Westerbeke 8.0KW BCDT60Hz User manual

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OWNERS MANUAL
8.0 KW BCDT 60Hz
7.0 KW BCDT 50Hz
. -
'MARINE DIESEL GENERATORS
.
PUBL ATION NO.46294
FIRST EDITION
... JULY2001
WESTERBEKE
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD· TAUNTON MA 02780-7319. TEL. [phone]
. FAX [phone]· WEBSITE: www.WESTERBEKE.COM
mm ....
< .AL"f1!A MemberNatiomd Marine ManufacturersAssociation

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.
AWARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness
-Nausea
-Headache
- Weakness and Sleepiness
- Throbbing in Temples
- Muscular TWitching
- Vomiting
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
A WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine or
generator.
WESTERBEKE also recommends installing CARBON
MONOXIDE DETECTORS in the living/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protectyourself, your personne~
andyour machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is lunning, 01 when connected to shole
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut off electrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage
to vessel's AC generator may
result
if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts 01
exhaust system components. A lunning engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury 01 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 01 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 orpermit 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 bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions flom fuel vapors can cause
injury 01 death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four minutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out ofthe 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.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starling can cause injury
or death!
• Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being
serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by elect?cal
arcing or by lit tobacco products. Shut off all electncal
equipment
in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terminal of the starter solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any 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. Remo~e
wristwatch, rings, and any otherjewelry before handlmg
the
battery.
• Always turn the battery charger off before disconnecting
the battery connections. Remove the negative lead
first
and reconnect it last whenservicing the battery.
BAnERYACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber
apron, and eye protec-
tion. Batteries contain sulfuric
acid which is destructive.
If it comes in contact with your skin, wash it off at once
with
water. Acid may splash on the skin or into the eyes
inadvertently
when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged
from the engine. Check the exhaust system
regularly
for leaks and make sure the exhaust manifold!
water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers
when running the generator set or engine.
• Don't run the generator set or engine unless the 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 nu-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 ofcopper 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 fume~. S?me o~ the
symptoms or signs ofcarbon monoXide mhalatlon or
poisoning
are:
Vomiting
Dizziness
Headache
Nausea
AVOID MOVING PARTS
Inability to think coherently
Throbbing in temples
Muscular twitching
Weakness and sleepiness
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situation
arises in which it
is absolutely necessary to make operat-
ing adjustments,
use extreme care to avoid touching mov-
ing parts and hot exhaust system components.
Engines &Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces
or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and wamings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination
of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections
of the ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9
DC Electrical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions
when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
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 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 injection port is at or below the load waterline will result in
raw water damage to the engine andpossibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
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 hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
Engines & Generators
.
IV

TABLE OF CONTENTS
Parts Identification .................................................................................... .2
Introduction . ................................................................................................ .3
Warranty Procedures.......................................................................... .3
Serial Number Location......................................................................3
Installation .................................................................................................. .5
Exhaust System...................................................................................7
Raw Water Cooling.............................................................................8
Control Panel ............................. : ............................................................... 10
Fuel, Engine Oil and Engine Coolant ................................................... 11
Preparations for Initial Start·Up .......................................................... 12
Starting/Stopping Procedure ............................................................... .13
Break·ln Procedure (Daily Operation) .................................................. 14
Safety Shutdown Switches ................................................................... 15
Maintenance Schedule ........................................................................ 16
Cooling System ..................................................................................... 18
Changing Coolant .............................................................................18
Thermostat ........................................................................................19
Raw Water Pump ..............................................................................
20
Raw Water Intake Strainer................................................................ 20
Heat Exchanger.................................................................................21
Engine Lubricating Oil ..........................................................................22
Oil Change........................................................................................22
Fuel System .......................................................................................... 23
Fuel Lift Pump..................................................................................23
Glow Plugs ............................................................................................ 24
Starter Motor ......................................................................................... 25
Control Box ............................................................................................ 27
12V DC Control Circuit .......................................................................... 28
Battery Specifications........................................................................28
Wiring Diagram (#41990) ...................................................................... 29
Wiring Schematic (#41990) .................................................................. 30
Engine Adjustments .................................................................................. .31
Frequency Adjustment....................................................................... 31
Fuel Run Solenoid.............................................................................31
Drive Belt Adjustments .....................................................................32
Torquing the Cylinder Head..............................................................32
Engine Compression..........................................................................32
Injection Pump Timing......................................................................33
Valve Clearance.................................................................................34
Testing Fuel Injectors ........................................................................34
Engine Troubleshooting ........................................................................ 35
Shore Power Transfer Switch .............................................................. .37
Generator Information .......................................................................... 38
Generator Troubleshooting .................................................................. .39
Lay·up and Recommissioning ............................................................... 40
Generator Specifications ..................................................................... .42
Metric Conversions .............................................................................. .43
Standard Hardware and Sealants ....................................................... .45
Torque Specification ............................................................................ .46
Suggested Spare Partso ......................... H ................... n.coo ••.••••••••••••.••••• 0 ••• 47
Engines & Generators
1

PARTS IDENTIFICATION
AIR INTAKE FILTER
~
THERMOSTAT
HOUSING
INTERNAL COOLANT PUMP
DRIVE BELT
VIBRATION MOUNTS~
OIL FILL
I
COOLANT FILL
PREHEAT SOLENOID~
ZINC---'
EXHAUST
MAN\FOlD~"""
THERMOSTAT
/HOUSING
~AIR INTAKE FILTER
.:;ft-'''\'I''---r''--:l7'''H'~I----'-FUEL LIFT PUMP
CONTROL BOX·
SIDE OIL FILL
.CONTROL BOX
t']'l/~%TI:_RAW WATER PUMP
EXHAUS.T
OUTLET
GENERATOR
BACK ENO
• OIL FILTER
Engines & Generators
2

INTRODUCTION
This WESTERBEKE marine generator is a product of
WESTERBEKE'S many 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.
This owner's manual contains infonnation and instructions for the
installation, operation, maintenance and service of your generator.
For additional installation information. see WESTERBEKE s
INSTALLATION MANUAL FOR MARINE ENGINES &
GENERATORS, Publication #43268.
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.
WARRANTY PROCEDURES
YourWESTERBEKE Warranty is included in the documentation
package. If you have not received a customer identification card
registering your warranty 60 days after submitting the warranty
registration form, please contact the factory in writing with model
information, including the unit's serial number and
commission date.
Cu~tomer Identification Card
,,,,.,,WESTERBEKE
, Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
ModelS KW SCOT Ser. #0703-xxxx
E~pires 9/2002 .
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures and
catalogs) provided from sources other
than WESTERBEKE
are not within WESTERBEKE'S CON1ROL.
I
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
WIU 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 ofWESTERBEKE
or the supplier in question
be consulted to determine the accuracy and currentness ofthe
product software being consulted
by the customer.
SERIAL NUMBER
Owners may find it convenient to enter the information on the
generator decal and engine identification plate shown below.
These will provide quick references when Seeking technical
information and/or ordering parts.
.- .. -~ ... ~.
• ! ~Tiii§ln:t#'3=i
.0 0
• MODEL SPEC SER.NO. •
Fill in the information for your reference. ~
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating pr~edures,
maintenance schedules, and troubleshooting of your marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures which, if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures which, if not properly fol-
lowed, can result in personal injury or loss of life .
..
Engines &Generators
3

INTRODUCTION
. Generator Serial Number
The generator model number and specifications are located on a
decal on the generator housing.
SPECIFICATION ~ .1
MODEL _______ _
RPM __________ _
KW ___________ _
KVA __________ _
VOLTS ________ _
AMPS ________ _
ENG. HP ____ • __
ENG. SER. NO.
GEN. SER. NO.
PF/PHASE ___ _
WIRES ________ _
RATING _______ _
INSUL CLASS __
TEMP. RISE ___ _
BATTERY _____ _
C.tD. _________ _
I
i ~. 'Fill in the information! for reference.
i . -
COMPONENT LOCATIONS
Component locations in this manual are referenced from the front
of the engine which is the end at which the raw water pump is
located. Left and right sides are determined as follows: imagine
straddling the engine, facing the front of the engine: the left side
is at your left, the right side is at your right. The left side is the
service side of the generator. The engine and generator controls
are located in an air-cooled air intake/control box.
ORDERING PARTS
Whenever replacement parts are needed, always provide the genera-
tor and engine model and serial numbers. You must provide us with
this information so we may properly identify your engine/generator.
In addition, include a complete part description and part number for
each part needed (see the Parts List). Insist upon WESTERBEKE
packaged parts because will fit or generic parts are frequently not
made to the same specifications as original equipment.
SPARES AND ACCESSORIES
Certain spare parts will be needed to support and maintain your
Westerbeke generator when cruising (see SUGGESTED SPARE
PARTS). Often even a simple item such as a proper fuel filter can
be difficult to obtain along the way.
UNDERSTANDING THE DIESEL ENGINE/GENERATOR
The diesel engine closely resembles the gasoline engine, since the
mechanism is essentially the same. The cylinder is arranged
above a closed crankcase. The crankshaft is of the same general
type as on a gasoline engine, and the diesel engine has the same
type of valves, camshaft, piston, connecting rod and
lubricating system.
Therefore, to a great extent, a diesel engine requires the same pre-
ventive maintenance as a gasoline engine. The most important
factors are proper ventilation and proper maintenance of the fuel,
lubricating and cooling systems. Fuel filter elements must be
replaced at the time periods specified, and frequent checking for
contaminants (water, sediment, etc.) in the fuel system is also
essential. Another important factor is the consistent use of the
same brand of high detergent diesel lubrication oil designed
specifically for diesel engines.
The diesel engine does differ from the gasoline engine, however,
in its method of handling and firing offuel. The carburetor and
ignition systems are replaced by a single component - the fuel
injection pump - which performs the function of both.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing have
resulted in a WESTERBEKE generator capable of many
thousands of hours of dependable service. However, the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner in which the unit is operated
and serviced in the field. This is up to the buyer/owner-operator.
NOTE: Six important steps to ensure long generator lifo:
• Proper engine and generator installation.
• An efficient well-designed exhaust system that includes an
anti-siphon break to prevent water from entering the engine.
• Changing the engine oil every 100 operating hours.
• Proper maintenance of all engine and generator components
according to the maintenance schedule in this manual.
• Use clean, filtered diesel fuel.
• Winterize your engine according to the LAY-UP AND
RECOMMISSIONING section in this manual.
Engines & Generators
4

INSTALLATION
The following installation instructions cover the Westerbeke 8 Kw
Diesel Generator. Additional general information may be found in
Westerbeke's INSTALLATION MANUALfor MARINE ENGINES
and GENERATORS, Publication #43268.
The following factors should be considered when planning the
installation of your Westerbeke 8Kw generator:
1. Size and weight of the generator.
2. Location and mounting surface.
i SPECIAL FUEl. SUPPLY.
I 1/4" HOSBilALE BARB
, iCONNECTION SUPPLIED
3. Ventilation.
4. Exhaust system.
! ~~~
S. Fuel supply and return.
6. Raw water inlet and outlet.
7. Oil fill and oil drain hose.
8. Electrical connections.
9. Maintenance and service accessibility.
10. Accessories.
Refer to the following illustrations for the generator's
overall dimensions.
',EXHAUST
2-D (50.8)1.0.
:23.8
1(605.~)
1""1-<~---i25.5~------,>-~1
\(647.n
(33.8)
1-----1, 19.0
;(482.6)
~13.3
1~2.6)
( 2.6
.28 (7. I) 8 HOLES
MOUNT I NG CENTERS
SOUND ENCLOSURE
o o
° 000 ° °
F-
'\16.3 in 13.6 in
(412 8 mm),(346.0 mm)
.L/_ t't:')q __ -_0 _o_e-=.o-=-o_o ~0--9!"0_~-=~
3.5
(88.9)
1-----1 21.8. .1
I (552.5)'
t------125~3~-. ------I
'(641.4)
-L3.1f"
;{77)
Engines & Generators
5
I SPECIAL FUEL RETURN
..i 1/4" HOSE-MALE BARB
" SUPPLIED
HOLES FOR CONNECTIONS

INSTALLATION
LOCATION AND MOUNTING
A solid, level mounting platform is very important for the proper
operation of your generator. Select a location that will allow
adequate space on all sides for ventilation and servicing. Locate
the generator away from living quarters, and away from bilge
splash and vapors.
The mounting platform may be of wood, metal or fiberglass. It <
must be horizontal and should be as small as possible to minimize
vibrations. A low mounting platform is preferred because it will
be stable and easy to build; .a higher mounting platform must be
very sturdy to avoid resonange and vibrations (see illustrations).
GENERATOR ..
·HIGH MOUNTiNG
PLATFORM
.'.(NOT PREFERRED)
. ."-.
"'" ...
LOW MOUNTING
PLATFORM
....... ; (PREFERRED) .
GENERATOR
If the vibration-dampening mounts furnished with the generator
are not adequate to muffle vibmtion or resonance in an installation
where the mounting surface is not ideal, then adding aplate
between the generator and the boat's mounting platform is a
possible solution. This will also improve the sound insulation. For
this plate, use 1" (2.54cm) thick wood that weighs 22 - 33 lbs
(10 - IS kg), and soft mounts (45 durometer rating) that are
rectangular. Position these mounts so they are on the diagonal
and not aligned with the generator's mounts (see illustration). The
generator's mounts may be turned in any direction. Mount the
plate to the boat's platform, then mount the generator to the plate.
VENTILATION
Allow for the sufficient intake of cool air for proper engine
combustion and the discharge of the heated air while the generator
is running. Since heated air rises, the intake of cool air should be
directed into the lower area of the generator compartment and the
heated air should be discharged from the upper area of the
compartment.
NOTE: Engine combustion air enters the generator s through holes
in the base of the enclosure. This area must be kept clear of
obstructions to help insure air entry.
FUEL LINES
Fuel Supply Line
In most installations, the generator would use the same fuel tank
as the vessel's propulsion engine. If this is the case, the fuel sup-
ply line to the generator should come from its own pickup in the
common fuel tank and not tee off the supply line to the
propulsion engine.
To assure proper suction, the generator's fuel pump should not be
more than 39" (lm) above the bottom of the fuel pickup tube.
Fuel Re.turn Line
The fuel return line at the fuel tank should extend down to the bot-
tom of the tank in the same manner as the fuel pickup tube. This
must be done in an installation where the fuel tank is located
below the engine's fuel system. This precaution insures against
hard starting due to air displacing fuel siphoning out of the
engine's fuel system through the return line when the generator is
shutdown
L_-I---+-VI16RATlO~iS DAMPER
GENERATOR TOP VIEW
MOUNTS-CAN BE
TURNED ANY DIRECTION
Engines & Generators
6

INSTALLATION
EXHAUST SYSTEM
It is important to install a proper exhaust system to avoid engine
flooding. The system must be designed to prevent water from
entering the exhaust line under any sea conditions and at any
angle of the vessel's hull. Exhaust system failures are not covered
by Westerbeke's warranty. The installer should have a basic
knowledge of marine installation requirements.
Westerbeke recommends installing an exhaust system having an
in-line mufller (see illustration). The in-line mufller should be
located below the engine's exhaust elbow. It must accumulate any
water that runs back down the exhaust line after the engine is shut
down. Design the system so there is an adequate drop in the line
between the exhaust elbow and the through-hull discharge end of
the line. The exhaust hose must be certified for marine use. Use
the following illustrations as a general guide when installing an
exhaust system.
A CAUTION: An exhaust line that is too long and/or
has a poor gradient can cause water to return back to
the generator's engine when the generator is shut off.
Westerbeke Corporation presumes that the installer of this marine
diesel generator is familiar with the safeguards a water-cooled
marine exhaust system will provide for the engine. Failure to
design and layout a proper exhaust system can result in
catastrophic damage to the diesel engine, and possibly result in the
sinking of the vessel in which the unit is installed.
).875 in (22.2 mm) OR
!1,~ in (25.4 mm) 1.0.
! EXHAUST SYSTEM
DIAGRAMS
CONTACT YOUR
WESTERBEKE
DEALER FOR
/
12 in (30 em)
. ABOVE ELBOW:
:MINIIV!.UM ...
ADDITIONAL INFORMATION
For more information about exhaust system design, see
Westerbeke's INSTALLATION MANUALfor MARINE ENGINES
and GENERATORS, Publication # 43268.
Carbon Monoxide
The best protection against carbon monoxide poisoning is a daily
inspection of the complete exhaust system. Check for leaks
around manifolds, gaskets, and welds. Make sure exhaust lines
are not heating surrounding areas excessively. If excessive heat is
present, correct the situation immediately. If you notice a change
in the sound or appearance of the exhaust system, shut down the
unit immediately and have the system inspected and repaired at
once by a qualified mechanic.
A WARNING: 00 not install thl! exhaust outlet near a
swim platform! When people are in the water or in a
dinghy near the boat shut the generator or engine down.
A carbon monoxide warning decal has been provided by
Westerbeke. Display this decal near your engine or generator, on
your cabin bulkhead, or in some other prominent location.
NOTE: It is extremely important that a carbon monoxide
detector(s) be installed in your boat s living and/or sleeping
quarters. Make sure it is manufactured for the marine industry.
They are inexpensive and easily available at your marine supplier.
i 1.875 in (47.6 mm)
" ._~f!------! OR 2.0 In (50.8 mm) 1.0. HOSE
: GENERATOR
... .... (122 eml MAXIMUM
NOTE: A BACK-PRESSURE TEST CAN
. OETERMINE HOW THIS HEIGHT MAY VARY
I SIPHON-BREAK
.... ((OWNER-SUPPLlEO)
112 IN (30 em)
.... L"'l~IMUj
i4i1:' (12ii:ml MAXIMUM ~
I NOTE: A BACK-PRESSURE TEST CAN· .
'OETERMINE HOW THIS HEIGHT MAY VARY
.. :1.875IN (47.6 mm) OR
.~ i 2.0 IN (50.8 m!ll) 1.0. HOSE
Engines & Generators
7

INSTALLATION
RAW WATER COOLING SYSTEM
Siphon-Break
For installations where the water-injected exhaust elbow is close to
or below the vessel's waterline, provisions must be made to install
a siphon-break in the raw water supply hose to the exhaust elbow.
The siphon-break provides an air vent in the raw water cooling
system to prevent raw water from filling the exhaust system and
the engine's cylinder when the engine is shut down.
A CAUTION: Failure to use a siphon-break when the
exhaust elbow is located at or below the load waterline
will result in raw water damage to the engine and
pOSSible flooding of the boat.
If you have any doubt about the position of the water-injected
exhaust elbow relative to the vessel's waterline under any of the
vessel's various operating conditions or when the vessel is not
under way, install a siphon-break. This precaution is necessary to
protect your engine.
The siphon-break must be installed in the high point ofa hose
that is looped a minimum of20 inches (51cm) above the vessel's
waterline. This siphon-break must always be above the
waterline during all angles of vessel operation to prevent,
siphohing. Use a separate hose for this loop, and rim it outside of
the sourtdshield. I-
1 SIPHON BREAK
SIPHON BREAK
AV/,IILABLE FROM YOUR
WESTERBEKE DEALER
I
SIPHON BREAK
DIAGRAM (TYPICAL)
NOTE: A siphon-break requires periodic' inspection and cleaning
to ensure proper operation. Failure to properly maintain a
siphon-break can result in severe engine damage. Consult the
siphon-break manufacturer for a proper maintenance schedule.
Raw Water Intake
A flush-type through-hull fitting is recommended for the raw
water intake. It should be located on the boat's hull where it will
be below the waterline during all angles of the boat's operation.
See Westerbeke's INSTALLATION MANUAL for MARINE
ENGINES and GENERATORS for complete
installation guidelines.
A WARNING: Do not use a scoop-type through-hull
fitting for supplying raw water to this generator. A
scoop-type raw water inlet can develop substantial pres-
sure and force water past the raw water pump, flooding
the exhaust system and allowing the water to enter the
engine's cylinder. Damage caused by raw water entry
into the engine's cylinder via the exhaust system is not
covered by Westerbeke's warranty.
Flooding of the exhaust system due to water pressure can also
occur with a flush-type raw water intake on a powerboat that has
its bow up. This pressure can be caused by the boat's decreased
waterline before the boat reaches its final trim, or by the angle of
the boat to the sea surface when it is underway.
STARTING BATTERY CONNECTIONS
The Westerbeke 18.0 KW Generator is negative grounded. The
generator should be connected to its own 12V starting battery
(125A minimum).
All ground wires should be tightly fastened to the ground bolt
located on the lower left side of the engine below the starter
motor. Make certain the ground terminals are clean.
GROUND BOLT
Engines & Generators
8

INSTALLATION
CONTROL PANEL
Mount this plug-in control panel in any desired remote location.
The panel is furnished with 32.8 ft. (10 m) of cable; additional
cable is available if more cable length is required. When
installing, pass the cable though bulkheads by disconnecting the
cable at the control panel. Refer to the following illustration for
control panel dimensions.
5-5/8" (142.9 mm)
I" 'I .
\ 1-15/16" (49.2 mm) J L
213116" (11.4 mm) 1M. "~0""-t.. .... .
GENERATOR
DDD~- 13-
11
T (9~.7 mm),
o 0
I. . .1
~MULTI-POLAR CABLE .
! 32.8FT (10MM) LONG
Engines & Generators

CONTROL PANEL
DESCRIPTION
This plug-in remote control panel provides the operator with all
the necessary information and controls to use the generator. The
panel has START and STOP buttons, an LED proportional load
indicator, and coolant and oil pressure warning lights.The engine
will shut down automatically if it overheats or there is an oil
pressure failure.
The load indicator is designed to avoid an excessive current draw
from the generator due to too many loads having been applied at
the same time. The indicator will begin to show the load after the
first halfof the required current is supplied, and it will indicate
that an acceptable load is being provided up to the point where all
the LED's except the last one are lit (5 green LED's are lit). Ifthe
last LED (red) becomes lit, it indicates an overload. The load that
caused this red LED to light up must be switched off to return the
indicator to a normal position.
LED PROPORTIONAL
LOAD INDICATOR
©
r
The oil pressure/coolant temperature warning light (red) lights up
when either the oil pressure is too low or the engine is overheated.
The engine will shut down if it overheats or there is an oil
pressure failure.
The fuel shutoff solenoid light (yellow) blinks when the START
button is pushed and goes off after the engine starts. If it continues
to blink and the engine doesn't start, it means the starting battery
is too low.
The engine/generator "ON" light (green) will be lit during normal
operation.
NOTE: If the engine is not running and the shutoff solenoid is
energized (yellow LED is blinking), the starting battery is
supplying unneeded power to the engine. Reset by pushing the
STOP button.
NOTE: If the START button is pushed by mistake while the engine
is running, an electrical safoty device protects the starter motor by
preventing its solenoid from energizing.
h
COOLANT/OIL PRESSURE
WARNING LIGHT
100% OVER LOAD
HOURMETER
©
FUEL SHUTOFF
SOLENOID LIGHT
(YELLOW)
PREHEAT
CONTROL PANEL (REMOTE)
Engines & Generators
10
ENGINE ON LIGHT
RUNNING (GREEN)

FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or specifications of Class
2-D (ASTM), and has a cetane rating of #45 or better.
Care of the Fuel Supply
Use only clean diesel 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 become 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, visual-type filter/water
separator between the fuel tank and the engine. Raycor models
220 or 225 are good examples of such spin-on filters.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF or
CG-4. Change the engine oil after an initial 50 hours of break-in
operation, and every 100 hours of operation thereafter. For
recommended oil viscosity, see the following chart:
Operating Temperature
Oil Viscosity
Above 68° F (20° C) SAE 30, 10W-30 or 15W-40
41° - 68° F (5° - 20° C)
SAE 20 or 1 OW-3~
Below 41 °F (5° C) SAE 1 OW-3~
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture to
produce properties harmful to your engine.
ENGINE COOLANT
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, as it allows the engine
to run at proper temperatures by transferring heat away from
the engine to the coolant. It also lubricates and protects the
cooling circuit from rust and corrosion. Look
for a good
quality antifreeze that contains Supplemental Cooling
Additives
(SCAs) that keep the antifreeze chemically
balanced, crucial
to long term protection.
The distilled water and antifreeze should
be premixed before
being poured into the cooling circuit.
NOTE: Use the new environmentally-friendly long lasting
antifreeze that
is now available.
Antifreeze mixtures will protect against
an unexpected freeze
and
they are beneficial to the engine's cooling system. They
retard rust and add to the life ofthe circulating pump seal.
ANTIFREEZE PROTECTION CHART
Antifreeze concentration
23% 30% 35% 50%
Freezing Temperature
14° F
8° F
_4° F
-40° F
(-10°C) (-13°C) (-20°C) (-40°C)
COOLANT RECOVERY TANK
Acoolant recovery tank kit is supplied with each
WESTERBEKE diesel engine.The purpose ofthis recovery
tank is to allow for engine coolant expansion and contraction
during engine operation, without the loss ofcoolant and
without introducing air into the cooling
system. This kit is
provided and must be installed before operating the engine.
NOTE: This tank, with its short run of plastic hose, is best
located at or above
the level of the enginesmanifold but it
can be located below the level of the enginesmanifold if the
particular installation makes this necessary.
Engines & Generators
11

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:
• Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: Afterthe initial running of the generator, the air in
the engines 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 engines cooling system to
replace the purged
air.
Before subsequent operation of the generator, the engines
manifold should be topped off, and the coolant recovery
tank may need to be filled to the
MAX level.
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
• Check load leads for correct connections as specified in
the wiring diagrams.
• Examine the air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
the load lines.
• Be sure that in power systems with a neutral line that the
neutral is properly grounded (or ungrounded)
as the system
requires, and that generator neutral is properly connected
to the load neutral. In single phase systems an incomplete
dr open neutral can supply the wrong line-to-neutral
voltage on unbalanced loads.
A CAUTION: When starting the generator.. it is
recommended that all AC loads, especiallyJarge
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 unantici-
pated operation of the AC machinery and will prevent a
cold engine from stalling.
SPIN ON
OIL FILTER
Engines & Generators
12
MANIFOLD PRESSURE
CAP
ADD OIL
USE THE MOST
CONVENIENT
OIL FILL
'OIL COOLER

STARTING/STOPPING PROCEDURE
ELECTRIC START
A CAUTION: All AC loads must be switched off
before starting. This precaution will prevent damage
caused by unanticipated operation of AC machinery and
will prevent a cold engine from stalling.
This generator has a 12 VDC electric starter. To start the
generator, push the START button on the control panel. The
yellow START indicator light will come on and start to blink:.
Once the engine fires and runs, the yellow START indicator light
will go out and the green run indicator light will come on.
NOTE: If a start attempt is ~borted, the yellow indicator light will
continue to blink To reset the circuit, depress the stop button.
OPERATING THE GENERATOR
After the generator has started, run it with a medium load for
warmup. Ifpossible, apply the load in stages.
A CAUTION: Never operate the engine for long
periods of time without an amperage load being
applied, otherwise carbon build-up may occur which
can cause severe damage to the engine.
STOPPING THE GENERATOR
Remove the AC loads from the generator one at a time and allow
the generator to run for an additional 3 to 5 minutes (this stabilizes
its operating temperature).
I LED PROPORTIONAL ..
II LOAD INDICATOR
• To stop the generator, press the STOP button on the control panel;
leOOLANT/OiL PRESSUR~ .JHOURMETER \ shutdown is automatic.
[WARNING LIGHT
After shutdown, carefully inspect the generator. Check for
@ @
possible leaks from all the connections inside the soundshield.
@
Apply a light load to the generator and allow the engine to warm
up to operating temperature before applying heavy loads
NOTE: Some unstable running may occur in a cold engine. This
condition should smooth out as the engine warms up and when
the generator loads are applied. .
Failure to Stop
If the engine should fail to stop after pressing the STOP button,
use the control lever: Push the lever all the way over and hold it
until the engine comes to a stop, then release it.
NOTE: Only use this lever when the engine doesn't stop after
pressing the STOP button.
Engines & Generators
·13

BREAK-IN PROCEDURE/DAILY OPERATION
BREAK-IN PROCEDURE
After the generator has been started, check for proper opera-
tion and then encourage a fast wann-up. Run the generator
between 20% to 60%
of full load for the fIrst 10 hours.
A CAUTION: 00 not attempt to break-in your genera-
tor 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 periodi-
cally vary the load.
Avoid overload at all times. An overload is signaled by a
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
it within the generators' rating. Since the generator operates
at 3600 rpm to produce 60 hertz, or at 3000 to produce 50
hertz, control of the generator's engine break-in is governed
by the current drawn from the generator.
To protect against unintentional overloading of the generator,
the generator's output leads should be routed through a cir-
cuit breaker that is rated at the rated output of the generator.
NOTE: Be aware of motor starting loads and the high
current drawn required
for starting motors. This starting
amperage drawn can be 3 to 5 times normal running amper-
age. See GENERATOR INFORMATION
in this manual.
CHECK LIST
Follow this checklist each day before starting your generator.
• Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule).
• Visually inspect the engil!e for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check the drive belt for wear and proper tension (weekly).
• Check for abnormal noise such as knocking, vibration and
blow-back sounds.
• Confmn exhaust smoke:
When the engine is cold -White Smoke.
When the engine is wann -almost Smokeless.
When the engine
is overloaded -some Black Smoke.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached and loads are applied.
A CAUTION: 00 not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove the major AC loads 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, there may
be governor adjustments required for engine speed (hertz)
during the engine's break-in period (fIrst 50 hours) or after
this period (see ENGINE SPEED (HER1Z) ADJUSTMENT
under ENGINEADJUSTMENTS. A no-load voltage adjust-
ment may also be required in conjunction with the engine's
speed adjustment (see GENERATIOR INFORMATION).
Engines &.Generators
14