Westerbeke 10.0KW-60Hz User manual

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OPERATORS MANUAL
8.0 KW • 60Hz 6.4 KW • 50Hz BEG
10.0 KW • 60Hz 8.0 KW • 50Hz BEG
12.5 KW • 60Hz 10.0 KW • 50Hz BEG
15.0 KW • 60Hz 12.0 KW • 50Hz BEG
----- .-- ,'- -- - -
MARINE GA L E GENERATORS
PUBLICATION N .046221
FIRST EDITION
JULY 2001
~ .. WESTERBEKE
member WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
;\/Wf 150 JOHN HANCOCK ROAD' TAUNTON MA 02780-7319' TEL. [phone]
---- FAX [phone]' WEBSITE: Www.WESTERBEKE.COM

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituents) are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
AWARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
- Dizziness
-Nausea
-Headache
- Weakness and Sleepiness
• Throbbing in Temples
- Muscular Twitching
• Vomiting
• Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
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. .
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused byfailure
to follow fundamental rules andprecau-
tions. Know when dangerous conditions exist andtake the
necessary precautions to protectyourself,
YOllr personnel,
and your machinery.
Thefollowing safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 not touch AC electrical connections
while engine is running. or when connected to shore
power. Lethal voltage is present 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 a ship-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 capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 not touch hot engine parts or
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 or 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 or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources
of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor,
or fuel filters.
• 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 permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free
of debris to minimize the
chances
of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
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 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 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. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources
of fire near the fuel system or engine when 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 shutoffval ve.
Be certain fuel line fittings are adequately tightened and
free
of leaks.
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 inthis environment.
Engines & Generators

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 first and reconnect
it last.
• Make celtain all personnel are clear of the engine before
stalting.
• 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!
• 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 ignite~ by elec~cal
arcing or by lit tobacco products. Shut off all electncal
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terminal
of the starter solenoid. Do
not test the battery condition by shorting the tenninals
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.
• 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.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last whenservicing 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
p~otec
tion. Batteries contain sulfuric acid which is destructIve.
If it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin
or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifold!
water-injected elbow
is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set
or engine.
• Don't 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 of carbon monoxide inhalation or
poisoning are:
Vomiting
Dizziness
Headache
Nausea
AVOID MOVING PARTS
Inability to think coherently
Throbbing in temples
Muscular twitching
Weakness and sleepiness
A WARNING: Rotating 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 operat-
ing adjustments, use extreme care to avoid touching mov-
ing parts and hot exhaust system components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• 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 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.
• 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 safety
procedures.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination
of the American 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 of particular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9
DC Electrical 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 recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards 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
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators
in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine
and possibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerforproper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
Engines & Generators
.
IV

TABLE OF CONTENTS
Parts Identification .................................................................................... .2
Introduction .................................................................................................. 3
Warranty Procedures...........................................................................3
Serial Number Location......................................................................3
Fuel, Engine Oil and Engine Coolant... .................................................. 5
Preparations for Initial Start·Up ............................................................ 6
Operating Instructions ........................................................................... 7
Operating Instructions (Remote Panels) ............................................... 8
Break·ln Procedure (Daily Operation) .................................................... 9
Safety Shutdown Switches ................................................................... 10
High RPM Shutdown Switch ........................... ...................................... 10
Maintenance Schedule ........................................................................ 12
Cooling System .....................................................................................14
Changing Coolant .............................................................................14
Thermostat ........................................................................................
15
Heat Exchanger................................................................................. 15
Raw Water Pump ..............................................................................16
Raw Water Intake Strainer................................................................16
Engine Lubricating Oil ..........................................................................17
Oil Change ........................................................................................17
Remote Oil Filter..............................................................................18
Oil Pressure.......................................................................................19
Fuel System .......................................................................................... 20
Fuel Lift Pump..................................................................................20
Carburetor Adjustments ........................................................................ 21
Engine Adjustments . .................................................................................. 22
Spark Plugs........................................................................................22
High Tension Cords...........................................................................22
Drive Belt Adjustments .....................................................................22
High Speed (Hertz) Adjustments ......................................................23
GovernorAdjustments.......................................................................23
Timing Belt Inspection
and Replacement.........................................24
Engine Compression Test..................................................................27
Ignition Tirning..................................................................................27
Engine Troubleshooting ........................................................................ 28
DC Electrical System ............................................................................ 30
Battery Care....................................................................................... 31
Generator Wiring Diagram (#46094) .................................................... 32
Generator Wiring Schematic (#46094) ................................................. 33
Remote Panel Wiring (#035698) .......................................................... 34
Remote Panel Wiring (#035706) .......................................................... 35
Remote Panel Wiring (#043912) .......................................................... 36
Starter Motor ......................................................................................... 37
Generator Information . ........................................................................ .39
BE Generator ................................. ....................................................... .40
Generator AC Voltage Connections .. ................................................... .41
BE Troubleshooting ...............................................................................42
Lay·up and Recommissioning ............................................................... 43
Generator Specifications .................................................................... .45
Metric Conversions ...............................................................................46
Standard Hardware and Sealants ....................................................... .47
Shorepower Transfer Switch ............................................................... .48
Suggested Spare Parts ........................................................................ .49
Engines & Generators
1

START MOTOR
20A DC BREAKER
PARTS IDENTIFICATION
CARBURETOR
DISTRIBUTOR
CONTROL PANEL
GENERATOR
WATER INJECTED
EXHAUST ELBOW
TEMPERATURE
HEAT EXCHANGER
SWITCH
LEFT SIDE
CONTROL PANEL~
HOURM
START/STOP
WATER TEMPERATURE
SWITCH
ZINC ANOD
NTROL BOX
HEAT EXCHANGER
OIL DRAIN HOSE
RIGHT sIDe
Engines & Generators
2
COOLANT
FILL
OIL FILL
DIPSTICK
BLOCK COOLANT
DRAIN
DRIP TRAY
MOUNTS

INTRODUCTION
This WESTERBEKE Generator is a product of
WESTERBEKE'S long years of experience and advanced
technology. We take great pride in the superior durability
and dependable perfonnance
of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator,
it is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout. Should your generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This is your Operators Manual. A Parts Catalog is also
provided and a Technical Manual is available from your
WESTERBEKE dealer. If you are planning to install this
equipment yourself, contact your WESTERBEKE dealer
for WESTERBEKE'S Installation Manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder.
If you have not received a customer identification
card registering your warranty 60 days after submitting the
warranty registration form, , please contact the factory in
writing with model information, including the unit's serial
number and commission date
I~'WESTERBEKE
I Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model BEG Ser. #D703XXXX
Expires 9/20/02
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures and
catalogs) provided from sources other than WESTERBEKE
are not within WESTERBEKE'S CONTROL.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES
OR REPRESENTATIONS WITH RESPECT THERETO,
INCLUDING ACCURACY, TIMELINESS OR COMPLETE-
NESS THEREOF AND WILL IN NO EVENT BE LIABLE
FOR ANY TYPE OF DAMAGE OR INJURY INCURRED IN
CONNECTION WITH OR ARISING OUT OF THE
FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the time
span between printings ofWESTERBEKE product software
and the unavoidable existence
of earlierWESTERBEKE
manuals. In summation, product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot
be relied upon exclu-
sively as the definitive authority on the respective product. It
not only makes good sense but is imperative that appropriate
representatives ofWESTERBEKE
or the supplier in question
be consulted to deternline the accuracy and currentness
of the
product software being consulted by the customer.
SERIAL NUMBER LOCATION
The generator serial number and model number are located
on a decal on the generator housing. Take the time to enter
the information on the blank decal provided. This will pro-
vide a quick reference when seeking technical information
and/or ordering repair parts.
SPECIFICATION
MODEL _______ _
RPM __________ _
KW ___________ _
KVA __________ _
VOLTS ________ _
AMPS ________ _
ENG. HP ______ _
ENG. SER. NO.
GEN. SER. NO.
PF IPHASE ___ _
WIRES ________ _
RATING _______ _
INSUL CLASS __
TEMP. RISE ___ _
BAITERY _____ _
C.I.O. _________ _
50 HZ.
I
Fill in the information for your reference.
Engine 1.0. Plate
60 HZ.
Engines & Generators
3

INTRODUCTION
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine model and serial numbers. In addition,
include a complete part description and part number for each
part needed (see the separately furnished Parts Catalog). Also
insist upon WESTERBEKE packaged parts because will
fit
or generic parts are frequently not made to the same specifi-
cations as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
of your genera-
tor, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage Dr destruction of
the engine Dr generator.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visable location in
the engine room.
SPARES AND ACCESSORIES
Certain spare parts will be needed to support and maintain
your WESTERBEKE generator
or engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filter can be difficult
to obtain along
the way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
on-board inventory
of the proper WESTERBEKE parts.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE generator capable
of
many thousands of hours of dependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Six important steps to ensure long generator lije:
• Proper engine
and generator installation and alignment.
• An efficient well-designed exhaust system that includes
an anti-siphon breakto prevent water
from enteringthe
engine.
• Changing the engine oil and oilfilters every 100 operat-
ing hours.
• Proper maintenance of all engine and generator compo-
nents accordingto the maintenance schedule in this
manual.
• Use clean, filtered unleadedfuel.
• Winterize your engine according to the "Lay-up and
Recommissioning"section in this manual.
UNDERSTANDING THE GASOLINE GENERATOR
The gasoline engine driving an AC generator is in many
ways similar
to a gasoline automobile engine. The cylinders
are verticle in-line, and the engine's cylinder head has an
overhead camshaft which is chain-driven. The engine utilizes
a solid-state distributor which is horizontally mounted and
camshaft-driven. The engine incorporates a pressure type
lubrication system, and a fresh water-cooled engine block
which is thermostatically-controlled.
To a large degree, the
generator's engine requires the same preventive maintenance
that is required
of a gasoline automobile engine. The most
important factors to the generator's longevity are proper
ventilation, maintenance
of the fuel system, ignition system,
cooling system and the generator backend.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
CARE OF THE FUEL SUPPLY
A CAUTION: Only use unleaded fuel with an
octane rating of 89 or higher. Leaded fuel will cause
serious harm to your engine and violate your warranty.
Use only clean fuel! 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. This filter rating must be 24 microns or
smaller.
ENGINE OIL
Use a heavy duty engine oil with an API classification ~f SJ.
Change the engine oil after an initial 50 hours ofbreak-m
operation, and every 100 hours
of operation thereafter. For
recommended oil viscosity, see the following chart:
Operating Temperature Oil Viscosity
Above 68° F (20° C)
SAE 30, 10W-30 or 15W-40
41 °- 68° F (5°-20° C)
SAE 20 or 10W-30
Below 41 °F (5° C)
SAE 1 OW-3~
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains its own addi-
tives; additives of different brands could react in the
mixture to produce properties harmful to your engine.
ENGINE COOLANT
Westerbeke recommends a mixture of 50% antifreeze and
50% distilled water, when possible. Distilled water is free
from the chemicals that can corrode internal engine surfaces.
The antifreeze performs double duty, as 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
cooling circuit from rust and corrosion. Use a good quality
antifreeze that contains supplemental cooling additives
(SCAs) that keep the antifreeze chemically balanced, crucial
to long term protection.
The water and antifreeze should
be pre-mixed before being
poured into the cooling circuit.
NOTE: Use the new environmentally-friendly long lasting
antifreeze that is now available.
ANTIFREEZE PROTECTION CHART
Antifreeze concentration 23% 30% 35%
50%
Freezing Temperature 14° F
8° F
_4° F
-40° F
(-10°C) (-13°C) (-20°C) (-40°C)
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each generator.
The purpose
of this recovery tank is to allow 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 for the first time or after a pro-
longed layoff, check the following items:
• Check the engine oil level: add oil to maintain the level at
the full 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 the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: Afterthe 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 and
after the engine has cooled, the coolantfrom the recovery
tank will be drawn into the engine's cooling system to
replace the purged
air.
Before subsequent operation of the generator; the engine's
manifold should be topped off,
and the coolant recovery
tank may need
to befilled to the MAX level.
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
• Check load leads for correct connections as specified in
the wiring diagrams.
• Examine the air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
the load lines.
• Be sure that in power systems with a neutral line that the
neutral is properly grounded (or ungrounded) as the system
requires, and that 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.
• Make certain the raw water thru-hull is open.
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.
TO HEAT EXCHANGER
AIR
BLEED
PETCOCK
Engines & Generators
6

OPERATING INSTRUCTIONS
GENERATOR CONTROL PANEL
Starting the Generator
Press up the ON switch and hold it up and press up the
START switch (both switches are held up together). After
approximately one second, the starter will engage and the
engine will crank . Once the engine
is running, the starter
will disengage, and the
START switch may then be released
to return to its center (run mode) position. Continue holding
the
ON switch until the engine has sufficient oil pressure,
then release it to its center position.
NOTE: Should the enginefail to start, release both switches.
wait
20 seconds, and try again. Never run the starter more
than
20 seconds at a time.
CONTROL PANEL
AND BOX
START/STOP SWITCH
/? START
ON SWITCH
HOURMETER: THE HOURMETER RECORDS
ELAPSED TIME OF ENGINE USAGE THE TOTAL
NUMBER OF HOURS SHOULD BE USED AS A
GUIDE FOR MAINTENANCE SCHEDULING.
",,,""''''/,,,,''
(" /'
UH~-- OFF/RUN
IH...:;'--- OFF/RUN
Starting under Cold Conditions
Make certain the lubricating oil conforms with the ratings for
the prevailing temperature. Check the table under ENGINE
LUBRICATING OIL. The battery should be fully charged to
minimize voltage drop.
Stopping the Generator
To stop the generator, press the STOP switch down then
release it to the center (normal) position.
EMERGENCY STOPPING
If the generator does not stop using the STOP switch,
remove the 8 amp fuse
or disconnect the battery.
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
cooling system during cranking. This raw water can
enter the engine's cylinders by way of the exhaust
manifold once the exhaust system fills. Prevent this
from happening by closing the raw water supply
through-hull shut-off. draining the exhaust muffler, and
correcting the cause of the excessive engine cranking.
Engine damage resulting from raw water entry is not a
warrantable issue; the owner/operator should keep this
in mind.
8A FUSE----
'sTART/STOP/ON
SWITCHES
Abnormal Stop (refer to SAFETY SHUTDOWN SWITCHES)
An abnormal stop is one in which the generator ceases to run
and comes to a stop as a result
of an operating fault which may
cause damage to the engine, the generator, or create an unsafe
operating condition. The fault stop conditions are:
1. Overspeed condition.
2. High engine temperature.
3. Low oil pressure.
4. High exhaust temperature.
5. Electrical overload.
a. Fuse at the control panel.
b. 20Abreaker
on the engine.
c. Main circuit breaker.
Should a fault condition occur, the engine will shutdown. On
the remote panel the green LED light will tum offindicating
an engine shutdown. Once detected, the fault should be
located and corrected (see
ENGINE TROUBLESHOOTING).
Engines & Generators
7

OPERATING INSTRUCTIONS (OPTIONAL PANELS)
NOTE: Remote panels cannot be inter-connected. Only one panel can be used.
REMOTE PANEL
Starting the Generator
To start the generator, hold the ON switch in the up position
(the green light will come on), then hold the
START/STOP
switch in the up (start) position (both switches are held up
together). After approximately one second, the starter will
engage and the engine will crank (the green light will dim).
Once the engine is running (the green light will brighten), the
starter will disengage, and the
START/STOP switch may
then be released to return to its center (run mode) position.
Continue holding the
ON switch until the engine has suffi-
cient oil pressure, then release it to its center position.
NOTE: Should the engineJail to start, release both switches,
wait
20 seconds, and try again. Never run the starter more
than 20 seconds
at a time.
START/STOP SWITCH
/:) START
;0' ............ 1' ....
<' /'
r1<..-:"--- OFF/RUN
I.. ' ....
-- "-
----~ STOP OFf
Stopping the Generator
ON SWITCH
/;> START
< ............ : .........
.tH.,;_._-- OFF/RUN
To stop the generator, move the START/STOP switch to the
down (stop) position then release it to the center (offlrun
mode) position.
REMOTE START/STOP PANEL (HARDWIRED)
An optional remote start/stop panel is available for
controlling the generator from a remote location.
This panel has the same
ON, START and STOP functions
previously described. Also included is a green LED light
which glows once the engine/generator has reached 600
rpm's. The purpose of the LED is to alert the operator to
release the
START switch. It is also an indication that the
engine/generator is running.
REMOTE INSTRUMENT PANEL (HARDWIRED)
An optional remote in,strument panel is available which
includes a water temperature gauge, oil pressure gauge, DC
charging voltmeter, operating hourmeter, and start/stop
switches.
REMOTE INSTRUMENT PANEL INSTALLATION
The remote instrument panel has two sending units to be
installed on the engine block, a water temperature sender
and an oil pressure gauge sender. Plugged ports for each are
located on the engine. The water temperature sender
is
installed in the thermostat housing and the oil pressure sender
is adjacent to the oil pressure switch. Use sealing compound
on the threads
of both senders. Electrical connections for
each sender are tied off next to the senders location (in the
wiring harness).
The blue wire is for the oil pressure sender and the tan wire
is for the water temperature sender.
If there is a jumper
between terminal board connections TBI-I and TBI-2, it
should
be removed. Refer to the REMOTE INSTRUMENT
WIRING DIAGRAMin this manual.
NOTE: When insialling the optional remote panels, it is the
installers responsibility to comply with the U.S. Coast Guard
standards 33 CFR part 183.
REMOTE
STOP/START
PANEL
(PLUG
CONNECTER)
This stop/start remote panel is available with eithera 15' or
30' harness that plugs directly into the generators control
panel. Operating instructions are the same as the remote
panel
to the left
Engines & Generators
8

BREAK-IN PROCEDURE/DAILY OPERATION
BREAK-IN PROCEDURE
After the generator has been started, check for proper opera-
tion and then encourage a fast warm-up. Run the generator
between 20% to 60%
of full load for the first 10 hours.
A CAUTION: 00 not attempt to break-in your genera-
tor by running without a load.
After the first 10 hours of the generators' 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 a
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
it within the generators' rating. Since the generator operates
at 1800 rpm to produce
60 hertz, or at 1500 rpm to produce
50 hertz, control of the generator's engine break-in is gov-
erned by the current drawn from the generator.
To protect against unintentional overloading of the generator,
the generator's output leads should be routed through a cir-
cuit breaker that is rated at the rated output
of the generator.
NOTE: Be aware of motorstarting loads and the high
current drawn required
for starting motors. This starting
amperage drawn can be 3 to 5 times normal running amper-
age. See GENERATOR INFORMATION in this manual.
CHECK LIST
Follow this checklist each day before starting your generator.
• Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule).
• Visually inspect the engine for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check the drive belt for wear and proper tension (weekly).
• Check for abnormal noise such as knocking, vibration and
blow-back sounds.
• 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.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached
and loads are applied.
A CAUTION: 00 not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove the major AC loads from the generator one at a time.
Allow the generator to run for a few minutes to stabilize the
operating temperature and press the STOP switch down, (see
CONTROL PANELS).
NOTE: After the first 50 hours of generator operation check
the maintenance schedule
for the 50 hour service check.
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
(see ENGINE SPEED (HER1Z) ADJUSTMENTunder
ENGINEADJUSTMENTS). A no-load voltage adjustment
may also be required in conjunction with the engine's speed
adjustment (see GENERATOR INFORMATION).
Engines & Generators

SAFETY SHUTDOWN SWITCHES
SAFETY SHUTDOWN SWITCHES
The engine is protected by five automatic shutdown
switches. Should a shutdown occur, do
not attempt to restmt
without finding and correcting the cause. Refer to the
heading Engine starts, runs
and then shuts down in the
ENGINE TROUBLESHOOTING section of this manual.
The following is a description of these automatic shutdown
switches:
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Normally closed, this switch will open and interrupt
the DC voltage (shutting off the engine) should the switch's
sensor indicate an excessive exhaust temperature (an inade-
quate supply
of raw water causes high exhaust temperatures).
This switch opens
at 260-270°F (127-132°C). This switch
resets at approximately 225°F (107°C).
~j
TO SIPHON .
BREAK
Low Oil Pressure Switch
I,
"
EXHAUST
A low oil pressure shutdown switch is located off the
engine's oil gallery. Nonnally open
in a static state, this
switch's sensor monitors the engine's oil pressure. Should the
engine's oil pressure
fall to 5-10 psi, this switch will open
interrupting the DC voltage thereby shutting off the engine.
ENGINE BLOCK
High Water Temperature Switch
A high water temperature switch is located at the thermostat
housing. Nom1ally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C), will open and inten'upt the DC voltage thereby
shutting offthe engine. This switch resets
at 195°F (107°C).
20 AMP CIRCUIT I
BREAKER
Engine Circuit Breaker
The generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere
in the instrument panel
wiring or engine wiring will cause the breaker to trip.
In this
event the generator will shut down because the opened
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.
Engines & Generators
10

HIGH RPM SHUTDOWN SWITCH
DESCRIPTION
An overspeed switch in the DC circuit shuts offthe
generators engine by grounding out the ignition system
if
the engine's speed reaches 2175 rpm (approximately).
After correcting the problem, this switch can be reset by
momentarily depressing the stop switch. Refer to the
WIRING DIAGRAMS in this manual.
If the overspeed switch is faulty, (resetting with the stop
switch fails to reset the circuit), lift the white/yellow wire
offthe T5 terminal and connect itwith the redJpurple wire
on the
T4 terminal. Now restart the generator.
If this bypa8.s is successful, replace the faulty overspeed
switch.
NOTE: Overspeed switches draw a small amount of amperage
(25 milliamps)
at all times once the generator is connected
to its starting battery. This amounts to approximately 18
amp-hours in a month. It is
not necessary to be concerned
with this slight amperage draw during normal seasonal
operation. However, ifthe generator set is to be unused
for
i many months, it is best to either remove the 8 amp ignition
I fusefrom the control
panel on the generator or tum off the
generator's starting battery switch.
· •. \~/OVERSPEED
'/" CIRCUIT
BOARD
A CAUTION: It is very important that the overs peed
shutdown always be installed and functioning. Any
tampering with the overs peed shutdown module, which
would cause it to malfunction. could be a cause of
injury should the generator's belt-driven governor fail
and cause the generator to run away.
Engines.& Generators
11

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenance procedures are simple but others are
more difficult and may require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EXPLANATION OF SCHEDULED MAINTENANCE
EACH
DAY
50
100 250 500 750 1000 1250
0
Unleaded gasoline with octane rating of 89 of higher
0
Check for water and dirt in fuel (drain/replace filter if
necessary) .
0
Oil level should indicate between MAX. and LOW on
dipstick.
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
0
Inspect for proper tension (3/8" to 1/2" deflection)
weekly and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine
0
NOTE: Keep engine surface clean. Dirt and
Check for fuel, oil and water leaks. Inspect wiring and
oil will inhibit the engine's ability to remain
electrical connections. Keep bolts & nuts tight. Check
cool.
for loose belt tension.
Sparks Plugs
0 D D 0 D 0
Check gap, inspect for burning and corrosion.
Starting Batteries
0
Every 50 operating hours check electrolyte levels
(and House Batteries) weekly and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hours. Then
change both every 100 hours.
Generator
0 0 0 0 0 D 0
Check that AC connections are clean and secure with
no chafing-see GENERATOR INFORMATION for
additional information.
Fuel Lift Pump
0
Periodically inspect for leaks.
and Gasdenser
Air Screen (Flame Arrester)
0
Clean at 50 hours, then every 100 hours.
Exhaust System
0 D 0 0 0 0
Initial clleck at 50 hours, then every 250 hours.
Inspect for leaks. Check anti-siphon valve operation.
Check the exhaust elbow for carbon and/or corrosion
buildup on inside passages; clean and replace as
necessary. Check that all connections are tight.
Engine Hoses
0 0 D 0 0 0 0
Hose should be hard & tight. Replace if hoses
become spongy. Check and tighten all hose clamps.
Raw Water Pump
0 D 0 0 0 0
Hose should be hard and tight, Replace if soft or
spongy. Check and tighten all hose clamps.
Belt Driven Governor
D 0 0 0 0
Change governor oil every 250 hours. Adjust
governor operation as needed.
REVISED MARCH 2005
Engines & Generators
12

SCHEDULED
MAINTENANCE
Heat Exchanger
Raw Water Pump
Coolant System
* Starter Motor
Distributor
*Engine Cylinder
Compression and
Valve Clearance
*Exhaust Elbow
MAINTENANCE SCHEDULE
NOTE: Use the engine hourmetergauge to log your engine hours or record your
engine hours by running time.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY 50 100
250
500
750 1000 1250 MAINTENANCE
0 0 0 0 0 0 0
Clean or replace anode. Open heat exchanger end
cap and clean out debris. Remove every 1000 hours
for professional cleaning and pressure testing.
0 0 0
Remove pump cover and inspect impeller for wear;
replace if needed. Also replace gasket. Lubricate
both wilen reassembling.
0
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
0 0
Cileck solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the start motor
pinion drive.
0 0
Check ignition timing. Check condition of
distributor cap and rotor.
0 0
Incorrect valve clearance will result in poor engine
performance; check compression pressure and timing,
and adjust valve clearances.
0
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteriorated.
WARNING: A defective exhaust elbow can cause
carbon monoxide leakage!
Carburetor Fuel Filter Screen
0 0 0 0 0
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteriorated.
WARNING: A defective exhaust elbow can cause
carbon monoxide leakage!
*Engine Timing Belt
at 3000 Operating Hours Remove and replace.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
13

COOLING SYSTEM
FRESH WATER COOLING CIRCUIT
NOTE: Refer to the ENGINE COOLANTsection for the
recommended antifreeze and water mixture to be used as the
fresh water coolant.
Fresh water coolant is pumped through the engine by a
circulating pump, absorbing heat from the engine. The
coolant then passes through the thermostat into the heat
exchanger where it
is cooled, and returned to the engine
block via the suction side
of the circulating pump.When the
engine
is started cold, external coolant flow is prevented by
the closed thermostat (although some coolant flow
is
bypassed around the thermostat to prevent the exhaust
manifold from overheating). As the engine'watms
up, the
thennostat gradually opens, allowing full flow
of the engine's
coolant to flow unrestricted to the external portion
of the
cooling system.
Coolant Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi-
cant loss
of coolant and without introducing air into the cool-
ing system. This tank should be located at
or above the
engine manifold level and should be easily accessible.
~"'-L'IJ'I' \f
NOTE: Periodically check the condition of the manifold pres-
sure cap. Ensure that the upper and lower ntbber seals are
in
good condition and check that the vacuum valve.opens and
closes tightly. Carry a spare cap.
SEAL
MANIFOLD
PRESSURE
CAP
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 maintenance is
critical; a substantial number of engine failures can be
traced back to cooling system corrosion.
Drain the engine coolant by removing the drain plug on the
engine block and opening the manifold pressure cap. Flush
the system with fresh water, then reinstall the drain and start
the refill process.
NOTE: The drain petcock on the heat exchanger should also
be used to help drain engine coolant.
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.
Refilling the Coolant
After replacing the engine block drain plug, close the heat
exchanger's coolant petcock. Then run the engine at idle and
slowly pour clean, premixed coolant into the manifold.
Monitor the coolant in the manifold and add as needed. Fill
the manifold to the filler neck and install the manifold
pressure cap.
Remove the cap on the coolant recovery tank and
fill with
coolant
mix to halfway between LOW and MAX and replace
the cap. Run the engine and observe the coolant expansion
flow into the recovery tank.
After checking for leaks, stop the engine and allow
it to cool.
Coolant should draw back into the cooling system
as the
engine cools down. Add coolant to the recovery
tank if
needed and check the coolant in the manifold. Clean up any
spilled coolant.
COOLANT RETRACTION
COOLANT EXPANSION
TO COOLANT RECOVERY
TANK
Engines & Generators
14