Westerbeke 6.4 KW-50Hz SBEG User manual

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OPERATORS MANUAL
8.0KW . 60Hz SBEG /6.4KW • 50 Hz SBEG
10.0KW • 60Hz SBEG / 8.0KW· 50 Hz SBEG
12.5KW· 60Hz SBEG /10.0KW • 50 Hz SBEG
14.0KW· 60Hz SBEG /11.6KW • 50 Hz SBEG
MARINE G E GENERATORS
PUBLICATION NO. 49735 FOURTH EDITION FEBRUARY 2009
, u) ra-Low Carbon Monoxide Emissio s

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

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituents) are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
AWARNING:
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 Temple.s
• Muscular Twitching
• Vomiting
• Weakness and Sleepiness
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
A WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine or
generator.
WESTERBEKE also recommends instafling CARBON
MONOXIDE DETECTORS in the living/sleeping quarters
of your vessel. Theyare inexpensive and easily
obtainable at your local marine store.
Engines & Generators
WARNING
GaooraIors Pn:xb;e CARBON MONOXIDE
RBgIJat~ReqtNed

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefuay. Most accidents are
caused by failure to follow funtlamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protectyourself, your
personne~ andyour machinery.
The following safety instructions are in complkmce with
the American Boat and Yacht Council (ABYC) stantlards.
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 off electrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessels AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessels AC generator may
result ifthis procedure is not followed.
• Electrical shock results from handling a charged capad-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery
tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
~fore touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or pennit flames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the
fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or pennit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to minimize the
chances
of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessels
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-
ventilated area away from spark-producing equipment
and out of the reach
of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the
fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open
flames, or other
sources of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
ordeathl
• 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
ordeathl
• Do not smoke or allow an open flarue near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut offall electrical
equipment
in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation 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
burns or sparks that could cause
an explosion. Remove
wristwatch,
rings, and any otherjewelry before handling
the battery.
• Always turn the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
selfllfll Injury or deathl
• 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.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gasl
• 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/water-injected
elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies
with ABYCA-24. Consult your
boat builder or dealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces Uu-like symptoms,
nausea or deathl
• 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. If the engine
exhaust discharge outlet
is near the waterline, water could
enter
the exhaust discharge outlet and close or restrict 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 fumes. Some of the
symptoms or signs of carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
ordeathl
• Do not service the engine while it is running. Ifa
situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving pafts and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair
and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught
in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belts tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when
the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not wade on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment,
and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination ofthe American Boat
and Yacht
Council's (ABYC) standards. These standards are a
combination ofsources including
the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
P-1 Exhaust Systems
P-4lnboard Engines
E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations
(FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order
from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order
from:
NFPA
II Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast
Guard)
"USCG 33CFR183"
Order
from:
U.S. Government Printing Office
Washington, D.C. 20404
""" WESTERBEKE
Engines & Generators
iii

CARBON MONOXIDE "CO" ISAFE-CO GENERATORS
IMPORTANT INFORMATION
DESCRIPTION
Carbon monoxide "CO" is a component of engine exhaust. It
is a colorless, tasteless, odorless, lighter than air poisonous
gas that can kill you without any warning. CO poisoning is
one ofthe major safety risks associated with boating.
It is a
threat that must not be underestimated.
Westerbeke Safe-CO generators are designed to reduce
normal levels
of CO in the engine exhaust by approximately
99%.
Several standards for CO have been published, expressed in
parts per million "ppm" and hours ofexposure:
Regulator CO ppm
Exposure Hours
EPA 9 8
ACGIH 25
8
EPA 35
1
NIOSH 35
8
OSHA 50
8
ACGIH 125
0.5
NIOSH 200
0.0
NIOSH 1200
0.0
(IDLH)
1200 ppm is the so-called IDLH concentration -
IMMEDIATELY DANGEROUS TO LIFE AND HEALTH.
A city in California characterizes the effect of CO
concentration this way:
Paris per Million
Responses
25
Pennissible exposure level, no
apparent toxic symptoms.
100
No poisoning for long period.
Allowable for several hours.
200 Shonld not be exposed above
this level for any period
of
time. A possible mild frontal
headache in two to three hours.
Even though the generator normally produces very low levels
ofCO,
an exhaust leak ofuntreated exhaust would be
extremely dangerous. For this reason it
is extremely impor-
tant
to install a CO detector near the generator and to be sure
it
is always turned on and functioning properly. Ifthis detec-
tor sounds, do not tum
it off, assuming it is a false signal.
You can not taste, smell, or otherwise detect CO. Leave the
detector on, tum off all engines and generators, evacuate the
boat leaving ports and hatches open,
and seek professional
help.
As soon as CO leaves the exhaust outlet, the level is subject
to dilution in the open air. The closer a person is to the
exhaust outlet, the higher the concentration of CO.
In a closed space, such as the engine compartment, the boat,
or underneath a stern swim platform, concentrations
will
potentially rise to the undiluted level emanating from the
exhaust system due to a lack offresh air to dilute the exhaust
gas. Therefore, one should never rely on dilution of the
exhaust to provide a margin of safety.
Westerbeke Safe-CO generators achieve
an approximate 99%
reduction
of typical CO by precise control control of the
engine's air/fuel ration coupled with after treatment in a
special catalyst. CO emissions are not the same for every
model because each engine is different. Also, certain fuel
system components are commonized across several engine
models being adequate for some and extra-adequate for
others, thus producing different CO levels for different
models.
The fuel system which accomplishes the required precise
air/fuel ratio control
is comprised of many different
components: purchased sub-assemblies, machined castings,
sensors, electronics
and others. Because of the extreme level
of CO reduction, any variability in the functioning of any
these components can and will cause variability of the CO
output.
CO concentration also varies with load. Usually, but not
always, the worst case CO concentration occurs at maximum
load.
INSPECTION
The catalyst is critical to optimizing CO levels. Any water
intrusion into the exhaust system will likely quickly
compromise the proper operation
of the catalyst.
Westerbeke's exhaust system installation instructions dated
on or after February 2004 must be adhered to.
NOTE: Water intrusion is not a product defect and is not cov-
ered under warranty. neither Westerbeke snonnal
product warranty rwr the emissions specific warranty
mandatedby various regulating authorities such as
EPA
and CARB.
Maintenance of any components affecting the flow ofair or
the
flow of fuel to the engine is critically important, such as
fuel filters and air filters (if any).
Inspection
of the catalyst at the prescribed intervals is
critically important. The exhaust elbow is removed by
loosening the metal clamp to provide a view of the output
surface ofthe catalyst. Any visual irregularity
of the normal
flush, honeycomb appearance is most likely a result ofwater
intrusion. The cause
of the irregularity must be identified and
addressed. If there
is irregularity, the catalyst and gasket must
be replaced. Upon careful reassembly of the catalyst, exhaust
elbow gasket, and exhaust elbow, check for
the presence of
CO while the engine is running. This must be performed with
a
CO analyzer.
~ WESTERBEKE
Engines & Generators
iv

CARBON MONOXIDE "CO" ISAFE-CO GENERATORS
IMPORTANT INFORMATION
Catalyst perfonnance will degrade over time. As the
generator accumulates operating hours,
CO concentrations
will increase.
The catalyst must be replaced every 2,000
bours of engine operation.
Verification of satisfactory CO levels must be done
seasonally or each 1,000 hours (which ever occurs first),
Verification involves actual sampling
of exhaust gas with an
appropriate CO analyzer.
There are two locations where exhaust gas can be sampled.
Dry,
but hot, exhaust can be sampled at the plugged tapped
hole
in the exhaust elbow intended for back pressure
measurements. Measurements at this location may not be
practical in all instances due to the high exhaust temperature,
temperature limits
of the analyzer, safety concerns over
temperatures involved or the possibility
of high levels of CO.
The other location is the boat's exhaust outlet, which
contains entrained cooling water (except dry stack exhaust
systems). Only analyzers with probes should be used at this
location and it is critical that the probe not ingest water.
Probe-type analyzers have an air pump drawing a gas sample
through the probe. As a result, they tend to ingest water when
it is present.
Be sure to aim the probe downwards with the
opening pointed in the direction of the water flow and just
out of the flow. Position the analyzer as high as possible with
the tubing leading to the probe running continuously down-
hill. Observe the usually translucent tubing between the
probe and the analyzer and be sure no water is being
ingested.
If any water is ingested into the analyzer, it must be
repaired or replaced and recalibrated.
When measuring
CO at the exhaust outlet be aware of the
ambient
CO level by also measuring CO away from and
upwind
of the exhaust outlet, especially in marinas. the CO
level at the exhaust will be influenced upwards by the
ambient level.
EXHAUST MANIFOLD
ADJUSTABLE
CLAMP
INSTALLING A NEW
CATALYST
Whenever taking the time to verify proper CO concentration
from the exhaust with a CO analyzer, always take the
opportunity to use the analyzer to
"sniff' around the engine
looking for CO from exhaust leaks. Pay close attention to the
connection
of the cylinder head to the exhaust manifold, the
exhaust manifold to the water injected exhaust elbow, and all
subsequent downstream exhaust components and hoses.
Remember, exhaust gas that has not yet passed through the
catalyst is raw, untreated exhaust and is very high in CO
content.
Analyzers usually require periodic calibration. Follow the
instructions that come with the analyzer very carefully
regarding calibration.
The following are manufacturers that offer CO analyzers:
Extech, TIP, Testo, TSI, Bacharach, Auke, Monoxor, Fyrite,
ZellwgwerAnalytics, Industrial Scientific Corp, GFG, TPI,
Teledyne and others. Westerbeke recommends analyzers with
a probe connected to the analyzer by a length
of transparent
tubing. They are slightly more expensive than those with the
sensor built into
one end of the analyzer, but they allow you
to sample the exhaust coming out
of the boat's exhaust outlet.
~ WESTERBEKE
Engines & Generators
v

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

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaustmanifoldinjection portis at
or below the waterline will result in raw
watertlamage to
the engine and 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 vessel's various operating conditions, install a
siphan-break.
NOTE: A siphon-break requires periodic inspection andcleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer for proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent waterfrom entering the exhaust under any sea conditions and at any angle
of the vessels hUll.
Carefullr review the Marine Installation manual provided with rour
WESTERBEKE Engine or Generator.
Additional manuals are available from rour WESTERBEKE dealer.
Engines & Generators
vii
t··
AVAILABLE fROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ............................................. 2
Introduction ................................ , ........................ 3
Warranty Procedures.........................................3
Serial
Number Location ...................................4
Fuel, Engine Oil, and Engine Coolanl... .............. 5
Preparations for Initial Start-Up ......................... 6
Starting/Stopping Procedure ............................... 7
Remote Panel ...................................................... 8
Break-In Procedure (Daily Operation) ................. 8
Safety Shutdown Switches .................................. 9
Maintenance Schedule ..................................... 10
Fuel System ....................................................... 12
Bleeding the Fuel System...........................
.l2A
Cooling System .................................................. 13
Changing Coolant...........................................13
Thermostat...............................
,.........,............14
Raw Water Pump............................................15
Raw Water Intake Strainer..............................15
Engine Lubricating Oil .......................................16
Oil Change......................................................16
Remote Oil Filter................................................17
Engine Adjustments ... ................. , ......... , ............ 19
Spark Plugs.....................................................19
High Tension Cords........................................19
Drive BeltAdjusment..............
,.........,............19
Fuel Pressure Test...........................................19
Engine Compression Test..................
,........., .. 20
Ignition Timing............................................... 20
Timing Belt Inspection and Replacement ...... 21
Engine Troubleshooting Guide ......................... .24
Electrical Troubleshooting Guide ..................... 26
DC Electrical System ........................................ .28
Battery Care.................................................... 29
Wiring Schematic #49167 .... ............................ .30
Starter Motor .................................................... .31
Generator Information ...................................... .33
BE Generator ..................................................... 34
Generator AC Voltage Connections ................. .35
Lay-up and Recommissioning ........................... 36
Generator Specifications ................................. .38
Shorepower Transfer Switch ............................. 39
Metric Conversion ........... .................................... .40
Standard Hardware and Sealants . ................... .41
Suggested Spare Parts ........................................ 42
-.,y: WESTERBEKE
Engines & Generators
1

VALVE
CONTROL
PANEL
EMERGENCY
STOP SWITCH
START/STOP
SWITCH
ASSEMBLY
MAGNETIC PICK-UP
FUEL FILTER -~~
ZINC
ANODE
FUEL LIFT
FRDNT
DC ALTERNAlroR-----
START SOLENOID
IN-LINE FUEL
FILTER
OIL FILL
STARTER Mn,rnD .--
HEAT
PARTS IDENTIFICATION
RIGHT SIDE
FUEL
PRESSURE
REGULATOR
LEFT SIDE
~ WESTERBEKE
Engines & Generators
2
----- OX1rGEN SENSOR 1
FRDNT
AIR TEMP SENSOR
DRAIN HgSE
SIPHON BREAK
SENSOR 2
,--",:::::o,"<~ DISTRIBUTOR
MOUNT
HIGH EXHAUST.
TEMPERATURE:SENSOR
GENERATOR
:--t-I'XHIIUST ELBOW
REAR
'-.E:(HAI~ST CHECK POINT
CONNECTION

INTRODUCTION
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine model and serial numbers. In addition,
include a complete part description
and part number for each
part needed (see the separately furnished Parts Catalog). Also
insist upon WESTERBEKE packaged parts because willfit
or generic parts are frequently not made to the same specifi-
cations as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules,
and troubleshooting of your genera-
tor, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essemial to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
the engine or generator.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
NOTE: A carbon nwnoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visable location in
the engine room.
SPARES AND ACCESSORIES
Certain spare parts will be needed to support and maintain
your WESTERBEKE generator or engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filter can be difficult to obtain along
the way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
on-board inventory of the proper WESTERBEKE parts.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted
in a WESTERBEKE generator capable of
many thousands ofhours of dependable service. However the
manufacturer cannol control how or where the generator is
installed in the vessel or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Six important steps /0 ensure long generator lite:
• Proper engine and generator illStallatWll and alignment.
• An efficient well-designed exhaust system thatincludes
an anti·siphon break to prevent water
from entering the
engine.
• Changing the engine oil am! oiljilters every 100 operat-
inghours.
• Proper maintenance of allengine andgenerator compo-
nents according
to the maintenance schedule in this
manual.
• Use clean,jiltered unleadedfuel.
• Wuzterize your ellgille according to the "Lay-up and
Recommissioning"section in this manual.
UNDERSTANDING THE GASOLINE GENERATOR
The gasoline engine driving an AC generator is in many
ways similar to a gasoline automobile engine. The cylinders
are verticle in-line, and the engine's cylinder head has an
overhead camshaft which is chain-driven. The engine utilizes
a solid-state distributor
which is horizontally mounted and
camshaft-driven. The engine incorporates a pressure type
lubrication system, and a fresh water-cooled engine block
which is thermostatically-controlled. To a large degree, the
generator's engine requires the same preventive maintenance
that is required ofa gasoline automobile engine. The most
important factors to the generator's longevity are proper
ventilation, maintenance of the fuel system, ignition system,
cooling system and the generator backend.
~ WESTERBEKE
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
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 DlL
Use a heavy duty engine oil with an API classification of SJ.
Change the engine oil and filter after an initial 50 hours of
break-in operation,
and every 100 hours of operation
thereafter.An
oil viscosity of SAE 15W-40 is recommended
for this engine in all conditions.
A CAUTION: 00 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
lenn protection.
The water and antifreeze should be premixed before being
poured into the cooling circuit.
NOTE: Use the new environmentallyfriendly, long lasting,
antifreeze thot is now available.
A proper 50/50 mixture as recommended will protect the
engine coolant to temperatures of -40'P
COOLANT RECOVERY TANK
Acoolant recovery tank kit is supplied with each generator.
The purpose ofthis recovery tank is to allow for engine
coolant expansion and contraction during engine operation,
without the loss of coolimt and without introducing air into
the cooling system.
~ WESTERBEKE
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTARTINSPECTION
Before starting your generator for the first time or after a pro-
longed layoff, check the following
items:
• Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls
for contamimmts.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: Afterthe initial running of the generator, the air in
the engine:r cooling system will bepurged to the coolant
recovery tank. Open the
air bleedpetcock to ensure that
the cooling system is purged
of air. Aftershutdown GJUi
afterthe engine has cooled, the coolantfrom the recovery
tank will be drawn into the engine:r cooling system to
replace the purged air.
Before subsequent operation of the generator, the engine's
manifold shauldbe topped off,
and the coolant recovery
tank may needto befilled to the
MAX level.
OIL FILL
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
• Check load leads for correct connections as specified in
the wiring diagrams.
• Examine the air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
the 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 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.
• Make certain the raw water thru-hull is open.
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.
AIR BLEED
PETCOCK
Engines & Generators
6

. STARTING/STOPPING PRO
GENERATOR CONTROL PANEL
AC CIRCUIT IrITii~~~
BREAKER ----+.Ii
HOURMETER
BA FUSE---_W
EMERGENCY" ","_L ,
"00
5'
START/STOP
o SWITCH --"""' __ -""
p
m
Starting
Simply press the START switch and the generator will start.
Agreen light will glow indicating the generator
is running.
Stopping
To stop-depress the STOP side of the start switch, the green
light will
go out and the generator is stopped.
Failure to Start
The start cycle will automatically tenninate if the unit fails to
start after 12-14 seconds ofcranking. Wait 20 seconds, then
repeat the start.
If the unit again fails to start, investigate the cause.
Sometimes after servicing the fuel system or changing the
fuel filter, air can accumulate in the fuel line or the throttle
body and prevent starting.
The Schrader
valves on the throttle body and the fuel cell are
used to remove trapped air. This air is mixed with fuel and
under high pressure. Follow
the BLEEDING THE FUEL
SYSTEM instructions in this manual.
•
START----'STOP
o
REMOTE CONTROL PANEL
ECU CONINECTIONS
~-~.-£'---EN["NE HARNESS
CONNECTION
FIREBOY, CO DETECTOR
AND/OR AUXILIARY STOP
CONNECTION
REMOTE START/STOP PANEL
The components on the panel are:
1. A three position start/stop rocker switch.
2. Agreen LED run indicator light on the rocker switch.
3. Afour position LED fault shut down display board.
The start/stop rocker switch functions
the sarne as the
start/stop rocker switch on the generator's control panel as
previously explained.
The start/stop rocker switch indicator light on the rocker
switch
will illuminate when the start circuit is energized. It
will go dim as the engine cranks and will brighten as the
engine sttuts to indicate the generator is running.
The
LED fault shut down display board has four separate LED
lights to display to the operator the cause of the generators
automatic shut
down. The four LED displays are: low oil
pressure, high engine operating temperature, high exhaust
temperature
and engine over-speedlunder-speed (flashes).
Should the generator shut down from one ofthese faults, the
fault LED will remain illuminated. To reset the LED, the stop
switch must be momentarily depressed.
This remote panel is a plug-in accessory and
is available with a
15' to 100' wiring harness.
~ WESTERBEKE
Engines & Generators
7

BREAK-IN PROCEDURE/DAILY OPERATION
BREAK-IN PROCEDURE
After the generator has been started, check for proper
operation and then encourage a fast wann-up. Run the
generator between
20% to 60% of full load for the first 10
hours.
A CAUTION: Do not attempt to break·in your
genllfBtor by running without a load.
After the first 10 hours of the generators' operation, the load
can be increased to the full-load rated output; then periodi-
cally 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
withinthe generators' rating. Since the generator operates
at 1800 rpm to produce 60 hertz, control
of the generator's
engine break-in is governed by the current drawn from the
generator.
To protect against unintentional overloading of the generator,
'. the generator's output leads should be routed thmugh a
circuit breaker thitt is rated at the rated output
of the
generator.
NOTE: Be aware afmotor starting loads andthe high
current drawn required/or starting motors. This starting
amperage drawn
can be 3 to 5 times nonnal running
amperage. See GENERATOR INFORMATION in this
manual.
CHECK LIST
Follow this checklist each day before starting your generator.
• 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 for abnormal noise such as knocking, vibration and
blow-back sounds.
• Confmn exhaust smoke:
When the engine is cold -White Smoke.
When the engine is wann -almost Smokeless.
When the engine is overloaded -some Black Smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition slwuld abate as nonnal operating temperature
is reached and loads are applied.
A CAUTION: 00 not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove the major AC loads from the generator one at a time.
Allow the generator to run for a few minutes to stabilize the
operating temperature and press the STOP switch down, (see
CONTROL PANELS).
NOTE: After the first 50 hours of generator operation check
the maintenance schedule
for the 50 hourservice check.
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 (HER1Z) ADJUSTMENT
under ENGINEADJUSTMENTS. A no-load voltage
adjustment may also be required in conjunction with the
engine's speed adjustment (see GENERATlOR
INFORMATION).
A WARNING: . VENTILATION
Gasoline vapors can explode. Before starting the engine,
operate the blower for at least four minutes and check both
the engine compartment and the bilge for gasoline vapors.
Run the blower below cruising speed.
Engines & Generators
8

SAFETY SHUTDOWN SWITCHES
DESCRIPTION
The engine/generator is protected by switches and sensors
that send signals
to the ECU that it interprets as a fault and
automatically shuts down the generator drive engine. When
an automatic shutdown occurs, one ofthe control panel fault
LED lights will illuminate indicating what fault caused the
engme to shutdown. TIlls LED will stay illuminated.
To
correct the fault, refer to ENGINE TROUBLESHOOTING in
this manual. Do not attempt to restart the generator
before correctiog
the fault.
WDISPlAY
PCBOARD
(INTERIOR
VIEW)
~I
CONTROL PANEL INDICATOR LIGHTS
PRESSURE
FUSE
Four LED fault ligbts are located on the generator control
panel
and the remote start/stop panels. Should a problem
occur during generator operation the individual light will
indicate
Where the problem is and at the same time shut the
generator down. The light wjll continue
to glow after the
generator shuts down. Should this occur, refer
to ENGINE
TROUBLESHOOTING in this manual.
OIL GALLERY
OIL PRESSURE SENSOR
An oil pressure sensor (located just below the oil filter) sends
a
DC Voltage to the ECU that it interprets as oil pressure.
Should this voltage faIl below a certain level, the ECU will
shut
the generator down and illuminate the low oil pressure
LED.
Should this occur, refer to ENGINE
TROUBLESHOOTING in this manual.
EXHAUST TEMPERATURE SWITCH
A temperature switch is mounted on the exhaust elbow to
monitor the temperature of the exhaust coolant and gasses.
Should the switch sense an excessive exhaust temperature, the
ECU will shut the generator down and the exhaust
temperature LED will illuminate on the control panel. Should
this occur, refer to ENGINE TROUBLESHOOTING in this
manual.
COOLANT SENSOR
THERMOSTAT
ASSEMBLY
COOLANT TEMPERATURE SENSOR
Acoolant temperature sensor is located on the thennostat
housing to monitor the engines fresh water coolant. Should
the coolant temperature reach 21O"F, the ECU will shut the
generator down and the engine temperature LED will
illuminate. Should this occur, refer
to ENGINE
TROUBLESHOOTING in this manual.
OVERSPEED SWITCH
An overspeed high RPM shutdown sensor in the ECU will
shut the engine down ifthe engine RPM"S exceed
the set
limit and the LED will remain
lit. If an underspeed problem
occurs, the engine
will shutdown and the LED will remain
flashing.
DC CIRCUIT BREAKER
The generators engine is protected by a panel mounted man-
ual reset circuit breaker (20 amp). An electrical overload in
the engine's wiring hamess or the instrument panel will trip
this breaker and shutdown the engine/generator. Ifthis should
occur, inspect and repair the problem. then reset the breaker
and sestart the engine/generator.
Engin~s. & Generators
9

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 co"ect tools for each job. Disconnect the battery terminals when
serviCing any of the engine's DC electrical equipment.
I SAFE IMaintenance items that are very imponant to the proper operation of
CD "Safe CO" generators.
CHECK
HOURS OF OPERATION
EACH
MAINTENANCE DESCRIPTION
DAY
50
100 250
500
750 1000 1250
0
Unleaded gasoline with octane rating of 89 of 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.
Visual Inspection of Engine
0
NOTE: Keep engine surface clean. Dirt and oif
Check for fuel, oil and water leaks. Inspect wiring and
will inhibit the engine's abifity to remain cool.
electrical connections. Keep bolts & nuts tight. Check
for loose belt tension.
Sparts Plugs I~EI
0 0 0 0 0 0
Check gap, inspect for burning and corrosion.
Starling Banerles
0
Every 50 operating hours check electrolyte levels
(and House Baneries) weekly and make sure connections are very tight. Clean off
excessive corrosion.
Engine 011
0 0 0 0 0 0 0
Initial engine oil and filter change at 50 hours, then
change both every 100 hours.
Generalor
0 0 0 0 0 0 0
Check that AC connections are clean and secure with
no chafing-see GENERATOR INFORMATION.
Fuel un Pump
0
Periodically inspect for leaks, electrical connections
are clean and tight.
Air Screen FcHI 0
Clean at 50 hrs., then every 100 hours.
Exhausl Syslem
0 0 0 0
Initial check at 50 hours, Ihen every 250 hours.
Inspecl for leaks. Check anti-siphon valve operation.
Check the exhaust elbow for carbon and/or corrosion
buildup on inside passages; clean and replace as
necessary. Check that all connections are tight.
Engine Hoses
0 0 0 0 0 0 0
Hose should be hard & tight. Replace if hoses
become spongy. Check and tighten all hose clamps.
Raw Waler Pump
0 0 0
Remove the pump cover and inspect for wear.
Inspect impeller, cam and wear plate. Replace gasket.
Lubricate impeller when reassembling.
Heal Exchanger
0 0 0 0 0 0 0
Clean or replace anode. Open heat exchanger end
cap and clean oul debris. Remove every 1000 hours
for professional cleaning and pressure testing.
Cootanl Syslem
0 0
Drain, flush, and refill COOling system with
appropriate antifreeze mix.
Fuel Filler
0 0 0 0 0 0
Change every 250 operating hours.
Inlel Fuel Filler
0 0 0 0 0 0
Change every 250 operating hours.
(continued)
Engines & Generators
10

SCHEDULED
MAINTENANCE
"Starter Motor
Distributor ~
"Engine Cylinder
CompreSSion and
Valve Clearances
"Engine Timing Belt
"Exhaust Elbow
MAINTENANCE SCHEDULE
NOTE: Use the engine Murmeter gauge to log your engine hours or recordyour
engine hours by running time.
CHECK
HOURS OF OPERATION
EACH
MAINTENANCE DESCRIPTION
DAY
50
100 250
500
750 1000 1250
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
0 0
Check ignition timing. Check condition of distributor
cap and rotor.
0 0
Incorrect valve clearance will result in poor engine
performance, check compression pressure and
timing and adjust valve clearances.
0
Remove and replace every 1000 hours.
NOTE: Failure to replace the timing belt at the
recommended interval could result in timing chain
failure resulting in major damage to the engine.
0
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteriorated.
NOTE: A defective exhaust elbow can cause
carbon monoxide leakage!
Catalyllc Converter ~
0
Remove water injected exhaust elbow and visually
inspect. Replace every 2000 hours.
"Exhaust System Back
0
Pressure
Catalyst .1mI
0
Oxygen Sensor 1"t1f1 0
CO In Exhaust
0
·WESTERBEKE recommends this service be performed by an authorized mechanic.
ADJUSTABLE
CLAMP
EXHAUST MANIFOLD .0~~"
Engines & Generators
11
Perform back pressure test to ensure system is not
developing restrictions that will increase pressure
above 1.5 PSI or 41 inches of water column at full
operating amperage load. Correct as needed.
Remove water injected exhaust elbow and visually
inspect every 2000 hours. Replace as needed.
Inspect every 1 000 hours. Replace every 2000 hours.
Sample with CO analyzer.