Westerbeke 10.0 KW-60Hz SBEG, 11.6KW-50 Hz SBEG, 12.5 KW-60Hz SBEG, 10.0 KW-5, 14.0 KW-60Hz SBEG Operator's Manual

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OPERATORS

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i

MANUAL

SBEG

/6.4KW •

/ 8.0KW·

/10.0KW •

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'"

50

Hz

SBEG

MARINE

PUBLICATION

,

u)

ra-Low

G E

NO.

Carbon

49735

FOURTH

Monoxide

GENERATORS

EDITION FEBRUARY 2009

Emissio

s

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

CALIFORNIA

WARNING

Exhaust gasoline its the cancer, reproductive

Exhaust colorless

gas

from

engines

constituents)

State

of

California

birth

defects,

harm.

gasses

gas.

contain

Carbon unconsciousness exposure

•

Dizziness

can

include:

.Nausea.

•

Headache

•

Weakness

IF

YOU

GET

OUT seek until

and

OR

ANYONE

INTO medical it

has

been

Sleepiness

THE

attention.

inspected

PROPOSITION

diesel

(and

are

known

and

some

to

cause

and

other

65

of

to

AWARNING:

Monoxide

and

death.

ELSE

FRESH

Carbon

Monoxide,

is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

• Inability

EXPERIENCE

AIR

IMMEDIATELY.

Shut

down

and

ANY

the

repaired.

an

of

Carbon

in

Twitching

to

Think

OF

If

unit

and

odorless

and

can

cause

Monoxide

Temple.s

Coherently

THESE

SYMPTOMS,

symptoms

do

not

and

persist,

restart

A

WARNING

should

be

generator.

WESTERBEKE MONOXIDE of

your

obtainable

DECAL

fixed

to a bulkhead

also

recommends

DETECTORS

vessel.

at

your

Theyare

is

provided

in

local

marine

by

WESTERBEKE

near

your

engine

instafling

the

living/sleeping

inexpensive

and

easily

CARBON

store.

Engines & Generators

and

or

quarters

WARNING

GaooraIors

Pn:xb;e

CARBON

RBgIJat~ReqtNed

MONOXIDE

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety manual caused precautions. take

personne~

The

by

failure

the

necessary

and your

following

Know

safety

the American Boat and

PREVENT

A

while

power.

• Do not operate this machinery without electrical

enclosures

• Shut off electrical power before accessing electrical equipment.

• Use insulated mats whenever working on electrical equipment.

• Make sure your clothing and skin are dry, (particularly shoes) when handling electrical equipment.

• Remove wristwatch and electrical equipment.

•

Do circuits, except through a ship-to-shore double transfer switch. Damage result if this procedure is not followed.

• Electrical shock results from handling a charged capadtor.

PREVENT

A

exhaust

very

• Always check the engine coolant level at the coolant recovery

A

•

In

~fore

ELECTRIC

WARNING:

engine

not connect utility shore power

Discharge capacitor by shorting terminals together.

Is

Lethal

and

voltage

BURNS -HOT

WARNING:

system

hot!

tank.

WARNING:

case

of

an engine overheat, allow the engine

touching the engine or checking the coolant.

carefuay.

to

follow

funtlamental

when

dangerous

precautions

Most

accidents

rules

conditions

to

protect yourself, your

machinery.

instructions

Yacht

are

Council

in

complkmce

(ABYC)

SHOCK

Do

not

touch

AC

electrical

running,

covers

or

when

connected

is

present

in

at

these

place.

all

jewelry when working on

to

vessels

to

vessels

AC

ENGINE

Do

not

touch

hot

engine

components. A running

Steam

can

cause

injury

are

and

exist and

with

stantlards.

connections

to

shore

connections!

not

damp

AC

throw

generator

parts

engine

or

may

or

gets

death!

to

cool

PREVENT

A

• Prevent sparks pump, or other potential sources vapors. Use a suitable container removing the

• Do

arrester

death.

•

Do

Backfire

• Do

the engine/generator clean and free chances

• Be aware - diesel fuel will bum.

PREVENT

A

injury

• Follow re-fueling safety instructions. hatches closed when fueling. after fueling. Check below for fumes/vapor before running the blower. Run the blower for four minutes before starting your engine.

•

All when ventilated area away from spark-producing equipment and out of the reach

•

Do

• Shut off the spill.

sources ing.

fuel

• Do

• Be sure

• Be certain fuel line fittings are adequately tightened free of leaks.

• Make sure a

properly maintained. Be familiar with Extinguishers rated ABC

for

BURNS -FIRE

WARNING:

to

not

operate with a Coast Guard Approved

removed.

not operate with the air cleaner/silencer removed.

not

smoke

fuel

system. Keep the compartment and

Fire

can

cause

flash

fires.

Do

not smoke or pennit

occur near the carburetor,

fuel

line, carburetor, or

can

of

cause

fire.

Backfire

or

pennit

Wipe

severe

injury

flames

up

all spilled

can

injury

or

fuel

of

spilled fuel or

to

catch

fuel

cause

severe

or

death.

or

sparks

of

debris

fuel

death!

flames

line,

filter,

all

fuel when

filters.

flame

injury

to

occur

the

to

minimize the

and

engine

BURNS -EXPLOSION

WARNING:

or

death!

fuel

handling and storing fuels. Store

not

fill

fuel

DO NOT allow any smoking, open

of

Ensure

system.

not

alter or modify the fuel system.

all

applications

Explosions

vapors

are

highly explosive.

the fuel tank(s) while the engine is running.

the

fuel

service

system.

all

Take

fire

near

the

proper

ventilation

fuel supplies have a positive shutoff

fire

extinguisher is installed nearby and

encountered

from

fuel

Open and ventilate cabin

of

children.

valve

at

the engine

care in catching

fuel

system

exists

by

the

NFPA

in

vapors

Keep

Use

extreme care

fuel

any

or

engine when

its

are

this

environment.

can

the vessels

in a well-

when

fuel that might

flames,

when

servicing

proper

appropriate

cause

valve.

use.

servicing or other

servic-

or fuel

fuel

or

near

oil.

the

and

is

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

STARTING

Accidental

starting

can

cause

injury

ordeathl

• Disconnect generator.

it

last.

•

Make starting.

• Make certain re-installed before starting

BATTERY

A

WARNING:

the

battery cables before servicing

Remove

certain

the

all

personnel are clear of

all

covers, guards,

EXPLOSION

Battery

negative lead

and

the

engine.

explosion

can

first

and

reconnect

the

engine before

hatches are

cause

injury

the

engine/

ordeathl

• Do not smoke or

being serviced. Lead acid batteries emit hydrogen, a

highly explosive arcing or by lit tobacco products.

equipment during servicing.

• Never connect the negative (-) battery cable

positive (+) connection terminal of Do

not test the battery condition by shorting

together.

Ventilate accumulation of explosive disturb the battery charger connections while is

•

Avoid burns or sparks that could cause wristwatch, the

• Always turn the battery charger off before disconnecting

the and

BATTERY

A

selfllfll

Sparks could ignite battery gases or

any

being charged.

contacting

battery.

battery connections. Remove

reconnect it last when disconnecting

ACID

WARNING:

Injury

allow

an

open

flarue

near

gas,

which can

in

the

vicinity

compartment containing batteries

the

terminals with tools, etc.,

rings,

and any

Sulfuric

or

deathl

acid

be

ignited

Shut off all electrical

to

prevent electrical arcing

the

starter solenoid.

gases.

To

avoid sparks,

an

explosion. Remove

other jewelry before handling

the

negative lead

in

batteries

the

by

the

can

battery

electrical

to

the

terminals

fuel

vapors.

to

prevent

the

battery

to

prevent

battery.

cause

do

first

not

TOXIC

• Ensure that

• Be

•

• For additional information refer

•

• Although diesel engine exhaust gases are not

AVOID

EXHAUST

A

WARNING:

discharged regularly

manifolds/water-injected

sure

the

Run

blowers

Do

not

run equipped detector that complies boat

builder or dealer for installation of approved

detectors.

(educational information

A

WARNING:

odorless nausea

gas.

or

deathl

Do

not

use fumes

can

systems.

copper tubing resulting Do

not install exhaust outlet where exhaust

through portholes,

exhaust discharge outlet

the

enter

flow

of exhaust.

exhaust gas

symptoms

poisoning

Vomiting

Dizziness

Headache

Nausea

is

present

fumes

MOVING

GASES

Carbon

the

from

for

leaks

unit

when

the

generator set or engine unless

with

a functioning marine carbon monoxide

Carbon

Inhalation

copper tubing

rapidly destroy copper

Exhaust sulfur causes rapid deterioration of

exhaust discharge outlet

from

in

or

signs

are:

Inability Throbbing Muscular twitching Weakness

monoxide

exhaust system

the

engine. Check

and

make

and

its

surroundings are

running

with

is

sure

elbow

is

the

generator

ABYCA-24. Consult your

to

on

Carbon Monoxide).

monoxide

produces

in

diesel

tubing

in

exhaust/water leakage.

vents,

or

air

conditioners.

is

near

the

and

Avoid

overloading

gasoline engines, carbon monoxide

diesel exhaust

of

carbon

fumes.

monoxide

to

think coherently

in

temples

and

sleepiness

PARTS

(CO)

is a deadly

adequate

the

securely

ABYC

(CO)

Uu-like

exhaust

waterline, water could the

to

exhaust system

exhaust

attached.

well

set

T-22

is

an

symptoms,

systems.

in

exhaust

close

or restrict

craft.

Some of

inhalation

gasl

expel

gases

ventilated.

or

engine.

the

boat

invisible

Diesel

can

be

drawn

If

the

engine

as

toxic

the

or

is

the

as

• When servicing the battery or checking level, wear rubber gloves, a rubber apron, protection. Batteries contain sulfuric acid

destructive.

off at once

the

into caps.

If

it

comes

in

with

water.

Acid

eyes inadvertently

contact

with

may

splash

when

removing electrolyte

the

and

which

your

on

electrolyte

eye

is

skin,

wash

the

skin

or

A

WARNING:

ordeathl

it

Engines & Generators

• Do

not

situation make

operating

touching moving pafts

components.

ii

service

arises

Rotating

the

in

adjustments,

engine

which

parts

it

and

can

while

it

is

absolutely use

extreme

hot

exhaust system

cause

injury

running. If a

necessary

care

to

avoid

SAFETY

•

Do

not wear loose clothing or jewelry

and

or

parts.

levels

and

guards

the

and

equipment; tie back long hair jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught

• Make sure all attaching hardware

Keep

protective shields

places at all times.

•

Do

not check

the

engine

• Stay clear of the

when

be

caught

HAZARDOUS

A

WARNING:

in

fluid

is

operating. the

drive shaft

engine

is

in

these rotating

NOISE

High

moving parts.

levels

running; hair

noise

loss!

• Never operate

• Do not run

removed.

•

Do

not run engines for

open.

A

WARNING:

mentally

or

an

engine without

an

engine with

Do

not

physically

incapacitated

the

air intake (silencer)

long

periods with their enclosures

wade

on

when

servicing

avoid wearing loose

is

properly tightened.

in

their respective

drive belts tension

the

transmission coupling

and

clothing can easily

can

cause

hearing

its

muffler installed.

machinery

by

fatigue!

when

INSTRUCTIONS

while

you

ABYC, INSTALLING

Read for

recommendations

ABYC (American Boat "Safety Standards

Order

NFPA (National Fire Protection Association) "Fire Protection Standard for Motor Craft"

Order

USCG "USCG 33CFR183"

Order

are

NFPA

the

following ABYC,

safety codes

from:

ABYC 3069

Solomon's Island

Edgewater,

from:

NFPA II Tracy Drive Avon

Industrial

Avon,

MA

(United States Coast

from:

U.S.

Government Printing

Washington,

AND

USCG

DIESEL

MD

02322

D.C.

ENGINES

NFPA

and

standards. Follow their

when

installing

and

Yacht

for

Small Craft"

Rd.

21037

Park

Guard)

20404

PUBLICATIONS

and

USCG

your

engine.

Council)

Office

FOR

publications

OPERATORS

Many

of

in

your Operators Manual along with other cautions

notes

to highlight critical information. Read your manual carefully, maintain your equipment, procedures.

GASOLINE

Preparations to install thorough examination of the American Boat Council's (ABYC) standards. These standards combination of sources including

Sections of

H-2 P-1 P-4lnboard E-9

All

installations must comply with

Regulations

MANUAL

the

preceding safety

ENGINE

the

Ventilation

Exhaust Systems

DC

Electrical Systems

(FCR).

AND

ABYC standards of particular interest

Engines

tips

and

GENERATOR

an

engine should begin

the

USCG

the

warnings are repeated

Federal Code of

follow all safety

INSTALLATIONS

and

with

are

and

a

Yacht

a

the

NFPA.

are:

"""

WESTERBEKE

Engines & Generators

iii

CARBON

MONOXIDE

"CO"

ISAFE-CO

GENERATORS

IMPORTANT

DESCRIPTION

Carbon monoxide "CO" is

a colorless, tasteless, odorless, lighter than air poisonous

gas

that can kill you without

one of the major safety risks associated with boating.

threat that must not

Westerbeke Safe-CO generators are designed

of

normal levels 99%.

Several standards parts per million

CO

"ppm" and hours of exposure:

Regulator

EPA

ACGIH

EPA NIOSH OSHA

ACGIH

NIOSH NIOSH

(IDLH)

1200

ppm

is

the

so-called

IMMEDIATELY

A city

in

concentration

Paris

DANGEROUS

California characterizes the effect

this

per

Million

25

100

200

Even though the generator normally produces very low levels

CO,

an

of extremely dangerous. For this reason it tant

is

it tor sounds, do not tum

You detector on, tum off all engines boat leaving ports and hatches open, help.

As

to dilution in the open

exhaust outlet, the higher the concentration

exhaust leak of untreated exhaust would be

to

install a

always turned on and functioning properly. If this detec-

can not taste, smell, or otherwise detect

soon

as

CO leaves

CO

is

a component

any

be

underestimated.

in the engine exhaust by approximately

for

CO

have been published, expressed in

CO

ppm

9 8

25 35 35 50 125 200 1200

IDLH

concentration

TO

LIFE

way:

warning.

Exposure

AND

of

engine exhaust.

CO

poisoning is

to

reduce

Hours

8

1

8 8

0.5

0.0

-

HEALTH.

of

CO

Responses

Pennissible exposure level, no apparent

No Allowable for several hours.

Shonld not be exposed above this level for any period time. A possible mild frontal headache in two

detector near the generator and

it

off,

assuming it

the

exhaust outlet,

air.

The closer a person is

toxic symptoms.

poisoning for long period.

to three hours.

is

extremely impor-

to

is

a false signal.

CO.

Leave

and

generators, evacuate the

and

seek professional

the

level

is

subject

to

the

of

CO.

It

is

a

of

be sure

the

INFORMATION

In a closed space, such

It

or underneath a stern swim platform, concentrations potentially rise exhaust system due gas.

Therefore, one should never rely on dilution of

exhaust Westerbeke

reduction engine's air/fuel ration coupled with after treatment special catalyst. model

because each engine is different. Also, certain system components are commonized across several engine models being adequate for some and extra-adequate for others, thus producing different models.

The fuel system which accomplishes the required precise air/fuel ratio control components: purchased sub-assemblies, machined castings, sensors, electronics of

CO

reduction, these components can and will cause variability of output.

CO

concentration also varies with load. Usually, but not

always, the worst case

load.

to

the undiluted level emanating from

to

provide a margin

Safe-CO generators achieve

of

typical

CO emissions are not the same for every

any

INSPECTION

The catalyst is critical intrusion into the exhaust system will likely quickly compromise the proper operation Westerbeke's exhaust system installation instructions dated on

or after February 2004 must be adhered

NOTE:

Water intrusion

ered under warranty. neither Westerbeke product warranty mandated by various regulating authorities such as and CARB.

Maintenance

flow

the fuel filters and air filters (if any).

Inspection critically important. The exhaust elbow loosening surface of the catalyst. Any visual irregularity flush, intrusion. The cause addressed. If there be elbow gasket, and exhaust elbow, check for CO a

of

the

honeycomb appearance

replaced. Upon careful reassembly

while the engine

CO

analyzer.

rwr the emissions specific warranty

of

any

fuel

to

the engine

of

the

catalyst at the prescribed intervals

metal clamp

is

as

the engine compartment, the boat,

will

to

a lack of fresh air

of

safety.

CO

by

precise control control of

CO levels for different

is

comprised

and

others. Because

variability

CO concentration occurs at maximum

to

optimizing CO levels. Any water

is

in

not a product defect and is not cov-

to

dilute the exhaust

an

approximate 99%

of

many different

of

the

extreme level

the functioning of

of

the catalyst.

to.

the

in

fuel

the

s nonnal

EPA

components affecting the

is

critically important, such

to

provide a view

is

most likely a result of water

of

the irregularity must be identified and

irregularity,

is

running. This must be performed with

the

catalyst and gasket must

of

flow

is

removed

of

the output

of

the normal

the

catalyst, exhaust

the

presence of

of air or

is

by

the

a

any

CO

as

~

WESTERBEKE

Engines & Generators

iv

CARBON

MONOXIDE

"CO"

ISAFE-CO

GENERATORS

IMPORTANT

Catalyst perfonnance will degrade over time. As the

CO

generator accumulates operating hours, will increase.

bours

Verification seasonally Verification involves actual sampling appropriate

There are two locations where exhaust gas can be sampled.

but

Dry,

in

hole measurements. Measurements at this location may not be

practical in temperature limits temperatures involved or the possibility The

other location is the boat's exhaust outlet, which contains entrained cooling water (except systems). location and it is critical that the probe not ingest water. Probe-type analyzers have an air pump drawing a gas sample through the probe. As a result, they tend to ingest water when it is present. opening pointed in the direction out

of

the flow. Position the analyzer the tubing leading to the probe running continuously downhill. Observe the usually translucent tubing between the

probe and the analyzer and be sure no water is being ingested. repaired

The

catalyst

of

engine

hot, exhaust can

the exhaust elbow intended for back pressure

If

or

operation.

of

satisfactory

or

each

1,000

CO

analyzer.

all instances due to the high exhaust temperature,

of

Only analyzers with probes should be used at this

Be

sure to aim the probe downwards with the

any water is ingested into the analyzer, it must be

replaced and recalibrated.

must

be

CO

levels

hours

(which

be

sampled at the plugged tapped

the analyzer, safety concerns over

of

the water flow and

concentrations

replaced

of

as

every

must

be

done

ever

occurs

exhaust gas with an

of

high levels

dry stack exhaust

high

as

possible with

2,000

first),

of

just

CO.

INFORMATION

Whenever taking the time to verify proper CO concentration from the exhaust with a opportunity to use the analyzer to looking for connection exhaust manifold to the water injected exhaust elbow, and all subsequent downstream exhaust components and hoses. Remember, exhaust gas that has not yet passed through the catalyst is raw, untreated exhaust and is very high in content.

Analyzers usually require periodic calibration. Follow the instructions that come with the analyzer very carefully regarding calibration.

The

Extech, TIP, Testo, Zellwgwer Analytics, Industrial Scientific Corp, GFG, Teledyne and others. Westerbeke recommends analyzers with

a probe connected to the analyzer by a length

tubing. They are slightly more expensive than those with the

sensor built into to sample the exhaust coming out

CO from exhaust leaks. Pay close attention to the

of

the cylinder head to the exhaust manifold, the

following are manufacturers that offer CO analyzers:

one

CO analyzer, always take the

"sniff'

around the engine

TSI, Bacharach, Auke, Monoxor, Fyrite,

of

transparent

end

of

the analyzer, but they allow you

of

the boat's exhaust outlet.

CO

TPI,

CO

When measuring

CO

ambient upwind level at the exhaust will be influenced upwards by the ambient level.

level by also measuring

of

the exhaust outlet, especially

at the exhaust outlet be aware

CO

away from and

in

marinas. the

EXHAUST

MANIFOLD

of

ADJUSTABLE CLAMP

INSTALLING A NEW CATALYST

the

CO

~

WESTERBEKE

Engines & Generators

v

EMISSIONS

This genset meets Emissions Standards

California users of this genset should unauthorized modifications or replacement of

air

intake, or speed control system components that affect engine emissions are prohibited. Unauthorized modification, removal or replacement of

Federal Emissions Compliance Period: The Federal

Emissions indicates has

Catagory C=

Compliance Period referred

the

been shown to meet Federal Emissions requirements.

Emissions Warranty Information packet, if information

Engine Fuel Requirements

Engine Engine Ignition Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS. Engine Adjustments

Engine Emission Contol System

Catalyst See MAINTENANCE SCHEDULE. Oxygen Sensor

Back Pressure See MAINTENANCE SCHEDULE.

the

requirements of Califomia's Exhaust

as

stated

on

the

nameplate.

be

aware that

fuel,

exhaust,

the

engine label

number of operating hours

250

hrs, B=500 hrs,m A

Valve

Adjustment See MAINTENANCE SCHEDULE.

TimIng

is

prohibited.

to

on

the

for

which

=IOOO.hrs.

EMISSIONS

nameplate

the

engine

CONTROL

The California emissions control warranty statement factory.

The engine

RECOMMENDATIONS.

See MAINTENANCE SCHEDULE.

ECU.

The

engine

manufacture.

See

MAINTENANCE SCHEDULE.

You

and

gensel.

maintenance

should seek assistance dealer.

Califorrtia genset users locating information related

Board

INFORMATION

is

certified

emission

should carefully review operator (Owner) Installation

other

manuals

If

you

are

or

requirements

TABLE

as

this

manual when

to

operate

control

on

system

and

information

unsure that

service

of

your

from

may

for

emissions

the

unleaded gasoline. See FUEL

consists

of

you

receive

the

installation, use,

genset

is

authorized,

an

approved WESTERBEKE

use

the

table below

to

the

California

control.

is

genset

engine

located

is

shipped

design

Air

in

from

and

with

the

your

you

as

an

aid

Resources

same

the

precision

in

-..v'

WESTERBEKE

Engines & Generators

vi

INSTALLATION

When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information:

CODES

Strict federal regulations, ABYC guidelines, and safety codes must be complied with

when

AND

installing

REGULATIONS

engines

and

generators

in a marine

environment.

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow is close to or

will be below the vessel's waterline, provisions must be made break in the raw water supply hose to the exhaust elbow. This hose must be looped a minimum

the exhaust water

If

you have any doubt about the position

to

the

siphan-break.

NOTE:

operation. Failure to properly maintain a siphon-break can result

engine damage. Consult the siphon-break manufacturer

EXHAUST

The exhaust hose must be certified for marine use. The system must be designed to prevent water from entering the exhaust under any sea conditions and at any angle of

of

20" above the vessel's waterline. Failure to use a siphon-break when

manifold injection port is at

tlamage to

vessel's

A siphon-break requires periodic inspection and cleaning to ensure

the

engine

waterline

and

under

possible flooding

the

vessel's

or

below the waterline will result in raw

of

the boat.

of

the water-injected exhaust elbow relative

various

operating

for

SYSTEM

the vessels

hUll.

to

install a siphon-

conditions,

proper maintenance.

install a

proper

in

catastrophic

t··

AVAILABLE YOUR

WESTERBEKE

DEALER

fROM

Carefullr

WESTERBEKE Additional

review

the

Engine

manuals

Marine

or

Generator.

are

available

Installation

from

rour

Engines & Generators

manual

provided

WESTERBEKE

vii

with

rour

dealer.

TABLE

Parts

Identification

Introduction

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

Serial

Fuel, Preparations Starting/Stopping Remote Break-In Safety

Maintenance

Fuel

Bleeding the Fuel System ...........................

Cooling

Changing Coolant ........................................... 13

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

Raw Raw

Engine

Oil Change ...................................................... 16

Remote

Engine

Spark Plugs ..................................................... 19

High

Drive Belt Adjusment ..............

Fuel Pressure Test ........................................... 19

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

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

Timing Belt Inspection and Replacement ......

Engine Electrical DC

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

Number

Engine

Panel

Procedure

Shutdown

System

Water Pump ........................................... .15

Water Intake Strainer. ............................. 15

Lubricating

Adjustments

Tension Cords ........................................ 19

Troubleshooting

Electrical

OF

CONTENTS

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

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

Location .................................. .4

Oil,

and

for

Initial

Procedure

Engine

Coolanl...

Start-Up

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

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

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

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

(Daily

Switches

Schedule

Operation)

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

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

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

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

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

, ......... , ............ 14

Oil

....................................... 16

Oil Filter. ............................................... 17

...

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

, ......... , ............ 19

, ......... ,

Guide

Troubleshooting

System

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

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

Guide

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

10 12

.l2A

13

19

..

20

21

.24

26

.28

29

2 3

5

6

7 8 8 9

Wiring Starter

Generator BE Generator Lay-up Generator Shorepower

Metric Standard

Suggested

Schematic

Motor

Information

Generator

AC

and

Recommissioning

Specifications

Transfer

Conversion

Hardware

Spare

-.,y:

#49167

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

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

Voltage

...........

and

Parts

....

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

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

Connections

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

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

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

Switch

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

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

Sealants ....................

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

.30

.31

.33

34

.35

36

.38

39

.40

.41

42

WESTERBEKE

Engines & Generators

1

VALVE

CONTROL

PANEL

EMERGENCY STOP

SWITCH

START/STOP SWITCH

PARTS

IDENTIFICATION

-----

OX1rGEN

SENSOR

1

FRDNT

MAGNETIC

PICK-UP

FRDNT

ASSEMBLY

FUEL

FILTER

ZINC

ANODE

FUEL

-~~

LIFT

IN-LINE

FILTER

OIL

FUEL

FILL

RIGHT

FUEL PRESSURE REGULATOR

SIDE

AIR

TEMP

DRAIN

HgSE

SIPHON

BREAK

SENSOR

,--",:::::o,"<~

2

DISTRIBUTOR

HIGH

EXHAUST.

TEMPERATURE:SENSOR

SENSOR

DC

ALTERNAlroR-----

START

SOLENOID

STARTER

Mn,rnD

HEAT

.--

LEFT

SIDE

~

WESTERBEKE

Engines & Generators

2

MOUNT

GENERATOR

:--t-I'XHIIUST

ELBOW

REAR

'-.E:(HAI~ST

CONNECTION

CHECK

POINT

INTRODUCTION

ORDERING

Whenever replacement parts are needed, always provide generator include a complete part description

part needed (see the separately furnished Parts Catalog).

insist

or generic parts are frequently not

cations

NOTES,

As

this maintenance schedules, tor,

critical information CAUTIONS,

NOTE:

A

observed, the

engine

A

followed,

NOTE:

by WESTERBEKE.

the

engine

SPARES

Certain spare parts will your WESTERBEKE generator or engine

SUGGESTED SPARE PARTS).

as

proper

the

way.

spares

on-board inventory of

PARTS

and

engine

model

and

serial

numbers.

and

part number

upon

WESTERBEKE packaged parts because will fit

made

to

as

original

CAUTIONS

manual

An

operating procedure essemial

CAUTION:

WARNING:

A carbon nwnoxide warning decal has been provided

room.

AND

fuel

WESTERBEKE

and

accessories

equipment.

AND

WARNINGS

takes

you

through

and

will

and

WARNINGS.

Procedures,

can

result

in

the

or

generator.

Procedures,

can

result

in

personal

Affix this decal in a visable location in

the

operating procedures,

troubleshooting of your genera-

be

highlighted

An

explanation

to

which

if

damage

or

which

if

injury

ACCESSORIES

be

and

needed

oil

filter can

will

brochure

the

proper WESTERBEKE

to

Often be

difficult

provide

to

assist

support

even

you

In

addition,

for

the

same specifi-

by

NOTES,

follows:

note.

not

strictly

destruction

not

properly

or

loss

of

life.

and

maintain

when

cruising (see

simple

items

to

obtain

along

with

a suggested

in

preparing

parts.

of

the

each

Also

such

an

PROTECTING

Care

at

the have resulted many

thousands of hours of dependable service.

manufacturer installed

operated

YOUR

INVESTMENT

factory

in

and

during assembly

in

a WESTERBEKE generator capable of

cannol

control

the

vessel

or

the

manner

serviced

in

the

how

field.

or

This

and

where

in

which

is

thorough testing

However

the

generator

the

unit

up

to

the

buyer/owner-operator.

NOTE:

Six important steps

• Proper engine

•

An

efficient well-designed exhaust system that includes

anti·siphon break to prevent water

an

engine.

• Changing the engine oil

inghours.

• Proper maintenance nents according

manual.

•

Use

clean,jiltered unleaded fuel.

• Wuzterize

Recommissioning" section in this manual.

and

your

ellgille according to the "Lay-up

UNDERSTANDING

The gasoline engine driving

ways

similar

to

a gasoline

are verticle in-line, overhead camshaft a solid-state distributor camshaft-driven. The engine incorporates a pressure lubrication system, which

is

thermostatically-controlled.

generator's

that important factors

ventilation,

cooling system

engine

is

required of a gasoline automobile engine.

which

requires

to

maintenance

and

/0

ensure long generator lite:

generator illStallatWll

from

am!

oil jilters every 100 operat-

of

all engine and generator compo-

to

the maintenance schedule

THE

GASOLINE

an

automobile

and

the

engine's cylinder head

is

chain-driven. The engine utilizes

which

is

and a fresh

the

generator

water-cooled engine

the

same

generator's longevity are proper

of

the

fuel

GENERATOR

AC

generator

engine.

horizontally

To

a large

preventive

system,

backend.

mounted

ignition

and

alignment.

entering the

in

is

in

many

The

cylinders

has

degree,

maintenance

The

the

is

this

and

an and

type

block

the

most

system,

~

WESTERBEKE

Engines & Generators

4

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

A

CAUTION:

rating

of

89

harm

to

your

Care

Of

The

Use

only clean

your

fuel

injection pump

particles which might pass through

finely

these and

keep it clean. The best unsatisfactory facilities.

engine's daily

advisable: Purchase a well-known brand of Install

metal

and

ENGINE

Use Change break-in operation, thereafter.An

for

To

and

regularly service a good, Coast Guard approved

bowl type filter/water separator between

the engine.

DlL

a heavy duty engine

the

this

engine

Only

use

unleaded

or

higher.

engine

Fuel

fuel!

finished

by

assure that

use

engine oil

oil

viscosity of

in

Leaded

and

fuel

violate

Supply

The clearance of

is

very

critical; invisible dirt

parts.

It

is

important

fuel

can

careless handling or improper storage

the

fuel

going into

is

clean

and

pure,

fuel.

oil

with

and

filter

after

and

every

100

SAE

all

conditions.

fuel

with

will

cause

your

warranty.

the

components

the

filter

to

be

rendered

the

following practice

an

API

classification of

an

initial

hours

of operation

15W-40

is

an

octane

serious

in

can

damage

buy

clean

fuel,

tank

for

your

the

fuel

tank

50

hours

recommended

of

SJ.

is

ENGINE

WESTERBEKE recommends a mixture of 50% antifreeze 50% that

The to the cooling circuit antifreeze that contains supplemental cooling additives that keep

lenn

The water poured

NOTE:

antifreeze thot is now available.

A proper 50/50 mixture engine coolant

COOLANT

A coolant recovery tank kit

The

coolant

without the

COOLANT

distilled

can

antifreeze performs double

run

engine

protection.

purpose of this recovery tank

cooling system.

water.

Distilled water

corrode internal engine surfaces.

at

proper temperatures

to

the

coolant.

from

the

antifreeze chemically balanced, crucial

and

antifreeze should

into

the

cooling circuit.

Use the new environmentallyfriendly, long lasting,

to

temperatures of -40'P

RECOVERY

expansion

the

loss

of

rust

as

and

contraction

coolimt

It

also lubricates

and

recommended

TANK

is

and

is

free

from

duty.

It

allows

by

transferring heat away

and

corrosion.

supplied with each

without introducing

Use

a good quality

be

premixed before

will

is

to

allow

during

engine

protect

for engine

the

protects

the

chemicals

engine

from the

(SCAs)

to

long

being

the

generator.

operation,

air

into

and

A

CAUTION:

engine

oil additives to

produce

00

to

mix.

Each

of

different

properties

not

allow

brand

brands

harmful

two

or

more

contains

could

react

to

your

brands

its

own

in

the

engine.

of

additives;

mixture

~

WESTERBEKE

Engines & Generators

5

PREPARATIONS

PRESTARTINSPECTION

Before starting your generator longed layoff,

• Check the engine the

full

• Check the bowls

• Check the and battery cable connections.

• Check the coolant and at

NOTE:

the engine:r cooling system will be purged recovery tank. Open the the cooling system is purged after the engine tank will be drawn into the engine:r cooling system replace the purged

Before subsequent operation

manifold shauld be topped off, tank may need to be filled to the

check the following

oil

mark

on

the

fuel

supply

for

contamimmts.

DC

electrical system. Inspect

level

the

manifold.

After the initial running

has

air.

for

the

first

time

items:

level:

add

oil

to

maintain

dipstick.

and

examine

in

both

air

cooled, the coolant from the recovery

the

fuel

wire

the plastic recovery tank

of

the generator, the air in

to bleed petcock to ensure that of

air.

After shutdown

of

the generator, the engine's

and

the coolant recovery

MAX

level.

FOR

or

after a pro-

the

level

at

filter/separator

connections

the coolant

GJUi

to

OIL

FILL

INITIAL

•

Visually parts, threaded

•

Check the

• Examine the air

•

Be the

•

Be neutral requires,

to

the

or

open

voltage

•

Make

A

recommended motors, up

to

This unanticipated prevent a cold

START-UP

examine

disconnected

connections. Search

load

leads

wiring

diagrams.

sure

no

other generator

load

lines.

sure

that

in

is

properly and

that generator

load

neutral.

neutral

on

unbalanced

certain

the

CAUTION:

be

switched

speed

and,

precaution

operation

the

unit.

wires,

for

correct connections

inlet

and

outlet for

power systems

grounded

In single phase

can

supply

loads.

raw

water

When

starting

that

all

AC

loads,

OFF

until

in

cold

climates,

will

prevent

of

engine

from

Look

for

unattached

for

any

or

utility

with a neutral

(or

ungrounded)

neutral

systems

the

wrong

thru-hull

the

especially

the

engine

starts

damage

the

AC

machinery

stalling.

loose

or

missing

hoses,

and

gasoline

as

specified

air

flow

obstructions.

power

is

connected

line

as

is

properly

an

line-to-neutral

is

open.

generator,

large

has

come

to

warm

caused

by

and

check

leaks.

in

that

the

system

connected

incomplete

it

is

up.

will

to

AIR

BLEED

PETCOCK

Engines & Generators

6

.

STARTING/STOPPING

PRO

GENERATOR

CONTROL

PANEL

AC

CIRCUIT

IrITii~~~

BREAKER

----+.Ii

HOURMETER

BA

FUSE---_W

EMERGENCY"

","_L

,

"00

5

'

START/STOP

o

SWITCH

--"""'

__

-""

p

m

Starting

Simply press

the

START switch

and

the

generator will start.

A green light will glow indicating the generator

is

running.

Stopping

To

stop-depress

the

STOP side of

the

start

switch,

the

green

light will

go

out

and

the

generator

is

stopped.

Failure

to

Start

The start cycle

will

automatically tenninate if

the

unit

fails

to

start after 12-14 seconds of cranking.

Wait

20

seconds,

then

repeat the start.

If

the

unit again

fails

to

start, investigate

the

cause.

Sometimes after servicing

the

fuel

system or changing

the

fuel

filter,

air can accumulate in

the

fuel

line or

the

throttle

body and prevent starting. The

Schrader

valves

on

the

throttle body

and

the

fuel

cell

are

used

to

remove trapped

air.

This air

is

mixed

with

fuel

and

under high pressure. Follow

the

BLEEDING THE FUEL

SYSTEM instructions in

this

manual.

•

START----'STOP

o

REMOTE

CONTROL

PANEL

ECU

CONINECTIONS

~-~.-£'---EN["NE

HARNESS

CONNECTION

FIREBOY,

CO

DETECTOR

AND/OR

AUXILIARY

STOP

CONNECTION

REMOTE

START/STOP

PANEL

The

components on

the

panel

are:

1.

A three position start/stop rocker

switch.

2.

A green

LED

run indicator light on the rocker

switch.

3. A four position LED fault shut down display board. The start/stop rocker switch functions

the

sarne

as

the

start/stop rocker switch

on

the generator's control

panel

as

previously explained. The start/stop rocker switch indicator light on the rocker

switch

will

illuminate when the start circuit

is

energized.

It

will

go

dim

as

the engine cranks and will brighten

as

the

engine sttuts

to

indicate the generator is running.

The

LED

fault

shut down display board has four separate

LED

lights

to

display

to

the operator the cause of

the

generators

automatic shut

down.

The four

LED

displays

are:

low

oil pressure, high engine operating temperature, high exhaust temperature

and

engine over-speedlunder-speed

(flashes).

Should

the

generator shut down

from

one

of these

faults,

the

fault

LED

will remain illuminated.

To

reset

the

LED,

the

stop

switch

must

be

momentarily depressed.

This remote panel is a plug-in accessory and

is

available with a

15'

to

100' wiring harness .

~

WESTERBEKE

Engines & Generators

7

BREAK-IN

PROCEDURE/DAILY

OPERATION

BREAK-IN

After the generator has been started, check for proper operation and then encourage a fast wann-up. Run the generator between hours.

A

genllfBtor

After the first 10 hours can be increased to the full-load rated output; then

cally vary the load. Avoid overload at all times. An overload is signaled by a

smoky exhaust with reduced output voltage and frequency. Monitor the current being drawn from the generator and keep

withinthe

it

at

1800 rpm to produce 60 hertz, control

engine break-in is governed by the current drawn from the

generator.

To protect against unintentional overloading

'.

the generator's output leads should be routed thmugh a circuit breaker

generator.

NOTE:

current drawn required/or starting motors.

amperage drawn

amperage. See GENERATOR INFORMATION in this manual.

PROCEDURE

20%

to

60%

of

full load for the first 10

CAUTION:

Be

aware

Do

not

attempt

by

running

generators' rating. Since the generator operates

thitt is rated at the rated output

without a load.

of

afmotor

can

be 3

the generators' operation, the load

starting loads and the high

to

break·in

of

5 times nonnal

the generator's

of

This

your

periodi-

the generator,

of

the

starting

running

NOTE:

Some unstable running may occur in a cold engine.

This

condition slwuld abate as nonnal operating temperature

is reached and loads are applied.

A

CAUTION:

periods

of

00

not

time

without a load

operate

the

generator

being

placed

for

on

long

the

generator.

STOPPING

Remove the major Allow the generator to run for a few minutes to stabilize the operating temperature and press the

CONTROL PANELS).

NOTE:

the maintenance schedule

GENERATOR

Once the generator has been placed in operation, there may be governor adjustments required for engine speed (hertz) during the engine's break-in period (first this period (see under ENGINE ADJUSTMENTS. A no-load voltage adjustment may also be required in conjunction with the engine's speed adjustment (see

INFORMATION).

A

THE

GENERATOR

AC

loads from the generator one at a time.

STOP switch down, (see

After the first

50

hours

for

of

generator operation check

the

50

hour service check.

ADJUSTMENTS

50

ENGINE SPEED (HER1Z) ADJUSTMENT

GENERATlOR

WARNING: . VENTILATION

hours) or after

CHECK

Follow this checklist each day before starting your generator.

• Record the hourmeter reading

• Visually inspect the engine for fuel, oil, or water leaks.

• Check the oil level (dipstick).

• Check the coolant level in the coolant recovery tank.

• Check your fuel supply.

• Check the starting batteries (weekly).

• Check the drive belt for wear and proper tension (weekly).

• Check for abnormal noise such as knocking, vibration and

•

LIST

in

your log (engine hours

relate to the maintenance schedule).

blow-back sounds.

Confmn

When the engine is cold - White When the engine is When the engine is overloaded - some Black

exhaust smoke:

wann

Smoke.

- almost Smokeless. Smoke.

Gasoline vapors can explode. Before starting the engine,

operate the blower for at least four minutes and check both the engine compartment and the bilge for gasoline vapors. Run the blower below cruising speed.

Engines & Generators

8

SAFETY

SHUTDOWN

SWITCHES

DESCRIPTION

The engine/generator is protected by switches and sensors

that send signals

to

the ECU that it interprets as a fault and automatically shuts down the generator drive engine. When an automatic shutdown occurs, one of the control panel fault

LED lights will illuminate indicating what fault caused the engme to shutdown.

TIlls LED will stay illuminated.

To

correct the fault, refer

to

ENGINE TROUBLESHOOTING

in

this manual. Do

not

attempt

to restart

the

generator

before correctiog

the

fault.

WDISPlAY

PCBOARD

(INTERIOR VIEW)

~I

CONTROL

PANEL

INDICATOR

LIGHTS

PRESSURE

FUSE

Four

LED

fault ligbts are located on the generator control

panel

and

the

remote start/stop panels. Should a problem occur during generator operation the individual light will indicate

Where

the problem

is

and at the same time shut the

generator down. The light

wjll continue

to

glow after the

generator shuts down.

Should this occur, refer

to

ENGINE

TROUBLESHOOTING in this manual.

OIL

GALLERY

OIL

PRESSURE

SENSOR

An oil pressure sensor (located just below the oil filter) sends

a

DC

Voltage to the ECU that it interprets

as

oil pressure.

Should

this

voltage faIl below a certain level, the ECU will

shut

the

generator down and illuminate the low oil pressure

LED.

Should

this occur, refer

to

ENGINE

TROUBLESHOOTING

in this manual.

EXHAUST

TEMPERATURE

SWITCH

A temperature switch is mounted on the exhaust elbow

to

monitor

the

temperature

of

the exhaust coolant and gasses.

Should

the

switch sense an excessive exhaust temperature,

the

ECU

will

shut the generator down and

the

exhaust

temperature LED will illuminate on the control panel.

Should

this

occur, refer

to

ENGINE TROUBLESHOOTING

in

this

manual.

COOLANT

SENSOR

THERMOSTAT ASSEMBLY

COOLANT

TEMPERATURE

SENSOR

A coolant temperature sensor is located on the thennostat

housing

to

monitor the engines fresh water coolant. Should

the

coolant temperature reach

21O"F,

the ECU will shut the generator down and the engine temperature LED will illuminate.

Should this occur, refer

to

ENGINE

TROUBLESHOOTING in this manual.

OVERSPEED

SWITCH

An

overspeed high RPM shutdown sensor

in

the ECU will

shut the engine down if the engine

RPM"S exceed

the

set

limit and the LED will remain

lit.

If

an

underspeed problem

occurs, the engine

will

shutdown

and

the LED will remain

flashing.

DC

CIRCUIT

BREAKER

The generators engine

is

protected

by

a panel mounted man-

ual

reset circuit breaker (20 amp).

An

electrical overload

in

the

engine's wiring hamess or the instrument panel

will

trip

this

breaker

and

shutdown the engine/generator. If this should occur, inspect and repair the problem. then reset the breaker and

sestart

the

engine/generator.

Engin~s.

& Generators

9

A

WARNING:

running. use serviCing

Wear

the

co"ect

any

I

SAFE

I Maintenance items that are very imponant to the proper operation

CD "Safe

MAINTENANCE

Never

the

tools

of

proper

the

engine's

CO"

attempt

for

generators.

safety

each

DC

to

perform

equipment

job.

Disconnect

electrical

SCHEDULE

any

such

equipment.

service

as

goggles

the

battery

while

and

terminals

the

engine

gloves,

when

is

and

of

SCHEDULED

MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Oil

Coolant

Level

Drive

Belts

Visual

Inspection

Sparts

Plugs

Starling

(and

Engine

Generalor

Fuel

Air Exhausl

Engine

Raw

Heal

Cootanl

Fuel Inlel

Banerles

House

011

un

Pump

Screen

Syslem

Hoses

Waler

Exchanger

Syslem

Filler Fuel

Filler

Separator

Level

of

Engine

I~EI

Baneries)

FcHI

Pump

CHECK

EACH

DAY

0 0

0 0 0

weekly

0

weekly

HOURS

OF

OPERATION

100

50

NOTE:

will

inhibit

0

0 0

0

250

500

Keep

engine

the

surface

engine's

0

0 0

abifity

0 0 0 0 0 0

0 0

0

0 0 0

0 0 0 0

0 0 0

0 0

0

0 0

0 0 0

0

0 0

750

1000 1250

clean.

Dirt

to

remain

0 0

0

0 0

0

0 0

0

and

cool.

oif

0

Unleaded Check

necessary). Oil

dipstick.

Check

Add

Inspect

and Check

electrical for

Check

Every and excessive

Initial change

Check

no

Periodically are

Clean

Initial

Inspecl Check buildup necessary.

Hose

become

Remove

Inspect Lubricate

Clean cap for

Drain, appropriate

Change Change

gasoline

for

water

level

should

at

recovery

coolant

for

proper

adjust

if

for

fuel,

connections.

loose

belt

gap,

50

operating

make

sure

corrosion.

engine

both

that

AC

chafing-see

clean

and

at

50

check

for

leaks.

the

exhaust

on

inside Check

should

spongy.

the

impeller,

impeller

or

replace

and

clean

professional

flush,

every every

MAINTENANCE

with

and

indicate

tank;

if

needed.

tension

needed.

oil

and

tension.

inspect

connections

oil

and

every

100

connections

GENERATOR

inspect

tight.

hrs.,

then

at

50

hours,

Check

elbow passages; that

be

hard & tight.

Check

pump

cover

cam

when

anode.

oul

debris.

cleaning

and

refill

antifreeze

250

operating

250

operating

DESCRIPTION

octane

dirt

in

fuel

between

if

empty,

(3/8'

Check

belt

water

leaks.

Keep

bolts & nuts

for

burning

hours

check

are

filter

change

hours.

are

for

leaks,

every

100

Ihen

anti-siphon

for

carbon

clean

all

connections

and

tighten

and

wear

reassembling.

Open

Remove

and

COOling mix.

hours. hours.

INFORMATION.

electrical

Replace

inspect

pressure

rating

of

89

(drain/replace

MAX.

and

check

at

manifold.

to

1/2'

deflection)

edges

for

wear.

Inspect

tight.

and

corrosion.

electrolyte

very

tight.

Clean

at

50

hours,

clean

and

secure

connections

hours.

every

250

hours.

valve

operation.

and/or

and

replace

are

tight.

if

hoses

all

hose

for

wear.

plate.

Replace

heat

exchanger

every

1000

testing.

system

with

(continued)

of

higher

filter

if

LOW

on

wiring

and

Check

levels

off

then

with

corrosion

as

clamps.

gasket.

end

hours

Engines & Generators

10

MAINTENANCE

NOTE:

Use the engine Murmeter gauge

engine hours by

running

time.

SCHEDULE

to

log your engine hours

or

record your

SCHEDULED

MAINTENANCE

"Starter

Distributor

"Engine

"Exhaust

Catalyllc

"Exhaust

Catalyst

Oxygen CO

Motor

~

Cylinder CompreSSion Valve

Clearances

Timing

Elbow

Converter

System

Pressure

.1mI

Sensor

In

Exhaust

and

Belt

~

Back

1"t1f1

CHECK

EACH

DAY

HOURS

OF

100

50

250

500

0

0 0

0

OPERATION

750

1000 1250

0

0 0

0

Check

0

and

lubricate.

pinion Check

cap

and

Incorrect performance,

timing Remove

NOTE:

recommended failure

Test

exhaust

casting

NOTE: A defective

carbon

Remove

inspect.

Perform developing above

operating Remove

inspect

Inspect

Sample

MAINTENANCE

solenoid

drive.

ignition

and

resulting

1.5

and

Clean

timing.

rotor.

valve

clearance

check

adjust

and

replace

Failure

to

replace

interval

in

elbow

is

corroded

monoxide

water

injected

Replace

every

back

pressure

restrictions

PSI

or

41

amperage

water

injected

every

2000

every 1 000

with

CO

analyzer.

valve

major

exhaust

leakage!

DESCRIPTION

motor

for

corrosion.

and

lubricate

Check

condition

will

result

compression

clearances.

every

1000

the

timing

could

result

damage

for

casting

integrity.

or

deteriorated.

elbow

exhaust

2000

that inches load.

hours.

test

to

ensure will of

water

Correct

exhaust

Replace Replace

elbow

increase

elbow

the

starter

of

in

poor

pressure

hours.

belt

at

in

timing

to

the

engine.

Replace

can

cause

and

system

column

as

needed.

and

as

needed.

every

Remove

motor

distributor

engine

and

the

chain

if

visually

is

not

pressure

at

full

visually

2000

hours.

·WESTERBEKE

recommends

this

service

EXHAUST

be

performed

MANIFOLD

by

an

authorized

ADJUSTABLE

CLAMP

.0~~"

Engines & Generators

mechanic.

11

FUEL

SYSTEM

GASOLINE

Use unleaded 89 octane follow

U.S Coats Guard regulations, close off all hatches and companionways to prevent fumes from entering the boat, and ventilate after fueling.

NOTE:

The generator compartment should hnve a gasoline

fume

detector/alarm properly installed

GASOLlNEJWATER

A primary fuel filter type

must

be

installed between and the engine to remove water and other contaminant's from the fuel before they can be carried to the fuel system on the engine.

Most installers include a type separator with the installation package as they are aware contaminant's

These gasoline filters must have (not

"see-through") to meet U.S. Coats Guard requirements. The metal bowls have drain valves to use when checking for water and

impurities.

of

in

the fuel can cause.

or

higher gasoline. When fueling,

SEPARATOR

of

the water separalting --,-,

th~

of

filter/water

the problems that

metal

and

working.

AND

bowls

WESTERBEKE

i

NUMBER

(49602)

__

PART

~\

ENGINE

Periodically check the fuel counections and the bowl for leakage. Replace the filter element after the first then follow the

Changing

1. Shut the fuel supply to the generator off.

2. Ensure there is no pressure in the fuel system by bleeding

S.

6.

7.

INLET

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

2. Thread

3.

FUEL

FILTER

50 hours

MAINTENANCE SCHEDULE.

Filter

Element

off any existing pressure using a Schrader valve on the throttle body and fuel cell.

shown on the next page.

Unscrew the fuel bowl from the housing and allow the bowl to come away from the housing.

Remove and replace the filter element and clean the bowl.

Inspect both

Press on a new filter and replace the filter bowl.

Open the fuel supply. Inspect for leaks.

FUEL

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.

fuel supply line.

tightening the fuel supply line so

inlet filter. Tum

generator. Ensure that there are

"0"

rings. Replace

FILTER

on

the replacement inlet filter and connect the

Use care when connecting and

on the fuel supply to the generator and start the

Use a pressure testing kit as

if

necessary.

as

not to distort the

no

leaks.

FUEL

CELL

ENGINE

FUEL

FILTER

1~;::::;i1ir11

FUEL

PUMP

Periodically check the fuel counections

and make sure that no leakage is present and that the fittings

are tight and secure. The engine mounted fuel pump is

maintenance

free.

to

and out

FUEL

TO

..

<.CooLER

PUMP

of

the pump

FUEL

,.yo

WESTERBEKE

Engines & Generators

12

FUEL

SYSTEM

BLEEDING

1. Insure that the fuel cell is

harness, and that the lift pump

2. Attach pressure gauge set

A

safe

THE

FUEL

Snap On MT337B, OTC

to

CAUTION:

use

of

the

Follow

gauge

SYSTEM

not

connected

is connected.

nIl

the Schrader valve on fuel cell.

manufacturer's

SlIts

to

purge a high·pressure

to

the

wiring

or equivalent

instructions

fuel

for

fuel

system.

3. While holding the stop switch

position, purge the air from the fuel cell. The fuel cell purged when no air bubbles are visible escaping from the

drain line attached to the Schrader valve.

typically be

4. Remove the pressure gauge set from the fuel cell and connect it

5. Connect the fuel cell Open the valve on the fuel pressure gauge purge line. Do

6. not prime the system without the fuel gauge purge valve

or

open happens, repeat steps I, air from the fuel cell.

7. Repeat step 3, this time purging the air completely from the

throttle

. throttle body after purging the system.

IoTE:

purged.

visible in the purge line. .

3-4 psi.

to

the Schrader valve on the throttle

to

the wiring harness.

air can be forced back into the fuel cell.

2,

body.

The pressure should be 40 psi in the

The

system

can develop

The

system

is

fully

in

the (prime) depressed

Pressure should

body.

If

this

and 3

to

remove the trapped

40

psi

without being

purged when no bubbles are

fully

is

TO

"SNAP-ONEXCELLENT FOR BLEEDING

8.

Remove the pressure gauge set, and cap all Schrader valves.

9.

Insure that all wire connections are secure and that there

are

no

leaks in the fuel system.

A

fuel that dispose

TOOL"

PROVIDES

PRESSURE

WARNING:

TESTING

SCHRADER

may

be spilled

of

the , __

Take

,

-".!r-----

GAUGE

AND

TEST

care

'.11.'

AN

KIT

PORTS

to

and

properly

catch

.".,

any

COOLER

KIT

ADAPTER

INCOMING

VALVE.

FUEL

CELL

FUEL

..t:~+--+---

\\j':_+-tL---INLET

FILTER

FUEL

PUMP

FILTER

12A

ELECTRONIC

FUEL

"«'UL'''U''\.

STEPPER THROTTLE ASSEMBLY

MOTOR

AND

SHAft

THRonLE

The above illustration shows tl,e throttle body assembly that

attaches to the intake manifold. An electronic control unit (ECU) controls the fuel injector

and the stepper motor.

The

sensors

temperature, map sensor (intake manifold absolute pressure), engine rpm and battery voltage.

The

appropriate injector pulse rate and throttle opening position. A high pressure fuel pump supplies fuel to the area around

the injector and the regulator maintains the fuel pressure in that area at 35 -

The injector is a solenoid operated pintle valve that meters fuel into the intake manifold depending on engine operating conditions and generator amperage load determined by the ECV.

Air flow into the intake manifold is controlled by the operation plate positioning for proper air flow accomplished through the operating conditions. The Schrader valve is used to monitor/check fuel pressure around the fuel injector.

ELECTRONIC

The and requires no adjustments by the generator operator. controls all starting, operating and safety shutdown features on the engine. The Gain Pot is set at #50 midpoint for

optimum

Dipswitch ON is for remaining switches #2, 3#. and

BODY

AIR

TEMPERATURE

SENSOR

ECV

is supplied with engine operating conditions from

that

monitor

ECV

interprets this information to determine the

of

the throttle plate via the stepper motor. Throttle

ECV

(Electronic Control Vnit) is factory programmed

system

#1

50

intake

air

temperature,

40

PSI maximum.

mto the engme is

ECV interpretation

CONTROL

response.

is used to charge the generators frequency.

hertz and OFF is for 60 hertz operation. The

UNIT

(ECU)

#4 service no functions.

LOWER BODY

engine

of

UPPER

THROTTLE

coolant

engine

FUEL

THROTTLE

ECV

It

PROGRAM

INJECTION

NOTE:

When changing the generator frequency. turn OFF

the

DC

20

amp breaker before moving the dipswich.

The vacant program connector is used by the factory to input the operating program into the

used

with

purchased

Safe

CO

systems.

The electrical connections from the engine electrical harness are made to the

pin and one 35 pin and may therefore vary in number

according to the generator model. For further details. consult

the

engine

circuit

The ECV is normally set for operation at 60Hz unless

specified otherwise, and is internally configured for a 4 pole generator. is configured by label for the generator in use.

ECU

Stability

When changing engine speed.

condition should occur, the gain pot may require adjustment.

There is no specific set point for this adjustment and it is normally set to the middle range which obtains optimal engine speed response without any tendency

Setting

The engine speed can be set for operation at either 50 or 60

Hz. Corresponding engine speeds for a 4 pole generator are 1500 rpm

1.

2.

3. Adjust the GAIN setting between

NOTE:

operation. In such cases, lessen the

Replacing

Remove

the ECU, turn Unplug the two engine harness connections. Then unscrew the four side screws securing the ECU and remove it from it's holder. To install a new

If

it is necessary

ADJUSTMENTS

Trim

Engine

or

1800 rpm.

Set

up whatever equipment is to

engine speed Start up and run the generator at the current operating

speed and frequency. .

reaction

to

A higher GAIN adjustment can induce unstable engine

the

control

software

ECV

through two plug connections, one 23

wiring

(Gain)

of

hunting.

Speed

or

generator output frequency.

AC

amperage load changes.

ECU

box

OFF

the 20 amp

ECU

ECV. This connector can be

to

monitor

diagram

to

replace the ECV, make sure it

or

if

of

its range

cover.

Before

DC

ECU, reverse the procedure.

the

operation

in

this

manual.

no engine hunting

or

to a point in its

be

used

to

measure

40

- 60 for best system

GAIN

adjustment.

attempting

control panel breaker.

to

remove

of

the

-..v-

WESTERBEKE

Engines & Generators

128

ADJUSTMENT

POT

COOLING

SYSTEM

FRESH

NOTE:

recommended antifreeze

. fresh water coolant.

Fresh water coolant is pumped through the engine by a circulating pump, absOIbing heat from the engine. The coolant then passes through the thermostat into the heat exchanger where it is cooled, and returned to the engine block via the suction side engine is started cold, external coolant flow is prevented by the closed thermostat (although some coolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheating). As the engine "'arms up, the

thermostat gradually opens, allowing full flow coolant to flow unrestricted to the external pOItion cooling system.

Coolant

A coolant recovery tank allows for engine coolant expansion and contraction during engine operation, without any significant loss ing system. This engine manifold level and should be easily accessible.

WATER

Refer

Recovery

of

COOLING

to

the

ENGINE

CIRCUIT

COOIANT

and water mixture to be used as the

of

the circulating pump. When the

section

for

of

Tank

coolant and without introducing air into the cool-

tank should be located at or above the

the

the engine's

of

the

COOLANT TANK

NOTE:

Periodically check the condition

sure cap. Ensure that the

good coTutition closes tightly. Carry a spare cap.

and

upper

check that the vacuwn valve .opens

of

the manifold pres-

alld

lower rubber seals are in

and

CHANGING

The engine's coolant must be changed according to the

MAINTENANCE SCHEDULE.

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

A

Wear

Refilling

After replacing the engine block drain plug, close the heat exchanger's coolant petcock. Slowly pour clean, premixed antifreeze coolant into the water jacketed exhaust manifold

filler neck opening. Fill the system full, then start the engine.

Monitor the coolant in the manifold and add as needed. Fill the manifold

pressure

Remove the cap on the coolant recovery tank and

coolant mix

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

COOLANT

If

the coolant is allowed to

CAUTION:

back

The drain petcock on the heat exchanger should also

to help drain engine coolant.

WARNING:

protective

the

cap.

Proper

to

cooling

number

system

Beware

of

the

system

of

maintenance

engine

corrosion.

hot

engine

fai/ures

gloves.

Coolant

to

the filler neck and install the manifold

to

halfway between

LOW

and

MAX

to

the recovery tank

can

coolant.

fill

with

and replace

as

the if

is

be

SEAL

MANIFOLO PRESSURE CAP

-.y-

WESTERBEKE

Engines & Generators

13

COOLANT

EXPANSION

KEEP

THESE

A

FULL

FLOW

THE

COOLANT

CLEANER

PASSAGES

OF

COOLANT

RECOVERY

WORKS

WELL)

CLEAR

TO

ANO

TANK

TO

ENSURE

FROM

( A

PIPE

HEAT

EXCHANGER

Cool

raw

water

flows

through exchanger. the which The and

The

this deposits

Heat

After approximately and motive radiator shop should

exchanger.)

NOTE:

that a heat exchanger cleaning be

every

As

the

engine

heat

of

the

internal

is

then

pumped

engine

coolant

(now

the

circuit

repeats

engine

coolant

and

keeps

the

engine's

found

in

raw

water.

Exchanger

pressure

Operating in silty andIor tropical waters

1000 hours.

ZINC

HEAT

EXCHANGER

Service

test

the engine's heat exchanger.

ANODE

---+\i'"tj

the

inner

coolant

passes

engine

is

conducted

into

the

exhaust

cooled)

itself

raw

water

1000

flows

water

are

passages

hours of operation,

be

able

tubes

of

around

to

tlJe

system

and

back

through

independent clean

from

to

clean

peljormed

COOLING

the

heat

these

tubes

raw

water

discharged.

the

engine

of

each

other,

the

hannful

remove, (A

and

mare often than

local test

may

clean

auto-

the

heat

require

SYSTEM

If

the

zinc

anodes

need

replacement,

into

which

the

zinc

anode

is

threaded loosening hex zinc flakes

exchanger

have

one Replace exchanger end gasket part install a new

NOTE:

do

may insulate the zinc from the metal

housing preventing electrolysis action

THERMOSTAT

A

thermostat, engine, continuously the

coolant

hole

overheating). gradually checked, and

the

anode

with

another

boss

from

possibly tearing off

is

in

poor condition,

within

the

exchanger.

and

clean

a spare heat exchanger end gasket

becomes

not require sealant. Sealant should

engine

in

gasket.

damaged

the

gasket (refer

zinc

The threads

located

controls

from

the

flows

is

first

flowing

thermostat

As

opens.

cleaned,

the

The

anode.

started,

or

there

are

Remove

the

inside of

when

removing

to

your engine model's heat

number),

of

the zinc anodes are pipe threads

near

the

manifold

coolant temperature

through

the

(some

coolant

to

prevent

engine

warms

thermostat

replaced

closed cooling

closed

the

is

easily.

hold

the

hex

with a wrench

wrench.

the

all

up,

accessible

This prevents

exchanger

probably a

the

end

zinc

in

the

O-ring

not

of

the heat exchanger

on

the

at

as

thermostat prevents

is

by-passed

exhaust

the

Carry

shell.

lot

of

the

debris.

Always

case

the

end

cover.

and

cover,

be

used as it

zinc.

the

front

the

coolant

circuit.

through

manifold

thermostat

and

can

a spare

thermostat

boss

while

zinc

heat

present

and

of

the

When

from

be

If

the

a

CLEAR

OUT

ZINC

DEBRIS

ZINC

ANODE

A

zinc

anode,

or

pencil,

is

located

circuit

witlrin

the

heat exchanger. The purpose of having

zinc

anodes

is

to

sacrifice

place

in

the

raw

water cooling circuit, thereby reducing

effects

of electrolysis The condition of and

the

anode cleaned or replaced

be

should

NOTE:

Electrolysis action is the result

installation and vessel location; not that

NEW

carried

,REPLACE

the

on

ZINC

them

on

other components of

zinc anode should

board.

ANODES

in

the

to

electrolysis

as

required. Spare anodes

of

WATER

DRAIN

raw

water

cooling

action

taking

the

system.

be

checked

each particular

oftJre

monthly

engine.

CLEAN & REUSE

Replacing

To

avoid

spilling coolant, manifold Remove housing gasket, gasket before pressing cap engine

--..;-~

.'"

the

Engines & Generators

apply a thin

screws.

and

leaks

level

the

as

at

the

Thermostat

drain

the

coolant

(REFER TO CHANGING

cap

screws

and

disassemble

shown.

When

installing

coat of sealant

it

into

Replace

check for normal temperatures

the

coolant

tllermostat

GASKET

APPLY

SEALANT

ATASSEMBLY

housing.

place.

in

the

new

on

both

Do

not over-tighten

the

manifold.

THERMOSTAT ASSEMBLY

down

below

COOlAN7).

the

thennostat

thermostat

sides

of

the

Run

and

that

there

the

and

the

are

14

,

RAW

WATER

The

raw non-ferrous housing flexible blades the impeller housing, producing

account lubricant

impeller Raw water pump impeller water)

is

are

not

warrantable, raw water has a limited lifetime

NOTE:

Should a failure occur with the pump ~ internal parts

(seals

and bearings), it

a

new

pump

Inspectlng/Changing

Close the

and,

with impeller out of the a

pair

of

care.

not to tear the impeller). Install the

();.ring.

and push assembling, apply a thin coating of lubricant

'and gasket.

Run

check for water discharge

dow indicates

Move the blades to conform

the

engine

PUMP

water pump

should this

for

the

and

impeller cover gasket

not present during engine operation. Such failures

flow

and

raw the proper size impeller

screwdrivers

the

impeller into the

Open the raw water intake valve.

is

a self-priming, rotary pump

and

a neoprene

which

wipe against a curved cam plate

pump

be

impeller. There should always be a spare

failures

and

operators

is

present

rebuild the original pump as a spare.

water intake

and

the

pump

at

start-up. The neoprene impeller

and

must

may

be more cost effective

the

Raw

valve.

pump

(the impeller can be pried out

if

an

impeller puller

check for leaks around

at

the

has

not

impeller.

the

pumping action.

run

dry as water acts as a

(an

impeller

occur

when

are

cautioned

be

inspected regularly.

Water

Remove

tool,

pumps

stern primed itself

Pump

the

carefully

is

new

to

the

curved

housing.

the

tube.

Absence of water

COOLING

with

a

The impeller

kit)

lubricant

to

make sure

to

Impeller

pump

pry

unavailable.

impeller

carn

When

to

the

impeller

pump.

properly.

within

On

no

aboard.

(raw

purchase

cover

the

using

Take

and

plate

Also

has

SYSTEM

RAW

WATER

NOTE:

Always install the strainer at

the strainer will always be self-priming.

A clean

engine's cooling

strainer

in

the glass

Perform

operation:

1.

Close the raw water seacock.

2.

Remove

3.

Clean

4.

Replace

5.

Reassemble

6.

Open the seacock.

7.

Run

NOTE:

Also follow the above procedure after having run hard

aground.

If

the

engine temperature gauge ever normal may raw

reading,

have

water

INTAKE

raw

water intake strainer

system.

when

should

the

following

and

the

engine

been

through

making

glass.

your periodic engine

be

clear.

clean

sealing and

install

and

the

cause

caught

the

STRAINER

is a vital

Include a

maintenance after every

the

strainer

washer if

check

may

up

in

cooling

the

necessary.

strainer.

for

leaks.

be

strainer,

system.

or

below the waterline so

component of

visual

inspection of

check.

100

filter.

shows

a higher

that

sil~

leaves

or

slowing

WASHER

the

The

hours

than

grass

this water

flow

the

of

THE

SLOT

NOTE:

Never allow the

of

dry rnnning may destroy the impeller.

INSPECT

.

ANO

IF OF

FITS

IN

THE

IMPELLER.

THEY

SHOW

WEAR.

INTO

THE

SHAFT.

A

CAUTION:

impeller, the

cooling circuit.

a-RING

REPLACE

SIGNS

____

they

-----...

LIGHTLY PUMP ANO

.

GLYCERIN.

If

any

must

be

They

pump

to ron dry. Even a short period

IMI'EL!ER

GREASE

CHAMBER,

IMPELLER

of

the

located

often

exchanger

THE

a-RING,

WITH

blades

to

prevent

can

.

have

be

.

broken

blockage

found

in

the

off

heat

in

the

FILTER

TYPICAL

DRAINING

When

can

be plate pump

Open

allow the raw water

THE

RAW

freezing temperatures

drained

screws.

and

the

by

This

also

drain

raw

water petcocklplug

WATER

loosening

should

allow

back

to

drain.

RAW

WATER

((]wner

COOLING

are

expected,

the

raw

the

strainer.

on

INTAKE

STRAINER

Installed)

SYSTEM

the

cooling system

water pump's cover

water

to

drain out of

the

heat

exchanger

the

to

Engines & Generators

15

ENGINE

OIL

GRADE

Use a heavy duty engine oil with an API classification Change the engine oil after an initial 50 hours operation, and every recommended oil viscosity, see the following chart:

OperatIng

Above

68' F (20'

41' -

68' F (5'_20'

Below

41' F (5'

A

CAUTION:

engine tires: mixture

CHANGING

The engine oil should be warm. Remove the oil drain hose from its attachment bracket and lower it into a container and allow the oil to drain, hose and pump the old oil out. Make sure the oil drain hose

is properly secured in its holder after all

been drained. Always observe the old oil as it is removed. A yellow/gray

emulsion indicates the presence this condition is rare, it does require prompt attention to prevent serious damage. Call a competent mechanic if water is present result and/or.a siphoning through the water cooling circuit into the exhaust, filling into the engine.

ail

til

additives

ta

produce

THE

in the oil. Raw water present in the oil can be the

of

a fault in the exhaust system attached to the engine

100 hours

Temperature

C)

Da

nat

mix.

Each

brand

af

different

properties

ENGINE

or

attach a pump to the end

of

operation thereafter. For

SAE

30, SAE

allaw

twa

cantains

brands

cauld

harmful

OIL

of

water in the oil. Although

of

011

ViscDsity

10W-30

20

or

SAE

10W-30

aT

maTe

its

awn

react

ta

,auT

of

the old oil has

10W-30

brands

LUBRICATING

of

S1.

break-in

or

15W-40

al

addi·

in

the

engine.

of

the drain

OIL

Replacing

When removing the used oil filter, you may find it helpful punch a hole in the upper and lower portion to

drain the oil into a container before removing to lessen spillage. An automotive filter wrench should be helpful in removing the old oil filter. and a plastic bag around the filter when unscrewing it to catch any oil that's in the filter. Inspect the old oil filter removed off with the old oil filter. sealed against the oil filter adapter, gently remove it. When installing the new oil filter element, wipe the filter gasket's sealing surface on the oil filter adapter free thin coat the oil filter. and tighten the filter finnly by hand.

NOTE:

are

not

REFILLING

Add fresh oil through the valve cover. After refilling the oil, run the engine for a few moments while checking the engine's oil pressure. Make sure there is no leakage around the new oil filter engine. Then check the quantity

dipstick. Fill

';~'(llrllllll(';~

the

Oil

Filler

to

of

the old filter

it.

This helps

Place some paper towels

as

it is

to

make sure that the rubber sealing gasket comes

If

this rubber sealing gasket remains

of

oil and apply a

of

clean engine oil to the rubber sealing gasket on

Screw the filter onto the threaded oil filter stub,

Use genuine WESTERBEKE oil filters. Generic filters

recommended.

THE

OIL

SUMP

or

from the oil drain system, and then stop the

of

oil with the lube oil

t~\ou

FULL

mark on the dipstick.

\~~~~

OIL

DRAIN

WARM

THE

ENGINE.

THE

OIL

INTO

SUITABLE

.

CONTAINER

A

SHUTDOWN

AND

11~i.1;@~

DRAIN

!®_-

--<---11 SOCKET

1/4"

FOR

AN

"""

OIL

The

by the oil'pressure gauge on the instrument Ranel. During normal operation, the

/16

"

60 psi (2.8 and 4.2 kg/em').

NDTE:

NPT

ADDING

EXTENSION

reading up an oil pressure reading as low as readings will vary depending upon the temperature engine and the rpms. Refer to ENGINE ADJUSTMENT

pages

WESTERBEKE

Engines & Generators

16

SPIN·ON OIL

FILTER

CHANGING

OIL

FILTER

PRESSURE

engine's

oil

pressure,

A newly started. cold engine can have an oil pressure

to

60

psi (4.2 kg/em". A

for

TESTING OIL PRESSURE.

during

operation.

oil pressure will range between

wanned

35

is

indicated

engine can have

psi

(2.5 kg/em". These

of

40

the

and

INSTALLATION

This popular

filter

from

an

engine

NOTE:

instructions

APPLY A THIN INSTAUING TIGHTEN CONTACTS

accessOIY

the

engine

room

bulkhead.

is

to a more

Refer to ENGINE OIL CHANGE

on

removing the oil

COAT

OF

CLEAN

THREAD

3/4

TURN

OIL

THE

THIS

KIT_

AN

ADDITIONAL

THE

BASE.

used

TO

THE

KIT

AFTER

REMOTE

to

relocate

convenient

filter.

O-RING

ON,

THEN

THE

in

WHEN

HAND

O-RING

the

location

this manual for

engine's

such

OIL

FILTER

oil

as

(OPTIONAL)

To

install,

simply

remove

WESTERBEKE's

install

this

kit

Contact your

NOTE:

Westerbeke

incorrect installation

A

CAUTION:

rectly.

If

the

pass

valve

from

reaching

failure.

If

immediately

remote

with

the

oil

WESTERBEKE

is

not

of

the

It

is

vital

oil

flows

in

the

filter

the

engine

there

is

no

oil

and

check

the

engine

oil

filter

oil

filter kit

filter

dealer

facing

as down

for

shown.

as

mare

responsible for engine

Remote

in

the

assembly

causing

pressure

the

to

install

reverse

hose

Oil

Filte1:

the

oil

direction,

will

prevent

an

internal

reading,

connections.

FASTEN

SECURElY

and

thread

Always

illustrated.

information

failure

due

lines

cor-

the

by-

the

oil

engine

shutdown

TO A BULKHEAD

SUPPLIED)

on

to

NOTE

THE

ON

THE

ADAPTER REMOVED WILL

BE

RECONNECTED

"IN"

"OUT"

WHEN

FOR

INSTALLATION

MARKINGS

THE

HOSES

ARE

SO

THEY

CORRECTLY

THE

IN

CONNECTION

MUsT

ATTACH

CONNECTION

THE

OUT

MUST

ATTACH CONNECTION REMOTE

OIL

AT

FIlTER.

TO

THE

AT

THE

FILTER.

I

TO

THE

HOSE

OUT

HOSE

IN

APPLY A THIN

GASKET

WHEN

CONTAC1S 3/4

THE

TURN.

COAT

OF

INSTALliNG.

BASE,

TIGHTEN

OIL

TO

AFTER

IT

AN

THE

FILTER

THE

FILTER

ADDITIONAL

.

Engines & Generators

17

PUSH

ON

SPAOE

CONNECTION

MAP

SENSOR

SCHRADER

VALVE

THROTTLE

FUEL

INJECTOR

BODY

FUEL PRESSURE

ASSEMBLY

AIR

TEMPERATURE

SENSOR

FROM

THE

THERMOSTAT

ASSEMBLY

i'

..

DESCRIPTION

The

above illustration shows the throttle body assembly

to

attached

An electronic control unit (ECU) controls the fuel injector

and the throttle actuator.

The

sensors

temperature, map sensor (intake manifold absolute pressure), engine

The appropriate injector pulse rate and throttle opening position.

A high pressure fuel pump supplies fuel

the injector and the regulator maintains the fuel pressure

that

area

the intake manifold.

ECU

is supplied with engine operating conditions from

that

monitor

rpm and battery voltage.

ECU

interprets this information

at 35 -

40

intake

PSI.

air

temperature,

engine

to

determine the

to the area around

coolant

RETURN

in

MANIFOLD

The injector fuel into the intake manifold depending on engine operating conditions and generator amperage load as ECU.

Air flow into the intake manifold is through the flame

arrester/air filter and is controlled by the

the throttle plate via the actuator. Throttle plate positioning for proper air flow into the engine the

ECU interpretation Schrader valve the fuel injector and to bleed air from that area after fuel

is

a solenoid operated pintle valve that meters

deteimined by the

ECU operation

is

accomplished through

of

engine operating conditions. The

is

used to monitor/check fuel pressure around

of

system servicing.

An air intake heater

incoming air during a cold start.

is

positioned in the intake to heat the

Engines. & Generators

18

ENGINE

ADJUSTMENTS

SPARK

The spark plugs should first thereafter and replaced as needed.

SPARK SPARK

NOTE:

the spark plugs will retard corrosion, making future removal of

INSPECT

PLUGS

be

cleaned and regapped after the

50

hour break-in period, then inspected every 250 hours

A

WARNING:

the

engine

removing

PLUG

GAP:

PLUG

TORQUE:

Loctite Anti-Seize applied to the threaded portion

the spark plugs easier.

FOR

00

is

hot.

them.

0.031 ± 0.002 25

DAMAGE

----..-

not

Allow

Nm.

remove

the

engine

in.

(0.8 -0.05

(18.45

«-Ib)

the

spark

plugs

to

cool

before

mm).

INSPECTING THE

while

of

SPARK

PLUGS

CHECK

FOR

Vl'BUILD

UP

CARBON

AND

BURNING

DRIVE

The drive belts must be properly tensioned. Excessive drive belt tension can cause rapid wear service life the presence resulting in high operating temperatures.

This generator has two drive belts, one drives the governor

and alternator and the other drives the raw water pump. The tension adjustment procedure for both belts is as follows:

1. Remove the belt guard.

2.

3. With the belt(s) loose, inspect for wear, cracks and frayed

4.

5. The drive belts are properly adjusted

BELT

ADJUSTMENT

of

the belts and reduce the

of

the fresh water pump's bearing A slack belt or

of

oil on the belt can cause belt slipping,

To

adjust the governor/alternator drive, 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.

edges and replace To

loosen or tighten the alternator drive belt, slide the alternator in or out bolts.

To loosen or tighten the raw water pump/fresh water pump drive belt, slide the raw water pump required, then retighten its mounting bolts.

no less than 3/8 inch (12mm) as the belt is depressed with the thumb at the midpoint between the two pulleys the belt.

if

necessary.

as

required, then retighten its mounting

in

or out as

if

it can be deflected

(lOmm) and no more than

on

the longest span

112

inch

of

..:

t

GAP

f

HIGH

TENSION

Check the ignition wires every 500 operating hours as engine compartment heat can deteriorate the wires.

Check the resistance because the wire connection inside the cap may become separated the wires from the spark plugs, grasp and twist the molded cap, then pull the cap off the spark plug.

The

or

resistance

CORDS

the insulator may

valne

(IGNITION

of

each wire. Do not pull on the wire

is

410

WIRES)

be

damaged. When removing

ohm

per

inch

of

wire.

CHECKING RESISTANCE

A

WARNING:

drive

belt's

6. Operate the engine for about 5 minutes, then shut down the engine and recheck the belts tension.

Replace the belt guard.

7.

Never

tension

attempt

while

the

to

check

engine

or

is

in

operation.

adjust

a

Engines & Generators

19

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjust-

ments

be

peifonned

below is provided to assist the mechanic.

ADJUSTMENTS

by a competent engine mechanic. The information

ENGINE

1. To check the engine's compression pressure,

2. Remove the spark plugs and install a compression

3. Close

4. Crank the engine with the start motor and unplug the

S. Measure the compression pressure for all the cylinders.

6.

7. Re-install plugs and ignition wires.

8.

COMPRESSION

engine then shut it down.

adapter (screws into a plug hole) with a gauge.

off

the raw water intake seacock.

ignition coil and allow the compression gauge to reach a maximum reading and record.

Ensure that compression pressure differential for each

is

cylinder

Compression

If

a cylinder's compression or pressure differential is below the limit, add a small amount the spark plug hole and repeat steps 3 and 4.

a)

If

piston ring and/or cylinder wall may be worn or

damaged. b)

If

pressure, suspect poor valve contact, valve seizure,

or

within the specified limit.

pressure

addition

additional oil does not increase compression

valve wear.

of

oil causes an increase

should

TEST

not

differ

bV

more

than

of

engine oil through

of

pressure, the

wann

14

psi

up the

(100Kpa).

Open the raw water seacock (thrn-hull).

IGNITION

TIMING

CRANKSHAFT

PULLEY

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

3.

Using the timing light, align the timing groove in the front crankshaft pulley with the proper timing the ignition timing scale embossed on the engine's front cover. Do this by loosening and slowly rotating the distributor body. refer to the timing specification:

IGNmON 15·

BToC

(33· -35·

TIMING

± 1·

STATIC

AT

NO-LOAD

OIL

PRESSURE

AT

1800

(NO

WITH

RPM:

VACUUM

ADVANCE)

VACUUM

TESTING

GAUGE

ADVANCE)

OIL

PRESSURE

f)

~

mad<:

))

OIL

on

GALLERY

DIAL

GAUGE

MEASURING COMPRESSION

IGNITION

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

TIMING

front crankshaft timing groove and the timing mark on

the scale embossed on the engine's front cover.

Each timing mark represents 5·.

"'"

WESTERBEKE

Engines & Generators

OIL:

PRE,SSU,RE

LOW

OIL

PRESSURE

The

specified safe minimum oil pressure is 4.3 - 1.4 psi(O.3 -

0.1 kg/em". An oil pressure down. A gradual loss bearings. For additional infonnation ings, see the ENGINE TROUBLESHOOTING chart.

TESTING

To test oil pressure, remove the oil gallery mechanical oil pressure gauge the engine, read the oil pressure gauge.

OIL

PRESSURE

SENooR

AND

OIL

PRESSURE

35.0 (depending

SWITCH

TORQUE 9 -13

of

5 PSI will shut the engine

of

oil pressure usually indicates worn

on

low oil pressure read-

"T'

and install a

in

its place. After warming up

IbM

(3.8

kg/em')

or

more

at

1800

rpm

on

temperature

H-Ib

and

(1.2

load)

-1.8

m-kg)

20

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjustments be The infonnation below is provided to assist the mechanic.

peiformed

ADJUSTMENTS

by

a competent engine mechanic.

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

tensioner

never

the

oil

seals

----..,..1.

life of

with

or

oil

be

dirt

front

for a

5

BELT

AND

REPLACEMENT

on

the

timing

the

belt.

Keep

the

free

of oil

and

cleaned.

or

case,

possible

TENSIONER

oil.

If

oil

7

SPROCKET

Replace oil

is

pump

leak.

belt

severly

timing

greese.

if

seri-

evident

oil

seals,

BOLT

on

9

ENGINE SUPPORT BRACKET

8

CAMSHAFT SPROCKET

TIMING

BELT

ASSEMBLY

10

BElT

REAR

COVER

2

LOWER

COVER

__

~

NUMBERS

ORDER

TIMING

Using it

from the oil

spring and

NOTE:

belt

to indicate the direction This will ensure the timing belt is fitted correctly when reused.

TIMING

BELT

TENSIONER

INDICATE

OF

DISASSEMBLY

BELT

pliers, grip

pump

the

If

the timing belt is to be reused, chalk

\2;;::;;~fOV

---:;;.i~~H

THE

REMOVAL

the

tensioner spring projection and remove

case stopper. Then, remove the tensioner

timing

belt

tensioner.

of

rotation before removing

t!

an

arrow on the

it.

V)

4

TENSIONER SPRING

TIMING

BELT

CRANKSHAFT PULLEY

MARKA DIRECTION ARROW

SPROCKET

Using the special tools shown in the illustration, lock the camshaft sprocket in position and then loosen the camshaft sprocket bolt.

BOLT

REMOVAL

~~'"

(CAMSHAFT)

~~~~=;;;1Jl

:::

CAMSHAFT SPROCKET

TENSIONER SPRING

15(:::;~~(c~~'1r

I

Engines & Generators

21

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE recommends tluit the following engine

adjustments be pelformed

by

a competent engine

mechanic.

The

infonnation below

is

provided

to

assist

the

mechanic.

Timing

Belt

Inspection

Replace the belt

if

any

of

the following conditions exist:

1.

Hardening

of

back rubber-back side is glossy, without

resilience, and leaves no indent when pressed

Witll

fingernail.

2.

Cracks on rubber back.

3.

Cracks

or

peeling

of

canvas.

4. Cracks

on

tooth bonom.

5. Cracks on belt.

6. Abnormal wear

of

belt sides. The sides are normal

if

they are sharp as

if

cut

by

a knife.

7. Abnormal wear on teeth.

8.

Tooth nUssing and canvas fiber exposed.

CRACKS

PEEUNG

~

.

-

-.

,

·:t~~;

.. : ..

,~

...

3.

5.

7.

4.

~

-

.~.

IROUNDED

EDGE

.-~

',

...

.'.:.:.

','

",:

.... :/,

..

,:

;'::::-.

ABNORMAL

WEAR

~

-i,"'"

;..,:,

..

!:

..

;.;.:~.\("

..

{FLUFFY

STRAND)

....

.

6.

8.

Sprocket

Bolt

Installation

(Camshaft)

Using the special tools shown in the illustration, lock the camshaft sprocket in position and tighten the camshaft sprocket bolt

to

the specified torque.

LOCKING

THE

CAMSHAFT

SPROCKET

Belt

Tensioner

Inspection

Replace the belt tensioner

if

it binds, rattles, or

is

noisy when

turned.

Tensioner

Spring

Installation

1.

Lock tlle tinung belt tensioner in the illustrated position.

TIMING

BELT

TENSIONER

2. Fit one

of

the tensioner spring projections over the hooked

portion

of

the

belt

tensioner

and

fit

the

tensioner

onto

the

oil pump case.

ENS

lONER

SPRING

3. Grip the other tensioner spring projection and fit it onto the oil pump case lug

as

shown in the illustration. Move

the

timing

belt

tensioner

in

the

direction

shown

and

.

temporarily tighten the bolt.

/

OIL

PUMP

CASE

.TlMING

BElT

'TENSIONER

TENSIONER

SPRING

Engines & Geperators

22

ENGINE

NOTE:

WESTERBEKE recommends that the following engine

adjustments be peiformed by a competent engine mechanic.

The infannalion below is provided

ADJUSTMENTS

to

assist the mechanic.

Timing

Belt

Installation

CAMSHAFT SPROCKET

1. Align the camshaft timing mark with the timing mark

--Ho-(,I

on the cylinder head.

I+_-CYLINDER

ALIGN

TIMING

ALIGN

TIMING

THE

MARKS

HEAD

THE

MARK

5. Tum the crankshaft twice in the normal rotating direction (clockwise) and check that the timing marks are correctly aligned.

2. Align the crankshaft timing mark with the timing mark on the front case.

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 112

of

a tum and allow the tensioner spring to apply

tension to the timing belt.

of

the timing belt tight, fit tl,e

bolts by

114

to

A

CAUTION:

camshaft's to

the

timing

as

described

This

driving

belt.

above.

procedure

torque

to

Be

sure

Do

not

apply

to

turn

utilizes

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

fl·lb)

(8

fl·lb)

the

evenly

in

Engines & Generators

23

ENGINE

TROUBLESHOOTING

The following troubleshooting tables are based upon certain engine problem indicators and the most likely causes

of

the

problems. When troubleshooting indicates an electrical problem, see the

El.ECfRICAL

SYSTEM WIRING DIAGRAM

as

these may

reveal other possible causes

of

the problem which are not

listed below.

PROBLEM

PROBABLE

CAUSE

Engine

does

not

1.

Battery

is

low

or

dead.

crank.

Z.

Loose

battery

connections.

*3.

Faulty

wire

connections.

*4.

Faulty

start

switch.

*5.

Faulty

starter

solenoid.

6.

Raw

water

filled

cylinders.

7.

Filters

are

clogged

by

contaminated

fuel.

Engine

cranks

but

1.

Out

of

fuel.

fails

to

start.

Z.

Engine

is

flooded.

3.

Fuel

pump

inoperative.

4.

Worn

or

faulty

spark

plugs.

5.

High

tension

wires

grounding

(wet

system).

6.

Faulty

ignition

coil.

7.

Faulty

distributor.

*8.

Faulty

wire

connections.

9.

Low

engine

compression.

10.

Air

in

the

fuel

system.

See

BLEEDING

THE

FUEL

SYSTEM

Engine

starts,

runs

*1.

Faulty

shutdown

switch.

but

then

shuts

(oil

pressure,

coolant

or

exhaust

down.

temperature).

Z.

High

engine

water

or

exhaust

temperature.

*3.

Oirty

fuellwater

separator

filter.

4.

Low

oil

level

in

sump.

5.

Faulty

fuel

pump

6.

Faulty

engine

temperature

sensor.

7.

Air

in

the

fuel

system.

See

BLEEDING

THE

FUEL

SYSTEM

NOTE:

The engines control system (electrical system) is

protected by a

8 Ampere manual fuse located on the control

panel.

The

generator has an

AC

circuit breaker at the control

panel which should be in the

off

position when peiforming

troubleshooting.

PROBLEM

PROBABLE

CAUSE

Engine

starts,

runs

8.

Fuel

line

restriction.

and

then

shuts

down

9.

Mechanical

check

valve

at

the

fuel

supply

is

faulty

10.

Throttle

plate

binding.

11.

Faulty

wire

connection.

*lZ.

AC

generator

overload.

13.

High

exhaust

pressure.

Engine

hunts.

1.

Low

battery

voltage.

Z.

Generator

is

overloaded.

3.

Cracked

distributor

cap.

4.

Faulty

high

tension

wires.

5.

Faulty

fuel

pump.

6.

High

exhaust

back·pressure.

7.

Valves

are

out

of

adjustment.

8.

Dirty

fuel

filters.

Engine

misfires.

1.

Poor

quality

fuel.

Z.

Incorrect

timing.

3.

Dirty

flame

arrester.

4.

Cracked

distributor

cap.

5.

Faulty

ignition

wires.

6.

Spark

plugs

are

worn.

7.

High

exhaust

back-pressure.

8.

Valve

clearances

are

incorrect.

• Refer to the

ELECfRICAL

TROUBLESHOOTING guide in this manual for detailed testing

of

these electrical connections.

Engines & Generators

24

ENGINE

TROUBLESHOOTING

PROBLEM

Engine

Low

oil

High

oil

backfires.

overheats.

pressure.

Spark

1.

wrong.

2.

Incorrect

3.

Engine

Dirty

4.

Cracked

5.

High

6.

1.

Coolant cooling

Faulty

2.

3.

Belts

4.

Raw

5.

Faulty

1.

Low

Wrong

2.

Faulty

3.

Relief

4.

5.

Faulty Faulty

6.

Faulty

7.

Dirty

1.

engine.

2.

Relief

PROBABLE

plug

wires

timing.

is

flooded.

flame

arrester.

distributor

exhaust

back-pressure.

loss.

Pressure

system.

raw

water

are

loose

or

water

pump

thermostat.

oil

level.

SAE

type

or

wrong

type

valve

is

stuck.

oil

pump.

engine

bearings.

oil

filter.

oil

or

wrong

valve

is

stuck.

CAUSE

are

connected

cap.

test

pump

impeller.

broken.

worn.

oil

in

the

oil

SAE

type

engine.

filter.

oil

in

the

PROBLEM

No

DC

charge

starting

battery.

Blue

exhaust discharged engine.

Black

exhaust

discharged

engine.

Poor

performance

at

generator

to

smoke

from

smoke

from

speed

the

Faulty

1.

battery

2.

Faulty

3.

Faulty

4.

Faulty

1.

Lube

High

2.

3.

Crankcase

4.

Valves

incorrectly. Piston

5.

or Dirty

1.

Valves

2.

adjusted. Lube

3.

4.

Piston Crankcase

5.

1.

Main Fuel

2.

replace.

Throttle

3.

Remove

PROBABLE

connections

charging battery bridge generator

oil

is

diluted.

lube

oil

breather

are

worn

rings

are

unseated.

flame

arrester.

are

worn

oil

is

diluted.

rings

are

breather

jet

clogged.

pump

clogged.

body

and

CAUSE

to

control.

charging

rectifier.

charger

level.

hose

or

adjusted

worn

or

incorrectly

worn

hose

Remove

filter

screen

clean.

control.

windings.

is

clogged.

or

unseated.

is

clogged.

and

Remove

dirty.

clean.

and

"""

WESTERBEKE

Engines & Generators

25

The

following test procedures

engine's wiring diagram (in this manual). Also refer to the

page. WESTERBEKE recommends

qualified technician.

will

require the use

that these tests be peiformed

of

a multimeter

and

relay testing

by

a

the

PROBLEM

Engine

does

not

crank

......

(12

TESTING

vac

is

battery + vo/mge

.

Test

for

board

terminal

If

OK

.....

Test

for

fuse

end

II

OK

.....

Test

for

terminal

II

OK

.....

Test

for

IIOK

.....

Test

lor

2

and

10.

II

OK

.....

Test

for

when

the

II

OK

.....

Test

for

II

OK

.....

II

OK

.....

Test

for

the

start

should

drop

II

OK

.....

Activate should

be

II

OK

.....

Activate Bt(I2v)

II

OK

.....

Inspect

Bt

(12v)

Bt

(12v)

and

to

Bt(12v)

Tf.

Bt(I2v)

Bt

(12v)

Bt

(12v)

switch

Bt

(12v)

Bt(12v)

switch

below

the

start

present

the

start

at

the

starter.

at

T4.

at

the

from

at

the

at

the

at

the

is

activated.

at

relay

at

relay

and

.5

switch,

at

switch,

start

solenoid.

the

PC

after a few

circuit

board

the

fuse

relay

Kl

starVstop

start

switch

Kl.

Kl

terminal

volts.

after

terminal

after

measured

breaker

to

breaker

to

terminal

T2.

end

to

the

terminal

switch

terminal

seconds

4-5

seconds

87

on

4-5

seconds

86.

85.

relay

to

ground)

the

PC

the

panel

PC

board

30.

terminals

1

Activate

the

voltage

Bt(12v)

Kl.

check

Check connector the terminal 4 and

Look to Replace

Inspect terminal

Check connector K2,

Look 82, PC and

Replace

Check 82, the PI,

Inspect strip connected

Inspect orange Replace

Look

for

Look orange Replace

Check yellow/red Replace

INSPECTION/SOLUTION

for

bad

PI,

starter.

for a bad

the

fuse

the

Tl.

for a bad

PI,

terminal

for

bad

1,

whitelblacklred

board

or

10. the

for

bad

3,

green engine pin 7 -grey

connections

T81

or

to

for a bad

wire

the

for a bad

wire

the

connections the

red

Check

the

at

the

connection

or

at

the

circuit

connections

Replace

connection

3.

30. connections

at

the

start

switch.

connections

wire

harness

wire.

between

T81.

connection

or

at

ECU

connection

or

at

the

ECU.

connections wire

or

at

starter.

at

wire,

or

connections

circuit

from

PC

board

breaker.

at

the

fuse.

The

red/white

at wire

starVstop

at

to

the

PC

connection

on

jumpers

any

external

Replace

the

connector

at

ECU

connector

at

relay

the

start

the

engine

at

the

at

breaker.

the

terminal

fuse

or

at

the

engine

wire

the

panel

to

the

switch

the

panel

board.

at

the

on

the

contacts

PC

board.

at

relay

P2,

relay

Kl.

relay

Kl,

Kl

terminal

solenoid.

harness battery t on the

PC

board

circuit

breaker

T2.

PC

board

harness

or

at

Kl,

connector

terminal

terminals

connector

Kl pin2.

P2

2

connector

Then

check

terminal

pin.

87.

8

85

~

WESTERBEKE

Engin.es ~ Generators

26

ELECTRICAL

The

following test procedures will require the use

engine~

page. WESTERBEKE recommends that these tests be peiformed by a qualified technician.

wiring diagram (in this manual). Also refer to the relay testing

TROUBLESHOOTING

of

a multimeter

GUIDE

and

the

Engine

PROBLEM

cranks

but

starts,

runs

fails

but

to

start

shuts

...

down.....

(12

vac

Test

for

B+

on

the

K2

II

OK

.....

Test

for

B+

activate

the than 5 volts. II

OK

.....

Activate

the

relay

K2,

terminal

NOTE:

For other possible causes (failure to

ignition, etc, refer to

Test

for

voltage

terminals,

be

less

than

If

OK

.....

Test

for

voltage switch,

when

read

zero

II

OK

.....

The

engine

TESTING

is

battery + voltage

(12v)

at

terminals

Relay

(12v)

at

start

switch.

start

switch,

87.

across

with

the

engine

1.0

volts.

across

the

engine

(0)

volts.

temperature

measured

30

relay

K2,

terminal

Voltage

test

for

,.

these sections in this manual.

the

oil

pressure

running

the

exhaust

shuts

down,

sensor

to

and

86

should

be

B+(12v)

sensor

voltage

temperature

it

should

maybe

faulty.

ground)

and

less

at

should

Check Replace

Inspect the Replace

Replace

stan)

Faulty

Faulty Loss High

Test

manual.

INSPECTIONJSOLUTION

for

bad

connections

the

K2

relay.

the

green

the

such

oil

exhaust

of

coolant

exhaust

sensor,

connections

wire,

or

ECU.

K2

relay.

asfuel

pressure

temperature

temperature.

refer

at

the

ECU

pump, speed sensor (MPU),

sensor.

thru

exhaust

to

component

at

both

relay

K2,

connector

Replace

switch.

elbow.

testing

terminals.

terminal

sensor/switch.

Replace

P2,

in

86,

switch.

this

19.

"'"

WESTERBEKE

Engines & Generators

27

DC

ELECTRICAL

SYSTEM

ALTERNATOR

The

charging system consists

with a voltage regulator, an engine

DC

mounted cables. Because electronic voltage regulator is very compact and is mounted internally

#16

ALTERNATOR

A

WARNING:

hot.

Do.not

Use this troubleshooting section to determine exists with the charging circuit determined that the alternator or voltage regulator is faulty, have a qualified technician check it.

The alternator charging circuit charges the starting battery and the service battery. or

a battery selector switch is usually mounted in the circuit

to isolate the batteries so the starting battery is not discharged

along with the service battery.

starting battery the service battery's charging circuit and not with the tor.

Testing

circuit breaker and abattery

of

the use

or

on the back

#12

GROUND

TROUBLESHOOTING

A failed alternator

touch

until

but

not the service battery, the problem is in

the

Alternator

of a DC

of

integrated circuits (IC's), the

of

the alternator.

QlArv

ATSTARTER

the

alternator

or

An

isolator with a diode, a solenoid

If

belt driven alternator

DC

wiring harness, a

Witll

connecting

"m

can

become

has

cooled

if

a problem

with the alternator.

the alternator is charging the

#10

REO

STARTER

51

AMP

SEE

WIRING

FOR

WIRE

very down.

If

alterna·

1. Start the engine.

2. After the engine has run for a few minutes, measure the

BATTERY

CONNECTOR

ALTERNATOR

DIAGRAM

CONNECTIONS.

3. Turn off tile engine. Inspect all wiring and connections.

it is

4.

S. Tum

6. Check the battelY voltage.

starting battery voltage at the battery terminals using a multimeter set on DC volts.

a.

If

the voltage is increasing toward 14 volts, the alterna·

tor

is

working; omit Steps 3 through 8 and go directly

to "Checking the Service Battery" on the'next page.

b.Ifthe

voltage remains around

exists

with either the alternator or the charging circuit;

continue with Steps 3 through 8 .

12

volts, a problem

..---.

MUlTIMETER

_......-to

oo:J

COM

8

TESTING BATTERY/ALTERNATOR (ENGINE

Ensure that the battery tenninals and the engine ground connections are

A

charging switch

If

a battery selector switch

ensure that

tion, tile reading should be 12 to

THE

STARTING

RUNNING)

-=

GROUND

tight and clean.

CAUTION:

circuit,

when

on

the ignition switch, but do not start the engine.

To

avoid

damage

never

shut

off

the

engine

it

is on the correct setting.

is

running!

is

in the charging circuit,

If

tlle battery is in good condi·

the

13

to

the

engine

volts.

STARTING

battery

BATTERY

A

CAUTION:

that

everyone

sheaves

A

DC applications. isolate before

made

and

WARNING:

and

AC

DC

perfonning

without a proper

Before

is clear

belts

circuits

Always

and

AC

starting

of

moving

during

test

procedures.

When

testing

are

often

mixed

disconnect a shore

converters,

DC

testing.

knowledge

and No

the

engine

make

parts!

Keep

away

with a multimeter:

together

shut

AC

tests

of

AC

in

power

down

should

circuits.

~

marine

cord,

the

certain

from

TESTING

engine

be

ALTERNATOR (IGNITION

WESTERBEKE

Engines & Generators

28

THE

VOLTAGE

ON • ENGINE

OFF

@:[J

0

COlI +

)8

~ggggees

~r

....

-

GROUND

.-J

STARTIN

MULTI

@

G

METER

BATTERY

DC

ELECTRICAL

7.

Now

check the voltage between the alternator output ter· minal (B+) and ground, the alternator will be the same as the battery, or tor is in neither between the alternator and the battery, Check all the connections - look for an opening in the charging circuit.

the

circuit the alternator voltage will

of

the above is true, a problem exists in the circuit

If

the circuit is good, the voltage at

if

be

zero,

an isola·

If

SYSTEM

Checking

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

the

Service

the

voltage

If

of

not, there is a problem in the service battery

Battery

the service battery, This battery should

the

service battery charging

STARTING

8. Start

alternator o\ltput The

should is service facility.

NOTE:

voltmeter to ensure that 12 volts

at tery voltage

If

wiring and look

BATTERY

ALTERNATOR

TESTING BATTERY (ENGINE

over·

the

12

THE

STARTING

IALTERNATOR

RUNNING)

the

engine again,

voltage reading

be

between 13.5 and 14,5 volts.

or

under-charging,

Before rerrwving the altemator

EXC

terminal

at

the B output terminal,

volts is

Mt

Check

and

ground,

for

if

the previous test showed only bat·

present

for

breaks

the

voltage between

a properly operating alternator

If

your

have

it

repaired

for

repair, use a

DC

excitation

at

the

EXC

terminal, trace

and

poor

connections,

alternator

at

a reliable

is

the

present

th,e

MULTIMETER

GROUNO

A

CAUTION:

diodes, when

do

perfonnlng

To

not

use a hIgh

avoid

tests

damaging

voltage

on

the

alternator

:

BATTERY

,

SERVICE

TESTING BATTERY

THE

(ENGINE

the

alternator

tester

(i.e. a megger)

charging

,

ALTERNATOR

SWITCHt?i",-

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 electrical system,

A

CAUTION:

circuit, the however, engine's

-'

BATTERY

The starting 12 volt Cranking Amps (CCA) rated,

never

engine

electrical

recommended "dedicated" battery used for the engine's

is

running.

to

avoid

To

shut

DC

CIRCUIT

DC

electrical control circuit that is

or

when servicing

avoid

damage

off

the Shut

electrical

circuit.

control circuit should

engine

off

the

shorts

to

battery

engine

the

when

be

battery

switch

working

the

DC

charging

while

battery

800·1000 Cold

switch,

on

the

Engines & Generators

Battery

Review establish

starting batteries and house batteries,

Care

the

manufacturer's

a systematic

recommendations

maintenance

schedule

and

for

then

your

o Monitor your voltmeter for proper charging during engine

operation.

o

Check

the electrolyte level and specific gravity witl) a

hydrometer,

o Use only distilled water to bring electrolytes to a proper

level.

o

Make

celtain that battery cable connections are clean and

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

o 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

29

engine's

Wear

WIRING

SCHEMATC

#49167

-

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Engines & Generators

30

STARTER

MOTOR

DESCRIPTION

The startu can

be

roughly divided into the following sections:

• A motor section which generates a drive power.

• An overrunning clutch section which transmits an anna-

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 on the pinion 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

AND

REPAIR

If

any abnormality is found by the following tests, the starter

should be disassembled and repaired.

Pinion

Gap

Inspection

I. Connect a battery (12V) between the starter terminal S

and the starter body, and the pinion drive should rotate out and stop.

A

CAUTION:

Never

apply

battery

voltage

for

over

10

seconds

continuously.

2.

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

3.

If

the

piniOli

gap is not within the standard range,

(0;5

to

2.0 mm), adjust it by increasing or decreasing the number

of

shims on the solenoid. The gap

is

decreased as the

number

of

shims

increases.

GENTLY

PUSH

BACK

0.5 - 2.0

mm

PINION

GAP

No-Load

Test

L Connect the ammeter, voltmeter, and battery

to

the starter

as illustrated.

2_

When the switch

is

closed, the pinion must protrude and

the starter must run smoothly (at

3000 rpm or more).

If

the current or starter speed

is

out

of

specification, disas-

semble the starter and repair

it.

BATTERY

A

CAUTION:

Use

thick

wires

as

much

as

possible

and

tighten

every

tenolnal

securely.

This

is a solenoid

shift-

type

starter

which

makes a rotating

sound

louder

than

that

of a direct-drive

type

starter.

When

detecting

starter

rotation

at

the

pinion

tip,

be

careful

not

to

come

in

contact

with

the

pinion

gear

when

it

protrudes.

SOLENOID

Perform the following tests.

If

any test result

is

not

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 will be found

between terminals

S and the body and terminal M and

the body.

MULTIMETER

NOTE:

Disconnect the wire from terminal

M.

2. Connect a battery

to

the solenoid's terminal S for (+)

and M for (-). Have a switch in the + lead and close it.

The pinion drive should extend fully out.

A

CAUTION:

Do

not

apply

battery

current

for

more

than

10

seconds

when

testing

the

solenoid.

Engines & Generators

31

STARTER

MOTOR

ATTRACTION

TEST

,.t;;~~-,

3. Holding

test.

With a battery connected to the solenoid terminal S (+) and to the starter body, manually pull out the pinion fully.

The pinion must remain at that position even

when released from holding with your hand.

HOLDING

TEST

~

C(INNECTOR

OFF

BATIERY

STARTER

DISASSEMBLY

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 wiII come off.

PINION

STARTER

MOTOR

SNAP

RING

LEVER

SPRING

INSPECT

FOR

WEAR

&

CHII'P/~IG

4.

Return

test:.

With a battery connected to the solenoid ter-

minal M

(-)

and to the starter body, manually pull out the

pinion

fully.

The pinion must return to its original position

when released from holding by hand.

RETURN

TEST

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

of

the armature, remove the ball bearing with

a

bearing puller. It is impossible to replace the ball bearing

press-fitted in the front bracket.

If

that bearing has worn

off, replace the front bracket assembly.

SHIMS

BRUSHES

----I.~

BRUSH

HOLDER

ASSEMBLY

NOTE:

-'~lean

and replace

if necessary brush,

connnuter,

solenoid, annature,

etc.

See the

following pages.

Engines & Generators

32

GENERATOR

USE

OF

ELECTRIC

The

power required

more

than

is

required

Some

motors

require

others.

Split-phase

under

similar

circumstances,

monly

used

on machines, or started,

7

times

avoided, ven

by

motors

to

run.

load connected

compressor,

motor

In

general,

to

medium

MOTOR

'NOTE:

more

for

this is that the hardest starting types (split-phase) are not

made

Because motors

be damaged if

seconds. off all other electrical loads on

the

Required

Run

the generator's capacity, indicted on the generator's data plate. The output voltage should the

generating plant voltmeter or ampmeter load, check

NOTE:

contains that the generator s vide one

panel. This will ensure

generator.

where

such

as

much

whenever possible, if

a small generator. Capacitor

require

The

current required

for

to

which no load

the

current

starting

SIZE

(HP)

1/6 114

1/3

112

3/4

1

In the above table the maximum

some small motors

in

larger sizes.

the

heavy surge of current

is

required

If

difficulty

electric

Operating

generator first

be

checked periodically

it

with

When the vessel in which the generator is installed

AC

equipment

120 volt

MOTORS

to

start

an

electric motor

to

keep

it

running after

much

more

current

(AC)

motors require

than

other

easy-starting loads,

loads are applied after

small power

current

from 2 to 4 times

to

example.

it

can bring

motor.

to

start

it.

An electric motor connected

will

is

connected.

required

loads

will be

AMPS

}UNNIN~)

AMPERES

for

only

an

the

is

experienced

such

tools.

Because

as

to

the

electric motor

as

to

start

require

to

start

approximately

FOR

3.2

4.6

5.2

7.2

10.2 13

than

for

instant, motor

and,

if possible, reduce

Speed

with

no

load

and

finally

loaded

to

ensure proper operation of

and

the

appliances

is

not installed

a portable meter

of

120 volts only, it is recommended

AC

terminal block be configured to pro-

AC

hot leg

for

the vessels distribution

good

motor starting response from the

is

considerably

it

is

to

start

them

more

current

types.

They

as

washing

the

motor

they

require 5

run,

their

use

and

repulsion-induction

much

current

any

motor varies

more

current

ll5-Volt

needed

in

applied,

and

motors as

follows·

AMPS

(~TARTIN~I

AMPERES

6.4

to

9.2

to

10.4

to

14.4

to

20.4

to

26

to

Amps

for

larger ones.

for starting

the

generator

up

to

speed

starting motors,

then

to

its

full

it

supplies. If

to

monitor voltage

amp

probe.

started.

than

to

are

is

should

is

to

be

to

start

with

to

an

than

connected

FOR

22.4'

32.2'

72.8'

29.2'

40.8' 52

Starting is

The

reason

will

in a few

tum

the

at

half

capacity

an

start,

com-

dri-

as

air

a

not

load

the

AC

and

INFORMATION

to

be

the

as

Generator

Frequency cated

o

When output frequency

Therefore, drive engine's speed must uring

Generator

o Maintaining reasonable cleanliness

Connections of terminal boards corroded,

salts,

build sive

o For unusually severe conditions,

petroleum-base coatings, should

over

o

In inspected overheated tenninaIs

o

The checked periodically if possible for

not

accelerate cracking. The bolts

to identified the

o

The

maintenance

noisy

o Examine bearing at periodic intervals.

of shaft should

motion

wear.

will

WESTERBEKE recommends mounting a carbon

monoxide detector

Monoxide, even in small amounts, is deadly. The

from exhaust

entering

If

carbon

air

Frequency

is

a direct result of engine/generator

by

the

following:

the

generator

is

to

change the generator's

of

the

AC

output connections at

Maintenance

and

insulation surfaces

dust,

engine

exhaust,

up.

Clogged ventilation openings

heating

all

addition

drive discs

any

be

the

head.

rear armature bearing

rub

presence of carbon monoxide indicates

the

and

reduced life of windings.

surfaces

evidence of incipient cracking

allowed

generator shaft must

by

or rough-sounding, have

is

Repair

and

engine or generator or

hose,

your

monoxide

correct

to

periodic cleaning,

for

tightness of

on

single bearing generators should be

to

become rusty because

6 radial marks, one at each of

is

required.

be

detectable, inspect

must

cause major damage

Carbon Monoxide Detector

or that

boat.

the

problem immediately!

Adjustment

speed,

is

run

at

1800

RPM,

the

60

Hertz.

frequency,

be

changed .along with a reconfig-

the

generator.

is

important.

and

rectifiers

may

start conducting if

carbon,

reduce

rusting

all

and

loose or

be

is

However,

detected

be

in

is

when

made

the

vesssei's living quarters. Carbon

fumes

from a nearby

present,

etc.

are

allowed

may

thin

rust-inhibiting

be

sprayed or brushed

and

corrosion.

the

generator should be

connections, evidence of

damaged

for

tightness of screws

which

fasten

hardened steel SAE grade

lubricated

if

it

replaced.

force

the

bearing

quickly

to

from

ventilate

wires.

failure.

rust

the

and

sealed;

the

bearing

No

side movement

is

applied.

and

or

major

generator.

an

the

exhaust

vessel

the

area

as

indi-

AC

voltage

the

generator's

may

become

to

cause exces-

Discs

should

may

drive

disc

6 comers of

no

becomes

If

side

shaft

for

components

exhaust

elbow! are

with

clean

and

8,

leak

-..y'

WESTERBEKE

Engines & Generators

33

BE

GENERATOR

DESCRIPTION

This

generator is a

generator to

produce exciter stator this voltage during voltage

field. through the windings of the

voltage produced is,

in produces a windings, output The voltage regulator senses adjusts to

amperage

constant voltage output

~---

which

AC

generator.

to

be induced into

rotation.

to

DC

This

creates

which

in

tum,

supplied

DC

enabling the generator

DC

excitation

---

!EXCITERr------ROTOR--,

ISTATOR

,I.

I

~-~-----------------

I I :

+11

1 _ : :

I I I r

I I I

L

__________

four-pole,

requires

output. The copper

are

respo.nsible

The magnetic field produced

Diodes located

and supply it

an

electromagnetic field

is supplied

the auxiliary windings of the

to

a voltage

voltage

to

load the generator

brushless, self-excited

only

the driving

and

laminated

for the self-exciting

the

related excitor rotor

in

the

exciter rotor

to

the windings of the rotating

main

stator,

to

a load. An

regnlator.

to

further excite the exciter stator

the exciter stator

is

AC

to

produce a

AC

furnishing.

-----------GENERAToR

r--~----STATOR·-,

RJII

_::

J I

force

of

the

engine

iron

in

the

feature

of

causes

an

AC. windings rectify

this

which

rotates

inducing

main

The regulator

voltage output

winding

an

AC

voltage

AC

is

stator

and

rated

AC

and

according

To

maintain

OUTPUT

..

O:UTP.UjiTiiW.IN.DijiIN.GSf-.l:"'-

-__________

_______

a

------.-----~

WINDINGS

Voltage

This engine

±2%

and up

With

with voltage clockwise. and

CIRCUIT

A circuit breaker generators. generator power in case breaker generator

Adjustments

potentiometer

operating

from a no-load

from

power

to

-6%.

the

alternator running

VOLT

adjust

will

The

stabilize_

BREAKER

This

can

be manually shut off

to

ensure

i

2 I I

__

-'-

________

I,

+_t--

I

J

is

used

to

adjust output

speed

the

output voltage

condition

factor

1.0

at

minimum,

oscillate.

Increase the voltage

Slowly

voltage output of the alternator

is

installed

circuit breaker

that

V12

to a full

with

engine drive

at

no-load,

it

is

rotate

to

on

all

WESTERBEKE

will

of

an

electrical

when

no

power is coming

possible

the

the desired

automatically

AUTOMATIC VOLTAGE REGULATOR

voltage.

should

rated

generator speed

at

nonnal

that

VOLT

overload.

servicing

into

At

proper

be

held

at

output

variations

speed,

and

output

adjustment

will

increase

value.

disconnect

The

circuit

the

boat

o

rE:J

VOLTAGE

ADJUSTMENT

GENERATOR

WIRING

INTERNAL

DIAGRAM

BAR

CONTROL

BOX

UNUSED

WIRE

AVR

CONNECTIONS

60

HZ -120

VOLTS

60HZ -1201240

VOLTS

T3:

T5

T2 : T4

WIRE

COLOR

T2 -YELLOW T3 -ORANGE T4 -LIGHT T5 -LIGHT

CIRCUIT

BREAKER

CODE

GREEN REO

Engines & Generators

34

AC

VOLTAGE

The

frame

when

changing terntinaJ block, multi the

hot

block.

use

strand

lead

connects

GENERATOR

CONNECTIONS

ground

wire (green) must

the

AC

output configuration of

For making connections

terntinal

between

ends

for

114

inch

copper wire sized

for.

the

connection. The frame ground

the

neutral

stud

and

be

properly

to

the

AC

studs

that

amperage

green

the generator

AC

positioned

the

AC terntinal

will

accept

rating

wire

frame.

VOLTAGE

from

CONNECTIONS

.120/240V

VII

60Hz

UI

U1

120V

"''''''"''''''

60Hz

U I

Generator

1.

Frequency 1800

2.

To

Configure frequency connected

Frequency

is

rpm =

change

generator

the

as

to

a direct result of engine/generator

60

hertz.

frequency,

AC

terntinaI block for the shown. the

Ensure that

correct terntinal block

follow

the

case

neutral

steps

desired

ground

stud.

3.

Remove (depending

NOTE:

installations where the

and ground circuit. This will prevent the unit from being

a ground source in

~---

!EXCITERr--- - --ROTORISTATOR

I + I I I

,I

or install the jumper

on

frequency). Refer

The green growui wire

the

---

-

----------GENERATOR

may

AC

circuit

vessel.

on

be remnved in those

-I

I I I

I I . I

I I I

I

L

__________

81':

the automatic regulator

to

BE

GENERATOR.

IlLls

a separate neutral

r-

---

AC

OUTPUT

AC

OUTPUT

I'

J I

speed:

below:

voltage

wire

ground

------.------

---STATOR'-,

WINDINGS

------_____

_______

is

230V

50Hz

NOT

/V\T!WESTERBEKE

}

'

2 I

I

1 .

-'-

________

F2

V12

CONNECT

FOR

I

J

50Hz

AVAILABLE

AUTOMATIC VOLTAGE

REGULATOR

46455

0

~

VOLTAGE ADJUSTMENT

GENERATOR

INTERNAL

WIRING

DIAGRAM

'----

<---

.....

U1

.....

U2

WIRE

COLOR

COOE

T2 -YELLOW

T3 -ORANGE T4 -LIGHT T5 -LIGHT

Engines & Generators

GREEN REO

35

AVR

CONNECTIONS

60

HZ

-120

VOLTS

60HZ

-1201240

VOLTS

T3 : T5 T2:

T4

LAY-UP & RECOMMISSIONING

GENERAL

Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the off-season or for long periods to accomplish lay-up preparation themselves.

The procedures which follow will allow you to perform your

own

lay-up

and

reconunissioning,

check list These procedures should afford your engine protection

during a lay-up and also help familiarize you with the

maintenance

If you have any questions regarding lay-up procedures, call

your local servicing dealer; he will be more than willing

provide

Propeller

The transmission and propeller half couplings should always be opened up and the bolts removed when the boat out

storage in the cradle. The flexibility severe strain on the propeller shaft or coupling or both, while the boat is taken out or put in the water. In some cases, the

shaft has actually been bent by these strains. This does not apply to small boats that are hauled out not in use, unless they have been dry for a considerable period

Fresh

A 50-50 solution recommended for use in the coolant system at all times.

This solution

antifreeze, depending on the area's winter climate. Check the

solution

Should more antifreeze be needed, drain

amount from the engine block and add a more concentrated

mixture.

and mixture cooling system. Now recheck the antifreeze solution's strength.

Lubrication

With the engine warm, drain all the engine oil from the oil

sump. Remove and replace the oil filter and

with new oil. Use the correct grade

ENGINE LUBRICATING OIL pages in this manual for the

oil changing procedure. Run the engine and check for proper

oil pressure and make sure there are no leaks.

A

in

combustion chemicals internal

if

others do the procedures.

needs

assistance.

Shaft

of

the water

of

time.

Water

may

to

make

Operate

of

System

CAUTION:

the

sump

over deposits

which

parts.

of

your

Coupling

or

moved from land to water, and during

Cooling

of

antifreeze and distilled water is

require a higher

sure

the

engine

the antifreeze concentration throughout the

00

not

the

can

of

inactivity. Others prefer

engine.

[Propulsion

Circuit

antifreeze

to

ensure a complete

leave

the

lay-up

period_

combine

reduce

to

the

or

you

may

use

Engine]

of

the boat often puts a

of

the water when

[Propulsion

concentration

protection

of

oil. Refer to the

engine's

Lubricating produce life

an

appropriate

fill

old

harmful

of

your

is

circulation

the sump

engine's

them

as

to

is

hauled

Engine]

of adequate.

engine

oil

and

a

Fuel

System

Top off your fuel tanks with unleaded gasoline or higher. A fuel conditioner such as Sta-Bil gasoline stabilizer should be added. gasoline/water separator and clean the metal bowl. Re-install and make certain there are no leaks. fuel.

Fuel

System

Top off your fuel tanks with

as

such added at this time to control algae and condition the fuel. Care should be taken that the additives used are compatible with the primary fuel filter/water separator used in the system. Change the element separator, sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, for 5 system. the fuel system during this servicing, correcting them

needed. Operating the engine for 5 - 10 minutes will help

allow movement

equipment

Raw

Close the through-hull seacock. Remove the raw water intake hose from the seacock. gallon bucket check the zinc anode found in the primary heat exchanger on

the

any zinc debris from inside the heat exchanger where the

zinc

Start the engine and allow the raw water pump to draw the fresh water through the system. When the bucket is empty,

stop the engine and refill the bucket with an antifreeze

solution slightly stronger than needed for winter freeze

protection

Start the engine and allow all

through the raw water system. Once the bucket is empty, stop

the engine. This antifreeze mixture should protect the raw water circuit from freezing during the winter lay-up,

as

Remove the impeller from your raw water pump (some

antifreeze mixture will accompany it, so catch it in a bucket). Examine the impeller. Acquire a replacement,

a cover gasket.

until recommissioning, but replace the cover and gasket.

BioBor and Diesel Kleen or Cetane Boost should be

10

Water

engine

anode

providing

Intake

Place a clean cloth, lightly soaked in lubricating oil, in the opening shove the cloth out

recommissioning,

you may need assistance note to remove the cloth prior to start-up. The thru-hull

exhaust

[Gasoline]

of

89

octane

Change the element in your

Clean up any spilled

[Diesel]

No.2

diesel fuel. Fuel additives

in

your primary fuel filter/water

if

the fuel system has one, and clean the separator

as

needed. Start the engine and allow it to run

minutes to make sure no air

Check for any leaks that may have been created in

of

the treated fuel through the injection

on

the

engine.

Cooling

of

and

clean

is

located.

in

your

corrosion

Do

Manifold

of

the intake manifold

port

can

Circuit

Place the end

clean fresh water. Before starting the engine,

or

replace

Clean

the

area.

of

protection.

not replace the impeller (into the pump)

and

Thru-Hull

of

sight.

(If

and

an

attempt

of

the servicing dealer. Make a

be

blocked

in

the

is

left in the fuel

of

this hose into a five

it

as

required,

raw

water

this mixture

and

strainer.

to

be drawn

if

needed, and

also

as

Exhaust

to

block the opening. Do not

it is not visible at

is

made

to

start

the

engine,

same

manner.

as

clean

well

Engines & Generators

36

LAY-UP & RECOMMISSIONING

Starter

Lubrication and cleaning

if access

battery

the starter. Take care in properly replacing any electrical

connections

Cylinder

If WESTERBEKE recommends removing the glow plugs for access to the cylinders. Squirt light oil into the cylinders prevent the piston rings from sticking Tum the engine two revolutions glow plugs.

Intake

Clean the filter screen in the flame arrester, and place a clean cloth lightly soaked in lube oil around the flame arrester block any opening. Also place an oil-soaked cloth in the through-hull exhaust port, Make a note to start-up!

Cylinder

Spray fogging oil into the open air intake, with the flame

arrester removed, while the engine will stall out the engine and coat the valves, cylinders and spark

plugs

NOTE:

and re-gapping at

Motor

of

the starter drive pinion is advisable,

to

the

starter

permits

connections

removed

are

from

Lubrication

you anticipate a long lay-up period (12 months or more)

Manifold

[Gasoline]

Lubrication

for

winter

protection.

The spark plugs will need

spn'ng

its

easy

shut

off

before

the

starter.

[Diesel]

by

[Gasoline]

is

to

commissioning.

removal.

attempting

to

hand and then re-install the

to

running. The fogging oil

be

removed for cleaning

Make

sure

to

remove

to

the cylinder walls.

to

remove cloths prior

the

to

Batteries

If

batteries are to be left on board during the lay-up period, make sure that they are fully charged, and will remain that way, to prevent them from freezing.

batteries will not remain fully charged, or that they will be

subjected

batteries and store them in a warmer, more compatible

environment.

A

highly-explosive arcing smoke

serviced.

to

Transmission

Check off grime and grease and touch up any unpainted areas. the coupling and the output flange with an anti-corrosion

coating.

additional information, refer

to

severe

environmental

WARNING:

Lead

gas, or a lighted or

allow Shut

prevent

electrical

Cigarette,

an

open

off

all

[Propulsion

or

change the fluid in the transmission

Check

that

the

If

there is any doubt that the

conditions,

acid

batteries

which

can

cigar,

flame

near

electrical

arcing

during

Engine]

transmission

to

the TRANSMISSION SECTION.

remove

emit

hydrogen,

be

ignited

by

or

pipe.

the

battery

equipment

in

servicing.

as

vent

is

open.

the

a

electrical

Do

not

being

the

vicinity

required Wipe

Protect

For

Spare

Lay-up time provides a good opportunity

Westerbeke or kit

during the lay-up, such as filters and zinc anodes. Refer

SPARE

Parts

engine

coolant hoses

and

order

items

PARTS

to

need

not

section

see if

external

replacement.

on

hand,

or

of

this manual.

items

Check

replace

to

inspect your

such

as

your

basic

those

items

drive

spares

Recommissioning

The

recorrunissioning

seasonal lay-up generally follows the same procedures

those described in the PREPARATIONS

tion regarding preparation for starting and nomnal starts. However, some counteracted before starting the engine.

1.

Remove the oil-soaked cloths from the intake manifold.

2. Remove the raw water pump cover and gasket and discard the old gasket. Install the raw water pump impeller removed during lay-up (or a replacement,

Install

the

raw

3.

Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making sure the tenninals are clean and that the connections are tight. Check

to

make sure that the batteries are fully charged.

A

CAUTION:

and

eye

protection batteries can

cigarette,

flame electrical arcing

4,

Remove the spark plugs, wipe clean, re-gap, and install proper tightness [gasoline].

5. Check the condition circuit and clean or replace the anode that solution from the raw water coolant system. When the engine is put into operation, the system will self-flush in a short period

advisable, service.

heat exchanger and clear any and all zinc debris from that

area.

6.

Start

in

manual.

emit

be

ignited

cigar,

near

the

equipment

during

it

is not necessary to flush the antifreeze/fresh water

as

to

the

engine

the PREPARATIONS

of

your

Westerbeke

FOR

of

the lay-up procedures will need

water

pump

cover

with

Wear

rubber

gloves, a rubber

when

servicing

hydrogen,

by

electrical

or

battery

pipe.

being

in

a

Do

the

highly

vicinity

batteries.

explosive

arCing

or a lighted

not

smoke

serviced.

to

serviCing.

of

the zinc anode in the raw water

of

time with no adverse affects.

either

an

end

of

season

inspect

the

area

where

the

in

accordance

with

procedures

FOR

STARTING section

engine

after

STARTING sec-

to

be

if

required).

a new

cover

apron,

Lead

gas,

which

or

allow

an

Shut

off

all

prevent

as

or

zinc

electrical

needed. Note

It

is

recorrunissioning

is

located

described

of

acid

belts

used

to

the

a

as

gasket.

open

to

in

the

this

Engines & Generators

37

WESTERBEKE

8.0/6.4KW

TO

14111.6KW

SBEG

ENGINE

SPECIFICATIONS

Engine

Type

Governor Combustion

Bore & Stroke

Piston Firing

Direction

Compression

Inclination

Fuel (at apprOXimate

Weight

Compression

(Limit between

Valve

(engine Engine

(1800 Horsepower

All

Chamber

Displacement

Order

of

Rotation

Ratio

Consumption

full

amperage

gph

Pressure

of

difference

cylinders)

Seat

Angle

Clearance

hot)

liming

rpm)

Output

models

60Hz

ENGINE

load (Iph)

TUNE-UP

(50Hz)

SPECIFICATIONS

Gasoline, fresh

overhead Electromagnetic

Semi-spherical

2.97 x 3.23

89.6 t-3-4-2

Clockwise,

9.0:t

Continuous

temporary

8.0Kw

10.0Kw

12.5Kw

14.0Kw

8.016.4Kw

8.0/l0.0Kw

10.0/l2.5Kw

11.6/f4.0Kw

SPECIFICATIONS

165 14

psi

Intake Exhaust

15

BTDe

(33 -35 24

hp

four·cycle,

water-cooled,

mechanism

type

inches

cubic

inches

when

Q

20

30°

(not

1.0

gph

1.1

gph

t.3

gph

1.4

gph

psi

at

300

rpm

45'

0.08

inches

0.09

inches

(no

vacuum

with

vacuum

(19

hoJ

four-cylinder,

Vertical,

(75.5 x 82.0

(t468

cubic

viewed

from

to

exceed

6.4Kw

(3.0

8.0Kw

(3.5

10Kw

(4.0

11.6Kw

4381bs

(199

4631bs

(210

495

Ibs

(225

5221bs

(237

(0.20

mm)

(0.25

advance

in-line

mm).

centimeters)

the

front

15

minutes)

Iph) Iph)

Iph)

(4.5Iph)

kgs) kgs) kgs) kgs)

mm)

connected.

connected)

General

Distributor

Spark

Plug

Throttle

Body

Spark

Plug

General Fuel

Filter

Fuel (on

engine)

Air

Cleaner

(flame

arrester)

Air

Flow

(engine

combustion(

Fuel

Hose

General

Operating

Fresh

Water

Raw

Water

Raw

Water

at

1800

rpm

System

Capacity

(coolant)

IGNITION

Thread

Size

Gap

Size

COOLING

Temperature

Pump

Flow,

Battery

ignition Distributor Ignition

Equipped coil

built-in

14mm X 1.25

Electronic

Governor

.030

inches

FUEL

SYSTEM

Throttle

Unleaded or

higher.

Replaceable

Metal

screen

1800

rpm

1500

rpm

1/4"

1.0.

Fresh

water-cooled

controlled

170

-190° F (77 -88°

Centrifugal

Positive

belt

driven

5.5

gpm

6.0

qts

(5.7

SYSTEM

12V

negative

with

ignition

coil

and

spark

with

auto

timing

breakerless

pitch

fuel

injection

(0.8

mm)

body

fuel

injection

gasoline

with

cartridge-screw

type -cleanable

47

cfm

(1.3

39cfm

(1.1

minimum -3/8"

SYSTEM

block,

with

heat

exchanger.

type,

metal

displacement,

(5.2

Ipm)

approx.

liters)

ground.

module

and

plug.

controller,

type

with

Electronic

an

octane

rating

on

cmm) cmm)

1.0.

maximum

thermostatically-

C) impeller,

belt-driven

rubber

impeller,

igniter.

ignition

of

89

General

Oil

Filter

Sump

Capacity

(not

including

fil1er)

Operating

(engine Oil

Starter Battery Starter OC OC

Oil

hot)

Grade

Battery Capacity

Charging Cold

Cranking

Pressure

Amps

Forced

lubrication

Full

flow,

spin-on

3.5

U.S.

q1s

plus 20-60

API

ELECTRICAL

12-Volt, 800-1000 12-Volt,(-) 12-VDC 150

(15.2

filter/cooler

psi

Specification

SYSTEM

reduction

amps

negative

belt

driven

-175

(cold

by

replaceable

liters)

assembly

of

gear/solenoid

engine)

geared

SJ.class

ground

alternator

pump

type

AC

General-Single

Voltage -Single

Voltage

Regulation

Frequency

Rating

8.0

10_0/8.0

12.5/10.0

14.0/11.6

NOTE:

compartmenttemperatures

Generator Air NOTE:

Engine

Cooling

Engines & Generators

Regulation

(Volts

I6A

Kw

Kw Kw

Forced

Cooling

Requirements

Increase

Compartment

Requirements

38

GENERATOR

Phase

AC)

ventilation

air

supply

Brushless Sealed

Reconnectable

with

120

or

230

volts -50

±2%

±

.5%

1201240

120/240

MUST

be

below

200 -300 (60

Hertz

15%

for

100 -200

(SINGLE

six

pole,

lubricated

solid

single

state

voltage

120/240

volts -60

hertz

no

load

to

no

load

to

volts -66/33 volts -83/41 volts

-104/52

volts

-116/58

provided

to

104° F (40°C).

cfm

(5.6 -8.4

at

1800

50

hertz

operation

cfm

(2.83 -5.66

PHASE)

revolving

single

bearing

phase

regulator

full

load.

full

load.

maintain

cmm)

RPM)

(1500

field.

design.

transformer

hertz

230

volts -27amps

230

volts -34

230

volts -43

230

volts -50

generator

rpm)

cmm)

amps

SHORE

POWER

TRANSFER

SWITCH

CONNECTIONS

SHORE

If

the

installer

cuit,

this

must Switch. Set OFF

position.

of

shore power

POWER

CONNECTIONS

NOTE,

DI.,g,am

wi,,,.

120-

use

dotted

connects be

done

the

transfer

'This

switch prevents

to

generator output.

shoWs

system.

linn

10'

the

power

connections

For a th,ee_

other

of

the

Voll

shore

by means

switch shown in

simultaneous

hOI

to

(60

lor a two-

wl,e

leg.

the

Shore

the

HERTZ)

syslem

SlIlp.IO-

Shore

PH

32008

(40AmpS/pol

PH

32009

(80Amps/Por.) PH

32010

(125

Am".,

PH

32133

(200Ampl/Pole'

vessel's

AC

Power

diagrams

connection

Switch

..

j

Pole)

cir-

Transfer

to

the

120

VOLT/60

Notice terminal

Gene,alor

IN

Gl'~

the

HZ

THREE

repositioning of

block

to

the

generator

NOTE,

Diagram

wire,

ttO-Volt

wllh

Ihree-wlre,120~VOlt

WIRE

the

white

case.

showl

conneo;:tions

sYst~m

,rom

CONFIGURATION

wire

ground

load

on

the

for

.. t ..

generalor,

system.

o~

the

boat

,

f3

Pole)

'---t-+-https://manualmachine.com/""-""~

~,/

~I

~\

%+

I S2

51

N

Shore

Powe.

SWitching

Shore

/

2

•

E

:!(-i-,-+,~

'--"/

I

~-j--';;;-

'-~...

Ground

(GRN)

Power

g

Neutral

(WHT)

to

"} Ll

N

Ships

Load

NOTE: No

240-Voll

{I.

Equipment

Generator

Ship-to,Shore

(40Amps/Pore)

r'~:!~https://manualmachine.com/Pole)

(200Amps/Pole)

5wilch(3Pole)

PN

32008

r8't,~~~~~

POle)

PN

32133

Power

.

A.

CAUTION:

utility

.

at

the covered slbllity

G

shOrB same

under

to

make

Damage power time.

This

the

wananty;

sure

to

and

generator

type

all

N Ll

L-

____

!"EVTAAL)'

the

generator

of

generator

It

Is

AC

connections

GENERATOR/SHORE

SWITCH

/--

~~.

7 • /

, ,

--~

output

the

installer's

....

,

~N

,

can

result

are

conne.cted

damage

are

correct.

if

Is

not

respon·

PN32133

SHIP'S

LOAD

A

CAUTION:

before

switching vicII-versa with

heavy

cause

damage

generator.

Heavy

shore

because

AC

loads

to

the

motor

power

voltage

on

the

exciter

leads

to

generator

surges

vessel

circuit

should

be

power

induced

being

by

operated

components

shut

off

or

switching

may

in

the

\L1

• N J

SHORE POWEJI

230V

50HZ

_

SHIP'S

- GROUND

""'"

WESTERBEKE

Engines & Generators

39

ENGLISH

TO

METRIC

CONVERSION

CHART

Mullinlu Temneralure

Denree Fahrenheit I'F) I"F-32) : 1.8

MuJtinlv

Inch/second2(inlsec

Acceleration

FooVsecond'lftlse~)

2

\

MultiDlv

Toraue

By

To

aet

Demee Celsius

Bv

0.3048

0.0254

To oet eouivalent number of:

MeterlsecondZ(m/s

Meterlsecond'

Bv To cet eauivalent number of:

Pound-inch Ilb·in.l 0.11298 Newton-meters

Pound-foot

Mullinly Power

Horsenower Ihn'

Multinlv

Pressure

Inches

of

Pounds/souare

Mullinlv

Br~ish

Thermal

Fool-nound Ift·lb'

kilowatt-hour

Mullinlv

Fool candle ltc' 1.0764

Multinlv

Fuel

Miles/nal Imile/oall

Gallons/mile

Mullinlv Velocm.

Miles/hour Imile/hr)

IIb·ft)

or

Stress

water (in. H

in.

Enerav

0)

2

)

(lblin.

or

Work Bv

Unil

IBtu)

(kW·hr)

L1nhl

Performance

'''aVmile\ 2.3527

1.3558 Newton-meters By

To

Clet

0.746

To

Bv

oet eauivalent number of:

0.2491 Kilonascals IkPa)

6.895 Kilonascals IkPa)

To

oet eauivalent number of:

1055 Joules

1.3558

3,600,000. or

·0.6x10' By

By

0.4251

By

1.6093

Joules

To

Qet

Lumens/meter2(lm/m

To oet eouivalent number of:

Kilometers/liter

Liter/kilometer

To

qet equivalent number of:

Kilometers/hour (kmlhr\

eauivalent number of:

'C)

2

)

Im/s~

IN·m) IN·m)

eQuivalent

Kilowatts

number

IkW'

of:

IJ) IJ)

Joules

(J

=

one

W/s)

eauivalent number of:

2

)

(km/L'

rUkm)

Mullinlv Lenolh

Inch lin.)

Fool

1ft'

Yard

'yd'

Mile

Imlle)

Multinlv Area

2

Inch2fin. Inch2(in.

\

2

}

Foot'ift')

Yard'lvd')

Multiolv

Volume

Inch"in') Inch"in." Inch'lin."

Quart

Inll

Gallonl,;;,!,

Yard'IYd~

Multinlv

Mass

Pound lib'

Ton

110n'

Ton

Iton)

Mullielv Force

Kllonram Iko'

Ounce loz)

lib)

Pound

By

To eet enuivalent number of:

25.4 Millimeters (mm)

0.3048 Meters

0.9144

1.609 Kilometers By

6462

To eet eouivalent number

MilUmeters2(mm

6.45 Centimeters

0.0929

0.8361 Bv

16387

To eet eouivalent number of:

Millimelers3(mm

16.387 Centimeters

0.0164

0.9464

3.785

0.7646 Bu

0.4536

To

Qel

equivalent number of:

Kiloqrams Ikn'

1m)

Meiers

1m'

fkm)

2

fcm

Melers'lm" Melers'lm')

3

(cm

Lilers

III IL)

Lners Lilers

III

Meters~(m3\

907.18 Kiloqrams Ikn'

0.907 By

9.807

0.2780

4.448

To

Tonne

III

Qet

eauivalent number of:

Newtons IN' Newtons IN'

Newtons (N'

of:"

2

)

2

)

3

\

3

\

Engines & Generators

40

BOLT

HEAD

MARKINGS

Bolt

strength

classes

are

Customary (strongpst). i.e.; a grade

(inch)

TIJ.e seven

bolts

marks

bolt

embossed

are correspond will

identifed

display

on

the

by

markings

to

two

five

embossed

head

marks

~"

NOTES:

1.

2,

3.

Use

the

These

torques

Reduce

torque

are

torques

values

based

by

30%

listed

on

or

STANDARD

of

each

bolt.

two

to

grade

eight

less

than

the

actual

marks.

below

when

specific

clean,

dry

more,

threads.

when

Reduce

threading

grade,

torque

values

torque

capscrews

HARDWARE

Metric

bolt

class

strongest.

are

not

by

10%

into

aluminum.

numbers

available.

when

engine

identify

oil

is

bolts

used.

by

their

strength

with

10.9

the

STANDARD

Capsrew

Body

1/4

5116

3/8

7/16

112

9/16

5/8-11

3/4

7/8

1 - 8

-

20

-28

-18

-

24

-16

-24

-14

-20

-13

-

20

-12

-18

-10

-16

- 9

-14

Siz.

(Inches) • (1Ilread)

BOLT & NUT

SAEGrad.5

To",.

A·Lb(Nm)

8

(11)

10

(14)

17

(23)

19(26) 31

(42)

35

(47)

49(66) 55

(75)

75

(102)

85

(115)

110

(149)

120

(163)

150

(203)

170

(231)

270

(366)

295

(400)

395

(536)

435

(590)

590

(800)

660

(895)

TORQUE

SPECIFICATIONS

SAE

Grad.

6·7

Torqua

A·Lb(Nm)

10

(14)

19(26)

34(46)

55

(75)

85

(115)

120

(163)

167

(226)

280

(380)

440

(597)

660

(895)

SAE

Grad.

Torqu.

FI-Lb

(Nm)

12

(16)

14(19) 24(33)

27

(37)

44(60) 49

(66)

70

(95)

78(106)

105

(142)

120(163)

155

(210)

170

(231)

210

(285)

240

(325)

375

(508)

420

(569)

605

(820)

675

(915)

910

(1234)

990

(1342)

METRIC

8

Boll Dia.

M3 M4 M5

M8 M9

Ml0

M12 M14 M16

M18 M20 M22

M24 M27 M30

M33 M36

Wrench

BOLT & NUT

Size

5.5mm 7mm 8mm

lOmm 13

mm

16mm

18

mm

21

mm

24mm

27

mm 30mm 33mm

36mm 41

mm 46mm

51

mm 55

mm

Grad.

Ft-Lb

0.3

0.8

1.5

3(4)

7

(9.5)

14

26 37

(50)

59

(80)

81

(110)

118

(160)

159

(215)

203

(275)

295

(400)

402

(545)

546

(740)

700

(950)

4.6

(Nm)

(0.5)

(1.1)

(2.5

(19)

(35)

TORQUE

Grad.

Ft-Lb

0.5 1

4

10

18

33 55

85

118 166 225

288 417

568

774

992

SPECIFICATIONS

4.8

(Nm)

(0.7)

(1.5)

2

(3)

(5.5)

(13) (25)

(45)

(75)

(115)

(160) (225) (305)

(390) (565) (770)

(1050) (1345)

Grad.

Ft-Lb

1

4.5

7.5 18 37

63(85) 103 159

225 321 435

553

811

1103

1500 1925

8.8 -9.8 (Nm)

(1.3)

2(3)

(6)

(10) (25) (50)

(140) (215)

(305) (435) (590)

(750)

(1100)

(1495)

(2035) (2610)

Grad. Ft-Lb

1.5

3

6.5

11 35

55

97 151 232

321

457 620

789 1154 1571

2139 2744

10.9

(Nm)

(2)

(45)

(9)

(15) (26) (75)

(130)

(205) (315)

(435) (620) (840)

(1070)

(1565)

(2130)

(2900) (3720)

NOTE.

Formula

to

convert

Ft-Lbs

to

Nm

(Newton

Meters)

GASKETSISEALANTS

Oil

based

PERMATEX

purpose

sealers.

coolant,

raw

A

light

coating

and

a-rings.

LOCTITE

filter

When

ing Specialized

ing copper

hydraulic

assembly.

Coat

both

surfaces

installing

sides

with

WHITE

High-copper

assembly.

gasket

non-hardening

cylinder-head

#2

They

are

water,

oil

or

of

OIL

or

red

sealant

of

the

gaskets

that

SILICONE

ADHESIVE

SPRAYS

sealers

properties.

gaskets

and

it's

effective

fuel.

LIQUID

should

oil

pan seal

grease.

such

HYLOMAR

as

HIGH

TACK

in

just

TEFLON

be

gasket around

are

useful

as

HYLOMAR

il

resists

equivalent

about

can

be

used

with

high

water

for

is

particlarly

fuel,

on

(coolant)

holding

work

oil

multiply

FHb x

1.356.

SEALANTS

are

excellent

all

any

joint

in

contact

with

used

on

rubber

gaskets

oil

adapler

hoses

and

the

temp

RED

well

and

SILICONE

passages,

gaskels

in

applicalions

effective

water.

~...v-~WESTERBEKE

sealer.

coal

bolh

in

position

requir-

on

Engines & t}enerators

&

LUBRICANTS

Use

LIQUID

TEFLON

for

sealing

pipe

passages.

Do

not

use

lap.

sealants!

BOLTS & FASTENERS/ASSEMBLIES

Lighlly

oil

head

bolts

and

other

fasteners

plugs

Ihat

oil

dur-

HIGH

TACK.

When

assembling

Anti-seize threaded

ing

use

components

LOCTITE

off.rs

LITHIUM

boxes.

Heavily

oil

clean

penetrate

compounds

based

all engine

the

levels

grease

sliding

oil!

the

water

jacket

flywheel,

and

thread

yet

allows

of

locking

is.waterproof,

and

reciprocating

coat

locking

them

according

41

plugs

and

as

you

should

be

the

bolt

threads

adhesives

to

came

to

the

ideal

for

components

fillings

assemble

sealed

with

such

apart

when

job.

wat.r

pump

when

that

connect

Ihem.

PERMATEX

LOCTITE as

LOCTITE

necessary.

bearings

assembling.

coolant

Bolts

blue.

and

#2

or

protect

stuff-

Always

CONTACI'

YOUR

SUGGESTED

WESTERBEKE

DEALER

SPARE

MARINE

FOR

GASOLINE

SUGGESTIONS

PARTS

GENERATORS

AND

ADDITIONAL INFORMAT

FUEL

FILTERS

!I

RAW

WATER

IMPELLER/GASKET

AND

WIRES

THERMOSTAT

GASKET

AND

MOlDED'·

HOSE

kIT

.

INA

CANVAS'·

CARRYING

WES1ERBEKE

each

packaged

KIT

A includes the basic spares.

KIT

B

is

KIT

Impeller Kit Heat Exchanger Gasket Oil Filter

Drive Belt Zinc Anodes Spark Plugs

also offers two Spare Parts Kits,

in

a rugged, rust free toolbox.

for

more

extensive off-shore

A

cruising.

SPARE

PARTS

WESTERBEKE ENGINE

OIL

ANO A GALLON

KITS

RECOMMENOS

(YOUR

BRANO)

OF

PREMIXED

CARRYING

FOR

AN

COOLANT.

ENOUGH

OIL

CHANGE

SPARE

(5

KITB

Impeller Kit

Pump Repair Kit

Water Thermostat Kit Zinc Anodes Complete Gasket Kit Heat Exchanger Gasket Oil Filter Drive Belt

Spark Plugs

DTS.)

Engines & Generators

42

-member

.

~

SAFE

CO

SERIES

WMDWl13B-4/09

WESTERBEKE

CORPORATION·

150

JOHN

HANCOCK

ROAD

MYLES

STANDISH INDUSTRIAL

PARK·

TAUNTON MA 02780

WEBSITE: WWWWESTERBEKE.COM

Westerbeke 10.0 KW-60Hz SBEG, 11.6KW-50 Hz SBEG, 12.5 KW-60Hz SBEG, 10.0 KW-5, 14.0 KW-60Hz SBEG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual