Westerbeke 10.0KW-60Hz User manual

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SERVICE MANUAL
8.0KW-60Hz . 6.0KW-50Hz EDT
10.0KW-60Hz· ·7.5KW-50Hz·EDT
.. 11.5KW-SOHz 9~2KW·50Hz EDT
12.5KW-60Hz9.4KW-50Hz EDT
12.6KW-60Hz 10.4KW-50Hz EDT
15.0KW-60Hz 12.0KW-50Hz EDT
. -
.- Single and Three Phase
:\D~NEt-D1ESEL-GENERATORS
PUBLICATION NO.54600
REVISIONl
JANUARY 2010
~ WESTERBEKE
WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780
WEBSITE: www.WESTERBEKE.COM
.... ..,.~~
NMMA Member National Marine Manufacturers Association
--
I]

A WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness - Throbbing in Temples
-Nausea
- Muscular1lvitching
-Headache
- Vomiting
- Weakness IIIId Sleepiness
-Inability to Think Coherently
IF YDU DR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been Inspected and repaired.
WARNING
Generators Produce CARBON MONOXIDE
Regular Maintenance Required
rry~~~;.~
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety lfUmual carefully. Most accidents are
caused by failure to follow fundamental rules andprecau-
tions. Know when dangerous conditions existand take the
necessary precautions
to protectyourself, your personne~
andyour machinery.
The following safety instructions are in compliance with the
American Boatand
Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 not touch AC electrical connections
while engine is running, Of when connected to shore
power. Lethal voltage Is pfesent at these connections!
• Do not operate this machinery without electrical
enclosures and. covers in place.
• Shut off electrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessel's AC
circuits, except through aship-to-shore double throw
transfer switch. Damage to vessel's AC generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged capad-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 not touch hot engine parts Of
exhaust system components. A running engIne gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury Of death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury Of death!
.• Prevent flash fires. Do not smoke or pennit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or pennit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator
clean and free of debris to ruiniruize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware - diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions ;fom fuel vapors can cause
injury Of death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed
when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four minutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out of the reach ofchildren.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve .t the engine when servicing
the fuel system. Take care in catching any fuel that ruight
spill. DO NOT allow any smoking, open fiames, or other
sources of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have 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.
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead fust and reconnect
it
last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Batteryexplosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing Or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
• 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 contaiuing batteries to prevent
accumulation ofexplosive
gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is
being charged.
• Avoid contacting the terminals with Iools, etc., 10 prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always turn the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
off
at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged
from the engine. Check the exhaust system
regularly
for leaks and make sure the exhaust
manifolds/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.
• Do not run the generator set or engine unless the boat is
equipped with a functiOning marine carbon monoxide
detector that
complies with ABYCA-24. Consult your
boat builder or
dealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu·like symptoms,
nausea or death! .
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing
resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes,
vents, or air conditioners. If the engine
exhaust discharge outlet
is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. Avoid overloading the craft.
• 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 Inability to thinkcoherently
Dizziness
Headache
Nausea
Throbbing in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rot~ting parts can cause injury
or death!
• 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.
...v' WESTERBEKE
Engines & Generators
ii

SAFETY INSTRUCTI'ONS
• Do not wear loose clothing or jewelry when servicing
equipment;'tie back long hair and avoid wearing loose
jackets. shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure 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 belts 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.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery 'when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings 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 sarety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination of the American Boat andYacht'
Council's (ABYC) standards. These standards are a
combination of sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
P-l Exhaust Systems
P-4 Inboard Engines
E-9 DC Electtical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Staudards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
~ WESTERBEKE
Engines & Generators
iii