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

OPERATORS

MANUAL

D·NET

22.0

.17

.0

EDE EDE

Single

DIESEL

60Hz

31J

PUBLICATION

REVISION

MARCH

GENERATORS

17.0

13.5

ree

NO.

053852

5

2015

EDE EDE

Phase

·

50Hz 50Hz

I

jr~

'WESTERBEKE

j

WESTERBEKE

j

MYLES

WEBSITE:

NMMA

---

CORPORATION

STANDISH

Member

INDUSTRIAL

WWW.WESTE:RBEKE.COM

National

Marine

. .

•150 JOHN HANCOCK PARK • TAUNTON

Manufacturers

MA

Association

_..

ROAD

02780

A

wARNING

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF GET seek until

gasses

gas. can

Weakness

YOU

DR

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 caused

by precautions. Know when dangerous conditions exist take the necessary precautions to protect yourself,

personne~

The following safety instructions.are

the American Boat

PREVENT

A

WARNING:

while

engine

these

connections!

•

Do

not operate this machinery without electrical

enclosures and

• Shut off electrical power before accessing electrical equipment.

• Use insulated mats whenever working equipment.

• Make sure your clothing and skin are dry, not damp (particularly shoes) when handling electrical equipment.

• Remove wristwatch and all jewelry when working electrical equipment.

PREVENT

A

WARNING:

exhaust

very

hot!

• Monitor engine antifreeze coolant location when

A

WARNING:

•

In

case

before touching the engine

manual

failure to follow

and

your

ELECTRIC

is

BURNS -HOT

system

recovery

.on

the water jacketed exhaust manifold,

the engine is COLD.

of

an

carefully. Most accidents are

fundamental

machinery.

in

compliance with

and

Yacht Council

(ABYC)

SHOCK

Do

not

touch

AC

electrical'

running.

cov~rs

Lethal

in place.

voltage

ENGINE

Do

not

touch

hot

engine

components. A running

coolant

tank

and periodicaly

Steam

can

engine overheat, allow the engine

level at.

cause

injury

or

checking the coolant.

rules

and

standards.

connections

is

present

on

electrical

parts

engine

gets

the_

plastic

at

thC?

filler

or

death!

your

at

or

to

and

on

cap

but

cool

only

PREVENT

A

• Prevent flash fires. sparks to occur pump; vapors.

..removing the fuel lines

•

Do Backfire

•

Do the fuel system. engine chances

•

Be

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. after fueling. Check below for fumes/vapor the blower.

starting, follow the recommendation

• All fuel vapors are highly explosive. Use extreme care when handling well-ventilated area away from spark-producing

.equipment

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

• 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

•

Be

free

• Make sure a fire extinguisher is installed nearby and is

properly maintained. ExtinguisHers rated for all applications encountered in this environment.

BURNS -FIRE

WARNING:

or

Use

not operate with the air cleaner/silencer removed.

not smolce

. clean

aware - diesel fuel will

Fire

can

cause

Injury

or

death!

Do

not

smoke

or

permit flames

near

the fuel injector, fuel line, filter, fuel

other potential sources

a suitable container tq catch all fuel when

or

can

cause severe injury

or

permit flames

K~IJ

the compartment and the

and

free

of

debris to minimize the

of

fire.

Wipe

up

all spilled fuel and engine oil.

of

fuel filters.

or

sparks to occur near

bum.

spilled fuel

death.

or

fuel

BURNS -EXPLOSION

WARNING:

or

de;i_t/J!

DO

of

not alter sure all fuel supplies certain fuel line fittings are adequately tightened and

of

leaks.

Explosions

Run

the engine compartment blower prior to

and

out

of

NOT

allow any smoking, open flames, or other

fire near the fuel system or engine when

or

modify the fuel system.

from

fuel

vapors

can

Open and ventilate the cabin

oefore running

of

the vessel builder.

storing fuels. Store fuel in a

the reach

Be

ABC

of

children.

have

a positive shutoff valve.

familiar with its proper use.

by

the NFPA are appropriate

cause

it

is running.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

•

To

prevent

tor,

turn

from

•

To

prevent when OFF

•

Make starting.

•

Make re-installed

BATIERY

A

WARNING:

or

death!

•

Do

not being highly

arcing equipment during

•

Never positive Do

not together. Ventilate accumulation disturb is

being

•

Avoid burns wristwatch, the

battery.

•

Always the

battery

and

A

WARNING:

or

death!

STARTING

accidential

OFF

the

DC

the

generators

accidential

servicing,

position.

certain

turn

all

personnel are clear of

all

covers,

before

EXPLOSION

Battery

smoke

or,allow

serviced.

explosive or

servicing.

connect

test

the

contacting

or

reconnect it last when disconnecting the

Lead acid batteries emit hydrogen, a

gas,

by

lit

tObacco

in

the

vicinity

the

( +) connection terminal

the

battery condition by shorting

Sparks

could ignite battery gases or fuel vapors.

any

compartment containing batteries to prevent

of explosive gases.

battery charger connections while

charged.

sparks

that could cause

rings,

turn

the

battery charger off before disconnecting

connections. Remove the negative lead first

Accidental

starting when servicing the genera-

breaker or remove

control panel.

starting of the

the

battery selector switch

guards, and

starting the engine.

expiBsion

an

open

flame

'which can be ignited

products. Shut off all electrical

to

prevent electrical

negative(-) battery cable

the

terminals with tools, etc.,

and

any

other jewelry before handling

starting

the

fuse

generat.:m

the

engine before

hatch«?S

can

of

the starter solenoid.

To

an

explosion. Remove

can

are

cause

injury

near the battery

by

electrical

arcing

to the

avoid sparks,

the

battery.

cause

,,

'to

the

terminals

do

battery

to

prevent

injury

not

TOXIC

• Ensure that the exhaust system is

• Be sure the unit and its sun:oundings are

•

• For additional information refer to

•

IIi

AVOID

EXHAUST

A

WARNING:

discharged from the engine. Check regularly for leaks and make sure manifolds/water-injected elbow

Run blowers when running the generator set or Do

not run the generator set or engine equipped with a functioning marine detector that complies with boat builder or dealer for installation of detectors.

(educational information on Carbon

A

WARNING:

odorless nausea

gas.

or

death!

Do

not use copper tubing in diesel fumes

can rapidly destroy copper systems. copper tubing resulting in exhaust/water

Do

not install exhaust outlet where exhaust

through portholes, yents, or air conditioners. exhaust discharge outlet is near enter

the

flow

of exhaust. Avoid overloading

Although diesel engine exhaust exhaust fumes from gasoline engines, gas

is

present in diesel exhaust symptoms or signs of carbon monoxide poisoning are:

Vomiting Dizziness Headache

Nausea

MOVING

GASES

Carbon

Inhalation

Exhaust sulfur causes rapid

exhaust discharge outlet

Inability Throbbing Muscular twitching Weakness and sleepiness

monoxide

(CO)

is

ABYCA-24.

monoxide

produces

to

flu-like

tubing

the

and

gases

fumes.

think coherently

in

temples

adequate the

securely

ABYC

(CO)

exhaust

PARTS

is a deadly

the

exhaust

unless

carbon

Monoxide).

i'

deterioration

waterline,

close

the

are carbon

to

expel

exhaust

system

attached.

well

ventilated.

engine.

the

monoxide

Consult

approved

T-22

an

invisible

boat your

symptoms,

systems.

in

exhaust

leakage.

can

be

If

the

water

or

restrict

craft.

not

as

toxic

monoxide

Some

of

the

inhalation

gas!

gases

is

Diesel

of

drawn engine

could

the

as

or

BATIERYACID

A

WARNING:

severe

injury

•

When

servicing the battery or checking the electrolyte

level,

wear protection. destructive.

at

once

off into

the

caps.

Sulfuric

or

death!

rubber gloves, a rubber apron, and eye

Batteries contain sulfuric acid which is

If it comes in contact with your

with

water.

eyes

inadvertently when removing electrolyte

acid

in

batteries

Acid may splash on

can

sk;in,

the

cause

wash

it

skin or

Engines & Generators

ii

A

WARNING:

or

death!

•

Do

not service the engine while it is

situation_

make operating adjustments,

touching moving parts and hot exhaust

components.

Rotating

arises in which it is absolutely

parts

use

can

cause

running.

extreme care

system

injury

If

a

necessary

to

avoid

SAFETY

INSTRUCTIONS

• Do not wear loose clothing equipment; avoid wearing loose jackets, shirts, sleeves, rings, necklaces moving parts.·

• Make sure all attaching hardware Keep protective shields and guards

at

places

• Do not check fluid levels or the drive belt's tension while the engine

• Stay clear when the engine be caught in these rotating parts.

HAZARDOUS

A

WARNING:

or

bracelets that could be caught

all times.

is

operating.

of

the drive shaft and the transmission coupling

is

running; hair and clothing can easily

NOISE

High

noise

or

jewelry when servicing

is

properly tightened.

in

their respective

levels

can

cause

hearing

in

loss!

• Never operate an engine without its muffler installed.

• Do not run removed.

A

WARNING:

mentally

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 all safety

procedures.

an

engine with the air intake (silencer)

Do

not

work

on

or

physically

machinery

incapacitated

by

fatigue!

when

you

are

MANUAL

the preceding safety tips and warnings arc repeated

ABYC, INSTALLING

Read the following ABYC, NFPA and USCG publications for safety codes and standards. Follow their recommenda-

tions when installing your UNIVERSAL engine ABYC (American Boat and Yacht Council)

"Safety Standards for Small Craft" Order ABYC

613 Third Dtreet, Suite 10

Annapolis,

(

www.abycinc.org NFPA (National Fire Protection Association)

"Fire Protection Standard for Motor Craft" Order NFPA

1 Batterymarch P.O. Quincy,

USCG "CFR 33 AND CFR46" Code

Order From: U.S. Government Printing Office

Washington, D.C. 20404

NFPA

AND

MARINE

From:

MD

21403

41

0) 990-4460

From:

Park

Box 9101

MA

02269-9101

(United States Coast Guard)

of

Federal Regulations

USCG

PUBLICATIONS

ENGINES

FOR

AND

GENERATORS

ENGINE

Preparations to install an engine should begin with a thor-

ough examination (ABYC) standards. These standards are a combination sources including the USCG and the NFPA.

Sections

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

AND

GENERATOR

of

the American Boat and Yacht Council's

of

the ABYC standards

H-32 Ventilation for boats using diesel fuel H-33 Diesel Fuel Systems P-1

Installatiion

and Auxilliary Engines P-4 Marine Inboard Engines and Transmissions E-ll

AC

TA

Batteries and Battery Chargers

of

& DC Electrical Systems on Boats

INSTALLATIONS

of

particular interest are:

Exhaust Systems for Propulsion

of

Engines & Generators

iii

When

installing

attention

WESTERBEKE

be

paid

to

the

following

INSTALLATION

engines

infonnation: · ·

and

generators

it

is

important

that

strict

CODES

Strict when

AND

federal

regulations,

installing

REGULATIONS

engines

SIPHON-BREAK

For

installations

or

will

be

break

in

minimum

the

exhaust

raw

water

If

you

have

to

the vessel's

siphon-b~ak.

NOTE:

A

operation.

engine

dimuige.'

EXHAUST

The

exhaust system's Exhaust and

turns and

turns. system

MUST

under

any

where

below

the

vessel's

the

raw

water

of

20"

above

manifc!ld

damage

any

doubt

waterline

to

siphon-break

Failure

to

Corisult

.SYSTEM

Hose

is

recommended.

without

In

this

be

sea

conditions

the

regard,

designed·to

the

supply

the vessel's waterline. Failure

injection port

the engine and possible flooding

about

requr,.;,s

properly

hose

need

ABYC

and

under the vessel's

guidelines,

generators

exhaust manifold/water

waterline,

hose

the

periodic

to

the

is

position

in

a marine

provisions"

exhaust

at

or

of

various

inspection and

maintain a siphon-break

the

siphon-break

. .

MUST

The

of

additional

a single

and

length

prevent

at

any

manufacturer

be

certified

use

of fitting of

corrugated

the entry of waterinto the exhaust

angle

of

and

safety

environment.

injected

inust

elbow.

below

the

water-injected

operating

for

marine

this

type

and

clamps

vessels

code~

mu_st

be

complied

exhaust

be

made

This

to

use a siphon-break when

load

waterline will result in

of

the

cleaning

can

result

for proper

use.

of

hose

to

exhaust

heel.

elbow

tO.

install a

hose must

boat.

exhaust

conditions~

elbow

to

ensure

in

catastrophic

maintenance.

Corrugated Marine

allows

for

extreme

accomplish

hose

can

be

is

close

siphon-

be

looped a

relative

install

proper

these

used.

system

with

to

a

AVAILABLE

YOUR

DEALER

SfPHON-BREAI( LOOP"

bends.

bends

..

The

FROM

WESTERBEKE

WITH

STAINLESS

A

detailed

engines

to

download

Marine

and

generators, from

Installation

is

supplied

our

website

Engines & Generators

Manual at

covering

with

each

gasoline

unit. A pdf

www.westerbeke.com.

iv

and

diesel,

is

available

TABLE

Parts

Identification Introduction Fuel,

Engine Preparations Digital Digital Generator Da;ty

Routlna

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

011

for Control Control

Break-In

Maintenance Fuel

System

Cooling

Raw Heat Thermosta.t Raw Changing Raw

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

Engine

Engine Oil Change .............................................

Testing

Engine LCD·Display Alternator

Battery

Engine

Valve Glow

Drive Belt Adjustment .......................................

Fuel

Injectors

Injection Testing ................................................. 28

Starter

Troubleshooting .................................................. 30

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

System

Water Intake Strainer .................. , .............

Exchangl!r ..................................................

Water Cooling Circuit ...............................

Water Pump ...............................................

Lubricating

Oil Pressure ........................................... 20

Troubleshooting

Faults

Testing

Care

Adjustments

Adjustments .............................................. 26

Plugs ......................................................... 27

Motor

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

and

Engine

Initial

Panel

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

Box

(Earlier

Procedure

Coolant

Start-Up

Model

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

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

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

9~)

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

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

Schedule

(Chart): ................................

....................... " ..................................

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

the·

Coolant. ........................................

011

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

(Chart)

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

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

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

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

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

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

OF

CONTENTS

2

3

5

6 7

9

10 10

ll

13

15 15 15

16 17 17 18 18

19 19

Generator Electronic Internal Generator Schematic· Twelve

Lead Changing BE

Troubleshooting

Exciter

Rotor Generator Generator/Maintenance Power Lay·Up

w· · o·

Transfer

and

tnng

#53731 - 12V ..................................................... 46

#52951 - 12V #53829 - 24V Single Phase #54544#53901-

#54577-

Engine/Generator

21

22

23 25

26

22.0/17.0

17.0/13.5 EDE .................................................... 52

Generators ..........................................................

Remote Remote

27

28

29

Water Metric Suggested

Heater

Conversion

Information

Regulation

Wiring

Diagram

Wiring

Rotating

Winding

Hertz

and

Troubleshooting

Servicing

Switch

Recommissioning

•a

grams

24V NMEA 2000 ................................

24V NMEA 2000 ................................ 50

12V Single Phase .................................

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

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

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

Schematics

Field/Exciter Connections

Voltage

(Chart) .......................................

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

Rotor

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

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

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

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

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

Parts

Breakdown

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

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

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

Three

Phase ................................

..

; .............................

Specifications

EDE

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

Stop/Start Oil

Filter

Spares

Switch

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

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

Connections

Data

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

(Chart)

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

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

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

.31

32 33

34

35

36

37

38

39

.40 .41

43 44 46

.47

48

49

50A

51

53

54

55

56

57

59

Engines & Generators

1

PARTS

ECU

CONNECTIONS·......___

IDENTIFICATION

THER.MOSTAT

ASSEMBLY

RAW

WATER

COOLANT

OIL

DRAIN

PUMP

HOSE

REMOTE

-------;~

S/5

r-1\NII:L.·~

CONNECTION

FRONT

COOLANT

PRESSURE

CAP.

LEFT

SIDE

OIL

INTAKE

ELBOW

FILL

AIR

DIGITAL PANEL

HEAT

rnliTDn!o...-

20A

DC

BREAKER

REAR

MOUNTS

RIGHT

ISOLATED

SIDE

N

PUMP

Engines & Generators

2

INTRODUCTION

This

WESTERBEKE Engine WESTERBEKE' S technology. dependable performance of our engines Thank

.you

for

In

order

to

get important manual manual throughout. your

This available in hard copy

website. self. Review the Installation Manual supplied with this product.

that

is

designed

carefully

nearest is

your Operators Manual. A Service Manual is also

If

you are planning to install this equipment your-

Customer

long

We

take.

great pride

selecting WESTERBEKE. the

full

you

operate and maintain it correctly. This

to

and

observe

Should

your

WESTERBEKE

Identification

I...,IWESTERBEKE

1

Engines & Generators

Customer Identification WESTERBEKE MAIN HOMETOWN, Model Expires

STREET

OWNER

USA

is

a product of

years

of experience

in

the

use

and

benefit

help

you

do

this.

all

the

engine require servicing, contact

dealer for assistance.

thru a dealer or

and

advanced

superior durability

and

generators.

from

your engine,

Please

read

safety precautions

in

pdf form

Card

Ser.

#

this

off

it

our

WESTERBEKE span

between printings of WESTERBEKE product

and

software WESTERBEKE provided WESTERBEKE

is

be the

but

WESTERBEKE

to product software being consulted

and

relied

upon

respective product. It not only makes good

is

imperative that appropriate representatives of

determine

NOTES,

As

this

manual maintenance schedules, and troubleshooting of your engine, CAUTIONS,

NOTE:

critical information will

An

A

CAUTION:

can

result

A

WARNING:

can

result

customers should also keep

the

unavoidable existence of earlier

manuals.

with

WESTERBEKE products, whether

or other suppliers, must not

exclusively

or the supplier

the

accuracy and currentness of

CAUTIONS

takes you through

and

WARNINGS.

operating procedure essential

Procedures,

in

the

damage

Procedures,

in

personal

In

summation, proquct

as

the

definitive authority

in

AND

WARNINGS

be

An

which

or

destruction

which

injury

or

question

by

the

operating

highlighted

explanation

if

loss

of

in

mind

the

time

software from

and

cannot

on

sense

be

consulted

the

customer.

procedures,

marine

by

NOTES,

follows:

to

note.

not

if

strictly

of

not

observed,

your

engine.

p~perly

followed,

life.

WARRANTY

Your

WESTERBEKE

in

the

product documentation warranty registeration card that register your beke.com should the

mail contact the and

providing

unit

was

PRODUCT

Product brochures WESTERBEKE

PROCEDURES

Warranty

warranty

and

register

receiye a Customer

within

factory

your

put

into

or

your

60

days

of registering. If you

via

help@westerbeke.com advising of

name,

service.

SOFTWARE

software,

and

(tech

catalogs),

are

not

data,

provided within

go

to our website

product's warranty online.

Warranty

unit

parts lists, manuals,

Policy Statement

package.

model,

There

you

can

fill

Registeration Card

serial number

from

sources other

WESTERBEKE's control.

is a mail

out

and

www.

do

is

included

mail

wester-

not,

in

You

in

please and

date

than

PROTECTING

to

this

Care at resulted of not the This

NOTE:

• Proper

•

the

factory

in

a WESTERBEKE engine capable of

hours

of dependable service. However,

control

how

maimer

An anti-syphon

•

Changing

• Proper maintenance of maintenance

•

Use

•

Winterize

RECOMMISSIONING section

in

is

up

to

the

Six

important steps

engine

efficient,

clean,

YOUR

INVESTMENT

during assembly and thorough

or where

which the unit

buyer/owner-operator.

installation.

well-designed exhaust system

break

the

engine oil every 250 operating

schedule in this manual.

filtered

your

the

engine

is

operated

to

ensure

to

prevent water

all

engine components

diesel

fuel.

engine according

in

is

installed

a long engine/generator

from

to

the

this

the

manufacturer

and

serviced

that

entering

lAY-UP

manual.

testing

many

thousands

in

the

vessel

in

includes

the

hours.

according

AND

have

can-

or

the

field.

life.

an

engine.

to

the

Engines & Generators

3

INTRODUCTION

SERIAL

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

NUMBER

LOCATION

is

mounted on the side of the water jacketed

is

to

enter this information on

0 HZ.

60HZ.

also stamped

NOTE:

A carbon monoxide warning decal has been provided by WESTERBEKE. Affix this decal engine

room.

UNDERSTANDING

The diesel engine closely resembles the gasoline engine,

since the mechanism are arranged above a closed crankcase; the crankshaft the same general type diesel engine has the same type connecting rods and

Therefore, same preventive maintenance most important factors are proper ventilation and proper maintenance of the fuel, lubricating and cooling systems. Replacement time periods specified contamination (that is, water, sediment, etc.) in the fuel system 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 which performs the function

to

is

also essential. Another important factor

is

THE

DIESEL

is

essentially the same. The cylinders

as

that

lublicating system.

a great extent, a diesel engine requires

of

fuel and lublicating filter elements at the

is

a must, and frequent checking for

of

high detergent diesel lubrication oil

of

handling and firing of

a single component - the fuel injection pump

in

a visible position

ENGINE

of

a gasoline engine; and the of

valves, camshaft, pistons,

as

a gasoline engine. The

is

fuel.

of

both.

in

is

the

the use

The

the

of

An

identification plate on the engine manifold also displays

the engine model and

CARBON

WESTERBEKE recommends mounting a carbon monoxide detector in the vessels living quarters. even in small amounts, is deadly.

The presence from the engine or generator or from the exhaust elbow/exhaust hose, or the fumes from a nearby vessel are entering your boat.

If

carbon monoxide

air and correct the problem immediately!

MONOXIDE

of

selial number.

DETECTOR

Carbon monoxide,

carbon monoxide indicated

is

present, ventilate the area with clean

an

exhaust leak

ORDERING

Whenever replacement/service parts are needed, always provide the generator model number, engine serial number, and generator black name plate located on the generator end. provide us with this information so we may properly identify

your generator set. In addition, include a complete part descliption and part number for each part needed (see the separately furnished WESTERBEKE packaged parts because parts are frequently not made oliginal equipment.

SPARES

Certain spares will be needed WESTERBEKE generator. dealer will assist you in preparing See the Generator

INSTALLATION

Publication #43400 provides detailed information for installing generators.

PARTS

selial number

AND

ACCESSORIES

SPARE

PARTS page in this manual. For Engine and

Accessolies, see the ACCESSORIES brochure.

as

they appear on the silver and

Parts List). Also insist upon

will fit or generic

to

the same specifications

to

support and maintain your

Your

local WESTERBEKE

an

inventory of spare parts.

You

MANUAL

must

as

Engines & Generators

4

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

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

OIL

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:

reading upwards have These readings will vary depending upon the temperature the engine, the load placed on the engine, and the RPM's.

FUEL

2-D

(SAE

J313)

Of

The

Fuel

To

assure that the fuel going into the tank for your

are good examples

WITH A CETANE

diesel

Supply

i~

clean and pure, the following practice is

RATING

OF

fuel

according

of

fuel.Install and regularly

of

such filters.

to

of

500

#45

OR

HIGHER.

ASTM

0975).

the components

MA

or 230

OIL

50 hours

OIL

all

temperatures

of

break-in operation. Then follow the oil and

MAINTENANCE

in this manual. Westerbeke Corporation does

of

the use

of

synthetic oils.

Oil change intervals must be as in the

SCHEDULE,

VISCOSITY

GRADES

use

SAE

not extended because

10W-40

or

15W-40.

PRESSURE

2

).

A newly started, cold engine can have an oil pressure

of

60 psi ( 4.2 kg/cm

an oil pressure reading as low as

2

>.

A wanned engine can

25

psi (1.8 kg/cm

of

If

CF,

2

>.

of

ENGINE

WESTERBEKE reconuncnds a mixture and 50% distilled water. Distilled water is free from the 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

Select a brand Antifreeze specified for diesel engines contain a special additive cylinder walls. Prestone and Zerex are two nationally known

brands that offer antifreeze specifically for use in diesel engines. Select the pre-mix variety so that the correct mixture will always needed. Change the antifreeze mixture according to the MAINTENANCE SCHEDULE in this manual.

COOLANT

of

50%

It

allows the engine to

(SCAs) that keep the antifreeze chemically

ANTIFREEZE

of

antifreeze specified for diesel engines.

to protect against cavitation erosion

be

added to the cooling system when

of

the engine's

anLifreeze

MAINTENANCE

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

COOLANT

A coolant recovery tank kit is supplied with each engine or generator. The purpose

allow for engine coolant expansion and contraction during engine operation, without the loss introducing air into the cooling system. This kit is provided and must

NOTE:

located at can be located below the level particular installation makes this necessary.

of

operating hours as the chemical additives that

RECOVERY

be

installed before operating the engine.

This tank, with its short run

or

above the level

TANK

of

this recovery tank

of

coolant and without

of

plastic hose,

of

the engine's manifold, but it

of

the engine's manifold

is

of

is

best

if

the

to

the

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

INSPECTION

items;

a Check the engine oil level: add oil to maintain the level at

the full mark on the dipstick.

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

bowls for contaminants.

a Check the DC electrical system. Inspect wire connections

and battery cable connections.

a Check the coolant level in both the plastic recovery tank

and at the manifold.

NOTE:

After

the

engine's recovery the

cooling

after

the

tank

will

replace

initial running

cooling system will

tank.

Open

system

is

purged

engine

has cooled,

be

drawn

into

the

purged

air.

the

of

the

generator;

be

purged

air bleed petcock

of

air.

After

shutdown.

the

coolant

the

engines cooling system

from.

to

the

coolant

ensure

the

recovery

air

that

and

to

in

W

Be

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

or

open neutral can supply the wrong line-to-

on

unbalanced loads. ·

In

single phase systems an

as

tilt:

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

A

CAUTION:

recommended

motors, up This unanticipated

prevent a cold

be

to

speed

precaution

When

that

all

switched

and,

in

cold

will

operation

engine

starting

AC

loads,

OFF

until

climates,

prevent

of

the

from

stalling.

the

generator,

especially

the

engine

starts

damage

AC

machinery

large

has

to

warm

caused

it

is

come

by

and

up.

will

a Check load lead$ for correct connections as specified in

the wiring diagrams.

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

a Be sure

the load lines.

DIPSTICK

PUSH

no

other generator

IN

TIGHT

or

utility power is connected to

KEEP

112

FULL

LOW

'ADD

OIL

6

DIGITAL

CONTROL

PANEL

DESCRIPTION

WESTERBEKE' S Digital Control Panel provides the · operator with all the operations

an

LCD display that contunuously monitors

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.

12AFUS!=

PROTECTS

ELECTRONICS

AMPERAGE

INDICATOR

SIX

WHERE A FAULT

20A

SHUT-OFF MAINTENANCE REPAIRING A FAULT.

RESTART

THE

CONTROL

FROM A HIGH

OVERLOAD.

LIGHTS

THAT

INDICATE

HAS

BREAKE~

SWITCH"'-

WHEN

PERFORMING

OR

THE

ENGINE.

WHEN

PANEL

OCCUR

~

RESET

ED.

TO

FAILURE

A

RED

LIGHT

THE

RUN

INTERUPTED

LIGHT

WILL

APPEAR

SEQUENCE

IS

BY A FAILURE.

IF

START

STARTS

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

BUTTON

THE

ENGINE

LCD

DISPLAY

Operating temperatures may cause the LCD

in

color. This is normal and a change in color will not affect

display to vary

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

SCROLL

DOWN

TO

AND

ARROWS

LCD

DISPLAY MODE, ARROWS

ADJUST

LIGHT

CONTRAST

u~ing

IS

THE

CAN

THE

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·

DOWN-ARROW

··WHEN

IN

SCROLL

LOCK

BY

PRESSING

FUEL

PURGE

TO

THE

ON

THE

MODE

CAN

SEQUENCE

FOLLOWING

PRIME

BUTTON

THISBUTTON

PUMP.

AFTER

OR

PERFORMING

PRESSING

AIR

LINES.

OUT

THIS

AND

INDIVIDUAL BE

THE

ENERGIZES REPAIRING A FAILURE

BUTTON

BRING

FUNCTIONS

MONITORED

OOWN·ARROW.

THE

MAINTENANCE,

WILL

FUEL

IN

LCD

DISPLAY

IS

SHOWN

a soft

CAN

..

PAGE.,.

*MANUAL

ENGINE

SHUT-OFF

Should the stop button fail in its normal function to stop the

is

engine, the engine located on the engine block to the right side pump. Simply hold comes to a complete stop. This shutdown lever

equipped with a manual shutdown lever

of

the injection

the

lever to the left until the engine

is

standard on

current D-Net generators.

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:

~WESTERBEKE

I 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

SCROLL

Coolant TemperaturP

81C

32

0

178F

300 100

SCROLL

STOP

SEQUENCE

To

stop the generator, press the STOP button. The display

~v

ill

cyd..:

thru

th..:

fulluwing

Shutting

Down

Waiting

FAILURE

If

a problem occurs, the generator will shutdown and the

for

operator

Press

start

to

engage generator

LIGHT/SHUTDOWN

FAILURE light will illuminate red. In addition, one

texlllle~~age~

Engine Shutdown

auJ

~hmJowu.

of indicator lights will change from green to orange to reveal 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.

Reset

ECU

to

Restart

the

Battery Voltage

13.5 VDC

0

Engine Hours

3~8

(/)

AC Phase Voltage

:i

(Q

ro

A120V

""0

B120V

~

ru

en

CD

Q)

en

ro

AB38QVo

.r=.

a..

Q)

BC378V

~

.r=.

CA 380.V

1-

SCROLL

To

0 0

AC

Phase Voltage AC Line Voltage

0 0

LOCK

stop the continuing sequence, press the SCROLL LOCK

HOURS

30

SCROLL

200

---;=-::=!

200

SCROLL

600

SCROLL

I

Oil Pressure

3.1

-BAR

0 100 0

AC Frequency

60.1Hz

0

AC Line Voltage

120V

AB

BC378V

CA380V

0

380V.

. 0

0

.

40

PSI

6.9

SCROLL

100

SCROLL

200

SCROLL

600 600

600

LOCK

button. This enables the operator to monitor a single function for any length

of

time. The word LOCK will appear in the comer. Use the up and down arrows to find and observe other functions.

To

resume scrolling, press the SCROLL LOCK

button again. ·

Failure Light is red.

Oil Pressure Light is orange.

When a failure occurs, refer to the troubleshooting chart, wiring diagram, and general operating text assist in solving the trouble.

There are many combinations

Q)

en

ro

.r=.

a..

Q)

Ol

c

(jj

~

¢

m output configuration

I

""0

~

ru

en

CD

•

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,

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

CAUTION:

in the engine's exhaust system filling with raw water. This raw water can enter the engine's cylinders by way

exhaust manifold. not start, drain the system's muffler correct the cause of

raw water entry, is not a warrantable issue.

Low

Oil Pressure

ECU

and

investigate

to Restart

in

this manual to

DC

circuit

AC

of

and

the

Reset

of

messages that can be

tlie 20 amp

of

the generator.

Repeated crank cycles without a start can result

If

after three crank cycles, the unit does

of

no start. Engine damage, the result

8

DIGITAL

CONTROL

BOX

FREQUENCY

FAULT

Frequency is displayed on the LCD display screen while the engine is running in

RPM'and frequency (hertz).

The ECU is receiving a low AC voltage signal and hertz

signal from the MPU which

is

positioned on the bellhousing over the flywheel ring gear teeth. The ECU interprets this signal

as

both RPM and hertz.

· · Should this signal vary approximately 2% either

up

or down, a frequency fault shut down will occur, initiated by the ECU. 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

"overspeed:'

COMMUNICATIONS

ARROW

ON

PLUG

GENERATOR

1.

2. Open the cover

3.

4. Access

5. Plug

CABLE

6. Once

7. Proceed to page

Tum

FREQUENCY

the

DC

breaker on the control pllnel to thP

ADJUSTMENT

·(HERTZ)

position.

of

the control

box

and view the

(Electronic Control Unit). Access the opening

visable

in

the elongated area

the

#1 dipswitch and

of

the ECU.

The

dips witches are

of

this opening.

move

it

to the position that corresponds to the hertz operation desired. illustration shows these dipswitches.

in

the communications cable from your laptop having the EC20 software. plug connection should the

ECU

connections. Reprogram the

corresponding

ACvoltage

The

communications cable

have

the arrow

on

the plug facing

ECU

for the

output the generator is being

changed to.

the

change is completed,

Unplug

the

communications cable from the ECU.

39A

of

procedures for reconfiguring the

turn

OFF

your laptop.

this manual and follow the

AC

voltage output

the generator that has been selected.

OFF

ECU

The

of

CONTROL

BOX

I

COMPONENTS

4

·WAY

CONNECTOR/

CAUTION

generator's starting battery

This can be as much as normal seasonal use. However; to the generator with a

NOTE:

(WESTERLINK

Keep

in

mind that the Westerbeke generator maybe the

or

NMEA·2000):

when the unit is

72 amp-hours

The electronic components

in

a sratic state.

in

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

if the generator set is not to be used

NMEA-2000 system or shut

This

off

the DC breaker

in

the Digital Diesels draw a vel)' small amount

maybe as much as

for

a number

C?n

the

DC

power supply

50

milli-amps f.or the system ECU and 50 milli-amps

of

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

generator~

for

control box

the vessels NMEA-2000 nerwork.

9

CONTROL

NOTE:

OF

THE CAUSED AND

NO

of

amperage (milli-amps) from the

for

a WESTERLINK system.

PANEL

DURING

LCD

DISPLAY

BY

HEAT.

CAUSE

OPERATION

FOR

THE

MAY

VARY.

THIS

IS

NORMAL

CONCERN.

for

each display.

COLOR

DIGITAL

CONTROL

BOX

EARLIER

FREQUENCY

Frequency is displayed on the LCD display screen while the

engine is running in RPM and frequency (hertz). The ECU

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

signal as both RPM and hertz. Should this signal vary approximately 2% either up or down,

a frequency fault shut down will occur, initiated by the ECU. 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

0/PSWITCH THE

OFF

SWITCHES FUNCTION.

FAULT

is

receiving a low AC voltage signal and hertz

MPU which

DIPSWITCHES

#1/S FREQUENCY. IS

FOR

60hz.

#2, #3,

is

positioned on the bellhousing

"overspeed".

USED

TO

L.rl,

..

IV<C>C

ON

IS

FOR

THE an

#4

50hz,

REMAiNiNG

SERVE

NO

MODELS

GENERATOR

CAUTION:

the

ECU,

box. Tum it back on

1. Thm the

position.

2.

Open the cover (Electronic Control Unit).

3. Locate position that

See the illustration below showing the

control box.

4. Replace the control box cover, tum the DC breaker and start the unit. Monitor the frequency that the engine/generator is operating is operating at the correct frequency.

FREQUENCY

ADJUSTMENT

When changing the generator frequency setting on

tum

off

the 20 amp

DC

circuit breaker on the control

after the setting has been changed

DC

breaker on the control panel

of

the control box and view the ECU

the

#1

dipswitch on the ECU and move it

con·espmids to the Hertz operation desired).

ECU

WIRING

HARNESS

CONNECTIONS

(HERTZ)

to

the.OFF

to

in

the

ON

CAUTION

ge1ieraror s starting battery when the' unit is 11zis normal seasonal use. However, to the

NOTE:

(WESTERLINK

can be as much as 72 amp-hours

or

NMEA·2000):

The electronic componenJs

in

a months timec with no generator use.

if the generator set is not to be used

generator with a NMEA-2000 system or shut

Keep

in

mind that the Westerbeke generator maybe the DC power supply for the vessels NMEA-2000 network.

NOTE:

DURING

LCD

DISPLAY

BY

HEAT,

CAUSE

OPERATION

FOR

OF

THE

CAUSED

AND

NO

in

a static state. This maybe as much as 50 milli-amps for the system ECU and 50 milli-amps for each display.

off

the

DC

the Digital Diesels draw a very small amount

It

for

breaker on the generators control box

Engines & Generators

is not necessary to be concerned with this slight amperage draw during

a number

of

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

for

a \VESTERLINK system.

of

amperage (milli-amps)frorn the

THE

MAY

VARY.

THIS

IS

NORMAL

CONCERN.

9A

COLOR

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 is required. The service life

of

your engine is dependent upon how the engine is

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 is caused by overloading the engine during the break-in period.

Your new engine requires approximately 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

START-UP

20% and 60%

of

full-load for the first

50 hours

of

use.

of

the engine.

10

of

one

of

initial

hours.

After the first can

be

cally vary the load. Avoid

exhaust

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.

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 period see

ENGINE ADJUSTMENTS

may also adjustment see

10 hours

increased to the full-load rated output, then periodi-

ove_rload

With

reduced output voltage and frequency. Monitor

of

Be aware

for

of

the generator's operation, the load

at all times.

the generator's break-in is governed by the

of

motor starting loads and the high current

starting motors. This starting amperage

An

overload is signaled by smoky

Since the generator operates at 1800

See

ADJUSTMENTS

50

hours) or after this

ENGINE SPEED (HERTZ) ADJUSTMENT) under

..

A no-load voltage adjustment

be

required in conjunction with the engine's speed

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 as knocking, vibrating and

• 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.

blow-back sounds.

When the engine is cold - White When the engine is warm - almost Smokeless. When the engine is overloaded - some Black Smoke.

Smoke.

DAILY

ROUTINE

NOTE:

Some unstable running may occur

This condition should abate as normal operating temperature

is reached

A

periods

and

loads are applied.

CAUTION:

of

Do

time

without a load

not

operate

being

generator.

STOPPING

Remove Allow temperature. down,

CAUTION

Digital Diesels draw a very small amount the generator's starting battery when the unit is maybe

for each display. This can be as much

with no generator use. It is not necessary to be amperage draw during normal seasonal use. set is not to be used for a number best to disconnect the DC power system or shut WESTERLINK system.

NOTE:

supply for the vessel's

THE

GENERATOR

the

AC

amperage loads from the generator one at a time.

the generator to run for 3-5 minutes to stabilize the operating

Then

push

the stop button. Once the generator shuts

tum

off

the panel

(WESTERLINK

as

much as 50 milli-amps

off

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

Keep

in

mind that the Westerbeke generator maybe the DC power

DC

breaker as a safety precaution.

or

NMEA·2000):

NMEA-2000 network.

The electronic components

for

the system ECU and 50 milli-amps

as

of

months, such as winter storage, it

to

the generator with a NMEA-2000

in

a cold engine.

the

generator

placed

of

amperage (milli-amps) from

in

72 amp-hours

concerned with this slight

Howeve1;

for

long

on

the

a static state. This

in

a months time

if the generator

in

the

is

10

A

wARNING:

and

gloves,

any

of

the

NOTE:

Use

MAINTENANCE

Never

attempt

and

use

the

engine's

DC

the engine hourmeter gauge to log your generator hours

to

correct

tools

electrical

perform

for

any

service

each

components.

type

while

of

the

unit

is

maintenance

performed.

SCHEDULE

operating.

or

Wear

Shut

record

the

proper

off

the

control

your

generator hours by running time.

safety

panel's

equipment

DC

such

breaker

as

goggles

when

servicing

INSPECTION

Coolant

Engine Fuel/Water

Fuel

*Visual

Drive

AFTER

Generator

*Inlet

*Fuel

Engine

*Exhaust

Heat

EVERY

AND

Level

Oil

Level

Separator

Supply

Inspection

Belts

THE

FIRST

(Back

Fuel

Filter

Filler

and

Oil

and

System

Exchanger

50

OPERATING

PREPARATION

(owner

installed)

of

Engine

50

HOURS

End)

"0"

Rings

Filter

HOURS

FOR

INITIAL

OF

OPERATION

OR

MONTHLY

START·UP

(Also

refer

Check Oil

The

operating

Fuel

Check securing connections.

Inspect

Check section

Initial Initial

Check Check

Open

to

the

PREPARATIONS

at

recovery

level

should

fuel

in

the

filter

hours

tank

must

for

fuel,

v-clamp

Look

for

proper

that

AC

connections

for

more

change,

then

change,

then

engine

oil

check

at

that

the

for

integrity/mounting

end

caps

tank,

if

indicate

between

should

or

once a year.

have

the

proper

oil

and

water

is

tight.

for

loose

tension

information.

every every

and

filter

50

hours,

exhaust

hoses

and

clean

for

empty,

check MAX

be

clean

and

amount

and

exhaust

No

exhaust

bolts/hardware

(3/8"

to

1/2"

are

clean

and

250

hours

or

250

hours

or

change

at

50

then

every

250

are

properly

security

out

debris.

START-UP

at

manifold.

and

LOW

on

the

valves

of

clean

diesel

leaks.

Check

leaks

around and

correct

deflection)

secure

with

once a year. once a year.

hours,

the

hours

or

attached

of

water

injected

Change

zinc

in

this

manual)

Add

coolant

dipstick.

open.

Replace

fuel

and

that

the

elbow.

as

needed.

and

adjust

no

chafing.

both

every

once a year.

and

that

exhaust

anode

if

necessary.

if

needed.

Do

not

the

water

Inspect

if

needed.

Refer

200

hours.

Carefully

the

securing

elbow.

overfill!

filter

fuel

valve

injected

wiring

to

inspect

every

250

must

be

exhaust and

electrical

the

GENERATOR

for

clamps

leaks.

are

open.

elbow

tight.

*Drive

Belt

(Fresh

Water)

Starting

Batteries

Electric

Fuel

Pump

Raw

Water

Pump

Filter/Water

EVERY 1 DO

Heat

*Drive

Starting

Electric Raw

NOTE:

Separator

OPERATING

Exchanger

Bell

(Fresh

Batteries

Fuel

Pump

Water

Pump

Keep the engine surface clean. Dirt and oil will inhibit the engines ability to remain cool.

Water)

HOURS

OR

YEARLY

Inspect for

slipping,

Check

electrolyte

off

corrosion Inspect Inspect

water

seal

Drain

and

Inspect

needs

replacing,

Replace

Inspect

for

slipping,

Check

electrolyte

off

corrosion Inspect Inspect

for

proper

cracking

if

for

leaks,

impeller

leak.

clean.

and

clean

zinc

if

for

proper

cracking

if

for

leaks,

impeller

tension

and

levels.

needed.

ensure

and

check

zinc

anode.

you

should

necessary.

tension

and

levels.

needed.

ensure

and

check

(3/8'

wear.

Make

Apply

fuel

the

(3/8"

wear.

Make

Apply

fuel

the

to

1/2'

Adjust

sure

cables

petroleum

and

electrical

shaft

and

Note

the

remove

the

to

1/2"

Adjust

sure

cables

petroleum

and

electrical

shaft.

Inspect

deflection)

tension

or

and

connections

jelly

to

connections

security

condition,

end

cap

deflection)

tension

or

and

connections

jelly

to

connections

that

and

adjust

replace

terminals

are

of

the

pulley.

then

determine

and

clean

and

adjust

replace

terminals

are

there

is

if

as

needed.

are

for

clean

out

if

as

needed.

are

for

clean

no

water

needed.

in

good

corrnsion

and

tight.

Inspect

your

the

debris.

needed.

Replace

in

good

corrosion

and

tight.

seal

Check

belt

order.

Clean

protection.

that

there

own

schedule.

Check

belt

cover.

order.

Clean

protection.

leak.

is

no

If

zinc

Engines & Generators

11

NOTE:

EVERY

250

Engine

Oil

Fuel

Filter

lnlel

Fuel

DC

Alternator

Electric

Fuel

*Vibration

Heat

Exchanger

*Exhaust

EVERY

500

*Fuel

Injectors

Coolant

*Valve

Clearances

*Starter

Motor

Raw

Water

*Preheat

*Cooling

MAINTENANCE

Use the engine hourmeter gauge to log your generator hours

OPERATING

and

Filler

Pump

Isolators/Engine

Elbow/Exhaust

OPERATING

System

Pump

Circuit

System

0-Rings

Hoses

HOURS

Mounts

System

HOURS

DR

YEARLY

DR

FIVE

YEARS

Change

the

Remove

and

Remove

and

Check

mounting

Inspect

for

Check

vibration·isolators,

Inspect

zinc

Check

the

of

the

exhaust

chaffing.

NOTE:

Check Drain,

thermostat Adjust Check

components

Check compounds

No

An

exhaust

and flush

valves.

solenoid

motor

pinion

Remove

from

re-assembling.

operation

Check

hose

SCHEDULE

or

record your generator hours by running time.

engine

oil

and

oil

filter

replace

fuel

filter

and

replace

inlet

fuel

filter.

bracket,

tighten

electrical

leaks,

ensure

fuel

and

electrical

brackets

anode

replace

if

necessary.

structural

adjust

systel)l

exhaust

leak

injection

and

re-fill

and

cooling

(Incorrect

and

drive.

engine,

showing

of

on

threads.

condition

integrity

attached

leaks.

will

the

pressure

valve

motor

remove

wear.

the

pre-heat.

and

of

the

to

Hoses

cause

exposure

opening

cooling

system

cap.

clearance

for

corrosion.

cover

If

needed,replace

Remove

securing

(always all

sealing

and

mounting

water

the

elbow.

and

muffler

pressure

will

Remove

and

inspect

clamps.

together)

0-rings.

connections.

connections

hardware.

injected

exhaust

All

hose

are

in

to

with

and

good

diesel

exhaust!

and

spray

appropriate

result

in

and

cam

the

impeller

clean

the

Replace

as

are

clean

Replace

elbow

serviceable

antifreeze

engine

Clean

wear

plate.

and

gasket.

glow

plugs.

needed.

casting.

connections

conditions.

poor

lubricate.

and

tight.

as

needed.

Check

should

be

secure.

condition.

mix.

Replace

performance)

and

lubricate

Replace

any

lubricate

Re-install

with

the

integrity

No

the

when

anti-seize

starter

EVERY

1000

OPERATING

*Heat

Exchanger

*Adjusting *Positive *Fuel *Starter

NOTE:

*WESTERBEKE

the

Crankcase

InJectors

Molar

A

wARNING:

and

gloves,

any

of

the

Keep

Valve

and

engines

the

recommends

Clearances

Ventilation

Never

use

engine

surface

HOURS

attempt

the

correct

DC

electrical

this

OR OR

Valve

clean.

service

(Rocker

to

Dirt

EVERY

FIVE

YEARS

Cover)

perform

tools

for

any each

components.

and

oil

will

be

performed

service

type

inhibit

the

by

an

knowledgeable

Remove antifreeze

Adjust Disassemble Pressure Remove,

while

the

of

maintenance

engine's

ability

the

heat

and

flush

the

valves.

and

test

injectors/re-build

clean

and

unit

Is

operating.

performed.

to

remain

mechanic.

exchanger

the

system.

clean.

Replace

lubricate

Shut

cool.

for

professional

as

needed.

at

1500

the

drive

Wear

the

OFF

hours.

proper

the

control

cleaning

safety

panel's

and

pressure

equipment

DC

testing.

such

breaker

Change

as

goggles

when

servicing

the

FUEL

SYSTEM·

DiESEL

Use #45 In additive Poirer restore

FUEL

The manufactured from must separator clean, schedule

FUEL

A installed water be

The fuel impurities.

maintaining a proper fuel a

FUEl

No.2-D or

conjunction

(SAE

higher.

such

Services

fuel

lubricity.

FILTERS

fuel

injection

water

and

pass

through

and

change these

in

this

WATER

primary

10

fuel

between

and

other contaminants

carried

to

the

owner/operator reaching

This

tank

and

micron

filter

Grade

with

as

Diesel

(product #3025)

pump

and

they

dirt.

the

engine's spin-on fuel

manual.

SEPARATOR

filter

the

fuel

the

engine's injection equipment

process

the

generator/engine. Westerbeke recommends

be

J313)

diesel

fuel

with a cetane rating of

diesel

fuel

according

Ultra

Low

Sulphur Diesel. Use

Kleen

+ Cetane Boost produced

or

and

the

fuel injectors are precisely

must receive clean diesel

To

ensure this

at

least

two

filters

of the water separating type must be

fuel

tank

system

is

responsible for making certain

is

accomplished

fuel

filter/water separator between

used.

flow

fuel according

and

from

on

the engine.

to

ASTM

an

equivalent

filters, a fuel

the engine

the fuel before they can

to

help

fuel,

of clean

filter.

to

by

fuel,

water

Visually inspect,

the maintenance .

to

remove

is

free

installing

D975.

by

free

the

of

and

the

fuel

ENGINE

Periodically check the fuel connections leakage. Replace the filter element after the then follow the MAINTENANCE SCHEDULE.

Changing

Refer to the illustration.

1. Shut off the

2.

3.

4.

5.

6.

FUEL

FILTER

and

the

bowl

first

50

the

Fuel

Filter

Element

fuel

supply.

Unthread the fuel filter from Ensure the sealing Apply some light oil

of

the new filter.

Thead

the

new

"0"

ring contacts the bracket, tighten securely.

Depressing panel activates-the engine's fuel pump and primes the

and

''0"

filter

onto its mounting bracket. When

holding

its

mounting bracket.

ring comes off with the

or

diesel to the sealing

the

PRIME

button on the control

system. Hold for approximatelt 20 seconds.

7.

Run

the

engine

and

inspect for

leaks.

for

hours

filter.

"0"

ring

the

FUEL

LIFT

PUMP

Periodically and

make

are

tight

pump's

the

mounting

When

purge of

fugl

INLET

To

ensure small this

filter

the

Maintenance Schedule

A

connections Make fuel

check

sure

that

and

secure.

mounting

bolt

energized

air

as

FUEL

inlet

from

the

engine

FILTER

properly

filter

after

thru

the

before

the

WARNING:

is a flre

sure

proper

system

components.

the

fuel

connections

no

leakage

The

DC

ground

bolts

should

to

ensure

proper

the

preheat

fuel

system

is

running.

filtered

fuel

the

inlet

initial 50

·Fuel.leakage

hours

in

this manual.

hazard

ventilation

to

and out of

is

present

be

and

into the

and

that the

connection

clean

and

well

pump operation.

circuit,

the

fuel

provide a continuous

fuel

pump, there

to

the fuel

of operation, then

at

exists

the

fuel

should.

whenever

pump.

be

the fittings

at

one

secured

lift

pump

Replace

follow

pump

or

co«ected.

servicing

pump

of

by

flow

its

the

will

is

FROM

FUEL

LIFT

PUMP

SEALING

~~~~~

a

FUEL

FILTER

APPLY

WHEN

GASKET

CLEA/fJ-OIL

ASSEMBLING

NEW

FILTER

/-TO

FUEL

FILTER

CARTRIDGE

#052985

) '\,

13

INCOMING FUEL

FUEL

INJECTION

The

fuel

injection

of

the

diesel

The

fuel

injection

and

the

owner/operator

it.

If

it

requires authorized attempt

to

PUMP

pump

engine,

fuel

disassembly

requiring

pump

servicing, injection

MANUAL

is

the

most important component

the

utmost caution in handling.

has been thoroughly bench-tested

is

cautioned not

remove it and take it to

pump

service

and

repair it.

ENGINE

to

attempt

facility.

SHUT~OFF

'f"'-TO

~

I

Do

INJECTORS

to

an

not

service

FUEL

SYSTEM

ACTUATOR

BLEED

The bleed screw open engine's air fuel

SCREW

position. This will

fuel

system and during engine operation

in

the

system

return system.

FROM

FUEL.

FILTER

A

WARNING:

when

servicing

any

fuel

that

open

names system when

when

servicing

on

the injection pump should

then

allow for ease

to

be delivered

Shut

the

fuel

may

spill.

or

other

servicing:

the

fuel

sources

off.the

system.

00

NOT

Ensure system.

to

the

fuel

allow

of

proper

fuel

TO

FUEL

valve

Take

fire

near

be

left

in

priming·the

allow

tank

through

INJECTORS

at

the

tank

care

In

catching

any

smoking,

the

fuel

ventilation

in

the

for

the

exists

FUEL

INJECTION

PUMP

A

WARNING:

Use

extreme

COOLANT

FUEL

RETURN

LINE

_____.-..._

Fuel

care

to

DRAIN

is

present

prevent

in

the

spillage

hosing

SPEED

FACTORY

and

lines.

ADJUSTMENT

SET

FROM

FUEL

GLOW

PLUGS

~

INJECTION

PUMP

14

COOLING

SYSTEM

DESCRIPTION

Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat bustion 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 in function to an automotive radiator. Raw 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 is then pumped into the exhaust system where finally it is discharged overboard. In other words, the engine is cooled by fresh water coolant, this coolant is cooled by raw water, and the raw water carries the 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.

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

7. Run the engine and check for leaks.

NOTE:

Also follow

the,

seacock.'

INTAKE

be

the

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.

TYPICAL

(OWNER

INCOMING RAW

WATER

produced in the engine

of

the heat exchanger while

STRAINER

the

strainer at or below

clear.

if

necessary.

above procedure after having

RAW

WATER

STRAINER

INSTALLED)

the

100 hours

INSPECT CLEAN

100HOURS

by

of

a heat

waterline

of

this

run

AND

EVERY

com-

of

so

the

of

hard

of

Heat

Exchanger

The heat exchanger is a copper tube which encloses a 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

of

small copper

EXCHANGER

,

tube::..

Raw

wate1

i::.

pumpeu illluut;:•

#052493

D-RING

#019321~

CLEAN DEBRIS,

Zinc

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 should be carried on board.

NOTE:

installation

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.)

GASKET~.-----::~

#022851;...-----

--/~

OUT

ACCUMULATED

BOTH

ENDS

Anode

or

pencil, is located in the raw water cooling

of

the zinc anode should be checked monthly and

or

Electrolysis action is

and

vessel location; not that

of

all zinc debris. Always have a spare heat

Exchanger

.--' '

BAD

of

the zinc

of

the system. The

replaced as required. Spare anodes

the

result

of

each

particular

of

the

generator.

of

it.

If

the zinc is in

of

zinc flakes within

of

the heat exchanger and

Service

of

operation, remove, clean

CLEAN AND

REUSE

SEACOCK

~

15

COOLING

THERMOSTAT

A thermostat,

engine, controls the coolant temperature continuously When the engine is first started, the closed thermostat pre-

vents 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 and can be checked, cleaned, or replaced easily. spare thermostat and gasket.

loc<tt.::J

flows through the closed cooling circuit.

llC:dl

tlK

HldHifvlJ

<tl

tlte fwul

as

the coolant

is

by-passed

is

vf

accessible

Can·y a

lltt:

SYSTEM.

TWIST THERMOSTAT ASSEMBLY

THE

AIR

BLEED

PETCOCK

LOOSEN

THIS

HOSE

CLAMP

FROM

COOLANT

RECOVERY

Replacing

1.

Drain off some coolant: Release the coolant pressure cap and drain the coolant to the approximate level off the thermostat housing. This can be done using the heat exchanger drain plug.

2. Rotate the thermostat assembly: Loosen the hose clamp

as

shown and remove the three allen screws that hold down the thermostat housing cover, the assembly can now be twisted enough

3.

Remove/replace the gasket and thermostat: When

installing the new parts, apply a thin coat both side

4. Re-assemble and test: Tum the cover back into place and

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.

TANK

the

Thermostat

to

access the gasket and thermostat

of

sealant on

of

the gasket before pressing it into place.

GASKET

#298843

APPLY

SEALANT

WHEN

INSTALLING

THERMOSTAT

HOUSING

A

CAUTION:

down

before

attempting

is

the

surface

temperatures

The

of

can

the

be

engine

these

engine

at

190°

must

be

allowed

procedures.

hot

but

coolant

F.

to

cool

Not

only

Engines & Generators

16

COOLING

SYSTEM

FRESH

NOTE:

recommended

fresh

Fresh lating then heat block engine the bypassed fold stat coolant cooling

Coolant

A coolant recovery tank allows for engine coolant expansion and cant

ing engine

WATER

Refer

water

water pump,

passes

exchanger

via

the

is

started

closed

around

from

gradually

to

system.

contraction during engine operation, without

loss

of coolant

system.

manifold

TO

COOLANT

RECOVERY

COOLING

to

the

ENGINE

antifreeze and water mixture

coolant.

coolant

through

thermostat (although some coolant

overheating).

flow

is

absorbing heat

the

where

suction side of

cold,

the

thermostat to prevent the exhaust

opens,

allowing

unrestricted

Recovery

and

This

tank should be located at or above

level

TANK

CIRCUIT

COOT

ANT

~r>rtinn

pumped through

from

thermostat

it

is

cooled,

the

external coolant

As

the

engine

full

to

the external portion of

the

engine. The coolant

into

the

and

returned

circulating

flow

warms

flow

of

the

Tank

without introducing air into

and

should be easily

KEEP

THE

COOLANT

CLEAR

PASSAGE

to

engine manifold,

pump.

is

a.cCessible.

for

thr>

be used as

by

to

the

When

prevented

flow

is

up,

the

thermo-

engine's

the

any

the

a circu-

the

engine

the

by

mani-

signifi-

cool-

CHANGING

The engine's coolant must be changed

MAINTENANCE SCHEDULE.

become contaminated, it can lead

A

critical; a substantial traced

Drain engine block and opening the

system

the

refill process.

NOTE:

be used

A

Wear

COOLANT

CAUTION:

back

the

engine coolant

The

drain petcock

to

help drain

WARNING:

protective•gloves.

witl;

Proper

to

cooling

fresh

Beware

number

by

water,

on

engine.

If

the coolant

to

overheating

cooling

system

the

system

of

engine

co«osion.

removing

manifold pressure

then reinstall

the

heat exchanger should

coolant.

of

the

hot

according

is

allowed

maintenance

failures

the

drain

plug

cap.

the

drain

engine

coolant.

to

the

to

problems;

is

can

be

on

the

Flush

and

start

also

FROM

COOLANT

RECOVERY

NOTE:

pressure

good the closes

cap. coolant coolant able to

TANK

Periodically

cap.

condition.

vacuum

and

valve

tightly.

Check

also

passage

within

to

expand and contract

from

COOLANT RECOVERY

TANK

1

check

Ensure

the

Check

to

opens and

Carry a spare

to

ensure

is

clear

the

system

the

coolant recovery

COOLANT

the

condition

upper and lower rubber seals

ensure

the

so

is

EXPANSION

RETRACTION

of

the

tank.

INSPECT

THE TANK

..

HOSE

PRESSURE

/CAP

manifold

AND

COOLANT

AND

ITS

EVERY 3 MONTHS

are

in

CLEAN

RECOVERY CONNECTING

l r

LEFT

·

BELOW

Refilling

After dosing all open drain plugs, pour

antifreeze'coolarit into

Fill sloWly'untilcoolant

Start

dperiihg, the

When

air bleed petcock

iti

that

Install

the

Coolant

ihe

·engine

filler neck opening.

coolant is stable

area.

the

arid

monitor coolant

adding coolant

on

the thermostat housing

Add·&olant

pressure

cap.

the

pressure cap filler

is

visible

in

as

in

needed

the

so

to

opening, momentarily

the

filler neck opening

the

in

maintain

FRONT

new

filler

the

SIDE

THE

ALTERNATOR

pre-mixed

neck

opening.

neck

filler

neck

the

level

to

release

OF

BLOCK

opening.

in

open

the

any

is

full.

air

17

COOLING

RAW

WATER

The raw water flow is created by a positive displacement impeller pump. This pump draws water directly from the

ocean, lake,

to the water strainer. The raw water passes from the strainer

through the pump to the heat exchanger (through the heat exchanger tubes) where it water coolant. The raw water is then discharged into the water-injected exhaust elbow, mixing with and cooling the exhaust gasses. This mixture driven through the exhaust system and overboard.

Raw

Water

The raw water pump is a self-p(iming, 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 be inspected periodically for broken

MAINTENANCE

COOUNG

or

river from a thru-hull opening through a hose

CIRCUIT

::ools the engine's circulating fresh

of

exhaust gas and raw water is

Pump

should this

SCHEDULE.

pump

be

run

dry. There should

or

tom impeller blades. See

SYSTEM

IMPELLER

INSPECTION: EACH REPLACE ARE

WHEN

THE KEY. EITHER

THE

IMPELLER

CHECK

BLADE

BY

THE

ANY

IMPELLER

FOLD

CORRECT

IMPELLER

CRACKS.

INSTALLING:

KEYWAY

THE

IMPELLER

DIRECTION

POSITION

STARTS

BENDING

AT

THE

VIGOROUSLY.

IF

TAKE

CARE

WITH

BLADES

(THEY

WILL

WHEN

TO

ROTATE).

BASE

THERE

TO

THE

TURN THE

ALIGN SHAFT

IN

·

RAW

WATER

#042175

.

IMPELLER

KIT

#200175

PUMP

IMPELLER-COAT BLADES

WITH

GLYCERINE

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.

4. Pull the impeller off the keyed shaft and install the replacement.

5. Lightly coat theinside 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

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 air to the engine. This system requires

AIR

INTAKE

FREE

PORT

FROM

KEEP OBSTRUCTION

CONTROL

NO maintenance.

NOTE:

If

the unit is being operated

in an area where air

(silicon) are present. must be added.

PANEL

born

An

contaminants

external air filter

AIR

INTAKE

SILENCER

Engines & Generators

18

ENGINE

1.

OIL

Draining the

the sump drain while

the replace securely.

NOTE:

is

114

NPT.

ENGINE

CHANGE

Oil

Sump.

Discharge the used oil

hose

(attached

engine

is

warm.

the

hose in its bracket, and replace the end

Thread

size for

the

Drain

lube

to

oil

the

front

used

drain

LUBRICATING

through

of

the

engine)

oil

completely,

cap

hose capped end

OIL

SPIN-ON OIL

FILTER

CARTRIDGE

#011951

GASKET

APPLY

CLEAN

TO

SEALING

OIL

GASKET

Always observe the used oil emulsion indicates the presence of water in this condition prevent serious water be present be

the

engine and/or a siphoning of

water cooling circuit into the exhaust, problem valve,

2.

Replacing the

filter, in the upper the helps should

NOTE:

filter

Place

filter (Oil cooling oil sealing gasket comes off rubber sealing gasket remains sealed against the filter bracket, gently remove

When installing the gasket's sealing surface on apply a thin coat of clean engine oil on filter nipple filter

is

rare, it

damage.

in

the

result of a fault

is

often caused by the absence of

its

poor location or lack of maintenance.

Oil

you

may

find

and

lower portion of the old

oil from it into a container before removing

to

lessen spillage. A small automotive filter wrench

be

helpful in removing the

Do

not punch

to

make

certain it

some

paper towels

when

unscrewing

or

any

other

ability.

Keep

filter

as

it

is

removed

the

new

oil

filter.

on

the oil

firmly

by

hand.

as

it

is

removed. A

the

does

require prompt attention

Call a qualified mechanic should

oil.

Raw

water present in the

in

the exhaust system attached

raw

water through

filling

the

an

anti-siphon

Filter.

When removing the used oil

it helpful

this

fluid

new

Screw the filter

and

cleaner

to

filter

old

oil

filter.

hole without first loosening

can

be

removed.

and

a plastic bag

it

to

catch

any

on

the

engine reduces the engine's

your engine clean.) Inspect

to

make

sure

with

the old oil

it.

oil filter element, wipe

the

bracket

filter

bracket,

around

oil left in the

that

the

filter.

free

to

the rubber gasket

onto

the

and

then tighten the

yeloow/gray

oil.

Although

to

oil

can

to

the

raw

engine.

punch a hole

of oil

This

to

drain

it:·

This

the

filter.

the

old

rubber

If

this

the

filter

and

threaded oil

NOTE:

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

Immediately after

run

the

engine

and

that-th~re

3. Filling the

cap engine for a pressure. Make sure there oil filter or from Then check the quantity of oil with Fill the engine require additional

A

WARNING:

contaminants. and

nails discard used

NOTE:

Change

the

first 50 hours

recommended change intervals

SCHEDULE

on

the

top

to,

but

not

thoroughly

clothing

oil

properly.

in

Oil

few

Avoid

the

this

are

not

recommended,

an

oil filter

to

make

sure

the

are

no

oil leaks around

Sump. Add

of

the

moments while checking

the

over the high mark

Used

new

engine.

After refilling, run

is

no

oil drain system,

oil.

engine

oil prolonged using

soap

or

rags

containing

engine

lube

oil and filter initially after

of

engine

break-in.

in

manual.

of

important

from

change

oil

pressure

the

new

oil

through

leakage

skin

and

the

around

and

stop

the

lube oil

on

the dipstick,

contains

harmful

contact.

water.

used

oil.

Then

follow

MAINTENANCE

as

the

items

genuine

and oil

is

normal oil

filter.

the

oil

filler

the

oil

the

engine.

dipstick.

should

Clean

Launder

Discard

the

on jill,

new

skin.

or

19

OIL

DESCRIPTION

The lubricating system

an oil pump. The engine oil 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 an oil pressure

to

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

60

is

a pressure feeding system using

is

to

2

).

psi (4.2 kg!cm

drawn from the oil sump by

the oil sump to repeat the

in

the oil

is

indicated

40 and

2

).

A

as

warmed

35

psi

engine can have

(2.5 kg/cm

2

).

of

These

the

PRESSURE

·&.ct~.

TESTING

NOTE:

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

gauge. Oil Pressure should

o<iSOO'Pm·.

OIL

PRE~\

To

test the oil pressure, install a mechanical pressure

be

35.0 lblin2 (3.8 Kglcm

~

3

)

or

more

LOW

OIL

PRESSURE

The specified safe minimum oil pressure

+

0.1

a worn bearings. For additional information on low oil pres-

sure readings, see the ENGINE TROUBLESHOOTING chart.

OIL

The oil pressure relief valve is located in the front gear case

cover below the lube oil filter. It is held in place by an allen head plug. This valve opens at approximately 50 psi (343kpa) and operates to maintain the pressure in the lube oil feed system.

2

kg/cm

).

A gradual loss

PRESSURE

RELIEF

of

oil pressure usually indicates

VALVE

is

4.3 +

1.4

psi (0.3

Smm

OIL

PRESSURE

An oil pressure sensor engine. It sends a voltage signal to the 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. Oil Pressure should be 35.0 lb!in2 (3.8 Kg/cm or

more at 1800 rpm.

SENSOR

is

mounted on the oil manifold for the

ECU that is interpreted

ECU will open the K2 run relay shutting the unit

will then display the fault on the LCD Display

10-

15

psi will cause

test the oil pressure, install a mechanical pressure

and

read the oil pres-

3

)

20

Problem

START

BUTTON

indicatiins.

switch

depressed

engagement.

switch

is

OK;

not

functioning.

engine

actuator

energized.

There

is

engine

does and a underspeed

on

the

LCD

runs

down.

not

charging

engine

display

under

There

is

does

not

screen.

starts,

runs,

smoking

depressed

depressed;

starter

an

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

8-10

sec

not

start,

display

stops.

speed)

8-10

sec

start,

the

fault

will

and

problems

panel

but

crank

screen.

crank

cycle

display

shuts

OK

does

the

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

Battery Circuit

Loose

Connection Faulty

Loose Low K1

Relay

Poor Defective

Faulty

Preheat High

Low Poor

DC

Alternator

1.

Switches

Fuel

2.

20

3.

(LCD

Exhaust

4.

5.

Water Air

6.

1.

Faulty Water

2.

Faulty

3.

Blue

1.

2.

White

3.

Switch

breaker

battery

solenoid.

battery

battery.

connections

Fueling

resistance

battery

Alternator

charge

starvation.

Amp

display

in

intake

oil

temperature exhaust

smoke.

1.

2.

3.

1.

2.

3.

4.

5.

1.

2.

1.

2.

1.

2.

3.

4.

1.

2.

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.

circuit

breaker

tripping.

blank)

system

is

restricted.

fuel.

obstruction.

pressure

sensor

sensor.

temperature

switch.

is

protected

on

the

by

control

Check

1.

Reset

2.

check Check(+)

3.

ground

1.

Check Check

2.

3.

Check Check

4.

Check

5.

Check

1.

2.

Remove Check

1.

1a.

Switch

1

b.

Replace

1

c.

Check

1

d.

Change

2.

Chech Check

1.

Do

not

located.

Check

2.

Check

3.

corrosion.

Check

4.

See Perform

1.

See Check

2.

connections. at

the

Inspect

1.

Inspect Check

2.

Check

3.

not

Check

4

Pump

5.

Check

6.

Check

1.

Check

2.

Check

3.

Incorrect

1. 1a.

Crankcase exhaust).

Engine

2. 2a.

Faulty Improper

3. 3a.

Fuel insufficient

system;

3b.

Improperly

3c.

Lack

a 20

amp

panel.

VerificationJRemedy

switch

and/or

battery

breaker;

if

breaker

circuit

for

connection

stud.

Check

connection. that

12 battery battery K1

relay.

connections.

and

check

that

the

to

combine

batteries.

fuel

lift

inlet

fuel

solenoid. wiring.

start

engine.

all

wires

cable

connections

connections,

DC

ELECTRICAL

DC

voltage

DC

ELECTRICAL

drive

belt

Exe

terminal.

wiring switches

fuel

supply,

for

High

overly

sensitive

for

blockage

water

from

air

intake

oil

pressure

water

temperature

grade

is

running

injector

grade

burn

incomplete

air

check

timed

of

air-

trips

shorts

to

starter

battery

volts

are

present connections. charge

state.

actuator.

valves

are

house

pump.

filter.

Insert

sensitive

Remove

for

temperature

check

SYSTEM/ALTERNATOR

check

SYSTEM/ALTERNATOR

tension.

Check

output

for

short

circuits

for

proper

fuel

valves,

DC

amperage

to

heat

or

collapsed

fuel

tank(s),

filter

cartridge.

sensor.

switch.

of

engine

overfilled

with

cold.

or

incorrect

of

fuel

or

due

for

proper

air

intake.).

injectors

check

air

intake

connections.

again,

ground.

solenoid

cable

connections.

at

the

open.

and

start

batteries.

(0-

.25

connections

rise

to

at

battery

for

belt

tension,

of

generator

Alternator

should

with

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

to

engine

lines.

after

short

is

Check

for

loose

are

present

breaker

fuel

system.

through

the

or

in

exhaust

ventilation.

FAULTS

and

is

~

21

ENGINE

TROUBLESHOOTING

LCD

DISPLAY

FAULTS

PROBLEM

LCD

DISPLAY

NOT

ILLUMINATE

LOW

OIL

PRESSURE

HIGH

COOLANT

HIGH

EXHAUST

BATTERY

GENERATOR Overspeed Underspeed

VOLTAGE

FREQUENCY

(steady

(flashing

DOES

TEMPERATURE

LED)

PROBABLE

1.

Check

2.

20

amp

3.

Loose

1

amp

4.

1.

Oil

level

Lack

2.

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

Faulty

6.

1.

Check Check

2.

3.

Check

4.

Faulty

1.

Check

2.

Check

3.

Amperage

4.

Crank (underspeed

5.

Faulty

battery.

breaker

display

connection.

fuse

blown

low/oil

of

oil

pressure

connection.

control

module

oil

pressure

system

coolant

pump.

water

pump

temperature

connection.

control

module

sea

water

exhaust

temperature

Connection.

control

module

water

pump.

fire

suppression alternator charge

voltage.

battery

connections.

control

module

engine

speed.

fuel

supply.

load. cycle

with

fault)

MPU

CAUSE

off.

(faulty).

leak.

(ECU).

sensor.

level.

drive

sensor.

(ECU).

flow.

(ECU).

drive

belt.

(ECU).

no

start.

belt.

switch.

system.

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

3.

Check

ground

4.

Inspect

all

the

5.

Check

sensor/replace.

1.

Add

coolant.

2.

Inspect

impeller/pump/replace.

3.

Adjust

belt

tension,

4.

Check

sensor/replace.

5.

Check

ground

6.

Check

plug

connections/replace.

1.

Inspect

thru

as

needed.

2.

TesVreplace.

3.

Check

ground

4.

Check

plug

connections.

5.

Inspect

impeller/replace.

By-pass

6.

1.

Adjust

2.

Check

3.

Check + and -cables

4.

Check

1.

Check

2.

3.

4.

5.

system/check.

tension/replace

excitation.

plug

connections/replace.

speed

Inspect

filters/replace Check + and -cables Check

cause

Check

MPU.

Signal

Cranking

Check

MPU

Check

for

damage.

on.

connections. Determine

add

oil

connection.

plug

Check

circuit.

hull

fitting,

circuit.

setting.

for

Coil

cause

oil

and

repair

If

OK,

test

pump.

connections/replace.

for

leaks.

replace

belt.

hose

if

worn.

Replace/repair

from

battery

filters.

from

no

start.

resistance

leaks.

oil

pressure

and

strainer.

alternator

Test

battery

to

engine.

fuel

pump

to

engine.

sendor,

Correct

operation.

I

inspect

LED

DISPLAY

TURN

PINK

WAITING

FOR

EDGES

ECU

1.

Compartment too

high.

1.

ECU

and

2.

Loose

cable

3.

Panel

DC

4.

Blown

12A

5.

Terminating

6.

Battery

ambient

LCD

display

connection.

breaker

fuse

Resistors.

Voltage

to

OFF.

ECU.

temperature

not

compatible

22

1.

Ventilate Note:

Heat

display.

1.

Check

compatibility

2.

Check

all

3.

Turn

ON,

4.

Check/replace

5.

Check

all

per

resister

6.

Check

between unplugged present,

compartment.

will

often

This

cable check

terminating

measured

from

ECU

change

will

not

effect

with

connections.

DC

voltage

fuse.

Check

pins

P2-24

ECU.

is

faulty.

the

t(le

Westerlink

across

DC

resistors

across

and

Power

turned

color

operation

or

breaker.

voltage

are

in

#4

and

P2-25.

ON.

of

an of

NMEA.

across

place.

#5.

P2

If

LCD

the

engine.

fuseholder

120

ohm

ECU

plug

voltage

is

-

ALTERNATORS

TESTING/TROUBLESHOOTING

#10

ORANGE

K3

B

SOLENOID

REFER

TO DIAGRAM MANUAL

WIRING

FOR

CONNECTIONS

THE

IN

WIRING

THIS

ALL

~~~~~

50

AMP

DENSO ALTERNATOR

o

TO

8 .

VIOLET RELAYTO

STARTER

TO

RED

ACTUATOR

DESCRIPTION

The following information applies to the standard alternators that are supplied with WESTERBEKE' 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 or on the 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 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

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

wiring harness, a mounted DC

of

DESCRIPTION

is

connected to a three-phase, full-wave bridge

is

achieved at approximately 6000 alternator

of

-40° to 212°F (-40° to 100°C).

S Engines and

an alternator with a voltage

the system and will then

of

the

of

the

of

the integral regulator

of

50 or

51

amps.

75°F (23.8°C). The

VOLTAGE

The integral voltage regulator 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 possible damage due to handling or vibration.

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

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 or corroded connections cause high 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 or misleading 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

is

an

electronic switching

the

components from

TROUBLESHOOTING

or

with the alternator.

it.

WARNING:

BATTERY

A

can

become

until

if

/FAULTY

working

very

has

cooled.

or

alternator

hot.

Do

runs

not

touch

CIRCUIT

makes a clicking sound instead

INSPECTION

it is worn or glazed.

or

damage to the charging system. Badly

of

the battery and charge

An

isolator with a diode, a solenoid,

If

the isolator is charging the

and

the problem is in the battery charging circuit.

if

a problem

If

hot. A failed

the

if

necessary.

or

a battery

it is

23

ALTERNATORS

TESTING

A

certain away

1.

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

THE

ALTERNATOR

CAUTION:

that

from

Before

everyone

sheaves

is

and

starting

clear

belts

during

the

of

moving

engine

parts!

test

procedures.

Start the Engine.

starting battery voltage at the battery terminals using a

multimeter set on DC volts.

If

the voltage is increasing toward

a.

alternator

b.

If

the voltage remains around

exists with either the alternator or the charging circuit;

continue with

is

working.

Steps 3 through

14

volts, the

12

volts, a problem

6-.

TESTING/TROUBLESHOOTING

make

Keep

MEASURING BATIERY

(IGNITION ENGINE

VOLTAGE

ON

OFF)

MEASURING BATIERY

(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

If

a battery selector switch is in the charging circuit,ensure

4. that it

5.

Thrn on the ignition switch, engine.

6. Check the battery voltage. condition the reading should be

VOLTAGE

RUNNING)

is

on the correct setting.

~~.._,J

but

do not start the

If

your battery is in good

12

to

13

volts.

TESTING

1. Connect the positive probe to the output terminal B and

2. Wiggle the engine wiring harness while observing the

3.

4. Repeat the same measurement, the negative probe to

5.

THE

OUTPUT

connect the negative probe to ground.

voltmeter. The meter should indicate the approximate

battery voltage, and should not vary.

if

obtained, or output circuit for loose

damaged wiring.

Start

the engine.

ground, the positive probe to B with the engine running. The voltage reading should volts.

If

it repaired at a reliable service shop.

If

the previous test reads only battery voltage at

terminal B, use the meter to measure the DC excitatidn

terminal. inspect the wiring for breaks and poor connections. Jump

12 battery) and operate the alternator. is 13-14

the reading varies, check the alternator

your alternator is over or under-charging, have

If

12 volts is not present at exciter terminal R,

volts from a 12 volt source (such

v.olts,

..

CIRCUIT

If

no reading is

or

dirty connections or

be

between 13.5 and 14.5

If

the voltage output

then the alternator is OK.

as

the

TESTING

CIRCUIT

THE

ENGIN,E

24

OUTPUT

RUNNING

(+)

ALTERNATORS

TESTING/TROUBLESHOOTING

TESTING

1. Connect the positive ( +) multimeter probe to the

THE

EXCITATION

excitation terminal R on the alternator and the negative

CIRCUIT

H lead to ground.

2.

Thrn

the

ignition switch

the multimeter reading. The reading should

2.5 volts (see illustration).

to

the

on

position

and note

be

TESTING

EXCITATION CIRCUIT

(ENGINE RUNNING)

3.

If

the

reading

rotor field circuit probably is shorted

4.

If

the

reading

field circuit probably is open.

5.

If

no

reading

alternator-excitation lead the regulator. Disconnect the lead from exc terminal R.

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.

is

between

is

between

is

obtained,

If

no voltage is indicated, check the

.75

and

1.1 volts, the

or

6.0

and

7.0 volts, the rotor

an open exists in the

or

in the excitation circuit

or

dirty connections

grounded.

1.3 to

or

of

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 disassembled and repaired. Any good alternator service shop can do the job.

NOTE:

instructions for standard

BATTERY

The minimum recommended capacity the engine's 12 volt 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~e

•

level.

• Make certain that battery cable connections are clean and

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

THE

SERVICE

of

the service battery. this b.iLLtl}'

If

not, there is a problem in the service battery

BATTERY

13

and 14 volts when the engine is

REPAIR

WESTERBEKE'S

the

alternators.

Service

Manual

disassembly and

has

repair

of

CARE

of

the battery used in

DC

control circuit is 600 - 900 Cold

·

only distilled water to bring electrolytes to a proper

~>lJuulu

detailed

their

TESTING

THE EXCITATION CIRCUIT

ENGINE RUNNING

EXCITER TERMINAL

25

A

CAUTION:

circuit, the

never

engine however, engine's

To

shut

is

running.

to

avoid

electrical

avoid

damage

off

the

engine

Shut

electrical

circuit.

off

the

shorts

to

the

battery

engine

when

charging

switch

while

battery

working

switch, on

the

ENGINE

NOTE:

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

performed by a competent engine mechanic. The information

ADJUSTMENTS

CHECKING

Valve is

cold.

1.

Remove the head cover.

2. Align the on the housing so that the No.1 piston comes to the compression

3. Check the following valve clearance

1:1:

4.

If

adjust with the adjusting screw.

VALVE

The

TC

There is no

piston comes to the top dead center position when the marking is aligned with the projection the flywheel-housing. clockwise and counterclockwise to the compression top dead center Now, referring to the table below, readjust the valve

clearance. The piston is the IN. and EX. valves position when both the valves move.

Finally, TC

marking and the projection perfectly. Adjust all the other

valve clearances as required.

After turning the flywheel counterclockwise twice

times, recheck the valve clearance.

After adjusting the valve clearance, firmly tighten the locknut of

the adjusting screw.

VALVE

clearance must be checked

lTC mark line

using a feeler gauge.

the clearance is not within

CLEARANCE

marking line

TC

tum

the flywheel 6.28 radius (360°) and align the

CLEARANCE

on

or

overlap top dead center.

0.18 • 0.22mm

on

the flywheel is

marking for the other cylinders.

Thm

the flywheel 0.26 radius (15°)

at

the top dead center

do

not

and

adjusted when engine

the flywheel and projection

(1) marked with

the

factory specification,

(0.0071 • 0.0087

just

for the No. 1

in

the window

see

if

the

or

the overlap position.

move.

It

is

at

the overlap

piston is

when

The

or

in)

No.1

TC

on

at

both

three

I I

Adjustable cylinder location of piston

When

No.

1 piston

compression top dead

center

When

No.

1 piston is

overlap position

is

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

--

Valve a·rrangement

3CYL.

IN.

EX.

IN.

* * * *

* *

*

- -

* *

- -

* *

4

CYL.

EX.

*

26

ENGINE

ADJUSTMENTS

GLOW

PLUG

_..-CONNECTION

FUEL

INJECTOR

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

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. plugs should seconds. circuit. compound

If

When

These

glow

plugs

will

become

Be

careful

not

to

burn

your

fingers

or

unclamp each plug from the cylinder head.

bum

an

ohmmeter.

of

the glow plug, as shown. A good glow

0.90

ohm

resistance. This method can

or

out

of

the engine. You can also use an

get

very hot (at the terminal end) within 7 to

the plugs

on

don't

heat up quickly, check for a short reinstalling the glow plugs, use anti-seize the threads.

very

hot

when

erosion;

be

The

STRAP

if

used

15

it

DRIVE

Proper inspection, service and is important for the efficient operation

Drive Belts under MAINTENANCE SCHEDULE).

Drive

will not provide proper alternator charging and will eventually damage the alternator. Drive belts that are too tight will pull the alternator out

the

tension can also cause rapid wear

service life presence in high operating temperatures and tachometer variations.

The no

(12mm) as the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span A spare belt

Adjusting

1.

2. With the belt loose, inspect for wear, cracks and

3.

BELT

ADJUSTMENT

Jr.aiHlcoaau~.-c

belts must

alternator to wear

drive belt is properly adjusted

less than 3/8 inch (lOmm) and no more than 1/2 inch

A

WARNING:

drive

belt's

Loosen the alternator adjusting strap bolt and the base

mounting bolt.

edges.

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

right as required, to loosen

be

properly tensioned. Loose drive belts

of

the coolant

of

oil

on

the belt can cause belt slipping, resulting

or

belts should always

Never

tension

Belt

Tension

of

aligmnent and/or cause

out

prematurely. Excessive drive belt

of

pump's

attempt

while

bearing. A slack belt

if

be

to

the

engine

or

u.lti1e

u1i

of

your engine (see

the belt and reduce the

the belt can

carried on board.

check

is

tighten.

be

or

adjust

in

operation.

frayC'n

deflected

of

ve

ueus

or

the belt.

the

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

the

TIGHTENING

2.0-2.5

m-kg

TORQUE

(14.5

-18.0

BODY

ft-lb)

ALTERNATOR

In case

injectors checked and overhauled by an authorized fuel

injection service center. loss in injector faults. Since fuel injectors must clean

injector as a spare should a problem occur.

following

Engines & Generators

27

of

severe vibrations and detonation noise, have the

Poor

fuel quality, contaminant's and

of

positive fuel pressure

room

environment, it is best to carry at least one extra

page

for

injector

to

the injection

testing.

pump

be

Refer

can

result

serviced in a

to

the

FUEL

INJECTORS

REMOVING

NOTE:

1.

Disconnect loosen and bending

2.

Using a 17mm its Jose

the

NOTE:

prior any hole.

by

side

it

and

3.

The ing injector tor

INJECTION

1.

Using tion limit, tester,

A

of

skin

enters

a. ·If

replace

b.

dust

c.

Mount tester.

d.

e.

THE

h'ljector

the

move

1he

entirety

the

two

fuel

return

Clean

to

lifting

rust

or

If

the

carbon.

with

the

then

injector

washer.

and

is

reinstalled.

must

1he

lines

1hem

lines.

from

debris

injector will not lift out easily

build

lift it

This

replaCed

TESTING

the

nozzle

starting pressure of nozzle

adjust or replace

take

the following precautions:

CAUTION:

such

velocity

of

fingers

the

bloodstream,

the

diesel

it

At the same time, clean or replace the

Set

the

nozzle

or

dirt.

the

Use

the

fuel

68° F (20°

of Operate

bleed lever ing

the

air

at intervals

the

injection starting

INJECTORS

be

serviced

high

at their attachment out of the

long socket,

1he

sealing

line

to

the

area

it out

from falling

up

aid

of

out.

seats

in

washer should be removed with the

tester,

The

that

and

fuel

of

tester

nozzle and nozzle holder

at

the

C)

hand

in

the nozzle line,

of

1

in

a

"clean

room"

pressure lines

way

top

of

the

washers

each

injector.

around the base

of

the

cylinder head

or

the

like,

the

17mm deep socket

1he

cylinder head

with a

check the spray pattern

the

nozzle.

spray

it

may

hands;

it

the

nozzle tester

in

a clean place where there

approximate temperature

lever of nozzle tester several times

one stroke per second while read-

pressw-e.

START

TO

1991 -2134

from

the injectors

to

the injection pump

of

the

injectors.

remove

new

injected

destroying may

the

fuel

injectors.

and

down work

and,

pf]netrate

INJECTION

psi

Take

banjo bolt that attaches

of

the injector to

into

the

and

the

injector

wrench

on

a copper seal-

washer when-the injec-

if it exceeds the

When

using nozzle

from

the

deeply

tissue.

cause

blood

is

discolored,

on

the nozzle

then

move

PRESSURE

(13.73

-14.71

enviro1mzent.

and

Avoid

return line

care not

help prevent

injector

is held

nozzle

into

If

poisoning.

tl1e

MPa)

side

to

and

it

hand

in. to

free

injec-

is

the

filter.

is

no

to

in

Inspecting

1.

Operate one rectly injects strips. defect. These defects ging cleaned before expose and

2.

Apply by nozzle on repl!J.ced. remain indicate a defect.

Spray

Pattern

1he

hand lever of the nozzle tester

stroke per second

in

its axial direction. A nozzle

fuel

in

an

Also, a spray

with

dust

ones

skin

cause infection.)

to

oblique direction

in

may

and,

therefore, ali parts

reassembly.

to

this

bl

,

,t

NORMAL

1

illi\1

mi:l

1he

operating the hand

tip.

the bottom, it

A very small amount of

on

CHATTERING

pressure of

Hit

drips or

is

considered defective

the

tip

of the nozzle;

1635 lever,

check if

1he

spray

l.

~~~

f/j

the.

form

of particles

sometimes

(Care should.be

as

it

FAULTY

~~~

·•~

TEST

lb/in2 (115

and

check

has

a large

fuel

however,

fuel

is

defective

or

in

several

be

should

may

penetrate

kg/cm

the

accumulation

and

may

DEl

DRIP

TEST

The injection starting pressure for the injectors increasing

The shim

(0.05 With increased approximately 71.1lb/in2 (5.0 replacing the remove tl1e

INJECTOR

36.2-

or

decreasing

has

mm):

between

each 0.0020in

shim,

tl1e

body

specified

50.6

torque;

TO

CYliNDER

(49-

the

thickness of

10

different thicknesses

0.0049in (1.25mm).to

(0.05mm)

grip

the

retaining

with a wrench.

HEAD

68.6

Nm)

TIGHTENING

increase,

nut

Tighten

ADJUSTING SHIM

the

for

every

0.0669in

injection

kg/cm

in a vise

the

retaining

TORQUE

adjusting

at

intervals

i~

injected

separate

indicates

caused

be

taken

2

)

to

drips

should

sometimes

this

does

is

adjusted

0.0020 pressure

2

).

When

and

!

SHIM

of

cor-

if

it

a

by

clog-

carefully

not

to

the

skin

nozzle

from

the

·of

fuel

be

not

by

shim.

in

(l.7mm)

is

nut

to

THICKNESS

INJECTOR

INJECTION

PRESSURE

TEST

.·

Engines & Generators

TYPICAL

INJECTOR

•

PRESSURE WITH

0.01

PSI

mm

(235

ADJUSTING

34

VARIATION

(0.004

WASHER

KPa)

in)

IS

28

STARTER

REFER

TO

THR DIAGRAM FOR

WIRE

The

solenoid, and the ignition switches - Start/Preheat. When

energizes the starter's solenoid coil. becomes an electromagnet, which pulls the plunger into the coil, and closes a set reach the starter motor. serves to push that starter pinion to mesh with the teeth on 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. 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

starting system includes the battery, starter motor and

the start button is depressed, current flows and

The

energized coil

of

contacts which allow high current to

At

the same time, the plunger also

The

rotation

of

the pinion

contact with the battery-to-start cables

EXHAUST

of

the running engine may speed the

but

not the starter motor itself.

of

the solenoid.

of

electricity is interrupted to the starter. This

MANIFOLD

The

plunger is pulled

by

a coil spring

~/

~--

--

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

To check the wiring, try cranking the starter for a few 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

on

terminal stud

(ground).

If

you

read

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

of

circuit).

from that ignition terminal to the positive battery connection terminal on the solenoid.

If If

motor

Use

the

starter

the

solenoid clicks

is

POSITIVE

TERMINAL

If

nothing current connections.

..

the start solenoid and the engine block

12

volts,

the

the small terminal studs and is wired to the ignition

a screwdriver,

cranks,

probably

(+)

happens

Check

It

the

but

faulty.

at

the battery and inspect the wiring

is also possible that the solenoid is defective.

Pay particular attention to

on

the engine block.

10 seconds at a time, then run your

or

replace any trouble spots.

starter

aU,

is faulty.

don't

touch the blade, to

fault

lies

with

nothing

the

happens,

solenoid

the

ignition circuit. the

starter

is

not

getting

jump

GROUND

REFER

TO DIAGRAM FOR

WIRING

WIRES

THE

WIRING

IN

THIS

MANUAL

CONNECTIONS

A

WARNING:

fly

when space gasoline, materials

Engines & Generators

29

jumping

is

free

and stored

There

will

terminals.

of potentially

that

there

are

nearby.

be

arching

Be

certain

explosive

NJl

flammable

and

sparks

the

engine

fumes,

solvents

will

especially

or

STARTER

MOTOR

Test again by jumping the positive terminal to the M terminal. Pull back the covering on the M terminal to expose the connection. Attach a jumper cable to the positive(+) terminal. terminal with the opposite end to see the results. Do not allow the jumper cable end to touch the solenoid or starter casing. This would cause a short.

If If If

solenoid.

REFER

TO DIAGRAM FOR

WIRE'CONECTIONS

Use a battery type cable #8 or better. Tap the M

A

WARNING:

starting

THR

IN

current

the starter spins, the solenoid is faulty. the starter fails to spin, the motor is probably faulty. no arching occurred, there

WLRlNG

THIS

MANUAL

There

should

will

be

flowing

be

arching

is

no juice reaching the

thru

as

the

jumper

full

NOTE:

Stq_rter In the pre-engaged model, the solenoid also moves an arm that engages the starter using a screwdriver to bypass the solenoid on such a starter

nm

will

A

WARNING:

position

the

engine

other

motqrs are either inertia type

motor

to the jlywheei

the motor without engaging the flywheel.

When

performing

yourself

crew

safely

in

case

the

members

away

engine

of

the

from

starts-up.

danger.

or

these

procedures,

the

moving

Also

pre-engaged.

of

the engme.

parts

of

warn

SEI\VICE

WESTERBEKE uses a standard starter motor which can be serviced or rebuilt at any starter motor automotive service center.

If

replacing the starter motor, make certain the new motor is certified for marine use. Automotive USCG standards. dealer.

TO

REMOVE

1.

Disconnect the negative battery cable.

If

necessary, remove any components

2. to the starter motor.

3. Label and disconnect the wiring from the starter. (Do not allow wires to touch, tape over the terminals).

4. Remove the starter mounting bolts.

5: Remove the starter from the engine. In some cases the

starter will have to obstructions,

If

in doubt, contact your WESTERBEKE

FOR

SERVICE

be

turned to a different angle

struters do not meet

to

gain full access

to

clear

Engines

30

& Generators

GENERATOR

USE

OF

ELECTRIC

The power required

more than Some motors require much more current others. Split-phase under similar circumstances, than other types. They are monly used machines, or where loads are applied after the motor is started, such

7 times

avoided, whenever possible, if ven motors require to

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

motor

In

general,

to

medium

*NOTE:

more

for this

made

Because the heavy surge of current needed for starting motors is required for only be damaged if it can bring seconds. If difficulty off on

REQUIRED

Run generators capacity, indicted on the generators data plate. The output voltage

should be checked periodically the voltmeter or ampmeter is not installed load, check it with a portable meter

is

required

on

as

much current

by

a small generator. Capacitor and repulsion-induction

The current required

to

which

the

current

starting

MOTOR

SIZE

(HP)

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

3/4

1

In

the

for some small motors

is

that

in

larger

all

other electrical loads

the

electric

OPERATING

the

generator first with

generating plant

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

from 2 to 4 times

to

it.

An electric motor connected

no

load is connected.

required

loads

will

AMPS

(AMPERES)

above

table

the

hardest starting types (split-phase)

as

to

start

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

as

washing

their

use

should be

is

to

start

motor varies

Volt

motors

as

AMPS

(~TARTING

6.4

9.2

1

0.4

14.4

20.4

Amps

ones.

with

to

an

connected

follows:

FOR

AMPERES)

to

22.4*

to

32.2*

to

72.8

to

29.2*

to

40.8*

26

to

52

for Starting

The

sizes.

an

instant, the generator will not

the

motor

up

to

speed in a

is

experienced in starting motors, tum

and,

if possible, reduce the load

motor.

SPEED

no

load applied, then at half

and

finally loaded

and

the appliances it supplies. If

to

its

full

capacity

to

ensure proper operation of

to

monitor voltage

and

amp

probe.

to

be dri-

air

•

reason

are

few

an

INFORMATION

start,

com-

to

as

the

not

the

as

AC

and

is

Generator

• Maintaining reasonable cleanliness Connections of terminal boards and rectifiers corroded, and insulation surfaces salts, build excessive heating and reduced life of windings.

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

• In addition inspected for tightness of overheated terminals and loose or damaged

• The drive discs on single bearing generators should checked periodically if possible for tightness of screws and should not be allowed accelerate cracking. The bolts which fasten to

8,

comers of the head.

• The rear armature bearing is lubricated and sealed; maintenance is required. However, if noisy or rough-sounding, have it replaced.

• Examine bearing at periodic intervals. of shaft should be detected when force motion

wear. will

CARBON

WESTERBEKE recommends mounting a carbon monoxide detector

small amounts

The presence of carbon monoxide indicates from the engine or generator or from elbow/exhaust hose, or that are

leaking in your

If carbon monoxide air

and

Maintenance

dust,

engine exhaust, carbon,

up.

Clogged ventilation openings

all

surfaces

to

for

any

evidence of incipient cracking

the generator shaft must be hardened steel identified

rub

by

is

detectable, inspect the bearing

Repair must be made quickly or major components

and cause major damage

MONOXIDE

in

the living quarters. Carbon Monoxide, even in

correct

the

to

reduce rusting

periodic cleaning,

all

connections, evidence of

to

become rusty because rust

6 radial marks, one

DETECTOR

is

deadly.

fumes

area.

is

present, ventilate

problem immediately!

is

important.

may

start conducting if

etc.

are allowed

may

cause

and

corrosion.

the

generator should be

wires.

failure.

the

SAE

at

each of

the

bearing becomes

No

side

is

applied.If side

and

shaft for

to

generator.

an

exhaust leak

the

exhaust

from

a nearby generator

the

area

become

to

be

Discs

may

drive

disc

grade

the

6

no

movement

with

clean

NOTE:

When

the

vessel contains AC equipment that

the

generators AC terminal block

vide one I 20 volt AC hot

panel.

This

will

ensure

generator.

in

which

the

generator

of

120 volts

leg

only,

be

for

the

vessels distribution

it configured

good motor starting

is

installed

is

recommended

to

response

from

pro-

the

31

ADJUSTABLE OF

UNDERSPEED

PROTECTION

THRESHOLD

INTERVENTION~

ELECTRONIC

ADJUSTABLE

OVERLOAD INTERVENTION

THRESHO

PROTECT/0

~

/ e

LD

N

I...-;

-Yioo

.

~mrtp

Stab

volt

~w

Z-:--'

@.:E

1-~

®::

--:;

~~·

11

f-

REGULATION

=

1-

®mmi

-

--r-r:-J

DESCRIPTION

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

AC

generator. The following

be

performed by a

D

#052944

:5AMP

FUSE

PN

0 ' /

DO

.

o D

D

I

0

Sensing: Sensing should be connected to terminals 4 and 5

and can vary from 80 to 350

·phase only and therefore is normally connected to one alternator phase.

Operation and 6 should low frequency protection correctly regulated.

~~"

-~

-I~

....-~

L

1-1

I~

~

-r

17

1""'-t~

·!-I~

-~

~

l-1--?--

!:::!.

1.

!

at

60 Hz: When operating at 60 Hz, terminals

be

connected to each other in order to keep the

#052951

-----;CONNECT

~REMOVE

:=J

EXCITER

VAC.

FOR

FIELD

The sensing

60Hz

50Hz

is

single

SA

TERMINAL

#1. Excitation field

#2. Not used.

#3. Exciter field #3A. #4. Sensing voltage. #5. #6. Jumper to SA for #7. Not used. #SB. Not used. #SC. Sensing voltage.

POSSIBLE

Exciter Field: The exciter field negative should connected to dark blue or black), while the positive (normally red

yellow) should be connected to terminal3.

Supply:

The supply separate connection to this generator's voltage regulator. Supply voltage (AC) is connected to terminals

CONNECTIONS

DC

negative.

DC

positive.

Supply voltage to regulator (AC).

60Hz

operation.

CONNECnONS

terminal!

(AUX winding) and sensing voltage are a

of

the electronic regulator (normally

be

3A

or

and 5.

A

WARNING:

present. against

Take

electrical

FUNCTIONS

Volt: With this potentiometer, it is possible to adjust the voltage generated the screw is turned clockwise, the voltage increases,

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

tur-ned

counterclockwise, the response time increases and the

voltage' tends to

In order to adjust this potentiometer using the following method.

1. The generator must be working,

and the potentiometer must (turned fully counterclockwise).

2. Slightly tum clockwise until the light generated by the filament potentiometer slowly counterclockwise until the light stabilizes.

Be

aware

all

necessary

hazards.

OF

THE

REGULATOR

by

the alternator in a very simple

be

more stable.

lap:~.p

oscillates,

that

high

voltages

precautionms

POTENTIOMETERS

con·ectly,

struting from zero load

be

at maximum stability

at

this point, turn the

may

to

sate

sta,_ble.

we

advise

be

guard

way.

if

the

If

Engines & Generators

32

Hertz:

With

ELECTRONIC

this

potentiometer, which is normally

REGULATION

pre-calibrated then sealed by the manufacturer, it is possible to

adjust

the

low

frequency protection intervention. recalibrate normal clockwise the counterclockwise

decreased When

value, generator protection possible

Amp: intervention level of

system overload, applications.

To by

minimum During condition the At voltage

this

zero

nominal

protection,

load condition, tum

until

the

speed

and

you

limit position

by

10

%.

measure

by 5 volts.

the

speed decreases

the

voltage also decreases proportionally, blocking

by

overheating. Even if

at

10%

of

the

nominal value, it is obviously

to

calibrate

With

has

necessary

this

an

the

threshold at other values.

potentiometer, it

the

overload protection. This protection

intervention

delay,

when

starting motors or similar

·

modify

this

15%

protection,

of

the

normallmid, tum the potentiometer

you

(counterclockwise) and wait about twenty seconds.

this

period of time the voltage value decreases. In

and

while

turning the potentiometer clockwise,

generator voltage value

this

point,

while

increases

to

at

the

initial overload is being removed, the

the

nominal value.

Fuse: The electronic regulator protects malfunction. replaced

the

alternator·

The

easily.

from overheating

fuse

(250V-5A,

INTERNAL 12

WIRE

WITH

REGULATOR

must take the generator

the

potentiometer

is

reached, then decrease

Then tum the potentiometer

the

voltage value until it has

more than

we

10%

advise calibrating this

is

possible

which permits a temporary

must overload the generator

10%

less than the nominal one.

is

equipped with a fuse, which

in

cases of regulator

quick acting, F type) can be

WIRING

DIAGRAM

RECONNECTABLE

To

to

of the nominal

to

adjust

the

to

a

this

fix

#052944

TO

CONNECTIONS

REFER.

TO WIRING IN

THIS

MANUAL.

AG

SENSE

THE

COMPLETE

DIAGRAM

AVR

LT.

BLU

#52951

BtU

TO

PANEL

FUSE

TERMINAL

SHOWN

fOR

LO·WY'

.TERMNAL

.,

--~-·=r~

--tt---;:::==J

EXCITER

r"-"l

•

BtU

~"-··-;

I·.

BLOCK ARE

CONfiGURED

1101106

!LOCK

0

TEL

CONNECTIONS

VAt

-

Amp·

Hertz

Slab

VOII·

VOLTAGE

REGULATOR

DCBREAKER

COMPONENT RESISTANCE VALUES (AT

STATOR

(each

winding)

AUXILIARY. EXCITER EXCITER

(each

pair)

ROTOR

JsoHz

REO

NOTE:

EXCITER

NO

LOAD

FULL

T

BLUE

YELLOW

WESTERS

Engines & Generators

EKE

LOAD

DC

VOLTAGE I AUXILIARY

7.0

VDC

14.0

VDC

IN

86°F)

___

____ STATOR ROTOR

___

VOLTAGE

215

VAC

222

VAG

OHMS

__

11.3

0.72

2.7

0.041

0.9

33

r.-----:-.1

10

STATOR·:

I I

~

...

a:

GREEN

.

AC

TERMINAL

5

BLOCK.

l.lr-:

E

VOLTAGE

AC

OUTPUT

DD

o

_.

NOTE:

ECU

REQUIRED RE-PROGRAMED CHANGING FOLLOWING

I.

2.

3.

ANY

CHANGING 60Hz

AND CHANGING BETWEEN AND

3-WIRE CHANGING BETWEEN AND

3-PHASE.

~r-:

REGULATOR

DC

BREAKER

CONFIGURATIONS

AVR

0

- - .

120·240V

,0

/60

Hz

[IJJITIJ

TO

BE WHEN OF

THE

SETTINGS

BETWEEM 50

Hz

AC

WIRING

2-WIRE

lcPH

I-PH

BACKEND

I-PHASE

BLUE

VOLTAGE

I]]

2 3 5

4 I 6

2 3 5

115V

SENSING

WI

Z"'

~!0::

I

'--

SINGLE

INTERNAL

50Hz:-

BOARD

120V

60

I-

0

w

,.,

"'

""

~~uno

fl'

pr~~~~

f!f~

H

.t.t,

0 "

0

I-

w

,.,

"'

""

[IT]

0

230V

Hz

t •

~

W2

[ill

WIRING

50Hz

CONNECTIONS

2

4

2 3

PHASE

SCHEMATIC

120V

5

3

I

6

[[]

5

60Hz -240V

WI

60Hz

.

AC

WIRING CONFIGURATION 22/17 SINGLE PHASE

EDE

·U1

4

I 6

220V

50

Engines_~_(le_ner,ators

Hz

[IT][[]

"34

nov

Ul

4 I 6

50

Hz

[IT]

[[]

INTERNAL

WIRING

SCHEMATIC

EXCITER

ROTOR/ROTATING

CONDENSER

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

1

I

EXCITER

I

WINDINGS

I

I I

:

1------

ROTOR

...:

__ ----------

FIELD

TRANSIENT

--

____

I

_,

35

(SERIES WYE)

TWELVE

L

LEAD

WINDING/TERMINAL

AND

(NOMINAL)

(PARALLEL.WYE)

VOLTAGES

BOARD

CONNECTIONS

SERIES STAR

10-'11

2-3

0

L1

50

Hz L-L 400 volts

50

Hz L-N 230 volts

60 Hz 60Hz

PARALLEL DELTA

2

3

6-7

0

5

9

L3 N

L-L480 L-N 277 volts

volts

L

N

L

5

4-8-12

SINGLE PARALLEL

PHASE

ZIG-ZAG

PARALLEL STAR

11

L

9

10-12

7

2-4

5-7

. 50 Hz L-L 200 volts

50 Hz 60Hz 60Hz

9-11

L·N

115 volts L-L 240 volts L-N 138 volts

N

0

L

SERIES DELTA

9

L

10-11

0 0

1-12

50 Hz L-L 230 volts 50 Hz L-N 115 volts 60Hz

60Hz

(Refer

THREE

PHASE

ZIG·ZAG

8

N7

6

2·3

6-7

'6

5-4

9-8

L2

L-L 277 volts L-N

to

Note #1)

L3

138

L'!.

"i~2

~L

10,

4 6 5

5

volts

4

L

0

L

~·

I 3 5 7

L1

50

60Hz

8-11

1 10 5

L2

Hz

L-L

115.volts

L-L

138

2-3 . 6-9

0 0

12

L1

N L2

50Hz

L-L 230 volts

50 Hz L-N 115 volts

60Hz

L-L 240

60Hz

L-N 120 volts

6-8

9 11

l3

volts

7 4

volt<:

L

0

L

0

L

10-12

r-{

1 3 5 7

N

1..1

50

Hz

· 50

Hz

60 Hz L-L 277 volts 60Hz

(Refer to Note #

Note

#1

phase

value.

#2

mted

Single

cun·ent must

11u~e

power

11w nominal

Note

The

0.866.

N

2-4

S-S

~

9-11

l2

L-L 230 volts L-N 115 volts

L-N 138 volts

1)

phase

ainpetuge load.

not

phase

zig-zag connection.

must

be m.ultiplied

0

exceed the

by

L

8-10

0

l1

50

50 60Hz

60

(Refer to Note #2)

DOUBLE DELTA

lwire

L

8-11

0

N

.s

2-12

0

4-6

0

3-7-11

r--0

L3 N

Hz

L-L 346 volts

Hz

L-N 200 volts L-L 415 volts

Hz

L-N 240 volts

7

J~--4 _ ___,~--1..._

2-3

~

5

12

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

10

N

6-9

0

7 4

L1

0

36

CHANGING

VOLTAGE

OUTPUT

AND

A

CAUTION:

unintentional on

the

control

1.

Refer to the previous page that illustrate the various AC voltage output configurations for both 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 AC terminal block. There 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 L2 and tie

4.

Inside the control box, locate the ECU and verify that the position of

the

#1

the generator will now be operating at.

As a precaution

start,

shut

off

the

against

20

Amp

an

IJC

breaker

panel.

60 & 50 hertz

MUST correspond to and be connected to the

or

L# is not present on the AC terminal block, insulate

off

the unused sensing connections.

dipswitch is in the correct position for the hertz/frequency

CHANGING

HERTZ

AUTOMATIC

VOLTAGE

PN.

052944

REGULATOR

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

from the Westerbeke Distributor). Connect your laptop with the

software installed to the communication pins on the

#055351 communications cable connected between your laptop and

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

the face the harness plug connection

7.

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

8.

Verify all connections are correct and

control panel. hertz. Adjust AC voltage as needed using the volt pod on the A

9. Turn ON the AC breaker and load test the generator monitoring operation. You can monitor the operation using the software in your laptop. When satisfied with generator operation. Stop the generator. Turn DC

breaker,

the control panel DC breaker back ON.

turn

5A and 6 for the hertz operation selected.

forD-Net

ofthe

ECU).

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

turn

Start the generator and monitor AC output voltage and

models. (available

ECU using the

OFF the AC breaker on the

VR.

OFF the panel

OFF your laptop and unplug it from the ECU. Then

turn

DIP

SWITCHES

DIPSWITCH THE

OFF

SWITCHES FUNCTION.

#1

IS

FREQUENCY.

IS

FOR 60hz. THE REMAINING

USED

#2, #3, an #4

ON

TO

IS

FOR

SERVE

CHANGE

50hz,

NO

Engines & Generators

37

BE

TROUBLESHOOTING

NOTE: AC generator troubleshooting must be performed with

the generator operating at the correct hertz.

NO

AC

VOLTAGE

RESIDUAl NO

lOAD

lOW

AC

VOLTAGE

NO

lOAD

HIGH

AC

VAC

OUTPUT

OR

150

FAULT

OUTPUT

VOlTAGE

15-

20

VOlTS

60 -100

HIGHER.

AT

PRODUCED

AC.

OUTPUT

VAC.

VOlTAGE

AT

NO

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

2.

Open

or

exciter

3.

Open

or

three

exciter

1.

Reset

2.

Faulty

PROBABLE

open

in

the

winding.

pozi-resistor

rotor.

mor.e

shorted

on

circuit

voltage

shorted

rotor 1 to 3 diodes.

short

rotor

voltage

or

exciter

rotor.

fuse

feed

to

AVR.

regulator

potentiometer.

diodes

in

one

of

windings.

potentiometer.

regulator.

in.

the

CAUSE

4.

Open stator

5.

Open

field

3.

Shorted stator

4.

Faulty

5.

Short

6.

Short

in

exciter

winding.

in

rotating

winding.

or

open

auxiliary

voltage

in

rotating

in

the

main

winding.

regulator.

field

exciter

winding.

stator

!

..

UNSTABlE (ENGINE

AC

60

NOTE:

REFER

ADJUSTMENTS,

VOlTAGE

SPEED

VOLTAGE

-100

VOLTS

TO

AND

OUTPUT.

STEADY)

DROP

UNDER

AC.

THE

SERVICE

DISASSEMBLY

lOAD

MANUAL

OF

THE

1.

FOR A COMPLETE

AC

GENERATOR.

STB needs

Diode(s) breaking applied

GUIDE

pod

on

regulator

adjustment.

on

exciter

rotor

down

when

(inductive)

TO

TROUBLESHOOTING,

load

1-3

diodes.

is

2.

Faulty

voltage

regulator.

38

LOW

VOLTAGE • EXCITER

AND

ROTATING

Position suppressor

the

exciter rotor/rotating

is

visible

FIELD

at the

EXCITER

ROTOR

field

so

12

O'Clock position.

ROTOR

the transient

TROUBLESHOOTING

TESTING

These windings are tested in pairs: A as

shown

THE

EXCITER

on

the drawing.

ROTOR

WINDINGS

to

B, B to

C,

and C to

A

TESTING

Place

and (-).

windings. These

unless,

continuity

this

If plates,

NOTE:

screws

THE

the

ohm

These

wires

when

to

occurs,

isolate

When

or

washers

ROTATING

meter probes on the two large red wires ( +)

are

the

do

not

need

testing,

ground

(the

lift

these

them,

and

removing

into

FIELD

WINDINGS

connecting wires for the rotating

to

be lifted off their connections

there

is

an

ohm valve discrepancy or a

rotor shaft).

two

flarge

field

wires off the diode

repeat

the

above

test.

these

wires,

be

careful

not.

to

prop

the

rotor.

field

the

EXCITER

GROUND

Disconnect these three wires from the diode bridge

taking care not With

the wires clear from the bridge plates, test

with

an

·No continuity should be found between the rotor these three winding pairs.

to

drop

ohm meter, A

any

screws or washers.

to

B, B to

C,

and C

to

A.

each

and

ROTOR

plates

pair

any

UNO

WINDINGS

of

VIEW

OF

ROTOR

FROM

THE

BEARING

12

END

0-CLOCK

POSITION

TESTING

Diodes can be checked with

wire of the particular diode and test its resistance directions. A perfectly functioning diode

· high resistance in one direction and a very the opposite direction. A faulty diode low

resistance, or

Should the screws with a suitable wrench and strictly the polarities and internal wiring diagrams

_ Engines & . Generators

the

THE

DIODES

an

ohmmeter. Disconnect

will

an

infinite resistance in both

whole bridge be replaced, remember

.

,_

'

will

show a very

low

show

comply

in

this

the

in

both

resistance

either a

directions.

to

tighten

with

manual.

~

in

very

39

GENERATOR

SERVICING

TESTING

Test the speed sensor connector for voltage and resistance values.

If

the values are correct, remove and inspect the magnetic pick 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

up.

With the wires disconnected, unscrew the

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

000

ohm

MAGNETIC

The MPU is installed in the threaded opening

of

the flywheel bellhousiri.g. 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 the

jam approximately 0.030 inches away from the ring gear teeth.

To

en~.ure

the crankshaft by physical contact between the

If

contact is felt between the MPU and the flywheel teeth,

the

MPU may 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

be

if necessary and repeat the above .

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

[MPU]

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

is positioned correctly, slowly rotate

360° by hand to assure there is no

damaged. Remove the MPU and inspect

INSTALLATION

ou

Gte

~>iue

of

one

of

the ring

MPU

of

this

of

the

it

in this position with

of

the MPU

flats

of

the

MPU and the ring gear teeth.

AC

f'/

--

~~ACKPUff

BE

GENERATOR

MAINTENANCE/PARTS

INSPECTION/CLEANING

Periodically inspect the rotor carrier bearing. Replace this

is

evident.

REAR

VENT

COVER

10,000 hours

bearing at

wear Inspect and clean the control box interior, look for loose,

broken, or burned wires and terminals. (25 psi max.) to remove dirt and dust from components.

of

normal operation

or

sooner

if

Use low air pressure

BREAKDOWN

Remove all dirt, oil, grease and dust build up from the

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

of

efficiency and

PARTS

BREAKDOWN

EXCITER

A~

MATURE'

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 generator from their connections in the control box.

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. wrench remove the four bolts that attach the generator stator housing assembly to the flywheel housing. carefully work the stator assembly and off and over the rotor assembly.

of

the engine to allow the

exit

if

needed whether

or

a replacement is to

Using a 17mm socket

off

the rear bearing

the

off

Be

of

the

4. Support the rotor assembly with a sling and using a

17mm box wrench, unbolt the rotor assembly from the

flywheel.

41

DISC

BE

GENERATOR

ASSEMBLY

1.

Position the rotor assembly onto the flywheel aligning the holes in the drive discs with the holes in the flywheel. Install the M8 x 1,25 x threads) and torque to rod M12 x 1.75 x

the rotm eh•ft.

THREADED ROD

2. With the aid the stator housing assembly and carefully guide it over the rotor assembly until the rear bearing contacts the

bearing boss in the rear support.

3.

Place a large washer center hole

12mm x 1.75 nut. Center the rear bearing in the bearing boss ing seats fully into the boss. Secure the stator housing assembly to the bell housing using the four screws. Torque to 35 washer and threaded rod.

OF

THE

GENERATOR

25mm

21

Nm

90mm

long into the threaded end

DRIVE

DISC/

of

a sling

or

fabricated lifting eye, support

of

at least

of

15mm onto the threaded rod followed

of

the support plate. Tighten the nut until the bear-

Nm

(25 ft-lb). remove the nut,

TO

THE

ENGINE

bolts (blue loctite on

(16 ft-lb). Install a threaded

80mm

in diameter with a

MlO x 35mm

4

•.

Rotate the generator ensu.re the generator rotates freely. Reinstall the rear vent

cover.

5. Secure the generator to its rear isolators. Route the

of

\,

by

a:

genenitorwiring control connections. test run.

REAR COVER

box

to the generator. Reconnect all wire

by

hand two full revolutions to

into the control box and mount the

NUT

. I

WASHER

Engines & Generators

42

SHORE

POWER

DESCRIPTION

Tf

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

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

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

respon-

are

correct.

TRANSFER

SWITCH

if

is

not

CONNECTIONS

GENERATOR

~I

w

!::

:z:

;:

.----T------T1:3

~

SHORE POWER

120

Volt/60

Note the repositioning

nal block to the generator case.

Hertz

IL1

·

NOTE:

Wllth

with

1

"'

0 GENERATOR/SHORE

:5

SWITCH

"'L_-f~-

I I

' /

l SHORE

- GROUND

Three

of

the white ground lead on the terllli-

Diagram

shows

120-von

three-wire,

--~,r-\-\--

2 I

,_

....

Wire

connections

system

trom

120-Volt

.

..

L1

J_

SHIP"S

-GROUND

Configuration

the

boat

SHIP"S

LOAD

for a twogenerator, system.

120/240-60HZ

Note the repositioning of the white ground lead on the tenni-

nal block to the generator case.

A

CAUTION:

before

switching vice-versa ing

with

may

cause

the

generator.

because

heavy

damage

Hertz

Heavy

shore

voltage

AC

loads

to

Three

motor

power

on

the

exciter

Wire

leads

to

generator

surges

the

vessel

Configuration

should

be

shut

power

induced

circuit

by

switch-

being

operated

components

oU

or

in

Generator

~

;;

..

z

230

Volt/50

Notice the repositioning minal block to the generator case.

NOTE: Diagram shows wire

.•

120·Volt

with

Hertz

system

three-wira~120-Volt

Two

Wire

of

the white ground lead

connections from

the

boat

for a twogenerator. system.

Configuration

on

the ter-

·

43

LAY-UP

&

RECOMMISSIONING

GENERAL

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

The procedures which follow will allow you to perform your own lay-up and 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

of

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

of

out storage in the cradle. The flexibility severe strain on the propeller shaft the boat is taken out or put in the water. In some cases, the shaft has actually been bent by these strains. This does not apply to small boats that are hauled out not in use, unless they have been 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 is adequate.

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more concentrated mixture. and mixture cooling system. Now recheck the antifreeze solution's strength.

Shaft

up

and the bolts removed when the boat is hauled

the water or moved from land to water, and during

of

time.

Water

Operate the engine to ensure a complete circulation

of

Lubrication

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

ENGINE

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

A

in

the

combustion

chemicals

internal

Use the correct grade

LUBRICATING

CAUTION:

sump

which

parts.

your engine.

Coupling

Cooling

of

antifreeze and distilled water is

the antifreeze concentration throughout the

System

Do

over

the

deposits

can

Circuit

OIL

not

leave

lay-up

combine

reduce

of

inactivity. Others prefer

[Propulsion

of

or

dry for a considerable

of

pages in this manual for the

the

engine's

period.

to

produce

the

life

Engine}

the boat often puts a

coupling or both, while

of

the water when

of

fill

the sump

oil. Refer to the

old

engine

Lubricating

of

your

oil

harmful

engine's

and

as

oil

a

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

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 as 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. Place the end gallon bucket check the zinc anode found in the primary heat exchanger on the engine and clean

any zinc debris from inside the heat exchanger where the zinc anode is located. Clean the raw water strainer.

Start the engine and allow the raw water pump to draw the fresh water through the system. When the bucket is empty, stop the engine and refill the bucket with 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 is running. The fogging

oil will stall out the engine and coat the valves, cylinders and spark plugs for winter protection.

[Gasoline}

of

Sta-Bil gasoline

[Diesel}

as

Bio-bor and Diesel Kleen + Cetane Boost

mah

sure no air

of

the treated fuel through the injection

Cooling

of

Lubrication

Circuit

clean fresh water. Before starting the engine,

or

replace it as required, and also clean

of

Once the bucket

[Gasoline}

is

left in the fuel

10 minutes will help

of

this hose into a five

an

antifreeze

this mixture to be drawn

is

it,

so catch it in a bucket).

89 octane

empty, stop

as

well

Engines & Generators

44

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. 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

Lubrication

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

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

Be

sure to have replacement sealing washers for

Manifold

[Gasoline]

ea'>y

[Diesel]

removal. Make sure the

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, 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

allow 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. additional information, refer to the TRANSMISSION

Lead

gas,

an

Shut

off

electrical

[Propulsion

cigarette,

open

all

If

acid

batteries

which

can

cigar,

name

electrical

arcing

during

Engine]

there is any doubt that the

or

that they will be

emit

hydrogen,

be

ignited

by

electrical

or

pipe.

Do

not

near

the

battery

equipment

in

being

the

servicing.

For

way,

a

vicinity

SECTION.

Spare

Lay-up time provides a good opportunity to inspect your Westerbeke engine to see or coolant hoses need replacement. Check your basic spares 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

PARTS

section

if

external items such as drive he

of

this manual.

it~

Recommissioning

The recommissioning

seasonal lay-up generally follows the same procedures those described in the PREPARATIONS 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, name electrical arcing

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

proper tightness [gasoline].

5. Check the condition circuit and clean that it is not necessary to flush the antifreeze/fresh water solution from the raw water coolant system. When the engine

6. Start the engine in accordance with procedures described

emit

be

ignited

cigar,

near

the

equipment

during

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

FOR

STARTING

of

the lay-up procedures will need to be

if

required).

Wear

rubber

gloves, a rubber

when

servicing

hydrogen, a highly

by

electrical

or

pipe.

battery

being

in

the

arcing

Do

not

serviced.

vicinity

smoke

batteries.

explosive

or a lighted

to

prevent

or

allow

Shut

apron,

Lead

gas,

off

servicing.

of

the zinc anode in the raw water

or

replace the anode as needed. Note

of

time with no adverse affects. It is

of

season or recommissioning

FOR

STARTING section

as

acid

which

an

open

all

electrical

of

this

Engines & Generators

45

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46

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22.0/17.0

EDE

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Type

HP@

1800/1500 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 Operating

(engine Oil

Chamber

Displacement

Order

(dry)

limit)

between

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Speed

Clearance

cold) Pressure

Timing

Battery

Capacity

Charging

Alternator

Aid

Cranking

Current

Filter

Capacity

Oil

hot)

Grade

ENGINE

rpm

Ratio

SPECIFICATIONS

Diesel,

water-cooled,

mechanism.

37.0/30.2 Naturally

22.6:1 Electronic Swirl 87 x 92.4

2.191iters 1-3-4-2

Continuous Temporary

829

TUNE-UP

Pressure

626 472

10% 18° 1800

1500

0.18 (0.0071

1991

Intake Intake

Exhaust Exhaust

ELECTRICAL

12-Volt

800-1

40

Amp

1.4Kw, Glow 170-180

LUBRICATION

Pressure Full

8.0

Pressure

28 -57

API SAE

four-cycle,

type

lbs

(376.0

vertical

aspirated

mms

(3.43 x 3.64

(134.1

cubic

20°

30°

(not

kgs)

four-cylinder,

in-line

overhead

inches)

to

exceed

1Q,min.)

fresh

SPECIFICATIONS

psi ( 44

kgf/cm')

at

250

psi

(30.5

kgf/cm')

or

less

BTDC

rpm

60

Hertz

rpm

50

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to

0.22

mm

to

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to

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36°

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45°

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at

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to

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BBDC ATDC

250

150

rpm

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SYSTEM

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000

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direct

drive

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type

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fed

system

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external

flow,

paper

element,

spin-on

type

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qts

(7.6

liters)

psi

(2.0 -4.0

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Specification

10W-40,

CF,

CG-4,

15W-40

CF-4,

CH-4,

relief

valve

Cl-4

General

Operating Fresh Raw

System (fresh

Raw (at

General

Fuel Fuel Fuel

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Fuel rated

General

Voltage -Single

ACAmperage

(Single

Voltage

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Generator Ambient

Recommendations

Coolant

Fresh Exhaust

Coolant

Heat

Temperature

Water

Pump

Water

Pump

Capacity

water)

Water

Flow

1800

rpm)

Injection

Pump

Injection

Timing

Nozzle

Filter

Intake

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amperage

-3

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Phase)

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Flow

Water

Pump

Connection

Hose

Size

Rejection

Rate

at

output

Phase

COOLING

Fresh

thermostatically-controlled 160-180° F

Centrifugal Positive

gear-driven. 6

6.0

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Open

(electromagnetic No. 2 diesel ( cetane Bosch 18° Bosch Spin-on Metal

1.99

1.22

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120 115/230

120 240 230

+ +

outlet 122°F

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to

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19,000

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or

1201240

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or -2%

no

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or

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be

provided

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rpm

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regulator.

outlet

amperage

Engines & Generators

51

SPECIFICAT-IONS

17.0/13.5

EDE

Engine

Type

Aspiration Compression Governor Combustion

Bore & Stroke Piston

Fuel

rated HP@

Engine Air

Firing

Inclination

Weight

Compression

(allowable

Variation cylinders

Injection

Engine

Valve

(engine Injector

Valve

Starting

Battery DC Starter Starting DC

General

Oil

Chamber

Displacement

Consumption

amperage

1800/1500

Combustion

Requirements

Order

(dry)

limit)

between

Timing

Speed

Clearance

cold) Pressure

liming

Battery

Capacity

Charging

Alternator

Aid

Cranking

Current

Filter

ENGINE

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at

outlet

RPM

SPECIFICATIONS

Diesel, water-cooled, mechanism.

Naturally

23.8:1 Electronic Spherical

87 x 102.4

1.82

1.50

1.22

31.0/26.0 1800

1500 1 -2-3 Continuous

Temporary

829

TUNE-UP

Pressure

512 -583 370

10% 18° 1800

1500

0.18 (0.0071

1991 Intake

Intake Exhaust

Exhaust

ELECTRICAL

12-Volt 800-1000 40

Amp

2.0Kw, Glow 240

LUBRICATION

Pressure Full

four-cycle,

liters gph

gph

rpm rpm

lbs

(376.0

vertical

aspirated

type

mm

(3.43 x 4.12

(111.43

(5.7

lph)

(4.6

lph)

58

elm

48

elm

20°

30°

(not kgs)

three-cylinder.

in-line

overhead

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cubic

inches)

at

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rpm

at

1500

rpm

(1.64

cmm)

(1.36

cmm)

to

exceed

10

fresh

min.)

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(36 -41

kgf/cm')

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250

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kgf/cm')

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(26

or

less

BTDC

rpm rpm

to

0.22 to

to

2134

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kgf/cm')

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50

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36°

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inches)

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at

250

to

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negative

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rated,

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drive

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sheathed

type

(includes

glow

plugs)

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fed

system

with

external

relief

flow,

paper

element,

spin-on

type

valve

rpm

valve

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Oil

Grade

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Temperature

Fresh

Water

Pump

Raw

Water

Pump

System

Capacity

(fresh

water)

Raw

Water

Flow

(at

1800

General

Fuel

Injection

Fuel Fuel

Injection Injector Fuel

Filter Air

Intake

Air

requirements

(generator

NOTE:

Generator Ambient

General -Single

Voltage -Single

Voltage Frequency

AC

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(Single

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Rate

rpm)

Pump liming

Nozzle

cooling)

Increase

cooling

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LUBRICATION

7.4

U.S.

API

Specification

SAE

COOLING

Fresh thermostatically-controlled

160-180° F Centrifugal Positive

gear-driven. 5

qts

6.0

gprn

FUEL

Open (electromagnetic

No.2 Bosch

18"

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GENERATOR

450

elm

air

flow

15%

122°F

AC

GENERATOR

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120

or 230

volts

+ or-

+oroutlet

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volts/58.7 122oF

NOTE:

maintain below

SYSTEM

qts

(7.0

10W-40,

15W-40

SYSTEM

water-cooled

(71

type,

displacement,

(4.71iters)

(22.7

lpm)

SYSTEM

flow,

self

bleeding,

diesel

(cetane

type

mini-pump

(spill)

throttle

type

screen/intake

COOLING

(12.7

crnm)

for

slower

(50°C)

maximum

less,

four

pole

single

with

120/240

volts

50

Hz

2%

no

load

.3hz

(.5%)

amps amps amps

(50°C)

maximum

Forced

ventilation

generator

122•F

(so•c;.

liters)

-82°

metal

fuel

CF,

CG-4,

CF-4,

engine

block,

with C) impeller, rubber

self

pump)

rating

of

silencer

box

turning

50

revolving

bearing

design. 6 wire

solid

state

60Hz

to

full

load

no

load

to

should

compartment

CH-4,

heat

belt-driven

impeller,

priming

45

or

higher)

Hertz

units.

field.

Sealed

voltage

full

rated

be

provided

temperatures

Cl-4

exchanger.

regulator.

amperage

to

'RBEKE

Engines & Generators

52

GENERATOR

SPECIFICATIONS 3 PHASE

AC

GENERATOR

Three

Phase

Voltage

• 3

(60

Voltage (50

Amperage (60

Amperage

(50

Generator Ambient

Recommendations

Generator Air

phase

Hertz)

• 3

Phase

Hertz)

• 3

phase

Hertz)

• 3

Hertz)

requirements

phase

Compartment

Temperature

Cooling

17.0/13.5

(Single

Brushless, lubricated,

reconnectable voltage with

Low

High

DELTA

High

DELTA

Low

High

DELTA

High

DELTA

122°F

NOTE:

to temperatures

450 (12.7

NOTE:

turning

Delta.

protection Voltage

Voltage

(50°C)

Forced

maintain

cfm

cmm)

Increase

50

six-pole, single

Solid

WYE

maximum

generator

below

Hertz

EDE

Phase)

revolving

bearing

for

low

voltage

state

circuitry.

ventilation

compartment

122"F

air

flow

units.

field

design.

WYE,

voltage

240

480 240

400 230

51 25

51

24 42

should

(50"C)

15%

for

Seal

12

lead

high

regulator

Volts Volts Volts

Volts Volts

Amps Amps Amps

Amps Amps

be

provided

slower

AC

Three

Phase

22.0

Kw -60

17.0

Voltage (60

Voltage

(50

Amperage

(60

Amperage

(50

Generator

Ambient Recommendations

Generator Air

Hertz

Kw-

50

Hertz

• 3

phase

Hertz)

-3

Phase

Hertz)

- 3

Hertz)

requirements

phase

- 3

phase

Compartment

Temperature

Cooling

22.0/17.0

GENERATOR

Brushless, lubricated, reconnectable voltage with

Low High DELTA

High DELTA

Low

High DELTA

122°F

NOTE:

to temperatures

500 (15.0

NOTE:

turning

Delta.

protection Voltage

Voltage

(50°C)

Forced

maintain

cfm

cmm)

Increase

50

six-pole,

single

WYE

generator

Hertz

EDE

(3

Phase)

revolving

bearing

for

low

voltage

Solid

state

circuitry.

maximum

ventilation

compartment

below

122"F

air

flow

units.

field.

design.

WYE,

voltage

240 480 2240

400

230 66

33

66 30

53

should

(50"C)

15%

for

Seal

12

lead

high

regulator

Volts Volts

Volts

Amps Amps Amps

Amps Amps

be

provided

slower

.

53

DESCRIPTION

A remote panel stopped and started from connecting harnesses

of

th~e

NOTE:

For

WESTERBEKE

is

available that

~orne

can be combined

additional infonnation, contact your

dealer.

REMOTE

AND

allows

the

generator

any

location on

in three different lengths

for a maximum

the

run

boat.

STOP/START

EXTENSION

to

be

The

and

two

at 75'

(22.17M).

local

PANEL

HARNESSES

REMOTE

PANEUPIG

PN

052560

TAll

L .

·~~

..

~.

LCD

DISPLAY

PART

053025 053026 1 053027 2 053028 3 053029 4

05303.0 053031 053032 7 053033 8 053034 9 053035 1 0

053061

Note:

These

Panel

This

kit allows for

switch

on

of

the

LCD

location.

EXTENSION

NMEA

NUMBER

___

6"

(152.4MM)

two

dimensions

Box

Cover

the

Display

Kit

the

installation of

generator control box

panel

MICRO-C

LENGTH

1/2

METER

METER METER METER -13.1

5

METER

. 6

METER

METER METER METER METER

2.2

METER ~ 40.0

- 1.6

- 3.2

- 6.5

- 9.8

- 16.4

-19.6

- 22.9

are

the

#053342

and

to a more

CABLES

FEET

FEET FEET FEET FEET FEET FEET

- 26.2

FEET

-29.5

FEET

- 32.8

FEET FEET

CONNECTING

.

·15'

(4.75M)

30'

(9.1M)

60'

(18.2M)

measurement

the

Analog

the

visible

Start/Stop remote meunting amd

EXTENSION

CABLES

PN PN PN

of

the

accessible

052959 052789 052960

cut-out

opening.

I'W'IWESTERSEKE

l Engines & Generstors

54

REMOTE

OIL

PN.#054372

INSTALLATION

This popular accessory

ter from the engine to a 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 install this kit with the oil filter facing down as illustrated.

Contact your WESTERBEKE dealer for more information.

is

used to relocate the engine's oil fil-

mo:·c

convenient location such

<i.>

for

FILTER

NOTE:

incorrect installation

.:ti•

A

rectly. pass

from failure. immediately

(OPTIONAL)

Westerbeke is

CAUTION:

If

the

valve

reaching

If

there

in

oil

the

and

not

responsible

of

the Remote Oil Filter.

It

is vital

to

flows

in

the

filter

assembly

engine

causing

is

no

oil

pressure

check

the

for

engine failure due

install

the

oil

lines

reverse

hose

direction,

will

prevent

an

intemal

reading,

.conrnec:tio~:rs.

the

engine

shutdown

to

cor-

by-

oil

THE

OUT

CONNECTION

MUST

ATTACH CONNECTION REMOTE

Oil

AT

FILTER.

TO

THE

APPLY A THIN INSTAlLING TIGHTEN CONTACTS

IN

COAT

OF

THIS

KIT.

AN

ADDITIONAl3/4

THE

BASE.

,;;a.~~---AI:Mn·r~

CLEAN

THREAD

TURN

OIL THE

TO

KIT AFTER

THE

O·RING

ON,

THE MUST CONNECTION

WHEN

THEN

HAND

THE

D-RING

IN

CONNECTION

ATTACH

Oil

TO

THE

AT

THE

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

Engines & Generators

55

WATER

HEATER

CONNECTIONS

WATER

These engines are equipped with connections for the plumbing: of The water heater should be mounted in a convenient locatiorl either in a high

that the connecting hoses from the heater to the engine can run trap

REMOVE ENGINE

HEATER

engine coolant to transfer heat to an on-board water hea,:ct.

in·

a reasonably direct line without any loops which might

INSTALLATIONS

or

low position

in

relation to the engine, so

air.

THE

EXISTING

HOSE

WATER

. -

COfVNECT FROM AS

SHOWN

INDICATE

OF

FLOW).

HEATER

two

HOSES

THE

HOTWATE£1

HERE.

THE

DIRECTION

CONNECTIONS

TO

AND

-

HEATER

(AF1ROWS

\

FRESH

WATER

CIRCULATING

PUMP

I

/.1

FRONT

GUARD

~

I

NOTE:

If

any portion engine's own pressure remote

expansion tank (Kit #024177) must

circuit

to

become tank into connections for single line engine's convenient location

The

system fill

when the remote expansion tank

tank

recovery tank

the

up

return.

remote

expansion tank will

point.

serves the same function. Remove and

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

if

it has been already installed.

FRESH CIRCULATING

HEATING

rises

a pressurized

Tee

the

heater,

expansion tank

now

serve as a check and

kit

is

(aluminum)

be

installed

the

remote

higher

and plumb a

the

other back

installed, since this

store

WATER

PUMP

CIRCUIT

above

the

in

expansion

of

the

two to

the

in

a

be

checked.

is

not used

the

plastic

the

ABOVE

THE

ENGINE

Engines & Generators

56

TYPICAL

HOT

WATER

TANK

DECIMAL

TO

METRIC

EQUIVALENT

CHART

Fractions of

an inch

1/64 1/32

3/64

1/16 5/64 3/32 0.09375 2.38125 19/32 7/64

1/8 0.125 3.175 9/64 0.140625 3.57187 41/64 0.640625 5/32

11/64 0.171875 4.36562 43/64 0.671875

3/16 0.1875 4.76250 11/16 0.6875 17.46250

13/64 0.203125 5.15937

7/32 0.21875 5.55625 23/32 0.71875 18.25625

15/64

1/4

17/64

9/32

19/64 0.296875

5/16 21/64 11/32 23/64

3/8 0.375 9.52500 7/8 25/64 13/32 27/64 0.421875 10.71562 59/64 0.921875

7/16 29/64 15/32 0.46875 11.90625 31/32 0.96875 31/64

1/2

D

ec1ma

("

.

0.015625 0.39688 33/64

0.03125

0.046875 1.19062 35/64

0.0625

0.078125 1.98437 37/64 0.578125

0.109375

0.15625 3.96875 21/32 0.65625

0.234375

0.250

0.265625

0.28125 7.14375 25/32 0.78125

0.3125

0.328125

0.34375 8.73125 27/32

0.359375 9.12812

0.390625 9.92187 57/64 0.890625 22.62187

0.40625

0.4375 11.11250

0.453125 11.50937 61/64

0.484375

0.500 12.70000 1 1.00 25.40000

) I M . ( ) I Fractions of I

1

m etnc mm ecrmal m

'

0.79375

1.58750

2.77812

5.95312

6.35000

6.74687 49/64 0.765625

7.54062 51/64 0.796875

7.93750

8.33437

10.31875 29/32 0.90625

12.30312 63/64 0.984375

an inch

17/32 0.53125 13.49375

9/16 0.5625

39/64 0.609375 15.47812

5/8

45/64 0.703125 17.85937

47/64

3/4

13/16 0.8125 20.63750

53/64 0.828125 21.03437

55/64 0.859375

15/16

.

("

0

0.515625 13.09687

0.546875

0.59375 15.08125

0.625

0.734375

0.750 19.05000

0.84375

0.875

0.9375 23.81250

0.953125

}

..

...

\IIIIUJ

13.89062

14.28750

14.68437

15.87500

16.27187

16.66875

17.06562

18.65312

19.44687

19.84375

20.24062

21.43125

21.82812

22.22500

23.01875

23.41562

24.20937

24.60625

25.00312

57

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

1 1

EQUIVALENTS

Degree

of

Latitude

Minute

of

Latitude

VOLUME

Cubic

Inches

(in') Imperial Imperial Imperial Imperial Imperial Fluid US US US

Pints Quarts Gallons Quarts Gallons

Ounces

Pints

(US Quarts Gallons

(IMP

x

pt)

(US

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

=

= 1

x

16.387

pt)

(IMP

29.573

x

.473

qt)

x

.946

gal)

x

=Grams

=

In

(psi)

(Hg)

(H20)

60

Nm

=

Nm

=

1.852

=Cubic

X

.568

=

qt)

x

1.137

gal)

x

4.546

qt)

x

1.201

gal)

x

1.201

=

Milliliters

=

Liters(L)

=

Liters

3.785

=

Liters

(g)

Kilograms

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

=

111.120

Liters

(kg)

=

= = =psi x

Kilopascals

km

Centimeters

(L)

X

=

Liters

(L)

=Liters

=US

Quarts

=US

Gallons

x

.034

=

x

2.113

(L)

x

1.057

(L)

x

.264

x

.035

=Ounces

x

2.205

Kilopascals

psi

x

2.036

Kilopascals

Inches

of

27.684

x

.061

1.76

=

x.88

=

(L)

x

.22

(US

qt)

(US Ounces =

Pints

=

Quarts

=

Gallons

=

Pounds

(kPa)

=

Hg

(kPa)

Mercury

=

H20

(kPa)

x

IMP

=

IMP

x

gal)

x

.145

x

.2961

x

13.783

4.026

=in'

pt

qt

.833

x

gal

.833

=

IMP

psi

=

Hg =

H20

=

IMP

H20

qt

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles Kilometers

Per

(Hp)

Hour

IMP

Per

Liter

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

(°C) = (°F

LIQUID

WEIGHTS

Diesel

Oil

= 1

US

fresh

Water

= 1 Gasoline= 1 US Salt

Water= 1 US

(in-lb)

(ft-lb)

x

.745

(MPG) (Km/L)

US

(MPG)

(Km/L)

·

(°F) = (°C

gallon

US

gallon

gallon=

gallon

x

.113

x

1.356

1.609

=

Kilowatts

x

.354

x

2.352

x

2.352

X

-

32) x .56

=

7.13

=

8.33

6.1

lbs

=

8.56

=Newton

=

Kilometers

(Kw)

=

Kilometers

=

IMP

.425

=Kilometers

=

US

1.8) + 32

lbs

Meters

Per

x

1.34

MPG

Hour

=

MPH

Per

(Nm)

(KPH)

Liter

x

8.85

x

.738

x

.621

(Km/L)

=in-lb

=

ft-lb

=

MPH

Engines & Generators

58

CONTACT

YOUR

SUGGESTED

WESTERBEKE

DEALER

SPARE

MARINE

FOR

GENERATORS

SUGGESTIONS

PARTS

AND

ADDITIONAL

INFORMATION

ZINC

ANODE

~

~·

OF

THE

12A

FUSE

(ON

FRONT

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

COOLANI

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

INA

CANVAS

CARRYING

KIT

BAG

Engines & Generators

1202-3/2015

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

Specifications and Main Features

Frequently Asked Questions

User Manual