Westerbeke 20.0 SBEGA User manual

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 • Throbbing in Temples
•Nausea
•Headache
• Muscular Twitching
• Vomiting
• Weakness and Sleepiness
• Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
A WARIIIIIG DECAL is provided by
WESTERBEKE and should be fixed to a
bulklleatl near your engine or generator.
WESTERBEKE also recommends installing
. CARBON MONOXIDE DETECTORS in the
·w.. AR N IN G· !iving/sleeping quarters ot your vessel.
. .· . They are iJiexpensive and easily
•Gene!alc!sProcb:eCARBONMONOXIDE ...fa. .... at I I . _,_
· RegularMalnlenanceRequlred • · ou rnauie youfioca manne ;,&ute.
- ."'/!!!!!!!!!!
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.

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 personnel,
and your machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
■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 vessel’s AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessel’s AC generator may
result if this procedure is not followed.
■Electrical shock results from handling a charged capacitor.
Discharge capacitor by shorting terminals together.
PREVENT BURNS — HOT ENGINE
■Always check the engine coolant level at the coolant
recovery tank.
■In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
▲WARNING: Steam can cause injury or death!
▲WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets very
hot!
PREVENT BURNS — FIRE
■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 of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
■Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
■Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
■Do not smoke or permit flames or sparks to occur near the
fuel system. Keep the compartment and the engine/genera-
tor clean and free of debris to minimize the chances of
fire. Wipe up all spilled fuel and engine oil.
■Be aware — diesel fuel will burn.
PREVENT BURNS — EXPLOSION
■Follow re-fueling safety instructions. Keep the vessel’s
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
■ All fuel vapors are highly explosive. Use extreme care when
handling and storing fuels. Store fuel in a well-ventilated
area away from spark-producing equipment and out of the
reach of children.
■Do not fill the fuel tank(s) while the engine is running.
■ Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
■Do not alter or modify the fuel system.
■Be sure all fuel supplies have a positive shutoff valve.
■Be certain fuel line fittings are adequately tightened and
free of leaks.
■Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
▲WARNING: Explosions from fuel vapors can cause
injury or death!
▲WARNING: Fire can cause injury or death!
i
SAFETY INSTRUCTIONS
▲WARNING: Do not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!

ACCIDENTAL STARTING
■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
■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 terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
■Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
■Always turn the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when servicing the battery.
BATTERY ACID
■When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. 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 inad-
vertently when removing electrolyte caps.
▲WARNING: Sulphuric acid in batteries can cause
severe injury or death!
▲WARNING: Battery explosion can cause injury
or death!
▲WARNING: Accidental starting can cause injury
or death!
TOXIC EXHAUST GASES
■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).
■Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust systems.
Exhaust sulfur causes rapid deterioration of copper tubing
resulting in exhaust/water leakage.
■Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. 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 Throbbing in temples
Headache Muscular twitching
Nausea Weakness and sleepiness
AVOID MOVING PARTS
■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.
▲WARNING: Rotating parts can cause injury
or death!
▲WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
▲WARNING: Carbon monoxide (CO) is a deadly gas!
ii
SAFETY INSTRUCTIONS

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

EMISSION-RELATED INSTALLATION INSTRUCTIONS
“Failing to follow these instructions when installing a certified engine in a piece of nonroad
equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described
in the Clean Air Act.”
If your product is equipped with OBD (on board diagnostics) go to www.WESTERBEKE.COM and follow
the free interface software download instructions specific to your engine to obtain and install the
appropriate diagnostic software. The following is a list of OBD compliant products:
20.0 SBEGA
22.5 SBEGA
To sample exhaust emissions on installed OBD compliant generators, gain access to the exhaust stream by
removing the test port plug on the exhaust elbow. Be sure to reinstall the plug securely when testing is
complete.
The Westerbeke generator that you purchased is certified for constant-speed operation only. The use
of any Westerbeke product in any manner inconsistent with its intended use could be a violation of
Federal Law.
“If you install the engine in a way that makes the engine's emission control information label hard to
read during normal engine maintenance, you must place a duplicate label on the equipment, as
described in 40 CFR 1068.105”. Contact the factory for an additional engine emission control
information label if needed to comply with this rule.
To comply with 40 CFR 1048.105 (a) “Fuel line permeation. For nonmetallic fuel lines, you must
specify and use products that meet the Category 1 specifications for permeation in SAE J2260
(incorporated by reference in §1048.810).”
To comply with 40 CFR 1048.105 (c) “Diurnal emissions. Evaporative hydrocarbon emissions may
not exceed 0.2 grams per gallon of fuel tank capacity when measured using the test procedures
specified in §1048.501. Diurnal emission controls must continue to function during engine operation.”
To comply with 40 CFR 1048.105 (d) “Running loss.Liquid fuel in the fuel tank may not reach
boiling during continuous engine operation in the final installation at an ambient temperature of 30
°C. Note that gasoline with a Reid vapor pressure of 62 kPa (9 psi) begins to boil at about 53 °C at
atmospheric pressure, and at about 60 °C for fuel tanks that hold pressure as described in
§1048.245(e)(1)(i)”.
To comply with 40 CFR 1048.245 (1) (i) “Use a tethered or self-closing gas cap on a fuel tank that
stays sealed up to a positive pressure of 24.5 kPa (3.5 psig); however, they may contain air inlets that
open when there is a vacuum pressure inside the tank. Nonmetal fuel tanks must also use one of the
qualifying designs for controlling permeation emissions specified in 40 CFR 1060.240.”
iv

v
SMALL SI EMISSION-RELATED INSTALLATION INSTRUCTIONS
“Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment
violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air
Act.”
The Westerbeke generator that you purchased is certified for constant-speed operation only. The use of any
Westerbeke product in any manner inconsistent with its intended use could be a violation of Federal Law.
“If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105”. Contact the factory for an additional engine emission control information label if needed to
comply with this rule.
It is the engine installers responsibility to ensure the installation meets the evaporative emission requirements
in 40 CFR 1054.112 and 40 CFR 1060.
To comply with 40 CFR 1054.112 (a) “Fuel line permeation. Nonmetal fuel lines must meet the permeation
requirements for EPA Nonroad Fuel Lines as specified in 40 CFR 1060.102.”
To comply with 40 CFR 1054.112 (b) “Tank permeation. Fuel tanks must meet the permeation requirements
specified in 40 CFR 1060.103.”
To comply with 40 CFR 1054.112 (c) “Running loss. Running loss requirements apply as specified in 40 CFR
1060.104.”
To comply with 40 CFR 1054.112 (d) “Diurnal emissions. Nonhandheld equipment may optionally be
certified to the diurnal emission standards specified in 40 CFR 1060.105, in which case the permeation
standards specified in paragraphs (a) and (b) of this section do not apply.”

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 manifold injection 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.
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. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
INSTALLATION

TABLE OF CONTENTS
Introduction ....................................................................... 2 Fuel System ..................................................................... 24
Installation Codes and Safety Standards......................2 Fuel Tanks -General ................................................. 24
Recommended Reading ...............................................2 Fuel Tanks -Gasoline................................................ 24
Product Software......................................................... .3 Fuel Tanks Located Above The Engine/Generator....25
Notes, Cautions
and Warnings .....................................3 Fuel Tanks Located Below The Engine/Generator.... 25
Inspection of Shipment ................................................3 Gasoline
Engine Fuel Tanks....................................... 25
Engine Location and Mounting .................................... ..4
Engine Location .......................................................... .4
Engine Bed ...................................................................4
SSB Radio/Electronic Grounding ................................4
Engine Mounting..........................................................S
Generator Location and Mounting ................................ 6
Generator Location.......................................................6
Generator Mounting .....................................................6
SOUND GUARD .........................................................?
Diesel Fuel System Anti-Siphon Devices.................. 25
Dual Purpose Fuel Tank............................................. 26
Fuel Lines................................................................... 26
Rigid Fuel Lines ...................................................... 26
Flexible Fuel Lines .................................................. 26
Shut-OffValves .......................................................... 27
Fuel Filters ................................................................. 27
Fuel............................................................................. 27
Cooling System ............................................................... 28
Rigging and Lifting ........................................................... 8
Propeller Shaft Alignment .............................................. 9
Propeller Shaft Coupling (Engines) .............................9
Flexible Couplings .......................................................9
Alignment...................................................................
IO
Propeller Selection ........................................................ 11
Exhaust System/ABYC Standards ................................ 11
Raw Water Intake.......................................................28
Raw Water Outlet ....................................................... 28
Fittings........................................................................28
Coolant Recovery Tank..............................................29
Coolant.......................................................................29
Engine Oil ......................................................................... 30
Oil Specifications.......................................................30
Oil Drain
Hose ...........................................................30
Exhaust System Installation ......................................... 12
Oil Dipstick................................................................30
Recommended Guidelines .........................................12 Pressure Sensing Devices...........................................30
Check Valves ..............................................................14 Relocating
Engine Parts.............................................30
Exhaust Back Pressure.......................................... l4,16
Remote Oil Filter .......... ' .................................................. 31
Water Separator Exhaust Systems.............................. l5
Installation.................................................................. 31
Dry Stack Exhaust Systems .......................................15
Exhaust Hose..............................................................
l6
Exhaust Elbow .......................·.................................... 17
Precautions ................................................................. 18
Electrical System ........................................................... 19
DC Electrical Connections......................................... 19
Control Panels for Propulsion Engines...................... 19
Diesel Generator Instrument Panels ............................ l9
Optional Instrument Panel (Gasoline Generators)..... l9
Optional Remote Start/Stop Panel
(Diesel and Gasoline Generators) ..............................19
D-Net Control Panels .................................................
21
Ventilation ....................................................................... 32
Water Heater Connections ............................................ 33
Installation..................................................................33
Transmission ................................................................... 34
Transmission ..............................................................34
Shipment.....................................................................34
Fluid ...........................................................................34
Control Cables -
ZF ...................................................34
Borg Warner Velvet Drive..........................................35
PRM Newage 801100.................................................36
Installation • Final Check ............................................. 38
Control Wiring ..................................,......................... 20
Metric Conversion Chart ............................................... 39
AC Wiring (Generators)............................................. 20
Batteries......................................................................20
Wire Sizing Chart ............................................................ 40
D-Net Control Panels................................................. 21
Admiral Control Panel ...............................................22
Captain Control Panel ................................................23
Engines & Generators
1

INTRODUCTION
This marine Installation Manual covers all WESTERBEKE
Engine and Generator models, both diesel and gasoline. The
purpose
of this manual is to provide boatyards and installers
who are already familiar with installation procedures, addi-
tional detailed installation instructions to ensure the safest
and most efficient operating conditions. These instructions
may vary due to the many WESTERBEKE Engines and
Generators available and the diversity
of boat designs.
Proper location and installation of the engine or generator in
the vessel are
of prime importance. Factors in the installation
that must be considered are:
1. Ventilation, to provide air for engine combustion and
to remove heat produced by the engine/generator while
operating.
2. Exhaust System, to properly discharge cooling water,
quiet the exbaust, and expel exhaust gas. Install a siphon-
break.
3. Cooling Water Supply, to cool the engine with a continu-
ous flow of filtered raw water.
4. Fuel System, to provide an unrestricted fuel supply and
properly filtered fuel to the fuel pump.
S. Electrical Connections, both AC and DC and proper
grounding.
6. Transmission Propeller Connections (Engines only)
Please read this manual carefully and observe the safety pre-
cautions. Should your engine or generator require servicing,
contact your WESTERBEKE dealer. For Serial Number
location, Decal information
or Parts Ordering information,
refer to your WESTERBEKE Operators Manual.
INSTALLATION CODES AND SAFETY STANDARDS
Recommended publications concerning Safety Codes and
standards are listed in this safety section. Following is a sum-
mary of what these standards include. Both the U.S. Code
(USC), which are the laws passed by Congress, and the Code
of Federal Regulations (CFR), which are agency-generated
rules, contain pertinent information.
Title 46 Chapter 43 of the USC applies specifically to recre-
ational vessels. It gives the Secretary of Transportation the
authority to set the standards for boats that are manufactured
and operated in the United States.
It also spells out the penal-
ties for violation of the standards.
According
to Title 46 USC 4307, a person may not manufac-
ture, construct, assemble, offer for sale, introduce into inter-
state commerce, or import into the United States any
recreational vessel that does not comply with the federal reg-
ulations. Any associated equipment or component used on
one
of these vessels must also be in compliance. Further, a
person is prohibited from operating any vessel that does not
comply with the regulations.
Within the CFRs are the detailed requirements applicable
to boats with gasoline engines.
The majority of requirements
pertinent to recreational vessels are contained in 33 CFR
Part 183.
• Subpart 1-Electrical Systems 183.401-183.460
• Subpart ]-Fuel Systems 183.501-183.572
• Subpart K-Ventilation 183.601-183.630
Standards for marine carburetors and the requirements for the
backfire flame arrester are contained in
46 CFR Subparts
25.35 and58.10. Also within Subpart 58.10 are the exhaust
manifold and exhaust system requirements for both gasoline
and diesel engine installations. Several publications that
address these federal mandates, making compliance easier,
include:
• The USCG Fuel System, Electrical System and
Ventilation Compliance Guidelines
• The USCG Safety Standards for Backyard Boat Builders
• The National Fire Prevention Association NFPA-302
Fire Protection Standard for Pleasure and Commercial
Motor Craft
• The ABYC Standards and RecommendedPractices for
Small Craft
TheABYC Standards Manual is the most comprehensive and
widely used reference.
ABYC constantly revises and updates
its "projects," as it calls each topic section. The manual is
easy to read and quite detailed. Adherence with these stan-
dards will put the recreational boater in compliance with
federal mandates. Anyone considering installing an engine
or generator should start with a thorough review
of these
standards:
• H-2-Ventilation of Boats Using Gasoline
• H-32-Ventilation of Boats Using Diesel
• H-24-Gasoline Fuel Systems
• H-33-Diesel Fuel Systems
• P-I-Installation
of Exhaust Systems
for Propulsion and Auxiliary Engines
• P-4-Marine Inboard Engines and Transmissions
• E-11-AC and DC Electrical Systems for Boats
USCG "inspected vessels," especially those carrying
passengers
for hire, are required to meet even more stringent
standards than those discussed above. Avery thorough
review
of the applicable CFRs is necessary before the Coast
Guard arrives for theirinspection.
Recommended Reading
For added information on installing Marine Engines and
Generators,
WESTERBEKE recommends the following
books:
• Elements of Yacht Design -Skene
• Marine Engines -Calder
• The Propeller
Handbook- Gerr
Engines & Generators
2 .

INTRODUCTION
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, TIMELINESS OR
COMPLETENESS THEREOF, AND WILL IN NO EVENT
BELMBLEFORANYTYPEOFDAMAGEORINJURY
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
of earlier
WESTERBEKE manuals.
In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE
or other suppliers, must not and cannot be
relied upon exclusively as the definitive authority
on the
respective product. It not only makes good sense
but is
imperative that appropriate representatives
of
WESTERBEKE or the supplier in question be consulted to
determine the accuracy and currentness
of the product
software being consulted
by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the installation procedures
for your engine/generator, critical information will
be high-
lighted 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
your engine.
A WARNING: Procedures which, if not properly
followed, can result in personal injury or loss of life.
INSPECTION OF SHIPMENT
The engine/generator is shipped from the factory securely
mounted and properly crated. Accessory equipment is
shipped in a separate small box, usually packed within the
engine's crate.
Before accepting shipment
of the engine from the
transportation company, the crate should be opened and the
contents inspected for damage.
If there is either visible or
concealed damages, you should require the delivery agent to
write "Received in damaged condition" on the delivery
receipt. Also compare the contents
of the shipment against
the packing list and make sure that any discrepancies are
properly noted. This is your protection against loss
or
damage. Claims concerning loss or damage must be made to
the carrier, not to WESTERBEKE Corporation.
NOTE: For safety reasons, the engine is NOTfilled with
lubricating oilfor shipment. Before leaving the factory,
however, each engine/generator is thoroughly tested with oil
in its engine. This testing, among other things, provides all
internal parts with a coating of oil. This oil acts as a
preservative, providing
reliable protection against corrosion
for at least
one year if the engine/generator is properly
stored.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visible position in the
vessels living quarters.
Engines & Generators
3

ENGINE LOCATION AND MOUNTING
ENGINE LOCATION
The overall layout ofthe engine room should be planned for
easy inspection, servicing, and handling of the engine;
Thoroughly study all the equipment to be installed and make
a paper plan to provide optimum engine room space.
Consider the following:
1. Ventilation -Since an increase in engine room
temperature causes a reduction in the intake air and thus a
drop in engine output, ventilation inside the engine room
must be ample. See your Operators Manual for the
ventilation requirements for your engine/generator.
a. Dimension
and capacity with a ventilator installed
b. Dimension and capacity with an intake duct
installed
2. Engine Room Height -For engines having a top oil fill,
the distance from the oil cap at the top of the rocker cover
to the overhead must be enough that oil can easily be
added.
3. Space to move the propeller shaftflange - Allow
approximately 3-4 in (7.7- 10.0 em) ofspace to move
the flange toward the stem for changing the transmission,
etc.
4. Exhaust System - Make sure there is adequate space for
all exhaust system components, including the exhaust
silencer.
Refer to EXHAUST SYSTEM INSTAUATION in this manual.
ENGINE BED
A strong mounting bed contributes to the satisfactory
alignment and operating of the engine. The bed must be
rigidly constructed, and neither deflect nor twist when it is
subjected to the engine's weight or to the pressures that the
boat may experience while. operating in rough seas. The bed
must be strong enough to keep the engine's alignment within
one or two thousands of an inch at all times. The bed has to
withstand the forward push of the propeller shaft. It is also
critical that the beds are parallel to one another and to the
line of the propeller shaft when viewed from above. They
also must be offset an equal distance from the line of fl1e.
propeller shaft. ·
In fiberglass hulls, we recommend that solid wooden support
stringers similar to those in wooden hulls be formed and
fitted, then glassed securely to the hull. This will allow the
hanger
bolts to be installed firmly in the wood, thereby
reducing noise and transmitted vibration.
The stringers must be as wide or wider than the engine
....... mountingisolator.~..excessiv.e.height. .Isolator.overhang ....
and/or rounded stringer surfaces are detrimental to the
flexible mounts' ability to retain vibration.
Supports between the bed stringers and supports extending at
right angles from the stringers to the hull may be required for
proper strength and to aid in the absorption of vibrations.
The engine bed must be constructed so that a wrench can be
set at the engine base to retighten the engine mounting bolts
at the mounting feet.
Many boat manufacturers are now providing preformed
figerglass mounting beds for their engine installations. These
beds, when used, should be of sufficient thickness for proper
support and should be well-glassed to the hull when installed.
Avoid the temptation to install the engine on a pair of angle
irons glassed in place. Such a construction will allow ·
vibration to pass through to the hull. Flexible engine
mounts require
Jl firm-foundation.
mEATEDWOOD
SmiNGER
FIBER GLASSED
IN-PLACE
ANGLE-TYPE
SmiNGER
PDOR DESIGN -
NOT ENOUGH
SUPPORT
ENGINE BEDS
When preparing the engine load, also plan out and build an
engine drip pan. To simplify cleai)ing up after oil changes,
consider a separate drip pan for use under the oil and fuel
filters.
SSB RADIO/ELECTRONIC GROUNDING
Ifyour boat needs a ground plane for a radio and other
electronic gear, this
is the ideal time to bond a substantial
area ofcopper mesh into the base of the engine
space while
it is accessible.
Engines &Generators
4

ENGINE LOCATION AND MOUNTING
ENGINE MOUNTING
Bronze or stainless steel hanger bolts ofappropriate sire are
recommended for use through the engine's flexible mounts.
Less preferred are lag screws because their hold on the wood
is weakened every time they are moved, whereas hanger
bolts stay in position. If the nut on top of the hanger bolt is
removed to allow the engine to be lifted, the hanger bolt
itself
remains in place as a stud. Consequently, the bond
between the hanger bolt and the wood is not weakened by
the removal of the nut or the engine.
To screw a hanger bolt onto a stringer, thread two nuts onto
the hanger bolt, jam them together, then tum the hanger bolt
into the stringer using a wrench on the uppermost nut.
HANGER BOLT..___
(PREFERRED
METHOD)
ENGINE MOUNTING
Th.e engine's mounting angle cannot exceed 15° from the
horizontal plane. Refer to the specification section in your
operating manual for the angle limit ofyour engine.
NOTE: There are various transmissions that provide down
angle outputflanges to help in positioning the engine on a
more level plane.
'---._ BED
• WAl:ERLINE "'--
ENGINE'S MOUNTING ANGLE
OFFSET
V-DRIVE
TRANSMISSIONs
Engines & Generators
5

GENERATOR LOCATION AND MOUNTING
GENERATOR LOCATION
A solid, level mounting platform is very important for the
proper operation
of your generator. Select a location that will
allow adequate space on all sides for ventilation and
servicing, preferably on, and parallel with, the keel or vessel
center line. Keep the generator away from living quarters,
and away from bilge splash and vapors.
Make sure there is room to access the following service
points:
• Negative and positive battery connections
• Fuel inlet and outlet connections
• Oil fill and oil drain hose
• Raw water inlet and outlet
• Location of the (owner supplied) fuel/water fuel filter.
A generator will rock on its mounts in rough seas, therefore
clearance is necessary on all sides. Larger generators require
up to a three-inch (76mm) clearance.
Avoid supporting the generator from bulkheads which can
create drumming effects and transmit noise and vibration
throughout the boat.
Generator location
is preferable in the same room or
compartment as the propulsion engine, as this is usually a
well ventilated area, insulated, close to the fuel supply and
the center
of the electrical load distribution. However, a
generator cannot be installed in the propulsion engine
compattment unless specific conditions are met.
USCG regulation 33CFR183 pertains to gasoline fuel
systems, and requires a generator operating in a gasoline fuel
environment to be "ignition protected." This means a
generator capable
of operating in an explosive environment
without igniting that environment. Properly installed and
operated, a WESTERBEKE gasoline generator can operate
in an explosive environment.
A WARNING: Gasoline fire or explosion can result in
severe personal injury or death. Do not install a gasoline
generator in the same room or compartment as a diesel
engine or generator. The diesel unit may not be ignition
protected and may ignite gasoline fumes. Be sure a
gasoline generator is installed in its own room or
compartment on a diesel powered boat.
Do not install a diesel generator in the same room or
compartment as a gasoline engine.
GJ:NERATOR MOUNTING
Generator mounting rails have numerous pre-drilled bolt
holes to ensure that the generator is properly positioned and
secured to its mounting platform.
GENERATOR
FOOT
STANDARD GENERATOR MOUNTING
3/4" DIVIIIInnl>~
MINIMUM
SMALL GENERATOR MOUNTING
Engines & Generators
6

SOUND ENCLOSURE
There are custom designed sound enclosures for each model
of WESTERBEKE generators. The Sound Guard is a rigid,
attractive, easy
to clean enclosure that reduces the generator
noise to a pleasant hum. The enclosure can be assembled
easily in close quarters.
Quick action fittings allow for easy access for inspection or
routine maintenance
of the generator. If majorrepairs are
needed, all the panels can
be disassembled in a few minutes.
No tools required.
Sound Guard is pre-packaged with the skirt and base
assembled to assure a safe arrival and easy assembly.
WESTERBEKE provides the necessary fittings and
connecting hoses for water, exhaust, fuel and battery
attachments and easy to follow assembly instructions.
When ordering a new generator (diesel only) it can be
ordered installed in an assembled Sound Guard as a package
for ease
of installation.
For a quiet, dependable sound enclosure, contact your
WESTERBEKE dealer.
7
TYPICAL SOUND GUARD
SOUND ENCLOSURE

RIGGING AND LIFTING
The engine/generator is fitted with lifting eyes. Attach wire
rope or chain slings capable
of supp01ting the engine/
generator's weight to the eyes and lift the engine/generator by
means
of tackle attached to these slings. The lifting eyes have
been designed to carry the full weight; auxiliary slings are
not necessary.
A WARNING: Sings must NOT be so short as to place
stress on the lifting eyes. A sling must be long enough so
that its angle to the vertical plane does not exceed 10°.
The general rule in moving an engine/generator is to ensure
that all equipment used is adequately strong and firmly fixed
in place. Move the engine/generator a little at a time and
make sure it is firmly supported. Eliminate the possibility
of
accidents by avoiding haste. Do not lift by the crankshaft
pulley.
A WARNING: M;ke certain all personnel stand clear
during lifting and lowering operations.
In certain situations it may be necessary to lift the
engine/generator in positions other than the horizontal
position. Certain situations require it to be lowered endwise
through a small hatchway which cannot be made larger.
If
the opening of the hatchway is extremely small, it is possible
to reduce the outside dimensions
of the engine/generator by
removing external components such as the cooling system
piping, the heat exchanger, certain filters, the mounting rails
(on generators) and other obstructive components. These
should be removed by a competent mechanic and special
care should be taken to avoid damage to any exposed parts.
Be cilreful not to allow dirt to enter any openings created by
the removal of equipment. Reinstall the components in their
original positions after the engine is in its installation area.
Replace gaskets as needed for the parts that were removed.
If it becomes necessary to hoist the engine/generator
front-end (pulley/drive belt end) upwards or rear-end (fly-
wheeVgenerator end) upwards, the attachment
of lifting
slings must
be done carefully to avoid damaging the parts on
which the weight
of the slings may bear.
NOTE: Rigging work is best done by someone experienced
and competent in handling heavy machinery.
....____10• MAXIMUM
Engines & Generators
8

PROPELLER SHAFT ALIGNMENT
PROPELLER SHAFT COUPLING (Engines)
Apropeller shaft half-coupling is available for all engine
models. It is bored to shaft size for the specific order, and has
either a keyway with set screws and two locking bolts, or is
of the clamping type with a keyway.
This coupling is carefully machined to allow a slight
forced-fit onto
the shaft and to make an accurate mating
surface between the coupling and the output flange of
the
transmission.
The
forward end of the propeller shaft has a long straight
keyway. Any burrs should be removed from the shaft's end.
The coupling should be a light drive fit onto the shaft, and
the .shaft should not have to be scraped down or filed in order
to get a fit. It is important that the key be properly fitted to
both the shaft and to the coupling. The key should fit the side
of
the keyway closely but should not touch the top of the
keyway in the hub ofthe coupling.
Ifdriving
the coupling over the shaft is difficult, the coupling
can
be expanded by heating it in a pail ofboiling water. The
face of the propeller coupling must be exactly perpendicular
to the center line (axis) of the propeller shaft. Have a
machine shop fit the coupling and face the coupling so that
the mating surface of the flange is at a perfect right angle to
the propeller shaft.
After driving
the coupling over the shaft, remove the two
locking bolts from the coupling and countersink the shaft
below each locking bolt hole. Insert and tighten the two
bolts, then wire the two bolt heads together with stainless
wire. This will secure the coupling to the shaft. For
additional security a stainless hose clamp can be tightened
around the coupling shoulder and over the two bolt heads.
PROPELLER SHAFT COUPLING
FLEXIBLE COUPLINGS
A flexible coupling or a "drive saver" can be installed
between
the WESTERBEKE shaft coupling and the ,
transmission coupling to reduce vibration and absorb thrust
and torque. This is an important consideration when using
flexible engine mounts. Follow the manufacturers'
recommendations and instructions.
DRIVESAVER is a product of Globe Marine, Rockland, MA.
FLEXIBLE
COUPLING
PROPELLER SHAFT INSTALLATIONS
These illustrations show typical propeller shaft installations
,with variations on stuffing boxes and stem tubes. The
propeller shaft on the boat with the spade rudder is supported
by the stem tube. An external strut supports the shaft on the
other boat.
Engines & Generators
9

PROPELLER SHAFT ALIGNMENT
ALIGNMENT
The engine must be exactly aligned with the propeller shaft.
No matter what material is used to build a boat, the material
will be flexible to some extent. The boat's hull will change
its shape to a greater extent than is usually realized when the
boat is launched and opemted in the water. Therefore, it
becomes extremely important to check the engine's
alignment at frequent intervals and to correct ~y errors
when they appear.
Misalignment between the engine and the propeller shaft
often creates serious problems which are often blamed on
other areas suspected ofcausing the trouble. Misalignment
will cause excessive bearing wear, rapid shaft wear, and will,
in many cases, reduce the life ofthe boat's hull by loosening
the hull's fastenings. Abent propeller shaft will produce these
same effects, therefore a perfectly straight propeller shaft is
absolutely necessary. One result ofmisalignment may be
leakage of transmission oil through the transmission's rear oil
seal. If oil should leak from this seal, check and make sure
that the alignment is within the limits prescribed.
Never attempt a final alignment when the boat is on land.
The boat should be in the water and have had an opportunity
to assume its final water form. The propeller shaft/
transmission coupling alignment is best performed with the
fuel and water tanks about half full, with all the usual
equipment on board, and, on sailboats, after the mainmast
has been stepped and the final rigging has been installed.
Take sufficient time to make this alignment- don't be
satisfied with less than perfect results.
FLANGE FACE
NOT SQUARE
DIFFERENT DIAMETER
fLANGES
SHAFT/COUPLING PROBLEMS THAT
AFFECT ENGINE ALIGNMENT
GOOD
ALIGNMENT
BAD
The alignment is correct when the propeller shaft can be
easily slipped backward and forward into
the counterbore,
and when a feeler gauge indicates that the flanges come
together at all points. The alignment between the propeller
shaft half-coupling and
the transmisson half-coupling can
contain an error no greater than .OOlin (.25 mm) per inch of
the coupling diameter. For example, if your propeller shaft
half-coupling
is 3" (76mm) in diameter, the maximum error
that
can be allowed in the alignment is .003 in (.076mm).
PROPER
HALF-COUPLING
ALIGNMENT
,,
" ..._...,A
~("""'"'
--, ,,
,,
--
In making the final check for alignment, the transmisson
half-coupling should be held in
one position and the align-
ment with the propeller shaft half-coupling tested with the
propeller shaft half-coupling in each offour positions A,
while rotated 90° between each position. This test will also
check whether the propeller shaft half-coupling is in exact
alignment on its shaft. Then, keeping
the propeller shaft
half-coupling in one position,
the alignment should be
checked by rotating the transmission half-coupling in 90°
increments, checking dimension A while in each 90°
position until it has been rotated full-circle.
The engine's alignment should be rechecked
after the boat
has been in service for one to three weeks and, if necessary,
the alignment performed again. Usually it will be found that
the engine is no longer in alignment. This does not mean that
the first alignment has been done improperly, rather, it means
that the boat has taken some time to take its final shape and
that the engine's bed and stringers have probably absorbed
some moisture. It may even be necessary to realign the
coupling halves again at a later time.
Engines & Generators
10

PROPELLER SELECTION
The type and size ofpropeller varies with the gear ratio and
must be selected to fit the application, based upon boat tests.
To utilize the full power of the engine and to achieve ideal
loading conditions, use a propeller which will pe~t the
engine to reach its full rated rpm at full throttle while under a
normal load and while the boat is tnoving forward through
the water.
The following information is needed to calculate and match a
marine propeller to a boat.
a. The engine output in hp.
b. The maximum rpm of the engine.
c. The reduction of the transmission.
d. The maximum hull speed of the boat.
e. The type ofboat and its displacement.
f. The waterline length (LWL).
Most propeller shops now have computer progr~s ~hat will
analyze all this data and select the propeller chOices m
number of blades, diameter and pitch. In-water testing
however, is always the final answer.
For more information on propellers, read The Propeller
Handbook by Gerr published by International Marine
Publishers.
Preparations to install an engine or generator set should begin
with a thorough examination of the ABYC standards. The
following sections in the ABYC standards pertaining to
Exhaust Systems are ofparticular interest:
• P- !-Exhaust Systems
• m-22-Educationallnfonnation about Carbon Monoxide
•TH-23-Design, Constnu:tion and Testing of Boats in
consideration of Carbon Monoxide.
MINIMUM PROPELLER CLEARANCES
.From TilE PROPELLER HANDBOOK
The engine exhaust system(s) should comply with the
requirements ofABYC P-1, Installation of the Exhaust Systems
for Propulsion andAuxiliary Machinery. See ABYC 1H-23,
Design, Construction and Testing of Boats in consideration of
Carbon Monoxide.
Selecting the appropriate tenninus (i) location may vary
depending upon the specific design of the boat. ABYC P-1,
Exhaust Systems;
Engines & Generators
11

EXHAUST SYSTEM INSTALLATION
INSTALLATION DIAGRAM
ENGINE OR GENERATOR
(BELOW THE WATERLINE)
RAW WATER.
INTAKE
RECOMMENDED GUIDELINES
{TYPICAL)
These guidelines dated July 2013 supersede all
previous guidelines published by Westerbeke
Corporation for all types
of exhaust systems. Water
intrusion
is not covered by Westerbeke warranty
because it
is not caused by a product defect. Please
study these guidelines carefully before planning
your exhaust system installation.
Throughout these guidelines our use ofthe word "engine" is
generic, it refers equally to either a propulsion engine or to
the engine driving a generator set, sea water and raw water
are the same.
Beyond conveying exhaust gases and cooling system sea
water out of the boat, the other purpose of the exhaust system
is to prevent sea water intrusion into the engine (at the
exhaust outlet) under all conceivable conditions ofboat trim,
boat operation, sea conditions, and heel angle while not
exceeding the manufacturer's back pressure recommenda-
tions. Seawater intrusion is usually catastrophic to catalytic
converters and engines. The enginelgenset supplier is not in a
position to judge what installation characteristics will prevent
water intrusion in all conceivable circumstances. That
judgment
is the responsibility ofthe engine installer. What
we as the manufacturer can do is advise the best practice, as
we see it, leaving final judgments to the installer.
DECK LEVEL
WATER LIFT
MUFFLER
POT TYPE OR IN-LINE
SELECT STYLE BEST
SUITED FOR INSTALLATION
Sea Water Intrusion Through The Exhaust Outlet
The diagram above illustrates a below waterline installation
of
an engine or genset. The letters Athrough H are the
important dimensions that are discussed in detail in the
following text:
Let's start with A, the difference between the highest
underside ofthe boat deck near the engine/generator
and the
high point ofthe exhaust run from the water lift muffler to
the exhaust outlet. Ashould be minimized. There is every
reason to attach the high point of the exhaust hose directly to
the underside ofthe deck. There is no reason to fail to take
full advantage ofthis maximum available height because it
forms the primary barrier to water intrusion.
We need to define the water line for exhaust installation
purposes. By water line
we mean the highest point the water
level can reach, at the location ofthe exhaust through hull
fitting, from all conceivable causes -other than passing
waves ofa duration ofnot more than a second or two. This
worst case water level could be caused by any of the
following: backing down aggressively, turning aggressively,
coming up onto a plane, decelerating off a plane, extreme
boat trim, high seas, wallowing in following seas, heeling,
etc. These instructions will refer exclusively to this worst
case water level as the relevant water level to plan a good
installation.
Engines &.Genprators
.12