Westerbeke 20.0KW sbeg User manual

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OPERATORS MANUAL
20.0 KW SBEG and SBEGA • 60 HZ
16.0 KW SBEG and SBEGA • 50 HZ
22.5 KW SBEG and SBEGA • 60 HZ
18.7KW SBEG and SBEGA • 50 HZ
. MARINE GASOLINE GENERATORS
I SINGL TH E PHASE
.: :
NO. 049800
REVISIONS
DECEMBER 2009
Ultra-Low Carbon Monoxide Emissions

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

A WARNING
bhaust gasses cuntaln &arblln Mllnllxide, an IIdllTless and
CIIIIItIess fIllS. t:arbIIn Mllnllxide ispllisllnllus and can cause
unt:tmst:IIIUSlless and death. Sympt/llllS lit Carblln Mllnllxlde
IIXpIISIIItI can include:
• DlzzfIlBSS •
Throbbing in Temples
• fifaIIsa
.Ilfadaehe •
Muscular '/WItching
• Vllmlting
• Weatness and Sleepiness
• Inability til Think Cllherently
IF YOU OR AIIYDNE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
IIET DUT INTO THE FRESH AIR IMMEDIATELY. "symptllms persist,
see/r medIcal attentilln. Shut dllwn the unit and dll nllt restart
until It has been Inspected and TIJfIIIlred.
A WARNING DECAL is provided by
WESTERBEKE and shlluld be fixed tila
bulkhead near Yllur engine lit generatllT.
WESTERBEKE afstJ recllmmends installing
CARBON MONOXIDE DETECTORS In the
livfnJ!sleeplng quarters lit Yllur vessel.
They are inexpensive and easily
IIbtainable at Yllur IlIcal marine stllre.
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
ImODUCTION
Retul this safety manual carefully. Most accidents are
caused by failure to follow fundamentol rules and precau-
tions. Know when dangerous conditions existand take the
necessory precautions to protectyourse//, your personnel,
and your machinery.
Thefollowing safety instructions are in compliance with
theAmerican Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
.
A WARNING: Do nat touch AC electrical connectiollS
,.,,1111 engine Is running. Lethal JOltage Is present at
Ihese I:Dllnectlons!
• 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
tulIIIIIsI sy.stem components. A running engine gets
relJhIIt!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• Incase 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 pennit flames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump, orother 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 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 of debris to minimize the
chances of
fire. Wipe up all spilled fuel and engine oil.
• Be aware -Diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• 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 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 starling 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
re-installed before starting the engine.
Engines & Generators

SAFETY INSTRUCTIONS
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection tenninal 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 tenninals 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 off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACIO
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
off at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
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 of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer
for installation ofapproved detectors.
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. fnhalation 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 of the
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 or jewelry when servicing
equipment; tie back
long hair and avoid wearing loose
jackets, shirts, sleeves,
rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places
at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally or physically Incapacitated by fatigue!
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 infonnation. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOUNE 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 Exbaust 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
~ WESTERBEKE
Engines & Generators
iii

CARBON MONOXIDE "CO" ISAFE-CO GENERATORS
IMPORTANT INFORMATION
DESCRIPTION
Carbon monoxide "CO" is a component of engine exhaust. It
is a colorless, tasteless, odorless, lighter than air poisonous
gas
that can kill you without any warning. CO poisoning is
one 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)
1_ ppm Is the so-called IDLH concentration -
IMllElllAmy DANGEROUS TO UFE AND HEALTH.
Acity in Califomia characterizes the effect of CO
concentration this way:
Parts per Million
Responses
25 Pennissible exposure level, no
apparent toxic symptoms.
100 No poisoning for long period.
Allowable for several hours.
200 Should
not be exposed above
this level for any period of
time. A possible mild frontal
headache in two to three hours.
Even though Westerbeke Safe·CO generators are designed
to
reduce normal levels 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 turn it
off, assuming it is a false signal. You can not taste, smell, or
otherwise detect
CO. Leave the detector on, turn 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 stem swim platform, concentrations will
potentially rise
to the undiluted level emanating from the
exhaust system due
to a lack of fresh air to dilute the exhaust
gas. Therefore, one should never rely
on dilution of the
exhaust
to provide a margin of safety.
Westerbeke Safe·CO generators achieve
an approximate 99%
reduction of typical CO by precise control control of the
engine's air/fuel ration coupled with after treatment
in a
special catalyst. CO emissions are not the same for every
model because each engine
is different. Also, certain fuel
system components are commonized across several engine
models being adequate for some and extra·adequate for
others,
thus producing different CO levels for different
models.
The
fuel system which accomplishes the required precise
air/fuel ratio control is comprised of many different
components: purchased sub·assemblies, machined castings,
sensors, electronics and others. Because
of the extreme level
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 deject and is nof
covered under warranty. neither Westerbeke~ nonnal
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
of the catalyst at the prescribed intervals is
critically important. The exhaust elbow is removed by
loosening the metal clamp to provide a view of the output
surface
of the catalyst. Any visual irregularity of the normal
flush, honeycomb appearance is most likely a result of water
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 performance will degrade over time. As the
generator accumulates operating hours,
CO concentrations
will increase. The catalyst MUST be replaced every 5000
bours
of engine operation or earlier if CO testing so
indicates.
Verification
of satisfactory COlevels must he done
seasonally
or eacb 1,000 hours (which everoccurs 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 ofthe analyzer, safety concerns over
temperatures involved
or the possibility of high levels of CO.
The other location is the boat's exhaust outlet, which
contains entrained cooling water (except dry stack exhaust
systems).
Only analyzers with probes should be used at this
location and it is critical that the probe not ingest water.
Probe-type analyzers have an air pump drawing a gas sample
through the probe. As a result, they tend to ingest water when
it is present. Be sure to aim the probe downwards with the
opening pointed in the direction of the water flow and just
out
of the flow. Position the analyzer as high as possible with
the tubing leading to the probe running continuously down-
hiD. Observe the usually translucent tubing between the
probe and the analyzer and be sure no water is being
ingested.
If any water is ingested into the analyzer, it must be
repaired or replaced and recaIibrated.
When measuring CO at the exhaust outlet be aware of the
ambient CO level by also measuring CO away from and
upwind of the exhaust outlet, especially in marinas. the CO
level at the exhaust will be influenced upwards by the
ambient level.
EXHAUST MANIFOLD
ADJUSTABLE
ClAMP
INSTAllING A NEW
CATALYST
Whenever taking the time to verify proper CO concentration
from the exhaust with a CO analyzer, always take the
opportunity to use the analyzer to "sniff' around the engine
lOOking for CO from exhaust leaks. Pay close attention to the
connection of the cylinder head to the exhaust manifold, the
exhaust manifold to the water injected exhaust elbow, and all
subsequent downstream exhaust components and hoses.
Remember, exhaust gas that has not yet passed through the
catalyst is raw, untreated exhaust and is very high in CO
content.
Analyzers usually require periodic calibration. Follow
the
instructions that come with the analyzer very carefully
regarding calibration.
The following
are manufacturers that offer CO analyzers:
Extech, TIF, Testa, 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 of transparent
tubing. They are slightly more expensive than those with the
sensor built into one end of the analyzer, but they allow you
to sample the exhaust coming out of the boat's exhaust outlet.
I
POSITION THE CLAMP OVER
THE TWO FLANGES (AND GASKET)
AND TIGHTEN
~~~SECURELY
Test run unit and verify
no exhaust leakage.
-.¥' WESTERBEKE
Engines & Generators
v

EMISSIONS
This geoset 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
gense!. If you are unsure that the installation, use,
maintenance or service ofyour genset is authorized, you
should seek assistance from an approved WESTERBEKE
dealer.
Califomia users ofthis genset should be aware that
unauthorized modifications or replacement of
fuel, exhaust,
air intake, orspeed control system components that affect
engine emissions are prohibited. Unauthorized
modification,
removal or replacement of the engine label is prohibited.
Federal Emilsions Compliance Period: The Federal
Emissions Compliance Period referred
to on the nameplate
indicates the number ofoperating
hours for which the engine
has been shown to meet Federal Emissions requirements.
Catagory C= 250 hrs, B=500 hrs,m A
=lOOO.hrs.
California genset users may use the table below as an aid in
locating information related to the California Air Resources
Board requirements
for emissions contro1.
EMISSIONS CONTROL INFORMATION TABLE
The California emissions control warranty statement is located in the same
Emissions Warranty Information packet, if information
as this manual when the genset is shipped from the
factory.
Engine Fuel Requirements The engine is certified to operate on unleaded gasoline. See FUEL
RECOMMENDATIONS.
Engine Valve Adjusbnent See MAINTENANCE SCHEDULE.
Engine Ignition Timing See MAINTENANCE SCHEDULE.
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS.
EngineAdjusbnents 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.
~ WESTERBEKE
Engines & Generators
vi

INSTALLATION
EMISSION·RELATED INSTALLATION INSTRUCTIONS
"Failing to follow these instructions when installing a certified engine in a piece of non mad
equipmentviolates federal law (40 CFR I068.I05(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.COMandfoliow
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:
20.0SBEGA
22.5 SBEGA
Tosample 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
ofany Westerbeke product in any manner inconsistent with its intended use could be a violation of
Federal Law.
"Iryou 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
speclOed
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 of62 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
§I048.245(e)(I)(i)"•
To comply with 40 CFR 1048.245 (I) (i) "Use a tethered or self-closing gas cap on a fuel tank tltat
stays sealed up to a positive pressure of24.5 kPa (3.5 psi); 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."
Engines & Generators
vii

. I
;
INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following infonnation:
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
Forinstallations 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 mw water supply hose to the exhaust elbow. This hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use asiphon-break when
theex/uuut manifold injecoon port is at or beww the wad waterline will result in
row water dJunage 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 opemting conditions, instaU 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.
Engines & Generators
v,iii
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
20KW SBEG/22.5KW SBEG Parts Identification ............. 2
Introduction ................................................................ .3,4
Fuel, Engine 011 and Engine Coolant ............................. 5
Preparations for Initial Start·Up .................................... 6
Operating Instructions .................................................... 7
Generator Control Panel ..........................................7
Remote Control Start/Stop Panel.............................7
Break·ln ProcedureJDaily Operation .............................. 8
Safety Shutdown Sensors/Switches ............................... 9
Maintenance Schedule ............................................ 1 0, II
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
Bleeding the Fuel System ...................................15A
Electronic Fuel Injection (EFI)..............................16
Engine Lubrication Oil .................................................. 17
Changing the Engine OiL .................................... .!7
Replacing the Oil Filter..........................................17
011 Pressure ................................................................... 18
Testing Oil pressure ............................................... 18
Remote 011 filter (Optional) ......................................... .!9
Timing Belt Inspectlon/lnstallation ........................ 20,21
Engine Adjustments ...................................................... 22
Spark Plugs ............................................................22
Drive Belt Adjustment ...........................................22
Engine Compression Test.......................................23
Valy~ CI~~nce Adjustment..................................24
Igmhon
hmmg .......................................................24
Torquing
the Cylinder Head Bolts.........................24
Generator Information ................................................. .25
Tbe SBEG Generator (Single and Three Phase) ........... 26
Internal Wiring Schematics
(Single and Three Phase) ............................................ .27
Generator AC Voltage Connections .................. 28, 29 30
SBEG lI'oubleshootlng .................................................. .31
Generator Voltage Regulator Adjustments
(Three Phase) ............................................................... .32
Shore Power Transfer Switch ...................................... .3 3
20IW SBEG and 22.5KW SBEG
Generator Wiring Diagram #49232 ........... ................... .34
R_Dle Control Panel
Wiring Diagram #49209 ................................................ 35
Engine lI'oubleshooting ................................ .36,37,38,39
Lar'Up and Recommissioning ............................ .... 040,41
20KW SBEG and 22.5KW SBEG
Generator Speclficatlons ........................................ A2,43
Torque SpeCifications ................................................. ..44
Standard and MetriC Conversion Oata ....................... ..45
Metric Conversions ................................ ...................... 046
Suggested Spare Parts .. ............................................... 047
... WES'lPRBEKE
Engines & Generators
1

FRONT
REAR
20KW SBEG/22.5KW SBEG PARTS IDENTIFICATION
OIL FilL CAP
DlITRIBIIJOR ---4-_
on ...
SEIISOR IWI) ~~~~~tl--:;:lkLll.~@?),
LEFT SIDE
COOLANT FILL
(MANIFOLD PRESSURE
PANEL
EXHAUST ELBOW
CIRCUIT
BREAKER
-\li~hl- EXHAUST
TEMPERATURE
SWITCH
EXHAUST
CONNECTION
MOUNT
AIR BLEED
BREAK
I
CAP) FILL CAP
COIfTROL
RAIL
RIGHT SIDE
IN-LINE
FUR FILTER
~ WESTERBEKE
Engines & Generators
2
}HERMIOSTAT ASSEMBLY
WATER
REAR
FRONT

INTRODUCTION
This WESTERBEKE Generator is a product of
WESTERBEKE's
long years of experience and advanced
technology. We take great pride in the superior durability and
dependable perfonnance ofour 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
WESTERBEKFJUNIVERSAL 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 conunission date.
,...,.",WESTERBEKE
, E,nglnes & Generators
CUskdnerIdentification
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, 0=1990's, E=2000's), the second
character represents the year in the decade, and
the fourth
and fifth numbers represent the month ofmanufacturer.
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
CONTENTOF SUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH
RESPECT THERETO, INCLUDINGACCURACY,
TIMEUNESS OR COMPLETENESS THEREOF AND
WILL IN NO EVENT BE UABLE FOR ANY TYPE OF
DAMAGE OR INJURY INCURRED IN CONNECTION
WITH OR ARISING OUTOF THE FURNISHING OR
USE OFSUCH 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 detennine the accuracy and currentness ofthe
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 and/or ordering repair parts.
Fill in the information for your own reference. Jl:n
Engines & Generators
3

INTRODUCTION
The engine/generator model number and serial number are
located on a plate mounted on the engine's valve cover. f!JJ
UNDERSTANDING THE GASOLINE ENGINE
The gasoline engine driving an AC generator is in many ways
similar to a gasoline automobile engine. The cylinders are
. verticle in-line, and the engine's cylinder head has an 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 thermostatically controlled. To a large degree, the
generator's engine requires the same preventative maintenance
that is required of a gasoline automobile engine. the most
important
factors to the generator's longevity are proper
ventilation, maintenance of the fuel system, ignition system,
cooling system and the generator 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 information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result In the damage or destruction of 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 e.lficient well-designed exhaust system that includes an
anti-siphon break to prevent water from entering the
engine.
• Changing the engine oil and oil filters every 100 operating
hours.
• Proper maintenance of all engine and generator
components according to the maintenance schedule in
this manual
•
Use clean, filtered unleuded fueL
• 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
GASOUNE
A Only use unleaded gasoline with an
.. CAUTION: Oetane rating of#89 or higher. A
.lowerOctane rating may result in a power loss.
Leaded fuels will harm your
CO system and engine
.and will void unit warranty.
Care Of The Fuel Supply
Usc only clean, well filtered gasoline. The passages in the
carburetors and the clearances in the fuel injection equipment
are very critical for proper fuel flow. Small contaminants not
captured in the primary filter/water seperator can clog these
passages and affect these clearances, 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 usc
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, SL or SM. Change the engine oil and filter after an initial
SO hours of engine break-n operation. Then follow the oil and
filter change intervals as specified in the MAINTENANCE
SCHEDULE in this manual.
Westerbeke Corporation does not approve or disapprove the
use
of synthetic oils. If synthetic oils are used, engine break-in
MUST be performed using conventional oil. Oil change
intervals must be as listed
in the MAINTENANCE
SCHEDULE section in this manual and not to be extended if
synthetic oils are used.
NOTE: The information above supersedes all previous
statements regarding synthetic oil useage.
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 engme to the coolant. It also lubricates and protects the
cooling circuit from rust and corrosion. Use a good quality
antIfreeze that contains supplemental cooling additives (SCAs')
that keep the antifreeze chemically balanced, crucial to long
tenn protection.
The water and antifreeze should be premixed before being
poured IOta the cooling circuit.
NOTE: Use the new environmentally{riendly, long lasting,
antifreeze that is now available.
A proper SO/50 mixture as recommended will protect the
engine coolant to temperatures of -40°F.
ANTIFREEZE PROTECTION CHART
Antifreeze concentration 23% 30% 35% 50%
Freezing Temperature 14° F 8' F
_4' F -40' F
(-10'C) (-13'C) (-20'C) (-40'C)
COOLANT RECOVERY TANK
Acoolant recovery tank kit is supplied with each generator.
The purpose of this recovery tank is to allow for engine
c~olant expansion and contraction during engine operation,
WIthout the loss of coolant and without introducing air into
the cooling system.
~ WESTERBEKE
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
~P:LA~cS;DTliiECliCyOOLANT
HI TANK
THIS LINE RETURNS
COOLANT TO THE ENGINE
PRESTARTINSPECTION
EXHAUST MANIFOLO
Before starting your generator for the first time or after a
prolonged
layoff, check the following items:
• Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
NOTE: The starting battery must be totally dedicated to the
generatorandmaintained
by the generator~ DC charging
altemalor and no othersource.
• 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
~ cooling system will be purgedto 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 ~ cooling system to
replace the purged air.
Before subsequent operation of the generator, the engine ~
manifoldshould be topped off and the coolant recovery
tank's level brought to
114 full.
MANIFOLO PRESSURE CAP
I BLEED
OIL DIPSTICK
• Visually examine unit. Look for loose or ntissing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
• Check load leads for correct connections as specified in
the wiring diagrams.
• Examine the air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
the load lines.
• Be sure that in power systems with a neutral line that the
neutral is properly grounded (or ungrounded) as the system
requires, and that generator neutral is properly connected
'to the-load neutral. In single phase systems an incomplete
or open neutral can supply the wrong line-to-neutral
voltage on unbalanced loads. ..
• Make certain the raw water thru-hull is open.
A CAUTION: When starting the generator, it is
recommended that all AC loads, especially large
motors, be switched OFF until the engine has come
up to speed and, in cold climates, starts to WBmI 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 off the 20 amp DC circuit breaker.
START SToP
=
'EMIERGIENCY STOP
o
AND FIREBOY
LED FAULT CONNECTIONS
INDICATOR
STOP SWITCH
LIGHTS
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
astationary 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.
Agreen light will glow indicating the generator is running.
Stopping
Depress the (STOP) side of the start switch, the green light
will go out and the generator is stopped.
Failure to Start
The start cycle will automatically terminate if the unit fails to
start after 5-6 seconds ofcranking. Wait 20 seconds, then
repeat the start.
Ifthe unit again fails to start, investigate the cause. Sometimes
after servicing the fuel.system or changing the fuel filter, air
can accumulate in the fuel line or the throttle body and prevent
starting.
The Schrader valves on the throttle body and the fuel cell are
used to remove trapped air. This air is mixed with fuel and
under high pressure. Follow the BLEEDING THE FUEL
CHECK ENGINE LIGHT
The check engine light indicates a potential 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. A three position start/stop rocker switch.
2. A green LED run indicator light on the rocker switch.
3. A four position LED fault shut down display board.
The start/stop rocker switch functions the same as the start/stop
rocker switch on the generator'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 will 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 generator shut down from one of these faults, the
fault LED will remain illuminated. To reset the LED, the DC
breaker on the control box must be turned OFF and then back
ON.
This remote panel is a plub-in accessory and is available with a
15' to 100' wiring harness.
SYSTEM instructions in this manual.
,. WESTERBEKE
Engines & Generators
7

BREAK-IN PROCEDURE/THE DAILY OPERATION
BREAK·IN PROCEDURE
Afterthe genemtor has been started, check for proper
operation
and then encoumge a fast wann-up. Run the
generator between 20% and 60% offull-load for the first
10 hours.
. A CAUTION: DII nllt attempt til break·ln Yllur
generattJt by running wlthllut a Iliad.
Afterthe first 10 hours of the generators opemtion, the load
can be increased to the full-load mted 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 genemtor and keep
it within the genemtors mting. Since the generator opemtes at
1800 rpm to produce 60 hertz, control of the generator's
engine break-in
is govemed by the current drawn from the
generator.
To protect against unintentional overloading of the gen~rator,
the genemtor's output leads should be routed through a
circuit breaker that
is rated at the mted output of the
generator.
NOTE: Be aware of motor starting loads and the high current
drawn requiredfor starting motors. The starting amperage
drawn can be 3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
CHECKLIST
Follow this check list each day before starting your generator.
• Record the hounneter reading in your log (engine hours
relate to
the maintenance schedule).
• Visually inspect the genemtor 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 abnonnal 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 enginoe.
This condition should lessen as normal operating temperature
is reached and loads are applied.
A CAUTION: DII nllt IIperate the generator fill Illng
perillds IIf time withllut a Iliad being placed on the
generatlll. .
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 schedulefor 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 cruisingspeed.
"S¥ WESTERBEKE
Engines & Generators
8

SAFETY SHUTDOWN SENSORS AND SWITCHES
SAFm SHUTDOWN SWITCH/SENSORS
The engine is protected by four automatic shutdown circuits.
Should a shutdown
occur, do notattempt to resflJtt without
finding and correctingthe cause. Refer to the heading
Engine statts, runs and then shuts down in the ENGINE
TROUBLESHOOTING section ofthis manual.
The following is a description of these automatic shutdown
circuits:
lil.-. 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 26(}.270F (I27-132C). This
switch resets (contacts close) at approximately 225F (I07C).
HIGH EXHAUST
. nMPERATURE SWITCH
water Temperature Sensor
If
fi
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.
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 paneJ 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.
Hlgh/Low RPM Shutdown
Should the generator's RPM go above 20% of the specified
1800 rpm @ 60 HzJI500 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% ofthe specified
1800 rpm @ 60 HZ/15oo 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