Westerbeke 10.0 EGTD, 8.0 EGTD, 11.0 EGTD, 15.0 EGTD, 6.0 EGTD Operator's Manual

OPERATO

S

MANUAL

·

MARINE

8.0

10.0

11.0

11.5

12.5

-15.0

EGTD

EGTD EGTD

EGTD

D.IESEL

•

60Hz

·•

60Hz

·60Hz

·60Hz.

·60Hz

Electronically

Singl·e

GENERATORS

6.0

7.5

8.8

9.2

9.4

12.0

-· . . .

Governed

a T . e

EGTD

•

50Hz

·50Hz

EGTD • 50Hz EGTD • 50Hz

E·GTD

Phase

·50Hz

·

.

·.

PUBLICATION

Af'if'Af"f

.-.--

NO:

056272 f REVISION 0 I

'DE~EMBER

2016

WESTERBEKE

MYLES

WEBSITE::

GORPORATION

STANDISH

WWW.

WE'STERBE;'KE:.COM

INDUSTRIAL

• I

50

JOHN

PARK • TAUNTON

HANCOCK

MA

ROAD

02780

PROPOSITION

Diesel engine exhaust and some of

its constituents are known the State cancer, birth defects, and other reproductive harm.

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

gasses

gas. can

Weakness

and

contain

Carbon

and

include:

Sleepiness • Inability

CALIFORNIA

65

of

California

A

wARNING:

Carbon

Monoxide,

Monoxide

death.

is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

WARNING

to

cause

an

odorless

and

can

of

Carbon

Monoxide

in

Temples

Twitching

to

Think

Coherently

and

cause

IF

YOU SET seek until

OR

ANYONE

OUT

INTO medical it

has

THE

attention.

been

Inspected

ELSE

EXPERIENCE

FRESH

AIR

IMMEDIATELY.

Shut

down

and

This

WARNING WESTERBEKE bulkhead

WESTERBEKE CARBON living/sleeping

They

are

obtainable

ANY

OF

the

unit

repaired.

DECAL

and

should

near

your

engine

also

recommends

MONOXIDE

quarters

inexpensive

at

your

local

THESE

SYMPTOMS,

If

symptoms

and

do

is

provided

be

DETECTORS

of

and

easily

marine

not

restart

fixed

or

generator.

installing

your

vessel. store.

persist,

by to

in

a

the

SAFETY

INSTRUCTIONS

INTRODUCTION

.Read

this

safety

manual

caused

by

failure

to

follow

precautions.

take

the

personne~

The

following

the

American

PREVENT

A

while

these

II

Do

enclosures

11

Shut off electrical equipment

11

Use equipment

11

Make (particularly

11

Remove electrical

PREVENT

A

exhaust

.

very

iii

Monitor coolant location when

A

11

In

before

Know

when

necessary

and

precautions

your

safety

Boat

and

machinery.

instructions

ELECTRIC

WARNING:

engine connections!

not

insulated

sure

WARNING:

system

hot!

the

WARNING:

case

Do

not

is

running.

operate

this

and

covers

power

mats

your

clothing

shoes)

wristwatch

equipment

BURNS

-HOT

Do

components. A nrnuing

engiile

·an~ze

recovery

on

the

engine

tank

water

is

Steam

of

an

engine

touching

the

carefully.

Most

accidents

fundamental rules and

dangerous

Yacht

conditions exist and

to

protect yourself, your

are

in compliance

Council

(ABYC)

SHOCK

touch

AC

electrical

Lethal

voltage

machinery

in

whenever

when

and

without electrical

place.

before accessing electrical

working

and

skin

are

dry,

handling

all

electrical equipment.

jewelry when working

ENGINE

not

touch

hot

engine

coolant

ievei at

and

jacketed

COLD.

can

overheat,

engine

periodicaly

cause

or

exhaust

injury

allow

the engine

checking

at

manifold,

are

standards.

connections

is

present

on

electrical

not damp

palfs

or

engine

gets

the

plastic

the

filler

but

or

death!

to

the

coolant

with

at

cap

cool

on

only

PREVENT

A

II

Prevent

II

1111

PREVENT

A

Injury

llill

111

Ill

1111

iii

llill

Ill Be certain

Ill Make sure a

BURNS-

WARNING:

flash

sparks

to

occur near the

pump,

or

other potential sources of spilled

vapors.

Use a suitable container

removing the fuel lines or Do

not operate

Backfire can cause severe injury or Do

not smoke or permit

the

fuel

sysfem.

engine

dean

aware

fire.

- diesel

chances of Be

FIRE

Fire

can

cause

fires.

Do

not smoke or pennit

fuel

with

the air cleaner/silencer

flames

~eep

the

compartment

and

free

of debris

Wipe

up

all spilled

fuel

will burn.

injury

injector, fuel line,

to

filters.

or to

BURNS -EXPLOSION

WARNING:

or

detftll!

Follow

re-fueling hatches after

fueling.

the

blower.

your

engine.

All

fuel

when

handling

well-ventilated area

equipment and out of the reach of children.

Do

not

Shut

off the

the

fuel system.

spill.

DO NOT sources servicing. the

fuel system.

Qo

not alter or

~~

sure

free

of leaks.

properly maintained. Be familiar Extinguishers rated for

all applications encountered

Explosions

safety

closed

when

Check

Run

the

vapors

are

highly

and

fill

the fuel tank(s) while

fuel

service

Take

allow

of

fire

near

Ensure proper ventilation exists

modify

all

fuel supplies have a positive shutoff

fuel

line

fire

extinguisher is installed

from

fuel

instructions.

fueling.

below

blower per

storing fuels. Store

away

the

fittings are adequately

ABC

Open

for

fumes/vapor

four

explosive.

from spark-producing

valve

at

the

care

in

catching

any

smoking,

fuel

system

the

fuel

system.

by

the

in

or

death!

flames

fuel

catch

all

fuel

removed.

death.

sparks

to

occur near

and

the

minimize the

fuel

and

engine

vapors

Keep

the

and

ventilate

before

minutes

the

or

with

NFPA

this

before

Use

extreme

fuel

in

.engine while it

engine

when

any

fuel

open

flames,

engine

when

tightened

nearby

its

proper

are

appropriate

environment.

filter,

or fuel

when

can

cause

vessel's

the

care

a

that

servici.1g

valve.

or

fuel

oil.

cabin

running

starting

is

running .

servicing

might

or other

and

is

use.

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

11

Disconnect generator. it

last.

11

Make starting.

11

Make installed before

BAnERY

A

WARNING:

or

death!

11

Do

not being highly explosive arcing equipment ing

servicing.

11

Never tive

not together.

Ventilate

accumulation of explosive disturb the is

being charged.

11

Avoid burns wristwatch, rings, the

battery.

1!11

Always

the

and

STARTING

Accidental

the

battery

Remove

·

certain

all

personnel

certain

all

covers,

starting

EXPLOSION

Battery

smoke or

serviced.

or

connect

( +) connection terminal of the starter solenoid.

test the battery condition

contacting

or sparks

turn

battery connections. Remove

reconnect it

allow

Lead

gas,

by

lit

tobacco

in

the

vicinity

the

Sparks

could

any

compartment containing batteries

battery

that

the

battery last

BAnERYACID

A

WARNING:

severe

injury

111

When

servicing

level,

wear rubber

tion.

Batteries If it comes with

water. inadvertently

Sulfuric

or

death!

the

contain

in

contact with your skin,

Acid

when

starting

cables

the

negative lead

are

guards,

the

explosion

an

open

acid

batteries emit hydrogen, a

which can

products. Shut off

to

negative(-) battery cable to

ignite battery

gases.

charger connections

the

terminals with

could cause

and

any

other jewelry before handling

charger off before disconnecting .

when

disconnecting

acid

battery or checking

gloves,

a rubber

sulfuric acid

may

splash

removing electrolyte caps.

can

cause

before servicing

first

and

clear of

the

and

hatches

engine.

can

cause

flame

near the

be

ignited

prevent electrical

by

shorting

an

In

batteries

on

the

gases

To

avoid sparks,

while

tools,

explosion. Remove

the

negative

the

can

the apron, which

wash

skin

or into

engine before

by

all

or

etc.,

and is

injury

the

engine/

reconnect

are

re-

Injury

battery

electrical electrical arcing

dur-

the

posi-

Do

terminals

fuel

vapors.

to

prevent

do

the

battery

to

prevent

lead

first

battery.

cause

electrolyte

eye

protec-

destructive.

it

off

at

once

the

eyes

not

TOXIC

EXHAUST

A

WARNING:

11!1

Ensure

that discharged regularly are

securely attention exhaust pipe nipple.

II

Be

sure

111

In

addition

install a carbon monoxide

builder

or dealer

11

For additional information refer

tional

information

A

WARNING:

odorless nausea

11

Do

not

use

fumes

can

tems.

Exhaust sulfur causes rapid deterioration of copper

tubing

resulting

111

Do

not

install exhaust outlet where exhaust through exhaust discharge outlet enter

the

flow

of exhaust.

11

Although

exhaust

gas

is

present

toms

or

are: Vomiting Dizziness Throbbing in temples

Muscular twitching Intense headache Weakness

AVOID

11

MOVING

A

WARNING:

or

death!

Do

not

tion

arises operating adjustments, ing

moving

GASES

Carbon

the

exhaust

from

the

engine.

for

leaks

and

attached

to

the

the unit

to

and

manifold, water injection

and

its

routine inspection of

for

installation

on

Carbon Monoxide).

Carbon

gas.

Inhalation

or

death!

copper

tubing

rapidly

destroy

in

exhaust/water leakage.

portholes,

exhaust

diesel engine exhaust

fumes signs of carbon monoxide

discharge

Avoid

from

in

diesel exhaust

and

sleepiness

vents,

gasoline engines,

PARTS

Rotating

service

the

engine while

in

which

it

parts

and

monoxide

system

make

surroundings

Check

sure

no

warping

detector.

(CO}

is

adequate the

of to

monoxide produces

in

diesel exhaust

copper

tubing

or

air

conditioners.

is

near the outlet

and

overloading

gases

fumes.

parts

can

it

is

absolutely

use

extreme

hot exhaust

is a deadly

the

exhaust system

exhaust manifolds

exists.

elbow,

are

well

the

exhaust system,

Consult

approved detectors.

ABYC

(CO}

flu·like

in

waterline,

dose

the

craft.

are carbon

Some

inhalation

cause

is

running.

necessary

care

system

gas!

to expel

T-22

Is

Pay

close

and

ventilated.

your

boat

(educa-

an

invisible

gases

symptoms,

systems.

exhaust

sys-

can

be

drawn

If

the

engine

water

or

restrict

not

as

toxic

monoxide

of

the

or poisoning

injury

If

a situa-

to

make

to

avoid

touch-

components.

Diesel

symp-

could

the

as

Engines & Generators

ii

II

Do

not

wear

loose

equipment;

rings,

.

moving

11

Make Keep places

111

Do

. the

11

Stay when

be

caught

HAZARDOUS

A

WARNING:

necklaces

parts

sure

protective

at

all

not

check

engine

clear

the

engine

avoid

..

all

attaching

times.

fluid

is

operating.

of

the

in

these

NOISE

High

loss/

II

Never

operate

an

11

Do

not

run

an

engine

removed.

A

WARNING:

.

mentally

OPERATORS

Many

of

the

in

your

Operators

notes

to

highlight carefully, procedures.

maintain

Do

or

physically

MANUAL

preceding

Manual

critical

clothing

wearing

or

bracelets

hardware

shields

and

levels

or the

drive

shaft

is

running;

rotating

noise

engine

without its

with

not

work

incapacitated

safety

along

information.

your

equipment,

or jewelry

loose jackets,

that

could

is

properly

guards

in

their

drive

belt's

and

the

transmission

hair

and

clothing

parts.

levels

can

cause

muffier

the air intake

on

machinery

by

tips

and

warnings

with

other

Read your

and

follow

SAFETY

when

servicing

shirts,

sleeves,

be

caught

tightened.

respective

tension

can

INSTRUCTIONS

in

while

coupling

easily

hearing

installed.

(silencer)

when

you

are

fatigue!

are repeated

cautions

manual

all

safety

and

ABYC,

.

INSTALLING

Read

for tions

ABYC "Safety

Order ABYC

613

Annapolis,

( 410)

www.abycinc.o_rg

NFPA

''Fire Protection Standard for Motor Craft''

Order

NFPA

P.O.

Quincy,

USCG

"CPR

Code Order U.S.

Washington,

NFPA

AND

USCG

MARINE

the

following

safety

codes

when

installing your

(American

Standartls

From:

Third

Dtreet,

MD

990-4460

(National

From:

1 Batterymarch

Box

9101

MA

(United

33

AND

of Federal Regulations

From:

Government Printing Office

ABYC,

and

standards.

Boat

for Small Craft'' ·

Suite

10

21403

Frre

Protection Association)

Park

02269-9101

States Coast

CFR46"

D.C.

20404

PUBLICATIONS

ENGINES

NFPA

UNIVERSAL

and

Follow

Yacht

Guard)

AND

and

Council)

FOR

GENERATORS

USCG

publications

their

recommenda~

engine

ENGINE

Preparations ough (ABYC) sources

Sections

All Regulations

AND

examination

standar:ds.

including

of

H-32 H-33 P-1

Installatiion

and

P-4

Marine

E-ll

TA

Batteries

installations

GENERATOR

to

install

an

engine

of

the

American

These

standards are a

the

USCG

the

ABYC

standards

Ventilation

Diesel

Auxilliary

AC & DC

(FCR).

for

boats

Fuel

Systems

of Exhaust Systems

Engines

Inboard

must

Electrical

and

Battery

comply

Engines

INSTALLATIONS

should

begin

with a thor-

Boat

and

Yacht

Council's

combination

and

the

NFPA.

of particular interest

using

diesel

fuel

for

Propulsion

and

Transmissions

Systems

Chargers

with

the

on

Federal

Boats

Code

of

are:

of

Engines & Generators

iii

When

installing

attention

WBSTERBEKE

be

paid

to

.INSTALLATION

the

following

engines

and

information:

generators

it

is

important

that

strict

CODES

Strict

when

AND

federal

regulations,

installing

REGULATIONS

engines

SIPHON-BREAK

For

installations

or

will

be

break

in

minimum

the

exlumst

raw

water

If

you

have

to·

the

vessel's

siphon-break.

NOTE:

A siphon-break

op_eration.

enq.ine

damage.

EXHAUST

Tiie

exhaus't

Exhaust

and

turns

and

turns

system

MUST

under

any

where

below

the

raw

water

of20"

manifold

damage

any

doubt

waterline

Failure

SYSTEM

system's

Hose

is

without

.In

this

be

sea

conditions

vessel's

above

to

the

to

properly

Consult

hose

recommended.

the

ne~d

regard, a single

designed

ABYC

guidelines,

and

generators

the

exhaust

waterline,

supply

hose

the

vessel's

injection

about"

requires

port

engine

and

the

positii;>n

:under

the

periodic

maintain a siphon-break

the

siphon-break

MD~T:~

The

of

additiinal

length

to

prevent

and

at

any

and

safety

in a marine

manifold/water

provisions

to

the

exhaust

waterline.

is

at

or

po~rible

of

vessel's

,

....

inspection

certified for

use

of

fitting

of

the

angle

environment

must

elbow.

Failure

beluw

flooding

th~.

w.ater-injected

various

manufacturer

marine

this

type

and

conugated

entry

of

vessels

codes

must

be

complied

injected

exhaust

be

made

This

to

use a siphon-break·

the

load

of

the

operating

and

cleaning

can·

for

use.

of

hose

clamps

to

exhaust

wa~·into

heal. ·

elbow

to

install a

hose

must

waterline

boat.

exhaust

oonditions,

to

ensure

result

in

proper

maintenance.

Conugated

a,llows

for

accomplish

hose

can

the

exhaust

be

will

elbow

install

catastrophic

extreme

be

with

is

close siphonlooped

when

result

relative

a

proper

MaJ:ine

these

bends

used.

syste$'·

to

a

in

•

AVAILABLE YOUR.

DEALER

SIPHON-BREAK LOOP PART

bends

The

.~

FROM

WESTERBEKE

WITH~-

FOR

1"

HOSE

NO.

044010

fAINLES,

A

detailed

engines

.is

also

available

Website:

Marine

Installation

and

generators

www.westerbeke.com

in

pdf

is

supplied

format

Engines & Generators

Manual

covering

with

on

our

website

iv

ev!lry

to

gasoline

unit

sold.

download

and

This

diesel

manual

TABLE

Parts

Identification Introduction Diesel Preparations Generator

Operating Instructions ...................................... 7

Remote

Operating Instructions ...................................... 8

Safety

Generator

Daily

Operation

Maintenance

Cooling

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

Thermostat ...................................................... 14

Raw Water Cooling ........................................ 14

Raw Water

Intake Strainer ................................................

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

Zinc Anode .....................................................

Air Intake/Silencer ..........................................

Filter Cartridge ............................................... 16

Fuel

System

Fuel Water Separator ......................................

Fuel Filter .......................................................

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

Engine

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

Oil Filter .........................................................

Oil

Pressure

Testing Oil Pressure ........................................

Remote

DC

Electrical

Alternator ........................................................

Alternator Troubleshooting ............................

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

Starter

Troubleshooting ............................................. .24

Engine

LED/Shutdown

Engine

Water and Oil Pressure Gauges .....................

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

Fuel,

Engine

for

Control

Shutdown

Break-In

Schedule

System

Pump ............................................

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

Lubrication

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

Oil

Filter

System

Motor Troubleshooting Troubleshooting

................................................ 2 Engine

Oil

and

Initial

Start-Up

Panel

Panels

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

Switches

Procedures

Coolant..

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

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

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

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

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

(Chart)

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

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

System

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

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

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

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

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

(Chart)

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

(Chart)

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

OF

CONTENTS

3

5 6

?

8

9

I o

10

11

13 13

l5

15 15

16 l6

17 17 17 17

18

18 18

19

19 20 21

21 21 22

23

Glow Plugs .....................................................

Fuel Injectors ................ : .................................

Valve Clearance ..............................................

Injection Timing ............................................ .29

Generator

Maintenance ....................................................

.

BT

Generator

Circuit Breaker ...............................................

BTGenerator

Wiring Schematic ....................

Generator

No-Load Adjustment ..... · .................................

Full-Load Adjustment .....................................

BT

Generator

Three Phase/Twelve Wire ...............................

BT

Generator

Three Phase/Twelve Wire ...............................

Generator

BE

Three Phase ..............................................

BT

Generator

Troubleshooting Chart ............................... , ...

Optional Voltage Regulator ...........................

Shore Lay-Up Specifications

8.0

EGTD,

11.5

Specifications

12.5 Wiring Wiring Wiring

Remote Start/Stop Panel.. ............................... 48

Water Power Raw

Water

Engine

25 25

Suggested

26 27

Adjustments

Information

Description

·Single

Voltage

Internal Internal

AC

Voltage

Single

Power

Transfer

and

Recommissioning

(Engine)

10.0

EGTD ..................................

EGTD,

11.0 (Engine)

EGTD,

Diagram Schematic Diagram

Heater

Take-Off

15.0

#56225

#56321

(Optional)

Discharge

Torque

Specifications

Spare

Parts

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

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

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

Phase

Adjustment

Phase

Switch

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

..-

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

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

Wiring Wiring

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

Connections

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

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

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

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

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

EGTD ...............................

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

EGTD ................................

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

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

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

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

Hose

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

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

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

28 28 28 29

30 30

31

.32 .32

34 34 35

35 35

35

35 36

36

.37 .37 .37

38 39

.41 .42

..43

~4

.45

46 .47 .48

.49

50

.51

52

Engines & Generators

1

This

WESTBRBEKE WESTBRBEKE's technology. dependable

Thank

In

order

is

important manual manual throughout your

This

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an

Manual

ordered Dealer

We perfonnance

you

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get

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carefully

Should

nearest

WESTBRBEKE

is

your

operators

Installation

is

available

in

book

WARRANTY

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product

documentation Registration Corporation register

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registering.

your

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available.

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Diesel

Generator

long

years

of

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pride

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selecting

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WESTERBEKE.

full

use

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benefit

you

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and

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observe

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Manual

in

fonn

all

generator

dealer

manual.

pdf

from a WESTERBEKEfUNIVERSAL

and

form.

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Parts

is a product of

experience

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maintain

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Please,

the

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require

for

servicing,

assistance.

wi!}i

Infonnation. A Servtee

on

our

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PROCEDURES

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package.

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1-..v-IWESIERSEKE

j Engines & Generators

Customer

MR.

MAIN

HOMETOWN, Model

E~~-------------

NOTES,

As maintenance engine, CAUTIONS,

NOTE:

A

observed,

your

Identification

GENERATOR

STREET

_____

CAUTIONS

this

manual

takes

schedules,

critical

information

and

An

operating

CAUTION:

can

result

engine.

OWNER

USA

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AND

WARNIN~S

you

through

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WARNINGS.

procedure

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the

damage

Serial#-----

the

operating

be

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An explanation

essential

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if

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INTRODUCTION

and

advanced

durability

generators.

your

generator

it

correctly.

read

precautions

~

manual,

can

is

included

Warranty

Westerbeke

should

recewe

60

days of

factory

and

service

procedures,

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NOTES,

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note.

strictly

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this

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·

:met

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PRODUCT

Pioduct brochures WESTERBEKE

WESTERBEKE

CONI'ENT

·

WARRANIIES

THEREI'O, COMPLETENESS

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OF

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time

software WESTERBEKE provided WESTERBEKE

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OR

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IN CONNECTION

customers should also

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tinavoidable existence of earlier · manuals.

WESTERBEKE

or other suppliers,

exclusiVely

product It not

that appropriate or the supplier

the accuracy and

being consulted by

YOUR.

at the

factory:

during assembly

in a WES'IERBEKE generat9f

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manuals,

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within WESTERBEKE's

BE RESPONSIBLE

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TIMEliNESS

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#2 dieselfoel.

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section in this manual.

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generator

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Engines & Generators

3

INTRODUCTION

SERIAL

The a exhaust The the the

~tion

NUMBER

engine's

nameplate

manifold.

engine's serial

engine

block

side

oil fill

below

model

mounted

on a flat

opening.

on

the

illustrated

LOCATION

and

serial number

on

the

side

of

the water jacketed

number

is

also

surface just

Take

time

nameplate.

found stamped

to

are

Iqcated on

above

the

enter this

in

inform-

NOTE:

A

carbon

monoxide

by

WESTERBEKE.

engine

room.

UNDERSTANDING

The

diesel

engine

closely

since

the

mechanism

are

arranged

the

same diesel cbnnecting

therefore, to a

same

most maintenance Replacement time

contanlination system of

the

designed The

however, carburetor their which

above

general

engine

rods

preventive

important

periods

is

also

same

brand

specifically

diesel

engine

in

its method of

and ignition

place

is

performs

type

bas

the

and

great

maintenance

factors

of the

of

fuel

specifi~

(that is,

essential.

a single component-the

the

warning

Affix

this

THE

DIESEL

resembles

is

essentially

a closed

fuel,

of

does

crankcase;

as

that of a

same

types

lubricating

extent, a diesel

are

proper

lubricating

and

lubricating

is a must,

water,

Another

high

detergent

for

diesel

differ

handling

systems

function

decal

in a visible

ENGINE

the

same.

the

gasoline

of

valves,

system.

engine

as a gasoline

ventilation

and

filter

and

frequent

sediment,

important

diesel

engines.

from

the

gasoline

and

are

done

fuel

of

both.

has

been

position in

gasoline

cooling

etc.)

firing

engine,

The

cylinders

crankshaft is of

engine;

and

camshaft,

requires

engine.

and

proper

systems.

elements

checking

in

the

factor

is the

lubrication

engine,

of

fueL

away

with

injection

provided

the

.

the

pistons,

the

The

at

the

for

fuel

use

oil

The

and

in

pump

An

identification

displays

CARBON

the

engine

MONOXIDE

WESTERBEKE

detector even

The from elbow/exhaust entering

If

air

in

the

vessels

in

small amounts, is deacny.

presence

the

carbon

and

of

engine'

your

boat.

monoxide

correct

carbon

or

hose,

the

plate

on

the

model

and

DETECTOR

recommends

living

quarters.

monoxide

generator

or

the

fumes

is

present,

problem

immediately!

top

of the

engine

serial

number.

mounting a carbon

Carbon monoxide,

or

from

from a

ventilate

indicates

the

an

exhaust

nearby

area

air

intake

monoxide

exhaust

vessel

with

also

leak

are

clean

ORDERING

Whenever provide and

generator

·black

provide your description separately WESTERBEKE parts original

·SPARES

Certain

WESTERBEKE

·

dealer See

the

Generator

INSTALLATION

The

Westerbeke

supplied

PARTS

replacement/service

the

generator

serial

number

name

plate located

us

with

this

information

generator

are

will assist

. . .

set.

In

and part

furnished

frequently

equipment.

AND

spares

SPARE

Accessories,

number

packaged

not

ACCESSORIES

will be

generator.

you

PARTS

MANUAL

Installation

with

this

unit.

model

addition,

Parts

in

as

on

the generator

for

Ust).

parts

made

needed

Your

preparing

page

see

the

parts

are

needed,

number,

in

Manual

engine

they

appear

end.

so

we

may

include a complete

each part

Also

becavse

to

the same

to

support

local

this

ACCESSORIES

needed

insist

will fit

specifications

and

WES'IERBEKE

an

inventory

manual.

publication

always

serial

on

the

You

properly

(see

upon

or

maintain

of

For

Engine

brochure.

#043268

number,

silver

and

must

identify

part

the

generic

as

your

spare

parts.

and

is

GENERATOR

ID

DECAL

Engines & Generators

4

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use a SAE J diesel

Care

Use in dirt particles secondary is fuel improper storage the tank following practice

Purchase a

combat mended

.Kleen + Cetane Boost

diesel Install

filter/water separator between The Raycor 500 MA such

E~&GINE

Use a

specification this· initial 100

Westerbeke use break-in must be performed change SCHEDULE section of this synthetic

NOTE:

statements

SAE

For

FUEL

diesel

fuel

313

and

fuel

according

Of

The

only

clean

your

engines

which

filters

important

can

to

be

rendered

for

your engine's

well-known

BACTERIAL

such

as

fuel

when

and

regularly service a

filters. A 10

OIL

good

brand of engine

as

manual. Change

50

hours

of operation

Corporation

of synthetic oils.

intervals

oils

are

The

infonnation regarding

OIL

VISCOSITY

all

temperatures

that

meets

has a Cetane

to

ASTM

Fuel

Supply

diesel

fuel!

The clearance of

fuel injection

might

pass

can

damage

buy

clean

fuel,

unsatisfactory

facilities.

is

Bio-Bor

an

micron

stated in

of engine break-in operation

must be

used.

To

daily

advisable:

brand

growth

and

to

help

Ultra

Low

or

230

filter

the

engine

thereafter.

does

If

synthetic

as

above.

synthetic

GRADES

ranges:

the

requirements

rating

of

D975.

pump

is

through

these

finely

and

keep

by

assure

use

is

of

fuel.

on

the

an

additive

restore

Sulfur

good,

visual-type

the

fuel

RMAM

element

oil

having

SPECIFICATIONS

oil

and

not

approve

oils

using

conventional

listed in the MAINTENANCE

manual

supersedes all

oil.

SAE

lOW-40

of

No.

#45

or

higher

the

components

very

critical;

the

primary

machined

it

clean.

The best

careless

that

clean

The

fuel

lubricjty

diesel

tank

are

and

handling

the

fuel

and

pure,

use

of

additives

tank

is

recqm-

such

as

Diesel

back

is

being

fuel

and

the

good examples of

is

recommended.

an

API

and

section

oil

filter

after

and

then

or

disapprove

used,

engine

oil.

not

be

extended if

15W-40.

2-D

grade

invisible and

parts.

going

the

into the

used.

engine.

SAE

the

every

Oil

or into

in

the

of

It

to

ENGINE

WESTERBEKE and chemicals

The antifreeze performs run

engine circuit antifreeze (SCAs) to

The distilled water being

NOTE:

antifreeze that

PURCHASING

Select a brand of antifreeze Antifreeze additive cylinder brands engines.

mixture needed. MAINTENANCE

COOLANT

50%

distilled

that

can

at

proper

temperatures

to

the

coolant,

from

rust

that

contains

that

keep

long

term

protection.

poured

into

Look for

is

specified

to

protect

walls.

Prestone

that offer antifreeze

Select

will

always

Change

recommends a mixture

water.

Distilled

corrode internal

double

and

corrosion.

Supplemental

the

antifreeze

and

antifreeze

the cooling

the

new environmentally-friendly

now

available.

ANTIFREEZE

for

diesel

against

and

the

pre-mixed

be

added

the

antifreeze

SCHEDULE

MAINTENANCE

Change number protect

COOLANT

The coolant

contraction of without introducing air provided

the engine coolant of operating hours

and

water

coolant

operating

lubricate

the

RECOVERY

recovery

with

the

allows

the

engines

fresh

water cooled

conversion

engine.

into

of

50%

antifreeze

water

is

free

from

the

engine

surfaces.

duty.

It

allows

the

engine

by

transferring

lubricates

Look

chemically

should

circuit.

specified

engines

cavitation erosion of the engine's

Zerex

specifically

variety to

the cooling

mixture

in

every

five

as

the

engine

have

heat away

and

protects the

for a good

Cooling

balanced,

be premixed

for

diesel

contains a special

are

two

nationally

for

use

so

that

the

system

according

this

manual.

years

regardless

chemical

additives

a limited

from cooling

quality

Additives

crucial

before

long

lasting

engines.

known

in

diesel

correct

when

to

the

that

life.

of

TANK

for the

coolant

the

kit

and

expansion

during

system.

models

must

engine

This

and

be

installed

and

operation

recovery

with

the

before

tank

fresh

to

the

is

NOTE:

This located at or can

be

located

particular installation makes

Engines & Generators

5

tank,

above

with

below

its

short

the level

the

level

of

this

run

the

of

plastic

hose,

engine's

the

necessary.

manifold,

engine's manifold

is best

but

if

it

the

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Befor~

prolonged layoff,

•

Make

•

Check the

•

Check

bowls

Check

• and

R

Check

wiring

•

Examine (SoundGuards

•

Be load

•

Be

the

system connected incomplete neutral

•

Visually parts,

threaded connections. Search for any fuel line leaks.

INSPECTION

starting your generator set for the

check

the

following

certain

the cooling

the engine

full mark

battery cable connections.

sure

lines.

sure that

neutral is properly grounded (or ungrounded)

on

the

the fuel

for contaminants.

the

load leads for correct connection diagrams.

disconnected wires, unattached hoses, and check

supply

DC

electrical

air

inlet

).

no other generator or utility power

in

power

requires,

voltage

and

to

the load neutral. In single phase

or

open

on

examine the unit. Look for loose

water

oil

level.

Add

dipstick.

and examine the fuel filter/separator

system.

and

outlet

for

systems with a neutral line that

that the generator neutral

neutral can supply the wrong line-to-

unbalanced loads.

first

time

items:

thru-hull is

oil

Inspect wire connections

air

open.

to

maintain the level at

as

specified

flow

obstructions

is

or.missing_

or after a

in

the

connected to

as

the

is

properly

systems

an

A

recommended motors, up

This unanticipated prevent a cold

II

Check the

and at the

NOTE:

the recovery cooling engine drawn air.

Before

·

manifold should may

CAUTION:

When

that

be

switched

to

speed

and,.

in

precaution

will

operation

engine

coolant

manifold.

After

the

initial

engine's

cooling

tank.

Open

system

is

purged

has

cooled,

the

into

the

engine's

subsequent operation

be

need

to

be

filled

starting

the

generator.

all

AC

loads,

especially

OFF

until

the

engine

cold

climates,

prevent

of

from

level in both the plastic recovery

running

system will

the

air bleed petcock

of

air.

coolant from the recovery

cooling

topped off,

to

the

MAX

starts

damage

the

caused

AC

machinery

stalling.

of

the

generator,

be

purged

After shutdown and

system

to

of

the

generator,

a:nd

the

coolant recovery tank

level.

it

large

has

come

to

warm

by

and

the air

to

the

to

ensure

replace

the

is

up.

will

tank

in

coolant

that

cifter

tank

will

the

purged

engine's

the

be

MAWFOLD

PRESS

TOUFTOFF

PRESSURE

DOWN

WAIT

FOR

BEFORE

REMOVING

CAP

AND

TURN

THE

ENGINE W COOL

THE

RADfATOR

.

CAP,-~=,.,_~,

Olll)IPSTICK

FROM

COOLANT

RECOVERY

TANK

ELECTRONIC

THE

.

TO

CONTROL

OF

THE

ECU

DRIVE

JS

CONlROLLER

FACTORY

ALL

PROGRAMMED

ASPECTS

ENGINE.

TO

NIPPLE

MANIFOLD

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.

At

PRESSURE

CAP

LOW

Engines & Generators

6

GENERATOR

INSTRUMENT

CONTROL

PANEL

OPERATING

DESCRIPTION

The Generators Instrument Control contains a compact gauge package, control rocker switches, circuit fuses, check engine light, emergency stop toggle switch and a recording hourmeter. These components are described below.

The

8 pin connector that is on the back

is

used to connect

second instrument panel.

an

When with jumper should be kept for future needs when troubleshooting. Secure it to the lifting eye.

FUSES:

5 amp fuse protects the ECU and a 7.5 amp fuse to protect the control circuit and instrument panel.

CHECK

illuminate Shutdown in this manual).

optional panel is connected, the 8 pin connector

The control box has two automotive type fuses. A

ENGINE

if

EMERGENCY

(Normally Closed) When depressed, it will open the DC circuit to the control box.

This switch can be used when servicing the unit to

prevent

REMOTE

box will allow for the remote mounting instrument panel or the remote panel start/stop.

COOLANT

temperature should normally indicate: (80o

ENGINE

depending on the generator load but should range between

35

DC

and should show

an

PANEL

TEMPERATURE:

to

90°C).

OIL

to

55

psi.

VOLTS:

HOURMETER:

for when to perform scheduled maintenance.

PREHEAT:

activates the preheat circuit and activates the K2 Run Relay. This supplies power to the DC altemator R, fuel pump, ECU, Instrument panel, switch.

START:

Kl

STOP:

opens the DC circuit supplying power to the K2 Run relay. De-activating

The PREHEAT rocker switch serves two purposes:

The START rocker switch when pressed activates the

Start Relay which activates the starter motor.

The STOP rocker switch when pressed and held,

an

optional remote start/stop panel

LIGHT:

The CHECK ENGINE LIGHT will

the engine shuts down. (Refer to the Safety

STOP:

The EMERGENCY stop toggle switch

is

located at the side

unwanted start.

PLUG-IN:

PRESSURE:

Indicates the amount the battery is being charged

13

Registers elapsed time and

it and shutting down the engine drive.

A plug on the side on the control

Engine coolant (water)

Oil Pressure (psi) may fluctuate

V to 14

V.

K3

Fault Relay pin #87 and Start toggle

of

the Control Box

of

the control box.

of

the remote

175° to 195°F

is

used as a guide

or

a

INSTRUCTIONS

NOTE:

It is important to

closely

monitor the panel gauges. Become aware the

nonnal

THIS

PANEL

CAN

ALSO REMOTELY TO

THE

FOLLOWING

LOCATED,

BE

-REFER

PAGE

STARTING/STOPPING

Depress the PREHEAT rocker switch for approximately 5-10 seconds. Then with the PREHEAT rocker still depressed, depress the the

START rocker.

Remote

register, release the Continue to hold the PREHEAT rocker depressed until the

oil pressure reaches rocker.

Once the generator has started, observe the meter readings

on the instrument panel. Ensure that raw water

discharged with the exhaust. Apply a light amperage load on the generator and allow it to warm up your higher amperage loads as needed.

FAILURE

START rocker has been depressed for both rocker switches and wait above start procedure. Preheat a few seconds longer. Never run the starter continually for more than

STOPPING:

and hold it depressed, Release the STOP rocker when the

generator comes to a complete stop.

REMOTE

the oil and voltmeter stop registering.

START rocker. When the engine starts, release

Control

TO

CONTROL

Panel:

When the oil and voltmeter start to

Start rocker.

10

psi. Then release the PREHEAT

START:

To stop the generator, depress the STOP rocker

Should the engine not start after the

PANEL:

and

if

these readings start to

INSTRUCTIONS

30 seconds and repeat the

Release the STOP rocker when

engine readings

take immediate action

is

being

to

140oF,

then apply

5-l

0 seconds, release

20-25 seconds.

of

Val)'·

7

OPTIONAL

REMOTE

CONTROL

PANELS

OPERATING

DESCRIPTION

There

are

several options available when selecting remote

location. remove_

box

and

Instrument

using

generator.

the

Instrument Control Panel

mount

it

as

a remote

Control

start~~top

to

panel

the

Panel

8 pin

in

the

plug

panel.

can

control

ina

from

be

replaced

remote

on

the

the extension harnesses listed below.

EXTENSION PNit056236 PN1t056235

HARNESS

EG

DIESEL

EG

DIESEL

(8 (8

PIN) PIN)

operation of your

1.

Mount a second (repeating) Instrument Control Panel

remote

2.

Simply

control

NOTE:

The

installing a basic

3.

Mount a remote start/stop control panel

location.

Remote the

panels connect

control box

box.

back

15FT 30FT

INSTRUCTIONS

in

a

the

by

of

INSTRUMENT CONTROL

PN56246

NOTE: on jumper it to running plug

When

the

back

of

found

the

rear lifting

issue

with jumper to

,

·.

PANEL(AS

connecting a remote panel to

the control

in

this plug connector.

eye.

by

eliminating

It will

the

connector.

A

REMOTE

box.

the

be

PANEL)

DO

NOT discard

Keep

useful

remote panel

the

plug connector

the

plug with

it with

the

~it.

Attach

in

troubleshootmg a DC/

and

returning

this

REMOTE

The switches the LED

this the rocker the rocker depressed reach

For and

START/STOP

Remote

as

the Instrument Control Panel. Their function

same.

This panel

will

illuminate when the

panel

is

generator

switch,

LED

will

switch.

for

10

psi,

the

REMOTE

wiring

harness, refer

PANEL • DESCRIPTION

Start/Stop Panel

has

remote mounted,

has

started. When depressing

this

LED

brighten. This indicates

The

PREHEAT

about

4-5

then

release

START/STOP

has

a RELEASE

PREHEAT

this

will dim. When

rocker switch

seconds

to

it.

the

to

Table

the

same

three

STARTER

is

depressed. When

LED will indicate

the

START

the

generator starts,

to

release

the

is

held

allow

the

oil

pressure

PANEL

wiring

of Contents.

rocker

LED.

when

START

diagram

is

This

to

REMOTE

PN56320

START/STOP

PANEL

Engines & Generators

8

SAFETY

SHUTDOWN

DESCRIPTION

The engine is protected by a number features as described below. Should a shutdown occur, as a result

of

one

of

these features, the Check Engine LED will

illuminate. The cause should be determined using the troubleshooting

ECU must be cleared

DC breaker and then back

High

Exhaust

An

exhaust

elbow.

Normally

the

DC

voltage

should

the switch's sensor indicate perature exhaust temperatures). l'his switch opens at 260-270°F

l320C}.

(an

This

Diagnostic Software. Once corrected, the

of

this fault by turning OFF the 20 amp

ON

Temperature

temperature

to

inadequate

switch

switch is located

closed, this switch will open

the

K2

relay (shutting OFF the engine)

supply of raw water causes

resets at approximately 225°F (l07°C).

·:;;::·-~:-

.~~'::----

//

of

safety shutdown

in order to start the engine.

Switch

on

the exhaust

and

interrupt

an

excessive exhaust

..

EXHAUST

ElBOW

tern-

hjgh

(127-

SWITCHES

low

Oil

Pressure

A

low

oil pressure shutdown switch is located off

oil

gallery.

monitors

pressure

DC

Normally open.in a static state, this switch's sensor

the engine's oil pre§sure. Should the engine's

fall

to

voltage

to

fROM

BLOCK

Switcn

5-10 psi, this switch

the

K2

relay,

thereby shutting off

'(""".

ENGINE

will

open interrupting

the

engine's

oil

engine.

OIL

PRESSURE

SEtl!JOR

the

Coolant

h high coolant temperature switch

housing. coolant's operating temperature reach approximately (99°C}, relay, 195°F

Temperature

Normally closed,

will open and intermpt the

thereby shutting off the engine. This switch

(107°C).

Switch

is

located

this

switch, should the

DC

on

voltage to

the

fresh the

re&ets

thermostat

water

210°F

K2

at

The

generator's engine manual reset circuit breaker (20 draw

or electrical overload anywhere

w~ng

or engine wiring will cause the breaker event the generator relay is terminated.

source of the problem. After repairing the fault; reset breaker and restart the generator.

Overspeed/Underspeed

The unit's ECU is monitoring the engine speed via a signal

from the wheel's ring gear teeth. Should the engine speed reach a programmed high rpm or low rpm, the engine down and the

MPU (magnetic pick-up) positioned over the

is

protected

will

shut down and

If

this should occur, check

by

amps

an

engine

DC).

Excessive

in

the instrument

to

the

voltage

and

mounted

trip.

In

to

the

repair

the

Shutdown

ECU will shut the

Check Engine LED will illuminate.

current

panel

this

K2

the

fly

THERMOSTAT

ASSEMBLY

9

GENERATOR

BREAK-IN

PROCEDURE

DESCRIPnON

Although your engine hour of test operations assembly procedures operated life of your engine ated

Breaking-in a piston and scored, the

Your

conditioning operation to

properly, a break-in

and

serviced

rings

to

smoky

operation indicate that the cylinder walls are

which

break-in

maximize

period.

new

engine

the performance and service life of the

is

during

new

engine

the

cylinder walls. Excessive oil consumption

is

caused

requires

has

experienced a minimum of

at

the

factory

to

make sure accurate

were

followed

dependent

its initial hours of

basically involves seating

by overloading the generator during

approximately 50 hours of initial

to

break

and

that the engine

time is required. The service

upon

how

the engine

use.

the

in

each moving part

in

engine.

one

is

order

oper-

AFTER

Once tion between

After

. can

cally

,

Avoid smoky Monitor

it

at

50

the

GENERATOR

Once the generator has be adjdstments required for engine speed engine's break-in period (first 50 hours) or after A no-load voltage adjusunent may also be

junction with the engine's

GENERATOR

START·UP

the

generator

and

then 20%

A

CAUTION:

generator

the

first

be

increased

vary

the

overload at all

exhaust witll reduced output voltage

the current

within

the generator's rating. Since the generator

1800

rpm

Hertz),

control of

current

drawn

has

been

started, check for proper

encourage

and

by

running

10

load.

to

produce 60 hertz (or at

a fast warm-up.

60%

of full-load for the

Do

not

attempt

without a load.

hours

of the generator's operation,

to

the

full-load rated

times.

An

being

drawn from the generator

the

generator's break-in is

from

the

generator.

to

overload

ADJUSTMENTS

l:!een

placed

speed

adjustmeqt

INFORMATION

in

this

Run

first

break·ln

output,

is

signaled

1500

in

operation,

(hertz)

required

mariual.

opera-

the generator

10

hours.

your

the

then

periodi-

by

and

frequency.

and

operates

rpm

to

produce

governed

there

during

this

period.

in

See

load

keep

by

may

the

con-

THE

DAILY

CHECKUST

·Follow

this

cheek list each

0

Check

th,at

alJ...generator

in the off position before starting.

0

Record

the liourmeter reading in your log (engine hours

relate

to

th~

maintenance schedule.)

0

VISually

0

Check

inspect

the oil level (dipstick).

0 Check the coolant level in the coolant recovery

0 eheck your fuel 0

Check

the·starting.batteries (weekly).

0

Check

drive belts for wear and proper tension (weekly).

CHECK

WITH

THE

daY'

before starting your

circuit breakerS (power panel) are

the

engine for fuel, oil, or water leaks.

supply.

ENGINE

RUNNING.

generator.

tank.

0 Check for abnormal noise such as knocking, vibrating

blow-back sounds.

0

Confirm When

When When

exhaust_ the engine the engine is the engine is overloaded- some Black

smoke:

is

cold- Whlte Smoke. .

warm-

almost Smokeless.

Smoke.

OPERATION

START

operating temperature of

and

THE

(See

STARTING

Allow

the engine

applying generator to adjust Check temperature, and DC voltage.

NOTE:

This

temperature

AC

the gauges for proper oil pressure, operating

. .

Some

condition

A

CAUTION:

periods

of

generator.

STOPPING

Remove the major time.

Allow lize the operating temperature (See

STOPPING

GENERATOR

PROCEDURES

to

wann

up

for 5 to

140°

to 150°F

loads.

Apply

loads systematically

to

each load before

·

unstable

is

time

THE

the generator

should

reached

Oo

runn,ing

lessen

not

as

and

loads

operate

may

without a load

·

GENERATOR

AC

loads from the generator one

to

run for a

and

PROCEDURES

nonnal

on

applying

occur

are

applied.

the

generator

being

few

depress

on

minutes

(60°-66°C)

allowing

the

in

!1

cold

operating

placed

on

minutes

the

stop pages.)

to

rea~h

before

next.

engine.

for

long

the

at

a

to

stabi-

switch.

an

the

Engines & Generators

10

MAINTENANCE

SCHEDULE

WARNING:

gloves, Control

SCHEDULED

Maintenance

I

DAILY

Coolant Engine Fuel/Water

Fuel

Visual

NOTE:

will

Drive

'INITIAL

Engine

*Exhaust

*Valve *Re-Torque

Inlet Fuel Generator AC

No-Load

Nev8f

and

use

Box

or

MAINTENANCE

procedures

CHECK

Level

Oil

Level

Separator

Supply

Inspection

Please

inhibit

the

engine's ability

Belts

50

HOURS

Oil

and

System

Adjustment

Cylinderhead

Fuel

Filter

attempt

the

correct

tum

off

are

BEFORE

(owner

of

Engine

keep

engine suiface

OF

Filter

Hold

to

perform

tools

DC

battery.

detailed

for

in

the

all

START-UP

installed)

clean.

to

remain

cool.

OPERATION

Down

Bolls

any

service

each

job.

this

manual.

Dirt and oil

while

the

engine

When

servicing/replacing

EXPLANATION

Check Oil

Check

hours Use

.

there Check

securing

connections.

Inspect

Initial

Check Ensure

Check Re-torque Remove Remove Check Check

is

at

recovery

level

should

for

water

or

once a year.

properly

is

adeqilate

for

fuel,

v-clamp

for

engine

security

there

adjustment

bolts, and and

that

AC

and

adjust

running.

DC

OF

SCHEDULED

tank,

indicate

and

dirt

filtered

#2

fuel

oil

and

is

tight.

Look

for

frayed

edges.

oil

and

filter

of

water

are

no

leaks.

of

engine

replace

inlet

replace

fuel

connections

the

Wear

the

proper

components,

MAINTENANCE

if

empty,

check

between

MAX

in

fuel.

Drain

diesel

with a Cetane

for

the

vessel's

water

and

exhaust

No

exhaust

loose

bolts/hardware

Belts

must

change

at

injected

exhaust

valves.

cold

then

check/adjust

fuel

filter.

filter

and

all

are

secure

no-toad

AC

output

tum

at

and

filter

needs.

leaks

be

properly

50

hours.

elbow

sealing

with

voltage

safety

off

the

manifold.

LOW

on

if

necessary.

rating

leaks.

Check

around

and

correct

tensioned.

to

valve

O·rings.

no

chafing.

as

equipment

Emergency

Add

coolant

dipstick.

Do

Replace

of

#45

or

higher.

that

the

elbow.

as

needed.

exhaust

manifold.

clearances.

needed.

such

Stop

if

needed.

not

overfill!

filter

Check

water

injected

Inspect

as

goggles

Switch

every

that

wiring

on

250

operating

exhaust and

electrical

and

the

elbow

I

EVERY

50

OPERATING

Drive

Bell

Starting

Batteries

Electric

Fuel

Pump

Zinc

Anode

I

EVERY

100

OPERATING

Engine

Oil

and

Filler

Air

Intake

and

Filter

*WESTERBEKE

recommends

HOURS

this

OR

MONTHLY

OR

YEARLY

service

be

performed

Inspect for

Check off

Inspect Inspect

your

Change Keep

by

an

knowledgeable

for

proper

slipping,

electrolyte

corrosion

for

leaks,

and

own

inspection

engine

air

intake

tension

cracking

lev'els

if

needed.

ensure

clean

zinc

oil

and

clear

mechanic.

(3/8"

and

wear.

Make

sure

Apply

petroleum

fuel

and

anode.

Replace

schedule.

filter

at

100

of

obstructions.

to

1/2'

Adjust

cables

electrical

operating

Clean

deflection)

tension

or

and

connections

jelly

to

terminals

connections

if

necessary.

hours

air

filter

and

adjust

replace

are

Note

or

yearly

and

replace

if

as

needed.

are

for

corrosion

clean

the

condition,

..

needed.

Replace

in

good

and

tight.

if

needed.

Check

belt

cover.

order.

Clean

protection.

then

determine

Engines & Generators

11

NOTE:

Use

the

engine

MAINTENANCE

hourmeter

gauge

to

log

your

SCHEDULE

engine

hours

or

record

your

engune

hours

running

time.

SCHEDULED

I

EVERY

*Exhaust

Fuel Inlet

*Generator

Hoses Fuel

DC

Impeller

EVERY

Raw

Coolant

*Valve *Starter

*Re·

Pre-Heal

Fuellnjeclors

MAINTENANCE

250

OPERATING

Elbow/Exhaust

Filler

and

Fuel

Filter

Water

Separator

Alternator

500

OPERATING

Water

Pump

System

Clearances

Motor

Torque

Cylinderhead

Circuli

O·Rings

System

Filter

Hold

HOURS

OR

HOURS

OR

Down

Bolts

YEARLY

FIVE

YEARS

EXPLANATION

Check

the

of

the

exhaust

chaffing.

NOTE:

An

Remove Remove Check

that

See

GENERATOR

Engine

delaminated.

Inspect Inspect

Check

mounting

Inspect

Remove

and

cover

at

re-assembly.

Drain,

flush condition and

connecting

Adjust

valves. Check

solenoid motor

pinion Re-torque Check

operation

Check

and

structual

No

exhaust

and

replace

and

replace

AC

heses

should

Check

bowl

for

wiring,

the

condition

and

disassemble

for

wear

and

of

the

(Incorrect

drive.

bolts,

adjust

OF

system

connections

INFORMATION.

dirt

connections

bracket

re-fill

sealing

hose.

and

engine of

injection

SCHEDULED

integrity

of

the

attached

to

leaks.

Hoses

leak

will

cause

exposure

fuel

filter

and

inlet

fuel

filter.

are

clean

be

firm

and

tighten

in

should

and

alternator

the

impeller,

the

pump

cooling

valve

clearance

for

corrosion.

then

solenoid.

opening

tight.

all

fuel.

system

of

check/adjust

and

or

water

of

and

corrosion.

the

gaskets

motor

cold

preheat

MAINTENANCE

water

injected

the

elbow.

and

muffler

all

sealing

and

Replace

hose

Drain

be

tight.

bolt.

replace

and

Replace

the

pressure

will

Remove

pressure

All

are

to

diesel

0-rings.

secure.

clamps

and

replace

Alternator All

should

as

inspect

the

impeller

with

appropriate

cap.

result

Remove

valve

glow

and

exhaust

hose

connections

in

good

exhaust!

Ensure

if

hoses

as

needed.

all

parts:

Clean

in

poor

and

lubricate.

clearances.

plugs,

spray

elbow

casting.

serviceable

wires

have

become

spongy,

filter.

.

should

be

tight.

drive

gear,

and

gasket.

antifreeze

out

coolant

engine

Clean

clean

tips

conditions.

Check

should

be

secure.

condition.

no

chafing.

brittle

clean

and

free

pump

shaft,

Lubricate

the

mil<.

Inspect

recovery

performance.)

and

lubricate

and

check

operation.

the

integrity

No

or

of

corrision.

wear

impeller

the

tank

the

plate

starter

EVERY

1000

OPERATING

Heat

Exchanger

*MPU

(Magnetic

*WESTERBEKE

Pick-Up)

recommends

HOURS

this

service

OR

be

EVERY

FIVE

performed

YEARS

Remove Remove,

by

an

knowledgeable

the

heat

check

exchanger

and

clean

mechanic.

for

professional

any

metal

debris

cleaning

from

the

and

tip

pressure

of

the

testing.

MPU.

DESCRIPTION

Westerbeke

for

fresh bustion which water parts,

from exchanger,

water fresh

ferred

tube exhaust other coolant transferred fresh each allows harmful

FRESH

NOTE:

ommended

fresh

F~sh

latmg then heat exchanger block

marine

diesel

water

cooling.

and

friction

is

circulates

coolant

and

the

flows

water

to

walls

system

words,

is

water

other.

the

deposits.

WATER

Refer

throughout

cools

the

engine

fresh

water

similar

in

through

coolant

flows

the

fresh

water

to the

raw

where

the

engine

cooled

by

heat

overboard

coolant

and

Using

only

cooling water passages

COOLING

to

the

ENGINE

antifreeze

water

coolant.

water

coolant !s pumped through the engine

pump,

absorbmg

passes

via

through

the

wheJ;e

suction

COOLING

engines are

Heat

produced in

transferred

the engine.

engine

oil.

The heat

coolant

to

function

the

tubes

of the heat exchanger

around the

coolant

water

which

finally

it

is

cooled

raw

water,

through the exhaust

raw

water circuits

fresh

water coolant within the engine

CIRCUIT

COOIANI'

and

water

heat from the engine. The coolant

thermostat into

it

is

cooled,

side

of the circulating

designed

the

to

fresh

water

This

block,

its

internal

is

transferred externally

raw

water

by

to

an

automotive

tubes;

is

conducted

is

then

pumped

is

discharged

by

fresh

water

and

the

raw

are

to

stay

clean

section

mixture

and

to

the

returned

and

engine

coolant

circulating

moving

means

radiator.

engine heat trans-

through

overboard.

coolant, this

water carries the

systep:t.

independent of

and

for

be

used

manifold,

to

pump.

equipped

by

comfresh

of a heat while

the

into

the

The

free

the

rec-

as

the

by

a circu-

to

the

en!rine

Raw

In

from

the

o

SYSTEM

When

the

engine

is

started

cold,

vented

by

the

closed thermostat (although some

is

bypassed manifold thermostat

coolant cooling

Coolant

A coolant and cant loss of coolant ing engine

CHANGING

The engine's coolant must

MAINTENANCE

. become contaminated, it can lead

A

critical; a substantial

traced

Drain

engine block

the system

NOTE:

be

used

A

Wear

around

from

overheating).

gradually

to

flow

unrestricted

system.

Recovery

recovery

contraction

system.

manifold

This

during

tank

level

COOLANT

SCHEDULE.

CAUTION:

back

to

cooling

the engine coolant

and

with

fresh

The

drain

petcock

to

help

drain

WARNING:

protective

the

thermostat

As

opens,

allowing

to

Tank

tank

allows

engine operation, without

and

without introducing air

should

be

and

should

be

Proper

cooling

number

system

by

loosening the drain

opening

the manifold pressure

water,

then

on

the

engine

Beware

of

gloves.

external coolant

to

prevent the

the

engine warms

full

flow

the

external portion

for engine coolant

located at or above

be

easily

accessible.

changed according

If

the coolant is

to

overheating

system

maintenance

of

engine

failures

corrosion.

start the refill

heat exchanger

coolant.

the

hot

engine

flow

is

coolant

exhaust

up,

the

of

the

engine's

of

the

expansion

any

signifi-

into

the

to

the

allowed

problems.

can

plug

on

cap.

Flush

process.

should

coolant.

pre-

flow

cool-

to

Is be

the

also

ENGINE

BLOCK

COOLANT

DRAIH

13

COOLING

Refilling

After replacing the engine block drain plug, close the heat exchanger's coolant petcock. Then pour clean, premixed coolant and when the coolant the engine.

NOTE:

exchanger. When a steady flow

petcock, close it

Monitor the sure

Remove coolant the flow

After Coolant engine needed.

RECOVERY

the

Coolant

is

visible

in

the manifold, start

When present, open the air-bleed pet cock on the heat

of

coolant appears at the

and

continue to fill the cooling system.

the

coolant

in

the

manifold

cap.

the

mix

cap.

Run

into

the

checking

should

cools

Clean

TO

COOLANT

to

the

cap to

halfway

the

recovery

for

draw

down.

up

TANk

manifold

filler

neck

on

the

coolant recovery tank between LOW

engine

and

tank.

leaks,

stop the engine and

back

into

Add

coolant

any

spilled

and add

and install

observe the coolant expansion

the

cooling system

to

the

coolant.

as

the

manifold

and

MAX

allow

recovery

needed.

fill

and

it

as

tank if

pres-

with

replace

to

the

Fill

cool.

SYSTEM

Replacing

Remove

ing

as

ket,

apply a thin before screws.

Run there

the

shown.

pressing

the

engine

are

no

the

cap

When

leaks

Thermostat

screws

and

disassemble

installing

coat of sealant

it

into

place.

Do

and

check

for normal

at

the

thermostat

the

new

thermostat

on

both

sides

not over-tighten

temperatures

housing.

thermostat

and

of

the

gasket

the

cap

and

BLEED

PET

COCK

hous-

gas-

that

NOTE:

sure good closes

Periodically

cap.

Ensure

condition

tightly.

check

that

and

check that the vacuum

Carry a spare

THERMOSTAT

A

thermostat, engine, uously engine from

thermostat

As

the

thermostat

replaced

controls flows is

first

flowing

to

engine

is

easily.

located

the

coolant temperature

through

started, (some prevent

warms

accessible

Carry

COOLANT

the

condition

the

upper

cap.

near

the manifold

the

closed cooling

the

closed thermostat prevents coolant

coolant

is

by-passed

the

exhaust manifold from

up,

the

thermostat

and

can

a spare thermostat

RETRACTION

of

the

and

lower rubber seals

valve

at

the

as

the

circuit.

through a hole

gradually

be

checked,

and

manifold

SEALS

front

coolant

When

cleaned,

gasket.

pres-

are

in

opens

and

of

the

contin-

the

in

the

overheating).

opens.

The

or

THERMOSTAT ASSEMBLY

RAW

WATER

The

raw

water impeller water water through the ing into ing water discharge

Raw

The

non-ferrous has within On lubricant impeller Raw water)

are

raw

NOTE:

(seals chase a new

pump.

source

(ocean,

strainer.

the

raw

heat

exchanger tubes) where it

fresh

water

the

water-injected exhaust

the

exhaust

is

discharged

pressure.

Water

raw

water

housing

flexible

vanes

the

impeller housing, producing

no

account

for

the

and

impeller cover gasket

water

pump

is

not

present during engine

not

warrantable,

water

flow

Should

and

bearings),

pump

COOLING

flow

This

The

water

coolant. The

gasses.

CIRCUIT

is

created

by

a positive displacement

pump

draws water directly

lake, or river) through a hose

raw

water passes

pump

to

the

raw

water

elbow,

This mixture of exhaust

overboard

by

the

Pump

pump

is

a self-priming,

and a neoprene

which

wipe

against a

should

this

pump

be

impeller.

impeller failures occur

is

a failure occur with

and

present

it

and

There should

operators

at

start-up.

may

be

more

rebuild

the

from

the

strainer

heat exchanger

cools

the

engine

is

then

discharged

mixing

with

gas

engine's exhaust

rotary

pump

impeller.

run (an operation.

are

the

cost

original

The

curved

cam

the

pumping

dry

as

water

always

be a spare

impeller

when

lubricant

Such

cautioned

pumps internal

efficient

pump

from

the

to

the

(through

circulat-

and

gas

with

impeller

plate

action.

acts

kit)

aboard.

failures

to

make

parts

to

pur-

as a spare.

raw

cool-

raw

a

as

(raw

sure

a

14

CHANGING

Close and

gasket

pliers. Lightly

Install

of

the

cover.

THE

the

raw

or 0-ring

Carefully

coat

the

new

curve

of

Open

the

water

pry/pull

inside of the

impeller,

the

raw

RAW

WATER

intake

with

the impeller

bending

cam

plate.

water

valve.

the

aid

pump

the

Re-assemble

intake

valve.

PUMP

Remove of two

screwdrivers

out

of

housing

blades

RAW

COOLING

IMPELLER

the

pump

cover

or

the

pump.

v1-th

glycerine.

in

the

direction

the

gasket

and

·

WATER

PUMP

SYSTEM

NOTE:

Also

follow

the

above

aground.

If

.the

engine normal may

have

raw

water

temperature

reading,

been through

·.

,

~.

the

cause

caught

the

gauge

may

up

in

cooling

RAW

procedure

the

system.

WATER

ever

be

that

strainer,

shows

after having

a higher

silt, leaves

slowing

or

the

STRAINER

run

than

grass

flow

hard

SEWNG~

GASKET.~·

of

INSPECTION:

EACH

REPLACE

ANY'CRACKS.

CHECK

BLADE

BY

THE

IMPELLER

A

CAUTION:

impeller,

cooling exchanger.

Raw

Water

NOTE:

Always

the

strainer

A

clean engine's strainer

in

the

glass

Perform operation:

1.

Close

2.

Remove

3.

Clean

4.

Replace

5.

Reassemble

6.

Open

7.

Run

THE

BASE

BfNDJNG

VIGOROUSLY.·

they

clrculf.

Intake

install

will

raw

water

cooling

when

making

should

the

following

the

raw

and

the

glass.

the

seacock.

the

engine

OF

«any

must

They

the

always

intake

system.

be

water

clean

washer

and

install

and

of

the

vanes

be

found

to

often

can

Strainer

strainer at or

be

self-priming.

strainer

Include a

your

periodic

clear.

maintenance

seacock.

the

strainer

if

necessary.

the

strainer.

check

for

have

prevent

be

found

below

is a vital

visual

engine

after

every

filter.

leaks.

broken

off

bloclcage

In

component of

inspection of

check.

the

waterline

100

In

heat

The

hours

the

the this water

of

so

TYPICAL

HEAT

EXCHANGER

The

heat

exchanger

number

the

engine removes

of small copper

small

copper

is

circulated

heat

CLEAN

DEBRIS

BOTH

tubes

from

RAW

WATER

(OWNER

is

a

copper tubes.

and

atound

the

fresh

OUT

AT

ENDS

INTAKE

STRAINER

INSTALLED)

cylinder

Raw

the

fresh water coolant

the

copper

water

HEAT ALSO CUPRO-NICKEL

which

water

tubes.

coolant.

EXCHANGERS

AVAILABLE

encloses

is pumped

The

raw

NC

ANODE

ARE'

WITH

TUBING

through

from

water

a

the

Enf!lnes ~ Generators

15

Zinc

Anode

A

zinc

anode,

circuit

within

zinc

anode

pJace

in

the

effects

of electrolysis

The

condition determine replacement Spare

NOTE:

installation

its

zinc

NEW

Electrolysis

or pencil,

the

is

to

sacrifice itself

raw

of

service

period

anodes

and vessel location; not that

is

located

in

the raw water cooling

heat exchanger. The purpose

to

electrolysis action taking

water cooling circuit, thereby reducing

on

other components

the

zinc

should be checked monthly

life.

Once that is established, the zinc

can

be

noted

in

your

maintenaJ;Jce

should

be

carried on board.

REPlACE

ZINC

action

REPlACE

ANODES

is

the

result

of

each particular

of

COOliNG

of

having

the

of

the system.

to

log.

CLEAN

AND

REUSE

the engine.

the

.SYSTEM

If

the

zinc anodes need replacement, hold the which the zinc anode is threaded with a wrench while ening the anode with another wrench. This prevents the boss

from possibly tearing off the exchanger removing poor condition, there are probably a lot

the exchanger. Remove the end

clean the inside

exchanger end gasket

aged

·

to ber), 0-ring and cover, and install a new zinc

NOTE:

~o

msulate ing

Heat

After approximately 1000 hours and motive radiator shop should be able exchanger.)

NOTE:

that a heat exchanger cleaning be performed every

the zinc, note the condition

of

all

zinc debris. Always have a spare in

case the present one

when removing the end cover. Replace

your engine model's heat exchanger end gasket part

Th£4

threads

not

require_

the

preventing electrolysis action on

Exchanger

pressure test the engine's heat exchanger.

Operating

JOOO"hours.

of

the zinc anodes

sealant. Sealant should not

zmc from

the

metal

Service

in

silty and/or tropical waters

of

the heat exchanger

are

of

the

of

operation,

to

hex

shell.

it.

If the

of

zinc

flakes

becomes

the

gasket

anode.

pipe

threads

be

used

heat exchanger

zinc.

remove; (A

local

clean

and

test

may

more

boss

After

zinc

as

often

into

loos-

hex

is

in

within

and

heat

darn-

(refer

num-

and

it

may

hous-

clean

auto-

the

heat

require

than

AIR

INTAKE I SILENCER

DESCRIPTION

A

marine

diesel

engine

running at 1800 consume only into

AIR

The be can if be

NOTE:

continuous and inrake.

FILTER

Remove the two bolts that secure the air intake silencer

housing the filter element, inspect, clean and/or replace. Reinstall and secure the housing to the base with the two bolts.

as

much

must

the

engine

the

engine

INTAKE

replaceable

inspected

be

the

element

replaced,

black

FILTER/SILENCER

every

shaken

off

is

cany a

To

operate

volume

exhaust

CARTRIDGE

to

the base exposing the

as

6,000

cubic feet

room

be

well

must

be

unrestricted.

canister contains a paper element that should

100

operating hours.

or

cleaned

greasy or black

spare.

efficiently a diesel engine must intake a

of

smoke

with

clem·

ail: Hard stm1ing, an erratic

are

all symptoms

INSTALLATION

fPID

will typically

of

air per

ventilated, the air

Dirt

in the element'

compressed

with

dirt,

air

air,

the canister

·

of

a restricted ait

filter element. Remove

hour.

however,

Not

flow

must

idle,

NOTE:

Regular inlet filter cartridge maintenance

to

for proper engine operation. Failure filter cartridge will result

causing poor fuel combustion and resulting exhaust discharge-along with lube oil consumption possible filter dete1ioration which could result engine damage.

in

air obstruction into

maintain

in

smokey/sooty

FILTER

PNIID39705

the

in

is

essential

the

inlet

engine,

and

internal

CARTRIDGE

Engines'&

16

Gj;nerators

.

FUEL

SYSTEM

DIESEL

Use a diesel

J

AS1MD975.

FUEL

A primary fuel installed between the fuel tank and the engine water be

Most installation package contaminant's

A typical is

separator type filter

tank will ment. the impurities. maintaining

FUEL WATER

FUEL

fuel

that

meets

the requirements of

313

and

has

a cetane

WATER

and other contaminant's from the fuel before they can

carried

to

the

installers include a filter/water separator with the

in

fuel

filter/water separator

the

Raycor

Model

and

engine~mounted

affect the

fuel

FILTER

fuel

The

owner/operator

reaching

This process

a proper filtration/separation system.

SEPERATOR

rating

of

45

or higher according to

SEPARATOR

filter

of the water separating type must be

fuel

system on the engine.

as

they

are aware of the problems that

the fuel can cause.

is

illustrated below.This

500

MA.

Keep

in

mind that

is

not installed between the fuel supply

fuel system,

pump,

engine filter, and injection equip-

is

responsible for making certain

the

engine's injection equipment

is

accomplished

any

by

tff:\1

.

water in the fuel

installing

No.

to

remove

if

2-D

a water

is

free

and

SAE.

of

FUEL

FILTERS

The fuel injection pump and the fuel injectors are precisely

fuel,

manufactured and they must receive clean diesel from water and dirt.

must pass through at least two fuel filters, a

sepru:ator clean, and change these filters according schedule in this manual.

INLET

To

small this

the

and the engine's spin-on fuel

FUEL

ensure properly filtered fuel into the fuel pump, there

inlet filter

filter after the initial 50 hours

Maintenance Schedule

To

ensure this

FILTER

befQre

the inlet

flow

filter.

to

the fuel pump. Replace

of

operation, then

in

thiS

manual. ·

of

clean fuel, the

fuel

Visually

to

the maintenance

free

filter/water

inspect,

is

follow

fuel

a

~

~l

FUEL

INJECTION

The

fuel

injection pump is the most important component of

the

diesel engine,requiring the utmost caution

fuel

injection pump has been thoroughly bench-tested and the owner-operator requires injection pump service and

Speed (hertz) and timing are the only adjustments the servicing dealer can perform on the injection pump. Other types qualified injection service shop.

FUEL

Periodically pump fittings one secured operations.

When

will flow

servicing, remove it and take it

repair

it.

of

adjustments or repairs must be performed by a

LIFT

and

make

are

tight

of

the

pumps

by

the

energized

purge

air

of

fuel

as

PUMP

is

cautioned not to attempt

to

facility.

Do not attempt to disassemble

PUMP

check

the

fuel

connections

sure

that

no

leakage is present and that

and

secure. The DC ground connection at

mounting bolts should be dearcand

mounting

thru

from

the

bolt

to

the

preheat circuit, the fuel lift pump

the

fuel

system and provide continuous

engine

is

running.

to

ensure proper pump

in

handling. The

to

service

it.

If

an authorized fuel

and

out of

the

well

it

FUEL

FILTER

ASSEMBLY

ENGINE

Periodically check the fuel connections leakage. Clean the filter element with kerosene or diesel after the first 50 hours then follow the

SCHEDULE

Changing/cleaning

1.

2. Unscrew the retainer ring that holds the filter

3. Remove and replace the filter element

4. Replace the sealing

FUEL

FILTER

and

MAINTENANCE

for cleaning and replacement.

the

filter

element

Shut off

housing and allow the bowl housing,

the housing. Thread the retainer ring to cross thread. When retainer contacts tighten 1/4 - 1/2 turns run

the

fuel supply.

the engine

"0"

to

inspect for

to

ring

by

hand. Open

leaks.

come

and

reassemble the

the bowl for

away

from

and

clean

on

carefully

the

"0"

the

fuel

bowl

the

bowl

so

ring,

supply

fuel

to

bowl.

as

and

the

to

not

17

ENGINE

LUBRICATING

OIL

LUBRICATION

Oll

OIL

ENG.INE

1. Draining the Oil

the

sump while replace the hose securely.

NOTE:

is l/4NPT.

BMM

11!161NCH SOCKET

Always observe yellow/gray emulsion indicates the presence of water the

oil. prompt attention fied

water present in

exhaust system attached to the engine and/or a siphoning

raw

of the

exhaust, filling

caused location

DIAGRAM

PRESSURE

OIL

CHANGE

Sump.

Discharge the used

drain hose (attached

the

engine

is

wann. Drain the

in

its

Thread

size for

the

used oil

Although

mechanic should water

water through the raw water cooling circuit

by

or

this

condition

to

prevent serious

the

oil can be

the

the absence

lack of maintenance.

to

the front

bracket, and replace the end

the

lube

oil

drain.hose

DRAIN

as

it

is

be

present

the

engine. This problem of

an anti-siphon

of

used

oil

HOSE

is

removed.

rare,

it

does

damage.

in

the

result of a fault

valve,

OIL

SCREEN

oil

through

the engine)

completely,

cap

capped

end

A

require

Call a quali-

oil.

Raw

in

into

is

often its poor

in

the

2.

Replacing

ter, the oil to

should

NOTE:

filter

Place ter

(Oil

cooling

oil sealing gasket comes off with ber sealing gasket remains sealed against the bracket,

APPLY

WHEN

When installing the new oil gasket's sealing surface apply a on

filter filter

NOTE:

ial parts Immediately engine

there

3.

Filling

cap After checking the oil pressure. Make sure around stop

lube the

the

Oil

Filter.

When removing the

you

may

find

it helpful and cleaner

upper

and

lower portion

from

it

into

a container before removing

lessen

spillage. A small automotive

be

helpful

in

Do

not

punch

to

make

certain

some

paper towels and a plastic

when

unscrewing it to catch

or

any

other fluid

ability.

Keep

filter

as

it

is

removed

gently

remove it.

CLEAN

ENGINE

INSTALLING

thin

the

new nipple finnly

Generic

standards

might

to

make

are

no

the

on

the

refilling,

the

engine. Then check the quantity of

oil

dipstick. Fill

dipstick, should the engine require

OIL

coat

of

oil

filter.

on

the oil filter bracket, and

by

hand.

filters

or diameters

be

entirely different

after

an

sure

oil leaks around

Oil Sump. Add

top

of

the engine

run the engine

new oil filter

of

the

removing

this

it

your engine clean.) Inspect

clean engine

Screw the filter

the

hole

without first

can

be

removed.

any

on

the engine reduces

to

make sure that the

the

SPIN

ON

TURN

ON

HAND

filter

on

the bracket

are

not

recommended,

of

important

oil filter

oil

pressure

change

the

new

or

for

or

from

to,

but

not

old oil

oil

from

oil

through

over

to

old

filter

filter.

bag

oil left in

filter.

TIGHT

element,

free

to

the

onto

genuine

and

is

normal

new

oil

through

the

a few

moments

there

the

oil

the

additional

used

oil

punch a

to

drain

it.

This

wrench

hole

loosening

around the

the

filter.

the

engine's

the

rubber

If

this

filter

wipe

the

of

oil

and

rubber gasket

the

threaded

then

tighten

as

the

items

on

generic

parts.

oil

fill,

run

and

filter.

the

oil

side

oil

while

is

no

leakage

drain

system,

oil

with

high

mark

oil.

fil-

in

the

helps

the

fil-

old

rub-

filter

oil

the

mater-

the

that

filler

fill.

and

the

on

Engines & Generators

18

OIL

PRESSURE

DESCRIPTION

The

lubricating

an

oil

pump.

the

oil

pump,

the

oil

filter,

engine. continuous fied

pressure,

pump

and

within

its

OIL

PRESSURE

The

engine's

by

the

oil

normal

operation,

60

psi

(2.8

NOTE:

A

reading

an

oil

pressure readings engine

and"the

oil

The

oil

cycle.

returns

specified

pressure

and

newly

up

to

will

system

The

engine

which

cooler

then

When

the

oil

to

oil

pressure,

the

4.2

staned,

60 psi (4.2

reading

vary

depending

rpms.

is

a pressure feeding system using

oil

is

drawn from the

drives

the

oil,

under pressure, through

and

various lubricating points

returns

to

the

oil

sump

the

oil

pressure exceeds

pushes

open

the

relief valve

the

oil

sump, keeping the oil pressure

range.

during operation,

gauge

on

the

instrument panel. During

oil

pressure will range between

2

kg/cm

).

cold

engine can

kg/em').

as

low

as

hav~

A warmed engine

35

psi (2.5 kg/cm

upon the temperature

oil

sump

in

the

to

repeat the

the

speci-

in

the

oil

is

indicated·

40

an oil pressure

can

have

2

).

These

of

the

by

and

TESTING

To install a mechanical warming and

Oil

Pressure

Sender

OIL

PRESSURE

test the

oil

pressure, remove the

oil

up

the engine, set the engine speed

read the oil pressure gauge.

35.0

lb/!n'

(3.8

and

Switch

Torgue

FROM

ENGINE

BLOCK

TESTING

OiL

PRESSURE

MECHANICAL PRESSURE

OIL

GAUGE

~

oil

pressure gauge

kg/em')

or

more

9 -13

ft-lb

(1.2 • 1.8

pressure

in

it's

at

1800

m •

place.

at

rpm.

kg).

sender,

After

1800

then

rpm

OIL

MANIFOLD

Oil

PRESSURE

SEND

OR

LOW

OIL

PRESSURE

The specified safe minimum

+

a

0.1 worn

2

kglcm

).

A gradual

bearings. For additional information

loss

oil

pressure

of

oil

pressure usually

is

4.3 + 1.4 on

low

sure readings, see the ENGINE TROUBLESHOOTING

.

OIL

PRESSURE

An

oil pressure relief valve

just below

appoximately 50 psi [343

LOCATED UNDER FUEL

INJECTION

PUMP

ON

ENGINE

RELIEF

th~

injection pump. Tills valve opens

JUST

THE

BLOCK.

VALVE

is

located

kpa]

and maintains

on

the

engine

at

that

pressure.

psi

(0.3

indicates

oil

pres-

chart.

block

19

(OPTIONAL)

INSTALLATION

This popular ter

from

engine room

NOTE:

instructions on

APPLY A THIN INSTALUNG TIGHTEN CONTACTS

accessory

the engine

bulkhead.

Refer

to

ENGINE

removing

COAT

OF

ClEAN

THIS

KIT.

AN

THREAD

ADDITIONAL3/4

THE

BASE.

to a more

Oil THE

TURN

is

used

OIL

the

TO

KIT AFTER

to

relocate

convenient

CHANGE

oil

filter.

THE

O·RING

ON,

THEN

THE

O·RING

NOTE ON

THE

REMOVED

, Will

REMOTE

PN.040078

the

engine's

location

in

WHEN

HAND

THE

"IN"

AND

ADAPTER

FOR

INSTAllATION

BE

RECONNECTED

this

manual for

"OUT"

WHEN

CORRECTLY.

such

MARKINGS

THE

HOSES

Oil

FILTER

oil

fil-

as

an

ARE

SO

THEY

(OPTIONAL)

To

install,

simply

remove the engine

WESTERBEKE'S

install

this

kit

Contact

NOTE:

your

Westerbeke

incorrect

A

CAUTION:

installation

correctly. by-pass from

failure.

valve

reaching

If

immediately

remote

with

the

WESTERBEKE

is

not

It

If

the

oil

in

the

there

is

and

check

oil filter

oil

filter

responsible

of

the

is

vital

flows

niter

engine

no

oil

the

kit

facing

dealer

Remote

to

install

in

the

reverse assembly causing

pressure

hose

oil

filter

and

as

shown.

down

as

illustrated.

for

more

information.

for

engine

failure

Oil

Filter.

the

oil

lines

direction,

will

prevent

an

internal

reading,

shutdown

connections

thread

Always

due

the

engine

on

to

oil

THE

OUT

CONNECTION

MUST

ATIACH

Oil

TO

AT

FILTER.

CONNECTION REMOTE

THE

HOSE IN

THE

IN

CONNECTION

MUST

ATIACH

OIL

TO

AT

FILTER.

CONNECTION

REMOTE

THE

HOSE

OUT

APPLY A THIN TER FILTER ADOITIONAL3/4

GASKET

WHEN

CONTACTS

COAT

TURN.

OF

ClEAN

OIL

INSTALUNG.

THE

BASE,

TIGHTEN

TO

THE

AFTER

THE

IT

FIL· AN

Engines & Generators

20

DC

ELECTRICAL

SYSTEM

ALTERNATOR

The

charging with a voltage mounted

cables.

electronic internally

1114

TO

·

FUEL TO

ALTERNATOR

A

hot.

Use

this

exists detennined have

a

The

alternator

and

the or a battery to

isolate along starting the

service

tor.

Testing

system

consists

regulator,

DC

circuit

breaker

Because

VIOLET

FUEL

PUMP,

T82

of

the

voltage

regulator

or

on

the

SOLENOID.

AND

{11

back

TROUBLESHOOTING

WARNING:

Do

not

troubleshooting

with

qualified

service

the

with

battery

the

A

touch

until

the

charging

that

the

alternator

technician

charging

battery.

selector

batteries

the

service

but

not

battery's

Alternator

failed

switch

charging

of a DC belt driven alternator

an

engine DC

and a

use

of integrated circuits (IC's),

is

very

of the

alternator

the

altemator

section

circuit or

or

check

circuit charges

An isolator with a diode, a solenoid

is usually mounted

so

the

starting battery

battery.

If

the service

circuit and

wiring

battery

with

compact

alternator.

to

determine

with

voltage regulator

it.

the

battery,

and

ALTERNATOR

can

become

has

cooled

the

·alternator.

the

starting

is

alternator

the

not

with

har.ness,

a

connecting

the

is

mounted

#10

ORANGE

START

MOUNT

very

down.

if

a

problem

If it

is

faulty,

battery

in

the

circuit not discharged is

charging

problem

the

is

alterna-

MOTOR

(GROUND)

is

the

in

1. Start

2.

SOLENOID

the

After

the starting multimeter

a.

If

the

tor

is

to

"Checking

b.

If

the exists continue

MULTIMETER

TESnNG

engine.

engine

has

run

battery

voltage at the battery terminals

set

on

DC

voltage

is

increasing toward 14

working;

voltage

with

THE

omit Steps 3 through 8

the

Service Battery"

remains around 12

either the

with

Steps 3 through

STARTING BATTERY/ALTERNATOR (ENGINE

3. Tum off

4.

5. Tum

6.

RUNNING)

the

Ensure

that

connections

A

CAUTION:

charging

switch

when

If

a

battery

ensure

that

on

the

Check

the

tion,

the

reading

engine

..

Inspect all wiring

the

.battery

are

tight and clean.

To

circuit,

never

the

engine

selector switch it

is

on the correct setting.

ignition

battecy

switch, but

voltage.

should

for a few

volts.

altema,tor

terminals and

avoid

damage

shut off

is

running!

is

in the

If

the

be

12

to

minutes,

or

8.

the

do

battery

13

measure

volts,

and

on

the

volts, a problem

the

charging

and

connections.

the

engine

to

the

battery

engine

charging

not

start

is

in

volts.

using

the

go

circuit,

the

engine.

good

the

a

alterna-

directly

page.

circuit;

ground

condi-

A

CAUTION:

that

everyone

sheaves

A

DC

and

WARNING:

1nd

AC

circuits applications. isolate

DC

and

before

perfonning

made

without a proper

Before

is

clear

belts

during

When

Always

AC

converters,

are

starting

o!

testing

often

the

moving

test

procedures.

parts!

with a moltimeter:

mixed

disconnect a shore

and

DC

testing.

No

AC

knowledge

engine

Keep

together

power

shut

down

tests

of

AC

circuits.

make

away

in

marine

cord,

the

should

certain

from

engine be

21

TESnNG BATTERY/·

THE

ENGINE

STARTING

OFF)

-:GROUND

~

G

COM

+ -----MULTIMETER

7.

Now minal the tor neither between connections

check

(B+)

alternator

is

in

the

of

the

voltage

and

ground.

will

be

circuit

above

alternator

-look

between

If

the

same

the

alternator

is

true, a problem and

the

for

an

opening

DC

the

alternator output

circuit

is

good,

as

the

battery,

voltage

will

exists in the

battery.

Check

in

the

charging

MULTIMETER

ELECTRICAL

ter-

the

voltage

at

or if

an

isola-

be

zero.

If

circuit

all

the

circuit.

SYSTEM

Checking

Check have

a voltage running. charging circuit isolator,

the

Service

the voltage of

between

If

not,

there

circuit.

Troubleshoot

by

checking

battery

switch,

Battery

the

service

13

and

is a problem

the

wiring

and

the

battery.

This battery should

14

volts

when

the engine

in

the

service battery

the

service battery charging

and

connections,

battery

itself.

the

is

solenoid,

TESTING BAmRY/ALTERNATOR (ENGINE

8.

Start alternator output

The

voltage should is

over-

service

NOTE:

voltmeter

at

the

tery

voltage

If

12

wiring

12

VOLT

The engine shown

on diagrams electrical

A

CAUTION:

circuit,

.

the

engine

however.

engine's

THE

RUNNING)

the

engine

reading

be

between

or

under-charging,

facility.

Before

removing

to

ensure

EXC

tenninal if

at

volts

is

not

and

look

DC

CONTROL

has a 12

the

wiring

when

troubleshooting

system.

never

shut

is

running.

to

avoid

electrical

BATTERY

The

minimum

the

engine's

Cranking

recommended

12

volt

Amps

(CCA).

STARTING

again.

Check

and

ground.

for a properly

13.5

that

the

B output

present

for

breaks

CIRCUIT

volt

DC

diagrams

To

avoid

off

the Shut

electrical

circuit.

DC

control

,.c:::::o---1

the

voltage between

operating alternator

and

14.5

volts.

If

your alternator

have

it repaired at a

the

alternator for

12

volts

DC

at

the

EXC

and poor connections.

electrical control circuit

that

follow.

or

when

damage

engine

off

the

to battery

engine

shorts

capacity of the battery

circuit

repair,

excitation

test showed only

terminal,

Refer

servicing the

the

battery

switch

battery

when

working

is

600-

900

ENGINE

GROUND

the

reliable

use

is

present

trace

the

that

to

these

DC

charging

while

switch, on

used

Cold

a bat-

is

the

in

GROUND

A

CAUTI,ON:

do

not

use a high

perfonnlng

Battery

Review establish a systematic engine's starting

0 Monitor your

Care

the manufacturer's recommendations and

engine operation.

tests

To

avoid

voltage

on

the

maintenance

batteries

voltmeter

0 Check the electrolyte

hydrometer.

0

Use

only distilled

level.

0 Make certain

tight

to

the

0

Keep

your

A

WARNING:

causs

severe

protective

gear.

that

battery

batteries

Sulfuric

burns

water

battery

damaging

tester

alternator

and

house

for

level

to

cable

posts

(and

clean

and

acid

on

skin

,SERVICE

TESTING

BAnERY

the

alternator

(I.e. a megger)

charging

schedule

batteries.

proper

charging

and

specific

bring

electrolytes

connections

to

your engine).

free

of corrosion.

in

lead

batteries

and

damage

BATTERY

THE

SERVICE

(ENGINE

when

circuit.

then

for

your

during

gravity

with

to a proper

are

clean

can

clothing.

RUNNING)

diodes~

a

and

Wear

22

·DESCRIPTION

The

starter

is a new

ibigh-speed

~eparate

jpinion

shaft

'exposed

~moothly

trnotor

~ever

;are

internal-reduction

from

shaft. A reduction

and

a pinion

outside

without

shaft is

mechanism,

identical

MOTOR

TYPICAL

STARTER

REFER

TO

DIAGRAM

STARTER

These are basically exclusively engines

wound

DC. provided crank motors provide good engine cranking

MOTOR

on

and

starter

On

larger horsepower

with

the

engine.

used

type,

small.

starter.

the

motor

shaft;

the

gear

is

shaft.

The

pinion

the

starter

so

that

becoming

supported

switch

to

conventional

fouled

at

both

and

overrunning

ones.

MOTOR

THE

WIRING

IN

THIS

MANUAL

DC

electric

small

and

large

generators. These are direct current

motors.

reduction

on

They operate either

diesels,

gears

You

will

also

many

smaller horsepower

TROUBLESHOOTING

Prior

to

testing,

make

certain

the

and

that

the

starting

clean

and

tight.

co1111ections To

check

the

never

more

than

the

wires

and

resistai1ce. Using a multin1eter,

stud

If

you

A

Repair

on

the

start

read

12

WARNING:

procedures

Sparks

could

Pay

on

the

wiring,

10

tenninals

or

solenoid

volts,

must

cause

system

particular

engine

block

try

cranking

seconds

looking

replace

test

the

and

the starter

The

following

not

be

an

wiring

attention

at a time,

for

ailY

voltage

the

used

explosion

light-weight

The

pinion

installed

sliding

the

with

ends

motors

marine

the

to

transmit higher

find

speeds.

ships

connections

the

staiter

wmm

trouble

between

engine

is

faulty.

and pinion slides between

part

pinion

may

dust

and

on

ball

bearings.

clutch

SOLENOID

and

used

diesel propulsion

on

starting

reduction gear starter

diesels

batteries

then

to

the

run

spots

spots.

block

are

(terminals)

ground

for a few

your

that

the

(ground).

emergency

with

gasoline

and

fire.

STARTER

is

called

shaft

is

only

on

the

motor

is

not slide

grease.

The

inner

circuit

almost

or

compound

12

or 24

motors

torque

to

help

at

full

charge

wire

seconds,

hand

along

indicate

positive

tenninal

MOTOR

a

The

volts

are

to

are

starting

engi11es.

IGNITION

TERMINAL

To

test

the

ignition

is

one

of

the

circuit).

from terminal

If

circuit.

If

motor is probably faulty.

Use a screwdriver,

that

ignition

on

the

starter

the solenoid clicks

circuit,

small

terminal

the

solenoid.

cranks, the fault lies with

but

~

SOLENOID

IGNITtON

TERMINAL

If

nothing happens

current..

wiring defective.

Check

co1111ections.

A

WARNING:

fly

when

jumping

space

is

free

gasoline,

materials

and

stored

at

the

battery

it is

There

terminals.

of

potentially

that

there

nearby.

locate

the

ignition(s)

studs

and

is

wired

don't

touch

the

to

the

positive

nothing happens,

all, the solenoid is

isolation

also

will

possible

be

arching

Be

certain

switch

that

explosive

are

NO

flammable

(M)

terminal

to

the

ignition

blade, to jump

battery

c01111ection

the

ignition

the

starter

.~

not

getting

and

inspect

the

solenoid

·

and

sparks

the

engine

fumes,

especially

solvents

TERMINAL

(it

the

is

will

or

Engines & Generators

23.

STARTER

MOTOR

A

WARNING:

position

the other

iGNITION

TERMINAL

Test

screwdriver blade firmly screwdriver blade would

yourself

engine

crew

again

by

cause a short.

When safely

in

case

members

jumping

to

touch

pedorming

away

from

the

engine

starts-up.

of

the

danger.

the

tw'cflarge"Wrminal

between

the

solenoid

these the

moving

studs.

or

starter

procedures,

parts

of

Also

wain

studs.

Hold

Do

not

allow

casing,

the

this

SERVICE

Corrosion

can cause

time but not

will need to

WES'IERBEKE

serviced

center,

If

replacing

certified

USCG

dealer.

TO

1.

2.

3. Label and

4. Remove

5. Remove

to

the starter

the

sporadic

another.

be

rebuilt.

uses

or

rebuilt

the

st2rter

for

marine

standards.

REMOVE

Disconnect the negative

If

necessary,

to

the

starter

wires

allow

starter will have

obstructions,

If

FOR

remove motor.

dis90nnect

to

touch,

the

starter

the

starter

brushes

pro'blem

If

corrosion

a

standard

at

any

starter

motor,

use.

Automotive

in

doubt,

SERVICE

battery

any

components

the

wiring

tape

mounting from

the

to

be turned

arid/or

of

the

is

the

starter motor

motor

make

certain

starters do

contact

your

cable.

from

over

the

bolts.

engine.

to

a different

the

solenoid

engine

starting

problem,

automotive

terminals).

In

the

which

the

new

not

WESTERBEKE

to

ga:in

full

·

the

starter.

some

cases

angle

contacts

one

starter

can

service

motor

meet

access

(Do

not

the

to

clear

be

·

is

A

WARNING:

starting

the

If

the starter fails

If

no

solenoid.

current

screwdriver.

the

starter

sp.ips, the solenoid is faulty.

arching occurred, there is

There

should

to

spin, the

will

be

flowing

be

arching

thm

motor

is probably faulty.

no

juice reaching die

as the

the

full

blade

of

24

ENGINE

!ENGINE

SHUTDOWN/CHECK

TROUBLESHOOTING

ENGINE

LIGHT

ELECTRONIC

The

Electronic aspects programmed

ECU injection an and fault re-set

breaker

shutdown (check engine

software for proper troubleshooting.

of

is

mounted

operating

illuminate

has.

to

on

CONTROLLER

Control

the

drive

engines

and

the

programming

on

the

pump

and

controls

fault

occurs,

the

Check Engine LED.

been

investigated

re-start

the

engine.

the

control

Unit

(ECU)

monitors

operation.

can

The

not

engine block adjacent

the

injection

the

ECU

will

shutdown·the

When

and

corrected,

To

re-set

the

ECU,

panel

OFF,

then

ON.

LED

illuminated)

This and communication cable is available from manufacturer:

Woodward,

Inc./Aerospace.

CHECK

LOW

OIL

PROBLEM

PRESSURE

1.

Oil

level

2.

Lack

3.

AGround

4.

Faulty

low/oil

of

oil

pressure.

connection.

oil

pressure

PROBABLE

and

controls

unit

is

factory

be

altered. to

the

pumps

operation.

the

operating

the

ECU

must

turn

the

NOTE:

Engine

requires

ECU

the

ECU

software

ECU

ENGINE

ENGINE/LED

CAUSE

leak.

switch.

all

The

fuel

If

engine

be

DC

SHUTDOWN

IS

IllUMINATED

1.

2.

3.

4.

ELECTRONIC

PN.8404·1021

WOODARD

VERIFICATION/REMEDY

Check

oil

level,

add

oil

and

Test

oil

pressure.

inspect

oil

Check

ground

Check

sensor/replace.

If

OK,

filter,

inspect

connection.

CONTROLLER

AEROSPACE

-

repair

leak.s.

test

oil

pressure

oil

pump.

sendor,

HIGH

COOLANT

TEMPERATURE

BATIERY (HIGH

GENERATOR

Overspeed Underspeed

HIGH

(External

.

----.

Under no circumstances should the Electronic Controller be removed form the unit without consulting with tbe factory first.

VOLTAGE

DC/LOW

DC)

FREQUENCY

EXHAUST

Fault)

1.

Check

2.

Sea

water

3.

Check

4.

Faulty

5.

Ground

1.

Check

2.

Check

3.

Check

4.

faulty

battery.

1.

Check

engine

2.

Check

fuel

3.

Amperage

4.

Crank

(underspeed

5.

Generator

(underspeed

1.

Check

sea

2.

Faulty

exhaust

3.

Ground

4

•.

Sea

water

5.

Faulty

tire

system

coolant

pump.

water

pump

temperature

connection.

alternator charge battery

cycle

connection.

drive

voltage.

connections.

speed. supply. load.

with

no

fault)

Shut-down.

fault)

water

flow.

temperature

pump.

suppression

level.

drive

belt.

switch.

belt..

start.

switch.

system.

1.

Add

coolant.

2.

Inspect

3.

Adjust

belt

4.

Check

sensor/replace.

5.

Check

ground

1.

Adjust

tension/replace

2.

Check

excitation.

3.

Check + and • cables

4.

Load

test

1.

Check

speed

2.

Inspect

filters/replace

3.

Check + and -cables

4.

Check

cause

5.

Check

MPU

(Check

MPU-

1.

Inspect

thru

as

needed.

2.

Test/replace.

3.

Check

ground

.

4.

Inspect

5.

By-pass

Check

for

leaks.

impeller/pump/replace.

tension,

replace

belt.

circuit.

if

worn.

Replace/repair

from

battery.

setting.

filters.

from

for

no

start.

(voltage

cranking.

coil

resistance)

hull

fitting,

hose

circuit.

lrnpeller/reptace.

system/check

.

battery

Test

fuel

battery

and

strainer.

alternator.

to

engine.

pump

engine.

Correct

operation.

25

ENGINE

TROUBLESHOOTING

PROBLEM

Generator but

Starting looses

Engine Low

Smokey

does

not

battery

charge.

shuts

oil

pressure.

exhaust.

engine

cranks

start.

down.

1.

Faulty

preheat

2.

Faulty

fuel

3.

Fuel

supply.

4.

Fuel

filter(s)

1.

Faulty

battery.

2.

Oil

pressure

3.

DC

alternator

1.

Loss

of

oil.

2.

Oil

pressure

3.

Contaminated

1.

Blue

smoke.

2.

White

smoke.

3.

Black

smoke.

PROBABLE

circuit.

pump.

contaminated.

switch

stuck,

faults.

switch.

oil.

CAUSE

closed

contacts.

1.

Testlcheck

2.

Test

fuel

3.

Check

fuel

4.

Inspect

1.

Load

test

2.

Panel/fuel

3.

Check

alternator

1.

Locate

leak

2.

Test/replace.

3.

Change

1.

Crankcase

2.

Incorrect

1.

Engine

2.

Faulty

injector.

1.

Lack

of

2.

Incorrect

3.

Valves

need

4.

Low

compression.

VERIFICATION/REMEDY

circuit

components.

pump

operation.

ON.

all

filters.

battery.

pump

and

oil,

locate

overfilled.

grade

running

air,

check

fuel

grade.

adjustment.

activated charge

correct.

of

cold,

after

rate.

source

of

oil.

thermostat

intakeiair

shutdown.

contaminates.

stuck

filter.

open.

Engine

starts,

then

shutsdown.

(stays

running

Preheat

depresed).

Engine

has

loss

horsepower.

runs

with

of

1.

Safety

MAP

sensor

shutdown

(manifold

switch

absolute

faulty.

pressure).

1.

Check

safety

exhaust)

1.

Test/replace.

shutdown

switch

(oil,

coolant,

J?ngines & Generators

26

ENGINE

The

following troubleshooting chart describes certain problems these these

is

manual.

relating problems, problems.If

to

and

the

illuminated), refer

engine service,

the

recommendations

engine shuts

to

ECU Troubleshooting Chart

the

probable causes of

to

down

(Check

overcome

Engine/LED

in

TROUBLESHOOTING

NOTE:

The

engines electrical system is protected by a 20ampere manual reset circuit breaker. mounted on the same bracket.

this

The

preheat

solenoid

is

PROBLEM

Engine

can

Starting

battery

Engine

slows

Engine

overheats

shuts

down.

Preheat

switch

No

panel

indications

electrical

Start

switch

No

starter

not

be

stopped.

not

being.

and

stops.

and

depressed

fuel

pump.

depressed

activation.

or

1.

Faulty

DC

1.

DC

charge

2.

Alternator

1.

Fuel

starvation.

2.

Contaminated

3.

Exhaust

1.

Antifreeze

1.

Battery

switch

2.

20

Amp

3.

Emergency

4.

7.5

amp

5.

Blocking

6.

K2

Relay

1.

K1

Relay

2.

Faulty

starter

3.

Low

DC

4.

Poor/loose

PROBABLE

alternator.

circuit

faulty.

drive.

fuel.

restriction.

coolant

not

off.

breaker

tripped.

stop

switch

fuse

faulty.

diode

open.

faulty. faulty.

solenoid.

battery

charge.

battery

cable

CAUSE

circulating.

open.

connection.

1.

Remove alternator.

1.

Perform alternator

2.

Check

drive

output,

1.

Check

fuel

2.

Check

filters

3.

Check

for

build

up

1.

Loss

of

2.

Air

in

system.

Check

recovery

3.

Thermostat

1.

Check

switch.

2.

Check/re-set

3.

Check/close

4.

Check/test

5.

Test

diode.

6.

Check/test

1.

Check/test

2.

Test

solenoid.

3.

Check

battery

4.

Check

connections.

VERIFICATION/REMEDY

Exc/R

connection

DC

voltage

section

belt

tension,

excitation

supply,

for

contaminates/water.

blockage,

in

water

coolant.

Check

Expei

circuit.

stuck

20

amp

switch.

fuse. K2

Relay.

K1

Relay. charge

off

alternator.

check

of

charge

in

this

manual.

loose

voltage

present

filters,

tank

collapsed

injected

exhaust

system

air.

Add

coolant

closed.

Check/test/replace.

breaker.

state.

connections,

at

Exo/R

vent.

exhaust

elbow.

for

leak.

Repair

circuit.

hose,

as

needed.

See

DC

voltage

terminal.

carbon

TROUBLESHOOTING

If

the

gauge reading

by

the

gauge

step

is

to

check

and

the

Negative

Assuming that there instrument panel energized

1.

Disconnect gauge

reads

situation.

2. Remove

and

ground it should register situation. to

ground

(1

0 -

11

VDC)

coolant

rises.

the

5 -

7VDC

nonnal oil

when

for

the

zero,

the

wire

DC

when

pressure

is

other than what

the

instrument panel

12

volts

(B-)

terminals of the

is

12

sender

which

attached

to

the

engine. The gauge

full

scale, which

voltage

the

engine

and

will

This

DC

range

depending

and

DC between

WATER

is

nonnally indicated

is

energized,

the

ignition

TEMPERATURE

the

(B+)

gauge.

volts as required, leave

and

wire

is

the nonnal

to

perfonn

at

the gauge

the

sender

is

nonnal

the

following

and

reading

on

the

in

the

for

the

see

for

engine

panel

this

if

steps: the

this

at the oil and temperature sender

is

first

started

will

be

high

fall

as

the

oil pressure

rises

and

voltage will generally stabilize

on

what

your

engines

coolant temperature

are.

Eng!fl~~

AND

If

both

of

first

undoubtedly conductor

If

either of

probably defective and should Assuming

sender

to

the

Check that Some starters have isolated ground terminals battery

is terminals), to

the

block.

in

&

Q_e_n~rators

.

27

OIL

PRESSURE

the

above

gauge

OK

and

from

the

sender

the

above

the

gauge

sender tenninal

the

engine block

connected to

the

ground

tlie

gauge

is

OK,

the

side

problem

GAUGES

tests

are

positive, the

lies

to

the

gauge or with the

tests

are negative,

be

replaced.

check

the

at

the

gauge

is

connected to

starter (both

will

not necessarily

either

with

conductor

for

continuity.

the

and

plus

and

gauge

the

gauge

from

ground.

if

minus

be

connected

is

sender.

is

the

GLOW

PLUGS

TYPICAL

DESCRIPTION

The

glow

plugs

are When should

PREHEAT

"click"

on

is

and

INSPECTION

To

inspect the tions, head. soft

brush

oil

deposits.

bum

erosion;

then Thoroughly

plug,

unscrew or

clean

a.J'!d

cleaning solution

While

if it

has

NOTE:

WESTERBI;:KE

ments

be

below

is

provided

wired

through

pressed

the

glow

remove the electrical

unclamp

each

cleaning,

eroded

the

at

the

control

plug should

each

plug's

to

remove examine too

much,

preheat

plug

tip

ENGINE

performed

and

the

replace the plug.

to

solenoid.

panel

this

begin

terminal

from

the

threads

all

the

tip

for

by

assist

to

connec-

cylinder

carbon

wear

ADJUSTMENTS

recommends that a competent

the

mechanic.

solenoid

get

hot.

with a

and

engine

the

following

mechanic.

FUEL

INJECTORS

In

case

of injectors injection loss

of

positive

in

injector

clean

room

injector

Before

removing base

of

the

falling

down

out

easily

.the

injector

free

it,

and

The

injector washer. replaced installed.

Injector

to

engine

The

severe checked service

fuel

faults.

enviroment,

as a spare

injector

into

and

is

side-to-side

then

lift it

seats

This

washer

with a new

Cylinder

Head

adjust-

information

vibrations

and

center.

Since

should a problem

the

to

the

held

in

and

overhauled

Poor

fuel

pressure

washer

Tightening

to

fuel

injectors must

it

is

best

old

injector,

help

prevent

injector

in

by

carbon build-up or

with

the

out.

the

cylinder

should

be

when

hole.

Torque

detonation

by

an

quality,

the

injection

to

carry

occur.

clean

any If

the

aid

of

head

removed

the

new

40

noise,

have

authorized

contaminants and

be

at

the

rust

injector

the

socket

on

a copper sealino

with

± 4 fl·lb

pump

serviced

least

area

around

or

debris the

the

injector

(5.5 ± 0.5

fuel

can

one

will

like,

wrench

injector

is

the

result

in

extra

the

from

not

work

kgf-m)

a

lift to

"'and

TESTING

An

accurate

Touch

one

prod

the

other

to

glow

plug

will method You (8

can

also

to 9 amps

A

WARNING:

to

the

touch.

testing

the

Re-install plugs 25 short circuit. compound

Glow

A

than

the

should

seconds.

Plug

Tightening

WARNING:

30

seconds

on

way

to

the

body of

have a

be

used

use

an

per plug).

Be

careful

plugs

get

very

If the

plugs

When

the

threads.

Torque

test

glow

plugs

glow

plug's wire

the

glow plug,

1.0-

to

1.5-ohm

with

the plug

ammeter

These

in

reinstalling the

Do

to

glow

not

the

engine

hot

(at

the

don't heat

7 -111b·f!

not

keep a glow

plugs

to

is

with

an

connection,

as

shown.

resistance.

in

or out of the engine.

test the power

will

become

bum

your

fingers

and

test

them

terminal

up

quickly,

glow

(1.0

end)

plugs,

-1.5

plug

kg-m)

on

ohmmeter.

and

A good

This

drain

very when

again.

The

within

20

check

for

use

anti-seize

for

more

hot

to

a

REFER

FOR

TESTING

TO

YOUR

WESTERBEKE

AND

SERVICING

SERVICE

OF

FUEL

INJECTOR

MANUAL

INJECTORS.

Engines & Generators

28

VALVE

Make

1.

2. Prior

CLEARANCE

the

following

Remove

to

head

hold loosening specified

Tightening

FRONT

the

cylinder

checking

down the

bolt

torque

Torque

ENGINE

NOTE:

WESTERBEKE ments be peiformed below

is

provided

ADJUSTMENT

adjustments

valve

bolts.

and

in

the

65

when

the engine

head

cover.

clearances, re-torque the cylinder

This

is

done

by by

then

re-ti~htening

sequence

± 4

FOUR

shown

lb·ft

(88

± 5

Nm)

CYLINDER

below.

to

slightly

the

bolt

recommends

by

a competent

assist

is

cold.

to

the

ADJUSTMENTS

that

the

following engine

engine

the

mechanic.

(b)

Rotate TDC. with

the

for

cylinder #1.

(c)

Rotate engines Adjust

(d)

Rotate engines

and

repeat this procedure

adjusted.

The

the

crankshaft

The

TDC

mark

timing

mark

the

crankshaft

firing

order

the

valves

the crankshaft

firing

order

information

for

adjust-

to

on

to

at

TDC

that

to

at

TDC.

position

the

crank

the

gear

position

of its

cylinder.

position

Adjust

until

# 1 cylinder

pulley

case.

Adjust

the

all

the

cylinder

piston

should

the

cylinder

cylinders

valves

at

align

valves

in

stroke.

in

valves

the

are

3. Find top piston

(a) Remove the

tion of cylinders

by

the

TDC

dead

using

pistons

(TOP

THREE

CYLINDER

center compression position

the

procedure

glow

plugs

crankshaft manually

at

TDC (fop

DEAD

CENTER)

\

\ \

that

from

the

INJECTION

23•-

~

engine

to

Dead

21··19•

.&

~

ROTATION

follows:

position

Center.

TIMING

TDC

EARLY

for

No.1

to

ease

the

various

MARKS

MODELS

the

(4)

rota-

4.

Loosen

gauge

inserted between

adjust

the

Make

certain

~~--~~~~~~

5.

Install

Head

INJECTION

21•-

20•-1g•. 18"-17°·16"

TDC

(TOP

DEAD

the

lock

nut

for

the

adjusting

the

rocker

valve clearance

to

adjust all

by

the

~...-."\!l~;;';l111_j

the cylinder

Cover

Bolt

TIMING

Tol'que

MARKS

head

(7)

TDC

cover.

2 • 3

screw.

arm

and

turning

the

adjusting

valves.

0.25mm

(0.0098

I

INTAKE & EXHAUST

ft·lb

(0.3 • 0.45

FIRING 3

4

With

a feeler

valve

cap,

screw.

INCHES)

m·kg)

ORDER: CYLINDER: CYLINDER:

1-3·2 1·3-4-2

\

CENTER)~

29

~

ROTATION

CURRENT

MODELS

GENERATOR

USE

OF

ELECTRIC

The power required to start an electric motor is considerably more than Some motors require much more current to start them than others. under similar circumstances, than other types. They are commonly machines, started, 7

times avoided, driven induction to

start varies connected more

In

general,

to

medium

*NOTE:

nwre

for this

made

Because the heavy surge motors be seconds.

off

on

REQUIRED

Run generator's capacity, and finally loaded indicted should the voltmeter or ampmeter is not installed load,

NOTE:

contains that vide

panel.

generat01:

is

required

Split-phase

used

on

or where loads are applied after the motor

such

as

much current

whenever possible,

by

a small generator. Capacitor and repulsion-

motors require from 2 to 4 times

as

to

run.

with

the load connected

to

an

current

than

the

current

starting

MOTOR

SIZE

(HP)

1/6 1/4 1/3

1/2

3/4

1

Jn

the

for some small motors

is

that

in

larger

is

required for only an instant, the generator will not

damaged if it

If

difficulty

all

other electrical loads and,

the

electric

OPERATING

the

generator first with no load applied, then at half the on the generator's data plate. The output voltage

be checked periodically

generating plant

check

it

with a portable meter and amp probe.

When

the

AC equipment

the

generator's AC temtinal block

one

120 volt AC lwt

This

will

MOTORS

to

keep it running after it

(AC)

motors require more current

easy-starting loads, such

small power tools. Because they require 5

to

start

as

to

run, their

if

the electric motor

The current required to start

to

it.

An

electric motor

air compressor, for example, will require

a motor

loads

above

the

hardest starting types (split-phase)

sizes.

can

motor.

to

which

no

load is connected.

required

table the maximwn Amps for Starting

bring the motor up

to

start

115-

will

be

approximately

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

than

for larger

of

current needed for starting

is

experienced in starting motors, tum

if

possible, reduce the load

as

washing

as

Volt

motors as

AMPS

STARTING

(AMPERES)

6.4

9.2

10.4

14.4

20.4

ones.

to

speed in a

is

started.

use

should be

is

to

much current

any

motor

connected

follows:

FOR

to

22.4*

to

32.2*

to

72.8*

to

29.2*

to

40.8*

26

to

52

The

SPEED

to

its

full

capacity

to

ensure proper operation of

and

the appliances it supplies.

vessel

in

which the generator

of

120 volts

leg

ensure

good motor starting response

only,

for

the

vessel's distribution

to

monitor voltage and

it

be

configured

If

is

installed

is

recommended

to

start,

is

be

reason

are

few

an

AC

to

pro-

from

not

INFORMATION

to

is

as

the

GENERATOR

The generators speed can not be changed in the the standard 60 hertz operation hertz generators must be specifically ordered overseas operation only certified to operate at 1800 rpm (60Hz) in the United States. Operating this drive engine at 1500 rpm (50Hz) in the

United States may be in violation of Federal

GENERATOR

0 Maintaining reasonable cleanliness

Connections corroded, and insulation surfaces salts, dust, engine exhaust, carbon, build up. Clogged ventilation excessive heating and reduced life of windings.

0 For unusually severe conditions, thin rust-inhibiting

petroleum-base coatings, should be sprayed or brushed over all surfaces to reduce rusting and corrosion.

0 In addition to periodic cleaning, the generator should be

inspected for tightness overheated terminals and loose or damaged

0 The drive discs on single bearing generators should be

checked periodically and

for any evidence should not be allowed to become rusty because rust accelerate cracking. The bolts which fasten the drive disc to

the generator shaft must be hardened steel SAE grade

8,

identified by 6 radial marks, one at each of the 6

comers

D The rear armature bearing

maintenance is required. However, if the bearing becomes noisy or rough-sounding, have it replaced.

0 Examine bearing at periodic intervals.

of

shaft should be detected motion wear. will rub and cause major damage

Carbon

WESTERBEKE recommends mounting a carbon monoxide detector in the vessels living quarters.

even

in small amounts, is

The presence leak from the engine or generator or from the exhaust elbow/exhaust hose, entering your boat.

If carbon monoxide

air

and

correct the problem immediately!

FREQUENCY

only.

MAINTENANCE

of

terminal boards and rectifiers

of

the head.

is

detectable, inspect the bearing

Repair must be made quickly or major components

Monoxide

of

carbon monoxide indicates an exhaust

field

to

50

hertz operation.

and

for

This is because the drive engine is

Law.

is

important.

may

start conducting

etc.

are allowed

OPenings

of

all connections, evidence

if

possible for tiglltness of screws

of

incipient cracking failure. Discs

is

lubricated and sealed;

when

force

to

generator.

may cause

wires.

No

side movement

is

applied.

and

shaft for

Detector

Carbon

deadly.

or

that fumes

is

present, ventilate the area with clean

from

monoxide,

a nearby vessel are

from

50

become

if

to

of

may

no

if

side

30

This

generator

which

requires

duce

AC

output.

stator

are

responsible

erator.

The

magnetic

be

induced

into

tion.

Diodes

located

DC

and

supply

creates

an

electromagnetic windings supplied parallel

produced

main tifier. the a available produce a more

exciter

rated

to

stator The

AC

to

of

the

a

load. A step

the

AC

in

the

and

rectifier

stator

output.

work

is a four-pole;

only

the

driving

The

copper

for

the

field

produced

the

in

the

excite~

it

to

the

windings

field

main

stator,

down

output

of the

auxiliary

is,

stable

windings

in

turn,

supplied

produces a DC

windings,

An

in

optional

tandem

AC

output

enabling

brushless,

force

and

laminated

self

-exciting rotor

rotor

of

which

inducing

transformer

main

of

to a full-wave

voltage

solid-state

with

the

self-excited

of

the

engine

iron

feature

causes

an

windings

rectify

the

rotating

rotates

an

AC

:voltage

is

stator.

An

the

transformer

to

further

the

generator

voltage

transformer

BT

generator

to

pro-

in

the

of

this

AC

voltage

during

this

voltage

field.

This

through

which

connected

AC

voltage

and

bridge

excite

to

produce

regulator

GENERATOR

A

circuit

breaker

top.

This

circuit

ator

power

to

ensure

can

This

kit

in

be

circuit

for

exciter

gen-

to

rota-

to

the

is

in

is

the

rec-

to

breaker tor

NOTE:

add-on WESTERBEKE.dealer.

·

is

b~er

case

of

manually

no

power

brea.ker

earlier

installed

will

an

electrical

shut

is

coming

model

.

on

all

WESTERBEKE

automatically

overload.

off

when intO

is

available

generations;

genera-

disconnect

The

servicing

the

boat.

circuit

the

genera-

gener-

as a WESTERBEKE

contact

your

AC

TERMINAL

BOARD

AC TERMINAl

BOARD (12STUD)

BT

GENERATOR

SINGLE

PHASE

(&STUD)

COMPOUND TRANSFORMER

31

BT

GENERATOR I SINGLE

r----------, r-----------,

I c : : D i

! ;

PHASE

·i

r-------------------,

l B i

A

I I

-/!~1

1 2 : 1 2

L-----------------~

RED

RED,-

GREEN

YELLOW

~.:..

1---

I_

F....

( . I I

ul'lt:~"

~'

'.

~~B~~K~,~i--~·~:-~_'

·t

1..--YEL="L""OW,.,......--------11

~

+

-1(]-

....___

GREEN

YELI.OW

·'

_______

I

3

--

AC'

~~

_,

~

~BU~~~----+-f_.

BLACK

__

~

IA.V.R.It-----,.---=----'

PLUG

11---------_::.=---

RED

GIJEEN

BUCK

BLUE

[SIX

:

to

.....

~

""

-.

STUD]

:\

3

2

7

t

60cyc.

50

•2

1\s

Vl

c>3

"'

3

"'

eye;

o5

W2

•7

•8

w

::>

__,

"'

...

60Hz

TERMINAl

INTERNAL

A.

EXCITER STATOR WINDINGS

A - 1

and

A - 2 Exciter Stator Windings

(Selector

B.

EXCI':fER ROTOR and FIELD

1.

2.

3.

4.

C. MA1N STATOR

1.

2.

3.

in

Auxiliary Diodes

(6) Rotating Posi

Resistor

Main

Stator

Main

Stator

Main

Stator

COMP position)

Windings

Field

(A - B -

Windings

Windings Wmdings Auxiliary

Windings

WIRING

W/OPTIONAL

1&

2

C)

AVR

PLUG

BI.UEJWHITE

(TO

BI..UEIWH!TE

(TO

18TERM-

HEm'ZIVOL!S

BAA)

SCHEMATIC

VOLTAGE

RED/

WHilE

(TO

HERI'lNOIJ'S

BLACK/WHITE

(TO

BRIDGE

BAR!

RECTifiER)

{SIX

YEU.C1N

/WHITE

(TO

SE!.ECTOR

STUD)

SWITCH)

REGULATOR

D.

COMPOUND TRANSFORMER

1.

Compound Transformer Windings

2. Compound Transformer Windings

3. Compound Transformer Auxiliary

Resistance readings and

easily

for

the components

D-3

by

locating the color

shown

points

. winding resistance values

component's electrical connections.

G.

BRIDGE

A.V.R.

Optional Automatic

on

RECTIFIER

voltage

in

the exciter circuit

coded

the above schematic.

be

sure

Voltage

CIRCUIT

Windings

checks

can

be accessed

wires at

Regulator Plug

to

When

lift

the

connection

both

checking

BREAKER

A,

G,

C-3

of

the

(6

Prong).

and

32

GENERATOR

NOTE:.

WESTERBEKE

tests

and adjustments

Generator

1.

Frequency

1800 1500

2.

To

a.

b.

If

installed, do Voltage/Hertz Connection Bar. Simply reconfigure AC tenninal for the hertz change.

c.

Frequency

is a direct

rpm:::

60

rpm

=

50

change

generator

Connect following

If

lead Voltage/Hertz

there

Start no-load between throttle 60 50

an

AVR

to

is

the

hertz:.

hertz:

the

is

correspond

no

automatic voltage regulator

not

engine,

speed.

the

lever

result

hertz

hertz.

frequency

AC

output

illustrations

installed,

to

Connection

change

monitor

Adjust

throttle

arm

on

the

injection

no-load

speed, 61.5-

no-load

speed, 51.5-

of engine/ generator

follow

the

leads

to

the

AC

on

this

page.

reposition

the

diesel

and

the

hertz

selected

Bar.

wiring

on

voltage and adjust

units

by

fuel

solenoid or the

pump

..

steps

terminal

blue

on

the

62.0

52.0

or

the

(A

linkage

hertz. hertz.

VOLTAGE

recommends

be

perfonned by a

speed:

below.

block,

blue/white

VR

the

engine

ADJUSTMENT

that

the

following generator

quailified

d.

e.

technician.

After

the

no-load

voltage

may

generator

the

previous changed In

ness

60

50

Load

corresponding

Rated

60 50 The

(amps)

60

50

hertz

the

event

under hertz: hertz:

the

generator

Loaded

hertz:

loaded

hertz:

loaded

lowest acceptable voltage

hertz: hertz:

hertz adjustment

need

was

producing

hertz

setting.

it

n.eeds

the laminated steel

no-load no-load

to

the

Speed

speed, speed, 48.5- 49.0 hertz

108 -110

205

- 210 volts

to

be

readjusted: In

the

setting,

it

adjustment,

voltage, voltage,

to

the

rated

hertz speed of

58.5- 59.0 hertz

volts

correct

would

adjust

bar

121-124

232-236

amperage

at

is

no-load

be

of

the

full

made,

most

cases,

correct

the

shim

the

transformer. volts. volts.

output

generator.

rated

output

lhe

no-load

voltage

at

the

thick-

if

the

at

The

frame

·

be

moved

from

volts

50

hertz. nectlons block. 1/4

Inch accept wire

sized

mting

nectlon.

wire

is

·

green

between

and

the

115V

@ @

ground

when

115

50

changing

voHs

and

hertz

to

230

From

making

to

the

AC

use

tennlnal

studs

that

multl-strand

for

the

from

the

hot

ihe

frame

whHe

or

white

strip.

It

connects

the

neutral

generator

50Hz

wire

must

1101220

volts

con·

tennlnal

ends

for

.

wiR

copper

amperage

lead

con·

ground

with

a

stud

frame.

•I

115V50Hz

o=D

7

0

SIX

230V50Hz

·®

@

~-

TWELVE

o·

~

l1

CIRCUIT

BREAKER

STUD

AC

VOLTAGE

STUD

AC

Z30V50Hz

6

0

~

0::::::0

6

b 8

N

l1

OJ

CONNECTIONS

120V

VOLTAGE

CONNECTIONS

••I

60HZ

1201160

Hz

0 0::::::0

120/240V

120J240V/60Hz

&OHZ

L1

\J~MPERIS

REQU!RED

L2

33

GENERATOR

NOTE:

WESTERBEKE recommends that the following generator

tests

and

adjustments

VOLTAGE

be

perfonned by a quailified technician.

ADJUSTMENT

NO-LOAD

Voltage being

1.

2.

NOTE:

produced load should removed. momentary load

3.

VOLTAGE

adjustment

governed

The

selector

position. To

confirm

a

momentary

The

voltage

tary

load

is

output

from

hertz).

The

volts

at

61.5-62

The

no-load

by

the

be

The

voltage produced by the generator after

To

raise

or

lower (non-conductive under

the

steel transformer. soften

at

temperatures

small

reduction

times

be

accomplished

laminated

shims

and

steel

the

ADJUSTMENT

is

made

with

the

generator

by

the

compound

switch,

if installed, must

no-load

voltage,

(moderate)

produced

removed

the

no-load

generator once started and a momentary

applied

is

The

transformer

by

is

generators

voltage

hertz

(232-

voltage

to

excite the transfonner

removed

the

voltage,

material)

laminated

material

in

no-load

bar

to

reduce

transformer.

start

the

load

to

excite

the generator after

no-load

should be adjusted to the voltage

by

voltage.

120

volt

should

be

236

volts at 51.5-52

is

no-load voltage.

shims

are placed

bar

on

top

used for shimming

the

176° F (80°

voltage

gently tapping

core.

the

(1

gap

regulation

be

in

the

generator

the

transformer.

the

Note

leg(s)

(230

between

of varying

or

removed

of

the

compound

C)

range.

to

3 volts)

the

between

COMP

and

momen-

the

voltage

volt

121-124

hertz).

and

thickness

from

should

can·some

top

of

the

apply

50

then

this

not

A

the

·

existing

FULL-LOAD

The

voltage hertz connection

from

60Hz

the

generators·

Fine

voltage wires A to progressively

have

to

Should (210

volts-50Hz),

VOLTAGE

to

50Hz

full-load

adjustments

leads

#1,

in

that

be

made

as

full~load

A

output

TWO WIRES

ADJUSTMENT

bar

that

can

also

be

used

output.

can

be

performed

#2,

and

#3

increasing

order. A no-load

well.

fall

below

the

voltage

should

RED

6

AND

12

STUD

CONNECnON

BARS

is

used

when

to

increase

by

the

voltage

108

volts-60Hz

be

adjusted.

12

STUD

VOLTAGE

HERTZ

changing

or

decrease

repositioning

loaded

voltage

adjustment

will

NOTE:

No-load

with

the

adjustments placed on Loss

of

cause a

Shim voltage material material

voltage

compound transfonner.

to

compensate for overload conditions being

the

generator/engine (inductive-motor

generator hertz/speed, the result

drop

in

voltage output.

thickness

of

by

approximately

raises

the

lowers

no-load

0.001 no-load

may

be effected needing readjustment

Do

not

use

these

type

of

overload, will

inch

will

4 - 6

voltage.

change the

volts.

Adding

Removing

no-load

shim

loads).

NOTE:

When

the optional voltage regulator

and

if the Blue/White (Blue) lead

to

correspond

regulator will

to

produce abnormally high output voltage.

to

the

Hertz

se~e

incorrect voltage

the

is

not correctly positioned

unit

is

operating

and

cause

installed

at,

the

generator

-

34

BT

GENERATOR

SINGLE

PHASE

OPTIONAL BT 6 STUD

An

optional

is

available installed, position, pound age

output excitation former

AUTOMATIC

MODELS

solid-state voltage regulator

for

and

the

regulator

transformer regulator

In

the

to

the

provides

Installation

1.

The

regulator

the

generator's

each

15mm

tor

board.

2.

Connect the

NOTE:

one

3.

Before

the the

Load

volts procedures

4.

With move the at

51.5 -52.0 allel voltage

FULL-Load.

NOTE:

down. the

regulator

exciter

for

loaded

the

regulator

The

plug

direction.

moving NO-Load COMP

voltage

(60Hz)

the

generators

the

regulator

120-

122

with

output

Do

not

Use

the

circuit

conditions.

Check

position

as

selection switch

Hertz).

the

use

compound transformer for

to

power.

VOLTAGE

ONLY

use

with

the

BT

series

regulation switch

works

ELEC

mode, groupl exciter excitation

is

case.

long,

6-prong

board.

is

keyed

voltage

to

mounted

Use

with

lock washers

generator plug

to

engage

this

and

the

selector

produced

will

should

be

adjusted

or

224 -228

explained earlier

no

load voltage

board potentiometer

volts

at 61.5- 62.0 Hertz (230-

The regulator board

compound transformer

within

±5

the

regulator

peiform this causes

This

leaves

·

is

together

to

regulate

the

regulator

windings,

the group 2 exciter

using existing

two

(2)

the

insert

switch

by

have

to

volts

(50Hz)

in

into

the

per cent

to

force

less

REGULATOR

(board

#3441

generators.

moved

with

the

M4 , 0

to

regulator.receptacle

it

comctly.

to

the

be

adjusted.

down

this

properly

ELEC

to

set

and

from

NO-Load

the

regulator

exciter

to

the

standard

generator's

provides

and

the

windings.

tapped

7mm

mount

the

receptacle

ELEC

generator

The

between

following

manual.

adjusted,

position.

NO-Load

234

is

operating

should

NO-Load

this

junction.

circuit

When

ELEC

trans-

holes

screws,

position,

when

114 -118

maintain

voltage to

power

(AVR)

0)

com-

volt-

in

regula-

on

in

NO-

the

·

Adjust

voltage

volts

at

in

par-

to

Using

use

more

in

BT

GENERATOR

·

NOTE:

WESTERBEKE

and

adjustments

TROUBLESHOOTING

recommends

be

peiformed

LOW VOLTAGE 60-I

COMPONENT

·F

SELECTOR

8

ROTOR

82.

EXCITER

83.

ROTOR

B1.

EXCITER

A

1-1+2

CHECKS:

SWITCH

COMPONENTS

ROTOR

FIELD

WINDING

ROTOR

ExCITER

STATOR

(6 Stud Models)

DIODES WINDING(S}

NO AC VOLTAGE

MAIN

STATOR,

COMPONENT

C

1+2

MAIN

8 4

POSI

RESISTOR

8 2

DIODES

D

1.+2

COMPOUND

8 3

ROTOR

RESIDUAL

COMPONENT CHECKS:

A 1·1+2

G

D 3

C 3

F

CIRCUIT CONNECTIONS

connections

EXCITER

BRIDGE

TRANSFORMER MAIN

SELECTOR

on

ROTOR

CHECKS:

STATOR

(4-6

OPEN/SHORTED)

TRANSFORMER

FIELD

WINDING

VOLTAGE

STATOR

RECTIFIER

STATOR

SWITCH

the

Bridge

AUX.

WINDING

AUX.

WINDING

(from

Reclif~er)

that

the

qualified

VOLTS

following

technician.

AC

a,b,c.

by

a

00

WINDING(S).

OUTPUT

COMPONENTS,

WINDING

EXCITER

WINDING(S)

WINDING

the

Transformer

Aux.

CHART

generator

CIRCUIT

winding

tests

TRANSFORMER

FAULTY

to

the

Switching

A

CAUTION:

before

switching

vlcB-versa

ing

with

heavy

may

cause

the

generator.

Shore

Power

Heavy

shore

because

AC

loads

damage

motor

power

voltage

on

to

the

to

Generator

leads

should

to

generator

surges

the

vessel

exciter

circuit

Power

be

indut:ed

being

components

shut

off

power

or

by

switch·

operated

in

Engines & Generators

35

BT

GENERATOR

3

PHASE

r-

-----------.,

t I

I A

I I

1 1 1

I I I I I 10 9

I I I C I

I I I I

1

I + I I I 6 5

I I I

L-

EXCITER

STATOR

r----

1

I I 4 3

-

,...-----J

I I

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

---------.1

..

red~

Ia

green

...

yellow

'-

7Hertz

-I--

TWELVE

I

- - - - - -

ROTORFIELD

I

INTERNAL

WIRE

6.3AFUSE

RECONNECTABLE

--

- ,

12-----1------+----·11

I

a---+----~----0

..

WIRING

2--_:_.....L-----+----1

r------,

DsrATOR

RED

l

7

GREEN

::

I

.

,.

Volt

~

....

BT

GENERATOR

THREE

PHASE

RED

AUX.

FULL-LOAD

EXCITER

FULL-LOAD

AC

VOLTAGE

189-190

DC

VOLTAGE

15-16

NO-LOAD

8.5-9.0

183-184

Engines; & t}enerators

36

/

GENERATOR

AC

VOLTAGE

BE

THREE

CONNECTIONS

PHASE

VOLTAGE THREE

.

The (0 shown figuration between connection

NOTE:

a jumper

PHASE

regulator

to

6)

and

connection

Either

of

on

REGULATORS

CONNECTIONS

is

their

the

#1

#2

Series

the

170·

--.,

__

and

equipped

and

regulator

J60

with

brass

points

and

The

#2

on

#0

on

the

voltage

configuration

board

270

v

Hz

seven

jumpers.

jumpers

sensing

the

numbered

for

AC

terminal

regulator

requires

between

The

illustrations

the 3 phase

leads

connect

block

board.

the

installation

terminal

terminals

con-

and

Band 0.

of

l·N

AC

TERMINAL

THREE

-120

VAC

-110

VAC

CONNECTIONS

PHASE

10 10

12

60Hz 50

Hz

WIRE

PARAUEL

l·ll·l-190

WYE

208

LI

L2

N

(STAR)

VAC VAC

10

30

60Hz 50

Hz

l-L-

l·N-

480

277

VAC VAG

30 10

60Hz 60

Hz

SERIES

WYE

l·ll·N-

(STAR)

400

VAC

230

VAC

30

10

50

Hz

Engines & Generators

37

~-

I

~

I.

~

t

l

S2

St

T N J

Shom

Powar

SHORE

POWER

.

.:..til

.

r;·

' I

....

__

./

I[;

--:'

G!t1UJ1d

NOTE:

wire,

, .

Diag;am

syS1em

hot

CONNECTIONS

SHORE

--~

I

,~~~}Ship's~ad

shows

connectlo~

120-volt

system.

usa

dotted

leg.

POWER

.

\1•

tort~

For

three-wire

lines

for

the

other

(60

HERTZ)

TRANSFER

Ship-to.

Shora

PN (40Amps/P.ole)

"PN

(SO

PN

{125 Amps/ Pole) PN32133

{200

Switch

32008

32009 Amps/

Pole)

32010

Amps/Poie).

SWITCH

GENERATOR

~

N

(3

Pole)

1

~

SHORE

POWER

230

VOLT/50

L1

.

_NOTE:

wfra.

""

with

~

GENERATORiSHORE

""'

Ill

'::' SHORE

GROUND

HZ

TWO

Diagram

shows

120-Volt

throe-wlre.120·V~It

SWITCH

WIRE

connections

system

from

the

genetato~~

boat

system.

SHIP'S

LOAD

-=-

SHIP'S

GROUND

.

CONFIGURATION

for a ;wo•

If

the

installer

cuit,

this

must

Switch.

OFF

of

Set

position.

shore

power

A

CAUTION:

utility

shore

at

the

same covered bility

to

120

VOLT/60HZ

Notice

the

terminal

block

Generat~r

~

'

-"'

connects be

the

transfer

'Ibis

to

power time.

under

make

repositioning

to

shore

done

by

means

switch

prevents

generator

Damage

the

sure

THREE

the

NOTE:

wire, 120-VoU system from the generator.

wJth

output

to

and

generator

This

type

warranty;

all

AC.

connectlons·are.correct •..

WIRE

of

the

generator

Olagnm

shows connections

three-wlrt~,

120-Volt

power

to

the

vessel's

AC

of

the

Shore

Power

shown

in

the

diagrams

simultaneous

the

generator

output

of

generator

it

is

the

installer's

connection

can

result

are

connected

damage

responsi·

CONFIGURATION

white

wire

ground

load

case.

.

for

a two

..

boat

system.

cir-

Transfer

to

the

if

is

not

on

the

SWitching

A

before

vice-versa

with

cause

Shore

CAUTION:

switching

because

heavy

AC

damage

generator.

Power

Heavy

shore

loads

to

the

motor

power

volta{le

on

tfie.

exciter

· ·

to

Generator

loads

should

to

generator

surges

induced

vessel

being

circuit

Power

be

shut

power

by

switching

operated

components

off

or

may

in

the

~

WESTERBEKE

Engines & Generators

38

LAY-UP

&

RECOMMISSIONING

GENERAL

Many

owners

rely

on including engines off-season to

accomplish

The

procedures

own

lay-up

check list if others These procedures

during a lay-up and maintenance

If

you

have

your

local

provide assistance.

Propeller

The transmission

be

opened out of the water or storage

in severe strain the

boat

is

shaft

has

actually

apply

to

small

not

in

use,

period of time.

Fresh

Water

A

50-50

solution of

recommended for

This solution

antifreeze, depending solution

Should amount

mixture. and cooling

to

more

from

Operate

mixture

system.

Lubrication

With

the

engine

sump.

Remove

with

new

ENGINE

oil

changing

oil pressure and

A

CAUTION:

in

the

sump

combustion

chemicals

internal

and

or

for

long

lay-up

which

and

recommissioning,

do

should

needs

any

questions

servicing

Shaft

and

up

and

the

the cradle.

on

the propeller shaft or

taken

out or put

been

boats

unless

they

Cooling

use

may

require

make

sure

antifreeze

the

engine

the

of the

antifreeze

Now

System

warm,

and

oil.

Use

the

LUBRICATING

procedure.

make

over deposits

which

parts.

their

boatyards

generators,

periods

preparation

follow

the

procedures.

afford

also

help

of

your

dealer;

Coupling

propeller half bolts

moved

The

bent

that

are

have

antifreeze

in

the

on

the

be

block

engine

recheck

drain

replace

correct

Run

sure

Do

not

the

lay-up

combine

can

reduce

for

of

inactivity.

themselves.

will

allow or

your

familiarize

engine.

regarding

he

will

be

[Propulsion

couplings

removed

from

land

flexibility

in

the

water.

by

these

hauled out of

been

dry

Circuit

a higher concentration of

antifreeze protection

needed,

OIL

leave

[Propulsion

and

distilled water

coolant system

area's

winter

drain

and add a more

to

ensure a complete

concentration

the

antifreeze

all

the

oil

filter

grade

pages

the engine

there

are

the

period.

to

the

to

prepare

their

lay-up

during

Others

prefer

you

to

perlorm

you

may

use

them

engine

protection

you

with

the

lay-up

procedures,

more

than

willing

Engine]

should

when

the

boat

to

water,

and

during

of

the

boat

often

coupling

strains.

for a considerable

In

some

This

the

or

both,

cases,

does

water

Engine]

is

at

all

times.

climate.

is

adequate.

an

appropriate

concentrated

circulation

throughout

solution's

engine

oil

from

and

fill

the

of

oil.

Refer

to

in

this

manual

and

check

no

leaks.

engine's

produce life

old

engine

Lubricating

harmful

of

your

engine's

craft,

the

call

always

is

hauled

puts

while the

not

when

Check

the

strength.

the

sump

the

for

proper

oil

and

your as

a

to

a

the

oil

the

oil

Fuel

System

Top

off

or

higher. A fuel stabilizer should gasoline/water separator and

make

fuel.

Fuel

System

Top

off

such

as

added

at

Care

should

with

the

tem.

Change separator, sediment

Change fuel

system, for

5 -

system. the

fuel needed. allow

movement

equipment

Raw

Water

Close

the

hose

from gallon check

the

engine

any

zinc

anode

Start

the

fresh

water

stop

the

solution protection

Start

the through the

engine.

water circuit

as

providing corrosion

Remove antifreeze Examine a cover until recommissioning, but replace

Intake

Place a opening shove recommissioning, you

may

note

to

exhaust

[Gasoline]

your

fuel

conditioner

certain

[Diesel]

your

fuel

BioBor

and

this

time

be

taken

primary

the

if

the

fuel

bowl.

the

fuel

filter

as

needed.

10

minutes

Check

for

system

during

Operating

on

the

Cooling

through-hull

the

seacock.

bucket of

zinc

anode

and

clean or

debris

from

is

located.

engine

through

engine

and

slightly

in

your

engine

the

raw

This

from

the

impeller

mixture

the

impeller.

gasket.

Manifold

clean

cloth, lightly

of

the

intake

the

cloth out of

need

assistance of

remove

port

can

tanks

with

be

added.

there

are

tanks

with

Diesel

to

control

that

fuel

filter/water

element

system

elements

to

make

any

leaks this

the

engine

of

the

engine.

seacock.

clean

fresh

found

inside

Clean

and

allow

the

refill

stronger

area.

and

allow

water

system.

antifreeze

freezing

from

will

Acquire

Do

not

and

manifold

sight.

and

the

cloth

be

blocked

unleaded

such

Change

and

clean

no

leaks.

No.2 diesel

Kleen + Cetane

algae

the

additives

in

your has

Start

the

sure

that

servicing, correcting

for

treated

Circuit

Place

the

water.

in

replace

the

system.

the

bucket

than

all

of

mixture

during

protection.

your

accompany replace

Thru-Hull

soaked

(If it

an

attempt

the

prior

in

gasoline

as

Sta-Bil

gasoline

the

element

the

metal

bowl.

Clean

up

any

fuel.

Boost

and

condition

used

are separator primary

one,

on

the engine and engine no

may

5 -

fuel

Remove

end

the primary heat

it

as

heat exchanger

raw

When the bucket

needed

this

Once

raw

a replacement, if the impeller

used

fuel

and

clean

and

allow

air

is

left

in

have been

10

minutes

through

Before starting

water

the

of

this

required,

water

pump

with

an

for

winter

mixture

the

bucket

should

winter

water

it,

so

catch

the

cover

the

raw

hose

strainer.

antifreeze

protect

pump

(into

Exhaust

in

lubricating

to

block

the

opening.

is

not

visible

is

made

to

servicing

to

start-up.

the

same

dealer.

The

manner.

of

89

octane

in

your

Re-install

spilled

Fuel

additives

should

the

fuel.

compatible

in

the

sys-

filter/water

the

separator

bleed

it

to

the

fuel

created

them

as

will

help

injection

water

into a five

the

engine,

exchanger

and

also

where

the

to

draw

is

empty,

freeze

to

be

drawn

is

empty,

the

raw

lay-up,

as

(some

it

in a bucket).

needed,

the

pump)

and

gasket.

oil,

in

Do

at

start

the

engine,

Make

thru-hull

be

the

run

in

intake

on

clean

the

stop

well

and

the

not

a

Engines & Generators

39

LAY·UP & RECOMMISSIONING

Starter

Lubrication

if

battery

the connections

Cylinder

If

WESTERBEKE

access the cylinder

revolutions

If

to be the

Intake

Clean cloth block through-hull exhaust to

Cylinder

After

small

crankshaft manually

spark

NOTE:

the

tighten each

Motor.

and

access

to

the

connections

starter.

Take

Lubrication

you

anticipate a long

to

the cylinders.

and

your

engine

removed.

injectors

Manifold

the

filter screen in

lightly

any

opening.

start-up!

Lubrication

engine amount

plugs

At

spn'ng

cranksJu:ift

properly

spark

plug.

cleaning

starter pennits its

are

shut

care

in

properly

removed

walls.

and

from

recommends

Rotate

re-install

does

not

Be

sure

return

lay-up Squirt

have to

fuel

[Gasoline]

soaked in

shutdown,

of

loosely for

lube

Also

port,

remove

fogging

two

winter

commissioning,

two

full

revolutions.

and

connect

of

[Diesel]

the

place

[Gasoline]

oil complete

Batteries

If

batteries make to

prevent them from batteries subjected batteries environment

A

hlgh/y·explosive arcing smolce serviced.

to

Transmission

Check off the coupling coating. Check additional information, refer

are

to be left

sure

that

they

will

not

to

severe environmental

and

store them in a

WARNING:

llt

a

lighted

or

allow Shut

prevent

grime

electrical

or

change the

and

grease

that the

on

are

fully

freezing.

remain

fully

Lead

acid

gas,

which

cigarette,

an

open

off all

electrical

arcing

[Propulsion

fluid and

the output

transmission

the

starter

drive

easy

removal.

off before

replacing

the

starter.

period

{12

removal

some

Marvel

the

engine crankshaft

glow

plugs.

glow

plugs,

have

replacement sealing

line

as

needed.

flame

arrester,

oil

around

the

an

oil-soaked

Make a note

the

spark

into

each

cylinder.

revolutions.

lay-up

remove

Re-install

the

high

board

during

charged,

If

there

charged,

conditions,

warmer,

more

batteries

can

be

cigar,

flame

near

equipment

during

Engine]

in

the

transmission

touch

up

any

flange

with

vent

to

the

TRANSMISSION

pinion

Make

attempting

any

electrical

months_9r

of

the

glow

Mystery

by

the

injectors

and

place a

flame

arrester

cloth in

to

remove

plugs

and Rotate Re-install

the

plugs

the

tension

leads

the

lay-up

and

will

remain

is

any

doubt that

or

that

they

remove

compatible

emit

hydrogen,

ignited

by

or

pipe;

D.o

the

battery

in

servicing.

as

unpainted

an

anti-corrosion

is

open.

is

advisable,

sure

to

remove

more)

plugs

for

Oill

into

hand

two

will

washers

clean

to

the

cloths prior

spray

the

and

rotate

spark

plugs,

fully

onto

period,

that

the

will

be

the

a

electrical

n.o,.

being

the

vicinity

required

areas.

Protect

For

SECTION.

the

have

for

a

way,

Wipe

Spare

Parts

Lay-up

time

provides a good Westerbeke or coolant

kit

and

during

SPARE

engine

hoses

order

the

lay-up,

PARTS

need

items

section

to not

such

Recommissioning

· The

recomiirissioning

lay-up

seasonal

described

those section

regarding However, counteracted

1.

Remove

2.

Remove discard

remov-ed

Install

3.

Reinstall lay-up, terminals Check

A

CAUTION:

and

eye batteries can

be

cigarette, flame electrical arcing

4.

Remove

proper

5.

Check circuit that solution engine

short advisable, service, heat area.

6.

Start

in

manual.

generally in

the

preparation

some

of

the

before

starting

the

oil-soaked

t;he

raw

the

old

gasket.

during

lay-up

the

raw

water

the

batteries that

and

reconnect

are

clean

to

make

sure

Wear

protection

emit

hydrogen, a highly

ignited

by

electrical

cigar,

or

near

the

battery

equipment

during

servicing.

the

spark

tightness the

condition

and

clean

it

is

not

necessary

from

the

is

put

into

period

of

time

as

either

to

inspect

exchanger

the

PREPARATIONS

and

engine

opportunity

see if external

replacement.

on

hand,

as

filters

of

this

of

your

follows

PREPARATIONS

lay-up

cloths

water

pump

Install

(or a replacement,

pump

the

and

that the connections

that

rubber

when

items

Check

or

replace

and

manual.

Westerbeke

the

for

starting

procedures

the

engine.

from

cover the

cover

were

removed

battery cables,

the

batteries

gloves, a rubber

servicing

arcing

pipe.

Do

not

smoke

being

serviced.

in

the

vicinity

plugs,

wipe

clean,

[gasoline].

of

the

zinc

or

replace the anode

to

flush

the

raw

water coolant

operation,

an

the

clear

in

accordance

with

end

area

the system

no

adverse

of

where

any

FOR

season and

with

STARTING

to

inspect your such your

basic spares

those

zinc

anodes.

engine

same

procedures

FOR

"STARTING

and

normal

will

need

the

intake

and

gasket

raw

water

pump

if

with a

new

during

making

are

fully

batteries.

explosive

gas,

or a lighted

or

allow

Shut

to

prevent

re-gap,

anode

in

the

as

needed.

antifreeze/fresh

system.

will affects. or

recommissioning

the

zinc

is·located

all

zinc

debris

procedures

section

as

drive

items

used

Refer

after

a

as

starts.

to

be

manifold.

and

impeller

required).

cover

gasket.

the

sure

are

tight.

charged.

apron,

Lead

acid

which

an

open

off

all

electrical

and

install to

raw

water

Note

water When self-flush

It

is

from

described

of

belts

to

the

in

this

in

the

that

a

Engines & Generators

40

SPECIFICATIONS

Engine

Type

Displacement Aspiration Combustion Bore & Stroke Firing Direction Compression Weight

Inclination

Engine Requirements @ 60Hz 1800

Compression Minimum

Spilled Valve Engine Injector Valve

Valve (engine

Chamber

Order

of

Rotation

Ratio

Combustion

rpm

Pressure

Timing

(Static}

Seat

Angle

Timing

Pressure

Seat

Angle

Clearance

cold)

Air

TUNE-UP

11.5

GENERAl

Diesel,

four-cycle,

cooled,

vertical

mechanism.

80.4

cubic Naturally Swirl

type.

3.07 x 3.62 1-3-2 Clockwise, 22:1

8.0

EGTD

10.0

EGTD

11.0

EGTD

11.5

EGTD Continuous

Temporary 41

cfm

(1.16

SPECIFICATIONS

427

psi

(30

384

psi

(27

17°

(spill) 45° 17"

BTDC

1991 + 71 Intake

45°

Exhaust

30°

0.25mm

three-cylinder,

in-line

inches

(1.3181iter)

aspirated.

inches

when

viewed

467 5131bs 513 513

15°

25°

(not

cmm)

kg/em') kg/em')

-0

psi

(140

(0.0098in)

overhead

(78 x 92

from

lbs

(211.8

(232.7

lbs

(232.7

lbs

(232.7

to

exceed

at

280

+5-0

EGTD,

fresh

valve

mm)

the

front

kilosl kilos kilos}

kilos}

30

min.)

rpm

kgf/cm').

water-

11.0

EGTD,

General Fuel

Fuel

Injection

Pump Nozzle Fuel

Filter

Air

cleaner

Fuel

Uft

Pump

Starting

Battery

Capacity

Battery DC

Charging

Alternator

Starting

Aid

Starter

General

Operating Fresh Raw

Raw at (Measured discharging exhaust

System (Fresh

Water

1800

Water)

Temperature

Pump

Row

rpm.

before

into

elbow).

Capacity

10.0

EGTD;

FUEl

Open No.

SAE ASTM

In-line Throttle Cartridge Replaceable 12

ElECTRICAl

12 400 -600 51 Glow 12

COOLING

Fresh controlled

170°-190° F (77°Centrifugal Positive

belt-driven.

7-8

5.0

8.0

SYSTEM

flow,

self

2-D

(Cetane

J313.

Grade

0975. plunger

type.

Type

paper

volt

DC

lift

Volt,

(-)

negative

Cold

Amp

rated,

plugs,

sheathed

Volt,

reduction

SYSTEM

water-cooled

with

type,

displacement,

gpm

(25.9-

US

qts

(4.71iters)

EGTD

priming.

rating

of

45

of

diesel

fuel

type

(BOSCH).

fHter

cartridge.

capacity

of

5'

SYSTEM

ground

Gran

king

Amps

belt-driven

type

gear

block,

exchanger.

88°

metal

impeller, rubber

29.6

gpm).

thermostatically·

C)

.•

heat

or

higher).

according

(1.5

mm)

(CCA)

belt-driven.

impeller,

to

solid

state

...

General Oil

Filter

Sump

Capacity

(not

including

Operating (engine

hot)

Oil

Grade

filter)

Oil

Pressure

lUBRICATION

Pressure Full

flow,

3.9

U.S.

50-

API

Specification

SAE 1 OW-40

60

fed

paper

qts

psi

SYSTEM

system.

(3.7

(3.5-

or

element,

liters)

4.2

kg/em')

CF.

CG-4,

15W-40.

spin-on

Cl-4

type.

or

CJ-4

Engines

& Generators

41

SPECIFICATIONS

AC

GENERATOR

Single

Phase

Voltage

regulation:

Voltage Frequency Rating

60

8.0KW

50

6.0KW

Generator Air

{60

Engine

Engine Cooling

Generator Ambient

Recommendations

regulation:

(Volts

Hertz

AC)

(1800

rpm)

(1500

rpm)

Cooling

Requirements

Hertz)

at

1800

Combustion Compartments

Air

Compartment

Temperature

rpm

(Single

Brushless, Pre-lubricated, Reconnectable, regulation regulation).

120 230

±

.5

120 120/240

230

175 • 200 NOTE:

Hertz

42 100-200

122"F NOTE:

provided compartment

or

120/240

Volts -50

5%

no

Hertz

(.6%)

Volts

Increase

operation

cfm

(1.19

(50"C)

Forced

four-pole,

(optional

load

Volts

cfm

to

maintain

8.0

Phase)

revolving

single

bearing

single

phase

solid-state

Volts -60

Hertz

to

full

load.

no

load

to

66

Amps

66/33

Amps

27

Amps

(4.95-5.66

air

supply

(1500

rpm)

cmm)

(2.83-5.66

maximum

ventilation

temperature

should

generator

EGTD

field.

design.

transformer

voltage

Hertz

full

load.

cmm)

15%

for

50

cmm)

be

below122'F

(50"C)

AC

GENERATOR

Single

Phase

Voltage

regulation: Frequency Rating

60

10.0 50

7.5KW

Generator Air (60

Engine Air

Engine

Cooling Generator

Ambient Recommendations

regulation:

(Volts

AC)

Hertz

(1800

KW

Hertz

Requirements

Hertz)

Requirements

rpm)

{1500

rpm)

Cooling

at

1800

Combustion

Compartments

Air

Compartment

Temperature

rpm

(Single

Brushless, Pre-lubricated, Reconnectable, regulation regulation).

120 230

±

.5

120 1201240

230Volts

225 -250

NOTE:

operation

42

100 -200

122•F

NOTE:

to temperature

(optional

or

1201240

Volts -50

5%

no

load

Hertz

(.6%)

Volts

elm

Increase

{1500

elm

(1.19

cfm

(50"C)

Forced

maintain

four-pole,

single

Hertz

to

no

(5.66-6.37

air

cmm)

(2.83-5.66

maximum

ventilation

generator

below122'F

SPECIFICATIONS

Phase)

revolving

bearing

phase

solid-state

Volts-

60

full

load.

load

to

83.3

Amps

83.3/41.6

34.1

Amps

supply

rpm)

compartment

field.

design.

transformer

voltage

Hertz

full

load.

Amps

cmm)

15%

for

cmm)

shOuld

be

(50-G)

50

Hertz

provided

General

10.0

7.5

Voltage

(60

Voltage-3 Phase (50

Amperage (60

Amperage (50

Generator Air (60

Engine Air

Engine Cooling

Generator Ambient Recommendations

10.0

EGTD

AC

-3

Phase

KW • 60

Hertz

KW -50

Hertz

-3

Phase

Hertz)

• 3

Phase

Hertz)

-3

Phase

Hertz)

Cooling

Requirements

Hertz)

at

1800

Combustion

Requirements

Compartments

Air

Compartment

Temperature

GENERATOR

Brushless lubricated reconnectable voltage

Delta.

with

protection

Low

voltage

High

voltage

DELTA High

voltage

DELTA Low

voltage

High

voltage

DELTA

High

voltage

DELTA

225-

250

rpm

NOTE:

Increase

operation

42

cfm

(1.19

100 • 200

122"F

(50•C)

NOTE:

Forced

to

maintain

temperature

(3

Phase)

six

pole,

single

bearing

for

low

Solid

circuitry.

WYE

cfm

(5.66 • 6.37

air

(1500

rpm)

cmm)

elm

(2.83-5.66

maximum

ventilation

generator

below122'F

revolving

field.

design.

voltage

WYE,

State

voltage

208vo!ts 480volts 240volts

380 230vo!ts

35Amps

15

30Amps 14

24

cmm)

supply

15%

cmm)

should

compartment

(50"C)

Sealed

12

Lead high

regulator

volts

Amps

Amps Amps

for

50

Hertz

be

provided

I~IWE!O#fiBEKE

l

Engtnss & Generators

42

AC

GENERATOR

Single

Phase

Voltage

regulation: Frequency Rating

60

11.0 50

8.8KW Generator

Air (60

Generator Ambient Recommendations

regulation:

(Volts

AC)

Hertz

(1800

KW

Hertz

Requirements

Hertz)

rpm)

(1500

rpm)

Cooling

at

1800

Compartment

Temperature

rpm

(Single

Brushless. Pre-lubricated, Reconnectable, regulation

regulation). 120

230

±

.5

120 120/240

230

225 -250

NOTE:

operation

122"f

NOTE:

to temperature

or

120/240

Volts -50

5%

no

Hertz

(.60%)

Volts

Increase

(50"C)

Forced

maintain

four-pole,

single

(optional

Hertz

load

to

cfm

(5.66-6.37

(1500

maximum

ventilation

generator

below122'F

SPECIFICATIONS

Phase)

revolving

bearing

single

phase

solid-state

Volts

-

60

full

load.

no

load

91.7

Amps

91.7/45.8

38.3Amps

air

supply

rpm)

compartment

design.

transformer

Hertz

to

full

load.

Amps

cmm)

15%

should

(50"C).

field.

voltage

for

50

be

provided

Hertz

General

11.0

8.8

Voltage (60

Voltage (50

Amperage

(60

Amperage

(50

Generator

Air (60

Generator Ambient Recommendations

11.0

KW

Hertz).

Hertz)

Requirements

Hertz)

-3

Phase

KW-

60

Hertz

-50

Hertz

- 3

Phase

-3

Phase

- 3

• 3

Cooling at

1800

Compartment

Temperature

EGTD

Phase

AC

GENERATOR

Brushless lubricated reconnectable voltage with

protection

low

voltage

High

voltage

DELTA High

voltage

DELTA Low

voltage

High

voltage

DELTA High

voltage

DELTA 225 -250

rpm

NOTE:

operation

122"f~50"C)

NOTE:

to

maintain

temperature

(3

six

pole,

single

for

Delta.

Solid

WYE

cfm

(5.66-

Increase

(1500

maximum

Forced

ventilation

generator

below122'F

Phase)

revolving

bearing

low

voltage

State

circuitry.

.

6.37

air

supply

rpm)

compartment

field.

design.

WYE,

voltage

208volts 480 240

400 230volts

37 16'Amps 33Amps

15Amps 27

cmm)

15%

should

(50"C).

Sealed

12

Lead high

regulator

volts volts

volts

Amps

for

50

Hertz

be

provided

AC

GENERATOR

Single

Phase

Voltage

regulation: Frequency Rating

60

11.5KW 50

9.2KW

Generator

Air (

Generator Ambient Recommendations

regulation:

(Volts

Hertz

(1800

Hertz

(1500

Cooling

Requirements

60

Hertz)

at

Compartment

Temperature

AC)

rpm)

1800

rpm

(Single

Brushless, Pre-lubricated, Reconnectable, regulation regulation).

120 230

±

.5

120 120/240

230

225 -250

NOTE:

operation

12~F

NOTE:

to

temperature

(optional

or

120/240

Volts · 50

5%

no

load

Hertz

(.6%)

Volts

cfm

Increase

(1500

(5Q•C)

Forced

maintain

four-pole,

single

Hertz

to

no

(5.66-

air

maximum

ventilation

generator

below

SPECIFICATIONS

Phase)

revolving

bearing

phase

solid-state

Volts-

60

full

load.

load

to

full

95.8Amps

95.8/47.0 40Amps

6.37

supply

rpm)

should

compartment

122•f

field.

design.

transformer

voltage

Hertz

load.

Amps

cmm)

15%

for

be

(50•C)

50

Hertz

provided

General

11.5

9.2

Voltage (60

Voltage

(50

Amperage

(60

Amperage

(50

Generator Air

(60

Generator Ambient

Recommendations

L

11.5

EGTD

-3

Phase

KW-

60

Hertz

KW -50

Hertz

-3

Phase

Hertz)

- 3

Phase

Hertz)

-3

Phase

Hertz)

• 3

Phase

Hertz)

Cooling

Requirements

Hertz)

at

1800

Compartment

Temperature

AC

GENERATOR

Brushless lubricated reconnectable voltage with

protection

low

voltage

High

voltage

DELTA High

voltage

DELTA Low

voltage

High

voltage

DELTA High

voltage

DELTA 225 • 250

rpm

NOTE:

operation

122•F

(50"C)

NOTE:

to

maintain

temperature

----------

(3

Phase)

six

pole,

single

bearing

for

low

Delta.

Solid

circuitry.

WYE

cfm

(5.66 • 6.37

Increase

air

supply

(1500

rpm)

maximum

Forced

ventilation

generator

below122'F

revolving

field.

design.

voltage

WYE,

State

voltage

208 480vofis 240volts

380 230

43Amps 17 37

17 30

cmm)

15%

for

should

compartment

(50"C)

Sealed

12lead

high

regulator

volts

volts volts

Amps Amps

50

Hertz

be

provided

IW'IWESIERBEKL

( Engln98

It

Generators ·

43

SPECIFICATIONS

12.5

EGTD

AND

15

EGTD

Engine

Type

Displacement Aspiration Combustion Bore & Stroke Firing Direction Compression Dimensions-

Engine

Weight Fuel

HP@

HP@1500

Compression Minimum

Spilled Valve

Engine

Valve Injector Engine

Starting Battery DC

Starting Starter Cold

Amp

Chamber

Order

of

Rotation

Only

(dry)

Consumption

1800

RPM PRM

liming

Seat

Angle

Speed

Clearance

Pressure

liming

Battery

Capacity

Charging

Aid

Cranking Draw

Diesel, cooled, mechanism.

107.3 Naturally

Swirl

3.07 x 3.62

1 -

ClockWise,

(mm)

22:1

Height: Width: Length:

569

1.42

25

21

Ratio inches

TUNE-UP

Pressure

(Static)

427 384

17"

Intake Exhaust

1800 1500

0.25 1991 + 71

1r

ELECTRICAL

12 400-600

Alternator

51 Glow 12

175 -200

(approximate)

GENERAL

four-cycle,

cubic

type.

3" 4 -2

24.0

19.0

lbs

g/hr HP HP

four-cylinder,

vertical

in-line

inches

aspirated.

inches

(78 x 92

when

viewed

inches

(5.38

(482.6

ltr/hr)

34.6 (258.1 0 kgs)

overhead

(1.758

from

(609.6

(878.8

at

1800

fresh valve

liter)

mm)

the

mm)

rpm

SPECIFICATIONS

psi

(30

kg/em')

at

280

mm)

(140

rpm

+5-0

kgl/cm').

psi

(27

(spill)

45°

30°

rpm

inches

BTDC

kg/em')

(60

Hz)

(50

Hz)

(0.0098

-0

psi

SYSTEM

Volt(-)

negative

ground

Cold

Cranking

Amps

(CCA)

Amp

rated,

belt-driven

plugs,

sheathed

type

Volt,

reduction

gear

amps

front.

·

water-

General

Fuel

Injection

Pump Nozzle Fuel

Riter

Air

cleaner

Fuel

Utt

Pump

General

Operating

Temperature

Fresh

Water

Pump

Raw

Water

Pump

System

Capacity

(Fresh

Water)

Raw

Water

1800

rpm.

elbow).

Combustion

rpm

Flow

before

into

Air

at

(Measured

discharging exhaust

Engine Requirements @ 60Hz 1800

LUBRICATION

General Oil

Filter

Sump

Capacity

(not

including

filter)

Operating

Oil

(engine Oil

Pressure

hot)

Grade

FUEL

SYSTEM

Open

flow,

self

No.

2-D

(Cetane

SAE

J313.

ASTM In-line Throttle Cartridge Replaceable 12

COOLING

Fresh controlled

170° -190° F (7r -88° Centrifugal Positive

belt-driven.

8.0

7-8

41

Pressure Full

4.5

50-

API SAE 1 OW-40

Grade

D975. plunger

type.

Type

paper

volt

DC

lift

SYSTEM

water-cooled

with

type,

displacement,

US

qts

(7.61iters)

gpm

(25.9 -29.6

cfm

(1.16

fed

system.

flow,

paper

U.S.

qts

(4.31iters)

60

psi

(3.5-

Specification

priming.

rating

of

45

of

diesel

fuel

type

(BOSCH).

(PN#D30200)

filter

cartridge.

capacity

of

5'

block,

thermostatically-

heat

exchanger.

C)

metal

impeller, rubber

gpm).

cmm)

SYSTEM

element,

spin-on

4.2

kg/em')

CF,

CG-4,

or

15W-40.

Cl-4

or

higher).

according

(1.5

mm)

belt-driven.

impeller,

type.

or

CJ-4

to

solid

state

En.qines & Generators

44

AC

GENERATOR

Single

Phase

Voltage

regulation:

Voltage Frequency Rating

60

12.5KW 50

9.3KW

Generator

Air (60

Generator Ambient Recommendations

regulation:

(Volts

AC)

Hertz

(1800

rpm)

Hertz

(1500

rpm)

Cooling

Requirements

Hertz)

at

1800

Compartment

Temperature

rpm

(Single

Brushless, Pre-lubricated, Reconnectable, regulation regulation).

120 230

±

.5

120 120/240

230

225 -250

NOTE:

operation

122oF

NOTE:

to temperature

or

120/240

Volts -50

5%

no

Hertz

(.6%)

Volts

Increase

(1500

(50°G)

Forced

maintain

tour-pole,

single

(optional

Hertz

load

to

no

cfm

(5.66-

maximum

ventilation

generator

below

SPECIFICATIONS

Phase)

revolving

bearing

single

phase

solid-state

Volts -60

full

load.

load

to

104

Amps

104/52 60Amps

6.37

air

supply

rpm)

compartment

122oF

field.

design.

transformer

voltage

Hertz

full

load.

Amps

cmm)

15%

should

(50°C)

for

50

be

provided

Hertz

General

12.5

9.3

Voltage (60

Voltage (50

Amperage (60

Amperage (50

Generator Air (60

Generator Ambient

Recommendations

12.5

EGTD

- 3

Phase

KW-

60

KW-

50

Hertz

-3

Phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Cooling

Requirements

Hertz)

at

1800

Compartment

Temperature

AC

GENERATOR

Hertz

Phase

rpm

Brushless lubricated reconnectable voltage with

Low High DELTA

High DELTA

Low High DELTA

High DELTA

225 -250

NOTE:

operation

122"F

NOTE:

to temperature

Delta.

protection voltage

voltage

Increase

(1500

(50°C)

Forced

maintain

(3

Phase)

six

pole,

single

bearing

for

low

Solid

circuitry.

WYE

elm

(5.66 -6.37

air

rpm)

maximum

ventilation

generator

below122'F

revolving

field.

design.

voltage

State

voltage

208 480 240

380 230

43Amps

17

37

17

30

cmm)

supply

15%

should

compartment

(SOOC)

Sealed

12

WYE,

regulator

volts volts volts

volts volts

Amps Amps

tor

50

be

Lead

high

Hertz

provided

AC

GENERATOR

Single

Phase

Voltage

regulation:

Frequency

Rating

60

50

Generator Air (60

Engine Requirements

1800

Generator Ambient Recommendations

regulation:

(Volts

AC)

Hertz

(1800

rpm)

Hertz

(1500

rpm)

Cooling

Requirements

Hertz)

at

1800

Combustion

@60Hz

rpm

Compartment

Temperature

rpm

Air

(Single

Brushless, Pre-lubricated, Reconnectable, regulation regulation)

120

230

± ±3

(Electronic Non-Electric

120

120/240 230 225-

NOTE:

operation

46

122°F

NOTE:

to

temperature

or

120/240

Volts -50

5%

no

Hertz

Volts

250

Increase

(1500

elm

(1.9

(so·c)

Forced

maintain

four-pole,

single

(optional

..

Hertz

load

to

(5%)

Governered)

± 3

,

cfm

(6.37 -705

cmm)

maximum

ventilation

generator

below122'F

SPECIFICATIONS

Phase)

revolving

field.

bearing

single

Volts -60

full

no

load

Hertz

125

195.8/49.9 60

air

supply

rpm)

design.

phase

transformer

solid-state

Amps

voltage

Hertz

load.

to

lull

load.

Amps

cmm)

15%

should

compartment

(50•C)

tor

50

be

provided

Hertz

15

EGTD

AC

General

-3

15.0

12.0

Voltage

(60

Voltage

(50

Amperage

(60

Amperage

(50

Generator Ambient Recommendations

Phase

KW-

60

KW-

50

-3

Phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Compartment

Temperature

Hertz Hertz

Phase

GENERATOR

Brush lubricated reconnectable voltage with

Low High DELTA

High DELTA

Low High DELTA

High DELTA

122°F

NOTE:

to

maintain

temperature

less

six

pole,

single

Delta.

Solid

protection voltage

WYE

voltage

WYE

voltage

WYE

voltage

WYE

voltage

WYE

voltage

WYE

(5o•c)

maximum

Forced

generator

below122'F

(3

bearing

for

low

circuitry.

ventilation

Phase)

revolving

field.

design.

voltage

WYE,

State

voltage

208 480 240

400 230

52 22 45

22Amps 39Amps

should

compartment

(50,G)

Sealed

12

Lead high

regulator

volts volts volts

volts volts

Amps

be

provided

Engfnes & Generators

45

31:

wATER

s

1

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8

CONTROlS

CONN[Cl[D

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SUPPRtSSION JUMPER

PAII[l

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47

HOUR

METER

REMOTE

START/STOP

PANEL

WIRING

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.....

....

RELEASE STARTER

LIGHT

DIAGRAM

#56321

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EXTENSION 15FT, 8 PIN; 30

FT, 8 PIN,

HARNESS

STOP

SWITCH

#14

RED

··-··-··-··-··-··-··-··-··-··-··-··-··-··-··-··--·--:

. PN#36236 PN#36235

START

SWITCH

I

WATER:HEAlER,;(QV\(N_ERS

OPTION))

INSTALLATION

This

engine

is

equipped

engine

coolant

to

transfer

The

water

heater

should

either

in a high that the run in a

trap

air.

or

connecting

reasonably

low

hoses direct

position

with

connections

heat

be

mounted

from

line

INSTALLATION

for

the

plumbing

to

an

on-board

in a convenient

in

relation

the

heater

without

any

to

the

loops

water

th~

engine,

engine

which

heater.

location

so

can

might

.INSTRUCTIONS

The

of

pressure installed coolant

tank

after good the

engine's

not

at heater supported enabling

of

the

a&.r

Finish

the

coolant

the

engine

to

the

so

any

system.

cap

on

the

engine's

filling

system

is

circulation.

coolant

should

manifold

remote

expansion

it

rises

continuously

air

in

the

engine's

the

cooling

filled

During

system

manifold

cooling

system

and

is

engine

be

done

cap. The

tank

to

rise

system

free

at

the hose should be

from

the

up

should

is

filled

from

the

of

air

and

operation,

remote

connection

routed

heater

to

the

tank

be

with

remote

exhibits'

checking

tank

and

from

and

to

the

tank,

and

out

the

Hoses

should

rise

healer

to

the

engine

heater

to

the

engine.

then

an

air

bleed

ting on

NOTE:

connections for

fill

the

heater

If

arry

portion engine's remote circuit tank

single engine's nient

remote

the remote serves the same

recovery

own

pressure

expansion

to

become

into

the

heater

line

up

return.

location

expansion

point.

The plastic coolant

expansion tank kit is insflllkd,

tank if it

continuously

so

that air will

If

petcock must

for

bleeding

of

cap,

tank

(Kit#024177) must

the

highest

circuit,

the

return.

to

the

tank's

Install

the

so

the

coolant

tank will

function.

has

been

from

rise

trapped air is

be

installed

air

while

the

heating

Tee

location

remote

Remove

circuit

then a pressurized

point.

Tee

choosing

at

the

and

expansion

level

can

now

serve

recovery

and

already

WATER

HEATER

BELOW

ENGINE

their

low

point

at the

naturally

able

filling

the

the higher

heater,

the

easily

as a

tank is not used when

store

installed.

to

rise

at

the

rises

above

(aluminum)

be

installed

remote

and

other

tank

be

check

since

the

from

to

the

higher

system.

expansion

of

the

plumb

back

in a conve-

checked.

and

system

this

tank

plastic

the

~r.

fit-

the

in

the

two

a

to

the

The

NOTE:

An

heat

exchanger. coolant Close

tightly

air

bleed

Open

system

to

allow

after all the air is

petcock

this

air

is located

petcock

in

the

removed.

on

the

when

filling

exchanger

engine's

the

engine's

to

escape.

1-w'IWESIERBEKE

f t:ngjnes & Gen!!rators

49

POWER

TAKE

OFF

SYSTEMS

POWER

A power take off adapter can be attached to the generator backend. This adapter allows access to the full power engine for a variety

The

(16hp The 11.5Kw produces 15hp at 1800 rpm (12hp at 1500 rpm) The 15.0Kw generator produces 25hp at

1500rpm.

This horsepower can be utilized either for generator AC output or to operate the power takeoff.

TAKE

OFF

ADAPTER.

of

hydraulic and electrical accessories.

8.0 and 10.0 Kw generators produce 18hp at 1800 rpm (l.t

1500 rpm):

1800 rpm (22hp at

__

(§JWVER

OPTIONAL

of

the

POWER

TAKE

OFF

KIT

#034785

KIT

#037134

Contact your WESTERBEKE DEALER infomwtion.

STUDS

AND.

HOLD

'ADAPTER

HARDWARE

ACCESSORY

TO

THE

KITS

FOR

12

FOR 6 STUD

~~~

STUO

BT

UNITS

for

additional

BOLTS

FASTEN

TO

GENERATOR

ADAP~

HOUSING

·

fWJWESTERBEKE

._..,Engines & Generators

50

RAW

WATER

DISCHARGE

HOSE

WIRE

RAISE

THE

LEVEL

OF

A

GENTLE

THE

EXHAUST

TIE

TO

HOSE

THE

MANIFOLD

LOOP

ELBOW

HOSE

HEAT

EXCHANGER

[When a siphon

ABOVE

THE

IN

DOWN

ro,

break

is

not

required)

RAW

WATER

DISCHARGE

[OWNER

TO

HOSE

INSTALLED}

EXHAUST

WHEN A SYPHON

WESTERBEKE (installi!r the

heat

exchanger

elbow

be

fitting

on·

a

plastic

BREAK

recommends

supplied) looped

the

elbow.

·wire

tie

above

as

IS

NOT

REQUIRED

that discharging to

the

water

and

down

The

hose

can

Illustrated.

the

hose

raw

water

injected

to

the

be

secured

from

exhaust

inlet

by

51

ENGINE

TORQUE

SPECIFICATIONS

BoH

or

Alternator

Back Connecting Coolant Coolant Coolant Coolant Crankshaft Cylinder Delivery

Engine Exhaust

Rywheel

Fuel Fuel Fuel Fuel Fuel Glow

Glow

Intake

Main Oil Oil Oil

Oil Oil

Pressure

Rear

Retaining Valve

Rocker

Sliding

Special Torque

Starter B Terminal

Stop

.Thermostat

Thermoswitch

Bracket

Plate

Rod

Pump

Temperature

Pulley

Head

Valve

Mounts

Manifold

Bolt

Filter

Assembly Injection Injection Leak-Off

Solenoid

Plug Plug

Connection

Manifold

Bearing Filter Pan

Bolt

Pan·

Drain Pressure Pressure

Refief

Plate

Bolt

Plate

Bolt

Nut

Holder

Cover

Shaft

Sleeve

Nut

Spring

Solenoid

Cap

Pulley

Bon Holder

Nozzle Pipe Pipe

Locknut

Cap

Piug Sender Switch

Valve

(stamping)

{standard)

for

Body

Bolt

Bracket

Shaft

for

Set

Housing

Nut

Sender Switch

Nut

Holder Nut Nut

Plate

Bolt

Delivery

Bolt

Diameter

M9

M18 M10

M12

M20 M12 M12

M10 M4

M10 M20 M8 M14

PT1/8 M22 M8 M12 M16

M8 M8 M10 M12

M8

M30

M16

MAJOR

BOLTS

Pitch

1.0

1.5

1.25

---

1.25

1.5

1.25

0.7

1.25

1.5

1.25

1.5

1.25

0.75

1.25

1.0

1.2~

1.5

AND

Width

across

flats

14

27

14

19

21

18

12 8

17

12 22

26

22

12 16 17

19 12

12 14 17

12 36

17

NUTS

Clamp

length

87

29

60

81

25

10

11 33

28

40 581

29.5

31.5

TORQUE

ft

kg·m

3.8-5.3

3.3-4.8

3.55±0.25

1.6±2.4

1.2±1.8

17.5±2.5 9±0.5

4.5±0.5 32±54

3.2±4.7

1.6±2.4

13.5±0.5 98±4

4.6±6.8

5.5±0.5 40±44 3±0.5

2.75±0.25

4.0±5.0

1.75±0.25

0.125:!:0.025

1.6±2.4

5.25:!:

0.25

1.2±0.1

2.8±0.3. 20.3±2.2 40±5

1.2±1.8 1 ±0.2 7.2±1.4 50±5

1.15:±:0.15

6.5±1

3.75±0.25

1.15±0.15

1.5:!:0.5

3.6±0.6 2±0.5 14±4

1.1

::t0.1

4.5±0.5 32±5 4.

0.3-0.45

2.3±0.4

-lb

27·38 24-35 27±72 12-17 12·17 9-13 9-13 127±18 65

± 4

23·34 12·17

33-49

22±4 20± 2

28.9±36.2 12±72

0.9±0.2 12-17

38:!:2

8.7±

' 29±4

9·13

36:±:4

8.3±1.1 47±7

27±2

8.3±1.1 11

±4

26±4

80±7

2-3

16.6

0.7

± 3

N-m

36.6

32.5

34.8±2.5

17.2

12.2

12.2 172±25 88± 5 44±5

31.1

7.2 132±5

44.7

54±5

29±5

27±2.5

39.18

17.2±2.5

1.2±0.2

16.2

51.5±2.5

12±1

27±5.3 39±5

12.2 10:±:2 49:±:5

11.3:±:1.5 64±10

37±2.5

11.3±1.5

14.7:±:5 35±6 20±5

10.8±1 44±5

2.7

22.6

± 4

52

CONTACT

WATER

PUMP

IMPELLER

KIT

YOUR

SUGGESTED

WESTERBEKE

DEALER

SPARE

MARINE

FOR

DIESEL

SUGGESTIONS

PARTS

GENERATORS

AND

ADDITIONAL

INFORMATION

DRIVE

BELTS

HARDWARE

KIT

WES1ERBEKE each

packaged

Kit

"A"

includes

Kit

"B"

is

for

more

A

Kit

Impeller Heat

Exchanger Gasket

Fuel

Filter

Oil

Filter

Drive

Belt

Zinc

Anodes

also

offers

two

Spare Parts Kits,

in

a rugged hinged toolbox.

the

basic spares.

extensive off-shore cruising.

Kit

with

Gasket

. .

WESTERBEKE ENGINE AND A GALLON

RECOMMENDS

OIL

(YOUR

SPARE

BRAND)

OF

PREMIXED

PARTS

53

CARR.YING

FOR

AN

OIL

COOLANT.

KITS

ENOUGH

CHANGE

SPARE

(5

OTS.)

B

Kit

Inipeller Water Thermostat Kit Zinc

Complete Gasket Heat Exchanger Gasket Injector Fuel Filter with

Oil Filter

Drive

Kit

Pump

Anodes

Belt

Repair Kit

Kit

Gaskc1

WESTERBEKE CORPORATION • 150

MYLES STANDISH INDUSTRIAL PARK •

WEBSITE:

WWW. WESTERBEKE.COM

JOHN

HANCOCK ROAD

TAUNTON MA 02780

1237-1212016

Westerbeke 10.0 EGTD, 8.0 EGTD, 11.0 EGTD, 15.0 EGTD, 6.0 EGTD Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual