Westerbeke 22.0 EDE 60Hz User manual

OPERATORS MANUAL
D·NET DIESEL GENERATORS
22.0 EDE 60Hz 17.0 EDE 50Hz
.17 .0 EDE 60Hz 13.5 EDE 50Hz I
Single 31J ree Phase
PUBLICATION NO. 053852
REVISION 5
MARCH 2015 ·
jr~ 'WESTERBEKE
j WESTERBEKE CORPORATION •150JOHN HANCOCK ROAD
j MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE: WWW.WESTE:RBEKE.COM
---
NMMA Member National Marine Manufacturers Association
--- . . _..

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 DR 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 and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protectyourself, your
personne~ and your 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
cov~rs 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.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Monitor engine antifreeze coolant level at. the_ plastic
coolant recovery
tank and periodicaly at thC? filler cap
location .on the waterjacketed exhaust manifold, but only
when the engine is COLD.
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 fuel injector, fuel line, filter, fuel
pump;
or other potential sources of spilled fuel or fuel
vapors.
Use a suitable container tq catch all fuel when
..removing the fuel lines
or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire
can cause severe injury or death.
• Do not smolce or permit flames or sparks to occur near
the fuel system.
K~IJ the compartment and the
engine .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 de;i_t/J!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate the cabin
after fueling. Checkbelow for fumes/vapor oefore running
the blower.
Run the engine compartmentblower priorto
starting, follow the recommendation
of thevessel builder.
• 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 while it is running.
• Shut offthe 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 orengine 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 shutoffvalve.
• Be certain fuel line fittings are adequately tightened and
free
of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained.
Be familiar with its proper use.
ExtinguisHers rated
ABC by the NFPA are appropriate
for all applications encountered in this environment.
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
• To prevent accidential starting when servicing the genera-
tor, turn OFF the DC breaker or remove the fuse
from the generators control panel.
• To prevent accidential starting ofthe generat.:m ,,
when servicing, turn the battery selector switch 'to the
OFF position.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatch«?S are
re-installed before starting the engine.
BATIERY EXPLOSION
A WARNING: Battery expiBsion 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 offall electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative(-) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation 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
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
A WARNING: Accidental starting can cause injury
or death!
BATIERYACID
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. Ifit comes in contact with your sk;in, wash it
off
at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust
manifolds/water-injected elbow is securely attached.
• Be sure the unit and its sun:oundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) i' 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, yents, or airconditioners. If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow ofexhaust. Avoid overloading the craft.
IIi 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 orsigns ofcarbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing
in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while itis running. If a
situation_ arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loose jackets, shirts, sleeves,
rings, necklaces
or bracelets that could be caught in
moving parts.·
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards
in their respective
places
at all times.
• Do not check fluid levels or the drive belt's tension while
the engine
is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine
is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
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.
A WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings arc 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.
ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination
of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections
of the ABYC standards of particular interest are:
H-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion of Exhaust Systems for Propulsion
and Auxilliary Engines
P-4 Marine Inboard Engines and Transmissions
E-ll AC & DC Electrical Systems on Boats
TA Batteries and Battery Chargers
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING MARINE ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your UNIVERSAL engine
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
ABYC
613 Third Dtreet, Suite 10
Annapolis, MD 21403
( 41 0) 990-4460
www.abycinc.org
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1 Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9101
USCG (United States Coast Guard)
"CFR 33 AND CFR46"
Code of Federal Regulations
Order From:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

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 code~ mu_st 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" inust be made tO. install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifc!ld injection port is at or below the load waterline will result in
raw water damage to the engine andpossibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions~ install a
siphon-b~ak.
NOTE: A siphon-break requr,.;,s periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine dimuige.' Corisult the siphon-break manufacturer for proper maintenance.
EXHAUST .SYSTEM
. .
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
SfPHON-BREAI( WITH STAINLESS
LOOP"
The exhaustsystem's hose MUST be certified for marine use. Corrugated Marine
Exhaust Hose is recommended. The use of this type of hose allows for extreme bends.
and turns without the need of additional fitting and clamps to accomplish these bends ..
and turns. In this regard, a single length of corrugated exhaust hose can be used. The
system MUST be designed·to prevent the entry ofwaterinto the exhaust system
under any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification .................................................... 2
Generator Information ............................................. .31
Introduction ................................................................ 3
Electronic Regulation ............................................... 32
Fuel, Engine 011 and Engine Coolant ......................... 5
Internal Wiring Diagram ........................................... 33
Preparations for Initial Start-Up ................................ 6
Generator Wiring Schematics .................................. 34
Digital Control Panel .................................................. 7
Digital Control Box (Earlier Model 9~) ....................... 9
Generator Break-In Procedure ................................. 10
Da;ty Routlna .......................... : ................................. 10
Maintenance Schedule (Chart):................................ ll
Fuel System .............................................................. 13
Cooling System ....................... " .................................. 15
Raw Water Intake Strainer.................., ............. 15
Heat Exchangl!r .................................................. 15
Thermosta.t .......................................................... 16
Raw Water Cooling Circuit ............................... 17
Changing the· Coolant......................................... 17
Raw Water Pump ............................................... 18
Air Intake Silencer............................................. 18
Engine Lubricating 011 .............................................. 19
Engine Oil Change............................................. 19
Schematic· Rotating Field/Exciter Rotor ................ 35
Twelve Lead Winding Connections .......................... 36
Changing Hertz and Voltage ..................................... 37
BE Troubleshooting (Chart)....................................... 38
Exciter Rotor Troubleshooting ................................. 39
Generator Servicing ................................................. .40
Generator/Maintenance Parts Breakdown ............. .41
Power Transfer Switch ............................................. 43
Lay·Up and Recommissioning ................................. 44
w· · o·
tnng •a grams ....................................................... 46
#53731 -12V .....................................................46
#52951 -12V
Three Phase................................ .47
#53829 -24V Single Phase .. ;............................. 48
#54544- 24V NMEA 2000................................ 49
#53901- 24V NMEA 2000................................50
#54577- 12V Single Phase................................. 50A
Testing Oil Pressure ...........................................20
Engine/Generator Specifications
Engine Troubleshooting (Chart) ................................ 21
22.0/17.0 EDE .................................................... 51
LCD·Display Faults .................................................... 22
17.0/13.5 EDE....................................................52
Alternator Testing ..................................................... 23
Generators .......................................................... 53
Battery Care ....................................................... 25
Engine Adjustments .................................................. 26
Valve Adjustments..............................................26
Remote Stop/Start Switch ........................................ 54
Remote Oil Filter ...................................................... 55
Glow Plugs .........................................................27
Water Heater Connections ....................................... 56
Drive Belt Adjustment ....................................... 27
Fuel Injectors ............................................................ 28
Injection Testing.................................................28
Metric Conversion Data (Chart) ............................... 57
Suggested Spares ..................................................... 59
Starter Motor ............................................................ 29
Troubleshooting..................................................30
Engines & Generators
1

PARTS IDENTIFICATION
ECU CONNECTIONS·......___
REMOTE S/5 r-1\NII:L.·~
CONNECTION
THER.MOSTAT -------;~
ASSEMBLY
RAW WATER
COOLANT PUMP
OIL DRAIN HOSE
FRONT
COOLANT PRESSURE CAP.
HEAT
AIR
DIGITAL rnliTDn!o...-
PANEL
20A
DC BREAKER
REAR
MOUNTS
Engines & Generators
2
LEFT SIDE
OIL FILL
RIGHT SIDE
ISOLATED
INTAKE
ELBOW
N PUMP

INTRODUCTION
This WESTERBEKE Engine 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 engine, 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 engine require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This
is your Operators Manual. A Service Manual is also
available in hard copy thru a dealer or
in pdfform off our
website.
If you are planning to install this equipment your-
self. Review the Installation Manual supplied with this
product.
Customer Identification Card
I...,IWESTERBEKE
1 Engines & Generators
Customer Identification
WESTERBEKE
OWNER
MAIN STREET
HOMETOWN, USA
Model Ser. #
Expires
WARRANTY PROCEDURES
Your WESTERBEKE Warranty Policy Statement is included
in the product documentation package. There is a mail in
warranty registeration card that you can fill out and mail in to
register your warranty or go to our website www. wester-
beke.com
and register your product's warranty online. You
should receiye a Customer Warranty Registeration Card in
the mail within 60 days ofregistering. Ifyou do not, please
contact the
factory via [email protected] advising of this
and providing your name, unit model, serial number and date
unit was put into service.
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 customers should also keep in mind the time
span between printings ofWESTERBEKE product
software and the unavoidable existence ofearlier
WESTERBEKE manuals. In summation, proquct software
provided with WESTERBEKE products, whether from
WESTERBEKE or other suppliers, must not and cannot
be relied upon exclusively as the definitive authority on
the respective product. It not only makes good sense
but is imperative that appropriate representatives of
WESTERBEKE or the supplier in question be consulted
to determine the accuracy and currentness of the
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour marine
engine, 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 p~perly 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 engine capable of many thousands
of hours ofdependable service. However, the manufacturer can-
not control how or where the engine is installed in the vessel or
the maimer 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 a long engine/generator life.
• Proper engine installation.
• An efficient, well-designed exhaust system that includes an
anti-syphon break to prevent water from entering the engine.
• Changing the engine oil every 250 operating hours.
• Proper maintenance of all engine components according to the
maintenance schedule in this manual.
• Use clean, filtered diesel fuel.
• Winterize your engine according to the lAY-UP AND
RECOMMISSIONING section in this manual.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model number and serial number are located on
an I.D. plate that
is mounted on the side of the water jacketed
exhaust manifold. The engine serial number
is also stamped
into the engine block on the flat surface just outboard ofthe
fuel injection pump. Take time
to enter this information on
the illustration below. It will provide a quick reference when
seeking technical information and/or ordering needed parts.
0 HZ.
60HZ.
An identification plate on the engine manifold also displays
the engine model and selial number.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters. Carbon monoxide,
even in small amounts, is deadly.
The presence of carbon monoxide indicated an exhaust leak
from the engine or generator or from the exhaust
elbow/exhaust hose, or the fumes from a nearby vessel are
entering your boat.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal
in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism
is essentially the same. The cylinders
are arranged above a closed crankcase; the crankshaft
is of
the same general type as that of a gasoline engine; and the
diesel engine has the same type
of valves, camshaft, pistons,
connecting rods and lublicating system.
Therefore,
to a great extent, a diesel engine requires the
same preventive maintenance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance ofthe fuel, lubricating and cooling systems.
Replacement
of fuel and lublicating filter elements at the
time periods specified
is a must, and frequent checking for
contamination (that is, water, sediment, etc.) in the fuel
system
is also essential. Another important factor is the use
of the same brand of high detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method
of handling and firing of fuel. The
carburetor and ignition systems are done away with and in
their place
is a single component -the fuel injection pump
which performs the function
of both.
ORDERING PARTS
Whenever replacement/service parts are needed, always
provide the generator model number, engine serial number,
and generator selial number
as they appear on the silver and
black name plate located on the generator end. You must
provide us with this information so we may properly identify
your generator set. In addition, include a complete part
descliption and part number for each part needed (see the
separately furnished Parts List). Also insist upon
WESTERBEKE packaged parts because willfit or generic
parts are frequently not made
to the same specifications as
oliginal equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator.
Your local WESTERBEKE
dealer will assist you in preparing
an inventory ofspare parts.
See the
SPARE PARTS page in this manual. For Engine and
Generator Accessolies, see the ACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed information for
installing generators.
Engines & Generators
4

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER.
(No. 2-D (SAE J313) diesel fuel according to ASTM 0975).
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your fuel injection pump is very critical; invisible 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
i~ clean and pure, the following practice is
advisable:
Purchase a well-known brand
of fuel.Install and regularly
service a good, visual-type fuel filter/water separator between
the fuel tank and the engine. The Raycor 500
MA or 230
RMAM are good examples of such filters.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF,
CG-4, CH-4 or CI-4. Change the engine oil and filter after an
initial 50 hours
of break-in operation. Then follow the oil and
filter change intervals as specified in the
MAINTENANCE
SCHEDULE in this manual. Westerbeke Corporation does
not approve or disapprove
of the use of synthetic oils. If
synthetic oils are used, engine break-in must be performed
using conventional oil. Oil change intervals must be as in the
MAINTENANCE SCHEDULE, not extended because
synthetic oils are used.
SAE OIL VISCOSITY GRADES
For all temperatures use SAE 10W-40 or 15W-40.
OIL PRESSURE
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure will range between 35 and
65 psi 2.5 and 3.9 kg/cm2
).
NOTE: A newly started, cold engine can have an oil pressure
reading upwards
of 60 psi (4.2 kg/cm2 >. A wanned engine can
have an oil pressure reading as low as
25 psi (1.8 kg/cm2 >.
These readings will vary depending upon the temperature of
the engine, the load placed on the engine, and the RPM's.
ENGINE COOLANT
WESTERBEKE reconuncnds a mixture of 50% anLifreeze
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, and lubricates and protects the
cooling circuit from rust and corrosion. Look for a good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs) that keep the antifreeze chemically
balanced, crucial to long term protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
PURCHASING ANTIFREEZE
Select a brand of antifreeze specified for diesel engines.
Antifreeze specified for diesel engines contain a special
additive to protect against cavitation erosion
of the engine's
cylinder walls. Prestone and Zerex are two nationally known
brands that offer antifreeze specifically for use in diesel
engines. Select the pre-mix variety so that the correct
mixture will always
be added to the cooling system when
needed. Change the antifreeze mixture according to the
MAINTENANCE SCHEDULE in this manual.
MAINTENANCE
Change the engine coolant every five years regardless of the
number
of operating hours as the chemical additives that
protect and lubricate the engine have a limited life.
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each
engine or generator. The purpose
of this recovery tank is to
allow for engine coolant expansion and contraction during
engine operation, without the loss
of coolant and without
introducing air into the cooling system. This kit is provided
and must
be installed before operating the engine.
NOTE: This tank, with its short run of plastic hose, is best
located at
or above the level of the engine's manifold, but it
can be located below the level
of the engine's manifold if the
particular installation makes this necessary.
Engines & Generators
5 .

PREPARATIONS FOR INITIAL START ·UP
PRESTART INSPECTION
Before starting your generator for the first time or after a pro-
longed layoff, check the following items;
a Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
a Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
a Check the DC electrical system. Inspect wire connections
and battery cable connections.
a 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 bleed petcock to ensure that
the cooling system is purged of air. After shutdown. and
after
the engine has cooled, the coolant from. the recovery
tank will be drawn into the engines cooling system to
replace the purged air.
a Check load lead$ for correct connections as specified in
the wiring diagrams.
a Examine the air inlet and outlet for air flow obstructions.
a Be sure no other generator or utility power is connected to
the load lines.
DIPSTICK
PUSH IN TIGHT
LOW
'ADD OIL
6
W Be sure that in power systems with a neutral line that
the neutral is properly.grounded (or ungrounded) as
tilt:
system requires, and that the generator neutral is properly
connected to the load neutral.
In single phase systems an
incomplete
or open neutral can supply the wrong line-to-
neutral voltage
on unbalanced loads. ·
a ·Make certain the cooling water thru-hull petcock is open.
A CAUTION: When starting the generator, it is
recommended that all AC loads, especially large
motors, be switched OFF until the engine has come
up to speed and, in cold climates, starts to warm up.
This precaution will prevent damage caused by
unanticipated operation of the AC machinery and will
prevent a cold engine from stalling.
KEEP 112 FULL

DIGITAL CONTROL PANEL
DESCRIPTION
LCD DISPLAY
WESTERBEKE'S Digital Control Panel provides the ·
operator with an LCD display that contunuously monitors
all the operations
of the generator in easy to understand
text messages.
Operating temperatures may cause the LCD display to vary
in color. This is normal and a change in color will not affect
the operation on the control panel.
CONTROL BOX
Periodically clean the control panel LCD screen u~ing a soft
cloth.
Note that the design and size
of the control box will vary
depending on the model generator.
12AFUS!=
PROTECTS THE CONTROL PANEL
ELECTRONICS FROM A HIGH
AMPERAGE OVERLOAD.
INDICATOR LIGHTS
SIX LIGHTS THAT INDICATE
WHERE A FAULT HAS OCCUR ED.
~
20A BREAKE~ SWITCH"'-
SHUT-OFF WHEN PERFORMING
MAINTENANCE OR WHEN
REPAIRING A FAULT. RESET TO
RESTART THE ENGINE. FAILURE LIGHT START BUTTON
A RED LIGHT WILL APPEAR IF STARTS THE ENGINE
THE RUN SEQUENCE IS
INTERUPTED BY A FAILURE.
UP AND DOWN ARROWS
WHEN THE LCD DISPLAY IS
IN ITS SCROLL MODE, THE
UP AND DOWN ARROWS CAN
BE USED TO ADJUST THE
DARK AND LIGHT CONTRAST
UP-ARROW
WHEN IN SCROLL LOCK MODE
INDIVIDUAL FUNCTIONS CAN
BE MONITORED BY PRESSING
THE UP-ARROW.
SCROLL LOCK
STOPS RUN SEQUENCE SO·
THAT A SINGLE FUNCTION CAN
BE MONITORED
DOWN-ARROW
··WHEN IN SCROLL LOCK MODE
INDIVIDUAL FUNCTIONS CAN
BE MONITORED BY PRESSING
THE OOWN·ARROW.
PRIME BUTTON
THISBUTTON ENERGIZES THE FUEL
PUMP. AFTER REPAIRING A FAILURE
OR PERFORMING MAINTENANCE,
PRESSING THIS BUTTON WILL PURGE
AIR OUT AND BRING FUEL IN TO THE
LINES.
LCD DISPLAY SEQUENCE ..
IS SHOWN ON THE FOLLOWING PAGE.,.
-----------------------------------------------------------
*MANUAL ENGINE SHUT-OFF
Should the stop button fail in its normal function to stop the
engine, the engine
is equipped with a manual shutdown lever
located on the engine block to the right side
of the injection
pump. Simply hold
the lever to the leftuntil the engine
comes to a complete stop. This shutdown lever
is standard on
current D-Net generators.
7

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DIGITAL CONTROL PANEL/LCD SEQUENCE
START SEQUENCE
With the pre-start inspection completed, press the START
button and the automatic sequence will begin. The six
indicator lights will illuminate green and the panel will
display the following text:
Waiting for operator
~WESTERBEKE
Press start to
I Engines & Generators engage generator
Pre Heating...... Cranking......
7 Seconds
RUN SEQUENCE •
As the display cycles thru the engine functions, the speed
will come up to 1800 rpms-60Hz (1500 rpms-50Hz) and
the oil pressure and engine coolant will rise to their normal
readings. The functions will cycle in the following sequemce:
Engine Speed
1800 RPM
0 2500
SCROLL
-·-·-
Battery Voltage
13.5VDC
0 30
SCROLL
Engine Hours
3~8 HOURS
SCROLL
AC Phase Voltage
A120V
B120V
0 200
---;=-::=!
0 200
SCROLL
Coolant TemperaturP
81C
178F
32 300
0
100
SCROLL
Oil Pressure
3.1
40
-BAR
PSI
0 100
0 6.9
SCROLL
AC Frequency
60.1Hz
0
100
SCROLL
AC Line Voltage
120V 200
0
SCROLL
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STOP SEQUENCE
To stop the generator, press the STOP button. The display
~v ill cyd..: thru th..: fulluwing texlllle~~age~ auJ ~hmJowu.
Shutting Engine Shutdown
Down
Waiting
for operator
Press
start to
engage generator
FAILURE LIGHT/SHUTDOWN
If a problem occurs, the generator will shutdown and the
FAILURE light will illuminate red. In addition, one of the
indicator lights will change from green to orange to reveal
where the trouble has occured and the display will text
message what has happened
Examples:
.----------..
Failure Light is red.
Coolant Temperature Light
is orange.
Failure Light is red.
Oil Pressure Light is orange.
High Engine Temp.
Reset
ECU to Restart
Low Oil Pressure
Reset
ECU to Restart
When a failure occurs, refer to the troubleshooting chart,
wiring diagram, and general operating text
in this manual to
assist in solving the trouble.
There are many combinations
of messages that can be
displayed but they are all selfexplanatory and the operator
can easily isolate and correct the problem should one occur.
Before re-starting the generator, tlie 20 amp
DC circuit
breaker must be reset. With the problem corrected and the
generator started, the sequences will begin cycling again.
~ ¢ NOTE: Three phase voltages will vary depending on the AC
m output configuration of the generator.
""0
AC Phase Voltage AC Line Voltage
AB38QVo 600 0 600
I
AB 380V. I
BC378V
0 600
BC378V
0. 600
CA 380.V0 600 . 0
CA380V
SCROLL
SCROLL LOCK
600
LOCK
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CD
•
To stop the continuing sequence, press the SCROLL LOCK
button. This enables the operator to monitor a single function
for any length
of time. The word LOCK will appear in the
comer. Use the up and down arrows to find and observe other
functions.
To resume scrolling, press the SCROLL LOCK
button again. ·
8
CAUTION: Repeatedcrank cycles without a start can result
in the engine's exhaust systemfilling with raw water. This
raw water can enter the engine's cylinders by way
of the
exhaust manifold.
If after three crankcycles, the unitdoes
not start, drain the system's muffler
and investigate and
correct the cause of no start. Engine damage, the result
of raw water entry, is not a warrantable issue.

DIGITAL CONTROL BOX
FREQUENCY FAULT
Frequency is displayed on the LCD display screen while the
engine is running in RPM'and frequency (hertz).
The ECU is receiving a low AC voltage signal and hertz
signal from the MPU which is positioned on the bellhousing
over the flywheel ring gear teeth. The ECU interprets this
signal as both RPM and hertz.
·· Should this signal vary approximately 2% either up or down,
a frequency fault shut down will occur, initiated by the ECU.
The red failure LED on the display panelwill illuminate,-the
frequency LED will tum from green to amber and the LCD
display screen will show the fault text "overspeed:'
CONTROL BOX I
COMPONENTS
4 ·WAY CONNECTOR/
COMMUNICATIONS CABLE
ARROW ON PLUG
GENERATOR FREQUENCY ADJUSTMENT ·(HERTZ)
1. Tum the DC breaker on the control pllnel to thP OFF
position.
2. Open the cover of the control box and view the ECU
(Electronic Control Unit).
3. Access the opening of the ECU. The dipswitches are
visable in the elongated area of this opening.
4. Access the #1 dipswitch and move it to the position
that corresponds to the hertz operation desired.
The
illustration shows these dipswitches.
5. Plug in the communications cable from your laptop
having the EC20 software. The communications cable
plug connection should
have the arrow on the plug facing
the ECU connections. Reprogram the ECU for the
corresponding
ACvoltage output the generator is being
changed to.
6. Once the change is completed, turn OFF your laptop.
Unplug the communications cable from the ECU.
7. Proceed to page 39A of this manual and follow the
procedures for reconfiguring the
AC voltage output of
the generator that has been selected.
CONTROL PANEL
NOTE: DURING OPERATION THE COLOR
OF THE LCD DISPLAY MAY VARY.
CAUSED BY HEAT. THIS IS NORMAL
AND NO CAUSE FOR CONCERN.
CAUTION (WESTERLINK or NMEA·2000): The electronic components in the Digital Diesels draw a vel)' small amount of amperage (milli-amps) from the
generator's starting battery when the unit is
in a sratic state. This maybe as much as 50 milli-ampsf.or the system ECU and 50 milli-amps for each display.
This can be as much as 72 amp-hours
in a months time with no generator use. It is not necessary to be concerned with this slight amperoge draw during
normal seasonal use. However; ifthe generator set is not to be used
for a number of months, such as winter storage, it is best to disconnect the DCpower
to the generator with a NMEA-2000 system or shut
off the DC breaker C?n the generator~ control box for a WESTERLINK system.
NOTE: Keep in mind that the Westerbeke generator maybe the DC powersupply for the vessels NMEA-2000 nerwork.
9

DIGITAL CONTROL BOX
EARLIER MODELS
FREQUENCY FAULT
Frequency is displayed on the LCD display screen while the
engine is running in RPM and frequency (hertz).
The ECU
is receiving a low AC voltage signal and hertz
signal from the MPU which
is positioned on the bellhousing
over the flywheel ring gear teeth. The ECU interprets this
signal as both RPM and hertz.
Should this signal vary approximately 2% either up or down,
a frequency fault shut down will occur, initiated by the ECU.
The red failure LED on the display panel will illuminate, the
frequency LED will tum from green to amber and the LCD
display screen will show the fault text "overspeed".
DIPSWITCHES
0/PSWITCH #1/S USED TO L.rl, .. IV<C>C
THE FREQUENCY. ON IS FOR 50hz,
OFF IS FOR 60hz. THE REMAiNiNG
SWITCHES #2, #3, an #4 SERVE NO
FUNCTION.
GENERATOR FREQUENCY ADJUSTMENT (HERTZ)
CAUTION: When changing the generatorfrequency setting on
the ECU,
tum off the 20 amp DC circuit breaker on the control
box. Tum it back on after the setting has been changed
1. Thm the DC breaker on the control panel to the.OFF
position.
2. Open the cover
of the control box and view the ECU
(Electronic Control Unit).
3. Locate the
#1 dipswitch on the ECU and move it to the
position that con·espmids to the Hertz operation desired).
See the illustration below showing the ECU
in the
control box.
4. Replace the control box cover, tum the DC breaker ON
and start the unit. Monitor the frequency that the
engine/generator is operating is operating at the correct
frequency.
WIRING HARNESS CONNECTIONS
NOTE: DURING OPERATION THE COLOR
OF THE LCD DISPLAY MAY VARY.
CAUSED BY HEAT, THIS IS NORMAL
AND NO CAUSE FOR CONCERN.
CAUTION (WESTERLINK or NMEA·2000): The electronic componenJs in the Digital Diesels draw a very small amount of amperage (milli-amps)frorn the
ge1ieraror s starting battery when the'unit is in a static state. This maybe as much as 50 milli-ampsfor the system ECU and 50 milli-amps for each display.
11zis can be as much as 72 amp-hours in a months timecwith no generator use. It is not necessary to be concerned with this slight amperage draw during
normal seasonal use. However, ifthe generator set is not to be used
for a number of months, such as willler storage, it is best to disconnect the DCpower
to the generator with a NMEA-2000 system or shut
off the DC breaker on the generators control box for a \VESTERLINKsystem.
NOTE: Keep in mind that the Westerbeke generator maybe the DCpower supply for the vessels NMEA-2000 network.
Engines & Generators
9A

GENERATOR BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine
· operated properly, a break-in time is required. The service
life
of your engine is dependent upon how the engine is
operated and serviced during its initial hours
of use.
Breaking-in a new engine basically involves seating the
piston rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
glazed or scored, which is caused by overloading the
engine during the break-in period.
Your new engine requires approximately 50 hours
of initial
conditioning operation to break in each moving part in order
to maximize the performance and service life
of the engine.
Perform this conditioning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems (raw
water pump, oil pressure, battery charging) are functioning.
AFTER START-UP
Once the generator has been started, check for proper opera-
tion and then encourage a fast warm-up. Run the generator
between 20% and 60%
of full-load for the first 10 hours.
After the first 10 hours
of the generator's operation, the load
can be increased to the full-load rated output, then periodi-
cally vary the load.
Avoid
ove_rload at all times. An overload is signaled by smoky
exhaust With reduced output voltage and frequency. Monitor
the current being drawn from the generator and keep it within
the generator's rating. Since the generator operates at 1800
rpm to produce 60 hertz (or at 1500 rpm to produce 50
Hertz), control of the generator's break-in is governed by the
current drawn from the generator.
NOTE: Be aware of motor starting loads and the high current
draw required
for starting motors. This starting amperage
draw can be 3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may be
governor adjustments required for engine speed (hertz) during
the engine's break-in period (first
50 hours) or after this
period see ENGINE SPEED (HERTZ) ADJUSTMENT) under
ENGINEADJUSTMENTS .. A no-load voltage adjustment
may also
be required in conjunction with the engine's speed
adjustment see GENERATOR INFORMATION.
THE DAILY ROUTINE
CHECK LIST
Follow this check list each day before starting your generator.
• Check that all generator circuit breakers (power panel) are
in the off position before starting.
• Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
Any deficiency or problems in the following items must
be corrected before start up.
• Visually inspect the engine for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check drive belts for wear and proper tension (weekly).
CHECK WITH THE ENGINE RUNNING.
• Check for abnormal noise such as knocking, vibrating and
blow-back sounds.
• Confirm exhaust smoke:
When the engine is cold -White Smoke.
When the engine is warm -almost Smokeless.
When the engine is overloaded -some Black Smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached and loads are applied.
A CAUTION: Do not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove the AC amperage loads from the generator one at a time.
Allow the generator to run for 3-5 minutes to stabilize the operating
temperature.
Then push the stop button. Once the generator shuts
down,
tum off the panel DC breaker as a safety precaution.
10
CAUTION (WESTERLINK or NMEA·2000): The electronic components in the
Digital Diesels draw a very small amount
of amperage (milli-amps) from
the generator's starting battery when the unit is
in a static state. This
maybe
as much as 50 milli-amps for the system ECU and 50 milli-amps
for each display. This can be as much
as 72 amp-hours in a months time
with no generator use. It is not necessary to be concerned with this slight
amperage draw during normal seasonal use.
Howeve1; ifthe generator
set is not to be usedfor a number
of months, such as winter storage, it is
best to disconnect the DC power to the generator with a NMEA-2000
system or shut off the DC breaker on the generator's colltrol box for a
WESTERLINK system.
NOTE: Keep in mind that the Westerbeke generator maybe the DC power
supply for the vessel's NMEA-2000 network.

MAINTENANCE SCHEDULE
A wARNING: Never attempt to perform any service while the unit is operating. Wear the proper safety equipment such as goggles
and gloves, and use the correct tools for each type of maintenance performed. Shut off the control panel's DC breaker when servicing
any of the engine's DC electrical components.
NOTE: Use the engine hourmeter gauge to log yourgenerator hours or record your generator hours by running time.
INSPECTION AND PREPARATION FOR INITIAL START·UP (Also refer to the PREPARATIONS for START-UP in this manual)
Coolant Level
Engine Oil Level
Fuel/Water Separator (owner installed)
Fuel Supply
*Visual Inspection of Engine
Drive Belts
AFTER THE FIRST 50 HOURS OF OPERATION
Generator (Back End)
*Inlet Fuel Filter
*Fuel Filler and "0" Rings
Engine Oil and Filter
*Exhaust System
Heat Exchanger
EVERY 50 OPERATING HOURS OR MONTHLY
*Drive Belt (Fresh Water)
Starting Batteries
Electric Fuel Pump
Raw Water Pump
Filter/Water Separator
EVERY 1 DO OPERATING HOURS OR YEARLY
Heat Exchanger
*Drive Bell (Fresh Water)
Starting Batteries
Electric Fuel Pump
Raw Water Pump
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
The fuel in the filter should be clean and the valves open. Replace the filter every 250
operating hours or once a year.
Fuel tank must have the proper amount of clean diesel fuel and the fuel valve must be open.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wiring and electrical
connections. Look for loose bolts/hardware and correct as needed.
Inspect for proper tension (3/8" to 1/2" deflection) and adjust if needed.
Check that AC connections are clean and secure with no chafing. Refer to the GENERATOR
section for more information.
Initial change, then every 250 hours or once a year.
Initial change, then every 250 hours or once a year.
Initial engine oil and filter change at 50 hours, the both every 200 hours.
Initial check at 50 hours, then every 250 hours or once a year. Carefully inspect for leaks.
Check that the exhaust hoses are properly attached and that the securing clamps are tight.
Check for integrity/mounting security of water injected exhaust elbow.
Open end caps and clean out debris. Change zinc anode if necessary.
Inspect for proper tension (3/8' to 1/2' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed.
Check electrolyte levels. Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrnsion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect impeller and check the shaft and security of the pulley. Inspect that there is no
water seal leak.
Drain and clean.
Inspect and clean zinc anode. Note the condition, then determine your own schedule. If zinc
needs replacing, you should remove the end cap and clean out the debris.
Replace zinc if necessary.
Inspect for proper tension (3/8" to 1/2" deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels. Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect impeller and check the shaft. Inspect that there is no water seal leak.
NOTE: Keep the engine surface clean. Dirt and oil will inhibit the engines ability to remain cool.
Engines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your generator hours or record your generator hours by running time.
EVERY 250 OPERATING HOURS DR YEARLY
Engine Oil
Fuel Filter and 0-Rings
lnlel Fuel Filler
DC Alternator
Electric Fuel Pump
*Vibration Isolators/Engine Mounts
Heat Exchanger
*Exhaust Elbow/Exhaust System
EVERY 500 OPERATING HOURS DR FIVE YEARS
*Fuel Injectors
Coolant System
*Valve Clearances
*Starter Motor
Raw Water Pump
*Preheat Circuit
*Cooling System Hoses
EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS
*Heat Exchanger
*Adjusting the Valve Clearances
*Positive Crankcase Ventilation Valve (Rocker Cover)
*Fuel InJectors
*Starter Molar
Change the engine oil and oil filter (always together)
Remove and replace fuel filter and all sealing 0-rings.
Remove and replace inlet fuel filter.
Check mounting bracket, tighten electrical connections.
Inspect for leaks, ensure fuel and electrical connections are clean tight.
Check vibration·isolators, brackets and mounting hardware. Replace as needed.
Inspect zinc anode replace if necessary.
Check the structural integrity of the water injected exhaust elbow casting. Check the integrity
of the exhaust systel)l attached to the elbow. All hose connections should be secure. No
chaffing. No exhaust leaks. Hoses and muffler are in good serviceable condition.
NOTE: An exhaust leak will cause exposure to diesel exhaust!
Check and adjust injection opening pressure and spray conditions.
Drain, flush and re-fill the cooling system with appropriate antifreeze mix. Replace the
thermostat and cooling pressure cap.
Adjust valves. (Incorrect valve clearance will result in poor engine performance)
Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the starter
motor pinion drive.
Remove from engine, remove cover and inspect cam and wear plate. Replace any
components showing wear. If needed,replace the impeller and gasket. lubricate when
re-assembling.
Check operation of the pre-heat. Remove and clean the glow plugs. Re-install with anti-seize
compounds on threads.
Check hose condition and securing clamps. Replace as needed.
Remove the heat exchanger for professional cleaning and pressure testing. Change the
antifreeze and flush the system.
Adjust the valves.
Disassemble and clean. Replace as needed.
Pressure test injectors/re-build at 1500 hours.
Remove, clean and lubricate the drive
A wARNING: Never attempt to perform any service while the unit Is operating. Wear the proper safety equipment such as goggles
and gloves, and use the correct tools for each type of maintenance performed. Shut OFF the control panel's DC breaker when servicing
any of the engines DC electrical components.
NOTE: Keep the engine surface clean. Dirt and oil will inhibit the engine's ability to remain cool.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.

FUEL SYSTEM·
DiESEL FUEl
Use No.2-D (SAE J313) diesel fuel with a cetane rating of
#45 or higher. Grade diesel fuel according to ASTM D975.
In conjunction with Ultra Low Sulphur Diesel. Use an
additive such as Diesel Kleen +Cetane Boost produced by
Poirer Services (product #3025) or equivalent to help
restore fuel lubricity.
FUEL FILTERS
The fuel injection pump and the fuel injectors are precisely
manufactured and they must receive clean diesel fuel, free
from water and dirt. To ensure this flow ofclean fuel, the fuel
must pass through at least two fuel filters, a fuel water
separator and the engine's spin-on fuel filter. Visually inspect,
clean, and change these filters according to the maintenance .
schedule in this manual.
FUEL WATER SEPARATOR
A primary fuel filter ofthe water separating type must be
installed between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
be carried to the fuel system on the engine.
The owner/operator is responsible for making certain the
fuel reaching the engine's injection equipment is free of
impurities. This process is accomplished by installing and
maintaining a proper fuel filter/water separator between the
fuel tank and the generator/engine. Westerbeke recommends
a
10 micron filter be used.
FUEL LIFT PUMP
Periodically check the fuel connections to and out of the pump
and make sure that no leakage is present and that the fittings
are tight and secure. The DC ground connection at one of the
pump's mounting bolts should be clean and well secured by
the mounting bolt to ensure proper pump operation.
When energized thru the preheat circuit, the fuel lift pump will
purge air from the fuel system and provide a continuous flow
of fugl as the engine is running.
INLET FUEL FILTER
To ensure properly filtered fuel into the fuel pump, there is a
small inlet filter before the inlet to the fuel pump. Replace
this filter after the initial 50 hours ofoperation, then follow
the Maintenance Schedule in this manual.
A WARNING: ·Fuel.leakage at the fuel pump or its
connections is a flre hazard and should. be co«ected.
Make sure proper ventilation exists whenever servicing
fuel system components.
13
ENGINE FUEL FILTER
Periodically check the fuel connections and the bowl for
leakage. Replace the filter element after the first 50 hours
then follow the MAINTENANCE SCHEDULE.
Changing the Fuel Filter Element
Refer to the illustration.
1. Shut offthe fuel supply.
2. Unthread the fuel filter from
its mounting bracket.
3. Ensure the sealing ''0" ring comes offwith the filter.
4. Apply some light oil or diesel to the sealing "0" ring
of the new filter.
5. Thead the new filter onto its mounting bracket. When the
"0" ring contacts the bracket, tighten securely.
6. Depressing and holding the PRIME button on the control
panel activates-the engine's fuel pump and primes the
system. Hold for approximatelt 20 seconds.
7. Run the engine and inspect for leaks.
SEALING GASKET
APPLY CLEA/fJ-OIL
~~~~~ WHEN ASSEMBLING
NEW FILTER
FUEL FILTER
CARTRIDGE
#052985
FROM FUEL
LIFT PUMP
/-TO FUEL FILTER
)'\,
INCOMING
FUEL