Westerbeke 3.0KW BPMG User manual

OPERATORS MANUAL ..
, 3.0KW BPMG 60Hz and 50Hz
. ,SINGLE PHASE
GASOLIN ENERATORS
,
i
I • 4
TH
EDITION
APRIL 2009
~ WESTERBEKE '

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.
A WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness - Throbbing in Temples
-Nausea
- Muscular Twitching
-Headache
- Vomiting
- Weakness and Sleepiness -Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
This WARNING DECAL is provided by
WESTERBEKE and should be Oxed to a
bulkhead nBar your Bnglno or gBnBrator.
WE$TERBEKEalso I'8commBnds installing
CARBON MONOXIDE DETECTORS In tho
IIvlng/sIBBplng quarters of your vessel.
ThBY al'8ln8Xpenslve and easily
obtainable at your local marino stOI'8.
-..v- WESTERBEKE
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefully. Most accidents are
causedbyfailure tofollow fundamental rules
and precau-
tions. Know when dangerous conditions exist
and take the
necessaryprecautions to protectyourself, yourpersonnel,
and your machinery.
Thefollowing safety instructions are
in compliance with
theAmerican Boat
and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connectioRS
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 vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessel's AC generator may
result ifthis procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting tenninals together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 not touch hot engine parts Dr
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 Dr death!
• Incase of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury Dr death!
• Prevent flash fires. Do not smoke or pennit flames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or pennit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free ofdebris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury Dr death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed
when fueling. Open and ventilate cabin
after
fueling. Check below for fumes/vapor before run-
ning 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-ven-
tilated
area away from spark-producing equipment and
out ofthe reach ofchildren.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill.
DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained'. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
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.
BAnERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead
acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off
all electrical
equipment
in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection 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 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: Su"uric 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 protec-
tion. Batteries contain sulfuric acid which is destructive.
If it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin or into the eyes
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
are securely attached and no warping exists. Pay close
attention
to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection ofthe exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer
for installation of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional information
on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces "u-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration ofcopper
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 symp-
toms or signs of carbon monoxide inhalation or poisoning
are:
Vomiting Muscular twitching
Dizziness Intense headache
Throbbing in temples Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
~ WESTERBEKE
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 belt's tension while
the engine is operating.
• Stay clear of the drive shaft and the transntission 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 of the preceding safety tips and wamings are repeated
in your Operators Manual along with other cautions and
notes
to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination of the American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination
of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
H-24 Gasoline Fuel Systems
P-l Exhaust Systems
P-4 Inboard Engines
E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater,
MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Orderfrom:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Orderfrom:
U.S. Govemment 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 codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will
be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifoldinjection 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, installa
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
Installation ........................................................................ 5
Rigging and Lifting......................................................5
Location and Mounting................................................5
Raw Water Discharge...................................................6
Raw Water Supply Hose ..............................................6
Fuel, Engine 011 and Engine Coolant.. .......................... 7
Fresh Water Cooled Models.........................................7
Control Panels - Starting/Stopplng Procedure ........... 8
Remote Panel ...............................................................8
Preparations for Initial Start-Up ................................... 9
Pre-start Inspection.......................................................9
Fresh Water Cooled Models.........................................9
Safety Shutdown Switches ........................................... 10
Overspeed Switch.......................................................
IO
Main Circuit Breaker .................................................10
Fuses...........................................................................
10
Exhaust Temperature Switch...................................... 10
Low Oil Switch .......................................................... 10
High Exhaust Temperature Switch.............................10
Maintenance Schedule .................................................. 11
Engine Lubricating 011 ................................................... 13
Changing the Oil Filter .............................................. 13
Fuel System ..................................................................... 14
Changing the Fuel Filter ............................................
14
Fuel Pump ................................................................. 14
Cooling System ............................................................... 15
Water Pump................................................................ 15
Water Intake Strainer.................................................. 15
Changing the Impeller................................................ 15
Cooling System [Fresh Water Cooled Modelsj*. ............. 16
Changing the Impeller................................................ 16
Raw Water Pump ........................................................ 16
i~~;:;:'o;~~I~n.t::::::::::::::::::::::::::::::::::: ::::::::::::::::::::::::: ~
Heat Exchanger.......................................................... 18
Zinc Anode................................................................. 18
Carburetor ........................................................................ 19
OC Clrcuit/Baltery .......................................................... 20
Shore Power Transfer Switch ....................................... 20
Electronic Governor ....................................................... 21
Engine Adjustments ....................................................... 22
Adjusting the Drive Belt ............................................
22
Oil Pressure................................................................22
Engine Compression Test...........................................23
Water Pump Belt ........................................................23
Spark Plug .................................................................. 24
Thermostat [Raw Water Cooled Model] .................... 24
Valve Clearance..........................................................25
Replacing the Timing Belt ......................................25A
Troubleshooting Guide ................................................... 26
AC Generator ................................................................... 28
Wiring Diagram ............................................................... 29
Lay-Up and RecommiSSioning ...................................... 30
Specifications ................................................................. 32
Metric Conversions ....................................................... .33
Standard and Metric Conversions Data ..................... 34
Suggested Spare Parts .................................................. 35
*Models manufactured wilh heat exchangers for cooling )Virhfresh
waterlcoolant or raw waler cooled models that have been cOl/verted to .
fresh cooling
via WESTERBEKE'S FRESH WATER COOLING KIT.
Engines & Generators
1

IIGNITION .u.'nu,.~
,MODULE
GENEHATOR
l£CHNICAl
GROUND
ENGINE SERIAL
DRIP
3.0 KW BPMG GENERATOR
PARTS IDENTIFICATION
~'""'''U" COIL
SERVICE SIDE
FRESHWATER
(COOlANn MODEL
lOA
I FIlTER
BREAK
'CONNECTION
CO(]lANT PRESSURE
IGNITION CONmOL
PUMP
ACTUATOR
. LEFT SIDE
-""lJIT'ORMOUNT
Engines & Generators
2
WATER INJECTED
WATER (COOLANT)
TEMPERATURE
SWITCH
=<- __ OIL DRAIN
HOSE
+---HEAT
EXCHANGER
; SERVICE SIDE
WATER PUMP

INTRODUCTION
These high perfonnance marine engines are products of
WESTERBEKE's long years of experience and advanced
technology.
We take great pride in the superior durability and
dependable perfonnance of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator,
it is important that you operate and maintain it correctly.
This manual is designed to help you do this. Please read this
manual carefully and observe allthe safety precautions
throughout. Should your engine require servicing, contact
your nearest WESTERBEKE dealer for assistance.
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 WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after
60 days of submitting the Warranty Registry
fonn you have not received acustomer identification card
registering your warranty, please contact the factory in
writing with model infonnation, including the unit's
serial number and commission date.
Customer Identification Card
,...,/WES,cRBEKE
Customer Identification
MR. WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires
PRODUCT SOFTWARE
Ser. #
Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT
BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLEFOR
ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH ORARISING
OUT
OF THE FURNISHING OR USE OF SUCHSOFTWARE.
WESTERBEKE customers should keep in mind the time
span between printings
of WESTERBEKE product software
and the unavoidable existence
of earlier WESTERBEKE
product software. The product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product.
SERIAL NUMBER LOCATION
The engine ~ serial and model number are etched on a name-
plate located on top of the unit (flywheel cover). The
engine's serial number is also stamped on the engine block.
• PEe A"g. M" uu, ;: 5ER NO •
ENGINE ~
SERIAL ~
NUMBER"
'. ",Cl
~"0~~
Take the time to enter this infonnation on the illustration of
the nameplate as shown above, as this will provide a quick
reference when seeking technical infonnation and/or ordering
parts.
The generator~ serial number and model number is located
on a decal on the the generator control panel. Take the time
to enter the infonnation on the blank decal below. This will
provide a quick reference when seeking technical infonna-
tion and/or ordering parts.
Fill in the information for your own reference_ $:n
Engines & Generators
3

INTRODUCTION
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine model and serial numbers, In addition,
include a complete part description and part number for each
part needed (see the separately furnished Parts Catalog).
Also insist upon
WESTERBEKE packaged parts because
willfit or generic parts are frequently not made to the same
specifications as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you tluough the operating procedures,
maintenance schedules,
and troubleshooting of your
generator, critical information will
be highlighted by
NOTES, CAUTIONS, and WARNINGS. An explanation
follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
the engine orgenerator.
A WARNING: Procedures, which if not properly
fol/owed, can result in personal injury or loss of life.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visible location in the
engine room.
SPARES AND ACCESSORIES
Certain spare parts will be needed to support and maintain
your
WESTERBEKE generator or engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filters can
be difficult to obtain along
the way.
WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
on-board inventory of the proper WESTERBEKE parts.
4
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a
WESTERBEKE generator capable of
many thousands of hours of dependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Seven important steps to ensure long generator life:
• Properengine and generator installation.
• An efficient weI/-designed exhaust systent that includes
an anti-siphon breakto prevent water from entering the
engine.
• Changing the engine oil and oi/filters every 100 operat-
ing hours.
• Proper maintenance of all engine and generator compo-
nents according to the maintenance schedule in this
manual.
• Use clean,jiltered unleadedfuel.
• Winterize your engine according to the "Lay-up and
Recommissioning" section in this manual.
• Raw Water Cooled Model -Flush the engine cooling
system according to
the procedures found in this
manual.
UNDERSTANDING THE GASOLINE GENERATOR
The gasoline engine driving an AC generator is in many
ways similar to a gasoline automobile engine. The cylinders
are in-line, and the engine's cylinder head has
an overhead
camshaft which is belt-driven. The engine incorporates a
pressure type lubrication system, and a water-cooled engine
block.
To a large degree, the generator's engine requires the same
preventive maintenance that is required of a gasoline
automobile engine. The most important factors to the
generator's longevity are proper ventilation, maintenance of
the fuel system, ignition system, and cooling system.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters.
Carbon monoxide,
even in smaU 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!

INSTALLATION
RIGGING AND LIFTING
The engine/generator is fitted with lifting eyes. Attach
r0
I D
wire rope or chain slings capable ofsupporting the
engine/generators weight to the eyes and lift the engine/gen-
erator by means oftackle attached to these slings. The lifting
eyes have been designed to carry the full weight: auxiliary
slings are not necessary.
14.481n (36B,mm)
NOTE: Rigging work is best done by someone experienced
andcompetent in handling machinery.
LOCATION AND MOUNTING
A solid, level mounting platform is very important for the
proper operation ofyour generator. Select a location that will
allow adequate space on all sides for ventilation and servic-
ing. Locate the generator away from living quarters, and
away from bilge splash and vapors.
Refer to WESTERBEKE'S installation manual for detailed
information on installing a Marine Generator in a boat.
3/4" PLYWOOD-BOLTEOIFIBERGLASSED
IN PLACE
USE THE PAN AS A TEMPLATEFOR
LOCATING THE PROPER MOUNTING
HOLES TO THE PLYWOOD BASE
AC CONNECTION
EXHAUST
'-""<1'_ I 2.tljn (50.Bmm)
1.0. HOSE
WATER OUTLET AND DISCHARGE
HOSES D.5in (2.7mm) 100.
L 11.9Sin (3~4mm)(.;,;;;i _____ J ~ FOUR 1/2~ BOLTS
I----- l8.SOiI! (470mm)
I 160gmmJl1--------l11
1--------24.641" (625,9mm)-------<
BATTERY ATTACHMENTS
TO STARTER MOTOR
REFER TO THE WIRING
DIAGRAM IN THIS MANUAL
(-) NEGATIVE
LEAD
DIMENSION (INCHES AND MM)
Engines & Generators
5

INSTALLATION
RAW WATER DISCHARGE
The raw water cooled 3.0KW Generator is cooled
internally
by a continuous flow ofraw water.
The fresh water cooled model is cooled internally by fresh
water (coolant). This coolant
is cooled by a continuous flow
of raw water (via the heat exchanger).
Both model generators use the engine cooling
raw water to
cool the exhaust system as it is discharged overboard. A raw
water supply hose delivers the raw water from the engine to
the water injected exhaust elbow.
RAW WATER SUPPLY HOSE
The raw water supply hose from the discharge connection on
the engines cooling system to the inlet connection ofthe
water injected exhaust elbow
must be looped a minimum of
12 inches (30cm) above the vessels loaded water line.
On installations where the water injected exhaust is close to
or below the vessels loaded water line, provisions must be
made to install a syphon break in the raw water supply hose.
The function
of the syphon break is to stop the raw water
flow after the engine is shutdown. This flow, if not stopped,
will fill the exhaust system and possibly the engine as well.
The raw water supply hose must be looped well above the
loaded water line
to allow the syphon break to function
during all attitudes
of vessel operation to prevent syphoning
when
the generator is not operating.
:"';~;:-_GOGILANI DRAIN
"'=''----·R''W WATER
'DRAIN
HEAT EXCHANGER
When the generators location is above the loaded waterline
ofthe vessel during all attitudes
of vessel operation, it is still
advisable
to loop the raw water discharge hose at least 6
inches or more above the generator and then down
to the
inlet connection on the water injected exhaust elbow.
NOTE: Always use quality hose with good wall integrity or
wire reinforced hose so
it will maintain its shape when
looped and also provide proper mechanical support for the
hose.
WHEN A SIPHON BREAK
SIPHON BREAK IS NOT REQUIRED
AVAILABLE FROM RAW WATER /---,
YOUR WESTERBEKE SUPPLY HOSE / ___ , \
~~I ~// / "~,I '"". \' \
~ I / \" I
~k:§ _ 1/ ~1
"~.' ___ ---', I I !
~/ \ I J I I
-<- \1" .;.~, 1 { " I I
~ ,_- \. I r I
....... "'- /' L I I I I
/--- 1- ...... "-""- I, 1 I I 1
/ ,
..... - I I I I ~ I
:,~,/ 1)[1 t!
I J I I I I I I I
I I I I I I '
I
'- I I
. "
I i
WATER :
INJECTED I
EXHAUST I
'.1.111;",," OPENING (l/BNPT)
FOR MEASURING BACK PRESSURE
EXHAUST
OVERBOARD
EXHAUST SYSTEM
DRAIN HOSE
""" WESTERBEKE
Engines & Generators
6

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: Only use unleaded fuel with an octane
rating of 8S or higher. Leaded fuel will cause serious
harm to your engine and violate your warranty.
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 is clean and pure, the following practice is
advisable.
Purchase a well-known brand
of fuel.
Install and regularly service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel tank
and the engine.
ENGINE OIL
Use a heavy duty engine oil with an API classification of SJ.
Change the engine oil and filter after an initial 50 hours of
break-in operation, and every 100 hours of operation
thereafter.An oil viscosity
of SAE 15W-40 is recommended
for this engine in all conditions.
A CAUTION: 00 not allow two or more brands of
ensine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
to produce properties harmful to your engine.
ENGINE COOLING
The 3.0KW Generator is cooled by raw water. This raw
water cooling system is described on the COOLING SYSTEMpage.
A fresh water cooling system kit is available from
WESTERBEKE that converta a raw water cooled model to a
fresh water system. Contact your WESTERBEKE dealer for
infonnation.
FRESH WATER COOLED MODELS
The 3.0KW Generator is also manufactured as a fresh water
cooled model. For operating instructions, refer to FRESH
WATER COOLED MODELS in this manual.
~ WESTERBEKE
Engines & Generators
7

CONTROL PANEL· START/STOP PROCEDURE
DESCRIPTION
The control panel provides the operator with a simple
stop/start rocker switch and a hourmeter.
The plug-in connections for the engine wiring harness,
governor sensor and remote panel are located on the side
of the control panel along with a 10 amp fuse.
The ignition control module with it's plug-in wiring is
mounted on the top
of the panel.
A CAUTION: All AC loads must be switched off
before starting. This precaution will prevent damage
caused by unanticipated operation of AC machinery
and will prevent a cold engine from starting
STARTING
The engine has a 12 VDC electric starter.
Th Start: Press the rocker switch to the start position and
release. The engine will crank and start electronically and
the switch will show a RED light to indicate the engine is
running.
Apply a light load
to the generator and allow the engine to
warm up to operating temperature before applying heavy
loads.
IIOTE: Some unstable running may occurin a cold engine
condition.
This shouldsmooth out as the engine wanns up
and the generator loads are applied.
A CAUTION: I18rt11 operate the engine for long
perItIds of time wltho/lt an amperage load being applied,
othetwlse CIIIboII build-up may o(:cur which. can cause
SIWtJtW danlage to the engine.
STOPPING
Th Stop: Press the rocker switch to stop and release. The
engine will shutdown and the,LED light
will tum off.
GENERATOR OPERATION
SlARf: Depreu swi Ich 10 START
posilion. START LEO wi II
lile. engine will cronk.
RUH LEO will remain on
when engine is running.
STOP: Depress swilch 10 STOP
posilio,. ['gi,e will slop.
RUH LEO wi" lurn off.
, ENGINESTOfllS7'ARTDECAL
Abnonnal Stop (refer to SAFETY SHUTDOWNSWITCHES)
An abnormal stop is one in which the generator ceases to run
and comes to a stop as a result of an operating fault which may
·cause damage to the engine, the generator, or create an unsafe
lOA FUSE ~~.
SWITCH
MAIN CIRCUIT
BREAKER
A WARNING: Should the engine fail to start once the
start switch has been depressed, a crank limitcircuit
will
disengage the starter and stop the starting cycle.
This will occur after approximately 15 seconds of
cranking with no start.
This Is to prevent prolonged cranking without the engine
starting which can result In the exhaust system filling
with water and backing Into the engine.
REMOTE PANEL
A remote panel is available that allows for remote operation
of the generator. The panel comes with either a
IS' or 30'
plug-in extension harness. The start/stop sequence
is
identical. Once installed, the engine can be operated by
either panel.
!V\T!WESTERBEKE
o
NOTE: Holding the start button
depressed will keep the start
circuit engaged.
• START
o
STOP.
operating condition.
~ WESTERBEKE
Engines & Generators
8

PREPARATIONS FOR.INITIAL START-UP
PRESTART INSPECTION
Before starting your generator set for the first time or after a
prolonged layoff, check the following items:
• Make certain the cooling water thru-hull petcock is open.
• 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 contaminant's.
• Check the DC electricall\;ystem. Inspect wire connections
and battery cable connections.
• Check load leads for correct connection as specified in the
wiring diagrams.
• Examine air inlet and outlet for air flow obsttuctions.
• Be sure no other generator or utility power is connected to
load lines.
• Be sure that in power systems with a neutral line that
the neutral is properly grounded (or ungrounded)
as the
system requires, and that 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.
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
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.
FRESH WATER
COOLED MODELS
FRESH IIfAT':"
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: Afterthe initial running of the generator, the air in
the engine ~ cooling system will bepurged to the coolant
recovery tank. Open the air bleedpetcock to ensure thot
the cooling system is purged
of air. After shutdown and
after the engine has cooled, the coolantfrom the recovery
tank will be drawn into the engine
~ cooling system to
replace the purged air.
Before subsequent operation of the generator, the
engine
~ manifold should be topped off, and the coolant
recovery tank may need to befilled to the MIIX level.
OIL
,-.----- Clll FIlTER
CONNEcrs
TOWArER
PUMP
FUll
...v' WESTERBEKE
Engines & Generators
9
INCOMING
FUE:

SAFETY SHUTDOWN SWITCHES
CONTROL
PANEL
SAFETY SHUTDOWN SWITCHES
This engine is protected by three shutdown switches and
two fuses. Should a shutdown occur, do not attempt to
restarl withoutfinding and correcting the cause. Refer to
the heading Engine sliirts, runs andthen shuts down in the
ENGINE TROUBLESHOOTING section of this manual.
OVERSPEED SWITCH
The overspeed PC board inside the control panel will shut
the engine down ifthe engine speed (RPM'S) exceeds the
operating speed required to run the generator. The oyerspeed
PC board will reset itself once the engine shuts down.
FUSE
SWITCH
IM-r---MA,IN CIRCUIT
BREAKER
MAIN CIRCUIT BREAKER AC
The main circuit breaker at the control panel will
automatically disconnect the AC power if there is an
electtical overload.
This circuit breaker should be manually switched off
when servicing the engine/generator to ensure that no
power is coming into the boat. The breaker is reset
manually.
FUSES
A lOAfuse located on the side of the control panel protects
the DC electtical wiring. Ifan electtical overload occurs the
fuse will blow and shut the engine down.
An 20A in-line fuse protects the battery charging circuit. If
this fuse fails, the engine will continue to run but the battery
will not be charging.
lOA FUSE
~
-=t) ) lP»=
20A FUSE
BATTERY CHARGING
EXHAUST TEMPERATURE SWITCH
An exhaust temperature switch located at the base of the
exhaust elbow sensors an excessive exhaust temperature
(an inadequate supply ofcooling water). A temperature
aboye 2400 F will shut the engine down. Inspect the cooling
system, water pump, pump belt, seacock, water strainer,
water hoses, etc. This switch will reset itself when the
exhaust cools.
TEMPERATURE
SWITCH
LOW DlL SWITCH
EXHAUST
ELBOW
Located just to the right' of the oil filter, this switch sensors
the engine's oil pressure if the oil pressure falls to below
5 psi. This switch will shut the engine down. Check the
angle ofoperation, dipstick oilleyel and oil filter. The switch
will reset itself.
LOW OIL PRESSURE SWITCH
. HIGH WATER TEMPERATURE SWITCH
(Fresh Water Cooled Model)
A high water temperature switch is located at the thermostat
housing. Normally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210"1'
(99'C), will open and shut the engine down. This switch
resets itself at 195"1' (107'C).
........,~==-
THERMqSTAT
HOUSING
OC()OL,qNTRECOVERY TANK
Engines & Generators
10

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Drive Belt
MAINTENANCE SCHEDULE
A WARNING: Never aUempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the co"ect tools for each job. Disconnect the baUery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of thefollowing maintenancejobs 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
Unleaded gasoline with octane rating of 89 or
higher
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
0
Maintain at the full level.
0
Inspect and adjust at first 25 hours. Measure
weekly
spring tension. Inspect edges for wear. Replace
every 1000 hours.
Visual Inspection 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.
Spark Plugs
0 0 0 0 0 0
Check gap. Inspect for burning and corrosion.
Generator
0 0 0 0 0 0 0
Check that AC connections are clean and secure
with no chafing - see GENERATOR INFORMATION
for additional information.
Fuel Filler
0 0 0 0 0 0
Initial change at 50 hrs, then change every 250 hrs.
Starting Banerles
0
Every 50 operating hours check electrolyte levels
(and House Baneries) weekly and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oll/Fllter
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
• Adjust the Valve
0 0 0
Initial adjustment at 50 hours, then every 500 hours .
Clearances
Carburetor Air Screen
0 0 0 0 0 0 0
Clean at 50 ours, then every 100 hours.
(Flame Arrester)
Exhaust System
0 0 0 0 0 0
Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check siphon brake 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 0 0 0 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Engine Zinc Anode
0 0 0 0 0 0 0
Inspect and replace if necessary.
'WESTERBEKE recommends this service be performed by an authorized mechanic.
~ WESTERBEKE
Engines & Generators
11

MAINTENANCE SCHEDULE
NDTE: Use the engine hour meter gauge to log your engine hours or record your
engine hours by running
lime.
"WESTERBEKE recommends this service be pertormed by an authorized mechanic.
CHECK
HOURS OF OPERATION
SCHEOULED
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 inspect the impeller for
At 800 operating hours,
wear. Replace if needed. Also inspect the a-rings.
disassemble and inspect
Lubricate both when reassembling .
. for overhaul.
Fresh Water Pump
0 0
Remove raw water pump to access the fresh water
(if appllca~le) pump. Remove the cover and inspect the impeller
and inside cover for wear. Also inspect the sealing
a-rings.
Raw Water Cooling System
0
At winter lay-up or if the generator is to be idle for
more than 3 months, flush with fresh water.
Fresh Water Cooling System
0
Drain, flush, and refill cooling system with
(if applicable)
appropriate antifreeze mix.
Heat Exchanger
0 0 0 0 0 0 0
Clean or replace anode. Open heat exchanger end
cap and clean out debris. Remove every 1000
hours for professional cleaning and pressure testing.
"Starter Motor
0 0
Check solenoid and motor for corrosion. Remove and
lubricate. Clean and lubricate the starter motor pinion
drive.
"Engine Cylinder
0 0 0
Incorrect valve clearance will result in poor engine
Compression
pertormance. Check compression pressure and timing
and adjust valve clearances.
"Exhaust Elbow
0
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteriorated.
WARNING: A defective exhaust elbow can cause
carbon monoxide leakage!
,..y- WESTERBEKE
Engines & Generators
12

ENGINE LUBRICATING OIL
DESCRIPTION
Use a heavy duty engine oil with an API classification of SJ.
Change the engine oil after an initial 50 hours
of break-in
operation, and every 100 hours
of operation thereafter. For
recommended oil viscosity, see the following chart:
Operating Temperature
Oil Viscosity
Above 68' F(20' C)
SAE 30, 10W-30 or 15W-4D
41' -68' F(5'-20' C)
SAE 20 or 1 OW-3D
Below 41' F(5' C)
SAE 10W-30
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains its own addi·
tives: additives of different brands could react in the
mixture to produce properties harmful to your engine.
CHANGING THE ENGINE OIL
The engine oil should be wann. Remove the oil drain hose
from its attachment bracket and lower it into a container and
allow the oil to drain, or attach a pump to the end of the drain
hose and pump the old oil out. Make sure the oil drain hose
is properly secured in its holder after all
of the old oil has
been drained.
9/16"
~f~~~O;'IL DRAIN
r-~~{I~--~---------------.
A WARNING: Used engine oil contains harmful
contaminants. Avoid prolonged skin contact. Clean skin
and nails thoroughly using soap and water. Launder or
discard clothing or rags containing used oil. Discard
used oil properly.
Always observe the old oil as it is removed. A yellow/gray
emulsion indicates the presence
of water in the oil. Although
this condition is rare, it does require prompt attention to
prevent serious damage. Call a competent mechanic if water
is present in the oil. Water present in the oil can be the result
of a fault in the exhaust system attached to the engine andlor
a siphoning through the water cooling circuit into the
exhaust, filling it up into the engine.
APPLY CLEAN
TO GASKET
WIPE THIS SURFACE
CLEAN BEFORE
IIV"'~LL.IIV" FILTER
OIL FILTER
CHANGING THE OIL FILTER
OIL FILTER ASSEMBLY
PRESSURE SWITCH
OIL FILTER
WRENCH
When removing the used oil filter, you may find it helpful to
punch a hole in the upper and lower portion of the old filter
to drain the oil into a container before removing it. This helps
to lessen spillage. An automotive filter wrench should be
helpful
in removing the old oil filter. Place some paper towels
and a plastic bag around the filter when unscrewing it to catch
any oil that's in the filter. Inspect the old oil filter as it is
removed
to make sure that the rubber sealing gasket comes
offwith the old oil filter. If this rubber sealing gasket remains
sealed against the oil filter adapter, gently remove it. When
installing the new oil filter element, wipe the filter gasket's
sealing surface on the oil filter adapter free
of oil and apply a
thin coat
of clean engine oil to the rubber sealing gasket on
the oil filter. Screw the filter onto the threaded oil filter stub,
and tighten the filter firmly by hand.
NOTE: Use genuine WESTERBEKE oilfilters. Genericfilters
are not recommended.
REFILLING THE OIL SUMP
Add fresh oil through the valve cover. After refilling the oil,
run the engine for a few moments while checking the engine's
oil pressure. Make sure there is no leakage around the new
oil filter or from the oil drain system, and then stop the
engine. Then check the quantity
of oil with the lube oil
dipstick. Fill to the FULL mark on the dipstick.
NOTE: It is impol1ant, because of the shallow oil sump to
keep the oil level at thefull mark.
.... WESTERBEKE
Engines & Genera/ors
13

FUEL SYSTEM
GASOLINE
Use unleaded 89 octane or higher gasoline. When fueling,
follow U.S Coats Guard regulations, close
off all hatches and
companionways to prevent fumes from entering the boat, and
ventilate after fueling.
NOTE: The generator compartment should have a gasoline
fume detectorlalarm properly installed
and working.
A WARNING: Shut off the fuel valve at the tank
when servicing the fuel system. Take CBlB In catching
any fuel that may spill. DO NOT allow any smoking,
open lIames or other sources of fire near the fuel
system when servicing. Ensun: proper ventilation exists
when servicing the fuel system.
GASOUNE/WATER SEPARATOR AND FILTER
A primary fuel filter of the water separating type must be
installed
be~een the fuel tank and the engine to remove
waterand other contaminant's from the fuel before they can
be carried to the fuel system on the engine.
Most installers include a filter/water separator with the
installation package as they are aware of the problems that
contaminant's in the fuel can cause.
These gasoline fiiters must have metal bowls (not "see-
through") to meet U.S..coats Guard requirements. The metal
bowls have drain valves to use when checking for water and
impurities.
FUEL 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 engine mounted fuel pump is
maintenance free.
A WARNING: Fuel leakage at the fuel pump or its
connections is a 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 filter bowl for
leakage. Change the filter element after the first
50 hours. See
the MAINTENANCE
SC,HEDULE.
Changing the Filter Element
1. Shut off the fuel supply.
2, Unscrew the filter bowl from the housing and allow bowl
to
come away from the housing.Remove and replace the
filter element and clean iIie bowl.
3. Remove and replace the filter element and clean the bowl
4. Inspect both O-rings. Replace
if necessary.
5. Press on a new filter and replace the filter bowl.
A WARNING: Fuel is present in the hosing and lines.
Use care to prevent spillage
ENGINE
FUEL
FILTER
LUBRICATE WITH
CLEAN FUEL AND
PRESS THE FILTER
ON OVER THE a-RING
...v" WESTERBEKE
Engines & Generators
14