Westerbeke 10.0 BEG, 15.0 BEG, 8.0 BEG, 12.5 BEG Operator's Manual

·.

~

£ R

It

OPERATORS

8.0

1·0.0

12.5

15.0

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~

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MANUAL

KW • &.OHz-

KW

'KW

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• 60Hz-

~

60Hz~10.0

·-60Hz~12.0

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6.4

8.0

KW • 50Hz

KW

•

50Hz

·50Hz

•

50Hz

BEG BEG

·aEG

BEG

MARINE

GASOLINE

Sin

·

REVISION3

JANUARY

Phase

GENERATORS

2018

member·

§.~.

.

WESTERBEKf'E

.150

·

FAX

JOHN

(508)884-9688 • WEBSITE:

CORPORATION • MYLES

HANCOCK

ROAD • TAUNTON

STANDISH

MA

WWW.

WESTERBEKE.COM

INDUSTRIAL

02780-7319 • Tf'EL.

PARK

(508)823-7677

.

CALIFORNIA

PROPOSITION

WARNING

Exhaust gasoline its the cancer, reproductive

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

Weakness

IF

YOU GET seek until

gas

engines

constituents)

State

of

birth

gasses

gas.

Carbon

can

include:

and

OR

ANYONE

OUT

INTO

THE

medical

it

has

attention.

been

from

California

defects,

harm.

contain

and

Sleepiness

inspected

65

diesel

and

(and

some

of

are

known

to

cause

and

other

A

WARNING:

Carbon

Monoxide,

Monoxide

death.

ELSE

EXPERIENCE

FRESH

Shut

is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

•Inability ANY

AIR

IMMEDIATELY. down

the

and

repaired.

of

unit

an

odorless

and

Carbon

in

Temples

Twitching

to

Think

OF

THESE

If

symptoms

and

do

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

not

restart

A

WARNING should generator.

be

WESTERBEKE MONOXIDE of

your

vessel.

obtainable

DECAL

is

provided

fixed

to a bulkhead

also

recommends

DETECTORS

They

at

your

in

are

local

by

WESTERBEKE

near

your

installing

the

living/sleeping inexpensive marine

store.

and

engine

easily

and

or

CARBON

quarters

·

Gasoline

with

an ETHANOL

content

higher

··

than

and

10°/o (E10)

may

void

is

not

allowed

warranty.

~r~

~

'WESTERBEKE™

Engines &

Generators

Blank

page

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure

to

follow

precautions.

take

the

personne~

The

foUowing

the

American

PREVENT

A

while

power.

111

Do

enclosures

Ill

Shut equipment.

1111

Use equipment.

Iiiii

Make (particularly

Ill

Remove electrical

PREVENT

A

exhaust hot!

Iiiii

Monitor coolant

location

when

A

II

In

before

Know

when

necessary

precautions

and your

safety

machinery.

instructions

Booi and

ELECTRIC

WARNING:

engine

Lethal

not

operate

off

insulated

sure

WARNING:

system

recovery

the

WARNING:

case

of

touching

Do

is

running,

voltage

this

and

covers

electrical

mats

your

clothing

shoes)

wristwatch

equipment.

BURNS

-HOT

Do

components. A running

engine antifreeze coolant

tank

on

the

water

engine

is

Steam

an

engine

the

carefully.

Most

fundamental

dangerous

Yacht

conditions

to

protect

are

Council

in

SHOCK

not

touch

AC

electrical

or

when

connected

is

present

machinery

in

power

whenever

when

and

at

without electrical

place. before accessing

working

and

skin

are

handling electrical

all

jewelry

ENGINE

not

touch

hot

engine

and

periodically at

jacketed exhaust

COLD.

can

cause

injury

overheat,

engine or checking

allow

accidents rules

yourself,

compliance

(ABYC)

connections

these

connections!

electrical

on

electrical

dry, not

when

working

parts

engine

level

at

the

manifold,

or

the engine

the

are

and

exist

and

your

with

standards.

to

shore

damp

equipment.

on

or

gets

plastic

filler

cap

but

death!

to

cool

coolant.

very

only

PREVENT

A

Iii Prevent

sparks

pump, vapors. removing

111

Do not Backfire

111

Do the fuel engine/generator clean chances

11

Be

PREVENT

A

injury

Ill

Follow hatches

after

running before starting your

Ill

All

when ventilated and

II

Do

Ill Shut off

the

spill. sources servicing.

the

Ill

Do

Ill

Be

Ill Be certain fuel line

free of

111

Make sure a

properly maintained. Be familiar Extinguishers rated for all applications encountered

BURNS

WARNING:

flash to or

Use

operate

can

not

smoke

system.

of

aware

-FIRE

Fire

can

fires.

Do

not

occur

near the

other

potential

a suitable container

the

fuelline,·carburetor, or fuel filters.

with the air cleaner/silencer

cause severe

or permit

Keep

the compartment

fire.

Wipe

up

- diesel fuel will

BURNS -EXPLOSION

WARNING:

or

death!

re-fueling safety

fueling.

fuel

handling

out of

not

fill

fuel

DO

fuel

not alter or

sure

all

leaks.

Explosions

closed

when

fueling.

Check

below

the

blower.

vapors

area

the

fuel

system.

Nar

of

fire

Ensure proper ventilation exists

system.

fuel

fire

Run engine.

are

highly

and

storing

away

from spark-producing

reach of children.

fuel tank(s)

service

Take care

allow

any

near

the

fuel

modify

the

supplies

fittings

extinguisher is installed

ABC

cause

injury

smoke

or permit

carburetor,

sources

flames

and

instructiOI¥J.

valve

have

of spilled .fuel or

to

injury

or

free of

all

spilled fuel

bum.

from

fuel

Open

for

fumes/vapor

the

blower

explosive.

fuels.

Store

while

the

at

the

in

catching

smoking;

system

fuel

system.

a positive shutoff

are adequately

by

the

NFPA

in

or

fuel line,

catch

death.

sparks

and

debris

and

vapors

Keep

and

for

four

Use

fuel

engine is

engine

any

open

6r

engine

with

its proper

this

environment.

death!

flames

filter,

all

fuel

removed.

to

occur the

to

minimize engine

can

the vessel's

ventilate

before

minutes

extreme

in a

equipment

running.

when

fuel

flames,

when

tightened

nearby

are

appropriate

or fuel

fuel

when

near

oil.

cause

cabin

care

well-

servicing

that

might

or

other

servicing

valve.

and

is

use.

the

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

11!11

Turn

unit's

engine.

Ill Make certain

starting.

111

Make certain all re-installed before starting

BATIERY

A

WARNING:

or

death!

111

Do not smoke or being highly explosive arcing equipment in the during

111

Never connect positive ( Do

not test the together. Ventilate accumulation of disturb is

being

111

Avoid

burns

wristwatch, the

battery.

1111

Always the

battery

and

reconnect it last

BATTERY

A

WARNING:

severe

1111

When servicing

level, protection.

destructive. it off at once into

caps.

STARTING

Accidental

OFF

the

DC

battery

selector

all

EXPLOSION

Battery

serviced.

or servicing.

the

contacting

or

Lead

by lit

tobacco

the

+)

connection

battery

Sparks

any

compartment containing batteries

battery charger connections while the battery

charged.

sparks

that

rings,

turn the

connections.

ACID

Sulfuric

injury

or

death!

the

wear

rubber

Batteries contain sulfuric acid which is

If

it

comes

with

the

eyes

inadvertently when removing electrolyte

starting

breaker

on

switch

to

personnel

covers,

are

guards,

the

explosion

allow

an

open

acid

batteries

gas,

which

products. Shut

vicinity

could

explosive

battery

to

prevent electrical

negative

the

and any

(-) battery cable

terminal of the starter condition by shorting the terminals ignite battery

gases.

terminals with tools, etc.,

could cause

other jewelry before handling

charger off before disconnecting Remove the

when

servicing the

acid

battery or checking the electrolyte

gloves,

a rubber

in contact with your

water.

Acid may splash

can

cause

injury

the

control

panel

o!

OFF

before

semcmg

clear of the engine before

and hatches

engine.

can

flame

~mi~

can be

1gmted

gases

To

avoid

an

explosion. Remove

in

batteries

apron,

are

cause

injury

near the battery

hydrogen,

by

elec~:?cal

o~

all

el~cal

arcmg

to

solenoi~.

or

fuel

sparks,

negative

lead

battery.

can

and eye

skin,

on

the

cause

~

the

vapors.

to

prevent do

to

prevent

wash

skin

the.

~

first

the

not

or

TOXIC

11

1111

11

111

11

AVOID

1111

EXHAUST

A

WARNING:

Ensure that discharged from the regularly for

water-injected Be

sure

the unit and its surroundings are well ventilated.

Run blowers

Do not run

equipped with a functioning marine carbon

detector that complies with boat builder or dealer for installation of approved detectors.

For additional information, refer (educational information

A

WARNING:

odorless nausea

gas.

or

death!

Do not use copper Diesel

fumes

systems.

tubing

copper

Do not install exhaust outlet where exhaust

through portholes, exhaust discharge outlet is near the waterline, enter the exhaust flow

of exhaust.

Although diesel engine exhaust exhaust gas

symptoms

poisoning

Vomiting Dizziness Headache Nausea

fumes

is present in diesel exhaust

MOVING

A

WARNING:

or

death!

Do not service the engine situation arises in which make operating adjustments, touching moving components.

GASES

Carbon

monoxide

the

exhaust system

engine.

leaks

and

make

elbow

is

securely

when

running the

the

generator set or engine unless the b?at is

on

Carbon

monoxide

Inhalation

can

Exhaust sulfur causes rapid deterioration of

resulting in exhaust/water

from gasoline

or

signs

are:

produces

tubing

rapidly

vents,

discharge

Avoid

overloading the

of carbon

destroy

Inability

Throbbing in

Muscular Weakness

(CO)

is a deadly

is

adequate

Check the exhaust

sure

the exhaust manifold/

attached.

gep.erator

ABYC

A-24.

to

ABYC

Carbon Monoxide).

(CO)

Is

Ru·like

in

diesel

exhaust

copper

tubing

or air conditioners.

outlet

apd

close

craft.

gases

are

engines,

monoXIde

carbon

fum~.

s~

inhalation

to

think

temples

twitching

and

sleepiness

PARTS

Rotating

parts

it

parts

and hot exhaust

can

cause

while

it is

running.

is absolutely

use

extreme

system

gas!

to

expel

gases

system:

set or

engine.

monoXIde

Consult your

TH-22

an

invisible

symptoms,

systems.

in

exhaust

leakage.

can

be

drawn

If

the

engine

water

or

restrict

not

as

toxic

monoxide

of.

the

or

coherently

injury

If

a

necessary

care

to

avoid

could

the

as

Engines & Generators

••

II

1!1

Do

not

wear

loose

equipment; jackets, could·

Iii

Make

Keep

places

l1ll

Do

not

the;

engine

!iii

Do

not

the

exhaust generator death

"JIININI~

tie

shirts,

be caught

sure

all

protective

at all

times.

check

fluid

is

operating.

allow-any

discharge

is

operating.

can

occur.

back

sleeves,

in

attaching

shields

Higb;itoise-let(el$·

.I

Iilii

Never

operate

an,.engine

11

Do

not

run

the

flame

arrester

II

Do

not

open

(when

A

WARNING:

mentally

removed

run

enginps

installed).

or

phjSiiially

eQ;gine

Qo

clothing

moving

levels

swimming

,not

or

jewelry when servicing

long

hair

and

avoid wearing loose

rings,

necklaces

parts.

hardware and

guards

or

the

drive

or

activity

opening

\vith

for

Carbon

Monoxide poisoning or

without

the

air

. .

long

periods.

work

on

machinery

int:Bpa~;itated.ty

or bracelets tluit

is

properly tightened.

in

their respective

belt's

tension

around or near

the

generator while

. .

t:;~n·

c,.us.e·hl!.atiilg

its

mui'fler

~talc~

(~Uencer)

with their enclosures

when

while

installed.

or

you

fatigue!

the

are

~!(:,

INSTAI.LJNG

Readthe following ABYC, NFPAand for

qqns

ABYC!(American Boat and

"Standards and Technical Information

Craft" Order

Orderfrom: .

Order

~FP~

A~IJ

. '

safe!:y

coqes

·

WPFP

iristalling your engine.

from:

ABYC

613

Third Street,

AJUiapolis,

':VV\fW

•.

aby~c.o~g

NFPA-

"Pl~e

Nati0rtaJ

No.302 ·(National Fite Protection

and Commercial MotoiCrilft"

Fire Protection Association

~$CG.

EN.GINESAND

-·

..

an<l

standards. Follow their

SAi(e

M.D

21403 ·

PUBLICATIO~S

-··.. ' . - -

.

GENERATORS

USCG

Yacht

Council)

Reports

10

...

--·

recommenda-

Association)

FOR

publications

for Small

·.

~~:g.~~r:

Us¢G:(t.Jmte!i

•'fegutatedioils.are Code

of

from:.

U.S.

Government Printing

Washington,

S~tc;m

Co~t

Gril!.td.)

'uilder

titJ.es.CFR33

Regulations" ·

Office

D.C. 20404

· .

and

CFR46

of

the

OPERATORS

Many

of the

in

your

notes

to

carefully, procedures.

GASOLINE

Preparations begin

with

Yacht

Council's

a

combination

Sections

H-2

Ventilatio~

·

H-24

Gasoline

P-1

Installation for

P-4

;Marine

E·l_lA.C

All

installations

Regulations (FCR).

www.abycinc.org

MANUAL

preceding

Operators

biglilight

maintain

ENGINE

to

install a gasoline

a

thorough

(ABYC)

of

the

ABYC

for

Fuel"

of

PropUlsion

Inboard

and

DC

Electrical must

Manual critical

your

sources

Exhaust

and

safety

tips

and

warnings are repeated

along

with

otlJ.~J:'

cautions and

information:

equipmerit,'ant:l.follow

AND

GENERATOR·-INSTALLATIONS

examinatiqn-

standards.

inc!uding

standards

Boats

using

Systems

Auxiliary

Engines

Systems

comply

and

with

Read

yo~

Irianual

"ail

· · ·

engine

or generator should

of the American Boat

These

st\Uldards.

the

USCG and

of particular interest

Gasoline

Engines Transmissions

on

Boats

the

Federal Code of

safety

and

are·

from .

the

NFPA.

ar~:

.

~

;WESTEFIBEifE

·Engines

& Generators

·•

iii

When

installing

attention

WESTERBEKE

be paid

to

INSTALLATION

the following

engines information:

and

generators

it

is

important

that

strict

CODES

Strict when

AND

federal

regulations,

installing

REGULATIONS

ABYC

engines

and

SIPHON·BREAK

For

installations

or

will

be

break

in

the

minimum

the

exhaust manifold injection port

raw

water

If

you

have

to

the

vessel's waterline under the vessel's

siphon-break.

NOTE:

A

siphon-break operation. engine

damage.

EXHAUST

The

exhaust Exhaust and and system under

Hose turns turns.

MUST

any

where

the exhaust manifold/water injected exhaust elbow

below the vessel's waterline, provisions must

raw

water supply hose

of

20"

above

the

vessel's

damage

any

doubt about

to

the

engine

requires

Failure

to

properly

Consult

the

SYSTEM

system's hose MUST be certified for marine

is

recommended.

without the need of additional

In

this

regard, a single length of corrugated exhaust hose can

be

designed

sea conditions

to

and

guidelines,

generators

to

waterline.

and

the

position of

periodic

and

safety

in a marine environment

the exhaust

Failure

is

at

or

below

possible

flooding

the

water-injected exhaust

various

inspection

maintain a siphon-break

siphon-break

The

prevent

at

any

mantifacturer

use

of this type of hose allows for extreme bends

fitting

and

the

entry

of

angle

of

vessels

codes must be

be

made

elbow.

This hose must be looped a

to

use a siphon-break

the load

operating conditions, install a

and

clamps

water

waterline

of

the

cleaning

can

result

for

proper

use.

to accomplish these bends

into

the

heel.

complied

is

close

to

install a siphon-

when

will

result

boat.

elbow

relative

to

ensure

proper

in

catastrophic

maintenance.

Corrugated Marine

be

used.

exhaust

system

with

to

in

AVAILABLE

YOUR

DEALER

SIPHON;BRtAKWITHSTAINLESS

·LOOP

The

FROM

WESTERBEKE

A

detailed

engines

to

and

download

Marine

Installation generators, from

our

Manual

is

supplied

website

at

Engines & Generators

covering

with

www.westerbeke.com.

iv

each

gasoline

unit. A pdf

and

diesel,

is

available

TABLE

Parts

Identification

Introduction

Warranty Procedures ........................................................ 3

Serial Number Location ................................................... 3

Fuel, Preparations Operating Operating Break-In Safety

High Maintenance Cooling

Changing Coolant ..........................................................

Thermostat .....................................................................

Heat Exchanger ..............................................................

Raw Water Pump ...........................................................

Raw Water Intake Strainer .............................................

Engine

Oil Change .....................................................................

Remote Oil Filter ...........................................................

Oil Pressure .................................................................... 19

Fuel

Fuel Lift Pump ...............................................................

Carburetor

Engine

Spark Plugs ....................................................................

High Tension Cords .......................................................

Drive Belt Adjustments ..................................................

High Speed (Hertz) Adjustments ...................................

Governor Adjustments ...................................................

Timing Belt Inspection and Replacement .....................

Engine Compression Test ..............................................

Ignition Timing ..............................................................

Engine

DC

Electrical

Battery Care ...................................................................

Generator Generator Remote Remote Remote Starter Generator BE

Generator Generator AC

Voltage BE

Troubleshooting Shore Engine Engine Lay-Up Standard Standard Suggested

.............................................................................

Engine

RPM

System

Oil

and

for Initial Instructions Instructions

Procedure

Shutdown

Schedule

System

Lubricating

Adjustments

Troubleshooting

Motor

Power

Specifications Specifications and

..................................................................

.......................................................................

.....................................

System

Wiring Wiring

Panel

Wiring

Panel

Wiring

Panel

Wiring

.........................................................................

Information

.........................................................................

AC

Voltage

Regulator

Transfer

Recommissioning metric Hardware

Spares

OF

CONTENTS

.................................................................

Engine

(Daily

Switches

Switch

Oil

..............................................................

Diagram Schematic

...............................................................

Data

................................................................

........................................... , .....................

Coolant

Start·Up

........................................................

(Remote

Operation)

................................................

..............................................

.....................................................

.......................................................

.....................................................

............................................................

(#46094)

(#035698)

(#035706) (#043912)

..........................................................

Connections

..........................................................

Switch

60Hz

.................................................

50Hz

..................................................

............................................................

..................................

.........................................

Panels)

.............................

.................................

21

(Early

Models)

..................................

(#46094)

..............................................

.............................................

...............................

........................................

.........................................

............................ : ...........

...................................

....

2

.3

5 6 7 8 9

1 o 11 12 14

14 15 15

16

l6

17 17 18

20 20

2la

22

22 22

23 23

24

27 27

28 30

31

.32

33

.34

35

.36

37

39 .40 .41 .43

44 .45 .46

47 .48

50 51 52

~

WESTERBEKE

Engines & Generators

1

PARTS

IDENTIFICATION

DC

START

MOTOR

HEAT

EXCHANGER

CONTROL

LEFT

SIDE

SWITCH

CONTROL

GENERATOR

WATER

INJECTED

EXHAUST

PCVVALVE

PANEL

ELBOW

OILFILL

·

WATER

TEMPERATURE

SWITCH

HEAT

EXCHANGER

OIL

DRAIN

Engines & Generators

RIGHT

2

SIDE

MOUNTS

INTRODUCTION

This WESTERBEKE Generator

long

WESTERBEKE'S technology. and

dependable performance of

Thank In order

it

is

important that manual manual carefully throughout. Should your your

This is your Operators

provided. A Service Manual is available in

you

to

is

designed

nearest

We

for selecting

get

take

the

WESTERBEKE

years

great pride

WESTERBEKE.

full

use

you

operate

to

help

and

observe all

Manual.

is

a product of

of experience

in

the

superior durability

our

engines

and

benefit

you

gene~ator

dealer for

from

and

maintain

do

this.

Please

the

safety precautions

require

assistance.

A Parts List is also

and

advanced

and

generators.

your

generator,

it

correctly.

read

servicing,

pdf

form

this

contact

on our website or a hardcopy may be purchased thru a Westerbeke Dealer. A Iristallation Manual is included

for your reference when installing the product.

WARRANTY

Your

WESTERBEKE folder. card registering your warranty registration

writing number

PROCEDURES

Warranty

If

you have not received a customer identification

warranty

form,

with

model

information, including

and

commission date

is

included

60

days

after submitting

, please contact

in

a separate

the

factory

the

unit's serial

in

This

the

WESTERBEKE span

between printings ofWESTERBEKE product

and

the

unavoidable existence of earlier

manuals. WESTERBEKE other suppliers, must not

sively

as

not

only

makes representatives of WESTERBEKE or be

consulted

product software

SERIAL

The engine's stickers affixed engine's engine block lube

illustration of the quick reference

· ordering service/repair

serial number can

oil

filter.

customers

In summation, product software

products, whether

the

definitive authority

good

to

determine

being

NUMBER

model

to

either side of the generator housing. The

on a fiat

Take

the

J.D.

when

should

also

from

and

cannot be relied

on

the respective

sense but

consulted

the

is

imperative

accuracy

by

the

LOCATION

and

serial number

also

be

found

surface just

time

sticker

seeking technical information and/or

parts.

to

enter

below,

above

this

as

keep

in

mind

WESTERBEKE

provided

WESTERBEKE

upon

product.

that

appropriate

the

supplier

and

customer.

can

stamped and

information

this

in

currentness of

be

found

into

inboard of

will

provide a

the

time

software

with

exclu-

question

on

J.D.

the

on

the

or

It

the

I.,.,.,IWESTERBEKE

I Engines & Generators

Customer Identification

WESTERBEKE OWNER

MAIN HOMETOWN, USA

Model

Expires'

PRODUCT

Product software (tech

catalogs) provided

are

not within WESTERBEKE' S

WESTERBEKE CANNOT CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT THERETO,

INCLUDING ACCURACY,

NESS THEREOF AND WILL FOR CONNECTION WITH OR FURNISHING OR USE OF SUCH SOFTWARE.

STREET

BEG

Ser.

#

SOFTWARE

data,

parts lists,

from

sources other than

BE

RESPONSIBLE FOR THE

TIMEUNESS

IN

ANY

TYPE OF DAMAGE OR INJURY INCURRED

ARISING

manuals,

CONTROL.

OR COMPLETE-

NO

EVENT

OUT OF THE

WESTERBEKE

brochures

BE

UABLE

and

IN

Fill

in

the

Engine

information

1.0.

Plate

for your

reference.

Engines & Generators

3

INTRODUCTION

ORDERING

Whenever replacement parts are needed, always provide the generator and engine include a complete part description part needed insist or generic parts cations

NOTES,

As

this

maintenance schedules, and troubleshooting of your generator,

critical information

CAUTIONS, and

NOTE:

A

observed,

the

A

followed,

NOTE:

by

WESTERBEKE.

the

engine

SPARES

Certain spares will be needed to support and maintain your WESTERBEKE generator. dealer See

the

Generator Accessories,

INSTALLATION

Publication #43400 provides detailed information for installing generators.

PARTS

model

and serial numbers.

and

part number for

(see

the separately furnished Parts Catalog).

upon

WES1ERBEKE packaged parts because will fit

are

frequently not

as

original equipment.

CAUTIONS

manual takes

An operating

CAUTION:

can

engine

or

WARNING:

can

A

carbon

room.

AND

will

assist you in preparing

SPARE

you

WARNINGS.

procedure

Procedures,

result

generator.

Procedures,

result

monoxide

Affix

ACCESSORIES

PARTS

AND

through the operating procedures,

will

in

the

in

personal

this

page in this manual. For Engine and

see

made

to

the

WARNINGS

be highlighted

An explanation

essential

which

damage

which

injury

warning

decal

in a visable

Your

local WES1ERBEKE

an

the ACCESSORIES brochure.

by

to

note.

if

not

strictly

or

destruction

if

not

or

loss

decal

has

inventory of spare

MANUAL

In

addition,

same

specifi-

NOTES,

follows:

properly

of life.

been

provided

location

each Also

of

in

parts.

PROTECTING

Care at

the have resulted in a WESTERBEKE generator capable of many

thousands manufacturer cannot control installed operated and serviced in the buyer/owner-operator.

NOTE:

Six

• Proper engine and generator installation and alignment.

• An efficient

an anti-siphon break to prevent water from entering the engine.

• Changing the engine oil

ing hours.

• Proper maintenance

nents according

manual.

•

Use

clean, filtered unleaded fueL

•

Wznterize Recommissioning" section in this manual.

UNDERSTANDING

The gasoline engine driving

similar

ways are verticle in-line, and overhead camshaft which is chain-driven.

a

soli.d-state

camshaft-driven. The engine incorporates a pressure type

lubrication system, and a fresh water-cooled engine block

which

is generator's engine requires the that

is

required important factors ventilation, maintenance cooling system and the generator backend.

.

CARBON

WESTERBEKE highly recommends mounting a carbon monoxide detector

quarters.

be

can

YOUR

factory during assembly

in

the vessel or

important

weU-des{gned

your engine according

to

distributor which is horizontally mounted

thermostatically-controlled.

of

MONOXIDE

Carbon

deadly.

INVESTMENT

and

thorough testing

of

hours

of

dependable service. However

how

or

where

the

manner in which the

field.

This

is

up

steps

to

ensure

long

generator

exhaust system that includes

and

oil filters

of

aU

engine and generator

to

the maintenance schedule in this

THE

GASOLINE

an

AC

a gasoline automobile engine. The cylinders

the

engine's cylinder head

same

a gasoline automobile engine.

to

the generator's longevity are proper

of

the

fuel

DETECTOR

in the vessels living and sleeping

monoxide

even

every

to

the

"Lo.y-up

GENERATOR

generator is in

The

To

a large

preventive maintenance

system, ignition system,

in

small amounts,

generator

unit

is

to

the

life:

100

operat-

compo-

and

many

has

an

engine utilizes

and

degree,

The

most

is

the

The presence exhaust leak from the

system, from the exhaust discharge location

or

from a neighboring vessel.

If

the dectector signals the presence

Ventilate the area, move

locate the source

Engines & Generators

4

of

carbon

inOnoxide

main engine or generator, it's exhaust

into a fresh air location and

of

the carbon monoxide and arrest it.

indicates a possible

of

carbon monoxide.

on

the vessel

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOUNE

A

CAUTION:

higher.

Gasoline

Ethanol

with

Use

unleaded

gasoline

higher

percentages

must

89

Octane

not

exceed of

gasoline

E10

Ethanol

(10%}.

are

not

or

=ftltaseiRIIJess-aml--a

Care

Of

The

Fuel

Supply

Use

only

clean properly filtered

some

components in

dirt particles which might

these

finely

finished and keep it clean. The best unsatisfactory by careless handling or improper storage facilities. engine's daily use advisable:

Purchase a well-known brand of fuel.

Install and regularly service a good, Coast metal bowl and the engine.

ENGINE

Use a good brand of engine oil with designations

this

Change the engine oil and filter after

engine break-in operation. Then follow the oil and filter

change intervals

SCHEDULE in this

Westerbeke Corporation

the use

break-in

change intervals must be

SCHEDULE section in this manual and

if synthetic oils

NOTE:

statements

To

assure that the fuel going into

type filter/water separator between the

OIL

as

manual.

of

synthetic

MUST be performed using conventional

The

information regarding

the

parts.

is

clean and pure, the following practice

listed in the SPECIFICATION Section of

as

specified in the MAINTENANCE

manual.

oils.

are

used.

above

synthetic oil

fueU

unit's

fuel

system

pass

through the

It

is

important

fuel

can be rendered

an

does

not approve or disapprove

If

synthetic oils

as

listed in the MAINTENANCE

supercedes all previous

usage.

The

API

an

initial

'0

fit

and

are

very critical;

filter

to

buy

the

tank for your

Guard

and

50

are

used,

not

to

be extended

tolerimce

can

damage

clean

fuel,

approved

fuel

SAE

hours of

engine oil.

dil

of

is

tank

ENGINE

WESTERBEKE recommends a mixture of and chemicals that can corrode internal engine

The to the engine cooling circuit from rust quality antifreeze that contains Supplemental Cooling Additives (SCAs') that balanced, crucial

The before being poured into the cooling circuit.

NOTE:

antifreeze

A proper 50/50 mixture engine coolant to temperatures of

COOLANT

A coolant recovery tank kit The coolant expansion and contraction during engine operation, without the loss of coolant and without introducing the

COOLANT

50%

distilled

antifreeze performs double

run at proper temperatures by transferring heat

distilled water and antifreeze should ben pre-mixed

Use

that is now

purpose

cooling system.

water.

Distilled water

to

the coolant. It also lubricates

and

keep

to

long term protection.

the

new

environmentally-friendly,

available.

as

RECOVERY

of

this recovery tank is

TANK

50%

antifreeze

is

free from the

surfaces.

duty.

It

allows

the

engine

away

and

protects the

corrosion. Look

the antifreeze chemically

recommended

-40"F.

is

supplied with each generator.

to

will

allow

for

a good

long

lasting,

protect the

for

engine

from

air into

NOTE:

This

located at or above

manifold.

Engines & Generators

5

tank, with

the

its

short

level

of

run

the

of

plastic

engine's

hose,

exhaust

is

best

PREPARATIONS

PRESTART

Before starting your generator longed

• Check the engine

the

• Check

bowls

• Check

and

• Check the coolant level in both the plastic recovery

and at the manifold.

NOTE:

the recovery the after tank will replace

Before subsequent operation manifold should be topped tank may need

INSPECTION

for

layoff,

check

the

following

oil

level:

add

full

mark

on

the

dipstick.

the

fuel

supply and examine

for

contaminants.

the

DC

electrical system. Inspect

battery cable connections.

After the initial running

engines cooling system will

tank.

Open

the

air bleed petcock

cooling system

the

engine has

be

the

drawn

purged

to

is

cooled,

into

air.

be

filled

purged

of

the

engines cooling system

of

off,

to

the

first time or after a pro-

items:

oil

to

maintain

the

of

the

generator,

be

purged

air.

After shutdown and

coolant

the

generator,

and

the

MAX

level.

the

fuel

filter/separator

wire

connections

to

the

to

ensure

from

the

coolant

recovery

the

coolant

recovery

OIL

FOR

level at

tank

a!r

in

that

to

engines

FILL

INITIAL

•

Visually parts, disconnected wires, unattached hoses, threaded connections. Search

• Check load leads for correct connections the

• Examine

•

Be the

• Be

neutral requires, to

the

or

open

voltage

• Make certain

A

recommended motors, up

to

This unanticipated prevent a cold

START-UP

examine

wiring diagrams.

the

sure

no

load

lines.

sure

that

is

properly

and

load neutral.

neutral

on

CAUTION:

be

speed

precaution

the

air

inlet and outlet for air

other generator or utility power

in power systems

that generator neutral

can

unbalanced loads.

the

raw water thru-hull

When

that

switched

and,

in

will

operation

engine

unit.

grounded

In

single phase

supply

starting

all

AC

loads,

OFF

until

cold

climates,

prevent

of

from

Look for

for

any

with

(or

ungrounded)

the

wrong

the

especially

the

damage

the

AC

stalling.

loose

gasoline leaks.

a neutral line

is

properly connected

systems

line-to-neutral

is

generator,

engine

starts

caused

machinery

. ·

as

flow

open.

to

or

specified

is

an

large

has

missing

and

check

in

obstructions.

connected

that

the

as

the

system

incomplete

it

is

come

warm

up.

by

and

wHI

to

Q

TO

HEAT

EXCHANGER

6

OPERATING

INSTRUCTIONS

GENERATOR

Starting

Move

the

second

for system. the

starter cranking and

runs

release

toggle

switch

to

NOTE:

Should wait 20 than

20

START/STOP

.(....,._

Starting

Make certain the lubricating

the

prevailing temperature. Check

LUBRICATING

minimize voltage drop.

Stopping

To

stop

release it

EMERGENCY

If

the generator

remove

A

CAUTION:

the

engine system the

pump cooling enter manifold from

through·hu/1 correcting

Engine

warrantable in

mind.

CONTROL

the

Generator

ON toggle switch

the

electric

Then

move

the

up

close and maintain

the

seconds,

seconds at a

.....

~~

'

~~.:)

under

the

generator,

to

the center

fuel

the START toggle switch

STA~T

for a

few

engine fail

and try

time.

SWITCH

STDPDFf

Cold

Conditions

OIL.

The

Generator

press

(normal)

STOPPING

does

not

the 8 amp

filling

system

the

happening

damage

fuse or disconnect the

Prolonged

starting

is

pumping

with

can

raw

during

engine's

once

cylinders

the

exhaust

by

closing

shut·off,

the

cause

resulting

issue;

the

toggle switch

again.

stop

raw

cranking.

draining

of

owner/operator

PANEL

up

and

hold

pump

to

prime the

engine.

seconds

battery should

result

water.

the

Once

to

the

run circuit

to

start,

Never

oil

conforms

the

STOP

position.

using

cranking

in

This

water

through

by

way system the

raw

the

excessive

from

raw

only.

allow

release

run

ON

table

switch

the

may

This

of

fills.

water

exhaust water

it.

Allow a few

engines

up

engaging

the

engine

Hold

the

oil

pressure

then

release

both

switches,

the

starter

SWITcH

. '

;..,;>

.,..-':--,,/

STOP switch,

intervals engine

STARr

,

with

the ratings

under ENGINE

be

fully

charged to

down

battery.

without

.exhaust

happen

raw

the

raw

water

exhaust

because

Prevent

supply

muffler,

engine

cranking.

entry

is

should

keep

fuel

fires

ON

it.

more

then

water

can

this

and

not

this

and

HDURMETER:

ELAPSED

TIME

NUMBER

OF

GUIDE

FOR

MAINTENANCE

for

a

THE

HOURMETER

OF

ENGINE

HOURS

SHOULD

Abnormal

An

abnormal

and

comes cause operating

1.

Overspeed condition.

2.

High

3.

Low

4.

High

5.

Electrical overload.

a.

Fuse

b.

20A

c.

Main

Should the

remote panel

an

engine

located

RECORDS

USAGE

THE

BE

USED

SCHEDULING

Stop

stop

to a stop

damage

to

condition. The fault

engine temperature.

oil

pressure.

exhaust temperature.

at

the

breaker

circuit

a fault condition

shutdown.

and

corrected

TOTAL.

AS

A

.

(refer

is

one

as

the

control

on

the

breaker.

the

to

SAFETY SHUTDOWN

in

which

the

a result of

engine,

panel.

engine.

occur,

green

Once

(see

an

operating fault

the

generator, or create

stop

conditions

the

engine will

LED

light

detected,

ENGINE

TROUBLESHOOTING).

CONTROL

AND

BOX

·.

AC

CIRCUIT

\

generator

will

the

ceases

are:

shutdown.

turn off indicating

fault

should

PANEL

BREAKER

START/STOP/ON

SWITCHES

SWITCHES)

to

run

which

may

an

unsafe

On

be

Engines & Generators

7-

OPERATING

NOTE:

Remote panels cannot

INSTRUCTIONS

be

inter-connected.

(OPTIONAL

Only

one panel

PANELS)

can

be

used.

REMOTE

Starting

To

start the generator, hold the ON toggle position (the panel green switch in this position for a fuel START starter cranking the engine (the green LED light will Once the engine Release the START toggle switch, but continue ON

: close to maintain the DC run circuit then release

NOTE:

wait than 20 seconds at a

Stopping

To down (stop) position then release it mode)

REMOTE

An controlling the generator from a remote location.

This panel previously described. which glows once the engine/generator has reached rpm's. The purpose release the START switch. It engine/generator

PANEL

the

Generator

switch

LED

light will

few

seconds

pump to

up for a few seconds to allow the oil pressure switch to

20

START/STOP

stop the generator,

optional remote start/stop panel is available for

·prime

the engines fuel system.

toggle;

switch

fires

Should

the

engine fail

secorids,

,,..-

<'

position.

and try

SWITCH

/'?START

......

,.....,,

,"'

the

Generator

time.

START/STOP

has

the same ON, START and STOP functions

of

is

running.

to

the

up

position,

and runs, the green

to

start,

again.

Never

move

the

START/STOP switch

PANEL

Also

included

the

LED

is

also

come

on).

to

allow

Then

this

will engage the

LED

will brighten.

to

release

both switches,

run

the

starter

ON

SWITCH·

to

the center

(off/run

(HARDWIRED)

is

to

a green

alert

an

LED

the

operator

indication that

in the up

Hold the

the electric

move the

dim).

hold the

it.

more

to

the

light 600

to

the

REMOTE

An optional remote

includes a water temperature gauge, oil pressure gauge, charging switches.

REMOTE

The remote instrument panel installed

and

located on the engine. The water temperature sender installed in the thermostat housing and the oil pressure sender is

adjacent on each sender wiring harness).

The blue wire is

for

betw~n

should be removed.

WIRING

NOTE:

installers responsibility standards

INSTRUMENT

voltmeter,

INSTRUMENT

on

the engine block, a water temperature sender

an

oil pressure

to

the oil pressure switch. Use sealing compound

the threads of both senders. Electrical connections

are

tied off next

is

for the oil

the water temperature

terminal board connections

DIAGRAM in

When

installing

33

CFRpart

PANEL

in_strument operating hourmeter, and start/stop

PANEL

gauge

sender. Plugged ports for each

preSsure

Refer

to

this

the

optional

to

comply with the

I83.

(HARDWIRED)

panel

is

available which

INSTALLATION

has

two sending units to be

to

the senders location (in the

sender

and

the

tan wire

sender.

If

there

is

a jumper

TBI-1

and

TBI-2, it

the REMOTE INSTRUMENT

manqal.

remote

panels,

U.S.

it

Coast

DC

is

for

is

the

Guard

are

REMOTE STOP/START PANEL (PLUG CONNECTER)

This stop/start remote panel is available with either a

15'

or

30' control panel. remote panel

Engines & Generators

8

harness that plugs directly into the generators

Operating instructions are the same as the

to

the left.

BREAK·IN

After tion

and

between

A

tor

After can be increased cally vary the load.

Avoid smoky Monitor it within at

1800 50 hertz, control of erned

To

protect against unintentional overloading of

the

generator's output leads should be routed through a cir-

cuit breaker that is rated

NOTE:

current drawn amperage drawn age.

PROCEDURE

the

generator

then encourage a fast warm-up.

20%

CAUTION:

by

running

the

first

overload at

exhaust with reduced output voltage

the

rpm

by

the

Be aware

See

GENERATOR INFORMATION in this

has

been started, check for proper opera-

to

60%

of

full

load for

Do

not

attempt

to

without a load.

10

hours of

to

current being drawn from

generators' rating. Since to

produce

current drawn

of

required

can

the

generators' operation,

the

full-load rated output;

all

times.

An

overload

60

hertz, or at

the

generator's engine break-in

from

the

at

the

rated output of

motor starting loads and

for starting

be 3 to

motors.

5 times normal

the

generator.

break-in

the

PROCEDURE/DAILY

Run

the

first

10

hours.

your

then

is

signaled

and

frequency.

the

generator

generator operates

1500

rpm

the

This

running

manual.

generator

genera-

the

load

periodi-

by

a

and

to

produce

is

gov-

generator,

generator.

high

starting

amper-

keep

OPERATION

NOTE:

Some

unstable running may occur in a cold

This

condition should abate as normal operating temperature

is

reached and

A

CAUTION:

periods

of

loads

are

Do

not

time

without a load

applied.

operate

the

generator

being

placed

generator.

STOPPING

Remove Allow operating temperature and press the STOP switch

CONTROL

NOTE:

the

maintenance schedule for

GENERATOR

Once be adjustments required for engine speed (hertz) during engine's break-in period (first 50 hours) or after (see

ENGINE

ENGINE ADJUSTMENTS). A no-load voltage adjustment

may adjustment (see

THE

GENERATOR

the

major

AC

loads

the

After

generator

PANELS).

the

to

run for a

first 50 hours

ADJUSTMENTS

the

generator has been placed

also

be

required

SPEED

(HERTZ)

in

conjunction with

GENERATOR

from

the

generator

few

minutes

of

generator operation check

the

50 hour service

in

operation,

ADJUSTMENT under

the

INFORMATION).

engine.

for

long

on

the

one

at a time.

to

stabilize

down,

check.

there

may

this

period

engine's speed

the (see

the

CHECK

Follow

• Record the hourmeter reading

•

• Check

• Check the coolant level

• Check your

• Check

• Check the drive belt for wear

• Check for abnormal noise such

• Confirm exhaust

LIST

this

checklist each

relate

to

the maintenance schedule).

Visually

blow-back sounds.

When the engine

When When

inspect

the

oil level (dipstick).

fuel

the

starting batteries (weekly).

the engine the

engine

day

before starting your generator.

the

engine for fuel, oil, or water leaks.

in

the

supply.

smoke:

is

cold

-White

is

warm

- almost Smokeless.

is

overloaded -

in

your

log

(engine hours

coolant recovery

and

proper tension (weekly).

as

knocking, vibration

Smoke.

some

Black

tank.

Smoke.

and

SAFETY

SHUTDOWN

SWITCHES

SAFETY

The

switches. Should a shutdown occur,

without finding and correcting the

heading

ENGINE TROUBLESHOOTING section

The following is a description

switches:

High

An exhaust temperature switch is located on the exhaust elbow. Normally closed, this switch will open and interrupt the sensor indicate an excessive exhaust temperature (an inadequate supply This switch opens at resets at approximately

SHUTDOWN

engine is protected by five automatic shutdown

Engine

starts,

Exhaust

DC

TOSIPHON BREAK

Temperature

voltage (shutting off the engine) should the switch's

of

raw water causes high exhaust temperatures).

·

SWITCHES

do

not attempt

cause.

Refer to the

runs

and

then

shuts

down

of

this manual.

of

these automatic shutdown

Switch

260-270"F (127-132°C). This switch

225°F (107°C).

,l

)\~

,,\\\~

to

in the

restart

/1

High

Water

Temperature

A high water temperature switch is located at the thermostat

housing. Normally closed, this switch, should the fresh water

coolant's operating temperature reach approximately (99°C), will open and interrupt the DC voltage thereby shutting off the engine.

SWitch

This

switch resets at 195"F {107°C).

210°F

EXHAUST

Low

Oil

Pressure

A low oil pressure shutdown switch is located engine's oil gallery . Normally open in a static state, this switch's sensor monitors the engine's oil pressure. Should the engine's oil pressure fall to interrupting the DC voltage thereby shutting off the engine.

Switch

off

5-l

0 psi, this switch will open

the

20

AMP

CIRCUIT

BREAKER

Engine

Circuit

Breaker

The generator's engine is protected by an engine mounted manual reset circuit breaker

draw or electrical overload anywhere in the instrument panel wiring or engine wiring will cause the breaker to trip. In this event the generator will shut down because the opened breaker interrupts the and repair the source fault, reset the breaker and restart the generator.

(20 amps DC). Excessive current

DC

circuit.

If

this should occur, check

of

the problem. After repairing the

Engines & Generators

10

DESCRIPTION

HIGH

RPM

SHUTDOWN

SWITCH

An overspeed switch in the generators engine by grounding out the ignition system the engine's speed reaches 2175 rpm (approximately). After correcting the problem, this switch can momentarily depressing the stop switch. Refer to the

WIRING

If

switch fails off the on the T4 terminal. Now restart the generator.

If

switch.

NOTE:

(25 to

amp-hours

with operation. many

fuse from

generator's starting battery

DIAGRAMS in this manual.

the overspeed switch

to

reset the circuit), lift the white/yellow wire

T5

terminal and connect it with the red/purple wire

this bypass

milliamps) at all times once

its starting

this

is

successful, replace the faulty overspeed

Overspeed switches

battery.

in

a

month.

slight amperage

However,

months,

it

is

the

control panel

best

DC

circuit shuts off the

is

faulty, (resetting with the stop

draw

a small amount

the

generator

This

amounts

It

is

draw

if

the

generator set

to

either

not necessary

on

switch.

to

approximately

to

be

during

normal seasonal

is

to

remove

the

the 8 amp

generator or tum off

be

reset

of

is

connected

concerned

be

unused for

amperage

ignition

by

18

if

the

A

CAUTION:

shutdown

tampering would injury

and

always

cause

should

cause

It

with

the

it

to

the

generator

is

very

important

be

installed

overspeed

malfunction.

generator's

and

shutdown

belt-driven

to

run

OVERSPEED CIRCUIT BOARD

that

the

functioning.

module,

could

be a cause

governor

away.

overspeed

Any

which

of

fail

11

A

WARNING:

running. use

the

co«ect

servicing

NOTE:

Many

more

difficult and

MAINTENANCE

Never

Wear

any

of

attempt

the

proper

tools

for

of

the

engine's

the

following maintenance procedures

may

require

safety

each

DC

the

to

perform

equipment

job.

electrical

expert

SCHEDULE

any

such

Disconnect

equipment.

knowledge

service

the

while

as

goggles

battery

of

terminals

are

simple but others

a service mechanic.

the

and

engine

gloves,

when

is and

are

SCHEDULED

MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Oil

Level

Coolant

Level

Drive

Belts

Visual

Inspection

Sparks

Plugs

Starting

(and

Engine

Generator

Fuel and

Air Exhaust

House

Oil

Lift

Gasdenser

Screen

Engine

Raw

Water

Belt

Driven

Batteries

Pump

System

Hoses

Separator

of

Engine

Batteries)

(Flame

Arrester)

Pump

Governor

CHECK

EACH

DAY

0

0 0 0 0

weekly

0

weekly

50

100

NOTE:

Keep

will

inhibit

0

0 0

D

0

D

0 0

0

HOURS

OF

250

500

engine

surface

the

engine's

0 0 0

0 0 0 0

D D D

D D D D

0

OPERATION

750

1000

1250

clean.

Dirt

and

ability

to

remain

cool.

0

0 0 0 0

D

0

0 0

D

0 0

D

Unleaded Check

necessary).

Oil dipstick.

Check Add

Inspect and

Check

oil

electrical for

Check

Every and excessive

Initial change

Check additional

D

MAINTENANCE

gasoline

for

water

level

should

at

recovery

coolant

for

proper

adjust

if

for

fuel,

connections.

loose

belt

gap,

inspect

50

operating

make

sure corrosion.

engine

both

that

AG

no

chafing-see

information.

Periodically

Clean

at

50

hrs.,

Initial

check

Inspect

for

leaks.

Check

the

exhaust

buildup

on

inside

necessary.

Hose become

Visually and

impeller.

wobble.

pump Change

governor

Check

should

spongy.

inspect

Ensure

Replace

as

needed.

governor

operation

with

octane

and

dirt

indicate

between

tank;

if

it

needed.

tension

needed.

Check

oil

and

water

Keep

tension.

for

burning

hours

connections

oil

and

filter

every 1 00

connections

inspect

at

be

cover

hours.

GENERATOR

for

leaks.

then

every

50

hours,

Check

elbow passages; that

all

hard & tight.

Check

and

for

leaks.

surface

impeller

items

as

oil

every

as

needed.

DESCRIPTION

rating

of

in

fuel

(drain/replace

MAX

and

empty,

check

(3/8"

to

1/2"

belt

edges

leaks.

Inspect

bolts & nuts

and

corrosion.

check

electrolyte

are

very

tight.

change

at

50

are

clean

and

INFORMATION

100

hours.

then

every

250

anti-siphon

for connections

Remove and

shaft

needed.

250

valve

carbon

and/or

clean

and

Replace

tighten

all

the

cam

for

is

secure

Rebuild/replace

hours.

are

89

of

higher

filter

LOW

on

at

manifold.

deflection)

for

wear.

wiring

tight.

Check

levels

Glean

off

hours,

then

secure

with

for

hours.

operation.

corrosion

replace

as

tight.

if

hoses

hose

clamps.

pump

cover

wear.

Inspect

and

does

Adjust

if

and

not

Inlet

Fuel

Filter

0 0

0 0 0

Engines & Generators

12

Replace.

NOTE:

engine

Use

hours

MAINTENANCE

the

engine

by

hourmeter

running

time.

gauge

SCHEDULE

to

log

your engine hours or record your

SCHEDUlED

MAINTENANCE

Heat

Exchanger

Coolant

System

*Starter

Distributor

*'Engine

*Exhaust

Carburetor

*Engine

*WESTERBEKE

Motor

Cylinder Compression Valve

and

Clearances

Elbow

Fuel

Timing

recommends

Fiter

Belt

Screen

this

CHECK

EACH

DAY

service

HOURS

OF

OPERATION

100

250

500

750

1000

0 0 0 0

0

50

0 0

0

0 D

0 0

D

0 0 0 0 0

0 0

be

performed

by

an_

authorizet;l

mechanic.

1250

Clean cap for

Drain, appropriate operation.

Check and pinion

Check cap

Incorrect performance,

timing

Test

casting

WARNING:

carbon

Test

casting

WARNING:

carbon

Visually inspect

Remove

MAINTENANCE

or

replace

and

clean

out

professional

flush,

and

antifreeze

solenoid

lubricate.

and

exhaust

Clean

drive. ignition

timing.

rotor.

valve

clearance

check

and

adjust

elbow

is

corroded

A

defective

monoxide

elbow

is

corroded

A

defective

monoxide

and

anode.

debris.

cleaning

refill

cooling

mix

and

motor and

Check

compression

valve

for

casting

or

deteriorated.

leakage!

for

casting

or

deteriorated.

leakage!

every

reJ>lace

DESCRIPTION

Open

heat

exchanger

Remove

every

and

pressure

system

every

500

for

corrosion.

lubricate

will

clearances.

exhaust

the

condition

result

in

poor

pressure

integrity.

elbow

integrity.

elbow

500 operating

at

3000

hours.

1000

testing.

with

hours

Remove

starter

of

distributor

engine

Replace

can

Replace

can

end

hours

of

motor

and

if

cause

if

cause

hours.

A

WARNING:

breaker

or

the

When

battery

servicing

switch.

generator/engine

components,

the

DC

power

Engines & Generators

13

must

be

turned

off

using

either

the

DC

COOLING

SYSTEM

FRESH

NOTE:

recommended antifreeze and water mixture to be used as the

fresh water coolant.

Fresh water coolant circulating pump, absorbing heat from the engine. The coolant then passes through the thermostat into the heat exchanger where it block via the suction side

engine the closed thermostat (although some coolant flow

bypassed around the thermostat to prevent the exhaust

manifold from overheating). As the engine warms thermostat gradually opens, allowing full flow coolant to flow unrestricted to the external portion cooling system.

Coolant

WATER

Refer to the ENGINE COOLANT section

is

started cold, external coolant flow is prevented by

COOLING

is

pumped through the engine by a

is

cooled, and returned to the engine

Recovery

Tank

CIRCUIT

for

of

the circulating pump.When the

is

up,

of

the engine's

of

the

COOLANT RECOVERY TANK

NOTE:

Periodically check the condition

sure cap. Ensure that the upper

good condition and check that the vacuum closes tightly.

Carry a spare cap.

of

the manifold pres-

and

lower rubber seals are

w1lve

.opens and

CHANGING

The engine's coolant must be changed according to the

MAINTENANCE

become contaminated, it can lead to overheating problems.

A

critical; a substantial traced

Drain the engine coolant by removing the drain plug on the engine block and opening the manifold pressure cap. Flush the system with fresh water, then reinstall the drain and start the refill process.

NOTE:

be used to help drain engine coolant.

A

Wear

Refilling

After replacing the engine block drain plug, close the heat exchanger's coolant petcock. Then run the engine at idle and slowly pour clean, premixed coolant into the manifold.

Monitor the coolant in the manifold and add the manifold to the filler neck and install the manifold pressure cap.

Remove the cap on the coolant recovery tank and fill with

coolant mix to halfway between

the cap. Run the engine and observe the coolant expansion

flow into the recovery tank.

After checking for leaks, stop the engine and allow it to cool. Coolant should draw back into the cooling system as the

in

engine cools down. Add coolant to the recovery tank needed and check the coolant in the manifold. Clean up any spilled coolant.

COOLANT

SCHEDULE.

CAUTION:

back

The drain petcock on the heat exchanger should also

WARNING:

protective

to

the

Coolant

Proper

coollng

Beware

gloves.

If

cooling

number

system

of

the

the coolant

system

of

maintenance

engine

corrosion.

hot

engine

LOW

and MAX and replace

is

allowed to

failures

coolant.

as

needed. Fill

can

if

is

be

·MANIFOLD PRESSURE CAP

14

COOLANT

EXPANSION

KEEP

THESE

A

FULL

FLOW

THE

COOLANT

CLEANER

PASSAGES

OF

COOLANT

RECOVERY

WORKS

WELL)

TO

COOLANT

TANK

CLEAR

TO

TANK

TO

ENSURE

AND

(A

FROM

PIPE

RECOVERY

COOLING

HEAT

EXCHANGER

Cool

raw

water

flows

through the inner

,

exchanger_ the heat of the internal engine which The engine coolant and the circuit repeats itself.

The engine coolant

this keeps deposits found

Heat

After approximately 1000 hours and pressure test the engine's heat exchanger. (A local automotive radiator shop should be able to clean and test the heat exchanger.)

NOTE:

that a heat exchanger cleaning be every

ZINE

#011885

DO

As

the engine coolant passes around these tubes

is

then pumped into the exhaust system and discharged.

(now

cooled)

and

raw

water

the

engine's water passages clean

in

raw

water.

Exchanger

Operating

1000 hours.

ANODE

NOT

USE

SEALANT

GASKET

Service

in

silty and/or tropical waters may require

__

~ILi,'·ll

tubes

of

the heat

eonducted

flows

are

to

the

raw

water

back through the engine

independent

of

operation, remove, clean

performed more often than

from

of

each

the harmful

other,

SYSTEM

If

the zinc anodes need replacement, hold the hex boss into which the zinc anode is threaded with a wrench while loosening the anode with another wrench. This prevents the hex boss from possibly tearing off the exchanger shell. zinc

is

in poor condition, there are probably a lot flakes within the exchanger. Remove the end exchanger and clean the inside

have a

spm·e

heat exchanger end gasket in case the present one becomes damaged when removing the end cover. Replace the gasket (refer to your engine model's heat exchanger end gasket part number), install a new zinc anode.

NOTE:

The threads

do

not require sealant. Sealant should not be used as it may insulate the zinc from the metal housing preventing electrolysis action

of

the zinc anodes are pipe threads

of

all zinc deb1is. Always

0-ring

of

and cover, and

the heat exchanger

on the zinc.

THERMOSTAT

A them10stat, located near the manifold at the front engine, controls the coolant temperature continuously flows through the closed cooling circuit. When the engine coolant from flowing (some coolant is by-passed through a hole in the thern1ostat to prevent the exhaust manifold from overheating). As the engine warms gradually opens. The checked, cleaned, or replaced easily. Carry a spare them10stat

and gasket.

is

first started, the closed thermostat prevents

thetmostat is accessible and can be

as

the coolant

up,

the thermostat

of

zinc

the heat

of

the

If

and

the

RAW

WATER

CLEAR

OUT

ZINC

DEBRIS

ZINC

ANODE

A zinc anode, or pencil, is located in the raw water cooling circuit within the heat exchanger. The purpose zinc anodes is to sacrifice them to electrnlysis action taking place in the raw water cooling circuit, thereby reducing the effects

of

electrolysis on other components

of

The condition and the anode cleaned or replaced

should be carried on board,

NOTE:

Electrolysis action

installation and vessel location; not that

the zinc anode should be checked monthly

as

is

the result

DRAIN

of

having

of

the system.

required. Spare anodes

of

each particular

of

the engine.

CLEAN & REUSE

Replacing

To

avoid spilling coolant, drain the coolant down below the

manifold level (REFER TO CHANGING COOLANT). Remove the cap screws and disassemble the thermostat

housing

gasket, apply a thin coat gasket before pressing it into place. Do cap screws. Replace the coolant in the manifold. Run the engine and check for normal temperatures and that there are no leaks at the thennostat housing.

the

Thermostat

as

shown. When installing the new thermostat and

of

APPLY

SEALANT

AT

ASSEMBLY

sealant on both sides

not over-tighten the

of

the

COOlANT TEMPERATURE

SWITCH

#033950

NEW

ZINC

ANODES

THERMOSTAT ASSEMBLY

15

RAW

WATER

The

raw non-ferrous flexible the

impeller

account should this pump lubricant for the

impeller Raw

water

water)

is not present

are

not warrantable,

raw

water

has

a limited lifetime

NOTE:

Should a

(seals

and

a

new

pump and

Inspecting/Changing

Close the raw water

and, with the proper impeller out of the a pair

of

care not

gasket. Move the blades to and

push the impeller assembling, and

gasket. Open the raw water intake

Run

the engine and

check for water

flow

indicates

PUMP

water

pump

housing

blades

which

housing,

impeller.

and

impeller

plimp

impeller

flow

is

failure

bearings),

rebuild

screwdrivers

to

tear the

apply

discharge

the

is

a self-priming,

and a neoprene

wipe

against a curved

producing

be

There

cover

gasket

failures

during

engine

and

operators

present

and

at

start-up.

must

occur

it

may

be

the

original

the

intake

valve.

size

impeller

pump

(the impeller

if

an

impeller puller

impeller).

conform

into

the

a:

thin

coating

check

fpr

at

pump

has

the not

impeller.

the

pumping

run dry

should

(an

occur

operation.

are

b~

inspected

with

the

more

Raw

Remove

tool,

Install

pu11J.p's

of lubricant

leaks

stern

primed

rotary

pump

The

cam

action.

as

water

always

impeller

when

cautioned

The

neoprene

regularly.

pump~

cost

effective

pump

as a spare.

Water

the to

Pump

the

carefully

can

be

is

unavailable.

new

impeller

the

curved

housing.

valve.

around

the

tube.

Absence

itseif

COOLING

with

a

impeller

plate

acts

be

kit)

lubricant

Such

to

internal

to

pump

pry

pried

cam

When

to

the

pump.

properly.

bas

within

On

no

as

a

spare

aboard.

(raw

failures

make

sure

impeller

par.ts

purchase

Impeller

cover

the

out

using

Take

and

plate

impeller

Also

of

water

·

SYSTEM.

RAW

WATER

NOTE:

Always

the

strainer

A clean engine's cooling

strainer

in

the

glass

Perform operation:

1.

Qose the

2.

Remove

3. Clean

4.

Replace

5. Reassemble

6.

Open the seacock.

7.

Run

NOTE:

Also follow

aground.

If

the

engine temperature normal may

have

raw

water through

INTAKE

install

will

always

raw

water intake strainer

when

making

should

the

following

raw

and

the

glass.

the

engine

reading, the

been caught

STRAINER

the

strainer

be

self-priming.

system.

clean

sealing washer

arid

Include a visual

your periodic

be

clear.

maintenance after

water seacock.

the

strainer

install

the

and

check for

the

above

procedure

gauge

cause

may

up

in

the

cooling

at

or

below

the

waterline

is a vital

filter.

if

necessary.

strainer.

leaks.

ever

be.that silt, leaves or

strainer,

system.

inspection

engine

every

after

shows

slowing the

component of

check.

T!:te

100

having

a higher

·

of

this water

hours

run

than

grass

flow

so

the

of

hard

of

NOTE:

of

dry

GREASE

THE

CHAMBER

TO

FEW

THE ONLY REPLACED SIGNS

WITH

PROVIDE

SECONDS

0-RING

NEEDS

IF

OF

WEAR.

A

Impeller,

the exchanger

Never

allow

running

BLADES

LUBRICATION

THE

LINE

GASKET

TO

IT

may

AND

PETROLEUM

PUMP

UP

SLOT

BE

SHOWS

CAUTION:

they

cooling

circuit.

THE

FOR

HAS

IN

must

the

pump

destroy

PUMP

JELLY

THE

TO

RUN

If

any

be

They

to

run

the

impeller.

DRY.

·.

RAW

of

the

located

often

dry.

Even a short

WATER

blades

have

tu

prevent

can

be

period

PUMP#42026

·broken

found

off

bluckage

in

the

in

heat

the

RAW

WATER

INTAKE.SmAINER

(OWNER

INSTALLED)

Engines & Generators

16

ENGINE

OIL

GRADE

Use

a heavy duty engine oil as called for in the Specifications engine

oil and filter after the initial 50 hours break-in operation. Then follow the oil and filter change

SCHEDULE

Section

intervals

in

of

this manual. Change the

as

specified in MAINTENANCE

this

manual.

of

LUBRICATING

A

contaminants. and discard used

OIL

.WARNING:

nails

thoroughly

clothing

iJ.i/

properly.

Used

Avoid

or

engine prolonged using

soap

rags

containing

oil

contains

skin

and

contact.

water.

used

oil.

baimful

Clean

Launder

Discard

skin

or

Westerbeke disapprove the use oils

are used, engine break-in must

using conventional be

as

section oils

a..re

CHANGING

The engine oil from

allow hose is

properly

been Always

emulsimi this

condition

prevent

is

present

be

the engine circuit

NOTE:

ofthe oil white-smokey/oil starting or

Corporation does not approve or

of

synthetic oils.

oil.

Oil change intervals.must

listed in the MAINTENANCE SCHEDULE

of

this manual and not extended

used.

THE

ENGINE

should

its

attachment bracket

the

oil

to

drain,

and

pump

the

secured

drained.

obser:ve

selious

result of a

and/or

into

Be

the

indicates

is

rare,

damage.

in

the

oil.

a siphoning

the

exhaust,

very

careful

sump

will

no

star(

the

fault

laden

old in

Raw

result

and fouled spark

OIL

be

warm.

and

or

attach a pump

oil

out.

its

holder after

old

oil

as

presence

it

does

Call

water present

in

the

through

filling

not

to

in

exhaust

require

exhaust system

overfill erratic

If

synthetic

be

performed

Remove lower it

to

Make

sure

all

it

is

removed. A yellow/gray

of

water

prompt

a competent

in

the

raw

into

the

engine.

the

operation

discharge,

plugs.

if

synthetic

the

oil

drain

hose

into a container

the

end

of

the

oil

drain

of

the

old

oil

has

in

the

oil.

Although

attention

mechanic

the

oil

attached

water

oil

sump.

possible

can

cooling

Overfilling

of

the

to

if water

to

engine,

ham

and

drain

hose

the

Replacing

Whe~

removing

punch

a hole

to

drain

the

to

lessen

helpful

in

and

a plastic

any

oil that's

removed

- off

with

the

sealed

against

installing

sealing

surface

thin

coat of

the

oil.

filter.

and

tighten

NOTE:

Use

·

are

not

recommended.

REFILLING

Add

fresh

run

the

engine

oil

Rressure

oil

filter or engine. dipstick:

Then

the

in

the

oil

into

spillage.

removing

bag

in

the

to

make

old

oil

the

new

on

clean

Screw

the

filter fmnly

genuine

THE

oil

through

for a few

..

Make

from

cheek

Fill

to,

Oil

Filter

the

used

oil

filter,

upper

and

lower portion of

a container before

An

automotive filter

the

old

oil

around

the

filter

filter.

Inspect

sure

that

the

filter.

If

this

oil filter

oil filter element,

the

engine

OIL

the

but

adapter,

oil

filter adapter

oil

to

the

filter onto

by

WESTERBEKE

SUMP

the

valve

moments

sure

there

is

oil

drain system,

the

quantity

not

over,

the

you

may

removing

wrench

filter.

Place

some

when

unscrewing

the

old

oil

rubber sealing

rubber

sealing

gently

remove

wipe

the

free

the rubber

the

hand.

cover.

while

no

pf

FULL

threaded

oil

filters.

After

checking

leakage

and

oil

with

mark

sealing

then

find

it

the

it.

should

paper

filter

gasket

filter

of

oil

Generic

refilling

around

stop

the

lube

on

helpful old

This

be

it

to

as

it

is

comes

remains

it.

When

gasket's

and

apply

gasket

filter

the

engine's

the

oil

the

dipstick.

to

filter

helps

towels

catch

a

on

stub,

filters

oil,

new

OIL

l:JRAiN

WARM

THE

ENGINE,

THE

OIL

JNTO

SUITABLE

SHUTDOWN

A

CONTAINER

AND

DRAIN

cC~<PL..t:.---'1/4"

NPT

FOR

ADDING

AN

EXTENSION

Engines & Generators

17

SPIN·ON

OIL

#036918

TURN

HAND

SEALING

APPLY

.

WHEN

NEW

FILTER

TIGHT

GASKET

CLEAN

OIL

ASSEMBLING

FILTER

REMOTE

OIL

PN

INSTALLATION

This popular accessory is used to relocate the engine's oil

filter from the engine an engine room bulkhead.

NOTE:

Refer to ENGINE OIL CHANGE

instructions on removing the oil filter.

to

a more convenient location such as

in

this manual

for

FILTER

(OPTIONAL)

#052537

To

install, simply remove the engine oil filter and thread WESTERBEKE's remote oil filter kit install this kit with the oil filter facing down as illustrated.

Contact your WESTERBEKE dealer for more infonnation

NOTE:

Westerbeke

incorrect installation

A

CAUTION:

rectly. pass

valve

from

reaching failure. immediately

If

the

in

there

is

not responsible

of

/t

is

oil

flows

the

filter

the

engine

is

no

and

check

for

the Remote Oil

vital

to

install

in

the

reverse

assembly

will

causing

oil

pressure

the

reading,

hose

connections.

as

shown. Always

engine failure due

Filter.

the

oil

lines

direction,

prevent

an

internal

the

engine

shutdown

on

to

cor·

by·

oil

APPLY A THIN INSTALLING TIGHTEN

AN

CONTACTS

NOTE

THE

"IN"

ON

THE

ADAPTER

REMOVED

FOR

WILl

BE

RECONNECTED

COAT

OF

THIS

KIT.

THREAD

ADDITIONAL

THE

BASE.

I

/

AND

"OUT"

WHEN

INSTALLATION

CORRECTLY

CLEAN

Oil THE

3/4

TURN

MARKINGS

THE

HOSES

SO

TO

KIT

AFTER

ARE

THEY

THE

ON,

0-RING

THEN

THE

D-RING

WHEN

HAND

THE

IN

CONNECTION

MUST

ATIACH CONNECTION REMOTE

OIL

THE

OUT

CONNECTION

MUST

ATIACH CONNECTION REMOTE

Oil

AT

FILTER.

TO

THE

AT

THE

FILTER.

TO

THE

HOSE

OUT

HOSE

IN

APPLY A THIN GASKET

WHEN CONTACTS 3/4

THE

TURN.

COAT

OF

ClEAN

INSTAlliNG.

BASE,

TIGHTEN

OIL

AFTER

IT

AN

TO

THE

FILTER

THE

FILTER

ADDITIONAL

Engines & Generators

18

OIL

NOTE:

WESTERBEKE recommends that the following engine

adjustments be peiformed by a competent engine mechanic.

The information below is provided

DESCRIPTION

The lubricating system

oil pump. The engine oil oil pump, which drives the oil, under pressure, through the oil filter, oil cooler and various lubricating points in the engine. The oil continuous cycle. When the oil pressure exceeds the specified pressure, oil pump and returns within its specified range.

TESTING

To

test the oil pressure, remove the hex head plug from the oil manifold and install a mechanical oil pressure gauge place. After warming up the engine, set the engine speed at

1800 rpm and read the oil pressure gauge.

Oil

Pressure

Note:

sure up to 70

pressure as low

on the load placed on the generator.

OIL

Belween

A newly started (cold) engine may have an oil pres-

or

is

a pressure feeding system using

is

drawn from the oil sump by the

then returns to the oil sump

the

oil pushes open the relief valve in the

to

the oil sump, keeping the oil pressure

to

repeat the

PRESSURE

50

and

60

psi

ai18DO

rp_m.

80

psi. A warmed engine can have an oil

as30

psi. Oil pressure will vary depending

in

PRESSURE

to

assist the mechanic.

LOW

OIL

PRESSURE

an

its

The specified safe minimum oil pressure

+

0.1 worn bearings. For additional information on readings,

OIL

The generator

pressure for some reason drop below the minimum, the switch contacts will open, breaking the DC circuit to the run

A

pliers, switch. Snap-on, switch

2

kg/cm

).

see

the

PRESSURE

relay,

shutting the unit down.

CAUTION:

vise

Use

Proto,

will

is

4.3 + 1.4

A gradual loss of oil pressure usually indicates

ENGINE TROUBLESHOOTING chart.

low

oil pressure

psi

(0.3

SWITCH

is

fitted with an oil pressure switch. Should oil

K2

OIL

grips

or

the

correct

New

cause

PRESSURE pipe

Britain

oil

leaks

SWITCH-Do

wrenches

socket

which

and

others.

and/or

on

the

is

available

Damage

switch

not

use

oil

pressure

failure.

lock

from

to

the

+

TESTING

OIL

PRESSURE

OIL

PRESSURE

SWITCH

(NORMALLY

OPEN)

t-

OIL

PRESSURE

Engines & Generators

19

FUEL

SYSTEM

GASOLINE

Use unleaded 89 octane or higher gasoline. When fueling,

U.S. Coast Guard regulations, close off all hatches and

follow companionways to prevent fumes from entering the boat, and ventilate after fueling.

NOTE:

The engine compartment should have a gasoline fume

detector/alann properly installed

GASOLINE/WATER

A primary fuel filter installed between the fuel tank and the engine to remove water and other contaminants from the fuel before they can be carried to the fuel system

Most installers include a type installation package as they are well aware that contaminates in the fuel can cause.

These gasoline filters must have through) to meet bowls have drain valves to use when checking for water and impurities. The Filter rating must

SEPARATOR

of

the water separating type must

U.S. Coast Guard requirements. The metal

GASOLINE/WATER·

SEPARATOR & FILTER

(OWNER

A

WARNING:

servicing

that

may

other

sources

Ensure

proper

the

fuel

spill.

of

ventilation

INSTALLED)

Shut

system.

DO

NOT

fire

near

system.

and working.

AND

on

the engine.

of

filter/water separator with the

metal bowls (not see-

10

off

the

fuel""''"'!;-""'"'"""'

Take

care

allow

any

smoking,

the

fuel

exists

when

FILTER

of

in

catching

system

servicing

be

the problems

any

open

flames

when

servicing. the

fuel

or

FUEL

LIFT

PUMP

Periodically check the fuel connections to and out

is

and make sure that no leakage are tight and secure. The pump's mounting bolts should be clean and well secured by the mounting bolt to ensure proper pump operation.

A

WARNING:

connections Make fuel

system

The start sequence energizes the fuel lift pump as the piston in the pump operates, it creates ticking

Also check that the ground wire is properly connected to the ground.

is a fire

sure

proper

components.

is

heard, check for 12 volts at the pump connections.

DC

Fuel

leakage

hazard

ventilation

present and that the fittings

ground connection at one

at

the

fuel

and

should

exists

whenever

an

audible ticking sound.

of

pump

be

corrected.

servicing

the pump

of

or

its

If

GASDENSER

The gasdenser cools the fuel to prevent vapor lock. There no maintenance required except making certain the fuel fittings are tight and secure.

TO

CARBURETOR

FUEL

LIFT

PUMP

#039273

the

no

is

CARBURETOR

The carburetor

solenoid operated choke. (Refer to the following pages)

INLET

FUEL

1. Shut off the fuel supply to the generator. Disconnect the

fuel supply line to the inlet filter and unscrew the filter from the pump inlet. Take care to catch any fuel that may

be present.

2.

Thread on the replacement inlet filter and connect the fuel supply line. Use care when connecting and tightening the

fuel supply line so as not to distort the inlet

3. Turn on the fuel supply to the generator and start the generator. Ensure that there are no leaks.

is

a single barrel downdraft type with

FILTER

filter.

an

electric

TO

EXCHANGER

Engines & Generators

20

HEAT

INLET

FUEL

FILTER

#048076

CARBURETOR

CURRENT

CARBURETOR

The carburetor cleanable metal screen air intake filter/spark arrester. The choke is operated by a 12-volt choke solenoid activated when

ON switch

the

Air

Screen/Flame

The air screen/flame arrester can easily be removed by releasing the hold-down clamp. Clean after the first of

operation, every

screen in a water soluble cleaner such

Fuel

Filter

To

ensure proper operation, there must be a Coast Guard approved filter/water seperator between the fuel supply and the engine. This filter must good quality and properly maintained.

is

a single barrel, down-draft type with a

is

depressed.

Arrester

100

hours from then on Clean the air

as

GUNK.

(10 microns or less) installed

50 hours

be

of

MODELS

PN.052315

ROCKER

COVER

COOLANT

PUMP

CHOKE SOLENOID

FUEL

SHUT-OFF

SOLENOID

--·u

__

..

__

CARBURETOR

Engines & Generators

21

PN.

052315

'

CARBURETOR

The carburetor

cleanable metal screen choke

is

the

ON

Air

Screen/Flame

The

ai[

releasing of

operation,

screen

in

Fuel

Filter

To

ensure proper operation, approved filter/water seperator between good

quality

is

operated

switch

a single

by

is

depressed.

barrel,

ai~

intake filter/spark

a 12-volt choke solenoid activated

Arrester

screen/flame

the

hold-down

a water soluble cleaner

the

fuel

arrester can easily

clamp.

every

100

hours

supply

and

and properly maintained

down-draft

Clean

from

such

there

(10

the

engine.

after

then

as

must

microns

..

·CARBURETOR

EARLIER MODEL #046444 (NLA)

type

with

a

arrester.

be

removed

the

on

Clean

GUNK.

be

a.

Coast

or less) installed

This

·

first

filter

The

by 50

the

air

Guard

must

when

hours

be

~

'~~

'-

of

AIR

BREATHER

MUST

BE

..

INSPECT

KEPT

LINE CLEAN

-----

-------

"--~---~

l'----1

~-1

)LJ

--

COOLANT. PUMP

THROTTLE

LIN~GE

KEEP

LINKAGE

LUBRICATED

(GRAPHITE)

FUEL SOLENOID

11043800

WELL

SHUT

·OFf;_·'

_...,_~

CARBURETOR. FILTER

SCREEN

#038090

CHOKE

SOLENOID

·11038038

HEX

PLUG

CHOK.E

(FUEL)

ASSEMBLY

INCOMING

FROM

FUEL

PUMP

Engin~s

FUEL

LIFT

-~-Generators

21a

ENGINE

ADJUSTMENTS

SPARKPWGS

The spark plugs should

first

50 hour break-in period, then inspected every 250 hours

thereafter and replaced as needed.

A

WARNING:

the

engine

is

hot.

removing

SPARK SPARK

NOTE:

the

spark plugs will

of

the

them.

PLUG

GAP:

0.027-

PLUG

TORQUE:

Loctite Anti-Seize applied

spark plugs

Do

not

Allow

0.031in.

101

-15

retard

easier.

be

cleaned and re-gapped after the

remove

the

lb·ft

the

spark

engine

(0.7 • 0.87mm).

(1.5-

to

cool

2.31

kg-m).

to

the

threaded portion

plugs

before

corrosion, making future

INSPECTING THE PLUGS

CHECK

~BUILD

t

~

HIGH

TENSION

Check the ignition wires compartment heat can deteriorate the wires.

Check the resistance

because the wire connection inside the

separated the wires cap, then pull the cap

The resistance value is 410 ohm per inch of wire.

or

from

CORDS

the

insulator

the spark plugs, grasp

(IGNITION

every

of

each

may

off

the

wire.

spark plug.

500 operating hours as engine

Do

be

damaged. When removing

i

GAP

T

WIRES)

not pull on the wire

cap

may become

and

twist the moulded

while

of

removal

SPARK

FOR

CARBON

UP

AND

DRIVE

The drive belts must be properly tensioned. Excessive drive belt tension can cause rapid wear

service life the presence resulting

The

BEG governor and alternator water belts is as follows:

A

drive

·

BURNIN~

1. Remove the belt guard.

2.

To

adjust the governor drive belt, loosen the two governor

mounting bolts. To

adjust the raw water pump/fresh water pump drive

belt, loosen the two raw water pump mounting bolts.

3.

With the belt(s) loose, inspect for wear, cracks, and frayed edges, and replace

4.

To

loosen governor in bolts.

To pump drive belt, slide the raw water pump in

· required, then retighten its mounting bolts.

5.

The drive belts are properly adjusted no less than 3/8 inch (lOmm) and

(12mm) as the belt is depressed with the thumb at the

midpoint between the two pulleys the belt.

NOTE:

proper belt operation.

carried

6.

Operate the generator for about 5 minutes then shut down and recheck the belt(s) tension.

7.

Replace the belt guard.

BELT

ADJUSTMENT

of

the belt and reduce the

of

the fresh water pump's bearing. A slack belt or

of

oil

on

the belt can cause belt slipping,

in

high operating temperatures.

generators have two drive belts,

and

the other drives

pump.

The tension adjustment procedure for

WARNING:

belt's

loosen

Maintain a 22lb pressure

on

Never

attempt

tension

or

while

if

necessary.

tighten the governor drive belt, slide the

or

out as required, then retighten its mounting

tighten the raw water pump/fresh water

Spare

to

check

the

engine

is

if

no

more than 1/2 inch

on

the longest span

to

the

belts should always

in

it can be deflected

belt's outer face for

board.

one

drives

the

raw

both

or

adjust

the

operation.

or

out as

be

the

of

CHECKING

RESISTANCE

ngines & Generators

22

ENGINE

NOTE:

WESTERBEKE adjustments The

information below

be

peiformed

ADJUSTMENTS

recommends

by

is

provided

that

a competent

to

assist

the

following engine

engine

mechanic.

the

mechanic.

ENGINE

SPEED

(HERTZ)

ADJUSTMENT

Governor

The belt-driven, mechanically operated governor maintains

the engine's rpm under various load conditions. Engine speed determines the hertz and voltage output

Governor

Operate the generator to bring the unit up to operating temperature before adjusting the governor.

NOTE:

adjust before

There are three adjusting points on the governor

(see illustration).

1.

Increase/Decrease Speed Adjustment. This adjusting bolt

sets the no-load speed between the governor arm and throttle lever should adjusted to hold the throttle full open when the engine is

not running.) Make sure this linkage moves freely and that the ball joint connectors are properly lubricated.

graphite lube for this purpose. Disconnect the ball joint

and apply graphite lube to the inside

Hunting/Regulation Adjustment.

2. engine speed between no-load and full-load is too great,

adjust this eye bolt to draw the spring closer to the lever hub. The increase/decrease speed bolt may need to be adjusted as well.

If move the spring away from the lever hub (check speed adjustment).

Bumper

3.

a no-load surge into the governor so far that it increases the no-load speed.

Adjustments

If

the

governor is severely out

the

linkage

proceeding

the governor surges under load, adjust this eye bolt to

at

no-load

with

Screw

Adjustment. This screw is used to remove

ONLY. NEVER tum the bumper screw

to

obtain a safe output voltage

the

adjustment.

of

the engine. (The linkage arm

of

the generator.

of

adjustment,

of

the joint.

If

the variation in

manually

be

Use

Governor

1. Periodically lubricate the linkage arm attaching points at the governor arm lubricant

NOTE:

Maintenance

and

throttle lever. Use a graphite

or

equivalent.

Free

movement

of

this

linkage arm

is

important for

proper governor/throttle operation.

2. Governor (Synthetic oil is recommended).

NOTE:

3. To change the oil, remove the oil fill plug. Place a small container under the governor and remove the governor drain plug.

Allow the oil to completely drain. Replace the governor

drain plug. Then located on the back with three ounces out plug and the oil fill plug.

KEEP

LINKAGE

WELL

LUBRICATED

Oil Capacity: 3 ounces

Do

not overfill

of

the oil fill level opening. Replace the allen head

LINKAGE

ARM

INunit:I\~>1:/Ut:urlt:Ai:.r:

SPEED

ADJUSTMENT

the

governor.

remove

the

of

the governor. Fill the governor

of

oil

or

SAE

1

OW

/30 oil.

alle~

head oil fill level plug

more until oil starts to flow

FILL

(UNDER)

4. Periodically adjust the governor belt tension (see DRIVE

ADJUSTMENTS). Since belts stretch slightly, this

BELT

stretching will, to some degree, affect the governor's

action.

23

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic.

ADJUSTMENTS

TIMING

BELT

A

CAUTION:

reduces belt

sprocket

These

parts

ously

contaminated

these

parts,

and

crankshaft

1

UPPER

INSPECTION

Water

the

service

should

check

COVER

and

oil

life of

tensioner

never

with

the

seals

AND

REPLACEMENT

or

oil

on

the

belt.

free

of oil

be

cleaned.

dirt

or

oil.

front

case,

for a possible

5

BELT

TENS

timing

Keep

the

and

Replace

If

oil

is

oil

pump

leak.

7

SPROCKET

lONER

belt

severly

timing

greese.

if

seri-

evident

oil

seals,

BOLT

on

9

ENGINE SUPPORT BRACKET

8

CAMSHAFT

SPROCKET

TIMING

BELT

ASSEMBLY

TIMING

BELT

1 0

BELT

REAR

COVER

NUMBERS

ORDER

TIMING

Using pliers, grip the tensioner spring projection and remove

it from the oil pump case stopper. Then, remove the tensioner

spring and the timing belt tensioner.

NOTE:

belt to indicate the direction This will ensure

~wd

INDICATE

OF

DISASSEMBLY

BELT

If

the timing belt is to be reused, chalk an arrow on the

THE

REMOVAL

of

rotation before removing

the

timing belt is fitted correctly when

VJ

it.

4

TENSIONER

SPRING

6

CRANKSHAFT

PULLEY

REMOVING THE

TIMING

BELT

·

SPROCKET

Using the special tools shown in the illustration, lock the camshaft sprocket

sprocket bolt.

·~

BOLT

REMOVAL

in

position and then loosen the camshaft

(CAMSHAFT)

·CAMSHAFT SPROCKET

24

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information below

ADJUSTMENTS

is provided to assist the mechanic.

Timing

Replace the belt

Belt

Inspection

if

any

of

the following conditions exist:

1.

Hardening resilience, and leaves

fingernail.

2.

Cracks on rubber back.

3. Cracks

4.

Cracks on tooth bottom.

5. Cracks on belt.

6.

Abnormal wear they are sharp as

7. Abnormal wear on teeth.

8.

Tooth missing and canvas fiber exposed.

of

back rubber-back side

or

peeling

of

canvas.

of

belt sides. The sides are normal

if

cut

no

indent when pressed with

by

a knife.

~

is

glossy, without

if

Belt

Tensioner

Replace the belt tensioner turned.

Tensioner

1.

Lock the timing belt tensioner in the illustrated position.

2. Fit one portion oil pump case.

Inspection

if

it binds, rattles, or is noisy when

Spring

of

Installation

TIMING TENS

the tensioner spring projections over the hooked

the belt tensioner and fit the tensioner onto the

BELT

lONER

5.

RUBBER EXPOSED

7.

Sprocket

Using the special tools shown camshaft sprocket in position and tighten the camshaft sprocket bolt to the specified torque.

Bolt

Installation

in

&.

8.

(Camshaft)

the illustration, lock the

JENSIONER

/SPRING

3. Grip the other tensioner spring projection and fit it onto the oil pump case lug as shown the timing belt tensioner in the direction shown and temporarily tighten the bolt.

PUMP

I

CASE

OIL

in

the illustration. Move

TENS SPRING

,

TIMING TENSIONER

lONER

BELT

LOCKING

THE

CAMSHAFT

SPROCKET

25

ENGINE

NOTE:

WESTERBEKE adjustments The

information below

ADJUSTMENTS

recommends

be

performed by a competent engine

is

provided

that

to

the

assist

following engine

meclumic.

the

mechanic.

Timing

CRANSHAFT PULLEY

Belt

Installation

CAMSHAFT-....___..,..._(;.~

SPROCKET

1.

Align the camshaft timing mark with the timing mark on the cylinder head.

ALIGN

TIMING

THE

MARK

5. Tum the crankshaft twice

direction (clockwise) and check that the timing marks are correctly aligned.

in

the normal rotating

2.

Align the crankshaft timing mark with the timing

on

mark

3. Keeping the tension side timing belt onto the crankshaft sprocket, camshaft sprocket, and tensioner pulley in that order.

4. Loosen the tensioner pulley mounting bolts by 1/4 to

112

tension to the timing belt.

the front case.

of

the timing belt tight, fit the

of

a turn and allow the tensioner spring to apply

A

CAUTION:

camshaft's

to

the

timing

as

described

This

driving

belt. above.

procedure

torque

to

Be

sure

to

Do

not

utilizes

apply

turn

the

tension

the

crankshaft

reverse.

6. Tighten the tensioner pulley mounting bolts.

IDLER

PULLEY

BOLTS

TORQUE

7. Replace the timing belt covers.

TIMING

BELT

COVER

BOLTS

23

Nm

TORQUE

11

(17

Nm

ft-lb)

(8

ft-lb)

evenly

in

.26

ENGINE

NOTE:

WESTERBEKE recommends that the following engine

adjustments be peifomzed by a competent engine mechanic.

ADJUSTMENTS

ENGINE

COMPRESSION

TEST

1. To check the engine's compression pressure, warm up the

engine then shut it down.

2. Remove the spark plug and install a compression adapter (screws into a plug hole) with a gauge.

3. Close off the raw water intake seacock.

4. Crank the engine with the start motor and unplug the ignition coil and allow the compression gauge maximum reading and record.

5. Measure the compression pressure for all the cylinders. Ensure that compression pressure differential for each cylinder

Compression

6.

If

below the limit, add a small amount the spark plug hole and repeat steps 3 and

(a)

piston ring and/or cylinder wall may be worn or damaged.

(b) sure suspect poor valve contact, valve seizure, or valve

wear,

7. Reinstall plugs and ignition wires.

8. Open the raw water

is

within the specified unit.

pressure

should

not

differ

by

more

a cylinder's compression or pressure differential is

of

If

additional

If

additional oil does not increase compression pres-

of

oil causes an increase

thru

seacock.

to

reach a

than

14

psi

(100

Kpa).

engine oil through

4.

of

pressure, the

IGNITION

TIMING

1. Attach a timing light to the # 1 spark plug and mark the

front crankshaft timing groove and the timing mark on the

scale embossed on the engine's front cover.

Each timing mark represents

CRANKSHAFT PULLEY

2. Start the engine and warm the engine to its normal operating temperature.

3. Using the timing light, position the timing groove in the front crankshaft pulley approximately top timing mark on the timing scale embossed on the engine's front gear case cover. Do this by loosening the Hex B securing screw for the distributor and slowly rotating the distributor body to position the crankshaft pulley mark.

IGNITION

TIMING

AT

1800RPM:

SO.

20°

BTDC ± 1°

114

inch above the

MEASURING COMPRESSION

Standard

Compression

(limit

of

difference

between

cylinders)

165 14

p.s.i.

at300

DIAL

rpm

GAUGE

27

ENGINE

The

following troubleshooting tables are based upon certain

most

engine problem indicators and the

problems.

.When troubleshooting indicates

ELECTRICAL SYSTEM WIRING

reveal other possible causes

listed below.

of

the problem which are not

an

likely causes

electrical problem, see the

DIAGRAMS.~

as these may

TROUBLESHOOTING

NOTE:

The

of

the

protected by a 20-Ampere manual reset circuit

located just outboard

engine's control system (electrical system) is

of

the starter motor.

breaker

PROBLEM

Engine crank.

Engine fails

to

does

not

cranks start.

but

1.

2.

3.

4.

5.

6.

7.

8.

9.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

PROBABLE

Voltage

drop

at

terminal.

Engine

20A

circuit

tripped.

Battery

is

low

or

Loose

battery

connections.

Faulty

wire

connection.

Faulty

start

switch.

Faulty

start

relay

Faulty

starter

solenoid.

Raw

water

filled

Out

of

fuel.

Engine

is

flooded.

a.

Carburetor

or

damaged.

needle

b.

Float

Repair

c.

Float

securing gasket

Fuel

pump Worn High

(wet Faulty Faulty Faulty Faulty No

engine

Filters

fuel. Voltage

switch.

Faulty and

float

valve

in

carburetor

or

replace

chamber

screws

and/or

inoperative.

or

faulty

spark

tension

wires

system}.

ignition

coil.

distributor.

run

relay

wire

connection.

compression.

are

clogged

drop

at(+)

overspeed switch. (by-pass

test

run)

CAUSE

starter

solenoid

breaker

dead.

(K1

).

cylinders.

needle

Clean

or

is

float.

gasket

are

loose.

tighten

plugs.

grounding

(K2}.

by

contaminated

at

overspeed

has

valve

open

replace

the

leaking.

damaged

Replace

screws.

or

PROBLEM

Engine and

then

down.

Engine

but

does

up

to

speed.

Engine

starts,

shuts

starts,

not

hunts.

runs

come

1.

Faulty (oil temperature

2.

High

temperature.

3.

Dirty

4.

Mechanical

supply

5.

Low

6.

Faulty

1.

Fuel

2.

Mechanical

fuel

3.

Throttle

4.

Faulty

5.

Faulty

6.

Choke

7.

AC

8.

High

1.

Low

2.

Generator

3.

Cracked

4.

Faulty

5.

Faulty

6.

High

7.

Valves

8.

Governor

9.

Dirty

10.

Throttle

PROBABLE

shutdown

pressure,

line

supply

generator

water,

or

engine

water

fueVwater

check

faulty

(if

oil

level

in

fuel

pump.

restriction.

check

is

restricting

plate

binding.

fuel

pump.

wire

connection.

stuck

closed.

overload.

exhaust

pressure.

battery

voltage.

is

overloaded.

distributor

high

tension

fuel

pump.

exhaust

back-pressure.

are

out

is

out

fuel

filters.

linkage

CAUSE

switch,

exhaust

overspeed).

or

exhaust

separator

installed).

sump.

of

ot

is

filters.

valve

at

valve

at

fuel

cap wires.

adjustment.

adjustemnt.

binding.

the

fuel

flow.

Engines & Generators

28

ENGINE

TROUBLESHOOTING

PROBLEM

Engine

Low

oil

High

oil

misfires.

backfires.

overheats.

pressure.

Poor

1.

Incorrect

2.

3.

Dirty

4.

Cracked Faulty

5.

6.

Spark

7.

8.

Valve

1.

Spark wrong.

2.

3.

4.

5.

6.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

6.

7.

1.

2.

PROBABLE

quality

flame

distributor ignition plugs

High

exhaust

clearances

plug

Incorrect Engine

is

flooded

under

to

start.

Dirty

flame Cracked High

exhaust Coolant

loss.

cooling

system.

Faulty

raw

Belts

are

Raw

water Faulty

thermostat.

Low

oil

level.

Wrong

SAE

Wrong

type

Relief

valve

Faulty

oil

Faulty

engine

Faulty

oil

Dirty

oil

engine. Relief

valve

CAUSE

fuel.

timing.

arrester.

wires.

are

worn.

back-pressure.

are

wires

are

timing.

flooded.

distributor

loose

or

See

Engine

arrester.

back-pressure. Pressure

water

pump

or

broken.

pump

worn.

type

oil

filter.

is

stuck.

pump.

bearings.

filter.

wrong

SAE

is

stuck.

cap.

incorrect.

connected

Engine

cranks

cap.

test

impeller.

in

the

engine.

type

oil

is

but

in

fails

the

PROBLEM

No

DC

charge

starting

battery.

Blue

exhaust discharge engine.

Black

exhaust discharge engine.

Poor

performance

at

generator

smoke

from

speed.

to

the

smoke

the

PROBABLE

1.

Alternator

2.

Loose/corroded DC

alternator

3.

No

excitation

4.

Faulty

regulator.

Faulty

5.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

6.

7.

8.

1.

2.

3.

4.

5.

alternator.

Lube

oil

High

lube Crankcase Valves

are

incorrectly. Piston

rings

or

unseated.

Dirty

flame

Faulty

carburetor.

Idle

mixture Accelerator Valves

are

adjusted. Lube

oil

Piston

rings

Crankcase

Main

jet

Carburetor

Remove Fuel

pump

clean.

Air

intake

and

clean.

Governor

drive

belt

connections

to

alternator

is

diluted.

oil

level.

breather

worn

or

are

arrester.

jet

too

diaphram

worn

is

diluted.

are

breather

clogged.

inlet

filter

and

clean.

clogged.

filter

screen

needs

CAUSE

slipping.

regulator.

hose

is

clogged.

adjusted

worn

rich.

leaking.

or

incorrectly

worn

or

unseated.

hose

is

clogged.

remove

and

clogged.

Remove

dirty.

adjustment.

on

clean.

and

Remove

Engines & Generators

29

ALTERNATOR

The charging system consists of a

with

a voltage regulator,

. mounted

cables. Because of the

electronic voltage regulator internally or

#14

DC

BROWN

TO

TB2-4

1114

VIOLET

TO

FUEL

SOLENOID,

LIFT

PUMP

.

DISTRIBUTOR

circuit breaker

on

the

AND

an

engine

and

use

of integrated circuits (IC's

is

very

back of

the

alternator.

DC

ELECTRICAL

DC

belt driven alternator

DC

wiring harness, a

a battery with connecting

),

the

compact and

is

mounted

/51

AMP

•

SEE

t

FOR

WIRING

WIRE

SYSTEM

1.

Start

2.

After the engine has starting battery voltage at multimeter set

a. If

b.If

TO

STARTER

·soLENOID

ALTERNATOR

DIAGRAM

CONNECTJQ!if$._

the

engine.

run

for a few

the

battery terminals

on

DC volts .

the

voltage

tor

is

working; omit Steps 3 through 8

to

"Checking the Service Battery"

the

voltage remains around exists continue with Steps 3 through

is

with

either

MULTIMETER

increasing toward

the

alternator or

;.._.·

__,'"'"G

minutes,

12

~oits,

8.

--

miD

COM

measure

14

volts,

and

on

the next

-~problem

the

charging

...

using

the

go

the

a

alterna-

directly

page.

circuit;

ALTERNATOR

A

WARNING:

hot.

Do

Use

this exists with determined that have a qualified technician check

The alternator charging circuit charges

· and the service or a battery selector switch to

isolate the batteries

along

with starting battery but the service battery's charging circuit tor.

Testing

A

CAUTION:

that

everyone

sheaves

TROUBLESHOOTING

A

failed

alternator

not

touch

until

the

alternator

troubleshooting section

the

charging circuit or

the

alternator or voltage regulator

battery.

the

service

the

Alternator

and

belts

not

Before

is

clear

An

isolator

is

usually mounted

so

the starting battery is

battery.

the

If

service

starting

of

moving

during

test

procedures.

to

the

can

become

has

cooled

determine if a

with

the

alternator.

it.

the

starting battery

with a diode,

alternator

battery,

the

and

engine

parts!

the

not

Keep

problem

a solenoid

in

the circuit

not

is

charging

problem

with

make

away

very

down.

If it

is

faulty,

discharged

the

is

in

the

alterna-

certain

from

TESTING BATTERY (ENGINE

3. Tum off the engine. Inspect Ensure that the battery terminals and connections

A

charging

switch

4.

If

a battery selector switch

ensure that it

5. Check the battery voltage. condition, the reading should be

THE

STARTING

/ALTERNATOR

RUNNING)

are

tight and clean.

CAUTION:

when

circuit,

the

is

on the

To

never

enginll

avoid

damage

shut

is

corr~ct

.

all

wiring and

off

the

to

the

engine

connections.

engine

battery

running!

is

in the charging circuit,

battery.

If

the battery

12

to

is

13

in good

volts.

ground

A

WARNING:

DC

and

AC applications. isolate

DC

before

performing

made

without a proper

circuits

Always

and

AC

When

are

testing

often

with a multimeter:

mixed

disconnect a shore

converters,

DC

testing.

and

No

knowledge

together

shut

AC

tests

of

AC

in

power

down

should

circuits.

marine

cord,

the

engine

be

TESTING THE BATTERY

30

·

-

GROUND

DC

ELECTRICAL

SYSTEM

7. Now check the voltage between the alternator output ter-

If

minal (B+) and ground.

the alternator will be the same as the battery, or tor is in the circuit the alternator voltage will be zero. neither

of

the above is true, a problem exists in the circuit between the alternator and the battery. Check all the connections - look for an opening in the charging circuit.

STARTING

BATTERY

TESTING

THE

STARTING

the circuit is good, the voltage at

if

an isola-

If

BATTERY/ALTERNATOR (ENGINE

8. Start the engine again. Check the voltage between the alternator output and ground.

The voltage reading should be between 13.5 and 14.5 volts. is

service facility.

NOTE:

voltmeter to ensure that 12 volts at the tery voltage

If

wiring

RUNNING)

for a properly operating alternator

over-

or

under-charging, have it repaired at a reliable

Before removing the alternator

EXC

terminal if the previous test showed only bat-

at

the B output terminal.

12

volts is not present

and

look

for

at

breaks

the and

-=

(ENGINE

If

your alternator

for

repair,

DC

excitation

EXC

terminal, trace the

poor

connections.

.GROUND

use a

is

present

Checking

Check the voltage have a voltage between 13 and 14 volts when the engine is running. charging circuit. Troubleshoot the service battery charging circuit by checking the wiring and connections, the solenoid, isolator, battery switch,

A

diodes, when

the

Service

of

If

not, there is a problem in the service battery

MULTIMETER

CCIII

GROUND

CAUTION:

do

performing

To

not

use a high

Battery

the service battery. This battery should

and

the

battery itself.

(KID

G

SERVICE

avoid

tests

damaging

voltage

on

the

alternator

TESTING BATTERY

THE

(ENGINE

the

alternator

tester

(I.e. a megger)

charging

BATTERY

SERVICE

RUNNING)

circuit.

12

VOLT

DC

CONTROL

The engine has a 12 volt shown on the wiring diagrams that follow. Refer to these diagrams when troubleshooting or when servicing the

electrical system.

A

CAUTION:

circuit, the however, engine's

never

engine

electrical

is

running.

to

avoid

To

shut

CIRCUIT

DC

electrical control circuit that is

avoid

damage

o"

the

engine

Shut

electrical

circuit.

o"

the

shorts

to battery

engine

BAnERY

The minimum recommended capacity the engine's 12 volt DC control circuit is Cranking Amps (CCA).

the

battery

when

of

the battery used in

600-

charging

switch

battery

working

900 Cold

DC

while

switch,

on

the

Battery

Review the manufacturer's recommendations and then establish a systematic maintenance schedule for your engine's

starting batteries and house batteries.

Care

0 Monitor your voltmeter for proper charging during engine

operation.

0 Check the electrolyte level and specific gravity with a

hydrometer.

0 Use only distilled water to bring electrolytes to a proper

level.

0 Make certain that battery cable connections are clean and

tight to the battery posts (and to your engine).

0 Keep your batteries clean and free

A

WARNING:

cause

severe

protective

burns

gear.

Sulfuric

on

skin

acid

and

of

In

lead

damage

corrosion.

batteries

clothing.

can

31

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NOTE:

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to # 12

wire

for connections over 1 00'.

NOTE:

When

installing this

connector.

panel,

remove

up

to

the

100',

increase

external

plug

4

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Engines & Generators

35

REMOTE

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END

Engines & Generators

36

STARTER

MOTOR

DESCRIPTION

The

starter can be roughly divided into the following sections:

• A motor section which generates a drive power.

• An overrunning clutch section which transmits an arma-

ture torque, preventing motor overrun after starting.

• A switch section (solenoid) which is operated when actuating the overrunning clutch through a lever and which supplies load current to the motor.

The starter is a new type, small, light-weight and is called a high-speed internal-reduction starter. The pinion shaft is separate from the motor shaft; the pinion slides only ion shaft. A reduction gear is installed between the motor

shaft and a pinion shaft. The pinion sliding part is not exposed outside the starter so that the pinion may slide smoothly without becoming fouled with dust and grease. The motor shaft is supported at both ends on ball bearings. The lever mechanism, switch and overrunning clutch inner circuit are identical to conventional ones.

ADJUSTMENT

If

any abnormality is found by the following tests, the starter

should be disassembled and repaired.

Pinion

1.

2.

3.

Gap

Connect a battery (12V) between the starter terminalS and the starter body, and the pinion drive should rotate out and stop.

A

CAUTION:

seconds

Lightly push the pinion back and measure the return stroke (called pinion gap).

If

the pinion gap is not within the standard range, (0.5

2.0 mm), adjust it of

shims on the solenoid. The gap is decreased as the

number

AND

REPAIR

Inspection

Never

apply

continuously.

by

increasing

of

shims increases.

battery

or

voltage

decreasing the number

for

on

the pin-

over

10

to

No·Load

1.

2.

r--------------1

A

tighten type that starter in

Test

Connect the ammeter, voltmeter, and battery to the starter

as illustrated. When the switch is closed, the pinion must protrude and

the starter must run smoothly (at 3000 rpm or more). the current or starter speed is out

semble the starter and

CAUTION:

starter

every

which

Use

terminal

of a direct-drive

rotation

contact

with

repair it.

thick

wires

securely.

makes a rotating

type

at

the

pinion

the

pinion

as

This

starter.

tip,

gear

when

of

specification, disas-

e

BATIERY

much

as

possible

is a solenoid

sound

louder

When

detecting

be

careful

not

it

protrudes.

to

SOLENOID

Perform the following tests.' satisfactory, replace the solenoid assembly.

1.

Inspect the solenoid for continuity between terminals ( +) and (-) and between terminals S and the body and M and the body. There should be no continuity found between terminals S and M. Continuity between terminals S and the body and terminal M and

the body.

If

any test result is not

will

be

found·

If

and

shift·

than

come

0.5 • 2.0

mm

PINION

GAP

NOTE:

Disconnect the wire from terminal

2. Connect a battery to the solenoid's and M for (The pinion drive should extend fully out.

A

CAUTION:

than

10

seconds

Engines & Generators

37

MULTIMETER

M.

terminalS

).

Have a switch in the + lead and close it.

Do

not

apply

when

battery

testing

current

the

solenoid.

for

for(+)

more

ATTRACTION

TEST

STARTER

MOTOR

4.

Return test:. With a battery connected

minal M pinion when released from holding by hand.

(-)and

fully.

to the starter body, manually pull out the

The pinion

must

return

to

the solenoid ter-

its original position

3. Holding test. With a battery connected minal S ( pinion fully.

when released from holding with your hand.

HOLDING

STARTER

1.

Disconnect the wire from the solenoid terminal M (-).

2.

Loosen the two screws fastening the solenoid. Remove the solenoid assembly.

3. Remove the two long through bolts and two screws fastening the brush holder. Remove the rear bracket.

4.

With the brushes pulled away from the armature, remove the yoke and brush holder assembly. Then pull

the armature out.

5.

Remove the cover, pry the snap ring out, and remove the washer.

6. Unscrew the bolts and remove the center bracket. At the

same time, the washers for the pinion shaft end play

adjustment will come off.

+) and

to

the starter body, manually pull out the

The pinion must remain at that position even

TEST

DISASSEMBLY

to

the solenoid ter-

RETURN

7. Pull out the reduction gear lever and lever spring from the

front bracket.

8.

On the pinion side, pry the snap ring out, and pull out the pinion and pinion shaft.

9. At each end

a bearing puller. It is impossible to replace the ball bearing press-fitted in the front bracket. off, replace the front bracket assembly.

SOLENOID

of

the armature, remove the ball bearing with

TEST

If

that bearing has worn

INSPECT

FOR

WEAR & CHIPPING

STARTER

MOTOR

PINION

SHAFT

"'ADJUSTING

Engines & Generators

38

SHIMS

~.,

~

'

\

-,

____

NOTE:

Inspect, clean and replace

if

necessary brush, commuter,

solenoid, armature,

following pages.

.

_

etc.

See the

USE

OF

ELECTRIC

The

power

required

than

is

required

require

(AC)

motors circumstances, easy-starting applied Because

run,

their

motor

is

repulsion-induction current varies

with

to an

air

motor

to

In

general,

to

medium

MOTOR

*NOTE:

more

for

this

is

that

larger

Because required

can

bring

experienced

and,

if

REQUIRED

Run

the

ator's

capacity,

on

the checked plant

and

meter

is

portable

NOTE:

tains

AC

generator~

volt

AC

good

motor

to

much

more

require

than

loads,

after

the

motor

they

require 5 to 7 times

use

should

to

be

driven

to

start

as

to

the

load

compressor,

which

no

the

current

starting

SIZE

(HP)

1/6 1/4 1/3 1/2 3/4

1

In

the

above

some

small

the

hardest

sizes.

the

heavy

for

only

an

the

motor

in

starting

possible,

reduce

OPERATING

generator

and

generator's

periodically

the

appliances

not

installed

meter

and

When

the

equipment

AC

terminal

hot

leg

for

starting

MOTORS

to

start

an

keep

it

running

current

to

more

current

other

types.

such

as

washing

is

started,

be

avoided,

by a small

motors

require

run.

The

connected

for

example,

load

is

connected.

required

loads

will

AMPS

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2

13

table

motors

starting

surge

of

instant,

up

to

speed

motors,

the

first

with

finally

loaded

data

plate.

to

ensure

it

supplies.

to

monitor

amprobe.

vessel

in

which

of

120

block

the

vessel~

response

electric

after

start

them

to

start,

They

machines,

such

as

much

whenever

generator.

from 2 to 4 times

current

to

it.

An

will

to

start

be

approximately

FOR

the

maximum

than

for

types

current

needed

the

genemtor

in

a

turn off

load

on

the

SPEED

no

load

applied,

to

its

The

output

proper

voltage

the

volts

only,

be

configured

distribution

from

the

GENERATOR

motor

is

considerably

it

is

started.

than

others.

under

similar

are

commonly

or

as

small

power current possible,

Capacitor

required

larger

electric

require

115-

Volt

Amps

ones.

to

motor

more

motors

as

for

(split-phase)

for

starting

will

not

few

seconds.

all

other

electrical

electric

motor.

then

full

capacity

voltage

operation

If

an

generator

it

of

AC

voltmeter

and

load,

is

recommended

to

provide

panel.

generator.

where

to

start

follows:

AMPS

STARTING

(AMPERES)

6.4

9.2

10.4

14.4

20.4

The

are

be

If

at half

should

the

check

installed

This

Some

motors

Split-phase

used

on

loads

tools.

start

as

if

the

electric

and

as

much

any

motor

connected

current

connected

FOR

to

22.4*

to

32.2*

to

72.8*

to

29.2*

to

40.8*

26

to

52

Starting

reason

not

made

motors

damaged

difficulty

loads

the

as

indicated

be

generating

or

it

with

that

one

will

more

are

to

than

is

for

in

is

if

is

gener-

amp-

a

con-

the

120

ensure

INFORMATION

GENERATOR

Frequency by

the

following:

•

When

output

•

When output

Therefore, drive

engine's

of

the

AC

GENERATOR

•

a

Maintaining

Connections corroded, salts,

up.

heating

•

For

petroleum all

•

In

addition inspected overheated

• The checked for not

cracking. generator identified the

•

it

The maintenance noisy

•

Examine of motion

Repair

and

CARBON

Westerbeke highly recommends mounting a carbon monoxide detector quarters.

can

be

The presence

exhaust leak from the main engine system, from the exhaust discharge location on the vessel or from a neighboring vessel.

if

the detector signals the presence ventilate the area, move into fresh air location and locate the source

FREQUENCY

is a direct

the

generator

frequency

the

generator

frequency

to

change

speed

output

connections

MAINTENANCE

reasonable

of

and

insulation

dust,

engine

Clogged

unusually

surfaces

drive

any

be

head.

the

ventilation

and

reduce

severe

based

to

reduce

to

for

tightness

terminals

discs

periodically

evidence

allowed

The shaft by 6 radial

rear

armature

is

or

rough-sounding,

the

bearing

shaft

should

is

detectable,

must

be

cause

major

MONOXIDE

Carbon

deadly.

of

carbon monoxide indicates a possible

of

ADJUSTMENT

result

of

engine/generator

is

run

at

1800

rpm,

the

is

60

Hertz.

is

run

at

1500

rpm,

the

is

50

Hertz.

the

generator's

must

be

terminal

exhaust,

life

conditions,

coatings

periodic

on

single

if

of

incipient

to

become

bolts

which

must

be

bearing

required.

be

made

damage

rusting

and

marks,

at

detected

inspect

quickly

frequency,

changed

at

the

generator.

cleanliness

boards

and

surfaces

carbon,

openings

of

windings.

should

and

cleaning,

of

all

connections,

loose

or

bearing

possible

cracking

rusty

fasten

hardened

one

is

lubricated

However,

have

it

periodic

when

the

or

to

the

along

with

is

important.

rectifiers

may

start

etc.

are

may

cause

thin

rust-inhibiting

be

sprayed

corrosion.

the

generator

damaged

generator's

for

tightness

failure.

because

the

drive

steel

SAE

at

each

and

if

the

replaced.

intervals.

force bearing major

components

generator.

rust

of

and

DETECTOR

in the vessels living

monoxide

the carbon monoxide and arrest it.

even

and

in

smaU

or

generator, its exhaust

of

carbon monoxide.

speed,

as

indicated

AC

voltage

AC

voltage

the

generator's

a

recon:figuring

may

become

conducting

allowed

to

excessive

or

brushed

should

evidence

of

wires.

should

of

screws

Discs

may

accelerate

disc

to

the

grade

8,

the 6 comers

sealed;

no

bearing

becomes

No

side

movement

is

applied.

shaft

for

sleeping

amounts

if

build

over

be

and

should

If

wear.

will

rub

of

side

Engines

39

& Generators

.BE

WITH

G.ENERAJOR

VOLTAGE

REGULATOR

#046446

DESCRIPTION

This

is a four residual magnetism the

generator on start-up.

of

nonimal (AVR) this

DC

indirectly controls

sequence exciter

TheAVR has a

the

generators.

AVR

controls and

The

AVR

should drop below a

AVR

can be modulated

instability that

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plus

or

working

keeps

monitors generator

may

arise.

generator.

guarantees

(The

residual voltage

the

Automatic

exciter windings. main

rotating

bridges-main rotating

minus

voltage precision of

range

with

the

voltage constant

frequency,

factory

set point, excitation

to

remove

_._.._ROTOR---·

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the

self excitation of

is

about

Voltage

DC

voltage

field

distortion

any

voltage output

r-

I I I • .

AC

:

.:

I

-

Regulator

and

supplies

This

DC

voltage

by

means

field.

1%

free

loads.

on

one

if

the

frequency

from

~-'----STATOR·-~

OUTPUT

WINDINGS

AC

01111'111

WINDINGS

Voltage

This

engine operating speed

of

the

in

phase.

10%

The

±

output variations

With

with age w,se.

stabilize.

CIRCUIT

the

2 I ! . .

1 .

A generators. generator breaker

generator

Adjustments

potentiometer

2%

from

a no-load condition

and

from

power

up

to

.5Hz

the

alternator running at

VOLT

adjust at minimum, it

will

oscillate. Slowly rotate

The

voltage

Increase

BREAKER

circuit

breaker

This

circuit breaker will

power

in

can

be manually

to

ensure that

I

1

m

V21

~

.

-t-V12

1

V11

is

used

the

factot

(1%).

output of

the

voltage

is

installed case

to

adjust output

output

voltage

to

a full

LO

with

no-load,

is.

possible that

the

VOLT

the

alternator

to

the

desired

on

all

WESTERBEKE

automatically

of

an

electrical

shut

off

when

no

power is coming

voltage.

should

be

rated

generator

~ngine

drive

at

normal

speed,

output

adjustment

will

increase

value.

overload;

servicing

into

the

The circuit

the

At

proper

held

at

speed

and

volt-

clock-

and

disconnect

boat

GENERATOR WIRING

INTERNAL

DIAGRAM

'-------4U1

~.,----:~

'CONNECTION

BAR

U2

UNUSED

WIRE

MOUNTING

lQCI,TjS

Engines & Generators

AVR

CONNECTIONS

60HZ

·120 60HZ 50HZ • 230

AVR

60 60HZ 50HZ • 230

VOLTS

·120/240

CONNECTIONS

HZ·

-120}240

VOLTS

120

VOLTS

VO~T]

VOLTS

U1;

V11

U.1:

V11

U;1 ; V12

T3 ; TS

T2 ; T4 T2 ; T4

WIRE

COLOR

T2·

YELLOW

T3

·ORANGE

T4 -LIGHT

.

T5 • LIGHT

CODE

GREEN RED

40

BE

GENERATOR

AC

VOLTAGE

The

frame ground wire (green) must be properly positioned when changing the AC output configuration terminal block. For making connections to the block, use tenninal ends for 1/4 inch studs that will accept

~mlti

strand copper wire sized

the hot

lead

connects between the neutral stud and the generator frame.

CONNECTIONS

connection.

The

frame ground green· wire

for;

the amperage

of

the

AC

rating

AC

tenninal

from

VOLTAGE

CONNECTIONS

120/240V

60Hz

120V

EiOHz

Generator

1.

Frequency is a direct result

1800

2. To change generator frequency, follow the steps below: Configure the AC terminal block for the desired voltage

frequency as shown. Ensure that the case ground wire is connected to the correct terminal block neutral ground stud.

3.

R,emove (depending

NOTE:

installations and ground a ground

Frequency

rpm=

or

The

green

source

9fi

,_____/

of

60

hertz; 1500

install the jumper

on

frequency). Refer

ground

where

the

circuit.

This

in

the

nnp

wire

may

AC

circuit

will prevent

vessel.

@I

--

---

engine/generator speed:

=50

hertz.

on

the automatic regulator

to

BE

GENERATOR.

be

removed

has

L?

)

r---~

in those

a separate

the

unit from

1

neuti·al

being

230V

50Hz

@~

rsu:;:gs

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VOLTAGE

REGULATOR

NOTE:

When

to

50 Hz

Check

~-

regulator.

AVA CONNECTIONS

60Hz·

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~

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60Hz • 120V

~"'.

changin~

see

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Hz

jumper

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on

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rv

T3(0RG)

from

60 Hz

voltage

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T4(GRN)

: TS(RED)

~,

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.,,

AC

TERMINAL

BLOCK

Engines

& Generators

41

AC

VOLTAGE

.CONNECTIONS

WITH

Small Green and Small . A

Blue Leads should be Insulated separately

and not used. <--_=a > +

RED

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VOLTAGE

#046446

REGULATOR

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120/240V

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42

AC

VOLTAGE

#046446

REGULATOR

VOLTAGE

The output voltage potentiometer with the generator running at its selected speed (frequency) by turning the adjustment until the desired voltage is obtained.

selected rated

POTENTIOMETER

of

the generator can

NOTE:

voltage,

If

the

generator

the

be

voltage

may

adjusted using the

is

set higher than

be damaged.\

FREQUENCY

A

jumper

pins for either

does

speed change is performed driven mechanical

on the regulator is connected to two

60

hertz

or

50 hertz operation.

not automatically change

the

using

the adjustment on

governor.

engine

NOTE:

speed.

of

the three

Engine

This

the

belt

STABILITY

lf

at no-load

AC

output voltage fluctuation is experienced. Adjust the

stability potentiometer. This modulates the reaction time

the regulator to external inputs, thereby eliminating any instability

or

while under load with steady engine speed,

in

the AC generator load system.

EXCITING

of

THE

UNDER

With the generator running at rated speed and producing

desired voltage, reduce the engine speed using the

mechanical governor by 4 hertz. Adjust the under frequency

potentiometer until the starts to drop. Then restore the engine speed to the original rated speed.

VOLTAGE

The voltage sensing connections are 0 and output voltage is between

0 and

and280V.

EXCITER

Proper polarity in this circuit F-

AUXILIARY

Connect the correct color wires to the terminals. Green

gray to

FREQUENCY

AC

output voltage

SENSING

1

OOV

and

140V.

230

when selected output voltage is between 200V

WINDING

must

be

maintained.

and

red

to F+. Failure to do so may damage the regulator.

WINDING

Aux

Land

blue

and

brown to

Aux

of

the generator

115

when selected

Connect between

White

or

N.

GENERATOR

to

Exciting the generator using an external when troubleshooting a generator/AC voltage output issue.

The following procedure should

1. The generator should not be operating. Remove the F electrical connections

2. Maintaining polarity. Connect pattery

to

the

the·

tnegative) to the F-white electrical

generator.

Start the generator and observe the reaction and voltage output

3. from the generator and react accordingly.

The

troubleshooting booklet for the

determine the cause

AC voltage found being produced by' the generator and

of

the generation to excitation. .

off

the regulator.

red

electrical lead coming from the generator and

of

a generator AC voltage output issue by the

DC

source can

be

followed:

th~

+ (plus) from a 9 volt dry cell

lead

BE

style generator will help you CONNECTr--f

9

be

coming from the

VOLT

DRY

• and F +

the

CELL

performed

reaction

.

f.2

(WHITE)-

.F1

(RED)

FOR

EXTERNAL

POTENTIOMETER

WHITE/RED

LEADS

FROM

GENERATOR

soHzL-..f

r

I-f

nz--=tll

Engines & Generators

43

BE

TROUBLESHOOTING

NOTE:

AC

GENERATOR TROUBLESHOOTING

BE

PERFORMED WITH ENGINE OPERATING

MUST

AT

60 HER1Z.

No

AC

voltage

Residual

15 -20

volts

Low

AC

voltage

60-100

High

AC

150

VAC

Unstable

AC

voltage

60

• 1

DO

PROBLEM

output

volta~e

produced

A .

output

VAC.

output

voltage

or

higher.

voltage

output.

drop

under

volts

AC.

at

load

no

load.

at

no

Engine

no

load

Speed

Steady

1.

Short

main Shorted

2.

on

3.

Four open

1.

Faulty

2.

Short to

Reset

1.

2.

Open exciter

3.

Open rotor

Reset

1.

2.

Faulty

Adjust

1.

Diode(s) breaking applied

or

open

in

stator

winding.

pozi-resistor

exciter

rotor.

or

more

shorted

diodes

on

exciter

voltage

regulator.

or

open

voltage

to

regulator.

voltage

potentiometer.

or

shorted

rotor 1 to 3 diodes.

or

shorted

winding.

voltage

potentiometer.

voltage

regulator.

voltage

regulator.

on

exciter

down

when

(inductive)

PROBABLE

the

or

rotor.

wiring

diodes

in

exciter

rotor.

load

1-3

diodes.

CAUSE

Open

in

stator

winding.

Open

in

field

winding.

Shorted stator

auxiliary

Faulty

voltage

Short

in

Short

in

Faulty

voltage

exciter

rotating

or

open

exciter

rotating

main

winding.

regulator.

stator

winding.

field

winding.

regulator.

4.

5.

3.

4.

5.

6.

2.

is

44

SHORE

POWER

TRANSFER

SWITCH

SHORE

Generator

~

If cuit, this must be done

POWER

t t

:

'--------,

I

L----

r-----~~

! '-..___,,/

I

CONNECTIONS

NOTE:

Diagram

120-

~\

®}-

Volt

system.

lines

shows

for

wire, use

/--,

-t-<D

\~

dotted

connections

For a three-

the

other

hot

{60

for a two-

wire

leg.

HERTZ)

system

Sh1p-to-

Shore

PN

32008

(40Amps/Pole)

PN

32009

(SO

Amps/

PN

32010

(125

Amps/

PN

32133

(200.Amps/Pole)

Sw1tch

Pole}

Pole)

the installer connects shore power to the vessel's AC cir-

by

means

of

the Shore Power Transfer Switch. Set the transfer switch shown in the diagrams to the OFF

position. This switch prevents simultaneous connection

of

shore power to generator output.

120

VOLT/60HZ

Notice the repositioning

THREE

WIRE

of

the white wire ground load on the

CONFIGURATION

terminal block to the generator case.

Generator

~

{3

Pole)

L---t-1---f.®

' 7

~

Shore

Switching

NOTE:

Diagram

wire,

120-Volt

with

three-wire,

,~..---..........,

~

I

Ground

(GRN)

Shore

r§I-1-_.::..:(W:.:.:H::.::T)'-N

Power

'§0..__:..,/

~~

Z

Power

shows

connections

system

from

120-Volt

to

Generator

for a two-

the

generator.

boat

system.

Ship-to·

Shore

PN

32008

(40

Amps/

L21

L1

Ships

~~~~:O-Volt

ll•

Equipment

is':,~~~~~

PN

32010

(125

Load

Amps/

PN

32133

(200Amps/Pole)

Power

Switch

Pole)

{3

Pole)

A

CAUTION:

utility

shore

at

the

same covered bility

to

230

G

z

w

IU

0:

"

Damage power time.

under

the

make

sure

VOLT/50

and

generator

This

type

warranty;

all

AC

HERTZ

TWO

N

L1

'------''-(5)5

(NEUTRAL.) I

to

the

generator

output

of

generator

it

is

the

connections

WIRE

GENERATOR/

SWITCH

/..--

~

®)

7

' /

--~

can

result

if

are

connected

damage

installer's

are

responsi-

correct.

is

not

.

CONFIGURATION

PN

32133

SHORE

SHIP'S

LOAD

.....

,

N

A

CAUTION:

before

switching vice-versa with

heavy

cause

damage

generator.

Heavy

shore

because

AC

loads

to

the

motor

leads

power

to

voltage

on

the

surges vessel

exciter circuit

should

generator

induced

being

operated

components

be

shut

power

by

switching

off

or

may

in

the

SHORE

~

SHORE POWER

230V

50HZ

GROUND

-

SHIP'S

-GROUND

45

WESTERBEKE

B.OKW

to

15KW

BEG

ENGINE

SPECIFICATIONS

(60HZ

MODELS)

Engine

Type

Governor Combustion

Bore & Stroke Piston Firing

Direction Compression

Weight

Compression (Limit

between

Valve

Valve (engine

Engine

Chamber

Displacement

Order

of

Rotation

of

difference

cylinders)

Seat

Angle

Clearance

hot)

Timing

ENGINE

Ratio

TUNE-UP

Pressure

SPECIFICATIONS

Gasoline,

four-cycle,

fresh

water-cooled,

overhead

mechanism

Hoof,

flyball

Semi-spherical

2.97 x 3.23

89.6

cubic 1-3-4-2 Clockwise,

9.0:1

B.OKw

10.0Kw

12.5Kw

15.0Kw

type.

type

inches

when

four-cylinder,

Vertical,

5%

speed

{75.5 x 82.0

{1468

cubic

viewed

from

440

lbs

{199

4661bs

{211

4971bs

{225

5251bs

(238

in-line

regulation

SPECIFICATIONS

Limit

14

psi

(100Kpa)

Intake

45"

Exhaust45• Intake

0.08

inches

(0.20

Exhaust 20"

BTDC

0.09 at

inches

1800

mm)

(0.25

mm)

rpm ± .5"

mm).

centimeters)

the

front

kgs) kgs)

Throttle

Body

Spark

Plug

General

Fuel

Consumption

B.OKw

to

Fuel

Filter

(on

engine)

Air

Cleaner

(flame

arrester)

Air

Row

(engine

General

Operating Fresh

Water

Raw

Water

Raw

Water

at

1800

System (coolant)

IGNITION

Gap

15.0Kw

·

combustion)

Temperature

Pump

Row,

rpm Capacity

SYSTEM

Electronic Governor

.030

inches

FUEL

SYSTEM

ConventiQn~l

pump:

Electric·lift.Q;y>ability

Regular rating

of

1.0

to

1.7

Replaceable

Metal

screen

46.6

cfm

COOLING

Fresh

water-cooled

controlled 140

·160" F (60

Centrifugal

Positive belt

driven

5.5

gpm

5.5

qts

(CONT.)

fuel

injection

(0.8

mm)

garburetor

or

unleaded

89

or

better.

U.S.

GPH

cartridge-screw

type -cleanable

(1.3

cmm)

SYSTEM

with

heat

type,

displacement,

(5.20

lpm)

(5.20

liters)

with

type

gasoline

at

1800

block,

exchanger.

-71"

C)

metal

impeller, rubber

Electronic

with

electric

of

.6

witt)

rpm

on

thermostatically-

impeller,

fuel

ft.

(18mm).

an

octane

atfullload

belt-driven

General

Oil

Riter

Sump

Capacity

(not

including

Operating

Oil

(engine

hot)

Grade

Starter

Motor

Starter

Battery

CCARating

Starter

Draw

General

Distributor

Spark

Plog

filter)

Pressure

ElECTRICAL

IGNITION

Thread

Size

Forced

lubrication

Full

flow,

spin-on

3.5

U.S.

qts

plus

filter/cooler

55-60

psi

SAE

lOW-30

API

Westerbeke 10.0 BEG, 15.0 BEG, 8.0 BEG, 12.5 BEG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual