Westerbeke 15.0BTD60-HERTZ User manual

OPERATOR'S MANUAL
&
INSTALLATION GUIDE
WESTERBEKE
15.0 BTD 60 - HERTZ
12.0 BTD 50 - HERTZ
MARINE DIESEL
GENERA TOR SETS
SINGLE & THREE PHASE
Publication #36856
Edition Two
May 1995
j'-..Y" rWESTERBEKE
. WESTERBEKE CORPORATION 0 MYLES.STANDISH INDUSTRIAL PARK .
j 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A. .
• TEL: [phone] FAX: [phone] WEBSITE: WWW.WESTERBEKE.COM

SAFETY PRECAUTIONS
The following symbols appear in this manual to call attention
to and emphasize conditions potentially dangerous to the
operator.
IIWARNINGI
The above symbol is used in the manual to warn of possible
serious personal injuryor loss of life.
CAUTION
The above symbol is used in the manual to caution personnel
of possible damage to equipment.
Read the manual carefully and thoroughly before attempting
to operate the equipment. Know when dangerous conditions
can exits and take necessary precautionsto protect personnel
and equipment.
Fuels, exhaust gases, batteries, electrical equipment, and
moving and hot partsare potential hazards that could result in
serious personal injury or death. Follow recommended proce-
dures carefully.
PJways operate bilge blowers for at least five minutes before
startingagasoline-fueledengine; ensure nogasolinefumesare
present before starting.
• Prevent Electric Shock
Shut off electric power before accessing electrical equip-
ment.
Use insulated matswhenever working on electrical equip-
ment.
Make sure your clothing is dry, not damp (particularly
shoes), and keep your skin surfaces dry when handling
electrical equipment.
Remove wristwatch and jewelry when working on electri-
cal equipment.
Do notconnect utilityshore power to vessel's AC circuits,
except through a ship-to-shore double-throw transfer
switch. Damage to vessel's AC generatormayresult if this
is notdone.
Be extremely careful when working on electrical com-
ponents. High voltage can cause injuryor death.
• Exhaust Gases Are Toxic
Ensurethattheexhaustsystem is adequateto expel gases
discharged from the engine. Check exhaust system
regularly for leaks and make sure the exhaust manifolds
are securelyattached and no warping exists.
Be sure the unitand its surroundings are well-ventilated.
• Use Extreme Care When Handling Engine Fuel
(A constant danger of explosion or fire exists)
Do not fill fuel tank(s) while the engine is running.
Do notsmoke oruse an open flame nearthe engine orthe
fuel tank.
• Do Not Alter or Modifythe Fuel System
Be sure all fuel supplies have a positive shutoffvalve.
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. Ex-
tinguishers rated ABC by the NFPAare appropriate for all
applications encountered in this environment.
• Use Extreme Care When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye protection
when servicing batteries.
Leadacidbatteriesemithydrogen,ahighly-explosivegas,
which can be ignited by electrical arcing or by a lighted
cigarette, cigar, or pipe. Do not smoke or allow an open
flame near the battery being serviced. Shut off all electri-
cal equipment in the vicinity to prevent electrical arcing
during servicing.
• Avoid Moving Parts
Do notservice the unitwhile the unit is running; if a situa-
tion arises in which it is absolutely necessary to make
operating adjustments, use extremecare to avoid moving
parts and hotexhaust system components.
Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loosejackets, shirts or sleeves,
rings, necklaces, or bracelets that might be caught in
moving parts.
Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
place at all times.
Do notcheckfluid levels ordrivebelttension whilethe unit
is operating.
Do notwork on the equipmentwhen mentallyor physical-
lyincapacitated
by fatigue.

IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Productsoftwareofall kinds, suchasbrochures,drawings,technical data, operator'sandworkshopmanuals,
parts lists and parts price lists (and other related information), instructions and specifications provided from
sources otherthan Westerbeke, is notwithin Westerbeke's control and, accordingly, is provided
to Wester-
bekecustomersonlyasacourtesyand service. WESTERBEKE CANNOTBE RESPONSIBLE FORTHE CON-
TENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDINGTHE ACCURACY, TIMELINESS OR COMPLETENESS THEREOF, AND WILL IN NO
EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH, OR
ARISING OUT OF, THE FURNISHING OR USE OF SUCH SOFTWARE.
For example, components and subassemblies incorporated into Westerbeke's products and supplied by
others (suchas engine blocks, fuel systemsand components, transmissions, electrical components, pumps
and otherproducts) aregenerallysupported
by theirmanufacturerswiththeir ownsoftware, and Westerbeke
must depend on such software
for the design of Westerbeke's own product software. Such software,
however,
may be outdated and no longeraccurate. Routine changes made by Westerbeke's suppliers, of
which Westerbeke rarely has notice in advance, are frequently not reflected in the supplier's software until
after such changes take place.
Westerbeke customers should also keep in mind the time span between printings
of Westerbeke product
software, andthe unavoidableexistence
of earlier, non-currentWesterbeke softwareeditionsin thefield. Ad-
ditionally, mostWesterbeke products include customer-requested special features that frequently do not in-
clude complete documentation.
Insummation, productsoftware providedwithWesterbeke products, whetherfrom Westerbeke or othersup-
pliers, must
not and cannot be relied upon exclusivelyas the definitive authority on the respective product.
It not only makes good sense, but is imperative that appropriate representatives of Westerbeke or the sup-
plier in question be consulted
to determine the accuracy and currency of the product software being con-
sulted
by the customer.

FOREWORD
Thankyou for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have
you as a customer.
Read this manual carefully and observe all safety precautions included throughout. Operating procedures,
periodic preventive maintenance procedures, installation checks, system descriptions and minor adjust-
ment proceduresare included herein so you can operate your equipment safely and properly, maintain the
equipment at a high level of efficiency, and expect dependable performance and long service life in return.
Should your unit require special attention, contactyourWesterbeke dealer for assistance. The Westerbeke
Service Organization is trained to provide the support necessary to ensure long-term dependable perfor-
mance.
If, within 60 days of submitting the Warranty Registration Form for your unit, you have not received a Cus-
tomer Identification Card (see below) registering your warranty, please contact the factory in writing with
Model information, including the unit's serial numberand commission date.
from:
WESTERBEKE CORPORA liON
AVON INDUSTRIAL PARK
AVON, MA 02322
Mail To:
WESTERBEKE
AUON J"_USTRUIIL P.RK, iIIIIUON. "'l1li e2322 • 'I'ZL (617) 588-77 ••
TBLIX: 92-4444" FAX: '1&017) SS'-9323 .. C •• LJ:: WBSTeORP
CUSTOMER IDENTIFICATION
Adam Smith
85 Maple Street
Alden, IN 12234
Model BTD 15.0KW
Expires 7/7/88
Ser .• 1234(706

TABLE OF CONTENTS
Section ......................................................................... Page
GENERAL ...........................................................................2
BTD 15.0KW GENERAL SPECIFICATIONS ......................3
SYSTEM SPECiFiCATIONS...............................................4
INSTALLATION CHECKS ...................................................7
OPERATION ..................................................................... 14
FUEL SYSTEM ................................................................. 18
ELECTRICAL SYSTEM ..................................................... 21
DC CONTROL CIRCUIT WIRING DIAGRAM ........... 22 & 23
COOLING SySTEM .......................................................... 25
LUBRICATION SYSTEM .................................................. 31
BT GENERATOR .............................................................. 33
GENERAL INFORMATION AND CARE
OF THE GENERATOR ..................................................... 39
ENGINE CONTROL PANEL. ............................................ 41
ENGINE TROUBLESHOOTING ....................................... 43
MAINTENANCE & ADJUSTMENTS ................................. 48
LAY-UP & RECOMMISSIONING ..................................... 56
TABLE OF STANDARD HARDWARE
TIGHTENING TORQUES ................................................. 59
SOUND GUARD INSTALLATION
INSTRUCTIONS ............................................................... 60
TORQUE SPECIFICATIONS ............................................ 61
INDEX ............................................................................... 62

Water Injected
Exhaust Elbow
Control Panel ~
Heat Exchanger
-----:.;:~
Zinc Anode
BTD 15.0 KW Generator
Lube Oil Fill Cap
Lube Oil Dipstick
Oil Pressure Sender
15KW BTD
1
Fresh Water Fill Cap
I.D. Plate
DC Charging
Alternator
Lube Oil Filter
Lube Oil Drain Hose
Oil Pressure Switch

GENERAL
Introduction
This manual contains the equipment operating procedures aswell as additional information needed to help
the operator keepthe marine equipment in properworking order. Studyand follow the instructions careful-
ly. A planned maintenance program is included in this manual; adhering
to the program will result in better
equipmentperformanceand longerequipmentlife. Properdiagnosis
of a problem isthe mostimportantstep
to satisfactory repair; consequently, a troubleshooting table is included.
Understanding the Diesel Engine
Thediesel engine closely resembles the gasoline engine, sincethe mechanism is essentiallythe same. The
cylinders are arranged above a closed crankcase; the crankshaft is
of the same general type as that of a
gasoline engine; and the diesel engine hasthe sametype
of valves, camshaft, pistons, connecting rods and
lubricating system.
Therefore,
to a greatextent, a diesel engine requires the same preventive maintenance as a gasoline engine.
The most important factors are properventilation and proper maintenance
of the fuel, lubricating and cool-
ing systems. Replacement
of fuel and lubricating filter elements at thetime periods specified is a must, and
frequentchecking
for contamination (that is, water, sediment, etc.) inthefuel systemisalsoessential. Another
importantfactoris the use
of the same brand of high detergent diesel lubricating oil designed specificallyfor
diesel engines.
The diesel engine doesdifferfrom the gasoline engine, however, in its method
of handling and firing offuel.
The carburetor and ignition systems are done away with and in their place is a single component -the fuel
injection
pump -which performs thefunction of both.
Ordering Parts
When contacting
your Westerbeke dealer, parts distributor, or the factory about your Westerbeke unit, al-
ways provide the generator's model number, the engine's serial numberand the generator's serial number
as they appear on the scarlet and gold nameplate located on the generator end. You must provide us with
this information
so we may properly identify your unit.
Note that component locations in the manual are referenced from the front
of the engine which is the pul-
ley/drive beltend. (Theflywheel/generator
or transmission end istherearend.) Leftand rightsides aredeter-
mined
by theengine; imaginestraddlingtheengineandfacing in thesamedirectionasthefront of theengine:
the left side is at
your left, the right side at your right.
Westerbeke engines and generator sets are thoroughly checked and given a final run under various load
conditionsbeforeleavingthefactory. This is done
to ensuredependableoperation, long service, and a satis-
fied owner.
Care at the factory during assembly, and thorough testing, have resulted in a Westerbeke diesel engine-
driven generator capable of many thousands
of hours of dependable service. However, the manufacturer
cannot control thetreatment the unit receives in
the field. That part is up to the owner/operator.
2

BTC 15.0 KW MARINE DIESEL GENERATOR SET
Engine Type
Governor
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
Maximum Torque
Compression Ratio
Compression Pressure
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
GENERAL SPECIFICATIONS
Diesel, 4-cycle, 4-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(30 hp at 1800 rpms maximum)
Mechanical, centrifugal weighttype
Swirl chambertype
3.307 x 3.701 inches (84 x 94 mm)
128 cubic inches
(2.1 liters)
1-3-4-2
Clockwise, when viewed from the front
79.6 Ib-ft
(11 kg-m) at 1900 rpm
21 :1
355.5 psi (25 kg/cm2) at 150 -200 rpm
Intake Opens 30° BTDC
Intake Closes 50° ABDC
Exhaust Opens 74° BBDC
Exhaust Closes
30° ATDC
Intake 30°
Exhaust 30°
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height: 25.06 inches (637 mm)
Width: 18.13 inches
(461 mm)
Length: 38.00 inches (945 mm)
3
683 Ibs (309.8 kgs)
1.8 gph
(6.81 Iph) at full rated
output (approximate)
Continuous
15°
Temporary 20° (not to exceed 20 min.)

FUEL SYSTEM
General
Fuel
Fuel Injection Pump
Fuel Injection Timing
Nozzle
Injectors
Lift Pump
Fuel Filter (on engine)
Air Cleaner
Air Flow (engine combustion)
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
Sea Water Pump
Sea Water Flow, at 1800 rpm
(measured before discharging
into exhaust elbow)
System Capacity
LUBRICATION SYSTEM
General
Oil Filter
Sump Capacity (includes filter)
SYSTEM SPECIFICATIONS
Open flow, totally self-bleeding
No.2 Diesel oil (cetane rating of 45 or higher)
CAY DPA Injection pump
230 BTDC ± 0.50 (static timing)
Throttle type
Bosch type
12-Volt; lift capacity 6 ft (1.8 m)
Spin-on replaceable cartridge
Metal screen type -cleanable
67 cfm (1.89 cmm)
Fresh water-cooled block
thermostatically-controlled
with heat exchanger
170
-190
0 F (77 -880
C)
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, gear-driven
5.6 gallons per minute (21.2 Ipm)
10 qts (9.5 liters) approximate
Pressure type
by Trochoid pump
gear-driven with external pressure relief valve
Full flow, paper element, spin-on type #35828
7 qts (6.6 liters)
4

Operating Oil Pressure (engine hot)
Oil Grade
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity(C.C.A.)
DC Charging Alternator
Regulator
Starting Aid
Starter
DC No-Load Current
DC Cranking Current
AC GENERATOR
General
Rating -Single Phase
60 Hertz (1800 rpm)
15KW
50 Hertz (1500 rpm)
12KW
35 -45 psi (2.8 -3.5 kg/cm2)
API specification CF OR CG-4
12-Volt,(-) negative ground
300 -400 cold cranking Amps
12-Volt DC, 50 Amp
Internal regulator built into alternator
Glow plug, sheathed type
12-Volt, 1.6KW, reduction type solenoid mounted
90 Amp. (max.) at 11.5 Volts
225 -250 Amps (engine cold)
Brushiess, four-pole, revolving field. Pre-lubricated, single-
bearing design. Reconnectable, single-phase transformer
regulation (optional solid-state voltage regulation).
Voltage 120
or 120/240 Volts -60 Hertz
220 Volts -50 Hertz
Voltage regulation: ±5% no load
to full load
Frequency rotation: ±3 Hertz (5%) no load
to full load
120 Volts
120/240 Volts
220 Volts
5
125 Amps
125/62.5 Amps
60 Amps

General
Rating -Three Phase
15KW -60 Hertz
12KW -50 Hertz
Voltage - 3 Phase (60 Hertz)
Voltage - 3 Phase (50 Hertz)
Amperage - 3 Phase (60 Hertz)
Amperage - 3 Phase (50 Hertz)
Generator Cooling
Air Requirements, (60 Hertz), at 1800 RPM
Brushless, six pole, revolving field. Sealed lubricated single bearing
design. 12 Lead reconnectable for low voltage WYE, high voltage
Delta. Solid State voltage regulator with protection circuitry.
Low voltage WYE 208 volts
High voltage WYE 480 volts
DELTA 240 volts
High voltage WYE 380 volts
DELTA 220 volts
Low voltage WYE 99 Amps
High voltage WYE 43 Amps
DELTA 86 Amps
High voltage WYE 43 Amps
DELTA 75 Amps
225 -250
din (6.37 -7.08 cmm)
NOTE: Increase air supply 15% for 50 Hertz operation (1500 rpm)
Engine Combustion Air
Requirements, (60 Hertz), at 1800 RPM 67
dm (1.89 cmm)
TUNE-UP SPECIFICATIONS
Injector Pressure 1707 psi (120 kglcm2 + 10kglcm2 -0 kglcm2)
Engine Timing 19° BTDC ± .5°
GENERATOR COMPARTMENT
Ambient Temperature 104° F(40°C) Maximum
NOTE: Forced ventilation should be provided as needed to maintain generator compartment ambient
temperature 1040 F.
6

INSTALLATION CHECKS
General
Becausethe crafts in which Westerbeke engines and generators are installed vary in design, installation pro-
cedures will vary according to your craft's specific design. It is not the intent of this section to advise
boatyards
or installers on procedures alreadywell-developed and well-understood. However, it is important
that the owner/operator realize there are details of the installation which require periodic checks to ensure
the best operating conditions for the equipment and safe operating conditions for the personnel on board.
Proper location and installation ofthe generator set in the vessel are of prime importance.
Factors in the installationthat must be considered are ventilation, so as to cool the generatorand to provide
air
for engine combustion; exhaust system, to properly discharge raw cooling water, to quiet the exhaust
and to expel the exhaust gas; cooling water supply; fuel supply; and electrical connections.
Factors
in the location that must be considered are proper support and access for servicing and repairs.
There are four 1/2-inch bolt holes in each generator mounting rail to properly secure the generator to its
mounting platform.
7

Location
The location should be such that it is dry, above low-lying vapor areas, and away from being splashed by
bilge water or water from above. It should be properly ventilated and accessible for minor servicing and
repairs. Access
for majorrepairs should be given consideration aswell. The location must be properlyven-
tilated
to providethe fresh cooling air for the generator end and for engine combustion. Hot generatordis-
chargeairmustbe removed from
the generatorarea. The platform on whichthe generatorand its mounting
rails are located should be strong enough
to supportthe generatorunitduring all angles ofvessel operation.
Exhaust System
The exhaust system provides an outlet line to vent engine exhaust gases out of and away from the vessel.
The system also discharges seawater which has passed through the engine's sea water circuit
by mixing it
with hot exhaust gases. This mixing helps
to cool the exhaust gases and exhaust elbows and pipe. The ex-
haust system and the sea water supply
to the exhaust must be configured to prevent the siphoning of sea
waterintothe exhaustthroughthe sea watercooling circuit and
to preventthe entry of sea waterintothe ex-
haust through the circuit's thru-hull discharge port. If not prevented, sea water entering through the dis-
charge
port can fill the exhaust system's muffler and enterthe engine's cylinders. This will prevent proper
starting and possibly cause damage
to internal engine components.
Generator Above Water Line
SeaWater
Fump
The sea watersupply hose to the exhaust system'swater injection elbow should be routed Oooped) at least
12 inchesabovethevessel'swaterline. An anti-siphon breakshould be installed atthe
top of this loop when
the generator set is installed at
or belowthe water line (see page 9). The top of the loop should be placed
high enoughabovethevessel's waterline
so as to remain abovethewaterlinewhen the vessel is underway,
no matterwhat the angle of heel or roll may be.
The seawatersupplythru-hull seacockfittings mustbe
of theflush-hull type. High-speed scoop typefittings
should not be used, astheytend
to encourage siphoning.
8

Generator BeloN Water Line
The exhaust dischargefrom thewaterlift muffler should be routed well above the water linethen downward
to the thru-hull discharge. This routing will prevent sea waterfrom entering ifthe thru-hull discharge fitting
becomes submerged when thevessel heels
or rolls while underway, or is subjected to following sea condi-
tions. Refer
to the figures for recommended exhaust system installations.
Exhaust Back-pressure
Exhaust back-pressure should be checked prior to
putting a generator into service. (Refer to the illustra-
tion.) Excessive back-pressurewill affecttheengine's
~
performance and the generator's power output. ~
Tomeasurethe engine's back-pressure, eithera mer- ~.
curymanometer or awatercolumnmustbe acquired.
A
boatyard or marine mechanic should have a . .. .
manometer. A water column can be made by taking ~/4
a clear plastic tube and taping one end to a yardstick NPT
and fitting the otherend with a 1/4 inch NPT (Nation-
al PipeTap) fitting. Fill thetube half-full with water. If
your generator set does not have a tapped hole in its
exhaust manifold, one must be drilled and tapped
for
a 1/4-inch NPTfitting.
Measure baCk-pressure
at the exhaust elbow when
the generator is under a full load. Back-pressure, as
measured
by a manometer or water column, should
not be overthe following specifications:
9
48
3S
38
2S
28
-Insulation
\
Exhaust
Elbow
Exhaust

2 inches of mercury
27 inches
of water in a water column
15.6 ounces
PSI
1.0 PSI
NOTE: Other pressure gauges may be available to test for exhaust back-pressure.
Oil Drain
An oil sumpdrain hose is installed onthe engine with the discharge end secured by a bracket atthefront of
the engine. Oil maybedrained from this hose by removing the cap and the discharge end of the hose from
the support bracket and lowering the hose into a container. The hose cap fitting is 1/4 inch-NPT (National
Pipe Tap) and can be extended, or have a pump added, for easier removal of the old oil, ifdesired.
Cooling System
The generator's engine is fresh water cooled by an engine-mounted heat exchanger. Sea water is used as
the heat exchange's cooling medium. Sea water is pumped intothe exchanger by a sea water pump and is
then injected intotheexhaustdischarge, carryingwith itthe heatremoved fromtheengine'sfreshwatercool-
ing system.
Seawater should be supplied to the sea water pump through a flush-type hull fitting using a wire-reinforced
hose between the thru-hull fitting and the sea water pump. This sea water should be directed through a
visual-type sea water strainer and then delivered
to the pump. Hoses routed from thethru-hull fitting to the
strainerand
to the seawater pump should bewire-reinforced to prevent the hosefrom collapsing during the
generator's operation (suction from the pump may collapse a non-reinforced hose). Sea water strainers
should be mounted at
or belowthe water line to make sure the sea water line remains primed.
CAUTION
Do not use a scoop-typethru-hull fitting as a means of supplying sea water to the generator.
Waterpressure againstthistypefitting, whilethevessel is underway, can push seawaterpast
the seawater pump's impeller intothe generator's exhaust system, filling it and the engine as
well. Flush-type, clear, thru-hull fittings are recommended and should be located on the hull
so as to be belowthe waterline during all angles of boat operation.
The use of common-type street elbows is not recommended for plumbing the sea water cir-
cuit. These generally have very restrictive inside diameters. Machined fittings are preferred.
Automatic Shutdown
High Exhaust Temperature Shutdown Switch (normally closed)
An exhaust temperature switch is located on the exhaust elbow. This switch will open and shut the fuel
solenoid OFF (which turns OFF the engine) should the switch's sensor indicate an excessive exhaust
temperature (an inadequate supply
of sea water coolant causes high exhaust temperatures). This switch
opens at 260 -2700 F (127 -132
0 C). This switch resets at approximately2250 F (10]0 C).
10

High Water Temperature Shutdown Switch (normally closed)
A high water temperature switch is located on the thermostat housing. This switch will open and shut the
fuel solenoids OFF (which turns OFF the engine) should the fresh water coolant's operating temperature
reach approximately 2050 F (960 C). This switch resets at 1950 F (10-r C).
Low Oil Pressure Shutdown Switch (normally open)
A lowoil pressure shutdown switch is located offthe engine's oil gallery. This switch's sensor monitors the
engine's oil pressure. Should the engine's oil pressure fall
to 10 -15 psi, the switch will open shutting OFF
the fuel solenoid (which turns OFF the engine).
Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline en-
gines, carbon monoxideis present in diesel exhaustfumes. Carbon monoxide is a dangerous
gasthat can cause unconsciousnessand is potentiallylethal. Some ofthe symptoms
or signs
of carbon monoxide inhalation or poisoning are listed below.
o Dizziness o Vomiting
o Intense headache o Musculartwitching
o Weakness and sleepiness o Throbbing in temples
If you experience any ofthe above symptoms, get out into fresh air immediately.
The best protection against carbon monoxide poisoning is a daily inspection of the complete exhaust sys-
tem. Check for leaks around manifolds, gaskets, and welds. Make sure exhaust lines are not heating sur-
rounding areas excessively. If excessive heat is present, correct the situation immediately. If you notice a
change
in the sound or appearance of the exhaust system, shut down the unit immediately and have the
system inspected and repaired at once by a qualified mechanic.
Make sure there are
no unnecessary objects suspended from any portion of the exhaust lines. Excessive
weight could cause deflection or distortion ofthe lines, resulting in damage or leaks. Inspect insulated por-
tions ofthe exhaust system
to ensure there is no deterioration ofthe insulation.
Intake System
Make surethe intakesystem (seawatercooling system) is in properorder. Checkthatthe hull inlet, seacock
and strainer are unobstructed. Seacocks and strainers should be at least one size greater than the inlet
thread of the sea water pump. The strainer should be ofthe type that may be withdrawn for cleaning while
thevessel is atsea and should be mounted belowthewaterline to ensure self-priming. Inspectthesea water
lines to ensure there are no collapsed sections, which would restrict water flow. Make sure there are no air
leaks at any ofthe connections.
11

Fuel System
The generator
must have its own fuel supply; in other words, it must have its own pickup tube and primary
filter/water separator. DO NOTtee off another engine's fuel supply. The fuel system should be installed in
such a manner as to allow the engine-mounted fuel lift pump to maintain a positive inlet pressure to the in-
jection pump underall operating conditions. The minimum size ofthe fuel supply line and fuel return line is
1/4inch, inside diameter, and there should be a primaryfuel filter installed between the fuel tank and the fuel
lift pump. A secondary fuel filter has been installed on the engine between the fuel lift pump and the injec-
tion pump; this filter has a replaceable filter element. Make sure that the fuel supply and return lines are
securely anchored to prevent chafing and that all fittings are sufficiently tightened to prevent leaking. Also
make sure yourfuel system has a positive shut-off valve; know its location and how it operates.
Note: Ensure that the fuel pickup tubes in the fuel tank supplying the generator are clear of
any gauze
or screen type strainers. These can easily clog and cause fuel starvation to the
generator's engine.
DO NOT use mechanical type checkvalves in lieu of a manual shut offvalve.
Be sure there is a fire extinguisher installed near the unit and that it is properly maintained. Be familiar with
its use. An extinguisherwith the NFPA rating of ABC is appropriate for all applications in this environment.
Electrical System
The electrical system should be checked
to ensure that all wiring harnesses are properly tied down with
clamps
or plastic ties and that all wiring harnesses are spaced at intervals close enough to prevent chafing
from vibration. Check to ensurethat all engine harness connections are tight and that they are made to the
appropriate terminals.
Generator (AC Output)
MakesurethattheAC output connectionswithinthe generator's distribution box aretight and in accordance
with thespecific AC Load Connectionsdiagram found later in this manual. (See the "BT GENERATOR" sec-
tion of this manual, page 33.)
IIWARNINGII
Do not smoke or allow an open flame near batteries. Lead acid batteries emit hydrogen, a
highly-explosive gas.
Batteries
Makesurethepositive (+)batteryconnection is connected to the batteryconnection of the starting solenoid.
The negative (-) battery connection should be connected to the system ground (engine block).
12

When servicing the battery or checking electrolyte level, wear rubber gloves, a rubber apron,
and eye protection. Battery acid may splash on the skin
or into the eyes inadvertentlywhen
removing electrolyte caps.
Checkthe battery's electrolytelevel and specific gravity
to ensure maximum engine starting efficiency. Make
sure the battery's terminals are clean and tight.
Ventilation
The ventilation requirements of the generator sets includethe following: combustion air is required for the
engine cylinders; cooling airis required for the generator end; and ventilating air is required
to clearthe bil-
ges below the generator, as well as the compartment in which the generator is located, of potentially toxic
and flammable diesel fumes. Refer
to the "SYSTEM SPECIFICATIONS" section ofthis manual for theairflow
requirements
of the generator set, page 5.
13

OPERATION
This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or
warm), and stopping procedures. Follow the procedures as presented, for the conditions indicated, and
your Westerbeke generator set will give you reliable performance and long service life.
Preparation for Starting
Take the steps described below in starting your engine for the first time or aftera prolonged shutdown or
lay-up.
Fill
your enginewith oil up to or nearthe upperlimit on the dipstick (the installation angle may have an effect
on the dipstick reading). Select a readily available lubricating oil with an API specification
of CC or CD and
an SAE number suitable
for the temperature in your operating area (see page 31). For the quantity of oil
needed in
your generator's engine, refer to the "SYSTEM SPECIFICATION" section of this manual, page 4.
Each unit is supplied with a coolant recovery kit (part #24977) as standard equipment, to which the follow-
ing applies:
a. Remove the pressure cap from the engine's exhaust manifold and slowlyfill the engine's cooling sys-
temwitha mixture
of waterand antifreeze suitable for your temperaturezone. (See the "COOLING SYS-
TEM" section
of this manual, page 26.) Replace the pressure cap on the manifold.
b. Make sure the plastic recovery tank is properly mounted nearthe unit (with the bracket provided) in a
locationwhereitcan bemonitored and filled easily (see page26). The recoverytankshould be mounted
at manifold level
or above.
c. Coolant should be added to the plastic recoverytank after the engine has been filled and started. After
its operating temperature has been reached, ensure that all air is expelled
out of the engine's manifold
and the engine's cooling system. With the manifold filled and the pressure cap installed, fill the plastic
recovery tank half full. Monitorthis recovery tank daily and add coolant as needed.
Fill the fuel tank with a good grade of No. 2 diesel fuel and prime the fuel system up to the engine. The
engine'sfuel system istotallyself-bleeding. Depress the PREHEAT switch
for 15 to 30 seconds and monitor
the return fuel flow. When the returning fuel is free
of air, the engine's fuel system is bled and the engine is
ready
to start.
NOTE: Whenthe PREHEAT switch isdepressed, the glow plugs in the cylinder head are ener-
gized; use the PREHEAT switch intermittently
to prevent overheating the glow plugs.
Activating the PREHEAT switch energizes the fuel run solenoid, drawing the throttle arm into
the preset run position. Ensure thatthe arm moves rapidly and smoothly.
Ensure that the Installation Checks have been made in accordance with those specified in the "INSTALLA-
TION CHECKS" section
of this manual (refer to page 7) and that there is no AC load on the generator.
14

Starting Procedure
0 PREHEAT
e
.~'.
START
@
. "."'- ...'.
'-."
STOP
~
'~ ... "'.'
GENERATOR
0
ELAPSED TIME
I mllUDI!I 0 II
Hours
Standard Instrument Panel,
Switches and Gauges
o
o
NOTE: When the generator is stopped after use, the water temperature and oil pressure
gauges may stayat their running readings.
When the generator is next used, depressing the PREHEAT switch will cause the water
temperatureandoil pressuregaugeindicators to return to zero(deflect to theleft of thegauge).
The DC voltmeterwill register system Voltage. The electric on-engine fuel pump, glow plugs,
and fuel run solenoid are also energized.
Depress and hold the PREHEAT switch. Preheat according to the following chart:
Atmospheric Temperature
+410 F (+5
0
C) or higher
+410 F (+5
0
C) to +23
0F
(_50 C)
+23
0F
(_50 C) or lower
Limit of continuous use
15
Preheating Time
Approx. 10 sec.
Approx.
20 sec.
Approx.
30 sec.
1 minute