Westerbeke 3.0KW BPMG User manual

3 0
K
"
'w··" BPM G' 'Fresh Water and "
".,y , ,Raw Water Cooled Models
,- .. - - _/ .
"'3
.
• .CGiFresh
Water Cooled Modell
, ~ ."
NO. 48009
REVISION 5
JUNE 2011
~ WESTERBEKE
WEsTcRBCKE CORPORATION. MYLeS STANDISH INDUSTRIAL PARK
160JOHN HANCOCK ROAD, TAUNTON, MA 0278{J-7319 U.S.A.
-- .... -------- --------- - - --- -. -----
Af.MMA MemberNotionalMarine ManufacturersAssociation

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

CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust alid some of its constituents '
are known to the State of California
to cause cancer, birth defects,
and other reproduCfive 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:
o Dizziness
o Nausea
o Headache
;0 Throbbing in Temples
'0 Muscular Twitching
o Vomiting
o Weakness and Sleepilress
o 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.
TlIls WARNING DECAL is provided by
WES7'ERBEKE and should be "xed to a
bulkheadneaf your eliglne 01 generator.
WE8TERBEKEalso recommends Installing
CARBON MONOXIDE DETECTORS In the
Ilvilig/steeping qualfers of YOUI vessel.
TlIeyare In8xpenslve and easily .
dbtalnable at yOUi" local filarine store.
""" WESTERBEKE
Englties & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protect yourself, your personnel,
and your machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running, or 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 off electrical 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 if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
.
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or pennit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with 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 of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware - diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed
when fueling. Open and ventilate cahin
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 encountere4in this environment.
EngInes & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injlllY
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 ofthe 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 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 termioals
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 termioals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
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 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) isa deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer
for installation 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 Ou-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tuhing in exhaust sys-
tems. 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 ofthe symp-
toms or sigus of carbon monoxide inhalation orpoisoning
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
operatingadjustrnents,
use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
~ WESTERBEKE
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clotlring or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clotlring can easily
be caught in these rotating parts.
HAZARDOUS NOISE .
A WARNING: High noise/eVl1ls 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 worlc on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in
your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a
thorough exantination ofthe American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination of sources including the USCG and the NFPA.
Sections ofthe ABYC standards ofparticular interest are:
H-2 Ventilation
H-24 Gasoline Fuel Systems
P-l Exhaust
Systems
P-4 Inboard Engines
&9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES·
Read the following ABYC, NFPA and USCG pUblications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
''USCG 33CFR183"
Order from:
U.S. Goverurnent Printing Office
Washington, D.C. 20404
-."y: WESTERBEKE
Engines & Generators
iii

INSTALLATION
When installing WESlERBEKE engines and generators it is important that strict
attention be
paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON·BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of20" above the vessel's waterline. Failure to use a siphon-break when
the exhaustmanifold injection port is at or below the load waterline wiu 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 manufacturer for 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
ofthe
vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is snpplied with each Westerbeke
Marine product. .
-.-v: WESTERBEKE
Engines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification BCG ................................................. 2
Parts Identification BPMG .............................................. 3
IntroducUon ...................................................................... .4
Installation ........................................................................ 6
Rigging and Lifting......................................................6
Lncation and
Mounting ................................................6
Raw Water Discharge...................................................7
Raw Water Supply Hose ..............................................7
Fuel, Engine Oil and Engine Coolant.. .......................... 8
Fresh Water Cooled Models.........................................8
Control Panels - Starting/Stopping Procedure ........... 9
Remote Panel ...............................................................9
Preparations for Initial Start-Up ................................. 10
Pre-start Inspection..................................................... l0
Fresh Water Cooled Models....................................... 10
Safety Shutdown Switches ........................................... 11
Overspeed Switch....................................................... 11
. Main Circuit Breaker.................................................. 11
Fuses ........................................................................... ll
Exhaust Temperature Switch...................................... ll
Lnw Oil Switch .......................................................... 11
High Exhaust Temperature Switch ............................. l1
Maintenance Scbedule .................................................. 12
Engine Lubricating DiI ................................................... 14
Changing the Oil Filter .............................................. 14
Fuel System ..................................................................... 15
Changing the Fuel Filter ............................................ 15
Fnel Pump ................................................................. 15
Cooling System ............................................................... 16
Water Pump ................................................................ 16
Water Intake Strainer.................................................. 16
Changing the Impeller................................................ 16
Cooling System [Fresh Water Cooled Models]· ............... 17
Raw Water Pumps [Overhaul] ......................................... 18
Re-Assembly .............................................................. 19
Cooling System ....................................................... , ... , .. ,20
ThermostaL........,........,................, .... , .. , .. ,................. ,il
Heat Exchanger ........, .... , .. ,.......,....................,.....,...... 21
Carburetor , ............ , .................. , ... , ........... , .... , .... , .. " ........ .22
·DC ClrcuitlBattery .......... , .. , ... , ........ , .. , .......... , ........ , ........ 23 -
Shore Power Transfer Switch ...... , .... , .. , ............ , ........ , .. 23
Electronic Governor .......................... , .. , ...................... , .. 24
Engine Adjustments .. , .... , ........ , .... , .... , ............................ 25
Adjusting the Drive Belt....................,...................., .. 25
Oil Pressure ,..............................,.................., .. ,.......... 25
Engine Compression Tes!"" ......., .. , .. ,..........,...., .. , .. " .. 26
Water Pump Belt .. ,.............., .. ,................., ...... ,.......... 26
Ignition Timing,............,..........,........,......................, .. 26
Spark Plug ,....,........,....,............................................ ,.27
Thermostat [Raw Water Cooled ModeIJ .................... 27
Valve Clearance..........,......................,.........., .. "........ .28
Replacing the Timing Belt ............, .... ,...................., .. 29
Troubleshooting Guide .................. , .... , .. , ............ " ........ ,.30
Wiring Diagram ............ , .............. , ...... , .... , .. , .................. ..32
Generator Information ................................... , ........ , ...... 33
BCG/BPMG Troubleshooting ............ , .... , ....................... .34
BCG Internal Wiring Diagram .......... , .. , .......... , .............. 35
Lay-Up and RecommiSSioning ........ , ........................ , .... 36
Flushing The Cooling System .............. , ........................ 37
Genetator Specifications .... , ......... , .......... , ......... , ...... , .. .38
Metric Conversions .............................................. , ........ .39
Suggested Spare Parts , .... , .. , ............ , ..... , ........ , .. , ...... , .. .42
*Models manufactured with heat exchangers for cooling with fresh
waterlcoolant or raw water
cooled models that have been converted to .
fresh cooling via WESTERBEKE'S FRESH WATER COOUNG KIT.
..-v: WESTERBEKE
Engines & Generators
1

BATTERY
VOLTAGE,
WATER INJO,EC,gTC;WED,,,,' "'f-~)f.
'EXHAUST«
EXHAust,
HOSE
CONNECTION'
METER
START/STOP
SWITCH
CONTROL
AC
3.0KW, BC\G GENERATOR I
PARTS lD'ENTlfICATION"'
., '
CONTROL MODULE
LEFT
sIDe
COOLANT TEMPERATURE
SWITCH
~CDOLAINT PRES!IURE
EXHAUST'
TEMPERATURE
SWITCH
. DIPSTICK
SERVICE SIDE
DRIP PAN
CIRCUIT BREIIKER
RIGIIT
SIDE ,
"IIV' WESTERBEKE
Engines & Generators
2

FUEL
ENGINE SERIAL
ENGINE
NUMBER
\ 3.0 KW BPMG GENERATOR
i, PARTS iDENTIFICATION
~'.""'u" COIL
. SERVICE SIDE
FRESHWATER
(COOLANT) MODEL
,-
MAGNErtC
" PICK·UP
'CONNECTION
CONTROL
PUMP
! LEFT SIDE
~"'OlATI!RMDUNT
Engin'I; & Generators
3
WATER INJECTED
ELBOW
HEAT
EXCHANGER
--ZING ANOOE
SERVICE SIDE
WATER PUMP
;~ \

INTRODUCTION
These high performance marine engines are products of
WES1ERBEKE's
long years ofexperience and advanced
technology. We take great pride in the superior durability and
dependable performance ofour engines and generators.
Thank
you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator,
it is important that you operate and maintain it correctly.
This
manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout. Should your engine require servicing, contact
your nearest WES1ERBEKE dealer for assistance.
This
is your operators manual. A parts catalog is also
provided and a technical manual is available'from your
WES1ERBEKE
dealer. If you are planning to install this
equipment, contact your WESTERBEKE dealer for
WES1ERBEKE'S installation
manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in aseparate
folder. If, after 60 days ofsubmitting the Warranty Registry
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
I "fIV'IWESTERBEKE
I
Customer Identification
MR. WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires
PRODUCT SOFTWARE
Product software, (technical data, parts lists, manuals,
hrochures
and catalogs), provided from sources other than
WESTERBEKE are not within WES1ERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLEFOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOFAND WILL
IN NO EVENT
BE LMBLE FOR 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 ofWES1ERBEKE product software
and the unavoidable existence of earlier WES1ERBEKE
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 ofthe lmit (flywheel cover). The .
engine's serial number
is also stamped on the engine block.
ENGINE
SERIAL
Take the time to 'enter on the illustration of
the nameplate as shown above, as this will provide a quick
reference when seeking technical information andlor ordering
parts.
The
generator~ serial number and model number is located
on a decal on the the generator control pane\. Take the time
to enterthe information on the blank decal
below. This will
provide a quick reference when seeking technical informa-
tion andlor ordering parts.
Fill in the information for your own reference. ~
EngInes & Generators
4

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
will fit or generic parts are frequently not made to the same
specifications as original equipment.
NDTES, CAUTlDNS AND WARNINGS
As tltis manual takes you through the operating procedares,
maintenance schedules, and troubleshooting of your
generator, critical infonnation will be highlighted by
NOTES, CAUTIONS, and WARNINGS. An explanation
follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
the engine or generator.
A· WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
NOTE: A carbon monoxide warning decalluls been provided
by WESTERBEKE. Affix this decal in a visible location in the
engine room.
SPARES AND ACCESSDRIES
;,
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 .s.uch
as proper fuel and oil filters can be difficult to obtain alol1g
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.
PRDTECTING YOUR INVESTMENT
Care at the factory during assembly and thorongh 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 mtit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Seven important steps t~ ensure long generator lite:
• Proper engine andgenerator installation.
• An efficient well-designed exhaust system that includes
an anti-siphon break to preveat water from entering the
engine.
• Changing the engine oil and oil filters every 100 operat-
inghours.
• Proper maintenance of all engine andgenerator compo-
nents according to the maintenance schedule in this
manual.
• Use clean, filtered unlendedfuel
• 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 sintilar to a gasoline automobile engine. The cylinders
are in-lioe, 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 small amounts, is deadly.
The presence ofcarbon monoxide indicated an exhaust leak
from the engine or generator or from the exhaust
elbow/exhaust
hose, orthe 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!
5

INSTALLATION
RIGGING AND LIFTING
The engine/generator is fitted with·lifting eyes: Attach
wire rope or chain slings capable of supporting the
engine/generators weight to the eyes and lift the engine/gen-
erator by means of tackle attached to these slings. The lifting
eyes have been designed to carry the full weight: auxiliary
slings are not necessary. .
NOTE: Rigging work is best done by someone experienced
.and competent in handling machinery.
LOCATION AND MOUNTING
A solid, level mounting platform is very important for the
proper operation of your 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-BOLTEDIFIBERGLASSED
. IN PLACE
BATTERY ATTACHMENTS.
TO STARTER MOTOR
REFER TO THE WIRING
DIAGRAM IN THIS MANUAL
(01 NEGATIVE·
LEAD
DRIP TRAY/P.AN
i/SE THE PAN AS A TEMPLATE FOR
LOCATING THE PROPER MOUNTING
HOLES TO THE PLYWOOO BASE
AC CDNNECUON
SIDE VIEW
RAW WATER INLET O.Sln (2.7mm)
1.0. HOSE
. .l.IflOERNEA.TH VIEW
WATER OUTlETilND DISCHARGE
HOSES D.51n (2.7mm) 1.0.
~~~~~
FOUR 1/2" BOLTS
DIMENSIONAL DRAWINGS
For dimensional drawings. View the drawings on the
Westerbeke website www.westerbeke.comforthemost
current drawings with dimensions,
Engines & Generators
6

INSTALLATION
RAW WATER DISCHARGE
The rawwatercooled 3.0KW Generator is cooled
internally by a continuous flow of raw 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 of the
water injected exhaust elbow must belooped a ntinimum 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.
~'M:t4--IRAWWATER
HEAT EXCHANGER
When the generators location is above the loaded waterline
of
the vessel during all attitudes of vessel operation, it is still
advisable to loop the raw water discharge hose atleast 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 slwpe when
looped and also provide proper mechanical supportfor the
hose.
WHEN A SIPHON BREAK
IS NOT REOYIREQ
SIPHON BREAK
AVAILABLE FROM
: YOUR WESTERBEKE
, DEALER, -, - '-
RAW WATER ./'--',
SU~PPLY HOSE /--7--,;:-\--
I // \ '. \
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"":")-\ ~'."'"', \ r: I I
<., ,..,../ "I I r I
..... ,/ \.- . I I [I I .
. / )........... 'I I 1
:':I/'I'''-'''~' :1,1 :1
." ! I I I
i I I : ;
Y<>- ;;& I :
1_- I
WATER --
: INJECTED ,
.
EXHAUST i
EXHAUST
OVERBOARD
EXHAUST SYSTEM
DRAIN HOSE
Engines &. Generators
7

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: Only use unleaded fuel with an octane
rating of ag or higher. Leaded fuel will cause serious
harm to your engine and violate your wa"anty.
Care Of The Fuel Supply
Use only clean fuel! The clearance ofthe components in
your
fuel injection pump is very critical; invisible dirt
particles which might pass through the filter can damage
these finely finished parts. It is important to buy clean fuel,
and
keep it clean. The best fuel can be rendered
unsatisfactory
by careless handling or improper storage
facilities. To assure that the fuel going into the tank for your
engine's
daily use is clean and pure, the following practice is
advisable:
Purchase a well-known brand of fuel.
Install and regnlarJy service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel tank
and the engine.
ENGINE OIL
Use a heavy duty engine oil with an API classification of SJ,
SL, or SM. Change the engine oil and filter after an initial 50
hours ofbreak-in operation. Then follow the oil change
interval as specified in the MAINTENANCE SCHEDULE
in this manual.
Anoil viscosity of SAE-1SW-40 is recommended for this
engine in all conditions and all seasons.
Westerbeke Corporation does not approve or disapprove
the use ofsynthetic oils. If synthetic oils are used, engine
break-in must be performed
using conventional oil. Oil
change intervals must be as listed inthe MAINTENANCE
SCHEDULE section of
this manual and not be extended if
synthetic oils are used.
NOTE: The information above supersedes all previous
statements regarding synthetic oil.
NOTE: Be very careful not to overfill the oil sump. Overfilling
of the oil sump will result in erratic operation of the engine,
white-smokeyloilladen exhaust discharge, possible hard
starting or no start andfouled spark plugs.
Reference Service Bulletin #256.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The
antifreeze perfonns double duty. It allows the engine
to run at proper temperatures by transfening heat away from
the engine to the coolant. It also lubricates and protects the
cooling circuit from rust and corrosion. Use a good quality
antifreeze that contains supplemental cooling additives
(SCAs') that keep the antifreeze chemically balanced, crucial
to long term protection.
The water and antifreeze should be premixed before being
poured into the cooling circuit.
NOTE: Use the new environmentally-friendly, long lasting,
antifreeze that is now available.
A proper 50/50 mixture as recommended willprotect the
engine coolant to temperatures of -40'F.
ANTIFREEZE PROTECTION CHART
Antifreeze concentration 23%
30% 35%
Freezing Temperature 14'F
8'F -4'F
(-10'C)
(-13'C) (-20'C)
COOLANT RECOVERY TANK
50%
-40'F
(-40'C)
Acoolant recovery tank kit is supplied with each generator.
The purpose of this recovery tank is to allow for engine
coolant
expansion and contraction during engine operation,
without the loss ofcoolant and without introducing air into
the cooling system.
Englne",.& (3ener~
8

CONTROL PANEL· START/STOP PROCEDURE
DESCRIPTION
The control panel provides the operator with a simple
stoplstart rocker switch and a hourmeter.
The plug-in connections for the engine wiring hamess,
goyemor 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 ofthe 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 engille has a 12 VDCelectric starter:'"
To Start;"~""s the rocker switch to the start position and
release. The engine will crank and start electrortically and
'the switch will show a RED light to indicate the engine is
runniog. .
Apply alight load
to the generator and allow the engine to
warm up to operating temperature before applying heavy
loads.
NOTE: Some unstable running may occur in a cold engine,
condition. This should smooth out as the engine warlizs up
and the generator loads are applied.
A CAUTION: Neller operate the engine for long
periods of timewithol/t an amperage load being applied,
otherwise carbon bulld'up tnayoccur whi"hcan calise
severe damage to the engine. '
STOPPING
To Stop: Press the rocker switclll<>stoP ,and release. The
engine will shutdown and the 'LED~¥ht will1.lJm off.
STAR:T:
GENERATOR OPERATION I"
Depre$$ $witch to START
pO$ition. STARTLED·.'II
lite. engine will crank.
RUN LED will remain on
when engine i$ running.
STOP: Depre$$ $witch to STOP
pO$ition. Engine will $t.,.
RUN LED wi II turn orr.
r&gESTEBBEKE
: ENOINESTOPJS7ARTDEcAL
Abnormal Stop (refer to SAFETY SHUTDOWN SWfTCm:Sj
, Ao abnonnal 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
operating condition. -" ,. , , ,- '-" ,. '.' ,
A WARNING: Should thllllngine fail to start IInce the
start switch hasfleendepressed, a crank limit cirt;uit
will diseqgl/ge the startllr and stupthe starting cyclll.
This will occur after approximately 15 secllnds IIf
cranking, with nil start.
rhis,is til preventprolllnged cranking without the engine
, starting which can result in the exhaust system filling
with water,and backing intll the engine.
REMOTE PANEL
IG-ilmote panel'is:available that allows for remote operation
o{The generator. The papel comeS with either a 15' or 30'
plug~in extension h~ess. The statlfstop seqllence 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
E1J9ine~ & Generators
9

PREPARATIONS FOfHNITIAL START-UP i
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 thro-hull petcock is open.
• Check the engine oil level: add oil to maiotain 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 electrical~ystem. Inspect wire connections
and battery cable connections.
• Check load leads for correct connection as specified in the
wiring diagrams.
• Examine air inlet an" outlet for air flow obstructions.
• 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 reqnires, 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 I IW""==
COOLED MODELS. »,.,...,..-""!
FRESH lIiATICa
COOLANT
• Check the coolant level in both the plastic coolant
recovery tank and at the filler neck opening on the unit.
NOTE: After the initial running of the generator, the air in
the engine's cooling system should be purged to the
plastic coolant recovery tank. After shutdown and and as
the engine cools, coolant should be drawn back into
the engines cooling syst~m to replace the displaced air.
Once cooled, open the air bleed, 'petcock on the engines
; heat exchanger to allow any air left in that area to be
'\ expelled. Then close it. Open thepressure cap on the
system filler neck and ensure tbe, S)I§tem is completely
full. the cap andfill'thii'plastic coolant recovery
tank between MAX and LOW.
'.
OIL
t+--- OIL FILTER
CONNECTS
\ TOWATER
PUMP
FULL
~ WESTERBEKE
Engines & Generators
10
INCOMING
FUE~

SAFETY SHUTDOWN SWITCHES
SAFETY SHUTDOWN SWITCHES
This~ngin~js Protected by three shutdowu switches and
two fuses: Should a shutdown occur, do notattempt to
restan without finding and co"ecting the callse. Refer to
the heading Engine sttirts, runs and then shuts down in the
ENGINE TROUBLESHOOTING section of this manual.
OVERSPEED SWITCH
EXHAUST TEMPERATURE SWITCH
An exhaust temperature switch located at the base of the
exhaust elbow sensors an excessive exhaust temperature
(an inadequate supply of cooling water). Atemperature
above 240° F will shut the engine down. Inspect the cooling
system, water pump, pump belt, seacock, water strainer,
water hoses, etc. This switch will reset itselfwhen the
exhaust cools.
The overspeed PC board inside the control panel will shut .' .
. CONTROL
'. PANEL
the engine down if the engine speed (RPM'S) exceeds the
operating speed required to run the generator. The overspeed
PC board will reset itself once the engine shuts down.
FUSE
PC BOARD
rrII--rC--c---MIIIN CIRCUIT
BREAKER
MAIN CIRCUIT BREAKER AC
The main circuit breaker at the control panel will
automatically disconnect the AC power if there is an
electrical overload.
This circuit breaker should be manually switched off
when servicing the engine/generator to ensure that no
poweris coming into the boat. The breaker is reset
manually.
FUSES
A IDA fuse located on the side ofthe control panel protects
the DC electrical wiring. If an electrical overload occurs the
fuse will blow and shut the engine down.
An 20Ain-1ine fuse protects the battery charging circuit. If
this fuse fails, the engine will continue to run but the battery
. will.~ot be charging.
~,
=4)) ~
20A FUSE
TEMPERATURE
SWITCH
LOW OIL 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 oil level and oil filter. The switch
willreset itself.
. LOW OIL PRESSURE SWITCH
\
HIGH
(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 approxiroately 210"1'
(99·C), will open and shut the engine down. This switch
, resets itself at 195"1' .
(LGIJOLANT_ RECOVERYTANK\
KEEP THIS HOSE .
flr§"'==="""iiIT1r'h~<L.f/ FREE FROM DEBRIS. .
- ~'-'
.. A PIPE CLEANER
WORKS NICELY
~ WESTERBEKE
10A FUSE
BAmRY CHA.RGING
- -~- ~ ... -
Engln_e'!:& Generators
11

MAINTENANCE SCHEDULE
A WARNING: Never attempt 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
SCHEDULED EACH
EXPLANATION OF SCHEDULED
MAINTENANCE DAY
50 100 250 500 750
1000 1250
MAINTENANCE
Fuel Supply
0
Unleaded gasoline with octane rating of 89 or
higher
FueljWater Separator
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
Engine Oil Level * 0
Maintain at the full level.
Drive Belt
CJ
0
Inspect and adjust at first 25 hours. Measure
GENERATOR
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 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 Oll/Filter
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
* OVER-FILLING
CAUTION: The oil sump on this generators engine can
unintentionally be over-filledl
'WESTERBEKE recommends this service be performed by an authorized
mechanic.
After shut·down, the oil in the engines internal passages can
linger and take a number of hours to drain back into the oil
sump. Allow at least a few hours for the oil to settle back
into
the sump before checking the dipstick. An overnight
period will provide
an even more accurate dipstick reading.
(Re-starting the engine is not a problem as the engine's
internal passages are
well lubricated).
Over-filling the engines sump will result in erratic operation,
and/or smokey white oil laden exhaust, hard starting and
possibly no start.
~ WESTERBEKE
EngJnes~_ Generators
12

MAINTENANCE SCHEDULE
NOTE: Use the engine hour meter gauge to log your engine hours or record your
engine hours by running time.
'WESTERBEKE recommends this service be pertormed by an authorized mechanic.
CHECK
SCHEDULED
EACH
MAINTENANCE
DAY
50
• Adjust the Valve
D
Clearances
Carburetor Air Screen
D
(Flame Arrester)
Exhaust System
D
Engine Hoses
Engine Zinc Anode
D
Raw Water Pump
At 800 operatIng hours,
disassemble and inspect for
overhaul.
Fresh Water Pump
(if applicable)
Raw Water Cooling System
See note below
Fresh Water Cooling System
(If applicable)
Heat Exchanger
D
'Starter Motor
'Engine Cylinder
D
Compression
'Exhaust Elbow
NOTE: Flushing the raw water cooled models is
shawn elsewhere in this manual.
HOURS OF OPERATION
EXPLANATION OF SCHEDULED
100 250 500 750 1000 1250
MAINTENANCE
D D
Initial adjustment at 50 hours, then every 500 hours .
D D D 0 0 D
Clean at 50 ours, then every 100 hours.
D D 0 D D
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.
D D D 0 D D
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
0 D D D D D
Inspect and replace if necessary.
D 0 D
Remove the pump cover and inspect the impeller for
wear. Replace if needed. Also inspect the O-rings.
Lubricate both when reassembling.
D D
Remove raw water pump to access the fresh water
pump. Remove the cover and inspect the impeller
and inside cover for wear. Also inspect the sealing
O-rings.
D D
Flush the system twice per season. If the unit is used
year round, flush every 4 months or every 100 hours.
D
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
D D D D D D
Clean or replace anode. Open heat exchanger end
cap and clean out debris. Remove every 1000
hours for professional cleaning and pressure testing.
D D
Check solenoid and motor for corrosion. Remove and
lubricate. Clean and lubricate the starter motor pinion
drive.
D D
Incorrect valve clearance will result in poor engine
performance. Check compression pressure and timing
and adjust valve clearances,.
D
Test exhaust elbow for CiiStingintegrily. Replace if
casting is corroded or deteriorated.
WARNING: A defective exhaust elbow can cause
carbon monoxide leakagel
~ WESTERBEKE
Engines & Generators
13