Westerbeke 5.0KW BCD User manual

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OPERATORS MANUAL
MARINE DIESEL GENERATORS
5.0Kw BCD. 5.0Kw BCDA 60Hz
4.0Kw BCD 4.0Kw BCDA. 50Hz
5.5Kw BCD 5.0Kw BCDB 60Hz
5.0Kw BCD 4 BCDB 50Hz
PUBLICATION NO.042871
FOURTH EDITION
APRIL 2008
member WESTERBEKE CORPORATION. MYLES STANDISH INDUSTRIAL PARK
§dd,l' 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
~""'~~

CALIFORNIA
PROPOSITION 65 WARNING
Diesel 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
-Nausea
-Headache
- Throbbing In Temples
- Muscular TWitching
- 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 prDvided by
WESTERBEKE and should be nxed tD a
bulkhead near your engine Dr generator.
WESTERBEKE a/so recommends Installing
CARBON MONOXIDE DETECTORS In the
living/sleeping quaT1ers of your vessel.
TIley are Inexpensive and easily
obtainable at your local marine store.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused byfailure tofollow fundamental rules
and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protectyourself,
your personne~
andyourmachinery.
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 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 wlistwatch and all jewelry when working on
electlical 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 permit 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 permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free
of deblis to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: ExploSions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the 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 stoling fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out
of the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of
fire near the fuel system or engine when 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 fuel1ine 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 ratedABC by the NFPA are appropriate
for all applications encountered
in this environment.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen,
a.
highly explosive gas, which can be ignited by elecl?cal
arcing or by lit tobacco products. Shut off all electncal
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 compm1ment containing batteries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums
or sparks that could cause an explosion. Remo~e
wristwatch, rings, and any otherjewelry before handlmg
the battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last whenservicing 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) 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 manifold!
water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Don't run the generator set or engine unless the bo~t is
equipped with a functioning marine carbon
monOXIde
detector that complies with ABYCA-24. Consult your boat
builder or dealer for installation
of approved detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust systems.
Exhaust sulfur causes rapid deterioration
of copper tubing
resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, 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
of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxi~ as
exhaust fumes from gasoline engines, carbon
monOXIde
gas is present in diesel exhaust fumes. Some of the
symptoms
or signs of carbon monoxide inhalation or
poisoning are:
Vomiting
Dizziness
Headache
Nausea
AVOID MOVING PARTS
Inability to think coherently
111robbing in temples
Muscular twitching
Weakness and sleepiness
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situation
arises in which it is absolutely necessary to make operat-
ing adjustments, use extreme care to avoid touching mov-
ing parts and hot exhaust system components.
Engines &Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught
in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally or physically incapaCitated by fatigue!
OPERATORS MANUAL
Many 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.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination
of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination
of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9
DC Electrical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
15 East 26th Street
New York, NY 10010
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
National Fire Protection Association
11 Tracy Drive
Avon Industrial Park
Avon,
MA02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators 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 exhaust manifold injection pori is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
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.
Carefully review the Marine Installation Manual provided with your
WESTERBEKEengine or generator. Additional WESTERBEKEManuals
are available from your WESTERBEKE dealer.
Engines &Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ............................................ 2 Engine Adjustments (Cont.)
Introduction ........................................................ 3 Testing Glow Plugs........................................ 26
Fuel, Engine Oil, and Engine Coolant ................ 5
Preparations for Initial Start-Up ., ...................... 6
Instrument Control Panel ................................... 7
Remote Panel ................................................... 6
Starting/Stopping Procedure .............................. 8
Remote Panels.................................................. 8
Generator Break-In Procedure ........................... 9
Daily Routine ....................................................... 9
Testing Oil Pressure....................................... 26
Injection Timing............................................. 27
Drive BeltAdjustment................................... 28
Torquing the Cylinder Head Bolts................. 28
Fuel Injectors ................................................. 28
Engine Troubleshooting (Chart) ....................... 29
Control Panel troubleshooting (Chart) ............ 31
Wiring Diagram #43783 .................................... 32
Wiring Schematic #43783 . ............................... 33
Safety Shutdown Switches ............................... 10
Wiring Diagram #44732 .................................... 34
Maintenance Schedule (Chart) ........................ 11
Wiring Schematic #44732 ... ............................. 35
Fuel System ..... .................................................. 13
Cooling System ................................................. 14
Fresh Water Cooling Circuit.......................... 15
Changing the Coolant .................................... 15
Thermostat ..................................................... 16
Wiring Diagram #45633 .. .................................. 36
Wiring Schematic #45633 .... ............................ 37
Wiring Diagram #038124 .................................. 38
Wiring Schematic #038124 .............................. 39
Wiring Diagram #038124 .................................. 40
Raw Water Intake Strainer............................. 16
Wiring Schematic #038124 ... ........................... 41
Raw Water Cooling System........................... 17
Remote Panel Wiring Diagram ......................... 42
Heat Exchanger....................................,......... 17
Raw Water Pump ........................................... 17
Engine Lubricating Oil ...................................... 18
Engine Oil Change......................................... 18
Remote Oil Filter (Optional) ............................. 19
DC Circuit Battery ............................................ 20
Engine/Generator Specifications ..................... 43
Generator Information ...................................... 44
BC Generator Single Phase .............................. 45
Circuit Breaker............................................... 45
No-Load Voltage Adjustment ........................ 46
Dual Exciter Circuit Model ........................... 47
Starter Motor .................................................... 21
Shore Power Connections.............................. 47
Troubleshooting ............................................. 22 Battery Charging Circuit................................
48
Engine Adjustments .......................................... 23
MetriC Conversion Data (Chart) ....................... 49
Generator Frequency Adjustment..................
23
Lay-Up and Recommissioning ........ .................. 50
Fuel Run Solenoid ......................................... 23
Electronic Governor (Optional).....................
24
Valve Clearance Adjustment.......................... 25
Power Take Off Systems ................................. 53
Suggested Spares ............................................. 54
Engine Compression...................................... 25
Engines &Generators
1

PARTS IDENTIFICATION
DRIVE
COVER
COOLANT PRESSURE CAP
AIR INTAKE SILENCER
TOP OIL
THERMOSTAT
ASSEMBLY
ZINC
ANODE
FRONT
ENCY STOP
WATER INJECTED
EXHAUST ELBOW
~~H.tP~:M~- EXHAUST
MANIFOLD
...(,.IJt>.--=¥-----t--- MANIFOLD
1.0. PLATE
-X-\--\\~L----r-- START SOLENOID
~P--J1J--~r--- STARTER
MOTOR
DRIP TRAY
COOLANT
FILL
FLEXIBLE ISOLATED
MOUNTS
LEFT
SIDE
REAR
COOLANT PRESSURE CAP -------"".r~~'-~~,......~~
EMERGENCY STOP
CONNECTION
SIPHON BREAK
EXHAUST ELBOW
START/STOP SWITCHES--:A-----
CONTROL
PANEL
PREHEAT
SOLENOI
POWER TAKE-OFF
FUEL FILTER
REAR
AC CIRCUIT
BREAKER
SIDE OIL FILTER
~~----RAW WATER PUMP
,""",,----HEAT
EXCHANGER
FILTER
DRAIN HOSE
INLET FUEL FILTER
RIGHT SIDE
Engines & Generators
2 •

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKE's long years of experience and advanced
teclmology. We take great pride in the superior durability and
dependable performance
of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator it
is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please, read this
manual carefully and observe all the safety precautions
throughout. Should your generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This is your operators manual. A parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer.
If you are planning to install this
equipment refer to
WESTERBEKE'S installation manual
supplied with this unit.
WARRANTY PROCEDURES
Your WESTERBEKEWarranty is included in a separate
folder. If, after
60 days of submitting 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
'-vtT) wa:slEHBEKE
I
Customer Identification
MR. GENERATOR
OWNER
MAIN STREET
HOMETOWN,
USA
Model Ser. #
Expires
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT
OF SUCHSOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEliNESS OR
COMPLETENESS THEREOF
AND WIUIN NO EVENT
BE liABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings
of WESTERBEKE product
software and the unavoidable existence
of earlier
WESTERBEKE manuals.
In summation, product software
provided with
WESTERBEKE products, whether from
WESTERBEKE
or other suppliers, must not and cannot
be relied upon exclusively as the definitive authority on
the respective product.
It not only makes good sense
but is imperative that appropriate representatives
of
WESTERBEKE or the supplier in question be consulted
to determine the accuracy and currentness
of the
product software being consulted
by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
of your marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS.
An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures, which if not properly fol-
lowed, can result in personal injury or loss of life.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on a decal on the generator housing. Take the
time to enter the information on the blank decal provided
below as this will provide a quick reference when seeking
technical information and/or ordering repair parts.
SPECIFICATION
MODEL _______ _
RPM __________ _
KW ___________ _
KVA __________ _
VOLTS ________ _
AMPS ________ _
ENG. HP ______ _
ENG. SER. NO.
GEN. SER. NO.
PF IPHASE ___ _
WIRES ________ _
RATlNG _______ _
INSUL CLASS __
TEMP. RISE ___ _
BATIERY _____ _
C-t.D. _________ _
50
HZ.
60 HZ.
I
The engine serial number can also be found stamped into the
engine blockjust adjacent to the the injection pump. The
generator serial number is stamped into the generator
housing on the flat surface on the left side
of the generator.
An identification plate on the enginc exhaust manifold also
displays the engine model and serial number.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal
in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed crankcase; the crankshaft is
of
the same general type as that of a gasoline engine; and the
diesel engine has the same type
of valves, camshaft, pistons,
connecting rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the
same preventive maintenance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance
of the fuel, lubricating and cooling systems.
Replacement
of fuel and lubricating filter elements at the
time periods specified is a must, and frequent checking for
contamination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of the same brand of high detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method
of handling and firing of fuel. The
carburetor and ignition systems are done away with and in
their place is a single component -the fuel injection pump -
which performs the function
of both.
ORDERING PARTS
Whenever replacement/service parts are needed, always
provide the generator model number, engine serial number,
and generator serial number as they appear on the silver and
black name plate located on the generator end.
You must
provide us with this information so
we may properly identify
your generator set.
In addition, include a complete part
description and part number for each part needed (see the
separately furnished Parts List). Also insist upon
WESTERBEKE packaged parts because willfit
or generic
parts are frequently not made to the same specifications as
original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator. Your local WESTERBEKE
dealer will assist you in preparing an inventory
of spare parts.
See the
SPARE PARTS page in this manual. ForEngine and
GeneratorAccessories, see the ACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed information for
installing generators.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
FUEL
A CAUTION: Use number 2 diesel fuel with a cetane
rating of 45 or higher.
Care Of The Fuel Supply
Use only clean fuel! The clearance of the components in
your fuel injection pump is very critical; invisible dirt
particles which might pass through the filter can damage
these finely finished pmts. It is important to buy clean fuel,
and keep
it clean. The best fuel can be rendered
unsatisfactory by careless handling or improper storage
facilities. To assure that the fuel going into the tank for your
engine's daily use is clean and pure, the following practice
is advisable:
Purchase a well-known brand of fuel.
Install and regularly service a good, Coast Guard approved
filter/water separator between the fuel tank and the engine.
ENGINE OIL
Use a heavy duty engine oil or a synthetic oil with an API
classification
of CF or CG-4. 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
engine 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 COOLANT
Engine coolant is a 50150 mixture of antifreeze and distilled
water. This coolant allows the engine to run at its proper
temperature by transferring heat from the engine to the
coolant.
It also lubricates and protects the cooling system
from rust and corrosion. A 50150 mixture
of antifreeze and
distilled water will protect the engine to -34°P (1.12C).
PURCHASING ANTIFREEZE
Rather than preparing the mixture, WESTERBEKE
recommends buying the premixed mltifreeze so that so that
when adding coolant the mixture will always
be correct.
There are two common types
of antifreeze, Ethylene Glycol
(green) and Propylene Glycol (red/purple), either can be used
but do not mix the two and
if changing from one to another,
flush the engine thoroughly.
Premixed antifreeze for DIESELEngines:
Specification #ASTM 5345.
MAINTENANCE
Change the engine coolant every two years regardless of the
number
of operating hours as the chemical additives that
protect.and lubricate the engine have a limited life.
COOLANT RECOVERY TANK
A coolant 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'
of coolant and without introducing airinto
the cooling system. This coolant recovery tank must be
installed to help prevent the loss
of antifreeze coolant.
Engines & Generators
5

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 electrical system. 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 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 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.
WAIT FOR THE ENGINE TO COOL
BEFORE REMOVING THE RADIATOR
CAP
MANIFOLD PRESSURE CAP.,--..~""=",,,,,,,,,~ .......
PRESS DOWN AND TURN
TO LIFTOFF
FROM COOLANT
RECOVERY TANK
OIL DIPSTICK
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.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: After the initial running of the generat01; the air in
the engine's cooling system will be purged to the coolant
recovery tank. Open the air bleedpetcock to ensure that
the cooling system is purged of air. Aftershutdown and
after the engine has cooled, the coolantfrom the recovery
tank will be drawn into the engine's cooling system to
replace the purged air.
Before subsequent operation of the generator, the
engine's manifold should be topped off, and the coolant
recovery tank may need to be.filled to the MAX level.
,COOLANT
_-:::-';;'~-G::::;':~~I\ RECOVERY
I TANK
/1'/
TO NIPPLE AT
MANIFOLD PRESSURE CAP
STOP BOLT ADJUSTMENT
SPEED ADJUSTMENT
FACTORY SET
Engines & Generators
6 •

INSTRUMENT CONTROL PANEL
INSTRUMENTS
COOLANT TEMPERATURE GAUGE
Engine coolant (water) temperature should normally indicate
1750 to 1950 F (800 to 900 C).
ENGINE OIL PRESSURE GAUGE
Oil Pressure (psi) may fluctuate depending on the generator
load but should range between 30 to 60 psi.
DC VOLTMETER GAUGE
Indicates the amount the battery is being charged and should
show 13V to
14Y.
HOURMETER GAUGE
Registers elapsed time and is used as a guide for when to
perform scheduled maintenance.
TOGGLE SWITCHES
All three switches are momentary contact type.
EMERGENCY STOP SWITCH
The emergency stop switch on the side of the
control box is normally closed. When
depressed, it will open the DC circuit to the
control panel and shut the engine down.
As the switch is not toggled it can
be used
when performing maintenance.
8 AMP FUSE
An 8 amp fuse protects the instrument panel
from an electrical overload.
It is importantto closely monitorthe panel gauges.
Become aware
of the 1lonnalengine readings and take
immediate action
if these readings start to vary.
STARTING
PREHEAT: The PREHEAT toggle switch serves two purposes:
preheating the engine for easy starting and defeating
of
bypassing the engine oil pressure switch. The defeat function
activates the K2 relay instrument power fuel pump and fuel
solenoid hold terminal.
When the PREHEAT switch is depressed, the voltmeter,
panel lights, gauges and meters and fuel solenoid will
activate.
START: The START toggle switch closes the Kl relay that
energizes the starter solenoid and activates the starter.
While the PREHEAT switch is still depressed, depressing the
START switch engages the strut solenoid. When the engine
begins to fire, the START switch should be released. The
PREHEAT switch should not be released until the oil
pressure reaches 5 - 10 psi.
Should the engine not start when the START switch is
depressed for 10 to 20 seconds, release both switches and
wait 30 seconds. repeat the procedure above and preheat
longer. Never run that starter
for more than 30 seconds.
12 , 14
~6
\.
t::J """"". VOLTS
I,,~
NOTE: When starting:
A voltage drop will occur
when the preheatswitch
is depressed.
Once the engine starts, check the engine's instruments for
proper oil pressure and battery charging voltage. Apply a
light load to the generator and allow the engine's operating
temperature to come up to 1400 -1500 F (600 -660 C) before
applying heavy loads.
NOTE: Some unstable running may occur in a cold engine.
Depressing the PREHEATbutton
for 10- 15 second
intervals will help stabilize the engine rpm until the
operating temperature reaches 140°
-190°F anda load is
applied to the engine.
STOPPING
The STOP toggle switch is a normally closed switch,
providing power to the K2 relay, after the oil pressure
switch has closed upon starting. Opening
of this switch
opens the K2 relay power circuit to the fuel solenoid,
stopping the flow
of fuel to the engine and shuts down
the engine.
To stop the engine, depress the STOP switch. When the
STOP switch is depressed, the power feed to the fuel
solenoid is opened, and the fuel flow to the engine is
stopped. The STOP switch should
be depressed until the
generator stops rotating.
NOTE: When the engine is shut down, the water temperature
gauge and the oilpressure gauge will continue to register the
last temperature
and oilpressure readings displayed. They
will return to zero once electrical power is restored.
Engines & Generators
7

STARTING/STOPPING PROCEDURE
STARTING
PREHEAT: Depress the PREHEAT switch for approximately
15 seconds then, with the PREHEAT switch still depressed,
depress that START switch.
ISTART: With both switches depressed the generator will start.
Release the START switch but continue to depress the
PREHEAT switch for about 5 more seconds. This allows the
oil pressure to rise enough to close the oil pressure safety
switch.
RUN: With both switches released and the oil pressure and
coolant temperature protective circuits nom1al, the generator
will remain energized and continue to run.
FAILURE TO START
Should the engine not start when the START switch is
depressed for 10 to 20 seconds, release both switches and
wait
30 seconds. Repeat the procedure above and preheat
longer.
Never run the starter for more than 30 seconds.
NOTE: Some unstable running may occur in a cold engine.
Depressing the
PREHEAT switch for 10-15 second intervals
will help stabilize the engine
RPM until the operating tem-
perature reaches normal
and a load is applied to the engine.
Do nDt apply heavy loads until the generator has warmed
up.
STOPPING
Remove the AC electrical load from the generator and
allow the generator to
run for 3 to 5 minutes to stabilize its
operating temperatures.
Depress the
STOP switch and hold it until the generator is
completely stopped.
Now release the STOP switch.
REMOTE PANEL
The remote panel uses the same three toggle switches with
an
LED light to indicate the generator is running.
STARTING
PREHEAT: Depress the PREHEAT switch for approximately
15 seconds (the LED light will illuminate). With the
PREHEAT switch still depressed, depress that START
switch.
. START: With both switches depressed the starter will crank
and the
LED light will dim.
RUN: When the engine starts the LED light will brighten
signaling to release the START switch. Continue to hold the
PREHEAT depressed for about 5 seconds to allow the'oil
pressure to build up which closes the oil pressure safety
switch. The green
LED will remain brightly illuminated
while the engine is running.
After the generator is started and the START switch is
released, the generator's starter will not crank unless the
PREHEAT switch is operated first because this switch
supplies voltage to the START switcb.
Once the generator starts, apply a light load but allow the
generator to warm up before applying heavy loads.
GENERATOR
RELEA.SE
STARTER
PREHEAT
MUST~
PRESS\'~~
1ST e
ft
STOP
START
~'PRESS
IS tND
WESTERSEKE
FAILURE TO START
Should the engine not start when the START switch is
depressed for
10 to 20 seconds, release both switches and
wait 30 seconds. Repeat the procedure above and preheat
longer.
Never run the starter for more than 30 seconds.
STOPPING
To stop the generator, depress the STOP switch until the
generator comes to a complete stop and the
LED light goes
out.
Engines & Generators
8

GENERATOR BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour
of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine
operated properly, a break-in time is required. The service
life
of your engine is dependent upon how the engine is
operated and serviced during its initial hours
of use.
Breaking-in a new engine basically involves seating the
piston rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
glazed or scored, which is caused by overloading the
engine during the break-in period.
Your new engine requires approximately 50 hours
of initial
conditioning operation
to break in each moving part in order
to maximize the performance and service life
of the engine.
Perform this conditioning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems (raw
water pump, oil pressure, battery charging) are functioning.
AFTER START-UP
Once the generator has been started, check for proper opera-
tion and then encourage a fast warm-up. Run the generator
between 20% and 60%
of full-load for the first 10 hours.
After the first 10 hours
of the generator's operation, the load
can be increased to the full-load rated output, then periodi-
cally vary the load.
Avoid overload at all times.
An overload is signaled by
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
it within the generator's rating. Since the generator operates
at 1800 rpm to produce
60 hertz (or at 1500 rpm to produce
50 Hertz), control of the generator's break-in is governed by
the current drawn from the generator.
NOTE: Be aware of motor starting loads and the high current
draw requiredfor starting motors. This starting amperage
draw can be 3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may
be adjustments required for engine speed (hertz) during the
engine's break-in period (first
50 hours) or after this period.
A no-load voltage adjustment may also be required in con-
junction with the engine's speed adjustment. See
GENERATOR INFORMATIONin this manual.
THE DAILY ROUTINE
CHECK LIST
Follow this check list each day before starting your generator.
D Check that all generator circuit breakers (power panel) are
in the offposition before starting.
D Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
D Visually inspect the engine for fuel, oil, or water leaks.
D Check the oil level (dipstick).
D Check the coolant level in the coolant recovery tank.
D Check your fuel supply.
D Check the starting batteries (weekly).
D Check drive belts for wear and proper tension (weekly).
CHECK WITH THE ENGINERUNNING.
D Check for abnormal noise such as knocking, vibrating and
blow-back sounds.
D Confirm exhaust smoke:
When the engine is cold -White Smoke.
When the engine is warm -almost Smokeless.
When the engine is overloaded -some Black Smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached and loads are applied.
A CAUTION: 00 not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove the AC loads from the generator one at a time.Allow
the generator to run for 3-5 minutes to stabilize the operating
temperature, then
tum the key to the offposition. Once the
generator is shutdown, close down all circuit breakers as a
safety precaution.
Engines & Generators
9
1
I
.I
I

SAFETY SHUTDOWN SWITCHES
SAFETY SHUTDOWN SWITCHES
1i'he engine is protected by three automatic shutdown
switches. Should a shutdown occur, do not attempt to restart
withoutfinding
and correcting the cause. Refer to the head-
ing Engine starts, runs and then shuts down in the ENGINE
tROUBLESHOOTING section of this manual.
']'he following is a description of these automatic shutdown
switches:
High Water Temperature Switch
A high water temperature switch is located at the thermostat
housing. Nonnally closed, this switch, should the fresh water
cbolant's operating temperature reach approximately 2100P
(99°C), will open and inten'Upt the
DC voltage thereby
shutting offthe engine. This switch resets at 195"F (IOrC}.
WATER
tI'EMPERATURE
'SWITCH \_->"'-
Low Oil Pressure Switch
A low oil pressure shutdown switch is located off the
e;ngine's oil gallery. Normally open in a static state, this
switch's sensor monitors the engine's oil pressure. Should the
engine's oil pressure fall to 5-10 psi, this switch will open
interrupting the
DC voltage thereby shutting off the engine.
OIL PRESSURE
SWITCH
OIL PRESSURE SWITCH
WIRED FOR OPTIONAL
AUDIBLE ALARM
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Nonnally closed, tins switch will open and interrupt
the
DC voltage (shutting offthe engine) should the switch's
sensor indicate an excessive exhaust temperature (an inade-
quate supply
of raw water causes high exhaust temperatures).
This switch opens
at 260-270oP (127-132°C). This switch
resets at approximately 225°P (107°C).
/
~'~-....."'.......-
/-:"............ EXHAUST ELBOW
'/ .
EXHAUST
TEMPERATURE
SWITCH
Engine Circuit Breaker
The generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere in the insllument panel
wiring or engine wiring will cause the breaker
to trip. In this
event the generator will shut down because the opened
breaker interrupts the
DC 'circuit. If this should occur, check
and repair the source
of the problem. After repairing the
fault, reset the breaker and restart the generator.
High RPM Shutdown Switch
(Optional Electronic Governing)
An overspeed switch in the DC circuit shuts offthe generators
engine when the engine's speed reaches 2175 rpm (approx.) by
opening the DC circuit to the K2 relay. After correcting the
problem, this switch can be re-set by momentarily depressing the
stop switch. refer to the WIRING DIAGRAMS
in this manual.
Engines & Generators
10

. SCHEDULED
: MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
it. 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 co"ect tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenance jobs are simple but others are more
difficult and may require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH EXPLANATION OF SCHEDULED
DAY
50
100 250 500 750 1000 1250
MAINTENANCE
0
Diesel No.2 rating of 45 cetane or higher.
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
0
Oil level should indicate between MAX. and LOW on
dipstick.
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
0
Inspect for proper tension (3/8" to 1/2" deflection)
weekly and adjust if needed. Check belt edges for wear.
Visual Inspection of Enlline
0
NOTE: Please keep engine surface clean. Dirt
Check for fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engine's ability to
and electrical connections. Keep bolts & nuts tight.
remain cool.
Check for loose belt tension.
Fuel Filter
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 Oil (and filter)
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
Generator
0 0 0 0 0 0 0
Check that AC connections are clean and secure
with no chafing. See GENERATOR SECTION
for additional information.
Heat Exchanger Zinc Anode
0 0 0 0 0 0 0
Inspect zinc anode, replace if needed, clear the heat
exchanger end of zinc anode debris.
Fuel/Water Separator
0 0 0 0 0 0
Change every 200 hours.
Electronic Governor Control
0 0
Check and or adjust the no-load speed in the panel,
(if applicable)
required (hertz) and the regulator board adjustment
as needed.
NOTE: These adjustment are not a warrantable
adjustment during or after the unit's break-in.
Exhaust System
0 0 0 0
Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check anti-siphon valve operation. Check
the exhaust elbow for carbon and/or corrosion
buildup on inside passages; clean and replace as
necessary. Check that all connections are tight.
Engine Hoses
0 0 0 0 0 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Engines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your
engine hours
by running time.
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 impeller,
At 800 operating lwurs,
gasket, cam and cover for wear. Check the bearings
disassemble and inspect
and seals (the shaft should not wobble). Lubricate
for overhaul.
when reassembling.
Coolant System
0 0
Drain, flush, and refill cooling system with the
appropriate antifreeze mix.
Electric Fuel Lift Pump
0 0 0 0 0 0
Periodically check the wiring connections and
inspect the fuel line connections.
*Fuellnjectors
0
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
*Starter Motor
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
*Preheat Circuit
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (4-6 ohms).
Reinstall with anti seize compound on ttl reads.
*Engine Cylinder
0 0
Check compression pressure and timing
Compression
(see Engine Adjustments).
*Torque Cylinder Head
0 0 0
At first 50 hours, then every 500 hours
Hold-down bolts (see ENGINE ADJUSTMENTS).
* Adjust the Valve Clearances
0 0 0
Adjust Valve Clearances
(see ENGINE ADJUSTMENTS).
*Heat Exchanger
0
Remove, have professionally cleaned and pressure
tested.
·Water Injected Exhaust
0 0
Check casting integrity every 500 hours of
Elbow
operation. Replace as needed.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
12

FUEL SYSTEM.
DIESEL FUEL
Use No.2 diesel fuel with a cetane rating of 45 or higher.
bo not use kerosene or home heating fuel.
FUEL FILTERS
'The fuel injection pump and the fuel injectors are precisely
tnanufactured and they must receive clean diesel fuel, free
from water and dirt. To ensure this flow of clean fuei, the fuel
must pass through at least two fuel filters, a fuel water
separator and the engine's spin-on fuel
filter. Visually inspect,
clean,
and change these filters according to the maintenance
schedule in this manual.
FUEL WATER SEPARATOR
Aprimary fuel filter ofthe water separating type must be
tnstalled between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
be carried to the fuel system on the engine.
The owner/operator is responsible for making certain the
fuel reaching the engine's injection equipment is free of
impurities. This process
is accomplished by installing and
inaintaining a proper fuel filter/water separator between the
fuel tank and the generator/engine. Westerbeke recommends
a
10 micron filter be used.
FUEL INJECTION PUMP
'The fuel injection pump is the most important component
ofthe diesel engine, requiring the utmost caution in handling.
'The fuel injection pump has been thoroughly bench-tested
and the owner/operator is cautioned not to attempt to service
it. If it requires servicing, remove it and take it to an
authorized fuel injection pump service facility. Do not
attempt
to disassembly and repair it.
The only adjustment the servicing mechanic should make
to
the fuel injection pump is the adjustment for the engine idle
speed (see IDLE SPEED ADJUSTMENTunder ENGINE
ADJUSTMENTS).
FUEL LIFT PUMP
Periodically check the fuel connections to and out ofthe pump
and make sure that no leakage is present and that the fittings
are tight and secure. The DC ground cOIDlection at one of the
pump's mounting bolts should be clean and well secured by
the mounting bolt to ensure proper pump operation.
When energized thru the preheat circuit, the fuel lift pump will
purge air
from the fuel system and provide a continuous flow
offuel as the engine is running.
INLET FUEL FILTER
To ensure clean fuel into the fuel lift pump, there is a small
in-line fuel filter connected to the fuel lift pump elbow. This
filter should be replaced every 250 hours of operation.
ENGINE FUEL FILTER
Periodically check the fuel connections and the bowl for
leakage. Replace the filter element after the first 50 hours
then follow the MAINTENANCE SCHEDULE.
Changing/cleaning the filter element
1. Shut off the fuel supply.
2. Unscrew the retainer ling that holds the filter bowl to'the
housing and allow the bowl to come away from the
housing,
3. Remove and replace the filter element and clean the bowl.
4. Replace the sealing "0" ring and reassemble the bowl
to the housing. Thread the retainer ring on carefully
so as not to cross thread. When retainer contacts the
"0" ring, tighten 114 - 1/2 turns by hand. Open the fuel
supply and
run the engine to inspect for leaks.
THE O-RING GASKET
ONLY NEEDS TO BE
REPLACES IF IT SHOWS'
SIGNS OF AGING.
FUEL
FILTER
FUEL LIFT PUMP
LIGHTLY WIPE
WITH CLEAN FUEL
Engines & Generators
13

ENGINE COOLING CIRCUIT
dESCRIPTION
Westerbeke marine diesel generators are designed and
equipped for fresh water cooling. Heat produced in the
engine by combustion and friction is transferred to fresh
water coolant which circulates throughout the engine. This
circulating fresh water coolant cools the engine block and its
iIj.ternal moving parts. The heat is transferred externally from
the fresh water coolant to raw water by means
of a heat
exchanger; similar in function to
an automotive radiator. Raw
water flows through the tubes
of the heat exchanger while
hesh water coolant flows around the tubes; engine heat trans-
ferred to the fresh water coolant is conducted through the
tube walls to the raw water which is then pumped into the
EXHAUST
/--..........
,#J '''--,
---
---
COOLING CIRCUIT DIAGRAM
FRESH WATER ¢
RAWWATER _
exhaust system where finally it is discharged overboard. In
other words, the engine is cooled
by fresh water coolant, this
coolant
is cooled by raw water, and the raw water carries the
transferred heat overboard through the exhaust system.
The
fresh water coolant and raw water circuits are independent of
each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
ham1ful deposits.
NOTE: Refer to ENGINE COOLANTparagraphs in this sec-
tion for the recommended antifreeze and water mixture to be
used as the fresh water coolant
and for information on filling
the fresh water system.
------..
NOTE: KEEP PASSAGE
THROUGH THE MANIFOLD
CLEAR (A PIPE CLEANER
WORKS WELL).
,
~ NOTE: AN ANTI-SIPHON
- ", VALVE MAY BE REQUIRED
\
FRESH WATER
DRAIN
Engines & Generators
14