DC Genset
Operations Manual

PC-750
PC-850
CAUTION!
Please read ALL of the
specific
information
included in this manual.
Failure to do so could
result in poor genset
performance, mechanical
and/or electrical damage,
and serious injury to the
operater and/or installer.
Improper
installation
and/or operation may
also
nullify
the
manufacturer's warranty
(see the "Warranty" page
in this manual).

 

19009 61st Ave. NE #4
Arlington, WA 98223
Phone: (360) 435-6100
Fax: (360) 435-3210
E-Mail: balmar@balmar.net
Web: www.balmar.net

TABLE OF CONTENTS

Setting Up Your Genset

Unpacking Your Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Preparation For Installation

Space & Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Exhausting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation Procedures

Seawater & Freshwater Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
System Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Alternator Direct Coupling Device . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Key Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Parts Required For Installation

Mounting Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Seawater Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Prior To Running DC Genset
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High-Output Alternator Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cooling and Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Toggle Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Regulator Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic Alarm Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Activation of Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
To Terminate Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

APV Checklist

Activation of APV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Manual Override Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Filter Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Final Thoughts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

SETTING UP YOUR DC GENSET

Unpacking Your Genset
Your genset was carefully packaged and inspected prior to shipping. Before uncrating the
genset, inspect the shipping container carefully for any signs of damage. If major
damage to the exterior of the shipping container is noted, notify the driver of the delivery
vehicle immediately. Arrangements for inspection by a claims representative of the
shipper should be arranged with the driver or with a shipping company customer
services representative. If a camera is available, it may be helpful to document any
damage with photographs.
Once inspection of the shipping crates exterior is complete, the crate may be opened by
unscrewing and removing the top panel. Inspect for any shipping damage and document.
Your DC Genset package will contain the following:

APC-750
APC-850

PC-750
PC-850
1. Engine
2. Control Panel
3. Expansion Tank
Mounting Kit
4. Owners Manual

1.
2.
3.
4.
5.

Engine
Control Panel
Expansion Tank
APV Control Panel
Pre-Filter Pack

6.
7.
8.
9.
10.
11.

Pre-Filter Mounting Kit

Water Puppy
Kitz Valve
Hayward Valve
RO Membranes
RO Membranes Order
Form
12. RO Pressure Vessels
13. RO Membrane

Mounting Kit
14. RO High-Pressure
Fittings
15. RO Low Pressure
Fittings
16. Bio Scrub Hose Kit
17. Cat Pump Oil
18. Owners Manual

Once the contents of the shipping container have been inventoried and inspected for
shipping damage, the four side panels may be removed by unscrewing the retaining
screws. The genset can be removed from its supporting panel by removing the lag
screws fastened at the four mounting feet.
CAUTION: The genset weighs approximately 190 lbs. alone and in excess of 225 lbs. with
the watermaker Cat Pump installed. DO NOT attempt to move the genset without
adequate assistance. Failure to follow this guideline could result in damage and/or
injury.
If possible, the genset should be transported to its installation location with the
assistance of a heavy duty hoist. The installation location must be capable of supporting
a weight load well in excess of the genset and watermaker pump.

Notes:

-1-

PREPARATION FOR INSTALLATION

Space and Ventilation Requirements
Several issues should be addressed when determining the optimal installation location for
your DC genset: Ventilation, Cooling, Fuel Supply, Exhausting, Ease of Maintenance and
Repair, Protection from the Elements.
Ventilation: Both the gensets diesel engine and high-output alternator require substantial
airflow to ensure adequate cooling. The installation site should be free of any potential
obstructions that could inhibit airflow. If
airflow at the installation site is
compromised, it may be necessary to
introduce additional airflow with the
addition of a fan or blower. Should you
want the fan or blower to operate only
when the genset is in operation, power
may be pulled from the gensets oil
pressure switch or from the positive side
of the gensets ignition switch.
Fuel System: Fuel input fittings at the
engine are 1/4" in and 1/4" out. Preferred
installations include a primary fuel filter
with water separator (Racor type) before
the engine. An electric or manual fuel
pump and inline filter is installed on the
genset. Adequate room for fuel filters and
fuel pump must be provided.
Exhausting: The DC genset is designed to
be matched with a 13/4 exhaust. The installation site should provide ample space for the
inclusion of the exhaust system. Each system will vary, based on ducting material, muffler
type and thru-hull. Exhaust can be directed toward the front or rear of the genset.
Maintenance: The DC Genset is designed to provide access to most commonly required
service points on the same side of the genset. Care should be taken when locating the
installation point to ensure that the access friendly side of the genset be located within
easy reach of the operator.
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.

-2-

INSTALLATION PROCEDURES
Seawater and Freshwater Supply
Seawater supply hose must be a minimum of 5/8" ID and must not be obstructed by
undersized sea water strainers, fittings, or sea cock valves. We recommend seawater hose
and fittings be a minimum of 3/4". The larger the sea strainer, the better. Do not share the
seawater inlet with the main engine through-hull unless a sea chest is available.
If your system is fitted with a watermaker, ensure that the seawater intake is located
forward of the head discharge or any other discharge that could foul your watermakers
supply source.
If the unit is installed below the waterline, a vented loop is required. The seawater supply
line feeding raw cooling water into the system must be routed to prevent siphoning of raw
water through this line into the exhaust system, filling the muffler and engine cylinders.
This line should be routed at least 12 inches above the waterline and an anti-siphon break
installed the top of its loop. This loop should be high enough above the waterline to ensure
that it remains dry even while heeling.
A small freshwater supply tank (expansion tank), bracket, and 10' of 3/8" clear hose are
supplied with the unit and should be mounted level with the gensets heat exchanger.

Exhaust System
Engine exhaust elbow is 13/4. Exhaust line installations will vary considerably and each
must be designed for the particular installation. The prime requirement is to provide an
outlet line with a minimum of restrictions, situated in a manner that ensures seawater,
rainwater and condensation cannot get back into the cylinders of the engine. Most exhaust
systems today use a water lift muffler such as the Vernay or Vetus type.

-3-

Starting System
The DC genset is equipped with its own dedicated charging system to support an
independent starting battery. Should you choose to utilize a dedicated battery, or start the
genset with the ships battery, ensure that battery cables are properly sized to support the
gensets starting load. The battery (+) lead will connect to the positive post of the small
alternator attached to the gensets engine. A jumper wire is already connected to the
starter solenoid. The negative battery lead attaches to the lower starter mounting post.

Fuel System
Fuel is supplied to the genset via the main diesel tanks or a dedicated genset fuel tank.
High quality 1/4 fuel line should be used to supply diesel to the genset. Fuel pre-filters and
fuel pumps, as described on the preceeding page, should be used as needed. A 1/4 fuel
return line is also required.

Coolant System
The genset is equipped with an onboard heat exchanger unit with an off-engine coolant
recovery tank. The gensets coolant system should be topped off after installation with a
50/50 mixture of water and coolant. The coolant recovery tank must be installed within
21" of the cap/manifold. This assures the cooling system will retain all fluids during normal
operation.

System Alternator
The DC genset is equipped with a Balmar high output alternator and the Max Charge
voltage regulator. An alternator temperature
sender is installed on the alternator to protect
it against over-heating. This alternator is a
single output alternator. If your alternator
model has a jumper strap supplied between
the terminals, it must be left in place. The
positive cable will connect to one of the ouput
posts. The negative cable should be
connected to one of the two bolt holes near
the rear bearing at the center of the
alternator. These cables should be properly
sized and supported to avoid undue strain on
the altnerator and fitting. For detailed
information, see Alternator and Regulator
Owners Manuals in the manual.
Brushless 98-Series Alternator

Voltage Regulator

The Max Charge voltage regulator is included with the DC genset in its own shipping
container within the crate. The regulator includes a 54" wiring harness, which allows
installation on stringer or bulkhead near the genset. The brown (switched) wire in the
regulator wiring harness should be connected to the (brown) switched source wire located
near the speed control box and oil pressure switch. Switched source wire is identified with
a marking tag.

-4-

Alternator Direct Coupling Device (Lovejoy #LF4 Coupler)

The alternator is coupled to the genset engine via a flexible torsional coupling (Lovejoy
#LF4). The coupling is installed prior to shipping and should require no user adjustment
thereafter.
Should you need to remove and replace the alternator and coupling, re-installation will
require strict adherence to the following procedural guidelines:
1. Inspect all contact surfaces on the Lovejoy coupler (bare metal surfaces on the
rubber coupling unit) for oil, dirt or other contaminants. Clean those surfaces
thoroughly with a medium grit sandpaper and wipe clean. Clean flex ring adapter
(metal ring attached to the engine flywheel) and pulley flange as well.
2. The Lovejoy is connected to the flex ring adapter under compression. When
installing the Lovejoy coupling you will find that the threaded holes on the flex ring
will not necessarily align with the Lovejoy without some manipulation of the
coupling.
3. Attach the Lovejoy to the
flex ring with a single
25mm capscrew. Turn the
capscrew a couple of
rotations -- just enough to
ensure proper threading.
4. One-by-one, insert the
Shows correct and incorrect axial coupling alignment.
remaining capscrews and
turn just enough to ensure proper threading. It may be necessary to compress the
Lovejoy to align with the threaded holes on the flex ring. Once all of the capscrews
have been started, each can be tightened to 20 ft.lb. Inspect coupling attachment
for proper alignment, as shown in illustration above.
Alternator Attachment
1. Ensure that the aligning capscrew is attached to the center bore on the tensioning
crown of the alternator. Align alternator so the flange in the pulley assembly fits
evenly inside the center hole in the Lovejoy coupling and the head of the aligning
capscrew fits in the indexing hole in the alternator bracket.
2. Once aligned, insert the 3/8 hex bolts in the two remaining holes in the alternator
tensioning crown (on either side of the indexing screw). These bolts will thread
into the alternator bracket. There may be some play in the bore containing the hex
bolts. Dont be concerned. The head of the indexing capscrew will ensure proper
alignment.
3. Insert the 1/2 hex bolt at the remaining alternator foot and thread into the
alternator bracket. Torque the alternator retaining bolts to 38 ft.lb.
4 Insert the Nordlock (locking washers) into the radial cavities of the Lovejoy
coupling. (Inserting the washer at an angle to the coupling makes it easier to
insert the washers).
5. Align the screw holes of the Lovejoy with the threaded holes in the pulley by
turning the alternator fan.
-5-

5. Once aligned, insert the 30mm Capscrews into the three radial cavities in the
Lovejoy. Tighten each capscrew just far enough to ensure proper threading until
all screws are properly aligned and threads are started.
6. When all three capscrews are in place, Tighten to 20 ft.lb. It may be necessary,
once all capscrews are in place, to turn the crank pulley on the engine to access
all of the capscrews for torqueing.
7. Inspect the Lovejoy for
proper alignment as
illustrated
at
right.
Loosen capscrews and
re-tighten, if necessary,
to ensure that the
Lovejoy is free from
distortion.
Shows correct and incorrect radial coupling alignment.
8. Re-check torque.
9. Replace Cat Pump platform.
10. Re-connect wiring connections at alternator as described in the alternator manual
included in the genset instructions.

Notes:

-6-

Key Panel
Electrical Connections for 12VDC motor functions are made at the molded plugs at the
engine. One 20' extension cable is supplied with each system. There is a 25-amp fuse at
the engine for panel and wire protection. The engine is supplied with oil pressure and
temperature switces, and will shut down the engine in the advent of a malfunction. A red
LED on key panel would indicate this.
Key Panel includes:
1. Key Switch
2. Hour Meter
3. Toggle-Adjustable Speed Control for manual control of engine throttle
4. Toggle switch to turn ON-OFF system alternator
5. Digital voltage meter indicating system voltage - gray wire at ESC box should be
connected directly to positive post at battery bank Wire should be fused near battery
at three (3) amps..
6. Mini toggle switch for ON-OFF system voltage meter
7. Pre-Heat, Run, and Alarm LEDs.

PARTS REQUIRED FOR INSTALLATION

Following is a general list of parts needed for installation. This is just a general list, as all
boats are different and installation is unique to each one.

Mounting Genset
1.
2.
3.

(8) 5\16 Hex Bolts or Lag Bolts, w/nuts and washers as needed. Primary Fuel Filter
and Water Separator w/ fittings
1
/4" Fuel Hose w/clamps (fuel supply)
1
/4" Fuel Hose w/clamps (fuel return)
Fittings as needed to install hoses to boats fuel system

Seawater Supply
1.
2.
3.
4.
5.
6.

Seawater Through-Hull fitting (3/4" or larger)

Seawater Intake Valve (ABYC approved)
Sea Strainer (minimum ")
Vented Loop fitting, optional (not necessary if mounting above water line).
Fittings as needed to make up intake valve, sea strainer and through-hull
5
\8" or 3\4" Intake Hose w/clamps

Exhaust System
1.
2.
3.

Exhaust Through-Hull fitting (1")

Water Lift Muffler (1")
13\4" Marine Exhaust Hose w/clamps

Starting System
1.
2.

Start Battery w/lugs

Start Battery Cables (minimum #6 AWG) w/terminals
-7-

Parts Required for Installation (Continued)

Battery Box
Alternator System
System Battery Cables (minimum #1\0 AWG - determined by length of run & percentage
of line loss).

Troubleshooting
Balmar equipment manuals contain a user friendly troubleshooting section. This information is also
available at our web site: www.balmar.net. Personal assistance in troubleshooting equipment is
available through our Technical Support Department via E-mail (balmar@balmar.net) or phone (360435-6100, ext. 3). Our hours of operation are Monday - Thursday, 7:30 am - 5:30 pm PST. We are
closed Friday - Sunday. There are endless possibilities that can cause a system to not operate
properly, other than equipment defect. It is the responsibility of the owner to either troubleshoot the
system or hire a qualified professional to do so.
Non-Warranty Repair: If failure is found to not be covered under the terms of this warranty, customer
will be presented with price to repair / replace. If repair / replacement is declined, equipment will be
returned to customer as stated under #4, Return to Customer, or will be disposed of upon request.
Loaner Equipment: Balmar does not provide equipment for loan to be used while failed equipment
is undergoing analysis. If replacement equipment is required prior to warranty analysis, new
equipment can be purchased. Used equipment may be offered for sale, subject to availability.

LIMITED PRODUCT WARRANTY

BALMAR warrants to the original consumer/purchaser the product is free from any defects in material or workmanship for a period of
one year from the date of purchase. This warranty DOES NOT apply to defects or physical damage resulting from abuse, neglect,
accident, improper installation, wiring, or repair, alteration, modification, or unreasonable use of the products resulting in breakdown,
cracked or broken cases, parts damaged by fire, water, freezing, collision, theft, explosion, rust, corrosion, overheating or items
damaged in shipment in route for repair. BALMAR assumes no responsibility for consequential damage or loss or expense arising from
these products or any labor required for service or repair. Alternators are not covered when used with manual regulation devices.
Following are requirements for determining warranty coverage:
1.

Proof of Purchase: All Balmar equipment is production dated. This date is not adequate for warranty consideration, as new
product can age significantly prior to end user purchase, installation, and placement in service. Proof of purchase is
required for accurate calendar consideration.

2.

Analysis of Failure: All equipment will be factory analyzed to determine warranty status prior to replacement or repair.
Contact Balmar for return authorization (RA) number. Balmar can not be held responsible for any product sent without
proper identification, return address, and RA number clearly marked on the package. Ship equipment prepaid to the
location specified by Balmar. This warranty is not extended to costs of troubleshooting, including time, labor, or
communication costs incurred either with Balmar or other marine specialists.

3.

Determination of Warranty: If the equipment is found, upon analysis, to have failed under the terms of this warranty, it will
be repaired or replaced. Balmar reserves the right to determine whether to repair or replace components. Allow 30 days
A.R.E. (after receipt of equipment - expedited service is available upon request whenever possible). This warranty is in lieu
of all implied or verbal warranties as to the merchant ability or fitness for a particular application. No person is authorized
to repair, modify or assume additional obligations for warranty without the written authorization of a Balmar corporate
officer.

4.

Return to Customer: Once analyzed, equipment will be returned by surface freight to continental US destinations.
International and offshore 'ship to' addresses, as well as 'rush' and expedited shipment requests, will require credit card for
payment of freight charges.

THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY
LASTS. NO PERSON, AGENT, DEALER IS AUTHORIZED TO GIVE ANY WARRANTY OR REPRESENTATION ON BEHALF OF BALMAR UNLESS
MADE IN WRITING BY AN OFFICER OF BALMAR.

-8-

 

DC Genset / Watermaker
Pre-Run Checklist
Prior to Running the DC Generator
The following checklist is intended to ensure dependable DC genset and watermaker
operation. Please follow the instructions carefully to ensure proper system performance.

Electrical Connections
Proper wiring connections are essential to genset operation. Ensure that all electrical
plugs are properly plugged in, wiring is complete, and fuses on engine are in place and
functional. Make sure that electrical plugs at the engine location are well protected against
water intrusion, and that all connections are secured so they can't fall into puddled water
or other sources of electrical danger. Plugs may be hermetically sealed with black
electrician's tape to add protection against water intrusion. In some installations, it may be
necessary to secure wiring with wire ties to minimize chafing and vibration.

High Output Alternator Cabling

Secure terminal connections and properly-sized cable runs are a necessity for charging
efficiency and system health. Ensure that both positive and negative output terminals from
the alternator are properly sized, based on the length of run. A 3% loss wiring chart is
included in the manual for the Max Charge regulator. Keep in mind that sizing should be
based on the round-trip distance between the alternator and the batteries being charged.
Both positive and negative cabling must be equally sized to support charging amperage.
The cabling between the alternator and battery bank
must be protected with a fuse or circuit breaker, as
outlined in ABYC electrical standards. Fusing must
exceed the output potential of the alternator. Ensure
that wiring is properly secured and is protected against
chafing. Wire ties or wire-relief fasteners should be
utilized at the genset to support the weight of the heavy
output wiring. This relieves the strain of the cable
connections at the alternator terminals, as copper
connectors may become loosened with engine
vibration.
Oil fill / dipstick locations.
-9-

Cooling and Lubrication Systems

Engine fluids must be inspected and levels adjusted
prior to startup. Add engine oil, if needed, to ensure
that the engine has adequate oil. See check and fill
locations at right.
Fresh water coolant (50% anti-freeze, 50% fresh water)
is filled to the bottom of the overflow tube on the
coolant reservoir. If watermaker option is installed, be
sure the Cat Pump has adequate oil (to the top of the
window's inner ring). See photo at right.

Fuel System
Ensure that primary fuel supply is connected to the fuel
inlet connection at the fuel pump. Disconnect the fuel
return line located at the top of the fuel filter assembly.
Pump the small mechanical fuel lever located beneath
the fuel pump (see photo) until fuel appears at return
hose. Reinstall and secure the fuel return line once the
system is properly primed.

Cat Pump fill window.

System Control Panel

Turn the key switch at the control panel to the ON
position. System voltage should be displayed on panel.
Red alarm light should be illuminated.

Toggle Speed Control

Fuel pump / priming lever.

With key in its ON position, toggle speed control switch up

or down to increase or decrease engine rpm. Verify movement of engine throttle lever when
speed control is activated.

Regulator Programming
The Max Charge MC-612/MC-624 regulator included with your genset is factory preset to
a Universal Factory Program, which is safe for most types of marine batteries. Should you
choose to program the regulator for your specific battery type, refer to the regulator
operation manual included in your DC genset documentation package. If battery
temperature sensing is desired, connect the sensing lug to the negative battery post
closest to the center of your battery bank.

Starting the Engine

Hold key in glow plug position for approximately 15 seconds, and then attempt to start the
engine. If the engine does not start immediately, check for fuel leaks, as most common
problem occurs from air being drawn into new fuel system lines. When engine starts,
immediately check the following:
1. Verify that coolant water is being discharged from exhaust.
2. If water is not observed, verify valve openings to raw water.
3. Ensure that Jabsco raw water pump is not getting hot by putting hand on bronze face
plate.
- 10 -

1. Exhaust heat detector.

2. Block temperature sensor.

3. Oil pressure sensor.

Automatic Alarm Shutdown

All sensors on the engine open their circuits in the alarm state, which will automatically
shut the engine down by discontinuing electrical current to the fuel solenoid.
The three automatic shutdown sensors include: 1.) Exhaust Water Inject Elbow Heat
detector; 2.) Engine Block Temperature Sensor; and, 3.) Oil Pressure Sensor.
Exhaust water inject elbow heat detector (1)
Located at elbow of engine exhaust pipe.
Engine block temperature sensor (2)
Located on the front of the engine, forward of the injector pump near the thermostat.
Oil pressure sensor (3)
Located under injector pump and aft towards fly wheel.

After the genset has run for a few moments, turn off the engine and inspect
for raw water, fresh water, and oil leaks.
Activation of Charging System
After the initial inspection, test run and post-run inspection are complete, start the genset
engine. Turn alternator toggle switch to 'ON' position at panel. Verify that the LED display
on your voltage regulator is cycling through the basic display. (Display should indicate
manufacturer, model number, program number, battery type, charging stage, "real time"
battery voltage, and target/calculated voltage. Values will vary based on your program
selection. See additional details in the accompanying regulator manual.)
After a 45 second delay, the regulator should indicate that voltage is ramping up at
alternator output
After 1 minute of ramp up, insure that battery voltage is stabilized at proper level
(assuming batteries are not deeply discharged or large load is not applied).
Verify that CV display (regulator calculated voltage) and BV display (battery voltage) at
regulator are nearly identical.
Apply electrical load to ship's DC system. Insure that voltage remains stable. If necessary,
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accelerate engine rpms to meet load demand.

It should be noted that alternator output will not exceed the acceptance rate of the battery
bank. Heavy loads produced by large inverters operating air conditioners, or windlass loads
may be better handled by low resistance batteries such as Optima or AGM types.

To Terminate Operation
Turn alternator switch to the 'off' position. The regulator display should be turned off when
the switch is in the 'off' position.
If engine has been run hard, and is hot, it is a good idea to run at low rpm for 5 minutes to
allow heat to transfer out of the system. The mini toggle for the digital voltage display may
be left on or turned off for system monitoring, whether the system is running or not.

APV Checklist
Watermaker option of this system may only be started up after the vessel has been
launched. Care should be taken that the water being used for test purposes is not
contaminated with plankton, oil, or heavy minerals that may be found in some inland
waterways and harbors. If water is questionable, a short perfunctory test using steps 1-3
may be performed, limiting pressure in Step 3 to 100 pounds. Cease test upon verification
of system.
The reason for this is that the water puppy impeller
requires water for lubrication and the high pressure
stainless steel Cat Pump requires water for operation
and setting of high pressure safety valve. In addition, RO
membranes should not be opened from plastic
packaging and installed prior than 2-3 weeks before
activation of system. Once the system is activated,
standard procedures for cleaning and membrane
APV auto/manual switch
preservation apply as described in the manual.

Activation of APV System

1. With engine running, the control panel toggle
should be switched to the Automatic position. See
photo.
2. Start button must be depressed and held until
needle on pressure gauge of filter pack lifts itself
to the point of opening contact from its resting
position. The Murphy gauge on this system insures
that the system will not operate in a vacuum and
theat the stainless steel Cat Pump will not be APV start button
damaged from cavitation. It should be noted here
that the lower limit contact of this gauge can be adjusted with the use of an Allen
wrench. This portion of the system protects against feed water pump failure, plugged
filters, or unsuspected intact of plastic bags or other such matter that may find its
way to the intake source of the system.
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3. Once the system is in operation, clutch engaged and

the feed water pump in operation, the start button
may be released. The regulator may now be turned
clockwise to increase system pressure. It is
suggested that pressure be brought up to 250-300
pounds and a general inspection of all water system
fittings be made.
4. Once visual inspection has been made, the
pressure regulator may be turned clockwise until
the flow meter indicates the proper amount of System OK / filling lights
product water on the flow meter located on the main
control panel. A two membrane system will produce approximately 40 gph.
Pressures will vary on the high pressure gauge depending upon temperature and
salinity of system intake water.

While system is operating at full capacity

another visual system check should be made.
High pressure Test
This test should be performed briefly to insure that all
connections and systems are operating properly. High
pressure relief valve located on the Cat Pump may be
adjusted at this time (reference operation manual).
Caution: the high pressure emergency discharge line may
be hooked to a hose to run spillage into the bilge,
protecting other equipment that may be in the vicinity.
This is, of course, mandatory if the system is enclosed in APV auto/manual switch
a sound shield.
Normal operation of this system will be indicated by two
green lights illuminated on the control panel. First green
light will indicate that pressure is applied to the Cat Pump,
filters are clean, feed water pump is in operation, valves
are open, and there are no obstructions. Second green
light will indicate that the water sampled is of acceptable
quality and is automatically being fed to ship's water
storage system.
To discontinue use of the system, the toggle switch on the
APV auto/manual switch
panel is simply turned to the 'OFF' position.

Manual Override Mode

This system is provided with a manual override mode, which allows system operation
should its primary electronics have a failure of any kind.
To activate this override, switch the toggle switch into the manual mode. Turn the pressure
regulator clockwise until the desired amount of product water appears on the flow gauge.
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Open the small spigot valve on the bottom of the flow

gauge. Sample the water by tasting or using a hand held
Auto/Manual
Switch
salinity probe.
If water is acceptable, close the spigot valve and rotate
primary control panel valve from normal to manual tank
fill.
Operating in this manner reduces the system to its
simplest form and assures water production without
necessitating complex electronic components.
Caution: The manual override valve is a high quality Auto/Man. switch / purge button
laboratory grade valve, designed not to allow fluids to
combine. There is, therefore, a small spot on its travel which we determine a spot X that
does not allow the product water to flow into the tank or the automatic selection valve on
the panel. It is possible to use this spot X to force all system product water through the
spigot valve at the bottom of the flow meter. This is used for filling up a bucket when the
system is to be preserved or to transfer RO watermaker through a hose to a friend's vessel
or for other special applications. It should be noted that if this main control valve is in
position X and the spigot valve on the flow meter is in the closed position, that the high
pressure will build to a point where the product water hose running from the RO membrane
to the control panel may be ruptured.

Filter Pack
The filter pack is provided with transfer relays to provide electrical current for the feed
water pump at the filter location, as well as a toggle switch to operate the feed water pump
during filter cleaning or replacement. This allows the operator to activate the feed water
pump while depressing the air release buttons on the top of each filter of the filter pack.
This switch is left normally in the DOWN and OFF position.

Final Thoughts
We appreciate your purchase of the APC-750 DC Genset and RO Watermaker, and we look
forward to supporting you throughout its use on your vessel. If you have any questions or
need for assistance, please feel free to contact our sales or technical service departments
at (360) 435-6100 or e-mail us at balmar@balmar.net.

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