Westerbeke 8.0KW BTDAR User manual

OPERATORS MANUAL
. MOBILE and INDUSTRIAL
I ..... ...GENERATORS .
.. . -- ,.
r -" •
. 8.0KW BIOAR 10.0KW BIOAR
. .
12.5KW BIOBR· ·15.0KW BIOCR
14.0 CR
REVISION 2
WESTERBEKE CORPORATION '150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
.. ...,~~
NMMA Member National Marine Manufacturers Association
--

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
- Throbbing in Temples
-Nausea - Muscular TWitching
-Headache
- 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. It 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. They are
~W· ~!"!A!!'ii!!R~' "!!N~I!'!N~G~ \, ,inexpensi~e and easily obtainable at your
, " local maflne or hardware store.
, 'G!lneratots Prod~ QARSON MONOXIDE 'j
Regular ~n!9nance Required i
1Fj=~~~
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive Jtarm.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accUIents are
caused by failure to follow fundamental rules and
precautions.
Know when dangerous conditions exist and
take the
necessary precautions to protect yourself, your
personnel, andyour
machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 not touch AC electrical connections
while engine is running. Lethal voltage is present at
these connections!
• Do not operate this machinery without electrical
enclosures and
covers in place.
• Shut 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.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 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 of an engine overheat, allow the engine to cool
before touching
the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch
all fuel when
removing the fuel line, carburetor, or fuel filters.
• 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 ofdebris to minimize the
chances offire.
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!
• 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 ofthe reach ofchildren.
• 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
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free oflealrs.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be faruiliar with its proper use.
Extinguishers rated
ABC by the NFPA are appropriate
for all applications encountered in this environment.
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• To prevent accidental starting when servicing the
generator, remove the 8 amp fuse from the control panel.
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
itlast.
• 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.
-..v WESTERBEKE
Engines & Generators

SAFETY INSTRUCTIONS
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid 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 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
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum 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.
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from
the engine. Check the exhaust system
regularly for leaks
and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention
to the manifold and exhaust.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your dealer
for installation of
approved detectors.
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water
leakage.
• Do not install exhaust outlet where exhaust can be drawn
through vents,
or air conditioners.
• 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
Dizziness Muscular twitching
Intense headache
Throbbing
in temples Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: RotaUng 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 parts and hot exhaust system
components.
• Do not wear loose clothing or jewelry when servicing
eqnipment;
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.
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: 00 not work on machinery when you are
mentally or physically incapacitated by tatigue!
...v' WESTERBEKE
Engines & Generators
ii

TABLE OF CONTENTS
Parts Identification ............................................. 2 Engine Troubleshooting [Chart] ........................ 28
Introduction ......................................................... 3 Engine Adjustme·nts ....... : ................................... 30
Warranty Procedures........................................ .3
Valve Clearance Adjustment ..........................30
Serial Number Location ...................................4 Testing Engine Compression..........................
31
Diesel Fuel, Engine Oil, and Coolant ................. 5
Generator Control Panels .................................... 6 Fuel Injectors.................................................
.31
Drive Belt Adjustment.................................... 31
Description of Switches....................................6
Control Panel Troubleshooting [Chart].............32
Description
of Gauges·......................................6
Electronic Governor Adjustments ..................... 33
Remote Panel....................................................6 Description....:............................................:.... 33
Preparations for Initial Start-Up ......................... 7
Prestart Inspection ............................................7
Generator Voltage .............................................7
ControllerAdjustment ....................................
33
Inspect and Adjust.......................................... 33
Linear Actuator Troubleshooting [Chart].......... 34
Starting/Stopping Procedure ............................... 8
GenRemote Calibration ..................................... 35
Safety Shutdown Switches ...............................9
GenRemote Control Station ............................. 36·
Generator Break-in Procedure ......................... .10
GenRemote Wiring Diagram ............................. .37
The Daily Operation .......................................... .11
GenRemote Installation Oiagram ..................... 38
Maintenance Schedule .................................... .12 Stop/Start Rocker Switch ..............................
.38
Cooling System .................................................. 14
GenRe mote Specifications .............................. .39
Changing Coolant...........................................14
Thermostat........:.............................................
15
Fuel System ....................................................... 16
Fuel FilterIWater Separator ............................16
Fuel Injection Pump .......................................16
. Generator litformation .. ..................................... 40
Power Take Off Systems ................................... .41
BT Generator .................................................... .42
BT Generator Wiring Schematic ...................... .43
Fuel Lift Pump................................................16
BT Generator Single Phase .. ............................ .44
Fuel Lift Pump Filter......................................16
Fuel Filter .......................................................16
Engine Fuel Filter.............:.............................16
Engine Lubricating OiL ....................................17
Engine Oil Change .........................................17
Generator Voltage Adjustment ........................ .45
BT Generator Voltage Regulator.. ...... ............... 47
BT Generator Internal Wiring .......................... .48
Regulator Sensing Wye-Delta Configurations .. 49
Remote Oil Filter ................................... : ........... 18
BT Generator Troubleshooting [Chart] ............50 .
Oil Pressure ....................................................... 19
Specifications 1D.DKW/B.DKW BTOAR,_ ............ 51
Testing Oil Pressure........................................19
Specifications 15KW/12.5KW BTOB R~ ............ 52
DC Electrical System .... ..................................... 20
Generator Specifications 1D.DKW/B.oKW ......... 53
Alternator Troubleshooting ............................20
12 Volt DC Control Circuit ............................21
Battery Care....................................................21
Starter Motor ..................................................... 22
Generator Specifications 15KW BTOCR .......... .54
Generator Specifications 12.5KW BTOBR" ........ .54
Generator Specifications14,KW BTOC'R _ ..... 54A
Troubleshooting..........................................:... 22
Engine Torque Specifications ........................... 55
Service ............................................................23
Standard Hardware ................................ : .. ; ........ 56
Glow Plugs . ........................................................ 24 Sealants and Lubricants..................................56
Generator Wiring Diagram #44744 ..................... 25 . Metric Conversion Data .................................... 57
Generator Wiring Schematic ~ .. ~.~ ............ 25A
Suggested Spare Parts ..................................... 58
Remote Instrument Panel ................................ 26
Generator Wiring Diagram #044927 .................. 27
Generator WiringSchematic ........................... 27 A
Engines & Generators
1

PARTS IDENTIFICATION
AIR INTAKE/AIR FILTER
.~SSEMBLY
FRONT
EXHAUST
CONTROL PANEL
BACKEND
PREHEAT
OIL FILTER.
OIL SUMP ______ ~
OIL FILL
20A CIRCUIT
REAR
At
BREAKER
Engines & Generators
2
STOP SWITCH
;REMOTE PANEL
CHARGING
ALTERNATOR
~~l----:;:;J~- START MOTOR
MOUNT
• LEFT SIDE
~-i~OOLANT PRESSURE CAP
,RADIATOR
RIGHT SIDE
J---EN'''N. SERIAL
NUMBER
PUMP
DRAIN HOSE
LIFT PUMP

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKE's
long years ofexperience and advanced
technology. We take great pride in the superior durability and
dependable perfonnance 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 contact your WESTERBEKE dealer for
WESTERBEKE'S installation
manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days of submitting the Warranty Registry
fonn
you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the unit's serial
number and commission date.
Customer Identification Card
L~ WESTERBEKE
J Engines & Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model15BTDAR Ser. #.
Expires 7120/2008
TheWESTERBEKE engine serial number is an
alphanumeric
number that can assist one in determining the
date of manufacture;A manufacturing date code is placed at
the end of the engine serial number. It consists of a character
followed by three numbers. Today it consists of two
characters. Previous date code. The character indicated the
decade E=2000s. The first number represented the year in
the decade, and the second and third, the month of that year.
Beginning in May 2008, the two characters HE. H
represented 2008
and the E the month of May and so on HF
2008 July, HG 2008 July.
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 CANNOTBE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLE
FOR ANYTYPE OFDAMAGE OR INJURY
INCURRED IN CONNECTION
WIlli 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. Insummation, product software
provided
with WESTERBEKE products, whether from
WESTERBEKE or other suppliers, must not and cannot
be relied
upon exclusively as the definitive authority on
the respective product. It not only makes good sense
but is imperative that appropriate representatives of
WESTERBEKE or the supplier in question be consulted
to determine the accuracy and currentness of the
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical infonnation will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NDTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine and generator serial numbers and model numbers
are located on a decal on the generator housing. Take the
time to enter this information on the illustration ofthe narDe-
plate shown below, as this will provide a quick reference
when
seeking techuical information and/or ordering repair
Parts.~~~~~~~~~~,.~~~ ..
--
MOOEL ________ _
RPM ___________ _
KVV ____________ _
KVA ___________ _
VOLTS _________ _
AMPS _________ _
ENG, HP ______ _
ENG. SER. NO.
GEN. SER. NO.
PF/PHASE
___ _
VVIRES ________ _
RATING _______ _
INSUL CiJ\SS __
TEMP. RISE ____
BATIERY ____ __
C.I.O. _________ _
The engine serial number can also be found staroped into the
engine block just above the injection
pump. The generator
serial number is staroped into the generator housing on the
flat surface on the left side ofthe generator.
An identification plate on the engine mauifold also displays
the
engine model and serial number.
ENGINE
SERIAL
NUMBER
GENERATOR
10 DECAL
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the SarDe. The cylioders
are arranged above a closed crankcase;the crankshaft is of
the
SarDe general type as that of a gasoline engine, and the
diesel
engine has the SarDe type of valves, camshaft, pistons,
conoecting
rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the
same preventive maintepance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance ofthe
fuel, lubricating and cooliog systems.
Replacement offuel and lubricating filter elements at the
time periods
specified is a must, and frequent checking for
contamination (that
is water, sediment, etc.) in the fuel sys-
tem is also essential. Another important factor is the use of
the
SarDe 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 ofhandling and firing of fuel. The
carburetor
and iguition systems are replaced by a single
component - the fuel injection pump - which performs the
function of both.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator
model number, engine serial number, and generator
serial
number as they appear on the silver and black narDe-
plate located on the generator end. You must provide us with
this information so we may properly identify your generator
set. In addition, include a complete part description and part
number for
each part needed (see the separately furuished
Parts List). Insist upon WESTERBEKE packaged parts
because willfit
or generic parts are frequently not made to
the SarDe specifications as original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE engine. Your local WESTERBEKE dealer
will assist
you in preparing an inventory of spare parts.
See the SPARE PARTS page in this manual. For engine
accessories,
see WESTERBEKE'S ACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed information for
installing generators and a copy is supplied with each unit.
Also the manual is available from our website at
www.westerbeke.com to download in a pdf format.
--'GEIIERIITOR SERIAL
'NUMBER
Engines & Generators
4

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or specification ofClass
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 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.
ENGINE OIL
Use a heavy duty diesel oil with an API classification of
CF, CG-4, CH-4 or CI-4. Change the engine oil and filter
after an initial 50 hours
of 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 of 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 state-
ments regarding synthetic oil.
Forrecommended 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, 10W-30 or 15W-40
Below 41'F (5'C)
SAE 10W-30 or 15W-40
A CAUTION: 00 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.
OIL PRESSURE
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure will range between 30
and
60 psi.
NOTE: A newly started, cold engine can have an oil pressure
reading upwards
of 60 psi (4.2 kg/cm". A warmed engine can
have an oil pressure reading as low as 25psi (1.8 kg/cm".
These readings will vary depending upon the temperature of
the engine, the loadplaced on the engine, andthe RPM~.
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, and 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
bal-
anced, crucial to long term protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
NOTE: Look for the new enviromnentallY1riendly 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 of the circulating pump seal.
ANTIFREEZE PROTECTION
Antifreeze concentration
Freezing Temperature
23%
14'F
(-5'C)
COOLANT RECOVERY TANK
30%
8'F
(-13'C)
35%
-4'F
(-20'C)
50%
-40'F
(-40'C)
Acoolant recovery tank kit is supplied with each
WESTERBEKE diesel engine. The purpose of this 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: 7his tank, with its short run of plastic hose, is best
located at
or above the level of the engine~ manifold, but it
can
be located below the level of the engine ~ manifold if the
particular ~nstallation makes this necessary.
Engines & Generators
5

GENERATOR CONTROL PANELS
DESCRIPTION OF SWITCHES
This manualJy controlJed series ofWES1ERBEKE marine
diesel
generators is equipped with toggle switches on the
engine control panel and, optionally, at remote panels.
All three switches are momentary contact type and serve the
following
functions:
PREHEAT: The PREHEAT toggle serves two purposes:
preheating the engine for easy starting and bypassing the
engine oil pressure switch. The PREHEAT function closes
the
K2 relay. as well as supplies current to the fuel solenoid
pull coil. .
When
the PREHEAT switch is depressed, the voltmeter,
panel lights, gauges and meters and the hold coil of the fuel
solenoid.
START: The START toggle switch closes the KI relay that
energizes
the starter solenoid and activates the starter.
While the PREHEAT switch is still depressed, depressing the
START switch engages the start solenoid. When the engine
begins to
fire, the START switch should be released. The
PREHEAT switch should not be released until the oil
pressure reaches 5 -
10 psi.
STOP: The STOP toggle switch is a normally closed switch
providing power
to the K2 relay. Opening of this switch
opens
the power circuit to the fuel solenoid, stopping the
flow of fuel to the engine and shuts down the engine.
To stop the engine, depress the STOP switch. When the
STOP switch is depressed, the power feed to the fuel sole-
noid
is opened, and the fuel flow to the engine is stopped.
The
STOP switch should be depressed until the generator
stops rotating
NOTE: When the engine is shut down, the water temperature
gauge and
the oil pressure gauge will continue to register the
last temperature and oil pressure readings displayed. They
will return to zero once-electricalpower is restored.
EMERGENCY STOP: The EMERGENCY
stop switch on the side of the control box, '
is normally closed. When depressed, it
will open the DC circuit to the control
panel and shut the engine down. As the
switch is not toggled it can be used when
performing maintenance.
DESCRIPTION OF GAUGES
Coolant Temperature
Engine coolant (water) temperature should normally indicate
175' to 195' F (80' to 90' C).
Engine Oil Pressure
Oil pressure (psi) may fluctuate depending on the generator
load but should range between between 30 to 60 psi.
DC Voltmeter
Indicates the amount the battery is being charged should show
l3V to 14V.
Hourmeter
Registers elapsed time and is used as a guide for when to
perform scheduled maintenance.
REMOTE PANEL
For remote operation of the generator system, the same three
switches are used. The PREHEAT and START switches are
connected in parallel with the gauge panel's switches and
serve the same functions as in the gauge panei. The STOP
switch is in series with the gauge panel's STOP switch and
serves the same function. There is a REM01E START/STOP
WIRING DIAGRAM in this manual.
GENERATOR
RELEASE
STARTER
PREHEAT
MUST ~
PRESS Cf!))
1ST e
f'li
STOP
START
I~~ PRESS
\,fIiJ 2 NO
WESTERBEKE
NOTE: For additional infonnation on Control Panels. Refer to:
STARTING/STOPPING PROCEDURE, DC WIRING
DIAGRAMS and TROUBLESHOOTING GAUGES.
Engines & Generators
6

PREPARATIONS FOR INITIAL START-UP
PRESTARTINSPECTION
This section of the manual provides the operator with prepa-
ration, initial starting, break-in, starting (warm or cold) and
stopping procedures. Follow the procedures as presented for
the conditions indicated
and your WESTERBEKE generator
set
will give reliable performance and long service life.
Before starting your generator set for the first time or after a
.prolonged layoff, check the following items:
o Check the engine oil level. Add oil to maintain the level
at
the high mark on the dipstick.
o Check the fuel supply and examine the fuel filter/separa-
tor bowls
for contaminants.
o Check the DC electrical system. Inspect wire connections
and battery cable connections. Make certain the (+) bat-
tery cable is connected to the starter solenoid and the
negative (-) cable
is connected to the engine ground stud
(this location
is tagged).
o Check the coolant level in both the plastic recovery tank
and
at the manifold.
o Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections.
o Check load leads for correct connection as specified in
the wiring diagrams.
o Examine air inlet and outlet for air flow obstructions.
o Be sure no other generator or utility power is connected
to load lines.
o Be sure that in power systems with a neutral line that
the neutral
is properly grounded (or ungrounded) as the
system requires,
and that the generator neutral is properly
connected
to the load neutral. In single phase and some
3-phase systemS an incomplete or open neutral can sup-
ply the wrong line-to-neutral voltage on unbalanced
loads.
o Make sure the mounting installation is secure.
o Make sure that the generator is properly grounded.
A CAUTION: When starting the generator, it is
recommended that all AC loads, especially large motors,
be switched OFF until the engine has come up tii speed
and, in cold climates, starts to warm up. This precaution
will preven{damage caused by unanticipated operation
of the AC machinery and will prevent a cold engine from
stalling.
GENERATOR VOLTAGE
The speed of the generator engine is adjusted at the factory,
however, it is advisable to verify.
60 Hz The engine no-load speed is set at 61.5 - 62 Hz.
50Hz
At rated amperage hertz output may decrease to
48.6 - 59.0 Hz.
The engine no-load speed is set at 61.5 Hz. At
rated amperage hertz output may decrease to
48.5 - 49.0 Hz.
The speed of the generator engine is adjusted at the factory,
however it is advisable to verify. The voltages are easily
adjusted to optimum values no-load and full load (refer to
VOLTAGE ADJUSTMENTin this manual). If possible, apply
actual service or test load ofthe same power factor as the
load to be used in service. If the voltage cannot be adjusted
to suitable values arid fault seems evident, contact your
authorized WESTERBEKE service
dealer.
GLOW PLUG
CONNECTION
Oil Fill CAP
~
DIPSTICK \l\> ~PPROXIMATELY
ONE QUART
Oil lEVEL Y
SIDE Oil
CAP
-.rN'" WESTERBEKE
Engines & Generators
7

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
Westerbeke diesel generators use electric starters assisted by
glow plugs for botb normal and cold weatber starting. The
illustration below shows a cross-sectional view of one
cylinder. The glow plug is located in tbe combustion cham-
ber so that its tip is in tbe injector nozzle's spray patb. When
tbe glow plug is energized by tbe PREHEAT button, the plug
glows red at !be tip and assists in igniting tbe fuel. The result
is a rapid start witb less wear on tbe starter.
This system is common to WESTERBEKE diesels. The start
circuitry
is desigued so tbat tbe PREHEAT button must be
depressed for tbe
time specified in tbe preheat chatt. Then,
while keeping tbe PREHEAT button engaged, tbe START
button is depressed to crank tbe engine.
NOTE: The STARTswitch will not energize unless the
PREHEAT switch is depressed. Depressing the PREHEAT
switch activates
the glow plugs in the cylinder head so use
the PREHEAT intermittently to avoid overheating the glow
plugs.
GLOW
PREHEAT: Depress tbe PREHEAT switch. The volttneter and
panel lights, gauges and meters will be activated. The
PREHEAT switch shouW be depressed in accordance witb
tbe following chatt:
Temperature/Preheat
Almospherlc Temperalure
Preheallng Time
+41°F(+5°G) or higher Approx. 10 seconds
+41°F(+5°G) to 23°F (-5°G) Approx. 15 seconds
+23°F(-5°G) or lower
Approx. 20 seconds
Limit 01 continuous use 30 seconds before cranking
START: While still depressing tbe PREHEAT switch, depress
tbe START switch. This will engage tbe starter solenoid.
Upon engine starting, release tbe START switch. Do not
release tbe PREHEAT switch until the oil pressure reaches
15 psi. Then as long as tbe high water temperature and low
oil pressure protective circuits do not activate, tbe engine will
remain energized and continue to run.
NOTE: When starting:
A voltage drop will occur
when
the preheat switch
is
depressed.
Should tbe engine not start when tbe START switch is
depressed
for 10 to 20 seconds, release botb switches and
wait 30 seconds; repeat tbe procedure above and preheat
longer. Never run the starterfor more than 30 seconds.
Remote Starting Procedure
The remote statt panel is tbe same as tbe engine-mounted
start panel except tbat it has a green LED light and no
guages. When starting at a remote location, tbe green LED
lights when tbe generator is runrrlng at approximately 600
rpm. This indicates when tbe START switch can bereleased
since tbe starting of tbe generator may not be audible.
A. When tbe PREHEAT switch is depressed at tbe remote
start/stop panel
tbe LED lightwill illuminate. When tbe
START switch is depressed and tbe starter cranks tbe
engine
this LED light will dim. When tbe engine statts
tbe
LED light will brighten sigualing to release tbe
START switch. Continue to hold tbe PREHEAT
depressed for a few seconds to allow oil pressure to build
up
which closes tbe oil pressure safety switch that is in
tbe series patb for 12V B+ to tbe fuel run solenoid. The
green LED will remain brightly illuminated while tbe
engine
is running.
B. After tbe generator is statted and tbe START switch is
released, tbe generator's starter will not crank uuless tbe
PREHEAT switch is operated first because tltis switch
supplies voltage
to tbe START switch.
Once tbe engine statts, check tbe engine's insttnments for
proper oil pressure and battery charging voltage. Apply a
light load
to tbe generator and allow tbe engine's operating
temperature to come up-to l40-lS0oP (60-66°C) before
applying heavy loads.
NOTE: Some unstable running may occur in a cold engine.
Depressing the PREHEATswitch for 10-15 second intervals
will
help stabilize the engine RPM until the operating
temperature reaches the 140-150°F and a load is applied to
the engine.
~ WESTERBEKE
Engines & Generators
8

STARTING/STOPPING PROCEDURE
STARTING UNDER COLD CONDITIONS
Make sure the lubricating oil conforms with the ratings for
the prevailiog temperatore. Check the table in the ENGINE
OIL section in this manual.
The battery should be fully charged to minimize voltage
drop.
Use a sufficient amount ofpreheat to aid in starting. See the
Temperature/Preheat chart elsewhere in this section.
STOPPING PROCEDURE
1. Remove the AC electrical load from the generator and
allow the generator to run for three to five minutes to
stabilize its operating temperatures.
2.
Depress the STOP switch and hold it until the generator
is completely stopped.
3. Now release the STOP switch.
SAFETY SHUTDOWN SWITCHES
The engine is protected by three automatic shutdown
switches. Should
shutdown occur, do not ottempt to restart
wilhontfinding and correcting the cause. Refer to the
heading ''Engine Stops"
in the TROUBLESHOOTING
section of this manual.
The following is a description ofthese automatic shutdown
switches:
Coolant Temperature Switch
A high water temperatore switch i.located on the thermostat
housing.
Normal1y closed, this switch, should the fresh water
coolant's operating temperatore reach approximately 21O'F
(99'C), will open and intermpt the DC voltage to the K2
relay, thereby shutting offthe engine. This switch resets at
195'F (107'C).
COOLANT
TEMPERATURE
SWITCH
SENSOR
Remote Stopping Procedure
To stop the generator, depress the STOP switch which opens
the normally closed B+ path for voltage to the engine's run
circuit. The STOP switch must be held open until the
generator comes
to a complete stop and the green LED light
goes out.
Low Oil Pressure Switch
A low oil pressure shutdown switch is located offthe
engine's
oil gallery. Normally open in a static state, this
switch's sensor mouitors the engine's oil pressure. Should the
engine's oil pressure fall to 5-10 psi, this switch will open,
interrupting the DC voltage to the K2 relay, thereby shutting
off the engine.
OIL PRESSURE .w""""
OIL PREilSUFIE-,L
SENOOR
Engine Circuit Breaker
The generator's engine is protected by an engine mounted
manual reset circuitbreaker (20
amps DC). Excessive current
draw or electrical overload anywhere in the instrument panel
wiring
or engine wiring will cause the breaker to trip. In this
event the generator will shut down and the voltage to the K2
relay is terminated. If this should occur, check and repair the
source ofthe
problem. After repairing the fault, reset the
breaker and restart
the generator.
"'" WESTERBEKE
Engines &Generators
9

GENERATOR BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour oftest operations at the factory to make sure accurate
assembly procedures were followed and that the engine
operated
properly, a break-in time is required. The service
life of
your engine is dependent upon how the engine is
operated and serviced during its initial hours of use.
Breaking-in a new engine basically involves seating the
piston
rings to the cylinder walls. Excessive oil consumption
and
smoky operation indicate that the cylinder walls are
scored, which is caused by overloading the generator during
the break-in period.
Your new engine requires approximately 50 hours ofinitial
conditioning operation
to break in each moving part in order
to maximize the performance and service life of the engine.
Perform
this conditioning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems
(water
pump, oil pressure, battery charging) are functioning.
AFTER START-UP
Once 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: 00 not attempt to break-in your
generator by running without a load.
After the first 10 hours of the generator's operation, the load
can
be increased to the full-load rated output, then
periodically vary the load.
CHECK THE FOLLOWING
D Monitor the control panel gauges.
D Check for leaks of fuel and engine oil.
D Check for abnormal noise such as knocking, friction,
vibration and blow-back sounds.
D 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.
To protect against unintentional overloading ofthe generator,
the generator's output leads should be routed through a circuit
breaker that
is rated at the rated output ofthe generator.
NOTE: Be aware of motor staning loads and the high current
draw requiredfor staning
motors. This staning amperage
draw can be 3 to 5 times normal running amperage. See
GENERAIDR INFORMATION in this manual.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may
be adjustments required for engine speed (hertz) during the
engine's break-in period
(first 50 hours) or after this period.
Ano-load
voltage adjustment may also be required in
conjunction with the engine's speed adjustment. See
GENERATOR INFORMATION in this manual.
""" WESTERBEKE
Engines & Generators
10

THE DAILY OPERATION
CHECK LIST
Follow this chdck list each day before starting your generator.
D Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
D Visually inspect the generator for fuel, oil, or water leaks.
D Check the oil level (dipstick).
D Check the coolant level in the coolant recovery
tanklradiator.
D Check your diesel fuel supply.
D Look for clean fuel in the fuel/separator transparent bowl.
D Check for loose wires at the alternator.
D Check the starting batteries (weekly).
D Check drive belts for wear and proper tension (weekly).
START THE GENERATOR
(See STARTING PROCEDURES on previous pages).
Allow the engine to warm up for 5 to 10 minutes to reach an
operating temperatures'of 140° to 150°F (60°-66°C) before
applying
AC loads. Apply loads systematically allowing the
generator to adjust to each load before applying the next.
Check the gauges for proper oil pressure, operating
temperature, and DC voltage.
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 loads from the generator one at a
time. Allow the generator to run for a few minutes to
stabilize the operating temperature and depress the stop
switch. (See STOPPING PROCEDURES on previous manu-
als).
~ WESTERBEKE
Engines & Generators
11

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is
running. Wear,theproper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenancejobs are simple but others are more
difficult andmay require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY 50 100
250 500
750
1000 1250 MAINTENANCE
0
Diesel No, 2 rating of 45 cetane or higher,
0
Check for water and dirt in fuel (drain/replace filter
if necessary),
0
Oil level should indicate between MAX, and LOW on
dipstick,
0
Check at recovery tank; if empty, check at manifold,
Add coolant if needed,
0
Inspect for proper tension (3/8" to 1/2" deflection)
weekly
and adjust if needed, Check bett edges for wear,
Visual Inspection of Engine
0 NOTE: Please keep engine surface clean. Dirt
Check for fuel, oil and water leaks, Inspect wiring
and oil will inhibit the engine's ability to
and electrical connections, Keep bolts & nuts tight
remain cool,
Check for loose belt tension,
Fuel Filler
0 0 0 0 0 0
Initial change at 50 hrs, then change every 250 hrs,
Sfarting Batteries
0
Every 50 operating hours check electrolyte levels
weekly
and make sure connections are very tight Clean off
excessive corrosion.
Engine Oil (and filter)
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs" then
change both every 100 hours.
Generator
0 0 0 0 0 0 0
Check that AC connections are clean and secure
with no chafing. See GENERATOR SECTION
for additional information,
Heat Exchanger Zinc Anode
0 0 0 0 0 0 0
Inspect zinc anode, replace if needed, clear the heat
exchanger end of zinc anode debris,
Fuel Filter/Water Separator
0 0 0 0 0 0
Inspect daily, Replace filter element every 250
hours of use or as found to be needed, Clean and
drain separator bowl as needed,
Electronic Governor Control
0 0
Check and or adjust the no·load speed in the panel,
(if applicable)
required (hertz) and the regulator board adjustment
as needed.
NOTE: These adjustment are not a warrantable
adjustment during or after the unit's break-in.
Exhaust System
0 0 0 0
Initial check at 50 hrs., then every 250 hrs, Ensure
the system is securely fastened to the exhaust
manifold. System is properly supported and muffler
and other components are in good serviceable con-
dilion. No leaks,
Engine Hoses
0 0 0 0 0 0
Hose should be hard & tight Replace if soft or
spongy. Check and tighten all hose clamps.
Inlet Fuel Filter
0 0 0 0 0 0 0
Replace initially at 50 hours and then once a year
or as needed.
Engines & Generators
12

SCHEDULED
MAINTENANCE
Coolant System
Air Intake Filler
Electric FuelliH
Pump
DC Alternator
"Fuelln]ectors
"Starter Motor
"Preheat Circuit
"Engine Cylinder
Compression
"Torque Cylinder Head
Hold-down bolts
MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your
engine hours by running time.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY
50 100 250 500 750 1000 1250
MAINTENANCE
0 0
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
0 0 0 0 0 0
Clean every 100 hours. Replace as needed.
0 0 0 0 0 0
Periodically check the wiring connections ..
0 0 0
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
0
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (4-6 ohms).
Reinstall with anti-seize compound on threads.
0 0
Check compression pressure and timing (see
ENGINE ADJUSTMENTS).
0 0 0
At first 50 hours, then every 500 hours (see
ENGINE ADJUSTMENTS).
"Adjust the Valve Clearances
0 0 0
Adjust Valve Clearances (see ENGINE
ADJUSTMENTS).
"Radiator
0
Remove, have professionally cleaned and pressure
tested.
"WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
13

COOLING SYSTEM
DESCRIPTION
Westerbeke diesel engines are designed and equipped for
fresh water
cooling. Heat produced in the engine by
combustion and friction is transferred to fresh water coolant
which circulates throughout the engine. This circulating fresh
water coolant cools the engine block and its internal moving
parts and the engine oil.
Fresh water coolant is pumped through the engine by a
circulating
pump, absorbing heat from the engine. The
coolant
then passes through the thermostat into the manifold,
to the radiator where it is cooled, and returned to the engine
block via
the suction side ofthe circulating pump.
FRESH WATER COOLING CIRCUIT
NOTE: Refer to ENGINE COOLANT section/or the
r~commended antifreeze and water mixture to be used as the
fresh watercoolant.
•
\
COOLANT DRAIN'
OIL
FILTER
When the engine is started cold, external coolant flow is
prevented by the closed thermostat (although some coolant
flow is bypassed around the thermostat to prevent the engine
manifold from overheating). As the engine warms up, the
thermostat gradually opens, allowing full flow ofthe engine's
coolant to flow unrestricted to the external portion of the
cooling system.
Coolant Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any
significant loss of coolant and without introducing air into
the cooling system. This tank should be located at or above
the engine manifold level and should be easily accessible.
CHANGING COOLANT
The engine's coolant must be changed according to the
MAINTENANCE SCHEDULE. If the coolant is allowed to
become contaminated, it can lead to overheating problems.
A CAUTION: Proper cooling system maintenance is
critical; a substantial number of engine failures can be
traced back to cooling system corrosion.
, Drain the engine coolant by loosening the drain plug on the
\' engine block and opening the radiator pressure cap. Flush the
,. system with fresh water, then start the refill process.
NOTE: The petcock on the radiator can also be usedto drain
engine coolant.
A WARNING: Beware of the hot engine coolant •
Wear protective gloves.
~ WESTERBEKE
Engines & Generators
14

COOLING SYSTEM
Refilling the Coolant
After replacing the engine block drain plug, close the radiator
coolant petcock. then pour clean, premixed coolant
into the
radiator and when the coolant is visible, start the engine.
Monitor the coolant in the radiator and add as needed. Fill
the radiator
to the filler neck and install the pressure cap.
Remove the cap on the coolant recovery tank and fill with
coolant mix to halfway between LOW and MAX and replace
the cap. Run the engine, observe the coolant expansion flow
into the recovery tank.
After checking for leaks, stop the engine and allow it to cool.
Coolant should draw back into the cooling system as the
engine cools down. Add' coolant (0 the recovery tank if
needed. Clean up any spilled coolant.
TO GUULAN.r 1
RECOVERY
MAKE CERTAIN THESE
PASSAGES ARE KEPT
NOTE: Periodically check the condition o!the'radiator
pressure cap. Ensure that the upper and lower rubber seals
are in good condition and check that the vacuum valve opens
and closes tightly. Carry a spare cap.
THERMOSTAT
A thermostat, located near the manifold at the front ofthe
engino, controls the coolant temperature as the coolant
continuously
flows through the closed cooling circuit. When
the engine is first started, the closed thermostat prevents
coolant from
flowing (some coolant is by-passed through a
hole in the thermostat
to prevent overheating). As the engine
warms
up, the thermostat gradually opens. The thermostat is
accessible and can be checked, cleaned, or replaced easily.
Carry a spare thermostat and gasket.
Replacing the Thermostat
Remove the cap screws and disassemble the thermostat
housing
as shown. When installing the new thermostat and
gasket,
apply a thin coat ofsealant on both sides ofthe
gasket
before pressing it into place. Do not over-tighten the
cap screws.
Run the engine and check for normal temperatures and that
there
are no leaks at the thermostat housing.
COOLANT
TEMPERATURE
SWITCH
THERMOSTAT
ASSEMBLY
AIR FILTER
,
BLEED
PETCOCK
SENDOR
[OPTIONALI
The air filter cartridge prevents engine room dust and dirt
from
entering the engine, it also extends engine life, and
quiets the engine.
MAINTENANCE
The filter should be cleaned every 100 operating hours. Tap
the cartridge on a flat surface to dislodge loose dirt or clean
off
with compressed air. If the cartridge is badly contaminated
or oily, replace it.
CARTRIDGE
INTAKE
SILEN.CER
~ WESTERBEKE
Engines & Generators
15

FUEL SYSTEM
DIESEL FUEL
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do
not use kerosene or home heating fuel.
FUEL FILTERJWATER SEPARATOR
A primary fuel filter ofthe water separating type must be
installed between the fuel tank and the engine
to remove
water
and other contaminants from the fuel before they can
be carried to the fuel system on the engine.
The owner/operator is responsible for making certain the
fuel reaching the engine's injection equipment is free of
impurities. This process is accomplished by installing and
,maintaining a proper fuel filter/water separator betwen'the
,fuel tank and the generator/engine. Westerbeke recommends
a
10 micron filter be used.
FUEL INJECTION PUMP
The fuel injection pump isa very important component of
the diesel engine, requiring the utmost care in handling. The
fuel injection pump has been thoroughly bench-tested and the
owner-operator is cautioned not to attempt
to service it. If it
requires servicing, remove it and take it
to an authorized fuel
injection pump service facility. Do not attempt
to disassem-
ble
and repair it.
The only adjustment the servicing mechanic should make
to
the fuel injection pump is the adjustment for engine idle
speed (see IDLE SPEED
ADJUSTMENT under ENGINE
ADJUSTMENTS).
FUEL LIFT PUMP
Periodically check the fuel connections to and out of the
pump and make sure that
no leakage is present and that the
fittings
are tight and secure. The DC ground connection at
one of
the pumps mounting bolts should be clean and well
secured
by the mounting bolt to ensure proper pump opera-
tions.
When energized thru the preheat circuit, the fuel lift pump
will purge air from the fuel system and provide a continuous
flow of fuel as the engine is running.
FUEL LIFT PUMP INLET FILTER
To help ensure clean fuel to the lift pump, there is small inlet
filter connected
to the fuel pump. This filter should be
replaced initially at 50 hours then once a year or
as needed.
FUEL FILTERS
The fuel injection pump and the fuel injectors are precisely
manufactured and they must receive clean diesel
fuel, free
from water
and dirt. To ensure this flow of clean fuel, the fuel
must pass through at least two fueLfilters, a fuel filter/water
separator
and the engine's spin-on fuel filter. Visually inspect,
clean, and change these filters according to the maintenance
schedule in this manual.
A WARNING: Shut off the fuel valve at the tank
when servicing the fuel system. Take care in catching
any fuel that may spill. DO NOT allow any smoking,
open flames or othe~-sources of fire near the fuel
system whenservicin~. Ensure proper lientilation exists
when servicing the fuel system.
FUEL FILTER
O·RING
ENGINE FUEL FILTER
Periodically check the fuel connections and the bowl for
leakage. Replace the filter element after the first
50 hours
then follow the MAINTENANCE SCHEDULE.
Changing/cleaning the filter element
1. Shut offthe fuel supply.
2. Unscrew the retainer ring that holds the
filter bowl to the
housing and allow the bowl to come away
from the
housing,
3. Remove and replace the filter element and clean the bowl.
4. Replace the sealing
"0" ring and reassemble the bowl to
,the housing. Thread the retainer ting on carefully so as not
to cross thread. When retainer contacts the "0" ring,
tighten 114 -1/2 tums by hand. Open the fuel supply and
run the engine
to inspect for leaks.
~ngine~ ~ ~~nerators
16