Westerbeke 7.6 kw EDT User manual

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OPERATORS MANUAL
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7 .6KW EDT 60 HZ
5.7KW EDT 50 HZ
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D·NET DIESEL GENERATORS
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PHASE .
NO. 52767
Rl'lfl!::fnN 3
JANUARY 2012
, WESTER~EKf;,CORPORATION .150 JOHN HANCOCK ROAD
'MYLES STANDIsH INDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
NAiJl-l Member National M~rine Manu/acwrers Association
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CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.
A WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonons and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
• Dizziness
• Throbbing in Temples
• Nausea
• Muscular Twitching
• Headache
• Vomiting
• Weakness and Sleepiness • Inability to Think Coherently
IF YDU 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.
\ ~WIill!!ll!!A!Iii!!!'R~-Ni!!i!-I!I!IN ~G \
! 'Generators Produce CARBON MON0XIDE.
Regular Maintenance Required
A WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine Dr
generator.
WESTERBEKE also recommends installing CARBON
MONOXIDE DETECTORS near the engine room. They
are inexpensive and easily obfainable at your local
hardware store.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protect yourself, your
personne~ audyour machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 nat lauch AC electrical connections
while engine is running, or when connected to share
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 if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS _. HOlENGlNE
A WARNING: 00 nat touch hat engine parts or
exhaust system components. A running engine gets
very hat!
• Always check the engine coolant level at the coolant
recovery tanle
A WARNING: Steam can cause injury or death!
• In case ofan engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury 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 alr cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to ntinimize 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. Checkbelow 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'ofchildren.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that ntight
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 shutoffvalve.
• 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
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, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection temtinal of the starter solenoid.
Do not test the battery condition by shorting the temtinals
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 wltile the battery
is being charged.
• Avoid contacting the temtinals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect itlast when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
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 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 flu-like symptoms,
nausea or death!
• Do not use copper titbing 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
or death!
• Do not service the engine wltile itis running. If a
situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
~ WESTERBEKE
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 ofthe drive shaft and the transntission 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
lossl
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally Of physically incapacitated by fatiguel
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.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination 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 of particular interest are:
H-2 Ventilation
P-I Exhaust Systems
P-4 Inboard Engines
E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standsrds. 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
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
~ WESTERBEKE
Engines & Generators
iii

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 gnidelines, 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. Tbis hose must be looped a
ntinirnum of20"
above the vessel's waterline. Failure to use a siphon-break when
the exhaustmanifold/water injected exhaust elbow is nearor below the loaded
water line of the vessel willresult in raw water damage to the engine and possible
, flooding of the vesseL
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 operaling conditions, installa
siphon-break. '
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer for proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. Th~ system must be designed to
prevent
water from entering the exhaust under any sea conditions and at any angle
A detailed40 page Marine Installation Manual covering gasoline and
diesel engines and generators
is provided with each unit sold. Additional
copies
can be obtain offour website in pdf form. www.westerbeke.com
Engines & Generators
iv
"
AVAILABLE FROM
YOUR WESTERBEKE
OEALER

TABLE OF CONTENTS
Parts Identification ............................................. 2
Engine Adjustments .......... , ................................ 23
Introduction .......................................................... 3 Drive BeltAdjustment............................:....
23
Fuel,Engine Oil and Engine Coolant... .............. .5
Torquing the Cylinder Head Bolts .............. 23
Prepllrations for Initial Start-Up ......................... 6 Generator Frequency ...................................
24
Digital Control Panel ........................................... 7 Electrouic Governor....................................
24
LCD Sequence ................................................... 7A Valve ClearauceAdjustment .......................
25
Digital Control Box .............................................. 8
Remote Stop/Start Panel .................................. 8A Engine Compression...................................
125
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Spill Timing................................................. 26
Generator Break-In Procedure ............................ 9 Oil Pressu,re .................................................
27
Daily RouUne ....................................................... 9 Glow Plugs ..................................................
27
Maintenance Schedule (Chari) ......................... 10
Fuel Injectors............................................... 28
Fuel System ....................................................... 12 Engine Troubleshooting (Chart) ........................ 29
Cooling·System .................................................. 13 Alternator Testing ............ , ................................ 31
Fresh Water Cooling Circuit...................../
.. 14 Battery Care.......
~ ......................................... 33
Chauging the Coolant..................................14 Shore PowerConnections ................................. 34
AirIntake ... ;.....i...........................................14
Thermostat.......l...........................................
15
Raw Water Intake Strainer.......................... 15
Generator Information ....................................... 35
7 _6Kw Generator Single Phase ......................... 36
9rcuit Breaker............................................ 36
Raw Water Cooling System ........................16 Troubleshooting...........................................
37
Heat Exchanger ...........................................16
No Load Voltage Adjustment......................38
Raw Water Pump.........................................
16
Generator Voltage Adjustment................. .38A
Engine Lubricating Oil .......................................17 Residual Voltage Check...............................39
'Engine Oil Chauge ......................................
17
Bridge Rectifier ...........................................40
Remote Oil Filter (optional)........................18 Exciter Rotor Field......................................41
Starter Motor .............. ~.: .................................... 19
Measuring Resistance..................................42
Troubleshooting;
... :........................................20
Generator Specifications .................................. 21
Voltage Connection Terminal ......................42
Lay-up and Recpmmissioning .......................... .43
Wiring Diagrams ................... , ........................... 22
Power Take-Off ................................................. .45
Metric Conversion Data (Chart) ....................... .46
Suggested Spares ............. ................................ .47
...v-WESTERBEKE
Engines & Generators
1

INJECTION
DRIVE DCLl,_-.;..~'"
COVER
7.6 KW GENERATOR
WIRING SCHEMATIC #044121
IREMOTE PANEL
~..al---EXHAUST ELBOW
OIL PRESSURE SEN1!OR.~"
i?l""11~~~ ,t1t-:;(VfL-ISTAI~TSOLENOIO
REAR
',ZINC ANOIOE-~~
FRONT
ALTERNATOR
LEFT
SIDE
EXCHANGER·
COOLANT'PRESSURE CAP
DIGITAL i:ONTROL_~£~
PANEL
AIR
CIRCUIT
!'OWER TAKI:·OFF
CONNECTION
FILTER
~~~w~~r-,' .. n'OIL FILTER
!:k--OIL DRAIN HOSE
RIGHT SIDE
MOUNTS
Engines & Generators
2

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WES1ERBEKE's long
years of experience and advanced
technology. We take great pride in the superior durability and
dependable performance of our engines and generators.
Thank you for selecting WESTERBEKE.
Inorder to get the full use and benefit from your generator it
is important
that you operate and maintain it correctly. This
manual is designed to help you do this. Please, read this' _
manual carefully and observe all the safety precautions
throughout. Should your generator require servicing, contact
your
nearest WESTERBEKE dealer for assi~tance.
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 tIns
equipment contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If,after 60 days ofsubmitting the Warranty Regiftry
form you have not received a customer identification card
registering
your warranty, please contact the factory in
writing
with model information, including the unit's serial
number and comnlission date.
Customer Identification Card _
L~ WESTERBEKE
4Engines & Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model Ser. #
Expires
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals,
brochures and catalogs), provided from sources other tllan
WESTERBEKE are not within WES1ERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WIUIN NO EVENT
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings of WESTERBEKE product
software and the unavoidable existence ofearlier
WESTERBEKE manuals. In summation, Produ9t software
provided with WES1ERBEKE products, whetIler from
WESTERBEKE or other suppliers, must not and carmot
be relied upon exclusively as the definitive authority on
the respective product. It Dot only makes go~d sense
but is imperative that appropriate representatives of
WESTERBEKE orthe supplier in question be consulted
to determine the accuracy and currentness ofthe
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance sChedules, and troubleshooting of your marine
engine, critical information will be .highligh~ by NOTES,
CAUTIONS, and WARNINGS. An explanatIOn follows:
NOTE: An operating plVcedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
~ WESTERBEKE
Engines & Generators
3

INTRODUCTION
I
SERIAL NUMBER LOCATION
, , The engine and generator serial numbers and model numbers
, are located on a decal on the generator housing, Thke the
time
to enter this infonnation on the illustration of the name-
plate shown below, as this will provide a quick reference
, when seeking technical infonnation and/or ordering repair
parts.
Eiii~~
MUlJI:L ________ _
RPM ___________ _
KVV ____________ _
KVA ___________ _
VOLTS _________ _
AMPS _________ _
ENG. HP ______ _
ENG. SER. NO.
GEN. SER. NO.
PF/PHASE ___ _
VVIRES ________ _
RATlNG _______ _
INSUL CLASS __
TEMP. RISE ___ _
BATTERY __ ~ __ _
C.I.D. _________ _
The engine serial number is also found stamped into the
I engine block on the flat outboard surface where the fuel
injection pump is bolted down onto.The generator serial
number is stamped into the flat surface just above the rear
carrier bearing.
r~!!i!:!~l=:!1
An identification 'plate on the engine manifold also displays
the engine model and serial nwubel'.
NOTE: A carbon nlOlwxide warning decal has been 'provided
by WESTERBEKE AffIX this decal ina visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine ciosely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed craokcase;the crankshaft is ~f
the same general type as that ofa gasoline engine, and the
diesel engine has the same type of valves, camshaft, pistons,
connecting rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the
same preventive mainlq1ance ?S a gasoline engine. The
most important factors are proper ventilation and proper
maintenance of the fuel, lubricating and cooling systems.
Replacement of fuel and lubricating filter elements at the
liI1!e periods specified is a must, and frequeut checking for
contamination (that is water, sediment, etc.) in the fuel sys-
tein is also essential. Another important factor is the use of
the same brand of high detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,
however, in 'its method of handling and firing of fueL The
carburetor and ignition systems are replaced by a single
component - the fuel injection pnmp - which perfonns the
function of both.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator model number, engine serial number, and generator
serial number as they appear on the silver and black name-
plate located on the generator end. 'You must provide us with
this infonnation so we may properly identify your generator
set In 'addition, include a complete part description and part
number for each part needed (see the separately furnished
Parts List). Insist upon WESTERBEKE packagedparts
because willjit or generic parts are frequently not made to
the same specifications as original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and rhaintsin your
WESTERBEKE engine. Your local WESTERBEKE dealer
will assist you in preparing an inventory of spare parts.
See the SPARE PARTS page in this manual. For engine
accessories, see WESTERBEKE' S ACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed information fur
installing generators and is available at your WESTERBEKE
dealer.
Engines & Generators
4

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER.
(No. 2-D (SAE J3/3) diesel fuel according to ASTM 0975}.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your fuel injection pump is very critical; invisible 9irt
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 offuel.Instail and regularly
service a good, visual-type fuel filter/water separator between
the fuel tank and the engine. The Raycor SOO MA or 230
RMAM are good examples of such filters.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF,
CG-4, CR-4 or CIA. Change the engine oil and filter after an
initial SO hours of break-in operation. Then follow the oil and
filter change intervais as specified in the MAINTENANCE
SCHEDULE
in this manual. Westerbeke Corporation does
not approve or disapprove of the use of synthetic oils. If
synthetic oils are used, engine break-in must be performed
using conventional oil. Oil change intervals must be as in the
MAINTENANCE SCHEDULE, not extended because
synthetic oils are used
SAE OIL VISCOSITY GRADES
For all temperatures USe SAE lOW- 30 or ISW-40.
OIL PRESSURE
The engine's oil pressure, during operation, is indicated
bythe
oil pressure gauge on the instrpment panel. During
normal operation, the oil pressure will range between 3S and
65 psi 2.5 and 3.9 kg/em').
NOTE: A newly staned, cold engine. can Mve an oil pressure
reading upwards of 60 psi (4.2 kg/em". A warmed engine can
have an oilpressure reading as low as 25 psi (I. 8 kglcm".
These readings will vary depending upon the temperature of
the engine, the load placed on the engine, and the RPM~.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and SO% distilled water. Distilled water is free from the
chemicais 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, and lubricates and protects the
cooling circuit from rust and corrosion. Look for a good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs) that keep the antifreeze chemically
balanced, crucial to long term protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
PURCHASING ANTIFREEZE
Rather than preparing the mixture, WESTERBEKE
recommends buying the premixed antifreeze so that so that
when adding coolant the mixture will always be correct.
There are two common types of antifreeze, Ethylene Glycol
(green) and Propylene Glycol (red/purple), either can be used
but do not mix the two and ifchanging from one to another,
flush the engine thoroughly.
Premixed antifreeze for DIESELEngines:
Specification #ASTM D53456.
MAINTENANCE
Change the engine coolant every five years regardless of the
number of operating hours as the chemical additives that
protect
and lubricate the engine have a limited life.
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each
engine
or generator. The purpose ofthis recovery tank is to
allow for engine coolant expansion and contraction during
engine
operation, without the loss of coolant and without
introducing air into the cooling system. This kit is provided
and must be installed before operating the engine.
NOTE: This tank, with its shan run of plastic hose, is best
located at or
above the level of the engine ~ manifold, but it
can be located below the leveL of the engine:S manifold if the
particular installation makes this necessary.
~ WESTERBEKE'
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTioN
Before starting your generator set for the first time or after a
prolonged
layoff, check the following items:
• Make certain the cooling water thrn-hull petcock is open.
• Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminant's. .
• Check the DC electrical system. Inspect wire connections
and battery
cable connections. .
• Checkload leads for correct connection as specified in the
wiring diagrams.
• Examine air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
load lines.
• Be sure that in power systems with a neutral line that
the
neutral is properly grounded (or ungrounded) as the
system
requires, and that the generator neutral is properly
connected
to the load neutral. In single phase systems an
incomplete or open neutral can supply the wrong line-to-
neutral voltage on unbalanced loads.
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, uuattached hoses, and check
threaded
connections. Search for any gasoline leaks.
WAIT FOR THE ENGINE TO COOL
BEFORE REMOVING THE RADIATOR
CAP
FROM COOLANT
RECOVERY TANK
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 acold engine from
stalling.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: After the initial rumii'ng of the generator, the air in
the engine s cooling system will be purged to the coolant
recovery tank. Open the air bleedpetcock to ensure that
the cooling system is purged of air. Aftershutdown and
after the engine has cooled, the coolantfrom the recovery
tank will be drawn into the enginescooling system to
replace the purged air.
Before subsequent operation of the generator, the
enginesmanifoldshould be topped off, andthe coolant
recovery tank may need to be filled to the MAX leveL
TOP OIL FILL
STOP BOLT ADJUSTMENT
SPEED ADJUSTMENT
FACTORY SEt
Engines & Generators
6

DIGITAL CONTROL PANEL
DESCRIPTION
WESTERBEKE'jS, Digital Control Panel provides the
operator with an LCD display that contunuously monitors
all the operations of the generator in easy to understand
text messages.
CONTROL BOX
Note that the design and size of the control box will vary
depending on tl,e model generator.
SA FUSE
PROTECTS THE CONTROL PANEL
ELECTRONICS FROM A HIGH
AMPERAGE OVERLOAD.
INDICATOR LIGHTS
SIX LIGHTS THAT INDICATE
c' WHERE A FAULT HAS OCCURED.
20A BREAKER SW~":
SHUT-OFF WHEN PERFORMING
MAINTENANCE OR WHEN
REPAIRING A FAULT RESET TO
RESTART THE ENGINE. FAILURE LIGHT
A RED LIGHT WILL APPEAR IF
THE RUN SEQUENCE IS
INTERUPTED BY A FAILURE. '
~",~¢')" '
/
LCD DISPLAY
Operating temperatures may cause the LCD display to vary
in color. This is normal and a change in color will not affect
the operation on the control panel.
Periodically clean the cQntrol panel LCD screen using a soft
cloth.
. UPAND DOWN ARROWS
WHEN THE LCD DISPLAY IS
IN ITS SCROLL MODE. THE
UP AND DOWN ARROWS CAN
BE USED TO ADJUST THE
, DARK AND LIGHT CONTRAST
UP..JlRROW
WHEN IN SCROLL LOCK MODE
INDIVIDUAL FUNCTIONS CAN
BE MONITORED BY PRESSING,
THE UP-ARROW.
SCROLL LOCK
STOPS RUN SEQUENCESO •.
THAT A SINGLEFUNCTlOii CAN
BE MONITORED
DOWN-ARROW
. WHEN IN SCROLL LOCK MODE
INDIVIDUAL FUNCTIONS CAN
BE MONITORED BY PRESSING
THE OOWN-ARROW.
PRIME BUTTON
THISHUTTON ENERGIZES THE FUEL
PUMP. AFTER REPAIRING A FAILURE
OR PERFORMING MAINTENANCE,
PRESSING THIS BUTTON WILL PURGE
AIR OUT AND BRING FUEL IN TO THE
LINES.
MANUAL ENGINE SltUT·OFF"k
LCD DISPLAY SEQUENCE ..
IS SHOWN ON THE FOLLOWING PAGE ..
Should the stop button on the panel fail in its nonnal
function to stop the engine. The engine
is equipped with
a manual shut-offlever located
on the engine blockjust
the
side oil fill, Simply move the lever to the left aud hold
it there until the engine comes
to a complete stop.
Engines & Generators
7'

DIGITAL CONTROL PANEL/LCD SEQUENCE
START SEQUENCE
With the pre-start inspection completed, press the,START
button and the automatic sequence will begin. The six
indicator lights will illuminate green and the panel will
display the following text:
, ,
.Waitlng'for operator
--
TERBEKE
Press start to
--,- Engtnes & Generators
.
engage generator
Pre l'Ieatlng...... Cranking......
7 Seconds
RUN SEQUENCE ....
As the display cycles thru the engine functions, the speed
will come up to 1800 rpms-60Hz (1500 rpms,50Hz) and
the oil pressure and engine coolant will rise to their normal
readings. The functions will cycle in the following sequemce:
'Engine Speed
,COOI,"it Teinperaiure
1800RPM81C 17SF
32".. 300'
2500' 0 10~'
o
~:::::::::::::~g:R:9L~,L ~:::;;;;::::::~:R:OL:L~
BatteryVoltage on Pressure "
3.1' ,40
13.5 VDC 'eM PSI
o 30 "
"~o 1IIiii ___ c::~,1!)'Q
o .6~9
!::::::::::;:, .. :_:SC:R:OL~L ~::::::::::::':SC:R:O:LL~
, AC Frequency
Engine Hours
3,8 HOURS
60.1Hz
o 100
I
::::::::===' : .. S:C:RO:L~L SCROLL
~ AC Phase Voltage AC Line Voltage
ro
120V':-0 -====;;;!
SCROLL LOCK
To. stop the continuing sequence, press the s' ':CI<~O~"L ][,(liCK
button. This enables the operator to monitor a
for any length of time. Theword LOCKwill appear
com:et. U~e,lhI' up and down arrows to find arid observeother
functio\lii. To resume scrolling, press the SCROLLLOCK '
button again. ..
, ~ - -
STOP SEQUENCE
To stop the generator, press the STOP button. The display
will cycle thru the following text messages and shutdown.
Shutting'
Down " Engine Shutdown
Waiting for operator
Pressstart to
engage generator
FAILURE LIGHT/SHUTDOWN
Ifa problem occurs, the generator will shutdown and the
FAILURE light will illuminate red. In addition, one ofthe
indicator lights will change from green to orange to reveal
where the trouble has occured and the display will text
message what has happened, ,,
, Examples:
Failure Light is red.
CoQldnt temperatlb"e' Light
is orange. ..
, Failure Light isred.
Oil Pressure Light is orl1nge.
High Engine Temp.
Reset ECU to Restart'
Low Oil Pressure
Reset
ECU to Restart
When a failure occurs, refer tothe troubleshooting chart,
wiring diagram, and general operating text in this manual to
assist in solving the trouble.
There are many combinations of messages that can be
displayed but they are all self explanatory and the operator
can easily isolate and correct the problem should one occur.
Before re-starting the generator, tlie 20 amp DC circuit
br~Yl<er must be reset. With the problem cOrrected and the
generator started, the sequences will begin cycling again.
Control Box Components t
and Frequency Adjustments
are on the fol!owing page.
Englne",,~"GenEirators
7:A---

DIGITAL CONTROL BOX
FREQUENCY FAULT
Frequency is displayed on the LCD display screen while the
engine is running in 'RPMand frequency (hertz),
The ECU is receiving a low AC voltage signa! and hertz
sigoa!
from the MPU which is positioned on the bellhousing
over
the flywheel ring gear teeth. The ECU interprets this
signal
as bOtll RPM and hertz.
Should this signal vary approximately 2% either up or down,
a frequency fault shut down will occur, initiated by the ECU.
The red failure LED on the display panel will illuntinate, the
frequency LED will turn from green to amber and the LCD
display screen will show the fault text "overspeed".
NOTE: If the unit shuts down for an underspeed condition, the
samefault lIoverspeed" will show on the screen but the
frequency LED will BUNK.
WHEN CHANGING T%~,f%:~:~~DJ.~S
, FREQUENCY (50160 'HZ)
ON THE CONTROL PANEL ECU
BOARD MUST BE SWITCHEI1:
.O,N FOR 50 HZ AND OFF FOR 60 HZ
CONTROL B_O,JX
M
IPONENTS
INTERNAL 101
SAM? F".F .... ~
GENERATOR FREQUENCY ADJUSTMENT (HERTZ)
CAUTION: When changing the generatorfrequency setting on
the ECU, tum off the 20 amp DC circuit breaker,on the control
box. Tum it back on after the setting has been changed
NOTE: If the unit shuts down for an underspeed condition, the
same fault "overspeed" will show on the screen but the
frequency LED will BLINK.
1. Turn the DC brenker on the control panel to th'-OFF
position.
2. Open the covel' of the control box and view the BCU
(Electronic Conu'ol Unit).
3. Locate the' #1 dipswitch on the ECU and move it to the
position that corresporids to the Hem operation desired).
See tile illustration below showing the ECU in the
control box.
4. Replace the control box cov.er, tum the DC brenker,ON
and start the unit. Monitor the frequency that the
engine/generator is operating is opemting at ihe COlTeC!
frequency. '
~5111t?l~;AMPDC
BREAKER
NOTE: DURING OPERATION THE COLOR
OF THE LCD DISPLAY MAY VARY.
CAUSED BY HEAT, THIS IS NORMAL
AND NO CAUSE FOR CONCERN.
CAUTION (WESTERLINK or NMEA-2000): The electronic components in the Digital Diesels draw a very small amount of amperage (milli-amps)jrQm the
generator! starting battery whell rile. unit is in a static state. This maybe as much as 50 mil/i-amps/ar the system ECU and 50 miUi-ampsfor each displp.y.
This can be as much as 72 amp-hours in a months time with no generator use. It is not necessary to' be concerned with this slight amperage draw during
~onnal ;reasonal use. However, ijrhe generator set is not to be used/or a number a/months, such as winter storage, it is best to disconnect the DCpower
to the generator with a NMEfi.-200Q $)Istem or shill offthe DC breaker ~n the generator's control box for a WESTERLINK system. .
NOTE: Keep in mind that the Westerbeke generator maybe the DCpower supply for the vessel'.s NlvlEA~2000 network.
~ WESTERSEKE
Engines & Generators
8·

REMOTE STOP/START PANEL
AND EXTENSION HARNESSES
DESCRIPTION
A remote panel is availal;Jle that allows the generator to be
stopped and started from any location ,on the boat. The
connecting harnesses come in three different lengths and two
ofthese can be combined for a maximum run at,75' (22.l7M).
NOTE: For additional information, contact your local
WESTERBEKE dealer.
3·1/4" \O'.'IOIVIIIIII'
6" (152.4MM)
CONNECTING EXTENSION
CABLES
15' (4.75M)
30' (9.1M)
60' (18.2M)
PN 052959
PN 052789
PN 052960
REMOTE PANel/PIG TA It
PN 052560 '
Note: These two dimensions are the measurement of the cut-out opening .
.....v- WESTERBEKE
Engines &: Gen~rators
8A

GENERATOR BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum ofone
hour of
test operations at the factory to make sure accurate
assembly procedures were followed and that the engine
operated properly, a break-in time is required. The service
life of your engine is dependent upon how the engine is
operated and serviced during its initial hours of use.
Breaking-in a new engine basically involves seating the
piston. rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
glazed or scored, which is caused by overloading the
engine during the break-in period.
Your new engine requires approximately 50 hours of initial
conditioning operation to break in each moving part in order
to maximize the performance and service life of the engine.
Perform this conditioning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems (raw
water pump, oil pressure, battery charging) are functioning.
AFTER START·UP
Once the generator has been started, check for proper opera-
tion and then encourage a fast warm-up. Run the generator
between
20% and 60% offull-load for the first 10 hours.
After the first 10 hours of the generator's 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 smoky
exhaust
with reduced output voltage and frequency. Monitor
the current being drawn from the generator and keep it within
the generator's rating. Since the generator operates at 1800
rpm to produce 60 hertz (or at 1500 rpm to produce 50
Hertz), control of the generator's break-in is governed by the
current drawn from the generator.
NOTE: Be aware of motor starting loads andthe high current
draw required for starting motors. This starting amperage
draw can be 3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may be
governor
adjustments required for engine speed (hertz) during
the engine's break-in period (first 50 hours) or after this
period see ENGINE SPEED (HER'lZ) ADJUSTMENT) under
ENGINE
ADJUSTMENTS .. A no-load voltage adjustment
may also be requirad in conjunction with the engine's speed
adjustment
see GENERATOR INFORMATION.
THE DAILY ROUTINE
CHECKLIST
Follow this check list each day before starting your generator.
• Check that all generator circuit breakers (power panel) are
in the off position before starting.
• Record the hourrneter reading in your log (engine hours
relate to me maintenance schedule.)
Any deficiency or problems in the following items must
be corrected before start up.
• 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 drive belts for wear and proper tension (weekly).
CHECK WITH THE ENGINE RUNNING.
• Check for abnonual noise such as knocking, vibrating imd
blow-back sounds. .
• Confirm exhaust smoke:
When the engine is cold - White Smoke.
When the engine is warm -almost Smokeless.
When the engine is overloaded - some Black Smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as IIOrmIll 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 AC loads from the generator one at a time.Allow
the generator to rnn for 3-5 minutes to stabilize the operating
temperature,
then tum the key to the off position. Once the
generator is
shutdown, close down all circuit breakers as a
safety precaution.
Engines & Generators
9

.. MAINTENANCE SCHEDULE
A WARNING: When servioing"geilemiij,iingineoiimpiiiieiils;ihil jjCpow,r iiiu,t be turned ofiuSing either the lie
. breaker or the ballery swi~~h. _
SCHEDULED
MAINTENANCE
Fuel Supply
Filel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
A WARNING: Never attempt to perform any service while theengl~e is
running. Wearfheproper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery tenninals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenance jobs are simple but others are more
difJicult and may require the expert knowledge of a service mechanic .
.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY
50
100 250
500 750
1000 1250
MA.INT£NANCE
D .
Diesel No.2 rating of 45 cetane or higher.
D
Check for water and dirt in fuel (drain/replace filter
if necessary).
D
Oil level should indicate between MAX. and LOW on
dipstick.
D
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
D
Inspect for proper tension (3/8" to 112" depression)
weekly and adjust if needed. Check belt edges for wear.
Visuai'lnspection of Engine
D
NOTE: Please keep engine surface clean. Dirt
Check ior fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engine's ability to
remain cool.
Fuel Fllter~nlet Filter
D D D D D
Starting Batteries
D
(and Hnuse Batteries) weekly
Engine Oil (and Iilter) D D D D D D D
Generator
D D D D D D D
Heat Exchanger Zinc Anode
D D D D D D D
Fuel/Water Separator
D D D D D D
Sea water Pump
D D
Exhaust System
0 D D D
Engine Hoses
D D D D D D
NOTE: Use the engine hour meter gql!ge. to log your engine hours or record your
engine hours by running time.
Engines & Generators
, 10
and electrical connections. Keep bolts & nuts tight
Check for loose belt tension.
Initial change at 50 hrs, then change every 250 hrs.
Every 50 operating hours check electrolyte levels
and make sure connections are very tight. Clean off
excessive corrosion.
.
Initial engine oil & filter change at 50 hrs., then
change .both every 100 hOurs.
Check.thal AC connections are clean and secure
with no chafing. See GENERATOR SECTION
for additional information.
.
Inspect zinc anode, replace if needed, clear the heat
exchanger end of zinc anode debris.
Change every 200 hours or each season.
Remove the pump and inspecHhe internal wear.
Check shaft that bearings, seals are in good order.
Inspect shaft end and drive gear slot for wear.
Repair/replace as needed.
Initial check at 50hrs., then every 250 hrs. Inspect
for leaks. Check anti-siphon vallie 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.
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.

MAINTENANCE SCHEDULE
A WARNING: When servicing generator/engine components, the DC power must be turned off using either the DC
breaker or the battery swItch.
NOTE: Use the engine hour meter gauge to log your engine hours or record your
engine hours by running time.
CHECK
HOURS OF OPERATION
SCHEDULEO EACH
EXPLANATION OF SCHEDULED
MAINTENANCE DAY
50 100 250 500 750 1000 1250 MAINTENANCE
Raw Waler Pumw
0 0 0
Remove the pump cover and inspect impeller, gas-
ket, cam and cover for wear.
Coolant System
0 0
Drain, flush, and refill cooling system with
appropriate antifreeze mi)(!ure compatible with
various COOling system metals.
Electric Fuel Lift Pump
0 0 0 0 0 0
Periodically check the wiring connections and
inspect the fuel line connections.
Inlet Fuel Filter
0 0 0 0 0
Replace.
DC Alternator
0 0 0
C.heck DC charge from alternator. Check the
mounting bracket; tighten electrical connections.
'Fuel Injectors
0
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
'Starter Motor
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
'Preheat Circuit
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (4-6 ohms).
Reinstall with anti seize compound on threads.
'Engine Cylinder
0 0
Check compression pressure and timing
Compression (see Engine Adjustments).
'Torque Cylinder Head
0 0 0
At first 50 hours, then every 500 hours
Hold-down bolts (see ENGINE ADJUSTMENTS).
'Adjust the Valve Clearances
0 0 0
Adjust Valve Clearances
(see ENGINE ADJUSTMENTS).
'Heat Exchanger
0
Remove, have professionally cleaned and
pressure tested.
'WESTERBEKE recommends this service be performed by an authorized mechanic.
CAUTION (WESTERLINK or NMEA
w
2000): The electronic components in the Digital Diesels draw a very small amouJtt of amperage (milli-amps)!rom the
generator's starting battery when the unit is in a static state. This maybe as much as 50 miUi-amps!or the system ECU and 50 mitli-amps/or each display.
This can
be as much as 72 amp-hours'in a months time with no generator use. It is no~ necessary to be concerned with this slight amperage draw dltring~
normal seasonal use. However, iflhe generator set is not to be usedfor a number a/months, stich as winter storage, it is best to disconnect the DC power
to the generator with a NMEA-2000 system or shut off the DC breaker 0It the generator's control box/or a WESTERLlNKsystem.
NOTE: Keep ill mind that the Westerbeke generator may be the DC power supply for the vessel's NMEA-2000 network,
-...: WESTERBEKE
Engines & Generators
11

FUEL SYSTEM.
DIESEL FUEL
USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER.
(No. 2-D (SAE J313) (liesel fuel according to ASTM D975).
FtiELFILTERS
Thefuel 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
must pass through at least two fuel filters, a fuel water
separator and the engine's spin-on fuel filter. Visually inspect,
clean, and change these filters according to the maintenance
schedule in this manual.
FUEL WATER SEPARATOR
A primary fuel filter of the 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 reacbing the engine's injection equipment is free of
imputities. This process is accomplished by installing and
maintaining a proper fuel filter/water separator between the
fuel tank and the generator/engine. Westerbeke recommends
a 10 micron filter be used.
FUEL INJECTION PUMP
The fuel injection pump is the most important component
of the diesel engine, requiting 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. IT 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 LIFT PUMP
Periodically check the fuel connections to and out ofthe pump
and make sure that no leakage is present and that the fittings
aretight arid secure. The DC ground connection at one of the
PIllDP'~ mountingbolts should be.clean and. wellsecured by
themouniingboltto,osure proPer PIllDPopeflltipp,' .. '
When energized thru the preheatcirtuit, the fuelliftPl!IDp will
purge air. from the fuel system and provide a continuous flow
of fueL as the engine isrnruting.
INLET FUEL FILTER
To ~Ilsure cleanfuel into the fuel lift pump, there isa small
in-line fuel filter connected to the fuel lift pump elbow.
ENGINE FUEL FILTER
..
Periodicaily~check the fuel connections and the bowl for
leakage. Replace the filter element after the first 50 hours
then follow the MAINTENANCE SCHEDULE.
Changing/cleaning the filter element
1. Shut off the fuel supply.
2. Unscrew the retainer ring that holds the filter bowl to the
housing and allow the boWl to come away from the
housing,
3. Remove and replace the filter element and clean the bowl.
4. Replace the sealing "0" ring and reassemble the bowl
to the housing. Thread the retainer ring on carefully
so as not to cross thread. When retainer contacts the
"0" ring, tighten 114 -1/2 turns by hand. Open the fuel
supply and run the engine to inspect for leaks.
: THE O-RING. GASKET
: ONLY NEEDS TO BE
, REPLACES IF IT SHOWS i '(fjJ)~~~~
,SIGNS OF AGING.
FUEL
FILTER
FUEL LIFT PUMP
~ WESTERBEKE
Engines & Generators
12