Westerbeke 10.0 BEG User manual

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OPERATORS MANUAL
8.0 KW • &.OHz- 6.4 KW • 50Hz BEG
1·0.0 KW • 60Hz- 8.0 KW • 50Hz BEG
12.5 'KW ~ 60Hz~10.0 KW ·50Hz ·aEG
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15.0 KW ·-60Hz~12.0 KW • 50Hz BEG
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MARINE GASOLINE GENERATORS
Sin · Phase
REVISION3
JANUARY 2018
member· WESTERBEKf'E CORPORATION • MYLES STANDISH INDUSTRIAL PARK
§.~. .150 JOHN HANCOCK ROAD • TAUNTON MA 02780-7319 • Tf'EL. [phone] .
. ·
FAX [phone] • WEBSITE: WWW. WESTERBEKE.COM

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.
A WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
•Dizziness
•Nausea
•Headache
• Weakness and Sleepiness
• Throbbing in Temples
• Muscular Twitching
• Vomiting
•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 installing CARBON
MONOXIDE DETECTORS in the living/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store. ·

Gasoline with an ETHANOL content
higher than 10°/o (E10) is not allowed
·· and may void warranty.
~r~ 'WESTERBEKE™
~ Engines & Generators

Blank page

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~ andyour machinery.
The foUowing safety instructions are in compliance with
the American Booi and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!
111 Do not operate this machinery without electrical
enclosures and covers in place.
Ill Shut off electrical power before accessing electrical
equipment.
1111 Use insulated mats whenever working on electrical
equipment.
Iiiii Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
Ill Remove wristwatch and all jewelry when working on
electrical equipment.
PREVENT BURNS -HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets very
hot!
Iiiii Monitor engine antifreeze coolant level at the plastic
coolant recovery tank and periodically at the filler cap
location on the water jacketed exhaust manifold, but only
when the engine is COLD.
A WARNING: Steam can cause injury or death!
II In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS -FIRE
A WARNING: Fire can cause injury or death!
Iii Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources ofspilled.fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuelline,·carburetor, orfuel filters.
111 Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
111 Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean
and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
11 Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
Ill Follow re-fueling safety instructiOI¥J. Keep the vessel's
hatches
closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running
the blower. Run the blower for four minutes
before starting your engine.
Ill 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.
II Do not fill the fuel tank(s) while the engine is running.
Ill Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO Nar allow any smoking; open flames, or other
sources of fire near the fuel system 6r engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
Ill Do not alter or modify the fuel system.
Ill Be sure all fuel supplies have a positive shutoff valve.
Ill Be certain fuel line fittings are adequately tightened and
free of leaks.
111 Make sure a fire extinguisher is installed nearby and is
properly maintained. Befamiliar 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!
11!11 Turn OFF the DC breaker on the control panel o! ~ the
unit's battery selector switch to OFF before semcmg the.
engine.
Ill Make certain all personnel are clear of the engine before
starting.
111 Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATIERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
111 Do not smoke or allow an open flame near the battery
being
serviced. Lead acid batteries ~mi~ hydrogen, ~
highly explosive gas, which can be 1gmted by elec~:?cal
arcing or by lit tobacco products. Shut o~ all el~cal
equipment in the vicinity to prevent electrical arcmg
during servicing.
111 Never connect the negative (-) battery cable to the
positive (
+) connection terminal ofthe starter solenoi~.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation of
explosive gases. To avoid sparks, do not
disturb
the battery charger connections while the battery
is being charged.
111 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.
1111 Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect itlast when servicing the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
1111 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!
11 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 manifold/
water-injected
elbow is securely attached.
1111 Be sure the unit and its surroundings are well ventilated.
Run blowers
when running the gep.erator set or engine.
11 Do not run the generator set or engine unless the b?atis
equipped with a functioning marine carbon
monoXIde
detector that complies with ABYC A-24. Consult your
boat builder or dealer for installation ofapproved
detectors.
111 For additional information, refer to ABYC TH-22
(educational information
on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) Is an invisible
odorless gas. Inhalation produces Ru·like symptoms,
nausea or death!
11 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.
11 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 apd close or restrict the
flow ofexhaust. Avoid overloading the craft.
11 Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fum~. s~ of. the
symptoms or signs ofcarbon monoXIde inhalation or
poisoning
are:
Vomiting
Dizziness
Headache
Inability
to think coherently
Throbbing in temples
Muscular twitching
Nausea Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
1111 Do not service the engine while it is running. If a
situation arises in which
it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving
parts and hot exhaust system
components.
Engines & Generators
••
II

1!1 Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces orbracelets tluit
could· be caught in moving parts.
Iii Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
l1ll Do not check fluid levels or the drive belt's tension while
the; engine is operating.
!iii Do not allow-any swimming or activity around or near
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning or
death can occur. . .
"JIININI~ Higb;itoise-let(el$· t:;~n· c,.us.e·hl!.atiilg
.I
Iilii Never operate an,.engine without its mui'fler installed.
11 Do not run the eQ;gine \vith the air ~talc~ (~Uencer) or
flame arrester removed . .
II Do not run enginps for long periods. with their enclosures
open (when installed).
A WARNING: Qo ,not work on machinery when you are
mentally or phjSiiially int:Bpa~;itated.ty fatigue!
OPERATORS MANUAL
Many ofthe preceding safety tips and warnings are repeated
in your Operators Manual along with otlJ.~J:' cautions and
notes to biglilight critical information: Read yo~ Irianual
carefully, maintain your equipmerit,'ant:l.follow "ail safety
procedures. · · ·
GASOLINE ENGINE AND GENERATOR·-INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examinatiqn- ofthe American Boat and
Yacht Council's (ABYC) standards. These st\Uldards. are· from .
a
combination of sources inc!uding the USCGand the NFPA.
Sections of the ABYC standards ofparticular interest ar~:
H-2 Ventilatio~ for Boats using Gasoline
· H-24 Gasoline Fuel" Systems
P-1 Installation of Exhaust Systems
for PropUlsion and Auxiliary Engines
P-4 ;Marine Inboard Engines and Transmissions
E·l_lA.C and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).
www.abycinc.org
~!(:, ~FP~ A~IJ ~$CG. PUBLICATIO~S FOR
INSTAI.LJNG EN.GINESAND GENERATORS
. ' -· .. -··.. ' . - - ... --·
Readthefollowing ABYC, NFPAand USCG publications
for safe!:y coqes an<l standards. Follow their recommenda-
qqns · WPFP iristalling yourengine.
ABYC!(American Boat and Yacht Council)
"Standards and Technical Information Reports for Small
Craft"
Order from:
ABYC .
613 Third Street, SAi(e 10
AJUiapolis, M.D 21403·
':VV\fW •. aby~c.o~g
NFPA- No.302·(National Fite Protection Association)
"Pl~e and Commercial MotoiCrilft" ·.
Orderfrom: .
Nati0rtaJ Fire Protection Association
~~:g.~~r:
Us¢G:(t.Jmte!i S~tc;m Co~t Gril!.td.) · .
•'fegutatedioils.are 'uilder titJ.es.CFR33 and CFR46 of the
Code of Regulations" ·
Order from:.
U.S. Government Printing Office
Washington, D.C. 20404
. ~ ;WESTEFIBEifE
·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 guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment
SIPHON·BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifoldinjection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
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 mantifacturer for proper maintenance.
EXHAUST SYSTEM
SIPHON;BRtAKWITHSTAINLESS
·LOOP
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust Hose is recommended. The use ofthis type ofhose allows for extreme bends
and turns without the need ofadditional fitting and clamps to accomplish these bends
and turns. In this regard, a single length ofcorrugated exhaust hose can be used. The
system MUST be designed to prevent the entry of water into the exhaust system
under any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification ................................................................. 2
Introduction ............................................................................. .3
Warranty Procedures........................................................3
Serial Number Location...................................................3
Fuel, Engine Oil and Engine Coolant .................................. 5
Preparations for Initial Start·Up ......................................... 6
Operating Instructions ........................................................ 7
Operating Instructions (Remote Panels) ............................. 8
Break-In Procedure (Daily Operation) ................................. 9
Safety Shutdown Switches ................................................ 1o
High RPM Shutdown Switch .............................................. 11
Maintenance Schedule ..................................................... 12
Cooling System .................................................................. 14
Changing Coolant .......................................................... 14
Thermostat ..................................................................... 15
HeatExchanger.............................................................. 15
Raw Water Pump ........................................................... 16
Raw Water Intake Strainer............................................. l6
Engine Lubricating Oil ....................................................... 17
Oil Change..................................................................... 17
Remote Oil Filter........................................................... 18
Oil Pressure....................................................................19
Fuel System ....................................................................... 20
Fuel Lift Pump............................................................... 20
Carburetor ..................................... 21 (Early Models) .... 2la
Engine Adjustments .............................................................. 22
Spark Plugs .................................................................... 22
High Tension Cords ....................................................... 22
Drive Belt Adjustments.................................................. 22
High Speed (Hertz) Adjustments................................... 23
Governor Adjustments ................................................... 23
Timing Belt Inspection and Replacement ..................... 24
Engine Compression Test .............................................. 27
Ignition Timing .............................................................. 27
Engine Troubleshooting ..................................................... 28
DC Electrical System ............................................................ 30
Battery Care................................................................... 31
Generator Wiring Diagram (#46094) .................................. .32
Generator Wiring Schematic (#46094) ............................... 33
Remote Panel Wiring (#035698) ........................................ .34
Remote Panel Wiring (#035706) ......................................... 35
Remote Panel Wiring (#043912) ............................ : ........... .36
Starter Motor ......................................................................... 37
Generator Information .......................................................... 39
BE Generator ......................................................................... .40
Generator AC Voltage Connections ................................... .41
AC Voltage Regulator .......................................................... .43
BE Troubleshooting ............................................................... 44
Shore Power Transfer Switch .............................................. .45
Engine Specifications 60Hz ................................................. .46
Engine Specifications 50Hz .................................................. 47
Lay-Up and Recommissioning ............................................. .48
Standard metric Data ............................................................ 50
Standard Hardware ................................................................ 51
Suggested Spares ........................................... , ..................... 52
~ WESTERBEKE
Engines & Generators
1

DC
START MOTOR
PARTS IDENTIFICATION
HEAT EXCHANGER
LEFT SIDE
CONTROL
· WATER TEMPERATURE
SWITCH
HEAT EXCHANGER
OIL DRAIN
SWITCH
CONTROL PANEL
GENERATOR
WATER INJECTED
EXHAUST ELBOW
PCVVALVE
RIGHT SIDE
Engines & Generators
2
OILFILL
MOUNTS

INTRODUCTION
This WESTERBEKE Generator is a product of
WESTERBEKE'S
long years ofexperience and advanced
technology. We take great pride in the superior durability
and dependable performance of our engines and generators.
Thank
you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator,
it is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please read this
manual carefully
and observe all the safety precautions
throughout. Should your
gene~ator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This is your Operators Manual. AParts List isalso
provided. A Service Manual is available in pdf form
on our website orahardcopymay be purchased thru
a Westerbeke Dealer. A IristallationManual is included
for your reference when installingthe product.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If you have not received a customer identification
card registering your
warranty 60 days after submitting the
warranty registration form, , please contact the factory in
writing with model information, including the unit's serial
number
and commission date
I.,.,.,IWESTERBEKE
I Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model BEG Ser. #
Expires'
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures and
catalogs) provided from sources other than WESTERBEKE
are not within WESTERBEKE'S CONTROL.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES
OR REPRESENTATIONS WITH RESPECT THERETO,
INCLUDING ACCURACY, TIMEUNESS OR COMPLETE-
NESS THEREOFAND WILL IN NO EVENT BE UABLE
FOR ANY TYPE OF DAMAGE OR INJURYINCURRED 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 ofWESTERBEKE product software
and the unavoidable existence ofearlier WESTERBEKE
manuals. In summation, product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product. It
not only makes good sense but is imperative that appropriate
representatives ofWESTERBEKE or
the supplier in question
be consulted to determine the accuracy and currentness of the
product software being consulted by the customer.
SERIAL NUMBER LOCATION
The engine's model and serial number can be found on J.D.
stickers affixed to either side ofthe generator housing. The
engine's serial number can
also be found stamped into the
engine block on a fiat surface just above and inboard of the
lube oil filter. Take the time to enter this information on the
illustration ofthe J.D. sticker below, as this will provide a
quick reference
when seeking technical information and/or
·ordering service/repair parts.
Fill in the information for your reference.
Engine 1.0. Plate
Engines &Generators
3

INTRODUCTION
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine
model and serial numbers. In addition,
include a complete part description
and part number for each
part needed (see the separately furnished Parts Catalog). Also
insist upon WES1ERBEKE 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 ofyour genera-
tor, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
the engine or generator.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss oflife.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visable location in
the engine room.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator.
Your local WES1ERBEKE
dealer will assist you in preparing an inventory ofspare parts.
See the SPARE PARTS page in this manual. For Engine and
GeneratorAccessories,
see the ACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed information for
installing generators.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE generator capable of
many thousands of hours of dependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Six important steps to ensure long generator life:
• Proper engine andgenerator installation andalignment.
• An efficient weU-des{gned exhaust system thatincludes
an anti-siphon break to prevent waterfrom entering the
engine.
• Changing the engine oil and oilfilters every 100 operat-
inghours.
• Proper maintenance of aU engine andgenerator compo-
nents according to the maintenance schedule in this
manual.
• Use clean, filtered unleadedfueL
• Wznterize yourengine according to the "Lo.y-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
soli.d-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 of a 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.
. CARBON MONOXIDE DETECTOR
WESTERBEKE highly recommends mounting a carbon
monoxide detector inthe vessels living and sleeping
quarters. Carbon monoxide even in small amounts,
can
be deadly.
The presence
of carbon inOnoxide indicates a possible
exhaust leak from the main engine orgenerator, it's exhaust
system, from the exhaust discharge location
on the vessel
or from a neighboring vessel.
If the dectector signals the presence of carbon monoxide.
Ventilate the area, move into a fresh airlocation and
locate the source
of the carbon monoxide and arrest it.
Engines & Generators
4

GASOUNE
FUEL, ENGINE OIL AND ENGINE COOLANT
ENGINE COOLANT
A CAUTION: Use unleaded 89 Octane gasoline or
higher. Ethanol gasoline must not exceed E10 (10%}.
Gasoline with higher percentages of Ethanol are not
=ftltaseiRIIJess-aml--a
Care Of The Fuel Supply '0
Use only clean properly filtered fueU The fit and tolerimce of
some components in the unit's fuel system are very critical;
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 offuel.
Install and regularly service a good, Coast
Guard approved
metal bowl type filter/water separator between the
fuel tank
and the engine.
ENGINE OIL
Use a good brand ofengine oil with an API and SAE
designations as listed in the SPECIFICATION Section of
this manual.
Change the engine oil and filter after
an initial 50 hours of
engine break-in operation. Then follow the oil and filter
change intervals
as specified in the MAINTENANCE
SCHEDULE in this
manual.
Westerbeke Corporation does not approve or disapprove
the use
of synthetic oils. If synthetic oils are used, engine
break-in MUST be performed using conventional
oil. dil
change intervals must be as listed in the MAINTENANCE
SCHEDULE section in this manual and
not to be extended
ifsynthetic oils
are used.
NOTE: The information above supercedes all previous
statements
regarding synthetic oil usage.
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. 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 ben pre-mixed
before being poured into the cooling circuit.
NOTE: Use the new environmentally-friendly, long lasting,
antifreeze that is now available.
Aproper 50/50 mixture as recommended will protect the
engine coolant to temperatures of
-40"F.
COOLANT RECOVERY TANK
Acoolant recovery tank kit is supplied with each generator.
The purpose of this recovery tank is to allow for engine
coolant expansion and contraction during engine operation,
without the loss ofcoolant and without introducing air into
the cooling system.
NOTE: This tank, with its short run of plastic hose, is best
located at orabove
the level of the engine's exhaust
manifold.
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
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 contaminants.
• 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 a!r in
the engines cooling system will be purged to the coolant
recovery
tank. Open the air bleedpetcock to ensure that
the cooling system is purged of air. After shutdown and
after
the engine has cooled, the coolant from the recovery
tank will be drawn into the engines cooling system to
replace the purged air.
Before subsequent operation of the generator, the engines
manifold should be topped
off, and the coolant recovery
tank may need to be filled to the MAX level.
OIL FILL
Q
6
• 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 wHI
prevent a cold engine from stalling. . ·
TO HEAT EXCHANGER

OPERATING INSTRUCTIONS
GENERATOR CONTROL PANEL
Starting the Generator
Move the ON toggle switch up and hold it. Allow a few
second for the electric fuel pump to prime the engines fuel
system. Then move the START toggle switch up engaging
the starter cranking and the engine. Once the engine fires and
runs release the STA~T toggle switch only. Hold the ON
toggle switch up for a few seconds to allow the oil pressure
switch to close and maintain the run circuit then release it.
NOTE: Should the enginefail to start, release both switches,
wait 20 seconds, and try again. Never run the starter more
than 20 seconds at a time.
CONTROL PANEL
AND BOX
·. AC CIRCUIT BREAKER
\
START/STOP SWITCH
ON SWITcH
.' ;..,;> STARr
HDURMETER: THE HOURMETER RECORDS
ELAPSED TIME OF ENGINE USAGE THE TOTAL.
NUMBER OF HOURS SHOULD BE USED AS A
GUIDE FOR MAINTENANCE SCHEDULING .
.(....,._ .....
~~ '
~~.:) STDPDFf
Starting under Cold Conditions
.,..-':--,,/
,
Make certain the lubricating oil conforms with the ratings for
the prevailing temperature. Check the table under ENGINE
LUBRICATING
OIL. The battery should be fully charged to
minimize voltage drop.
Stopping the Generator
To stop the generator, press the STOP switch down then
release it to the center (normal) position.
EMERGENCY STOPPING
If the generator does not stop using the STOP switch,
remove the 8 amp fuse or disconnect the battery.
A CAUTION: Prolonged cranking intervals without
the engine starting can result in the engine .exhaust
system filling with raw water. This may happen because
the pump is pumping raw water through the raw water
cooling system during cranking. This raw water can
enter the engine's cylinders by way of the exhaust
manifold once the exhaust system fills. Prevent this
from happening by closing the raw water supply
through·hu/1 shut·off, draining the exhaust muffler, and
correcting the cause of the excessive engine cranking.
Engine damage resulting from raw water entry is not a
warrantable issue; the owner/operator should keep this
in mind.
START/STOP/ON
SWITCHES
Abnormal Stop (refer to SAFETYSHUTDOWN SWITCHES)
An abnormal stop is one in which the generator ceases to run
and comes to a stop as a result of an operating fault which may
cause damage to the engine, the generator, or create an unsafe
operating condition. The fault stop conditions are:
1. Overspeed condition.
2. High engine temperature.
3. Low oil pressure.
4. High exhaust temperature.
5. Electrical overload.
a. Fuse at the control panel.
b. 20A breaker on the engine.
c. Main circuit breaker.
Should afault condition occur, the engine will shutdown. On
the remote panel the green LED light will turn offindicating
an engine shutdown. Once detected, the fault should be
located and corrected (see ENGINE TROUBLESHOOTING).
Engines & Generators
7-

OPERATING INSTRUCTIONS (OPTIONAL PANELS)
NOTE: Remote panels cannot be inter-connected. Only one panel can be used.
REMOTE PANEL
Starting the Generator
To start the generator, hold the ON toggle switch in the up
position (the panel green
LED light will come on). Hold the
switch in this position for a
few seconds to allow the electric
fuel pump to ·prime the engines fuel system. Then move the
START
toggle; switch to the up position, this will engage the
starter cranking the engine (the green LED light will
dim).
Once the engine fires andruns, the green LED will brighten.
Release the START toggle switch, but continue
to hold the
ON up for a few seconds to allow the oilpressure switchto
:close to maintain the DC run circuit thenrelease it.
NOTE: Should the enginefail to start, release both switches,
wait 20
secorids, andtry again. Never run the starter more
than 20 seconds at a time.
START/STOP SWITCH
/'?START
,,..- ...... ,.....,,
<' ,"'
Stopping the Generator
ON SWITCH·
To stop the generator, move the START/STOP switch to the
down (stop) position then release it
to the center (off/run
mode) position.
REMOTE START/STOP PANEL (HARDWIRED)
An optional remote start/stop panel is available for
controlling the generator from a remote location.
This panel
has the same ON, START and STOPfunctions
previously described.
Also included is a green LED light
which glows once the engine/generator has reached 600
rpm's. The purpose of the LED is to alert the operator to
release the START switch. It is also an indication that the
engine/generator is running.
REMOTE INSTRUMENT PANEL (HARDWIRED)
An optional remote in_strument panel is available which
includes a water temperature gauge, oil pressure gauge,
DC
charging voltmeter, operating hourmeter, and start/stop
switches.
REMOTE INSTRUMENT PANEL INSTALLATION
The remote instrument panel has two sending units to be
installed
on the engine block, a water temperature sender
and an oil pressure gauge sender. Plugged ports for each are
located on the engine. The water temperature sender is
installed in the thermostat housing and the oil pressure sender
is adjacent to the oil pressure switch. Use sealing compound
on the threads ofboth senders. Electrical connections for
each sender are tied off next to the senders location (in the
wiring harness).
The blue wire
is for the oil preSsure sender and the tan wire
is for the water temperature sender. If there is ajumper
betw~n terminal board connections TBI-1 and TBI-2, it
should be removed. Refer
to the REMOTE INSTRUMENT
WIRING DIAGRAM in this manqal.
NOTE: When installing the optional remote panels, it is the
installers responsibility
to comply with the U.S. Coast Guard
standards 33 CFRpart I83.
REMOTE
STOP/START
PANEL
(PLUG
CONNECTER)
This stop/start remote panel is available with either a
15'
or 30' harness thatplugs directly into the generators
control panel. Operating instructions are the same as the
remote panel
to the left.
Engines &Generators
8

BREAK·IN PROCEDURE/DAILY OPERATION
BREAK·IN PROCEDURE
After the generator has been started, check for proper opera-
tion
and then encourage a fast warm-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 genera-
tor 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 within
the generators' 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 engine break-in is gov-
erned by the current drawn from the generator.
To protect against unintentional overloading of the generator,
the generator's output leads should be routed through a cir-
cuit breaker that is rated
at the rated output of the generator.
NOTE: Be aware of motor starting loads and the high
current drawn
required for starting motors. This starting
amperage drawn
can be 3 to 5 times normal running amper-
age. 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.
• Confirm exhaust smoke:
When the engine is cold -White Smoke.
When the engine is warm -almost Smokeless.
When the engine is overloaded - some Black Smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached and loads are applied.
A CAUTION: Do not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove the 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 hour service check.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may
be adjustments required for engine speed (hertz) during the
engine's break-in period (first 50 hours) or after this period
(see ENGINE SPEED (HERTZ) ADJUSTMENTunder
ENGINE ADJUSTMENTS). Ano-load voltage adjustment
may also be required in conjunction with the engine's speed
adjustment (see
GENERATOR INFORMATION).

SAFETY SHUTDOWN SWITCHES
SAFETY SHUTDOWN SWITCHES
The engine is protected by five automatic shutdown
switches. Should a shutdown occur,
do not attempt to restart
withoutfinding and correcting the cause. Refer to the
heading Engine
starts, runs and then shuts down in the
ENGINE TROUBLESHOOTING section of this manual.
The following is a description of these automatic shutdown
switches:
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Normally closed, this switch will open and interrupt
the
DC voltage (shutting off the engine) should the switch's
sensor indicate an excessive exhaust temperature (an inade-
quate supply
of raw water causes high exhaust temperatures).
This switch opens at 260-270"F (127-132°C). This switch
resets at approximately 225°F (107°C).
TOSIPHON ·
BREAK
,l )\~
,,\\\~
/1
Low Oil Pressure Switch
EXHAUST
A low oil pressure shutdown switch is located off the
engine's oil gallery . Normally open in a static state, this
switch's sensor monitors the engine's oil pressure. Should the
engine's oil pressure fall to
5-l 0 psi, this switch will open
interrupting the DC voltage thereby shutting offthe engine.
High Water Temperature SWitch
A high water temperature switch is located at the thermostat
housing. Normally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C), will open and interrupt the DC voltage thereby
shutting offthe engine.
This switch resets at 195"F {107°C).
20 AMP CIRCUIT
BREAKER
Engine Circuit Breaker
The generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere in the instrument panel
wiring or engine wiring will cause the breaker to trip. In this
event the generator will shut down because the opened
breaker interrupts the
DC circuit. If this should occur, check
and repair the source
of the problem. After repairing the
fault, reset the breaker and restart the generator.
Engines & Generators
10

HIGH RPM SHUTDOWN SWITCH
DESCRIPTION
An overspeed switch in the DC circuit shuts offthe
generators engine by grounding out the ignition system
if
the engine's speed reaches 2175 rpm (approximately).
After correcting the problem, this switch can be reset by
momentarily depressing the stop switch. Refer to the
WIRING DIAGRAMS in this manual.
If the overspeed switch is faulty, (resetting with the stop
switch fails
to reset the circuit), lift the white/yellow wire
offthe
T5 terminal and connect it with the red/purple wire
on the T4 terminal. Now restart the generator.
If this bypass is successful, replace the faulty overspeed
switch.
NOTE: Overspeed switches draw a small amount of amperage
(25 milliamps) at all times once the generator is connected
to its starting battery. This amounts to approximately 18
amp-hours in a month. It is not necessary to be concerned
with this slight amperage draw during normal seasonal
operation. However, if the generator set is to be unusedfor
many
months, it is best to either remove the 8 amp ignition
fuse from
the control panel on the generator or tum off the
generator's starting battery switch.
11
OVERSPEED
CIRCUIT
BOARD
A CAUTION: It is very important that the overspeed
shutdown always be installed and functioning. Any
tampering with the overspeed shutdown module, which
would cause it to malfunction. could be a cause of
injury should the generator's belt-driven governor fail
and cause the generator to run away.

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.
NOTE: Many of the following maintenance procedures are simple but others are
more difficult and may require the expert knowledge of a service mechanic.
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 it 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 oil
Check for fuel, oil and water leaks. Inspect wiring and
will inhibit the engine's ability to remain cool.
electrical connections. Keep bolts & nuts tight. Check
for loose belt tension.
Sparks Plugs
0 0 0 0 0 0
Check gap, inspect for burning and corrosion.
Starting Batteries
0
Every 50 operating hours check electrolyte levels
(and House Batteries) weekly
and make sure connections are very tight. Glean off
excessive corrosion.
Engine Oil
0 0 0 0 0 0 0
Initial engine oil and filter change at 50 hours, then
change both every 1 00 hours.
Generator
0 0 0 0 0 0 0
Check that AG connections are clean and secure with
no chafing-see GENERATOR INFORMATION for
additional information.
Fuel Lift Pump
D
Periodically inspect for leaks.
and Gasdenser
Air Screen (Flame Arrester)
0
Clean at 50 hrs., then every 100 hours.
Exhaust System
D D D D D D
Initial check at 50 hours, then every 250 hours.
Inspect 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 D D D 0 0
Hose should be hard & tight. Replace if hoses
become spongy. Check and tighten all hose clamps.
Raw Water Pump
0 D D 0 0 0
Visually inspect for leaks. Remove the pump cover
and inspect cover surface and cam for wear. Inspect
impeller. Ensure impeller shaft is secure and does not
wobble. Replace items as needed. Rebuild/replace
pump as needed.
Belt Driven Governor
0 D D 0 D
Change governor oil every 250 hours. Adjust
governor operation as needed.
Inlet Fuel Filter
0 0 0 0 0
Replace.
Engines & Generators
12