Westerbeke 5.0Kw BCDR User manual

-
OPERATORS MANUAL
MOBILE and INDUSTRIAL
GENERATORS
5.0Kw BCDR 15.0Kw BCDBR
7.6Kw B R
PUBLICATION NO. 041283
. SECOND EDITION
APRIL 2006 ..
~ WESIERBEKE
WESTERBEKE CORPORATION .150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
§JTAI'r MDtrber NlIIltHffll Mflrine Mfl"./lIdIIrm Assoclfltlo"
.u:_w

'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:
-Oizziness
- 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 IMMEOIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
WARNING
'GGnerators Produce CARBON MONOXIDE
Regular Maintenance Required
rry~~.!'!~~~
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS.
They are inexpensive and easily obtainable
at your local hardware store
CALIFORNIA
PROPOSITION 65 WARNING
Diesel and gasoline engine exhaust and
some of its constituents areknown.to the
State of California to cause cancer, birth
defects, and other reproductive harm.

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual corefuUy. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dongerous conditions exist and
take the necessary precautions to protect yourself, your
personne4 and your machinery.
PREVENT ELECTRIC SHOCK
A WARNING: 00 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 wolring on electrical
equipment
• Makesure your clothing and skin are dry. not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewehy when working on
electrical equipment.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 not touch hot engine parts or
exhaust system components. A running engine gets
reryhot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury Dr death!
• Incase ofan engine overheat, allow the engine to cool
before touching
the engine or checking the coolant
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury Dr death!
• Prevent flash fires. Do not smoke orpermit flames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel orfuel
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 occur near
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·bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury Dr death!
• 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 of children.
• Do not fillthe 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 ormodify 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
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause Injury
Dr 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 ofthe engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
Engines & Generators
i

SAFETY INSTRUCTIONS
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
01 death!
• Do not smoke orallow 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 ofthe starter'solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartmentcontaining batteries to prevent
accumulation ofexplosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being
charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or
sparks that could cause an explosion. Remove
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 disconnecting the battery.
BATTERY ACID
A WARNING: Sultulic acid In batteries can cause
severe Injury 01 death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber
apron, and eye
protection. Batteries contain'sulfuric acid which is
destructive.
If it comes in contact with your skin, wash it
off
at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
A WARNING:' Catbon 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 and exhaust
• Besure the unit and its surroundings are well ventilated.
• In addition to routine inspection ofthe exhaust system,
install a carbon monoxide detector. Consultyour dealer
for installation
of approved detectors.
A WARNING: Carbon monoxide (CO) Is an Invisible
odorless gas. Inhalation produces f1u~lIke symptoms,
nausea 01 death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper
tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through vents, or airconditioners.
• 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 ofthe
symptoms or signs ofcarbon monoxide inhalation or
poisoning
are:
Vomiting Muscular twitching
Dizziness
Intense headache
Throbbing in temples Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rota,tlng parts can cause Injury
01 death!
• Do not service the engine while itis 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.
• Do not wear loose clothing orjewelry 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 hardwareis properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belts tension while
the engine is operating.
HAZARDOUS NOISE
A WARNING: High noise levels can cause healing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the airintake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not wolk on machinery when you are
mentally 01 physically incapacItated by fatigue!
Engines & Generators
ii

TABLE OF CONTENTS
Parts Identification ................................................... .2
Engine Adjustments (cont.) ...................................... 22
Introduction ................................................................ 3 Injection Timing.................................................
25
Warranty Procedures ............................................3 Frequency Adjustment .......................................26
Remote Panel .......................................................3 Fuel Run Solenoid..............................................26
Diesel Fuel, Engine Oil and Engine Coolant.. ............ 5
Generator Control Panels ..................................... : ..... 6 Electronic Governor...........................................27
Alternator Testing/Troubleshooting ........................ .28
Description
of Switches .......................................6
Description
of Gauges..........................................6
Battery Care .......................................................29
DC Circuit/BaHery .... ................................................ .30
Remote Panel ...............................................'.....'...6
Control Panel Troubleshooting .. ............................... 31
Preparations for Initial Start-Up ................................ 7
7.6 BTDR Wiring Diagram (#44743) ..........................32
Prestart Inspections ..............................................7 ,
7.6 BTDR Wiring Schematic (#44743) ...................... 33
StartingJStopping Procedure ...................................... 8
5.0 BTDR Wiring Diagram (#44742) ..........................34
Safety Shutdown Switches .... ..................................... 9
5.0 BTDR Wiring SchematiC (#44742) ......................35
Generator Break-In Procedure ................................. 10
The Daily Routine..............................................
l0
Remote Stop/Start Panel Wiring (#44329) .... .......... .36
Generator Information ............................................. .37
Maintenance Schedule ............................................. 12
Fuel System .............................................................. 13
Fuel FilterlWater Separator................................ 13
Fuel Injection Pump........................................... 13
Fuel Lift Pump ................................................... 13
Fuel Lift Pump Filter ......................................... 13
Fuel Filter........................................................... 13
Engine Fuel Filter............................................... 13
Cooling System ......................................................... 14
Changing Coolant...............................................14
Thermostat..........................................................
15
AirIntake Filter/Silencer ................................... 15
Engine Lubricating Oil .............................................. 16
Engine Oil Change............................................. 16
Remote Oil Filter , ..................................................... 17
Starter Motor ............................................................ 18
BT Generator Troubleshooting ................................ .38
7.6KW BT Generator Single Phase ........................... 39
Circuit Breaker................................................... 39
No-Load Adjustment..........................................40
Residual Voltage Check .................................... .41
Bridge Rectifier..................................................42
Exciter RotorlField.............................................43
Measuring Resistance........................................
.44
Voltage Connection Terminal............................ .44
7.6,KW BTOR Generator Specifications ................... .45
5~OKW BC Generator Single Phase .......................... 46
5.0KW BC Troubleshooting ...................................... .47
Dual Exciter Voltage Adjustment.......................48
Single Exciter Voltage Adjustment ....................49
Integral Controller..............................................
50
Testing Battery Charging Circuit.......................50
Engine Troubleshooting ............................................ 20 Testing Exciter Windings ................................... 51
Engine Adjustments .................................................. 22
Drive BeltAdjustment .......................................22
Torquing The Cylinder Head Bolts....................22
Testing the Capacitor..........................................
51
Testing Resistance Valves ..................................53
5.0KW BCDBR Generator Specifications ................. 54
Fuel Injectors......................................................22
GenRemote Controls (optional) ................................ 55
Valve Clearance Adjustment..............................23
Engine Compression ..........................................23
Glow Plugs.........................................................24
Oil Pressure........................................................24
Power Take-Off Systems ........................................... 60
Metric Conversion Data ............................................ 61
Suggested Spare ....................................................... 62
Engines &Generators
1

PARTS IDENTIFICATION
RADIATOR
PRESSURE
FAN COVER _...--l-.~-~-""t=
RADIATOR
FRONT
CONTROL
PANEL
START/STOP/ON
SWITCHES
INJECTORS
INSTRUMENT GAUGES------£~~-.JI1I
AC CIRCUIT
BREAKER
GENERATOR
HOUSING
POWER
TAKE-OFF PORT
REAR
FUEL LIFT
PUMP
'FAN COVER
Engines & Generators
2
FRONT
CONTROL PANEL
___ FMFRf.:FNIr.V STOP SWITCH
SA FUSE
'EXHAUST
THERMOSTAT
. HOUSING
LEFT SIDE
PRESSURE CAP
AIR INTAKE/SILENCER
OIL DRAIN HOSE
RIGHT SIDE

INTRODUCTION
This WES'IERBEKE Diesel Generator is a product of
WES'IERBEKE's
long years ofexperience and advanced
technology. We take great pride in the superior durability and
dependable performance ofour engines and generators.
Thank you for selecting WES'IERBEKE.
In order to get the full use and benefit from your generator it
is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please, read this .
manual carefully
and observe all the safety precautions
throughout
Should your generator require servicing, contact
your nearest WES'IERBEKE dealer
for assistance.
This is your operators manual. A parts catalog is also
provided and a technical manual is available from your
WES1ERBEKE dealer. If you are planning to install this
equipment contact your WES'IERBEKE dealer for
WES'IERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WES1ERBEKE 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
I~'WESTERBEKE
JEngines &Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires Ser.#
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WES'IERBEKE are not within WES'IERBEKE's control.
WESTERBEKE CANNOTBERESPONSIBLE FOR THE
CONTENT OF SUCH SOFIWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS THEREOF AND WIlLIN NO EVENT
BEUABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF
THE FURNISHING OR USE OF SUCH SOFIWARE.
WES'IERBEKE customers should also keep in mind the
time span between printings ofWES1ERBEKE product
software and the unavoidable existence ofearlier
WES'IERBEKE
manuals. In summation, product software
provided with WES'IERBEKE products, whether from
WES1ERBEKE or other suppliers, must not and cannot
be relied
upon exclusively as the definitive authority on
the respective product. It not only makes good sense
but is imperative that appropriate representatives of
WES'IERBEKE or
the supplier in question be consulted
to determine the accuracy and currentness of the
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour marine
engine, critical information will be .highlighted by NO'IES,
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
your engine.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on a decal on the generator housing. Take the
time to enter this information on the illustration of the name-
plate shown
below, as this will provide a quick reference
when seeking technical information and/or ordering repair
parts.
~~~~~~ ..
The engine serial number can also be found stamped into the
engine blockjust above the injection
pump. The generator
serial number is stamped irito the generator housing on the
flat surface on the left side ofthe generator.
An identification plate on the engine manifold also displays
the engine model and serial number.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed crankcilse;the crankshaft is of
the same general type as that ofa gasoline engine, and the
diesel engine has the same type of valves, camshaft, pistons,
connecting rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the
same preventive maintep.ance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance of
the fuel, lubricating and cooling systems.
Replacement of fuel and lubricating filter elements at the
tin).e periods specified is a must, and frequent checking for
contamination (that
is water, sediment, etc.) in the fuel sys-
tem is also essential, Another important factor is the use of
the same brand of high detergent diesel lubrication oil
designed specifically for diesel
engines.
The diesel engine does differ from the gasoline engine,
however, in its method of handling and firing of fuel. The
carburetor
and ignition systems are replaced by a single
component -
the fuel injection pump - which performs the
function of both.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator model number, engine serial number, and generator
serial number as they appear on the silver and black name-
plate located on the generator end. You must provide us with
this information so we may properly identify your generator
set. In addition, include a complete part description and part
number for each part needed (see the separately furnished
Parts List). Insist upon WESTERBEKE packaged parts
because will fit or generic parts are frequently not made to
the same specifications as original equipment.
SPARES AND ACCESSORIES
Celtain spares will be needed to support and maintain your
WESTERBEKE engine. Your local WESTERBEKE dealer
will assist you in preparing an inventory of spare parts.
See the SPARE PARTS page in this manual. For engine
accessories, see WESTERBEKE'S ACCESSORIES brochure.
INSTALLATION MANUAL
Publi.cation #43400 provides detailed information for
installing generators and is available at your WESTERBEKE
dealer.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
FUEL
A CAUTION: Only use unleaded fuel with an octane
rating of 89 or higher. Leaded fuel will cause serious
harm to your engine and violate your warranty.
Care Of The Fuel Supply
Use only clean fuel! The clearance of the components in
your fuel injection pump is very critical; invisible dirt
particles which might pass through the filter can damage
these finely finished parts. 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.
ENGINE OIL
Use an engine oil regular or synthetic with an API classifica-
tion of CF and/or CG-4. An oil viscosity rating of 15W-40 is
recommended for all operating conditions. Change the
engine lube oil and filter after the initial 50 hours of break-in
operation and every 100 hours or less of operations there
after.
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
to produce properties harmful to your engine.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze performs double duty. It allows the engine
to run at proper temperatures by transferring heat away from
the engine to the coolant.
It also lubricates and protects the
cooling circuit from rust and corrosion. Use a good quality
antifreeze that contains supplemental cooling additives
(SCAs') that keep the antifreeze chemically balanced, crucial
to long term protection.
The water and antifreeze should
be premixed before being
poured into the cooling circuit.
NOTE: Use the new environmentally-friendly, long lasting,
antifreeze that is now available.
A proper 50/50 mixture as recommended will protect the
engine coolant to temperatures of -40°F.
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each generator.
The purpose
of this recovery tank is to allow for engine
coolant expansion and contraction during engine operation,
without the loss
of coolant and without introducing air into
the cooling system.
Engines & Generators
5

GENERATOR CONTROL PANELS
DESCRIPTION OF SWITCHES
This manually controlled series ofWES1ERBEKE marine
diesel generators
is equipped wi1h toggle switches on 1he
engine control panel and, optionally, at remote panels.
All three
switches are momentary contact type and serve 1he
following functions:
PREHEAT: The PREHEAT toggle serves two purposes:
preheating the engine for easy starting and bypassing the
engine oil pressure switch. The
PREHEAT function closes
the
K2 relay. as well as supplies current to the fuel" solenoid
pull coil.
When the PREHEAT switch is depressed, the voltmeter,
panel lights, gauges and meters and the hold coil of the fuel .
solenoid.
START: The START toggle switch closes the Kl relay that
energizes the starter solenoid
and activates the starter.
While the PREHEAT switch is still depressed, depressing the
START switch engages the start solenoid. When the engine
begins
to fire, the START switch should be released. The
PREHEAT switch should not be released until the oil
pressure reaches 5 -
10 psi.
STOP: The STOP toggle switch is a normally closed switch
providing power
to the K2 relay. Opening of this switch
opens
the power circuit to the fuel solenoid, stopping the
flow of fuel to the engine and shuts down 1he engine.
To stop 1he engine, depress 1he STOP switch. When the
STOP switch is depressed, the powe~ feed to the fuel sole-
noid
is opened, and the fuel flow to the engine is stopped.
The
STOP switch should be depressed until the generator
stops rotating
NOTE: When the engine is shut down, the water temperature
gauge
and the oil pressure gauge will continue to register the
last temperature and oil pressure readings displayed. They
will return to zero once electrical power is restored.
EMERGENCY STOP: The EMERGENCY
stop switch on 1he side of the control box,
is normally closed. When depressed, it
will open the DC circuit to the control
panel and shut the engine down. As the
switch is not toggled it can be used when
performing maintenance.
DESCRIPTION OF GAUGES
Coolant Temperature
Engine coolant (water) temperature should normally indicate
175
0
to 195
0 F (800
to 900 C).
Engine Oil Pressure
Oil pressure (psi) may fluctuate depending on the generator
load but should range be~een 35 to 55 psi.
DC Voltmeter
Indicates 1he amount the battery is being charged should show
13Vto 14V.
Hourmeter
Registers elapsed time and is used as a guide for when to
perform scheduled maintenance.
REMOTE PANEL
For remote operation of the generator system, the same three
switches are used. The PREHEAT and START switches are
connected in parallel with the gauge panel's switches and
serve the same functions as in the gauge panel. The STOP
switch is in series wi1h the gauge panel's STOP switch and
serves the same function. There is a REM01E START/STOP
WIRING DIAGRAM in this manual.
GENERATOR
RELEASE
STARTER
PREHEAT
MUST ~
PRESS r~)
1ST ~
6i
1
STOP
START
{
~~ PRESS
,{1ft) 2 ND
WESTERSEKE
NOTE: For additional infonnation on Control Panels. Refer to:
STARTING/STOPPING PROCEDURE, DC WIRING
DIAGRAMS and TROUBLESHOOTING GAUGES.
Engines & Generators
6

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:
• Check the engine oil level. Add oil to maintain the level at
the high mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
• Check the coolant level inboth the plastic recovery tank
and at the manifold.
NOTE: After the initial running of the generator, the air in
the engine's cooling system should be purged through the
plastic coolant recovery tank. Allow the engine to cool
and then carefully
remove the pressure cap on the
radiator. Ensure that the radiator is completelyfull of
antifreeze. If not, add mixture as needed to fill the
radiator. Replace the pressure cap and then add antifreeze
mixture
to the plastic coolant recovery tank to fill it to half
way between "add" and "max".
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded
connections. Search for any leaks.
• Check loiui 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.
A CAUTION: When starting the generator, it is
recommended that all AC loads, especially large
motors, be switched OFF until the engine has come
up to speed and, in cold climates, starts to warm up.
This precaution will prevent damage caused by
unanticipated operation of the AC machinery and will
prevent a cold engine from stalling.
I
'-
RADIATOR
SIDE OIL FILL
TOP OIL FILL
Engines & Generators
7

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
Westerbeke diesel generators use electric starters assisted by
glow plugs for both nonnal and cold weather starting. The
illustration below
shows a cross-sectional view of one
cylinder. The glow plug is located in the pre-combustion
chamber
so that its tip is in the injector nozzle's spray path.
When the glow plug is energized by the PREHEAT button,
the
plug glows red at the tip and assists in igniting the fuel.
The result is a rapid start with less wear on the starter.
This system is common to WESTERBEKE diesels. The start
circuitry
is designed so that the PREHEAT button must be
depressed for
the time specified in the preheat chart. Then,
while keeping the PREHEAT button engaged, the START
button is depressed to crank the engine.
NOTE: The STARTswitch will not energize unless the
PREHEATswitch is depressed. Depressing the PREHEAT
switch activates
the glow plugs in the cylinder head so use
the PREHEATintermittently to avoid overheating the glow
plugs.
GLOW PLUGS
. ~~~~~~ PRE-COMBUSTION
\' CHAMBER
-------
PREHEAT: Depress the PREHEAT switch. The voltmeter and
panel lights, gauges and meters will be activated. The PRE-
HEAT switch should be depressed in accordance with the
following chart:
Temperatu eJPreheat
Abnospherlc Temperatura Preheating nme
+41 °F( +5°C) or higher
Approx. 10 seconds
+41°F(+5°C) to 23°F (-5°C) Approx. 15 seconds
+23°F(-5°C) or lower Approx. 20 seconds
limit of continuous usa 30 seconds before cranking
START: While still depressing the PREHEAT switch, depress
the START switch. This willengage the starter solenoid.
Upon engine starting, release the START switch. Do not
release the PREHEAT switch until the oil pressure reaches
15 psi. Then as long as the high water temperature and low
oil pressure protective circuits do not activate, the engine will
remain energized
and continue to run.
12 I 14
~6
\
t::l \""" VOLTS
"'
NOTE: When starting:
.A voltage drop will occur
when the preheat switch
is depressed.
Should the engine not start when the START switch is
depressed for 10 to 20 seconds, release both switches and
wait 30 seconds; repeat the procedure above and preheat
longer. Never run the starter for more than 30 seconds.
Remote Starting Procedure
The remote start panel is the same as the engine-mounted
start panel except that ithas a green
LED light and no
gauges. When starting at a remote location, the green LED
lights when the generator is running at approximately 600
rpm. This indicates when the START switch can be released
since the starting ofthe generator may not be audible.
A. When the PREHEAT switch is depressed at the remote
start/stop panel
the LED light willilluminate. When the
START switch is depressed and the starter cranks the
engine this LED light will dim. When the engine starts
the LED light will brighten signaling to release the
START switch. Continue to hold the PREHEAT depressed
for a few seconds to allow oil pressure to build up which
closes the oil pressure safety switch that is in the series
path for
12V B+ to the K2 run relay/fuel run solenoid.
The green LED will remain brightly illuminated
while the
engine
is running.
B. After the generator is started and the START switch is
released, the generator's starter willnot crank unless the
PREHEAT switch is operated first because this switch
supplies voltage to the START switch.
Once the engine starts, check the engine's instruments for
proper oil pressure and battery charging
voltage. Apply a
light load
to the generator and allow the engine's operating
temperature
to come up to 140-1500 (60-66
0 C) before
applying heavy loads.
NOTE: Some unstable running may occur in a cold engine.
Depressing the PREHEATswitchfor 10-15 second intervals
will help stabilize the engine RPMuntil the operating
temperature
reaches the 140 -1500 F and a load is applied
to the engine.
Engines & Generators
8

STARTING/STOPPING PROCEDURE
STARTING UNDER COLD CONDITIONS
.Make sure !he lubricating oil conforms with the ratings for
the prevailing temperature.
Check the table in the ENGINE
OIL section in this manual.
The battery should be fully charged to minimize voltage
drop.
.usea sufficient amount of prehea~ to aid in starting. Seethe
Temperature!Preheat chart elsewhere in this section.
STOPPING PROCEDURE
1. Remove the AC electrical load from the generator and
allow the generator to run for three to five minutes to
stabilize its operating temperatures.
2. Depress the STOP switch and hold it until the generator
is completely stopped.
3. Now release the STOP switch .
. SAFETY SHUTDOWN SWITCHES
The engine is protected by three automatic shutdown
switches. Should shutdown
occur, do notattempt to restart
withoutfinding and correcting the cause. Refer to the
heading "Engine Stops" inthe TROUBLESHOOTING
section of this manual.
. The following is a description ofthese automatic shutdown
switches:
Coolant Temperature Switch
Ahigh water temperature switch is' located on the thermostat
housing. Nonnally closed,
this switch, should the fresh water
coolant's operating temperature reach approximately
210
0P
(99°C), will open and interrupt the DC voltage to the K2'
relay, thereby shutting off the engine. Tins switch resets at
195°P (107°C).
THERMOSTAT
ASSEMBLY
Remote Stopping Procedure
To stop the generator, depress the STOP switch which opens
the normally closed B+ path for voltage to the engine's run
circuit. The STOP switch must beheld open until the
generator comes to a complete stop and the green LED light
goes out.
Low Oil Pressure Switch
A low oil pressure shutdown switch is located off the
engine's oil gallery. Normally open in a static state, this
switch's sensor monitors the engine's oil pressure. Should the
engine's oil pressure fall to 5-10 psi, this switch will open,
interrupting the DC voltage to the K2 relay, thereby shutting
off the engine. .
OIL GALLERY
OIL PRESSURE
SWITCH
Engine Circuit Breaker
OIL PRESSURE SWITCH
WIRED FOR OPTIONAL
. AUDIBLE ALARM
The generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere in the instrument panel
wiring or engine wiring will cause the breaker to trip. In this
event
the generator will shut down and the voltage to the K2
relay is terminated. If this should occur, check and repair the
source of the problem. After repairing the fault, reset the
breaker and restart
the generator.
Engines &Generators
9

GENERATOR BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum ofone
hour oftest operations at
the factory to make sure accurate
assembly procedures
were followed and that the engine
operated
properly, a break-in time is required. The service
life ofyour engine
is dependent upon how the engine is
operated and serviced during its initial hours of use.
Breaking-in a new engine basically involves seating the
piston
rings to the cylinder walls. Excessive oil consumption
and
smoky operation indicate that the cylinder walls are
scored, which is caused by overloading the engine during the
break-in period.
Your new engine requires approximately 50 hours ofinitial
conditioning operation
to break in each moving part in order
to maximize the performance and service life ofthe engine.
Perform this conditioning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems (raw
water pump, oil pressure, battery charging) are functioning.
reach
its full rated speed are signs of an overload.
AFTER START-UP
Once the generator has been started, check for proper opera-
tion
and then encourage a fast warm-up. Run the generator
between
20% and 60% of full load for the first 10 hours.
After the first 10 hours of the generators operation, the
load can be increased
to the full-load rated output, then
periodically
vary the load.
Avoid overload at all times. An ovefload is signaled by a
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
it within the generators' rating. Since the generator operates at
1800 rpm to produce 60 hertz, or at 1500 to produce 50 hertz,
control ofthe generators engine break-in
is governed by the
current drawn from the generator.
NOTE: Be aware of motor starting loads and the high
current
drawn requiredfor starting motors. This starting
amperage
draw can be 3 to 5 times normal running
amperage. See GENERATOR INFORMATION in this manual.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may be
governor adjustments required for engine speed (hertz) during
the engine's break-in period (first 50 hours) or after this
period (see ENGINE SPEED (HERTZ) ADJUSTMENTunder
ENGINE ADJUSTMENTS. A no-load voltage adjustment
may
also be required in conjunction with the engine's speed adjust-
ment
(see GENERATOR INFORMATION).
THE DAILY ROUTINE
CHECK LIST
Follow this checklist each day before starting your generator.
• Check that all generator circuit breakers (power panel) are in
the offposition before starting.
• Record the hourmeter reading in your log (engine hours relate
to the maintenance schedule).
• Visually inspect the engine for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check the drive belt for wear and proper tension (weekly).
CHECK WITH THE ENGINE RUNNING.
• Check for abnormal noise such as knocking, vibration and
blow-back sounds.
• Confirm exhaust smoke:
When the engine is cold -White Smoke.
When the engine is warm -almost Smokeless.
When the engine is overloaded - some Black Smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached and loads are applied.
A CAUTION: Do not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove the AC loads from the generator one at a time. Allow
the generator to run for 3-5 minutes to stabilize the operating
temperature, then turn the
key to the off position. Once the
generator
is shutdown, close down all circuit breakers as a
safety precaution.
Engines & Generators
10

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenance jobs are simple but others are more
difficult
and may require the expert krwwledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY 50 100 250
500
750 1000 1250 MAINTENANCE
0
Diesel No.2 rating of 45 cetane or higher.
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
0
Oil level should indicate between MAX. and LOW on
dipstick.
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
0
Inspect for proper tension (3/8" to 1/2" deflection)
weekly
and adjust if needed. Check belt edges for wear.
Visuallnspeclion of Engine
0
NOTE: Please keep engine surface clean. Dirt
Check for fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engine's ability to
and electrical connections. Keep bolts & nuts tight.
remain cool.
Check for loose belt tension.
Fuel Filter
0 0 0 0 0 0
Initial change at 50 hrs, then change every 250 hrs.
Starting Batteries
0
Every 50 operating hours check electrolyte levels
weekly
and make sure connections are very tight. Clean off
excessive corrosion.
Engine 011 (and filter)
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
Generator
0 0 0 0 0 0 0
Check that AC connections are clean and secure
with no chafing. See GENERATOR SECTION
for additional information.
Fuel/Water Separator
0 0 0 0 0 0
Change every 200 hours.
Electronic Governor Control
0 0
Check and or adjust the no-load speed in the panel,
(If applicable)
required (hertz) and the regulator board adjustment
as needed.
NOTE: These adjustment are not a warrantable
adjustment during or after the unit's break-in.
Exhaust System
0 0 0 0
Initial check at 50 hrs., then every 250 hrs. Inspect
the system and that connections are tight and
secure. Ensure that the muffler and piping are
properly supported and not being affected by
vibration or chaffing.
Engine Hoses
0 0 0 0 0 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Engines &Generators
11

SCHEDULED
MAINTENANCE
Coolant System
Electric Fuel (ift
Pump
DC Alternator
*Fuellnjectors
*Starter Motor
*Preheat Circuit
*Englne Cylinder
Compression
*Torque Cylinder Head
Hold-down bolts
MAINTENANCE SCHEDULE
NOTE: Use the engine hour meter gauge to log your engine hours or record your
engine hours by running time.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY 50 100
250
500 750 1000 1250
MAINTENANCE
D D
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
D D D D D D
Periodically check the wiring connections ..
D D D
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
D
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
D D
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
D D
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (4-6 ohms).
D D
Check compression pressure and timing
(see ENGINE ADJUSTMENTS).
D D D
At first 50 hours, then every 500 hours
(see ENGINE ADJUSTMENTS).
*Adjust the Valve Clearances
D D D
Adjust Valve Clearances
(see ENGINE ADJUSTMENTS).
*Radlator
D
Remove, have professionally cleaned and pressure
tested.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
12

FUEL SYSTEM
DIESEL- FUEL
Use No.2 diesel fuel with a cetane rating of 45 or higher.
Do not use kerosene or home heating fuel.
FUEL FILTERS
The fuel injection pump and the fuel injectors are precisely
manufactured and they must receive clean diesel fuel, free
from water
and dirt. To ensure this flow ofclean fuel, the fuel
must pass through at least two fuel filters, a fuel water
separator
and the engine's spin-on fuel filter. VIsually inspect,
clean, and change these filters according
to the maintenance
schedule in this manual.
FUEL WATER SEPARATOR
Aprimary fuel filter ofthe water separating type must be
installed between the
fuel tank and the,engine to remove
water and other contaminants from the
fuel before they can
be carried
to the fuel system on the engine.
The owner/operator is responsible for making certain the
fuel reaching the engine's
injectlQn equipment is free of
impurities.
This process is accomvij.shed by installing and
maintaining a proper fuel filter/water separator between the
fuel tank and the generator/engine.
Westerbeke recommends
.a 10 micron filter be used.
FUEL INJECTION PUMP
The fuel injection pump is the most important component of
the diesel engine, requiring the utmost caution in handling.
The
fuel injection pump has been thoroughly bench-tested
and the owner-operator
is cautioned not to attempt to service
it. If it requires servicing, remove it and take it to an
authorized fuel injection pump service facility. Do not
attempt
to disassemble and repair it. Do not send the timing
shims with the injection pump, leave on engine.
The only adjustment the servicing mechanic should make to
the fuel injection pump is the adjustment for the engines
running speed
(see IDLE SPEED ADJUSTMENTunder
ENGINEAPJUSTMENTS).
FUEL LIFT PUMP
Periodically check the fuel connections to aud out of the pump
and make sure that no leakage is present and that the fittings
are tight and secure. The DC ground connection at one ofthe
pump's mounting bolts should be clean
and well secured by
the mounting bolt
to ensure proper pump operation.
When energized thru the preheat circuit, the fuel lift pump will
purge air from the
fuel system and provide a continuous flow
of fuel as the engine is running.
INLET FUEL FILTER
To ensure clean fuel into the fuel lift pump, there is a small
in-line fuel filter connected
to the fuel lift pump elbow. This
filter should be replaced every 250 hours ofoperation.
ENGINE FUEL FILTER
Periodically check the fuel connections and the bowl for
leakage. Replace the filter element after the
first 50 hours
then follow the
MAINTENANCE SCHEDULE.
Changing/cleaning the filter element
1. Shut offthe fuel supply.
2. Unscrew the retainer ring that holds the filter bowl to the
housing and allow the bowl to come
away from the
housing,
3. Remove
and replace the filter element and clean the bowl.
4. Replace the sealing "0" ring and reassemble the bowl
to the housing. Thread the retainer ring on carefully
so as not to cross thread. When retainer contacts the
"0" ring, tighten 114 - 112 turns by hand. Open the fuel
supply and run the engine to inspect for leaks.
THE O-RING GASKET
ONLY NEEDS TO BE
REPLACES IF IT SHOWS"
SIGNS OF AGING.
FUEL
FILTER
FUEL LIFT PUMP
LIGHTLY WIPE
WITH CLEAN FUEL
Engines & Generators
13

COOLING CIRCUIT
DESCRIPTION
Westerbeke diesel engines are designed and equipped for
fresh water cooling. Heat produced in the engine by
combustion and friction is transferred to fresh water coolant
which circulates throughout the engine. This circulating fresh
water coolant cools the engine block and its internal moving
parts and the engine oil.
Fresh water coolant is pumped through the engine by a
circulating pump, absorbing heat from the engine.
The
coolant then passes through the thermostat into the radiator
where it is cooled, and returned to the engine block
via the
suction side
of the circulating pump.
FRESH WATER COOLING CIRCUIT
NOTE: Refer to ENGINE COOlANT section for the
recommended antifreeze andwater mixture to be usedas the
fresh water coolant.
When the engine is started cold, external coolant flow is pre-
vented by the closed thennostat (although some coolant
flow
is bypassed around the thermostat to prevent the engine from
overheating).
As the engine warms up, the thermostat gradu-
ally opens, allowing full flow
of the engine's coolant to flow
unrestricted to the external portion of the cooling system.
Coolant Recovery Tank
Acoolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any
significant loss
of coolant and without introducing air into
the cooling system. This tank should be located at or above
the engine manifold level and should be easily accessible.
CHANGING COOLANT
The engine's coolant must be changed according to the
MAINTENANCE SCHEDULE. If the coolant is allowed to
become contaminated, it can lead to overheating problems.
A CAUTION: Proper cooling system maintenance is
critical; a substantial number of engine failures can be
traced back to cooling system corrosion.
Drain the engine coolant by removing the drain plug under
the manifold and opening the manifold pressure cap. Flush
the system with fresh water, then start the refill process.
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.
Refilling the Antifreeze Coolant System
Re-install the engine block drain plug. Close the drain
pluglpetcock on the radiator. Pre-mix your antifreeze and add
it
to the radiator until the system is visibly near full.
Start the generator and continue to add the antifreeze mix as
air is expelled. Observe the engine operating temperature.
As the temperature nears 180°F. The thermostat should be
opening
and flow through the radiator observed.
When all the air
is expelled, top off the radiator and install
the pressure cap, now add more antifreeze mixture to the
remote recovery
tank until halffull.
Inspect the system for any leaks. Stop the engine and allow
the system
to cool down. Coolant in the plastic coolant •
recovery tank should be drawn into the engines cooling
system. Add enough coolant to the recovery tank to place the
level between the add and max marks.
Engines & Generators
14

ENGINE COOLING CIRCUIT
TO COOLANT
; RECOVERY TANK
FROM COOLANT
RECOVERY TANK
COOLANT EXPANSION
COOLANT RETRACTION
NOTE: Periodically check the condition of the radiator
pressure cap. Ensure that the
upper and lower rubber seals
are in good condition
and check that the vacuum valve opens
and closes tightly. Carry a spare cap.~ __
RUBBER
. AIR INTAKE FILTER/SILENCER
There is a replaceable paper intake filter that should be
inspected every 100 hours of unit operation or more fre-
quently
in dusty operating conditions. Contaminants in the
filter can
be shaken out or removed with the aid of com-
pressed air. However,
if this can notbe accomplished the ele-
ment/filter must
be replaced.
NOTE: T9 operate efficiently a diesel ~ngine must intake a
continuous volume
of clean air. Hard starting, an erratic idle,
and black exhaustsmoke are all symptoms of a restricted air
intake.
AIR INTAKE
SILENCER·
~--AIR SCREEN
. FILTER
THERMOSTAT
A thermostat, located near the front of the engine, controls
the engine's coolant temperature, as the coolant continuously
flows through the engine's
closed cooling system .. When the
engine is first started and the thermostatis closed, engine
coolant by passes the thermostat to provide proper circulation
and cooling via a by-pass
hose locatedbetween the circulat-
ing pump and below the thermostat. As the engine coolant
reaches operating temperature,
the thermostat gradually
opens to allow coolant to flow through it.
The thermostat is
accessible and can
be checked. cleaned or replaced as
needed. Carry a spare thermostat and housing gasket.
15
To Replace the Thermostat
Remove the cap screws and disassemble the thermostat
housing as shown. When installing the new thermostat and
gasket, apply a thin coat
of sealant on both sides of the
gasket before pressing
it into place. Do notover-tighten the
cap screws.
Roo the engine and check for normal temperatures and that
there are no leaks atthe housing.
~_.-.,-.rfiJ GASKET
III II
,
COOLANT
TEMPERATURE.
SENDER
SEAL WITH HI-TACK

ENGINE LUBRICATING OIL
LUBRICATION DIAGRAM
OIL PRESSURE
SENDOR
OIL PRESSURE -~-:ItlIIIIDoii""
SWITCH
ENGINE OIL CHANGE
1. Draining the Oil Sump. Discharge the used oil through
the sump drain hose (attached to the front ofthe engine)
while the engine i~ still warm. Drain the used oil completely,
replace the hose in its bracket, and replace the end cap
securely.
NOTE: Thread size oil drain hose capped end is .
airiin-11/16"
7/i1l!tl'!'il~ :SOCKET
1W~NPT-
NOTE: During this procedure, fuel and oil may spill from the
engine, have a suitable tray under the engine.
2. Replacing the Oil Filter. When removing the used oil
filter, you may find ithelpful and cleaner to punch a hole
in the upper and lower portion of the old filter to drain the
oil
from it into a container before removing it. Thls helps
to lessen spillage. A small style automotive filter wrench
should be helpful in removing the old oil filter.
NOTE: Do notpunch this hole withoutfirst loosening the
filter to make certain it can be removed!
Place some paper towels and a plastic bag around the
filter when unscrewing it to catch any oil left in the filter.
(Oil or any other fluid on the engine reduces the engine's
cooling
ability. Please keep your engine clean.) Inspect the
old oil filter as it is removed to make sure that the rubber
sealing gasket came offwith the old
oil filter. If this
rubber sealing gasket remains sealed against the engine
block, gently remove it. .
1!!!II'iZ!1oI-IJ--1"- SEALING GASKET
, COAT WITH CLEAN OIL
WHEN INSTALLING '
When installing the new oil filter element, wipe the filter
gasket's sealing surface on the engine block free of oil and
apply a thin coat of clean engine oil to the rubber gasket
on the new oil filter. Screw the filter onto the threaded oil
filter nipple, and then tighten the filter firmly by hand.
NOTE: Generic filters are not recommended, as the
, material standards dr diameters of important items on
generic parts might be entirely different from genuine
parts. Immediately after an oilfilter change andoil fill,
rWl the engine to make sure the oil pressure is normal and
that
there are no oil leaks around the new oil filter.
3. Filling the Oil Sump. Add new oil through the oil filler
cap on the top of the engine or through the side oil fill..
After refilling, run the engine for a few moments while
checking the oil pressure. Make sure there is no leakage
around the new oil filter or from the oil drain system, and
stop the engine. Then check the quantity of oil with the
lube oil dipstick. Fill to, but not over the high mark on
the dipstick, should the engine require additional oil.
Engines & Generators
16