INSTALLATION MANUAL
Contents
1. 18 Coolant A A A _ Remote Radiators e a READ 19 19 Optional Remote Start Stop Pl ooa rrr 19 AC amp DC Wiring Grounding the Generator Generator Frequency Changing the Generator Frequency PENES Changing the 20 Engine Speed Adjustment 2 20 Battery Selection eren ead Mounting the Battery 0 Battery Cables da Battery Maintenance 21 installation Prestart Initial Start Up Check USAS Prestari Check List ESA Initial Start Up Check List 22 Daily amp 50 Hour Maintenance Check List 23 Accessories LS Aue 1 eee eee am Pt oy XRT Hydraulic Pump Rescue Tool Power System SEEM UIS SIE T EN GenRemote Remote Star Stop Selon 24 Fuel Filter Water Wicca mari Power Take Off Power Take Off Assembly 25 Power Take Off Adapter Kit 25 Power Take Off Remote Oil Filter Heav2. 0 11 ke icm To check the exhaust back pressure tap into the exhaust pipe near thc exhaust manifold at a section free of bends and install a metal tube Then connect either a psi gauge or a water column to the metal tube see illustrations A water column can be made by taping one end of a clear plastic tube along a yardstick and fitting the other end of the tube with a 1 4 NPT National Pipe Thread pipe fitting The back pressure should not exceed 27 in 69 cm of water in the water column CARBON MONOXIDE The best protection against carbon monoxide porsoning i5 daily inspection of the complete exhaust system Check for leaks around manifolds gaskets and welds Make sure exhaust lines are not heating surrounding areas excessively lf excessive heat is present correct the situation immediately If vou notice a change in the sound or appearance of the exhaust system shut down the generator immediately and have the svstem inspected and repaired at once by a Qualified mechanic WARNING Carbon Monoxide Gas is Deadly Carbon monoxide is a dangerous gas that can cause and is potentially lethal Some af the symptoms or signs of carbon monoxide inhalation or poi soning o Bii Nausea rame Weakness and Sleepiness Coherently If you experience any of the above symptoms get out NOTE Carbon Monoxide warning decal is included in the WESTERBEKE documentation package for your generator
3. INSTALLATION MANUAL DIESEL GENERATORS FOR MOBILE APPLICATIONS dh WARNING air oik A tat haus RN EE symptoms persist seek medical attention Shii down the unit and do not restart INSTALLATION MANUAL DIESEL GENERATORS FOR MOBILE APPLICATIONS WESTERBEXE CORPORATION AVON INDUSTRIAL PARK AVON MA 02322 TEL S08 588 7700 508 559 9323 WERSITE WWW WESTERBEXE SAFETY INSTRUCTIONS Read these safety instructions carefully Most accidents are neni Ey Jum A E GENERAL Use eve protection and suitable protective clothing when installing and servicing the generator Make certain that the installation of the generator is performed by qualified personnel WARNING improper installation maintenance or injury death or property damage Make sure all clectrical installations are performed by a qualified licensed electrician Follow all state and local Use extreme caution when working on electrical components WARNING High voltages can cause severe per enclosures and covers in place Use insulated mats whenever working on electrical shoes when handling electrical equipment Remove wristwatch rings and any other jewelry when working on electrical equipment These articles can short out electrical contacts and cause a shock or burns Always use a double th
4. compartment and will protect against the possibility of severe burns due to accidental contact with the piping To ensure that generator vibration and thermal expansion will not damage the exhaust system install a flexible section as close to the engine as possible This section should be no less than 12 in 31 long overall and threaded at cach end It should be installed with no bends covered with insulating material and properly supported by brackets to prevent sag ging bending and strain on the manifold flange The exhaust system is the greatest source of noise in most generator installations Exhaust gas intermittently expelled from the engine s cylinders under high pressure reverberates m the exhaust system producing noise that drsseminates from the exhaust pipe at the muffler s surface and out of the tailpipe A well designed exhaust system will provide efficient noise a enuation and will minimize the engine power loss thai is inherent in exhaust systems When designing vour exhaust system and choosing a muffler consider the following 1 The amount of noise reduction desired 4 The amount of back pressure that is acceptable manifold and expansion chamber types A muffler s shape can be either cylindrical or oval The size of a muffler is defined by both the muffler s volume 3 to 5 times the engine s cubic inch capacity and its cross sectional area The muffler s diameter for a cylindrical muffler
5. Display this decal in a visible location in the vehicle s living AX WARNING is extremely important that a carbon FUEL SYSTEM It is very important that the design construction and installation of all fuel system components the highest possible standards to msure that the fuel delivered to the engine will be clean free of water and air and at the correct Plan the fuel system so that adequate fuel is delivered during all angles of vehicle operation Make sure there is easy access lo the fuel filler and that all of the fuel system components are accessible for servicing WARNING The improper installation of fuel sys sources of ignition or fire in the installation area or near the fuel tank fuel system components or other potential sources of spilled fuel or fuel vapors Observe all af the safety precautions described in the SAFETY sacon af Mo ameni Use No 2 diese fuel with a minimum cetane rating of 45 Use a winterized fuel blend when operating the generator in temperatures below freezing Use only clean diesel fuel and keep it clean The clearance of the fuel injection pump s components is critical din finely finished parts Purchase well known brands of fuel To keep the fuel clean and pure install and regularly service fuel filter water separator between the fuel tank and the generator s engine FUEL TANKS Fuel tanks may be made of fiberglass aluminum or steel If made of fibergla
6. FOR 10 DROP IN VOLTAGE Length of Conductor trom Source of Current to Device and Back to Source Feel 20 25 40 so 60 70 o 120 120 140 150 160 MM Ev RM CH 8 16 14 12 12 12 12 10 10 10 10 10 CSS P3 ra r Son geezssseusaso eec 2 14 12 12 12 10 10 10 0 8 E 8 8 6 6 6 6 6 6 4 6 4 4 4 ES ooorr mco ooorrm d poco Em ooommagcoo R3 RJ PRO n en ds ch on 5 loo ee dO o II 24 Volts 10 Drop Wire Sizes gauge Based on Minimum i 18 18 16 16 16 AEREA 4 P3 PO PO de On OD 5 de de CO Ch CO a II ISO PONO de Ch f Ch ES FS 18 16 14 14 12 12 10 10 8 El 8 8 AI Ch 00 cO MMMM d c on 00 00 MALELE E METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES 140 175 212 0 5 10 15 20 2 20 35 40 60 80 100
7. documentation package is attached to the generators lifting eve Before accepting shipment of the generator from the trans portation company the crate should be opened and the con tents inspected for damage If there is either visible or concealed damage vou should require the delivery agent to write Received in damaged condition on the delivery receipt Also compare the contents of the shipment against the packing list and make sure thal any discrepancies are properly noted This is vour protection against loss or dam ETE EHE ee ee carrier not WESTERBEKE Cot NOTE SE Mad ui ever each generator is thoroughly tested with oil in its engine This testing among other things provides all internal parts wah a coating of This oil acts as a preservative providing reliable protection against corrosion for at least one year if the generator is properly stored GENERATOR LOCATION There are three main locations for a vehicle s generator 1 In a compartment at the side of the vehicle 2 In a compartment transversing the vehicle 3 In a dunnage pan on the vehicle s rooftop The most important factors in choosing a generator compart ment location are 1 The size of the eenerator 2 The size of the access opening 3 The strength of the structural support for the senerator 4 The air intake and discharge capability 5 Protection from outside elements Choose a location for the generator or generator compa
8. fatigue Manv of the precedinp safety tips and warnines are repeated in your Operators Manual along with other cautions and notes to highlight information Read vour manual carefully maintain your equipment and follow all safety Read the following NFPA and ANSI publications for safcty codes and standards Follow their recommendations when installing vour generator NFPA 70 National Electric Code NFPA 79 Electrical Standard for Industrial Machinery Order From National Fire Protection Association H Tracy Drive Avon Industrial Park Avon MA 02322 ANSILAHS Z NFPA 501C Standard for Recreational Vehicles ANSURVIA EGS 1 1993 American Nanonal Standard Order From Recreation Vehicle Industry Association 1896 Preston White Drive Reston VA 2019 wr WESTERBEKE Engines amp Generators TABLE OF CONTENTS introduction A General 2 Generator Selection and Planning the Installation 2 One Sude Servicing BIENES Load Requirements rea Air Conditioner Loads ess 2 Angle of Operation TER 2 DO cr ii Installation Codes and Safety a 3 Notes Cautions on Warnings 3 ni of AS 4 4 Side TE E rre Transverse Compartment Installation 4 Dunnage Pan installati
9. good ventilation and giving casy access for service and maintenance The slidme drawer mount is more appropriate for commercial vehicles where minimal noise reduction may be acceptable and maximum nosse reduction is not as essential as would be for a recreational vehicle a typical sliding drawer mount the generators radiator faces the compartment door and the exhaust system slides in and out of the vehicle along with the eenerator means mast be provided to hold the drawer in a fixed position both in and out its compartment With the generator in the com partment and the compartment door s closed the muffler and tailpipe project out through the door then bend down ward These exhaust system components require adequate AX WARNING Contacting hot exhaust system com tailpipe must be covered with a metal screen attached Sliding drawer mounts generally custom designed and built Rollers may be used with steel channels boxes and angies for the structural members The sliding drawer must bc strong enough to support the entire weight of the genera tor and its related systems when extended outside of the vehicle Because of the weight factor sliding drawer installa tions are usually preferred for smaller generators particularly those generators that will be removed from the vehicle for VENTILATION amp NOISE REDUCTION GENERAL The ventilation system should be designed so it will always provide
10. pipi when the generator i sds Gas ease canes Although diesel engine exhaust gases not as toxic as SAFETY INSTRUCTIONS gas 15 present in diesel exhaust fumes Some of the symp toms or signs of carbon monoxide inhalation or poisoning are Vomiting Dizziness Throbbing in temples Muscular twitching Intense headache Weakness and sleepiness WARNING Do nat touch any moving part on your personal injury or death E Do not service the generator while it is running If a situa arises in which it is absolutely necessary to make operating adjustments while the generator is running use extreme care to avoid touching moving parts and hot exhaust system components Do not wear loose clothing or jewelry when servicing equipment tie back long hair avoid wearing loose jack ets shirts sleeves nngs necklaces or bracelets that could bc caught in moving parts Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective places at al times B Do not check fluid levels or the drive belts tension while the generator is operating Never operate a generator without its muffler installed Do not run a generator with the air intake silencer E Do not run a generator for long period with its enclo sures open WARNING Do not work on machinery when you are mentally or physically incapacitated by
11. play in the cables to prevent stress at the battery terminals Install a battery disconnect switch in the B cable so the bal tery can be disconnected when the generator 15 serviced Battery Maintenance gt The following preventive maintenance will increase the life of your battery sure to observe all safety precautions 1 Keep the battery charged Recharge as soon as possible after use Do not allow a discharged battery to sit for a long period of time Avoid overchargino 2 Maintain the level of the electrolyte Add distilled water or drinking water to the level of the split ring Always add water before recharging Never let ihe electrolyte level drop as low as the top of the plates 3 Keep the top of the battery clean and dry 4 Make certain the cable connections are clean and tight 5 Keep the battery terminals clean Coat the terminals with a dielectric grease or petroleum jellv to reduce corrosion and oxidation 6 Make sure the battery cables are properly identified as positive or negative before making a connection Always connect the ground cable last INSTALLATION PRESTART amp INITIAL START UP CHECK LISTS Review the following checklists after your generator has been installed Make sure that all applicable state and local codes have been followed WARNING improper installation maintenance or isthe compartment lined with metal or with mater
12. service can be affected by the eenerator particular location in the compartment or by whatever other uses the transverse compartment may serve such as storape In dunnage pan installation on a vehicle s rooftop the generator is typically mounted in a well and protected by a ventilated sheet metal enclosure The open location of this type of installation provides more options for the design of the ventilation and exhaust systems COMPARTMENT DESIGN The generator compartment space must be large enough to contain the generator and meet its minimum requirements for ventilation clearances and exhaust system clearances from the compartment walls ceiling refer to the VENTILA TION and EXHAUST SYSTEM secuons When planning these clearances include acoustic insulation or fire ner materials that will be installed There should also be adequate space on all sides of the pen erator for servicing and maintenance Allow enough space to access the following generator components 1 Control panel 2 Air intake silencer fiiter 3 Oil dipstick 4 Oil fill 5 Oil filter 6 Fuel inlet and outlet connections 7 Fuel water separator fuel filter owner supplied 8 Fuel injectors 9 Manifold pressure cap 10 Coolant recovery tank 11 Coolant drain 12 Batterv s 13 Generator mounting bolts for retishtening It is very important to provide a structurally sound support framework for the generator due to its w
13. should be at least four tumes the diameter of its inlet pipe and larger if possible Locate the muffler closer to the exhaust manifold than to the tailpipe outlet Contact your WESTERBEKE dealer for mformation on the type of muffler that would be appropriate for your installation Connect the tailpipe to the muffler outlet with an automotive U Bolt muffler clamp If necessary install an automo tive tailpipe hanger for additional support and use these hangers every 2 to 3 feet 61 92 cm for long tailpipe runs Support the tailpipe or near the vehicle s perimeter WARNING Use only rigid steel tubing for the tailpipe Do not use flexible tailpipe because it may fatique and then leak ar break due to vibration and or shock The tailpipe must terminate at least 1 25 mm beyond the vehicle s perimeter If the tailpipe is to be on the same side of the vehicle as the generator s cooling air intake then locate the tailpipe aft of the air intake to prevent exhaust gasses from entering the cooling air system and lowering the gener ator s efficiency A vertical tailpipe must have a proper WARNING Do not terminate the tailpipe under Close ail openings above or to the rear of the tailpipe when the generator is running The tailpipe must terminate at least 3 fi 92 cm away from the vehicle s make certam it is large enough to prevent excessive pressure
14. to 3 parts 4 All oil compatibility gt Radiator cooling with a fan The GenRemote system provides remote starting and stop put and the engine s functions This monito 1 DC voltage 2 pressure 4 5 AC current L 1 6 7 AC current L 2 Line frequency hertz amp Engine hours The GenRemote system consists of a Power Logic Module a Display Panel and a six conductor shielded Display Cable The Power Logic Module ts powered directly from the erator s starting battery and can be mounted in the cenera tor 5 compartment or up to 10 ft m away The Display Cable links the Power Logic Module to the Display Panel The Cable is easily installed and can be up to 500 ft 152 m long An optional programmable automatic SIDER shutdown feature is also available An Operators Manual is provided GenRemote s circuitry 15 isolated from your generator 5 elec trical system and will not interfere with your generator s normal operation It is designed to interface with the existing sensors and display 15 easily calibrated to match the readings of your generator s gauges service a good quality visual tvpe fuel filter water separator between the fuel tank and the generators engine This is nec essary to prevent any contaminants or water that may be in the fuel from reaching the fuel lift pump and causing damag io the fuel campanis Sack disais rantab
15. vent should be located so that its discharpe route cannot allow water to enter through to the fuel tank Mosture must not be allowed to accumulate in the vent 5 Ime Kec puso us vie vid 5 propulsion engine use the same kind of fuel then they could both use the same fuel tank If this is the case the vehicle manufacturer s installa following factors There musti be adequate fuel tank capacity for both the generator s engine and the vehicle s propulsion engine refer to the WESTERBEKE data sheet for your B The fuel returning to the tank will be warm To obtam maximum engine efficiency fuel delivered to the injectors must be cooled therefore the fuel tank vol Nate fan existing fuel tank cannot be tapped into then the The fuel supply line to the generator should come from its own pick up in the fuel tank and not lead off the supply Ime to the vehicle s propulsion engine unless necessary A tee can cause erratic generator operation due to fuel starvation The generator s fuel pump may not have the capacity to over come the draw of the propulsion engine s fuel pump This is also true of the return lines Pressure from one engine enter the tank a reasonable distance from the supply lines propulsion engine s fuel pickup This is to ensure that the be operated if the generator runs out of fuel FUEL SYSTEM The fucl system should be designed and installed in such a way as to ensure that the engine mounted fuel lif
16. ARNING Check the capacity of the sling hoist WARNING Stings must NOT be so short as to place stress an the lifting eyes A sling must be long TONES APA UNDC UN SE exceed 10 see illustra The general rule in moving a generator is to ensure that all equipment used is adequately strong and firmly fixed in place Move the generator a little at a time and make sure it is firmly supported Eliminate the possibility of accidents by avoiding haste Do not lifi by the crankshaft pulley If it becomes necessary to hoist the generator front end pul ley dnve belt end upwards or rear end flywheel generator end upwards the attachment of lifting slings must be done carefully to avoid damaging the parts on which the weight of the slines may bear NOTE Rigging work is best done by someone experienced and competen in handling heavy machinery MOUNTING THE GENERATOR Mount the generator to the compartment floor with four sets of 1 2 dia bolts nuts and washers see illustrations Gencrators mounted on drip pans have a predrilled hole through each of the four isolator brackets for mounting the generator to the compartment floor Generators mounted on rails have either three or four depending on the model predniled holes in the bottom of each rail for mounting to the compartment floor use two holes in cach rail If the penera tor is being mounted with the bolts coming up through the bottom of the compartment floor t
17. D TEFLON for sealing pipe plugs and filings that connect coolant passages Do mat use tape sealants plugs that penetrate the water jacket should be sealed with PERMATEX 2 or HIGH TACK When asser DIT 2 the coat the threads with LOCTITE Blue compounds and thread locking adhesives such 25 LOCTITE protect threaded components yet allows them to came apart when necessary LOCTITE offers levels af locking according to the job LITHIUM based grease is waterproo ideal for water pump bearings and stufi components when assem Gling Always WIRE SIZING CONDUCTOR SIZES FOR 3 DROP IN VOLTAGE Length of Conductor trom Source of Current lo Device and Back to Source Feel 5 20 25 40 so e 70 s soo 110 120 130 140 150 160 170 XV PR TO SPAN TURIN ee 10 B Area 6 4 2 1 2 0 a0 A D 55988e evsocf BS S8o nvanel So sao EEEN 55 Circuil Current in AMPS 5 10 15 25 50 60 70 80 90 100 PO PO RO de ds o os 2 DO e ds ds OS OD 2 558889 wwuaaoa do FIND di de Ch en mn 2 oo2o sesacoosah 4 E u 55885 SESEO nnana SEER s li ES SSSSeosnnaam names 8 BIS SS SOON Egi POR Ch e CONDUCTOR SIZES
18. Manual or Service Manual or contact your When converting from 60 Hz to 50 Hz it is necessary to replace the circuit breaker and reconfigure the AC terminal block wiring HIGH VOLTAGE WARNIME LASEL Jen Model shown When changing the voltage from 120V to 120V 240V the circuit breaker wiring and the AC terminal block wiring must For component testing and resistance values refer to the Service Manual After the generator has been placed in operation there may be adjustments required for engine speed hertz during the engine s break in period first 50 hours or after this NOTE The engine speed on all models has been set at the factory and in most cases a speed adjustment should not be necessary If an engine speed adjustment is necessary a no load voltage adjustment may also be required These adjustments are con sidered normal mamtenance For engine speed and no load voltage adjustments see your Operators Manual necessary safeguards to protect yourself your person proper safety precautions Battery Selection Choose a starting battery and cables that will supply enough cranking power to start your generator under its various oper ating conditions A starting battery must be a type that allows high rate of discharge Westerbeke recommends selecting a starting battery having Cold Cranking Amps capacity that is at least three times the DC cranking current engine co
19. ade eight strongest The marks correspond to two marks less than the actual grada Le a grade seven bolt will display five embossed marks Metric class numbers identity bolts by their strength with 10 9 the NOTES 1 Use the torgue values listed below when specific torque values are not available 2 These torques are based on clean dry threads Reduce torque by 10 when engine oil is used 3 cH MESURE Or On We cari ng capscrews into aluminum 10 14 sii 17 23 505 85 115 120 163 19 26 MOTE Lo Heli Am ies mucus 795 14 18 manst 166 225 225 305 53050 811 1100 1103 1496 789 1079 1154 1555 1571 2130 SEALANTS amp LUBRICANTS Dii based 2 and its HIGH TACK equivalent are excellent purpose sealers They are effective in just about joint in contact with coolant raw water od or fuel light of DIL or LIQUID TEFLON can be used on rubber gaskets and O rings LOCTITE hydraulic red sealant should be used on adapter hoses and the oil filter assembly Coat both surfaces of the pan gasket with high temp RED SILICONE sealer High copper ADHESIVE SPRAYS are useful for holding Gaskets in position dur ing assembly Specialized gasket sealers such HYLOMAR work well in applications requir copper cylinder hesd gaskets as resists fuel od and water Use LIQUI
20. an mounted to the flywheel At the same time heated air that is around the generator end and the engine is drawn through a large fan at the radiator end pushed out through the radiator then discharped Keep in mind that hot air rises so cool fresh air Should be directed to the lower arca of the generator compartme the heated air should be removed from the bern of ffe compartment The best location for the cooling air intake 15 the side of the vehicle as high as possible to keep out road dirt dust and road splash The intake may also be located m the vehicle s ceiling or roof Do not locate the intake al the rear of the vehicle because the air pressure is lower at the rear of the vehicle when the vehicle 15 in motion Avoid locating the intake where exhaust cases might be drawn into the ventila tion system For side compartment or transverse compartment applica tions the cooling air can be discharged from the generators radiator into a plenum installed with gasket next to the radiator then directed through ductwork out of the vehicle Fer a side compariment the ductwork can go down through the vehicle s chassis for a transverse compartment the duct work can go either out through the side of the vehicle or up through the vehicle s roof Make sure that the discharged air is not restricted in any way AX WARNING Never use discharged cooling air for When designing your ventilation system refer to the follow ing
21. di below sud sil of generator This to keep the exhaust discharge away from the generator s cooling air intake For vertical from the generator s cooling air intake and where exhaust noise will not affect the operator of the vehicle Direct the exhaust outlet away from the operator s sight line A vertical exhaust system musi be flexibly attached to the engine s manifold and properly supported The tailpipe must be pro tected against water entry by a raincap Vertical exhaust sys tems are customary for dunnage rooftop generator EXHAUST SYSTEM Prowide adequate clearance for the exhaust pipe where it passes through the compartment floor to prevent damage from vibration and chafing To avoid a fire hazard make a raised rim around the exhaust pipe outlet in the compartment floor so fuel cannot onto the exhaust system The exhaust system must be at least 3 in 76 mm away from any combustible materials or rubber parts It should not touch or be close to the fuel tank fuel system lubrication system electrical wiring starter motor alternator or battery Suitable insulating andor shielding should be used where the proxim ity of these components to the fuel system is unavoidable INSULATION Exposed exhaust piping especially a generator compart ment should be covered with non asbestos heat resistant lag ging tape The lagging will reduce ambient heat in the
22. ectrical installation standards and safety codes are listed in the SAFETY INSTRUCTIONS section of this manual Make sure that all electrical connections tests and adjustments are performed by qualified personnel N TE WESTERBEKE manufactures generators using com ponents that meet very rigid safety standards If a component on the generator is replaced with one that is non compliant then safety is jeopardized Make certain that any component you replace is a genuine WESTERBEKE replacement part OPTIONAL REMOTE START STOP PANEL An optional remote Start Stop panel is available containing three switches and a run indicator light green see ACCES SORIES This panel must be wired into the terminal strip in the main control panel on the generator and mounted m a remote location Refer to the WIRE SIZING page in this manual when select ing the wire size to be used between the generator control panel and the remote StaruStop panel See your WESTER Operators Manual for the remote panel wiring schematic Various AC output voltages and frequencies are available for your generator For these specifications and for information about AC wiring connections and adjustments refer to your NOTE Al wiring should be properly secured with clamps or plastic ties spaced at intervals close enough to prevent chafing from vibration Check to make sure all the harness connections are tight and that they are made to the appro priate termi
23. ed personnel Follow state and local electrical codes All electrical installations should be done by a qualified licensed eiectrician A o Product software technical data parts lists manuals brochures catalogs provided from sources other than WESTERBEKE are not within WESTERBEKE s control WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE MAKES NO WAR RANTIES OR REPRESENTATIONS WITH RESPECT THERETO INCLUDING ACCURACY TIMELINESS OR COMPLETENESS THEREOF AND WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY INCURRED IN CONNECTION WITH OR ARISING OUT OF THE FURNISHING OR USE OF SUCH SOFTWARE should mind the t time whether from WESTERBEKE or other suppliers good esses le imperios pmen ekanda NOTES CAUTIONS AND WARNINGS As this manual takes you through the installation procedures for your generator critical information will be c highlighted by NOTES CAUTIONS and WARNINGS An explanation NOTE A procedure essential to note CAUTION Procedures which if not strictly observed can result in the damage or destruction of WARNING Procedures which if not properly fol lowed can result in personal injury or loss of life Thecuimitil Si mounted and properly crated Accessory equipment is shipped in a separate small box usually packed within the engine s crate WESTERBEKE s
24. eight and the weight of its compartment or well in the case of a dunnage pan installation The best location is between the main frame members of the vehicle but this location may not be possible The most common location for generator compartment 15 the side of the vehicle but this location can be difficult to reinforce if reinforcement 15 necessarv At this location the inside edge of the compartment can be attached to the vehi cle s frame and the outside of the compartment attached to the vehicle s body ee below the vehicles main frame then the compartim Provide an opening mto the compartment large enough to permit the generator to be removed This opening can be at Ihe side of the compartment or at the bottom of the Jesign the compartment doors for casy maintenance service sid removal of the generator Measure the generator compartment carefully to provide the proper clearances Make certain that these clearances permit the required intake of cool air and discharge of heated air when the generator is running and provide for convection cooling with heated air escaping the compartment when the generator is shut down NOTE Since an increase in generator compartment tempera lure causes a reduction in the intake of cooling air and thus a drop in engine output ventilation inside the compartment must be ample A minimum 1 25 mm clearance should be allowed between the g
25. enerator and a cooling air intake opening at the generator end Allow for restricted amflow that might be caused by grilles or ductwork Allow a minimum 3 76mm clearance between the penera tor and the walls or door of the compartment and a 6 152 mm minimum clearance to the compartment ceiling These same clearances apply to the penerator s exhaust system com ponents Mcasure these clearances from any acoustic insula tion or fire barrier materials that may be used If the compart ment 15 large allow additional space at the generator end The clearances given above are minimum clearances and exhaust systems are all factors that will influence the actual clearances that will be appropriate for your generator COMPARTMENT CONSTRUCTION Use steel angles channels and boxes for the compartment s structural members with sheet metal for the bulkheads ceil ing and compartment floor Make sure the compartment is strong enough to withstand force and stress from any direc tion These standards appiv to all of the generator s possible locations Bulkheads Line the generator compariment or separate the generator from the work area or living quarters with a frre barrier of galvanized steel 22 minimum or other noncom bustible material of equal strength and quality Install lighting on the compartment ceiling or bulkheads Seal the compart ment 50 it 15 vapor tight to prevent the entry of noxious fumes in
26. hen cach bolt s thread musi not extend up more than 1 2 bevond the drip pan or rail The use of fender washers will provide a more secure mounting especiallv when the compartment floor is made of wood Tighten all the bolts securely CAUTION The rubber vibration isolators that are supplied with WESTERBEKE generators are designed to type of A coolant recovery tank kit is supplied with each WESTER generator The purpose of this recovery tank is to allow for engine coolant expansion and contraction during engine operation without the loss of coolant and without introducing air into the cooling system The coolant recovery tank should be installed at or above the engine manifold level in a convement location where the coolant can be easily monitored and added A wire mounting bracket is supplied with each along with a 30 inch length of clear plastic hose and clamps to connect the hose between the engine s manifold fitting and the hose spud on the base of the recovery tank On Models 10 0 BTDR 11 0 BTDR and 12 5 BTDAR only mounting holes for the coolant recovery tank are provided on the service side of the eenerator sec COOLANT RECOVERY TANK under COOLING SYSTEM MOUNTING THE GENERATOR Mounting the generator on a sliding drawer or a roll out tray is an alternative to mounting the generator in a fixed location The sliding drawer allows the generator to be moved in or out of the vehicle providing
27. ial of comparable strength and fire resistance Are its joints and edges sealed vapor hent Is the generator protected from the weather road din and road splash Is access to the generator adequate for easv routine maintenance service and removal of the generator Are holes into Irving spaces sealed to prevent entry of exhaust gases Is the air inlet protected against the entry of road dirt waler and road splash Are fuel lines and electrical wiring insulated from each other and protected from chafing Are all connections and hose clamps tight EF EF 5 C Is all electrical wiring correctly connected and properly bed down and or supported L Are the exhaust system s components and fittings tight and secure Before starting the generator complete the following check list Also refer to PREPARATIONS FOR INITIAL START UP in your Operators Manual Is there fuel in the tank and are the fuel valves open Check the piping for leaks Prime the fuel system Has lube oil been added to the engine Check for leaks Has the proper coolant mix been added Vent air out of the system Check for leaks Check the battery electrolyte level Are the battery cables properly connected Check for loose bolts and nuts Are the AC and load connection wires securely con nected to the circuit breaker Li Ll L O 0 Switch is in the RUN up position Note This switch is O Allow the generator to come up t
28. l be void The oil filter can be relocated to more corvement location using a WESTERBEKE Remote Oil Filter Kit see ACCESSORIES This kit can be installed by the owner operator A coolant recovery tank kit is supplied with each WESTER generator The purpose of this recovery tank is to allow for engine coolant expansion and contraction during engine operation without the loss of coolant and without introducing air into the cooling svsiem The coolant recovery tank should be installed at a level equal lo or above the top of the radiator but this may not be possi ble for some installations It should always be installed in location where can be casily monitored On Models 10 0 BTDR 11 0 BTDR and 125 BTDAR only there are mount ing holes for the coolant recovery tank located in the radiator support and the radiator support strap on the service side of the generator A wire mounting bracket is supplied with each kit along with 307 76 cm length of clear plastic hose and clamps to connect the hose berween the radiator fitting and the connec tion on the base of the recovery tank COOLING SYSTEM WESTERBEKE recommends using a premix If a premix is not available use a mixture of 50 antifreeze and 50 distilled water for year round use Choose sood quality antifreeze that is compatible with aluminum engine com ponents An antifreeze mixture will asd in cooling and will protect agains an unexpec
29. ld of vour genera tor see Battery Capacity and DC Cranking Current under ELECTRICAL SYSTEM in the SPECIFICATIONS section of vour Operators Manual If the starter battery is to be used to provide power for other services a larger capacity battery may be needed Generally it is not good practice to use the starter battery for other services unless those services require low amperage or are intermittent In cases where there are substantial loads lights refrigerator radio etc it is essential to have a completely separate system and to provide charging current for this sys tem by means of a second alternator dual alternator or alter nator output splitter Hg ter miu M TUN is not recommended because certam operating condi might cause tbc buttery become discharged la addition long cable may be necessary depending on the generator s location The best location for the battery is in its own compartment away from the generator and any other spark producing equipment but close enough to the generator to avoid volt age drop due to long cables Choose location where any accidental leaks or electrolyte spills will not damage the pen erator or any of its wiring fuel lines battery cables or any other equipment The location should be away from sources of heat and vibration and afford protecnon from ram road splash and road dirt sure the battery compartment is appropriate for the bat tery you
30. le is the responsibility of the owner operator to install the fuel filter water separator A typical example is shown below This 15 the Raycor Model 500 MA ee rent ACCESSORIES POWER TAKE OFF 0 WESTERBEKE offers three types of power take off devices These devices allow a hydraulic pump accessory tool or other equipment to be driven off the crankshafi through the generator at the generator end of the unit Power Take Off Assembly Models 20 0 BEDAR 25 BEDR 32 BEDAR 9357 This is closely coupled to and aligned with the eener ator has a flexible coupling which drives an clectromag netic clutch These components are mounted in an aluminum housing Air flows through the housing cooling the clutch and the flexible coupling The hydraulic pump or other dri ven equipment attaches to an adapter plate located at the rear end of the housing This 15 supported a pair of vibration mounts attached to the gencrator s mounting rails Models 5 0 BCDR 7 6 BTDR 8 0 PN34786 Models 10 0 BTDR 11 0 BTDR 12 5 BTDAR 15 0 BTDBR PN37134 This kit consists of a spline coupling that screws onto the generator 5 armature shaft an adapter and attaching hard ware The hydraulic pump or other driven equipment mounts onto the generator housing with the adapter and is driven Availabe tor all Models This consists of a shaft coupling that screws onto the generator
31. lo ensure thal all nuts and a e E o AER Replace theo ter Change Te oi Check the air ier replace 1 necessary Hoses should be hard and tight replace if soft and spongy Check and tighten hose ciamps EXMAUSTSYSIEM ieaks Check Tat connections are tight DRIVE SS inspect for proper tension 3 8 1 2 1 125 cm deflec tion and adjust if necessary Check bell edges Tor wear BATTERIES Check electrolyte level Make sure connections are tight Clean off excessive corrosion ina we Mond panel required hertz and the regulator board adjustment as Check that AC connections are clean and secure with ACCESSORIES For additional information about of the following WESTERBEKE Generator accessories contact your WESTERBEKE distributor XRT HYDRAULIC cgi This high pressure hydraulic pump ts direct driven by vour WESTERBEKE generator and provides remote tool only power for fire and rescue vehicles The XRT Hydraulic Pump supplies continuous power for all makes of cutting spreading and jacking tools plus safety lighting electrical accessories and reel tool operation ht is available for WESTERBEKE generators from 5 0 KW to 70 0 KW An Installation Manual is provided The ART Hydraulic Pump features 1 Quiet safe running 2 Long range full power over 100 fr 30 m from the pump 3 Simultaneous too operation with up
32. ly line A primary fuel filter water separator should be installed in the fuel supply line between the fuel tank and the generator to help remove contaminants and water in the fuel before the fucl reaches the engine mounted fuel lift pump Contamin ants and water can cause the failure of components and such failures are not warrantable The fuel filter water separator should be mounted in an accessible location for ease of mon itoring and servicing See the ACCESSORIES section for a recommended type of fuel filter water separator A secondary fuel filter is supplied with the generator and it has a replacement filter element In a dunnage pan installation on a vehicle s rooftop an aux fuel pump is usually added near the fuel tank This 15 to provide additional lift to prevent the fuel from backing up due to the high location of the generator An auxiliary fuel pump also be required in an installa lion where the generator is at a considerable distance from the fuel tank LUBRICATION SYSTEM Use a heavy duty engine oi with an API classification of CF or CG 4 SAE 30 10W 30 or 15W 40 Change the engine oil after an initial 50 hours of break in operation then every 100 hours of operation thereafter For the recommended viscosity see the following chart 41 68 F 520 C _ Below 41 F 5 SAE 10W 30 15W 40 CAUTION Do not mix two or more brands of they could react to pr
33. nals AX CAUTION Do not tie AC and DC wiring into the The generator s data plate gives the voltage current and fre quency rating of the generator A diagram of the various AC voltage connections is provided on the AC wiring decal that is affixed to the mside of the louvered cover at the generator end of the unit The generator including its AC output is grounded to the cen erator s base a pan or two rails depending on the model with a braided ground strap When installing the generator in the vehicle the generator s base must be erounded to the vehicle s chassis with a suitable ground strap owner sup plied If the vehicle has an aluminum body make sure the ground strap is bolted directly to the vehicie s steel chassis If the generator s base 15 to be bolted directly to the chassis then a ground strap from the generator s base to the chassis 15 WARNING Make sure the generator is properly grounded An improper ground can cause severe per injury ar death from fire or explosion Frequency is a direct result of the generator s engine speed When the generator is run at 1800 rpm the AC voltage output frequency is 60 hertz When the generator is run at 1500 rpm the voltage output frequency is 50 bertz WESTERBEKE generators are designed for operation at either 60 or 50 hertz and can be easily field converted from one to the other To field convert the generator 5 output refer to the Operators
34. ng Drill the holes through the frame members of the vehicle where possible 4 j tA AX WARNING avoid a fire hazard do not locate NOTE Do not route the fuel line through the vehicle s interior ii tem floor so fuel cannot leak onto the exhaust system Make additional holes near the corners of the compartment floor as required or in any other suitable location s on the floor to ensure that fuel l or water cannot accumulate Have as few holes as possible in the compartment floor to reduce the noise level and to minimize the entry of road dirt road splash and salt TRANSVERSE COMPARTMENT CONSTRUC A transverse compartment goes through the vehicle fr from one side to the other and can be open both ends Transverse compartments are generally multi use The con struction of the bulkheads and floor and the information on holes and msulation as described under SIDE COMPART MENT CONSTRUCTION would also apply transverse compartments but could be modified by whatever other uses Roll up doors are usually installed in a transverse compart ment to allow easy access to the generator and unobstructed use of other that may be kept the compartment dunnage pan installation 15 located on the vehicle s roof usually to one side of the vehicle or the other In a typical installation the generator is mounted in a shallow sheet metal well and is co
35. ngs and other jewelry before handling the battery Always turn the battery charger off before disconnecting WARNING Suipharic acid in Batteries can cause severe personal injury or death When servicing the battery or checking the electrolyte level wear rubber gloves a rubber apron and eve protec tion Ba enes contain sulfuric acid which 15 destructive If it comes in contact with vour skin wash it off at once with water Acid may splash on the skin or into the inadvertently when removing electrolyte caps TOXIC EXHAUST Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists Pay close attention to the manifold and the exhaust pipe nipple Do not use copper tubing in diesel exhaust systems Diesel fumes can rapidly destroy copper tubing in exhaust 5 5 tems Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust water leakage Be sure the generator and its surroundings are well tor 16 running INING Carbon monoxide CO is a deadly gas It is invisible and odoriess Inhalation produces flu like Do not discharge exhaust gases under a vehicle Direct x veia 00 other openines Close openings that are either above orto the rear of ihe exhaust
36. o be avosded by not using street elbows and by having as few clbows as possible Choi quee Me sjam with a minimum of restrictions so Jensation cannot get back to the engine A well designed vapor ihi exhaust system will allow your genera tor to be run safely and quictly NOTE Liability for damage or injury and warranty expenses becomes the responsibility of the person installing an exhaust system Contact WESTERBEKE or vour WESTERBEKE dealer regarding anv exhaust system problems vou may entre that bo system is tight and free of leaks Exhaust gasses are deadly A Carbon Monoxide warning decal is included in the Westerbeke documen tation package for your generator Dispiay this decal in the vehicle s living space or in some other prominent location The exhaust system must be totally supported to prevent strain on the engine s exhaust manifold Use automotive exhaust pipe hangers 1o suspend the exhaust system under the vehicle Mount the hangers directly above the compo nents being suspended not at an angle Mounting at an angle can cause damage to the exhaust system Attach the hangers to the vehicle s steel frame not to wood or any other materi als Do not twist the rubber sections of the hangers Some installations may require damping supports or hangers to lessen the transmission of exhaust noise vibration nent floor then angled back and out to the side of codes pits de bo
37. o its operating O Apply a load to the generator and check the output frequency Check the instrument gauges for proper readings Inspect the engine for fuel water coolant and oil leaks Ll Listen for unusual sounds and vibrations After shutdown check the generator carefully Inspect all fluid levels Check the hose clamps and fuel lines DAILY amp 50 HOUR MAINTENANCE CHECK LIST It is very important to complete this check list to make cer tain your generator has been installed correctiy and to assure warranty protection For safe operation and maximum ser WARNING Never attempt to perform any service vice life inspect your generator every day following the while the engine is running Wear the proper safety Check Daily portion of the chart After the first 50 hours equipment such as goggles and gloves and use the of operation check all of the items the chart Be sure to OF NOTE Some of the following maintenance procedures are trical easy bur others are more difficult and may require the expert knowled of a service mechanic CHECK AFTER 50 HOURS OF Check for water and diri in the fuel Drain ar replace the fifter necessary Check coolant at the recovery tank empty check at the 4l radiator Add coolant A necessary O VISUAL INSPECTION OF ENGINE Check for tuel l and water leaks Inspect wiring and electrical connections Check
38. oduce properties harmful to your DIL DRAIN HOSE An oil sump dram hose is located either at the front or the side of the engine depending on the model may be drained from this hose by removing the cap and the discharge end of the hose from its mounting bracket and lowering the hose into a container The hose cap fitting is 1 4 NPT A pump can be added or the drain hose extended for casier removal of the old oil When installing the generator make certain that this drain hose is accessible and that ends below the vehicle 5 chassis to avoid problems with spillage must be connected to an engine sump using extended mpples or tees The reason is that continued engine vibration would cause these fittings to fatigue If these fittings fail during engine operation lubricating oil will be lost and internal engine damage will result When these sensing devices need to be installed they must be mounted elsewhere and connected to the oil sump using an appropriate grade of flexible lubricating hose Anv fit tings used to connect the hose to the sump must be of steel or malleable iron composition Brass must not be used for this Any reassembly or relocation of engine parts such as fuel filters dipstick senders and switches accommodate restricted engine space must be authorized by the WESTER Corporation and the work must be performed bv a WESTERBEKE approved mechanic or else the engine s warranty wil
39. on AA 4 NCTETETTUUTTTETENTSUTFETESTIFESZSESETHTEZETNHENHZZ4EJAMEZG Sd M Holes for Mounting and Connections Transverse Compartment Construction NT Dunnage Pan Construction 6 ree TANE Rigging amp Lifting Mounting the Generator Mounting M Coolant Recovery Tank Sliding Drawer Mount 9 amp Noise Reduction 10 Rcx dosis 10 Ma eases Louvers Vents Grilles Baffles ee he a Noise Exhaust Systsm ned Exhaust System 12 Supporting the Exhaust System 12 Horizontal Exhaust Systems 12 Vertical Exhaust Systems eee 12 13 Lat i IA E Flexible Exhaust Line 13 Fuel Tanks 15 Common Fuel Tank 15 a Flexible Fuel Lines __ T6 Rigid Fuel Lines 16 Shutoff Valves a C RA Auxiliary Fuel Pumps F Lubrication System o 7 Oil Specifications ST Oil Drain Hose Oil Pressure Sensing Devic ices Relocating Engine AIRIS Cooling System SSF AAA Coolant Recovery Tank
40. ooling air to prevent an accumulation of fuel vapors 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 WARNING Accidental starting of the generator To prevent accidental starting and electrical arcing do not connect the battery cables to the generators starting bat tery until the generator is completely installed Disconnect the battery cables before servicing the gencra tor Remove the negative lead first to reduce the risk of Make certain all personnel are clear of the generator before starting L Make certain all covers and guards are re installed before Do not smoke or allow an open flame near the battery being serviced Lead acid batteries emit hydrogen a highly explosive gas which be ignited by electrical arcing by lit tobacco products Shut off all electrical equipment in the vicinity to prevent electrical arcing dur ing servicing Never connect the negative banery cable to the posi tive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals gether Sparks could ignite battery gases or fuel vapors Ventilate any compartment containing batteries to prevent hina Avoid contacting the terminals with tools to prevent burns or sparks that could cause an explosion Remove wrist watch ri
41. r compartment clean to minimize the risk of fire B Remove unnecessary oil and grease from the generator Accumulated and grease can cause overheating with possible engine damage and a risk of fire Wipe up all spilled fuel and engine oil Keep the generator compan ment Loc or on Do not store any equipment in the mpartment or any supplies such as oil or rags B Be aware diesel fuel will burn persanal injury or death Use extreme care when handling and storing fuels Keep fuel away from your generator Store fuel in a well venti lated arta away from spark producing equipment and out of the reach of children Do not fill the fuel tank s while the engine is hot or Shut off the fuel service valve at the engine when servicing the fuel svstem Take care in catching fuel that might producing equipment or other sources of fire near the fuel tank fuel svstem or generator when servicing Ensure proper ventilation exists when servicing the fuel system Fuel lines must be of steel piping Have a flexible fuel line between the generator and the stationary fuel line in the to prevent it from being used as a conductor Do not alter or modify the fuel system Be sure all fuel supply lines have a positive shutoff valve Be certain that fuel lines are secured and that fuel line fit tings are adequately tightened and free of leaks sure the penerator s ventilation system provides continuous flow of c
42. reational vehicles should have soundproof generator compartments Noise caused bv generator vibration 15 reduced to a large extent bv the generator s vibration isolators which prevent vibration transmission te the vehicle s frame and bodywork Airborne noise from the generator and its related components be reduced by lining the generators compartment with 1 inch 25 mm thick sound insulation material Face the insulator s vapor barrier inward then adhere the insulation to the compartment s bulkheads with adhesive sec illustration Cover the seams with aluminum tape exhaust gases out and away from the vehicle must be a separate svstem from the vehicle s propulsion engine exhausi lo prevent water vapor from one engine damaging the other engine Exhaust systems vary considerably and each must be designed for the particular vehicle Plan your exhaust system carefully Ensure that it will not contact the road when the vehicle is operating on inferior road surfaces Make sure that your exhaust svstem installation conforms with all applicable codes and regulations The exhaust line must be at least as large in diameter as the engine s exhaust manifold flange Make certain the exhaust pipe and muffler are of sufficient diameter to the exhaust gasses and prevent excessive back pressure Long exhaust systems may require larger pipe sizes to prevent excessive back pressure Excessive back pressure can als
43. row transfer switch with a standby generator Never connect a standby generator directly to a building s electrical system this is done dangerous voltages can flow from the generator the utility line injury or property damage Make this connection only with an approved device and after the building s main switch has been opened Consult a qualified electrician CN EO eR TU HUMO BOE m Electrical shock results from handling a charged capacitor charge capacitor by shorting terminals together with an WARNING Do not touch hot engine parts or exhaust system components A running engine gets very hot Always check the engine coolant level at the coolant recovery tank WARNING Steam can cause personal injury or death in case of an engine overheat allow the engine to cool before touching the engine or checking the coolant WARNING Fire can cause personal injury or death Prevent flash fires Do not allow any smoking open flames spark producing equipment or other sources of ignition or fire in the installation area or near the fuel tank fuel system components or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line or fuel filters B Do not operate the generator with the air intake silencer removed Backfire can cause severe injury or death Keep the generator and generato
44. rt ment that wil provide ample space on all sides for ventila tion servicing and maintenance The most common location 15 in compartment at the side of the vehicle Locating the generator in its own compartment at the side of the vehicle can protect it from extreme ambient temperatures adverse weather conditions road din road splash and salt It also allows easier installation of acoustic insulation or fire barrier materials The compartment must be large enough to accommodare the generator and its minimum clearances to the compartment bulkheads and ceiling including any acoustic insulation or fire barrier materials that might be used The compartment location should allow the senerator to be properly ventilated and should be close to both the fuel supply and the center of the electrical load distribution To avoid generator noise locate the compartment away from a vehicie s living quarters side compartment can be designed with solid doors which would be open while the generator is being operated or with louvered doors which could be closed while the generator is being operated transverse compartment goes through the vehicle from one side lo the other and can be open at both ends In a transverse compartment installation the space mus be large enough 10 allow ambient air to be used for the cooling intake so the generator can be run with the compartment doors closed Access to the generator for maint nance and
45. s armature shaft and pulley Pulleys are available in different sizes allowing this to drive wide vanety of belt driven equipment This popular accessory is used to relocate the engine s oil filter from the engine to a more convenient location To install simply remove the engine oil filter and thread on WESTERBEKE s Remote Oil Filter kit as shown Always install this kit with the filter facing down as illus trated Contact your WESTERBEKE dealer for more infor due 10 incorrect installation of the Remote Oil Filter E hosprtal 2rade but there may be a loss of power For information about additional muftling and quieter generator operation contact your WESTERBEKE dealer This beavy duty DC Alternator will run lights charge batter ies and provide back up for operational electrical systems and equipment WESTERBEKE s heavy dutv alternator package includes the alternator two drive belts belt guard Gnve belt tensioner and external regulator in the main control panel on the generator and mounted in a remote location Note it ees ibis hinged toolbox The kit includes the following spare Oil filter B Thermostat kit Complete gasket kit B Drive Fuel filter Fuel injector Glow plug STANDARD HARDWARE strength classes are embossed on the head of each bol Customary inch bolts are identifed by markings two to gr
46. select The compartment must be well ventilated to avoid the accumulation of explosive battery pases Provide ventilation openings of at least 2 sq in 13 cnr in both the top and bottom of the compartment Mount the battery in an acid resistant tray on a firm support It must be secured with holdown straps or other means to prevent shifting If the battery is be mounted in a propulsion engine s com partment install a non metallic cover to prevent battery dam age and from accidentally dropped tools Battery Cables WESTERBEKE recommends using the following cable sizes Io ensure starting in cold weather The sizes shown will allow starting down to 20 F 29 C The cable lengths shown are from the battery to the 12 15 21 27 34 as 2L WARNING Do not connect the starting battery APTO positive cable to the starter solenoid terminal tagged for this connection Connect this cable first A common ground for negative DC i5 located at the bell housing of the generator next to the starter motor in the form of a threaded grounding stud This location 15 tagged The battery ground must be connected here Failure to do so can cause arcing or resistance in the cranking circuit ELECTRICAL SYSTEM Make sure both and battery cables are the same size and that all the connections are tight Have a little
47. should be test run to check all the connections and elbows for exhaust leaks See INSTALLATION PRESTART amp INITIAL START UP CHECKLISTS in this manual A back pressure Ut ou pe De peo d Wi tne Rind unes sicca OE o flow of exhaust gases causing back pressure Back pressure must be kept within a certain limit EXHAUST SYSTEM Excessive back pressure occurs when the flow of exhausi gases is restricted resulting in a loss of engine power poor fuel economy and a high combustion temperature These conditions will lead to overheating shorter valve head and valve seat life and excessive smoke The restrictions the exhaust system that can cause exces sive back pressure 1 The diameter of the exhaust pipe 15 too small 2 The muffler is too small 3 The exhaust pipe between the exhaust manifold and the muffler is 100 long There are too many sharp bends in the exhaust system Limit the use of elbows and other fittings as these will create flow restrictions Tailpipe deflector is too small de 5 AX CAUTION The use of common street elbows is Check the exhaust back pressure before the generator is put into service Measure the back pressure after the engine has reached its normal operating temperature and at the point where it is about to reach its rated load at either 1500 rpm for 50 Hz applications or 1800 rpm for 60 Hz applica tions Back pressure should not exceed 1 5
48. ss be certain that the interior is gel coated to prevent fibers from contaminating the fuel system Copper or fuel tanks should not be used The nominal thick ness of a fuel tank depends on the material used Any fittings or openings must be at the top of the tank A drain plug at the bottom of the tank is not acceptable Ud M Urt de aluminum tank should be 300 Series stainless steel rum Odi Rove Qe cages vali as the fue lift provided will rare the fuel from the The amount of BR soul be kept 10 2 minimem 6 fort 1 8 m beine maximum If tank is already installed above engine level it can be utilized in this position tank 15 installed because any dirt left in the tank could cause foulme when the engine is started for the first time The fuel tank s fuel pickup tube should be clear and unob structed without screens or gauze strainers should be above the bottom of the tank to ensure that sediment and din are not drawn into it The fuel return line should be arranged the same as the pickup using a pickup stvle tube Make sure that all fittings are sufficiently tightened to prevent Fuel tanks that are located below the engine s fuel svstem level must have their fuel return connection al the tank extending down into the tank in the same manner as the pickup tube otherwise air will replace fuel siphoning out of the engine s fuel system through the retum The fuel tank s
49. t least 2 5 cm away from an unshielded exhaust pipe Run the fuel lines a level not lower than the top of the fuel tank to a location as clase to the generator as possible to reduce the danger of fuel siphoning out of the tank if the line should break Fuel piping should always be routed and supported and or securely anchored to prevent leaks from vibration and chat ing Locate fuel lines valves and fittings so that leakage that occur will not run off or drip on electrical svstem or exhaust system parts Fuel piping is usually secured by cop per straps every 12 to 147 30 to 35 cm Use as few connec tions as possible and install the lines so they accessible and protected Avoid sharp bends and other configurations that might produce flow resistance or the trapping of air Avoid locked in torsional stresses Use erommets to reduce vibration and prevent chafing where the fuel Ime through holes in bulkheads or partitions if the fuel lines are not made of metal they should be bonded to the vehicle s frame After installation check the fuel system for tightness Make sure your fuel system has manual in line positive fuel shut off valve s to close the fuel line when the generator 15 serviced A fuel shutoff valve is necessary in the return line if the fuel tank is located above the generator Fuel shutoff valves are also necessary where the generator s fuel supply line is teed off the vehicles fuel supp
50. t pump maintains positive inlet pressure t the injection pump under all operating conditions Install a flexible non organic fuel line without metal rein forcement between the ngid fuel line and the generator to absorb vibration Make sure this line is long enough to pre vent binding or stretching due to generator movement Flexible fuel lines should be used only where necessary to absorb vibration Always use flexible non organic tubing Do nol use wire reinforced tubing where it can create an electri cal path from the engine to any other part of the electrical system if there should be bad ground or if the ground strap is removed A bad ground in the cranking circuit could cause wire reinforced hose to become charged and ignite the fuel Tio proper of if fad lines very important Keep the length of the fuel lines to a minimum Westerbeke recommends using steel or rubber tubing with suitable flared fittings both for the supply line and the return line Use seamless annealed double flared fuel lines Run the tubing in si pieces obtainable to avoid the use of unnecessary Shines and comercios The minimum size of the fuel supply Ime and fuel return line is 1 4 inch ID Do not run the fuel lines together with electrical wiring Route support or shield fuel lines so they cannot contact the electrical winne Keep the fuel lines as far as possible from the exhaust svstem and hot engine areas Keep the fuel line a
51. table for the total cooling air cfm required for your WESTERBEKE generator VENTILATION amp NOISE REDUCTION Louvers vents and grilles can be installed in a generator LAUTIUN Make sure the compartment is vapor compartment s bulkheads ceiling floor or door as needed for tight including around the door before appiying the air intake They can be particularly useful for installations where air intake is restricted The free inlet areas of these malerials be obtamed from the manufacturer Use metal grilles over the cooling air intake and discharae openings Note that a grille will reduce an 5 area to between 60 and 90 of its original area Louvers and vents 1 and that it has not be used to allow the passage of air without admitting tubis in eis compartment to less than the mini ig mum clearance requirements Baffles are useful to reduce nose They can be designed to _ gt indirectly the intake while reducing noise bv block ing the line of sight to the generator Manv generator compartment designs can combine sound msulation with louvers vents grilles or baffles Whether or not notse reduction 15 an important factor in designing generator installation depends on the type of vehicle and how it is used Noise reduction be essential in vehicles that use communications or computer equipment or that have a command center Rec
52. ted freeze Antifreeze mixtures are benefi cial to the engine 5 cooling system because they retard rust and scale formation and are beneficial to the service of A remote radiator should be used under the following condis A The particular location or configuration of the genera tor compartment will not allow adequate heated air discharge see the VENTILATION REQUIREMENTS chart under AIR INTAKE DISCHARGE B A radiator attached to the generator would make the generator too long to fit in its location Custom remote radialors are available frnm WESTERBEKE For more Compact your WESTERBERE dealer Remote Radiator package that will be appropriate for your Type of vehicle 2 Generator model 3 Location of the generator on the vehicle 6 Air flow potential of the remote radiator location ELECTRICAL SYSTEM A Wiring Diagram and Wiring Schematic are included in the documentation package that is furnished with each generator They are also found in the Operators Manual for each pener ator Make sure the wiring diagram or wiring schematic you are using 15 the correct one for your generator model DC ELECTRICAL CON WESTERBEKE generators are mom pre wired and with plug in connectors Never make or break connections while the engine is running Carefully follow all instructions on the wiring diagram supplied especially those relating to fuse cir cuit breaker requirements Recommended publications concerning el
53. the necessarv cooling air for the generator under all of the generator s anticipated operating conditions For some vehicie applications this would mean in all kinds of weather under all conceivable road conditions Ventilation systems vary widely due to generator size and location The generator s ventilation system and the generator compartment s acoustics should be designed at the same lime since the configuration of the ventilation system influence acoustics and noise reduction and acoustic materi als can affect the efficiency of the ventilation system Design the ventilation system with as few restrictions 35 pos sible The sufficient intake of clean dry cooling air for proper engine combustion and the discharge of heated air while the generator running are both essential for the proper operation of the generator They can directly affect the engine s output fuel consumption and exhaust emissions The cooling air requirement varies with the size of the pener ator The size of the generator s discharpe area at the radiator cannot be changed therefore it rs important to provide ade quate mtake and outlet openings to accommodate this dis charge area Provide for the necessary convection cooling of the generator when it is shut down Two fans cool the generator Cool air entering at the intake end of the unit is heated as it is drawn through and over the generator end is then discharged out through a centrifugal f
54. to the 5 interior WARNING Do not use any flammable material partment bulkheads ceiling or floor could be high vapor tight to the interior of the vehicle to prevent work area A solid level compartment floor is very important for the proper operation of your generator A sheet metal floor is pre ferred plywood of a sufficient thickness can be used if it 15 CAUTION Do not install any absorbent material on the compartment it may absorb fuel or engine oil creating a fire hazard Doors A side compartment can be designed with solid doors which would be open while the penerator 15 being operated or with louvered doors which could be closed while the generator is being operated Make four holes in the compartment flor for mounting the generator To reduce the chance of the generator mounting DURO larger Also make holes in the floor or elsewhere in the compart ment for the following connections Exhaust pipe Ar outlet Fuel supply and return lines Oil drain the oil drain hose must end below the vehicle s chassis Remote control panel harness 1f used AC conduit Battery cable Holes through a wood floor must provide enough clearance to ensure that exposed wood will not be a fire hazard Design the holes so they will not constrict or chafe the lines that pass through them Use grommets where necessary to prevent chafi
55. ur Operators Manual io adio Sox Xon model Operating the generator at an excessive angle in direc tion can lead to various engine problems Frequent operation and long running periods at an excessive angle increases the elihood of a problem When selecting a generator allow for the possibility that may occasionally operate at an angle that exceeds its normal expected angle of operation rometric pressure and altitude rn conditions can make your generator 5 diesel engine work harder Take these deration factors into account when select ing your generator Temperature humidity and barometric bons Altitude is a constant condition and its deration can be INTRODUCTION Altitude Deration The lower density air less oxygen that exists al higher altitudes can cause engine power loss result ing in a lower generator cooling capability Each 1 000 ft 305 m increase in altitude above 1 000 ft 305 m above sea level Can cause 3 nominal deration Note Low air temperatures only diminish the engine s ability to start This can be remedied by using heavy duty battery See the battery size chart under BATTERIES Recommended publications concerning installation codes and safety standards are listed in the SAFETY INSTRUC TIONS section of this manual Make certain that the installation of the generator is done by qualifi
56. ust system 7 Fuel supply 8 Service and maintenance accessibili Refer to specific sections in this manual for information about the various systems that should be considered when neci EE generators are designed with the main service points on one electrical e ali cid dcc 1 The total loads to be used Le pumps heater lights refrigerator air conditioner etc Note that starting loads are higher than running loads 2 Loads that occur or might occur simultaneously 4 New loads that may be added in the future 5 6 Deration due to temperature humidity barometric pressure and altitude AIR CONI qb is usually the largest load for a generator in recreational vehicle Air conditioners are usually designed to run on com mercial power so care should be taken when choosing gen SM SCHO ESE SSE dee dM c penes dough ds operating places ai star the cur rent draw will be high then it will decrease then increase as refrigerant is pumped then decrease again when the tempera ture in the vehicle goes down after running for while the air conditioner will stop Restarting it will require the largest current draw because the internal temperature of the air con ditioner s compressor has risen The type of air conditioner and its starting time are additional variables that can affect the air conditioner s current draw Refer to the Section in yo
57. vered by a ventilated sheet metal enclo sure with access door The generator s radiator faces oul ward In general the construction information given under SIDE COMPARTMENT CONSTRUCTION would also apply to dunnage pan installation UNPACKING RIGGING amp LIFTING To remove the generator from its carton follow this procedure 1 Remove the banding straps 2 Remove the staples from the top of the carton and open iL or remove the cover if the carton has a cover 3 Pull out the staples that hold the sides of the carton to the skid then carefully remove the carton 4 Remove the plastic covering from the generator 5 Remove the plastic WESTERBEKE documentation package that is attached to the generator 5 lifiing eve This package contains the following items Operators Manual Parts List B Winng Diagram and Wiring Schematic Warranty forms Spares amp Accessories form B Carbon Monoxide CO Warning decal California Proposition 65 Warning 6 Remove the accessories that were shipped with the generator if any 7 Remove the four mounting bolts that attach the genera tor to the skid The generator is with lifting eyes Attach rope or chain slings capable of supporting the generator weight to the eyes and lift the generator by means of tackle attached to these slings The lifting eyes have been designed to carry the generator s full weight auxiliary slings are not necessary W
58. y Duty Continuous High Output Alternators 65 INTRODUCTION This installation manual covers those Westerbeke generators that designed for mobile applications The purpose of this manual is to provide generator installation mstructions that will insure the reliable starting of your generator delivery of its rated output safe operation and ease of service and main tenance These instructions are general in nature due to the many WESTERBEKE generator models available and the diversity of vehicle applications and designs In addition to these instructions the installation of your generator should be based on the specific requirements of your particular vehicle and codes and regulations that may apply Please read this manual carefully and observe the safety precautions Cono see sud good caliza for with all Should your generator require servicing contact your ESTERBEKE dealer For Serial Number location Decal information or Parts Ordering information refer to your MAN AA and weight of the generator are vour main considerations when choosing a generator Where the generator is located in the vehicle and how its systems are configured are also very important The factors to consider for both sclecting a generator and k 1 std gh gps S Lodo ad mE OK NON 4 Ventilation 6 Exha
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