Westerbeke BTG 8.5 User manual

OPERATORS MANUAL
. - .. ·,
- 8~:5;!Kw. BTG 50Hz ·6.8Kw BTG 50Hz
8.5Kw BTGA 6,0Hz 6.8Kw BTGA 50Hz
12.5Kw BTG 60Hz 10.0Kw BTG 50Hz
15.0Kw BTG 60Hz . 12.0Kw BTG 50Hz
MARINE GASOLINE GENERATORS
PUBLICATION #035909
REVISIONS
-MARCH2018
~,.._. rWESTERBEKE
J WESTERBEKE CORPORATION •150JOHN HANCOCK ROAD
J MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02TBo
WEBSITE: WWW.WESTERBEKE.COM
am.,_.
NAIHA Member Ntditmal Marine MllnufacturersAssoclaJion
...... .

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituents) are known to
the state of California to cause
cancer, birth defects, and other
reproductive harm.
A WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. carbon Monoxide is poisonoiiS and can cause
unconsciousness and death. SympfDms of Carbon Monoxide
exposure can include:
•Dizziness
•NaiiSea.
•Headache
• Weakness and Sleepiness
• Throbbing in Temples
• Muscular Twitching
• Vomiting
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
SET OUT INTO THE FRESH AIR IMMEDIAmY. If symptiJ!US persist,
seek medical attention. Shut down the unit and do not restart
until it bas 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.

Gasoline with an ETHANOL content
higher than 10°/o (E10) is not allowed
·and may void warranty.
AJ~ •WESTERBEKE™
~ Engines & Generators

Blank page

SAFETY INSTRUCTIONS
'INTRODUCTION
Read this safety manuol carefully. Most accidents are
causedbyfoilure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
.toke the necessary precautions to protect yourself, your
perso~eJ.~ your machinBr!: _ .. _ _
As the.dftmer or ope(8toF, always~ the following ,safe#¥ roles
and advisories provided for your c:onvenience. 1his safely information
Is in af1g11menfwitft the~ Boat and Yacht Cormcil ( ABYC)
· stimdatd8; hovrevel; safety riSks are not limited to the lnfonnation
in the followilg pages. The responsNlyforthe ldenfilication of
potential E!rKI ar;:tual risks for comp(tanCe with all safety~~
l'1lfiln1enarlce aCiMlies. and other conditions belong eXClusiVely·
to the QWRef/operator.
:PREVENT ELECTRIC SHOCK
A WARNING: Do not. trlllt:h Ai: electrical CtJIIIIectitms
wblle engine is ruDlling, or when oolmecteil tD shore
power.l.etha/ voltage is present at th~ titJDllections!
1111 Do not operate tbis machinery withoutelectrical
enclosures and covers
in place.
111 Shut offelectrical ,power before accessing electrical
equipment
111 Use ilisulatedmats whenever working on electrical
equipment
111 Make sure yourclothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment
Ill Remove wristwatch and all jewelry when working on
electrlca1 equipment
PREVENT BURNS- HOT ENGINE
A WARNING: Do llot-tDut:h hot engl11e parts or
exhallst system components. A tullning engine gets very
hot!
111 Monitor engine antifreeze coolant level at the plastic
coolant recovery tankandperiodically
at the filler cap
location on the waterjacketed exhaust manifold, but only
when the engine
is COLD.
A WARNING: Steam can cause injury or death!
1111 Incase of an engine overheat, allow the engine to cool
before touching the engine orchecking the coolant.
PREVENT BURNS- FIRE
IA WAJIIIIIIG: F/rB .......... /tljtlry Dr-
111 Prevent :6ash fires. Donot smoke orpermit flames or
sparks to occur nearthe carburetor, fuel line,
filter, fuel
pump, orother potential
sources of spilled fuel orfuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, orfuel filters.
111 Do not operate with the air cleaner/silemcer removed.
Backfire can cause severe injury ordeath.
Ill Do not smoke orpermit flames or sparks to occur near
the fuel system.
Keep the compamnent and the
engine/generatorclean and free of debris to minimize the
chan~ of fire; Wipe up all spilled fuel and engine oil.
1111 Be aware- diesel fuel will burn.
PREVENT BURNS- EXPLOSION
.A WARNING: ExploslollS from fuel 'llllfJOI'S t:a11 t:aiiSII
injury or death!
1111 •Follow n>-fueling safety instructi.OJ:!S. Keepthe vessel's
hatches closed when fueling. Open
and ventilate cabin
afterfueling. Check below forfumes/vapor before
running
the blower. Run the blow~ for four minutes
before starting your engine. ··
111 All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel ina well-
ventilated area away from spark-producing equipment
and
out of the reach of children.
-
Ill Donot fill the fuel tank(s) while theengine is running.
111 Shut'·off the fuel service valve atthe engine when servicing
the fue~ system. Thke care in ca~b4J.g any fuel that might
spill. DO NOT allow any smoKing, open flames, orother
SQl.n"ceS of fire near the fuel system or engine when
servicing. Ensure properventilation exists when servicing
the fuel system.
Ill Do not alter or modify the fuel system.
Ill Be sure all fuel supplies have a positive shutoff valve.
Ill Be certain fuel line fittings are adequately tightened and
free ofleaks.
1111 Make sure a fire extinguisheris installed nearby and is
properly maintained. Befamiliar with its
proper use.
Extinguishers ratedABC by the NFPA are apptopriate
for all applications encountered in ~ environment
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Thm OFF the DC breaker on the control panel or tum the
unit's battery selector switch to OFF before servicing the.
engine.
• Make certain all personnel are clear ofthe engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BAnERY EXPLOSION
A WARNING: Battery explosion can cause Injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead
acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by ele~cal
arcing or by lit tobacco products. Shut off all electncal
equipment in the
vicinity to prevent electrical arcing
during servicing.
• Never connect the negative(-) battery cable to the
positive (+) connection terminal of the starter solenoi?.
Do not test the battery condition by shorting the termmals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive
gases. To avoid sparks, do not
disturb the battery charger connections
while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause
an explosion. Remove
wristwatch, rings,
and any otherjewelry before handling
the battery.
• Always turn the battery charger off before disconnecting
the battery connections .. Remove the negative lead first
and reconnect it last when servicing the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery orchecking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash
it offat once with water. Acid may splash on the skin or
into the
eyes inadvertently when removing electrolyte
caps.
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.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder ordealer for installation of approved
detectors.
• For additional information, refer to ABYC TH-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CD} is an invisible
odorless gas. Inhalation produces flu·llke symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow ofexhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fume~. S?me of. the
symptoms or signs of carbon monoXlde mhalation or
poisoning are:
Vomiting
Dizziness
Headache
Inability
to think coherently
Throbbing in temples
Muscular twitching
Nausea
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a
situation arises in
which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
1!11 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.
1:1 Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
19 Do not check fluid levels or the drive belt's tension while
the engine is operating.
!1il Do not allow any swimming or activity around or near
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning or
death can occur.
4kW:«\RNING: High noise levels can cause hearing
I(J~!
II Never operate an engine without its muffler installed.
1'1 Do not run the engine with the air intake (silencer) or
flame arrester removed.
1!11 Do not run engines for long periods with their enclosures
open {when installed).
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 warnings are repeated
in your Operators Manual along with other <;autions and
notes to highlight critical information. Read yoU:r manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install agasoline engine or generator should
begin with a thorough examination oftheAmerican Boat and
Yacht Council's (ABYC) standards. These standards are· from
a combination of sources tnc~uding the USCG and the NFPA.
Sections ofthe ABYC standards ofparticular interest are:
H-2 Ventilation .for Boats using Gasoline
· H-24 Gasoline Fuel' Systems
P-1 Installation of Exhaust Systems
for Propulsion and Auxiliary Engines
P-4 ;M:arine Inboard Engines and Transmissions
EllAC
and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).
www.abycinc.org
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions .when installing your engine.
AB:YC (American Boat and Yacht Council)
"Standards and Technical Information Reports for Small
Craft"
Order from:
ABYC
613 Third Street, St1ite 10
Aprtapolis, MD 21403
www.abycinc.org
NFPA- No.302 (National Fire Protection Association)
"Pleasure and Commercial Motor Craft"
Order
from:
National Fire Protection Association
Battery Match Park
Quincy, MA02269
USCfl(Uritted States Coast Guard)
"regulatedions are under titles
CFR33 and CFR46 of the
Code ofRegulations"
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 wiU 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 the vessel's various operating conditions, instaU 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 manufacturer for proper maintenance.
AVAILABLE FROM
YOUR WESTERBEKE
'DEALER
EXHAUST SYSTEM
:·s/PHON4fREAiWirif STAINLESS
LOOP'
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust
Hose is recommended. The use of this type ofhose allows for extreme bends
and turns without the Iieed ofadditional fitting and clamps to accomplish these bends
and turns. In this regard, a single length of corrugated exhaust hose can be used. The
system MUST be designed to prevent the entry of water into the exhaust system
under any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification .................................................... 2
Introduction ................................................................ 4
Fuel, Engine 011, and Engine Coolant ........................ s
Control Panels ............................................................ 6
Operating Instructions ................................................ 7
Generator Break·ln Procedure ................................... 8
The Dally Routine ....................................................... 8
Alarms and Circuit Breakers ...................................... 9
Maintenance Schedule ............................................. 10
Fuel System .............................................................. 12
Fuel Lift Pumps.....................................................
12
Gasoline/Water Separator......................................12
Cooling System ......................................................... 13
Changing Coolant..................................................13
Heat Exchanger .....................................................14
Replacing the Thermostat......................................14
Raw Water Intake Strainer ....................................15
Raw Water Pump...................................................15
Engine Lubricating Oil .............................................. t6
Changing the Oil Filter..........................................16
Remote 011 Filter ...................................................... 17
Carburetor Adjustments ........................................... 18
Engine Adjustments .................................................. 19
Electric Choke.......................................................19
Engine Compression..............................................19
Ignition Wires ........................................................19
Valve Clearance.....................................................20
Oil Pressure ...........................................................20
Spark Plugs............................................................21
Drive BeltAdjustment...........................................21
Govemor................................................................
22
Alternator Testing .................................................... 23
12 Volt DC Circuit................................................. 23
Engine Troubleshooting ............................................ 25
Lay-up and Recommissioning ................................. .27
Wiring Diagrams and Schematics ....................... 28-3S
Generator Information .............................................. 36
BT Generator Description ......................................... 37
12 Stud Internal Wiring Schematic ......................... 38
BT Single Phase Wiring Schematic .......................... 39
Voltage Regulator Adjustments ............................... 40
BT Generator Troubleshooting ............................ 41-50
BTGJBTGA 8.5Kw Speclfications .............................. S1
BTG 12.5Kw Specifications ........................................ 53
BTG 15.0Kw Speclficatlons ........................................ ss
Metric Conversion Data .............................................. 57
Engines & Generators
1

J.D. PLATE
RAW WATER PUMP
FRONT
STARTER
12.5KW BTG 15.0KW BTG
GASOLINE GENERATOR
AC CONNECTIONS PORT
RH SIDE
PARTS IDENTIFICATION
AIR INTAKE
FLAME
LUBE OIL FILL
LH SIDE
OIL FILTER
SIPHON BREAK
CONNECTION
LUBE OIL FILL
Engines & Generators
2
DISTRIBUTOR
WATER INJECTED
ELBOW
BT GENERATOR
REAR
20A CIRCUIT
BREAKER
ANODE
HEAT EXCHANGER

PARTS IDENTIFICATION
OIL DIPSTICK
FRONT
HEAT EXCHANGER
STARTER MOTOR
LH SIDE
AC CONNECTIONS PORT
LUBE OIL DRAIN
FUEL LIFT PUMP
SIPHON BREAK
CONNECTION
WATER INJECTED
DISTRIBUTOR
AIR INTAKE
FLAME ARRESTER
RHSIDE
GENERATOR
COMPONENTS
.20A CIRCUIT
BREAKER
8,5KWBTG
REAR
GASOLINE GENERATOR
OIL FILL
ANODE

INTRODUCTION
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine model and serial numbers. In addition,
include a complete part description and part number for each
part needed (see the separately furnished Parts Catalog). Also
insist upon WESTERBEKE packaged parts because will fit
or generic parts are frequently not made to the same specifi-
cations as original equipment
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour genera-
tor, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Prot:edures, which U not strictly
observed, can teSUif in the damage 01 destruction of
tile engine 01 generator. ·
A WARNING: Procedures, which if not properly
followed, can result in personal injury 01loss of life.
NOTE: A carbon monoxide warning decal has been provided
. by WESfERBEKE. Affix this decal in a visable location in
the engine room.
SPARES AND ACCESSORIES
Certain spare parts willbe needed to support and maintain
your WESTERBEKE generator or engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filter can be difficult to obtain along
the way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
on-board inventory of the proper WESTERBEKE parts.
PROTECnNG YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a WES1ERBEKE generator capable of
many thousands ofhours 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 life:
• Proper engine and generator installation and olignment.
• An ejJicient weU-designed exhaustsystem that includes
an anti-siphon breakto prevent waterfrom enteringthe
engine.
• Changing the engine oil and oil filters every 100 operat-
inghours.
•
Proper maintenance of allengine and generator compo•
nents according to the maintenance schedule in this
manuol.
• Use clean, filtered unleaiJed fueL
• Winterize your engine according to the "Lay-upand
Recommissioning"section in this manual.
UNDERSTANDING THE GASOLINE GENERATOR
The gasoline engine driving an AC generator is in many
ways similar to a gasoline automobile engine. The cylinders
are verticle in-line, and the engine's cylinder head has an
overhead GamShaft which is chain-driven. The engine utilizes
a solid-state distributor which is horizontally mounted and
camshaft-driven. The engine incorporates a pressure type
lubrication system, and a fresh water-cooled engine block
which is thennostatically-controlled. To a large degree, the
generator's engine requires the same preventive maintenance
that is required ofa gasoline automobile engine. The most
important factors to the generator's longevity are proper
ventilation, maintenance of the fuel system, ignition system,
cooling system and the generator backend.
CARBON MONOXIDE DETECTOR
WESTERBEKE highly recommends mounting a carbon
monoxide detector inthe vessels living and sleeping
quarters. Carbon monoxide even in small amounts,
ean be deadly.
The presence of carbon monoxide indicates a possible
exhaust
leak from the main engfu.e or generator, it's exhaust
system, from the exhaust discharge location onthe vessel
or from a neighboring vessel.
If the dectector signals the presence of carbon monoxide.
Ventilate the area, move into a fresh airlocation and
locate the source of the carbon monoxide and arrest it.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: Only use unleaded fuel with an octane
rating of 89 or higher. Leaded fuel will cause serious
harm to your engine and violate your warranty.
Care Of The Fuel Supply
Use only clean fuel! The clearance ofthe components in
your
fuel iqjection pump is very critical; invisible dirt
particles which might pass through the fllter can damage
these finely finished parts. Itis important to buy clean fuel,
and keep itclean. The bestfuel can be rendered
unsatisfactory by careless handling orimproper storage
facilities. To assure that thefuel going into the tank for your
engine's daily
use is clean and pure, the following practice is
advisable:
Purchase a well~known brand of fuel.
Install
and regularly service a good, Coast Guard approved
metalbowl type filter/water separator between the fuel tank
and tile engine.
ENGINE OIL
Use aheavy duty engine on as called for inthe
Specificati~ Section of this manual. ~the
eilgine on and filter afterthe initial- 50 hours of
break~in operation. Then follow the ollandfilter
change intervalS 'as specified inMAINTENANCE
SCHEDULE inthis manual.
Westerbeke Corporation does not approve or
disapprove the use of synthetic oils. If ~thetic
oils are used, engine break-in ...ust be perfor.tn!'d
using conveirtional oil. on change ~tervals __ must
be as listed inthe MAINTENANCE SCHEDULE
section
of this manua1 and not extended if sYnthetic
oils are used.
NOTE: The informationabove supersedes all
previous statementsregarding synthetic on.
ENGINE COOLANT
WESTERBEKB recommends amixture of 50% antifreeze and
50% distilled water. Distilled water is free from the chemicals
that can corrode internal engine surfaces.
The antifreeze perfonns double duty. It allows the engine
to run at propertemperatures by transferring heat away from
the engine to the coolant. Italso lubricates and protects the
cooling circuit from rust and corrosion. Use a good quality
antifreeze that contains supplemental cooling additives {SCAs)
that keep the antifreeze chemically balanced, crucial to long
term protection.
The waterand antifreeze should be premixed before being
pouredinto the cooling circuit
NOTE: Use the new environmentally-friendly~ long lasting~
ontij'ree~ thatis now available.
Aproper 50/50 mixture as recommended will protect the
engine coolant to temperatures of -40"F
COOLANT RECOVERY TANK
Acoolant recovery tank kit is suppliedwith each generator.
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.
Engines & Generators
5

CONTROL PANELS
DESCRIPTION
The generator mounted control_panelis equipped with an
ON switch (black), a STARTswitch(white) and a STOP
switch (red).
The ONswitch provides power to the start circuit This
switch by-passes the protective oil pressure shutdown switch
until the oil pressure reaches 5 - I0 psi.
The STARTswitch energizes the start solenoid/starter which
cranks the engine. This switch will not operate unless the on
switch is depressed and held at the same time.
The
STOP switch will turn offthe engine/generator, .This
switch must be depressed until the stop sequence is complete.
The panel also has two
fuses to protect the DC circUit: ·
• A 15 amp slow bluwfuse protects the start circuit.
•An 8ampfuse protects the engine operating circuit Ond .. ·
any optional rembte start/stop or instrument panel.
REMOTE START/STOP PANR (OPTIONAL)
An optional remote start/stop panel is available for
controlling the generator from aremote location.
This panel
has the same ON, START, and STOP functions
previously described. Also included is a green LED light
which glows once the engine/generator has
reached 600
rpm's. The purpose of the LED is to alert the operator to
release the START switch. Itis also an indication that the
engine/generator is running. ·
REMOTE INSTRUMENT PANEL (OPTIONAL)
An optiol)al remote instrument panel is available which
includes a water temperature gauge, oil pressure gauge,
DC charging voltmeter, operating hourmeter, and start/stop
switches.
REMOTE INSTRUMENT PANEL INSTALLAnON
The remote instrument panel has two sending units to be
installed on the engine block, a water temperature sender and
an oilpressure gauge sender. Plugged ports for each are
located on the engine. The watertemperature senderis
installed in the thermostat housing and the oilpressuresender
is adjace~~ to the oil pressure switch. Use sealing compound
on the-thi:eads of both senders. Electrical connections for
each sender are tied off next to the senders location ( in the
wiring harD.ess), ··· . . .
The blue wire iS .'for the oil j»:essure sender and. the tan wire
is for the water temperature sender. If there is a jumper
between tenninal board connections T-1 and T-2, it should be
removed.Refer
to. the. REMOTE INSTRUMENT WIRING
DIAGRAM in this manual.
NOTE: When installing the optional rembte panels, it is the
installers responsibility to comply with the U.S. Coast Guard
standards 33 CFR part 183.
. Engines & Generators
6

OPERATING INSTRUCTIONS
PRESTART INSPECTION
Before starting your generator for the first time or after a pro-
longed layoff, check the following items:
a Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
a Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
a Checkthe DC electrical system. Inspect wire connections
and battery cable connections.
a Check the coolantlevel in both the plastic recovery tank
and at the manifold.
NOTE: Afterthe initial running of the generator, the air in
the engine's cooling system will be purged to the coolant
recovery tank. Open the air bleedpetcock to ensure that
the cooling system is purged of air. Aftershutdown and
after the engine has cooled, the coolant from the recovery
tank will be drawn into the engine's cooling system to
replace the purged air.
Before subsequent operation of the generator, the engine's
manifold should
be topped off, and the coolant recovery
tank may need to be filled to the MAX level. .
STARTING THE GENERATOR
A WARNING: Ventilate the generator compartment
fora minimum of five minutes prior to starting. The
· ventilating blowers remove any explosive gasoline
fumes from the generator compartment and bilges.
1. Depress the ON switch and hold it down (5-15 seconds),
this primes carburetor. Continue to depress ON.
2. Depress the START (white), when the generator
starts, release the START switch. Continue to engage
the ON switch a few seconds longer.
NOTE: Keeping the ON switch, depressed by-passes
the oilpressure shutdown circuit allowing the oil
pressure to rise enough
to close the switch and
maintain the ignition circuit
3. Release the ON switch.
Once The engine is running apply a light load to the gener-
ator
and allow the engine to warm up to operating temper-
ature (130°-150°
F/ 55°-56°C) before applying heavy loads.
If an optional instrument panel is installed, monitor the
gauges for normal readings.
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
a Checkload leads for correct connections as specified in
the wiring diagrams.
a Examine the air inlet and outlet for air flow obstructions.
a Be sure no other generator or utility power is connected to
the load lines.
a Be sure that in power systems with a neutral linethat the
neutral is properly grounded (or ungrounded) as the system
requires, and that generator neutral is properly connected
to the load neutral. Insingle phase systems
an incomplete
or open neutral can supply the wrong line-to-neutral volt-
age on unbalanced loads.
A CAUTION: When starting the generator, it Is
recommended thatall AC loads, especially large
motors, be switched OFF until the engine has come up
to speed and, In cold climates, starts to warm up. This
precaution will prevent damage caused by unanticl·
pated operation of the AC machinery and will prevent a
cold engine from stalling.
A CAUTION: Prolonged cranking intervals without
the engine starting can result in filling the engine
exhaust with raw water. This may happen because the
pump is pumping raw water through the raw water
cooling system during cranking. This raw water can
enter the enginets cylinders by way of the exhaust
manifold once the exhaust system fills. Prevent this
from happening by closing the raw water supply
through~hull shutoff~ draining the exhaust muffler, and·
co«ecting the cause of the excessive engine cranking.
Engine damage resulting from raw water entry Is not a
wa«antable Issue: the owner/operator should keep this
in mind.
STOPPING THE GENERATOR
1. Remove the AC loads from the generator and allow the
generator to run for an added 3 to 5 minutes (this stabilizes
its qperating temperature).
2. Depress the
STOP (red) switch.
3. When the generator stops, release the
STOP switch.
NOTE: In an emergency, if the generator will not stop using
the stop
switch, remove the 8 amp fuse in the control
panel.
Engines & Generators
7

GENERATOR BREAK·IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour of
test operations at the factory to make sure accurate
assembly procedures
were followed and that the 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 engine 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 perlormance and service life of the engine.
Perlorm 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 (raw
water pump, oil pressure, battery charging)· are functioning.
reach
its full rated speed are signs of an overload.
AFTER START-UP
Once the generator has been started, check for proper opera-
tion
and then encourage a fast warm-up. Run the generator
between 20% and
60% of full load for the first 10 hours.
After
the first 10 hours of the generators operation, the
load can be increased to the full-load rated output, then
periodically vary the load.
Avoid overload at all times. An 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
1800 rpm to produce 60 hertz, or at 1500 to produce 50 hertz,
control ofthe generators
engine break -in is governed by the
current
drawn from the generator.
NOTE: Be aware of motor starting loads and the high
current drawn requiredfor starting motors. This starting
amperage draw can be 3 to 5 times normal running
amperage. See GENERATOR INFORMATION in this manual.
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 (HERIZ)ADJUSTMENTunder
ENGINE ADJUSTMENTS. A
no-load voltage adjustment may
also be required in conjunction with the engine's speed adjust-
ment (see GENERATOR INFORMATION).
THE DAILY ROUTINE
CHECK LIST
Follow this checklist each day before starting your generator.
• Check that all generator circuit breakers (power panel) are in
the off position before starting.
• Record the hourmeter reading in your log (engine hours relate
to the maintenance schedule).
• Visually inspect the engine 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 WITH THE ENGINE RUNNING.
• Check for abnormal noise such as knocking, vibration an:tf
blow-back sounds.
• Confirm exhaust smoke:
When the engine is cold -White Smoke.
When the engine is warm - almost Smokeless.
When the engine is overloaded - some Black Smoke.
8
NOTE: Some unstable running may occur in a cold engine.
This condition should abate 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.

ALARMS AND CIRCUIT BREAKER
SAFETY SHUTDOWN SWITCHES
The engine is protected by three automatic shutdown
switches. Should a shutdown occur, do notattemptto restart
withoutfinding andcorrecting the cause.
Refer to the ·head-
~ng Engine starts, runs and then shuts down in the ENGINE
TROUBLESHOOTING section ofthis manual. .
The following 1s a description ofthese autoJIUltic shutdown
switches:
High Exhaust Temperature SWitch
An exhaust temperatllre switch is located on the exhaust
elbow. Normally closed, this switch will open and interrupt
the DC voltage (shutting off the engine) should the switch's
sensor indicate an excessive exhaust temperature (an inade-
quate.supply
of raw water causes high exhaust temperatures).
This switch opens at 260-270"F (127-132°C). This switch
resets at approximately 225'"F (107°C).
··~ '
HIGH EXHAUST
TEMPERATURE.
SWITCH
MOUNTED AT THE
EXHAUS(ELBOW
COOLAIT.TEMPERATURE SWITCH
Acoolant temperature switch· is located on tbe>thermostat
housing. This switch will activate a continuous alarm if the
coolant's 6peta.ting temperature reaches aPproximately
210"F (9~C). . .
THERMOSTAT ASSEMBLY
ALARM SWITCH
LOW OIL PRESSURE ALARM SWITCH
Allow oil pressure !llarm switch is located off the engine's oil
gallery. This switch's sensor monitors the engine's oil pres-
sure. Should the engine's oil pressure fall to 5-10 psi
(0.4- 0.7 kg/cD).
2
), this switch will activate a pulsating alann.
'DIL PRESSURE
AlARM SWITCH
DIL PRESSURE SWITCH
Engine Circuit Breaker
Tlie generator's engine is protected by an engine mol!Jlted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywtrere in the inst:rum.ent panel
wiring or engine wiring- willcause the breaker to trip. • In this
event the generator will-shut down because the opened
breaker interrupts the DC circuiUf this shoUld occur, check
and repair the sourc;e of the problem. After repairing the
fault, reset the breaker andrestart the generator.
High RPM Shutdown SWitch
OVEilSPUD TERMINAL
BOARD
An overspeed switch in the DC circuit shuts off th~
generators engine by grounding out the ignition system if the
engine's speed
reaches 2175 rpm(approximately). After
correcting the problem, this switch can be reset by momeq'-
tarily depressing the stop switch. Refer to the WIRJNG
DIAGRAMS in this manual.
NOTE: When troubleshooting a possible faulty
switch. For test purposes toby-pass the switch.
Move connection T4 onto TS.
DONOTpurposely by-pass a faulty switch so as
to be able to operate the generator. This could
create a potential
safetY hazard.
l"'fAriWESTERBEKE
Engines:& Generators
9

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's BC electrical equipment.
NOTE: Many of the following maintenance jobs are simple but others are
more difficult and may require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH EXPLANATION OF SCHEDULED
DAY
50 100 250 500 750 1000 1250 MAINTENANCE
D
Unleaded gasoline with octane rating of 89 or
higher.
D
Check for water and dirt in fuel (drain/replace filter
if necessary).
D
Oil level should indicate between FULL and LOW on
dipstick.
D
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
D
Inspect for proper tension (3/8" to 1/2" deflection)
weekly and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine
D
NOTE: Please keep engine surface clean. Dirt
Check for fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engine's ability to
and electrical connections. Keep bolts & nuts tight.
remain cool.
Check for loose belt tension.
Spark Plugs
D D D D D D
Check gap; inspect for burning and corrosion.
Generator (if applicable)
D 0 0 D D D D
Check that AC connections are clean and secure
with no chafing - see GENERATOR INFORMATION
(if applicable) for addition information.
Fuel Filter (Lift Pump)
D D D D D D
Inspect for fuel leaks. Check wire connections.
Starting Batteries
D D
Every 50 operating hours check electrolyte levels
(and House Batteries)
weekly and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil
D D D D D D D
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
Re-torque Cylinder Head
D D D
retorque at 50 hrs., them every 500 hours.
*Adjust the Valve
D D D
Initial adjustment at 50 hrs., then every 500 hrs.
Clearances
Air Screen (Flame Arrester)
D
Clean at 50 hours, then every 100 hours.
Exhaust System
D D D 0
Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check siphon brake operation. Check the
exhaust elbow for carbon and/or corrosion buildup
on inside passages; clean andreplace as necessary.
Check that all connections are tight.
Engine Hoses
D D D D 0 D
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Inlet Fuel Filter
D D 0 D 0 0 Replace every 250 operating hours.
continued
Engines & Generatnrs
10

SCHEDULED
MAINTENANCE
Heat Exchanger
Raw Water Pump
Coolant System
*Starter Motor
Distributor
*Engine Cylinder
Compression and
Valve Clearance
*Exhaust Elbow
Carburetor Filter
Screen
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 0 0 0 0 0
Clean or replace anode. Open heat exchanger end
cap and clean out debris. remove every 1 000 hours
for professional cleaning and pressure testing.
0 0 0
Remove the pump cover and inspect the impeller
for wear, replace if needed. Also replace the gasket
Lubricate both when re-assembling.
0 0
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
0 0
Check ignition timing. Check condition of
distributor cap and rotor.
0 0
Incorrect valve clearance will result in poor engine
performance. Check compression pressure and
timing and adjust valve clearances.
0
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteriorated.
WARNING: A defective exhaust elbow can cause
carbon monoxide leakage.
0 0 0 0 0
Clean at first 50 hours and every 250 hours.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
11

FUEL SYSTEM
GASOUNE
Use -,.leaded 89 .octane or higher gasoline. When fueling,
follow U.S. Coast Guard regulations, clare. offall hatcQes and
companionways to prevent fumes from enteij11g ·the boat, and·
ventilate after fueling, .
NOTE: The engine torrtpartment should have a gasqline fuine
detector/alarm properly installed and: working, ···
GASOLINfJWATER SEPARATOR AfiJ FILTER
A primary :fuel filterofthe water separating type must be
installed between the fuel·
tank and the engine to remove
water and other contamirulnts from the fuel before they can
be carried to the fuel syStem ,on the engine.
Most instaliers ~lude a type of filter/water~ with
the installation ~kage as they are well aware of the problems
that contaminants in the fuel can cause.
These gas
0
~e filiers must have metal bowls (not .. see-
through'') to meet U;S. Coa8t Guard requirements. Tbe'metai·
bowls have drain valves to use when checking for water and
impurities,
·C~
GASOUNE/WATER
SEPERATOR & RlTER
Thecarburetor is a single barrel downdraft type with an electric
by metalic choke. Referto CARBURETOR ADJUSI'MENTS .
for more information. ·
RJa UFI' PUMP
Periodically check the fuel connections to and out of the pump
and make sure thatno leakage is present and that the fittings
are tight and secure. The DC ground connection at one ofthe
pump's mounting bolts should be clean and well
secured by
the mo~ting bolt toensure proper pump operation.
The start sequence energizes the fuel lift pump as the piston in
the pump operates, itcreates an audible ticking sound. If no
ticking is heard, check for 12 volts at the pump connections.
Also checkthatthe ground wire is properly connected to
ground.
NOTE: At initial start-up orwhen re-commissioning the engine,
it maybe necessary to prime the engine's fuel system.
To do this
depress and hold the ON switch. This will activate the engine's
electric fuel pump which will pump fuel through the engine's
fuel system and
fill the carburetor's fuel bowl. Do this for
4-6 seconds then proceed to startthe engine.
The pump filter should be cleaned every 250 operating hoi!rS;
also clean offthe magnet [the magnet removes metal particles
from the fuel]. The pumpbase can be removed by twisting the
base hex nutwith a wrench. When reaSsembling, rephice the
~ggasket
AwARN•G: Fuel leakage atthefuel PIIIIIP orits
CDIIIIBI:fioJJS isafire bazanl and should be t:DITBI:ted.
Malee Sllre proper relltilation exiSts WJ.flnerel simnt:ing
fuel system t:DIRptments.
.FUR UFT PUMP
#14PURPLE ·
PRESTART BIJ7TON
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 ofthe pump's mounting bolts should be clean and well
secured.l:zy the mounting bolt to ensure proper pump
operations.
IW'IWESIERBEKE
f Engirtf!S &_Generators
12