Westerbeke 8.0 KW-60Hz SBEG User manual

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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

INTRODUCTION
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine model and serial numbers. In addition,
include a complete pmt description and part number for each
part needed (see the separately furnished Parts Catalog). Also
insist upon WESTERBEKE packaged parts because willfit
or generic parts are frequently not made to the same specifi-
cations as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
of your genera-
tor, critical information will
be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
the engine or generator.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visable location in
the engine room.
SPARES AND ACCESSORIES
Certain spm·e parts will be needed to support and maintain
your WESTERBEKE 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. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
on-board inventory
of the proper WESTERBEKE pmts.
4
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE generator capable
of
many thousm1ds of hours of dependable service. However tl1e
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
tl1e field. This is up to the
buyer/owner-operator.
NOTE: Six important steps to ensure long generator life:
• Proper engine and generator installation and alignment.
• An effiCient well-designed exhaustsystem that includes
an anti-siphon break to prevent water from entering the
engine.
• Changing the engine oil and oilfilters every I00 operat-
ing hours.
• Proper maintenance of all engine and generatorcompo-
nents according to the maintenance schedule in this
manual.
• Use clean,ftltered unleadedfuel.
• Winterize 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
overhead caiTishaft which is chain-driven. The engine utilizes
a solid-state distributor which is horizontally mounted and
caiTishaft-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 Saine preventive maintenance
that is required
of a gasoline automobile engine. The most
important factors to the generator's longevity are proper
ventilation, maintenance
of the fuel system, ignition system,
cooling system and the generator backend.

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: Use unleaded 89 Octane gasoline or
higher. Ethanol gasoline must not exceed must not
exceed E10 (100/o). Gasoline with higher percentages of
Ethanol are not acceptable for use in these models and
can void the warranty.
When fueling, follow U.S. Coast Guard procedures, closing
hatches and companionways to prevent fumes from entering
the boat and cabins.
Be sure to ventilate after fueling.
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.
NOTE: It is recommended that the fuel system be bledduring
each oil andfilter change interval to ensure no air has
accumulated in the fuel system.
ENGINE OIL
Use a heavy duty engine oil with an API classification of SJ,
SL,
or SM. Change the engine oil and filter after an initial 50
hours of engine break-in operation. Then follow the oil and
filter change intervals as specified in the
MAINTENANCE
SCHEDULE in this manual.
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 used.
NOTE: The information above supersedes 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. Use a
good quality
antifreeze that contains supplemental cooling additives (SCAs)
that keep the antifreeze chemically balanced, crucial to long
term protection.
The water and antifreeze should be premixed before being
poured into the cooling circuit.
NOTE: Use the new environmentally-friendly, long lasting,
antifreeze that is now available.
A proper 50/50 mixture as recommended will protect the
engine coolant to temperatures
of -400F
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 for the first time or after a pro-
longed layoff, check the following items:
a Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
a Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
a Check the DC electrical system. Inspect wire connections
and battery cable connections.
a Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: After the initial rwming of the generator, the air in
tho! engine's cooling system will be purged to the coolant
recovery tank. Open the air bleedpetcock to ensure that
the cooling system is purged
of air. Aftershutdown and
after the engine has cooled, the coolantfrom the recovery
tank will be drawn into the engine's cooling system to
replace the purged
air.
Before subsequent operation of the generatm; the engine's
manifold should be topped off,
and the coolant recovery
tank may need to befilled to the
MAX level.
OIL FILL
6
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
a Check load leads for con·ect connections as specified in
the wiring diagrams.
• Examine the air inlet and outlet for air flow obstructions.
a Be sure no other generator or utility power is connected to
the load lines.
a 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
oropen neutral can supply the wrong line-to-neutral
voltage on unbalanced loads.
a Make certain the raw water thru-hull is open.
A CAUTION: Wheil 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.
AIR BLEED
PETCOCK

STARTING/STOPPING PROCED
GENERATOR CONTROL PANEL
AC CIRCUIT
BREAKER ---~1
Starting
Simply press the START switch and the generator will start.
.A green light will glow indicating the generator is running.
Stopping
To stop-depress the STOP side of the start switch, the green
light will go out and the generator is stopped.
Failure to Start
The start cycle will automatically terminate if the unit fails to
start after 12-14 seconds of cranking. Wait 20 seconds, then
repeat the start.
If the unit again fails to start, investigate the cause.
Sometimes after servicing the fuel system or changing the
fuel filter, air can accumulate in the fuel line or the throttle
body and prevent starting.
The Schrader valves on the throttle body and the fuel cell are
used to remove trapped air. This air is mixed with fuel and
under high pressure. Follow the BLEEDING THE FUEL
SYSTEM instructions in this manual. ·
O rw=jWESTERBEKE O
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EJ\IGINE TEMP £XH TEMP
•
START STOP
D 0
REMOTE CONTROL PANEL
7
CONNECTIONS
FIREBOY, CO DETECTOR
AND/OR AUXILIARY STOP
CONNECTION
REMOTE START/STOP PANEL
The components on the panel are:
1. A three position start/stoprocker 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 start/stop rocker switch 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 to indicate 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 stop
switch must be momentarily depressed.
This remote panel is a plug-in accessory and is available with a
15' to 100' wiring harness.
CAUTION: Repeated crank cycles without a start can result
in the engine's exhaust system filling with raw water. This
raw water can enter the engine's cylinders
by way of the
exhaust manifold once the system fills.
If after three crank
cycles the unit does not start. Drain the system's muffler
and investigate and correct the cause
of no start. Engine
damage the result
of raw water entry is not a warrantable
issue. The operator should keep this
in mind.

STARTING/STOPPING PROC
GENERATOR CONTROL PANEL
AC CIRCUIT
BREAKER ---+Ji.
Starting
Simply press the START switch and the generator will start.
Agreen light will glow indicating the generator is running.
Stopping
To stop-depress the STOP side of the start switch, the green
light will go out and the generator is stopped.
Failure to Start
The start cycle will automatically terminate if the unit fails to
start after 12-14 seconds of cranking. Wait 20 seconds, then
repeat the start.
If the unit again fails to start, investigate the cause.
Sometimes after servicing the fuel system or changing the
fuel filter, air can accumulate in the fuel line or the throttle
body and prevent starting.
The Schrader valves on the throttle body and the fuel cell are
used to remove trapped air. This air is mixed with fuel and
under high pressure. Follow the BLEEDING THE FUEL
SYSTEM instructions in this manual.
0 OT
fW{WESTERBEKE
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ENGII\E TEMP EXH TEMP
• 3.94
START STOP
D 0
REMOTE CONlROL PANEL
7
FIREBOY, CO DETECTOR
AND/OR AUXILIARY STOP
CONNECTION
REMOTE START/STOP PANEL
The components on the panel are:
1. Athree 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 start/stop rocker switch 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 to indicate 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 stop
switch must be momentarily depressed.
This remote panel is a plug-in accessory and is available with a
15' to 100' wiring harness.
CAUTION: Repeated crank cycles without a start can result
in the engine's exhaust system filling with raw water. This
raw water can enter the engine's cylinders by way
of the
exhaust manifold once the system fills.
If after three crank
cycles the unit does not start. Drain the system's muffler
and investigate and correct the cause
of no start. Engine
damage the result
of raw water entry is not a warrantable
issue. The operator should keep this in mind.

BREAK-IN PROCEDURE/THE DAILY OPERATION
BREAK-IN PROCEDURE
After the generator has been started, check for proper
operation and then encourage a fast warm-up. Run the
generator between 20% and 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
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, 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. The starting amperage
drawn can be 3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
CHECK LIST
Follow this check list each day before starting your generator.
• Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule).
• Visually inspect the generator 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 drive belts for wear and proper tension (weekly).
• Check for abnormal noise such as knocking, vibration and
blow-back sounds.
• Check drive belts for wear and proper tension (weekly).
• Confirm exhaust smoke:
When the engine
is cold- white smoke.
When the engine is warm -almost smokeless.
When the engine is overloaded -some black smoke.
8
NOTE: Some unstable running may occur in a cold engine.
This condition should lessen as normal operating temperature
is reached and loads are 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 the major AC liads from the generator one at a time.
Allow the generator to run for a few minutes to stabilize the
operating temperature and press the STOP switch down.
(See CONTROL PANELS).
NOTE: After the first 50 hours of generator operation, check
the maintenance schedule
for the 50 hour service check.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation and ad
break-in is/has taken place, a no-load voltage adjustment
maybe needed along with a GAIN adjustment. See VOLTAGE
ADJUSTMENTand ECU ADJUSTMENTS in this manual.
A CAUTION: VENTILATION
Gasoline vapors can explode. Before starting the engine,
operate the blower for at least four minutes and check both
the engine compartment and bilge for gasoline vapors.
Run the blower below cruising speed.

SAFETY SHUTDOWN SWITCHES
DESCRIPTION
The engine/generator is protected by switches and sensors
that send signals to the ECU that
it interprets as a fault and
automatically shuts down the generator drive engine. When
an automatic shutdown occurs, one
of the control panel fault
LED lights will illuminate indicating what fault caused the
engine to shutdown. This LED will stay illuminated.
To
correct the fault, refer to ENGINE TROUBLESHOOTING in
this manual. Do not attempt to restart the generator
before correcting the fault.
~EXHAUST TEMPERATURE
~~
· ~) ENGINE
1 ~ TEMPERATURE
I
OIL PRESSURE
TO FUSE
CONTROL PANEL INDICATOR LIGHTS
Four LED fault lights are located on the generator control
panel and the remote start/stop panels. Should a problem
occur during generator operation the individual light will
indicate where the problem is and at the same time shut the
generator down. The light will continue to glow after the
generator shuts down. Should this occur, refer to f;NGINE
TROUBLESHOOTING in this manual.
OIL PRESSURE SENSOR
An oil pressure sensor (located just below the oil filter) sends
a DC voltage to the ECU that
it interprets as oil pressure.
Should this voltage fall below a certain level, the ECU will
shut the generator down and illuminate the low oil pressure
LED. Should this occur, refer to ENGINE
TROUBLESHOOTING in this manual.
EXHAUST TEMPERATURE SWITCH
A temperature switch is mounted on the exhaust elbow to
monitor the temperature
of the exhaust coolant and gasses.
Should the switch sense an excessive exhaust temperature, the
ECU will shut the generator down and the exhaust
temperature LED will illuminate on the control panel. Should
this occur, refer to ENGINE TROUBLESHOOTING in this
manual.
THERMOSTAT
ASSEMBLY
COOLANT TEMPERATURE SENSOR
Acoolant temperature sensor is located on the thermostat
housing to monitor the engines fresh water coolant. Should
the coolant temperature reach 210°F, the ECU will shut the
generator down and the engine temperature LED will
illuminate. Should this occur, refer to ENGINE
TROUBLESHOOTING in this manual.
OVERSPEED SWITCH
An overspeed high RPM shutdown sensor in the ECU will
shut the engine down
if the engine RPM''S exceed the set
limit and the LED will remain lit. If an underspeed problem
occurs, the engine will shutdown and the LED will remain
flashing.
DC CIRCUIT BREAKER
The generators engine is protected by a panel mounted man-
ual reset circuit breaker (20 amp). An electrical overload in
the engine's wiring harness
or the instrument panel will trip
this breaker and shutdown the engine/generator.
If this should
occur, inspect and repair the problem. then reset the breaker
and sestart the engine/generator.

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.
ISAEElMaintenance items that are very important to the proper operation of
~ "Safe CO" generators.
CHECK
HOURS OF OPERATION
EACH
MAINTENANCE DESCRIPTION
DAY
50 100 250 500 750 1000 1250
D
Unleaded gasoline with octane rating of 89 of 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: Keep engine surface clean. Dirt and oil
Check for fuel, oil and water leaks. Inspect wiring and
will inhibit the engine's ability to remain cool.
electrical connections. Keep bolts & nuts tight. Check
for loose belt tension.
Sparks Plugs ·ISN>EI
D D D D D D
Check gap, inspect for burning and corrosion.
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
D D D D D D D
Initial engine oil and filter change at 50 hours, 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 INFORMATION.
Fuel Lift Pump
D
Periodically inspect for leaks, electrical connections
are clean and tight.
Air Screen I5 N>EI
D
Clean at 50 hrs., then every 100 hours.
Exhaust System
D D D D
Initial check at 50 hours, then every 250 hours.
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 D
Hose should be hard & tight. Replace if hoses
become spongy. Check and tighten all hose clamps.
Raw Water Pump
D D D
Remove the pump cover and inspect for wear.
Inspect impeller, cam and wear plate. Replace gasket.
Lubricate impeller when reassembling.
Heat Exchanger
D D D D D D D
Clean or replace anode. Open heat exchanger end
cap and clean out debris. Remove every 1000 hours
for professional cleaning and pressure testing.
Coolant System
D D
Drain, flush, arid refill cooling system with
appropriate antifreeze mix.
Fuel Filter
D D D D D D
Change every 250 operating hours.
Inlet Fuel Filter
D D D D D D
Change every 250 operating hours.
(continued)
Engines & Generators
10

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your
engine hours by running time.
SCHEDULED
CHECK
HOURS OF OPERATION
MAINTENANCE
EACH
MAINTENANCE DESCRIPTION
DAY 50 100 250 500 750 1000 1250
*Starter Motor
D D
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
Distributor 1m]
D D
Check ignition timing. Check condition of distributor
cap and rotor.
*Engine Cylinder
D D
Incorrect valve clearance will result in poor engine
Compression and performance, check compression pressure and
Valve Clearances
timing and adjust valve clearances.
*Engine Timing Belt
D
Remove and replace every 1000 hours.
NOTE: Failure to replace the timing belt at the
recommended interval could result in timing chain
failure resulting in major damage to the engine.
*Exhaust Elbow
D
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteriorated.
I
NOTE: A defective exhaust elbow can cause
carbon monoxide leakage!
Catalytic Converter @.]
D
Remove water injected exhaust elbow and visually
inspect. Replace every 2000 hours.
*Exhaust System Back
D
Perform back pressure test to ensure system is not
Pressure
developing restrictions that will increase pressure
above 1.5 PSI or 41 inches of water column at full
operating amperage load. Correct as needed.
Catalyst .lmJ D
Remove water injected exhaust elbow and visually
inspect every 2000 hours. Replace as needed.
Oxygen Sensor l
5
~~J
D
Inspect every 1000 hours. Replace every 2000 hours.
CO in Exhaust
D
Sample with CO analyzer.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
MEASURING EXHAUST BACK PRESSURE
PSI
GAUGE
Exhaust systems normally produce resistance to the flow of
exhaust gases, causing back-pressure. Back-pressure must be
kept within a certain limit.
Check the back-pressure before
the generator is put back into service.
To test exhaust pressure, connect either a water colunm
or
PSI tube to the test part on the exhaust elbow as shown.
Check the exhaust back-pressure before the generator
is put
into service. Measure the back-pressure after the engine has
reached its normal operating temperature, and at the point
where it
is about to reach its rated load at either 1500 rpm
(for 50Hz applications) or 1800 rpm (for 60Hz applications).
Back-pressure should not exceed
1.5 psi (0.11 kg/em\
A water colunm can be made by taping one end of a clear
plastic tube along a yardstick and fitting the other end
of the
tube with a 1/4" NPT pipe fitting.
Back-pressure should not exceed 27in (69cm) of water in the·
water colunm.
Engines & Generators
11
MEASURING EXHAUST BACK
PRESSURE

FUEL SYSTEM
GASOLINE·
Use unleaded 89 Octane gasoline or higher. Ethanol gasoline
must not exceed ElO (10%). Gasoline with higher percent-
ages ofEthanol are not acceptable for use in these models
and can void ;the warrenty.
When fueling, follow US. Coast Guard procedures, closing
hatches and companionways to prevent fumes from entering
the boat and cabins. Be sure to ventilate after fueling.
NOTE: The generator compartment should have a gasoline
fume detector/alarm properly installed and working.
GASOLINE/WATER SEPARATOR AND
A primary fuel filter of the water separating ~---·-,
type must be installed between the fuel
and the engine to remove water and other
contaminant's
from the fuel before they can
be carried to the fuel system on the engine.
Most installers include a type offilter/water
separator
with the installation package as
they are aware of the problems that
contaminant's in the fuel can cause.
These gasoline filters must have metal bowls
(not "see-through") to meet U.S. Coats Guard
requirements. The metal bowls bave drain
valves
to use when checking for water and
impurities. WESTERBEKE oAr:J•T.-.::=r
. NUMBER (49602)
I
I I
f'FROMFUEL
j COOLER
I
FUEL CELL
ENGINE FUEL FILTER
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 Filter Element
1. Shut the fuel supply to the generator off.
2. Ensure there is no pressure in the fuel system by bleeding
off
any existing pressure using a Schrader valve on the
throttle body and fuel cell. Use a pressure testing kit as
shown on the next page.
3. Unscrew the fuel bowl from the housing and allow the
bowl to come away from the housing.
4. Remove and replace the filter element and clean the
bowl.
5. Inspect both "0" rings. Replace if necessary.
6. Press on a new filter and replace the filter bowl.
7. Open the fuel supply. Inspect for leaks.
INLET FUEL FILTER
1. Shut off the fuel supply to the generator. Disconnect the
fuel supply line to the inlet filter and unscrew the filter
from the pump inlet. Take care to catch any fuel that may
be present.
2. Thread on the replacement inlet filter and connect the
fuel supply line. Use care when connecting and
tightening the fuel supply line so as not to distort the
inlet filter.
3. Tum on the fuel supply to the generator and start the
generator. Ensure that there are no leaks.
FUEL 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 engine mounted fuel pump is
maintenance free.
·..v- WESTERBEKE
NOTE: It is recommended that the fuel system be bled during
each oil andfilter change interval to ensure no air has
accumulated
in the fuel system.
Engines & Generators
12