Westerbeke 8.0 KW-60Hz SBEG User manual

~ *
Jf Jf
SINCE 19'l1 *
~
ic
OPERATORS MANUAL
B.OKW ·60Hz SBEG /6.4KW • 50 Hz SBEG
1 O.OKW • 60Hz SBEG I B.OKW • 50 Hz SBEG
12.5KW • 60Hz SBEG /1 O.OKW • 50 Hz SBEG
14.0KW • 60Hz SBEG /11.6KW • 50 Hz SBEG
MARINE G E GENERATORS
OCTOBER 2012

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
• Throbbing in Temples
• Muscular Twitching
• Vomiting
• Weakness and Sleepiness •Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
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.
/-.y/WESTERBEKE
)GENERATORS
SAFE
co
I lAIII
WESTERBEKE CORPORA T/ON • MYLES STANDISH INDUSTRIAL PARK
!50JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
WARNING
G-=-~~
~
TEL: [phone] • FAX: [phone]· • Website: www. westerbeke.com

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

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefuUy. Most accidents are
caused by failure to foUow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protectyourself, your
personne~ andyour machinery.
The foUowing safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Oo 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 through a ship-to-shore double throw
transfer switch. Damage
to vessels AC generator may
result ifthis 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: Oo not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• In case ofan engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources
of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel
filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free
of 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 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 is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow
any smoking, open flames, or other
sources of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
• 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.

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove
the negative lead first and reconnect
it last.
• Make certain all personnel are clear ofthe engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BAnERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut offall electrical
equipment in
the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative(-) battery cable to the
positive (
+) connection terminal ofthe starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive
gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause
an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the
battery.
• Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negative lead
first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber
apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
off at once with
water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly
for leaks and make sure the exhaust
manifolds/water-injected elbow
is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator
set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder
or dealer for installation ofapproved
detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water
leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet
is near the waterline, water could
enter
the exhaust discharge outlet and close or restrict the
flow ofexhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or signs ofcarbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing
in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a
situation arises in which it
is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving paits and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair
and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving
parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at
all times.
• Do not check fluid levels or the drive belts tension while
the engine is operating.
• Stay clear ofthe drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many ofthe 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 ofthe American Boat
and Yacht
Council's (ABYC) standards. These standards are a
combination ofsources including
the USCG and the NFPA.
Sections ofthe ABYC standards ofparticular interest are:
H-2 Ventilation
P-1 Exhaust Systems
P-4 Inboard Engines
E-9
DC Electrical Systems
All installations must comply with the Federal Code of
Regulations
(FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
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. 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
mu~t 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 andpossible
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 inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust system's hose MUST be certified for marine use. Conugated Mmine
Exhaust Hose is recommended. The use of this type of hose allows for extreme bends
and turns without the need
of additiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length
of conugated exhaust hose can be used. The
system MUST be designed to prevent the entry
of water into the exhaust system
under any sea conditions and at any angle
of vessels heal.
A detailed Marine Installation Manual covering gasoline and diesel
engines and generators is supplied with every unit sold. This manual
.is also available in pdf format on our website to download
Website: www.westerbeke.com
Engines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
SIPHON-BREAK WITH STAINLESS
LOOP FOR 1" HOSE
PART NO. 044010

TABLE OF CONTENTS
Parts Identification ............................................ .2
Engine Troubleshooting Guide .......................... 27
Introduction ......................................................... 3 Electrical
Troubleshooting Guide ..................... 29
Warranty Procedure......................................
.3
Serial Number Location ................................4
Fuel, Engine Oil and Engine Coolant .................. 5
Preparations for Initial Start-Up ......................... 6
Starting/Stopping Procedure ............................... 7
System Monitoring Software ............................. 30
Data Logging (Troubleshooting) ........................ 31
DC Electrical System ........................................ .35
Battery Care.................................................36
Wiring Schematic #49167 ................................ .37
Remote Panel ...................................................... 8
Remote Panel Wiring ........................................ .38
Break-In Procedure/Daily Operation ................... 8
Starter Motor ..................................................... 39
Safety Shutdown Sensors .................................... 9
Generator Information ...................................... .41
Maintenance Schedule ..................................... 10
Measuring Exhaust Back Pressure .................... 11
AC Voltage Regulator (Current Models) ........... .42
Exciting the Generator.................................42
Fuel System ....................................................... 12 AC Voltage Connections .............................43
Bleeding the Fuel System............................
13
BE Generators/Early Models.......................44
Electronic Fuel Injection (EFI) ...................14
AC Voltage Regulator (Early Models) ............... .46
Cooling System .................................................. l5 AC Voltage Connections .............................47
Changing Coolant........................................
l5
Exciting the Generator.................................47
Thermostat...................................................16
BE Generator (Troubleshooting) ....................... .48
Raw Water Pump.........................................
17
Engine/Generator Specifications ..................... .49
Raw Water Intake Strainer...........................
17
Shore Power Transfer Switch ............................ 50
Engine Lubrication Oil.. ..................................... 18
Oil Filter ...................................................... 18
Remote Oil Filter......................................... 19
Throttle Body Assembly .................................... 20
Engine Adjustments ........................................... 21
Spark Plugs.................................................. 21
High Tension Cords.................................... .21
Lay-Up and Recommissioning ........................... 51
"CO" Data (Important) ...................................... 53
Installing a New Catalyst.. ................................ 54
Emissions Data ..................................... : ............ 55
Metric Conversions ........................................... 56
Suggested Spare Parts ...................................... 57
Drive Belt Adjustment................................
.21
Fuel Pressure Test........................................ 21
Engine Compression Test............................22
Ignition timing.............................................22
Valve Clearance...........................................23
Testing the Igniter........................................23
Timing Belt Inspection and Replacement...24
Engines & Generators
1

DC
CIRCUIT
BREAKER
HEAT EXCHANGER.
20A CIRCUIT BREAKER RESET
PARTS IDENTIFICATION .
SENSOR 1
FRONT
SPIN-ON OIL FILTER
RIGHT SIDE
MOUNT
LEFT SIDE
Engines & Generators
2

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
of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator,
it is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout. Should your generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This is your Operators Manual. A Parts Catalog is also
provided and a Technical Manual is available from your
WESTERBEKE dealer.
If you are planning to install this
equipment yourself, contact your WESTERBEKE dealer
for WESTERBEKE'S Installation Manual.
WARRANTY PROCEDURES
Your WESTERBEKEWarranty is included in a separate
folder.
If you have not received a customer identification
card registering your warranty 60 days after submitting the
warranty registration form, , please
contatt the factory in
writing with model infom1ation, including the unit's serial
number and commission date
1-.v-IWESTERBEKE
I Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires
Ser. #
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 COMPLETE-
NESS THEREOF AND WILL IN NO EVENT BE LIABLE
FOR ANY TYPE OF DAMAGE OR INJURY INCURRED IN
CONNECTION WITH OR ARISING OUT OF THE
FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the time
span between printings
of WESTERBEKE product software
and the unavoidable existence
of earlier WESTERBEKE
manuals. In summation, product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively 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.
SERIAL NUMBER LOCATION
The generator serial number and model number are located
on a decal on the generator housing. Take the time to enter
the information on the blank decal provided. This will pro-
vide a quick reference when seeking technical infonnation
an~.or•o•r•d•en···ng .. re•p•ru•.r•p•ar•ts .......... ~ .... ~ .... ~
SPECIFICATI N
MODEL _______ _
RPM.·---------
KW ------------
KVA -----------
VOLTS---------
AMPS ---------
ENG. HP -------
ENG. SER. NO.
GEN. SEA. NO.
PF /PHASE ----
WIRES ________ _
RATING _______ _
INSUL CLASS __
TEMP. RISE ----
BATIERY ------
C.I.D. ----------
••
Fill in the infomwtionfor your reference.
••
~~~~~~~~~
E~f!i=t:t =i=t~l
Engine I.D. Plate
Engines & Generators
3