Westerbeke 20.0KW sbeg User manual

OPERATORS MANUAL
20.0KW SBEG and SBEGA • 60HZ
22.5KW SBEG and SBEGA • 60HZ
MARINE GASOLINE GENERATORS
Single and Three Phase
PUBLICATION NO.049800
THIRD EDITION
MARCH 2008
Ultra-Low Carbon Monoxide Emissions

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
- Muscular Twitching
-Headache
- Vomiting
- Weakness and Sleepiness
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
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.

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefully. Most accidents are
caused by failure to follow fundamental rules andprecau-
tions. Know when dangerous conditions exist andtake the
necessary precautions to protectyourself, yourpersonnel,
andyour
machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running. Lethal voltage is present at
these connections!
• Do not operate this machinery without electrical
enclosures
and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes)
when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor
by shorting terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery
tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching
the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or 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 fuel line, carburetor, or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean
and free ofdebris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -Diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: explOSions from fuel vapors can cause
injury or death!
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area
away from spark-producing
equipment
and out of the reach ofchildren.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that 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 ofleaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered
in this environment.
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• To prevent accidental starting when servicing the
generator, remove
the 8 amp fuse from the control panel.
• 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
fe-installed before starting the engine.
EngInes & Generators

SAFETY INSTRUCTIONS
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
ordeathl
• 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 dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terminal of the starter solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or deathl
• 'When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
off at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
A WARNING: Carbon monoxide (CO) is a deadly gasl
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection ofthe exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation of approved detectors.
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms!
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners.
• 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 ofthe
symptoms or signs ofcarbon monoxide inhalation or
poisoning are:
Vomiting Muscular twitching
Dizziness Intense headache
Throbbing in temples Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• 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.
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
lossl
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: 00 not work on machinery when you are
mentally 01 physically incapacitated by fatiguel
Engines & Generators
ii

SAFETY INSTRUCTIONS
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 a gasoline engine or generator should
begin with a thorough examination
of the American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination ofsources including the USCG and the NFPA.
Sections ofthe ABYC standards ofparticular interest are:
H-2 Ventilation
H-24 Gasoline Fuel Systems
P-l Exhaust Systems
P-4 Inboard Engines
E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations
(FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions
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
Engines & Generators
iii

CARBON MONOXIDE "CO"/SAFE-CO GENERATORS
IMPORTANT INFORMATION
DESCRIPTION
Carbon monoxide "CO" is a component ofengine exhaust. It
is a colorless, tasteless, odorless, lighter
than air poisonous
gas that can kill you without any warning. CO poisoning is
one of the major safety risks associated with boating. It is a
threat that must
not be underestimated.
Several standards for
CO have been published, expressed in
parts per million "ppm" and hours of exposure:
Regulator CO ppm
Exposure Hours
EPA 9 8
ACGm
25 8
EPA 35
1
NIOSH 35
8
OSHA 50 8
ACGm
125
0.5
NIOSH 200 0.0
NIOSH 1200
0.0
(IDLH)
1200 ppm is the so-called IDLH concentration -
IMMEDIATELY DANGEROUS TO LIFE AND HEALTH.
Acity inCalifornia characterizes the effect of CO
concentration this way:
Parts per Million
Responses
25 Permissible exposure level, no
apparent toxic symptoms.
100
No poisoning for long period.
Allowable
for severalhours.
200
Should not be exposed above
this level for any period of
time. A possible mildfrontal
headache intwo to three hours.
Even though Westerbeke Safe-CO generators are designed to
reduce nonnallevels of CO in the engine exhaust by
approximately 99%, an exhaust leak of untreated exhaust
would be extremely dangerous. For this reason it is
extremely important to install a CO detector near the
generator and to be sure it is always turned on and
functioning properly. If this detector sounds, do not tum it
off, assuming it is a false signal. You can not taste, smell, or
otherwise detect
CO. Leave the detector on, tum off all
engines and generators, evacuate the boat leaving ports and
hatches open, and seek professional help.
As soon as CO leaves the exhaust outlet, the level is subject
to dilution in the open air. The closer a person is to the
exhaust outlet, the higher the concentration of CO.
In a closed space, such as the engine compartment, the boat,
or underneath a stern swim platform, concentrations will
potentially rise to the undiluted level emanating from the
exhaust system due to a lack offresh air to dilute the exhaust
gas. Therefore, one should never rely on dilution of the
exhaust to provide a margin of safety.
Westerbeke Safe-CO generators achieve an approximate 99%
reduction oftypical CO by precise control control ofthe
engine's air/fuel ration coupled with after treatment
in a
special catalyst.
CO emissions are not the same for every
model because each engine is different. Also, certain fuel
system components are commonized across several engine
models being adequate for some and extra-adequate for
others, thus producing different CO levels for different
models.
The fuel system which accomplishes the required precise
airlfuel ratio control
is comprised of many different
components: purchased sub-assemblies, machined castings,
sensors, electronics and others. Because of
the extreme level
ofCO reduction,
any variability in the functioning of any
these components can and will cause variability of the CO
output.
CO concentration also varies with load. Usually, but not
always, the worst case CO concentration occurs at maximum
load.
INSPECTION
The catalyst is critical to optimizing CO levels. Any water
intrusion into the exhaust system will likely quickly
compromise
the proper operation of the catalyst.
Westerbeke's exhaust system installation instructions
dated
on or after February 2004 must be adhered to.
NOTE: Water intrusion is not a product defect and is not
covered under
warranty, neither Westerbeke's normal
product warranty nor
the emissions specific warranty
mandated by various regulating authorities such as EPA
andCARB.
Maintenance of
any components affecting the flow of air or
the flow of fuel to the engine is critically important, such as
fuel filters and air filters (if any).
Inspection ofthe catalyst at the prescribed intervals is
critically important. The exhaust elbow is removed by
loosening the metal clamp to provide a view ofthe output
surface of
the catalyst. Any visual irregUlarity ofthe nonnal
flush, honeycomb appearance is most likely a result ofwater
intrusion. The cause of
the irregularity must be identified and
addressed.
If there is irregularity, the catalyst and gasket must
be replaced. Upon careful reassembly of the catalyst, exhaust
elbow
gasket, and exhaust elbow, check for the presence of
CO while the engine is running. This must be performed with
a
CO analyzer.
Engines & Generators
iv

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

EMISSIONS
This genset meets the requirements ofCalifornia's Exhaust
Emissions Standards
as stated on the nameplate.
You should carefully review operator (Owner) Installation
and other manuals and information you receive with your
genset. If you are unsure that the installation, use,
maintenance or service of your genset is authorized, you
should seek assistance from an approved WESTERBEKE
dealer.
California users of this genset should be aware that
unauthorized modifications
or replacement of fuel, exhaust,
air intake, or speed control system components that affect
engine emissions are prohibited. Unauthorized modification,
removal or replacement of the engine label is prohibited.
California genset users may use the table below as an aid in
locating information related to the California Air Resources
Board requirements for emissions control.
Federal Emissions Compliance Period: The Federal
Emissions Compliance Period referred to on the nameplate
indicates the number of operating hours for which the engine
has been shown to meet Federal Emissions requirements.
Catagory C= 250 hrs, B=500 hrs,m A =1000.hrs.
EMISSIONS CONTROL INFORMATION TABLE
The California emissions control warranty statement is located in the same
Emissions Warranty Infonnation packet, ifinformation as this manual when the genset is shipped from the
factory.
Engine Fuel Reqnirements
The engine is certified to operate on unleaded ga'>oline. See FUEL
RECOMMENDATIONS.
Engine Valve Adjustment
See MAINTENANCE SCHEDULE.
Engine Ignition Timing See
MAINTENANCE SCHEDULE.
Engine Lubricating on Reqnirements See ENGINE OIL RECOMMENDATIONS.
EngineAdjustments
ECU.
Engine Emission Contol System The engine emission control system consists of engine design and precision
manufacture.
Catalyst
See MAINTENANCE SCHEDULE.
Oxygen Sensor
See MAINTENANCE SCHEDULE.
Back Pressure
See MAINTENANCE SCHEDULE.
Engines &Generators
vi

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention
be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break
in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of20" 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 ofthe water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
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.
EMISSION-RELATED INSTALLATION INSTRUCTIONS
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
"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 ofOBD 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 u~e
of any Westerbeke product in any manner inconsistent with its intended use could be a viol,ation 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 ifneeded to comply with this rule.
Engines & Generators

TABLE OF CONTENTS
20KW SBEG/22.5KW SBEG Parts Identification .......... 2
Introduction .................................................................... 3,4
Fuel, Engine Oil and Engine Coolant.. .......................... 5
Preparations for Initial Start-Up .. ................................. 6
Operating Instructlons ..................................................... 7
Generator Control Panel...............................................7
Remote Control Start/Stop Panel.................................7
Break-In Procedure/Dally Operation ............................. 8
Safety Shutdown Sensors/Switches .............................. 9
Maintenance Sehedule ............................................. lO,11
Cooling System ............................................................... 12
Changing Coolant....................................................... 12
Thermostat.................................................................. 13
Zinc Anode ................................................................. 13
Heat Exchanger.......................................................... 13
Raw Water Intake Strainer......................................... 14
Raw Water Pump........................................................ 14
Fuel System ..................................................................... 15
GasolinelWater Separator and Filter......................... .15
Engine Fuel Filter....................................................... 15
Electronic Fuel Injection (EFI) .................................. 16
Engine Lubrication 011 ................................................... 17
Changing the Engine OiL ......................................... 17
Replacing the Oil Filter.............................................. 17
011 Pressure ............... ...................................................... 18
Testing Oil pressure.................................................... 18
Remote Oil filter (Optional) .......................................... 19
Timing Belt Inspection/lnstallation ....................... 20,21
Engine Adjustments ....................................................... 22
Spark Plugs................................................................. 22
Drive Belt Adjustment ............................................... 22
Engine Compression Test........................................... 23
Valy~ Cl~~ce Adjustment ......................................24
IgnItIOn tlmlng............................................................24
Torquing the Cylinder Head Bolts ............................. 24
Generator Information ................................................... 25
The SBEG Generator (Single and Three Phase) ........ 26
Internal Wiring Schematics
(Single and Three Phase) .............................................. 27
Generator AC Voltage Connections ................. 28, 29 30
SBEG Troubleshootlng .................................................... 31
Generator Voltage Regulator Adjustments
(Three Phase) .................................................................. 32
Shore Power Transfer Switch ....................................... 33
20KW SBEG and 22.5KW SBEG
Generator Wiring Diagram #49232 .................. ............ 34
Remote Control Panel
Wiring Diagram #49209 .......... ...................................... .35
Engine Troubleshootlng .................................. 36,37,38,39
Lay-Up and Recommissioning ................................. 40,41
20KW SBEG and 22.5KW SBEG
Generator Specifications ......................................... 42,43
Torque Specifications .................................................... 44
Standard and Metric Conversion Data ..................... ..45
Metric Conversions ....................................................... .46
Suggested Spare Parts ................................................. .47
...,y' WESTERBEKE
Engines & Generators
1

fRONT
REAR
20KW SBEG/22.5KW SBEG PARTS IDENTIFICATION
SCHRAIIER VAlVE
FUEL PRESSURE REGULATOR
AIR HEATER
OXYGEN
SENSOR tIVBli7~?~~;+_-\L
BELT GUARD
HEAT
EXCHANGER
RAW WATER
DISCHARGE
OXYGEN SENSOR (NB)
CONTROL PANEL
GEIIERATOR
8ACKENO
HOUR METER
fAULT lEO
LIGHTS
RAll
lEFT SIDE
OIL SUMP
AIR BLEED PETCOCK
SYPHON BREAK
CONNECTION
RAIL
COIIJBALLAST
REGISTER
\
COOLANT FILL
(MANIFOLD PRESSURE
CAP) Oil Fill CAP
I
RIGHT SIDE
IN-LINE
FUEL FILTER
Engines & Generators
2
SENSOR (liB)
CIRCUIT
BREAKER
~'" _T--_ EXHAUST
TEMPERATURE
SWITCH
EXHAUST
CONNECTION
ISOLATOR MOUNT
THERMOSTAT ASSEMBLY
RAW WATER
PUMP
OIL FILTER
REAR
FRONT

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 generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This
is your operators manual. Along with this manual there
is an Installation manual and a unit parts print. AService
manual is available and can be ordered from your local
WESTERBEKElUl\lVERSAL dealer.
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 registry form, please contact the factory in
writing with model information, including the unit's serial
number and commission date.
,..".".,WESTERBEKE
I E.ngines & Generators
CustomerIdentification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires Ser.#
CUSTOMER IDENTIFICATION CARD (TYPICAL)
The WESTERBEKE serial number is an alphanumeric
number that can assist in determining the date
of
manufacture ofyour WESTERBEKE engine/generator.
The first character indicates the decade (A=1960's,
B=1970', C=1980's, D=1990's, E=2000's), the second
character represents the year in the decade, and the fourth
and
fifth numbers represent the month of manufacturer.
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 OFSUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH
RESPECTTHERETO, INCLUDING ACCURACY,
TIMEUNESS OR COMPLETENESS THEREOFAND
WIUIN NO EVENT BE UABLE FOR ANY TYPE OF
DAMAGE OR INJURY INCURRED IN CONNECTION
WITH OR ARISING OUT OF THE FURNISHING OR
USE OF SUCHSOFTWARE.
WESTERBEKE customers should also kcep 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 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.
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on a decal on the generator housing. Take the
time to enter the information on the blank decal provided
below
as this will provide a quick reference when seeking
technical information andlor ordering repair parts.
SPECIFICATION
MODEL ___ ~ ___ _
RPM._. _______ _
KW ___________ _
KVA __________ _
VOLTS ________ _
AMPS ________ _
ENG. HP ______ _
ENG. SER. NO.
GEN. SER. NO.
PF/PHASE ___ _
WIRES ________ _
RATING. ______ _
INSUL CLASS __
TEMP. RISE ___ _
BAlTERY _____ _
e.I.D. _________ _
50 HZ.
60 HZ.
I
Fin in the information for your own reference.
Engines & Generators
3

INTRODUCTION
The engine/generator model number and serial number are
located on a plate mounted on the engine's valve cover.
UNDERSTANDING THE DIESEL ENGINE
The gasoline engine driving an AC generator is in many ways
similar to a gasoline automobile engine. The cylinders are
vertic1e in-line, and the engine's cylinder head has an over-
head camshaft which is chain-driven. The engine utilizes a
solid-state distributor
which is horizontally mounted and
camshaft-driven. The engine incorporates a pressure type
lubrication system, and a fresh water-cooled engine block
which
is thennostatically controlled. To a large degree, the
generator's engine requires the same preventative maintenance
that
is required ofa gasoline automobile engine. the most
important factors to the generator's longevity are proper
ventilation, maintenance of
the fuel system, ignition system,
cooling system and the generator back-end.
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. Also insist upon WESTERBEKE packaged parts
because willfit or generic parts
are frequently not made to the
same specifications as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance
schedules, and troubleshooting of your
generator" critical infonnation 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 your
engine.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE generator capable of
many thousands of hours ofdependable 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 lifo:
• Proper engine and generator installation.
• An efficient weU-designed exhaust system that includes an
anti-siphon break to prevent water from entering the
engine.
• Changing the engine oil and oilfilters every 100 operating
hours.
• Proper maintenance of all engine and generator
components according to the maintenance schedule in
this manual.
• Use clean,filtered unleadedfuel.
• Winterize your engine according to the lAY-UP AND
RECOMMISSIONING section in this manual.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator or engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filters can be difficult to obtain along
the way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
on-board inventory of the proper WESTERBEKE parts.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: Only use unleaded fuel with an octane
rating of 89 or higher. Leaded fuel will cause serious
harm to your engine and violate your warranty.
Care Of The Fuel Supply
Use only clean fuel! The clearance ofthe components in
your fuel injection pump is very critical; invisible dirt
particles which might pass through
the filter can damage
these finely finished parts. It is important to buy clean fuel,
and keep it clean. The best fuel can be rendered
unsatisfactory
by careless handling or improper storage
facilities.
To assure that the fuel going into the tank for your
engine's daily
use is clean and pure, the following practice is
advisable:
Purchase a well-known brand of fuel.
Install and regularly service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel tank
and the engine.
ENGINE OIL
Use a heavy duty engine oil with an API classification of SJ.
Change the engine oil and filter after an initial 50 hours of
break-in operation, and every 100 hours ofoperation
thereafter. An oil viscosity ofSAE 15W-40 is recommended
for
this engine in all conditions.
A CAUTION: Do not allow two Dr more brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
to produce properties harmful to your engine.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals
that can corrode internal engine surfaces.
The antifreeze performs double duty. It allows the engine
to run at proper temperatures by transferring heat away from
the engine
to the coolant. It also lubricates and protects the
cooling circuit from rust and corrosion. Use a good quality
antifreeze
that contains supplemental cooling additives
(SeAs')
that keep the antifreeze chemically balanced, crucial
to long term protection.
The water
and antifreeze should be premixed 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-4()0F.
ANTIfREEZE PROTECTION
Antifreeze Concentration 23% 30% 35% 50%
Freezing Temperature 14°F
8°F
-4°F
-40°F
(-10°C) (-13"C) (-20"C)
(-40°G)
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.
Some loss ofcoolant may occur as a result ofevaporation
and the effects ofexhaust manifold
working temperature.
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PLASTIC COOLANT
RECOVERY TANK
THIS LINE RETURNS
COOLANT TO THE ENGINE
PRESTART INSPECTION
EXHAUST MANIFOLD
Before starting your generator for the first time or after a
prolonged layoff, checkthe 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.
NOTE: The starting battery must be totally dedicated to the
generator and maintained by the generator's DC charging
alternator and no other source.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: After the initial running of the generator, the air in
the engine's cooling system will be purged to the coolant
recovery
tank. Open the air bleedpetcock to ensure that
the cooling system is purged of air. After shutdown and
after
the engine has cooled, the coolantfrom the recovery
tank will be drawn into the engine's cooling system to
replace the purged air.
Before subsequent operation of the generator, the engine's
manifold should be topped
off and the coolant recovery
tank's level brought to 114 full.
MANIFOLD PRESSURE CAP
OIL DIPSTICK
AIR BLEElJ
PETCOCK
• 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
oropen neutral can supply the wrong line-to-neutral
voltage on unbalanced loads.
• Make certain the raw water tbm-hull is open.
A CAUTION: When starling the generator, it is
recommended that all AC loads. especially large
motors. be switched OFF until the engine has come
up to speed and. in cold climates, starts to warm up.
This precaution will prevent damage caused by
unanticipated operation of the AC machinery and will
prevent a cold engine from stalling.
Engines & Generators
6

OPERATING INSTRUCTIONS
DC CIRCUIT
BREAKER
ON/OFF
CAUTION: When servicing or replacing DC
components, tum offtbe 20 amp DC circuit breaker.
fW'/WES1ERBEKE 0 T
'-r--r--r---r-'~
START STOP
EMERGENCY STOP
AND FIREBOY
CONNECTIONS
o
STOP SWITCH
GENERATOR CONTROL PANEL
The start/stop rocker switch is the only functional component
on the generator control panel used to start and stop the
generator.
The start/stop rocker switch is a three position switch with
momentary contacts in the (START) and (STOP) position and
a stationary contact function in the center (NORMAL). This
position allows the generator to run once started and also
enables the remote start/stop panel(s) to control the start/stop
functions of the generator.
The (START) position starts the generator and once released
reverts to the center position. The (STOP) position stops the
engine in normal operation as well as in an emergency
situation. This position opens the K2 run relay which
de-energizes the engine's run circuit and shuts down the
engine.
Starting
Simply press the (START) switch and the generator will start.
A green light will glow indicating the generator is running.
Stopping
Depress the (STOP) side ofthe start switch, the green light
will go out and the generator is stopped.
Failure to Start
The start cycle will automatically terminate if the unit fails to
start after 5-6 seconds of cranking. Wait 20 seconds, then
repeat the start.
If the unit again fails to start, investigate the cause. Sometimes
after servicing the fuel system or changing the fuel filter, air
can accumulate in the fuel line or the throttle body and prevent
starting.
The Schrader valves on the throttle body and the fuel cell are
used to remove trapped air. This air is mixed with fuel and
under high pressure. Follow the BLEEDING 11IEFUEL
SYSTEM instructions in this manual. -
CHECK ENGINE LIGHT
The check engine light indicates apotential emission's control
issue. Immediate action by the operator should be taken to
troubleshoot and correct the emission's related issue.
REMOTE START/STOP PANEL
The components on the panel are:
1. Athree position start/stop rocker switch.
2. A green LED run indicator light on the rocker switch.
3. Afour position LED fault shut down display board.
The start/stop rocker switch functions the same as the start/stop
rocker switch on the genemtor's control panel as previously
explained.
The green LED run indicator light on the rocker switch will
illuminate when the start circuit is energized. It ,vill go dim as
the engine cranks and will brighten as the engine starts
indicating the generator is running.
The LED fault shut down display board has four separate LED
lights to display to the operator the cause of the generators
automatic shut down. The four LED displays are: low oil
pressure, high engine operating temperature, high exhaust
temperature and engine over-speedlunder-speed (flashes).
Should the genemtor shut down from one of these faults, the
fault LED will remain illuminated. To reset the LED, the DC
breaker on the control box mustbeturned OFF and then back
ON.
This remote panel is a plub-in accessory and is availab;e with a
15'
to 100' wiring harness.
Engines &Generators
7

BREAK-IN PROCEDURE/THE DAILY OPERATION
BREAK~IN PROCEDURE
After the generator has been started, check for proper
operation and then encourage a fast wann-up. Run the
generator
between 20% and 60% of full-load for the first
10 hours.
A CAUTION: 00 not attempt to break-in your
generator 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
periodically vary the load.
Avoid overload at all times. An overload is signaled by
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
it within the generators rating. Since the generator operates at
1800 rpm to produce 60 hertz, control of the generator's
engine break-in
is governed by the current drawn from the
generator.
To protect against unintentional overloading of the gen!<rator,
the generator's output leads should be routed through a
circuit breaker that
is rated at the rated output ofthe
generator.
NOTE: Be aware of motor starting loads andthe high current
drawn required for starting motors. The starting amperage
drawn can be 3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
CHECK LIST
Follow this check list each day before starting your generator.
• Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule).
• Visually inspect the generator for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check drive belts for wear and proper tension (weekly).
• Check for abnormal noise such as knocking, vibration and
blow-back sounds.
• Check drive belts for wear and proper tension (weekly).
• Confirm exhaust smoke:
When the engine is cold - white smoke.
When the engine is wann -almost smokeless.
When the engine is overloaded -some black smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition should lessen 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. '
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may
be governor adjustments required for engine speed (hertz)
during the engine's break-in period (first 50 hours) or after
this period.See ENGINE SPEED (HERTZ) ADJUSTMENT
under ENGINE ADJUSTMENTS).
NOTE: After the first 50 hours of generator operation, check
the maintenance schedule for the 50 hour service check.
A WARNING: VENTILATION
GaSoline vapors can explode. Before starting the engine,
operate the blower for at least four minutes and check both
'the engine compartment and bilge for gasoline vapors. Run
the blower below cruising.speed.
Engines & Generators
8

SAFETY SHUTDOWN SENSORS AND SWITCHES
SAFETY SHUTDOWN SWITCH/SENSORS
The engine is protected by four automatic shutdown circuits.
Should a shutdown occur, do not attempt to restart without
finding and correcting the
cause. Refer to the heading
Engine starts, rWlS and then shuts down in the ENGINE
TROUBLESHOOTING section of this manuaL
The following is a description ofthese automatic shutdown
circuits:
High Exhaust Temperature Switch
An exhaust temperature switch is located on the water
injected exhaust
elbow. Normally closed, this switch will
open and the ECU will interpret this as a high exhaust
temperature
and open the K2 run relay, stopping the
generator. The exhaust temperature LED on the panel will
illuminate. The switch opens at 260-270F (127-132C). This
switch resets (contacts close) at approximately 225F (107C).
HIGH EXHAUST
TEMPERATURE
SWITCH
Water Temperature Sensor
If
i'
MOUNTED ATTHE
EXHAUST ELBOW
Awater temperature sensor is located at the thermostat
housing. This sensor sends a DC voltage to the ECU that it
interprets
as engine antifreeze coolant temperature. Should
this voltage reach a set value, the ECU will interpret this as
high antifreeze coolant temperature and open the K2 run
relay, stopping the generator. The overheat LED on the panel
will then illuminate.
Oil Pressure Sensor
An oil pressure sensor is located off the engines oil gallery.
Oil pressure on the sensor affects the DC voltage through the
sensor to the ECU. Should the voltage reach a preset value,
the ECU will interpret this as a low oil pressure issue and
open the K2 run relay, stopping the generator. The oil
pressure LED on the panel will illuminate.
JiO
~ ~
~q.~
:3 ~
P
Engine DC Circuit Breaker
Oil PRESSURE
SENSOR
The generator's engine DC circuit is protected by a rocker
type DC 20 amp breaker mounted on the control box. This
also serves as an Emergency Stop Switch. Excessive DC
current draw or DC electrical overload anywhere in the
instrument panel wiring or engine wiring will cause the
breaker to trip to the OFF position. In this event, the DC
power to the ECU will be interrupted, stopping the generator.
No panel LED will illuminate. Check and repair the source
of the problem. After repairing the fault, reset the breaker and
restart the generator.
High/Low RPM Shutdown
Should the generator's RPM go above 20% of the specified
1800 rpm @ 60 HzJ1500 rpm @ 50 Hz, the ECU will shut
the engine down on an over speed fault and illuminate the
overspeed LED on the control panel and remote start/stop
panel
when installed
Should
the generator's RPM fall below 20% of the specified
1800 rpm @ 60 HZ/I500 rpm @ 50 Hz, the ECU will shut
the engine down on an under speed fault and this will cause
the over speed LED to flash.
The
OBD (On Board Diagnostic) will also show these faults.
Engines &Generators
9

SCHEDULED
MAINTENANCE
Fuel Supply
fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to pedorm any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
I SAFE IMaintenance items that are very important to the proper operation of
CO "Safe CO" generators.
CHECK
HOURS OF OPERATION
EACH
MAINTENANCE DESCRIPTION
DAY
50 100
250
500
750 1000 1250
0
Unleaded gasoline with octane rating of 89 of higher
0
Check for water and dirt in fuel (drain/replace filter if
necessary).
0
Oil level should indicate between MAX. and LOW on
dipstick.
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
~y
Inspect for proper tension (3/8" to 1/2" deflection)
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 eoo/.
Sparks Plugs ISfbEI
0
Starting BaHeries
0
(and House Batteries) weekly
Engine Oil
DID
Generator
0
Fuel Lift Pump
0
Air Screen ISfbEI
0
Exhaust System
0
Engine Hoses
0
Raw Water Pump
Heat Exchanger
10
Coolant System
Fuel Filter
Inlet fuel Filter
CAUTION: When servicing or replacing DC
components, tum off the 20 amp DC circuit breaker.
0
0
0
0
0
0 0 0 0 0
0 0 0 0 0
1010
0
DID
0 0 0
0 0
[J
0 0
0 0 0
0 0 0 0 0
0
10
0 0 0 0 0
0 0 0 0 0
Engines & Generators
10
electrical connections. Keep bolts & nuts tight. Check
for loose belt tension.
Check gap, inspect for burning and corrosion.
Every 50 operating hours check electrolyte levels
and make sure connections are very tight. Clean off
excessive corrOSion.
Initial engine oil and filter change at 50 hours, then
change both every 100 hours.
Check that AC connections are clean and secure with
no chafing-see GENERATOR INFORMATION.
Periodically inspect for leaks, electrical connections
are clean and tight.
Clean at 50 hrs., then every 100 hours.
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.
Hose should be hard & tight. Replace if hoses
become spongy. Check and tighten all hose clamps.
Remove the pump cover and inspect for wear.
Inspect impeller, cam and wear plate. Replace gasket.
Lubricate impeller when reassembling.
Clean or replace anode. Open heat exchanger end
cap and clean out debris. Remove every 1000 hours
for professional cleaning and pressure testing.
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
Change every 250 operating hours.
Change every 250 operating hours.
(continued)

MAINTENANCE SCHEDULE
CAUTION: When servicing or replacing DC
components, tum off the 20 amp DC circuit breaker.
NOTE: Use the engine hourmeter gauge to log your engine hours or record your
engine hours
by running time.
SCHEDULED
CHECK
HOURS OF OPERATION
MAINTENANCE
EACH
DAY 50 100 250 500 750 1000 1250
"'Starter Motor
0
Distri b utor
0 10
*Engine Cylinder
0 0
Compression and
Valve Clearances
*Engine Timing Belt
0
*Exhaust Elbow
0
Catalytic Converter
0
"'Exhaust System Back
0
Pressure
Catalyst
0
-
Oxygen Sensor
0
CO in Exhaust
0
*WESTERBEKE recommends this service be performed by an authorized mechanic.
r
41"
I
MEASURING EXHAUST BACK-PRESSURE •
i
EXHAUST MANIFOLD
,
ADJUSTABLE
CLAMP
INSTALLING A NEW
CATALYST
Engines & Generators
11
MAINTENANCE DESCRIPTION
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
Check ignition timing. Check condition of distributor
cap and rotor.
Incorrect valve clearance will result in poor engine
performance, check compression pressure and
timing and adjust valve clearances.
Remove and replace every 1000 hours.
NOTE: Failure to replace the timing belt at the
recommended inteNal could result in timing chain
failure resulting in major damage to the engine.
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteriorated.
NOTE: A defective exhaust elbow can cause
carbon monoxide leakage!
Remove water injected exhaust elbow and visually
inspect. Replace every 2000 hours.
Perform back pressure test to ensure system is not
developing restrictions that will increase pressure
above 1.5 PSI or 41 inches of water column at full
operating amperage load. Correct as needed.
Remove water injected exhaust elbow and visually
inspect every 2000 hours. Replace as needed.
Inspect every 1000 hours. Replace every 2000 hours.
Sample with CO analyzer.