Westerbeke 6.5 SBCG-60HZ User manual

OPERATORS MANUAL
•
MARINE GASOLINE GENERATORS
. .. -
6.5 SBCG-60HZ 5.4 SBCG-50HZ ·
5.0 SBCG-&OHZ -4.2 SBCG-50HZ
Single.~~'T'
U It r a -L o w C a r b o n _M o ·n oxide Em is s i o fJ_ s

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (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
• Weakness and Sleepiness
• Throbbing in Temples
• Muscular Twitching
• Vomiting
•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.
A WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine or
generator.
WESTERBEKE also recommends installing CARBON
MONOXIDE DETECTORS in the living/sleeping
quarters of your vessel. They are inexpensive and
easily obtainable at your local marine store.

Gasoline with an ETHANOL content
higher than 10°/o (E10) is not ai~O\Ated
and ·may yoid warranty.
TM
·~.
Engines & Generators

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SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions existand
take the necessary precautions to protectyourself, your
personne~ andyour machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine Is running. Lethal voltage is present at
these connections!
• Do not operate this machinery without electrical
enclosures and 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.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine patfs or
exhaust system components. A running engine gets
.. veryhot!
• Monitor engine antifreeze coolantlevel at the. plastic
coolant recovery tank and periodicaly at the filler cap
location on the waterjacketed exhaust manifold, but only
when the engine is COLD.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching
the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the fuel injector, fuel line, filter, fuel
pump; or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel lines orfuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smolce or permit flames or sparks to occur near
the fuel system. ,KeeiJ the compartment and the
engine clean and
free ofdebris to minimize the
chances of
fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or det!.t/J!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate the cabin
after fueling. Check below for fumes/vapor Defore running
the blower. Run the blower per four minutes before starting
your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area away from spark-producing
equipment and out
of the reach of children.
• Do not fill the fuel tank(s) while the ,engine while it is running .
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill.
DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
• Make sure a fire extinguisher
is installed nearby and is
properly maintained. Be familiar with its proper use.
E!{tinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• To prevent accidental starting when servicing the
generator, remove the 8 amp fuse from the control panel.
• 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: B;~ttery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emithydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut offall electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative(-) battery cable to the
positive (
+) connection terminal of the starter so'lenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases
or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
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
protection. Batteries contain sulfuric acid, which is
destructive.
If it comes in contact with your skin, wash it
offat
OIJCe with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
A WARNING: Carbon monoxide (CO) is a dea.dly gas!
• E.nsure that the, exhaust system is adequate to expel gases
discharged
from the engine. Check the exhaustsystem
regularly
for leaks and make sure the exhaust
manifolds/water-injected
elbow is securely attached.
• Be sure the unit and its surr,pundings are well ventilated.
Run blowers when running. the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped
with a functioning marine carbon monoxide
detector
that complles withABYCA-24. Consult your
boat builder
or dealer for installation of approved
detectors.
.. For additional information, refer to ABYC TH-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 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
~rtholes, vents, or air condition~rs. 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 toxic 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
Throbbing
in temples
AVOID MOVING PARTS
Muscular twitching
Intense headache
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 operating adjustments, use extreme care to avoid
touching
movin~ parts and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
II 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.
II Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
Ill Do not check fluid levels or the drive belt's tension while
the engine is operating.
Iii! Do not allow-any swimming or activity around or near
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning or
death can occur.
HA,MilD.OU$ NOISE .
6:'WJU(Nl8G: High noise levels can cause hearing
lb~!
II Never operate an engine without its muffler installed.
11 Do not run the engine with the air intake (silencer) or
flame arrester removed.
1!11 Do not run engines for long periods with their enclosures
open (when installed).
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. R~ad yolkmanual
carefully, maintain your equipment, and follow ai1 safety
procedures. · ·
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination of the American Boat and
Yacht Council's (ABYC) standards. These standards are-from
a combination of sources lncJuding the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 VentilatioQ_for Boats using Gasoline
· H-24 Gasoline Fuer Systems
P-1 Installation of Exhaust Systems
for Propulsion and Auxiliary Engines
P-4 Marine Inboard Engines and Transmissions
E-l_lAC and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).
www.abycinc.org
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING ENGINES AND GENERATORS
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)
"Standards and Technical Information Reports for Small
Craft"
Order
from:
ABYC
613 Third Street, Suite 10
Aprtapolis, MD 21403
ww,w.abycinc.org
NFPA -No.302 (National Fire Protection Association)
"Pleasure and Commercial MotorCraft"
Order
from:
Natiomil Fire ProtectionAssociation
Battery MarchPark
Quhi.cy. MA 02269
USC({(Uruted States Coast Guard)
"regulatedions are 'mider titles CFR.33 and CFR46 of the
Code of Regulations"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid
to the following 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 port is at or below the load waterUne 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, installa
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
AVAILABLE FROM
YOUR WESTERBEKE
'DEALER
. .. SIPHON~BifEAfw/'iit·STAINLESS
LOOP'
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust
Hose is recommended. The use of this type ofhose allows for extreme bends
and turns without the Iieed ofadditional fitting and clamps to accomplish these bends
and turns. In this regard, a single length ofcorrugated exhaust hose can be used. The
system
MUST be designed to prevent the entry ofwater into the exhaust system
under
any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines &Generators
iv

CARBON MONOXIDE "G.O"/LOW·CO GENERATORS
. . . iMPORTANT INF·ORMATION ..
Catalyst performance will degrade over time. As the
generator accumulates operating hours, CO concentrations
will increase. The catalystmust be replaced every 2,000
hours of engine operation.
Verlflcatlon ofsatisfactory CO levels must be done
seasonally or each 1,000 hours (which ever occurs first).
Verification involves actual sampling of exhaust gas with an
appropriate CO analyzer.
There are two locations where exhaust gas can be sampled
Dry, but hot, exhaust can be sampled at the plugged tapped
hole in the exhaust elbow intended for back pressure
measurements. Measurements at this location may not be
practical in all instances due to the high exhaust temperature,
temperature limits of the analyzer, safety concerns over
temperatures involved or the possibility of high levels of CO.
The other location is the boat's exhaust outlet, which
contains entrained cooling water (except dry stack exhaust
systems). Only analyzers with probes should be used at this
location and it is critical that the probe not ingest water.
Probe-type analyzers have an air pump drawing a gas sample
through the probe. As a result, they tend to ingest water when
it is present. Be sure to aim the probe downwards with the
opening pointed in the direction ofthe water flow and just
out of the flow. Position the analyzer as high as possible with
the tubing leading to the probe running continuously down~
hill. Observe the usually translucent tubing between the
probe and the analyzer and be sure no water is being
ingested. If any water is ingested into the analyzer, it must be
repaired or replaced and recalibrated.
When measuring CO at the exhaust outlet be aware of the
ambient CO level by also measuring CO away from and
upwind of the exhaust outlet, especially in marinas. the CO
level at the exhaust will be influenced upwards by the
ambient level.
Whenever taking the time to verify proper CO concentration
from the exhaust with a CO analyzer, always take the
opportunity to use the analyzer to "sniff' around the engine
looking for CO from exhaust leaks. Pay close attention to the
connection of the cylinder head to the exhaust manifold, the
exhaust manifold to the water injected exhaust elbow, and all
subsequent downstream exhaust components and hoses.
Remember, exhaust gas that has not yet passed through the
catalyst is raw, untreated exhaust and is very high in CO
content.
Analyzers usually require periodic calibration. Follow the
instructions that come with the analyzer very carefully
regarding calibration.
The following are manufacturers that offer CO analyzers:
Extech, TIF, Testo, TSI, Bacharach, Fluke, Monoxor, Pyrite,
Zellwgwer Analytics, Industrial Scientific Corp, GFG, TPI,
Teledyne and others. Westerbeke recommends analyzers with
a probe connected to the analyzer by a length of transparent
tubing. They are slightly more expensive than those with the
sensor built into one end of the analyzer, but they allow you
to sample the exhaust coming out of the boat's exhaust outlet.
Engines & Generators
v

EMISSIONS
This genset meets the requirements of California's Exhaust
Emissions Standards as stated on the nameplate.
You should carefully review the Operators Manual and
Installation Manual and any other information you receive
with your genset. If you are unsure that the installation, use,
maintenance, or service of your genset is authorized, you
should seek approval from your WESTERBEKE dealer.
California users of this genset should be aware that
unauthorized modificati~ns or replacement of fuel, exhaust,
air intake, or speed control system components that affect
engine emissions are prohibited. Unauthorized modification,
removal or replacement of the engine label is prohibited.
California genset users may use the table below as an aid in
locating information related to the California Air Resources
Board requirements for emissions control.
Federal Emissions Compliance Period: The Federal
Emissions Compliance Period referred to on the nameplate
indicates the number of operating hours for which the engine
has been shown to meet Federal Emissions requirements.
Catagory C= 250 hrs, B=500 hrs,m A =lOOO.hrs.
EMISSIONS CONTROL INFORMATION TABLE
The California emissions control wan'anty statement is located in the same
Emissions Warranty Information packet, if information as this manual when the genset is shipped from the
factory.
Engine Fuel Requirements The engine is certified to operate on unleaded gasoline. See FUEL
RECOMMENDATIONS.
Engine Valve Acijustment See MAINTENANCE SCHEDULE.
Engine Ignition Timing
See MAINTENANCE SCHEDULE.
Engine Lubrlcating-00 Requirements See ENGINE OIL RECOMMENDATIONS.
EngineAdjustments
ECU.
Engine Emission Contol System . The engine emission control system consists of engine design and precision
manufacture.
Catalyst
See MAINTENANCE SCHEDULE.
Oxygen Sensor See MAINTENANCE SCHEDULE.
.
Back Pressure See MAINTENANCE SCHEDULE.
IW'IWESTERBEKE
l Engines & Giinerators
vi

TABLE OF CONTENTS
5.0Kw SBCGJ6.5Kw SBCG Parts Identification ................... 2
Introduction ...................................................................... 3,4
Fuel, Engine Oil and Engine Coolant.. ................................ 5
Preparations for Initial Start·Up .........................................6
Operating Instructions ........................................................ 7
Generator Control Panel...............................................7
Remote Start/Stop Panel ..............................................?
Break-in Procedure/Daily Operation ................................... s
Safety Shutdown SensorsJSwitches .................................... 9
Maintenance Schedule ................................................ 10.11
Cooling System .................................................................. l2
Changing Coolant....................................................... l2
Thermostat.................................................................. l3
Zinc Anode................................................................. l3
Raw Water Intake Strainer.........................................14
Raw Water Pump ........................................................14
Fuel System ....................................................................... 15
Gasoline/Water Separator & Filter.............................IS
Inlet Fuel Filter...........................................................IS
Remote Oil Filter (Optional) ........................................... 15A
Bectronic Fuel Injector (EFI} .......................................... 16
Engine Oil ............ .: ....... ....................................................17
Engine Oil Change.....................................................
!?
Engine Oil Pressure ........................................................... I8
Testing Oil Pressure ...................................................18
Engine Adjustments .......................................................... 20
Timing Belt .................................................20,21,22,23
Battery
Care ...............................................................23
Valve ClearanceAdjustment ...................................... 24
Injection Timing......................................................... 24
Torquing the Cylinder Head Bolts............................. 24
Spark Plugs.................................................................25
Drive
Belt Adjustment ...............................................25
Starter Motor (Testlng) ................................................. 26,27
Engine Troubleshooting (Chart) ........................................ 28
Generator Information ....................................................... 29
Changing Voltage/Hertz ..................................................... 30
AC Terminal Connections .................................................. 30
Shore Power Transfer Switch ................................. ; .......... 31
Wiring Schematic (#49166) ...............................:.............. 32
Remote Panel Wiring (#49209).........................................33
5.0Kw SBCG Generator Specifications ............................. 34
6.5Kw SBCG Generator Speclfications ............................. 35
Generator Hardware Torques ............................................ 36
Lay-up and Recommissioning ...................................... 37,38
Important Carbon Monoxide Data ..................................... 39
Suggested Spare Parts ...................................................... 40
Engines & Generators
1
·,.r

EXHAUST
TEMPERATURE
SWITCH
EXHAUST
CONNECTION
FAULT
SCHRADER VALVE
SBCG PARTS IDENTIFICATION
FRESHWATER
DRAIN
2
SUMP
CHARGER
BUS FUSE
GENERATOR BACK·ENO
...
AIR BLEED
PETCOCK
LEFT
SIDE
.c...,-JI.'"ffi'-----RAW WATER
PUMP
FUEL FILTER
RIGHT
SIDE

INTRODUCTION
This WESTERBEKE Generator is a product of
WESTERBEKE's long years of experience 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 generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This
is your Operators Manual. Along with this manual there
is an Installation Manual and a Parts Information. A service
Manual is available and can be ordered from your local
WESTERBEKEJUNIVERSAL dealer.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty Statement is included in the
product documentation package. There
is a warranty
registeration card
you can fill out and mail to Westerbeke
Corporation or go
to our website www.westerbeke.com and
register your product's warranty on line.
You should receive a
customer warranty identification card in the mail within 60
days ofregistering. If you do not, please contact the factory
and have your product model number, serial number and in
service date available.
/~/WESTERBEKE
) Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET ___ _
HOMETOWN, USA ________________ __
Model _____ Ser. # _______ _
Expires ________________ _
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting. Critical
information will be highlightetl byNOTES, CAUTIONS, ' ·
and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures. which if not strictly observed,
cau result in the damage or destruction of your engine.
A WARN ~"'G: Procedures. which if not properly
followed. can result in personal injury or loss oflife.
WESTERBEKE customers should also keep in mind the
time span between printings ofWESTERBEKE product
Westerbeke frequently updates manuals and software. Please
insure that you will have the latest information by consulting
your WESTERBEKE representative or visit our website at
www. westerbeke.com
The generator serial
number is stamped
on
the top the
generator
Fill in the informoJionforyour own reference.
NOTE: Technical information is provided in our Manuals for
your
reference and convenience. Westerbeke recommends
that your engine, generator orclimate control system is
serviced and/or installed only by a qualified Westerbeke
distributor or dealer.
The 5.0/6.5 SBCG Service Manual (#055051) is available
as a PDF download at www.westerbeke.com. This Service
Manu&! can also be purchased from your WESTERBEKE
DEALER as a book.
Engines & Generators
3

INTRODUCTION
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine model and serial numbers. In addition,
include a complete part description and part number
for each
part needed (see the separately furnished Parts Catalog). Also
insist upon WES1ERBEKE packaged parts because will ftt
orgeneric parts are frequently not made to the same sp~ifi
cations as original equip~ent
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour genera-
tor, critical information will be highlighted by N01ES,
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 persona/Injury or loss of lite.
NOTE: A carbon monoxide warning decal has been provided
by
WESTERBEKE. Affix this decal in a visable location in
the engine room.
SPARES AND ACCESSORIES
Certain spare parts will be needed to support and maintain
·your WES1ERBEKE generator or engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filter can be difficult to obtain along
the
way. WES1ERBEKE will provide you with a suggested
spares and accessories brochure
to assist you in preparing an
on-board inventory of the proper WES1ERBEKE parts.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted
in a WES1ERBEKE generator capable of
many
thousands ofhours ofdependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Six important steps tO ensure long generator life:
• Proper engine aiulgenerator installation andalignment.
•
An efficient well-designed exhaustsystem thatincludes
an anti-siphon break to prevent waterfrom entering the
engine.
• Changing the engine oil
and oilfilters every 100 operat-
inghours.
•
Proper maintenance of all engine and generator compo-
nents according to the maintenance schedule in this
manuaL
• Use clean, filtered unleaded fuel
• 'Klnterize your engine according to the "Lay-up and
Recommissioning''section in this manuaL
UNDERSTANDING THE GASOLINE GENERATOR
The gasoline engine driving an AC generator is in many
ways similar to a gasoline automobile engine. The cylinders
are verticle in-line, and the engine's cylinder
head has an
overllead camshaft which is chain-driven. The engine utilizes
a solid-state distributor which
is horizontally mounted and
camshaft-driven. The engine incorporates a pressure type
lubrication system, and a fresh water-cooled engine block
which
is thermostatically-controlled. 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 ofthe fuel system, ignition system,
cooling system and the generator backend.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT·
CARE OF FUEL SUPPLY
A CAUTION: Only use unleaded gasoline with an
Octane rating of 89 or"higher. The use ofa lower
. Octane gasoline will result in a loss of engine power
and performance.
Ethanol blended gasoline must not exceed E10 (111"/o).
Use ofa higher blend is not acceptable for use in these
models and may void the warranty.
Care Of The Fuel Supply
Use only clean properly filtered fuel! The fit and tolerance of
some compo~nts in the unit's fuel system are very critical;
dirtfjahicles which might pass through the filter can damage
these finely finished parts. It is important to buy clean fuel,
and keep it clean. The best fuel can be rendered
unsatisfactory
by careless handling or improper storage
facilities. To assure .that the fuel going into the tank for your
engine's daily use
is clean and pure, the following practice is
advisable:
Purchase a well-known brand of fuel.
Install and regularly service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel tank
and the engine.
ENGINE OIL
Use a good brand ofengine oil with an API and SAE
designations
as listed in the SPECIFICATION Section of
this manual.
Change the engine oil and filter after an initial 50 hours of
engine break-in operation. Then follow the oil and filter
change intervals as specified in the MAINTENANCE
SCHEDULE in
this nianual.
Westerbeke Corporation does not approve or disapprove
the use.of synthetic oils. If synthetic oils are used, engine
break-in MUST be performed using conventional oil. Oil
change intervals must be as listed in the MAINTENANCE
SCHEDULE section in
this manual and not to be extended
if
synthetic oils are tised.
NOTE: The information above supercedes all previous
statements
regarding synthetic oil usage.
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 performs double
duty. It allows the engine
to run at proper temperatures by transferring heat away from
the engine to the coolant. It also lubricates and protects the
cooling circuit from rust and corrosion. Look for a good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs') that keep the antifreeze chemically
balanced, crucial to long term protection.
The distilled water and antifreeze should ben pre-mixed
before being poured into the cooling circuit.
NOTE: Use the new environmentally-friendly, long lasting,
antifreeze that is now available.
Aproper
50150 mixture as recommended will protect the
engine coolant to temperatures of -40"F.
COOLANT RECOVERY TANK
Acoolant recovery tank kit is supplied with each generator.
The purpose ofthis recovery tank is to allow for engine
coolant expansion and contraction during engine operation,
without the loss
of coolantand without introducing air into
the cooling system. ·
NOTE: This.tank, with its short run of plastic hose, is best
located
at orabove the level of the engine :S exhaust
manifold. ·
Engines & Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your generator for the first time or after a
prolonged layoff, check the following items:
• Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and ba~ry cable connections.
• Check the coolant level in both the plastic recovery tank
and at the manifold. ·
NOTE: During the initialfilling of the cooling system, the
air bleedpetcock on the manifold should be opened to
purge airfrom the engine block. Once coolant, free of air
bubbles, flows from the petcock -close the petcock.
After
shutdown, and after the engine has cooled, the
coolantfrom the recovery tank will be drawn into the
engine's cooling system to replace the purged air.
Before subsequent operation of the generator, the engine :SO
manifold should be topped off, and the coolant recovery
tank may need to have coolant added to it. Do not
as coolant loss will occur.
AIR BLEED
PETCOCK
MAX. FULL
MANIFOLD
PRESSURE
CAP
THERMOSTAT
HOUSING
RAW WATER DRAIN
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
• Check load leads for correct connections as specified in
the wiring diagrams.
• Examine the air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
the load lines.
• Be sure that in power systems with a neutral line that the
neutral is properly grounded (or ungrounded) as the system
requires, and that generator neutral is properly connected
to the load neutral. In single phase systems an incomplete
or open neutral can supply the wrong line-to-neutral
voltage on unbalanced loads.
• Make certain the raw water thru-hull is open.
A CAUTION: When starting the generator, It Is
· recommended that all AC loads, especially large
mofllrs, be switched OFF until the engine has come
up to speed and, In cold climates, starts to wann up.
This precaution will preretit damage caused by
unanticipated operation of the AC machinery and will
prevent a cold engine frDm stalling.
ROCKER COVER
1-.viWESTERBEICE
FRESH WATER
DRAIN
) Engines & Generators
6

OPERATING INSTRUCTIONS
START SWITCH
GENERATOR CONTROL PANEL
F1 FUSE
·DC CIRCUIT
·BREAKER
ON/OFF
. LED FAULT
INDICATOR LIGHTS
The start/stop rocker switch is the only functional component
on the generator control panel used to start and stop the ·
generator.
The start/stop rocker switch is a three position switch with
momentary contacts in the (START) and (STOP) position and
a stationary contact function in the center (NORMAL) this
position allows the generator to run once started and also
enables the remote start/stop panel(s) to control the start/stop
functions of the genemtor.
The (START) position starts the generator and once released
reverts to the center position. The (STOP) position stops the
engine in normal operation as well as in an emergency
situation. This position opens the K2 run relay which
de-energizes the engine's run. circuit and shuts down the :engine.
Starting
Simply press the (START) switch momentarily. The ECU will
take the command and start the generator. The green LED on
the start switch will illuminate and dim as the engine cranks
and glow bright once the engine starts.
Stopping
oepress ihe (STOP) switch momentarily and release. The
ECU will receive the (STOP) command and shut the
generator down.
Failure to Start
The start cycle will automatically terminate if the unit fails to
start after 6 seconds (approximately) ofcranking time. The
fault LED for ''Underspeed" will illuminate and flash. To
initiate another another crank cycle, the panel DC breaker
must be. turned OFF and then back ON. ·
•·
REMOTE START/STOP PANEL
The components on the panel are:
1. A three position start/stop rocker switch.
2. A green LED run indicator light on the rocker switch.
3. A four position LED fault shut.down display board.
The start/stop rocker switch functions the same as the start/stop
rocker switch on the generator's control panel as previously
explained.
The green LED run indicator light on the rocker switch will
illuminate when the start circuit is energized. It will go dim as
the engine cranks and will brighten as the engine starts
indicating the generator is running.
The LED fault shut down display board has four separate LED
lights to display to the operator the cause of the generators
automatic shut down. The four LED displays are: low oil
pressure, high engine operating temperature, high exhaust
temperature and engine over-speed/under-speed (flashes).
Should the generator shut down from one of these faults, the
fault LED will remain illuminated. To reset- the LED, the DC
breaker must be turned OFF and then back ON.
The remote start/stop panel is a plug-in accessory and has
extension harnesses available in varying lengths from 15 feet
up to lOOfeet in length.
1+-----3.35----~
0 0
fW'JWESTERBEKE
T
START·----.STOP
0
Engines &Generators
7

BREAK-IN PROCEDURE/DAILY OPERATION
BREAK-IN PROCEDURE
After the generator has been started, check for proper
operation and then encourage a fast wann-up. Run the gener-
ator between 20% to 60%
of full load for the first 10 hours.
A CAUTION: Do not attempt to break-in your
generator by running without a load. .
After the first 10 hours of the generators' operation, the load
can be increased to the full-load
rated output; then
periodically
vary the load.
Avoid overload at all times. An overload
is signaled by a
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 engine break-in is
governed by the current drawn from the generator.
To protect against unintentional overloading of the generator,
the generator's output leads should be routed through a
circuit breaker that is rated at the rated output
of the
generator.
NOTE: Be aware of motor starting loads and the high
current drawn required for starting motors. This starting
amperage drawn can be 3 to 5 times normal running
amperage. See GENERATOR INFORMATION in this
manual.
CHECK LIST
Follow this checklist each day before starting your generator.
• Record the hourrneter reading in your log (engine hours
relate to the maintenance schedule).
• Visually inspect the engine for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check the drive belts for wear and proper tension
(weekly).
• Check for abnonnal noise such as knocking, vibration and
blow-by sounds.
• Confinn exhaust smoke:
When the engine is
cold- white smoke ..
When the engine is wann -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 ait.d loads are applied.
A CAUTION: Do not operate the generator tor long
periods of time without a load being placed on the
generator.
GENERATOR ADJUSTMENTS
Once the generator has been placed inoperation, there may
be governor adjustments required for engine speed {hertz)
during the engine's break-in period (first 50 hours) orafter
this period (see
ENGINE SPEED (HERTZ) ADJUSTMENT
under ENGINE ADJUSTMENTS.
NOTE: After the first 50 hours of generator operation check
the maintenance schedulefor the 50 hour service check.
Engines & Generators
8

SAFETY SHUTDOWN SENSORS AND SWITCHES-
SAFETY SHUTDOWN SENSORS AND SWITCHES
The engine is protected by a variety of shutdown sensors and
switches that signal the ECU (Electronic Control Unit) when
a fault occurs. Should an automatic shutdown occur from a
fault, one of the four fault LED lights on the control panel
will illuminate to indicate the cause:Correct the cause of the
shutdown. To reset the ECU and tum off the fault LED,
momentarily turn offthe panel DC breaker. The following
are descriptions ofthese safety shutdown sensors and
switches.
Exhaust Temperature Switch
A exhaust temperature switch is located on the exhaust elbow.
Normally closed, this switch will open and and interrupt the
DC voltage to the K2-nm relay (shutting off the engine)
should the switch's sensor indicate an excessive exhaust
temperature (an inadequate supply of raw water causes high
exhaust temperatures). This switch opens at 260-270"F (127-
1320C). This switch resets at approximately 225"F (107°C).
TO SIPHON BREAK ·
Water Temperature Sensor
A water temperature sensor is located on the waterjacketed
intake manifold to monitor engine antifreeze coolant
temperature. The sensor is sending a DC voltage.to the ECU
that interprets this as engine coolant temperature. Should the
DC voltage reach an overheat threshold, the ECU will shut
the engine down and will illuminate the over temp fault LED
light on the control panel.
WATER TEMPERATURE
SENSOR
WIPE SURFACE CLEAN
BEFORE INSTALLING
Low Oil Pressure Sensor·
FILTER GASKET
APPLY CLEAN OIL WHEN
ASSEMBLING NEW FILTER
Alow oil pressure sensor is \ocated adjacent to the lube oil
filter. It sends a DC voltage to the ECU that is interpreted as
oil pressure. Should this DC voltage drop to a preset
threshold. The ECU will shut the engine
down and will
illuminate the low oil pressure fault LED on the control
panel.
·. ·
Overspeed shutdown
The ECU is monitoring engine rpm from an AC signal sent
to it from the MPU (Magnetic Pick-up) positioned over the
flywheel ring gear teeth. Should the engine speed cause the
MPU to generate an AC voltage indicating an overspeed con-
dition. The ECU will shut the engine down and illuminate
the overspeed fault LED on the control panel. Likewise
with
an under-speed, the ECU will shut the unit down and the
LED will flash.
Engine DC Circuit Breaker
The generator's engine is protected by a panel mounted
manual reset circuit breaker. Excessive DC current draw or
electrical overload anywhere in the instrument panel wiring
or engine wiring will cause the breaker to trip. In this event
the generator will shutdown because the opened breaker
interrupts the
DC circuit to the the ECU. If this should occur,
check and repair the source of the problem. After repairing
the fault, reset the breaker and restart the generator.
Engines & Generators
9

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. When servicing/replacing DC components, tum off the DC circuit breaker on the
control panel, or tum off the battery switch.
SCHEDULED MAINTENANCE
I DAILY CHECK BEFORE START-UP
Coolant Level
Engine Oil Level
Fuel/Water Separator (owner installed)
Fuel Supply
*Visual Inspection of Engine
I INITIAL 50 HOURS OF OPERATION
*Spark Plugs
Engine Oil and Filter
*Exhaust System
*Air Screen/Flame Arrestor
*Valve Adjustment
*Inlet Fuel Filter
*Fuel Filter and "0" Rings
I EVERY 50 OPERATING HOURS OR MONTHLY
*Drive Belts
(Fresh Water/Raw Water Pumps)
Starting Batteries
Electric Fuel Pump
Zinc Anode
EVERY 100 OPERATING HOURS OR YEARLY
Engine Oil and Filter
*Air Screen/Flame Arrestor
EXPLANATION OF SCHEDULED MAINTENANCE
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Check for water and dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Fresh unleaded gasoline with an octane rating of 89 or higher. Lower octane will affect
engine performance. 10% ethanol maximum.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight. Insure there are no exhaust leaks around the elbow. Inspect wiring
and electrical connections. Look for loose bolts/hardware and possible corrosion.
Clean/re-gap.
Initial engine oil and filter change at 50 hours, then change both every 100 hours.
Initial check at 50 hours, then every 250 hours or once a year. Carefully inspect for leaks.
Check that the exhaust hoses are properly attached and that the securing clamps are tight.
Check the integrity/mounting security of the water injected exhaust elbow.
Remove, clean and re-install screen pack. Inspect rubber sealing ring and replace if
necessary, then once a year.
Check adjustment of valves. Check again at 500 hours.
Initial change, then every 250 hours or once a year.
Initial change, then every 250 hours or once a year.
Inspect for proper tension (3/8' to 1/2' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
our own ins ection schedule.
Change engine oil and filter.
Remove, clean and re-install screen pack. Inspect rubber sealing ring and replace if
necessary.
*WESTERBEKE recommends this service be performed by a knowledgeable mechanic.
AMPERAGE DRAIN
There is a very small amount of amperage being drawn from
the unit's starting battery by the electronics on the unit when
the generator is not in use. To prevent this and draw down of ·
the starting battery charge. Tum OFFeither the panel DC
breaker or the startingbattery switch when the unit will not
be operated for a period oftime.
Engines & Generators
10