Westerbeke 22.0 KW EDE-60Hz User manual

OPERATORS MANUAL
D-NET DIESEL GENERATORS
22.0 KW EDE • 60Hz 17.0 KW EDE· 60Hz
17 .0 KW EDE· 50Hz 13.5 KW EDE· 50Hz
SINGLE & THREE PHASE
DIIRI 1~A'TlnN NO. 053852
SECOND EDITION
JULY 2008
WESTERBEKE CORPORATION' t50JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780
W£BSITf£: www.W£8Tf£RBEK£.COM
§i1',d;t'" Member National MIlI'iM. ManufaclilrersAslociauqp
oiIIIUI ••

A WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cauSB
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness
- Throbbing in Temples
-Nausea
- Muscular Twitching
-Headache
- Vomiting
- Weakness and Sleepiness
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS.
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
SBek medical anention. 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.
Engines & Generators

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
personnel, andyour machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do nDt tDuch AC electrical cDnnections
while engine Is running, Dr when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessels AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessels AC generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause InJury or death!
• Prevent flash fires. Do not smoke orpermit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate without a Coast Guard Approved flame
arrester. Backfire can cause severe injury or death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/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 burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessels
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area away from spark-producing
equipment and out of the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free 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.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause Injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it
last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY EXPLOSION
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
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation of explosive
gases. To avoid sparks, do not
disturb
the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BAnERYACID
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.
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 surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational infonnation on Carbon Monoxide).
A WARNING: Carbon monoxide (CD) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea Dr deathl
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting
in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow ofexhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or signs 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 it is running. If a
situation arises
in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines &Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment;
tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught
in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belts 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.
• 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!
OPERATORS MANUAL
Many ofthe preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination ofthe American Boat and
Yacht
Council's (ABYC) standards. These standards are a
combination ofsources including the USCG and the
NFPA.
Sections ofthe ABYC standards ofparticular interest are:
H-2 Ventilation
P-l Exhaust Systems
P
-4 Inboard Engines
E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order
from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order
from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators itis important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the
raw water supply bose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection pori is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
Engines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification .. .................................................. 2
Introduction . ............................................................... 3
Fuel, Engine Oil, and Engine Coolant.. ...................... 5
Preparations for Initial Start-Up ................................ 6
Digital Control Panel .................................................. 7
Remote Start/Stop Panel ............................................ 9
Generator Break-In Procedure ................................. 10
Daily Routine ............................................................ 10
Maintenance Schedule (Chart) ................................. l1
Fuel System .. ............................................................ 13
Cooling System ......................................................... 15
Raw Water Intake Strainer .................................... 15
Raw Water Cooling Circuit................................... 15
Heat Exchanger .....................................................16
Raw Water Pump...................................................16
Fresh Water Cooling System.................................17
Changing the Coolant............................................
17
Air Intake/Silencer ................................................ 18
Thermostat.............................................................18
Engine Lubricating Oil ..............................................19
Engine Oil Change ................................................19
Testing Oil Pressure...............................................20
Remote Oil Filter (optional)...................................... 21
Wiring Diagrams ............................................................ 22
Engine Troubleshooting (Chart) ................................ 23
Alternator Testing ........................................................ .25
Battery Care...........................................................27
Engine Adjustments .................................................. 28
Valve Clearance.....................................................28
Glow Plugs ............................................................29
Drive BeltAdjustment...........................................29
Fuel Injectors.........................................................29
Fuellnjectors ............................................................ 30
Injection Testing ....................................................30
Starter Motor .. .......................................................... 31
Troubleshooting..................................................... 31
Emergency Start ....................................................32
Engine/Generator Specifications ............................. 33
Generator Information .............................................. 34
Electronic Regulation ............................................... 35
Internal Wiring Diagram .. ......................................... 36
Generator Wiring Schematics .................................. 37
Schematic-Rotating Field/Exciter Rotor .................. 38
Twelve Lead Winding Connections ......................... 39
BE Troubleshooting (Chart) ...................................... .40
Exciter Rotor Troubleshooting ............................... ..41
Generator Servicing ................................................. .42
Generator/Maintenance Parts Breakdown ............. ..43
Power Transfer Switch ........................................... ..45
Lay-up and Recommlssioning .................................... .46
Metric Conversion Charts ....................................... .48
Suggested Spares ..................................................... 50
1

PARTS IDENTIFICATION
THER,MOSTAT
ASSEMBLY
OIL DRAIN
ECU CONNECTIONS
REMOTE PANEL
CONNECTION
FRONT
COOLANT PRESSURE
HEAT
AIR
CONTROL BOX
DIGITAL
PANEl.
20A
DC BREAKER
REAR
MOUNTS
Engines & Generators
2
LEFT SIDE
INTAKE
~-Llr~I;ANODE
ELBOW
DRIP TRAY
OIL FILL
PUMP
FILTER
AIR INTAKE SILENCER
DIPSTICK
SPIN-ON
FUEL FILTER
RIGHT SIDE
ISOLATED

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKB's long years of experience and advanced
technology. We take great pride ill the superior durability and
dependable p"errormance ofour engines and generators.
Thank you for selecting WESTERBEKB.
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 assi~tance.
This is your operators manual. A parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer. If you are planning to install this
equipment contact your WESTERBEKB dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If,after 60 days of submittiI:lg the Warranty Regijtry
form you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the unit's serial
number and commission date.
Customer Identification Card
,.....,.,WESTERBEKE
I Engines & Generators
Customer Identification
:MR.. GEl'\TERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model Ser.#
Expires
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKB are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEliNESS OR
COMPLETENESS THEREOF AND WlILIN NO EVENT
BEliABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE custOmers should also keep in mind fue
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 autllority 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 fue
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you furough the operating procedures,
maintenance schedules, and troubleshooting of your marine
erigine, 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: PrDcedures, which if not prDperly
followed, can result in personal injury or loss of life.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model number and serial number are located on
a nameplate mounted on the side of the engine's manifold.
The engine's serial number can also be found stamped into
the engine block on the flat surface of the blockjust above
and inboard of the h*ction pump. Take the time to enter this
information on the illustration of the nameplate shown below,
as this will provide a quick reference when seeking technical
information andlor ordering repair parts.
An identification plate on the engine manifold also displays
the engine model and serial 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 ofa gasoline engine; and the
diesel engine has the same type of valves, camshaft, pistons,
connecting rods and lubricating 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 of the fuel, lubricating and cooling systems.
Replacement of fuel and lubricating 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 usa
of the same brand ofhigh detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ
from the gasoline engine,
however, in its method ofhandling 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 serial 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
description
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
original 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 of spare parts.
See the SPARE PARTS page in this manual. For Engine and
Generator Accessories. see the ACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed information for
installing generators.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
FUEL
A CAUTION: Use number 2 diesel fuel with a celane
rating of 45 or higher.
Care Of The Fuel Supply
Use only-clean 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 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
filter/water separator between the fuel tank and the engine.
ENGINE OIL
Use a heavy duty engine oil with an API classification of
CF, CGA, CH-4 or CI-4. Change the engine oil after an
initial 50 hours ofbreak-in operation, and every 100 hours of
operation
thereafter. For reconunended oil use SAE 15W-40
(oil viscosity). WES1ERBEKE recommends the use of
synthetic
oil.
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in tlie mixture
to produce properties harmful to your engine.
ENGINE COOLANT
Engine coolant is a 50150 mixture ofantifreeze and distilled
water. This coolant allows the engine to run at its proper
temperature
by transferring heat from the engine to the
coolant. It also lubricates and protects the cooling system
fTom rust and corrosion. A 50/50 mixture of antifTeeze and
distilled water will protect the engine to -34°F C1.12C).
PURCHASING ANTIFREEZE
Rather than preparing the mixture, WES1ERBEKE
recommends buying
the premixed antifreeze so that so that
when adding coolant the mixture will always be correct.
There are two common types ofantifreeze, Ethylene Glycol
(green) and Propylene Glycol (red/purple), either can be used
but do not mix the two and if changing from one to another,
flush the engine thoroughly.
Premixed antifreeze for DIESEL Engines:
,Specification #ASTM 5345.
MAINTENANCE
Change the engine coolant every two 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
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your generator for the first time or after a pro-
longed layoff, check the following items:
• Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
• Check the coolant level in both the plastic recovery' tank .
and at the manifold.
NOTE: 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 coolantfrom the recovery
tank
will be drawn into the engine:S cooling system to
replace the purged air.
Before subsequent operation of the generator, the engine's
manifold should
be topped off, aJ1d the coolant recovery
• 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.
DIPSTICK
PUSH IN TIGHT
~ ___ -FULL
• Be sure that in power systems with a neutral line that
the neutral is properly grounded (or ungrounded) as the
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.
• Make cerJ;ain the cooling water tbru-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
Engines &Generators
6

DIGITAL CONTROL PANEL
NOTE: DURING OPERATION THE COLOR
OF THE LCD DfSPLA Y MAY VARY
CAUSED BY HEAT. THIS IS NORMAL
AND NO CAUSE FOR CONCERN.
I
CONTROL BOX
INDICATOR LIGHTS
DESCRIPTION
WESTERBEKE'S Digital Control panel provides the
operator with an LCD display that continuously monitors
all the operations of the generator in easy to understand
text
messages.
START SEQUENCE
With the pre~tart 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:
Engines &. Generators
Pre Heating......
7 Seconds
RUN SEQUENCE
Waiting for operator
Press start to
engage generator
Cranking ......
As the display cycles thru the engine functions, the speed
will
come up to 1800 rpms-60Hz (1500 rpms-50Hz) and
LIGHT
the oil pressure and engine coolant will rise to their normal
readings. The functions will cycle in t1le following sequence:
a
Engine Speed
1800 RPM
2500
,SCROLL
Coolant Temperature
172F
o
11 I
300
SCROLL
DOWN ARROW
8 AMP FUSE
PROTECTS THE PANEL
ELECTRONICS FROM A
HIGH AMP OVERLOAD
'~---/.-- 20 AMP DC CIRCUIT
BREAKER (ECU)
---=.,...,,::.::........._- PRIME BUTTON
ENERGIZES THE FUEL PUMP
START BUTTON
Battery Voltage
. 13.5 VDC
Engine Hours
3.8 HOURS
I
SCROL.L
SCROLL LOCK
Oil Pressure
40 PSI
o 100
SCROLL
Coolant Temperature
172F
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
corner. use the up and down arrows to find and observe other
functions. To resume scrolling, press the SCROLL LOCK
button again.
Up and Down Arrows
When the display is in its cycling mode, the UP and DOWN
arrows can be used to adjust the dark and light contrast ofthe
screen.
FUEL PRIMING
Use the PRIME button on the digital control panel to purge
air and bring fuel back into the fuel lines after performing
fuel filter maintenance.
LCD DISPLAY
Periodically clean the control panel and its LCD screen using
a soft cloth.
NOTE: Operating temperatures may cause the LCD display to
vary in color. This is normal anda change in color will not
affect
the operation of the control panel.
Engines & Generators
7

DIGITAL CONTROL PANEL·
STOP SEQUENCE
To stop the generator, press the STOP button. The display
will cycle thru the following text messages and shutdown.
Shutting
Down
Waiting
for operator
Press
start to
engage generator
THE CONTROL PANEL WILL POWER DOWN
AND IN A FEW MOMENTS THE DISPLAY
WILL GO BLANK
Engine Shutdown
FAILURE LIGHT/SHUTDOWN
If a problem occurs, the generator will shutdown and the
FAILURE light will illuminate red. In addition, one ofthe
indicator lights
will change from green to orange to reveal
where the trouble has occurred and the display will text
message what has happened.
A CAUTION: When servicing/changing DC
electrical components. The DC power must be turned
off using either the DC breaker mounted on the control
box or the unit's battery switch.
WHEN CHANGING THE GENERATORS
FREQUENCY (50/60 HZ) SWITCH #1
ON THE CONTROL PANEL ECU
BOARD MUST BE SWITCHED:
ON FOR 50 HZ AND OFF FOR 60 HZ
CONTROL BOX
INTERNAL COMPONENTS
CONTROL BOX
8
Examples:
Failure Light is red.
Coolant Temperature Light is orange.
High Engine Temp.
Reset ECU
to ReStart
Failure Light is red.
Oil Pressure Light is orange.
Low Oil Pressure
Reset ECU
to Restart
When a failure occurs,.refer to the troubleshooting chart,
wiring diagram, and general operating text ill' 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 restarting. the generator, the 20 amp DC circuit
breakermustbe pushed
to the OFF position, and back to the
ON position to reset the BCD. Once the problem is corrected
and the generator is restarted, the LCD display will begin
cycling again.
LCD DISPLAY PANEL
NOTE: During operation the color
of the LCD display may vary.
Caused by heat. this is IWnnal
and no eause for cOlleen!.

DESCRIPTION
REMOTE STOP/START PANEL
AND EXTENSION HARNESSES
A remote panel is available that allows the generator to be
stopped and started from any location on the boat. The
connecting harnesses come in three different lengths and two
ofthese can be combined for a maximum run at 75' (22.17M).
NOTE: For additioMl information, contact your local
WESTERBEKE dealer.
3·1/4» IO"-:.;,:aIYIIYII
I
REMOTE PANEL/PIG TAil
CONNECTING EXTENSION
CABLES
15' (4.75M)
3~' (9.1M)
60' (18.2M)
PN 052959
PN 052789
PN 052960
PN 052560 L
Note: These two dimensions are the measurement of the cut-out opening.
'~!.~
Engines &Generators
9

GENERATOR BREAK-IN PROCEDURE
DESCRIPTION
Although your engine bas experienced a miniQ1um of one
hour oftest 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 SO hours ofinitial
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 overload at all times. An overload is signaled by smoky
exhaust with reduced output voltage and frequency, Monitor
the current being drawn from the generator and keep it within
the 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 0/ motor starting loads and the high current
draw required/or 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 (HERn) ADJUSTMENT) under
ENGINE ADJUSTMENTS .. Ano-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
• 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 nomlal operating temperature
is reached and loads are appUed,
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 loads from the generator one at a time.Allow
the generator to run for 3-5 minutes to stabilize the operating
temperature, then turn the key to the off position. Once the
generator is shutdown, close down all circuit breakers as a
safety precaution.
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 mol!lhs time
with no generator use.
It is not necessary to be cOl1cerned with this slight
amperage draw duril1g
nonnal seasol1al use. However, if the gel1erator
set is
not to be used for a number of months, such as winter storage, it is
best to discol1nect the DC power to the gel1erator with a NMEA-2000
system or shut off the DC breaker on the generator:v col1trol box for a
WESTERLlNK systel1L
NOTE: Keep in mind that the Westerbeke generator maybe the DC power
supply for the vessel's NMEA-2000 network.
Engines & Generators
10 '

SCHEDULED
MAINTENANCE
~PIY
Fuel/Water Separator
Engine Oil Level
Coolant Level
I Drive Belts
MAINTENANCE SCHEDULE
AWARNING: Never aHempt to perform any service while the engine is
runnIng. Wear the proper safety equipment such as goggles and gloves. and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenance jobs are simple but others are more
difficult and may require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH EXPLANATION OF SCHEDULED
DAY
50
100 250 500 750 1000 1250
MAINTENANCE
0
Diesel No.2 rating of 45 cetane or higher.
0
Check for water and dirt in fuel (d rain/replace filter
if necessary).
0
Oil level should indicate between MAX. and LOW on
dipstick.
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
c:::!
Inspect for proper tension (3/8" to 1/2" depression)
weekly
and adjust if needed. Check belt edges for wear.
Visuallnspectlon of Engine
0
NOTE: Please keep engine surface clean. Dirt
Check for fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engine's ability to
and electrical connections. Keep bolts & nuts tight.
remain cool.
Check for loose belt tension.
Fuel Filter/lnlet Filter
0 0 0 0 0
Initial change at 50 hrs, then change every 250 hrs.
Sta rting Batteries
0
Every 50 operating hours check electrolyte levels
(and House Batteries)
weekly
and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil (and filter)
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 150 hrs.
Generator
0 0 0 0 0 0 0
Check that AC connections are clean and secure
with no chafing. See GENERATOR SECTION
for additional information.
Heat Exchanger Zinc Anode
0 0 0 0 0 0 0
Inspect zinc anode. replace if needed, clear the heat
exchanger end of zinc anode debris.
Fuel/Water Separator
0 0 0 0 0 0
Change every 200 hours or each season.
Exhaust System
0 0 0 0
Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check anti-Siphon valve operation. Check
the exhaust elbow for carbon and/or corrosion
buildup on inside passages; clean and replace as
necessary. Check that all connections are tight.
Engine Hoses
0 0
10
0 0 0
Hose should be hard & tight. Replace if soft or
I
spongy. Check and tighten all hose clamps.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
(continued)
Engines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmetergauge to log yourengine hours or record your
engine hours by running time.
CHECK
HOURS OF OPERATION
SCHEDULED
EACH
EXPLANATION OF SCHEDULED
MAINTENANCE DAY
50 100 250 500 750
1000 1250 MAINTENANCE
Raw Water Pump
0 0 0
Remove the pump cover and impeller. Inspect the
impeller, cam, cover and inner wear plate for wear.
At 800 operating hours,
Inspect housing weep holes for Signs of shaft water
disassemble and inspect
for
overhaul.
seal or oil leaks. Check shaft bearings (the shaft
should turn, not wobble).
-
Raw Water Pump Drive
0 0
Remove pump and inspect pump shaft and drive
slot for wear.
Air Inlet Filter
0 0 0 0 0 0
Inspect every 100 hours. Remove and clean.
Replace as needed.
Coolant System
0 0
Drain, flush, and refill cooling system with
appropriate antifreeze mixture compatible with
various cooling system metals.
Electric Fuel lift Pump
0 0 0 0 0 0
Periodically check the wiring connections and
inspect the fuel line connections.
DC Alternator
0 0 0
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
*Fuellnjectors
0 I
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
*Starter Motor
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
"'Preheat Circuit
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (0.4-0.6 ohms).
Reinstall with anti seize compound on threads.
"'Engine Cylinder
0 0
Check compression pressure and timing
Compression
(see Engine Adjustments).
*Torque Cylinder Head
0 0 0
At first 50 hours, then every 500 hours
Hold-down bolts
(see ENGINE ADJUSTMENTS).
* Adjust the Valve Clearances
0 0 0
Adjust Valve Clearances
(see ENGINE ADJUSTMENTS).
*Heat Exchanger
0 r= have professionally cleaned and
pressure tested.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
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 coneemed with this slight amperage draw during
nonnal seasonal use. However. if the 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 on the generator's control boxfora WESTERUNK system.
NOTE: Keep in mind that the Wcsterbeke generator maybe the DC power supply for the vessel's NMEA-2000 network.
Engines & Generators
12

FUEL SYSTEM'
DIESEL FUEL
Use No.2 diesel fuel with a Cetane rating of45 or higher. In
conjunction with Ultra Low Sulphur Diesel. Use an additive
such
as "Diesel Kleen" produced by Power Services PS to
help restore fuel lubricity (product #3025).
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
Aprimary fuel filter of the 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 fu~l as the engine is running.
INLET FUEL FILTER
To ensure clean fuel·into the fuel lift pump, there is a small
in-line fuel filter connected to the fuel lift pump elbow. This
filter should be replaced every 200 hours of operation.
A WARNING: Fuel leakage at the fuel pump or its
connections isa fire hazard and should be corrected.
Make sure proper ventilation exists whenever servicing
fuel system components.
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 off the fuel supply.
2. Turn the fuel filter bowl counterclockwise to remove.
3.: Pull the filter element straight down and off.
4. Inspect both O-rings and replace if worn.
5. Wipe the O-rings with clean fuel and snap the new filter
up into place over the small O-ring.
6. Clean offthe filter bowl and threads. (The bowl can be
pre-filled with fuel). Screw the bowl into place when the
O-ring contacts the housing. Tighten the bowl
firmly by
hand.
7. The preheat sequence will allow the lift pump to
fill the fuel filter.
S. Run the engines and inspect for leaks.
\ FROM FUEL
\LlffPUMP
FUEl FILTER
CARTRIDGE
I
I TO FUEL FILTER
')
INCOMING
FUEL
Engines & Generators
13

FUEL SYSTEM
FUEL INJECTION PUMP
The fuel injection pump is the most important component
of the diesel engine, requiring the utmost caution in handling.
The fuel injection pump has been thoroughly bench-tested
and the owner/operator is cautioned not to attempt to service
it.
If it requires servicing, remove it and take it to an
authorized fuel injection pump service facility.
Do not
attempt to disassembly and repair it.
The only adjustment the servicing mechanic should make to
the fuel injection pump is the adjustment for the engine idle
speed (see IDLE SPEEDADJUSTMENTunder ENGINE
ADJUSTMENTS).
r-- TO INJECTORS
, \
I
,
BLEED SCREW
The bleed screw on the injection pump should be left in the
open position. This will then allow for ease in priming the
engine's fuel system and during engine operation allow for
air in the system to be delivered to the fuel
tank through the
fuel return system.
FROM FUEL
FILTER
TO FUEL INJECTORS
ACTUATOR
A WARNING: Shut off the fuel valve at the tank
when servicing the fuel system. Take care in catching
any fuel that may spill. DO NOT allow any smoking,
open flames or other sources of fire near the fuel
system when servicing. Ensure proper ventilation exists
when servicing the fuel system.
SPEED ADJUSTMENT
FACTORY SET
FUEL INJECTION
PUMP
COOLANT DRAIN
FUEL RETURN
LINE ,.-----',,--,
A WARNING: Fuel is present in the hosing and lines.
Use extreme care to prevent spillage
Engines & Generators
14
GLOW PLUGS
J
FROM FUEL INJECTION PUMP