Westerbeke 3.5 SBCG User manual

. OPERATORS. MANUAL
3.5 SBCG 60Hz and 50Hz ··
Single Phase
GASOLINE ERATOR

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.
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
•Nausea
•Headache
• Throbbing in Temples
• Muscular Twitching
• Vomiting
• Weakness and Sleepiness • 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.
This WARNING DECAL is provided by
WESTERBEKE and should be nxed 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.

Gasoline with an ETHANOL content
h
11
h th 10°' (E10)
11
"" f!l!l\1 t
19 er an 10 as not a~iOY~'et~
and may void warranty.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefuUy. Most accidents are
caused by failure to foUow fundamental rules and
precautions. Know when tfongerous conditions exist and
takethe necessary precautions to protectyourself, your
personnel,
and your machinery.
Thefollowing safety instructions are in compliance with
the American Boatand Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical Cllllllet:fions
while engine is running, 01 when connected to shore
power. Letbal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
PREVENT BURNS- HOT ENGINE
A WARNING: Do not touch hot engine parts 01
exhaust system CDIII/IDnents. A running engine gets very
bot!
• Monitor engine antifreeze coolant level at the plastic
coolant recovery tank and periodically at the filler cap
location on the waterjacketedexhaust manifold, but only
when the engine is COLD.
IA WARIIIIG: S!Baar...,....., i#jaryor-!
• 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 01 death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, orother potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury ordeath.
• Do not smoke orpermit flames or sparks to occurnear
the fuel system. Keep the compartment and the
engine/generator clean and free ofdebris 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 01 death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
• Allfuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-
ventilated area away from spark-producing equipment
and out of the reach of children.
• Do not fillthe fuel tank{s) while the engine is runnitig.
• Shut offthe fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOf allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do 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 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 in this environment.
Engines &Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
Dtt/ealh!
11 Thm OFF theDC breaker on the control panel or tum the
unit's battery selector switch to OFF before servicing the.
engine.
• 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.
BATIERY 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 ignited by elec~cal
arcing or by lit tobacco products. Shut o~ all el~trical
equipment in the vicinity to prevent electrical arcmg
during servicing.
• Never connect the negative{-) battery cable to the
positive (+) connection terminal of the starter solenoi?.
Do not test the battery condition by shorting the tennmals
together. Sparks could ignite b~ gases o~ 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
burns or sparks that could cause ~ 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 when servicing the battery.
BATTERY ACID
A WARNING: SUlfuric acid In batteries can cause
severe Injury 111 death!
11 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 itcomes in contact with your skin, wash
it offat 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} isa 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 ge11erator 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 ABYC A-24. Consult your
boat builder ordealer for installation of approved
detectors.
• For additional information, refer to ABYCTii-22
(educational infonnation on Carbon Monoxide).
A WARNING: carbon lllflllllxide (CD} is an lnrlslb/e
odorless gas. Inhalation prodllces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly destroy coppertubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where 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 3.tld close orrestrict 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 presentin diesel exhaust fumes. Some ofthe
symptoms orsigns of carbon monoxide inhalation or
poisoning are:
Vomiting
Dizziness
Headache
Inability to think coherently
Throbbing in temples
Muscular twitching
Nausea Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• 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.
j..,.,IWESTERBEICE
l Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearlng lOose
jackets, shirtst sleeves, rings, necklaces orbracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in theirrespective
places at all times.
• Do not check fluid levels or the drive belt's tension while
~e engine is operating.
• Do not allow any swimming or activity around ornear
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning or
death can occur.
HAZARDOUS NOISE
A WARNING: High nDise levels can cause hearing
,,.,
• Never operate an engine without its muffier installed.
• Do not run the engine with the air intake (silencer) or
flame arrester removed.
• Do not run engines for long periods with their enclosures
open (when installed).
A WARNING: BD nDt WDik Dn machinery when you are
llflllltally Dr 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. Readyour manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOUNE ENGINE AND GENERATOR INSTALLATIONS
Preparations to il)stall a gasoline engine or generator should
begin with a thorough examination of the American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination of sources l:ncJuding the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventiiatio~ for Boats using Gasoline
H-24 Gasoline Fuel' Systems
P-1 Installation of Exhaust Systems
for Propulsion and Auxiliary Engines
P-4 ;Marine Inboard Engines and Transmissions
BllAC and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTAI!LING ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow theirrecommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Standards and Technical Ipformation Reports for Small
Craft" . ·
Order from:
ABYC
613 Third Street, Suite 10
Annapolis, MD 21403
www.abycinc.org
NFPA (National Frre Protection Association)
''Frre Protection Standard for Motor Craft"
Orderfrom:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA02322
USCG (United States ~t Quard)
"USCG 33CFR183"
Order from:
U.S. Government PrintingOffice
Washington, D.C. 20404·
Engines &Generators
iii

CARBON MONOXIDE "CO"/ LOW-CO GENERATORS
IMPORTANT INFORMATION
DESCRIPTION
Carbon monoxide "CO" is a component ofengine eXhaust. It
is a colorless, tasteless, odorless, lighter than air poisonous
gas that can kill you without any warning. CO poisoning is
one of the major safety risks associated with boating. It is a
threat that must not
be underestimated.
Westerbeke Low-CO generators are designed to reduce
normal levels of CO in the engine exhaust by approximately
99%.
Several standards for CO have been published, expressed in
parts permillion "ppm" and hours of exposure:
Regulator CO ppm Exposure Hours
EPA 9 8
ACGffi.
25 8
EPA 35
1
NIOSH 35 8
OSHA 50 8
ACGffi 125 0.5
NIOSH
200 0.0
NIOSH
1200
0.0
(IDLH)
1200 ppm is the so-called IDLH concentration·
IMMEDIATELY DANGEROUS TO LIFE AND HEALTH.
Acity in California characterizes the effect of CO
concentration this way:
Parts per Million
Responses
25 Permissible exposure level, no
apparent toxic symptoms.
100
No poisoning for long period.
Allowable for several hours.
200
Should not be exposed above
this level for any period of
time. A
possible mild frontal
headache
in two to three hours.
Even though the generator normally produces very low levels
Westerbeke Low-CO generators are designed to reduce
normal levels
of CO in the engine exhaust by approximately
99%., an exhaust leak ofuntreated exhaust would be
extremely dangerous. For this
reason it is extremely
important
to install a CO detector near the generator and to
be sure it is always turned on and functioning properly. If this
detector sounds, do not tum it off, assuming it is a false
signal. You can not taste, smell, or otherwise detect CO.
Leave the detector on, tum off all engines and generators,
evacuate the boat
leaving ports and hatches open, and seek
professional help.
As soon as CO leaves the exhaust outlet, the level is subject
to dilution in the open air. The closer a person is to the
exhaust outlet, the higher the concentration of CO.
In a closed space, such as the engine compartment, the boat,
or underneath a stem swim platform, concentrations will
potentially rise to the undiluted level emanating from the
exhaust system due to a lack of fresh air to dilute the exhaust
gas. Therefore, one should never rely on dilution of the
eXhaust to provide a margin of safety.
Westerbeke Low-CO generators achieve an approximate
99% reduction oftypical CO by precise control control of the
engine's air/fuel ration coupled with after treatment in a
special catalyst.
CO emissions are not the same for every
model because each engine is different. Also, certain fuel
system components are commonized aeross several engine
models being adequate for some and extra-adequate for
others,
thus producing different CO levels for different
models.
The fuel system which accomplishes the required precise
air/fuel ratio control is comprised of
many different
components: purchased sub-assemblies, machined castings,
sensors, electronics and others. Because of the extreme level
of CO reduction, any variability in the functioning of any
these components can and will cause variability of the CO
output.
CO concentration also varies with load. Usually, but not
always, the worst case CO concentration occurs at maximum
load.
IV
INSPECTION
The catalyst is critical to optimizing CO levels. Any water
intrusion into the engine's exhaust system will likely quickly
compromise the proper operation of the catalyst.
Westerbeke's exhaust system installation instructions
dated June 2016 Revision 4 must be adhered to.
NOTE: Water intrusion is not a product defect and is not
covered
under warranty, neither Westerbeke snormal
product
warranty nor the emissions specific warranty
mandated
by various regulating authorities such as EPA
andCARB.
Maintenance of any components affecting the flow ofair into
the engine or the flow of fuel to the engine is critically
important. Fuel
filters, air filters, flame arrester screens
MUST be properly maintained.
Inspection of the catalyst at the prescribed intervals is
critically
important. The exhaust elbow is removed by
loosening the metal clamp to provide a view ofthe output
surface of the catalyst. Any visual irregularity of the nonnal
flush, honeycomb appearance is most likely aresult of water
intrusion. The cause of the irregularity must be identified and
addressed. If there is irregularity, the catalyst and sealing
gasket must be replaced. The water injected exhaust elbow
casting must be inspected also for corrosion and replaced as
needed. Upon careful reassembly of the catalyst, new sealing
gasket, and exhaust elbow, check for the presence of CO
while the engine is running. This must be performed with a
CO analyzer.

EMISSIONS
This genset meets the requirements of California's Exhaust
Emissions Standards
as stated on the nameplate.
You should carefully review operator (Owner) Installation
and other manuals and information you receive with your
genset. If you are unsure that the installation, use,
maintenance or service
of your genset is authorized, you
should seek assistance from an approved WESTERBEKE
dealer.
California users
of this genset should be aware that
unauthorized modifications or replacement
of fuel, exhaust,
air intake, or speed control system components that affect
engine emissions are prohibited. Unauthorized modification,
removal or replacement
of the engine label is prohibited. California genset users may use the table below
as an aid in
locating information related to the Califomia Air Resources
Board requirements for emissions control.
Federal Emissions Compliance Period: The Federal
Emissions Compliance Period referred
to on the nameplate
indicates the number
of operating hours for which the engine
has been shown
to meet Federal Emissions requirements.
Catagory C= 250 hrs, B=500 hrs, A
=lOOO.hrs.
EMISSIONS CONTROL INFORMATION TABLE
111e California emissions control warranty statement is located in the same
Emissions
Warranty Information
packet, if information as this manual when the genset is shipped from the
factory.
Engine Fuel Requirements The engine
is certified to operate on unleaded gasoline. See FUEL
RECOMMENDATIONS.
Engine Valve Adjustment See MAINTENANCE SCHEDULE.
Engine Ignition Timing See MAINTENANCE SCHEDULE.
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS.
Engine Adjustments ECU.
Engine Emission Contol System The engine emission control system consists
of engine design and precision
manufacture.
Catalyst See MAINTENANCE SCHEDULE.
Oxygen Sensor See MAINTENANCE SCHEDULE.
Back Pressure See MAINTENANCE SCHEDULE.
v

CARBON MONOXIDE "CO" I LOW-CO GENERATORS
IMPORTANT INFORMATION
Catalyst performance will degrade over time. As the
generator accumulates operating hours,
CO concentrations
will increase.
The catalyst must be replaced every 2,000
hours of engine operation.
Verification
of satisfactory CO levels must be done
seasonally or each 500 hours (which ever occurs first).
Verification involves actual sampling
of exhaust gas with an
appropriate
CO analyzer.
There are two locations where exhaust gas can
be sampled.
Dry, but hot, exhaust gas can be sampled at the 118NPf
plugged opening on the top of the water injected exhaust
elbow's casting. Measurements at this location may not be
practical in all instances due to the high exhaust temperature,
temperature limits
of the analyzer, safety concerns over
temperatures involved or the possibility
of high levels of CO.
The other location is the boat's exhaust outlet, which
contains entrained cooling water (except dry stack exhaust
systems). Only analyzers with probes should be used at this
location and it is critical that the probe not ingest water.
Probe-type analyzers have an air pump drawing a gas sample
through the probe. As a result, they tend to ingest water when
it is present.
Be sure to aim the probe downwards with the
opening pointed in the direction
of the water flow and just
out
of the flow. Position the analyzer as high as possible with
the tubing leading to the probe running continuously down-
hill. Observe the usually translucent tubing between the
probe and the analyzer and
be sure no water is being
ingested.
If any water is ingested into the analyzer, it must be
repaired
or replaced and recalibrated.
When measuring
CO at the exhaust outlet be aware of the
ambient
CO level by also measuring CO away from and
upwind
of the exhaust outlet. especially in marinas. the CO
level at the exhaust will be influenced upwards by the
ambient level.
For changing the exhaust catalyst and measuring the
exhaust back pressure, refer to the Table of Contents.
Whenever taking the time to verify proper CO levels from the
exhaust with a
CO analyzer, always take theopportunity to
use the analyzer to
"sniff' around the engine looking for CO
from exhaust leaks. Pay close attention to the connection of
the cylinder block to the sump plate, the sump plated to the
water injected exhaust elbow casting and all subsequent
downstream exhaust components and hoses and connection
points. Remember, exhaust gas that has not yet passed
through the catalyst is raw exhaust, untreated exhaust gas and
is very high in
CO content.
Analyzers usually require periodic calibration. Follow the
instructions that come with the analyzer very carefully
regarding calibration.
The following are manufacturers that offer CO analyzers:
Extech, TIF, Testo, TSI, Bacharach, Fluke, Monoxor, Fyrite,
ZellwgwerAnalytics, Industrial Scientific Corp, GFG, TPI,
Teledyne and others. Westerbeke recommends analyzers with
a probe connected to the analyzer by a length
of transparent
tubing. They are slightly more expensive than those with the
sensor built into one end
of the analyzer, but they allow you
to sample the exhaust coming out
of the boat's exhaust outlet.
Engines & Generators
vi

INSTALLATION
When installing WES1ERBEKE engines and generators it is important that strict
attention
be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON· BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's 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
minim~ of20" above the vessel's waterline. Failure to use a siphon-break when
the exhaustmanifoldinjection port
is ator below the load waterline will result in
raw water damage
to the engine andpossibleflooding of the boat.
H 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
damag~. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust Hose is
recommended. The use of this type ofhose allows for extreme bends
and turns without the need ofadditiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length ofcorrugated exhaust hose can be used. The
system MUST be designed
to prevent the entry ofwater into the exhaust system
under
any sea conditions and at any angle ofvessels heal.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators .
VJii
AVAILABLE fROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ............................................. 2
Introduction ......................................................... 3
Engine Components ........................................... 20
Spark Plugs....:.............................................22
lnstanation .......................................................... 5 Catn Sensor..................................................23
Rigging and Lifting.......................................
5
Location andMounting.................................5
Raw Water Discharge ....................................6
Air Screen...........................................;........20
ECU............................................................. 20
Engine Adjustments ........................................... 21
Raw Water Supply Hose................................6 Adjusting the Drive Belt.............................
21
Measuring Back Pressure ................................... 6
Changing Catalyst ............................................... 6
Fuel, Engine Oil and Engine Coolaat .................. 7
Control Panels • Starting/Stopping Procedure ... 8
Remote Panel.................................................8
Preparations for Initial Start·Up ......................... 9
Pre-Start Inspection.......................................9
Initial Priming the Fuel System ........................ 1o
Safety ShutdOWD SWitches ................................ 11·
Maintenance Schedule ..................................... 12
Engine Lubricating System ............................... 14
Changing the Engine Oil.............................14
Fuel System....................................................... 15
Changing the Fuel Filter.............................. 15
Fuel Pump.................................................... 15
Inlet Fuel Filter............................................ 15
Cooling System .................................................. l6
Changing Coolant........................................ 16
Thermostat................................................... 17
' ' Hear Exchanger.................................... ,.~ ..... 11
Water Pumps........................................ :.: .....18
Water Intake Strainer...................................18
Oil Pressure .................................................
21
Engine Compression Test............................22
WaterPump Belt..........................................22
Valve Clearance........................................... 23
Replacing the TuningBelt........................... 24
Bleeding the Fuel System.................................25
Raw Water Pump (Exploded View) .................... 26
Engine Troubleshooting ..................................... 28
Software Diagnostics...................................30
Wiring Diagrams
DC Control Panel ........................................ 36
ECU Components........................................ 37
Engine Block ~.omponents ..........................38
Exhaust System Components......................
39
Fuel Systein..................................................39
Throttle Body...............................................39
Auxiliary Hamess..... ~ ............ ~ .....................39
Generator· lnfoi'IQ8tion ....................................... 40
BCG Troubleshooting ........................................ .41
SBCG Internal Wiring Dlagram .......................... 42.
Lay·Up,and Recommissioning .......................... .43
Generator SpecHicaUons .................................. 44
DC Circuit/Battery ............... ~ ............................. 19
Suggested Spare Parts....................................... 45
Shore Power Traasfer Switch ............................ l9
I..,.,~WESTII!ERSilKE
Engines& Generators
1

REAR
PARTS IDENTIFICATION 3.5 SBCG GENERATOR
~-'J'~:HCHiiU.t£rER
FAULT LED'S
START/STOP SWITCH
, CIRCUIT BREAKER
IGNITION MODULE
FRONT
STEPPER MOTOR
Engines &Generators
2
IGNITION MODl!LE
under this cover
l(l ~K2-K3-RELAYSJTifi8ER MODULE
EXTERNAL CONNECTION TERMINAL STRIP'
LEFT SIDE
FILTER'
VOLTAGE REGULATOR
~ EXIHAUI!rr ELBOW
RIGHT SIDE

INTRODUCTION
These high performance marine engines are products of
WESTERBEKE's long years of experience and advanced
technology. We take great pride in the superior durability and
dependable performance
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 engine 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, contact your WESTERBEKE dealer for
WESTERBEKE'
S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days
of submitting the Warranty Registry
form you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the unit's
serial number and commission date.
Customer Identification Card
IWIWESTERBEKE
I
Customer Identification
MR. WESTERBEKE
OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires
PRODUCT SOFTWARE
Ser.#
Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BERESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS THEREOF AND WIU IN NO EVENT
BEUABLE FOR ANYTYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH
OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should keep in mind the time
span between printings
of WESTERBEKE product software
and the unavoidable existence
of earlier WESTERBEKE
product software. The 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.
SERIAL NUMBER LOCATION
ENGINE.
SERIAL ,
NUMBER
. . ·I LOCATED BEHIND
. ~t
'::,., Q_ ~'-._
~ ......::..- .. .::::;
. ~~ ~~ THE INTAKE MANIFOLD
Take the time to enterthis information on the illustration of
the nameplate as shown above, as this will provide a quick
reference when seeking technical information and/or ordering
parts.
The generator's serial number and model number is located
on a decal on the the generator control panel. Take the time
to enter the information
on the blank decal below. This will
provide a quick reference
when seeking technical informa-
tion and/or ordering parts.
SPECIACATION
MODEL ___ ~----
FtP~-----------
KW ___________ _
KVA -----------
VOLTS---------
AMPS---------
ENG. HP -------
ENG. SER. NO.
GEN. SER. NO.
PF/PHASE ----
WIRES ________ _
RATING _______ _
INSUL ClASS __
TEMP. RISE ----
BAITERY ------
C.I.O. ----------
50 HZ.
HZ.
I
Fill in the information for your own reference. lbJ
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
willfit or generic parts are frequently not made to the same
specifications as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules,
and troubleshooting of your
generator, 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 or destruction of
the engine or 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 visible 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 filters 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 aWESTERBEKE generator capable of
many thousands ofhours of dependable service. However the
manufacturer cannot control how or where the generator is
installed inthe vessel or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Seven important steps to ensure long generator life:
• Proper engine andgenerator installation.
• An
ej]icient well-designed exhaust system that includes
an anti-siphon break to prevent water from entering t.'te
engine.
• Changing the engine oil and oilfilters every 100 operat·
ing hours.
• Proper maintenance of all engine and generator compo-
nents according to the maintenance schedule in this
manual.
• 1/se clean,:, unleaded fuel #89 octane. No higher than EJO ethanol blend.
• Winterize your engine according to the "loy-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 in-line, and the engine's cylinder head has an overhead
camshaft which
is belt-driven. The engine incorporates a
pressure
type lubrication system, and a water-cooled engine
block.
To a large degree, the generator's engine requires the same
preventive maintenance that is required of a gasoline
automobile engine. The most impottant
factors to the
generator's longevity are proper ventilation, maintenance of
the fuel system, ignition system, and cooling system.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters. Carbon monoxide,
even in small amounts,
is deadly.
The presence ofcarbon monoxide indicated
an exhaust leak
from the engine or generator or from the exhaust
elbow/exhaust hose, or the fumes
from a nearby vessel are
entering your boat.
If carbon monoxide is present, ventilate the area with clean
air and cotTect the problem immediately!
Engines & Generators
4

INSTALLATION
RIGGING AND LIFTING
The engine/generator is fitted with lifting eyes. Attach
wire rope or chain slings capable ofsupporting the
engine/generators weight to the eyes and lift the engine/gen-
erator by means oftackle attached to these slings. The lifting
eyes
have been designed to carry the full weight: auxiliary
slings are not necessary.
NOTE: Rigging work is best done by someone experienced
and competent
in handling machinery.
LOCATION AND MOUNTING
Asolid, level mounting platform is very important for the
proper operation of your generator. Select a location that will
allow adequate space
on all sides for ventilation and servic-
ing. Locate the generator away from living quarters, and
away from bilge splash and vapors.
Refer to WESTERBEKE'S installation manual for detailed
information on installing a Marine Generator in a boat.
USE THE PAN AS A TEMPLATE FOR
LOCATING THE PROPER MOUNTING
HOLES TO THE PLYWOOD BASE
3/4" PLYWOOD-BOLTED/FIBERGLASSED
IN PLACE
BATTERY ATTACHMENTS .
TO STARTER MOTOR
REFER TO THE WIRING
DIAGRAM IN THIS MANUAL
{-)NEGATIVE
LEAD
· (+) POSITIVE
NOTE: Ensure that the B+ battery cable connected to the LEAD
remote mowued starter solenoid is properly supported to
prevent unwanted stress on the solenoid.
5
"': SIDE VIEW
RAW WATER INLET0.5in (2.7mm)
J.D. HOSE
TDPVIEW.
WATER OUTLET AND DISCHARGE
HOSES 0.51n (2.7mm) I.D.
·FOUR 1/2" BOlTS
DIMENSION (INCHES AND MM)
DIMENSIONAL DRAWINGS
For dimensional drawings. View the drawings on the
Westerbeke website www.westerbeke.com for the most
cun-ent drawings with dimensions.

INSTALLATION/EXHAUST SYSTEM
RAW WATER DISCHARGE
The fresh water that flows thru the engine is cooled by a
continuous flow
of raw water (via the heat exchanger). As
the raw water
is discharged overboard, it is used to cool
the exhaust system.
RAW WATER SUPPLY HOSE (INSTALLING)
The raw water supply hose from the discharge conne-::tion on
the engines cooling system to the inlet connection of the
water injected exhaust elbow
must be looped a minimum of
12 inches (30cm) above the vessels loaded water line..
On installations where the water injected exhaust is close to
or below the vessels loaded water line, provisions must be
made to install a syphon break in the raw water supply hose.
The function
of the syphon break is to stop the raw water
flow after the engine is shutdown. This flow,
if not stopped,
will fill the exhaust system and possibly the engine as well.
The raw water supply hose must be looped well above the
loaded water line to allow the syphon break to function
during all attitudes
of vessel operation to prevent syphoning
when the generator is not operating.
When the generators location is above the loaded water line
of the vessel during all attitudes of vessel operation, it is still
advisable to loop
theraw water discharge hose at least 6 •
inches or more above the generator and then down to the
inlet connection on the water injected exhaust elbow.
NOTE: Always use a quality hose with good wall integrity or
wire reinforced hose so it will maintain its shape when
looped
and also provide proper mechanical support for the
hose.
CO TEST PORT
SIPHON BREAK
WHEN A SIPHON BREAK AVAILABLE FROM
IS NOT REQUIRED I YOUR WESTERBEKE
,-- DEALER
/
1/ .......... ---,, .
I /1' 1\ ,.--'\
/ / '' .... , .............. ~, \
/ / : //// \ I
Il
l ' !/ ----
: : I I
! : ~·( I I ~
RAWWATER : II I I ~(((;r. ,,,,
SUPPLYHOSE : . II (II··~
I I
HEAT EXCHANGER
EXHAUST BACK PRESSURE
Measure back pressure after the engine has
reached its normal operating temperature and
with rated an1perage output applied to the
generator (30 amps @60Hz and
15 amps @ 50Hz).
Westerbekes Installation Manual Pub. #43400
has detailed information on back pressure.
BACK PRESSURE SHOULD
NOT EXCEED 41" (102.5cm)
IN THE WATER COLUMN OR
EXCEED 1.5 PSI WHEN USING
A PSI GAUGE.
I
I
t
I
I
~---:::----
//'
WATER
COLUMN
MEASURING
EXHAUST BACK
PRESSURE
Engine$ & Generators
6
'\ '
POSITION THE CLAMP OVER
""
THE TWO FLANGES (AND GASKET)
AND TIGHTEN SECURELY
'

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
Use only unleaded gasoline with an octane rating of 89 or
higher. Higher octane is recommended. The use oflower
octane gasoline will adversly affect engine performance.
Ethanol blends must not exceed
E-10.
When fueling, follow U.S. Coats Guard Regulations. Close all
hatches
and companionways to prevent fumes from entering
the
vessel. Ventilate properly after fueling and before starting
the generator or main engines.
Use only clean fresh 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. Thisfilter rating mustbe 10 microns or
smaller.
ENGINE OIL
Use aheavy duty engine oil as called for inthe
Specifications Section of
this manual. Change the
engine oil and filter after the initial 50 hours of
break-in operation. Then follow the oiland filter
change intervals as specified in MAINTENANCE
SCHEDULE in this manual.
Westerbeke Corporationdoes not approve or
disapprove the use of synthetic oils. If synthetic
oils are used, engine break-in must be performed
using conventional oil. Oil change.intervals must
be
as listed inthe MAINTENANCE SCHEDULE
section of this manual and.not extended if synthetic
oils
are used.
NOTE: The information above supersedes all
previous statements regarding synthetic oil.
OVER· FILLING
CAUTION: The oil sump on this generator's engine can
unintenUonally be over-filled!
After shutdown, the oil in the engines internal pasages can
linger and take a number of hours to drain back into the
sump. Allow at least afew hours f()r the oil to settle back
into the
sump before checking the dipstick reading.
(Re-starting the engine is not a problem
as the engine's
internal passages
are well lubricated).
Over-filling the engine's
sump willresult inerratic operation,
and/or a smokey oilladen exhaust, hard starting
and possible
no start.
ENGINE COOLANT
Engine coolant a 50/50 mixture ofantifreeze and distilled
water. This coolant allows the engine to run at its proper
temperature by transferring heatfrom
the engine to the
coolant. It also lubricates and protects the cooling system
from rust and corrosion. A50/50 mixture of antifreeze and
distilled water will protect the engine to -34"F (l.l2°C).
PURCHASING ANTIFREEZE
Rather than preparing the mixture, WESTERBEKE
recommends buying the premixed antifreeze so that when
adding coolant; the mixture willalways be correct.
There are two common types ofantifreeze, Ethylene Glycol
(green) and Propylene Glycol (red/purple). Either can be used
but do not mix the two and if changing from one to another,
flush the engine thoroughly.
COOLANT RECOVERY TANK
A,f.Oolant recovery tank kit is supplied with each generator.
The purpose of this recovery tank is to allow for engine
cool~ expansion and contraction during engine ()peration,
without the loss ofcoolant and without introducing air into
the cooling system.
NOTE: This coolant recovery tank, with its short length of
hose, is best located at or above the cooling systems
pressure/jill
cap.
.Engines & Generators
-·r.

CONTROL PANEL • START/STOP PANEL
DESCRIPTION
To Start: Press the rocker switch to the start position and
release. (The switch will revert to its center position). The
engine will crank and start electronically. Agreen LED
on the switch will indicate the engine is running.
NOTE: There is a briefdelay while the ECU self-tests before
the start button responds.
Apply a light load to the generator and allow the engine
to warm up to operating temperature before applying heavy
loads.
To Stop: Press the rocker switch to stop and release. The
ECU will receive the signal to shut the engine down. The
green LED will go offindicating the unit has shut-down.
NOTE: This green LED may illuminate dimly when the engine
is not running. This is part of the selfdiagnostic circuit and is
normal.
HOURMETER
~~~~----LED DISPLAYS/FAULT LED'S
START/STOP
ROCKER SWITCH
.GREEN LED
lv;t---~1---- 20A CIRCUIT
BREAKER
SA FUSE
PN 033769
MAIN CIRCUIT
BREAKER
SHUTDOWN (Refer to SAFETY SHUIDOWN SWITCHES)
A shutdown is when the EC: U (Electronic Control Unit)
stops the generator because it has detected an operating fault
which could cause damage to the engine, the generator, or
create
an unsafe operating condition.
AMPERAGE DRAIN
There is a very small amount ofamperage being drawn from
the unit's starting battery by the electronics on the unit when
the generator is not in use. To prevent this and draw down of
the starting battery, turn OFF either the panel DC breaker or
the starting battery switch when the unit will not be operated
for a period of time.
FAILURE TO START
The start cycle will automatically terminate if the engine fails
to start after 8 seconds ofcranking. Three start attempts can
be performed before an underspeed fault occurs. This
prevents prolonged cranking which can result in the
exhaustfilling with water
and backing into the engine.
To try repeat start attempts while solving and repairing the
problem, close the thru-hull (water intake valve). When
the starting problem is corrected do not forget to open the
thru-hull.
(101.6mm)
~t~<r------3.34" (84.84mm) --,)o.l
REMOTE PANEL (withFaultLEDs)
An optional remote panel and plug-in extension
harness are available that allows for remote operation
of the generator. The Start/Stop sequence is identical.
Once installed, the engine can
be operatedby either
panel.
3.190" (81.03 mm)
0
0.
L 2.60" ((66.04mm) __J
REMOTE PANEL (STOP/START SWITCH ONLY)
NOTE: For wiring these remote panels,
refer to the Wiring Diagram section
in thus manual.
Engines & Generators
8