Westerbeke 3.5KW SBCG-60Hz User manual

OPERATORS MANUAL
-.
3.5KW SBCG 60Hz and 50Hz
Single Phase
/
GASOLINE RATOH
. ow Ca,bon Monoxide Emissions

Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed
and may void warranty.
Engines & Generators

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
- Throbbing in Temples
-Nausea
- Muscular Twitching
-Headache
- 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 fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends Installing
CARBON MONOXIDE DETECTORS in the
IIvlng/sleeplng 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
causedbyfailure to follow fundamental rules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protectyourself, your personnel,
and your machinery.
The following safety instructions are in compliance with
theAmerican Boat
and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running. Lethal 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.
• Do noit 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 ifthis procedure is not followed.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do 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 lines, fuel filters, or other fuel system
components ..
• Do not opeerate 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 and gasoline 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 running 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-ventilated area away from spark-producing
equipment and out ofthe reach ofchildren.
• 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
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 ofleaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• To prevent accidental starting when servicing the
generator, remove the 8 amp fuse from the control panel.
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY EXPLOSION
~ ________________________________________ -, 4
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 electrical
arcing or by lit tobacco products. Shut offall electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection terminal
of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment 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. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATIERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid, which
is
destructive. If it comes in contact with your skin, wash it
offat once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. 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 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 Muscular twitching
Dizziness Intense headache
Throbbing in temples 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.
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.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination ofthe American Boat
and
Yacht Council's (ABYC) standards. These standards are from
a combination ofsources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
H-24 Gasoline Fuel Systems
P-I 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

CARBON MONOXIDE "CO"I LOW-CO· GENERATORS
IMPORTANT INFORMATION
DESCRIPTION
Carbon monoxide "CO" is a component of engine 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 dramatically_
reduce normal levels of CO in the engine exhaust.
Several standards for CO have been published, expressed in
parts per miliion "ppm" and hours of exposure:
Regulator CO ppm Exposure Hours
EPA
9 8
ACGW 25 8
EPA 35 1
NIOSH 35 8
OSHA
50
8
ACGm 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. Apossible mild frontal
headache in
two to three hours.
Even though Westerbeke Low-CO generators
are designed
to reduce normal levels of
CO in the engine exhaust
dramatically, an exhaust
leak of untreated exhaust would be
extremely dangerous. For this reason it is extremely important
to install a
CO detector near the generatoP--afld to be sure it is
always turned ON and FUNCTIONING properly. If this
d~tector sounds, do not turn it off, assuming it is afalse signal.
You can not taste, smell, or otherwise detect CO. Leave the
::(lefector on, turn offall engines and generators, evacuate the
boat leaving ports and hatches open, and seek professional
h~lp.
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.
Ina 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 reduction oftypical
CO by precise control of the engine's air/fuel ratio coupled
with-after treatment
of the exhaust in a special catalyst. CO
emissions are not the sa~e for every model because each
engine
is different. Also, certain fuel system components
are .c.ommonized across several engine models being
ad~quate 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: purc~ased 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.
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
May 2004 2
nd
Edition must be adhered to.
NOTE: Water intrusion is not a product defect and is not
covered under warranty, neither Westerbeke s normal
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 of the output
surface of the catalyst. Any visual irregularity of the nonnal
flush, honeycomb appear~ce is most likely a result of water
intrusion. The cause ofthe 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 exhau~t elbow, check for the presence of CO
while the engine is running. This must be performed with a
CO analyzer.
Engines & Generators
IV

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 California 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 =1000.hrs.
EMISSIONS CONTROL INFORMATION TABLE
The California emissions control walTanty 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.
Engines & Generators
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 1I8NPT
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 colevels from the
exhaust with a coanalyzer, 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 cocontent.
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, TIP, 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 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 andpossibleflooding 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 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 of hose allows for extreme bends
and turns without the need
of additiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length
of corrugated exhaust hose can be used. The
system MUST
be designed to prevent the entry of water into the exhaust system
under any sea conditions and at any angle
of vessels 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
AVAILABLE fF\OM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ... ................................................. 2 Shore Power Transfer Switch .................................. . 19
Introduction ................................................................ 3 Engine Components .................................................. 20
Installation .................................................................. 5 Spark Plugs............................................................20
Rigging and Lifting .................................................5
Location and Mounting ...........................................5
Raw Water Discharge..............................................6
Cam Sensor............................................................
20
Air Screen..............................................................20
ECU .......................................................................20
Raw Water Supply Hose..........................................6 Engine Adjustments .................................................. 21
Measuring Back Pressure .......................................... 6 Adjusting the Drive Belt ......................................
21
Changing Catalyst ...................................................... 6
Fuel, Engine Oil, and Engine Coolant.. ...................... 7
Control Panels - Starting/Stopping Procedure .......... 8
Remote Panel...........................................................8
Oil Pressure ........................................................... 21
Engine Compression Test......................................22
Remote Oil Filter...................................................22
Water Pump Belt ...................................................22
Valve Clearance.....................................................
23
Preparations for Initial Start-Up ................................ 9
Pre-Start Inspection .................................................9
Initial Priming the Fuel System .. ............................. 10
Safety Shutdown Switches ...................................... . 11
Maintenance Schedule .... ......................................... 12
Replacing the Timing Belt.....................................24
Bleeding the Fuel System .... .................................... 25
Raw Water Pump (Exploded View) ............................ 26
Engine Troubleshooting ............................................ 28
Software Diagnostics.............................................30
Engine Lubricating 0i1.. ............................................ 14
Wiring Diagrams
Changing the Oil Filter.......................................... 14
DC Control Panel ..................................................36
Fuel System .............................................................. 15
ECU Components..................................................37
Changing the Fuel Filter........................................
15
Engine Block Components....................................38
Fuel Pump..............................................................
15
Exhaust System Components ................................39
Inlet Fuel Filter......................................................
15
Generator Information ............................................. .40
Cooling System ......................................................... 16
BCG Troubleshooting ................................................ 41
Changing Coolant.................................................. 16
Thermostat............................................................. 17
Heat Exchanger ..................................................... 17
Water Pumps.......................................................... 18
Water Intake Strainer............................................. 18
SBCG Internal Wiring Diagram .... ............................ .42
Lay-Up and Recommissioning .................................. 43
Generator Specifications ......................................... .44
Metric Conversions . ................................................ .45
DC Circuit/Battery ..................................................... 19
Suggested Spare Parts ............................................ .46
Engines & Generators
1

PARTS IDENTIFICATION 3.5 SBCG GENERATOR
DC VOLTAGE REGUL,A'~;l:::';;~~~
REAR
~'W'-f-. HOURMETER
FAULT LED'S
,e:;~!J..o.I.stARTISTOP SWITCH
CIRCUIT BREAKER
C MAlNJlREAKER
IGNITION MODUL,E
FRONT
AC CIRCUIT BREAKEI~"
STEPPER MOTOR
Engines & Generators
2
under this cover
K1-K2-K3-RELAYSfTIMER MODULE
EXTERNAL CONNECTION TERMINAL STRIP
MODULE
LEFT SIDE
VOLTAGE REGULATOR
,ExtIAUl)T TEMP. SWITCH
rrII.~'--~"L DRAIN HOSE
HEAT EXCHANGER
OIL PRESSURE SWITCH
MOTOR
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, lifter
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 BE RESPONSIBLE FOR THE
CONTENT
OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS 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 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
The engines serial and model number are etched on a name-
plate located
on top of the unit (flywheel cover). The
engine's serial number is also stamped on the engine block.
ENGINE
SERIAL
NUMBER'
.. 0 " LOCATED BEHIND
,.~~:: THE INTAKE MANIFOLD
. i
<_ ... a ~'-
<. .~ .::
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 generators serial number and model number is located
on a decal on the the generator control panel. Take the time
to enterthe information on the blank decal below. This will
provide a quick reference
when seeking technical informa-
tion and/or ordering parts.
~.
MODEl _______ _
RPM __________ _
KW ___________ _
KVA __________ _
VOLTS ________ _
AMPS ________ _
ENG. HP ______ _
ENG. SER. NO.
GEN. SER. NO.
PF IPHASE ___ _
WIRES ________ _
RATING _______ _
INSUL
CLASS __
TEMP. RISE ___ _
BATTERY _____ _
C.I.D. _________ _
60 HZ.
I
Fill in the information for your own reference. $:J]
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
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 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: Seven important steps to ensure long generator life:
• Proper engine and generator installation.
• An efficient well-designed exhaust system that includes
an anti-siphon break to prevent water
from entering t.'ie
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.
• Use clean" unleadedfuel #89 octane. No higherthan E10 ethanol blend.
• 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 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 impOltant 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
of carbon 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.
Ifcarbon monoxide is present, ventilate the area with clean
air and
COlTect 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 of tackle 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
A solid, 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.
3/4" PLYWOOD-BOLTED/FIBERGLASSED
IN PLACE
BATTERY ATTACHMENTS,
TO STARTER MOTOR
REFER TO THE WIRING
DIAGRAM IN THIS MANUAL
(-) NEGATIVE
LEAD
USE THE PAN AS A TEMPLATEFOR
LOCATING THE PROPER MOUNTING
HOLES TO THE PLYWOOD BASE
(+) POSITIVE
LEAD
SIDE VIEW
RAW WATER INLET O.Sin (2.7mm)
1.0. HOSE
BOTTOM VIEW
TOP VIEW '
WATER OUTLET AND DlSCHr.RGE.
HOSES O.Sln (2.7mm) 1.0.
·FDUR 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
current drawings with
dimensions.
Engines & Generators
5

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 the raw 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.
I
I
(
I
:I
EXHAUST ELBOW
HEAT EXCHANGER
EXHAUST BACK PRESSURE
Measure back pressure afterthe engine has
reached its normal operating temperature and
with rated amperage output applied to the
generator (30 amps @60Hz and
15 amps @ 50Hz).
Westerbekes Installation Manual Pub. #43400
has detailed information on back pressure.
I
BACK PRESSURE SHOULD I
NOT EXCEED 41" (102.5cm) I
IN THE WATER COLUMN OR
EXCEED 1.5 PSI WHEN USING I
A PSI GAUGE.
.... ~
/"
WATER
COLUMN
MEASURING
EXHAUST BACK
PRESSURE
Engines & ,Generators
6
POSITION THE CLAMP DVER
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 of lower
octane gasoline will adversly affect engine performance.
Ethanol blends must not exceed E-lO.
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. This filter
rating must be 10 microns or
smaller.
ENGINE OIL
Use a heavy duty engine oil with an API classification ofSJ,
SL, or SM. Change the engine oil and filter after
an" initial
50 hours of break-in operation. Thenfolrow the oil change
interval
as specified in the MAINTENANCE SCHEDULE
section of this manual and not be extended if synthetic oils
are used.
An oil viscosity of SAE 15W-40 is recommended for this
engine in all conditions
and all seasons.
Westerbeke Corporation does not approve or disapprove the
use ofsynthetic oils.
If synthetic oils are use, engine break-in
must
be performed using conventional oil. Oil change
intervals must be
as listed in the MAINTENANCE
SCHEDULE section of this manual and not be extended if
synthetic oils are used.
NOTE: The infonnation above supersedes all previous
statements regarding synthetic oil.
OVER-FILLING
CAUTION: The oil sump on this generator's engine can
unintentionally 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 a few hours for 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 will result in erratic operation,
andlor a smokey oil laden exhaust, hard starting and possible
no start.
ENGINE COOLANT
Engine coolant a 50/50 mixture of antifreeze and distilled
water. This coolant allows the engine to run at its proper
temperature by transferring heat from the engine to the
coolant. It also lubricates and protects the cooling system
from rust and corrosion. A 50/50 mixture of antifreeze and
distilled water will protect the engine
to _34°P (1.12°C).
PURCHASING ANTIFREEZE
Rather than preparing the mixture, WESTERBEKE
recommends buying the premixed antifreeze so that when
adding coolant, the mixture will always be correct.
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.
NOTE: This coolant recovery tank, with its short length of
hose, is best located at or above the cooling systems
pressurelfill cap.
Engines & Generators
7

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. A
green 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
wann 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 off indicating 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
7iAI~J.--- LED DISPLAYS/FAULT LED'S
START/STOP
~~-1\ 1.--1---- ROCKER SWITCH
GREEN LED
\..---Joo--f---_ 2DA CIRCUIT
BREAKER
8AFUSE
PN 033769
MAIN CIRCUIT
BREAKER
SHUTDOWN (Refer to SAFETY SHUTDOWN SWITCHES)
A shutdown is when the ECru (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.
FAILURE TO START
The start cycle will automatically terminate if the engine fails
to start after 8 seconds of cranking. Three start attempts can
be performed before an underspeed fault occurs.
This
prevents prolonged cranking which can result in the
exhaust filling 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.
~:' ·~f~·
OIL..IIIIJWUIIR! . II!XT. £Un
__ "II"1I1IP ImIAIUI8T TRIP
(l01.6mm)
~ ... ([ . 911)-
o 0
~----3.34" (84.84mm) --~
REMOTE PANEL (with Fault Display)
A remote panel is available that allows for remote operation
of the generator. The panel comes with either a 15' or 30'
plug-in extension harness. The start/stop sequence is
identical. Once installed, the engine can be operated by
either panel.
IT.
3.190" (81.03 mm)
o o
~ 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

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your generator set for the first time or after a
prolonged layoff, check the following items:
• Make certain the cooling water thru-hull petcock is open.
• 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 load leads for correct connection as specified in the
wiring diagrams.
• Examine air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
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 the 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.
• Visually examine the unit. Look for loose or missing parts,
disconnect wires, unattached hoses, and check threaded
connections. Make sure there·is no leakage.
A CAUTION:. When starting the generator, it is
recommended that alMC loads, especially large motors,
be switched OFF until the engine has come up to speed
and 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.
Coolant
• Check the coolant level in both the plastic coolant
recovery tank and at the filler neck opening
on the unit.
NOTE: After the initial running of the generator, the air in
the engine's cooling system shouldbe purged to the plastic
coolant recovery tank.
After shutdown and as the engine
cools, coolant should be drawn back into the engine's
cooling system to replace the displaced air. Once cooled,
open the
air bleedpetcock on the engine's heat exchanger
to allow any
air left in that area to be expelled. Thtm close
it. Open the pressure cap on the systemfiller neck and
ensure the system is completelyfull. Replace the cap· and
fill the plastic coolant recovery tank half way between MAX
and LOW.
OIL FILL CAP
(YELLOW)
r-t---- OIL FILTER
CONNECTS
TO WATER
PUMP
FULL
COOLING
WATER BY·PASS
INSPECT PERIODICALLY
Engines &Generators
9

MING OF THE FUEL SYSTEM
NOTE: The generatorsfuel system must be primed with fuel
before its initial start.
INSTRUCTIONS
1. Connect a Snap On MT337B, OTC 7211 or equivalent
fuel bleed/pressure gauge set (available at auto supply
stores) to the schrader valve on the fuel rail at the
injectors. Direct the purge line from this tool into a
container and open the valve to the purge line.
2. Temporarily attach a seperate fuel supply hose with
Primer Bulb to the fuel inlet connection on the engine.
3. Operate the primer bulb moving fuel into the engines fuel
system. Monitor the fuel/air flow through the purge line
into the container. Once clear fuel free
of air is moving
through the purge line, stop priming.
4. Remove the fuel bleed/pressure gauge set and replace the
cap on the schrader valve.
5. Remove the seperate fuel supply hose from the inlet
connection and connect the ships internal supply. Be
careful to prevent any fuel spillage.
6. Start the unit and allow the unit to warm up and load test.
Check for any fuel system leaks.
7. Re-bleed once running, low first then high pressure
schrader.
SCHRADER
VALVE
FUEL
. MODULE
DIS_CONNECT
TO HARNESS
INLET
FUEL FILTER
~
~,
DETACH FUEL LINE .,
ANDFITriNG
.~
FROM SHIPS INTERNAL
FUEL SUPPLY
·~SCHRADER
~ VALVE CAP
NOTE: The fuel bleed/pressure gauge set c~~ be connected to
the schrader valve on the fuel module while the engine is
running with the purge line directed into a container and be
used to bleed any air that may have entered the system while
peiforming step #5. Care should be taken when opening the
valve on the purge line. It need only be opened slightly to
allow any air to escape.
A CAUTION: Fuel and fuel vapors are explosive! Do
not allow any smoking, open flames or other source of
fire near the fuel system. be certain that fuel lines are
tight and free of leaks. Wipe up any spilled fuel and
properly dispose of soiled rags.
I ""fIY'IWESTERBEKE
I Engines & Generators
10