circuitbreaker (20 amps DC). Excessive
current draw or electrical overload an,ywhere in the
instrument panel 'wiring or engine wiring will cause the
breaker to trip. In this event, the generator will shutdown
because the open breaker interrupts the DC 'Circuit. If this
should occur, check and repair the source of the problem.
After repairing the fault, reset the breaker and restart the
generator.
OVERSPEED SHUTDOWN
The unit's ECU is monitoring the engine speed via a signal
from the MPU (Magnetic Pick-Up) positioned over the
flywheel's ring gear teeth. Should the engine speed reach
2200 rpm (73 hertz), the ECU will shut the engine down and
the Check Engine LED will illuminate.
Engines & Generators
10

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 this information on the illustration ofthe name-
plate shown below, as this will provide a quick reference
when seeking technical information and/or ordering repair
parts.
------~~--~-----.
50 HZ. 60HZ.
The engine serial number can be found STAMPED into
the engine block on the flat surface just outboard of the
fuel injection pump. The generator's serial number is
stamped on the flat surface just above the rear bearing.
AD identification ·plate onthe engine manifold also displays
theengine model and serial number.
4
NOTE: A carbon monoxide waming decal has been provided
by WESTERBEKE. AjflX this decal in a visible position in the
engine room ..
UNDERSTANDING THE DIESEL ENGINE
The diesel engine ciosely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed crankcase;the crankshaft is of
the
same general type as that ofa gasoline engine, and the
diesel engine has the same type of valves, camshaft, pistons,
connecting rods and lubricating system.
Therefore, to a great ex."tent, a diesel engine requires the
same preventive maintepance 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
t:infe periods specified is a must, and frequent checking for
contamination (that is water, sediment, etc.) in the fuel sys-
tem 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 replaced by 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 ajJpear 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). Insist upon WESIERBEKE packaged parts
because will fitor 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
WESIERBEKE engine. Your local WES1ERBEKE dealer
will assist you in preparing an inventory of spare parts.
See the SPARE PARTS page in this manual. For engine
accessories, see WES1ERBEKE'S ACCESSORIES brochure.

FUEL, ENGINE OIL AND ENGINE COOLANT
FUEL
A CAUTION: Use only No.2·D (SAE J313) diesel that
has a Cetane rating of #45 or higher. Grade of diesel
according to ASTM 0975.
Care Of The Fuel Supply
Use only clean fuel! The clearance of the components in
your
fuel injection pump is very critical; invisible dirt
particles which might pass through the filter can damage
these
finely finished parts. It is important to buy clean fuel,
and keep it clean. The best fuel can be rendered
unsatisfactory by careless handling or improper storage
facilities.
To assure that the fuel going into the tank for your
engine's daily use
is clean and pure, the following practice is
advisable:
Purchase a well-known brand of
fuel.
Install and regularly service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel
tank
and the engine.
ENGINE OIL
Use a well known brand of lubricating oil, with an API
classification and SAE
as listed in the SPECIFICATION
pages ofthis manual
Change the oil and
filter after the initial 50 hours of break-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 of
the use ofsynthetic
oil. If synthetic oil is used, engine
break-in must be performed using convential oil. Oil change
intervals must be
as listed in the MAINTENANCE
SCHEDULE section ofthis manual and the change intervals
are not
to be extended if synthetic oil is used.
NOTE: The information above supersedes all previous
statements
regarding synthetic oil.
ENGINE COOLANT
WESTERBEKE recommends a mixture of50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze performs double duty. It allows the engine
to run at proper temperatures by transferring heat away from
the engine to the coolant. It also lubricates and protects the
co~ling circuit from.rust and corrosion. Use a goodquality
antifreeze that contams supplemental cooling additives
(SCAs) that keep the antifreeze chemically balanced, crucial
to long term protection.
Select a brand 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 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.
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each generator.
The purpose ofthis recovery tankis toallow for engine
coolant expansion and contraction during engine operation
without the loss
of coolant and without introducing air into
the cooling system.
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before' starting your generator set for 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
thefull mark 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.
• Check load leads for correct connection as specified in the
wiring diagrams.
• Examine air inlet and outletfor air flow obstructions
(SoundGuards).
• Be sure no other generator or utility power is connected to
load lines.
• Besure 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 gasoline leaks.
WAIT FOR THE ENGINE TO COOL FROM COOLANT
BEFORE REMOVING THE RADIATOR. · . RECOVERY TANK
CAP .
MANIFOLD PRESSURE CAP,:--.....,.~~~
PRESS DOWN AND TURN
TO LIFTOFF
OIL DIPSTICK
A CAUTION: When starting the generator, it Is
recommended that all AC loads, especially large
motors, be switched OFF until the engine has come
up to speed and,. in cold climates, starts to warm up.
This precaution will prevent damage caused by
unanticipated operation of the AC machinery and will
prevent a cold engine from stalling.
• Check the coolant level in both the plastic recovery tank
and atthe manifold.
NOTE: After the initial running of the generator, the air in
the engine's cooling system will be purged to the coolant
recovery tank. Open the air bleedpetcock to ensure that the
cooling system is purged of air. After shutdown andafter the
engine has cooled, the coolant from the recovery tank will be
drawn into the engine's cooling system to replace the purged
air.
Before subsequent operation of the generator, the engine's
manifold should
be topped off, and the coolant recovery tank
may need to be filled to the MAX level.
TOMPUAND
MAIN WIRING.
HARNESS
TO NIPPLE AT
MANIFOLD PRESSURE CAP
ElECTRONIC CONTROLLER JJ!.
THE ECU IS FACTORY PROGRAMMED
TO CONTROL ALL ASPECTS
OF THE DRIVE ENGINE.
Engines & Generators
6

GENERATOR CONTROL PANELS
ENGINE MOUNTED and REMOTE CONTROL PANELS
DESCRIPTION
The Control Box instrument panel is equipped with rocker
switches that activate preheat, start and stop controls. There
is also a check engine light and two spade type fuses.
On the
side of the box is an emergency stop toggle switch and a
phig~in for a remote control panel.
PREHEAT: The PREHEAT rocker switchrserves two purposes:
activates the preheat circuit
and :activates_ithe K2 Run Relay.
This supplies power to the
DC alternator R, fuel pump, ECU,
Instrument panel, K3 Fault Relay pin #87 and Start toggle
switch.
START: The STARTrocker switch when pressed activates the
Kl-Start Rel~y whkh activates the·starter motor.
STOP: The STOP rocker switch when pressed and held,
opens the DCcircuit supplying power to the K2 Run Relay.
De-activating
it and.shutting,down the engine drive.
FUS~S: The control box has two automotive type fuses. A 5
amp fuse protects the ECU anda 7.5 amp to protect the
control circuit-and instrument panel.
CHECK ENGiNE LIGHT: The CHECK ENGINE LED 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
pi:event an unwanted start.
REMOTE PANEL PLUG IN: A plug on the side on the control
box wilfallow for the remote mounting of the remote
instrument panel or the remote stop/start panel.
REMOTE PANELS
There are tWo control panels available for remote operation
of the generator that plug into the standard panel with a 15'
extension harness.
Both use the same three rocker switches
for operating the generator and they perform the same
function.
REMOTE INSTRUMENT
CONTROl PAI'IEL
DESCRIPTION OF THE REMOTE INSTRUMENT
CONTROL PANEL .
COOLANT TEMPERATURE: Engine coolant (water)
temperature
should normally indicate: 175• to 195°F
(80° to 90°C).
ENGINE OIL PRESSURE: Oil Pressure(:psi) may fluctuate
depending
on the generator load bufshould range between
35
to 55 psi.
DC VOLTS: Indicates the amount the battery is being
charged and should
show 13V to 14V.
HOURMETER: Registers elapsed time and is used as a guide
for when to
perform scheduled maintenance.
EXTENSION HARNESSES
. PN. 056236 EG DIESEL (8 PIN) ~15 feet
PN. 056235 EG DIESEL (8 PIN) ...:.30 feet
REMOrE STOP/START PANEL
Refer to the following pages.
t"t'N"/WESIERBEKE
) Engfn8S & Generators
7

STARTING/STOPPING PROCEDURE
STARTING: ENGINE MOUNTED PANEL
PREHEAT: Depress the PREHEAT rocker switch for
approximately 5-10 seconds. then -with the PREHEAT rocker
still depressed, depress the START rocker.
START: When the generator cranks and starts, release the
START rocker switch but continue to hold the preheat rocker
for about 4-5 seconds to allow the safety oil pressure switch
contacts
to close to maintain a DC circuit to the K2 Run
Relay. Then release.
RUN: With both rockers released and the oil pressure, engine
coolant temperature and exhaust temperature safety
protection switches normal, the K2 Run Relay will remain
energized and
the generator wi}l continue to run.
FAILURE TO START: Should the engine not start when the
START roc!cer switch has been depressed for 5-10 seconds,
release both rocker switches and wait 30 seconds and repeat
the above procedure. Preheat a few seconds longer. Never
run the starter for more than 20-25 seconds. ·
STOPPING: Remove the AC amperage loads from the
generator and allow the generator to run for 3 to 5 minutes to
stabilize its operating temperature. Depress the STOP rocker
switch
and hold it until the generator comes to a complete
stop. Then release
the STOP rocker switch. ·
ENGINE MOUNTED
CONTROL PANEL
REMOTE STOP/START PANEL
STARTING: REMOTE INSTRUMENT PANEL
PREHEAT: Depress the PREHEAT rocker switch for
approximately 5-10 seconds. then with the PREHEAT rocker
still depressed. depress the START rocker.
START: Observe the oil and DC voltmeter gauges in the
instrument. When the oil and voltmeter start to register a
reading, release the START rocker switch but continue to
hold the PREHEAT rocker depressed until the oil pressure
passes l0 psi. Then release the PREHEAT rocker switch.
Once the generator has started, observe the meter readings
on the instrument paneL Ensure the raw water is being
discharged with the exhaust. Apply a light amperage load
on
the generator and allow it to wann up to l40°F, then apply
your higher amperage loads.
FAILURE TO START: Should the engine not start when the
START rocker switch has been depressed for 5-10 seconds,
release both rocker switches and wait 30 seconds and repeat
the above procedure. Preheat a few seconds longer. Never
run the starter for more than 20-25 seconds.
STOPPING: To stop the generator, depress the STOP rocker
switch and hold it depressed. Observe the oil pressure meter
on the instrument panel. When the oil pressuredrops to zero,
release the STOP rocker switch.
REMOTE INSTRUMENT
CONTROL PANEL
REMOTE STOP/START
PANEL·.
~~
NOTE: The same Preheat, Start and Stop instructions apply to
the Remote Stop/StartpaneL A Release Starter LED will light
to indicate when to release the Start button.
For the REMOTE STOP/START PAl\TEL wiring diagram
and wiring harness, refer
to the Table of Contents.
1...-v-IWESIERBEKE
) EnglntJS & Generators
8

GENERATOR BREAK·IN PROCEDURE
. DESCRIPTION
Although your engine bas experienced a minimum of one
houroftest operations at the factory to make sure accurate
assembly procedures were followed and thatthe engine
operated properly, a break-in time i& required. The service
life of your engine is dependent upon how the engine is
operated and serviced dming its initial hours of ~e.
Breaking-in a new engine basically involves seating the
piston rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate thatthe cylinder walls are
scored, which is caused by overloading the engine dming the
~in perl<?d-. . .
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.
Pexfonn this conditioning carefully, ~ing in mind the
following:
S~ the engine according to the STARTING PROCEDURE
section. Run the engine while checking thatall systems (raw
water pump, oil pressure, batterycharging) are functioning.
· AFTER START·UP
Once the generator bas 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 fi:tSt 10 hours.
After the first 10 hours of the generators operation, the
load can be increased to the full-load rated output, then
periodically
vary the load.
Avoid overload at all times. An overload is signaled by a
smoky exhaust with reduced output voltage and frequency.
Monitor the current
being drawn from the genemtor and keep
it within the generators' rating. Since the generatoroperates at
1800 xpm to produce 60 hertz, or at .1500 to produce 50 hertz,
control of the generato~ engine break-in 'govemed by the
current drawn from the generator.
NOTE: Be aware of motor starting loads and the high
currentdrawn required for starting motors. This starting
amperage draw can be 3 to 5 times normal ruruzing
amperage. See GENERATOR INFORMATION in this 11UJJ'JJJ.Oi..
GENERATOR ADJUSTMENTS
Once the generator hasbeen placed into operation, theremay be
the need for a
AC no-load voltage adjustment before oratthe
50 hour break-in service. (see GeneratorInformation).
THE DAILY ROUTINE
CHECKUST
•. Follow this checklisteach day before starting your generator.
a Cleekthat all generator circuit breakers (power panel) are in
the off position before starting.
a Record the hourmeter reading in your log (engine hours relate
to the maintenance sChedule).
a Visually inspectthe engine for fuel, oil,or water leaks.
a Cleekthe oil level (dipstick).
a Cleekthe coolant level in the coolant recovery tank.
a Cleek your fuel supply.
a Cleek the starting batteries (weekly).
a Cleekthe drive beltfor wear and proper tension (weekly)
CHECKWlfH 11IE ENGINE RUNNING.
• Cleek for abnormal noise such as lmocking, vibration and
blow-back SOUnds.
a Confirm exhaust smoke:
When the engine is cold- White Smoke.
When the engine is warm-almost Smokeless. .
When the engine ·is overloaded-some BIRck Smoke. ·
NOTE: Some unstable 17l1'117ing may occur in acold engine.
This condition should abate as nomli1l operating temperature
is reqched .and loads ai·e applied.
A CAUTION: Do 1101 operate the ge11erator tOr long
periotls of time witboot a load beiog placed· on the
geilerator. . .
:&J18!1N111R.hl\INER.AtOR;:
Remove the AC amperage loads from the generator one at a
time. Allow the generator to run for 3 - 5 minutes to stabilize
the operating temperatures. Then depress the STOP switch
and hold depressed until the generator
comes to a complete
STOP.
--- .
Nm: This engine is certified to operate at 1800 rpm (60 H(.)
in the United States. Operating this engine at 1500 rpm
(50 Hz) in the 'United States may be a' violation of
Federal Law. ·
1-.v-IWESTERBEKE
l Engines & Generators
g

SAFETY SHUTDOWN SWITCHES
CHECK ENGINE LED
SAFETY SHUTDOWN SWITCHES/SENSORS
The engine is protected by three safety shutdown switches.
Should a shutdown occur due to one· of these switches, the
Cbeck Engine LED will illuminate. The cause should be
detennined and corrected. The ECU must be cleared of tlns
fault by turning off the 20 amp DC breaker and turning it
back ON in order to start the engine.
High Water Temperature Switch
A high water temperature switch is located at the ~ermostat
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 thereby
shutting offthe engine. This switch resets at 1?5°F (107°C.
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-lOpsi, this switch will open
interrupting the DC voltage thereby shutting off the engine.
OIL PRESSURE
SEND OR
~
•mE\~~~
~~
~ ~ ~
-. .
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 (shutting offthe 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).
1).lls switch resets at approximately 225°F (1 O?"C).
EXHAUST
TEMPERATURE
SWITCH
Engine Circuit Breaker
EXHAUST ELBOW
The generator's engine is protected by an engine mounted
manual reset circuitbreaker (20 amps DC). Excessive
current draw or electrical overload an,ywhere in the
instrument panel 'wiring or engine wiring will cause the
breaker to trip. In this event, the generator will shutdown
because the open breaker interrupts the DC 'Circuit. If this
should occur, check and repair the source of the problem.
After repairing the fault, reset the breaker and restart the
generator.
OVERSPEED SHUTDOWN
The unit's ECU is monitoring the engine speed via a signal
from the MPU (Magnetic Pick-Up) positioned over the
flywheel's ring gear teeth. Should the engine speed reach
2200 rpm (73 hertz), the ECU will shut the engine down and
the Check Engine LED will illuminate.
Engines & Generators
10

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 correct tools tor each job. When servicing/replacing DC components, tum ott the DC circuit breaker on the
control panel; or tum off the battery switch.
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
Drive Belts
I INITIAL 50 HOURS OF OPERATION
Engine Oil and Filler
*Exhaust System
*Valve Adjustment
Inlet Fuel Filter
Fuel Filter
Generator
Electronic Governor .Control
Re-Torque Cylinder Head Hold Down Bolts
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 Filter
Air Intake and Filter (if applicable)
EXPLANATION OF SCHEDULED MAINTENANCE
.•
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Check for water anEI dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Use properly filtered #2 diesel with a Cetane rating of #45 or higher. Check that
there is adequate fuel for the vessel's needs.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wiring and electrical
connections. Look for loose bolts/hardware and correct as needed.
Inspect for frayed edges. Belts must be tight.
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.
Remove and replace inlet fuel filter.
Remove and replace fuel filter and all sealing 0-rio.gs,
Check that AC connections are secure with no chafing.
Factory programmed - No adjustment.
Re-torque bolts. Engine cold, then check the valve clearance adjustments.
Inspect for proper tension (3/8" to 112' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
your own inspection schedule.
Change engine oil and filter at 1 00 operating hours or yearly .•
Keep air intake clear of obstructions. Clean air filter (if applicable)
*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.
SCHEDWD MAINTENANCE
I EVERY 250 OPERATING HOURS OR YEARLY
*Exhaust Elbow/EXIIaust System
Fuel Filter and 0-Rings
Inlet Fuel Alter
*Generator
Hoses
Fuel Water Separator Filter
DC Alternator
I EVERY 500 OPERATING HOURS OR AVE YEARS
Raw Water Pump
Coolant System
*Valve Clearances
EXPLANATION OF SCHEDULED MAINTENANCE
Check the structural integrity of the water injected exhaust elbow casting. Check the integrity
of the exhaust system attached to the elbow. All hose connections shoulg 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 repl~ fuel filter and all sealing 0-rings.
Remove and replap,e Inlet fuel filter.
Check that AC connections are clean and secure. Ensure wires have no chafing.
See GENERATOR INFORMATION.
Engine hoses should be firm and tight ~eplace if hoses become spongy, brittle or
delaminated. Check and tighten all hose clamps as needed.
Inspect bowl tor dirt or water in fuel. Drain and replace fUter.
Inspect wiring, connections should be tight. Alternator should be clean and free of corrosion.
Check mounting bracket and alternator bolt. All should be tight.
Remove and disassemble the pump and inspect all parts: drive gear, pump shaft, wear plate
and cover tor wear and corrosion. Replace the impeller and gasket. lubricate the impeDer
at re-assembly.
· Drain, flush and re-fill the cooling system with appropriate antifreeze mix. Inspect the
condition of the sealing gaskets of the pressure cap. Clean out coolant recovery tank
and connecting hose.
· Adjust valves. (Incorrect valve clearance will result in poor engine performance.)·
I
*Starter Motor Check solenoid and motor tor corrosion. Remove and lubricate. Clean and lubricate the starter
motor pinion drive
Fuel Injectors
Check and adjust injection opening pressu~ and spray conditions.
Re- Torque Cylinder Head Hold Down Bolls Re-torque bolts. Engine cold, then check the valve clearance adjustments.
Pre-Heal Circuli
Check operation of preheat solenoid. Remove glow plugs, clean tips arid check operation.
I EVERY 1000 OPERATING HOURS OR OR EVERY AVE YEARS
Heat Exchanger
Remove the heat exchanger tor professional cleaning and pressure testing.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
/"''fffV'IWESTERBEKE
l:E.na/ne, ~~Generators
12

FUEL SYSTEM
DIESEL FUEL
Use No. 2-D (SAEJ313) diesel that has a Cetane rating of
#45 or higher grade of giesel according to ASTM D975.
(DO NOT add any alcohol based additives.
FUEL FILTERS
The fuel injection pump and the fuel injectors are precisely
manufactured
and they must receive clean diesel fuel, free
from water and dirt. To ensure this flow of clean fuel, the fuel
must pass through at least two fuel filters, a fuel water
separator and the engine's spin-on fuel filter. Visually inspect,
clean, and change these filters according to the maintenance
schedule in this manual.
FUEL WATER SEPARATOR
A primary fuel filter of the water separating type must be
installed between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
be carried to the fuel system on the engine.
The owner/operatoris responsible for making certain the
fuel reaching the engine's injection equipmentis free
of
impurities. This process is accomplished by installing and
maintaining a proper fuel filter/water separator between the
fuel
tank and the generator/engine. Westerbeke recommends
a
10 micron filter be used.
FUEL INJECTION PUMP
The fuel injection pump is the most important component
of the diesel engine, requiring the utmost caution in handling.
The fuel injection pump has been thoroughly bench-tested
and the owner/operator is cautioned not to attempt to service
it.
If it requires servicing, remove it and take it to an
authorized fuel injection
pump service facility. Do not
attempt to disassembly and repair it.
FUEL LIFT PUMP
Periodically check the fuel connections to and out of the pump
and make sure that no leakage is present and that the fittings
are tight and secure. The
DC ground connection at one of the
pump's mounting bolts should
be clean and well secured by
the mounting bolt to ensure proper pump operation.
When energized thru the preheat circuit, the fuel lift pump will
purge air from the fuel system and provide a continuous
flow
of fuel as the engine is running.
INLET FUEL FILTER
To ensure clean fuel into the fuel lift pump, there is a small
in-line fuel filter connected
to the fuel lift pump elbow. This
filter should be replaced every 250 hours
of operation.
ENGINE FUEL FILTER
Periodically check the fuel connections and the bowl for
leakage. Replace the filter element after the first
50 hours
then follow the MAINTENANCE SCHEDULE.
Changing/cleaning the filter element
1. Shutoffthe fuel supply.
2. Unscrew the retainer ring that holds the filter
bowl to the
housing and allow the bowl
to come away from the
housing,
3. Remove and replace the filter element and clean the bowl.
4. Replace the sealing "0" ring and reassemble the bowl
to the housing. Thread the retainer ring on carefully
so as
not to cross thread. When retainer contacts the
"0" ring, tighten 114 -1/2 turns by hand. Open the·fuel
supply an.d run the engine to inspect for leaks.
REPLACE THE 7WO 0-RINGS
WITH THE NEW 0-RINGS
SUPPLIED WITH THE NEW
FILTER ELEMENT TO ENSURE
A PROPER SEAL.
FUEL
FILTER
FUEL LIFT PUMP
LIGHTLY WIPE
WITH CLEAN FUEL
Engines &GetJerators
13

COOLING SYSTEM
DESCRIPTION
Westerbeke marine diesel engines are designed and equipped
for
fresh water cooling. Heat produced in the engine by com-
bustion and friction is transferred to fresh water coolant
which circulates throughout the engine. This circulating
fresh
water coolant c9ols the engine block, its internal moving
parts, and the engine
oil. The heat is transferred externally
from the fresh watercoolant to raw water
by means of a beat
exchanger, similar
in function to an automotive radiator. Raw
water flows through the tubes of the heat exchanger while
---- ---.:__ -----
COOLING CIRCUIT DIAGRAM
fRESH WATER ¢
RAWWATER . ..._..
fresh water coolant flows around the tubes; engine heat trans-
ferred to the fresh water coolant is conducted through the
tube walls to the raw water which is then pumped into the
exhaust system where
finally it is discharged overboard. In
other words, the engine is cooled by fresh water coolant, this
coolant is cooled
by raw water, and the raw water carries the
transferred heat overboard through the exhaust system.
The
fresh water coolant and raw water ci:Ccuits 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.
.------
J:n.Jl[lte§~ g~D~~tcj_r~
14