Westerbeke 8.0 BTD User manual

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OPERATORS MANUAL
MARINE .DIESEL GENERATORS ·
SINGLE AND THREE PHASE .
· 8.0 • 60Hz_.6.0. ·50Hz BJD
:10.0 •60Hz_7.5.• 50Hz BtD·
11 .. 0• 60Hz_8.·8 ·50Hz BTD .
. 1·2 .. 5· 60Hz_... .9.4 · 50Hz BTO.{Al
. PUBLICATION NO: 36146 l Rt:V. 5 - JULY2018
~ ~ .. ~ -,>,.,, ~ ~.-
~,~~-·TEBBE/fe
-· . . . . Wf4STERSEKE CORPOIMTfON • 150 JOHN HANCOCK ROAD
.Af.W ;j .. MYLES STANDISH INDUSTRIAL PAIJK • TAUNTON MA 02780
. WEBSITE: WWW.WESTERBEKE.COM
-··-

..
CALIFORNIA
PROPOSITION ·65 WARNING
Marine diesel and gasoUn(t engine
exhaust and some of Its constituents
are knovin to the State of California
to cause cancer, birth defects,
and other reproductive harm.
A wARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide Is poisonous and can cause
unconsclousnll$$ and dealfl~ Symptoms of Carbon.Monoxlde
exposure can Include:
•Dizziness
• Nausea
•Headache
• Weakness and Sleep/nBS$
• Throbbing In Temples
• Muscular 'fiNitcbing
•· Vomiting
•lfllfbility to Think Coherently
IF YOU OR ANJ'ONE ELSE EXPERIENC~JINY OF THESE SYMPTOMS,
(JET OUT INTO THE FRESH AIR IMM. 'EDIA. TELY.If symptoms persist,
'
seek medical attention. Shut down tileunit and dq not restart
until it bas been inspected and repaired.
A WARNING DECAL Is provided by WESTERB£KE and
should be fixed to a bulkhead near your engine or
generator.
WESTERBEKE also recommends installing CARBON
MONOXIDE DETECTORS near the engine room. They
are Inexpensive and easily obtainable at your local
hardware· store.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manualcarefully. Most accidents are
caused byfailure to follow fut«/limental rules and
precautions. /UUJW when dangerous eonditions exist and
take the necessary precautions to protect)ourseff, your
personne4 and your machinery.
PREVENT ELECTRIC SHOCK
A.WARIINS: • lllltiDul:b AC elllt:ttit:al t:III8Cfi1Rls
11/lite engine i$mllllillg, iw whtilt t:IJii1iel:tl1t ttJ $htJte
,_,.I.Biflal rmttagels ,_,at t11ese t:tHaJt:tltiDsl.
• Do not operate this machi:nety without electrical
enclosures and CO'VetS inplace;
•
Shut offelectricalpowerbefore accessing electrical
equipment '
• Use insulated mats whenever working on electrical
equipment
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when~ electrical equipment.
•
Remove wristwatch and an jewehy when working on
electrical equipment.
PREVENT BURNS- HOT ENG.
A WARNING: Dllllllt,. bOI engine parts Ill
exbaust system t:llllfiDIIIIII Afllllllillg fiii!J/De gets very
hot!
• 'Monitor engine antifreeze coolant level at the plastic
coolantrecovery tank and periodicaJly at the fillercap
location on the
water jacketed exhaUst manifold, hilt only
when the engine is COLD.
I AwAIIIIIIIII: ___ .,.,_
• In case of an engme overheat, allOw tb.e erigine to cool
before touching the engine.or checldng the coolant·
PREVENT BURNS- FIRE
• Prevent flash fires. Do not smoke orpermit :ftam.es or
sparks to occur near tb.e carburetor, fuel line, filter, fuel
pump, orother potential sources ofspilledfuel or fuel
vapors. Use a suitable container to catch all fuel when
removing tb.e fuel line, carburetor, oi: fuel filters.
• Do not operate With the air cleaner/sUencer removed.
Backfire can cause severe injuty ordeath.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generatorclean and free of debris to mininri1.e the
chances of fire. Wipe up an spilled fuel and engine oiL
• Be aware-dieselfuel Will burn.
· PREVENT BURNS- EXPLOSION
I
A WAIIIIIIIG: --. from fuel vapiiiS. t:a11 cause
_ill/lilt or tlealb!
• Followre·fuclmg safety instructions. Keep thevessel's
batches closed when fueling. Open and ventilate cabin
afterfueling. Check below for fumes/vapor before
running tb.e blower. Run the engine compartmentblower
prior to starting, following the rec()1TIJ'Tleililatiin ofthe
vessel builder.
• All fuel vapors are highly explosive. Use extreme care
when handling and ~g fuels. Store fuel ina well-
ventilated area away from spark-prQducing equipment
and out of tb.e reach of children. ·
• Do notfillthe fuel tank(s) whilethe engine is running.
• Shut offthe fuel service valve at the engine when servicing
the fuel system. 'Thke care in·catcbing any fuel that might
spill. DO NOf allow any smoking, open flames, or other
sources of fire near the fuel system or engine when ··
servicing. Ensure proper ventilation exists when serVicing
the fuel system. ·
• Do notalter ormodify the fuel sys•
• Be sure an fuel supplies have a posi~ve shutoff valve.
• Be certain fuel·line fittings are adequately tightened and
free ofleaks. ·
• Make sure a fire extinguisher is installed nea.tby and is
properly maintained. Befamiliarwith its proper use. ·
Extinguishers rated ABC by the NFPA are appropriate
for an applications encountered inthis environment.
•' .
1-w'IWEBTERBEKE
l Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
11 Disconnect the battery cables before servicing the engine/
generator. Remove
the negative lead first and reconnect
it last.
11 Make certain all personnel are clear ofthe engine before
starting.
11 Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BAmRY 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
hydrogcm, a
highly explosive
gas, which can be ignited by electrical
arcing orby lit tobacco products. Shut offall electrical
equipment in the vicinity to prevent electrical arcing
dming servicing.
11 Never connect thenegative (-) battery cable to the
positive (+) connection terminal ofthe starter solenoi~
Do not test the battery condition by shorting the tenmnals
together. Sparks could ignite battery gases orfuel vapors.
Ventilate any compartment containing batteries
to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
11 Avoid contacting the tenninals with tools, etc., to prevent
burns orsparks that could cause
an explosion. Remove
wristwatch, rings,
and any otherjewelry before handling
the battery.
11 Always turn the battery charger offbefore 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!
11 When servicing the battery or checking the electrolyte
level wear rubber gloves, a rubber apron, and eye
pron;;ction. Batteries contain sulfuri~ acid wbic~ is
destructive. If it comes in contact With your skin, wash
itoff 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 (CD) is a deadly gas!
11 Ensure that the exhaust system is adequate to expel ga8es
discharged from the engine. Check the exhaustsystem
regularly for leaks and
make sure the exhaust manifold/
water-injected elbow
is securely attached. ·
11 Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
11 Do not run the generator set orengineunless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder or dealerfor installation ofapproved
detectors.
11 For additional information, refertoABYC1H-22
(educational information on Carbon Monoxide).
.A WARNING: carbon monoxide (CD) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
11 Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly
destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/waterleakage. .
II Do not install exhaust outlet where emanst canbe <kawn
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 of exhaust: Avoid overloading the craft.
11 Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or signs 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
or death!
11 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 clotbing or jewe]ry when servicing
equipment; avoid wearing loose jackets~ shirts, sleeves,
rings, necklaces orbracelets that could becaught in
moving parts. ' ..
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in theirrespective
places at all times.
• Do not check fluid levels orthe drive belt's tension while
the engine is operating.
• Stay clear of the drive shaft andthe transmission coupling
when the engine is running; hairand clothing can easily
be ~ught inthese rotating parts.
HAZARDOUS NOISE
I
A WARNI. NG: lligb lltlise levels t:all t:allSB hearbig
. IIISS! .
• · Never operate an engine without itS nmffler installed.
• Donot run an engine with theairintake (silencer)
removed.
A WARNING: liD""'wmi'llll mat:hillett .. , atB
IIIINifally 111 phpit:aiJy i11capat;/tatBII by fatigue/
OPERATORS MANUAL
Many of the preceding safety tips and warnings are~
in your Operators Manuai along with other cautions and
notes to highlight critical information. Read your manual
carefiill.y, maintain your equipment, and follow allsafety
procedures.
ENGINE AND GENERATOR INSTALLAnONS
Preparations to install an engine.shouldbegin with a thor-
oughexamination of theAmerican Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA
Sections of the ABYC standards ofparticularinterest are:
H-32Ventilati.on for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Instal1atiion of Exhaust Systems for Propulsion
and Auxilliary Engines
P-4 Marine Inboard Engines and Transmissions
E-ll AC & DC Elec1rlcal Systems onBoats
TABatteries and Battery Chargers
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND .USCG PUBUCADO. FOR
INSTALUNG MARINE ENGINES AID GENERATORS
Read the following ABYC, NFPA and USCG publications
for
safety Codes and standards. Follow their recommenda-
tions when installing your UNIVERSAL engine
ABYC (AmericanBoat and Yacht Council)
"Safety Standards for Small Craft"
Order from;
A_BYC
'613 ThirdDtreet, Suite 10
Annapolis. MD 21403
[phone]
www.abycinc.org.
NFPA (National FJie Protection Association)
''Fire Protection Standardfor Motor Craft"
Order From:
NFPA
lB~Park:
P.O. Box 9101
· Quincy, MA ()2269.:.9101
USCG (United States Coast Guard)
"CFR 33 AND CFR46"
Code of Federal Regtilations
Order From:
U.S. GovernmentPrintingOffice
WashingtoJt. D.C. 20404
j...,.,.IWESTERBEKE
fEngines &Generators
iii

INSTALLATION
When iilstalling WEST.BRBEKE engines and generators it is important that strict
attention· be paid to the following information: · ·
CODES AND·-ULATIONS .
· S~ federal reguiations, ABYC guid8nnes, and sa.fety codes ml¥Jt be cornpU~ with
when installing engines and generators in a marine environment.'
SIPHON-BREAK
For installations where the~ manifold/water inject.Cd exhaust elb9w is close to
or -Will be beloW die ·v-essers waterlirie, proViSiOnS iniist ~ maae 'io 'llisfiilla 'SipliOii-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20'' abo'Ve the vessel's water~ Failareto use a Biphon-bretilc when
the ex1uzust manifr!ldinjectionport is lit or below the'to¢ waterline will resrilt in
raw waterdamage to tk;e ~anti pQssibk jl.ooding. of the !Joat.
If you have ~y doubt about the position ofthe water .. injected exhaust elbow ~ve
to the vessel's waterline under the ~·s various operating conditi~ inBtall a
rtphon..bretilc. · · · · ·
NO'I'E: A. sq,hoti-b~k reqili.rns Periofl!.c flwJection and cleaning to ensure p10per
operation. Failure_ tp_properly_ mabitain a siphon-break can result in catastrophic
engine dimiilge~' CiJMiift the sijihmi-break manufacturer for proper riuiintenance.
EXHAUST-SYSTEM ...
AVAILAB~FROM
:aWES'IEM.EKE
SIPHON-BJ:iEAK WITH STAiNLESS
LOOP'
The exhaust' system's hase MUS'J; be certified for marine use. Conugated Marine
Exhaust~ is recommended.. The use of this tYPe of hose allows for eXtreme bends
and-~ without the need of additional fitting and. clamps to accomplish these beMs .
and toms. In tbis ~~ a single lengtb of corrugated~ hose can be used The
system MU$'1'· be designed·to prevent the .entry of waterlnto the exhaust system
under any sea conditions· aixl at -any angle of vessels heel.
A detailed Marlne.lnstallatiiJD Manual covering gBSQiine and diesel, ·
engines and generators, Is supplied v.ritb each unit A pdf is available
to download frail oar wibsite at \VViW.westerbeke.com.
IW'IWESTERBEKE
l Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification ............................................ .2 Specifications ....................................................... .
Introduction ......................................................... 3 8.0 Kw
BTD ................................................28
Diesel Fuel, Engine Oil and Engine Coolant. ...... 5 10.0 Kw BTD ..............................................30
Generator Control .Panels .................................... 6 11.0 Kw BTD ..............................................32
Preparations for Initial Start-Up ......................... 7 12.5 Kw BTD(A).........................................34
Safety Shutdown Switches and Sensors ............. 8
BT Generator 6 and 12 Stud .............................. 37
Starting/Stopping Procedure ............................... 9 Voltage Regulator........................................38
Generator Break-In Procedure ......................... .1 o
BT Troubleshooting Chart...........................38
Maintenance Schedule ...................................... 11
Internal Wiring Schematic (12 Stud) ............... .39
Cooling System .................................................. 13 Resistance Values ........................................39
Raw Water Pumps.......................................
14
Generator Voltage Adjustment ........................ .40
Intake Strainer ............................................. 14
No Load....................................................... 40
Heat Exchanger ...........................................14 Full Load .....................................................
40
Thermostat................................................... 15
Generator Frequency .................................. .41
Zinc Anode ..................................................16 6 Stud
AC Connections .............................. .41
Air Intake Silencer ............................................ 16
Internal Wiring Schematic (&Stud) ................. .42
Fuel System ....................................................... 17
Resistance Values ........................................42
Fuel Filters...................................................
17
Internal Wiring Diagram
Fuel Lift Pump............................................. 18
3 Phase, 12 Wire, Reconnectable ................... .43
Engine Lubricating Oil ....................................... 19
AC Voltage Connections BE 3 Phase ................ 44
Oil Change...................................................19
Shore Power Transfer Switch ........................... .45
Oil Pressure .................................................19 w..
o·
1nng sagrams ................................................... .
DC Electrical System ......................................... 20 #34651 -8
BT ............................................. 46
Alternator..................................................... 20
#36412- No Relays.....................................47
Starter Motor ..................................................... 22
#36412- Schematic No Relays...................48
Testing ..................,......................................22 #36412
-Two Relays...................................49
Disassembly.................................................23 #36412 -Schematic Two Relays.................50
Engine Adjustments ........................................... 24
#41479- BTD and BTD(A)....................... .51
Glow Plugs ..................................................24 #41479 -Schematic.....................................
52
Injector.........................................................24
#43853- BTD and BTDA...........................53
Throttle Control/Generator Frequency........25 #43853
-Schematic .....................................54
Drive BeltAdjustment.................................25
#43944- BTDA Diagram............................55
Valve Clearance and Timing ............................. 26 #43944 -
BTDA Schematic .........................56
11.0 BTD and 12.5 BTD(A)........................26
Remote Oil Fill ................................................... 57
8.0 and 10.0 BTD ........................................27
Power Take Off System ..................................... 58
Lay-Up and Recommissioning ........................... 59
Suggested Spare Parts ...................................... 61
Engines & Generators
1

· PARTS IDE . NTIFIC . ATIO N. /ALL MODELS
The Control Panel faces aft on some of these models
_with the .emergency Stop Swi~ch on the back.
CONTRO L
P AN EL .
OI L Fi ll
AC CONNECTION OUTLET
DRIVE BEl
COVER
REA R
THERMOSTA Ti
ASSEMBLY
RAW WATER PUMP
FRONT
RIGHT SIDE
MANIFOLD PRESSURE CAP
COOLANT FILL ,_ ,- ~ _
OIL SUMP
2
AIR INTAKE
SILENCER -
DC ALTERNAT OR
FUEL-RUN SOLENOID
OIL PRESSURE SWITCH
OIL DRAIN HOSE
FRONT
GENERATOR EMERGENCY
STOP SWITCH
ART SOL E NOID

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 ofour engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefitfrom your generator it
is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please~ re8.d this
manual carefully and observe all the safety precautions
throughout. Should your generator require servicing, contact
your nearest WESTERBEK;E dealer for assistance.
This is your operators manual. Along wi~ this manual, .there
is an Installation Manual and Parts Information. A Serv1ce
Manual is available in pdfform on our website or can be
ordered in book fonn from a WESTERBEKEIUNIVERSAL
Dealer
WARRANTY PROCEDURES
Your WESTERBEKE Warranty Statement is included in the
product documentation package. There is a Warranty
Registration Card you can fill out and mail to Westerbeke ·
Corporation or go to our website:~.westerbeke.com ~d
register your products warranty on line. You should rece1ve a
Customer Identification card in the mail within 60 days of
registering. If 'you do not, please contact the factory and have
your product model number, serial number and in service
date available.
Customer Identification Card
I.....,.IWESTERSEKE
JEngines &Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model ______ _
Expires _____ _ Serial#
____ _
NOTES, CAUTIONS AND WARNIN~S
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical.infonnation will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if notstrictly
observed, can result In the damage or destruction of
your engine.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
PRODUCT SOFTWARE
Pioduct software, (tech data, paltS, 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 SOFIWARE, MAKES NO . ·
WARRANTIES OR REPRESENTATIONS WITH RESPECI'
THEREJ'O, INCLUDING ACCURACY; TIMEliNESS OR
COMPLETENESS THEREOF AND WIU IN NO EVENT .
BE UABLE FOR ANY TYPE OF DAMAGE OR INJURY
iNCURRED IN CONNECTION WITH OR ARISING OUT
. OF THE FURNISHING OR USE OF SUCH SOFIWARE.
WESTERBEKE customers should also keep in mind the
time span between printings of WESTERBEKE product
software and the l.inavoidable existence of earlier ·
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERl3EKE or other suppliers, must not and cannot
be relied upon· exclusfvely as the definitive authority on
the respective product. It not qnly makes good sense
but is imperative that appropriate representatives of .
WESTER.BEKE or the supplier in questi,on be consulted
to determine the accuracy and currentness of the
product
software being consulted by the customer.
PROTECTING.Y~UR.INVESTMENT
Care at 'f:4e factory during assembly and ~orough testing
have resiuted in a WESTERBEKE generat9r capable of
maiJy thousands ofhours ofdependable ~ervice; However the
manufiicturer cannot control how orwhere the generator is
install~· in the vessel or the mannerin which the unit is
operaftd 'and serviced in the field. This is up to the
buyer/owner.:.Operator. ·
NOTE: SiX imp~'(tant steps to ensure long generator life:
• Proper engine and generator instDllaiion and. alignment.
• Anefficient well-designt!fd ex1uiust systt!fm that includes
ananf:t.siphon breafc toprevent waterfrom entering the
engine. · .
w Changing the engine oiland oil fi1ters1 (lCcording .. io tlie
mainte~UZ'nce sclledule.
• Proper maintettillibe of all engine and generator colf!.PO•
n.eitts i:Zecording to the m.ai:tttenance schedule in this
manuaL ·· ·
a Use cledli;:filter{!d #2 dieaelfnet.
•· Wmterize yourengine ticcoramg to the ~'LD.y·tzp atul
Recommis~rtin~' section in this manual.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model and serial number are lqcated.on
a
nameplate mounted on the side ofthe waterjacketed
eJiliaust manifold.
The engine's serial number is also found stamped in
the engine block on a flat surfacejust above the
the side oil flU opening. Take time to enter this infonn-
~tion below on the illustrated nameplate.
An identification plate on the top ofthe engine air intake also
displays the engine model and serial number.
CARBON MONOXIDE DETECTOR
WES1ERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters. Carbon mono:xide,
even in small amounts, is deadly.
The presence of carbon monoxide indicates an exhaust leak
from the engine· or generator or from the exhaust
elbow/exhaust hose, or the fumes from a nearby vessel are
entering your boat. .
If
carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!
NOTE: A carbon monoxide warning decal has been provided
by WESTSRBEKE. Affix this decal in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same .. The cylinders
are arranged above a closed crankcase; the crankshaft is of
the same general type as that ofa gasoline engine; and the
diesel engine has the same types ofvalves, camshaft, pistons,
cbnnecting rods andlubricating system.
Therefore, to a great extent, a diesel engine requires the
same preventive maintenance as a gasoline engine. The
mostimportant factors are proper ventilation and proper
maintenance of the fuel, ·lubricating arid cooling systems.
Replacement offueland lubricating filter elementsat the
time periods specifi~d is a must, and frequent checking for
contanlination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of the same brand of high detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ fromthe gasoline engine,
however, in its methodof.han.~g and firing of fuel. The
carburetor and ignition systems ttre done away with and in
their place is a single component- the fuel injection pump -
which performs the function of both.
ORDERING PARTS
Whenever replacement/service parts are needed, always
provide the generator model number, engine serial number,
and generator serial number as they appear on the silver and
black name platelocated on the generator end. You must
provide us with this information so we rnay properly identify
your generator set. In addition, include acomplete part
description and part number for each part needed (see the
separately furnished Parts List). Also insist upon
WESTERBEKE packaged parts because will fit or generic
parts are frequently not made to the same specifications as
original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator. Your local WES'IERBEKE
dealer will assist youin preparing an inventory ofspare parts.
See the SPARE PARTS page in this manual. For Engine and
Generator Accessories, see the ACCESSORIES brochure.
. . .
INSTALLATION MANUAL
The Westerbeke Installation Manual publication #043268 is
supplied with this unit.
GENERATOR
10 DECAL
Engines&.Generators
4

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use a diesel fuel that meets the requirements of No. 2-D
SAE J 313 and has a Cetane rating of #45 or higher grade of
dies~! fuel according to ASTM 0975.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your engines fuel injection pump is very critical; invisible
dirt particles which might pass through the primary and
secondary filters can damage these finely machined parts. It
is important to buy clean fuel, and keep it clean. The best
fuel can be rendered unsatisfactory by careless handling or
improper storage facilities. To assure that the fuel going into
the tank for your engine's daily use is clean and pure, the
following practice is advisable:
Purchase a well-known brand of fuel. The use of additives to
combat BACTERIAL growth on the fuel tank is recqm-
mended such as Bio-Bor and an additive such as Diesel
'Klee~1 + Cetane Boost to help restore lubricity back intO the
diesel fuel when an Ultra Low Sulfur diesel is being used.
Install and regularly service a good, visual-type fuel
fiHeriwater 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 good brand ofengine oil, with an API classification
and SAE
as stated in the SPECIFICATIONS section ofthis
manual.Change the engine oil and oil
filter after the initial 50
hours ofengine break-in operation and then every 100 hours
of operation thereafter.
Westerbeke Corporation does not
approve or disapprove of
the use ofsynthetic
oil. If synthetic oil is 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 to be extended
if synthetic oil is used.
NOTE: The infonnation above supersedes all previous
statements regarding synthetic
oil.
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 1ww available.
PURCHASING ANTIFREEZE
Select a brand of antifreeze specified for diesel engines.
Antifreeze speci11~d 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 (fiesel
engines. Select the pre-mixed variety so that the cO!TeC:t
mixture will always be added to the cooling system when
needed. Change the antifreeze mixture according to the
MAINTENANCE SCHEDULE in this manual.
MAINTENANCE
Change the engine coolant every five years regardless of the
number of operating hours as the chemical additives that
protect and lubricate the engine have a limited life.
COOLANT RECOVERY TANK
TI1e coolant recovery 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.
NOTE: T7lis tank, with its sh01t run of plastic hose, is best
located at or above the level of the engine's manifold, but it
can be located below the level of the engine's manifold if the
particular installation makes this necessary.
Engines & Generators
5

GENERATOR CONTROL PANELS
DESCRIPTION OF SWITCHES
Thls manually controlled ,series ofWES1ERBEKE marine
diesel generators is equipped with toggle switches on the
engine control panel and, optionally, at remote panels.
All three switches are momentary contact type and serve the
following functions:
PREHEAT: TI1e PREHEAT toggle switch serves two purposes:
preheating the engine for easy starting and defeating of
bypassing the engine oil pressure switch. The defeat function
turns on the fuel solenoid .. instrument power and alternator
excitation.
When the PREHEAT switch is depressed, the voltmeter,
·panel lights, gauges and meters and fuel solenoid will
activate.
START: The START toggle switch closesthe Kl relay that
energizes the starter solenoid and activates the starter ..
While the PREHEAT switch is still depressed, depressing the
START switch engages· the start solenoid. When.the engine
begins to fire, the START switch should be released. The .
PREHEAt
switch should not be released until the oil
pressure reaches 5 - 10 psi.
STOPPING: The STOP toggle switch is a nonnally closed
switch a
DC path through the three automatic shutdown
switches to the
K2 run relay. Opening this switch termi-
nates this
DC path to the K2 run relay shutting down the
engine.
To stop the engine, simply depress the STOPswitch. The
DC path to the K2 run relay is terminated, de-energizing
the relay and the engine shuts down. The STOP switch
should be held depressed until
the generator shuts down
completely.
NOTE: When the engine is shut down, the water temperature
gauge and the oil pressure gauge will continue to register the
last temperature and oil press we readings displayed. They
will retwn to zero once electrical power is restored.
EMERGENCY STOP: The EMERGENCY.
stop switch
on the side of the control box.
is normally closed. When depressed, it
will open the DC circuit to the control
panel and shut the engine down.
As ~he
switch is not toggled it can be used when
petforming maintenance.
DESCRIPTION OF GAUGES
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 but should range between between 30
to 60 psi.
DC Voltmeter
Indicates the amount the battery is being charged should show
13.5V to 14.4V. .
Hourmeter
Registers elapsed timeand is used as aguide for when to
petform scheduled maintenance.
REMOTE PANEL
For remote operation of the generator system, the same three
switches are used. The PREHEAT and START switches are
connected in parallel with the gauge panel's switches and
serve the same functions as in the gauge panel. The STOP
switch is in series with the gauge panel's STOP switch and
serves the same function. There is a REMOTE START/STOP
WIRING DIAGRAM in this manual.
GENERATOR
:J%
~l~
RELEASE
STARTER
:: PREHEAT
• MUST -
PRESS. tO
1ST. e
ty
. STOP
START
(
~'). PRESS
,f~~ 2ND
·wESTERBEKE.
, ..... ,:
NOTE: For additional information on Control Panels. Refer to:
STARTING/STOPPING PROCEDURE, DC WIRING
DIAGRAMS and TROUBLESHOOTING GAUGES.
£Engines & Generators
6

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 examine 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.
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.
GENERATOR VOLTAGE
The speed of the generator engine is adjusted at the factory,
however, it is advisable to verify.
60 hertz The engine no-load speed is set at 61.5 -62 Hz.
At rated amperage hertz output may decrease to
58.5- 59.0 Hz.
50 hertz The engine no-load speed is set at 51.5 Hz.
At rated amperage hertz output may decrease
to
48.5 -49.0 Hz.
The speed ofthe generator engine
is adjusted at the factory,
however it is advisable to verify. The voltages are easily
adjusted to optimum values no-load andfull-load (refer to
·VOLTAGE ADJUSTMENT in this manual). Ifpossible, apply
actual service load or test load of the same power factor as
the load to be used in service. If the voltage cannot be
adjusted to suitable values and a faultseems evident, contact
your authorized WESTERBEKE service dealer.
GLOW PLU
CONNECTION
RECAP
OIL FILL CAP
SIDE OIL FILL CAP
Engines & Generators
7

SAFETY SHUTDOWN SWITCHES AND SENSORS
SAFETY SHUTDOWN SWITCHES
The engine is protected by three automatic shutdown
switches. Should shutdown
occur, do not attempt to restart
without finding 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 exhausttemperature switchis located on the water
injected exhaust
elbow. Its contacts are normally closed.
If the contacts open due to a high coolant temperature, the
DCruncircuitisinterrupted and
the unit shuts down.
The switch's contact openat 260° "270°F(l27° -127°C).
The switch's contacts:elose whenthe temperature lowersto
approximately 225°F(l07°C).
EXHAU$1 (HIGH)
TEMPERAfURE SWITCH
Engine Coolant Temperature SWitch
Ahigh enginecoolant temperature switch located on the
thermostat housing. Its contacts are norma1ly closed. If the
contacts open
due to a high coolanttemperature, the DC run
circuit is interruptedand the unit shuts down. The switch's
contact open
at approximately 210°F (99°C). Theswitch's
contacts close when the coolant
tem.perature.lowers to
195°F (107°C).
THERMOSTAT
ASSEMBLY
Low Oil Pressure Switch
A low oil pressure switch is located offthe engine's oil
gallery adjacent to the oil filter. Its contacts are normally
open when
the engine is in a static state, this switch's sensor
monitors the engine's oil pressure. Oil pressure closes
the
contacts. Should the engine's oil pressure fall to 5-l0psi, the
contacts open interrupting the
DC run circuit shutting the unit
down.
OIL PRESSURE SENDOR
Engine DC Circuit Breaker
The engine's DC circuitis protected b}'~'l engine mounted
230amp DC breaker. Should amperage in excess of20 amps
by draw through thebreaker caused by an issue with the
engine's DC circuit, it will open and shut the unit down.
Investigate the issue and then manually reset the breaker.
This is· done by pushing the red b1.1tton in.
ENGINE DC CIRCUIT .
BREAKER
The· wiring connections to ·these components are
shown in the WIRING DIAGRAMS in this manual.
/"W'JWESTERBEICE
. · E'ngfnes &Generators
' 8

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
Westerbeke diesel generators use electric starters assisted by
glow plugs for both normal and cold weather starting. The
illustration
below shows a cross-sectional view of one cylin-
der. The glow plug is located in the combustion chamber so
that its tip is in the injector nozzle's spray path. When the
glow plug is energized by the PREHEAT button, the plug
glows red at the tip and assists in igniting the fuel. The result
is a rapid start with less wear on the starter.
This system is common to WESTERBEKE diesels. The start
circuitry
is designed so that the PREHEAT button must be
depressed 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 START switch 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
START: While still depressing the PREHEAT switch, depress
the START switch. This will engage the starter solenoid.
Upon engine starting, release the START switch. Do not
release the PREHEAT switch until the oil pressure reaches
5- 10 psi. Then as long as the high water temperature and
low oil pressure protective circuits do not activate, the engine
will remain energized and continue to run.
NOTE: When starting:
A voltage drop will occur
when the preheat ~witch
is depressed.
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 PREHEAT switch for 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.
Failure to Start
Should the engine not start when the START switch is
depressed for 10 to 20 seconds, release both switches and
wait 30 seconds; repeat the procedure above and preheat
longer. Never run the starter for 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·
lng system during cranking. This raw water can enter the
engine's cylinders by way of the exhaust manifold once
the exhaust system fills. Prevsnt this from happening by
closing the raw water supply through-hull shut-off,
draining the exhaust muff/sr, and correcting the cause
of the e,x~esslvsengine cranking. Engine damage result·
lng 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 as the engine-mounted
start
panel except that it has a green LEP light and no
gauges. When starting at a remote location, the green LED
lights when the generator is running at approximately 600
rpm. This indicates when the START switch can be released
since the starting of the generator may not be audible.
A. When the 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 i2V B+ to the fuel run solenoid. The
green LED will remain brightly illuminated while the
engine is running.
B. After the generator is started and the START switch is
released, the generator's starter will not crank unless the
PREHEAT switch is operated first because this switch
supplies
voltage to the START switch.
STOPPING PROCEDURE .
1. Remove the AC electrical load from the generator and
· allow the generator·to run for three to five minutes to
stabilize its operating temperatures.
2. Depress the STOP switch and hold it until the generator
is coinpletely stopped.
3. Now release the STOP switch.
Remote·Stopping. Procedure
To stop the generator, depress the STOP switch which opens
the normally closed B+ path for voltage to the engine's run.
-circuit. The STOP switch must be hel'd open until the
generator comes to a complete stop and the green LED light
goes out.
Engine., & Generators
9

GENERATOR BREAK·IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minbnum of one
hour oftest operations at the factory to make sure accurate
assembly procedures were followed and that the engine
operated properly, a break-in time is required. The service
life of your engine is dependent upon how the engine is oper-
ated and serviced during its initial hours of use.
Breaking-in a new engine basically involves seating the
piston rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
scored, which is caused by overloading the generator during
the break-in period.
Your new engine requires approximately 50 hours of initial
conditioning operation to break in each moving part in order
to maximize the performance and service life of the engine.
Perform this conditioning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems (raw
water pump, oil pressure, battery charging) are functioning.
AFTER START-UP
Once the generator has been started, check for proper opera-
tion and then encourage a fast warm-up. Run the generator
between 20% and 60% of 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 ratif!.g •. Since the· gen~rator operates
at 1800 rpm to produce 60 hertz (or at 1500 ipm to produce
50 Hertz), control of the generator's break-in is governed by
the current drawn from the generator.
CHECK THE FOLLOWING
0 Monitor the control panel gauges.
0 Check for leaks of fuel and engine oil.
0 Check for abnonnal noise such as knocking, friction,
vibration and blow-back sounds.
0 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: 8e aware of motor starting loads and the high current
draw required for starting motors. This starting amperage
draw can be 3 to 5 times nonnal 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 INFORMATION in this manuaL
Engines & Generators
10

MAINTENANCE SCHEDULE
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 for each Job. When servicing/replacing DC components, turn off the DC circuit breaker on. the control
panel or turn 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
NOTE: Please keep engine swface clean. Dirt anil oil
will inhibit the engine 3- ability to remain cool.
I INITIAL 50 HOURS OF OPERATION
Engine Oil and Filter
*Exhaust System
*Valve Adjustment (cold)
*Cylinder Head (cold)
Fuel Filter( s)
Generator
Engine Speed
Water Pump
I EVERY 50 OPERATING HOURS OR MONTHLY
Drive Belt
Starting Batteries
Electric Fuel Pump
Zinc Anode
I EVERY 100 OPERATING HOURS OR YEARLY
Engine Oil and FiHer
Air Intake Silencer
Speed Linkage
Impeller
Syphon Break
EXPlANATION OF SCHEDULED MAINTENANCE
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Check for water and dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Use properly filtered #2 diesel with a Cetane rating of #45 or higher. Check that
there is 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 eiectrical
connections. Look for loose bolts/hardware and correct as needed.
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.
Torque cylinder head hold-down bolts.
Initial change.
Check that AC connections are secure with no chafing.
Adjust as needed. Lubricate linkage.
Adjust belt tension (3/8 -t/2 deflection).
Inspect for proper tension (3/8' to 1/2' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels. Make ~ure 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.
Lubricate linkage between throttle and solenoid.
Inspect impeller for condition. Replace as needed.
Check for proper operation (when installed).
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
{.~ WESTERBEKE
Engines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your engune hours running time.
SCHEDULED MAINTENANCE
I EVERY 250 OPERATING HOURS OR YEARLY
Exhaust Elbow/Exhaust Svstem
Fuel Filler and O·Rings
*Otlnerator
Ho&e&
Fuel Water Separator Filter
DC Alternator
Impeller
I EVERY 500 OPERATING HOURS OR FIVE YEARS
Raw Water Pump
COolant System
*Valve Clearances/Cylinder Head( cold)
----------
• :ltarter Motor
Fuel InJectors
EXPLANATION OF SCHEDULED MAINTENANCE
Check the structural integrity of the water injectecl ~xhaust elbow casting. Check
of the exhaust system attached to the elbow. All hose connections should be
chaffing. No exhaust leaks. Hoses and muffler are in good serviceable condition.
NOTE: An exhaust leak will cause exposure to diesel exhaust!
Remove and replace fuel filter and all sealing 0-rings.
Check that AC connections are clean and secure. Ensure wires have no chafing.
See GENERATOR INFORMATION.
Engine hoses should be firm and tight. Replace if hoses become spongy, brittle or
delaminated. Check and tighten all hose clamps as neeoed.
Inspect bowl for dirt or water in fuel. Drain and replace filter.
Inspect wiring, connections should be tight. Alternator should be clean and free of corrosion.
Check mounting bracket and alternator bolt. All should be tight
Remove impeller from raw water pump. Inspect impellers condition. Replace as needed.
Remove and disassemble the pump and inspect all parts: drive gear, pump shaft, wear plate
and cover for wear and corrosion. Replace the impeller and gasket. Lubricate the impeller
at re-assembly.
-----
Drain, flush and re-fill the cooling system with appropriate antifree4e mix. Inspect the
condition of the sealing gaskets of the pressure cap. Clean out coolant recovery tank
and connecting hose.
Torque head bolts then adjust valves.
Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the
starter motor pinion drive.
Check and adjust injection opening pressure and spray conditions.
I EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS
Heat Exchanger
Remove the heat exchanger for professional cleaning and pressure testing.
Glow Plug:;
Check circuit. Remove, clean, check resistance.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
IW'IWESTBRBEKE.
l Enalnes &,.QIJnerators
12
l

COOLING SYSTEM
DESCRIPTION
Westerbeke marine diesel engines are designed and equipped
for fresh water cooling. Heat produced in the engine by com-
bustion and friction is transferred to fresh water coolant
which circulates throughout the engine. This circulating fresh
water coolant cools the engine block, its internal moving
parts, and the engine oil. The heat is transferred externally
from the fresh water coolant to raw water by means of a heat
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes of the heat exchanger while
fresh water coolant flows around the tubes; engine heat trans-
ferred to the fresh water coolant is conducted through the
tube walls to the raw water which is then pumped into the
exhaust system where finally it is discharged overboard. In
other 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 syste~. The
fresh water coolant and raw water circuits are independent of
· each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.
FRESH WATER COOLING CIRCUIT
NOTE: Refer to the ENGINE COOLANT section for the rec-
ommended 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 whete it is cooled, and returned to the engine
block via the suction side ofthe circulating pump.
~
ENGINE BLOCK COOLANT DRAIN
When the engine is started cold, external coolant flow is pre-
vented by the closed thermostat (although some coolant flow
is bypassed around the thermostat to prevent the exhaust
manifold from overheating). As the engine warms up, the
thermostat gradually opens, allowing full flow of the engine's
coolant to flow unrestricted to the external portion of the
cooling system.
Coolant Recovery Tank
Acoolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi-
cant loss ofcoolant and without introducing air into the cool-
ing system. This tank should be located at or above the
engine manifold level and should be easily accessible.
CHANGING COOLANT
The engine's coolant must be changed according to the
MAINTENANCE SCHEDULE. If the coolant is allowed to
become contaminated, it can lead to overheating problems.
A CAUTION: Proper cooling system malllfenance is
critical; a substantlal11umber of engine failures can be
traced back to cooling system corrosion.
D~n the engine coolant by loosening the drain plug on the
engme block and opening the manifold pressure cap. Flush
the system with fresh water, then start the refill process.
NOTE: The drain petcock on the heat exchanger should also
be used to help drain engine coolant.
A WARNING: Beware of the bot engine coolant.
Wear protective gloves.
COOLANT
RECOVERY
TANK t
INSF}ECT AND CLEAN
THE COOLANT RECOVERY
TANK AND ITS CONNECTING.
HOSE EVERY 3 MONTHS
IW'/WESJERBEKE
· f En_Qines & Generators
. 13

COOLING SYSTEM
CHANGING THE RAW WATER PUMP IMPELLER
Close the raw water intake valve. Remove the pump cover
and gasket or 0-rlng With the aid of two screwdrivers or
pliers. Carefully pry/pull the impellerout of the pump.
Lightly coat the inside of the pump housing ~ith glycerine.
Install the new impeller, bending the blades in the direction
of the curve of the cam plate. Re-assemble the gasket and
cover. Open the raw water intake valve. ".
INSPECTION: CHECK fflE BASE OF
EACH BLADE BY BENDING VIGOROUSLY.·
REPLACE THE IMPELLER IF
ANY'CRACKS.
RAW WATER PUMP
A CAUTION: If any of the vanes have broken off the
Impeller, they must be found to prevent blockage In the
cooling circuit.· They often can be found In the heat
exchanger.
Raw Water Intake Strainer
NOTE: Always install the strainer at or below the waterline so
the strainer will always be self-priming.
A clean raw water intake strainer is a vital component of the
engine's cooling system. Include a visual inspection of this
strainer when making your periodic engine check. The water
in 'the glass should be clear.
Perform the following maintenance after every 100 hours of
operation:
1. Close the raw water seacock.
2. Remove and clean the strainer filter.
3. Clean the glass.
4. Replace the washer if necessary.
s. Reassemble and install the strainer.
6. Open the seacock.
7. Run the engine and check for leaks.
:NOTE: Also follow the above procedure after having nm hard
a [/round.
If .the engine temperature gauge ever shows a higher than
norinal reading, the cause may be that silt, leaves or grass
may have been caught up in the strainer, slowing the flow of
raw water through the cooling system.
RAW WATER STRAINER
WASHER
TYPICAL RAW WATER INTAKE STRAINER
(OWNER INSTALLED)
HEAT EXCHANGER
The heat exchangeris a copper cylinder which encloses a
number ofsmall copper tubes. Raw water is pumped through
the small copper tuJ?es and the fresh water coolant from the
engine is circulated around the copper tubes. The raw water
removes heat from the fresh water coolant.
CLEAN
DEBRIS
Ci.EANd.Jr
DEBRIS AT
BOTH ENDS
HEAT EJ{CHANGER$ ARE
AWJAVA/LABLE WITH
CUPRO·NICKEL TUBING
t-w-IWESTERBEICE
l Engines & Generators
14