Westerbeke 22.0 KW EDE, 17.0 KW EDE, 13.0 KW EDE, 13.5 KW EDE Operator's Manual

OPERATORS

MANUAL

0-NET

22.0

17

..

0

KW

Single

EDE·:.&OHz

EDE

DIESEL

GENERATORS

17.0

·50.Hz

31J

PUBLICATION

REVISION

DECEMBER

13.5

ree

NO.

053852

4

2012

KW

EDE·.&O:Hz EDE-50

Phase

Hz

~

WESTERBEKE

MYLES

WEBSITE:

IVMMA

---

CORPORATION •

STANDISH

WWW.

Member

Marine

150

PARK •

Manufacturers

INDUSTRIAL

WESTERBEKE.COM

National

JOHN HANCOCK

TAUNTON

MA

Association

--

ROAD

02780

A

wARNING

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF GET seek until

gasses

gas. can

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

contain

Carbon

and

include:

and

Sleepiness

THE

attention.

inspected

Carbon

Monoxide

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

A

WESTERBEKE

bulkhead

WESTERBEKE CARBON living/sleeping

They obtainable

Monoxide,

is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

•Inability

IMMEDIATELY. down

repaired.

WARNING

are

an

of

Carbon

in

Twitching

to

Think

ANY

OF

If

the

unit

and

DECAL

and

near

your

also

MONOXIDE

quarters

inexpensive

at

your

odorless

and

Temples

THESE

symptoms

is

should

engine

recommends

DETECTORS

local

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

do

not

restart

provided

and

be

fixed

or

generator.

of

your

easily

marine

by

to

a

installing in

the

vessel. store.

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

and

of

State

65

WARNING

gasoline

its

constituents

of

California

birth

defects,

harm.

engine

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety manual carefully. Most accidents are

caused by failure to follow fundamental rules precautions. Know when dangerous conditions exist take the necessary precautions to protect yourself, your personnel,

The following safety instructions are in compliance with the American Boat

PREVENT

A

while

power.

• Do not operate this machinery without electrical

• Shut off electrical power before accessing electrical

• Use insulated mats whenever working on electrical

• Make sure your clothing and skin are

• Remove wristwatch and all jewelry when working on

• Do not connect utility shore power to vessels AC

• Electrical shock results from handling a charged

PREVENT

A

exhaust

very

• Always check the engine coolant level at the coolant

A

• In case

and

your machinery.

and

Yacht Council (ABYC) standards.

ELECTRIC

WARNING:

engine

is

Lethal

voltage

enclosures and covers in place.

equipment.

(particularly shoes) when handling electrical equipment.

electrical equipment.

circuits, except through a ship-to-shore double throw transfer switch. Damage to vessels AC generator may result

if

this procedure is not followed.

capacitor. Discharge capacitor by shorting terminals together.

BURNS -HOT

WARNING:

system

SHOCK

Do

not

touch

AC

electrical

running,

or

is

present

when

at

connected

these

ENGINE

Do

not

touch

hot

engine

components. A running

hot!

recovery tank.

WARNING:

of

before touching the engine or checking the coolant.

Steam

can

cause

injury

an engine overheat, allow the engine to cool

and

connections

to

shore

connections!

dry,

not damp

parts

or

engine

gets

or

death!

and

PREVENT

A

• Prevent flash fires. Do not smoke or permit flames or sparks to occur near the carburetor, fuel line, filter, fuel

pump, vapors. removing the fuel line, carburetor, or fuel filters.

• Do not operate without a Coast Guard Approved flame

arrester. Backfire can cause severe injury or death.

•

Do Backfire can cause severe injury or death.

• Do not smoke or permit flames or sparks to occur near

the fuel system. Keep the compartment and the engine/generator clean and free chances

• Be aware - diesel fuel will bum.

PREVENT

A

injury

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

• All fuel vapors are highly explosive. Use extreme care

when handling and storing fuels. Store fuel in a well-ventilated area away from spark-producing equipment and out

• Do not fill the fuel tank(s) while the engine is running.

• Shut off the fuel service valve at the engine when servicing

the fuel system. Take care in catching any fuel that might spill. sources servicing. Ensure proper ventilation exists when servicing

the fuel system.

•

Do

• Be sure all fuel supplies have a positive shutoff valve.

• Be certain fuel line fittings are adequately tightened and

free

• Make sure a fire extinguisher is installed nearby and is

properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment.

BURNS -FIRE

WARNING:

or

Use a suitable container to catch all fuel when

not operate with the air cleaner/silencer removed.

Fire

can

cause

injury

or

death!

other potential sources

of

fire. Wipe up all spilled fuel and engine oil.

of

spilled fuel or fuel

of

debris

to

minimize the

BURNS -EXPLOSION

WARNING:

or

death!

DO

not alter or modify the fuel system.

of

leaks.

Explosions

NOT

allow any smoking, open flames, or other

of

fire

near the fuel system or engine when

of

the reach

from

fuel

Open and ventilate cabin

of

vapors

children.

can

cause

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the battery cables before servicing the engine/ generator. Remove the negative lead first and reconnect it last.

• Make certain all personnel are clear starting.

• Make certain all covers, guards, and hatches are re-installed before starting the engine.

BATTERY

A

WARNING:

or

death!

• Do not smoke being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing dming servicing.

• Never connect the positive ( Do not test the battery condition by shorting the terminals together. Sparks could ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation disturb the battery charger connections while the battery is being charged.

• Avoid contacting the terminals with tools, etc., to prevent bums or sparks that could cause an explosion. Remove

wristwatch, rings, and any other jewelry before handling the battery.

• Always tum the battery charger off before disconnecting

the battery connections. Remove the negative lead first and reconnect it last when disconnecting the battery.

BATTERY

A

WARNING:

severe

STARTING

Accidental

EXPLOSION

Battery

or

allow an open flame near the battery

negative(-)

+) connection terminal

of

explosive gases.

ACID

Sulfuric

injury

or

death!

starting

explosion

battery cable to the

of

To

acid

in

batteries

can

cause

injury

of

the engine before

can

cause

injury

the starter solenoid.

avoid sparks, do not

can

cause

TOXIC

• Ensure that the exhaust system is adequate to expel gases

• Be sure the unit and its surroundings are well ventilated.

• Do not run the generator set or engine unless the boat is

• For additional information refer to ABYC T-22

• Do not use copper tubing in diesel exhaust systems. Diesel

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds/water-injected elbow is securely attached.

Run blowers when running the generator set or engine.

equipped with a functioning marine carbon monoxide detector that complies with ABYCA-24. Consult your boat builder or dealer for installation detectors.

(educational information on Carbon Monoxide).

A

WARNING:

odorless nausea

•

• Although diesel engine exhaust gases are not as toxic

AVOID

gas.

or

fumes can rapidly destroy copper tubing in exhaust

systems. Exhaust sulfur causes rapid deterioration copper tubing resulting in exhaust/water leakage.

Do

not install exhaust outlet where exhaust can be drawn through portholes, vents, or air conditioners. exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow

of

exhaust. Avoid overloading the craft.

exhaust fumes from gasoline engines, carbon monoxide

gas is present in diesel exhaust fumes. Some symptoms or signs poisoning are:

Vomiting Inability to think coherently Dizziness Headache Nausea

MOVING

GASES

Carbon

monoxide

Carbon

monoxide

Inhalation

produces

death!

of

carbon monoxide inhalation or

Throbbing in temples

Muscular twitching Weakness and sleepiness

PARTS

(CO)

is a deadly

of

approved

(CO)

is

flu-like

gas!

an

invisible

symptoms,

of

If

the engine

of

the

as

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid which is destructive.

off at once with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps.

If

it comes in contact with your skin, wash it

A

WARNING:

or

death!

• Do not service the engine while it is running. situation arises in which it is absolutely necessary to make operating adjustments, use extreme care to avoid touching moving parts and hot exhaust system components .

Rotating

parts

can

cause

..

II

injury

If

a

SAFETY

INSTRUCTIONS

• Do not wear loose clothing equipment; tie back long hair and avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that

could be caught in moving parts.

• Make sure all attaching hardware is properly tightened.

Keep protective shields and guards in their respective places at all times.

• Do not check fluid levels

the engine is operating.

• Stay clear

when the engine is running; hair and clothing can easily be caught in these rotating parts.

HAZARDOUS

A

WARNING:

of

the drive shaft and the transmission coupling

NOISE

High

or

jewelry when servicing

or

the drive belts tension while

noise

levels

can

cause

hearing

loss!

• Never operate an engine without its muffler installed.

• Do not run an engine with the air intake (silencer) removed.

• Do not run engines for long periods with their enclosures open.

A

WARNING:

mentally

or

Do

not

physically

incapacitated

work

on

machinery

by

when

fatigue!

you

are

ABYC, INSTALLING

Read the following ABYC, NFPA and USCG publications for safety codes and standards. Follow their recommendations when installing your engine.

ABYC (American Boat and Yacht Council)

"Safety Standards for Small Craft" Order from:

NFPA (National Fire Protection Association)

"Fire Protection Standard for Motor Craft" Order from:

USCG

"USCG 33CFR183" Order from:

NFPA

AND

USCG

PUBLICATIONS

DIESEL

ABYC 3069 Solomon's Island Rd. Edgewater,

NFPA 11

Tracy Drive Avon Industrial Avon,

U.S. Government Printing Office Washington, D.C.

MD

MA02322

(United States Coast Guard)

ENGINES

21037

Park

20404

FOR

OPERATORS

Many

of in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow

procedures.

GASOLINE

Preparations to install an engine should begin with a

thorough examination

Council's (ABYC) standards. These standards are a

combination Sections

H-2 Ventilation

P-1 Exhaust Systems

P-4 Inboard Engines

E-9 DC Electrical Systems

All installations must comply with the Federal Code Regulations (FCR).

MANUAL

the preceding safety tips and warnings are repeated

all safety

ENGINE

of

the ABYC standards

AND

GENERATOR

of

the American Boat and Yacht

sources including the

of

INSTALLATIONS

USCG

and the NFPA.

particular interest are:

of

Engines & Generators

iii

INSTALLATION

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

CODES

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

when installing engines and generators in a marine environment.

AND

REGULATIONS

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow is close to or will be below the vessel's waterline, provisions must be made to install a siphonbreak in the raw water supply hose to the exhaust elbow. This hose must be looped a minimum

the

raw

If

you have any doubt about the position

to the vessel's waterline under the vessel's various operating conditions,

siphon-break.

NOTE:

operation. Failure to properly maintain a siphon-break can result in catastrophic engine damage. Consult the siphon-break manufacturer

EXHAUST

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

of

20" above the vessel's waterline.

exhaust manifold

water

damage

A siphon-break requires periodic inspection

injection

to

the

engine

port

and

is

at

possible

of

SYSTEM

the vessels hull.

A

detailed

engines

.Is

also

Website:

Marine

and

available

Installation

generators

in

pdf

is

format

supplied

www.westerbeke.com

Manual on

Failure

or

below

flooding

the water-injected exhaust elbow relative

the

to

use

a siphon-break

load

waterline

of

the

boat.

will

when

result

install a

and

cleaning to ensure proper

for

proper maintenance.

with

our

website

covering

every

gasoline

unit

sold.

to

download

and This

diesel

manual

in

AVAILABLE YOUR OEALER

SIPHON-BREAK LOOP PART

FROM

WESTERBEKE

FOR

NO.

WITH

1"

HOSE

044010

STAINLESS

Engines

iv

& Generators

TABLE

OF

CONTENTS

Parts Identification

oo

........................................................... 2

Introduction ......................................................................... 3

Fuel,

Engine Preparations Digital LCD

Sequence ...................................................................... 8

Digital Remote Generator

Daily

Routine Maintenance Schedule Fuel

System

Cooling

Raw Raw Heat Raw Fresh Changing Air Thermostat.

Engine

Testing

Remote

Wiring Engine LCD

Display

Alternator

Battery

Engine

Valve Glow Drive Fuel

Fuel

Injectors ..............

Injection

Starter

Troubleshooting

Emergency Engine/Generator Generator Electronic Internal Generator Schematic Twelve

Changing BE

Troubleshooting Exciter Generator Generator/Maintenance Parts Power Lay-Up Water Metric Suggested Spares.

Oil

and

Engine

Coolant... ............................... s

for

Initial

Control

Panel ....................................

Control

Stop/Start

Break-In

Start-Up

Panei ........................................................

Panel

Procedure .......................................... 1 o

......................................... 6

oo

..................... 7

......................... , ........................... 9

..................................................................... 1 o

(Chart)

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

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

System

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

Water

Intake

Strainer. ........................................ l5

Water

Cooling

Exchanger

Water

Pump

Water

Cooling

the

........

Circuit...

oo

..................................... IS

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

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

System

...................................... l7

Coolant...

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

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

..

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

Lubricating

Diagrams

Troubleshooting

Testing

Adjustments

Adjustments Plugs Belt

Injectors

Motor

lnformation

Regulation

Wiring

Lead

Hertz

Rotor

Servicing

Transfer

and

Heater

Conversion

Oil

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

Oil

Change.oo

Oil

Pressure

Oil

Filter

..........

Faults

Care

....

Adjustment

Testing

oooooooo·oooo·oooo·oooo.oooo.

Start

Diagram

Rotating

Winding

and

Troubleshooting

..

oooooo

..

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...

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..

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......

oo.oo•······················

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Schematics

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Voltage.oo

(Chart)

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....

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..

Breakdown

Switch

oooo

..

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00

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

Recommissioning

Connections.

Data

oo,

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

00

.......

(Chart)

...

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5 1

1

PARTS

ECU

CONNECTIONS-~

IDENTIFICATION

THER.MOSTAT

ASSEMBLY

REMOTE CONNECTION

FRONT

PANEl

COOLANT

PRESSURE

CAP.

LEFT

SIDE

DRIP

TRAY

Oil FILl

INTAKE

ELBOW

AIR

INTAKE

DIGITAL PANEL

HEAT EXCHANGER

FUSL

CONTROL

CONTROl

20A DC

BREAKER

BOX

REAR

LEXIBLE

MOUNTS

RIGHT

ISOLATED

SIDE

INJECTION

OIL

AIR

INTAKE

SPIN-ON FUEL

FILTER

PUMP

FILTER

SILENCER

Engines & Generators

2

This

WESTERBEKB WESTERBEKB's technology. dependable

Thank

In order

is important manual manual throughout. your

This provided WESTERBEKB equipment contact your WESTERBEKE'S installation

WARRANTY

Your folder. If, after 60 form registering writing

number

Customer.

We

p'erformance

you

for selecting

to

get the

that

is

designed

carefully

Should your generator

nearest

WESTERBEKB

is

your

operators

and

a technical

PROCEDURES

WESTERBEKE

you

have not received a

your

with

model

and

commission

Identification

Diesel

Generator

long

years

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take great plide

of our

WESTERBEKE.

full

use

and

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operate

to

and

observe all

dealer.

days

warranty,

information,

and

help

you

dealer

manual. A parts

manual

If

you

WESTERBEKE

Warranty

of

submittil;tg

customer

please

date.

Card

experience

in

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engines

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tllis.

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safety

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are

planning

manual.

is

included

the

contact

including

.

superior

catalog

1"""/WESTERBEKE

I Engines & Generators

Customer Identification

MR.

GEl\TERATOR

MAIN

STREET

HOMETOWN, USA

Model

Expires

OWNER

Ser.

#

INTRODUCTION

is a product

and

generators.

your

it

correctly.

Please,

precautions

servicing,

assi~tance.

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dealer

in a separate

Warranty

identification

the

factory

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advanced

durability

generator

read

tllis

Contact

is

also

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install

for

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card

in

unit's

serial

and

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Tllis

·

tllis

·

PRODUCT

Product brochures WESTERBEKE

WESTERBEKE CONTENT WARRANTIES THERETO,

SOFTWARE

software,

and

catalogs),

CANNOT

OF

SUCH

OR

INCLUDING

COMPLETENESS

BE

LIABLE

INCURRED

OF

THE

WESTERBEKE time software WESTERBEKE provided WESTERBEKE be relied the

respective product It

but

is WESTERBEKE to

determine

product

NOTES,

AB

this

maintenance

erigine, CAUTIONS,

NOTE:

A

observed,

your

FOR

IN

CONNECTION

FURNISHING

span

between

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unavoidable manuals.

with

WESTERBEKE

or

upon

exclusively

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software

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critical

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that or

the

accuracy

CA~TIONS

takes

schedules,

information

and

CAUTION:

can

result

engine.

(tech

data,

parts

lists,

are

not

witllin

provided

BE

from

WESTERBEKE's

RESPONSIBLE

SOFTWARE,

REPRESENTATiuNS

ACCURACY,

THEREOF

ANY

TYPE

AND

OF

DAMAGE

WITH

OR

USE

OF

custOmers

printings

other

the

being

WARNINGS.

procedure

Procedures,

should

of

existence

In

summation,

suppliers,

as

the

not

only

appropriate

supplier

and

currentness

consulted

AND

WARNINGS

you

through

and

troubleshooting

will be

essential

in

the

damage

also

WESTERBEKE

products,

must

definitive

makes

representatives

in

question

by

the

.highlighted

An

explanation

which

manuals, sources

MAKES

NO

WITH

TIMEliNESS

WI/LIN

OR

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SUCH

SOFTWARE.

keep

in

of

earlier

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whether

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and

authority

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of

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customer.

operating

of

to

note

..

if

not

strictly

or

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other

than

control.

FOR

THE

RESPECT

OR

NO

EVENT

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OUT

mind

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product

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on

sense

of

consulted

procedu~es,

your

manne

by

NOTES,

follows:

.

of

A

WARNING:

followed,

Engines & Generators

3

can

Procedures,

result

in

personal

which

injury

if

not

or

properly

loss

of

life.

INTRODUCTION

SERIAL

The engine's model number and serial number are located on an I.D. plate that is mounted exhaust manifold. into the engine block on the fiat surface just outboard fuel injection pump. Take time to enter this information on the illustration below. It will provide a quick reference when seeking technical information and/or ordering needed parts.

NUMBER

LOCATION

The

on

the side

engine serial number is also stamped

of

the water jacketed

of

the

HZ.

NOTE:

A carbon monoxide warning decal

WESTERBEKE.

by

engine

room.

UNDERSTANDING

The diesel engine closely resembles the gasoline engine,

since the mechanism is essentially the same. The cylinders are arranged above a closed crankcase; the crankshaft is the same general type as that diesel engine has the same connecting rods and lubricating system.

Therefore, to a great extent, a diesel engine requires the same preventive maintenance as a gasoline engine. The

most important factors are proper ventilation and proper maintenance Replacement time periods specified is a must, and frequent checking for contamination (that is, water, sediment, etc.) in the fuel

system is also essential. Another important factor is the

of

the same brand

designed specifically for diesel engines.

The diesel engine does differ from the gasoline engine,

however, in its method

carburetor and ignition systems are done away with and in

their place is a single component - the fuel injection pump

which performs the function

Affix this

THE

of

the fuel, lubricating and cooling systems.

of

fuel and lubricating filter elements at the

of

high detergent diesel lubrication oil

decal

DIESEL

of

a gasoline engine; and the

type

of

handling and firing

of

both.

has

been provided

in

a visible position

in

ENGINE

valves, camshaft, pistons,

use

of

fuel. The

the

of

An identification plate on the engine manifold also displays the engine model and setial number.

CARBON

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

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

If

carbon monoxide is present, ventilate the area with clean

air and correct the problem immediately!

MONOXIDE

in

small

amounts,

of

DETECTOR

Carbon

is deadly.

carbon monoxide indicated an exhaust leak

or

from the exhaust

or

the fumes from a nearby vessel are

monoxide,

ORDERING

Whenever replacement/service parts are needed, always

provide the generator model number, engine serial number,

and generator serial number as they appear on the silver and

black name plate located on the generator end.

provide us with this information so your generator set. In addition, include a complete part description and part number for each part needed (see the separately furnished WESTERBEKE packaged parts because parts are frequently not made to the same specifications as original equipment.

SPARES

Certain spares will be needed to support and maintain your WESTERBEKE generator. Your local WESTERBEKE dealer will assist you in preparing an inventory See the Generator Accessories, see the

INSTALLATION

Publication #43400 provides detailed information for installing generators.

PARTS

AND

SPARE

we

may properly identify

Parts List). Also insist upon

will fit or generic

ACCESSORIES

PARTS

page in this manual. For Engine and

ACCESSORIES brochure.

MANUAL

You

must

of

spare parts.

Engines

4

& Generators

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

USE A DIESEL

(No.

Care

Use only clean diesel fuel! The clearance in your fuel injection pump is very critical; invisible dirt particles which might pass through the filter can damage these finely finished parts. It is important to buy clean fuel,

and keep it clean. The best fuel can be rendered

unsatisfactory by careless handling or improper storage

facilities. engine's daily use advisable:

Purchase a well-known brand service a good, visual-type fuel filter/water separator between

the fuel tank and the engine. The Raycor

RMAM are good examples

ENGINE

Use a heavy duty engine oil with an API classification CG-4, CH-4 or CI-4. Change the engine oil and filter after an initial filter change intervals as specified in the

SCHEDULE

not approve or disapprove

synthetic oils are used, engine break-in must be performed

using conventional oil.

MAINTENANCE

synthetic oils are used.

SAE

For

FUEL

2-D

(SAE

J313)

Of

The

Fuel

To

assure that the fuel going into the tank for your

OIL

50 hours

OIL

all

temperatures

of

in this manual. Westerbeke Corporation does

VISCOSITY

WITH A CETANE

diesel

fuel

according

RATING

OF

to

ASTM

#45

OR

HIGHER.

0975).

Supply

of

the components

i~

clean and pure, the following practice is

of

fuel.Install and regularly

500

MA

or 230

of

such filters.

of

CF,

break-in operation. Then follow the oil and

MAINTENANCE

of

the use

of

synthetic oils.

Oil change intervals must be as in the

SCHEDULE,

not extended because

If

GRADES

use

SAE

1DW-40

or

15W-40.

ENGINE

WESTERBEKE recommends a mixture

and chemicals that can corrode internal engine surfaces.

The antifreeze performs double duty.

run at proper temperatures by transferring heat away from the engine to the coolant, and lubricates and protects the cooling circuit from rust and corrosion. Look for a good quality antifreeze that contains Supplemental Cooling Additives balanced, crucial to long term protection.

The distilled water and antifreeze should be premixed before being poured into the cooling circuit.

PURCHASING

Rather than preparing the mixture, WESTERBEKE recommends buying the premixed antifreeze so that so that when adding coolant the mixture will always be correct. There are two common types (green) and Propylene Glycol (red/purple), either can be used but flush the engine thoroughly.

Premixed Specification

COOLANT

of

50% antifreeze

50% distilled water. Distilled water is free from the

It

allows the engine to

(SCAs) that keep the antifreeze chemically

ANTIFREEZE

of

antifreeze, Ethylene Glycol

do not mix the two and

antifreeze

#ASTM

for

DIESEL

D53456.

if

changing from one to another,

Engines:

MAINTENANCE

Change the engine coolant every five years regardless number protect and lubricate the engine have a limited life.

COOLANT

of

operating hours as the chemical additives that

RECOVERY

TANK

of

the

OIL

PRESSURE

The engine's oil pressure, during operation, is indicated

by the oil pressure gauge on the instrument panel. During normal operation, the oil pressure will range between 35 and 65 psi 2.5 and 3.9 kg/cm

NOTE:

A newly started, cold engine can have an oil pressure reading upwards have an oil pressure reading as low as These readings will vary depending upon the temperature the engine, the load placed on the engine, and the RPM's.

2

of60

psi (4.2 kg/cm

).

2

>.

A warmed engine can

25

psi (1.8 kg/cm

2

>.

of

Engines & Generators

5 .

PREPARATIONS

FOR

INITIAL

START

·UP

PRESTART

Before starting your generator for the first time or after a prolonged layoff, check the following items:

• Check the engine oil level: add oil to maintain the level at the full mark on the dipstick.

• Check the fuel supply and examine the fuel filter/separator

bowls for contaminants.

• Check the DC electrical system. Inspect wire connections

and battery cable connections.

• Check the coolant level in both the plastic recovery tank ·

and at the manifold.

NOTE:

the recovery the

after

tank replace

Before manifold should

INSPECTION

After

the

initial running

engine's cooling system will

tank.

Open

the

air bleed petcock

cooling system

the

engine has

will

be

the

subsequent operation

drawn

purged

be

is

purged

cooled, into air.

topped

of

the

engine's cooling system

of

off,

of

the

generator;

be

purged

to

air.

After shutdown and

coolant from

the

generator;

and

the

coolant recovery

the

coolant

ensure

the

recovery

the

air

in

that

to

engine's

• Be sure that in power systems with a neutral line that the neutral is properly grounded (or ungrounded) as the system requires, and that the generator neutral is properly connected to the load neutral. incomplete neutral voltage

• Make certain the cooling water thru-hull petcock is open.

A

CAUTION:

recommended motors, up

to

This

precaution

unanticipated

prevent a cold

be

switched

speed

or

open neutral can supply the wrong line-to-

on

unbalanced loads.

When

starting

that

all

AC

OFF

and,

in

cold

will

prevent

operation

engine

from

In

single phase systems an

the

loads,

especially

until

the

climates,

damage

of

the

AC

stalling.

generator,

large

engine

has

starts

to

warm

caused

machinery

by

and

it

is

come

up.

will

• Check load leads for the wiring diagrams.

• Examine the air inlet and outlet for air flow obstructions.

•

Be

sure no other generator or utility power is connected to

the load lines.

conect

connections as specified in

DIPSTICK

PUSH

IN

TIGHT

CLEAN

THIS

.

PERIODICALLY

PASSAGEWAY

KEEP

112

FULL

LOW

--_ADD

OIL

Engines &

Gen~rators

6

DIGITAL

CONTROL

PANEL

DESCRIPTION

WESTERBEKE' S Digital Control Panel provides the

operator with an LCD display that contunuously monitors all the operations

of

the generator in easy to understand

text messages.

CONTROL

Note that the design and size

BOX

of

the control box will vary

depending on the model generator.

BA

FUSE

PROTECTS ELECTRONICS AMPERAGE

INDICATOR

SIX

WHERE A FAULT

LIGHTS

THE

CONTROL

FROM A HIGH

OVERLOAD.

LIGHTS

THAT

INDICATE

HAS

OCCURED.

PANEL

~

20A

BREAKE~

SHUT-OFF MAINTENANCE REPAIRING A FAULT.

RESTART

SWITCH""

WHEN

PERFORMING

OR

THE

ENGINE.

WHEN

RESET

TO

FAILURE

A

RED

LIGHT

THE

RUN

SEQUENCE

INTERUPTED

LIGHT

WILL

APPEAR

IS

BY A FAILURE.

IF

START

STARTS

----------------------------------------------------

BUTTON

THE

ENGINE

LCD

DISPLAY

Operating temperatures may cause the LCD display to vary in color. This is normal and a change.in color will not affect the operation on the control panel.

Periodically clean the control panel LCD screen cloth.

UP

AND

WHEN

IN

ITS

UP

AND

BE

USED

DARK

DOWN

THE

LCD

SCROLL

DOWN

TO

AND

LIGHT

ARROWS

DISPLAY

MODE,

ARROWS

ADJUST

CONTRAST

U?ing

IS

THE

CAN

THE

a soft

UP-ARROW

WHEN

IN

SCROLL

LOCK

MODE INDIVIDUAL BE

THE

SCROLL

STOPS

THAT A SINGLE

BE

MONITORED

FUNCTIONS

MONITORED

UP-ARROW.

BY

LOCK

RUN

SEQUENCE

FUNCTION

CAN

PRESSING

SO·

CAN

DOWN-ARROW

··WHEN

IN

SCROLL

LOCK

BY

PRESSING

FUEL

PURGE

TO

THE

DN

MODE

CAN

SEQUENCE

THE

FOLLOWING

PRIME

BUTTON

THISBUTTON PUMP. OR

PERFORMING PRESSING AIR

OUT

LINES.

ENERGIZES

AFTER

REPAIRING A FAILURE

THIS

AND

BRING

INDIVIDUAL BE THE

FUNCTIONS

MONITORED

DOWN-ARROW.

.

THE

MAINTENANCE,

BUTTON

WILL

FUEL

IN

LCD

DISPLAY

IS

SHOWN

..

PAGE.,.

*MANUAL

ENGINE

SHUT-OFF

Should the stop button fail in its normal function to stop the engine, the engine is equipped with a manual shutdown lever located on the engine block to the right side pump. Simply hold

the lever to the left until the engine comes to a complete stop. This shutdown lever is standard on current D-Net generators.

of

the injection

7

DIGITAL

CONTROL

PANEL/LCD

SEQUENCE

START

SEQUENCE

With the pre-start inspection completed, press the START button and the automatic sequence will begin. The six indicator lights will illuminate green and the panel

will

display the following text:

tw1WEST£RBEKE

1 Engines & Generators

Pre Heating ......

7 Seconds

RUN

SEQUENCE

Waiting

..

for

operator

Press

start

to

engage generator

Cranking ......

As the display cycles thru the engine functions, the speed will come up to

1800 rpms-60Hz (1500 rpms-50Hz) and the oil pressure and engine coolant will rise to their normal readings. The functions will cycle in the following sequemce:

Engine Speed

1800

0

.

·-

RPM

2500

SC_R!)LL

Coolant TemperaturP

'

81C

32 0

178F

300 100

SCROLL

STOP

SEQUENCE

To

stop the generator, press the STOP button. The display

will cycle thru the following text messages and shutdown.

Shutting

Down

Waiting

FAILURE

for

Press

start

engage generator

LIGHT/SHUTDOWN

operator

to

Engine Shutdown

If a problem occurs, the generator will shutdown and the

of

to

the

reveal

FAILURE light will illuminate red. In addition, one indicator lights will change from green to orange where the trouble has occured and the display will text message what has happened

Examples:

Failure Light Coolant Temperature Light

is

orange.

is

red.

,_

________

High Engine Temp.

ECU

Reset

to

Restart

.,.

Battery Voltage

13.5 VDC

0

Engine Hours

30

SCROLL

3.8 HOURS

SCROLL

..

(/)

AC Phase Voltage

s

co

Cil

A120V

"'U

B 120V

=r-

ru

en

co

(])

en

til

AB3BOVo

.r::.

a..

(])

BC

~

CA380.V

.r::.

f-

SCROLL

To

0

AC Phase Voltage

0

378V

0

~~

SCROLL

200

600 600 600

I

LOCK

stop the continuing sequence, press the SCROLL LOCK

Oil

Pressure

3.1

BAR

0 100 0

AC Frequency

60.1Hz

0

AC

Line Voltage

120V

AB380V. BC378V

CA

0

AC Line Voltage

a

0

. 0

380.V

.

40

PSI

6.9

SCROLL

100

SCROLL

200

SCROLl

600

LOCK

button. This enables the operator to monitor a single function

for any length comer. functions.

of

time. The word LOCK will appear in the

Use the up and down an·ows

To

resume scrolling, press the SCROLL LOCK

to

find and observe other

button again.

(])

en

til

.r::.

a..

(])

c:n

c:

(jj

"d

¢

~

I

600

"'U

=r-

600

ru

en

co

•

Low

Oil

ECU

Pressure

to Restart

Failure Light

Oil Pressure Light

is

red.

is

orange.

Reset

When a failure occurs, refer to the troubleshooting chart, wiring diagram, and general operating text in this manual assist

in

solving the trouble.

of

There arc many combinations

messages that can be displayed but they are all self explanatory and the operator can easily isolate and correct the problem should one occur.

Before re-starting the generator, the

20 amp DC circuit

breaker must be reset. With the problem corrected and the

generator started, the sequences will begin cycling again.

NOTE:

Three phase voltages will vary depending on the

output configuration

CAUTION:

in the engine's exhaust system filling with raw water. This raw water can enter the engine's cylinders exhaust manifold. not start, drain the system's muffler and investigate correct the cause

of

raw water entry, is not a warrantable issue.

of

the generator.

Repeated

If

of

no start. Engine damage, the result

ctank

cycles without a start can result

by

way

after three crank cycles, the unit does

AC

of

to

the

and

8

DIGITAL

CONTROL

BOX

EARLIER

FREQUENCY

Frequency

is

engine The

ECU signal from the over the flywheel ring gear teeth. The signal

as

Should this signal vary approximately 2% either up or down,

a frequency fault shut down will occur, initiated

The

red failure LED on the display panel will illuminate, the frequency LED will tum from green to amber and the LCD display screen will show the fault text

NOTE:

If

same fault "overspeed" will show on the screen but the

frequency LED will..

DIPSWITCHES

FAULT

is

displayed on the LCD display screen while the

running in

is

receiving a low AC voltage signal and hertz

both RPM and hertz.

the unit shuts down

RPM

and frequency (hertz).

MPU which

K.

is

positioned on the bellhousing

ECU interprets this

by the ECU.

"overspeed".

for

an underspeed condition, the

MODELS

GENERATOR

CAUTION:

the

ECU,

box. Tum it back on after the setting has been changed

1.

Thm the

position.

2.

Open the cover (Electronic Control Unit).

3. Locate the position that See the illustration below showing the conti·ol box.

4.

Replace the control box cover, tum the DC breaker ON

and start the unit. Monitor the frequency that the engine/generator

frequency.

ECtJ

CONECTIONS

FREQUENCY

ADJUSTMENT

When changing the generator ji·equer;cy setting on

tum

off

the 20 amp

DC

breaker on the control panel

of

#1

dipswitch on the ECU and move it

DC

circuit breaker on the contml

the control box and view the ECU

con-esporids to the Hertz operation desired).

ECU

is

operating

is

operating at the correct

(HERTZ)

to

the OFF

to

the

in

the

CAUTION

generators starting battery when the unit

normal seasonal use. However.

(WESTERLINK

This can be as much as

to the

generator with a NMEA-2000 system

NOTE:

Keep

in

or

NMEA~2000):

72 amp-hours in a months time with no generator use. It is not necessary to be concerned with this slight amperage draw during

mind that the Westerbeke generator maybe the

if the generator set is not to be used

The electronic componems in the Digital Diesels draw a very small amount

is

in

a static state. This maybe as much as 50 milli-amps

for

or

shut

off

the DC breaker on the generators control box

DC

Engines & Generators

a number

power supply for the vessel's NMEA-2000 network.

of

months, such as willfer storage, it is best to disconnect the DC power

for

the system ECU and 50 milli-amps for each display.

for

a WESTERLINK system.

LCD

DISPLAY

PANEL

TEST

PORT

NOTE:

DURING

LCD

DISPLAY

BY

HEAT.

CAUSE

OPERATION

MAY

THIS

IS

FOR

NORMAL

CONCERN.

OF

THE CAUSED AND

NO

of

amperage (milli-amps)froni the

THE

COLOR

VARY.

8A

DIGITAL

CONTROL

PANEL

FREQUENCY

Frequency

engine

is

The ECU signal from the over the flywheel ring

as

signal

FAULT

is

displayed·on the LCD display screen while the

running

both RPM and hertz.

in

RPM and frequency (hertz).

is

receiving a low AC voltage signal and hertz

MPU which

is

positioned on the bellhousing

gear teeth. The ECU interprets this

· Should this signal vary approximately 2% either a frequency fault shut down will occur, initiated The red failure LED on the display panel will

frequency LED will turn from green

to

display screen will show the fault text

illuminate,-the

amber and the LCD

"overspeed".

up

or down,

by

the ECU.

GENERATOR

1.

Tum

FREQUENCY

the

DC

breaker

ADJUSTMENT·(HERTZ)

on

the control panel to the

OFF

position.

2. Open the cover

of

the control box and view the

ECU

(Electronic Control Unit).

3.

Access the opening visable in the elongated area

of

the ECU.

The

dipswitches are

of

this opening.

4. Access the #1 dipswitch and move it to the position that corresponds to the hertz operation desired. The illustration

shows these dipswitches.

5. Plug in the communications cable from your laptop having the plug connection should have the arrow

ECU

the corresponding

EC20 software.

The

communications cable

connections. Reprogram the

AC

voltage output the generator is being

on

the plug facing

ECU

for the

changed to.

6. Once the change is completed,

tum

OFF

your laptop.

Unplug the communications cable from the ECU.

7. Proceed to page

procedures for reconfiguring the

39Aofthis

manual and follow the

AC

voltage output

the generator that has been selected.

of

CONTROL

BOX

I

COMPONENTS

NMEA2000

T

CONNECTION

CAUTION

generator's starting battery This can be as much normal seasonal use. However, if the generator set to

NOTE:

(WESTERLINK

the generator with a NMEA-2000 system or shut

Keep

in

or

NMEA-2000):

whe.n

as

72

mind that the Westerbeke generator maybe the DC power supply for the

the

amp-hours

The electronic components

unit

is

in

a static state. This maybe as much as 50 milli-amps

in

a months time with no generator use.

is

not

ro

off

the DC breaker

be used

in

the Digital Diesels draw a vel)' small amount

for

a number

on

the generator's control box for a WESTERLINK system.

WIRING

HARNESS

CONNECTION

REMOTE CONNECTION

~~41-711S"~f'9"....-~ECU-ELECTRONIC

CONTROL

NOTE:

OF CAUSED AND

for

It

is not necessary

of

mollths, such as winter storage,

vessel~·

the system ECU and 50 milli-amps for each display.

to

be concerned with this slight amperage draw during

NMEA-2000 network.

PANEL

UNIT

PANEL

DURING

LCD

DISPLAY

BY

HEAT,

CAUSE

OPERATION

FOR

THE

NO

of

amperage (milli-amps) froni the

it

is best to disconnect the DC power

THE

MAY

VARY.

THIS

IS

NORMAL

CONCERN.

COLOR

Engines & Generators

88

DESCRIPTION

A remote panel

stopped connecting harnesses of

th~e

NOTE:

For

WESTERBEKE

is

available that

and

started

can be combined

additionol

dealer.

from

any

~me

in

for

information,

REMOTE

allows

the

location

three

a maximum

on

different lengths

contact your

AND

EXTENSION

generator

the

boat.

run

at

75'

local

STOP/START

HARNESSES

to

be

The

and

two

(22.17M).

PANEL

REMOTE

PANEL/PIG

Pil

052560

CONNECTING

6"

(152.4MM)

.

·15' 30'

TAll

Note:

These

two

~

'~5~"(68.~

...

Panel

Box

This

kit

switch

on

of

the

LCD

location.

LCD

DISPLAY

EXTENSION

NMEA

PART

NUMBER

053025 053026 053027 053028 053029 4 MErER 053030 053031

053032 7 053033 053034 053035 10 MErER 053061

___

allows

the

MICRO-C

1/2 MErER - 1.6 FEEr

2.2

dimensions

Cover

Display

Kit

for

the

installation of

generator control box

panel

LENGTH

1 MErER - 3.2 FEEr 2 MErER - 6.5 FEEr 3 MErER - 9.8 FEEr

5 MErER - 16.4 FEEr

. 6 MErER - 19.6

METER 8 MErER - 26.2 FEEr 9 MErER - 29.5 FEEr

METER ~ 40.0 FEEr

are

#053342

to a more

CABLES

-

13.1

FEEr FEET

- 22.9 FEEr

-32.8

FEET

60'

the

measurement

the

Analog

and

the

visible

EXTENSION

CABLES

(4.75M) (9.1M) (18.2M)

Start/Stop remote meunting amd

accessible

of

PN

PN PN

the

052959 052789 052960

cut-out

opening.

9

GENERATOR

BREAK-IN

PROCEDURE

DESCRIPTION

Although your engine has experienced a minimum hour

of

test operations at the factory to make sure accurate

assembly procedures were followed and that the engine

· operated properly, a break-in time life

of

your engine

operated and serviced during its initial hours Breaking-in a new engine basically involves seating the

piston rings to the cylinder walls. Excessive oil consumption and smoky operation indicate that the cylinder walls are glazed or scored, which

engine during the break-in period. Your new engine requires approximately 50 hours

conditioning operation to break in each moving part in order to maximize the performance and service life Perform this conditioning carefully, keeping in mind the following:

Start the engine according to the STARTING PROCEDURE section. Run the engine while checking that all systems (raw

water pump, oil pressure, battery charging) are functioning.

AFTER

Once the generator has been started, check for proper operation and then encourage a fast warm-up. Run the generator between 20% and 60%

START-UP

is

dependent upon how the engine

is

of

is

required. The service

caused by overloading the

full-load for the first 10 hours.

of

use.

of

the engine.

of

one

is

initial

After the first can be increased to the full-load rated output, then periodically vary the load.

Avoid overload at all times. exhaust with reduced output voltage and frequency. Monitor the current being drawn from the generator and keep it within the generator's rating. rpm to produce 60 hertz (or at 1500 rpm to produce 50 Hertz), control current drawn from the generator.

NOTE:

draw required draw can be 3 to 5 times normal running amperage. See

GENERATOR INFORMATION in this manual.

GENERATOR

Once the generator has been placed in operation, there may be governor adjustments required for engine speed (hertz) during the engine's break-in period (first 50 hours) or after this

period see

ENGINE ADJUSTMENTS

may also be required in conjunction with the engine's speed adjustment see

10

hours

of

the generator's operation, the load

An

Be aware

for

overload

Since the generator operates at 1800

of

the generator's break-in

of

motor starting loads

starting motors. This starting amperage

is

signaled by smoky

is

governed by the

and

the high current

ADJUSTMENTS

ENGINE SPEED (HERTZ) ADJUSTMENT) under

..

A no-load voltage adjustment

GENERATOR INFORMATION.

THE

CHECK

Follow this check list each day before starting your generator.

• Check that all generator circuit breakers (power panel) are

• Record the hourmeter reading in your log (engine hours

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

• Check the oil level (dipstick).

• Check the coolant level in the coolant recovery tank.

• Check your fuel supply.

• Check the starting batteries (weekly).

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

CHECK WITH THE ENGINE RUNNING.

• Check for abnormal noise such

• Confirm exhaust smoke:

LIST

in

the off position before starting.

relate to the maintenance schedule.) Any deficiency or problems in the following items must

be corrected before start up.

as

knocking, vibrating and

blow-back sounds.

When the engine is cold When the engine When the engine

-White

is

warm - almost Smokeless.

is

overloaded - some Black Smoke.

Smoke.

DAILY

ROUTINE

NOTE:

Some unstable running may occur in a cold engine. This condition should abate as normal operating temperature is reached

A

periods generator.

STOPPING

Remove the

Allow the generator to run for 3-5 minutes to stabilize the operating temperature. Then push the stop button.

down,

CAUTION

Digital Diesels draw a very small amount the generator's starting maybe as much as 50 milli-amps

for each display. This can be as much as

with no generator amperage draw set is not

best system or shut WESTERLINK system.

NOTE:

supply for the vessel's NMEA-2000 network.

and

loads are applied.

CAUTION:

of

tum

off

(WESTERLINK

to

be used

to

disconnect the DC power

Keep

Do

not

time

without a load

THE

GENERATOR

AC

amperage loads from the generator one at a time.

the panel

or

battery when the unit is

use. It is not necessary to be concerned with this slight

during normal seasonal use. However,

for

a number

off

the DC breaker on the generator's control box for a

in

mind that the Westerbeke generator maybe the DC power

operate

DC

NMEA-2000):

the

generator

being

placed

Once the generator shuts

breaker as a safety precaution.

The electronic components

of

amperage (milli-amps) from

in

for

the system ECU and 50 milli-amps

of

months, such as winter storage,

to

the generator with a NMEA-2000

a static state. This

72 amp-hours

for

long

on

the

in

a months time

if

the generator

in

the

it

is

10

MAINTENANCE

A

WARNING:

running. use

the

correct

servicing

NOTE:

Many

difficult and may require the expert knowledge

Never

attempt

Wear

the

proper

tools

for

any

of

the

engine's

of

the following maintenance jobs are simple but others are more

safety

each

DC

to

perform

equipment

job.

Disconnect

electrical

SCHEDULE

any

service

such

the

equipment.

of

a service mechanic.

as

goggles

battery

while

terminals

the

and

engine gloves,

is

and

when

SCHEDULED MAINTENANCE

Fue.l

Supply

Fuel/Water

Engine

Coolant

Drive

Visual

Fuel Starting

(and

Engine

Generator

Heat

Fuel/Water

Exhaust

Engine

Separator

Oil

Level

level

Belts

Inspection

Filter/Inlet

Batteries

House

Batteries)

qil

(ami

Exchanger

Separator

System

Hoses

Filter

of

Engine

filteri

Zinc

Anode

CHECK

EACH

DAY

D D

D

0

D

weekly

0

weekly

HOURS

OF

OPERATION

100

Please will

inhibit

cool.

250

keep

the

0 0

500

engine

engine's

750

1000

surface

clean.

ability

to

0 0

50

NOTE:

and

oil

remain

0

0 D D 0 0 0

0 0 0 0 0 0 0

0 0

0

0 0

0 D 0 0

0 D

0

0 0 0

-,

EXPLANATION

1250

Diesel

No. 2 rating

Check

for

if

necessary).

Oil

level

should

dipstick.

Check

at

recovery

Add

coolant

Inspect

for

and

adjust

Check

Dirt

0

for

and

electrical

Check

for

Initial

change

Every

50

and

make

excessive Initial

engine

change

both

Check

that

with

no

chafing.

for

additional

Inspect

zinc

exchanger

Drain/Clean every 200 hrs or seasonally.

Initial

check

for

leaks.

the

exhaust

buildup

on

necessary. Hose

should

spongy.

Check

MAINTENANCE

water

and

indicate

tank;

if

needed.

proper

if

needed.

fuel,

oil

and

connections.

loose

belt

at

50

operating

sure

connections

corrosion.

oil & filter

every

AC

connections

See

information.

anode,

end

of

zinc

at

50

Check

anti-siphon

elbow inside Check

that

be

hard & tight.

and

of

tension

150

hrs.,

for

passages;

OF

SCHEDULED

45

cetane

or

dirt

in

fuel

(drain/replace

between

if

empty,

(3/8"

to 1 /2"

Check

belt

edges

water

leaks.

Keep

bolts & nuts

tension.

hrs,

then

change

hours

check

electrolyte

are

very

change

at

hours.

are

clean

GENERATOR

replace

if

needed,

anode

debris.

then

every valve

carbon

and/or

clean

all

connections

Replace

tighten

all

hose

higher.

1\~AX.

and

LOW

check

at

manifold.

depression) for

wear.

Inspect

wiring

every

250 levels

tight.

Clean

50

hrs.,

then

and

secure

SECTION

clear

the

250

hrs.

Inspect

operation.

and

clamps.

Check

corrosion

replace

are

tight.

if

soft

or

filter

on

tight.

hrs.

off

heat

as

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

Engines

& Generators

11

mechanic.

(continued)

MAINTENANCE

NOTE:

Use the engine hour meter gauge

engine hours by running time.

SCHEDULE

to

log your engine hours

or

record your

SCHEDULED MAINTENANCE

Raw

Water

Pump

At

800 operating hours,

disassemble and inspect

for

overhaul.

Raw

Water

Pump

Drive

Coolant

System

Electric

Fuel

Lift

Pump

DC

Alternator

*Fuel

Injectors

*Starter

Motor

*Preheat

*Adjust

the

*Heat

Exchanger

Circuit

Valve

Clearances

CHECK

EACH

DAY

50

D

HOURS

OF

OPERATION

250

100

500

D D D

D

D D D

D

D D

750

D

1000 1250

D

D D

D

EXPLANATION

MAINTENANCE

Remove

the

pump

cover

impeller,

Inspect seal should

Remove

slot

Drain,

appropriate

various

Periodically

inspect

Check

bracket;

Check

spray

Check

and

pinion

Check operation glow plugs; check resistance small amount

Adjust

cam,

housing

or

oil

turn,

pump

for

wear.

flush,

cooling

the

DC

tighten

and

condition

solenoid

lubricate.

drive.

Valve

(see

ENGINE

Remove, pressure

cover

and

weep

holes

leaks.

Check

shaft

not

wobble).

and

inspect

and

refill

cooling

antifreeze

check

fuel

charge

mixture

system

metals.

the

wiring

line

connections.

from

alternator.

electrical

adjust

injection

(see

ENGINE

and

motor

Clean

and

of

preheat solenoid. Remove and clean

of

anti-seize on threads.

Clearances

ADJUSTMENTS).

have

professionally

tested.

OF

SCHEDULED

and

impeller.

inner

for

bearings

pump

wear

plate

signs

shaft

system

Inspect

of

(the

and

with

compatible

connections

Check

connections.

opening

pressure

ADJUSTMENTS).

for

corrosion.

lubricate

the

starter

0.

9 Ohm. Reinstall with

cleaned

and

the

for

wear.

shaft

water

shaft

drive

with

and

mounting

and

Remove

motor

*WESTERBEKE

CAUTION

generators starting battery when the unit is in a static state. This maybe as much as 50.milli-amps This can be as much as normal seasonal use. However, to the generator with a

NOTE:

Keep

recommends

(WESTERLINK

this

or

NMEA-2000):

72

amp-hours

service

be

The electronic components

in

a months time with no generator use. It is not necessary to be concerned with this slight amperage draw during

if the generator set is not to be used

NMEA-2000 system

in

mind that the Westerbeke generator maybe the DC power supply

or

performed

shut

by

an

authorized

in

off

the DC breaker on the generators control box

for

Engines & Generators

mechanic.

the Digital Diesels draw a very small amount

a number

of

for

the vessel's NMEA-2000 network.

12

for

the system ECU and 50 milli-amps for each display.

months, such as winter storage,

for

a WESTERLINK system.

of

amperage (milli-amps) from the

it

is best to disconnect the DC power

FUEL

SYSTEM·

DIESEL

Use No.2-D (SAE 1313) diesel fuel with a cetane rating

#45

In conjunction with Ultra Low Sulphur Diesel. additive such as Diesel Kleen Power Services (product #3025) or equivalent to help restore fuel lubricity.

FUEL

The fuel injection pump and the fuel injectors are precisely

manufactured and they must receive clean diesel fuel, free from water and dirt. must pass through at least two fuel filters, a fuel water separator and the engine's spin-on fuel filter. Visually inspect, clean, and change these filters according to the maintenance schedule in this manual.

FUEL

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

The owner/operator is responsible for making certain the fuel reaching the engine's injection equipment is free impurities. This process is accomplished by installing and

maintaining a proper fuel filter/water separator between the fuel a

FUEL

or

higher. Grade diesel fuel according to ASTM D975.

Use an

+ Cetane Boost produced by

FILTERS

To

ensure this flow

WATER

tank

10

micron filter be used.

SEPARATOR

of

the water separating type must be

and the generator/engine. Westerbeke recommends

of

clean fuel, the fuel

of

ENGINE

Periodically check the fuel connections and the bowl for

leakage. Replace the filter element after the first then follow the MAINTENANCE SCHEDULE.

Changing

Refer to the illustration.

1.

2. Tum the fuel filter bowl counterclockwise to remove.

3..

4. Inspect both

5. Wipe the

6. Clean off the filter bowl and threads. (The bowl can be

7. The preheat sequence will allow the lift pump to

8. Run the engines and inspect for leaks.

FUEL

FILTER

50 hours

the

Fuel

Filter

Element

Shut off the fuel supply.

Pull the filter element straight down and off.

0-rings

up into place over the small 0-ring.

pre-filled with fuel). Screw the bowl into place when the 0-ring

contacts the housing. Tighten the bowl firmly by

hand.

fill the fuel filter.

and replace

with clean fuel and snap the new filter

if

worn.

FUEL

LIFT

PUMP

Periodically check the fuel connections to and out and make sure that no leakage is present and that the fittings are tight and secure. The DC ground connection at one pump's mounting bolts should be clean and well secured by

the mounting bolt to ensure proper pump operation.

When energized

purge

air from the fuel system and provide a continuous flow

of

fu~l

as

INLET

To

FUEL

ensure clean fuel into the fuel lift pump, there is a small in-line fuel filter connected to the fuel lift pump elbow. This filter should be replaced every

A

WARNING:

connections Make

sure

fuel

system

thru the preheat circuit, the fuel lift pump will

the engine is running.

FILTER

Fuel

leakage

is a fire

proper

hazard

ventilation

components.

200 hours

and

exists

at

the

should

of

fuel

whenever

of

operation.

pump

be

corrected.

servicing

the pump

of

the

or

its

SEALING

...-:::;~$~~

FUEL

FILTER

APPLY

WHEN

NEW

CARTRIDGE

#052985

GASKET

CLEANOIL

ASSEMBLING

FILTER

FROM

'\

L/FTPUMP

I

TO

j

INCOMING FUEL

FUEL

·"·

FILTER

13

FUEL

INJECTION

The fuel injection pump is the most important component of

the diesel engine, requiring the utmost caution in handling. The fuel injection pump has been thoroughly bench-tested and the owner/operator is cautioned not to attempt to service it.

If

it requires servicing, remove it and take it to an

authorized fuel injection pump service facility.

attempt to disassembly and repair it.

FROM

FUEL

FILTER

PUMP

Do

not

FUEL

SYSTEM

ACTUATOR

BLEED

The bleed screw on the injection pump should open position. This will then allow for ease in priming the engine's fuel system and during engine operation allow for

air in the system to be delivered to the fuel

fuel return system.

SCREW

FROM

FUEL

FILTER

A

WARNING:

when

servicing

any

fuel

that

open

flames system when

when

servicing

Shut

the

fuel

may

spill.

or

other

sources

servicing.

the

fuel

off

the

system.

DO

NOT

Ensure system.

TO

fuel

Take

allow

of

fire

proper

FUEL

valve

care

any

near

ventilation

be

left in the

tank

through the

INJECTORS

at

the

tank

in

catching

smoking,

the

fuel

exists

FUEL

INJECTION

PUMP

A

WARNING:

Use

extreme

FUEL

Ll

N E .

care

RETURN

.-----

'--

•

Fuel

is

to

prevent

present

spillage

in

the

hosing

SPEED

FACTORY

and

lines.

ADJUSTMENT

SET

FROM

FUEL

GLOW

J

INJECTION

PLUGS

PUMP

14

COOLING

SYSTEM

DESCRIPTION

Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to fresh water coolant which circulates throughout the engine. This circulating fresh water coolant cools the engine block, its internal moving parts, and the engine oil. The heat is transferred externally from the fresh water coolant to raw water by means exchanger, similar water flows through the tubes fresh water coolant flows around the tubes; engine heat transferred to the fresh water coolant is conducted through the tube walls to the raw water which exhaust system where finally it other words, the engine coolant transferred heat overboard through the exhaust system. The fresh water coolant and raw water circuits are independent each other. Using only fresh water coolant within the engine allows the cooling water passages to stay clean and free from harmful deposits.

is

cooled

RAW

WATER

NOTE:

Always install

the

strainer will always be self-priming.

A clean raw water intake strainer is a vital component engine's cooling system. Include a visual inspection strainer when making your periodic engine check. The water in the glass should

Perform the following maintenance after every operation:

1. Close the raw water seacock.

2. Remove and clean the strainer filter.

3. Clean the glass.

4. Replace the washer

5. Reassemble and install the strainer.

6. Open the, seacock. ·

7. Run the engine and check for leaks.

NOTE:

Also follow

aground.

If

the engine temperature gauge ever shows a higher than normal reading, the cause may be that silt, leaves or grass may have been caught up in the strainer, slowing the flow raw water through the cooling system.

INCOMING RAW

WATER

in

function to an automotive radiator. Raw

of

the heat exchanger while

is

then pumped into the

is

discharged overboard. In

is

cooled by fresh water coolant, this

by

raw water, and the raw water carries the

INTAKE

TYPICAL

STRAINER

the

strainer at or below

be

clear.

if

necessary.

the

above procedure after having

RAW

(OWNER

INSTALLED)

WATER

STRAINER

INSPECT CLEAN

tOO

the

waterline

100 hours

AND

EVERY

HOURS

of

run

a heat

of

the

this

of

hard

of

so

Heat

Exchanger

The heat exchanger is a copper tube which encloses a

of

number the small copper tubes and the freshwater coolant from the engine is circulated around the copper tubes. The raw water removes heat from the freshwater coolant.

HEAT

#052493

small copper tubes. Raw water is pumped through

HEAT

EXCHANGER

,

EXCHANGERS

ALOO

AVAILABLE

CUPRO-N/CKEL

ARE

WITH

TUBING

\

.L

COVER

#022850

BAD

•

Zinc

Anode

A zinc anode, circuit within the heat exchanger. The purpose anode is to sacrifice itself to electrolysis action taking place in the raw water cooling circuit, thereby reducing the effects of

electrolysis on other components condition the anode cleaned or replaced as required. Spare anodes should be carried on board.

NOTE:

installation and vessel location; not that

If

the zinc pencil needs replacement, hold the hex boss into

which the zinc pencil is threaded with a wrench while loosening the anode with another wrench. This prevents the hex boss from possibly tearing off the exchanger shell. After removing the zinc, note the condition

poor condition, there are probably a lot

the exchanger. Remove the end

clean the inside

exchanger end gasket in case the present one becomes

damaged when removing the end cover. Replace the gasket

(refer to your engine model's heat exchanger end gasket part

number), o-ring, cover, and install a new zinc pencil.

Heat

After approximately 1000 hours

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

heat exchanger.)

or

pencil, is located in the raw water cooling

of

the zinc anode should

Electrolysis action

of

all zinc debris. Always have a spare heat

Exchanger

Service

is

the

•

of

the system. The

be

checked monthly and

result

of

each

of

the

of

it.

If

of

zinc flakes within

of

the heat exchanger and

of

operation, remove, clean

CLEAN

·

AND

BAD

REUSE

of

the zinc

particular

generator.

the zinc

is

in

SEACOCK

15

COOLING

THERMOSTAT

A thermostat, located near the manifold at the front

as

engine, controls the coolant temperature continuously flows through the closed cooling circuit. When the engine is first started, the closed thermostat prevents coolant from flowing (some coolant through a hole in the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the thermostat gradually opens. The thermostat is accessible and can be checked, cleaned, or replaced easily. Carry a

spare thermostat and gasket.

the coolant

is

of

by-passed

the

SYSTEM.

TWIST THERMOSTAT ASSEMBLY

THE

LOOSEN

THIS

HOSE

1.

Drain

and drain the coolant

thermostat housing. This can be done using the heat

exchanger drain plug.

2. Rotate the as

shown and remove the three allen screws that hold

down the thennostat housing cover, the assembly can now

be twisted enough to access the gasket and thermostat.

3. Remove/replace installing the new parts, apply a thin coat both side

4. Re-assemble tighten the three screws. Do not over-tighten! Tighten the hose clamp and tighten the drains. Top off the coolant and run the engine. Check for normal temperature and for any leaks around the thermostat assembly.

CLAMP

off some coolant: Release the coolant pressure cap

to

the approximate level off the

thermostat

of

the gasket before pressing it into place.

and

assembly: Loosen the hose clamp

the

gasket

and

thermostat: When

of

sealant on

test: Tum the cover back into place and

GASKET

#298843

APPLY

SEALANT

WHEN

INSTALLING

THERMOSTAT

HOUSING

A

CAUTION:

down

before

is

the

surface

temperatures

The

engine

attempting

of

the

engine

can

be

at

must

these

hot but

190°

procedures.

F.

be

allowed

coolant

to

cool

Not

only

Engines & Generators

16

COOLING

SYSTEM

FRESH

NOTE:

recommended antifreeze

fresh water coolant.

Fresh water coolant is pumped through the engine lating pump, absorbing heat from the engine. then passes through the thermostat into the manifold, to the heat exchanger where it is cooled, and returned to the engine block via the suction side engine is started cold, external coolant flow is prevented by the closed thermostat (although some coolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheating). stat gradually opens, allowing full flow coolant to flow unrestricted to the external portion cooling system.

Coolant

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

WATER

Refer to the ENGINE COOLANT section

loss

of

TO

COOLANT

RECOVERY

COOLING

Recovery

coolant and without introducing air into the cool-

TANK

CIRCUIT

and

water mixture to be used as the

of

the circulating pump.When the

As

the engine warms up, the thermo-

Tank

be

located

be

easily accessible.

KEEP

THE

COOLANT

CLEAR

for

The

of

the engine's

at

or

above the

PASSAGE

the

by

a circu-

coolant

of

the

CHANGING

The engine's coolant must

MAINTENANCE SCHEDULE.

become contaminated, it can lead to overheating problems.

A

critical; a substantial traced

Drain the engine coolant by removing the drain plug on the engine block and opening the manifold pressure cap. Flush the system the refill process.

NOTE:

be used to help drain engine coolant.

A

Wear

COOLANT

be

changed according to the

If

the coolant is allowed to

CAUTION:

back

The drain petcock on the heat exchanger should also

WARNING:

protective

Proper

cooling

number

to

cooling

witli fresh water, then reinstall the drain and start

system

Beware

of

the

system

maintenance

engine

failures

corrosion.

hot

engine

can

coolant.

is be

gloves.

FROM

COOLANT

RECOVERY

NOTE:

pressure cap. Ensure the upper

good condition. Check to ensure the vacuum valve opens closes tightly. Carry a spare cap. coolant passage is clear so coolant within the system is able

to and from the coolant recovery tank.

TANK

COOLANT

Periodically check the condition

and

Check also to ensure the

to

expand

and

contract

1

~~~

~

COOLANT

RECOVERY

TANK

I

COOLANT

\(

EXPANSION

PRESSURE

/CAP

RETRACTION

of

the manifold

and

lower rubber seals are

~

1

f\ · engine cools down.

~

INSPECT

AND

I

THE

I

COOLANT TANK HOSE

CLEAN

AND

RECOVERY

ITS

CONNECTING

EVERY 3 MONTHS

Refilling

After closing the engine block drain, pour clean, premixed coolant into the manifold and when the coolant is visible in the manifold, start the engine and run it at slow idle. the air bleed petcocks on the manifold and the thermostat housing.

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

in

the manifold to the filler neck and when the coolant flowing from the petcock is free install the pressure cap.

Remove the cap on the coolant recovery tank and fill with coolant mix to halfway between the cap. Run the engine and observe the c.oolant expansion flow into the recovery tank. stat housing is free

After checking for leaks, stop the engine and allow it to cool. Coolant should draw

needed. Clean up any spilled coolant.

the

l

LE~TFRONT

.

BELOW

Coolant

of

air bubbles, close the petcock and

LOW

When

the petcock on the thermo-

of

air bubbles, close that petcock.

back

into the cooling system as the

Add

coolant to the recovery tank

and

SIDE

THE

ALTERNATOR

MAX

and replace

OF

Open

if

BLOCK

COOLING

RAW

WATER

The raw water flow is created impeller pump. This pump draws water directly from the ocean, lake, or river from a thru-hull opening through a hose to the water strainer. The raw water passes from the strainer through the pump to the heat exchanger (through exchanger tubes) where it cools the engine's circulating fresh water coolant. The raw water is then discharged into the

water-injected exhaust elbow, mixing with, and exhaust gasses. This mixture driven through the stem tube and overboard.

Raw

Watet

The raw water pump is a self-priming, rotary pump with a non-ferrous housing and a Neoprene impeller. The impeller has flexible blades which wipe against a curved cam plate within the impeller housing, producing the pumping action. On

no

account

always be a spare impeller and impeller cover gasket aboard

(an impeller kit). Raw water pump impeller failures occur when lubricant (raw water) is not present during engine operation. Such failures are not warrantable, and operators are cautioned to make sure raw water flow is present at start-up. The raw water pump should periodically for broken

MAINTENANCE

COOLING

Pump

should this

SCHEDULE.

CIRCUIT

by

a positive displacement

of

exhaust gas and raw water is

pump

be

run

dry. There should

be

inspected

or

tom impeller blades. See

the heat

coolirtg the

SYSTEM

IMPELLER

INSPECTION: EACH

REPLACE

ARE

ANY

WHEN THE

IMPELLER KEY. EITHER THE

CORRECT IMPELLER

CHECK

BLADE

BY

THE

IMPELLER

CRACKS.

INSTALLING:

FOLD

KEYWAY

THE

IMPELLER

DIRECTION

POSITION

STARTS

BENDING

AT

THE

BASE

VIGOROUSLY.

IF

THERE

TAKE

CARE

WITH

BLADES

{THEY WILL

WHEN

TO

ROTATE).

TO

THE

TURN

THE

ALIGN SHAFT

IN

IMPEUERKIT

#200175

RAW

WATER

#042175

IMPELLER-COAT BLADES GLYCERINE

PUMP

WITH

HOUSING

CHANGING

1. Close hose connection on the inlet and outlet nipples pump.

2. Remove the cap screws and hold down brackets that

secure the pump to the front gear case and lift the pump

off the engine. Check the pump's shaft drive tang for wear

and also the drive in the engine.

3. Remove the three cap screws that secure the impeller housing to the pump body (note the position

housing to the pump body) and remove the housing exposing the sea water impeller.

Pull the impeller off the keyed shaft and install the

4. replacement.

5. Lightly coat the glycerine lubricant. Check the condition

sealing

6.

Replace the impeller housing over the impeller

positioning it correctly on the body and secure it in place

with the three cap screws.

7. Secure the pump onto the gear case aligning the pump's

shaft tang with the drive slot.

8. Reattach the water hoses and valve. Run the unit and check for leaks.

THE

RAW

the

raw

water

inside

0-ring. Replace

WATER

intake

of

PUMP

valve and unfasten the two

the impeller housing with

if

needed.

open

IMPELLER

of

the

water

of

the

of

the

.

the housing

intake

AIR

INTAKE/SILENCER

The air intake port supplies cooling air to the control panel electronics. this air flow continues to the engines air intake/silencer to supply fresh This system requires

NO maintenance.

NOTE:

air to the engine.

If

the unit is being operated

in an area where air born contaminants

(silicon) are present. An external air filter must be added.

AIR

INTAKE

FREE

PORT

FROM

KEEP

OBSTRUCTION

CONTROL

PANEL

AIR

INTAKE

SILENCER

Engines

18

& Generators

ENGINE

1.

OIL

DRAIN

11/16"

SOCKET

FOR

EXTENSION

114"

NPT

ENGINE

OIL

CHANGE

Draining the Oil Sump. Discharge the used oil through

to

Drain

lube

the front of

the

used

oil

drain

~·

oil

completely,

the

hose

....

.~'-'~

the sump drain hose (attached

while

the

engine

is

warm.

replace

securely.

NOTE:

Thread

is

114

NPT.

the

hose

in

its brocket, and replace

size for

the

LUBRICATING

the

engine)

end cap

capped end

OIL

SPIN-ON OIL

FILTER

CARTRIDGE

#011951

GASKET

APPLY

CLEAN

TO

SEALING

OIL

GASKET

Always observe emulsion indicates the presence of water this condition prevent serious

water be present

be

the

result of a fault in engine and/or a siphoning of water cooling circuit into problem valve, its poor location or lack of maintenance.

2.

Replacing the Oil

filter, in

the

oil from it into a container before removing it:·This helps should be helpful

NOTE:

filter

Place some paper towels filter (Oil

or cooling oil

filter sealing gasket comes off rubber sealing gasket remains sealed against brocket, gently remove

When installing the gasket's sealing surface on

apply

the

on filter nipple filter

the

used oil

is

mre,

damage.

in

the oil.

is

often caused by

you

may

find

upper

and

lower portion of the old

to

lessen spillage. A small automotive

Do

not punch

to

make certain it

when unscrewing it

any

other

ability.

Keep

as

it

is

removed

a thin coat of clean engine

new

oil

filter.

on

the oil filter bracket,

firmly

by

hand.

as

it

is

removed. A

it does require prompt attention

Call a qualified mechanic should

Raw

water present

the

exhaust system attached

raw

water through

the

exhaust, filling the engine. This

the

absence of

Filter.

When removing

it helpful

in

removing the old oil

this

fluid

your engine clean.) Inspect

new

Screw the filter onto the threaded oil

and

cleaner

hole without first

can

be

removed.

and

a plastic bag around

to

catch

any

on

the

engine reduces

to

make sure that

with

the

old oil

it.

oil filter element, wipe

the

bracket

oil

in

the

an

oil left

free

to

the rubber gasket

and

then tighten the

yelh>w/gmy

oil.

Although

to

in

the oil can

to

the

raw

anti-siphon

the

used

to

punch a hole

filter

to

drain

filter

wrench

filter.

loosening

in

the

engine's

the

rubber

filter.

If

this

the

filter

the

of oil

and

oil

the

filter.

old

filter

NOTE:

Generic filters material standards or diameters generic parts might be entirely different from

parts. Immediately after

nin

the

engine

and

that-tl'tr.tre

3.

Filling the Oil Sump. Add new oil through

cap

on

the

top engine for a pressure. Make sure there is oil

filter

Then check the quantity of oil with

to,

Fill

the

engine require additional

A

WARNING:

contaminants. and

nails discard used

oil

few

or from the oil drain system,

but not over the high mark

Avoid

thoroughly

clothing

properly.

are

not

recommended,

of

important

an

oil filter

to

make

sure

the

oil pressure

are

no

oil leaks around

of the engine. After refilling,

moments while checking

no

leakage around the

on

oil.

Used

engine

oil

contains

prolonged

using

or

rags

skin

soap

and

containing

used

as

the

items

genuine

change

and oil

is

normal

the

new

oil

filter.

the

oil

filler

run

the

oil

and

stop

the

engine.

the

lube oil dipstick.

the dipstick, should

harmful

contact.

water.

Clean

Launder

oil.

Discard

on fill,

new

skin

or

NOTE:

Change

first

50

and filter at 150 hour

hours

the

engine

of

engine break

intervals.

lube

oil and filter initially after

in.

Then

change

the

lube

the

oil

19

DESCRIPTION

OIL

PRESSURE

The lubricating system an oil pump. The engine oil is drawn from the oil sump by the oil pump, which drives the oil, under pressure, through the oil filter, oil cooler and various lubricating points in the engine. The oil then returns continuous cycle. When the oil pressure exceeds the specified pressure, the oil pushes open the relief valve pump and returns to the oil sump, keeping the oil pressure

within its specified range.

OIL

PRESSURE

The engine's oil pressure, during operation, by

the oil pressure gauge on the instrument panel. During

normal operation, the oil pressure will range between

60 psi (2.8 and 4.2 kg/cm

NOTE:

A newly started, cold engine can have

up

to

reading an oil pressure reading as low as

readings will vary depending upon the temperature

engine

LOW

The specified safe minimum oil pressure

+

0.1

kg/cm a worn bearings. For additional information on low oil pressure readings, see the

OIL

PRESSURE

The oil pressure relief valve is located in the front gear case cover below the lube oil filter. It allen head plug. This valve opens at approximately 50 psi

(343kpa) and operates to maintain the pressure in the lube oil

feed system.

60

and

the rpms.

OIL

PRESSURE

2

).

A gradual loss

is

a pressure feeding system using

to

the oil sump

2

).

psi (4.2 kg!cm

ENGINE TROUBLESHOOTING chart.

RELIEF

2

).

A

warmed

35

of

oil pressure usually indicates

VALVE

is

held in place by an Smm

psi

(2.5 kg/cm

is

to

repeat the

is

indicated

an

oil pressure

engine can have

4.3 +

1.4

in

2

}.

of

the oil

40 and

These

the

psi (0.3

TESTING

NOTE:

gauge as shown. Warm up the engine and read the oil pressure gauge.

o<i801hpm.-

OIL

PRESSURE

An oil pressure sensor is mounted on the oil manifold for the engine.

as pressure. Should this signal fall below a set point in the

ECu. The

It

down. screen. Engine oil pressure dropping this to occur.

NOTE:

To gauge as shown. Warm up the engine sure gauge. or

more

SENSOR

It

sends a voltage signal to the ECU that

ECU will open the K2 run relay shutting the unit

will then display the fault on the LCD Display

test the oil pressure, install a mechanical pressure

Oil Pressure should be 35.0 lb/in2 (3.8 Kg/cm

at

1800 rpm.

OIL

PRESSURE

To

test the oil pressure, install a mechanical pressure

Oil Pressure should be 35.0 lb/in' (3.8 Kg/em')

\

~~

is

interpreted

10-

15

psi will cause

and

read the oil pres-

3

)

or

more

20

REMOTE

OIL

PN.#054372

INSTALLATION

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

ter from the engine to a more convenient location such as

engine room bulkhead.

NOTE:

Refer to ENGINE OIL CHANGE

in

this manual

instructions on removing the oil filter.

To

install, simply remove the engine oil filter and thread on

WESTERBEKE's remote oil filter kit as shown. Always

as

install this kit with the oil filter facing down

illustrated.

Contact your WESTERBEKE dealer for more information.

an

for

FILTER

(OPTIONAL)

NOTE:

Westerbeke is not responsible

incorrect installation

A

CAUTION:

rectly.

If

pass

valve

from

reaching

failure.

immediately

the

If

oil

in

the

there

and

of

the Remote Oil Filter.

It

flows

the

is

is vital

filter

engine

no

check

to

in

the

assembly

causing

oil

pressure

the

for

engine failure due

install

the

oil

lines

reverse

direction,

will

prevent

an

internal

reading,

shutdown

hose. c onnreclrton1s.

cor-

the

oil

engine

to

by-

THE

OUT

CONNECTION

MUST

ATTACH

OIL

TO

AT

FILTER.

CONNECTION REMOTE

THE

APPLY A THIN INSTALLING TIGHTEN CONTACTS

IN

COAT

THIS

KIT.

AN

ADDITIONAL

THE

BASE.

OF

CLEAN

OIL

TO

THE

THREAD

THE

3/4

TURN

,"G~

...

f-----l~~llllnH

D-RING

KIT

ON,

THEN

AFTER

THE

IN MUST CONNECTION

WHEN

HAND

D-RING

CONNECTION

ATTACH

TO

THE

AT

THE

OIL

FILTER.

HOSE

OUT

APPLY A THIN GASKET

WHEN

CONTACTS

THE

COAT

OF

CLEAN

INSTALLING.

BASE,

TIGHTEN

OIL

TO

AFTER

IT

AN

THE

FILTER

THE

FILTER

ADDITIONAL

WESTERS

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Problem

START

BUTION

indicatiins.

switch

depressed

engagement.

switch

OK;

not

functioning.

engine

actuator

There

is

engine

does

and a underspeed

on

the

runs

down.

not

charging

engine

display

under

There

is

does

not

screen.

starts,

smoking

depressed

is

depressed;

starter

energized.

an

LCD

an

start,

runs,

no

panel

START no

starter

START indications actuator

Generator start,

NOTE:

If

the

will

terminate

display

Battery

Generator (Fault

NOTE:

engine

and a underspeed

display

Engine

Exhaust

solenoid

cranks

but

8-10

sec

not

start,

display

stops.

speed)

8-10

sec

the

fault

will

and

shuts

problems

panel

OK

does

crank

the

screen.

crank

cycle

display

down.

not

cycle. cycle fault

cycle. will

terminate

on

Note:

rocker

will

If

the

LCD

ENGINE

The

engine's DC electrical system

type

reset

circuit breaker mounted

Probable

1.

Battery

Switch

2.

Circuit

breaker

Loose

battery

3.

1.

Connection Faulty

solenoid.

2.

Loose

battery

3.

4.

Low

battery.

5.

K1

Relay

Poor

connections

1.

2.

Defective

1.

Faulty

Fueling

2.

Preheat High

resistance

1.

2.

Low

resistance

Poor

battery

3.

DC

Alternator

4.

DC

charge

1.

2.

Alternator

Switches

1.

2.

Fuel

starvation.

3.

20

Amp

(LCD

display

4.

Exhaust

5.

Water

in

Air

intake

6.

1.

Faulty

oil

2.

Water

temperature

Faulty

exhaust

3.

Blue

smoke.

1.

2.

White

smoke.

White

smoke.

3.

TROUBLESHOOTING

Cause

not

on.

tripped/off.

connections.

to

solenoid

faulty.

connection.

to

actuator.

system.

solenoid

faulty.

leak

to

ground.

leak.

connections.

not

charging.

circuit

faulty.

drive.

and/or

wiring

loose.

circu~

breaker

tripping.

blank)

system

is

restricted.

fuel.

obstruction.

pressure

sensor

sensor.

temperature

switch.

is

protected by a 20 amp

on

the

control

panel.

Check

switch

1.

Reset

breaker;

2.

check

circu~

Check(+)

3.

1.

2.

3.

4.

5.

1.

2.

1.

1a.

1

b.

1c.

1

d.

2.

1.

2.

3.

corrosion.

4.

1.

2.

1.

2.

3.

4

5.

6.

1.

2.

3.

1.

1a.

2.

2a.

3. 3a.

3b. 3c.

connection

ground

stud.

Check

connection.

Check

that

12

Check

battery

Check

battery

Check

K1

relay.

Check

connections.

Remove

and

Check

that

the

Sw~ch

to

combine

Replace

batteries.

Check

fuel

lift

Change

inlet

Chech

solenoid.

Check

wiring.

Do

not

start

located. Check

all

wires

Check

cable

Check

connections,

See

DC

ELECTRICAL

Perform

DC

See

DC

ELECTRICAL

Check

drive connections. at

the

Exe

terminal.

Inspect

wiring

Inspect

sw~ches

Check

fuel

supply,

Check

for

High

not

overly

sensitive

Check

for

blockage

Pump

water

Check

air

intake

Check

oil

pressure

Check

water

Check

temperature

Incorrect

grade

Crankcase

is

exhaust). Engine

is

running

Faulty

injector

Improper

grade

Fuel

burn

incomplete insufficient system;

check Improperly Lack

of

air-

air

timed

Verification/Remedy

and/or

battery

connections.

if

breaker

trips

again,

for

shorts

to

starter

Check

battery

volts

are

present connections. charge

state.

check

actuator.

valves

are

house

pump.

fuel

filter.

Insert

sensitive

engine.

Remove

for

temperature

connections

voltage

belt

Check

from

temperature

overfilled

at

check

SYSTEM/ALTERNATOR

check

SYSTEM/ALTERNATOR

tension.

Alternator

output

for

short

circu~s

for

proper

fuel

valves,

DC

amperage

to

heat

or

collapsed

fuel

tank(s),

filter

cartridge.

sensor.

switch.

of

engine

with

cold.

or

incorrect

of

fuel

or

due

for

proper

air

intake.).

injectors

check

air

intake

ground.

solenoid

cable

connections.

at

the

open.

and

start

batteries.

(0-

.25

connections

rise

to

battery

for

belt

tension,

of

generator

should

w~h

voltmeter.

and

operation.

fuel

feed

draw

during

which

would

muffler.

change

sensor.

oil.

engine

oil

injector

timing.

possible

generator

to

high

back

combustion

or

valves

and

air

check

and(-)

solenoid

amp)

locate loose

test

charging

loose

strainer.

cause

filters

(oil

pressure

(Check

or

poor

filter.

LCD

preheat

solenoid

connection

connection.

meter

in

battery

and

replace

the

fault.

connections,

alternator.

in

ths

manual.

circuit.

in

ths

manual.

turn

freely.

Ensure

12

volts

connections

operation.

is

Ensure

tripping.

and

bleed

blowing

out

overload.

in

exhaust

for

restrictions

compression.

Check

for

proper

DISPLAY

(continued)

circuit

and

to

engine

lines.

after

short

is

Check

for

loose

are

present

breaker

fuel

system.

through

the

or

in

exhaust

ventilation.

FAULTS

is

•

Engines & Generators

23

ENGINE

TROUBLESHOOTING

LCD

DISPLAY

FAULTS

PROBLEM

LCD

DISPLAY

NOT

ILLUMINATE

LOW

OIL

PRESSURE

HIGH

COOLANT

HIGH

EXHAUST

BATTERY

GENERATOR

Overspeed Underspeed

LED TURN

WAITING

VOLTAGE

FREQUENCY

(steady

(flashing

DISPLAY

PINK

FOR

EDGES

DOES

TEMPERATURE

LED)

ECU

PROBABLE

1.

Check

2.

20

amp

Loose

3.

4.

1

amp

1.

Dillevel

2.

Lack

of

Ground

3.

4.

Faulty

5.

Faulty

1.

Check

2.

Sea

water

3.

Check

4.

Faulty

5.

Ground

6.

Faulty

1.

Check

2.

Faulty

3.

Ground

4.

Faulty

5.

Sea

water

Faulty

6.

1.

Check

2.

Check

3.

Check

4.

Faulty

1.

Check

2.

Check

3.

Amperage

4.

Crank (underspeed

1.

Compartment too

high.

1.

ECU

and

2.

Loose

3.

Panel

4.

Blown 8 amp

5.

Terminating

6.

Battery

CAUSE

battery.

breaker

off.

display

connection.

fuse

blown

low/oil

leak.

oil

pressure

connection.

control

module

oil

pressure

system

coolant

pump.

water

pump

temperature

connection.

control

module

sea

water

flow.

exhaust

temperature

Connection.

control

module

pump.

fire

suppression alternator charge battery

control

engine fuel

cycle

cable

DC

Voltage

drive

voltage.

connections. module

speed. supply. load.

with

no

fault)

ambient

LCD

display

connection.

breaker

fuse.

Resistors.

to

(faulty).

(ECU).

sensor.

level.

drive

belt.

sensor.

(ECU).

system.

belt.

(ECU).

start.

temperature

not

OFF.

ECU.

switch.

compatible

VERIFICATION/REMEDY

1.

Battery

on.

2.

Turn

breaker

3.

Check

all

cable

4.

Check/replace.

1.

Check

oil

level,

2.

Test

oil

pressure.

oil

filter,

inspect

Check

3.

4.

5.

1.

2.

3.

4.

5.

6.

1.

2.

3.

4.

5.

6.

1.

2.

3.

4.

1.

2.

3.

4.

1.

2.

3.

4.

5.

6.

ground

Inspect

all

the

Check

sensor/replace.

Add

coolant.

Inspect

impeller/pump/replace.

Adjust

belt

tension,

Check

sensor/replace.

Check

ground

Check

plug

connections/replace.

Inspect

thru

as

needed.

TesVreplace.

Check

ground

Check

plug

connections.

Inspect

impeller/replace.

By-pass

system/check.

Adjust

tension/replace

Check

excitation. Check + and -cables Check

plug

connections/replace.

Check

speed Inspect

filters/replace Check + and -cables Check

cause

Ventilate

Note:

display.

Check Check Turn Check/replace

Check per

Check unplugged present,

compartment.

Heat

will

This

compatibility all

cable

ON,

check

all

terminating

resister

measured

between

from

ECU

on.

connections. Determine

add

oil connection. plug

Check

circuit.

hull

fitting,

circuit.

setting.

for

no

often

will

connections.

DC

fuse.

pins

ECU.

is

faulty.

cause

oil

and

repair

If

OK,

test

pump.

connections/replace.

for

leaks.

replace

belt.

hose

if

worn.

Replace/repair

from

battery

filters.

from

battery

start.

change

not

effect

the

with

Westerlink

voltage

Check

DC

resistors

across

P2-24

Power

leaks.

oil

pressure

and

alternator

Test

the

color

operation

across

voltage

are

and

P2-25.

turned

sendor,

strainer.

to

engine.

fuel

pump

to

engine.

of

an of

or

NMEA.

breaker.

across

in

place.

#4

and

P2

ON.

Correct

operation.

LCD

the

engine.

fuseholder

120

#5.

ECU

plug

If

voltage

inspect

ohm

is

24

ALTERNATORS

TESTING/TROUBLESHOOTING

#10

ORANGE

B

SOLENOID

REFER

TO DIAGRAM MANUAL

.

WIRING

CONNECTIONS

THE IN

FOR

WIRING

THIS

ALL

50

AMP

DENSO

O

TO

B .

STARTER

ALTERNATOR

DESCRIPTION

The following information applies to the standard alternators that are supplied with WESTERBEKE' S Engines and Generators.

ELECTRICAL

The charging system consists regulator, an engine

circuit breaker and a battery with connecting cables. Because of

the use

regulator is very compact and is mounted internally

back

of

It

is desirable to test the charging system (alternator and voltage regulator) using the wiring harness and electrical loads that are a permanent part provide the technician with an operational test charging system as well as the major components electrical system.

ALTERNATOR

The stator is connected to a three-phase, full-wave bridge rectifier package which contains six diodes. The bridge converts the AC generated in the stator to a DC output for battery charging and accessories,

Power to the regulator and the field alternator is provided by the field diode (or diode trio) package contained in the alternator.

These alternators produce a rated output rated output is achieved at approximately rpm at an ambient temperature alternators are designed to operate in an ambient temperature range

of

CHARGING

DC

of

integrated circuits (IC's), the electronic voltage

the alternator.

CIRCUIT

of

an alternator with a voltage

wiring harness, a mounted DC

of

the system and will then

of

DESCRIPTION

of

the integral regulator

of

50

or

6000 alternator

of

75°F (23.8°C). The

-40° to 212°F (-40° to 100°C).

the

of

51

or

on

the

amps.

the

VOLTAGE

The integral voltage regulator is an electronic switching device which senses the system voltage level and switches the voltage applied to the field in order to maintain a proper system voltage.

The regulator design utilizes all-silicon semi conductors and thick-film assembly techniques. After the voltage has been adjusted to the proper regulating valve, the entire circuit is encapsulated to protect the circuit and the components from possible damage due to handling

ALTERNATOR

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

A

alternator alternator

LOW

If

the starter only moans

of

spinning the engine to life it is likely a low battery or a faulty connection in the starting circuit and not an alternator problem.

PRELIMINARY

Before starting the actual alternator and voltage regulator, testing the following checks are recommended.

1. Make certain your alternator is securely mounted.

2. Check the drive belts for proper tension. Replace the belt

if

3. Check that all terminals, connectors and plugs are clean

and tight. Loose resistance and this could cause overcharging, undercharging corroded battery cables could prevent the battery from reaching a fully charged condition.

4. Check the condition

A low or discharged battery may cause false readings in the tests.

NOTE:

selector switch is usually mounted in the circuit to isolate the batteries so the starting battery is not discharged along with the house batteries. starting battery but not the house battery, the alternator is OK

REGULATOR

TROUBLESHOOTING

WARNING:

BATTERY

A

can

become

until

if

/FAULTY

working

very

has

cooled.

or

CIRCUIT

makes a clicking sound instead

INSPECTION

it is worn

An

and

or

glazed.

or

corroded connections cause high

or

damage to the charging system. Badly

of

the battery and charge

isolator with a diode, a solenoid,

If

the isolator is charging the

the problem is

in

the battery charging circuit.

or

vibration.

or

with the alternator.

alternator

hot.

Do

runs

not

touch

if

a problem

If

hot. A failed

the

if

necessary.

or

misleading

or

a battery

it is

25

ALTERNATORS

TESTING

A

certain

away

1.

2.

THE

ALTERNATOR

CAUTION:

that

from

Start

the Engine.

After the engine has run for a few minutes, measure the starting battery voltage at the battery terminals using a multimeter set on DC volts.

a.

If

the voltage

alternator

b. If the voltage remains around

exists with either the alternator or the charging circuit; continue with Steps 3 through 6.

Before

everyone

sheaves

is

working.

starting

is

clear

and

belts

increasing toward

the

of

moving

during

12

engine

make

parts!

test

procedures.

14

volts, the

volts, a problem

TESTING/TROUBLESHOOTING

MEASURING BATTERY

{IGNITION ENGINE

Keep

VOLTAGE

ON

OFF)

MEASURING BATTERY

(ENGINE

3.

Thrn off the engine. Inspect all wiring and connections.

Ensure that the battery terminals and the engine ground connections are tight and clean

4.

If

a battery selector switch

that

5.

Thrn on the ignition switch,

engine.

6.

Check the battery voltage. condition the reading should be

VOLTAGE

RUNNING)

it

is

on the correct setting.

EEQJ

~llfL&t2~,l

is

in

the charging circuit,ensure

but

do

not

start

If

your battery

12

to

13

is

volts.

in

the

good

TESTING

1.

2. Wiggle the engine wiring harness while observing the

3.

4. Repeat the same measurement, the negative probe

5.

THE

OUTPUT

Connect the positive probe to the output terminal B and connect the negative probe to ground.

voltmeter. The meter should indicate the approximate battery voltage, and should not vary. obtained, or output circuit for loose or dirty connections or damaged wiring.

Start

ground, the positive probe to B with the engine running. The voltage reading should be between 13.5 and 14.5

volts.

it repaired at a reliable service shop.

If

the previous test reads only battery voltage at terminal terminal. inspect the wiring for breaks and poor connections. Jump battery) and operate the alternator. is 13-14 volts,

if

the reading varies, check the alternator

the

engine.

If

your alternator is over or under-charging, have

B,

use the meter to measure the DC excitation

If

12

volts is not present at exciter terminal R,

12

volts from a

..

CIRCUIT

If

no

12

volt source (such

If

the voltage output

then the alternator is OK.

reading is

as

the

to

\

TESTING

CIRCUIT

26

THE

OUTPUT

ENGINE

RUNNING

(+)

ALTERNATORS

TESTING/TROUBLESHOOTING

TESTING

1. Connect the

2.

THE

EXCITATION

positive(+) excitation terminal R on the alternator and the negative (-)

lead to ground.

Thrn the ignition switch to the on position and note

the multimeter reading. The reading should

2.5 volts (see illustration).

CIRCUIT

multimeter probe to the

be

TESTING EXCITATION

CIRCUIT

(ENGINE RUNNING)

3.

If

the reading is between .75

rotor field circuit probably is shorted If

the reading is between 6.0

4. field circuit probably is open.

5.

If

no reading is obtained, an open exists

alternator-excitation lead the regulator. Disconnect the lead from exc terminal Connect the positive multimeter probe to the excitation

lead and the negative multimeter probe to ground.

If

the multimeter now indicates an approximate battery

voltage, the voltage regulator is defective and must replaced. excitation circuit for loose damaged wiring.

If

no voltage is indicated, check the

and

1.1 volts, the

or

grounded.

and

7.0 volts, the rotor

in

or

in the excitation circuit

or

dirty connections

the

1.3 to

or

of

R.

be

CHECKING

Check the voltage have a voltage between running. charging circuit. Troubleshoot the service battery charging circuit by checking the wiring and connections, the solenoid, isolator, battery switch, and the battery itself.

THE

When the problem has been solved and before the alternator is back in operation, take the time to tighten and clean the terminal studs. Also clean the connecting terminals from the

wiring harness.

ALTERNATOR

If

tests indicate a failed alternator, it will need to be disas-

sembled and repaired. Any good alternator service shop can

do the job.

NOTE:

instructions for standard alternators.

THE

SERVICE

of

the service battery. this battery should

If

not, there is a problem in the service battery

BAnERY

13

and 14 volts when the engine is

REPAIR

WESTERBEKE'S

the

Service

disassembly and repair

Manual

has

of

BAnERYCARE

The minimum recommended capacity the engine's 12 volt DC control circuit is

Cranking Amps (CCA).

Review the manufacturer's recommendations and then

establish a systematic maintenance schedule for your engine's starting batteries and house batteries.

• Monitor your voltmeter for proper charging during engine operation.

• Check the electrolyte level and specific gravity with a hydrometer.

•

U,se

only distilled water to bring electrolytes to a proper

level.

• Make certain that battery cable connections are clean and tight to the battery posts (and to your engine).

of

the battery used in

600-

detailed

their

900 Cold

TESTING

THE EXCITATION CIRCUIT

ENGINE RUNNING

EXCITER TERMINAL

27

A

CAUTION:

circuit, the

never

engine

however.

engine's

electrical circuit.

is

to

avoid

To

avoid

shut

off

running.

electrical

damage

the

engine

Shut

off

the

shorts

to

the

battery

engine

when

battery

switch

battery

working

charging

while

switch, on

the

ENGINE

NOTE:

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

is

provided to assist the mechanic.

ADJUSTMENTS

CHECKING

Valve is

cold.

1. Remove the head cover.

2.

Align the on the housing so that the No. I piston comes to the compression or overlap top dead center.

3. Check the following valve clearance (1) marked with

VALVE

clearance must be checked and adjusted when engine

lTC

CLEARANCE

mark line on the flywheel and projection

* using a feeler gauge.

4.

If

the clearance is not within the factory specification,

adjust with the adjusting screw.

VALVE

CLEARANCE

The TC marking line on the flywheel is just for the No. 1 There is no piston comes to the top dead center position when the marking is aligned with the projection in the window on

the flywheel-housing. Turn the flywheel clockwise and counterclockwise to see if the piston is at the compression top dead center or the overlap position. Now, referring to the table below, readjust the valve clearance. The piston is at the top dead center when both the IN. and position when both the valves move.

Finally, turn the flywheel 6.28 radius

TC marking and the projection perfectly. Adjust

valve clearances After turning the flywheel counterclockwise twice or three

times, recheck the valve clearance. After adjusting the valve clearance, firmly tighten the locknut

of

the adjusting screw.

TC marking for the other cylinders. The No.1

EX. valves do not move. It is at the overlap

as

required.

0.18 • 0.22mm

(0.0071 -0.0087

0.26 radius (15°)

(360°) and align the

all

the other

in)

TC

PROJECTION

~

lTC

MARK

TIMING

WINDOW

l \

FLYWHEEL

\I

I

FLYWHEEL

J

HOUSING

Adjustable

cylinder location of piston

When

No.

1 piston is compression top dead center

When

No.

1 piston is overlap position

No.1 No.2 No.3 No.4 No.1 No.2

No.3 No.4

Valve arrangement

4

IN.

CYL.

EX.

*

3

CYL.

IN.

EX.

* * *

* *

-

*

-

* *

-

*

* *

""

28

ENGINE

ADJUSTMENTS

GLOW

PLUG

CONNECTION

GLOW

PLUGS

A

WARNING:

·to

the

touch.

testing

plugs.

To

inspect the plug, remove the electrical terminal connections, then unscrew Thoroughly clean each plug's tip and threads with a soft brush and cleaning solution to remove all the carbon and oil deposits. While cleaning, examine the tip for wear and has eroded too much, replace the plug.

An accurate way to test glow plugs is with an ohmmeter. Touch one prod to the glow plug's wire connection, and the other to the body

plug will have a with the plug in ammeter to test the power drain (12-13 amps per plug)

Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 7 to seconds. circuit. When reinstalling the glow plugs, use anti-seize compound on the threads.

If

These

glow

plugs

will

become

Be

careful

or

unclamp each plug from the cylinder head.

of

0.90 ohm resistance. This method can be used or

the plugs don't heat up quickly, check for a short

not

to

burn

your

the glow plug, as shown. A good glow

out

of

the engine. You can also use an

very

fingers

bum

hot

when

erosion;

STRAP

if

15

it

DRIVE

Proper inspection, service and maintenance is important for the efficient operation

Drive Belts under MAINTENANCE SCHEDULE).

Drive belts must will not provide proper alternator charging and will eventually damage the alternator. Drive belts that are too tight will pull the alternator out the alternator to wear out prematurely. Excessive drive belt tension can also cause rapid wear service life presence in high operating temperatures and tachometer variations.

The drive belt is properly adjusted no less than 3/8 inch (lOmm) and no more than 1/2 inch (12mm) as the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span A spare belt or belts should always

Adjusting

BELT

of

A

WARNING:

drive

belt's

ADJUSTMENT

of

the drive belts

of

your engine (see

be

properly tensioned. Loose d1ive belts

of

alignment and/or cause

of

the belt and reduce the

of

the coolant pump's bearing. A slack belt

oil on the belt can cause belt slipping, resulting

if

the belt can be deflected

be

canied on board.

Never

tension

Belt

Tension

attempt

while

the

to

check

engine

is

in

or

adjust

operation.

of

the belt.

the

or

the

1. Loosen the alternator adjusting strap bolt and the base

mounting bolt.

2. With the belt loose, inspect for

wear,

cracks and

frayt>-d.

edges.

3.

Pivot the alternator on the base mounting bolt to the left or

right as required, to loosen

4.

Tighten the base mounting bolt and the adjusting strap bolt.

5. Run the engine for about 5 minutes, then shut down and recheck the belt tensions.

ADJUSTING BOLT

STRAP

or

tighten.

WIRE

TIGHTENING

2.0-2.5

TORQUE

m-kg

(14.5

CONNECTION~

-

GLOWPLUG

BODY

-18.0

tt-lb)

29

ALTERNATOR

In case

of

severe vibrations and detonation noise, have the

injectors checked and overhauled by an authorized fuel

injection service center. loss

of

positive fuel pressure to the injection pump can result in injector faults. Since fuel injectors must be serviced in a clean room environment, it is best to carry at least one extra injector as a spare should a problem occur. following

page

for

Poor fuel quality, contaminant's and

Refer

to

injector

testing.

the

FUEL

INJECTORS

REMOVING

NOTE:

1.

Disconnect the high pressure lines from the injectors and loosen the lines and move them out bending the lines.

2.

Using a 17mm long socket, remove the fuel return line in its entirety from the top lose the two sealing washers and banjo bolt that attaches

the fuel return line to each injector.

NOTE:

prior

any hole. by side it and

3. The injector seats in the cylinder head on a copper seal-

ing washer. This washer should injector and replaced with a new washer when the injector is reinstalled.

INJECTION

1. Using the nozzle tester, check the spray pattern and injec-

tion starting linlit, adjust tester, take the following precautions:

A

of

skin

enters

a.

If replace it.

b. Set the nozzle tester in a clean place where there is

dust or dirt.

c. Mount the nozzle and nozzle holder on the nozzle

tester.

d. Use

of

e. Operate the hand lever

bleed the lever at intervals ing the injection starting pressure.

THE

INJECTORS

Injector

must

be

Clean

the

to

lifting it out

rust

or debris from falling

If

the

injector will not lift out easily and

carbon

build

with

the

aid

then

lift it

TESTING

preSsure or

replace the nozzle. \Vhen using nozzle

CAUTION:

such

velocity

of

fingers

the

bloodstream,

the diesel fuel

At

the same time, clean or replace the filter.

tl1e

fuel

at

68°

F (20° C)

air in the nozzle line, then move the hand

serviced

at

their attachment to the injection pump

area

up

of

in a "clean

of

the way

of

the injectors. Take care not to

around the base

of

the

cylinder head

or

the

like,

the I 7mm

room"

of

the injectors. Avoid

of

down

into

work

the

deep

socket

emirmunent.

the injector to

help prevent

the

injector

is

held

injector

side

wrench

to

out.

be

removed with the

of

nozzle and,

The

spray

injected

that

it

may

and

hands,

destroying

it

may

of

the nozzle tester

the approximate temperature

of

nozzle tester several times to

of

one stroke per second while read-

START

TO

1991

-2134

if

from

penetrate

cause

INJECTION

psi

(13.73

it exceeds the

the

nozzle

deeply

into

tissue.

If

it

blood

poisoning.

is

discolored,

PRESSURE

-14.71

MPa)

in

to

free

is

the

no

Inspecting

1.

Operate the hand lever one stroke per second to check

rectly

injects fuel in an oblique direction or in several strips. Also, a spray defect. These defects may sometimes be caused

ging with dust and, therefore, cleaned before reassembly. (Care should be taken not to expose ones skin to this spray as it may penetrate the skin and cause infection.)

~

2.

Apply the pressure by operating the hand lever, and check the drips from the nozzle tip. on the bottom, it is considered defective and should be repl!lced. A very small amount remain on the tip indicate a defect.

Spray

Pattern

of

the nozzle tester at intervals of

if

the fuel is injected cor-

in

its axial direction. A nozzle is defective

in

~1,rr

NORMAL

1

j

1r

1

•/rill

1

lrriJ

:J!l;\

If

the fonn

td

CHATTERING

of

1635lb/in2 (115 kg/cm

it

drips or has a large accumulation

of

the nozzle; however, tins does not

of

particles indicates a

ali pmts should be cm·efully

~

~~~

;:•

FAULTY

Ill

¥~~

.-~~

'

TEST

of

fuel may sometimes

if

it

separate

by

clog-

~

ll

"

!;,

,FAULTY

\.

II

~I

,,,

I"

...

2

to

nozzle

)

of

fuel

hOI

DRIP

TEST

The injection starting pressure for the injectors is adjusted

increasing or decreasing the tlllckness

TI1e

shim has I 0 different tlllcknesses for every 0.0020

(0.05

rnrn)~

between 0.0049in (1.25mm).to 0.0669in (1.7mm)

With each increased approximately replacing

remove

the specified torque;

INJECTOR

36.2-

0.0020in

tl1e

ti1e

body with a wrench. Tighten

TO

50.6

(49 -68.6

(0.05mm) increase, injection pressure is

7l.llb/in2 (5.0 kg/cm

shim, grip the retaining nut in a vise and

CYLINDER

HEAD

Nm)

TIGHTENING

of

the adjusting shim.

2

).

ti1e

retaining nut to

TORQUE

ADJUSTING SHIM

!

\Vhen

SHIM

in

THICKNESS

by

INJECTOR

. I

Engines

30

TYPICAL

& Generators

INJECTOR

PRESSURE

WITH ADJUSTING 34

PSI

0.01 (235

mm

VARIATION

KPa)

(0.004

WASHER

in) IS

STARTER

REFER

TO

THR DIAGRAM FOR

WIRE

The starting system includes the battery, starter motor and solenoid, and the ignition switches - Start/Preheat.

When the start button is depressed, current flows and energizes the starter's solenoid coil. becomes an electromagnet, which pulls the plunger into the coil, and closes a set reach the starter motor. At the same time, the plunger also serves to push that starter pinion to mesh with the teeth the flywheel.

To

prevent damage to the starter motor when the engine starts, the pinion gear incorporates an over-running (one-way) clutch which is splined to the starter armature shaft. The rotation

rotation

Once the start switch is released, the current flow ceases, stopping the activation out

of and the flow weakens the magnetic fields and the starter ceases its rotation. As the solenoid plunger is released, its movement

also pulls the starter drive gear from its engagement with

the engine flywheel.

WIRING

IN

THIS

MANUAL

CONECTIONS

The

energized coil

of

contacts which allow high current to

on

of

the running engine may speed the

of

the pinion but not the starter motor itself.

of

the solenoid. The plunger is pulled

contact with the battery-to-start cables by a coil spring

of

electricity is interrupted to the starter. This

MOTOR

TROUBLESHOOTING

Prior to testing, make certain the ships batteries are at full charge and that the starting system wiring connections

(terminals) are clean and tight. the ground wire connections on the engine block.

To check the wiring, seconds, never more than hand along the wires and terminals looking for warm spots that indicate resistance. Repair

Using a multimeter, test the voltage between the positive terminal stud on the start solenoid and the engine block (ground).

If

you

read

12

To test the ignition circuit, locate the ignition(s) terminal (it

of

is one circuit). from that ignition terminal to the positive battery connection terminal on the solenoid.

If If

motor

the small terminal studs and is wired to the ignition

Use a screwdriver,

the

starter

the

solenoid clicks

is

probably

POSITIVE

TERMINAL

try cranking the starter for a few

volts,

the

cranks,

(+)

the

but

faulty.

Pay particular attention to

10 seconds at a time, then run your

or

replace any trouble spots.

starter

is faulty.

don't

touch the blade, to jump

fault

lies with

nothing

the

happens,

ignition circuit. the

starter

EXHAUST

MANIFOLD

REFER

DIAGRAM

FOR

GROUND

TO

THE

IN

WIRING

WIRES

WIRING

THIS

MANUAL

CONNECTIONS

If

nothing current.. connections.

A

WARNING:

fly

when

space

gasoline,

materials

Engines & Generators

31

happens

Check the battery and inspect the wiring

jumping

is

free

and stored

at

all,

the

solenoid is

It

is also possible that the solenoid is defective.

There

will

be

arching

terminals.

of potentially

that

there

Be

explosive

are

NO

certain

flammable

not

and

the

fumes,

solvents

nearby.

getting

sparks engine

especially

will

or

STARTER

MOTOR

Test again by jumping the positive terminal to the M terminal. Pull the connection. Attach a terminal. terminal with the opposite allow the casing. This would cause a short.

A

starting

If

the

If

the

If

no arching occurred, there

solenoid.

back

the covering

Use

a battery type cable #8

jumper

WARNING:

starter starter

cable end to touch the solenoid

There

current

should

spins, the solenoid fails to spin, the motor is probably faulty.

on

jumper

cable to the positive(+)

end

to see the results.

will

be

arching

be

flowing

is

the M terminal to expose

or

better. Tap

as

thru

the

is

faulty.

no juice reaching the

Do

or

the

full

jumper

theM

not

starter

EMERGENCY

Con·osion to the stmter brushes and/or the solenoid contacts

can cause the sporadic problem

but

time will need to

It is however, sometimes possible to get started

starter lightly with a small hammer.

With the battery switch

starter/solenoid casing as shown, then try to start the engine.

START

not another.

be

rebuilt.

If

corrosion is the problem, the starter

off

and

fiY

EXHAUST

MANIFOLD

, /

1

#'''

,,,,,

,,,

~,,,

,~.A

.,

of

the engine starting one

by

taping the

no

ignition, tap lightly on the

REFER

TO DIAGRAM FOR

WIRE

NOTE:

In that engages using will

THR

WIRING

IN

THIS

MANUAL

CONECTIONS

Starter motors

the

pre-engaged

a screwdriver

run

the

motor without engaging

A

WARNING:

position the other

yourself

engine

crew

are

model,

the

starter motor

to

When safely

in

case

the

members

either inertia

the

solenoid also moves

to

the

bypass

the

performing

away

from

engine

starts-up.

of

the

danger.

type

flywheel

solenoid

the

flywheel.

these

the

or pre-engaged.

an

of

the

engine.

on

such

a starter

procedures,

moving

Also

parts

warn

arm

of

If

that fails, turn the battery switch on and have a crew

member

with the hammer., This

contact to start the engine.

the starter will need to

tum

the ignition on and

off

rapidly as you tap again

may

loosen the brushes and allow

When

you reach a repair facility,

be

repaired.

SERVICE

WESTERBEKE serviced center.

If certified for marine use. Automotive starters do not meet USCG dealer.

TO

1. Disconnect the negative battery cable.

2.

3.

4.

5. Remove the starter from the engine.

or

replacing the starter motor, make certain the new motor is

standards.

REMOVE

If

necessary, remove any components to gain full access

to the starter motor. Label and disconnect the wiring from the starter. (Do not

allow wires to touch, tape over the terminals). Remove the starter mounting bolts.

starter will have to obstructions,

uses a standard starter motor which can

rebuilt at any starter motor automotive service

If

in

doubt, contact your WESTERBEKE

FOR

SERVICE

In

some cases the

be

turned to a different angle to clear

be

32

SPECIFICATIONS

22.0/17.0

EDE

Engine

Type

Aspiration Compression Governor Combustion

Bore & Stroke Piston Firing Inclination

Weight

Compression

(allowable

Variation

cylinders Injection Engine

Valve

(engine Injector

Valve

Starting

Battery

DC Starter Starting

DC

General Oil Sump

(includes Operating

(engine Oil

Chamber

Displacement

Order

(dry)

limit)

between

Timing

Speed

Clearance

cold)

Pressure

Timing

Battery

Capacity

Charging

Alternator

Aid

Cranking

Current

Filter

Capacity

oil

filter)

Oil

hot)

Grade

ENGINE

Diesel, water-cooled, mechanism

Naturally

Ratio

22.6:1 Electronic Swirl 87 x 92.4

2.19 1-3-4-2 Continuous

Temporary

829

TUNE-UP

Pressure

626

472

10% 18° 1800

1500

0.18-0.22 (0.0071 -0.0087

1991 Intake

Intake Exhaust

Exhaust

ELECTRICAL

12-Volt 800-1000

40

1.4Kw, Glow 170

LUBRICATION

Pressure Full

8.0

Pressure

28 -57

API SAE

SPECIFICATIONS

four-cycle,

type

liters

lbs

(376.0

vertical

(35.5

aspirated

mms

(3.43 x 3.64

(134.07

20°

30°

(not

kgs)

four-cylinder,

in-line

at

cubic

to

exceed

overhead

1800

iinches)

inches)

rpm

10

hp

fresh

min.)

SPECIFICATIONS

psi ( 44

kgf/cm')

at

250

psi

(30.5

or

less

BTDC

rpm rpm

to

2134

Opens Closes

kgf/cm')

60

Hertz

50

Hertz

mm

psi

14° 36°

inches) (140

BTDC ABDC

45°

1

7"

at

to

BBDC

ATDC

250

150

rpm

kgf/cm')

SYSTEM

DC(-)

negative

ground

CCA

Amp

rated,

belt-driven

12VDC

direct

drive

plugs,

sheathed

type

-180

Amps

SYSTEM

fed

system

with

external

flow,

paper

element,

spin-on

type

U.S.

qts

(7.5

liters)

psi

(2.0 -4.0

kg/em')

Specification

IOW-40

or

15W-40

CF,

CG-4,

CF-4,

valve

maximum)

relief

valve

CH-4,

CI-4

General

Operating Fresh Raw

System (fresh

Raw (at

General

Fuel Fuel Fuel Injector Fuel Air Air

Air (generator

NOTE:

General -Single

Voltage -Single

Voltage Frequency

Generator Ambient Recommendations

Coolant Fresh

Exhaust Coolant Heat

Temperature

Water

Pump

Water

Pump

Capacity

water)

Water

Flow

1800

Injection Injection

Filter Intake Flow

Requirements

Water

Rejection

Rate

rpm)

Pump Timing

Nozzle

Combustion

cooling)

Increase

cooling

Phase

Regulation

Compartment

Temperature

Flow

Pump

Connection

Hose

Size

COOLING

Fresh thermostatically-controlled

160-180° F

Centrifugal Positive

gear-driven.

6

6.0

FUEL

Open (electromagnetic

No.2

Bosch

18°

Bosch Spin-on Metal

70.0

GENERATOR

0.8

air

flow

AC

Brushless, lubricated reconnectable

120 115/230

+ +or-

outlet 122° F (50°

NOTE:

maintain below

KEEL

16

2 1 76,000

19,000

SYSTEM

water-cooled

(71

type,

displacement,

qts

(5.61iters)

gpm

(22.7

lpm)

SYSTEM

flow,

self

bleeding,

diesel

(cetane

type

mini-pump

BTDC

throttle

type

screen/intake

ocfm

(1.9

cmm)

COOLING

Power

factor

15%

for

slower

GENERATOR

four

single

with

or

120/240

volts

50

or -2%

no

load

.3hz

(.5%)

C)

maximum

Forced

ventilation

gererator

12Z' F (50°C).

COOLING

gal/min

(60.51itres)@

y,

NPT

Female

1/4

I.D.

(31.75

BTU/Hr KcaVHr

engine

-82°

C)

metal

impeller, rubber

self

fuel

pump)

rating

silencer

unit.

500

turning

pole

revolving

bearing

design. 6 wire

solid

state

volts

60

Hz

to

full

rated

no

load

to

should

compartment

1800

mm)

block,

with

heat

belt-driven

impeller,

priming

of

45

or

box

CFM

(15.0

50hz

units.

field, voltage

amperage

full

rated

be

temperature

rpm

exchanger.

higher)

CMM)

sealed

regulator.

outlet

amperage

provided

to

Engines & Generators

33

SPECIFICATIONS

17.0/13.5

EDE

Engine

Type

Aspiration Compression Governor Combustion Bore & Stroke Piston Fuel

rated HP @ 1800/1500 Engine

Requirements Firing Inclination

Weight

Ratio

Chamber

Displacement

Consumption

amperage

outlet

Combustion

Order

(dry)

TUNE-UP

Compression (allowable

Variation cylinders

Injection Engine

Valve (engine

Injector Valve

Starting Battery DC

Charging Starter Starting DC

Cranking

General

Oil

Filter Sump

(includes

Pressure

limit)

between

liming

Speed

Clearance

cold) Pressure

liming

Battery

Capacity

Alternator

Aid

Current

Capacity

oil

filter)

ENGINE

at

RPM

Air

SPECIFICATIONS

Diesel,

four-cycle, water-cooled, mechanism.

Naturally

aspirated

23.8:1 Electronic Spherical

type

87 x 92.4

mm

2.191iters

1.50

1.22

38.0/25.6 1800

1500

1

Continuous Temporary

829

-2-

gph gph

rpm rpm

lbs

(134.07

(5.7 (4.6

58

48

3

20°

30°

(376.0

SPECIFICATIONS

512-

583

psi

(26

or

less

BTDC

rpm rpm

to

2134

Opens Closes

DC(-)

000

Amp

rated,

Kw,

12VDC

plugs,

(includes

fed

flow,

U.S.

qts

psi

kgf/cm')

60 50

mm

SYSTEM

CCA

sheathed

SYSTEM

paper

(6.0

370

10% 18° 1800

1500

0.18-0.22 (0.0071- 0.0087

1991 Intake

Intake Exhaust

Exhaust

ELECTRICAL

12-Volt 800-1 40

2.0 Glow 240

LUBRICATION

Pressure valve

Full

6.3

three-cylinder,

vertical

in-line

(3.43 x 3.64

cubic

lph)

at

1800

lph)

at

1500

cfm

(1.64

cfm

(1.36

(not

to

exceed

kgs)

(36-

41

kgf/cm')

at

Hertz Hertz

inches)

psi

(140

to

14°

BTDC

36°

ABDC

45°

BBDC

17°

ATDC

negative

belt-driven

direct

drive type

glow

plugs)

system

with

element,

liters)

overhead

inches)

pm rpm

cmm) cmm)

250

rpm

150

ground

external

spin-on

fresh

10

min.)

at

250

kgf/cm')

relief

type

valve

rpm

LUBRICATION

Operating

(engine

Oil

General

Operating Fresh

Raw

System (fresh

Raw (at

General

Fuel Fuel Fuel

Injector Fuel Air Air

hot)

Grade

Water

Capacity

water)

Water

1800

rpm)

Injection Injection

Nozzle

Filter Intake Flow

Combustion

Oil

Pressure

Temperature

Pump

Flow

Rate

Pump

liming

GENERATOR

Air

Requirement~

(generator

NOTE:

Generator Ambient

General-Single

Voltage -Single

Voltage

Frequency

AC

Generator Ambient Recommendations

cooling)

Increase

Compartment

Temperature

AC

Regulation

Amperage

Compartment

temperature

cooling

GENERATOR

phase

Phase

SYSTEM

28 -57

psi

(2.0 -4.0

API

Specification

SAE IOW-40

COOLING

Fresh thermostatically-controlled exchanger.

160-180° F Centrifugal Positive

gear-driven. 5

qts

(4.7

6.0

gpm

FUEL

Open

flow,

(electromagnetic

No.2

Bosch

18°

BTDC

Bosch

Spin-on

Metal

70.0

cfm

CF, CG-4, CF-4, CH-4, CI-4

or

ISW-40

SYSTEM

water-cooled

(71

type,

metal

displacement,

liters)

(22.7

lpm)

SYSTEM

self

bleeding,

diesel

(cetane

type

mini-pump

throttle

type

screen/intake

(1.9

cmm)

COOLING

250-

275

cfm

(7.08-

air

flow

15%

for

slower

122° F (50°

C)

maximum

(Single

Brushless, lubricated, reconnectable

120

230

±

±)

amperage 120

240 230

122° F (50°

Note-

maintain below

four-pole, single-bearing

or

120/240

volts

50

2%

no

load

Hertz

(.5%)

outlet

volts/141.7 volts70.8 volts/58.7

C)

Forced

generator

122° F (50°

with

volts

Hz

to

amps

maximum

ventilation

kg/em')

engine

block, with

-82°

C) impeller, rubber

self

fuel

pump)

rating

of

silencer

box

7.8

cmm)

turning

50hz

Phase)

revolving

design. 6 wire

solid

state

60

Hz

full

load.

no

load

to

should

compartment

C)

heat

belt-driven

impeller,

priming

45

or

higher)

units.

field.

voltage

full

rated

be

provided

temperature

Sealed

regulator.

to

Engines & Generators

33a

GENERATOR

SPECIFICATION 3 PHASE

AC

Three

Phase

17.0

Kw-

60

13.5

Voltage (60

Voltage (50

Amperage (60

Amperage

(50 Generator

Ambient Recommendations

Air Generator

Hertz

Kw -50

Hertz

-3

phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

Requirement

phase

-3

phase

Compartment

Temperature

Cooling

17.0/13.5

GENERATOR

Brushless, lubricated, reconnectable voltage protection

Low High

DELTA

High

DELTA Low

High

DELTA High

DELTA 122°F

NOTE:

to

maintain

temperatures

250-275 (7.08-

NOTE:

turning

sixsingle-bearing

Delta.

Solid

circuitry.

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

(50°C)

Forced

generator

cfm

7.8

cmm)

Increase

50

Hz

(3

pole,

for

maximum

ventilation

below

units.

EDE

Phase)

revolving

design.

low

voltage

state

voltage

should

compartment

122°F

air

flow

by

field.

12

WYE,

regulator

240

Volts

480

Volts

240

Volts

400

Volts

230

Volts

51

Amps 25Amps 51

Amps 24Amps

42Amps

be

(50°C).

15%

for

Sealed

Lead

high

with

provided

slower

AC

Three

Phase

22.0

Kw -60

17.0

Voltage (60

Voltage (50

Amperage (60

Amperage

(50

Generator

Ambient Recommendations

Air Generator

Hertz

Kw-

50

Hertz

-3

phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

Requirement

phase

-3

phase

Compartment

Temperature

Cooling

22.0/17.0

GENERATOR

Brushless, lubricated, reconnectable

voltage

protection Low

High DELTA

High

DELTA

Low

High

DELTA High

DELTA 122°F

NOTE:

to

maintain

temperatures

250-300

(7.08-

NOTE:

turning

sixsingle-bearing

Delta.

circuitry.

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

(50°C)

Forced

generator

cfm

8.5

cmm)

Increase

50

Hz

(3

pole,

for

Solid

WYE

maximum

ventilation

below

units.

EDE

Phase)

revolving

design.

low

voltage

state

voltage

should

compartment

122•F

air

flow

by

field.

WYE,

regulator

240 480 240

400 230

66

Amps

33

Amps

66Amps 30Amps

53

Amps

be

(50°C).

15%

for

Sealed

12

Lead

high

Volts Volts Volts

Volts Volts

provided

slower

with

Engines & Generators

33b

GENERATOR

USE

OF

ELECTRIC

The power required

is

more than Some motors require much more current

others. Split-phase

under similar circumstances, than other types. They

monly

machines, or where loads are applied after the motor

started, such

7 times

avoided, whenever possible, if ven

by motors require to

run. load connected compressor, for example, will require more current than a motor

In

general, to

medium

MOTOR

*NOTE:

more

for

this

made

Because motors is required for only

be

damaged if it can bring seconds. off

all

the

on

REQUIRED

Run

the generators capacity, indicted should be checked periodically the

generating plant voltmeter or ampmeter is not installed load,

required

used

on

as

much current

a small generator. Capacitor

The current required

to

which

the

current

starting

SIZE

(HP)

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

1

In

the

for

some

is

that

in

larger

the

heavy surge of current needed for starting

If

difficulty

other electrical loads

electric

OPERATING

generator on

the

check it

MOTORS

to

start

an

electric motor

to

keep it running after it is started.

(AC)

motors require more current

easy-starting loads, such

small power tools. Because they require 5

to

start

as

to

run,

the

electric motor

and

from 2 to 4 times

to

it.

An electric motor connected

no

load

is

required

loads

will

AMPS

(AMPERES) (AMPERES)

above

table

small motors

the

hardest starting types (split-phase)

as

to

start

connected.

to

start

be

approximately

FOR

RUNNING

3.2

4.6

5.2

7.2

10.2 13

the

maximum

than

for larger

much current

any

115-

is

considerably

to

start them than

are

as

washing

their use should be

is

to

repulsion-induction

to

start

motor varies

to

an

Volt

motors

connected

as

follows:

AMPS

FOR

STARTING

6.4

to

22.4*

9.2

to

32.2*

10.4

to

72.8*

14.4

to

29.2*

20.4

to

40.8

26

to

52

Amps

for Starting

ones.

The

sizes.

an

instant, the generator will not

the

motor

up

to

speed

in a few

is

experienced

and,

motor.

in

starting motors, tum

if possible, reduce

the

SPEED

first

with

no

load applied, then

and

finally loaded

generators data plate. The output voltage

and

the appliances it supplies.

with

a portable meter

to

its

to

ensure proper operation of

to

monitor voltage

and

amp

full

probe.

at

half

capacity

If

to

is

be

with

air

*

reason

are

load

an

INFORMATION

start,

com-

to

dri-

as

the

not

the

as

AC

and

is

Generator

• Maintaining reasonable cleanliness Connections of terminal boards and rectifiers corroded, salts, build excessive heating

• For unusually severe conditions, thin rust-inhibiting petroleum-base coatings, should be sprayed or brushed over

• In addition inspected for tightness of all connections, evidence of overheated terminals and loose or damaged

• The drive discs checked periodically if possible for tightness of screws and for

should not accelerate cracking. The bolts which fasten to 8, comers of the head.

• The rear armature bearing maintenance noisy

• Examine bearing of shaft should motion wear. will

CARBON

WESTERBEKE recommends mounting a carbon monoxide detector in

small amounts

The presence of carbon monoxide indicates from elbow/exhaust hose, or that fumes

are

leaking in your

If

carbon monoxide is present, ventilate

and

air

Maintenance

and

dust,

engine exhaust, carbon,

up.

Clogged ventilation openings

all

surfaces

to

any

evidence of incipient cracking failure. Discs

be

the

generator shaft must be hardened steel

identified

rub

by

or rough-sounding, have it replaced.

is

detectable, inspect

Repair must be made quickly or major components

and cause major damage

MONOXIDE

the

living quarters.

the engine or generator or

correct the problem immediately!

is

important.

may

become

insulation surfaces

and

reduced life of windings.

to

reduce rusting and corrosion.

periodic cleaning, the generator should be

on

single bearing generators should be

allowed

is

to

become rusty because rust

6 radial marks, one at each of

required. However, if

at

periodic intervals.

be

detected

may

start conducting if

etc.

are allowed

may

wires.

the

is

lubricated and sealed;

the

bearing becomes

No

side

when

force

is applied.lf side

the

bearing

to

generator.

and

cause

drive disc

SAE

grade

the

6

movement

shaft

for

to

no

DETECTOR

is

deadly.

area.

Carbon

Monoxide, even

from

the exhaust

from

an

exhaust leak

a nearby generator

the

area

with

clean

may

in

NOTE:

When

the

vessel

in

which

the

generator

of

contains AC equipment that

the

generators AC terminal block

vide one 120 volt AC hot

panel.

This

will

ensure

120 volts

leg

good motor starting

only,

be

for

the

vessels distribution

generator.

is

installed

it

is

recommended

configured

response

to

pro-

from

the

Engines & Generators

34

ELECTRONIC

ADJUSTABLE

OF

UNDERSPEED

PROTECTION

THRESHOLD

INTERVENTION~

OVERLOAD INTERVENTION

PROTECT/0

/

DESCRIPTION

The voltage regulator (AVR) ensures optimum AC generator performance. This advanced design AVR circuitry protection to guard against operating conditions that could be detrimental to the information details the voltage regulators adjustments and connections. These procedures should be performed by a qualified technician.

TERMINAL

#1. Excitation field #2. Exciter field jumper to 3

#3. Exciter field #3A. Supply voltage to regulator (AC). #4. Sensing voltage. #S. Supply voltage to regulator (AC). #6. Jumper to SA for

#7. Not used.

#SB. N0t used. #SC. Sensing voltage.

POSSIBLE

Exciter Field: The exciter field negative should be

connected to terminal dark blue or black), while the positive (normally red or yellow) should

Supply: There are two possibilities.

1. The supply coincides with the sensing. In this case the SR7/2 supply should be connected to terminals 3 and S (in case connected with the star point). Tenninals 3 and 4 should be connected to each other in such a way that the supply is also sensing. This connection in necessary when the generator does not have the regulator.

2. The supply and sensing separate. generator equipped with auxiliary winding for regulator supply. Supply is always connected to of

CONNECTIONS

between

Sand

DC

CONNECTIONS

be

connected to terminal3.

of

three-phase generators, tenninal S is normally

the regulator.

AC

generator. The following

DC

negative.

if

3A is less than 160

positive.

60 Hz operation.

1

of

the electronic regulator (nonnally

auxilimy winding for supplying

OLD

THRESH

N

l=:l

QO

~

p-.--;

HAm

ert

.

Stab

volt

~~

Z---'.

@~

~0

1-~

G}-

-------:;

~~

!_

- !"'-t

-

=oo

is

equipped with

the regulator AC supply

VAC.

Tl1i.s

is the case

tem1i.nals

of

a

3 and S

REGULATION

0 /

#052944

5

AMP

FUSE

PN

#052951

·D/~

liJon~~

.

J D

J

I

0

In both 270

should be bridged for supply with voltage between

160

voltage Sensing: Sensing should be connected to terminals 4 and S

and can vary from phase only and therefore alternator phase.

Operation and 6 should be connected to each other in order to keep the low frequency protection correctly regulated.

A

present. against

FUNCTIONS

Volt: With this potentiometer, it is possible to adjust the voltage generated by the alternator the screw screw is turned counterclockwise it decreases.

Stab: This potentiometer optimizes alternator performance.

If

turned clockwise, the stability decreases and the response time decreases but the voltage tends to be less stable. If turned counterclockwise, the response time increases voltage tends to be more stable.

In order to adjust this potentiometer correctly, we advise using

1. The generator must be working, and the potentiometer must be at maximum stability (turned fully counterclockwise).

2. Slightly tum clockwise until filmnent lamp oscillates, at potentiometer slowly counterclockwise until stabilizes.

-7

~-

l-oi

~

_,I~

~~

1-j

~+

~

-----tCONNECT

I~

___J

:t

1$,.

I~

-:==J

11..-

REMOVE

EXCITER

FOR

FIELD

60Hz

50Hz

I

of

these cases, the SR7/2 supply can vary from 80

VAC.

But it should be noted that terminals 2 and 3

VAC,

while the same terminals should be left open

is

between 160 and 270

80 to 350

at

60 Hz: When operating at 60 Hz, terminals

WARNING:

Take

electrical

is

tl1e

following method.

Be

aware

all

necessary

hazards.

OF

THE

REGULATOR

turned clockwise, the voltage increases,

VAC.

The sensing

is

normally connected to one

that

high

voltages

precautionms

POTENTIOMETERS

in

a very simple

stmting from zero load

t11e

light generated by the

tl1is

point, tum the

to

is

single

may

sate

tl1e

80 and

if

be

guard

way.

if

tl1e

m1d

light

to

the

SA

If

the

35

ELECTRONIC

REGULATION

#052944

TERMINAL

SHOWN

FOR

LO·WYE

TERI.INAL

BLOCK

CONNECTIONS

ARE

CONFIGUREO 110/108

ElOCK

VAC

Hertz: With this potentiometer, which

by

pre-calibrated then sealed

the manufacturer, it is possible

is

normally

to adjust the low frequency protection intervention. To recalibrate this protection, you must take the generator to a normal zero load condition, tum the potentiometer clockwise until the limit position is reached, then decrease

10

%.

the nominal speed by

Then tum the potentiometer

counterclockwise and measure the voltage value until it has

decreased by 5 volts.

10%

of

When the speed decreases by more than

the nominal

value, the voltage also decreases proportionally, blocking

if

generator overheating. Even protection at 10%

of

the nominal value, it is obviously

we advise calibrating this

possible to calibrate the threshold at other values. Amp:

With this potentiometer, it

intervention level

of

the overload protection. This protection

is

possible to adjust the

system has an intervention delay, which permits a temporary

overload, necessary when starting motors or similar applications. To

modify this protection, you must overload the generator

by 15%

of

the normal load, tum the potentiometer to minimum (counterclockwise) and wait about twenty seconds. During this period

of

time the voltage value decreases. In this

condition and while turning the potentiometer clockwise, fix

the generator voltage value at 10% less than the nominal one. At this point, while the initial overload is being removed, the voltage increases to the nominal value.

Fuse: The electronic regulator

protects the alternator from overheating in cases

is

equipped with a fuse, which

of malfunction. The fuse (250V-5A, quick acting, F type) can be replaced easily.

INTERNAL 12 WITH

r---·-----

I I

I . I

I

EXCITER

--~

~----,----------~

1 I 1

WIRE

WIRING

DIAGRAM

RECONNECTABLE

REGULATOR

I A I I I

I I I I

I I I

1 I 1

I I I

I I

I I I I

I L 1 -

I

--------

Amp-

Hertz

stab.

vol!-

___

---------

___

1--1---1

)

_____

FUSE

1.

J

regulator

REO

REFER

TO WIRING IN

THIS

THE

COMPLETE

DIAGRAM

MANUAL.

AVR

0

LT.

BtU

'"

TO FUSE

#52951

118

V(

PANEL

-;T~;OR

-

r===1----"'-..J

7

r=:=='H--"--___J

-

c::=J-:--"---

~

~~~:~-_t~c~~~~-_j_J

EXCITER

r

.. -...

-

aLl!

12

l

m -

~"-"l

I

ROTOR

COMPONENT RESISTANCE VALUES (AT

STATOR

(each

winding)

AUXILIARY EXCITER EXCITER

(each

pair)

ROTOR

IN

86°F)

__

____ STATOR. ROTOR

__

___

OHMS

·

_0.041

0.9

11.3

0.72

2.7

D

VOLTAGE

L--------~---4 T ~~-

REGULATOR

oc

BREAKER

YELLOW

RED

WESTERS

Engines & Generators

EKE

36

NOTE:

NO

LOAD

FULL

LOAD

EXCITER

DC

VOLTAGE I AUXILIARY

7.0

VDC

14.0

VDC

VOLTAGE

215

VAC

222

VAC

r-----------~

:

_A

EXCITER

I i-8--:----c----~ I

BLUE

_________

L

STATOR

:

EXCITER : ROTOR

I

ROTOR

I I I

I I

I I . I I I

I I .

L----

GENERATOR

. -

. :

I . I

DIDOES

_j

_T~E~~s_-

_j

WIRING

CONDENSER

FIELD

~~E~~

_j

SCHEMATICS

r-;----~

10

:

I

STATOR

I

1

_BLACK

GREEN

.

AC

TERMINAL

... 5

BLOC!(

·

'-~.r:.~~

VOLTAGE

AC

OUTPUT

NOTE:

ECU

REQUIRED RE-PROGRAMED CHANGING FOLLOWING

I.

2.

3.

ANY

SETTINGS

CHANGING

60Hz

AND CHANGING BETWEEN

AND

3-WI

CHANGING

BETWEEN AND

3-PHASE.

REGULATOR

DC

BREAKER

CONFIGURATIONS

. -

120-240V

/60

Hz

2 3 5

4 I

[IJJ[DJ

TO

BE WHEN OF

THE

BETWEEM 50

Hz

AC

WIRING

2-WIRE

I-PH

RE

I-PH

BACKEND

I-PHASE

BLUE

VOLTAGE

[EJ

6

2 3 5

INTERNAL

1

115V

50Hz:_.

SENSING

I

120V

BOARD

60

SINGLE

23DV

PHASE

WIRING

51JHz

SCHEMATIC

120V

CONNECTIONS

Hz 2

4 I

[IJJ[E]

2 3

5

3

6

5

60Hz -24DV

60Hz

AC

WIRING CONFIGURATION 22/17 SINGLE PHASE

EDE

·UI

4

220V

50

Hz

Engines & Generators

37

I 6

[I]

[E)

nov

4 I 6

50

Hz [IJJ

[E)

INTERNAL

WIRING

SCHEMATIC

EXCITER

ROTOR/ROTATING

CONDENSER

FIELD

TRANSIENT

,------------

1

I

EXCITER

I

WINDINGS

I

I I

I -

I I

~------

ROTOR

-------------

----..J

Erygines &

38

Generators

(SERIES WYE)

SERIES STAR

TWELVE

L

2

3

LEAD

N

WINDING/TERMINAL

AND

(NOMINAL)

(PARALLEL

PARALLEL STAR

WYE)

VOLTAGES

BOARD

N

CONNECTIONS

L

12

1

SERIES

DELTA

11

y

Lg

10..:11

0

L1

PARALLEL DELTA

2-3

0

5

50

Hz

L-L 400 volts

50

Hz

L-N 230 volts

60 Hz L-L.480 volts

60Hz

L-N

~·

1 3

5 7

6-7

0

9

L3 N

277

volts

L

9

11

5

4-8-12

L

SINGLE

PARALLEL

0

L

9

10-12

50 Hz L-L 200 volts 50 60 Hz L-L 240 volts 60Hz

PHASE

ZIG-ZAG

7 10

5

L N

10-12

.-{'-L-_...}.J

0'

1 3 5 7

2-4

5-7

Hz

L-N 115 volts

L-N 138 volts

2-4

L

0

~

9-11

L

10-11

0

1-12

50 Hz L-L 230 volts 50 Hz 60Hz 60Hz (Refer to Note

L~

THREE

PHASE

ZIG-ZAG

J.

8-10

0 0

1 5

7

N

---~

2-3

·o

5-4

6-7

0

9-8

t-N

115 volts L-L 277 volts L-N

138

volts

#

1)

L

0

~·~2

11

~

I

N

46

4-6

0

9

_l

5

3-7-11

r-0

n

':'"3~

2-12

Q

L1

50

60Hz

DOUBLE

DELTA

3wire 7

l

8-11

L2

Hz

L-L 115 volts

L-L 138 volts

,.__,.___...:~-...__...

2-3

l3

L

6-9

0 0

0

1

10 5 12

L1

50

N

Hz

L-L 230 volts 50 Hz L-N 60 Hz L-L 240 60Hz

115

L-N 120 volts

l2

volts

volt~

N

1..1

50 Hz L-L 230 volts

50

Hz

60Hz 60Hz

(Refer to Note #1)

Note

#1

Single The phase nominal value.

Note

The rated power

0.866.

current must not exceed the

#2

17tree

l2

L-N 115 volts L-L 277 volts L-N 138 volts

phase

ainpemge load.

phase

zig-zag connection,

must

be multiplied by

39

L1

50 50

60Hz 60 Hz L-N 240 volts (Refer to Note #2)

DOUBLE DELTA

lwire

L

8-11

0

1

10

N

'

L2

'

Hz

L-L 346 volts

Hz

L-N 200 volts

L-L 415 volts

2-3

~

5

12

50

Hz

L-N 230 volts

60Hz

L-N 240 volts

L3

7 4

N

6-9

0

L1

A

CAUTION:

unintentional on

the

control

As a precaution

start,

shut

off

panel.

the

CHANGING

AND HERTZ

against

20

Amp

an

DC

breaker

VOLTAGE

OUTPUT

1.

Refer to the previous page that illustrate the various AC voltage output configurations for both 60 & 50 hertz

applications. Select the configuration for the hertz/voltage required.

2.

Reconfigure the AC connections on the terminal block carefully following the illustration. Reference the voltage sensing board illustration and its connections to the are three line connections when needed and a neutral. These connections line (L) connection(s) and neutral on the AC terminal block.

3. When an

and tie

4. Inside the control box, locate the ECU and verify that the position

of

the

the generator will now be operating at.

5.

Connect or remove the jumper on the voltage regulator board between connections Reference the illustration on this page.

6. Using the EC20 Monitoring Software forD-Net models. (available

from the Westerbeke Distributor).

software installed to the communication pins #055351 communications cable connected between your laptop and the

ECU. (Note: The arrow on the plug connection for the ECU must

face the harness plug connection

MUST

L2

or L# is not present on the

offthe

#I

dipswitch

correspond to and be connected to the

unused sensing connections.

is

in

SA

the correct position for the hertz/frequency

and 6 for the hertz operation selected.

AC terminal block. There

AC

terminal block, insulate

Connect your laptop with the

on

the ECU using the

of

the ECU).

volt

AUTOMATIC

VOLTAGE

PN.

052944

REGULATOR

0

VOLTAGE

SENSING BOARD

EXCITER

FIElD

7.

Tum

ON the 20 amp panel DC breaker and then tum ON your laptop. Reconfigure the that the generator has been reconfigured to.

8. Verify all connections are correct and tum OFF the AC breaker on the

control panel. Start the generator and monitor hertz. Adjust AC voltage

9.

Tum ON the AC breaker and load test the generator monitoring operation. You can monitor the operation using the software satisfied with generator operation. Stop the generator. Tum DC breaker, tum OFF your laptop and unplug the control panel DC breaker back ON.

ECU using the software to the AC voltage(s) out put

DIPSWITCHES

0/PSW/TCH THE FREQUENCY.

OFF

SWITCHES #2, #3, an #4 SERVE FUNCTION.

as

needed using the volt pod on the A YR.

#1/S

USED TO CHANGE . n

ON

IS

FOR 60hz. THE REMAINING

FOR 50hz, .

AC output voltage and

in

your laptop. When

it

from the ECU. Then tum

d~~J

·~t'L~~

NO

OFF the panel

39A

#1

~nuJ

NOTE:

BE

TROUBLESHOOTING

AC generator troubleshooting must be performed with

the generator operating at the correct hertz.

NO

AC

VOLTAGE

RESIDUAL NO

LOW NO

HIGH

150

UNSTABLE (ENGINE

LOAD

AC

VOLTAGE

LOAD

AC

VAG

VOLTAGE

15-

60-

OUTPUT

OR

SPEED

FAULT

OUTPUT

PRODUCED

20

VOLTS

OUTPUT

100

VAG.

VOLTAGE

HIGHER.

VOLTAGE

OUTPUT.

STEADY)

AT

AC.

NO

AT

LOAD.

AT

1.

Short

or

main

stator

2.

Shorted on

exciter

3.

Four

or

open

diodes

1.

Blown 5 AMP auxiliary

2.

Faulty

1.

Reset

voltage

2.

Open

or

exciter

3.

Open

or

three

exciter

1.

Reset

voltage

2.

Faulty

1.

STB

pod

needs

PROBABLE

open

in

the

winding.

pozi-resistor

rota

r.

more

shorted

or

on

exciter

rotor.

fuse

circuit

feed

to

AVR.

voltage

regulator

potentiometer.

shorted

rotor 1 to 3 diodes.

voltage

adjustment.

diodes

short

in

one

rotor

potentiometer.

regulator.

on

regulator

of

windings.

in.

the

CAUSE

4.

Open stator

5.

Open

field

3.

Shorted stator

4.

Faulty

5.

Short

6.

Short

2.

Faulty

in

exciter

winding.

in

rotating

winding.

or

open

auxiliary

voltage

in

rotating

in

the

voltage

main

winding.

regulator.

field

exciter

regulator.

winding.

stator

..

AC

VOLTAGE

60

-100

DROP

VOLTS

AC.

UNDER

LOAD

1.

Diode(s) breaking applied

on

exciter

down

when

(inductive)

rotor

load

1-3

is

diodes.

Engines & Generators

40

EXCITER

LOW

VOLTAGE • EXCITER

AND

ROTATING

Position the exciter rotor/rotating field suppressor

FIELD

is

visible at the

ROTOR

12

O'Clock position.

so

the transient

ROTOR

TROUBLESHOOTING

TESTING

These windings as

shown

THE

on

the drawing.

EXCITER

are

ROTOR

tested in pairs: A to

WINDINGS

B,

B to

C,

and

C to A

TESTING

Place the ohm meter probes on

and (-). windings.

These wires

unless, when testing, there continuity

If

this

plates, isolate

NOTE:

screws

THE

ROTATING

These are the connecting wires for the rotating

do

not

need

to

ground

occurs, lift these

them,

and

When

removing

or

washers

into

FIELD

to

be lifted off their connections

is

an ohm valve discrepancy or a

(the

rotor shaft).

two

flarge

repeat

these

wires,

the

rotor.

WINDINGS

the

two

large red wires ( +)

field wires off

the

above

be

careful

test.

not.

the

to

diode

drop

field

the

GROUND

Disconnect these three wires from taking care not

With

the

with

an

No

continuity should be found between the rotor

these three winding pairs.

to

drop

wires clear from

ohm

meter,

A to

any

screws or washers.

the

bridge plates, test each pair

B,

B to

C,

the

diode bridge

and

C to

EXCITER

A.

ROTOR

plates

and

any

FIELD(-)

WINDINGS

of

VIEW

OF

ROTOR

FROM

THE

BEARING

12

END

0-CLOCK

POSITION

TESTING

Diodes can be checked with wire

of

the directions. A perfectly functioning diode high resistance in one direction the

opposite direction. A faulty diode will

low

resistance, or

the

Should the

screws with a suitable wrench

the

polarities

Engines & Generators

41

THE

DIODES

an

ohmmeter.

particular diode

an

whole bridge be replaced, remember

and

internal wiring diagrams

'

and

test its resistance

and a very

infinite resistance in both directions.

and

strictly

'

Disconnect

will

show a very

low

resistance

show

either a

comply

in

this

in

both

to

tighten

manual.

~

·,

the

in

very

with

GENERATOR

.

SERVICING

TESTING

Test the speed sensor connector for voltage and resistance values.

If

the values are correct, remove and inspect the magnetic pick up. With the wires disconnected, unscrew the magnetic pick up from the generator housing and visually inspect the contact end. the unit.

NOTE:

provided with the new magnetic

SPEED VOLTAGE

1.5-2.5

RESISTANCE

THE

MAGNETIC

Carefully follow the installation instructions

SENSOR

(while

VAC

(at

TEST

VALUES

cranking)

rest)

PICK

UP

COIL

If

any damage is detected, replace

pick

up coil.

950

-1

DOD

ohm

MAGNETIC

The MPU is installed of

the flywheel bellhousing. This positions the MPU over the teeth Viewing through this opening, manually rotate the engine crankshaft so as to position the flat gear's teeth directly under the opening. Thread the into the opening until it gently contacts the flat tooth (Thread is opening one turn and then lock it in this position with

jam

the approximately 0.030 inches away from the flats ring gear teeth.

To

en~.ure

the crankshaft by

physical contact between the

If

contact is felt between the MPU and the flywheel teeth,

MPU may be damaged. Remove the MPU and inspect

the it. Replace installation procedure.

NOTE:

MUST existing wiring cable. Doing so will cause a erratic signal to the controller.

PICK·UP

of

the flywheel ring gear.

nut. This will position the end

the MPU is positioned correctly, slowly rotate

if

necessary and repeat the above

When replacing the Magnetic Pick-Up (MPU) it be replaced without cutting and splicing into the

[MPU]

in

3/8" x 24). Back the MPU out

360° by hand to assure there is no

INSTALLATION

the threaded opening on the side

of

one

of

the ring

of

the MPU

MPU and the ring gear teeth.

of of

of

MPU this the

the

AC

--

Engines

42

& Generators

BE

GENERATOR

MAINTENANCE/PARTS

INSPECTION/CLEANING

Periodically inspect the rotor carrier bearing. Replace this bearing at wear is evident.

Inspect and clean the control box interior, look for loose, broken, (25 psi max.) to remove dirt and dust from components.

10,000 hours

or

burned wires and terminals. Use low air pressure

REAR

VENT

COVER

of

normal operation

or

sooner

if

BREAKDOWN

Remove all dirt, oil, grease and dust build external surface dissipation and causes the higher temperature. This results in a loss reduces service life.

of

the generator. Build-up reduces heat

AC

generator end to operate at a

up

from the

of

efficiency and

PARTS

BREAKDOWN

EXCITER

.~!JMATURE

DISASSEMBLY

Should it become necessary to disassemble the stator/rotor assembly from the engine, use the following as a guide.

1.

Properly support/lift the rear generator to be unbolted from the rear support isolators.

2. Mark, then disconnect the electricalleds that exit the generator from their connections in the control box. Be sure to properly mark the connection points the generator leds connect to. Make an illustration the generator is to be reinstalled be installed. This is to ensure proper reconnection electricalleds. Unbolt the control box and lift it generator.

3. Remove the rear vent cover. Support the generator with a sling

or

fabricated lifting eye. Using a 17mm socket wrench remove the four bolts that attach the generator stator housing assembly to the flywheel housing. carefully work the stator assembly off the rear bearing and off and over the rotor assembly.

of

the engine to allow the

if

needed whether

or

a replacement is to

off

of

the

4. Support the rotor assembly with a sling and using a 17mm box wrench, unbolt the rotor assembly from the flywheel.

REAR

VENT

·

COVER

DISC

Engines & Generators

43

BE

GENERATOR

ASSEMBLY

1. Position

holes Install threads) rod

the

THREADED

ROD

2.

With the the bearing

3.

Place

center

12mm x 1.75 boss ing assembly screws. washer

OF

the

in

the

and

M12 x 1.75 x 90mm

rotor

shaft.

the

aid stator housing assembly rotor

assembly

boss

a large washer of at least

hole

of

the

seats

fully

to Torque and

THE

GENERATOR

rotor

assembly

drive

discs

with

M8 x 1,25 x 25mm

torque

to

21

Nm

long

DRIVE

DISC/

of a sling or fabricated lifting

until

the

in

the

rear

support.

of

15mm

onto

nut.

Center

the

support

plate.

into

the

boss.

the

bell

housing

to

35

Nm

threaded rod.

Tighten

(25

onto

the

(16

and

rear

the

rear

Secure

using

ft-lb).

TO

the

holes

bolts

ft-lb).

into

the

carefully bearing

80mm

threaded

bearing the

the

THE

ENGINE

flywheel

in

(blue

nut

the

remove

aligning

the

flywheel.

loctite

Install a threaded

threaded

eye,

guide

contacts

in

diameter

rod

followed

in

the

until

the

stator

housing

four

MlO x 35mm

the

on

end

of

'

support

it over

the

with

by

bearing

bear-

nut.

the

a

4. Rotate

·

5.

a

the

generator

ensu.re

the

vent

cover.

Secure

the genenitor control connections.

wiring

box

generator

into

to

the

generator.

test

run.

by

hand

rotates

to

its

the

control box

two

freely.

rear

isolators.

Reconnect

full

revolutions

Reinstall

and

all

the

Route

mount

wire

to

rear

the

44

SHORE

POWER

TRANSFER

SWITCH

CONNECTIONS

DESCRIPTION

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

of

cuit, this must be done by means OFF SHIPS grams to the ous connection

A

utility at

the covered sibility

~

1

N

L1

GEN. Set the transfer switch shown in the dia-

OFF position. This switch prevents simultane-

of

shore power to generator output.

CAUTION:

shore same

to

L2

• I

power time.

under

make

Damage

and

This

the

warranty;

sure

all

to

generator

type

AC

the SHORE POWER

the

generator

output

of

generator

it

is

the

installer's

connections

can

result

are

connected

damage

are

correct.

if

is

not

respon-

t =

I

'-------,

I

I /

L-----{{D

~-----~

I ,

I

....

--,,

~~

I +--

I

__

./

---,

I

-=;,.

0

z

:I

0

a:

Cl

GENERATOR

~

N

w

!::

ll:

"

~

"'WD---~\

.----7-----\-(:3

(NEUTRAL)!

.--'---~c-{7

l SHORE

~

SHORE POWER

120

Volt/60

Note the repositioning

nal block to the generator case.

Generator

~

Hertz

Three

NOTE:

Diagram

wire.

120·Volt

with

three-wlre.'120-Volt

of

L1

NOTE:

Diagram

_..

2 I

shows

system

..

wire,

120-Volt

with

three-wire,120-Volt

GENERATORiSHORE

SWITCH

I I

' /

---

...--,

/5

~\

'1

6 I

__

....

' /

.J:.

-

GROUND

Wire

Configuration

the white ground lead

shows

connections

system

from

the

generator.

boat

system.

connections from

the

boat

L1

SHIP'S

LOAD

SHIP'S

-GROUND

on

for a two-

for a twogenerator. system.

the termi-

L_

..

L21

Ll

,

N J

JShip's

It•

connection~

For

dotted

Wire

three-wire

lines

for

the

Configuration

iii~!

j

~

't

Shore

~

Power

120/240-60HZ

,

__

...

./

GrOund

NOTE:

Hertz

I

Diagram wire,

120-voltsystem. system hot

leg.

Three

Neutral

shows

use

Note the repositioning of the white ground lead

nal block to the generator case.

A

CAUTION:

before

switching vice-versa ing

with

may

cause

the

generator.

because

heavy

damage

Heavy

shore

voltage

AC

loads

to

motor

leads

power

to

surges

on

the

exciter circuit

should

generator

induced

vessel

being

be

components

Load

for

two-

other

on

the tenni-

shut

power

by

switch·

operated

off

or

in

~

::J

z

"

I

__

_..

' /

/

......

-

....

I

iii!?

~

z

~

Shore

Po'wer

230

Volt/50

Notice the repositioning

.,,/

-c;ound (GRN)

Hertz

~

..J

,,

"'.______.~]

~-+-:.c.:..::=--N

Two

Neutral

(WHT)

II•

Wire

Configuration

of

the white ground lead

Ships

Load

~~T2~'o-Volt

Equipment

on

the

ter-

minal block to the generator case.

·

Engines & Generators

45

LAY·UP

&

RECOMMISSIONING

GENERAL

Many owners rely on their boatyards to prepare their craft,

including engines and generators, for lay-up during the

of

off-season or for long periods to accomplish lay-up preparation themselves.

The procedures which follow will allow you to perform your own lay-up and recommissioning, or you may use them check list if others do the procedures.

These procedures should afford your engine protection during a lay-up and also help familiarize you with the maintenance needs

If

you have any questions regarding lay-up procedures, call your local servicing dealer; he will be more than willing to provide assistance.

Propeller

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

of

the water or moved from land to water, and during

out storage in the cradle. The flexibility severe strain on the propeller shaft or coupling or both, while the boat shaft has actually been bent by these strains. This does not apply to small boats that are hauled out not in use, unless they have been period

Fresh

A 50-50 solution recommended for use in the coolant system at all times. This solution may require a higher concentration

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

solution to make sure the antifreeze protection Should more antifreeze be needed, drain

amount from the engine block and add a more concentrated mixture. and mixture cooling system. Now recheck the antifreeze solution's strength.

is

taken out or put in the water. In some cases, the

of

time.

Water

Operate the engine to ensure a complete circulation

Lubrication

With the engine warm, drain all the engine oil from the oil sump. Remove and replace the oil filter and with new oil. Use the correct grade

ENGINE LUBRICATING OIL pages in this manual for the

oil changing procedure. Run the engine and check for proper oil pressure and make sure there are no leaks.

A

CAUTION:

in

the

sump combustion chemicals internal

parts.

of

your engine.

Shaft

Coupling

Cooling

of

antifreeze and distilled water is

of

the antifreeze concentration throughout the

System

Do

not

over

the

lay-up

deposits

which

combine

can

reduce

inactivity. Others prefer

[Propulsion

of

the boat often puts a

of

dry for a considerable

Circuit

leave

[Propulsion

of

oil. Refer to the

the

engine's

period.

to

produce

the

life

Lubricating

an

of

as

Engine]

is

hauled

the water when

Engine]

of

is

adequate.

appropriate

fill

the sump

old

engine

oil

and

harmful

your

engine's

a

oil

Fuel

System

Top off your fuel tanks with unleaded gasoline

or higher. A fuel conditioner such as stabilizer should be added. Change the element in your gasoline/water separator and clean the metal bowl. Re-install and make certain there are no leaks. Clean up any spilled fuel.

Fuel

System

Top off your fuel tanks with No. 2D diesel fuel. Fuel additives should be added prior to topping off to ensure they mix with the fuel being added and fuel still in the tank. Additives. such as Bio-bor and Diesel Kleen + Cetane Boost should be added at this time to control bacteria growth and condition the fuel. Care should be taken that the additives used are compatible with the primary fuel filter/water separator used in the system. Change the element in your primary fuel filter/water separator clean the separator sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, as needed. Start the engine and allow it to run for

5-

10 minutes to system. Check for any leaks that may have been created in the fuel system during this servicing, correcting them needed. Operating the engine for 5 allow movement equipment on the engine.

Raw

Water

Close the through-hull seacock. Remove the raw water intake hose from the seacock. gallon bucket check the zinc anode found in the primary heat exchanger on the engine and clean or replace it as required, and also clean any zinc debris from inside the heat exchanger where the zinc anode

Start the engine and allow the raw water pump to draw the fresh water through the system. When the bucket stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed for winter freeze protection in your area.

Start the engine and allow all through the raw water system. the engine. This antifreeze mixture should protect the raw

water circuit from freezing during the winter lay-up,

as

providing corrosion protection.

Remove the impeller from your raw water pump (some

antifreeze mixture will accompany Examine the impeller. Acquire a replacement, if needed, and

a cover gasket. Do not replace the impeller (into the pump)

until recommissioning, but replace the cover and gasket.

Cylinder

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

arrester removed, while the engine

oil will stall out the engine and coat the valves, cylinders and

spark plugs for winter protection.

[Gasoline]

of

Sta-Bil gasoline

[Diesel]

maJre

sure no air

of

the treated fuel through the injection

Cooling

of

is

located. Clean the raw water strainer.

Lubrication

Circuit

Place the end

clean fresh water. Before starting the engine,

of

Once the bucket

[Gasoline]

is

left in the fuel

10

minutes will help

of

this hose into a five

this mixture to be drawn

is

it,

so catch it in a bucket).

is

running. The fogging

89 octane

as

is

empty,

empty, stop

as

well

46

LAY-UP & RECOMMISSIONING

Starter

Lubrication and cleaning if battery connections are shut off before attempting to remove the starter. Take care in properly replacing any electrical connections removed from the starter.

Cylinder

If WESTERBEKE recommends removal access to the cylinders. Squirt some Marvel Mystery the cylinder walls. Rotate the engine crankshaft by hand two revolutions and re-install the glow plugs.

If to be removed. Be sure to have replacement sealing washers for the injectors and return fuel line as needed.

Intake

Clean the filter screen in the flame arrester, and place a clean cloth lightly soaked in lube oil around the flame arrester to block any opening. Also place an oil-soaked cloth in the

through-hull exhaust port, Make a note to remove cloths prior

to start-up!

Motor

of

the starter drive pinion is advisable,

access to the starter permits its easy removal. Make sure the

Lubrication

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

your engine does not have glow plugs, the injectors will have

Manifold

[Diesel]

[Gasoline]

of

the glow plugs for

Oill into

Batteries

If

batteries are to be left on board during the lay-up period, make sure that they are fully charged, and will remain that to prevent them from freezing. batteries will not remain fully charged, or that they will be subjected to severe environmental conditions, remove the batteries and store them in a warmer, more compatible environment.

A

WARNING:

highly-explosive arcing

or a lighted

smoke

or

serviced.

to

prevent

Transmission

Check or change the fluid in the transmission as required Wipe off grime and grease and touch up any unpainted areas. Protect the coupling and the output flange with an anti-corrosion coating. Check that the transmission vent is open. For additional information, refer to the

Lead

gas,

allow

an

Shut

off

electrical

[Propulsion

cigarette,

open

all

If

acid

batteries

which

can

cigar,

Bame

electrical

arcing

during

Engine]

there is any doubt that the

emit

hydrogen,

be

ignited

near

the

equipment

or

pipe.

by

electrical

Do

battery

in

the

not

being

servicing.

TRANSMISSION

way,

a

vicinity

SECTION.

Spare

Lay-up time provides a good opportunity to inspect your Westerbeke engine to see or kit and order items not on hand, or replace those items used during the lay-up, such as filters and zinc anodes. Refer to the

SPARE

Parts

if

external items such as drive belts

coolant hoses need replacement. Check your basic spares

PARTS

section

of

this manual.

Recommissioning

The recommissioning seasonal lay-up generally follows the same procedures as those described in the section regarding preparation for starting and normal starts. However, some counteracted before starting the engine.

1.

Remove the oil-soaked cloths from the intake manifold.

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

3. Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making sure the terminals are clean and that the connections are tight. Check to make sure that the batteries are fully charged.

A

CAUTION:

and

eye

protection batteries can cigarette, Bame electrical arcing

4. Remove the spark plugs, wipe clean, re-gap, and install to

5. Check the condition

6. Start the engine in accordance with procedures described

emit

be

ignited

cigar,

near

the

equipment

during

proper tightness [gasoline].

circuit and clean that it is not necessary to flush the antifreeze/fresh water solution from the raw water coolant system. When the engine is put into operation, the system will self-flush in a short period advisable, as either an end service, to inspect the area where the zinc is located in the heat exchanger and clear any and all zinc debris from that area.

in the

PREPARATIONS

manual.

of

your Westerbeke engine after a

PREPARATIONS

of

the lay-up procedures will need to be

Wear

rubber

gloves, a rubber

when

servicing

hydrogen, a highly

by

electrical

or

pipe.

battery

Do

being

in

the

arcing

not

serviced.

vicinity

FOR

batteries.

explosive

or a lighted

smoke

or

Shut

to

prevent

STARTING

if

required).

Lead

gas,

allow

off

servicing.

of

the zinc anode in the raw water

or

replace the anode as needed. Note

of

time with no adverse affects.

of

season or recommissioning

FOR

STARTING section

apron,

acid

which

an

open

all

electrical

It

is

of

this

47

WATER

HEATER

CONNECTIONS

WATER

These engines are equipped with connections for the plumbing of The

either in a high that the connecting hoses from the heater to the engine can run in a reasonably direct line without any loops which might trap

REMOVE

HEATER

engine coolant to transfer heat to an on·board water hea,:et. ·

water heater should be mounted in a convenient locatiorl

INSTALLATIONS

or

low position in relation to the engine, so

air.

THE

EXISTING

WATER

CONNECT FROM

AS

SHOWN INDICATE OF

FLOW).

HEATER

two

HOSES

THE

HOT

WATER

HERE.

THE

DIRECTION

CONNECTIONS

TO

ANi)-

HEATER

(ARROWS

FRESH

WATER

CIRCULATING

PUMP

NOTE:

If

any portion engines own pressure remote

expansion tank (Kit #024177) must

circuit

to

become

tank

into

the

connections for

single line

engines convenient location The system fill when the remote expansion tank

tank serves the same

recovery

up

return.

remote

expansion tank will now serve

point.

tank if it

of

the

heating circuit

cap,

then

the

highest

point.

heater

circuit,

choosing

the

return.

Tee

at

to

the

tanks location and

Install

the

remote

so

the

coolant level can easily

The plastic coolant recovery tank

functiotJ. Remove and

has

been already

HEATING

rises

a pressurized

be

Tee

the

remote

the

higher

the

heater,

the

other back

expansion tank

as

kit

is

installed, since this

installed.

FRESH

WATER

CIRCULATING

PUMP

CIRCUIT

above

the

(aluminum)

installed

and plumb a

a check and

store

expansion

of

the

in

a

be

is

the

in two to

checked.

not used plastic

the

ABOVE

THE

ENGINE

TYPICAL

HOT

WATER

TANK

48

DECIMAL

TO

METRIC

EQUIVALENT

CHART

Fractions of

an inch an inch

1/64 1/32 0.03125 0.79375 17/32 0.53125 3/64 1/16 5/64 0.078125 1.98437 37/64 0.578125 14.68437 3/32 7/64 0.109375 2.77812 39/64

1/8 9/64 5/32 0.15625 3.96875 21/32 0.65625

11/64

3/16 0.1875

13/64 0.203125 5.15937 45/64

7/32 0.21875 5.55625 23/32

15/64 0.234375 5.95312 47/64

1/4

17/64 0.265625 6.74687

9/32

19/64

5/16 0.3125 7.93750 13/16

21/64 0.328125 8.33437 53/64

11/32 0.34375 8.73125 27/32

23/64 0.359375 9.12812

3/8

25/64

13/32 0.40625

27/64

7/16 0.4375 11.11250 15/16

29/64

15/32 0.46875 31/64 0.484375 12.30312

1/2

Decimal (in.)

0.015625

0.046875 1.19062

0.0625 1.58750

0.09375 2.38125

0.125 3.175

0.140625 3.57187 41/64 0.640625

0.171875 4.36562 43/64 0.671875 17.06562

0.250 6.35000

0.28125 7.14375 25/32

0.296875 7.54062

0.375 9.52500 7/8

0.390625

0.421875 10.71562 59/64 0.921875

0.453125 11.50937

0.500 12.70000 1

Metric (mm)

0.39688 33/64 0.515625 13.09687

4.76250 11/16

9.92187 57/64 0.890625

10.31875 29/32

11.90625 31/32

Fractions of

35/64 0.546875 13.89062

9116

19/32

5/8

3/4 0.750 19.05000

49/64 0.765625 19.44687

51/64 0.796875

55/64 0.859375

61/64 0.953125

63/64 0.984375

Decimal (in.) Metric (mm)

0.5625

0.59375 15.08125

0.609375 15.47812

0.625 15.87500

0.6875 17.46250

0.703125 17.85937

0.71875 18.25625

0.734375

0.78125 19.84375

0.8125 20.63750

0.828125 21.03437

0.84375

0.875

0.90625 23.01875

0.9375

0.96875 24.60625

1.00

13.49375

14.28750

16.27187

16.66875

18.65312

20.24062

21.43125

21.82812

22.22500

22.62187

23.41562

23.81250

24.20937

25.00312

25.40000

Engines & Generators

4:9

STANDARD

AND

LENGTH-DISTANCE

Inches

(in)

x

25.4

=

Millimeters

Feet

(ft)

x

.305

=

Meters

Miles

x

1.609

=

Kilometers

METRIC

(mm)

x

.0394

(m)

x

3.281

=

Feet

(km)

x

.0621

CONVERSION

=

Inches

=

Miles

DATA

DISTANCE

EQUIVALENTS

1

Degree

of

1

Minute

of

Latitude Latitude

VOLUME

Cubic

Inches

(in

Imperial

Imperial Imperial Imperial Fluid US US US

Pints Quarts Gallons Quarts Gallons

Ounces

Pints

(US

Quarts

Gallons

x

(US

(IMP

29.573

pt)

qt)

MASS-WEIGHT

Ounces

(oz)

x

28.35

Pounds

(lb)

x

.454

PRESSURE

Pounds

Per

Sq

lnch.es

of

Mercury

Inches

of

Mercury

Inches

of

Water

Inches

of

Water

Inches

of

Water

3

)

x

16.387

pt)

(IMP

x

.473

x

gal)

=

In

(psi)

(Hg)

(Hg) (HzO) (H20)

(H20)

=

60

Nm

= 1

Nm

=

=Cubic

x

.568

qt)

x

1.137

gal)

x

4.546

qt)

x

1.201

gal)

x

1.201

=

Milliliters

=

Liters(L)

.946

=

Liters

x

3.785

=Liters

=Grams

Kilograms

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

=

111.120

1.852

km

Centimeters

=

Liters

(L)

=

Liters =Liters

=US

Quarts

=US

x

.034

x

2.113

(L)

x

(L)

(g)

x

.035

(kg)

x

2.205

=

Kilopascals

=

psi

x

=

Kilopascals

=Inches

=psi

x

=

Kilopascals

km

x

1.76

(L)

x.88

(L)

x

(US

Gallons

=

Ounces =

Pints

1.057

=

x

.264

=Ounces

=

Pounds

(kPa)

2.036

=

(kPa)

of

Mercury

27.684

=

(kPa)

x

.061

=in

=

IMP

pt

=

IMP

.22

=

IMP

qt)

x

.833

(US

gal)

Quarts

=Gallons

x

.145

Hg

x

.2961

x

13.783

H20

x

4.026

qt

x

3

gal

=

.833

=psi

=

H20

IMP

=

Hg =

HzO

qt

IMP

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers

TEMPERATURE

Degree Degree

LIQUID

Diesel fresh Gasoline= 1 US

Salt

(Hp)

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

·

Fahrenheit Celsius

(°C) = (°F-

WEIGHTS

Oil= 1 US

Water

= 1

US

gallon=

Water

= 1

US

(in-lb)

(ft-lb)

x

1.609

x

.745

=Kilowatts

(MPG)

(Km/L)

US

(MPG)

(Km/L)

(°F) = (°C

gallon=

gallon

x

.113

x

1.356

=Kilometers

x

.354

x

2.352

x

.425

x

2.352

X

1.8) + 32

32) x .56

7.13

lbs

=

8.33

6.1

lbs

=

8.56

=Newton

(Kw)

=

Kilometers

=

IMP

=

Kilometers

=

US

lbs

Meters

Per

x

1.34

MPG

(Nm)

Hour

=MPH

Per

Liter

Per

(Nm)

x

(KPH)

(Km/L)

Liter

x

8.85

.738

=

x

.621

(Km/L)

=in-lb

ft-lb

=MPH

Engines. & Generators

50

CONTACT

YOUR

SUGGESTED

WESTERBEKE

DEALER

SPARE

MARINE

FOR

GENERATORS

SUGGESTIONS

PARTS

AND

ADDITIONAL

INFORMATION

.SA

FUSE

(ON

FRONT

OF

THE

CONTROL

PANEL)

WESTERBEKE

ENGINE

OIL

AND A GALLON

(YOUR

--------SPARE

WESTERBEKE also offers two Spare Parts Kits, each packaged in a rugged, rust free toolbox.

Kit A includes the basic spares. Kit B is for more extensive off-shore cruising.

Kit

A

Drive Belts

Oil Filter

Fuel Filter

Fuel System Hardware Kit Fuel Pump Inlet Filter

RECOMMENDS

BRAND)

OF

PREMIXED

HAVING

FOR

COOLANT.

PARTS

AN

OIL

HARDWARE

ENOUGH

SPARE

CHANGE

(5

QTS.)

KITS--------

KIT

IN·LINE FUEL FILTERS

(OWNER

Kit

B

Drive Belts Oil Filter Fuel Filter Fuel System Hardware Kit Fuel Pump Inlet Filter Injector Overhaul Gasket Kit Glow Plug

INSTALLED)

MOLDED

HOSE

IN A CANVAS CARRYING

KIT

BAG

51

Engines & Generators

12/2012-1180

Westerbeke 22.0 KW EDE, 17.0 KW EDE, 13.0 KW EDE, 13.5 KW EDE Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual