Westerbeke 7.6KW BTD 60Hz User manual

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OPERATORS MANUAL
7.6KW BTD 60HZ
5.7KW BTD 50HZ
ARINE DIESEL GENERAT
81 HA8E
PUBLICATION 040457
SECOND EDITION
FEBRUARY 2006
l""llY" rWESTERBEKE
J WESTERBEK£ CORPORATION f 150 JOHN HANCOCK ROAD
• MYLES STANDISH INDUSTRIAL PARK ~ TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKECOM
...............
!VMMA Member National Marine Manufacturers Association
4JI""~

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
untilIt has been Inspected and repaired.
This 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.

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefully. Most accidents are
caused by failure to follow fundamental rules
and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protectyourself, your
personnel, and your machinery.
The following safety instructions are ill 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 wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessels AC
circuits, except tlu'ough a ship-to-shore double throw
transfcr switch. Damage to vessels 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!
III 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.
II 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 debris to minimize the
chances
of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessels
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before statting your engine.
II All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel
in a well-
ventilated area away from spark-producing equipment
and out
of the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill.
DO NOT allow any smoking, open flames, or other
sources
of fire near the fuel system or engine when sel'Vic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
II1II Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
.. Be certain fuel line flttings are adequately tightened and
free
of leaks.
II Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
Engines & Generators

SAFETY INSTRUCTIONS
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 butteries emit hydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment
in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terminal
of the statier solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any cOmpatiment containing batteries
to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause
an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect
it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive.
If it comes in contact with your skin, wash it
offat once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
A WARNING: Carbon monoxide (CO) is a deadly gas!
.. Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
II Be sure the unit and its sunoundings are well ventilated.
II In addition to routine inspection of the exhaust system,
install a
carbon monoxide detector. Consult your boat
builder or dealer for installation
of approved detectors.
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.
II Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners.
II 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
ordeathl
II Do not service the engine while it is running. If a
situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
• 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.
I! Make sure all attaching hardware is properly tightened.
Keep protective shields and guards
in their respective
places at all times.
II Do not check fluid levels or the drive belt's tension while
the engine is operating.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
II Never operate an engine without its muffler installed.
II Do not run an engine with the air intake (silencer)
removed.
II 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!
Engines & Generators
ii

SAFETY INSTRUCTIONS
III Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught
in moving parts.
III Make sure all attaching hardware IS properly tightened.
Keep protective shields and guards in their respective
places at all times.
III Do not check fluid levels or the drive belts tension while
the engine is operating.
II1II 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!
III Never operate an engine without its muffler installed.
III Do not run an engine with the air intake (silencer)
removed.
III Do not run engines for long periods with their enclosures
open.
A WARNING: 00 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.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough 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 m'e:
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 (FeR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater,
MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Govel11l11ent 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
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold/water injected exhaust elbow is near or below the loaded
water line
of the vessel will result in raw water damage to the engine and possible
flooding
of the vessel.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic in!Jpection and cleaning to ensure proper
operation. Failure to pmperly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer
for proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
Engines &Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ............................................. 2
Engine Adjustments (cont.)
Introduction ......................................................... 3 Generator Frequency Adjustment................24
Fuel, Engine Oil and Engine Coolant .................. 5 Fuel Run Solenoid.......................................24
Preparations for Initial Start-Up ......................... 6 Electronic Governor (optional).................24A
Generator Control Panels .................................... 7 Valve Clearance Adjusttnent ....................... 25
Remote Pallels ...............................................7 Spill Timing.................................................26
Starting/Stopping Procedure ............................... 8 Testing Glow Plugs .....................................
27
Remote Panels ...............................................8 Testing Oil Pressure.....................................
27
Complete Instrument Panel ................................ 9
Engine Troubleshooting (Chart) ........................ 28
Starting/Stopping Procedure..........................9 Alternator Testing ............................................. 30
Generator Break-In Procedure .......................... 10 Control Panel Troubleshooting (Chart) .............32
Daily Routine ..................................................... 10
DC Circuit Battery ............................................ . 33
Safety Shutdown Switches .......................... 11
Wiring Diagram #44734 ................................ ..... 34
Maintenance Schedule (Chart) ......................... 12
Wiring Schematic #44734 ............................ ..... 35
Fuel System ...................................................... .14
Wiring Diagram #039284 ...................................36
Cooling System .................................................. 15
Wiring Schematic #039284 .......................... ..... 37
Fresh Water Cooling Circuit........................16
Wiring Diagram #44121 ..................................... 38
Changing the Coolant.................................. 16 Wiring Schematic #44121 ................................. 39
Thermostat...................................................
17
Remote Panel Wiring Diagram ......................... .40
Raw Water Intake Strainer.......................... 17
Shore Power Connections ................................ .41
Raw Water Cooling System ........................ 18
Engine/Generator Specifications ..................... .42
Heat Exchanger ...........................................
18
Generator Information ...................................... .43
Raw Water Pump......................................... 18
7.6Kw Generator Single Phase ......................... 44
Engine Lubricating Oil .......................................19 Circuit Breaker ............................................44
Engine Oil Change ......................................19 Troubleshooting...........................................45
Remote Oil Filter (optional) ........................20 No Load Voltage Adjustment ......................46
Starter Motor .................................................... . 21
Residual Voltage Check...............................47
Troubleshooting...........................................
21
Bridge Rectifier ...........................................48
Engine Adjustments ........................................... 23
Exciter Rotor Field ......................................49
Drive Belt Adjustment.................................23 Measuring Resistance..................................
50
Engine Compression.................................... 23
Voltage Connection Terminal ......................50
Torquing the Cylinder Head Bolts .............. 23
lay-up and Recommissioning ........................... 51
Fuel Injectors ............................................... 23
Metric Conversion Data (Chart) ........................ 53
Suggested Spares .............................................. 54
Engines & Generators
1

7.6KW BTD PARTS IDENTIFICATION
TOP OIL FILL",
THERMOSTAT ~
ASSEMBLY ~
DRIVE BELTS
COVER
1.0. PLATE ENGINE-----
DC ALTERNATOR--------
EXHAUST
MANIFOLD
FLEXIBLE ISOLATED
MOUNTS
~
STARTER MOTOR //
INJECTORS
LEFT SIDE
REMOVE PANEl 8A
PLUG-IN - ___ ,_
HOURMETER_
CONTROL
PANEL
20A CIRCUIT BREAKER
PRE-HEAT SOLENOIO ___ -~~---;3~~;J,~~~J~~-,k
AC CIRCUIT
BREAKER
FUEl RUN SOLENOID
OIL
FUELUFT PUMP
/'
IN-LET FUEL FILTER/
RIGHT SIDE
CONNECTION FOR
SIPHON BREAK
_________ WATER INJECTED
/-- -.-"'"---. EXHAUST ELBOW
rlr;Tz~---::;;~-,__:;--+_-_L-.--_ EXHAUST TEMPERATURE
SHUTDOWN SWITCH
REAR
-~~
~POWER TAKE-OFF
GENERATOR
BACK-END
-~
~ MOUNTING RAIL
EMERGENCY STOP SWITCH
COOLANT PRESSURE CAP
TOP OIL Fill
~~-+----t---- COOLANT
TEMPERATURE
SWITCH
IL DIPSTICK
FRONT
SIDE OIL FILL
HEAT EXCHANGER
ZINC ANODE
RAW WATER PUMP
LUBE OIL DRAIN HOSE
Engines & Generators
2

INTRODUCTION
This WESTERBEKE Diesel 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
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. TIns
manual is designed to help you do this. Please, read tIns'
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 contact your "WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days
of submitting the Warranty Regi~stry
fonn you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model infonnation, including the unit's serial
number and commission date.
Customer Identification Card
Engines & Generators
Customer Identification
MR. GE:t\lERATOR OWNER
MAIN STREET
HO:M:ETO'WN, USA
Model ScI". #
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 SUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLE FOR ANY7YPE 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 detennine 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 infonnation will behighlighted 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
followed, can result in personal injury or loss of life.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The and generator serial numbers and model numbers
are located on a decal on the generator housing. Take the
time to enter this information on the illustration of the name-
plate shown below, as this will provide a quick reference
when seeking teclm.ical information and/or ordering repair
PaIts.
.. ------ .. ----~-- ....
The engine serial number can also be found into the
engine' block just above the injection pump. The generator
serial number is stamped into the generator housing on the
fiat slllface on the left side
of the generator.
An identification plate on the engine manifold also displays
the engine model and serial number.
NOTE: A carbon l1wnoxide wanling decal has been provided
by WESTERBEKE. Affzx this decal in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine ciosely 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
tl1e same type of valves, camshaft, pistons,
connecting rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the
same preventive maintep.ance 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
tin?e periods specified is a must, and frequent checking for
contamination (that is water, sediment, etc.) in the fuel
tem is also essential. Another important factor is the use
the same brand
of high detergent diesel lubrication oil
desjgned specifically for diesel engines.
The diesel engine does differ from ilie gasoline engine,
however, in its method
of handling and firing of fuel. The
carburetor and ignition systems are replaced by a single
component -the fuel injection pump -which perioDns
tl1e
function of both.
ORDERING PARTS
\Vhenever replacement 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 prot
number for each part needed (see the separately furnished
Parts List). Insist upon 'WESTERBEKE packaged paItB
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 engine. Your local \VESTERBEKE dealer
will assist you in prepaIing an inventOlY
of spare P31ts.
See the SPARE PARTS page in this manual. Forengine
accessories, see WESTERBEKE'S
ACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed infonl1ation for
installing generators
3l1d is available at your WESTERBEKE
dealer.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
FUEL
A CAUTION: Only use unleaded fuel with an octane
rating of 89 or higher. Leaded fuel will cause serious
harm to your engine and violate your warranty.
Care Of The Fuel Supply
Use only clean fuel! The clearance of the components in
your fuel injection pump
is very critical; invisible dirt
particles which might pass through the filter can damage
these finely finished parts.
It is important to buy clean fuel,
and keep it clean. The best fuel can be rendered
unsatisfactory by careless handling or improper storage
facilities.
To assure that the fuel going into the tank for your
engine's daily use
is clean and pure, the following practice is
advisable:
Purchase a well-known brand of fuel.
Install and regularly service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel tank
and the engine.
ENGINE OIL
Use an engine oil regular or synthetic with an API classifica-
tion
of CF and/or CG-4. An oil viscosity rating of 15W-40 is
recommended for all operating conditions. Change the
engine lube oil and filter after the initial 50 hours
of break-in
operation and every 100 hours or less
of operations there
after.
A CAUTION: 00 not aI/ow 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
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can con"ode 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. Use a good quality
antifreeze that contains supplemental cooling additives
(SCAs') that keep the antifreeze chemically balanced, crucial
to long term protection.
The water and antifreeze should
be premixed before being
poured into the cooling circuit.
NOTE: Use the new environmentallyjriendly, long lasting,
ant~freeze that is now available.
A proper 50/50 mixture as recommended will protect the
engine coolant to temperatures
of ~40°F.
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 air into
the cooling system.
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 tilter/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 LlFf OFF
FROM COOLANT
RECOVERY TANK
OIL DIPSTICK
lOW
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 generatof; the air in
the engine
~s' cooling system will be purged to the coolant
recovery tank. Open the
air bleed petcock to ensure that
the cooling system is
purged of air. After shutdown and
after the engine has cooled, the coolantfrom the recovery
tank will be drawn into
the engine:s cooling system to
replace the purged air:
TO NIPPLE AT
MANIFOLD PRESSURE CAP
STOP BOLT ADJUSTMENT
SPEED ADJUSTMENT
FACTORY SET
Engines & Generators
6

GENERATOR CONTROL PANELS
DESCRIPTION
The control panel is equipped with an hourmeter that
registers elapsed time
is used as a guide for scheduled
maintenance. The three toggle switches for operating the
generator are momentary contact type and are described
below.
PREHEAT: The PREHEAT toggle switch serves two pUlvoses:
preheating the engine for easy stmiing and bypassing the
engine oil pressure switch. The PREHEAT function closes
the k2 relay as well as supplies current to the
fuel solenoid
that activates the glow plugs in the cylinder head.
START: The START toggle switch closes the KI relay that
em~rglzes the starter solenoid and activates the starter.
STOP: The STOP toggle switch is a normally closed
switch, providing power to the K2 relay. Opening
of this
switch opens the power circuit to the fuel solenoid,
stopping the flow
of fuel to the engine and shuts down the
engine.
The control has an emergency stop switch, an 8 amp fuse,
and a plug-in port for remote operation.
EMERGENCY STOP 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.
REMOTE PANELS
There are two controls panels available for remote opera-
tion
of the generator that plug into the standard panel with
a 15' extension harness.
Both LIse the same three toggle
switches for operating
the generator.
REMOTE PANEL WITH FULL INSTRUMENT PACKAGE
REMOTE PANEL WITH TOGGLE SWITCH
NOTE: Wiring schematics for all three control panels are
included in this manual.
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.
START: 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 normal, 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 ~,'/arterfor 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 not apply heavy loads until the generator has wanned
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 Iight 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 nmning.
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 switch.
Once the generator starts, apply a light load but allow the
generator to warm up before applying heavy loads.
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 Jar 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

COMPLETE INSTRU ENT CONTROL PANEL
S ING I STOPPING PROCEDURE
INSTRUMENTS
COOLANT TEMPERATURE GAUGE
Engine coolant (water) temperature should normally indicate
175
0 to 1950 F (800 to 90° C).
ENGINE Oil PRESSURE GAUGE
Oil Pressure (psi) may fluctuate depending on the generator
load but should range between
35 to 55 psi.
DC VOLTMETER GAUGE
Indicates the amount the battery is being charged and should
show
l3V to 14V.
HOURMETER GAUGE
Registers elapsed time and is used as a guide for when to
pelform scheduled maintenance.
TOGGLE SWITCHES
All three switches are momentary contact type.
EMERGENCY STOP SWITCH
The emergency stop switch on the side ofthe
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 important to closely monitor the panel gauges,
Become aware of the normal engine 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
turns on the
fuel solenoid, instrument power and alternator
excitation.
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
start 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
nm that starter for more than 30 seconds.
~
\
NOTE: When starting:
A voltage drop will occur
when the preheat switch
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 140
0 -1500 F (60° 66° C) before
applying heavy loads.
NOTIE: Some unstable running may occur in a cold engine.
Depressing the
PREHEAT button/or 10 15 second
intervals will help stabilize
the engine 'pm until the
operating temperature reaches 1400 190°F and a load
is
applied to the engine.
STOPPING
The STOP toggle switch.is a nonnally closed switch,
providing power to the fuel solenoid, instrument cluster
and alternator excitation,
after the oil pressure switch has
closed upon starting.
Opening of this switch opens the
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 oil pressure
gauge will continue to register the
last temperature and oil pressure readings
di51)layed. They
will retum
to zero once electrical pmver is restored.
Engines & Generators
9

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
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
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 prut in order
to maximize the petformance and service life
of the engine.
Pelform this conditioning carefuJIy, 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.
reach its full rated speed are signs
of an overload.
AFTER START-UP
Once the generator has been started, check for proper opera··
tion and then encourage a fast wann-up. Run the generator
between 20% and 60%
of full load for the first 10 hours.
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 ove'rload 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 generators' rating. Since the generator operates at
1800 rpm to produce 60 hertz, or at 1500 to produce 50 hertz,
control
of the generators engine break-in is governed by the
cutTent drawn from the generator.
NOTE: Be aware of motor starting loads and the high
current drawn requiredfor starting motors. This starting
amperage draw can be 3 to 5 times normal running
amperage. See GENERATOR INFORMATlON
in this manual.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may be
govemor adjustments required for engine speed (hertz) dming
the break-in period (first
50 hours) or after this
period (see ENGINE SPEED (HERTZ) ADJUSTMENT under
ENGINEADJUSTMENTS. A no-load voltage adjustment may
also be required in conjunction with the engine's
speed adjust-
ment (see GENERATOR INFORMATION).
THE DAILY ROUTINE
CHECK LIST
Follow this checklist each day before staIting your generator.
• Check that all generator circuit breakers (power panel) are in
the offposition before statting.
• Record the hounneter reading in your log hours relate
to the maintenance schedule).
• Visually inspect the engine for fuel, oil, or water leaks.
• Check tile oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the staIting batteries (weekly).
• Check the drive belt for weru' aIld proper tension (weekly).
CHECK WITH THE ENGINE RUNNING.
• Check for abnon'nal noise such as knocking, vibration and
blow-back sounds.
• COnfil111 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 nonnal operating temperature
is reached and loads
al~e applied.
A CAUTION: Do not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove tile 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 off position. Once the
generator is shutdown, close down all circuit breakers as a
safety precaution.
Engines & Generators
10

SAFETY SHUTDOWN SWITCHES
SAFETY SHUTDOWN SWITCHES
The engine is protected by three automatic shutdown
switches. Should a shutdown occur, do 110t attempt to restart
without
finding and correcting the cause. Refer to the head-
ing Engine starts, runs and then shuts down in the ENGINE
l1?OUBLESHOOTING section of this manual.
The following is a description
of these automatic shutdown
switches:
High Water Temperature Switch
A high water temperature switch is located at the thennostat
housing. Nonnally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210ClF
(99°C), will open and interrupt tbe DC voltage thereby
shutting
off the engine. This switch resets at 195°P (107°C).
THERMOSTAT
HOUSING
WATER
TEMPERATURE
SWITCH ' ~-----
Low Oil Pressure Switch
WATER
TEMPERATURE
SENDER
A low oil pressure shutdown switch is located off the
engine's oil gallery. Nonnally 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
wil1 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, tius
switch will open and interrupt
the DC voltage (shutting
off the 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°F (107°C).
EXHAUST
TEMPERATURE
SWITCH
Engine Circuit Breaker
EXHAUST ELBOW
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 instrument 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
An overspecd switch in the DC circuit shuts off the
generators engine by
grounding out the ignition system if the
engine's speed reaches 2175 rpm(approximately). After
correcting the problem, this
switch can be reset by momen-
tarily depressing the stop
switch. Refer to the WIRING
DIAGRAMS in this manual.
Engines & Generators
11

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil level
Coolant level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenancejobs are simple but others are more
difficult and may require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY
50 100
250
500
750
1000 1250
MAINTENANCE
D
Diesel No.2 rating of 45 cetane or higher.
D
Check for water and dirt in fuel (drain/replace filter
if necessary).
D
Oil level should indicate between MAX. and LOW on
dipstick.
D
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
D
Inspect for proper tension (3/8" to 1/2" deflection)
weekly
and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine
D
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
D D D D D D
Initial change at 50 hrs, then change every 250 hrs.
Starting Batteries
D
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)
D D D D D D D
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
Generator
D D D D D D D
Check that AC connections are clean and secure
with no chafing. See GENERATOR SECTION
for additional information.
Heat Exchanger Zinc Anode
D D D D D D D
Inspect zinc anode, replace if needed, clear the heat
exchanger end of zinc anode debris.
Fuel/Water Separator
D D D D D D
Change every 200 hours.
Electronic Governor Control
D D
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 units break-in.
Exhaust System
D D D D
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
D D D D D D
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Engines & Generators
12

SCHEDULED
MAINTENANCE
Raw Water Pump
Coolant System
Electric Fuel Lift Pump
DC Alternator
*Fuellnjectors
*Starter Motor
*Preheat Circuit
*Engine Cylinder
Compression
*Torque Cylinder Head
Hold·down bolts
MAINTENANCE SCHEDULE
NOTE: Use the engine hour meter gauge to log your engine hours or record your
engine hours
by running time.
CHECK
HOURS OF OPERATION
EACH EXPLANATION OF SCHEDULED
DAY
50
100
250 500
750 1000
1250
MAINTENANCE
0 0 0
Remove the pump cover and inspect the impeller,
gasket, cam and cover for wear. Check the bearings
and seals (the shaft can turn, but not wobble).
Lubricate when reassembling.
D 0
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
0 0 0 0 0 0
Periodically check the wiring connections and
inspect the fuel line connections.
0 0 0
Check DC charge to alternator. Check mounting
bracket, tighten electrical connections.
0
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (4·6 ohms).
Reinstall with anti seize compound on threads.
0 0
Check compression pressure and timing
(see Engine Adjustments).
0 D D
At first 50 hours, then every 500 hours
(see ENGINE ADJUSTMENTS).
* Adjust the Valve Clearances
D 0 D
Adjust Valve Clearances
(see ENGINE ADJUSTMENTS).
*Heat Exchanger
D
Remove, have professionally cleaned and pressure
tested.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines &Generators
13

FUEL SYSTEM.
DIESEL FUEL
Use No.2 diesel fuel with a cetane rating of 45 or higher.
Do not use kerosene
or horne heating fuel.
FUEL FILTERS
The fuel injection pump and the fuel injectors are precisely
manufactured and they must receive clean diesel fuel, free
from water and dirt.
To ensure this flow of clean fuel, the fuel
must pass through at least two fuel filters, a fuel water
separator and the engine's spin-on fuel filter. Visually inspect,
clean, and change these filters according to the maintenance
schedule in this manual.
FUEL WATER SEPARATOR
A primary fuel filter of the water separating type must be
installed between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
be carried to the fuel system on the engine.
The owner/operator
is responsible for making certain the
fuel reaching the engine's injection equipment
is free of
impurities. This process is accomplished by instaIling and
maintaining a proper fuel filter/water separator between the
fuel tank and the generator/engine. Westerbeke recommends
a 10 micron filter be used.
FUEL INJECTION PUMP
The fuel injection pump is the most impOitant component
of the diesel engine, requiring the utmost caution in handling.
The fuel injection pump has been thoroughly bench-tested
and the owner/operator is cautioned not to attempt to service
it.
If it requires servicing, remove it and take it to an
authorized fuel injection pump service facility. Do not
attempt to disassembly and repair it.
The only adjustment the servicing mechanic should make to
the fuel injection pump is the adjustment for the engine idle
speed (see IDLE SPEED ADJUSTMENTunder ENGINE
ADJUSTMENTS).
FUEL LIFT PUMP
Periodically check the fuel connections to and out of the pump
and make sure that no leakage is present and that the fittings
are tight and secure. The
DC ground connection at one of the
pump's mounting bolts should be clean and well secured by
the mounting bolt to ensure proper pump operation.
When energized thm the preheat circuit, the fuel lift pump will
purge air from the fuel system and provide a continuolls
flow
of fuel 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
fue11ift pump elbow. This
filter should be replaced evelY 200 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 ring
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" ri ng 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
Engines & Generators
14