Westerbeke 5.5 EGCD User manual

OPERATORS· MANUA.L
·5 •. 5 EGCD &OH.Z
5.0 EGCD 50HZ ..
. MARINE DIESEL GENERATORS .
·siNG SE ·
'PUBLICATION NO. 056308
REV/SIONO
. JULY 2016 ..
........... ····.
l.., 'WESTERBEKE
~ WESTERBEKE CORPORATION •150JOHN HANCOCK ROAD
I .MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
Afj,]f'"f Mt!lltbu N«illln«l M«rlMMa••ftldltrers Anociatio~
.,..,_.,.. .

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
A wARNING:
Exhaust gasseS contain Carbon Monoxide~ an odorless and
colorless gas. Carbon Monoxide Is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can Include:
• Dizziness
•Nausea
•Headache
• Throbbing In Temples
• Muscular 1Witchlng
• 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 flxed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are Inexpensive and easily
obtainable at your local marine store.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefuUy. Most acciilents are
caused by failure to foUow fundamental rules and
precautions. Know when dangerous conditions exist and
toke the necessary precautions to protect yourself, your
personne4 and your machinery.
The following safety instructions are in compliance with the
American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment
• Use insulated mats whenever working on electrical
equipment
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hilt engine parts or
exhaust system t:11mp11nents. A running engine gets very
hot!
• Monitor engine antifreeze coolant level at the plastic
coolant recovery tank and periodically at the filler cap
location on the waterjacketedexhaust manifold, but only
when the engine is COLD.
IA WARIIJNG:-- ..... /#jrltyllfdealll!
• In case of an engine overheat. allow the engine to cool
before touching the engine orchecking 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 ofspilled fuel or fuel
vapors. Use a suitable containerto 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 or death.
• Do not smoke or permit flames or sparks to occurnear
the fuel system. Keep the compartmentand the
engine/generator clean and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware- diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
Injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the engine compartment blower
prior to starting, following the recommendatiin ofthe
vessel builder.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel ina well-
ventilated area away from spark~producing equipment
and out of the reach of children. ·
• Do not fill the fuel tank(s) while the engine is running.
• Shut offthe 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 of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
Engines &Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• 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
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.
~
highly explosive gas, which can be ignited by el~cal
arcing or by littobacco products. Shut o~ all el~tncal
equipment in the vicinity to prevent electrical arcmg
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 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 otherjewelry before handling
the
battery.
• Always tum the battery charger offbefore _disconnecting
the battery connections. Remove the negattve lead first
and reconnect itlast when servicing the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injllry or death!
• When servicing the battery orchecking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. H it comes in contact with your skin, wash
it off
at once with water. Acid may splash on the skin or
into
the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel ga5es
discharged from the engine. Check the exhaust system
regularly for leaks and
make sure the exhaust manifold/
water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set orengine.
• Do not run the generator set orengine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with
ABYC A-24. Consult your
boat builder or dealer for installation ofapproved
detectors.
• For additional information, refer to ABYC TH-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu·like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. H the engine
exhaust discharge outlet
is near the waterline, water could
enter the exhaust discharge outlet and closeorrestrict the
flow ofexhaust. 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 fume~. S?me of. the
symptoms or signs ofcarbon monoxtde inhalation or
poisoning
are:
Vomiting
Dizziness
Headache
Inability to think coherently
Throbbing in temples
Muscular
twitching
Nausea Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while itis running. Ha
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 orjewehy when servicing
equipment;
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.
·A WARNING: Do not WDtk on 11111J:hinery when you are
meDially or physically incapacitated by fatigue!
OPERATORS MANUAL
'
Many ofthe preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE AND GENERATOR INSTALLAnONS
Preparations to install an engine should begin with a thor-
oughexamination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the
USCG and the NFPA.
Sections ofthe ABYC standards ofparticularinterest are:
H-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion ofExhaust Systems for Propulsion
and Auxilliary Engines
P-4 Marine Inboard Engines and Transmissions
E-ll AC & DC Electrical Systems onBoats
TA Batteries and Battery Chargers
All
installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICAnONS FOR
INSTALLING MARINE ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your UNIVERSAL engine
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
AJJYC
613 ThirdDtreet, Suite 10
Annapolis, MD 21403
[phone]
www.abycinc.org
NFPA (National Fire Protection Association)
''Ftre Protection Standard for Motor Craft"
Order From:
NFPA
1Batterymarch Park
P.O. Box 9101
· Quincy, MA 02269-9101
USCG (United States Coast Guard)
"CPR 33 AND CFR46"
Code ofFederal RegUlations
Order From:
U.S. Government PrintingOffice
Washington, D.C. 20404
Engines &Generators
iii

INSTALLATION
When installing WES1ERBEK.E engines and generators it is important that strict
attention be paid to the following infonnation: ·
CODES AND ~GULATIONS .
Strict federal reguiations, ABYC guidelines, and safety code~ mu.st 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 die vessel's waterlirie, proViSionS inUst be maae tO irisfull a Siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline wiU result in
raw water damage to the engine ant! possibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the ves~l's various operating conditions~ installa
siphon-break. ·
NOTE: A siphon-break reqUires periodic in,spection and cleaning to ensure proper
operation. Fa.ilr.cre ~o properly maititain a siphon-break can result in catastrophic
engine diiiritige.' consult the siphon-break manufacturer for proper riuiintenance.
EXHAUSTSYSTEM ..
AVAILABLE ffiOM
YOUR WESTERBEKE
DEALER .
SIPHON-BREAK' WITH STAiNLESS
LOOP'
The exhaust' system's bOse 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 additional fitting and clamps to accomplish these bends
and turns. In this regard; a single lengtb of corrugated exhaust hose can be used. The
system MUST be designed to prevent the .entry ofwater'into the exhaust system
under any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gBSQiine and diesel,
engines and generators, is supplied with each uniL A pdf is available
to download from our website at \WiW.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification ............................................. 2 Engine Adjustments ........................................... 22
Introduction ......................................................... 3 Drive BeltAdjustment................................. 22
Fuel, Engine Oil and Engine Coolant .................. 5 Torquing the Cylinder Head Bolts ..............
22
Preparations for Initial Start-Up ......................... 6 Valve Clearance Adjustment .......................
23
Generator Control Panels .................................... ? Spill Timing.................................................
24
Remote Panels ...............................................? Testing Glow Plugs .....................................
25
Starting/Stopping Procedure ............................... s Testing Oil Pressure.....................................
25
Remote Panels ...............................................8
Engine Troubleshooting (Chart) ........................ 26
Generator Break-In Procedure ............................ 9 Electronic Governor ....................................
26
Daily Routine ....................................................... 9 Troubleshooting Gauges..............................
27
Safety Shutdown Switches ................................ 1o
Maintenance Schedule (Chart) ......................... 11
Alternator Testing ............................................. 29
Battery Circuit ............ · ....................................... 31
Fuel System ....................................................... 13
Wiring Diagram #056225 .................................. .32
Cooling System .................................................. 14
Wiring Schematic #056225 ............................... 33
Fresh Water Cooling Circuit........................ l5
Remote Panel Wiring Diagram .......................... 34
Changing the Coolant.................................. 15
Engine/Generator Specifications ...................... 35
Thermostat................................................... 16
Generator lnformation ....................................... 36
Raw Water Intake Strainer.......................... 16
Generator Single Phase ..................................... 37
Raw Water Cooling System ........................ 17
Circuit Breaker ........................................... .37
Heat Exchanger ........................................... 17
Internal Wiring Schetnatic........................... 37
Raw Water Pump......................................... l7
Single Exciter Model ......................................... 38
Engine Lubricating Oil ....................................... 18
Dual Exciter Model ............................................ 39
Engine Oil Change ...................................... 18
Shore Power Connections ................................. 39
Remote Oil Filter (optional)........................ 19
Integral Controller ............................................ .40
Starter Motor ..................................................... 20 Battery Charging Circuit............................ .40
Troubleshooting........................................... 20
Optional Water Heater ...................................... .41
Installation ................................................... 41
Optional Power Take-Off ................................. .43
Sugge~ted Spares ............................................. .44
Engines & Generators
1

DRIVE BELTS
COVER
CONTROL BOX
PRE~HEAT
START
STOP
7.5AMPFUSE
5AMPFU$£
. ENGINE LIGHT
EMERGENCY STOP
EGTD' PARTS IDENTIFICATION
INTAKE SILENCER
REAR
LEFT SIDE
,.EMERGENICY STOP SWITCH
FRONT
SIDE 01~ fliLL
RIGHT SIDE
/w-IWESTERBEKE
l Engines & Generators
2

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKE's long years of experience and advanced
technology. We take great pride in the superior durability and
dependable performance ofour engines and generators.
Thank you for selecting WESTERBEKE.
In order to get th~ full use and benefit from your generator it
is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please, read this
manual carefully and observe all the safety precautions
throughout.. Should your generator require servicing, contact
your nearest WESTERBEKE dealer for assistance. .
This is your operators manual. A parts catalog is also
provided and a technical manual is available from your·
WESTERBEKE dealer. If you are planning to install this
equipment contact your WESTERBEKE dealer for
WESTERBEKE' S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in the
documentation package supplied with ths product.lt.includes
a
Warranty Registeration Cardthat can be filled out and
mailed in or you can register your warranty on our
website:www.westerbeke.com. You should receive a
Customer Identification Card afterregistering your warranty
within 60 days. If you do not, please contact the factory
having available the unit's model designation, engine serial
number and date you purchased the unit.
Customer Identification Card
: 1-.vtWESTERBEKE
j Engines & Generators
Customer Identification
MR. GENERATOR OWNER
. MAIN STREET
HOMETOWN, USA
Model:
Serial#
Expires:
PRODUCT SOFTWARE
Product software, (tech· data, parts lists, manuals,
brochures and catalogs), provided from sources other than
. WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOTBERESPONSmLEFOR THE
CONTENT OF SUCH SOF7WARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS wrni RESPECT
lliEREl'O, INCLUDING
ACCURACY, TIMELINESS OR
COMPLETENESS THEREOFAND WlU INNO EVEN!'
BELIABLE FOR ANYTYPE OF DAMAGE OR INJURY
INCURRED INCONNECTION WIT'H OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFIWARE..
WESTERBEKE customers should also keep in mind the
time span between printings ofWESTERBEKE product
software and the unavoidable existence ofearlier .
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE or other suppliers, must not and cannot
berelied upon exclusively as the definitive authority on
the respective product. It not only makes good sense
but is imperative that appropriate representatives of
WESTERBEKE or the supplier in question beconsulted
to determine the accuracy and cunentness of the
product software being consulted.by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you throughthe operating procedures,
maintenance schedules, and troubleshooting ofyour marine
engine, criticalinformation will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows: .
NOTE: An operating p'roeedure essential to note.
A CAUTION: Procedures, which N .. 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.
ENGINE OPERA DON ··
This engine is certified to operate atl800 rpm (60 Hertz)
in the United States. Operating this engine at 1500 rpm
(50 Hertz) in the United States may be a violation of
Federal Law.
1....,.,./WESJERBEKE
) Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on adecal on the generatorhousing. Take the
time to enter tllis information on the illustration ofthe name-
plate shown below, as tllis will provide aquick reference
when seeking technical information and/or ordering repair
parts.
t=~~~...,.-:~ ..
The engine serial number canalso be found stamped into the -
engineblockjustabove the injection pump. The generator
serial number is stamped irito the gener~r housing on the
fiat surface on the leftside of the gener.a:tor.
AD. identification·plate ontheengine manifold also displays
fbe enginemodeland serial number.
NOTE: A carbon m01wxide warning decal ho.s been provided
by WESTERBEKE. Affrx this decal in a visible position in the
engine room.
UNDERSTANDIN~ THE DIESEL ENGINE
The diesel engine closely resembles 1he gasoline engine,
since 1he mechanism is essentially the same. The cylinders
are arranged above a closed crankcase;the crankshaft is of
1he same general type as 1hat 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 1he
same preventive maintepance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance of 1he 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 (fuat is water, sediment, etc.) in the fuel sys-
tem is also essential. Another important factor is the use of
the same brand ofhigh detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from 1he gasoline engine,
however, in its method of handling and firing offuel The
carburetor and ignition systems are replaced by a single
component-the
fuel injection pump- which pexfonns the
function of bo1h.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator
model number, engine serial number, and generator
serial number as they ajlpear 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 partneeded (see the separately furnished
Parts List). Insist upon WESTERBEKE packaged parts
because willfit or generic parts are frequently not made to
the same specifications as original equipment
SPARES AND ACCESSORIES
Certain spares willbe needed to support and maintain your
WBSTERBEKE engine. Your local WBSTERBEKE dealer
will assist you in preparing an inventory of spare parts.
See the SPARE PARTS page in this manual. For engine
accessories, see WBSTERBEKE' S ACCESSORIES brochure.
/'"tt~V"IWESTERBEKE
(Engines_ & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
FUEL
A CAUTION: Use only No.2·D (SAE J313} diesel that
has a Cetane rating of 145 or higher. Grade of diesel
according to ASTM 8975.
Care Of The Fuel Supply
Use only clean fuel! The clearance ofthe 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 awell known brand oflubricating oil, with an API
classification and
SAE as listed in the SPECIFICATION
pages of this manual
Change the oil and
filter after the initial 50 hours of break-in
· operation. Then follow the oil and filter change intervals as
specified in the MAINTENANCE SCHEDULE in this
manual.
Westerbeke Corporation does not approve ordisapprove of
the use ofsynthetic
oil. If synthetic oil is used, engine
break-in must
be performed using convential oil. Oil change
intervals must
be as listed in the MAINTENANCE
SCHEDULE section ofthis manual and the change intervals
are not to
be extended if synthetic oil is used
NOTE: The information above supersedes all previous
statements
regarding synthetic oil.
ENGINE COOLANT
WESTERBEKE recommends a mixture of50% 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.
Select a brand ofantifreeze specified for diesel engines.
Antifreeze specified for diesel engines contains a special
additive to protectagainst cavitation erosion ofthe engine's
cylinder walls.
Prestone and Zerex are two nationally known brands that
offer antifreeze specifically for use in diesel engines.
Select the pre-mixed variety so that the correct mixture will ·
always be added to the cooling system when needed.
Change the antifreeze mixture according to the
MAINTENANCE SCHEDULE in this manual.
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each generator.
The purpose of this recovery tankis to: Bnow for engine
coolant expansion and contraction during engine operation
without the lass ofcoolant and without introducing airinto
the cooling system.
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your generator set for the first time orafter a
prolonged layoff, check the following items:
• Make certain the cooling water thru-hull is open.
• Check the engine oil level. Add oil to maintain the level at
thefull mark
on the dipstick.
• Checkthe fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
andbattery cable connections.
• Check load leads for correct connection as specified in the
wiring diagrams.
• Examine air inlet and outlet for air flow obstructions
(SoundGuards).
• 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 theunit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
WAIT FOR THE ENGINE TO COOL FROM COOLANT
BEFORE REMOVING THE RADIATOR. . RECOVERY TANK
CAP .
MANIFOLD PRESSURE CAP..--...-""'="~~
PRESS DOWN AND TURN
TO LIFTOFF
OIL DIPSTICK
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 .
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: After the initial running of the generator, the air in
the engine's cooling system will be purged to the coolant
recovery tank. Open the air bleed petcock to ensure that the
cooling system is purged of air. After shutdown andafter the
engine has cooled, the coolantfrom the recovery tank will be
drawn into the engine's cooling system to replace the purged
air.
Before subsequent operation of the generator; the engine's
manifold should
be topped off, and the coolant recovery tank
may need to be filled to the MAX level.
TO NIPPLE AT
MANIFOLD PRESSURE CAP
ELECTRONIC CONTROLLER \5)
THE ECU IS FACTORY PROGRAMMED
TO CONTROL ALL ASPECTS I
OF THE DRIVE ENGINE (5))
Engines & Generators
6

GENERATOR INSTRUMENT CONTROL PANEL
ENGINE MOUNTED
DESCRIPTION
The Generators Instrument Control Box contains a compact
gauge package, control rocker switches, circuit fuses, check
engine light, emergency stop toggle switch and a recording
hounneter. These components are
de~cribed below.
The 8 pin connector that is on the back of the Control Box
is used to connect an optional remote start/stop panel or a
second instrument panel.
When
an optional panel is connected, the 8pin connector
with jumper should be kept for future needs when
troubleshooting. Secure it
to the lifting eye.
COOLANT TEMPERATURE: Engine coolant (water)
temperature should normally indicate: 175• to 195°F
(80" to 90"C)
ENGINE OIL PRESSURE: Oil Pressure )psi) may fluctuate
depending on the generator load but should range between
35 to 55 psi.
DC VOLTS: Indicates the amount the battery is being
charged and should show 13V to
14V.
HOURMETER: Registers elapsed time and is used as a guide
for when to perform scheduled maintenance.
PREHEAT: The PREHEAT rocker switch serves two purposes:
activates the preheat circuit and activated the K2 Run Relay.
This supplies power
to the DC alternator R, fuel pump, ECU,
Instrument panel,
K3 Fault Relay pin #87 and Start toggle
switch.
START: The START rocker switch when pressed activat~:.; the
·Kl-Start Relay which activates the starter motor.
STOP: The STOP rocker switch when pressed and held,
opens the DC circuit supplying power to the K2 Run Relay.
De-activating it and shutting down the engine drive.
NOTE: It is important to
closely monitor the panel
gauges. Become aware
of
· the normal engine readings
and take immediate action
·ifthese readings start to vmy.
FUSES: The control box has two automotive type fuses. A 5
amp fuse protects the ECU and a 7.5 amp to protect the con-
trol circuit and instrument panel.
CHECK ENGINE LIGHT: The CHECK ENGINE LED will
illuminate
if the engine shuts down. (Refer to the Safety
Shutdown in this manual).
EMERGENCY STOP: The EMERGENCY stop toggle switch
(Normally Closed) is located at the side
of the control box.
When depressed, it will open the DC circuit to the control
box. This switch can be used when servicing the unit
to
prevent an unwanted start.
REMOTE PANEL PLUG IN: A plug on the side on the control
box will allow for the remote mounting
of the remote
instrument panel or the remote stop/start panel.
l...v-IWESIERBEKE
l Engines & Generators
7

STARTING/STOPPING PROCEDURE ,
ENGINE MOUNTED INSTRUMENT CONTROL PANEL
PREHEAT: Depress the PREHEAT rocker switch for
approximately 5-10 seconds. Then with the PREHEAT
rocker still depressed. depress the START rocker.
START: With a remote panel, observe the oil and DC
voltmeter gauges. When the oil and voltmeter start to
register a reading, release the START rocker. With a panel
mounted
on the generator, release the START rocker.
Continue to hold the PREHEAT rocker switch depressed
until the oil pressure reaches 10 psi. Then release the
PREHEAT rocker switch.
Once the generator has started, observe the meter readings
on the instrument panel. Ensure that raw water is being
discharged with the exhaust. Apply alight amperage load
00. t,l\e generator and allow it to warm up to 140"F, then
apply your higher amperage loads as needed.
FAILURE TO START: Should the engine not start after the
START rocker has been depressed for 5-10 seconds, release
both rocker switches and wait 30 seconds and repeat the
above start procedure. Preheat a few seconds longer. Never
run the startercontinuously for more than 20-25 seconds.
STOPPING: To stop the generator, depress the STOP rocker
switch
and hold it depressed. With a remote panel, observe
the oil pressure. When it drops to zero, release the STOP
rocker switch. With the panel mounted on the generator,
release the STOP rocker switch when the generator comes
to a complete
stop.
REMOTE START/STOP PANEL
The Remote Start/Stop Panel has the same three rocker
switches
as the Instrument Control Panel. Their function is
the same. This panel has a RELEASE STARTER LED.
This LED will illuminate when the PREHEAT is depressed.
When this panel is remote mounted, this LED will indicate
when the generator has started. When depressing the
START rocker switch, this LED will dim. When the
generator starts, the LED will brighten. This indicates to
release the START rocker switch. The PREHEAT rocker
switch
is held depressed for about 4-5 seconds to allow the
oil pressure to reach 10 psi, then release it. _
/----/~
For the REMOTE STOP/START PANEL wiring diagrain /~ .
and wiring harness, refer to the Table of Contents.~<,,
1
EXTENSION ·HARNESSES
1 ·
PN. 056236 EG DIESEL (8 PINJ ~~ 5 feet'
PN. 056235 EG DIESEL (8 PIN) ~30 feet
.I..,..IWESISIBEICE
l Engines a GenetlltOI'rl
8

GENERATOR BREAK·IN PROCEDURE
. DESCRIPTION
Although your engine has experienced aminimum of one
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine
operated properly, abreak-in time is required. The service
life of
your engine is dependent upon how the engine is
operated and serviced during its initial hours of ~e.
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 engme requires approximately 50 hours ofinitial
conditioning
operation to break in each moving partin order
to maximize the performance and servicelife of the engine.
Perform this
conditioning carefully, ~ing in mind the
following:
Startthe engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems (raw
water pump, oil pressure, battery charging) are functioning.
· AFTER START·UP
Once the generatorhas been started, check for proper opera-
tion and
then encourage a fast wann-:up. Run the generator
between 20% and 60% offull load for the fifst 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 overload is signaled by a
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
it within the generators' rating. Since the generator operates at
1800 rpm to produce 60 hertz, or at .1500 to produce 50 hertz,
control of the generato~ engine break -in ~ governed by the
current drawn from the generator.
NOTE: Be aware ofnwtor starting loads OJ7d the high
current drawn required for starting nwtors. This starting
amperage draw can be 3 to 5 times nonnal running
amperage. See GENERATOR INFORMATION in this manuaL
GENERATOR ACJUSTMENTS
Once the generator has been placed into operation, there may be
the need for a
AC no-load voltage adjustment before or at the
50 hour break-in service. (see Generator Information).
THE DAILY ROUTINE
CHECKLIST
Follow this checklist each day before starting your generator.
• Check that all generator circuit breakers (power panel) are in
the off position before starting.
•
Record the hourmeter reading in your log (engine hours relate
to the maintenance schedule).
• Visually inspectthe 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)
CHECKWll'H THE ENGINE RUNNING.
• Check for abnom13l noise such as knocking, vibration and
blow-back sounds.
• Confinn 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 1U1111ing may occurin a cold engine.
This condition should abate as nonnal operating temperature
is reached .arulloads afe applied.
A CAUTION: Do not operate the geniJI'Bfor for long
periods of time without a load being placed· on the
generator. ·
·STOitflNii'RIE,GENEMTOR:'
. . .·. ~- . . . . . . .·. ..
Remove the AC amperage loads from the generator one at a
time. Allow the generator
to run for 3- 5 minutes to stabilize
the operating temperatures. Then depress the STOP switch
and hold depressed until the generator comes to a complete
STOP.
NOTE: This engine is certifiedto operate at 1800 rpm (60 Hi}
in the United States. Operating this engine at 1500 rpm
(50 Hz) in the 'United States may be a" violation of
Federal Law. ·
Engines & Generators
-9

SAFETY SHUTDOWN SWITCHES
CHECK ENGINE- LED
SAFETY SHUTDOWN SWITCHES/SENSORS
The engine is protected by three safety shutdown switches.
Should a shutdown occur due to one,. of these switches, the
Check EngineLED will illuminate. The cause should be
detennined and corrected. The ECU must be cleared of this
fault by turning off the 20 amp DC breaker and turning it
back ON in order to start the engine.
High Water Temperature Switch
A high water temperature switch is located at the tl}ermostat
housing. Normally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C), will open and interrupt the DC voltage thereby
shutting off the engine. This switch resets at I?5°F (107°C.
Low Oil Pressure Switch
A low oil pressure shutdown switch is located offthe
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-lOpsi, this switch will open
interrupting the DC voltage thereby shutting offthe engine.
· OIL PRESSURE
SENDOR .
.
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Normally closed, this switch will open and interrupt
the DC voltage (shutting offthe engine) should the switch's
sensor indicate an excessive exhaust temperature
(an
inadequate supply ofraw water causes high exhaust
temperatures). This switch opens at 260°·270°F
(127°·132°C).
1Jris switch resets at approximately 225°F (107°C).
EXHAUST ELBOW
Engine Circuit Breaker
The generator's engine isprotected by an engine mounted
manual reset circuitbreaker (20 amps DC). Excessive ·
current draw or electrical overload ~ywhere in the
instrument panel
Wiring orengine wiring will cause the
breaker to trip. In tlif~ event, the generator will shutdown
because the open breaker interrupts the DC circuit. If this
should occur, check and repair the source ofthe problem.
After repairing the fault, reset the breaker and restart the
· generator.
OVERSPEED SHUTDOWN
The unit's ECU is monitoring the engine speed via a signal
from the MPU (Magnetic Pick-Up) positioned over the
flywheel's ring gear teeth. Should the engine speed reach
2200 rpm (73 hertz), the ECU will shut the engine down and
the Check Engine LED will illuminate.
Engines &Generators
10

MAINTENANCE SCHEDULE
A WARNING: Never attempt to perfDnn any servit:e while the engine is nmnlng. Wear the proper safety equipment such as goggles
and gloves, and use the correct tools for each job. When servicing/replacing DC components, turn offthe DC cll't:llit breaker tin the
control panel; or film off the batteryswitch. ·
SCHEDULED MAimNANCE
Maintenance procedures are all detailed in this manual.
I DAILY CHECK BEFORE START-UP
Coolant Level
Engine Oil Level
Fuel/Water Separator (owner installed)
Fuel Supply
Visual Inspection of Engine
Drive Belts
II~ITIAL 50 HOURS OF OPERATION
Engine Oil and FiHer
*Exhaust System
*Valve Adjustment
Inlet Fuel Filter
Fuel Filter
Generator
Electronic Governor .Control
Re·Torque Cylinder Head Hold Down Bolts
I EVERY 50 OPERATING HOURS OR MONTHLY
Drive BeH
Starting Batteries
Electric Fuel Pump
Zinc Anode
I EVERY 100 OPERATING HOURS OR YEARLY
Engine Oil and Filter
Air lnlake and Filter (if applicable)
EXPLANATION OF SCHEDULED MAINTENANCE
Gheck at recovery tank, if empty, check at manifold. Add coolant if neetled.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Check for water and dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Use properly filtered #2 diesel with a Cetane rating of #45 or higher. Check that
there is adequate fuel for the V8$Sel's needs.
Check for fuel, oil and water and exhaust leaks. Gheck that the water injected exhaust elbow
securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wiring and electrical
connections. Look for loose bolts/hardware and correct as needed.
Inspect for frayed edges. Belts must be tight.
Initial engine oil and filter change at 50 hours.
Check security of water injected exhaust elbow to exhaust manifold.
Ensure there are no leaks.
Check adjustment of valves.
Remove and replace inlel fuel filter.
Remove and replace fuel filter and all sealing Q-rings.
Check that AC comiections are secure with no chafing.
Factory programmed - No adjustment.
Re-torque bolts. Engine colll, then check the valve clearance adjustments.
Inspect for proper tension (318" to 1/2" deflection) and adjust H neooed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
your ·own inspection schedule.
Change engine oil and filter at 1 00 operating hours or yearly ..
Keep air intake clear of obstructions. Clean air filter (if applicable)
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
I....,.IWESTERBEKE
lEngines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your engune hours running time.
SCHEDULED MAINTENANCE
I EVERY 250 OPERATING HOURS OR YEARLY
*Exhaust Elbow/Exhaust System
Fuel After and O·Rings
Inlet Fuel Alter
*Generator
Hoses
Fuel Water Separator RHer
DC Alternator
I EVERY 500 OPERATING HOURS OR FIVE YEARS
Raw Water Pump
Coolant System
*Valve Clearances
EXPLANATION OF SCHEDULED MAINTENANCE
Check the structural integrity of the water injected exhaust elbow casting. Check the integrity
of the exhaust system attached to the elbow. All hose connections shoulg be secure. No
chaffing. No exhaust leaks. Hoses and muffler are in good serviceable· condition.
ROTE: An exhaust leak wiU cause exposure to diesel exhaust!
Remove and repla~ fuel filter and all sealing O·rings.
Remove and repla~ inlet fuel filter.
Check that AC connections are clean and secure. Ensure wires have no chafing.
See GENERATOR INFORMATION. .
Engine hoses should be firm and tight ~eplate if hoses become spongy, brittle or
delaminated. Check and tighten all hose clamps as needed.
Inspect bowl for dirt or water in fuel. Drain and replace filter.
Inspect wiring, connections should be tight. Alternator should be clean and free of corrosion.
Check mounting bracket and alternator bolt. All should be tight
Remove and disassemble the pump and inspect all parts: drive gear, pump shaft, wear plate
and cover for wear and corrosion. Replace the impeller and gasket. lubricate the impeller·
at re-assembly.
· Drain, flush and re-fill the cooling system with appropriate antifreeze mix. Inspect the
condition of the seating gaskets of the pressure cap. Clean out coolant recovery tank
and connecting hose.
· .Mjust valves. (Incorrect valve clearance will result in poor engine performance.)·
I
*Starter Motor
Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the starter
motor pinion driVe
Fuel Infectors
Check and adjust injection opening pressure and spray conditions.
He-Torque Cylinder Head Hold Down Bolts Re-torque bolts. Engine cold, then check the valve clearance adjustments.
Pre·Heat CircuH Check operation of preheat solenoid. Remove glow plugs, clean tips arid check operation.
I EVERY 1000 OPERATING HOURS OR OR EVERY FiVE YEARS
Heat Exchanger
Remove the heat exchanger for professional cleaning and pressure testing.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
1,...,./WESTERBEKE
l Enalnes & Generators
12

FUEL SYSTEM.
DIESEL FUEL
Use No. 2-D (SAE J313) diesel that has a Cetane rating of
#45 or higher grade ofgiesel according to AS1M 0975.
(DO Nar add any alcohol based additives.
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 of clean fuel, the fuel
mustpass 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
A primary 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 injection equipment is free of
impurities. This process is accomplished byinstalling 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
Thefuel 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 disassembly and repair it.
FUEL UFT PUMP
Periodically check the fuel connections to and out ofthe pump
and make sure that no leakage is present and that the fittings
are tight and secure. The DC ground connection at one of the
pump's mounting bolts should beclean and well secured by
the mounting bolt to ensure proper pump operation.
Whenenergized 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 liftpump, there is a small
in-line fuel filter connected to the fuel lift pump elbow. This
filter should be replaced every 250 hours of operation.
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. Shutoffthe 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 cleanthe 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 -1/2 turns by hand. Open the-fuel
supply aqd run the engine to inspect for leaks. ·
FUEL
FILTER
LIGHTLY WIPE
WITH CLEAN FUEL
Engines.~ GeQerators
13

COOLING SYSTEM
DESCRIPTION
Westerbeke marine diesel engines are designed and equipped
for fresh water cooling. Heat produced in the engine by com-
bustion and friction is transferred to fresh water coolant
which circulates
throughout the engine. This circulating fresh
water coolant c~ols the engine block, its internal moving
parts, lmd the engine oil. The heat is transferred extemally
from
the fresh water coolant to raw water by means ofa heat
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes ofthe heat exchanger while
. "' ~
------.:...
COOLING CIRCUIT DIAGRAM
f-RESH WATER ¢
RAWWATER ..
----·
fresh water coolant flows around the tubes; engine heat trans-
ferred to the fresh water coolant is conducted through the
tube walls to the raw water which is then pumped into the
exhaust system where finally it is discharged overboard. In
other words, the engine is cooled by fresh water coolant, this
coolant is cooled by raw water, and the raw water carries the
transferred heat overboard through the exhaust system. The
fresh water coolant and raw water ciicuits are independent of
each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.