OPERATO S MANUAL ·

MARINE D.IESEL GENERATORS .

8.0 EGTD • 60Hz 6.0 EGTD • 50Hz
10.0 EGTD ·• 60Hz 7.5 EGTD ·50Hz
11.0 EGTD ·60Hz 8.8 EGTD ·50Hz
11.5 EGTD ·60Hz 9.2 EGTD • 50Hz
12.5 EGTD ·60Hz. 9.4 EGTD • 50Hz
-15.0 EGTD ·60Hz -·
12.0 E·GTD
. . .
·50Hz ·.
Electronically Governed
Singl·e a T . e Phase ·

PUBLICATION NO: 056272 f REVISION 0 I 'DE~EMBER 2016

WESTERBEKE
Af'if'Af"f WESTERBEKE GORPORATION • I 50 JOHN HANCOCK ROAD
.-.-- MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE:: WWW. WE'STERBE;'KE:.COM
 CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.

A wARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
•Dizziness • 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,

SET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been Inspected and repaired.

This 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.
 SAFETY INSTRUCTIONS
INTRODUCTION PREVENT BURNS- FIRE
.Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and A WARNING: Fire can cause injury or death!
precautions. Know when dangerous conditions exist and
take the necessary precautions to protect yourself, your II Prevent flash fires. Do not smoke or pennit flames or
personne~ and your machinery. sparks to occur near the fuel injector, fuel line, filter, fuel
The following safety instructions are in compliance with pump, or other potential sources of spilled fuel or fuel
the American Boat and Yacht Council (ABYC) standards. vapors. Use a suitable container to catch all fuel when
removing the fuel lines or fuel filters.
PREVENT ELECTRIC SHOCK II Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
II Do not smoke or permit flames or sparks to occur near
A WARNING: Do not touch AC electrical connections the fuel sysfem. ~eep the compartment and the
while engine is running. Lethal voltage is present at engine deanand free of debris to minimize the
these connections! chances of fire. Wipe up all spilled fuel and engine oil.
1111 Be aware - diesel fuel will burn.
II Do not operate this machinery without electrical
enclosures and covers in place.
PREVENT BURNS - EXPLOSION
11 Shut off electrical power before accessing electrical
equipment
11 Use insulated mats whenever working on electrical
A WARNING: Explosions from fuel vapors can cause
equipment Injury or detftll!
11 Make sure your clothing and skin are dry, not damp llill Follow re-fueling safety instructions. Keep the vessel's
(particularly shoes) when handling electrical equipment. hatches closed when fueling. Open and ventilate the cabin
11 Remove wristwatch and all jewelry when working on after fueling. Check below for fumes/vapor before running
electrical equipment the blower. Run the blower per four minutes before starting
your engine.
PREVENT BURNS -HOT ENGINE 111 All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
A WARNING: Do not touch hot engine palfs or well-ventilated area away from spark-producing
equipment and out of the reach of children.
exhaust system components. Anrnuing engine gets
Ill Do not fill the fuel tank(s) while the .engine while it is running.
. very hot!
1111 Shut off the fuel service valve at the engine when servicing

iii Monitor engiile ·an~ze coolant ievei at the plastic the fuel system. Take care in catching any fuel that might
coolant recovery tank and periodicaly at the filler cap spill. DO NOT allow any smoking, open flames, or other
location on the water jacketed exhaust manifold, but only sources of fire near the fuel system or engine when
when the engine is COLD. servicing. Ensure proper ventilation exists when servici.1g
the fuel system.
iii Qo not alter or modify the fuel system.
A WARNING: Steam can cause injury or death! llill ~~ sure all fuel supplies have a positive shutoff valve.

11 In case of an engine overheat, allow the engine to cool Ill Be certain fuel line fittings are adequately tightened and
before touching the engine or checking the coolant free of leaks.
Ill Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
 SAFETY INSTRUCTIONS
ACCIDENTAL STARTING TOXIC EXHAUST GASES
A WARNING: Accidental starting can cause injury A WARNING: Carbon monoxide (CO} is a deadly gas!
or death!
11 Disconnect the battery cables before servicing the engine/ 11!1Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
generator. Remove the negative lead first and reconnect
it last. · regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
11 Make certain all personnel are clear of the engine before attention to the manifold, water injection elbow, and
starting. exhaust pipe nipple.
11 Make certain all covers, guards, and hatches are re- II Be sure the unit and its surroundings are well ventilated.
installed before starting the engine.
111 In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
BAnERY EXPLOSION builder or dealer for installation of approved detectors.
11 For additional information refer to ABYC T-22 (educa-
A WARNING: Battery explosion can cause Injury tional information on Carbon Monoxide).
or death!
11 Do not smoke or allow an open flame near the battery A WARNING: Carbon monoxide (CO} Is an invisible
being serviced. Lead acid batteries emit hydrogen, a odorless gas. Inhalation produces flu·like symptoms,
highly explosive gas, which can be ignited by electrical nausea or death!
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur- 11 Do not use copper tubing in diesel exhaust systems. Diesel
ing servicing. fumes can rapidly destroy copper tubing in exhaust sys-
11 Never connect the negative(-) battery cable to the posi- tems. Exhaust sulfur causes rapid deterioration of copper
tive (+) connection terminal of the starter solenoid. Do tubing resulting in exhaust/water leakage.
not test the battery condition by shorting the terminals 111 Do not install exhaust outlet where exhaust can be drawn
together. Sparks could ignite battery gases or fuel vapors. through portholes, vents, or air conditioners. If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline, water could
accumulation of explosive gases. To avoid sparks, do not enter the exhaust discharge outlet and dose or restrict the
disturb the battery charger connections while the battery flow of exhaust. Avoid overloading the craft.
is being charged.
11 Although diesel engine exhaust gases are not as toxic as
11 Avoid contacting the terminals with tools, etc., to prevent exhaust fumes from gasoline engines, carbon monoxide
burns or sparks that could cause an explosion. Remove gas is present in diesel exhaust fumes. Some of the symp-
wristwatch, rings, and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning
the battery. are:
1!11 Always turn the battery charger off before disconnecting . Vomiting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery. Dizziness
Throbbing in temples
BAnERYACID Muscular twitching
Intense headache
A WARNING: Sulfuric acid In batteries can cause Weakness and sleepiness
severe injury or death!
AVOID MOVING PARTS
111 When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which is destructive.
A WARNING: Rotating parts can cause injury
If it comes in contact with your skin, wash it off at once or death!
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps. 11 Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.

Engines &Generators

ii
 SAFETY INSTRUCTIONS
II Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBLICATIONS FOR
equipment; avoid wearing loose jackets, shirts, sleeves,
rings, necklaces or bracelets that could be caught in . INSTALLING MARINE ENGINES AND GENERATORS
. moving parts.. Read the following ABYC, NFPA and USCG publications
11 Make sure all attaching hardware is properly tightened. for safety codes and standards. Follow their recommenda~
Keep protective shields and guards in their respective tions when installing your UNIVERSAL engine
places at all times. ABYC (American Boat and Yacht Council)
111 Do not check fluid levels or the drive belt's tension while
"Safety Standartls for Small Craft'' ·
.the engine is operating. Order From:
11 Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running; hair and clothing can easily 613 Third Dtreet, Suite 10
be caught in these rotating parts. Annapolis, MD 21403
(410) 990-4460
HAZARDOUS NOISE www.abycinc.o_rg
NFPA (National Frre Protection Association)
A WARNING: High noise levels can cause hearing ''Fire Protection Standard for Motor Craft''
loss/ Order From:
NFPA
II Never operate an engine without its muffier installed.
1 Batterymarch Park
11 Do not run an engine with the air intake (silencer) P.O. Box 9101
removed. Quincy, MA 02269-9101
A WARNING: Do not work on machinery when you are USCG (United States Coast Guard)
"CPR 33 AND CFR46"
. mentally or physically incapacitated by fatigue! Code of Federal Regulations
Order From:
OPERATORS MANUAL U.S. Government Printing Office
Many of the preceding safety tips and warnings are repeated Washington, D.C. 20404
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standar:ds. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion of Exhaust Systems for Propulsion
and Auxilliary Engines
P-4 Marine Inboard Engines and Transmissions
E-ll AC & DC Electrical Systems on Boats
TA Batteries and Battery Chargers
All installations must comply with the Federal Code of
Regulations (FCR).

Engines & Generators

iii
 .INSTALLATION
When installing WBSTERBEKE 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 of20" above the vessel's waterline. Failure to use a siphon-break· when
the exlumst manifold injection port is at or beluw the load waterline will result in
raw water damage to the engine and po~rible flooding of the boat.
If you have any doubt about" the positii;>n of th~. w.ater-injected exhaust elbow relative •
to· the vessel's waterline :under the vessel's various operating oonditions, install a AVAILABLE FROM
siphon-break. , .... YOUR. WESTERBEKE
DEALER
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
op_eration. Failure to properly maintain a siphon-break can· result in catastrophic SIPHON-BREAK WITH~- fAINLES,
LOOP FOR 1" HOSE
enq.ine damage. Consult the siphon-break manufacturer for proper maintenance. PART NO. 044010

EXHAUST SYSTEM
Tiie exhaus't system's hose MD~T:~ certified for marine use. Conugated MaJ:ine
Exhaust Hose is recommended. The use of this type of hose a,llows for extreme bends
and turns without the ne~d of additiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length of conugated exhaust hose can be used. The
system MUST be designed to prevent the entry of wa~·into the exhaust syste$'·
under any sea conditions and at any angle of vessels heal. · .~

Adetailed Marine Installation Manual covering gasoline and diesel

engines and generators is supplied with ev!lry unit sold. This manual
.is also available in pdf format on our website to download
Website: www.westerbeke.com

Engines & Generators

iv
 TABLE OF CONTENTS
Parts Identification ................................................2 Engine Adjustments .............................................28
Introduction .............................................................3 Glow Plugs ..................................................... 28
Diesel Fuel, Engine Oil and Coolant.. .................5 Fuel Injectors ................ :................................. 28
Valve Clearance .............................................. 29
Preparations for Initial Start-Up ..........................6
Injection Timing ............................................ .29
Generator Control Panel ........................................?
Operating Instructions ...................................... 7
Generator Information .........................................30
Maintenance .................................................... 30
Remote Control Panels .......................................... 8
Operating Instructions ...................................... 8
. BT Generator Description ....................................31
Circuit Breaker ............................................... 31
Safety Shutdown Switches ....................................9
BTGenerator ·Single Phase .............................. .32
Generator Break-In Procedures .......................... I o Wiring Schematic .................... ..-.................... .32
Daily Operation ................................... :.................. 10 Generator Voltage Adjustment ........................... 34
Maintenance Schedule (Chart) ........................... 11 No-Load Adjustment .....·................................. 34
Cooling System ..................................................... 13 Full-Load Adjustment ..................................... 35
Changing Coolant ........................................... 13 BT Generator Internal Wiring .............................35
Thermostat ...................................................... 14 Three Phase/Twelve Wire ............................... 35
Raw Water Cooling ........................................ 14 BT Generator Internal Wiring ............................. 35
Raw Water Pump ............................................ l5 Three Phase/Twelve Wire ............................... 35
Intake Strainer ................................................ 15
Heat Exchanger .............................................. 15
Generator AC Voltage Connections ...................36
BE Three Phase .............................................. 36
Zinc Anode ..................................................... 16
Air Intake/Silencer.......................................... l6 BT Generator Single Phase ............................. :.. .37
Filter Cartridge ............................................... 16 Troubleshooting Chart ............................... ,... .37
Optional Voltage Regulator ........................... .37
Fuel System ...........................................................17
Fuel Water Separator ...................................... 17 Shore Power Transfer Switch ..............................38
Fuel Filter ....................................................... 17 Lay-Up and Recommissioning .............................39
Fuel Lift Pump ................................................ 17 Specifications (Engine) ......................................41
Engine Lubrication System ................................. 18 8.0 EGTD, 10.0 EGTD .................................. .42
Oil Change ...................................................... 18 11.5 EGTD, 11.0 EGTD ............................... ..43
Oil Filter ......................................................... 18 Specifications (Engine) ........................................~4
Oil Pressure ........................................................... 19 12.5 EGTD, 15.0 EGTD ................................ .45
Testing Oil Pressure ........................................ 19 Wiring Diagram #56225 .......................................46
Remote Oil Filter ..................................................20 Wiring Schematic #56225 .................................. .47
DC Electrical System ...........................................21 Wiring Diagram #56321 ...................................... .48
Alternator ........................................................ 21 Remote Start/Stop Panel.. ............................... 48
Alternator Troubleshooting ............................ 21 Water Heater (Optional) .......................................49
Battery Care .................................................... 22 Power Take-Off (Optional) ...................................50
Starter Motor ........................................................23 Raw Water Discharge Hose .................................51
Troubleshooting ............................................. .24
Engine Torque Specifications .............................52
Engine Troubleshooting .......................................25 Suggested Spare Parts ........................................52
LED/Shutdown (Chart) ...................................25
Engine Troubleshooting (Chart) ..........................26
Water and Oil Pressure Gauges ..................... 27

Engines & Generators

1
 INTRODUCTION
This WESTBRBEKE Diesel Generator is a product of PRODUCT SOFTWARE
WESTBRBEKE's long years of experience and advanced . Pioduct software, (tech d$l. pans, lists, manuals,
technology. We take great pride in the superior durability and brochures and catalogs), provided from sources other than
dependable perfonnance of our engines and generators. WESTERBEKE are riot within WESTERBEKE's control.
Thank you for selecting WESTERBEKE.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your generator it CONI'ENT OF SUCH SOFIWARE, MAKES NO .
is important that you operate and maintain it correctly. This · WARRANIIES OR REPRESENTATIONS WITH RESPECT
manual is designed to help you do this. Please, read this
THEREI'O, INCLUDING ACCURACY; TIMEliNESS OR
manual carefully and observe all the safety precautions COMPLETENESS THEREOF AND WII..L IN NO EVENr ·
throughout Should your generator require servicing, contact BE IJAB.LE FOR ANY TYPE OF DAMAGE OR INJURY
your nearest WESTBRBEKE dealer for assistance. INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual. Along wi!}i ~ manual, .there .. OF THE FURNISHING OR USE OF SUCH SOFTWARE.
is an Installation Manual and Parts Infonnation. A Servtee
WESTERBEKE customers should also keep in mind the
Manual is available in pdf form. on our website or can be time span between printi:rigs ofWESTERBEKE product
ordered in book fonn from a WESTERBEKEfUNIVERSAL software and the tinavoidable existence of earlier ·
Dealer WESTERBEKE manuals. In summation, product software
WARRANTY PROCEDURES provided with WESTERBEKE products, whether from
WESTERBEKE or other suppliers, must not and cannot
Your WESTERBEKE Warranty Statement is included in the be relied upon· exclusiVely as the definitive authority on
product documentation package. There is a Warranty the respective product It not .only makes good sense
Registration Card you can fill out and mail to Westerbeke · but is inlperative that appropriate representatives of
Corporation or go to ourwebsite:www.westerbeke.com :met WESlERBEKE or the supplier in question be consulted
register your products warranty on line. You should recewe a to determine the accuracy and current:ness of the
Customer Identification card in the mail within 60 days of product software being consulted by the cuStomer.
registering. I{you do not, please contact the factory and have
your protiuct mociei numoer, seriai number and in service PROTECTING YOUR. INVESTMENT·
date available.
care at the factory: during assembly and tt,orough testing
Customer Identification .Card have~ in a WES'IERBEKE generat9f capable of
Ill8.ey tt,.ousands of hours of dependable ~cerHowever the
manu.fiicturer cannot control how or where the generator is
1-..v-IWESIERSEKE inStall~ in the vessel or· the manner in which the unit is
j Engines & Generators opemt~ iind serviced in the field. This is up to the
buyer/owner.:operator. ·
Customer Identification
MR. GENERATOR OWNER NOTE: Sa imp~rtant steps to ensure long generator life:
MAIN STREET • Proper engine and generator insttziiLziion t1114.alignment.
HOMETOWN, USA
Model _ _ _ _ __ S e r i a l # - - - - - • An ejJi.ci.ent well-designed exluiu.st 8.Y*m thal iltcltides
an antf.&iphon brea'K to prevent waterfrom entenng the
E~~------------- engine. ..
• Changing .the engine oil and oil filters! tzccordiitg. to tlie
mainterurnce scl1edrde.
NOTES, CAUTIONS AND WARNIN~S
As this manual takes you through the operating procedures, • .Proper mlzinte'iti.rftbe o/all engine tuid 'generfztDT conq,o- ·
maintenance schedules, and troubleshooting of your marine 1lti.rn1liit; . .
to
tts1its aieordjng the '11111itt.tenane schedule in this
. .
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows: • Use cletfii;~d #2 dieselfoel.
' '
NOTE: An operating procedure essential to note. • Winterize your engine ciccOrilmg to the ~'lay-lip mul
Reco,mmissiotting" section in this manual.
A CAUTION: Procet/uress which if not strictly
observed, can result In the damage or destruction of
your engine.

A ·WARNING: Procedures, which If not property

followed, can result In personal injury or loss of life.

Engines & Generators

3
 INTRODUCTION
SERIAL NUMBER LOCATION NOTE: A carbon monoxide warning decal has been provided
The engine's model and serial number are Iqcated on by WESTERBEKE. Affix this decal in a visible position in the
a nameplate mounted on the side of the water jacketed engine room.
exhaust manifold.
The engine's serial number is also found stamped in UNDERSTANDING THE DIESEL ENGINE
the engine block on a flat surface just above the The diesel engine closely resembles the gasoline engine, .
the side oil fill opening. Take time to enter this inform- since the mechanism is essentially the same. The cylinders
~tion below on the illustrated nameplate. are arranged above a closed crankcase; the crankshaft is of
the same general type as that of a gasoline engine; and the
diesel engine bas the same types of valves, camshaft, pistons,
cbnnecting rods and lubricating system.
therefore, to a great extent, a diesel engine requires the
same preventive maintenance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance of the fuel, lubricating and cooling systems.
Replacement of fuel and lubricating filter elements at the
time periods specifi~ is a must, and frequent checking for
contanlination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of the same brand of high detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method of handling and firing of fueL The
carburetor and ignition systems are done away with and in
their place is a single component- the fuel injection pump
which performs the function of both.
ORDERING PARTS
Whenever replacement/service parts are needed, always
provide the generator model number, engine serial number,
and generator serial number as they appear on the silver and
·black name 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 furnished Parts Ust). Also insist upon
WESTERBEKE packaged parts becavse will fit or generic
parts are frequently not made to the same specifications as
original equipment.
·SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator. Your local WES'IERBEKE
· dealer will assist you in preparing an inventory of spare parts.
See the SPARE PARTS page in this manual. For Engine and
An identification plate on the top of the engine air intake also Generator
displays the engine model and serial number. . Accessories,. see. the ACCESSORIES brochure.
INSTALLATION MANUAL
CARBON MONOXIDE DETECTOR The Westerbeke Installation Manual publication #043268 is
WESTERBEKE recommends mounting a carbon monoxide supplied with this unit.
detector in the vessels living quarters. Carbon monoxide,
even in small amounts, is deacny.
The presence of carbon monoxide indicates an exhaust leak GENERATOR
from the engine' or generator or from the exhaust ID DECAL
elbow/exhaust hose, or the fumes from a nearby vessel are
entering your boat.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!

Engines & Generators

4
 DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL ENGINE COOLANT
Use a diesel fuel that meets the requirements of No. 2-D WESTERBEKE recommends a mixture of 50% antifreeze
SAE J 313 and has a Cetane rating of #45 or higher grade of and 50% distilled water. Distilled water is free from the
diesel fuel according to ASTM D975. chemicals that can corrode internal engine surfaces.
The antifreeze performs double duty. It allows the engine to
Care Of The Fuel Supply run at proper temperatures by transferring heat away from the
Use only clean diesel fuel! The clearance of the components engine to the coolant, and lubricates and protects the cooling
in your engines fuel injection pump is very critical; invisible circuit from rust and corrosion. Look for a good quality
dirt particles which might pass through the primary and antifreeze that contains Supplemental Cooling Additives
secondary filters can damage these finely machined parts. It (SCAs) that keep the antifreeze chemically balanced, crucial
is important to buy clean fuel, and keep it clean. The best to long term protection.
fuel can be rendered unsatisfactory by careless handling or The distilled water and antifreeze should be premixed before
improper storage facilities. To assure that the fuel going into being poured into the cooling circuit.
the tank for your engine's daily use is clean and pure, the
following practice is advisable: NOTE: Look for the new environmentally-friendly long lasting
Purchase a well-known brand of fuel. The use of additives to antifreeze that is now available.
combat BACTERIAL growth on the fuel tank is recqm-
mended such as Bio-Bor and an additive such as Diesel PURCHASING ANTIFREEZE
.Kleen + Cetane Boost to help restore lubricjty back into the Select a brand of antifreeze specified for diesel engines.
diesel fuel when an Ultra Low Sulfur diesel is being used. Antifreeze specified for diesel engines contains a special
Install and regularly service a good, visual-type fuel additive to protect against cavitation erosion of the engine's
filter/water separator between the fuel tank and the engine. cylinder walls. Prestone and Zerex are two nationally known
The Raycor 500 MA or 230 RMAM are good examples of brands that offer antifreeze specifically for use in diesel
such filters. A 10 micron filter element is recommended. engines. Select the pre-mixed variety so that the correct
mixture will always be added to the cooling system when
E~&GINE OIL needed. Change the antifreeze mixture according to the
Use a good brand of engine oil having an API and SAE MAINTENANCE SCHEDULE in this manual.
specification as stated in the SPECIFICATIONS section in
this· manual. Change the engine oil and oil filter after the
initial 50 hours of engine break-in operation and then every MAINTENANCE
100 hours of operation thereafter. Change the engine coolant every five years regardless of the
number of operating hours as the chemical additives that
Westerbeke Corporation does not approve or disapprove the
protect and lubricate the engine have a limited life.
use of synthetic oils. If synthetic oils are used, engine
break-in must be performed using conventional oil. Oil COOLANT RECOVERY TANK
change intervals must be as listed in the MAINTENANCE
SCHEDULE section of this manual and not be extended if The coolant recovery allows for the expansion and
synthetic oils are used. contraction of the engines coolant during engine operation
without introducing air into the system. This recovery tank is
NOTE: The infonnation above. supersedes all previous provided with fresh water cooled models and with the fresh
statements regarding synthetic oil. water coolant conversion kit and must be installed before
operating the engine.
SAE OIL VISCOSITY GRADES
For all temperatures ranges: SAE lOW-40 or 15W-40.

NOTE: This tank, with its short run of plastic hose, is best
located at or above the level of the engine's manifold, but it
can be located below the level of the engine's manifold if the
particular installation makes this necessary.

Engines & Generators

5
 PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Befor~ starting your generator set for the first time or after a
prolonged layoff, check the following items:
A CAUTION: When starting the generator. it is
recommended that all AC loads, especially large
• Make certain the cooling water thru-hull is open.
motors, be switched OFF until the engine has come
• Check the engine oil level. Add oil to maintain the level at up to speed and,. in cold climates, starts to warm up.
the full mark on the dipstick.
This precaution will prevent damage caused by
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants. unanticipated operation of the AC machinery and will
prevent a cold engine from stalling.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
II Check the coolant level in both the plastic recovery tank
R Check load leads for correct connection as specified in the and at the manifold.
wiring diagrams.
NOTE: After the initial running of the generator, the air in
• Examine air inlet and outlet for air flow obstructions the engine's cooling system will be purged to the coolant
(SoundGuards). recovery tank. Open the air bleed petcock to ensure that the
• Be sure no other generator or utility power is connected to cooling system is purged of air. After shutdown and cifter the
load lines. engine has cooled, the coolant from the recovery tank will be
• Be sure that in power systems with a neutral line that drawn into the engine's cooling system to replace the purged
the neutral is properly grounded (or ungrounded) as the air.
system requires, and that the generator neutral is properly Before subsequent operation of the generator, the engine's
connected to the load neutral. In single phase systems an · manifold should be topped off, a:nd the coolant recovery tank
incomplete or open neutral can supply the wrong line-to- may need to be filled to the MAX level.
neutral voltage on unbalanced loads.
• Visually examine the unit. Look for loose or.missing_
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any fuel line leaks.

WAIT FOR THE ENGINE W COOL FROM COOLANT

BEFORE REMOVING THE RADfATOR RECOVERY TANK
CAP .

MAWFOLD PRESSURE CAP,-~=,.,_~,

PRESS DOWN AND TURN
TOUFTOFF
TO NIPPLE At
MANIFOLD PRESSURE CAP

Olll)IPSTICK
ELECTRONIC CONlROLLER jJ_)_
THE ECU JS FACTORY PROGRAMMED
. TO CONTROL ALL ASPECTS
OF THE DRIVE ENGINE.
J.
.()) .

LOW

Engines & Generators

6
 GENERATOR INSTRUMENT CONTROL PANEL
OPERATING INSTRUCTIONS
DESCRIPTION
The Generators Instrument Control contains a compact
gauge package, control rocker switches, circuit fuses, check
engine light, emergency stop toggle switch and a recording
hourmeter. These components are described below.
The 8 pin connector that is on the back of the Control Box
is used to connect an optional remote start/stop panel or a
second instrument panel.
When an optional panel is connected, the 8 pin connector
with jumper should be kept for future needs when
troubleshooting. Secure it to the lifting eye.
FUSES: The control box has two automotive type fuses. A
5 amp fuse protects the ECU and a 7.5 amp fuse to protect
the control circuit and instrument panel.
CHECK ENGINE LIGHT: The CHECK ENGINE LIGHT will NOTE: It is important to
illuminate if the engine shuts down. (Refer to the Safety closely monitor the panel
gauges. Become aware of
Shutdown in this manual). the nonnal engine readings
EMERGENCY STOP: The EMERGENCY stop toggle switch THIS PANEL CAN ALSO BE and take immediate action
(Normally Closed) is located at the side of the control box. REMOTELY LOCATED, -REFER if these readings start to Val)'·
TO THE FOLLOWING PAGE
When depressed, it will open the DC circuit to the control
box. This switch can be used when servicing the unit to
prevent an unwanted start.
REMOTE PANEL PLUG-IN: A plug on the side on the control STARTING/STOPPING INSTRUCTIONS
box will allow for the remote mounting of the remote Depress the PREHEAT rocker switch for approximately 5-10
instrument panel or the remote panel start/stop. seconds. Then with the PREHEAT rocker still depressed,
depress the START rocker. When the engine starts, release
COOLANT TEMPERATURE: Engine coolant (water) the START rocker.
temperature should normally indicate: 175° to 195°F
(80o to 90°C). Remote Control Panel: When the oil and voltmeter start to
register, release the Start rocker.
ENGINE OIL PRESSURE: Oil Pressure (psi) may fluctuate
Continue to hold the PREHEAT rocker depressed until the
depending on the generator load but should range between
oil pressure reaches 10 psi. Then release the PREHEAT
35 to 55 psi.
rocker.
DC VOLTS: Indicates the amount the battery is being charged
and should show 13 V to 14V. Once the generator has started, observe the meter readings
on the instrument panel. Ensure that raw water is being
HOURMETER: Registers elapsed time and is used as a guide discharged with the exhaust. Apply a light amperage load on
for when to perform scheduled maintenance. the generator and allow it to warm up to 140oF, then apply
your higher amperage loads as needed.
PREHEAT: The PREHEAT rocker switch serves two purposes:
activates the preheat circuit and activates the K2 Run Relay. FAILURE TO START: Should the engine not start after the
This supplies power to the DC altemator R, fuel pump, ECU, START rocker has been depressed for 5-l 0 seconds, release
Instrument panel, K3 Fault Relay pin #87 and Start toggle both rocker switches and wait 30 seconds and repeat the
switch. above start procedure. Preheat a few seconds longer. Never
run the starter continually for more than 20-25 seconds.
START: The START rocker switch when pressed activates the
Kl Start Relay which activates the starter motor. STOPPING: To stop the generator, depress the STOP rocker
and hold it depressed, Release the STOP rocker when the
STOP: The STOP rocker switch when pressed and held, generator comes to a complete stop.
opens the DC circuit supplying power to the K2 Run relay.
De-activating it and shutting down the engine drive. REMOTE CONTROL PANEL: Release the STOP rocker when
the oil and voltmeter stop registering.

7
 OPTIONAL REMOTE CONTROL PANELS
OPERATING INSTRUCTIONS ,

DESCRIPTION
There are several options available when selecting remote
operation of your generator.
1. Mount a second (repeating) Instrument Control Panel in a
remote location.
2. Simply remove_ the Instrument Control Panel from the
control box and mount it as a remote panel.
NOTE: The Instrument Control Panel can be replaced by
installing a basic start~~top panel in the control box.
3. Mount a remote start/stop control panel ina remote
location.
Remote panels connect to the 8 pin plug on the back of
the control box using the extension harnesses listed below.
INSTRUMENT ·.
CONTROL PANEL(AS A REMOTE PANEL)
EXTENSION HARNESS PN56246
PNit056236 EG DIESEL (8 PIN) 15FT
PN1t056235 EG DIESEL (8 PIN) 30FT

NOTE: When connecting a remote panel to the plug connector

on the back of the control box. DO NOT discard the plug with
jumper found in this plug connector. Keep it with the ~it. Attach
it to the rear lifting eye. It will be useful in troubleshootmg a DC/
running issue by eliminating the remote panel and returning this
plug with jumper to the connector.

REMOTE START/STOP PANEL • DESCRIPTION

The Remote Start/Stop Panel has the same three rocker
switches as the Instrument Control Panel. Their function is
the same. This panel has a RELEASE STARTER LED. This
LED will illuminate when the PREHEAT is depressed. When
this panel is remote mounted, this LED will indicate when
the generator has started. When depressing the START
rocker switch, this LED will dim. When the generator starts,
the LED will brighten. This indicates to release the START
rocker switch. The PREHEAT rocker switch is held
depressed for about 4-5 seconds to allow the oil pressure to
reach 10 psi, then release it.
For the REMOTE START/STOP PANEL wiring diagram
and wiring harness, refer to the Table of Contents. REMOTE START/STOP PANEL
PN56320

Engines & Generators

8
 SAFETY SHUTDOWN SWITCHES

DESCRIPTION low Oil Pressure Switcn

The engine is protected by a number of safety shutdown A low oil pressure shutdown switch is located off the engine's
features as described below. Should a shutdown occur, as a oil gallery. Normally open.in a static state, this switch's sensor
result of one of these features, the Check Engine LED will monitors the engine's oil pre§sure. Should the engine's oil
illuminate. The cause should be determined using the pressure fall to 5-10 psi, this switch will open interrupting the
troubleshooting Diagnostic Software. Once corrected, the DC voltage to the K2 relay, thereby shutting off the engine.
'(""".
ECU must be cleared of this fault by turning OFF the 20 amp
fROM ENGINE
DC breaker and then back ON in order to start the engine. BLOCK
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Normally closed, this switch will open and interrupt
the DC voltage to the K2 relay (shutting OFF the engine)
should the switch's sensor indicate an excessive exhaust tern-
perature (an inadequate supply of raw water causes hjgh
exhaust temperatures). l'his switch opens at 260-270°F (127-
l320C}. This switch resets at approximately 225°F (l07°C).

·:;;::·-~:- OIL PRESSURE

SEtl!JOR
.~~'::---- .. EXHAUST ElBOW
//

The generator's engine is protected by an engine mounted

manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere in the instrument panel
w~ng 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 of the problem. After repairing the fault; reset the
breaker and restart the generator.
Coolant Temperature Switch
h high coolant temperature switch is located on the thermostat
housing. Normally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C}, will open and intermpt the DC voltage to the K2
relay, thereby shutting off the engine. This switch re&ets at
195°F (107°C).

Overspeed/Underspeed Shutdown
The unit's ECU is monitoring the engine speed via a signal
from the MPU (magnetic pick-up) positioned over the fly
wheel's ring gear teeth. Should the engine speed reach a
programmed high rpm or low rpm, the ECU will shut the
engine down and the Check Engine LED will illuminate.

THERMOSTAT
ASSEMBLY

9
 GENERATOR BREAK-IN PROCEDURE
DESCRIPnON AFTER START·UP
Although your engine has experienced a minimum of one Once the generator has been started, check for proper opera-
hour of test operations at the factory to make sure accurate tion and then encourage a fast warm-up. Run the generator
assembly procedures were followed and that the engine between 20% and 60% of full-load for the first 10 hours.
operated properly, a break-in time is required. The service
life of your engine is dependent upon how the engine is oper-
ated and serviced during its initial hours of use.
A CAUTION: Do not attempt to break·ln your
Breaking-in a new engine basically involves seating the
generatorby running without a load.
piston rings to the cylinder walls. Excessive oil consumption After the first 10 hours of the generator's operation, the load
and smoky operation indicate that the cylinder walls are . can be increased to the full-load rated output, then periodi-
scored, which is caused by overloading the generator during cally vary the load.
the break-in period.
, Avoid overload at all times. An overload is signaled by
Your new engine requires approximately 50 hours of initial smoky exhaust witll reduced output voltage and frequency.
conditioning operation to break in each moving part in order Monitor the current being drawn from the generator and keep
to maximize the performance and service life of the engine. it within the generator's rating. Since the generator operates
at 1800 rpm to produce 60 hertz (or at 1500 rpm to produce
50 Hertz), control of the generator's break-in is governed by
the current drawn from the generator.

GENERATOR ADJUSTMENTS
Once the generator has l:!een placed in operation, there may
be adjdstments required for engine speed (hertz) during the
engine's break-in period (first 50 hours) or after this period.
A no-load voltage adjusunent may also be required in con-
junction with the engine's speed adjustmeqt See
GENERATOR INFORMATION in this mariual.

THE DAILY OPERATION

CHECKUST START THE GENERATOR
·Follow this cheek list each daY' before starting your generator. (See STARTING PROCEDURES on previous pages).
0 Check th,at alJ...generator circuit breakerS (power panel) are Allow the engine to wann up for 5 to 10 minutes to rea~h an
in the off position before starting. operating temperature of 140° to 150°F (60°-66°C) before
applying AC loads. Apply loads systematically allowing the
0 Record the liourmeter reading in your log (engine hours generator to adjust to each load before applying the next.
relate to th~ maintenance schedule.) Check the gauges for proper oil pressure, operating
0 VISually inspect the engine for fuel, oil, or water leaks. temperature, and DC voltage. ·
. .
0 Check the oil level (dipstick). NOTE: Some unstable runn,ing may occur in !1 cold engine.
This condition should lessen as nonnal operating
0 Check the coolant level in the coolant recovery tank. temperature is reached and loads are applied.
0 eheck your fuel supply.
0 Check the·starting.batteries (weekly). A CAUTION: Oo not operate the generator for long
0 Check drive belts for wear and proper tension (weekly). periods of time without a load being placed on the
generator. ·
CHECK WITH THE ENGINE RUNNING.
0 Check for abnormal noise such as knocking, vibrating and STOPPING THE GENERATOR
blow-back sounds.
Remove the major AC loads from the generator one at a
0 Confirm exhaust_ smoke: time. Allow the generator to run for a few minutes to stabi-
When the engine is cold- Whlte Smoke. . lize the operating temperature and depress the stop switch.
When the engine is warm- almost Smokeless. (See STOPPING PROCEDURES on previous pages.)
When the engine is overloaded- some Black Smoke.

Engines & Generators

10
 MAINTENANCE SCHEDULE
WARNING: Nev8f 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. When servicing/replacing DC components, tum off the Emergency Stop Switch on the
Control Box or tum off the DC battery.

SCHEDULED MAINTENANCE EXPLANATION OF SCHEDULED MAINTENANCE

Maintenance procedures are all detailed in this manual.
IDAILY CHECK BEFORE START-UP
Coolant Level Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Engine Oil Level Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Fuel/Water Separator (owner installed) Check for water and dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Fuel Supply Use properly filtered #2 diesel with a Cetane rating of #45 or higher. Check that
. there is adeqilate fuel for the vessel's needs.
Visual Inspection of Engine Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
NOTE: Please keep engine suiface clean. Dirt and oil securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wiring and electrical
will inhibit the engine's ability to remain cool. connections. Look for loose bolts/hardware and correct as needed.
Drive Belts Inspect for frayed edges. Belts must be properly tensioned.

'INITIAL 50 HOURS OF OPERATION

Engine Oil and Filter Initial engine oil and filter change at 50 hours.
*Exhaust System Check security of water injected exhaust elbow to exhaust manifold.
Ensure there are no leaks.
*Valve Adjustment Check adjustment of valves.
*Re-Torque Cylinderhead Hold Down Bolls Re-torque bolts, engine cold then check/adjust valve clearances.
Inlet Fuel Filter Remove and replace inlet fuel filter.
Fuel Filter Remove and replace fuel filter and all sealing O·rings.
Generator Check that AC connections are secure with no chafing.
AC No-Load Check and adjust the no-toad AC output voltage as needed.

IEVERY 50 OPERATING HOURS OR MONTHLY

Drive Bell Inspect for proper tension (3/8" to 1/2' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Starting Batteries Check electrolyte lev'els Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Electric Fuel Pump Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Zinc Anode Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
your own inspection schedule.

IEVERY 100 OPERATING HOURS OR YEARLY

Engine Oil and Filler Change engine oil and filter at 100 operating hours or yearly..
Air Intake and Filter Keep air intake clear of obstructions. Clean air filter and replace if needed.

*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.

Engines & Generators

11
 MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your engune hours running time.

SCHEDULED MAINTENANCE EXPLANATION OF SCHEDULED MAINTENANCE

IEVERY 250 OPERATING HOURS OR YEARLY

*Exhaust Elbow/Exhaust System Check the structual integrity of the water injected exhaust elbow casting. Check the integrity
of the exhaust system attached to the elbow. All hose connections should be secure. No
chaffing. No exhaust leaks. Hoses and muffler are in good serviceable condition.
NOTE: An exhaust leak will cause exposure to diesel exhaust!
Fuel Filler and O·Rings Remove and replace fuel filter and all sealing 0-rings.
Inlet Fuel Filter Remove and replace inlet fuel filter.
*Generator Check that AC connections are clean and secure. Ensure wires have no chafing.
See GENERATOR INFORMATION.
Hoses Engine heses should be firm and tight. Replace if hoses become spongy, brittle or
delaminated. Check and tighten all hose clamps as needed.
Fuel Water Separator Filter Inspect bowl for dirt or water in fuel. Drain and replace filter. .
DC Alternator Inspect wiring, connections should be tight. Alternator should be clean and free of corrision.
Check mounting bracket and alternator bolt. All should be tight.
Impeller Inspect the condition of the impeller, replace as needed.

EVERY 500 OPERATING HOURS OR FIVE YEARS

Raw Water Pump Remove and disassemble the pump and inspect all parts: drive gear, pump shaft, wear plate
and cover for wear and corrosion. Replace the impeller and gasket. Lubricate the impeller
at re-assembly.
Coolant System Drain, flush and re-fill the cooling system with appropriate antifreeze mil<. Inspect the
condition of the sealing gaskets of the pressure cap. Clean out coolant recovery tank
and connecting hose.
*Valve Clearances Adjust valves. (Incorrect valve clearance will result in poor engine performance.)
*Starter Motor Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the starter
motor pinion drive.
*Re·Torque Cylinderhead Hold Down Bolts Re-torque bolts, engine cold then check/adjust valve clearances.
Pre-Heal Circuli Check operation of preheat solenoid. Remove glow plugs, clean tips and check operation.
Fuellnjeclors Check and adjust injection opening pressure and spray conditions.

EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS

Heat Exchanger Remove the heat exchanger for professional cleaning and pressure testing.
*MPU (Magnetic Pick-Up) Remove, check and clean any metal debris from the tip of the MPU.

*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.

 COOLING SYSTEM

DESCRIPTION When the engine is started cold, external coolant flow is pre-
vented by the closed thermostat (although some coolant flow
Westerbeke marine diesel engines are designed and equipped
is bypassed around the thermostat to prevent the exhaust
for fresh water cooling. Heat produced in the engine by com-
manifold from overheating). As the engine warms up, the
bustion and friction is transferred to fresh water coolant
thermostat gradually opens, allowing full flow of the engine's
which circulates throughout the engine. This circulating fresh
coolant to flow unrestricted to the external portion of the
water coolant cools the engine block, its internal moving
cooling system.
parts, and the engine oil. The heat is transferred externally
from the fresh water coolant to raw water by means of a heat Coolant Recovery Tank
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes of the heat exchanger while A coolant recovery tank allows for engine coolant expansion
fresh water coolant flows around the tubes; engine heat trans- and contraction during engine operation, without any signifi-
ferred to the fresh water coolant is conducted through the cant loss of coolant and without introducing air into the cool-
tube walls to the raw water which is then pumped into the ing system. This tank should be located at or above the
exhaust system where finally it is discharged overboard. In engine manifold level and should be easily accessible.
other words, the engine is cooled by fresh water coolant, this CHANGING COOLANT
coolant is cooled by raw water, and the raw water carries the
The engine's coolant must be changed according to the
transferred heat overboard through the exhaust systep:t. The
fresh water coolant and raw water circuits are independent of MAINTENANCE SCHEDULE. If the coolant is allowed to
each other. Using only fresh water coolant within the engine . become contaminated, it can lead to overheating problems.
allows the cooling water passages to stay clean and free from
harmful deposits. A CAUTION: Proper cooling system maintenance Is
FRESH WATER COOLING CIRCUIT critical; a substantial number of engine failures can be
traced back to cooling system corrosion.
NOTE: Refer to the ENGINE COOIANI' section for the rec-
ommended antifreeze and water mixture to be used as the Drain the engine coolant by loosening the drain plug on the
fresh water coolant. engine block and opening the manifold pressure cap. Flush
F~sh water coolant !s pumped through the engine by a circu- the system with fresh water, then start the refill process.
latmg pump, absorbmg heat from the engine. The coolant NOTE: The drain petcock on the heat exchanger should also
then passes through the thermostat into the manifold, to the be used to help drain engine coolant.
heat exchanger wheJ;e it is cooled, and returned to the en!rine
block via the suction side of the circulating pump. o
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.

ENGINE BLOCK COOLANT DRAIH

13
 COOLING SYSTEM
Refilling the Coolant
After replacing the engine block drain plug, close the heat
Replacing the Thermostat
exchanger's coolant petcock. Then pour clean, premixed Remove the cap screws and disassemble the thermostat hous-
coolant and when the coolant is visible in the manifold, start ing as shown. When installing the new thermostat and gas-
the engine. ket, apply a thin coat of sealant on both sides of the gasket
before pressing it into place. Do not over-tighten the cap
NOTE: When present, open the air-bleed petcock on the heat screws.
exchanger. When a steady flow of coolant appears at the
petcock, close it and continue to fill the cooling system. Run the engine and check for normal temperatures and that
there are no leaks at the thermostat housing.
Monitor the coolant in the manifold and add as needed. Fill
the manifold to the filler neck and install the manifold pres-
sure 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 and observe the coolant expansion
BLEED
flow into the recovery tank. PETCOCK
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 to the recovery tank if
needed. Clean up any spilled coolant.
TO COOLANT
RECOVERY TANk

THERMOSTAT
ASSEMBLY

RAW WATER COOLING CIRCUIT

The raw water flow is created by a positive displacement
impeller pump. This pump draws water directly from the raw
water source (ocean, lake, or river) through a hose to the
COOLANT RETRACTION water strainer. The raw water passes from the strainer
NOTE: Periodically check the condition of the manifold pres- through the raw water pump to the heat exchanger (through
sure cap. Ensure that the upper and lower rubber seals are in the heat exchanger tubes) where it cools the engine circulat-
good condition and check that the vacuum valve opens and ing fresh water coolant. The raw water is then discharged
closes tightly. Carry a spare cap. into the water-injected exhaust elbow, mixing with and cool-
ing the exhaust gasses. This mixture of exhaust gas and raw
water is discharged overboard by the engine's exhaust gas
discharge pressure.
Raw Water Pump
The raw water pump is a self-priming, rotary pump with a
SEALS non-ferrous housing and a neoprene impeller. The impeller
THERMOSTAT has flexible vanes which wipe against a curved cam plate
A thermostat, located near the manifold at the front of the within the impeller housing, producing the pumping action.
engine, controls the coolant temperature as the coolant contin- On no account should this pump be run dry as water acts as a
uously flows through the closed cooling circuit. When the lubricant for the impeller. There should always be a spare
engine is first started, the closed thermostat prevents coolant impeller and impeller cover gasket (an impeller kit) aboard.
from flowing (some coolant is by-passed through a hole in the Raw water pump impeller failures occur when lubricant (raw
thermostat to prevent the exhaust manifold from overheating). water) is not present during engine operation. Such failures
As the engine warms up, the thermostat gradually opens. The are not warrantable, and operators are cautioned to make sure
thermostat is accessible and can be checked, cleaned, or raw water flow is present at start-up.
replaced easily. Carry a spare thermostat and gasket.
NOTE: Should a failure occur with the pumps internal parts
(seals and bearings), it may be more cost efficient to pur-
chase a new pump and rebuild the original pump as a spare.

14
 COOLING SYSTEM
CHANGING THE RAW WATER PUMP IMPELLER NOTE: Also follow the above procedure after having run hard
Close the raw water intake valve. Remove the pump cover aground.
and gasket or 0-ring with the aid of two screwdrivers or If.the engine temperature gauge ever shows a higher than
pliers. Carefully pry/pull the impeller out of the pump. normal reading, the cause may be that silt, leaves or grass
Lightly coat the inside of the pump housing v1-th glycerine. may have been caught up in the strainer, slowing the flow of
Install the new impeller, bending the blades in the direction raw water through the cooling system.
of the curve of the cam plate. Re-assemble the gasket and
cover. Open the raw water intake valve. ·
·. , ~. RAW WATER STRAINER

RAW WATER PUMP SEWNG~

GASKET.~·

INSPECTION: CHECK THE BASE OF

EACH BLADE BY BfNDJNG VIGOROUSLY.·
REPLACE THE IMPELLER
ANY'CRACKS.

TYPICAL RAW WATER INTAKE STRAINER

(OWNER INSTALLED)

HEAT EXCHANGER
The heat exchanger is a copper cylinder which encloses a
number of small copper tubes. Raw water is pumped through
the small copper tubes and the fresh water coolant from the
engine is circulated atound the copper tubes. The raw water
A CAUTION: «any of the vanes have broken off the removes heat from the fresh water coolant.
impeller, they must be found to prevent bloclcage In the
cooling clrculf. They often can be found In the heat
exchanger.

Raw Water Intake Strainer

NOTE: Always install the strainer at or below the waterline so
the strainer will always be self-priming.
A clean raw water intake strainer is a vital component of the
engine's cooling system. Include a visual inspection of this
strainer when making your periodic engine check. The water
in the glass should be clear.
Perform the following maintenance after every 100 hours of
operation: CLEAN OUT
DEBRIS AT
1. Close the raw water seacock. BOTH ENDS
2. Remove and clean the strainer filter.
3. Clean the glass. NC
ANODE
4. Replace the washer if necessary.
5. Reassemble and install the strainer.
HEAT EXCHANGERS ARE'
6. Open the seacock. ALSO AVAILABLE WITH
7. Run the engine and check for leaks. CUPRO-NICKEL TUBING

Enf!lnes ~ Generators

15
 COOliNG .SYSTEM
Zinc Anode If the zinc anodes need replacement, hold the hex boss into
A zinc anode, or pencil, is located in the raw water cooling
which the zinc anode is threaded with a wrench while loos-
circuit within the heat exchanger. The purpose of having the ening the anode with another wrench. This prevents the hex
zinc anode is to sacrifice itself to electrolysis action taking boss from possibly tearing off the exchanger shell. After
pJace in the raw water cooling circuit, thereby reducing the removing the zinc, note the condition of it. If the zinc is in
effects of electrolysis on other components of the system. poor condition, there are probably a lot of zinc flakes within
The condition of the zinc should be checked monthly to the exchanger. Remove the end of the heat exchanger and
determine its service life. Once that is established, the zinc clean the inside of all zinc debris. Always have a spare heat
replacement period can be noted in your maintenaJ;Jce log. exchanger end gasket in case the present one becomes darn-
Spare zinc anodes should be carried on board. aged when removing the end cover. Replace the gasket (refer
· to your engine model's heat exchanger end gasket part num-
ber), 0-ring and cover, and install a new zinc anode.
NOTE: Th£4 threads of the zinc anodes are pipe threads and
~onot require_ sealant. Sealant should not be used as it may
msulate the zmc from the metal of the heat exchanger hous-
ing preventing electrolysis action on the zinc.

Heat Exchanger Service

After approximately 1000 hours of operation, remove; clean
NEW REPlACE REPlACE CLEAN AND and pressure test the engine's heat exchanger. (A local auto-
REUSE motive radiator shop should be able to clean and test the heat
ZINC ANODES exchanger.)
NOTE: Operating in silty and/or tropical waters may require
NOTE: Electrolysis action is the result of each particular that a heat exchanger cleaning be performed more often than
installation and vessel location; not that of the engine. every JOOO"hours.

AIR INTAKE I SILENCER

DESCRIPTION
A marine diesel engine running at 1800 fPID will typically NOTE: Regular inlet filter cartridge maintenance is essential
consume as much as 6,000 cubic feet of air per hour. Not for proper engine operation. Failure to maintain the inlet
only must the engine room be well ventilated, the air flow filter cartridge will result in air obstruction into the engine,
into the engine must be unrestricted. causing poor fuel combustion and resulting in smokey/sooty
exhaust discharge-along with lube oil consumption and
AIR INTAKE FILTER/SILENCER possible filter dete1ioration which could result in internal
engine damage.
The replaceable canister contains a paper element that should
be inspected every 100 operating hours. Dirt in the element'
can be shaken off or cleaned with compressed air, however,
if the element is greasy or black with dirt, the canister must FILTER CARTRIDGE
be replaced, cany a spare. · PNIID39705

NOTE: To operate efficiently a diesel engine must intake a

continuous volume of clem· ail: Hard stm1ing, an erratic idle,
and black exhaust smoke are all symptoms of a restricted ait
inrake.

FILTER CARTRIDGE INSTALLATION

Remove the two bolts that secure the air intake silencer
housing to the base exposing the air filter element. Remove
the filter element, inspect, clean and/or replace. Reinstall and
secure the housing to the base with the two bolts.

Engines'& Gj;nerators
16 .
 FUEL SYSTEM
DIESEL FUEL FUEL FILTERS
Use a diesel fuel that meets the requirements of No. 2-D SAE.
J 313 and has a cetane rating of 45 or higher according to The fuel injection pump and the fuel injectors are precisely
AS1MD975. manufactured and they must receive clean diesel fuel, free
FUEL WATER SEPARATOR from water and dirt. To ensure this flow of clean fuel, the fuel
must pass through at least two fuel filters, a fuel filter/water
A primary fuel filter of the water separating type must be sepru:ator and the engine's spin-on fuel filter. Visually inspect,
installed between the fuel tank and the engine to remove clean, and change these filters according to the maintenance
water and other contaminant's from the fuel before they can schedule in this manual.
be carried to the fuel system on the engine.
Most installers include a filter/water separator with the INLET FUEL FILTER
installation package as they are aware of the problems that To ensure properly filtered fuel into the fuel pump, there is a
contaminant's in the fuel can cause. small inlet filter befQre the inlet to the fuel pump. Replace
A typical fuel filter/water separator is illustrated below.This this filter after the initial 50 hours of operation, then follow
is the Raycor Model 500 MA. Keep in mind that if a water the Maintenance Schedule in thiS manual. ·
separator type filter is not installed between the fuel supply
tank and engine~mounted fuel system, any water in the fuel
will affect the fuel pump, engine filter, and injection equip-
ment. 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 filtration/separation system.
tff:\1 .
FUEL FILTER
WATER SEPERATOR

~
~l
FUEL INJECTION PUMP
The fuel injection pump is the most important component of FUEL FILTER ASSEMBLY
the diesel engine,requiring the utmost caution 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 ENGINE FUEL FILTER
requires servicing, remove it and take it to an authorized fuel Periodically check the fuel connections and the bowl for
injection pump service facility. Do not attempt to disassemble leakage. Clean the filter element with kerosene or diesel fuel
and repair it. after the first 50 hours then follow the MAINTENANCE
Speed (hertz) and timing are the only adjustments the SCHEDULE for cleaning and replacement.
servicing dealer can perform on the injection pump. Other
types of adjustments or repairs must be performed by a Changing/cleaning the filter element
qualified injection service shop. 1. Shut off the fuel supply.
2. Unscrew the retainer ring that holds the filter bowl to the
FUEL LIFT PUMP housing and allow the bowl to come away from the
Periodically check the fuel connections to and out of the housing,
pump and make sure that no leakage is present and that the 3. Remove and replace the filter element and clean the bowl.
fittings are tight and secure. The DC ground connection at
one of the pumps mounting bolts should be dearcand well 4. Replace the sealing "0" ring and reassemble the bowl to
secured by the mounting bolt to ensure proper pump the housing. Thread the retainer ring on carefully so as not
operations. to cross thread. When retainer contacts the "0" ring,
tighten 1/4 - 1/2 turns by hand. Open the fuel supply and
When energized thru the preheat circuit, the fuel lift pump run the engine to inspect for leaks.
will purge air from the fuel system and provide continuous
flow of fuel as the engine is running.

17
 ENGINE LUBRICATING OIL
LUBRICATION DIAGRAM 2. Replacing the Oil Filter. When removing the used oil fil-
ter, you may find it helpful and cleaner to punch a hole in
Oll PRESSURE
the upper and lower portion of the old filter to drain the
oil from it into a container before removing it. This helps
to lessen spillage. A small automotive filter wrench
should be helpful in removing the old oil filter.
NOTE: Do not punch this hole without first loosening the
filter to make certain it can be removed.
Place some paper towels and a plastic bag around the fil-
ter when unscrewing it to catch any oil left in the filter.
(Oil or any other fluid on the engine reduces the engine's
cooling ability. Keep your engine clean.) Inspect the old
oil filter as it is removed to make sure that the rubber
sealing gasket comes off with the old oil filter. If this rub-
ber sealing gasket remains sealed against the filter
OIL bracket, gently remove it.

OIL SCREEN

ENG.INE OIL CHANGE

1. Draining the Oil Sump. Discharge the used oil through
the sump drain hose (attached to the front of the engine)
while the engine is wann. Drain the used oil completely,
replace the hose in its bracket, and replace the end cap
securely.
NOTE: Thread size for the lube oil drain.hose capped end
is l/4NPT.
APPLY CLEAN ENGINE OIL
WHEN INSTALLING
SPIN ON
TURN ON HAND TIGHT
BMM
11!161NCH
SOCKET
When installing the new oil filter element, wipe the filter
gasket's sealing surface on the bracket free of oil and
apply a thin coat of clean engine oil to the rubber gasket
on the new oil filter. Screw the filter onto the threaded oil
filter nipple on the oil filter bracket, and then tighten the
filter finnly by hand.
NOTE: Generic filters are not recommended, as the mater-
ial standards or diameters of important items on generic
DRAIN HOSE parts might be entirely different from genuine parts.
Immediately after an oil filter change and oil fill, run the
engine to make sure the oil pressure is normal and that
Always observe the used oil as it is removed. A there are no oil leaks around the new oil filter.
yellow/gray emulsion indicates the presence of water in
the oil. Although this condition is rare, it does require 3. Filling the Oil Sump. Add new oil through the oil filler
prompt attention to prevent serious damage. Call a quali- cap on the top of the engine or through the side oil fill.
fied mechanic should water be present in the oil. Raw After refilling, run the engine for a few moments while
water present in the oil can be the result of a fault in the checking the oil pressure. Make sure there is no leakage
exhaust system attached to the engine and/or a siphoning around the new oil filter or from the oil drain system, and
of raw water through the raw water cooling circuit into stop the engine. Then check the quantity of oil with the
the exhaust, filling the engine. This problem is often lube oil dipstick. Fill to, but not over the high mark on
caused by the absence of an anti-siphon valve, its poor the dipstick, should the engine require additional oil.
location or lack of maintenance.

Engines & Generators

18
 OIL PRESSURE
DESCRIPTION TESTING OIL PRESSURE
The lubricating system is a pressure feeding system using To test the oil pressure, remove the oil pressure sender, then
an oil pump. The engine oil is drawn from the oil sump by install a mechanical oil pressure gauge in it's place. After
the oil pump, which drives the oil, under pressure, through warming up the engine, set the engine speed at 1800 rpm
the oil filter, oil cooler and various lubricating points in the and read the oil pressure gauge.
engine. The oil then returns to the oil sump to repeat the
continuous cycle. When the oil pressure exceeds the speci- Oil Pressure 35.0 lb/!n' (3.8 kg/em') or more at 1800 rpm.
fied pressure, the oil pushes open the relief valve in the oil Sender and Switch Torgue 9 -13 ft-lb (1.2 • 1.8 m • kg).
pump and returns to the oil sump, keeping the oil pressure
within its specified range.
FROM ENGINE
BLOCK
OIL PRESSURE
The engine's oil pressure, during operation, is indicated·
by the oil pressure gauge on the instrument panel. During TESTING OiL
normal operation, the oil pressure will range between 40 and PRESSURE
60 psi (2.8 and 4.2 kg/cm2).
NOTE: A newly staned, cold engine can hav~ an oil pressure
reading up to 60 psi (4.2 kg/em'). A warmed engine can have
MECHANICAL OIL
an oil pressure reading as low as 35 psi (2.5 kg/cm 2). These PRESSURE GAUGE
readings will vary depending upon the temperature of the ~
engine and"the rpms.

OIL MANIFOLD

LOW OIL PRESSURE

The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3
+ 0.1 kglcm2). A gradual loss of oil pressure usually indicates
a worn bearings. For additional information on low oil pres-
Oil PRESSURE sure readings, see the ENGINE TROUBLESHOOTING chart.
SEND OR

. OIL PRESSURE RELIEF VALVE

An oil pressure relief valve is located on the engine block
just below th~ injection pump. Tills valve opens at
appoximately 50 psi [343 kpa] and maintains that pressure.

LOCATED JUST
UNDER THE
FUEL INJECTION
PUMP ON THE
ENGINE BLOCK.

19
 (OPTIONAL)
REMOTE Oil FILTER (OPTIONAL)
PN.040078
INSTALLATION To install, simply remove the engine oil filter and thread on
WESTERBEKE'S remote oil filter kit as shown. Always
This popular accessory is used to relocate the engine's oil fil- install this kit with the oil filter facing down as illustrated.
ter from the engine to a more convenient location such as an
engine room bulkhead. Contact your WESTERBEKE dealer for more information.
NOTE: Refer to ENGINE OIL CHANGE in this manual for NOTE: Westerbeke is not responsible for engine failure due to
instructions on removing the oil filter. incorrect installation of the Remote Oil Filter.

A CAUTION: It is vital to install the oil lines

correctly. If the oil flows in the reverse direction, the
by-pass valve in the niter assembly will prevent the oil
from reaching the engine causing an internal engine
failure. If there is no oil pressure reading, shutdown
APPLY ATHIN COAT OF ClEAN Oil TO THE O·RING WHEN immediately and check the hose connections
INSTALUNG THIS KIT. THREAD THE KIT ON, THEN HAND
TIGHTEN AN ADDITIONAL3/4 TURN AFTER THE O·RING
CONTACTS THE BASE.

NOTE THE "IN" AND "OUT" MARKINGS

ON THE ADAPTER WHEN THE HOSES ARE
REMOVED FOR INSTAllATION SO THEY
, Will BE RECONNECTED CORRECTLY.

THE IN CONNECTION HOSE

MUST ATIACH TO THE OUT
CONNECTION AT THE
REMOTE OIL FILTER.

THE OUT CONNECTION HOSE

MUST ATIACH TO THE IN
CONNECTION AT THE
REMOTE Oil FILTER.

APPLY ATHIN COAT OF ClEAN OIL TO THE FIL·

TER GASKET WHEN INSTALUNG. AFTER THE
FILTER CONTACTS THE BASE, TIGHTEN IT AN
ADOITIONAL3/4 TURN.

Engines & Generators

20
 DC ELECTRICAL SYSTEM
ALTERNATOR 1. Start the engine.
The charging system consists of a DC belt driven alternator 2. After the engine has run for a few minutes, measure the
with a voltage regulator, an engine DC wiring har.ness, a starting battery voltage at the battery terminals using a
mounted DC circuit breaker and a battery with connecting multimeter set on DC volts.
cables. Because of the use of integrated circuits (IC's), the a. If the voltage is increasing toward 14 volts, the alterna-
electronic voltage regulator is very compact and is mounted tor is working; omit Steps 3 through 8 and go directly
internally or on the back of the alternator. to "Checking the Service Battery" on the next page.
b. If the voltage remains around 12 volts, a problem
exists with either the altema,tor or the charging circuit;
continue with Steps 3 through 8.
#10 ORANGE
START MOTOR SOLENOID
MULTIMETER

1114 VIOLET
TO FUEL SOLENOID.
· FUEL PUMP, AND
TO T82 {11

ALTERNATOR MOUNT (GROUND)

ALTERNATOR TROUBLESHOOTING TESnNG THE STARTING

BATTERY/ALTERNATOR
(ENGINE RUNNING)
A WARNING: A failed alternator can become very
hot. Do not touch until the altemator has cooled down.
Use this troubleshooting section to determine if a problem 3. Tum off the engine.. Inspect all wiring and connections.
exists with the charging circuit or with the ·alternator. If it is Ensure that the .battery terminals and the engine ground
detennined that the alternator or voltage regulator is faulty, connections are tight and clean.
have a qualified technician check it.
The alternator charging circuit charges the starting battery A CAUTION: To avoid damage to the battery
and the service battery. An isolator with a diode, a solenoid charging circuit, never shut off the engine battery
or a battery selector switch is usually mounted in the circuit switch when the engine is running!
to isolate the batteries so the starting battery is not discharged
along with the service battery. If the alternator is charging the 4. If a battery selector switch is in the charging circuit,
starting battery but not the service battery, the problem is in ensure that it is on the correct setting.
the service battery's charging circuit and not with the alterna-
5. Tum on the ignition switch, but do not start the engine.
tor.
6. Check the battecy voltage. If the battery is in good condi-
Testing the Alternator tion, the reading should be 12 to 13 volts.
~
A CAUTION: Before starting the engine make certain
that everyone is clear o! moving parts! Keep away from
sheaves and belts during test procedures.
G
COM + -----MULTIMETER

A WARNING: When testing with a moltimeter:

DC 1nd AC circuits are often mixed together in marine
applications. Always disconnect a shore power cord,
isolate DC and AC converters, and shut down the engine
before perfonning DC testing. No AC tests should be TESnNG THE STARTING
made without a proper knowledge of AC circuits. BATTERY/· ENGINE OFF)

-:GROUND

21
 DC ELECTRICAL SYSTEM
7. Now check the voltage between the alternator output ter- Checking the Service Battery
minal (B+) and ground. If the circuit is good, the voltage at
Check the voltage of the service battery. This battery should
the alternator will be the same as the battery, or if an isola- have a voltage between 13 and 14 volts when the engine is
tor is in the circuit the alternator voltage will be zero. If running. If not, there is a problem in the service battery
neither of the above is true, a problem exists in the circuit charging circuit. Troubleshoot the service battery charging
between the alternator and the battery. Check all the
circuit by checking the wiring and connections, the solenoid,
connections -look for an opening in the charging circuit. isolator, battery switch, and the battery itself.

MULTIMETER

TESTING THE STARTING

BAmRY/ALTERNATOR ENGINE
(ENGINE RUNNING) ,.c:::::o---1 GROUND

8. Start the engine again. Check the voltage between the

alternator output and ground. ,SERVICE BATTERY
The voltage reading for a properly operating alternator
should be between 13.5 and 14.5 volts. If your alternator GROUND TESTING THE SERVICE
is over- or under-charging, have it repaired at a reliable
service facility.
BAnERY (ENGINE RUNNING)
NOTE: Before removing the alternator for repair, use a
voltmeter to ensure that 12 volts DC excitation is present
at the EXC tenninal if the previous test showed only bat- A CAUTI,ON: To avoid damaging the alternator diodes~
tery voltage at the B output tenninal. do not use a high voltage tester (I.e. a megger) when
perfonnlng tests on the alternator charging circuit.
If 12 volts is not present at the EXC terminal, trace the
wiring and look for breaks and poor connections.

12 VOLT DC CONTROL CIRCUIT Battery Care

The engine has a 12 volt DC electrical control circuit that is Review the manufacturer's recommendations and then
shown on the wiring diagrams that follow. Refer to these establish a systematic maintenance schedule for your
diagrams when troubleshooting or when servicing the DC engine's starting batteries and house batteries.
electrical system. 0 Monitor your voltmeter for proper charging during
engine operation.
A CAUTION: To avoid damage to the battery charging 0 Check the electrolyte level and specific gravity with a
hydrometer.
circuit, never shut off the engine battery switch while
.the engine is running. Shut off the engine battery switch, 0 Use only distilled water to bring electrolytes to a proper
level.
however. to avoid electrical shorts when working on the
engine's electrical circuit.
0 Make certain that battery cable connections are clean and
tight to the battery posts (and to your engine).
BATTERY 0 Keep your batteries clean and free of corrosion.
The minimum recommended capacity of the battery used in
the engine's 12 volt DC control circuit is 600- 900 Cold
Cranking Amps (CCA).
A WARNING: Sulfuric acid in lead batteries can
causs severe burns on skin and damage clothing. Wear
protective gear.

22
 STARTER MOTOR
·DESCRIPTION
The starter is a new type, small. light-weight and is called a
ibigh-speed internal-reduction starter. The pinion shaft is
~eparate from the motor shaft; the pinion slides only on the
jpinion shaft. A reduction gear is installed between the motor
shaft and a pinion shaft. The pinion sliding part is not
'exposed outside the starter so that the pinion may slide
(M) TERMINAL
~moothly without becoming fouled with dust and grease. The
trnotor shaft is supported at both ends on ball bearings. The IGNITION
TERMINAL
~ever mechanism, switch and overrunning clutch inner circuit
;are identical to conventional ones.
SOLENOID

To test the ignition circuit, locate the ignition(s) terminal (it

MOTOR is one of the small terminal studs and is wired to the ignition
circuit). Use a screwdriver, don't touch the blade, to jump
from that ignition terminal to the positive battery c01111ection
TYPICAL terminal on the solenoid.
STARTER MOTOR If the starter cranks, the fault lies with the ignition
REFER TO THE WIRING
DIAGRAM IN THIS MANUAL circuit.
If the solenoid clicks but nothing happens, the starter
STARTER MOTOR motor is probably faulty.
These are basically DC electric motors and used almost
exclusively on small and large marine diesel propulsion
~
SOLENOID
engines and generators. These are direct current or compound
wound starter motors. They operate either on 12 or 24 volts
DC. On larger horsepower diesels, the starting motors are
provided with reduction gears to transmit higher torque to
crank the engine. You will also find reduction gear starter
motors used on many smaller horsepower diesels to help
provide good engine cranking speeds. IGNITtON
TERMINAL
TROUBLESHOOTING
Prior to testing, make certain the ships batteries are at full charge
and that the starting system wiring connections (terminals) are
clean and tight. Pay particular attention to the ground wire .~
co1111ections on the engine block If nothing happens at all, the solenoid is not getting
To check the wiring, try cranking the staiter for a few seconds, current.. Check the battery isolation switch and inspect the
never more than 10 seconds at a time, then run your hand along wiring co1111ections. it is also possible that the solenoid is
defective. ·
the wires and tenninals looking for wmm spots that indicate
resistai1ce. Repair or replace ailY trouble spots.
Using a multin1eter, test the voltage between the positive tenninal A WARNING: There will be arching and sparks will
stud on the start solenoid and the engine block (ground). fly when jumping terminals. Be certain the engine
If you read 12 volts, the starter is faulty. space is free of potentially explosive fumes, especially
gasoline, and that there are NO flammable solvents or
materials stored nearby.
A WARNING: The following emergency starting
procedures must not be used with gasoline engi11es.
Sparks could cause an explosion and fire.

Engines & Generators

23.
 STARTER MOTOR

SERVICE
A WARNING: When pedorming these procedures, Corrosion to the starter brushes arid/or the solenoid contacts
position yourself safely away from the moving parts of can cause the sporadic pro'blem of the engine starting one
the engine in case the engine starts-up. Also wain time but not another. If corrosion is the problem, the starter
other crew members of the danger. will need to be rebuilt.
WES'IERBEKE uses a standard starter motor which can be
serviced or rebuilt at any starter motor automotive service ·
center,
If replacing the st2rter motor, make certain the new motor is
certified for marine use. Automotive starters do not meet
USCG standards. If in doubt, contact your WESTERBEKE
dealer.

TO REMOVE FOR SERVICE

1. Disconnect the negative battery cable.
2. If necessary, remove any components to ga:in full access
to the starter motor. ·
iGNITION 3. Label and dis90nnect the wiring from the starter. (Do not
TERMINAL allow wires to touch, tape over the terminals).
4. Remove the starter mounting bolts.
5. Remove the starter from the engine. In some cases the
Test again by jumping the tw'cflarge"Wrminal studs. Hold the starter will have to be turned to a different angle to clear
screwdriver blade firmly between the studs. Do not allow the obstructions,
screwdriver blade to touch the solenoid or starter casing, this
would cause a short.

A WARNING: There will be arching as the full

starting current should be flowing thm the blade of
the screwdriver.

If the starter sp.ips, the solenoid is faulty.

If the starter fails to spin, the motor is probably faulty.
If no arching occurred, there is no juice reaching die
solenoid.

24
 ENGINE TROUBLESHOOTING
!ENGINE SHUTDOWN/CHECK ENGINE LIGHT
ELECTRONIC CONTROLLER
The Electronic Control Unit (ECU) monitors and controls all
aspects of the drive engines operation. The unit is factory
programmed and the programming can not be altered. The
ECU is mounted on the engine block adjacent to the fuel
injection pump and controls the injection pumps operation. If
an operating fault occurs, the ECU will shutdown·the engine
and illuminate the Check Engine LED. When the operating
fault has. been investigated and corrected, the ECU must be
re-set to re-start the engine. To re-set the ECU, turn the DC
breaker on the control panel OFF, then ON. NOTE: Engine
shutdown (check engine LED illuminated) requires ECU
software for proper troubleshooting. This ECU software
and communication cable is available from the ECU
manufacturer: Woodward, Inc./Aerospace. ELECTRONIC CONTROLLER
PN.8404·1021
WOODARD AEROSPACE
ENGINE SHUTDOWN
CHECK ENGINE/LED IS IllUMINATED
PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY
-
LOW OIL PRESSURE 1. Oil level low/oil leak. 1. Check oil level, add oil and repair leak.s.
2. Lack of oil pressure. 2. Test oil pressure. If OK, test oil pressure sendor,
inspect oil filter, inspect oil pump.
3. AGround connection. 3. Check ground connection.
4. Faulty oil pressure switch. 4. Check sensor/replace.

HIGH COOLANT 1. Check system coolant level. 1. Add coolant. Check for leaks.
TEMPERATURE 2. Sea water pump. 2. Inspect impeller/pump/replace.
3. Check water pump drive belt. 3. Adjust belt tension, replace belt.
4. Faulty temperature switch. 4. Check sensor/replace.
5. Ground connection. 5. Check ground circuit.

BATIERY VOLTAGE
(HIGH DC/LOW DC) 1. Check alternator drive belt.. 1. Adjust tension/replace if worn.
2. Check charge voltage. 2. Check excitation. Replace/repair alternator.
3. Check battery connections. 3. Check + and • cables from battery to engine.
4. faulty battery. 4. Load test battery.
GENERATOR FREQUENCY 1. Check engine speed. 1. Check speed setting.
Overspeed 2. Check fuel supply. 2. Inspect filters/replace filters. Test fuel pump operation.
Underspeed 3. Amperage load. 3. Check + and - cables from battery to engine.
4. Crank cycle with no start. 4. Check cause for no start.
(underspeed fault)
5. Generator Shut-down. 5. Check MPU (voltage cranking.
(underspeed fault) (Check MPU- coil resistance)
HIGH EXHAUST 1. Check sea water flow. 1. Inspect thru hull fitting, hose and strainer. Correct
(External Fault) as needed.
2. Faulty exhaust temperature switch. 2. Test/replace.
3. Ground connection. 3. Check ground circuit.
4•. Sea water pump. . 4. Inspect lrnpeller/reptace.
.- - - - . 5. Faulty tire suppression system. 5. By-pass system/check.
Under no circumstances should the Electronic Controller be removed form the unit without consulting
with tbe factory first.

25
 ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY
Generator engine cranks
but does not start. 1. Faulty preheat circuit. 1. Testlcheck circuit components.
2. Faulty fuel pump. 2. Test fuel pump operation.
3. Fuel supply. 3. Check fuel ON.
4. Fuel filter(s) contaminated. 4. Inspect all filters.

Starting battery
looses charge. 1. Faulty battery. 1. Load test battery.
2. Oil pressure switch stuck, closed contacts. 2. Panel/fuel pump activated after shutdown.
3. DC alternator faults. 3. Check alternator charge rate.
Engine shuts down.
Low oil pressure. 1. Loss of oil. 1. Locate leak and correct.
2. Oil pressure switch. 2. Test/replace.
3. Contaminated oil. 3. Change oil, locate source of contaminates.
Smokey exhaust. 1. Blue smoke. 1. Crankcase overfilled.
2. Incorrect grade of oil.
2. White smoke. 1. Engine running cold, thermostat stuck open.
2. Faulty injector.
3. Black smoke. 1. Lack of air, check intakeiair filter.
2. Incorrect fuel grade.
3. Valves need adjustment.
4. Low compression.
Engine starts, runs
then shutsdown. 1. Safety shutdown switch faulty. 1. Check safety shutdown switch (oil, coolant,
(stays running with exhaust)
Preheat depresed).

Engine has loss of

horsepower. 1. MAP sensor (manifold absolute pressure). 1. Test/replace.

J?ngines & Generators

26
 ENGINE TROUBLESHOOTING
The following troubleshooting chart describes certain NOTE: The engines electrical system is protected by a 20-
problems relating to engine service, the probable causes of ampere manual reset circuit breaker. The preheat solenoid is
these problems, and the recommendations to overcome mounted on the same bracket.
these problems.If the engine shuts down (Check Engine/LED
is illuminated), refer to ECU Troubleshooting Chart in this
manual.

PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY

Engine can not be stopped. 1. Faulty DC alternator. 1. Remove Exc/R connection off alternator. Repair
alternator.

Starting battery not being. 1. DC charge circuit faulty. 1. Perform DC voltage check of charge circuit. See DC
alternator section in this manual.
2. Alternator drive. 2. Check drive belt tension, loose connections, voltage
output, excitation voltage present at Exo/R terminal.
Engine slows and stops. 1. Fuel starvation. 1. Check fuel supply, filters, tank vent.
2. Contaminated fuel. 2. Check filters for contaminates/water.
3. Exhaust restriction. 3. Check for blockage, collapsed exhaust hose, carbon
build up in water injected exhaust elbow.
Engine overheats and
shuts down. 1. Antifreeze coolant not circulating. 1. Loss of coolant. Check system for leak.
2. Air in system. Expei air. Add coolant as needed.
Check recovery circuit.
3. Thermostat stuck closed. Check/test/replace.
Preheat switch depressed 1. Battery switch off. 1. Check switch.
No panel indications or 2. 20 Amp breaker tripped. 2. Check/re-set 20 amp breaker.
electrical fuel pump. 3. Emergency stop switch open. 3. Check/close switch.
4. 7.5 amp fuse faulty. 4. Check/test fuse.
5. Blocking diode open. 5. Test diode.
6. K2 Relay faulty. 6. Check/test K2 Relay.
Start switch depressed 1. K1 Relay faulty. 1. Check/test K1 Relay.
No starter activation. 2. Faulty starter solenoid. 2. Test solenoid.
3. Low DC battery charge. 3. Check battery charge state.
4. Poor/loose battery cable connection. 4. Check connections.

TROUBLESHOOTING WATER TEMPERATURE AND OIL PRESSURE GAUGES

If the gauge reading is other than what is nonnally indicated If both of the above gauge tests are positive, the gauge is
by the gauge when the instrument panel is energized, the first undoubtedly OK and tlie problem lies either with the
step is to check for 12 volts DC between the ignition (B+) conductor from the sender to the gauge or with the sender.
and the Negative (B-) terminals of the gauge. If either of the above gauge tests are negative, the gauge is
Assuming that there is 12 volts as required, leave the probably defective and should be replaced.
instrument panel energized and perfonn the following steps: Assuming the gauge is OK, check the conductor from the
1. Disconnect the sender wire at the gauge and see if the sender to the sender tenninal at the gauge for continuity.
gauge reads zero, which is the nonnal reading for this Check that the engine block is connected to the ground.
situation. Some starters have isolated ground terminals and if the
2. Remove the wire attached to the sender on the engine battery is connected to the starter (both plus and minus
and ground it to the engine. The gauge in the panel terminals), the ground side will not necessarily be connected
should register full scale, which is nonnal for this to the block.
situation. DC voltage at the oil and temperature sender
to ground when the engine is first started will be high
(1 0 - 11 VDC) and will fall as the oil pressure rises and
coolant rises. This DC voltage will generally stabilize in
the 5 - 7VDC range depending on what your engines
nonnal oil pressure and coolant temperature are.

Eng!fl~~ &Q_e_n~rators .
27
 ENGINE ADJUSTMENTS
NOTE: WESTERBI;:KE recommends that the following engine adjust-
ments be performed by a competent engine mechanic. The information
below is provided to assist the mechanic.

GLOW PLUGS FUEL INJECTORS

TYPICAL In case of severe vibrations and detonation noise, have the
injectors checked and overhauled by an authorized fuel
injection service center. Poor fuel quality, contaminants and
loss of positive fuel pressure to the injection pump can result
in injector faults. Since fuel injectors must be serviced in a
clean room enviroment, it is best to carry at least one extra
injector as a spare should a problem occur.
DESCRIPTION Before removing the old injector, clean the area around the
The glow plugs are wired through the preheat solenoid. base of the injector to help prevent any rust or debris from
When PREHEAT is pressed at the control panel this solenoid falling down into the injector hole. If the injector will not lift
should "click" on and the glow plug should begin to get hot. out easily and is held in by carbon build-up or the like, work
.the injector side-to-side with the aid of the socket wrench to
INSPECTION free it, and then lift it out.
To inspect the plug, remove the electrical terminal connec- The injector seats in the cylinder head on a copper sealino
tions, then unscrew or unclamp each plug from the cylinder washer. This washer should be removed with the injector"'and
head. Thoroughly clean each plug's tip and threads with a replaced with a new washer when the new injector is
soft brush a.J'!d cleaning solution to remove all the carbon and installed.
oil deposits. While cleaning, examine the tip for wear and Injector to Cylinder Head Tightening Torque 40 ± 4 fl·lb (5.5 ± 0.5 kgf-m)
bum erosion; if it has eroded too much, replace the plug.

TESTING
An accurate way to test glow plugs is with an ohmmeter.
Touch one prod to the glow plug's wire connection, and
the other to the body of the glow plug, as shown. A good
glow plug will have a 1.0- to 1.5-ohm resistance. This
method can be used with the plug in or out of the engine. FUEL INJECTOR
You can also use an ammeter to test the power drain
(8 to 9 amps per plug).

A WARNING: These glow plugs will become very hot REFER TO YOUR WESTERBEKE SERVICE MANUAL
FOR TESTING AND SERVICING OF FUEL INJECTORS.
to the touch. Be careful not to bum your fingers when
testing the plugs

Re-install the plugs in the engine and test them again. The
plugs should get very hot (at the terminal end) within 20 to
25 seconds. If the plugs don't heat up quickly, check for a
short circuit. When reinstalling the glow plugs, use anti-seize
compound on the threads.
Glow Plug Tightening Torque 7 -111b·f! (1.0 -1.5 kg-m)

A WARNING: Do not keep a glow plug on for more

than 30 seconds

Engines & Generators

28
 ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following engine adjust-
ments be peiformed by a competent engine mechanic. The information
below is provided to assist the mechanic.

VALVE CLEARANCE ADJUSTMENT (b) Rotate the crankshaft to position # 1 cylinder piston at
TDC. The TDC mark on the crank pulley should align
Make the following adjustments when the engine is cold. with the timing mark on the gear case. Adjust the valves
1. Remove the cylinder head cover. for cylinder #1.
2. Prior to checking valve clearances, re-torque the cylinder (c) Rotate the crankshaft to position the next cylinder in the
head hold down bolts. This is done by by slightly engines firing order at TDC of its compression stroke.
loosening the bolt and then re-ti~htening the bolt to the Adjust the valves for that cylinder.
specified torque in the sequence shown below. (d) Rotate the crankshaft to position the next cylinder in the
Tightening Torque 65 ± 4 lb·ft (88 ± 5 Nm) engines firing order at TDC. Adjust the cylinders valves
and repeat this procedure until all the cylinder valves are
adjusted.

FOUR CYLINDER
FRONT

4. Loosen the lock nut for the adjusting screw. With a feeler
gauge inserted between the rocker arm and valve cap,
THREE CYLINDER adjust the valve clearance by turning the adjusting screw.
3. Find top dead center compression position for No.1 Make certain to adjust all the valves.

~...-."\!l~;;';l111_j
piston by using the procedure that follows:
(a) Remove the glow plugs from the engine to ease the rota- 0.25mm
tion of the crankshaft manually to position the various
cylinders pistons at TDC (fop Dead Center. I (0.0098 INCHES)
INTAKE & EXHAUST

TDC (TOP DEAD CENTER) ~~--~~~~~~

\ INJECTION TIMING MARKS (4)

5. Install the cylinder head cover.
\ \
23•- 21··19• TDC
Head Cover Bolt Tol'que 2 • 3 ft·lb (0.3 • 0.45 m·kg)
.&
~ FIRING ORDER:
3 CYLINDER: 1-3·2
~ INJECTION TIMING MARKS (7) 4 CYLINDER: 1·3-4-2
21•- 20•-1g•. 18"-17°·16" TDC

TDC (TOP DEAD CENTER)~

\
ROTATION EARLY MODELS

~
ROTATION CURRENT MODELS

29
 GENERATOR INFORMATION
USE OF ELECTRIC MOTORS GENERATOR FREQUENCY
The power required to start an electric motor is considerably The generators speed can not be changed in the field from
more than is required to keep it running after it is started. the standard 60 hertz operation to 50 hertz operation. 50
Some motors require much more current to start them than hertz generators must be specifically ordered and for
others. Split-phase (AC) motors require more current to start, overseas operation only. This is because the drive engine is
under similar circumstances, than other types. They are com- only certified to operate at 1800 rpm (60Hz) in the United
monly used on easy-starting loads, such as washing States. Operating this drive engine at 1500 rpm (50Hz) in the
machines, or where loads are applied after the motor is United States may be in violation of Federal Law.
started, such as small power tools. Because they require 5 to
7 times as much current to start as to run, their use should be GENERATOR MAINTENANCE
avoided, whenever possible, if the electric motor is to be 0 Maintaining reasonable cleanliness is important.
driven by a small generator. Capacitor and repulsion- Connections of terminal boards and rectifiers may become
induction motors require from 2 to 4 times as much current corroded, and insulation surfaces may start conducting if
to start as to run. The current required to start any motor salts, dust, engine exhaust, carbon, etc. are allowed to
varies with the load connected to it. An electric motor build up. Clogged ventilation OPenings may cause
connected to an air compressor, for example, will require excessive heating and reduced life of windings.
more current than a motor to which no load is connected. 0 For unusually severe conditions, thin rust-inhibiting
In general, the current required to start 115-Volt motors connected petroleum-base coatings, should be sprayed or brushed
to medium starting loads will be approximately as follows: over all surfaces to reduce rusting and corrosion.
MOTOR SIZE AMPS FOR AMPS FOR 0 In addition to periodic cleaning, the generator should be
(HP) RUNNING STARTING
(AMPERES) (AMPERES) inspected for tightness of all connections, evidence of
1/6 3.2 6.4 to 22.4* overheated terminals and loose or damaged wires.
1/4 4.6 9.2 to 32.2* 0 The drive discs on single bearing generators should be
1/3 5.2 10.4 to 72.8* checked periodically if possible for tiglltness of screws
1/2 7.2 14.4 to 29.2* and for any evidence of incipient cracking failure. Discs
3/4 10.2 20.4 to 40.8* should not be allowed to become rusty because rust may
1 13 26 to 52 accelerate cracking. The bolts which fasten the drive disc
to the generator shaft must be hardened steel SAE grade
*NOTE: Jn the above table the maximwn Amps for Starting is 8, identified by 6 radial marks, one at each of the 6
nwre for some small motors than for larger ones. The reason comers of the head.
for this is that the hardest starting types (split-phase) are not
D The rear armature bearing is lubricated and sealed; no
made in larger sizes.
maintenance is required. However, if the bearing becomes
Because the heavy surge of current needed for starting noisy or rough-sounding, have it replaced.
motors is required for only an instant, the generator will not 0 Examine bearing at periodic intervals. No side movement
be damaged if it can bring the motor up to speed in a few of shaft should be detected when force is applied. if side
seconds. If difficulty is experienced in starting motors, tum motion is detectable, inspect the bearing and shaft for
off all other electrical loads and, if possible, reduce the load wear. Repair must be made quickly or major components
on the electric motor. will rub and cause major damage to generator.
REQUIRED OPERATING SPEED Carbon Monoxide Detector
Run the generator first with no load applied, then at half the WESTERBEKE recommends mounting a carbon monoxide
generator's capacity, and finally loaded to its full capacity as detector in the vessels living quarters. Carbon monoxide,
indicted on the generator's data plate. The output voltage even in small amounts, is deadly.
should be checked periodically to ensure proper operation of
The presence of carbon monoxide indicates an exhaust
the generating plant and the appliances it supplies. If an AC
leak from the engine or generator or from the exhaust
voltmeter or ampmeter is not installed to monitor voltage and
elbow/exhaust hose, or that fumes from a nearby vessel are
load, check it with a portable meter and amp probe.
entering your boat.
NOTE: When the vessel in which the generator is installed If carbon monoxide is present, ventilate the area with clean
contains AC equipment of 120 volts only, it is recommended air and correct the problem immediately!
that the generator's AC temtinal block be configured to pro-
vide one 120 volt AC lwt leg for the vessel's distribution
panel. This will ensure good motor starting response from the
generat01:

30
 BT GENERATOR
This generator is a four-pole; brushless, self-excited generator A circuit breaker is installed on all WESTERBEKE genera-
which requires only the driving force of the engine to pro- top. This circuit b~er will automatically disconnect gener-
duce AC output. The copper and laminated iron in the exciter ator power in case of an electrical overload. The circuit
stator are responsible for the self-exciting feature of this gen- breaker can be manually shut off when servicing the genera-
erator. The magnetic field produced causes an AC voltage to tor to ensure no power is coming intO the boat.
be induced into the related exciter rotor windings during rota-
tion. Diodes located in the excite~ rotor rectify this voltage to
NOTE: This circuit brea.ker is available as a WESTERBEKE
add-on kit for earlier model generations; contact your
DC and supply it to the windings of the rotating field. This
WESTERBEKE.dealer. .
creates an electromagnetic field which rotates through the
windings of the main stator, inducing an AC :voltage which is
supplied to a load. A step down transformer is connected in
parallel to the AC output of the main stator. An AC voltage is ·
produced in the auxiliary windings of the transformer and the
main stator and is, in turn, supplied to a full-wave bridge rec-
tifier. The rectifier produces a DC voltage to further excite
the exciter stator windings, enabling the generator to produce
a rated AC output. An optional solid-state voltage regulator is
available to work in tandem with the transformer regulator to
produce a more stable AC output

BT GENERATOR
SINGLE PHASE COMPOUND
(&STUD) TRANSFORMER

AC TERMINAL BOARD

AC
TERMINAl
BOARD
(12STUD)

31
 BT GENERATOR I SINGLE PHASE [SIX STUD]

r----------,
I c : :r-----------,
D i
! ; ·i :
A
r-------------------,
lI B iI :\ •2 o5 ...
W2
60Hz TERMINAl

1\sVl
-/!~1
•7
3
2

7
c>3 •8
1 2 : 1 2 3 I
L-----------------~

RED +
~ --
RED
to
.....
~
RED,- -1(]- AC' RED ""
GREEN ~.:..
1--- I_ ul'lt:~" ....___
~~
_, w
F.... ~' GREEN ~ 3"' __,
::>

YELLOW ( . I I YELI.OW GIJEEN "' "'

'. ·'
~~B~~K~,~i--~·~:-~_'
·t _______~BU~~~----+-f_.
BLACK
__~ BUCK BLUE t 60cyc.
IA.V.R.It-----,.---=----'
BLUE
1..--YEL="L""OW,.,......--------11 PLUG 11---------_::.=--- 50 eye;
-.

AVR RED/ WHilE

(TO HERI'lNOIJ'S BAR!
PLUG
BI.UEJWHITE
(TO PIN 18TERM-
BI..UEIWH!TE
(TO HEm'ZIVOL!S BAA) YEU.C1N /WHITE
(TO SE!.ECTOR SWITCH)

BLACK/WHITE
(TO BRIDGE RECTifiER)
CIRCUIT BREAKER

INTERNAL WIRING SCHEMATIC {SIX STUD)

W/OPTIONAL VOLTAGE REGULATOR

A. EXCITER STATOR WINDINGS 1& 2 D. COMPOUND TRANSFORMER

A - 1 and A - 2 Exciter Stator Windings 1. Compound Transformer Windings
(Selector in COMP position) 2. Compound Transformer Windings
3. Compound Transformer Auxiliary Windings
B. EXCI':fER ROTOR and FIELD Resistance readings and voltage checks can be accessed
1. Auxiliary Windings (A - B - C) easily for the components in the exciter circuit A, G, C-3 and
2. Diodes (6) D-3 by locating the color coded wires at the connection
3. Rotating Field Windings points shown on the above schematic. When checking
4. Posi Resistor . winding resistance values be sure to lift both of the
component's electrical connections.
C. MA1N STATOR G. BRIDGE RECTIFIER
1. Main Stator Windings A.V.R.
2. Main Stator Wmdings Optional Automatic Voltage Regulator Plug (6 Prong).
3. Main Stator Auxiliary Windings

32
 GENERATOR VOLTAGE ADJUSTMENT
NOTE:. WESTERBEKE recommends that the following generator
tests and adjustments be perfonned by a quailified technician.

Generator Frequency d. After the no-load hertz adjustment is made, lhe no-load
voltage may need to be readjusted: In most cases, if the
1. Frequency is a direct result of engine/generator speed: generator was producing the correct no-load voltage at
1800 rpm::: 60 hertz the previous hertz setting, it would be correct at the
1500 rpm = 50 hertz. changed hertz setting.
In the event it n.eeds adjustment, adjust the shim thick-
2. To change generator frequency follow the steps below.
ness under the laminated steel bar of the transformer.
a. Connect the AC output leads to the AC terminal block, 60 hertz: no-load voltage, 121-124 volts.
following the illustrations on this page. 50 hertz: no-load voltage, 232-236 volts.
b. If an AVR is installed, reposition the blue or blue/white e. Load the generator to the rated amperage output
lead to correspond to the hertz selected on the corresponding to the hertz speed of the generator.
Voltage/Hertz Connection Bar. Rated Loaded Speed
60 hertz: loaded speed, 58.5- 59.0 hertz
If there is no automatic voltage regulator (AVR 50 hertz: loaded speed, 48.5- 49.0 hertz
installed, do not change the wiring on the The lowest acceptable voltage at full rated output
Voltage/Hertz Connection Bar. Simply reconfigure the (amps)
AC tenninal for the hertz change. 60 hertz: 108 - 110 volts
c. Start the engine, monitor voltage and adjust engine 50 hertz: 205 - 210 volts
no-load speed. Adjust diesel units by the linkage
between the throttle arm and fuel solenoid or the
throttle lever on the injection pump..
60 hertz:. no-load speed, 61.5- 62.0 hertz.
50 hertz: no-load speed, 51.5- 52.0 hertz.

SIX STUD AC VOLTAGE CONNECTIONS

115V 50Hz 230V50Hz 120V 60HZ 120/240V &OHZ
@ @ ·® @

~-

TWELVE STUD AC VOLTAGE CONNECTIONS

115V50Hz Z30V50Hz 1201160 Hz 120J240V/60Hz
The frame ground wire must o=D o· 0::::::0 0 0 0::::::0
· be moved when changing 7
from 115 voHs and 1101220 0 ~ 6 6 ~ ••I L2
volts 50 hertz to 230 volts
50 hertz. From making con· b 8
nectlons to the AC tennlnal
block. use tennlnal ends for . •I l1
1/4 Inch studs that wiR
accept multl-strand copper
wire sized for the amperage N l1
mting from the hot lead con· L1

OJ
nectlon. ihe frame ground
wire is whHe or white with a
· green strip. It connects
between the neutral stud CIRCUIT
and the generator frame. BREAKER
\J~MPERIS
REQU!RED

33
 GENERATOR VOLTAGE ADJUSTMENT
NOTE: WESTERBEKE recommends that the following generator
tests and adjustments be perfonned by a quailified technician.

NO-LOAD VOLTAGE ADJUSTMENT FULL-LOAD VOLTAGE ADJUSTMENT

Voltage adjustment is made with the generator regulation The voltage hertz connection bar that is used when changing
being governed by the compound transformer. from 60Hz to 50Hz can also be used to increase or decrease
1. The selector switch, if installed, must be in the COMP the generators· full-load output.
position. Fine voltage adjustments can be performed by repositioning
2. To confirm no-load voltage, start the generator and apply wires Ato leads #1, #2, and #3 increasing the loaded voltage
a momentary (moderate) load to excite the transformer. progressively in that order. A no-load voltage adjustment will
The voltage produced by the generator after the momen- have to be made as well.
tary load is removed is no-load voltage. Note the voltage Should full~load output fall below 108 volts-60Hz
output from the generators 120 volt leg(s) (230 volt 50 (210 volts-50Hz), the voltage should be adjusted.
hertz). The no-load voltage should be between 121-124
volts at 61.5-62 hertz (232- 236 volts at 51.5-52 hertz). A TWO RED
WIRES
NOTE: The no-load voltage should be adjusted to the voltage
produced by the generator once started and a momentary 12 STUD
load should be applied to excite the transfonner and then
removed. The voltage produced by the generator after this
momentary load is removed is no-load voltage.
3. To raise or lower the voltage, shims of varying thickness
(non-conductive material) are placed or removed from
under the steel laminated bar on top of the compound
transformer. The material used for shimming should not
soften at temperatures in the 176° F (80° C) range. A
small reduction in no-load voltage (1 to 3 volts) can·some
times be accomplished by gently tapping the top of the ·
laminated steel bar to reduce the gap between the existing 6 AND 12 STUD VOLTAGE HERTZ
shims and the transformer core. CONNECnON BARS

NOTE: No-load voltage may be effected needing readjustment

NOTE: When the optional voltage regulator is installed
with the compound transfonner. Do not use these
and if the Blue/White (Blue) lead is not correctly positioned
adjustments to compensate for overload conditions being
to correspond to the Hertz the unit is operating at, the
placed on the generator/engine (inductive-motor type loads).
regulator will se~e incorrect voltage and cause the generator
Loss of generator hertz/speed, the result of overload, will
to produce abnormally high output voltage.
cause a drop in voltage output.
Shim thickness of 0.001 inch will change the no-load
voltage by approximately 4 - 6 volts. Adding shim
material raises the no-load voltage. Removing shim
material lowers no-load voltage.

34
 BT GENERATOR SINGLE PHASE

OPTIONAL AUTOMATIC VOLTAGE REGULATOR (AVR) BT GENERATOR TROUBLESHOOTING CHART

BT 6 STUD MODELS ONLY · NOTE: WESTERBEKE recommends that the following generator tests
and adjustments be peiformed by a qualified technician.
An optional solid-state voltage regulator (board #3441 0)
is available for use with the BT series generators. When
installed, and the regulation switch is moved to the ELEC LOW VOLTAGE 60-I 00 VOLTS AC
position, the regulator works together with the standard com- COMPONENT CHECKS:
pound transformer regulator to regulate the generator's volt- ·F SELECTOR SWITCH (6 Stud Models)
age output In the ELEC mode, the regulator provides 8 ROTOR COMPONENTS
excitation to the groupl exciter windings, and the trans- 82. EXCITER ROTOR DIODES
former provides excitation to the group 2 exciter windings. 83. ROTOR FIELD WINDING
B1. EXCITER ROTOR WINDING(S} a,b,c.
Installation A 1-1+2 ExCITER STATOR WINDING(S).
1. The regulator is mounted using existing tapped holes in
the generator's case. Use two (2) M4 , 0 7mm screws, NO AC VOLTAGE OUTPUT
each 15mm long, with lock washers to mount the regula- MAIN STATOR, ROTOR COMPONENTS, TRANSFORMER
tor board. COMPONENT CHECKS:
2. Connect the 6-prong generator plug to the receptacle on C 1+2 MAIN STATOR WINDING
the regulator board. 8 4 POSI RESISTOR
8 2 DIODES (4-6 OPEN/SHORTED)
NOTE: The plug is keyed to engage the regulator.receptacle in D 1.+2 COMPOUND TRANSFORMER WINDING
one direction. Check this and insert it comctly. 8 3 ROTOR FIELD WINDING
3. Before moving the selector switch to the ELEC position, RESIDUAL VOLTAGE EXCITER CIRCUIT FAULTY
the NO-Load voltage produced by the generator when in COMPONENT CHECKS:
the COMP position will have to be adjusted. The NO-
Load voltage should be adjusted down between 114 - 118 A 1·1+2 EXCITER STATOR WINDING(S)
G BRIDGE RECTIFIER
volts (60Hz) or 224 - 228 volts (50Hz) following the D 3 TRANSFORMER AUX. WINDING
procedures as explained earlier in this manual. C 3 MAIN STATOR AUX. WINDING
4. With the generators no load voltage properly adjusted, · F SELECTOR SWITCH
move the selection switch into the ELEC position. Adjust CIRCUIT CONNECTIONS (from the Transformer Aux. winding to the
the regulator board potentiometer to set NO-Load voltage connections on the Bridge Reclif~er)
at 120- 122 volts at 61.5- 62.0 Hertz (230- 234 volts at
51.5 - 52.0 Hertz). The regulator board is operating in par-
allel with the compound transformer and should maintain
voltage output within ±5 per cent from NO-Load to
FULL-Load.
NOTE: Do not use the regulator to force NO-Load voltage
down. Use the compound transformer for this junction. Using
the regulator to peiform this causes the regulator to use more
exciter circuit power. This leaves less exciter circuit power
for loaded conditions. ·

Switching Shore Power to Generator Power

A CAUTION: Heavy motor leads should be shut off
before switching shore power to generator power or
vlcB-versa because voltage surges indut:ed by switch·
ing with heavy AC loads on the vessel being operated
may cause damage to the exciter circuit components in
the generator.

Engines & Generators

35
 BT GENERATOR INTERNAL WIRING
3 PHASE TWELVE WIRE RECONNECTABLE
r- - - - - - - - - - - - . ,
t I
I A EXCITER STATOR I
I I r------,
1
I r----
1 1 DsrATOR
-I-- - - - - - - -- - , 12-----1------+----·11
l
I I I I 10 9
I I I C I
I I I I
1 1 I ROTORFIELD I a---+----~----07
I + I I I 6 5
I I I
I I I 2--_:_.....L-----+----1
I I I
I I 4 3
- I I
,...-----J I I
~-----~----------~
L- ---------.1 ..
6.3AFUSE

.. red~
Ia green
... yellow '- GREEN
7Hertz RED
.I ::
~
,. Volt
AUX. AC VOLTAGE
....
FULL-LOAD 189-190 NO-LOAD 183-184

RED
EXCITER DC VOLTAGE
FULL-LOAD 15-16 NO-LOAD 8.5-9.0

BT GENERATOR
THREE PHASE

Engines; & t}enerators

36
 GENERATOR AC VOLTAGE CONNECTIONS
BE THREE PHASE
VOLTAGE REGULATORS AC TERMINAL CONNECTIONS
THREE PHASE CONNECTIONS THREE PHASE 12 WIRE
. The regulator is equipped with seven numbered terminals
(0 to 6) and their related brass jumpers. The illustrations
shown connection points and jumpers for the 3 phase con- LI
figuration of the generator. The sensing leads connect
between pin #1 and pin #2 on the AC terminal block and L2
connection #2 and #0 on the voltage regulator board.
NOTE: Either Series configuration requires the installation of
a jumper on the regulator board between terminal Band 0.
N
PARAUEL WYE (STAR)
l·N -120 VAC 10 60Hz l·l- 208 VAC 30 60Hz
l·N -110 VAC 10 50 Hz l·l-190 VAC 10 50 Hz

170· 270 v

--.,
__ J60 Hz

SERIES WYE (STAR)

l-L- 480 VAC 30 60Hz l·l- 400 VAC 30 50 Hz
l·N- 277 VAG 10 60 Hz l·N- 230 VAC 10 50 Hz

Engines & Generators

37
 SHORE POWER TRANSFER SWITCH
GENERATOR

~
N L1 .
. _NOTE: Diagram shows connections for a ;wo•
wfra. 120-Volt system from the genetato~~
"" with throe-wlre.120·V~It boat system.
--~ ~ GENERATORiSHORE
""' SWITCH
I Ill
I
I
I
I
I SHIP'S
~-.. .:..til
.... __./' I Ship-to. Shora Switch (3 Pole) LOAD
PN 32008

II I[; ,~~~}Ship's~ad
(40Amps/P.ole)
"PN 32009
(SO Amps/ Pole)
PN 32010
r ; · {125 Amps/ Pole)
PN32133
~ --:' . {200 Amps/Poie).
I. ~
t
l S2 St T N J
G!t1UJ1d \1•

NOTE: Diag;am shows connectlo~ tort~

wire, 120-volt system. For three-wire ~
1 '::' SHORE
GROUND
-=- SHIP'S
GROUND .

Shom Powar , . syS1em usa dotted lines for the other SHORE POWER
hot leg.

230 VOLT/50 HZ TWO WIRE CONFIGURATION

SHORE POWER CONNECTIONS (60 HERTZ)

If the installer connects shore power to the vessel's AC cir- SWitching Shore Power to Generator Power
cuit, this must be done by means of the Shore Power Transfer
Switch. Set the transfer switch shown in the diagrams to the
OFF position. 'Ibis switch prevents simultaneous connection
A CAUTION: Heavy motor loads should be shut off
before switching shore power to generator power or
of shore power to generator output
vice-versa because volta{le surges induced by switching
with heavy AC loads on tfie. vessel being operated may
A the
CAUTION: Damage to generator can result if cause damage to the exciter circuit components in the
utility shore power and generator output are connected generator. · ·
at the same time. This type of generator damage is not
covered under the warranty; it is the installer's responsi·
bility to make sure all AC. connectlons·are.correct•. .

120 VOLT/60HZ THREE WIRE CONFIGURATION

Notice the repositioning of the white wire ground load on the
terminal block to the generator case. .

Generat~r NOTE: Olagnm shows connections for a two ..

~
' -"'
wire, 120-VoU system from the generator.
wJth three-wlrt~, 120-Volt boat system.

~ WESTERBEKE
Engines & Generators

38
 LAY-UP &RECOMMISSIONING
GENERAL Fuel System [Gasoline]
Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with unleaded gasoline of 89 octane
including engines and generators, for lay-up during the or higher. A fuel conditioner such as Sta-Bil gasoline
off-season or for long periods of inactivity. Others prefer stabilizer should be added. Change the element in your
to accomplish lay-up preparation themselves. gasoline/water separator and clean the metal bowl. Re-install
The procedures which follow will allow you to perlorm your and make certain there are no leaks. Clean up any spilled
own lay-up and recommissioning, or you may use them as a fuel.
check list if others do the procedures. Fuel System [Diesel]
These procedures should afford your engine protection Top off your fuel tanks with No.2 diesel fuel. Fuel additives
during a lay-up and also help familiarize you with the such as BioBor and Diesel Kleen + Cetane Boost should be
maintenance needs of your engine. added at this time to control algae and condition the fuel.
If you have any questions regarding lay-up procedures, call Care should be taken that the additives used are compatible
your local servicing dealer; he will be more than willing to with the primary fuel filter/water separator used in the sys-
provide assistance. tem. Change the element in your primary fuel filter/water
separator, if the fuel system has one, and clean the separator
Propeller Shaft Coupling [Propulsion Engine] sediment bowl.
The transmission and propeller half couplings should always Change the fuel filter elements on the engine and bleed the
be opened up and the bolts removed when the boat is hauled fuel system, as needed. Start the engine and allow it to run
out of the water or moved from land to water, and during for 5 - 10 minutes to make sure no air is left in the fuel
storage in the cradle. The flexibility of the boat often puts a system. Check for any leaks that may have been created in
severe strain on the propeller shaft or coupling or both, while the fuel system during this servicing, correcting them as
the boat is taken out or put in the water. In some cases, the needed. Operating the engine for 5 - 10 minutes will help
shaft has actually been bent by these strains. This does not allow movement of the treated fuel through the injection
apply to small boats that are hauled out of the water when equipment on the engine.
not in use, unless they have been dry for a considerable
period of time. Raw Water Cooling Circuit
Fresh Water Cooling Circuit [Propulsion Engine] Close the through-hull seacock. Remove the raw water intake
hose from the seacock. Place the end of this hose into a five
A 50-50 solution of antifreeze and distilled water is gallon bucket of clean fresh water. Before starting the engine,
recommended for use in the coolant system at all times. check the zinc anode found in the primary heat exchanger on
This solution may require a higher concentration of the engine and clean or replace it as required, and also clean
antifreeze, depending on the area's winter climate. Check the any zinc debris from inside the heat exchanger where the
solution to make sure the antifreeze protection is adequate. zinc anode is located. Clean the raw water strainer.
Should more antifreeze be needed, drain an appropriate Start the engine and allow the raw water pump to draw the
amount from the engine block and add a more concentrated fresh water through the system. When the bucket is empty,
mixture. Operate the engine to ensure a complete circulation stop the engine and refill the bucket with an antifreeze
and mixture of the antifreeze concentration throughout the solution slightly stronger than needed for winter freeze
cooling system. Now recheck the antifreeze solution's strength. protection in your area.
Lubrication System Start the engine and allow all of this mixture to be drawn
With the engine warm, drain all the engine oil from the oil through the raw water system. Once the bucket is empty, stop
sump. Remove and replace the oil filter and fill the sump the engine. This antifreeze mixture should protect the raw
with new oil. Use the correct grade of oil. Refer to the water circuit from freezing during the winter lay-up, as well
ENGINE LUBRICATING OIL pages in this manual for the as providing corrosion protection.
oil changing procedure. Run the engine and check for proper Remove the impeller from your raw water pump (some
oil pressure and make sure there are no leaks. antifreeze mixture will accompany it, so catch it in a bucket).
Examine the impeller. Acquire a replacement, if needed, and
a cover gasket. Do not replace the impeller (into the pump)
A CAUTION: Do not leave the engine's old engine oil until recommissioning, but replace the cover and gasket.
in the sump over the lay-up period. Lubricating oil and Intake Manifold and Thru-Hull Exhaust
combustion deposits combine to produce harmful
Place a clean cloth, lightly soaked in lubricating oil, in the
chemicals which can reduce the life of your engine's opening of the intake manifold to block the opening. Do not
internal parts. shove the cloth out of sight. (If it is not visible at
recommissioning, and an attempt is made to start the engine,
you may need assistance of the servicing dealer. Make a
note to remove the cloth prior to start-up. The thru-hull
exhaust port can be blocked in the same manner.

Engines & Generators

39
 LAY·UP & RECOMMISSIONING
Starter Motor. Spare Parts
Lubrication and cleaning of the starter drive pinion is advisable, Lay-up time provides a good opportunity to inspect your
if access to the starter pennits its easy removal. Make sure the Westerbeke engine to see if external items such as drive belts
battery connections are shut off before attempting to remove or coolant hoses need replacement. Check your basic spares
the starter. Take care in properly replacing any electrical kit and order items not on hand, or replace those items used
connections removed from the starter. during the lay-up, such as filters and zinc anodes. Refer to the
SPARE PARTS section of this manual.
Cylinder Lubrication [Diesel]
Recommissioning
If you anticipate a long lay-up period {12 months_9r more)
WESTERBEKE recommends removal of the glow plugs for · The recomiirissioning of your Westerbeke engine after a
access to the cylinders. Squirt some Marvel Mystery Oill into seasonal lay-up generally follows the same procedures as
the cylinder walls. Rotate the engine crankshaft by hand two those described in the PREPARATIONS FOR "STARTING
revolutions and re-install the glow plugs. section regarding preparation for starting and normal starts.
However, some of the lay-up procedures will need to be
If your engine does not have glow plugs, the injectors will have counteracted before starting the engine.
to be removed. Be sure to have replacement sealing washers for
the injectors and return fuel line as needed. 1. Remove the oil-soaked cloths from the intake manifold.
2. Remove t;he raw water pump cover and gasket and
Intake Manifold [Gasoline] discard the old gasket. Install the raw water pump impeller
Clean the filter screen in the flame arrester, and place a clean remov-ed during lay-up (or a replacement, if required).
cloth lightly soaked in lube oil around the flame arrester to Install the raw water pump cover with a new cover gasket.
block any opening. Also place an oil-soaked cloth in the 3. Reinstall the batteries that were removed during the
through-hull exhaust port, Make a note to remove cloths prior lay-up, and reconnect the battery cables, making sure the
to start-up! terminals are clean and that the connections are tight.
Cylinder Lubrication [Gasoline] Check to make sure that the batteries are fully charged.
After engine shutdown, remove the spark plugs and spray a
small amount of fogging oil into each cylinder. Rotate the
crankshaft manually two complete revolutions. Re-install the
A CAUTION: Wear rubber gloves, a rubber apron,
and eye protection when servicing batteries. Lead acid
spark plugs loosely for winter lay-up
batteries emit hydrogen, a highly explosive gas, which
NOTE: At spn'ng commissioning, remove the plugs and rotate can be ignited by electrical arcing or a lighted
the cranksJu:ift two full revolutions. Re-install the spark plugs,
tighten properly and connect the high tension leads fully onto cigarette, cigar, or pipe. Do not smoke or allow an open
each spark plug. flame near the battery being serviced. Shut off all
electrical equipment in the vicinity to prevent electrical
Batteries
arcing during servicing.
If batteries are to be left on board during the lay-up period,
make sure that they are fully charged, and will remain that way,
to prevent them from freezing. If there is any doubt that the 4. Remove the spark plugs, wipe clean, re-gap, and install to
batteries will not remain fully charged, or that they will be proper tightness [gasoline].
subjected to severe environmental conditions, remove the 5. Check the condition of the zinc anode in the raw water
batteries and store them in a warmer, more compatible circuit and clean or replace the anode as needed. Note
environment
that it is not necessary to flush the antifreeze/fresh water
solution from the raw water coolant system. When the
A WARNING: Lead acid batteries emit hydrogen, a engine is put into operation, the system will self-flush in a
short period of time with no adverse affects. It is
hlgh/y·explosive gas, which can be ignited by electrical
arcing llt a lighted cigarette, cigar, or pipe; D.o n.o,. advisable, as either an end of season or recommissioning
service, to inspect the area where the zinc is·located in the
smolce or allow an open flame near the battery being heat exchanger and clear any and all zinc debris from that
serviced. Shut off all electrical equipment in the vicinity area.
to prevent electrical arcing during servicing. 6. Start the engine in accordance with procedures described
in the PREPARATIONS FOR STARTING section of this
Transmission [Propulsion Engine] manual.
Check or change the fluid in the transmission as required Wipe
off grime and grease and touch up any unpainted areas. Protect
the coupling and the output flange with an anti-corrosion
coating. Check that the transmission vent is open. For
additional information, refer to the TRANSMISSION SECTION.

Engines & Generators

40
 SPECIFICATIONS 11.5 EGTD, 11.0 EGTD, 10.0 EGTD; 8.0 EGTD
GENERAl FUEl SYSTEM
Engine Type Diesel, four-cycle, three-cylinder, fresh water- General Open flow, self priming.
cooled, vertical in-line overhead valve
Fuel No. 2-D (Cetane rating of 45 or higher).
mechanism.
SAE J313. Grade of diesel fuel according to
Displacement 80.4 cubic inches (1.3181iter) ASTM 0975.
Aspiration Naturally aspirated. Fuel Injection Pump In-line plunger type (BOSCH).
Combustion Chamber Swirl type. Nozzle Throttle type.
Bore & Stroke 3.07 x 3.62 inches (78 x 92 mm) Fuel Filter Cartridge Type
Firing Order 1-3-2 Air cleaner Replaceable paper fHter cartridge.
Direction of Rotation Clockwise, when viewed from the front Fuel Uft Pump 12 volt DC lift capacity of 5' (1.5 mm) solid state
Compression Ratio 22:1
ElECTRICAl SYSTEM
Weight 8.0 EGTD 467 lbs (211.8 kilosl
10.0 EGTD 5131bs (232.7 kilos Starting Battery 12 Volt, (-) negative ground
11.0 EGTD 513 lbs (232.7 kilos}
Battery Capacity 400 - 600 Cold Granking Amps (CCA)
11.5 EGTD 513 lbs (232.7 kilos}
DC Charging Alternator 51 Amp rated, belt-driven
Inclination Continuous 15°
Temporary 25° (not to exceed 30 min.) Starting Aid Glow plugs, sheathed type
Engine Combustion Air 41 cfm (1.16 cmm) Starter 12 Volt, reduction gear
Requirements @ 60Hz
1800 rpm
COOLING SYSTEM
TUNE-UP SPECIFICATIONS General Fresh water-cooled block, thermostatically·
controlled with heat exchanger.
Compression Pressure 427 psi (30 kg/em') at 280 rpm
384 psi (27 kg/em') Operating Temperature 170°-190° F (77°- 88° C)
Minimum .•
Spilled Timing (Static} 17° (spill) Fresh Water Pump Centrifugal type, metal impeller, belt-driven.

Valve Seat Angle 45° Raw Water Pump Positive displacement, rubber impeller,
belt-driven.
Engine Timing 17" BTDC
Raw Water Row
Injector Pressure 1991 + 71 -0 psi (140 +5-0 kgf/cm'). at 1800 rpm. 7-8 gpm (25.9- 29.6 gpm).
(Measured before
Valve Seat Angle Intake 45°
discharging into
Exhaust 30°
exhaust elbow).
Valve Clearance 0.25mm (0.0098in) ...
System Capacity 5.0 US qts (4.71iters)
(engine cold)
(Fresh Water)

lUBRICATION SYSTEM
General Pressure fed system.
Oil Filter Full flow, paper element, spin-on type.
Sump Capacity 3.9 U.S. qts (3.7 liters)
(not including filter)
Operating Oil Pressure 50- 60 psi (3.5- 4.2 kg/em')
(engine hot)
Oil Grade API Specification CF. CG-4, Cl-4 or CJ-4
SAE 1OW-40 or 15W-40.

Engines & Generators

41
 SPECIFICATIONS 8.0 EGTD
AC GENERATOR (Single Phase)
Single Phase Brushless, four-pole, revolving field.
Pre-lubricated, single bearing design.
Reconnectable, single phase transformer
regulation (optional solid-state voltage
regulation).
Voltage 120 or 120/240 Volts - 60 Hertz
230 Volts - 50 Hertz
Voltage regulation: ± 5% no load to full load.
Frequency regulation: .5 Hertz (.6%) no load to full load.
Rating (Volts AC)
60 Hertz (1800 rpm) 120 Volts 66 Amps
8.0KW 120/240 Volts 66/33 Amps
50 Hertz (1500 rpm) 230 Volts 27 Amps
6.0KW
Generator Cooling 175 • 200 cfm (4.95-5.66 cmm)
Air Requirements
{60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50
Hertz operation (1500 rpm)
Engine Combustion 42 cfm (1.19 cmm)
Engine Compartments 100-200 cfm (2.83-5.66 cmm)
Cooling Air
Generator Compartment 122"F (50"C) maximum
Ambient Temperature
Recommendations NOTE: Forced ventilation should be
provided to maintain generator
compartment temperature below122'F (50"C)

SPECIFICATIONS 10.0 EGTD

AC GENERATOR (Single Phase) AC GENERATOR (3 Phase)
Single Phase Brushless, four-pole, revolving field. General - 3 Phase Brushless six pole, revolving field. Sealed
Pre-lubricated, single bearing design. 10.0 KW • 60 Hertz lubricated single bearing design. 12 Lead
Reconnectable, single phase transformer 7.5 KW - 50 Hertz reconnectable for low voltage WYE, high
regulation (optional solid-state voltage voltage Delta. Solid State voltage regulator
regulation). with protection circuitry.
Voltage 120 or 1201240 Volts- 60 Hertz Voltage - 3 Phase Low voltage WYE 208vo!ts
230 Volts - 50 Hertz (60 Hertz) High voltage WYE 480volts
DELTA 240volts
Voltage regulation: ± 5% no load to full load.
Voltage- 3 Phase High voltage WYE 380 volts
Frequency regulation: .5 Hertz (.6%) no load to full load. (50 Hertz) DELTA 230vo!ts
Rating (Volts AC) Amperage • 3 Phase Low voltage WYE 35Amps
60 Hertz (1800 rpm) 120 Volts 83.3 Amps (60 Hertz) High voltage WYE 15 Amps
10.0 KW 1201240 Volts 83.3/41.6 Amps DELTA 30Amps
50 Hertz {1500 rpm) 230Volts 34.1 Amps Amperage - 3 Phase High voltage WYE 14 Amps
7.5KW (50 Hertz) DELTA 24 Amps
Generator Cooling 225 - 250 elm (5.66-6.37 cmm) Generator Cooling 225- 250 cfm (5.66 • 6.37 cmm)
Air Requirements Air Requirements
(60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50 Hertz (60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50 Hertz
operation {1500 rpm) operation (1500 rpm)
Engine Combustion 42 elm (1.19 cmm) Engine Combustion 42 cfm (1.19 cmm)
Air Requirements Air Requirements
Engine Compartments 100 - 200 cfm (2.83-5.66 cmm) Engine Compartments 100 • 200 elm (2.83-5.66 cmm)
Cooling Air Cooling Air
Generator Compartment 122•F (50"C) maximum Generator Compartment 122"F (50•C) maximum
Ambient Temperature Ambient Temperature
Recommendations NOTE: Forced ventilation shOuld be provided Recommendations NOTE: Forced ventilation should be provided
to maintain generator compartment to maintain generator compartment
temperature below122'F (50-G) temperature below122'F (50"C)

I~IWE!O#fiBEKE
l Engtnss & Generators
42
 SPECIFICATIONS 11.0 EGTD
AC GENERATOR (Single Phase) AC GENERATOR (3 Phase)
Single Phase Brushless. four-pole, revolving field. General - 3 Phase Brushless six pole, revolving field. Sealed
Pre-lubricated, single bearing design. 11.0 KW- 60 Hertz lubricated single bearing design. 12 Lead
Reconnectable, single phase transformer 8.8 KW -50 Hertz reconnectable for low voltage WYE, high
regulation (optional solid-state voltage voltage Delta. Solid State voltage regulator
regulation). with protection circuitry.

Voltage 120 or 120/240 Volts - 60 Hertz Voltage - 3 Phase low voltage WYE 208volts
230 Volts - 50 Hertz (60 Hertz). High voltage WYE 480 volts
DELTA 240 volts
Voltage regulation: ± 5% no load to full load.
Voltage - 3 Phase High voltage WYE 400 volts
Frequency regulation: .5 Hertz (.60%) no load to full load. (50 Hertz) DELTA 230volts
Rating (Volts AC) Amperage - 3 Phase Low voltage WYE 37 Amps
60 Hertz (1800 rpm) 120 Volts 91.7 Amps (60 Hertz) High voltage WYE 16'Amps
11.0 KW 120/240 Volts 91.7/45.8 Amps DELTA 33Amps
50 Hertz (1500 rpm) 230 Volts 38.3Amps Amperage • 3 Phase High voltage WYE . 15Amps
8.8KW (50 Hertz) DELTA 27 Amps
Generator Cooling 225 - 250 cfm (5.66-6.37 cmm) Generator Cooling 225 - 250 cfm (5.66- 6.37 cmm)
Air Requirements Air Requirements
(60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50 Hertz (60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50 Hertz
operation (1500 rpm) operation (1500 rpm)
Generator Compartment 122"f (50"C) maximum Generator Compartment 122"f~50"C) maximum
Ambient Temperature Ambient Temperature
Recommendations NOTE: Forced ventilation should be provided Recommendations NOTE: Forced ventilation should be provided
to maintain generator compartment to maintain generator compartment
temperature below122'F (50"C). temperature below122'F (50"C).

----------

SPECIFICATIONS 11.5 EGTD

AC GENERATOR (Single Phase) AC GENERATOR (3 Phase)
Single Phase Brushless, four-pole, revolving field. General - 3 Phase Brushless six pole, revolving field. Sealed
Pre-lubricated, single bearing design. 11.5 KW- 60 Hertz lubricated single bearing design. 12lead
Reconnectable, single phase transformer 9.2 KW - 50 Hertz reconnectable for low voltage WYE, high
regulation (optional solid-state voltage voltage Delta. Solid State voltage regulator
regulation). with protection circuitry.
Voltage 120 or 120/240 Volts- 60 Hertz Voltage - 3 Phase low voltage WYE 208 volts
230 Volts · 50 Hertz (60 Hertz) High voltage WYE 480vofis
DELTA 240volts
Voltage regulation: ± 5% no load to full load.
Voltage - 3 Phase High voltage WYE 380 volts
Frequency regulation: .5 Hertz (.6%) no load to full load. (50 Hertz) DELTA 230 volts
Rating (Volts AC) Amperage - 3 Phase Low voltage WYE 43Amps
60 Hertz (1800 rpm) 120 Volts 95.8Amps (60 Hertz) High voltage WYE 17 Amps
11.5KW 120/240 Volts 95.8/47.0 Amps DELTA 37 Amps
50 Hertz (1500 rpm) 230 Volts 40Amps Amperage • 3 Phase High voltage WYE 17 Amps
9.2KW (50 Hertz) DELTA 30 Amps
Generator Cooling 225 - 250 cfm (5.66- 6.37 cmm) Generator Cooling 225 • 250 cfm (5.66 • 6.37 cmm)
Air Requirements Air Requirements
(60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50 Hertz (60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50 Hertz
operation (1500 rpm) operation (1500 rpm)
Generator Compartment 12~F (5Q•C) maximum Generator Compartment 122•F (50"C) maximum
Ambient Temperature Ambient Temperature
Recommendations NOTE: Forced ventilation should be provided Recommendations NOTE: Forced ventilation should be provided
to maintain generator compartment to maintain generator compartment
temperature below 122•f (50•C) temperature below122'F (50"C)
L

IW'IWESIERBEKL
( Engln98 It Generators ·
43
 SPECIFICATIONS 12.5 EGTD AND 15 EGTD
GENERAL FUEL SYSTEM
Engine Type Diesel, four-cycle, four-cylinder, fresh water- General Open flow, self priming.
cooled, vertical in-line overhead valve
mechanism. Fuel No. 2-D (Cetane rating of 45 or higher).
SAE J313. Grade of diesel fuel according to
Displacement 107.3 cubic inches (1.758 liter) ASTM D975.
Aspiration Naturally aspirated. Fuel Injection Pump In-line plunger type (BOSCH).
Combustion Chamber Swirl type. Nozzle Throttle type.
Bore & Stroke 3.07 x3.62 inches (78 x 92 mm) Fuel Riter Cartridge Type (PN#D30200)
Firing Order 1 - 3" 4 -2 Air cleaner Replaceable paper filter cartridge.
Direction of Rotation ClockWise, when viewed from the front. Fuel Utt Pump 12 volt DC lift capacity of 5' (1.5 mm) solid state
Compression Ratio 22:1
Dimensions- inches (mm) Height: 24.0 inches (609.6 mm) ·
COOLING SYSTEM
Engine Only Width: 19.0 inches (482.6 mm) General Fresh water-cooled block, thermostatically-
Length: 34.6 inches (878.8 mm) controlled with heat exchanger.
Weight (dry) 569 lbs (258.1 0 kgs) Operating Temperature 170° - 190° F(7r - 88° C)
Fuel Consumption 1.42 g/hr (5.38 ltr/hr) at 1800 rpm Fresh Water Pump Centrifugal type, metal impeller, belt-driven.
HP@ 1800 RPM 25 HP Raw Water Pump Positive displacement, rubber impeller,
belt-driven.
HP@1500 PRM 21 HP
System Capacity 8.0 US qts (7.61iters)
(Fresh Water)
TUNE-UP SPECIFICATIONS
Raw Water Flow
Compression Pressure 427 psi (30 kg/em') at 280 rpm at 1800 rpm. 7-8 gpm (25.9 - 29.6 gpm).
Minimum 384 psi (27 kg/em')
(Measured before
Spilled liming (Static) 17" (spill) discharging into
exhaust elbow).
Valve Seat Angle Intake 45°
Exhaust 30° Engine Combustion Air 41 cfm (1.16 cmm)
Requirements @ 60Hz
Engine Speed 1800 rpm (60 Hz) 1800 rpm
1500 rpm (50 Hz)
Valve Clearance 0.25 inches (0.0098 mm) LUBRICATION SYSTEM
Injector Pressure 1991 + 71 -0 psi (140 +5-0 kgl/cm'). General Pressure fed system.
Engine liming 1r BTDC Oil Filter Full flow, paper element, spin-on type.
Sump Capacity 4.5 U.S. qts (4.31iters)
ELECTRICAL SYSTEM (not including filter)
Starting Battery 12 Volt(-) negative ground Operating Oil Pressure 50- 60 psi (3.5- 4.2 kg/em')
Battery Capacity 400-600 Cold Cranking Amps (CCA) (engine hot)
DC Charging Alternator 51 Amp rated, belt-driven Oil Grade API Specification CF, CG-4, Cl-4 or CJ-4
SAE 1OW-40 or 15W-40.
Starting Aid Glow plugs, sheathed type
Starter 12 Volt, reduction gear
Cold Cranking 175 - 200 amps
Amp Draw (approximate)

En.qines & Generators

44
 SPECIFICATIONS 12.5 EGTD
AC GENERATOR (Single Phase) AC GENERATOR (3 Phase)
Single Phase Brushless, tour-pole, revolving field. General - 3 Phase Brushless six pole, revolving field. Sealed
Pre-lubricated, single bearing design. 12.5 KW- 60 Hertz lubricated single bearing design. 12 Lead
Reconnectable, single phase transformer 9.3 KW- 50 Hertz reconnectable for low voltage WYE, high
regulation (optional solid-state voltage voltage Delta. Solid State voltage regulator
regulation). with protection circuitry.
Voltage 120 or 120/240 Volts - 60 Hertz Voltage - 3 Phase Low voltage WYE 208 volts
230 Volts - 50 Hertz (60 Hertz) High voltage WYE 480 volts
DELTA 240 volts
Voltage regulation: ± 5% no load to full load.
Voltage - 3 Phase High voltage WYE 380 volts
Frequency regulation: .5 Hertz (.6%) no load to full load. (50 Hertz) DELTA 230 volts
Rating (Volts AC) Amperage - 3 Phase Low voltage WYE 43Amps
60 Hertz (1800 rpm) 120 Volts 104 Amps (60 Hertz) High voltage WYE 17 Amps
12.5KW 120/240 Volts 104/52 Amps DELTA 37 Amps
50 Hertz (1500 rpm) 230 Volts 60Amps Amperage - 3 Phase High voltage WYE 17 Amps
9.3KW (50 Hertz) DELTA 30 Amps
Generator Cooling 225 - 250 cfm (5.66- 6.37 cmm) Generator Cooling 225 - 250 elm (5.66 - 6.37 cmm)
Air Requirements Air Requirements
(60 Hertz) at 1800 rpm NOTE: Increase air supply 15% for 50 Hertz (60 Hertz) at 1800 rpm NOTE: Increase air supply 15% tor 50 Hertz
operation (1500 rpm) operation (1500 rpm)
Generator Compartment 122oF (50°G) maximum Generator Compartment 122"F (50°C) maximum
Ambient Temperature Ambient Temperature
Recommendations NOTE: Forced ventilation should be provided Recommendations NOTE: Forced ventilation should be provided
to maintain generator compartment to maintain generator compartment
temperature below 122oF (50°C) temperature below122'F (SOOC)

SPECIFICATIONS 15 EGTD
AC GENERATOR (Single Phase) AC GENERATOR (3 Phase)
Single Phase Brushless, four-pole, revolving field. General - 3 Phase Brush less six pole, revolving field. Sealed
Pre-lubricated, single bearing design. 15.0 KW- 60 Hertz lubricated single bearing design. 12 Lead
Reconnectable, single phase transformer 12.0 KW- 50 Hertz reconnectable for low voltage WYE, high
regulation (optional solid-state voltage voltage Delta. Solid State voltage regulator
regulation) .. with protection circuitry.
Voltage 120 or 120/240 Volts - 60 Hertz Voltage - 3 Phase Low voltage WYE 208 volts
230 Volts - 50 Hertz (60 Hertz) High voltage WYE 480 volts
DELTA 240 volts
Voltage regulation: ± 5% no load to full load.
Voltage - 3 Phase High voltage WYE 400 volts
Frequency regulation: ±3 Hertz (5%) no load to lull load. (50 Hertz) DELTA 230 volts
(Electronic Governered)
Amperage - 3 Phase Low voltage WYE 52 Amps
Non-Electric ± 3 Hertz (60 Hertz) High voltage WYE 22 Amps
Rating (Volts AC) DELTA 45 Amps
60 Hertz (1800 rpm) 120 Volts 125 Amps Amperage - 3 Phase High voltage WYE 22Amps
120/240 Volts 195.8/49.9 Amps (50 Hertz) DELTA 39Amps
50 Hertz (1500 rpm) 230 Volts , 60 Amps Generator Compartment 122°F (5o•c) maximum
Generator Cooling 225- 250 cfm (6.37 - 705 cmm) Ambient Temperature
Air Requirements Recommendations NOTE: Forced ventilation should be provided
(60 Hertz) at 1800 rpm NOTE: Increase air supply 15% tor 50 Hertz to maintain generator compartment
operation (1500 rpm) temperature below122'F (50,G)

Engine Combustion Air 46 elm (1.9 cmm)

Requirements @60Hz
1800 rpm
Generator Compartment 122°F (so·c) maximum
Ambient Temperature
Recommendations NOTE: Forced ventilation should be provided
to maintain generator compartment
temperature below122'F (50•C)

Engfnes & Generators

45
 r I
I
-l
Lf)
N
N
c.o r--PR-EHEAT HOUR
STOP
SW llCH
_j
Lf) ~~ so~.~-~~ 1.o ~···--~-~--~t?.L~Ejl__
1 METER
~ )' ·
~
......_ ;
. . iiiJiliJ (o) GLOW PLUG
:E [HiiiJI.. •. .
t·s:_:~ ~'ill l
ONE
CYLINDER
PER
cz: [lUJ.Qi.W_HT_ _ _ _ ______ ___!_ULj!_fJJ_~-·-------1
a:
~
-Q
[l EC TRON IC
GOVERNOR
I
I
=
z
a: 011. PRESSURE . •J.<!.. R.~.ol_w!n
=t-~----~·-J
l
31:
<J
<
~
0 0 =
"211
" fUSE SA IUS[ !.SA
CHECK
[ NG I NE
0
"'
Q
~ ~~
LIGHT L...l .............. ......, ...... 0
s1wE,"{l:~~;;©tC-' ~-
CL- :z:: -V>~N
~§§~ 3~j~j~
3
wATER . '-."-'.v.cQJ - - ,:,.,:,:
~4 RJ1!.Y.!Q._____ T£MPfRATUR(
~00~
~--V>
~nco;::;
. . : ;:
o.n_.._j~:><...J
:;;c
~o...o...e:c:o::
0..::
- SWITCH ...1~-.Jo.....J
0!-1--:Z
;z.::.:: ;c v.>
..._.,_,....,:z::;:::o.:
_.X
~~~§;
oz:::;::<.n
~~::;::;::~
1/).:,I)V)(I')V>o::::
UOOa....te>:: ......,.....,.......,,_,,_.,_.
<..JUC'X:L<.l ;;;e;;;;e;;r::.:=zo...
cc o..o.. o:::e:::er:a::o::.x
~<:OO...::E <<<<<::>
:z: ::I::> :::r;: :c :r.:: :r.:: :::c,
o::~=<.l;l...,
~§ii~! ~~~~~§
%- N ••••••
 WIRING SCHEMATIC
#56225
s,.~IT£RY <2 VDC

PREHEAT
SOLENOID
GLOWPLUGS
ONE PER CYL
Jl_fls~·________
---·
~
-
i
1'
I

~
1
r j r=-~-~~->-
I STARTER I
"__________::~)-R---------------J
~ I

~5:
!
l
20A r(h
.'i I " - - ~ AL HRNATOR
·------+'-------------~8-r( ~'\~·-----
I' 'yR/
1
CIRCUITi- i IH
BREAKER' "' I I'
c r~

[·STOP lr r~
I
1

svnTCH !:"1 KI·START

c+L
RELAY
161·1~~

I K2-RUN

I LJ~EL:~

,J,I
F US£ •1

NOTE I"
ECU PIN 8 CONTROlS [NGitl[ SPEED FOR AC Llll[ POWER IF.EOUU<CI
60Hz Pill 8 CONN[Cl[D 10 181"6 r
lOH1 PIN 8 CONNECTED TO 181·8
1" fiR[ SUPPRtSSION SYSTEM COilN[Cli0/1"
RE~OV[ JUMPER

Q INSTRUMEHl PAII[l COllECTOR PillS

HOUR
METER
- IllS! Ri.IM[ IH PANEl COit(CT IO!tS

·lwiWESI#RBEKE-
1EnalntiB & Generators
47
 REMOTE START/STOP PANEL
WIRING DIAGRAM #56321

Q
.....
0::
.....
....
RELEASE
STARTER Q
......
LIGHT ""
co
...

STOP
SWITCH #14 RED START
SWITCH
-··-··-··- ··-··-··-··-··-··-··-··-··-··-··-··-··-··-··-··--·--:I

EXTENSION HARNESS .
15FT, 8 PIN; PN#36236
30 FT, 8 PIN, PN#36235
 WATER:HEAlER,;(QV\(N_ERS OPTION))
INSTALLATION .INSTRUCTIONS
INSTALLATION The pressure cap on the engine's manifold should be
installed a&.r the engine's cooling system is filled with
This engine is equipped with connections for the plumbing of
engine coolant to transfer heat to an on-board water heater. coolant Finish filling the cooling system from the remote
tank after the system is filled and is free of air and exhibits'
The water heater should be mounted in a convenient location
good coolant circulation. During engine operation, checking
either in a high or low position in relation to th~ engine, so
the engine's coolant should be done at the remote tank and
that the connecting hoses from the heater to the engine can
not at the engine manifold cap. The hose connection from the
run in a reasonably direct line without any loops which might
heater to the remote expansion tank should be routed and
trap air.
supported so it rises continuously from the heater to the tank,
enabling any air in the system to rise up to the tank and out
of the system.

WATER HEATER
BELOW ENGINE

Hoses should rise continuously from their low point at the NOTE: An air bleed petcock is located on the engine's
healer to the engine so that air will rise naturally from the heat exchanger. Open this petcock when filling the engine's
heater to the engine. If trapped air is able to rise to the ~r. coolant system to allow air in the exchanger to escape.
then an air bleed petcock must be installed at the higher fit- Close tightly after all the air is removed.
ting on the heater for bleeding air while filling the system.
NOTE: If arry portion of the heating circuit rises above the
engine's own pressure cap, then a pressurized (aluminum)
remote expansion tank (Kit#024177) must be installed in the
circuit to become the highest point. Tee the remote expansion
tank into the heater circuit, choosing the higher ofthe two
connections for the return. Tee at the heater, and plumb a
single line up to the tank's location and the other back to the
engine's return. Install the remote expansion tank in a conve-
nient location so the coolant level can easily be checked. The
remote expansion tank will now serve as a check and system
fill point. The plastic coolant recovery tank is not used when
the remote expansion tank kit is insflllkd, since this tank
serves the same function. Remove and store the plastic
recovery tank if it has been already installed.

1-w'IWESIERBEKE
f t:ngjnes & Gen!!rators
49
 POWER TAKE OFF SYSTEMS
POWER TAKE OFF ADAPTER.
OPTIONAL
A power take off adapter can be attached to the generator
backend. This adapter allows access to the full power of the
engine for a variety of hydraulic and electrical accessories.
The 8.0 and 10.0 Kw generators produce 18hp at 1800 rpm
(16hp (l.t 1500 rpm):
The 11.5Kw produces 15hp at 1800 rpm (12hp at 1500 rpm)
POWER TAKE OFF KITS
The 15.0Kw generator produces 25hp at 1800 rpm (22hp at KIT #034785 FOR 12 STUO BT UNITS
1500rpm. KIT #037134 FOR 6 STUD BT UNITS
This horsepower can be utilized either for generator AC
Contact your WESTERBEKE DEALER for additional
output or to operate the power takeoff.
__ (§JWVER infomwtion.

STUDS AND. HARDWARE

HOLD ACCESSORY TO THE
'ADAPTER

~~~
ADAP~·
BOLTS FASTEN
TO GENERATOR HOUSING

fWJWESTERBEKE
._..,Engines & Generators
50
 RAW WATER DISCHARGE HOSE
[When a siphon break is not required)

RAW WATER TO EXHAUST

DISCHARGE HOSE
[OWNER INSTALLED}
RAISE THE HOSE ABOVE THE
LEVEL OF THE MANIFOLD IN
A GENTLE LOOP DOWN ro,
THE EXHAUST ELBOW

WIRE TIE TO HOSE

HEAT EXCHANGER

WHEN ASYPHON BREAK IS NOT REQUIRED

WESTERBEKE recommends that the hose
(installi!r supplied) discharging raw water from
the heat exchanger to the water injected exhaust
elbow be looped above and down to the inlet
fitting on· the elbow. The hose can be secured by
a plastic ·wire tie as Illustrated.

51
 ENGINE TORQUE SPECIFICATIONS
MAJOR BOLTS AND NUTS
TORQUE
Width Clamp
BoH or Nut Diameter Pitch across flats length kg·m ft -lb N-m
Alternator Bracket 3.8-5.3 27·38 36.6
Back Plate 3.3-4.8 24-35 32.5
Connecting Rod Cap M9 1.0 14 3.55±0.25 27±72 34.8±2.5
Coolant Pump 1.6±2.4 12-17 17.2
Coolant Pump Pulley 1.6±2.4 12·17 17.2
Coolant Temperature Sender 1.2±1.8 9-13 12.2
Coolant Temperature Switch 1.2±1.8 9-13 12.2
Crankshaft Pulley Nut M18 1.5 27 17.5±2.5 127±18 172±25
Cylinder Head Bon M10 1.25 14 87 9±0.5 65 ± 4 88± 5
Delivery Valve Holder --- 19 4.5±0.5 32±54 44±5
Engine Mounts 3.2±4.7 23·34 31.1
Exhaust Manifold 1.6±2.4 12·17 7.2
Rywheel Bolt M12 1.25 19 29 13.5±0.5 98±4 132±5
Fuel Filter Assembly 4.6±6.8 33-49 44.7
Fuel Injection Nozzle Holder M20 1.5 21 5.5±0.5 40±44 54±5
Fuel Injection Pipe Nut M12 1.5 3±0.5 22±4 29±5
Fuel Leak-Off Pipe Nut M12 1.5 18 2.75±0.25 20± 2 27±2.5
Fuel Solenoid Locknut 4.0±5.0 28.9±36.2 39.18
Glow Plug M10 1.25 12 60 1.75±0.25 12±72 17.2±2.5
Glow Plug Connection Plate M4 0.7 8 0.125:!:0.025 0.9±0.2 1.2±0.2
Intake Manifold 1.6±2.4 12-17 16.2
Main Bearing Cap Bolt M10 1.25 17 81 5.25:!: 0.25 38:!:2 51.5±2.5
Oil Filter M20 1.5 1.2±0.1 8.7± 0.7 12±1
Oil Pan Bolt M8 1.25 12 25 2.8±0.3. 20.3±2.2 27±5.3
Oil Pan· Drain Piug M14 1.5 22 10 40±5 ' 29±4 39±5
Oil Pressure Sender 1.2±1.8 9·13 12.2
Oil Pressure Switch PT1/8 26 11 1 ±0.2 7.2±1.4 10:±:2
Pressure Refief Valve M22 1.5 22 33 50±5 36:±:4 49:±:5
Rear Plate Bolt (stamping) M8 1.25 12 16 1.15:±:0.15 8.3±1.1 11.3:±:1.5
Rear Plate Bolt {standard) M12 1.25 17 28 6.5±1 47±7 64±10
Retaining Nut for Delivery M16 0.75 19 3.75±0.25 27±2 37±2.5
Valve Holder Body
Rocker Cover Bolt M8 1.25 12 40 1.15±0.15 8.3±1.1 11.3±1.5
Rocker Shaft Bracket Bolt M8 1.25 12 581 1.5:!:0.5 11 ±4 14.7:±:5
Sliding Sleeve Shaft M10 1.25 14 29.5 3.6±0.6 26±4 35±6
Special Nut for M12 1.0 17 2±0.5 14±4 20±5
Torque Spring Set
Starter BTerminal M8 1.2~ 12 1.1 ::t0.1 80±7 10.8±1
Stop Solenoid M30 1.5 36 4.5±0.5 32±5 4. 44±5
.Thermostat Housing 0.3-0.45 2-3 2.7
Thermoswitch M16 1.5 17 31.5 2.3±0.4 16.6 ± 3 22.6 ± 4

52
 SUGGESTED SPARE PARTS
WESTERBEKE MARINE DIESEL GENERATORS
CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION

WATER PUMP
IMPELLER KIT

HARDWARE KIT
DRIVE BELTS

. .
WESTERBEKE RECOMMENDS CARR.YING ENOUGH SPARE
ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE (5 OTS.)
AND A GALLON OF PREMIXED COOLANT.

SPARE PARTS KITS

WES1ERBEKE also offers two Spare Parts Kits,
each packaged in a rugged hinged toolbox. B Kit
Kit "A" includes the basic spares. Inipeller Kit
Kit "B" is for more extensive off-shore cruising. Water Pump Repair Kit
AKit Thermostat Kit
Impeller Kit Zinc Anodes
Heat Exchanger Gasket Complete Gasket Kit
Fuel Filter with Gasket Heat Exchanger Gasket
Oil Filter Injector
Drive Belt Fuel Filter with Gaskc1
Zinc Anodes Oil Filter
Drive Belt

53
 WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE: WWW. WESTERBEKE.COM

1237-1212016