Westerbeke 23.5 KW-50Hz, 25.5 KW-60Hz, 21.0 KW-50Hz, 28.5 KW-60Hz, 26.0 KW-50Hz Operator's Manual

-it

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SINCE

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19'?11

OPERATORS

D·NET

33.0KW·60Hz

26.0KW·50Hz

EDE

SIN.GLE

DIESEL

and

MANUAL

GENERATORS

28.5KW·60Hz

23.5KW·50Hz 21.0KW·50Hz

EDEA

and.

THRE

MODELS

25.5KW·60Hz

HASE

~

member

§ddf

_,_,_,_.

PUBLICATION

REVISIONS

NOVEMBER

N0-053042

2012

WESTERBEKE

WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK

150

JOHN

FAX [phone] • WEBSITE: WWW.WESTERBEKE.COM

HANCOCK ROAD • TAUNTON MA 02780-7319 •

TEL.

1-508-823-7677

·

CALIFORNIA

PROPOSITION

65

WARNING

Marine

exhaust

are

known

to

cause

and

Exhaust
colorless
unconsciousness
exposure

•Dizziness

•Nausea

•Headache

•

gasses

gas.
can

Weakness

contain

Carbon

and

include:

and

Sleepiness

diesel

and

some

to

the

cancer,

other

reproductive

A

Carbon

Monoxide

death.

and

gasoline

of

its

constituents

State

of

birth

wARNING

Monoxide,

is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

•Inability

engine

California

defects,

harm.

an

of

Carbon

in

Twitching

to

Think

odorless

and

can
Monoxide

Temples

Coherently

and

cause

IF

YOU

OR

GET

OUT

seek

medical

until

it

has

·wAR·NING

Genemtors

Produce

Regular

CARBON

Maintenance

'7[~!"!

Required

A
should
generator.

WESTERBEKE
MONOXIDE
of
obtainable

MONOXIDE.

WARNING

your

DECAL

be

fixed

DETECTORS

vessel.

at

ANYONE

INTO

THE

FRESH

attention.

been

inspected

is

provided

to a bulkhead

also

recommends

in

They

are

inexpensive

your

local

marine

ELSE

EXPERIENCE

AIR

Shut

and

by

WESTERBEKE

near

installing

the

living/sleeping

store.

ANY

OF

THESE
IMMEDIATELY.
down

the

repaired.

your

engine

CARBON

and

easily

If

unit

and

and

or

quarters

SYMPTOMS,

symptoms

df!

not

restart

persist,

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety manual
caused

by

failure
precautions.
take the

personne~

The

following safety instructions

Know

necessary

and your machinery.

the American Boat and

PREVENT

A

while

power.

• Do not operate this machinery without electrical
enclosures and covers in place.

• Shut off electrical power before accessing electrical
equipment.

• Use insulated mats whenever working on electrical
equipment.

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

• Remove wristwatch and
electrical equipment.

•

Do
circuits, except through a ship-to-shore double throw
transfer switch. Damage
result

• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.

PREVENT

A

exhaust
very

• Always check the engine coolant level at the coolant
recovery tank.

A

•

In

before touching the engine or checking the coolant.

ELECTRIC

WARNING:

engine

is

Lethal

voltage

not connect utility shore power to vessels

if

this procedure

BURNS -HOT

WARNING:

system

hot!

WARNING:

case

of

an engine overheat, allow the engine

carefuUy.

to

follow fundamental

when

dangerous

precautions

Yacht

Most

accidents

rules

conditions exist and

to

protect yourself, your

are

in

compliance

Council

(ABYC)

SHOCK

Do

not

touch

AC

electrical

running,

or

when

connected

is

present

is

at

these

dry,

all

jewelry when working on

to

vessels

AC

not followed.

ENGINE

Do

not

touch

hot

engine

components. A running

Steam

can

cause

injury

are

and

with

standards.

connections

to

shore

connections!

not

damp

AC

generator

parts

engine

or

may

or

gets

death!

to

cool

PREVENT

A

• Prevent
sparks to occur near the carburetor,
pump, or other potential sources
vapors. Use a suitable container to catch
removing the

• Do not operate without a Coast Guard Approved
arrester. Backfire can cause severe injury or death.

• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.

•

Do
the
engine/generator clean and free of debris
chances of

• Be aware - diesel fuel will burn.

PREVENT

A

injury

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

•

All
when
well-ventilated area away from spark-producing
equipment and out

• Do not

• Shut off the
the fuel system.
spill.
sources
servicing.
the

• Do not alter or modify the fuel system.

• Be sure

• Be certain

free

• Make sure a
properly maintained. Be familiar with its proper
Extinguishers rated ABC by the
for

BURNS -FIRE

WARNING:

flash

not smoke or permit flames or sparks
fuel

system.

Fire

can

fires.

Do not smoke or permit

fuel

line, carburetor, or

Keep

fire.

Wipe

cause

injury

or

death!

fuel

line,

of

spilled

all

fuel

to

the compartment and the

to

up

all

spilled

fuel

and engine

BURNS -EXPLOSION

WARNING:

or

death!

fuel

handling and storing fuels. Store

DO

fuel

of

leaks.

all

applications encountered in this environment.

Explosions

vapors

are

highly

fill

the fuel tank(s) while the engine

fuel

service

Take

NOT allow any smoking, open

of

fire

near

the

Ensure proper ventilation exists

system.

all

fuel supplies have a positive shutoff

fuel

line fittings are adequately tightened

fire

extinguisher

from

fuel

vapors

explosive.

of

the reach

valve

care in catching any fuel that might

fuel

system

Use

of

children.

at

the engine

or

engine

is

installed nearby and

NFPA

extreme

fuel

flames,

are appropriate

flames

or

filter,

fuel

fuel

or

fuel

fuel

when

filters.

flame

occur near
minimize the

can

cause

care

in

a

is

running.

when

servicing
or other

when

when

servicing

valve.

use.

oil.

and

is

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the battery cables before servicing
generator.
it

last.

• Make certain all personnel
starting.

•

Make
re-installed before starting

BATIERY

A

WARNING:

or

death!

•

Do

not smoke or allow
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
arcing or by lit tobacco products. Shut off all electrical
equipment in
during

• Never connect the negative(-) battery cable
positive ( +) connection terminal of
Do

not
together.
Ventilate
accumulation of explosive
disturb the battery charger connections while
is

being charged.

•

Avoid
burns or
wristwatch, rings, and

battery.

the

•

Always
the

battery connections. Remove
and reconnect it last

BATTERY

A

WARNING:

severe

STARTING

Accidental

Remove the negative lead

certain

all

covers, guards, and hatches

EXPLOSION

Battery

the

servicing.

test

the

battery condition

Sparks could ignite battery

any

compartment containing batteries

contacting

sparks

that could cause

turn

the

explosion

an

gas,

which

vicinity

battery charger off before disconnecting

to

the

terminals with tools, etc.,

any

when

ACID

injury

Sulfuric

or

death!

acid

starting

are

the

open

prevent electrical

gases.

other jewelry before handling

disconnecting

can

first

clear of

engine.

can

in

the

can

cause

flame

near the battery

be ignited

the

starter solenoid.

by

shorting

gases

To

avoid

an

explosion. Remove

the

negative lead

batteries

cause

and

engine before

are

injury

by

to

the

or

sparks,

the

battery.

can

injury

the

engine/

reconnect

electrical

arcing

the

terminals

fuel

vapors.

to

prevent

do

the

battery

to

prevent

first

cause

not

TOXIC

• Ensure that the exhaust system

•

•

• For additional information refer

•

•

• Although diesel engine exhaust gases

AVOID

EXHAUST

A

WARNING:

discharged
regularly
manifolds/water-injected elbow

Be

sure the unit and its surroundings

Run

blowers

Do

not

run
equipped with a functioning marine carbon
detector that complies with
boat builder or dealer for installation of approved
detectors.

(educational information

A

WARNING:

odorless
nausea

gas.

or

death!

Do

not

use
fumes

can
systems.
copper tubing resulting

Do

not install exhaust outlet where exhaust

through portholes, vents, or air conditioners.
exhaust discharge outlet
enter

the

flow

of exhaust.

exhaust
gas
symptoms or signs of carbon monoxide inhalation or
poisoning

Vomiting
Dizziness
Headache
Nausea

fumes

is

present in diesel exhaust

MOVING

GASES

Carbon

from

for

leaks

when

the

generator set or engine

Inhalation

copper

rapidly

Exhaust sulfur causes rapid deterioration of

exhaust

from gasoline engines, carbon

are:

Inability
Throbbing
Muscular twitching
Weakness

monoxide

the

engine. Check

and

make

running

Carbon

monoxide

produces

tubing

destroy

discharge

Avoid

overloading

(CO}

is a deadly

is

adequate

the

sure

the

is

securely

the

generator

ABYCA-24.

to

ABYC

on

Carbon

(CO}

flu-like

in

diesel

exhaust

copper

tubing

in

exhaust/water

is

near the waterline, water
outlet

and

fumes.

to

think coherently

in

temples

and sleepiness

to

exhaust system

exhaust

attached.

are

well

set

unless

Consult

T-22

Monoxide).

is

an
symptoms,

systems.

in

exhaust

leakage.

close

or

the

craft.

are

not

Some

monoxide

invisible

can

PARTS

gas!

expel

gases

ventilated.

or

engine.

the

boat
your

Diesel

be

drawn

If

the engine

could

restrict

as

toxic

monoxide

of

the

is

the

as

•

When

servicing
level, wear rubber gloves, a rubber
protection. Batteries contain sulfuric acid
destructive.
off

at

once with
into the
caps.

eyes

the

battery or checking

If

it comes

water.

inadvertently

in

contact with your

Acid

may

splash

when

removing electrolyte

apron,

the

electrolyte

and

which

skin,

on

the

eye

is

wash

it

skin

or

Engines & Generators

ii

A

WARNING:

or

death!

•

Do

not
situation arises in which it
make

operating adjustments, use extreme care

touching moving parts and hot exhaust system

components.

service

Rotating

the

engine

parts

can

cause

while

it

is

running.

is

absolutely necessary

injury

If

to

a

to

avoid

SAFETY

•

Do

not

wear loose clothing or jewelry

equipment; tie back long hair

jackets, shirts, sleeves, rings, necklaces or bracelets that

could be caught in moving parts.

• Make sure all attaching hardware
Keep

protective shields and guards

places at

•

Do
the engine

• Stay clear of the drive shaft
when
be

HAZARDOUS

A

all

times.

not

check

fluid

levels or

is

operating.

the engine

caught in these rotating parts.

is

running; hair

NOISE

WARNING:

High

noise

and

the

and

levels

loss!

• Never operate

• Do not run
removed.

•

Do

not run engines

open.

A

WARNING:

mentally

an

engine without its

an

engine with the air intake (silencer)

for

long periods with their enclosures

Do

not

work

on

or

physically

incapacitated

when

servicing

avoid wearing loose

is

properly tightened.

in

their respective

drive belts tension

the transmission coupling

and

clothing

can

muffler

machinery

by

cause

hearing

installed.

when

fatigue!

can

INSTRUCTIONS

while

easily

you

ABYC,
INSTALLING

Read
for safety codes
recommendations

ABYC (American Boat
"Safety Standards

Order

NFPA (National Fire Protection Association)

"Fire Protection Standard for Motor Craft"
Order

USCG
"USCG 33CFR183"

Order

are

NFPA

the

following

from:

ABYC
3069 Solomon's Island
Edgewater,

from:

NFPA

11

Tracy Drive

Avon

Industrial Park

Avon,

MA 02322

(United States Coast Guard)

from:

U.S.

Government Printing

Washington,

AND

USCG

PUBLICATIONS

DIESEL

MD

ENGINES

ABYC,

and

when

for

21037

D.C.

NFPA

standards. Follow their

installing your
and

Yacht

Small Craft"

Rd.

20404

and

Office

USCG

engine.

Council)

FOR

publications

OPERATORS

Many

of the preceding safety tips
in your
notes

to
carefully, maintain your equipment,
procedures.

GASOLINE

Preparations to install
thorough examination of the American Boat

Council's

combination of sources including the USCG and

Sections of the

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

All

installations must comply

Regulations

MANUAL

and

warnings

Operators Manual

highlight critical information. Read your

ENGINE

(ABYC)

ABYC

Ventilation
Exhaust Systems
Inboard Engines

DC

Electrical Systems

(FCR).

along

with other cautions

and

follow

AND

GENERATOR

an

engine should begin with a

standards. These standards

standards of particular interest

with

the Federal Code of

INSTALLATIONS

and

are

are

repeated

and

manual

all safety

Yacht

a

the

NFPA.

are:

Engines & Generators

iii

When

installing WES1ERBEKE

attention be paid

to

the

following

INSTALLATION

engines

information:

and

generators it

.

is

important that strict

CODES

Strict
when

AND

REGULATIONS

federal

regulations,

installing engines

SIPHON-BREAK

For installations

or

will

be

break

in

the

minimum

the

exhaust manifold

raw

water

If

you

have

to

the

vessel's waterline under

siphon-break.

NOTE: A siphon-break

operation.

engine

damage.

EXHAUST

The

exhaust system's

Exhaust

ru1d

turns

and

turns

system

MUST

under

any

where

below

the

raw

water supply hose

of 20"

damage

any

doubt about

Failure

SYSTEM

Hose

is

recommended.

without

.In

this

be

sea

conditions

vessel's waterline, provisions must be

above

to

the

to

properly

Consult

hose

the

need

regard, a single

designed

ABYC

guidelines,

and

generators

the

exhaust manifold/water injected exhaust elbow

to

the

vessel's

injection

engine

requires

the

MUST
of additiinal

to

and

waterline.

port

and

the

position of

the

vessel's

periodic

maintain

siphon-break

be

The

length

prevent

at

any

and

safety codes must be complied

in a marine

the

exhaust

is

at

or

possible

inspection
a siphon-break

manufacturer

certified

use

of

fitting

of corrugated exhaust hose

the

entry

angle

of

environment.

elbow.

This hose must

Failure

below

flooding

the

various

for

this

and

vessels

to

use

the

load

of

water-injected exhaust elbow relative

operating conditions, install a

and cleaning

can

for proper

marine

use.

type of hose

clamps

of water

into

heal.

made

a siphon-break

waterline

the

boat.

result

Corrugated

allows

to

accomplish

the

to

install a

be

will

to

ensure

in

catastrophic

maintenance.

for

extreme

these

can

be

exhaust

system.

with

is

close
siphon­looped a

when

result

proper

Mruine

bends

used.

to

in

bends

The

AVAILABLE
YOUR
DEALER

SIPHON-BREAK
LOOP
PART

FROM

WESTERBEKE

FOR
NO.

WITH

1"

HOSE

044010

STAINLESS

A

detailed
engines
.Is

Website:

and

also

available

www.westerbeke.com

Marine

Installation

generators

in

pdf

is

supplied

format

Manual

with

on

our

website

.

IV

covering

every

gasoline

unit

to

and

sold.

This

download

diesel

manual

·

TABLE

OF

CONTENTS

Parts

Identification

I~II~CJn

Fuel,

Engine

· Preparations for Initial Start-Up ••••••••••••••••• 6

Digital

Manual Engine Shut-off
Digital Control Box

LCD Sequence ...

Remote
Generator

Daily Routine ••••••••••••••••••••••••••••••••••••••.

Maintenance

Fuel System ••••••••••••••••••••••••••• ~ ••••••••••••

Cooling

Raw Water intake

Draining the Raw Water System
Fresh Water Cooling Circuit
Changing the Coolant
Thermostat

Raw Water Cooling Circuit
Heat Exchanger

~aw

Engine

Engine Oil
Remote Oil Filter (Optional)

••••••••••••••••••••••••••••••••••••••••• 3

Oil

Control

Stop/Start

Break-In

System

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

Water Pump

Lubrication

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

and

Engine

Panel

•••••••••••••••••••••••••••••••

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

,.··································

Panel

Procedure

Schedule

•••••••••••••••••••••••••••••• ~ •••••

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

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

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

Oil

Chru1ge

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

Coolant

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

••••••••••••••••••••••••

••••••••••••••••••••••••••

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

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

•••••••••••• , 5

••••••••••••••••••

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

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

··············18

•••••••••••••••••••••••••••

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

2

7

7

8

9

,10·

11
11

12

14

15

15

16
16
16

17

1a

18

19

19

20

Starter

Wiring

Specifications

33.0Kw Generator.

28/25

Engine

Alte~ator

Glow
Engine

Generator
Twelve
Changing
Electronic Regulation
Internal Wiring Diagram
Shore
Lay-Up
Metric

Water

Suggested

Motor

•••.•••••••••••••••••••••••••••.•••••••• , 21

Diagrams............................ . . . . • . . .

(Engines)

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

K w Generator

Troubleshooting •••••••••••••••••••••••••••.

Testing •••••••••••• ~ ••••••••••••••••••••• ,

Battery Care .. H

Plugs

•••••••••••••••••••••••••••••••••••••••••••

Ad)usbnents

. 34

Valve Adjustment.
Oil Pressure
Drive Belt Adjustment.

Fuel Injectors
Magnetic Pick-Up

Power Transfer Switch ••••••••••••••••••••.

Conversion

Heater

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

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

lnfonnation •••••••••••••••••••••••••••••.

Lead

Winding

Hertz

Recommissioning •••••••••••••••••••••••••.

Connections (Optional) ••••••••••••

Spares

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

•••••••••••••••••••••••••••••••••••

••••••

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

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

Connections

and

Voltage

••••

Data

••••••••••••••••••••••••••••••••••

23

••••••••••••••••••••••••••.

~·~·······················

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

••••••••••••••.

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

.'

•••••••••••

•••

· ••••••••••••••••••••••••

(Chart)

~

•••••••••••••

•••••••••••••••••••

26

27

28

29

3D.

32

33

34

.

.

34

35

36
36

37
28

,39

41
42
43
44
46
47

~4B

Engines & Generators

1

PARTS

IDENTIFICATION

OIL

ALL

CONNECTION
SIPHON

BREAK

REAR

FOR

COOLANT

RIGHT

PUMP

SIDE

DRIVE
COVER

DCAL

BELT

FRONT

FLEXIBLE
MOUNTS

CONTROL

BREAKER

LEFl
SIDE

ISOLATED

Engines & Generators

.

2-

INTRODUCTION

This WES1ERBEKE Diesel Generator is a product
WES1ERBEKE's long years

We

technology.
dependable performance
Thank you

In

order to get the full use and benefit from your generator,

it

is important that you operate and
This manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout.
your nearest

This is your operators manual. A parts catalog is also
provided and a technical manual is available from your
WES1ERBEKE dealer.
equipment, contact your

WES1ERBEKE' S installation manual.

WARRANTY

Your WES1ERBEKE Warranty is included in a separate

folder.

If, after 60 days

form you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the unit's

serial number and commission date.

Customer

take great pride in the superior durability and

for

selecting WES1ERBEKE.

Should your engine require servicing, contact

WES1ERBEKE

PROCEDURES

Identification

of

experience and advanced

of

our engines and generators.

maintai"n

dealer for assistance.

If

you are planning to install this

WES1ERBEKE

of

submitting the Warranty Registry

dealer for

Card

of

it correctly.

l"'ffV"IWESTERBEKE

I

Customer Identification
MR. GENERATOR
MAIN STREET
HOMETOWN, USA
Model
Expires

OWNER

Ser. #

PRODUCT

Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WES1ERBEKE are not within WES1ERBEKE's control.

WESTERBEKE

CONTENT
RANTIES
THERETO,
COMPLETENESS

BE UABLE
INCURRED

OF

THE

WES1ERBEKE customers should keep in mind the time
span between printings
and the unavoidable existence
product software. The product software provided with
WES1ERBEKE products, whether from WES1ERBEKE or
other suppliers, must not and cannot be relied upon
sively as the definitive authority on the respective product.
not only makes good sense but is imperative that appropriate
representatives
be consulted to determine the accuracy and currentness

product software being consulted by the customer.

PROTECTING

Care at the factory during assembly and thorough testing

have resulted in a WESTERBEKE generator capable
many thousands
manufacturer cannot control how
installed
operated and serviced in the field. This is
buyer/owner-operator.

NOTE:

SOFTWARE

CANNOT

OF

SUCH

SOFTWARE,

OR

REPRESENTATIONS

INCLUDING

THEREOF

FOR

ANY

TYPE

IN

CONNECTION

FURNISHING

ofWES1ERBEKE

YOUR

of

in

the vessel

Six important steps

OR

of

INVESTMENT

hours

or

BE RESPONSIBLE

MAKES
WITH

ACCURACY,

AND

WILL

OF

DAMAGE

WITH

USE

OF

SUCH

WES1ERBEKE product software

of

earlier WES1ERBEKE

or the supplier

of

dependable service. However the

or

where the generator is

the manner in which the unit is

to

ensure

long

FOR

NO

WAR-

RESPECT

TIMEliNESS

IN

NO

EVENT

OR

INJURY

OR

ARISING

SOFTWARE.

in

up

to the

generator

THE

OR

OUT

exclu-

question

of

of

life:

It

the

• Proper engine and generator installation and alignment.

•

An

efficient

an anti-siphon break

weU-designed

to

prevent water from entering the

exhaust system that includes

engine.

NOTES,

As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
engine, critical information will be highlighted by
CAUTIONS, and WARNINGS. An explanation follows:

NOTE:

A

observed,

your

A

followed,

CAUTIONS

An operating

CAUTION:

can

engine.

WARNING:

can

procedure

Procedures

result

Procedures

result

AND

WARNINGS

essential

which,

in

the

daniage

which,

In

persona/Injury

of

your marine

to

note.

if

not

strictly

or

destruction

If

not

properly

or

loss

N01ES,

of

of

life.

• Changing the engine oil and oil filters according to the

maintenance schedule.

• Proper maintenance

nents according

manual. .

•

Use

• Winterize your engine according

Recommissioning" section in this manual.

Engines & Generators

3

of

all engine and generator compo-

to

the maintenance schedule in this

clean,filteredunleadedfueL

to

the "Lay-up and

INTRODUCTION

SERIAL

The
a nameplate
exhaust manifold.

The
the engine
the side oil fill opening.

ation below

NUMBER

engine's

engine's

block

LOCATION

model

and

mounted

serial

on

on

number

on

a flat surface

the illustrated nameplate.

serial

number

the

side

is also found stamped in

Take

time to enter this inform-

50

of

just

HZ.

are located

the water

above the

60HZ.

I

on

jacketed

NOTE:

A carbon monoxide warning decal
by WESTERBEKE. Affix this decal
engine

room.

UNDERSTANDING

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

Therefore, to a great extent, a diesel engine requires the
same preventive maintenance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance
Replacement
time periods specified is a must, and frequent checking for
contamination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of

the same brand

designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,

however, in its method
carburetor and ignition systems are done away with and in
their place is a single
which performs the function

ORDERING

Whenever replacement/service parts are needed, always
provide the generator model number, engine serial number,
and generator serial number as they appear

black name plate located

provide us with this information so we may properly identify
your generator set. In addition, include a complete part
description and part number for each part needed (see the
separately furnished
WESTERBEKE packaged parts because

parts are frequently not made to the same specifications as

original equipment.

of

PAins

THE

DIESEL

of

a gasoline engine; and the

of

the fuel, lubricating and cooling systems.

of

fuel and lubricating filter elements at the

of

high detergent diesel lubrication oil

of

handling and firing

component-

of

both.

on

the generator end. You must

Parts List). Also insist upon

has

been provided

in

a visible position

in

the

ENGINE

of

valves, camshaft, pistons,

of

fuel. The

the fuel injection pump -

on

the silver and

will fit or generic

An identification plate
displays the engine model and serial number.

CARBON

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

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

If

carbon monoxide is present, ventilate the area with clean

air and correct the problem immediately!

MONOXIDE

in

small

amounts,

of

on

the top

of

the engine air intake also

DETECTOR

Carbon

is deadly.

carbon monoxide indicates an exhaust leak

or

generator

or

or

from the exhaust

the fumes from a nearby vessel are

monoxide,

SPARES

Certain spares will
WESTERBEKE generator. Your local WESTERBEKE
dealer will assist you in preparing an inventory
See the
Generator Accessories, see the

AND

SPARE

INSTALLATION

Publication #43400 provides detailed information for
installing generators.

Engines & Generators

4

ACCESSORIES

be

needed to support and maintain your

PARTS

page in this manual. For Engine and

ACCESSORIES brochure.

MANUAL

of

spare parts.

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use a diesel fuel that meets the requirements
SAE
diesel fuel according

Care

Use only clean diesel fuel! The clearance

in
dirt particles which might pass through the primary and sec­ondm·y

impm1ant

can be rendered unsatisfactory

improper storage facilities. To ensure that the fuel going into

the tank for your engine's daily use is clean and pure, the

following practice

Purchase a welt-known brand

to

recommended such

Diesel Kleen + Centane Boost to help restore lubricity back

into the diesel fuel when an Ultra Low Sulfur diesel is being

used.

Install and

filter/water separator between the fuel tank and the engine.

The Raycor

such filters. A

ENGINE

Use a heavy duty diesel oil with an API classification
CG-4, CH-4 or CI-4. Change the engine oil and filter after
initial 50 itours
filter change intervals

SCHEDULE

not approve or disapprove the use

synthetic oils are used, engine break-in must be perfmmed
using conventional oil.
in the MAINTENANCE SCHEDULE section
manual and not be extended

NOTE:

statements regarding synthetic oil.

SAE

For all temperature ranges: SAE

FUEL

of

No. 2-D

1 313 and has a Cetane rating

to

ASTM D975

Of

The

Fuel

Supply

your engines fuel injection pump

filters can damage these finely machined

to

buy clean fuel, and keep

is

advisable:

combat BACTERIAL growth in the fuel tank is

as

Bio-Bor and an additive such

regulmly service a good, visual-type fuel

500 MA or 230 RMAM are good examples

10

micron filter element is recommended.

of

#45 or higher grade

of

the components

is

very critical; invisible

it

clean. The best fuel

by

careless handling or

of

fuel. The use

of

OIL

of

break-in operation. Then follow the oil and

as

specified in the MAINTENANCE

in

this manual. Westerbeke Corporation does

of

synthetic oils. If

Oil change intervals must be

if

synthetic oils are used.

The information above supersedes all previous

OIL

VISCOSITY

GRADE

l5W

-40 or SAE lOW-40.

pm1s.

It

additives

as

of

as

of

this

of

is

of

CF,

listed

an

ENGINE

WESTERBEKE recommends a mixture
and
chemicals that can corrode internal engine surfaces.

The antifreeze perfonns double duty. It allows the engine to
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 (SCAs) that keep the antifreeze chemically
balanced, crucial

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

NOTE:

antifreeze that is now available.

PURCHASING

Rather than preparing the mixture, WESTERBEKE
recommends buying the premixed antifreeze so that so that
when adding coolant the mixture will always be correct.
There
(green) and
but do not mix the two and
flush the engine thoroughly.

Premixed antifreeze for DIESEL Engines:
Specification #ASTM D53456.

COOLANT

50% distilled water. Distilled water

to

long term protection.

Look

for

the new environmentally-friendly long lasting

ANTIFREEZE

me two common types

Propylene Glycol (red/purple), either can be used

of

antifreeze, Ethylene Glycol

if

changing from one

of

50% antifreeze

is

free from the

to

another,

MAINTENANCE

Change the engine coolant every five yems regmdless

of

number
protect and lubricate the engine have

COOLANT

The coolant recovery tank allows for the expansion and
contraction
without introducing air into the system. This recovery tank
provided with fresh water cooled models and with the fresh
water coolant conversion kit and must be installed before
operating the engine.

operating hours

RECOVERY

of

the engines coolant during engine operation

as

the chemical additives that

a limited life.

TANK

of

the

is

Engines & Generators

5

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

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

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

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

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

bowls for contaminants.

• Check the
and battery cable connections.

• Check load leads for correct connections as specified in
the wiring diagrams.

• Examine the air inlet and outlet for air flow obstructions

(Soundguard).

.

• Be sure no other generator or utility power is connected to

the load lines.

• Be sure that in power systems with a neutral line that the

neutral is properly grounded (or ungrounded) as the system
requires, and that generator neutral is properly connected
to the load neutral.
or open neutral can supply the wrong line-to-neutral volt-

age on unbalanced loads.

• Visually examine the unit. Look for loose
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any fuel leaks.

INSPECTION

on

the dipstick.

DC

electrical system. Inspect wire connections

In

single phase systems an incomplete

or

missing

A

CAUTION:

recommended
motors,

up

This

unanticipated

prevent a cold

• Check the coolant level in both the plastic recovery tank

be

to

speed

precaution

and at the manifold.

NOTE:

After

the

engines cooling system will
recovery
the

cooling system

the

after

tank will
replace

Before
manifold should
tank

engine has

the

subsequent operation

may

When

that

switched

and,

in

will

operation

engine

the

initial

tank.

Open

be

drawn

purged

be

need

to

COOLANT

RECOVERY
MAINTAIN

COOLANT
AT

starting

all

AC

loads,

OFF

until

cold

climates,

prevent

of

from

running

the

air bleed petcock

is

purged

cooled,

into

the

air.

topped

be

filled

TANK

LEVEL

1/2

FULL

the

generator,

especially

the

engine

starts

damage

the

caused

AC

machinery

stalling.

of

the

generator;

be

purged

of

air.

After

the

coolant

engines cooling

of

the

off,

and

to

the

generator;
the

MAX

level.

from

coolant

it

is

large

has

come

to

warm

by

and

the

to

the

to

ensure

shutdown

the

system

the

recovery

up.

will

air

coolant

that

and

recovery

to

engines

in

-~~~

.SIDE

A

IS

THE

'"

OIL

FILTER--

SIDE

OIL

FILL

LOCATED

OIL

FILTER

ABOVE

OIL

~

FILL

,,

---~/

6

DIGITAL

CONTROL

PANEL

DESCRIPTION

WESTERBEKE'E Digital Control Panel provides the
operator with an LCD display that contunuously monitors
all the operations

the generator in easy

to

understand

of

text messages.

CONTROL

Note that the design and size

BOX

of

the control box will vary

depending on the model generator.

BA

FUSE

PROTECTS
ELECTRONICS
AMPERAGE

INDICATOR

SIX
WHERE A FAULT

LIGHTS

THE

CONTROL

FROM A HIGH

OVERLOAD.

LIGHTS

THAT

INDICATE

HAS

OCCURED.

PANEL

~

20A

BREAKER

SHUT-OFF
MAINTENANCE
REPAIRING A FAULT.

RESTART

SWITCH"-

WHEN

PERFORMING

OR

THE

ENGINE.

WHEN

RESET

TO

FAILURE

A

REO

LIGHT

THE

RUN

SEQUENCE

INTERUPTED

LIGHT

WILL

APPEAR

IS

BY A FAILURE.

IF

START

STARTS

BUTTON

THE

ENGINE

LCD

DISPLAY

Operating temperatures may cause

th~

LCD display to vary

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

C<Ontrol

the operation on the

panel.

Periodically clean the control panel LCD screen using a soft
cloth.

UP

AND

WHEN
IN

ITS

UP

AND

BE

USED

DARK

DOWN

THE

LCD

SCROLL

DOWN

TO

ADJUST

AND

LIGHT

ARROWS

DISPLAY

MODE,

THE

ARROWS

THE

CONTRAST

IS
CAN

UP-ARROW

WHEN

IN

SCROLL

LOCK

MODE
INDIVIDUAL
BE
THE

SCROLL

STOPS
THAT A SINGLE
BE

MONITORED

FUNCTIONS

MONITORED

UP-ARROW.

BY

LOCK

RUN

SEQUENCE

FUNCTION

CAN

PRESSING

SO·

CAN

DOWN-ARROW

WHEN

IN

SCROLL

LOCK

MODE

THIS

BUTTON

USE

IT

TO

AIR

AFTER
ENGINE'S
THE

ON

ENGINE

INDIVIDUAL
BE

THE

ENERGIZES

PURGE

PERFORMING

FUEL

SYSTEM

FULE

FUNCTIONS

MONITORED

DOWN-ARROW.

THE

THE

FUEL

FUEL

SYSTEM

REPAIRS

OR

SERVICING

FILTERS.

LCD

DISPLAY

IS

SHOWN

BY

ON

CAN

PRESSING

PUMP.

OF

TO

THE

SEQUENCE

THE

FOLLOWING

..

PAGE.,

*MANUAL

ENGINE

SHUT-OFF

Should the engine faile to stop when the fuel shut
is de-energised when the

STOP button is depressed. The engine
is equiped with a manual shut-off lever. This is located
the fixed throttle lever

the side

ofthe

on
the fuel injection pump. Move this lever to the left and hold
it there until the engine comes to a stop. Then release.

off

solenoid

just

engine block below

7

below

·Manual

Engine

ShutOff

t

DIGITAL

CONTROL

BOX

FREQUENCY

FAULT

Frequency is displayed on the LCD display screen while the

is

engine
The

running in

ECU is receiving a low AC voltage signal and hertz

signal from the
over the flywheel ring gear teeth. The

RPM

and frequency (hertz).

MPU which

is

positioned on the bellhousing

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 turn from green to amber and the LCD
display screen will show the fault text

NOTE:

If

same fault

frequency

WHEN
FREQUENCY
ON

THE

BOARD

ON

FOR

the unit shuts down

"overspeed" will show on the screen but the

LED

will BUNK.

CHANGING

CONTROL

MUST

50

(50160

BE

HZ

AND

THE

PANEL

SWITCHED:

for

GENERATORS

HZ)

SWITCH

ECU

OFF

fOR

60HZ.

"overspeed".

an underspeed condition, the

#1

GENERATOR

CAUTION:

the

ECU,

box.

Tum

NOTE:

If

same fault

FREQUENCY

ADJUSTMENT

(HERTZ)

When changing the generator frequency setting on

tum

off

the 20 amp DC circuit breaker on the control

it back on after the setting has been changed

the unit shuts down

for

an underspeed condition, the

"overspeed" will show on the screen but the

frequency LED will BUNK.

1.

Turn the

DC

breaker on the control panel to the. OFF

position.

Open the cover

2.

of

the control box and view the ECU

(Electronic Control Unit).
Locate the

3.
position that
See the illustration below showing the

#1

dipswitch on the ECU and move it

to

corresponds to the Hertz operation desired).

ECU in the

the

control box.

4. Replace the control box cover, tum the DC breaker ON

and start the unit. Monitor the frequency that the

is

engine/generator is operating
fTequency.

operating at the cotTect

CONTROL
INTERNAL

CAUTION

generator's starting battery when the unit
This can be as much as
normal seasonal use. However,

to

the generator with a NMEA-2000 system or shut

NOTE:

BOX

COMPO

(WESTERLINK

Keep

in

or

NMEA-2000):

72

amp-hours

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

in

if the generator set is not to be used

mind that the Westerbeke generator maybe the DC power supply

is in a sratic state. This maybe as much as 50 milli-amps

a months time with no generator use. It is not necessary

off

the

DC

for

a number

breaker on the generator's control box for a WESTERLINK system.

Engines & Generators

of

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

for

the

vessel>·

PORT

NOTE:

DURING

OF

THE
CAUSED
AND

NO

of

for

the system ECU and

to

be concerned with this slight amperage draw during

NMEA-2000 network.

amperage (milli-amps) from the

50

OPERATION

LCD

DISPlAY

BY

HEAT,

CAUSE

milli·amps for each display.

THIS

FOR

CONCERN.

MAY

IS

DC

THE

COLOR

VARY.

NORMAL

power

8

DIGITAL

CONTROL

PANEL/LCD

SEQUENCE

START

With
button

SEQUENCE

the pre-start inspection completed, press

and

the automatic sequence will begin.
indicator lights will illuminate green and
display the following

l"'fN'{WESTERBEKE

Engines & Generators

Pre Heating ......

Seconds

7

RUN

SEQUENCE

As

the display cycles

will

come

up

to

the

oil pressure and engine coolant will rise

readings. The functions will cycle

Engine Speed

1800

0

-··--·

text:

· Waiting for operator

Press start to

engage generator

Cranking ......

...

thru

the engine functions, the speed

1800

rpms-60Hz (1500 rpms-50Hz) and

in

the following sequemce:

.Coolant Temperature

RPM

2500

Sl;.R9LL

81C

32 300

0

the

to

panel

178F

the

START

The

six
will

their normal

100

SCROLL

STOP

SEQUENCE

To

stop

the

generator, press

will

cycle

thru

the

following text messages

SJ1utting

Down

Waiting for operator

Press start to

engage generator

FAILURE

If

a problem occurs, the generator

FAILURE light

LIGHT/SHUTDOWN

will

indicator lights will change from green

the

illuminate

STOP button. The display

Engine Shutdown

will

shutdown and

red.

In

addition,

to
where the trouble has occured and the display
message what

Examples:

Failure Light is red.
Coolant Temperature Light

is

orange.

has

happened.

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

High Engine Temp.

ECU to Restart·

Reset

and

shutdown.

orange

will

one

to

the

of

reveal

text

the

Battery Voltage Oil Pressure

40

PSI

10Q

6.9

SCROLL

100

SCROLL

SCROLL

..

.

.·LOCK

appear

and observe other

200
200

. I

600
600

The

3.1

'BAR

. 0

0

AC Frequency

60.1Hz

0

AC Line Voltage

120V

AC Line Voltage

..

Aeasovf

BC378V
CA380V

to

monitor a single function

word

LOCK

to

0

0
0

will

find

the

SCROLL LOCK

13.5

VDC'

0

Engine Hours

30

SCROLL

3.8 HOURS

SCROLL

..

AC Phase Voltage

A120V
B120V

AB380V..
BC
CA380.V

SCROLL

To
button. This enables the operator
for
comer. Use
functions.

0

0

AC Phase Voltage

..

a '600

0

378V

0

SCROLL

SCROll

LOCK

stop the continuing sequence, press the SCROLL LOCK

any

length

of

time.

the

up and down arrows

To

resume scrolling, press

button again.

200

·eoo
lioo

tioo

in

I

the

Failure Light

Oil Pressure Light

is

red.

is

or~nge.

When a failure occurs, refer
wiring diagram, and general operating text
assist

in

solving the trouble.

Low Oil Pressure

Reset

ECU to Restart

to

the troubleshooting chart,

in

There are many combinations of messages that can
displayed but

they

are

all

self explanatory and

can easily isolate and correct the problem should
Before re-starting the generator,

breaker must

be

reset. With the problem corrected and the

tlie

20

amp

generator started, the sequences will begin cycling again.

A

NOTE:

Three phase voltages will vary depending on the

"\J

output configuration

of

the generator.

Control
and
are

Box

Components

Frequency

on

the

following

Adjustments

this

DC

the

one

circuit

page.

manual

be

operator

occur.

AC

t

to

9

REMOTE

AND

STOP/START

EXTENSION

DESCRIPTION

A remote panel is available that allows the generator to be

on

stopped and started from any location
connecting harnesses come in three different lengths and two
of

these can

NOTE:

WESTERBEKE

For

be

combined for a maximum run at

additional

information,

dealer.

the boat. The

contact your

75'

local

(22.17M).

PANEL

HARNESSES

PN

052560

Note:

These

LCD

DISPLAY

NMEA

PART

NUMBER

053025,
053026 1 MEfER ­053027
053028

053029
053030
053031
053032
053033
053034
053035

053061

___

EXTENSION

MICRO-C

6"

(152.4MM)

two

dimensions

are

the

CABLES

LENGTH

1/2 MEfER - 1.6 FEEf

3.2 FEEf
2 MEfER - 6.5 FEEf
3 MEfER - 9.8 FEEf
4 MEfER -

5 MEfER - 16.4 FEEf
6 MEfER - 19.6 FEEf
7

METER
8 MEfER - 26.2 FEEf
9 MEfER - 29.5 FEEf

1 0 MEfER - 32.8 FEEf

2.2 MEfER - 40.0 FEEf

13.1

FEEf

- 22.9 FEEf

CONNECTING

CABLES

15'

(4.75M)

30'

(9.1M)

60'

(18.2M)

measurement

EXTENSION

PN

052959

PN

052789

PN

052960

of

the

cut-out

opening.

Engines

10

& Generators

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
section. Run the engine while checking that all systems (raw
water pump, oil pressure,, battery charging) are functioning.

AFTER

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

START-UP

of

STARTING

full-load for the first 10 hours.

50 hours

of

one

of

use.

of

initial

of

the engine.

PROCEDURE

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

Avoid overload at all times. An overload is signaled by smoky
exhaust with reduced output voltage and frequency. Monitor
the current being drawn from the generator and keep it within

the generator's rating. Since the generator operates at

rpm to produce 60 hertz (or at 1500 rpm to produce 50

Hertz), control
current drawn from the generator.

NOTE:

draw required
draw can

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

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

10 hours

of

Be

aware

for

be

3 to 5 times normal running amperage. See

ADJUSTMENTS

ENGINE

ADJUSTMENTS

GENERATOR INFORMATION.

of

the generator's operation, the load

.

1800

the generator's break-in is governed by the

of

motor

starting loads

starting motors. This starting amperage

SPEED (HER1Z) ADJUSTMENT) under

..

A no-load voltage adjustment

and

the high current

50 hours) or after this

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,

• 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

• 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.

or

water leaks.

WITH

THE

ENGINE

blow-back sounds.

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

RUNNING.

DAILY

ROUTINE

NOTE:

Some unstable running

This condition should abate as normal operating temperature

and

is reached

A

CAUTION:

periods

loads are applied.

Do

of

time

without a load

not

generator.

STOPPING

Remove the AC loads from the generator one at a time.Allow
the generator to run for 3-5 minutes to stabilize the operating
temperature, then momentarily depress the stop button and
release. The generator will automatically shut down.

DC

the
safety precaution.

THE

GENERATOR

circuit breaker to prevent unintentional starts as a

may

operate

being

occur in a cold engine.

the

generator

placed

on

for

the

long

Tum off

.

Engines & Generators

11

A

WARNING:

running.
use
servicing

NOTE:

the

co«ect

Many

Wear

any

of

difficult and may

MAINTENANCE

Never

attempt

the

proper

safety

tools

for

each

of

the

engine's

the

following maintenance jobs

require

the

job.

DC

expert

to

equipment

Disconnect

electrical

knowledge

SCHEDULE

perform

such

equipment.

any

service

as

goggles

the

battery

are

simple but others

of

a service

while

the

and

terminals

mechanic.

engine

gloves,

when

are

more

is

and

SCHEDUlED
MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

Visual

Fuel
Inlet
Starting

(and

Engine

Generator

Heat

Filter/Water Separator

Exhaust

Engine

. -

Separator

Oil

level

level

Belts

Inspection

Filter
Fuel

Filter

Batteries

House

Batteries)

Oil

(and

Exchanger

System

Hoses

of

filter)

Zinc

Engine

Anode

CHECK

EACH

DAY

D
D

D

D

D

weekly

D

D

weekly

HOURS

OF

OPERATION

50

100

250

500

750

1000 1250

NOTE:

Please

keep

engine

surface

and

oil

remain

D

will

inhibit

the

cool.

D D D D

engine's

clean.

ability

to

D D D D

D

D D D D D

D D D D D

D D D D

D D D D

D D

D

D

D D D D

D D D

D D D

Dirt

D
D

D

D

D

Diesel

No. 2 rating

Check

for

if

necessary).

Oil

level

dipstick.

Check

at

Add

coolant

Inspect
and

adjust

Check

for

and

electrical

Check

for

Initial

change

·

Replace.
Every

50

and

make

excessive

Initial

engine

change
Check

that

with

no

for

additional

Inspect
exchanger

Change

Initial

check

for

leaks.

the

exhaust
buildup
necessary.

Hose

should

spongy.

EXPlANATION

MAINTENANCE

of

45

water

and

dirt

should

indicate

recovery

for

operating

both

chafing.

zinc

the

on

Check

tank;

if

needed.

proper

tension

if

needed.

fuel,

oil

and

connections.

loose

belt

at

50

hours

sure

connections

corrosion.

oil & filter

every

250

AC

connections

See

information.

anode,

end

of

zinc

filter

and/or

at

50

hrs.,

Check

anti-siphon

elbow

for

inside

passages;

Check

that

be

hard & tight.

and

Check

tension.

hrs,

GENERATOR

replace

tighten

OF

SCHEDUlED

cetane

in

fuel

(drain/replace

between

if

empty,

(3/8'

belt

water

leaks.

Keep

then

change

check

are

change

hours.

are

clean

if

needed,

anode

debris.

drain

water

then

every
valve

carbon

and/or

clean

all

connections

Replace

all

hose

or

higher.

filter

MAX.

and

lOW

check

at

manifold.

to

1/2'

depression)

edges

for

wear.

Inspect

wiring

bolts & nuts

electrolyte

very

at

50

MAINTENANCE

every

250

operation.

and

clamps

tight.

every

250

levels

tight.

Clean

hrs.,

then

and

secure

clear

the

200

hrs.

hrs.

Inspect

Check

corrosion

replace

are

tight.

if

soft

or

.

on

hrs.

off

heat

as

CAUTION:

A

components,
either

the

DC

When

the

DC

breaker

servicing/changing

power

must

be

tumed

or

the

battery

switch.

DC

off

using

12

NOTE:

Use

engine

hours

MAINTENANCE

the

engine

hour

meter

gauge

to

by

running

nine.

SCHEDULE

log

your

engine

hours

or

record

your

SCHEDULED
MAINTENANCE

Raw

Water

Pump

AI

80Q

operating

disassemble

for

overhalil.

Coolant

System

Electric

t=uel

*Fuel

InJectors

*Starter

Motor

*Preheat

*Adjust

th~r

*Heat

Exchanger

*Water

InJected

and

·

Uft

Circuit

Valve

hours,

inspect

Pump

Clearances

Exhaust

Elbow

CHECK

EACH

DAY

HOURS

OF

OPERATION

50

100

250

.

500

..

7.5Q

0

0

0 0 0 0

0

0

0

.

1000

.

1250

0 0

0
0 0

D

0

0

0

0

0

EXPLANATION

Remove

the

gasket,

cam

and

seals

(the

When

reassembling.

Drain~

flush~

appraprtata
Periodically

Inspect

.

Check

spray

Check
and
pinion

Check
clean

~elnstaO

;

Adjust

(See

.

Remove,

antifree:ze

check

the

fuel

and

adjust

condition

solenoid

lubri&te.

drive.
operation

glow

plugs;

with

Valve

Clearances

ENGINE

have

testetl.

Check

casting

.

operation,

Replace

OF

SCHEDULED

MAINTENANCE

pump

cover

and

Inspect

and

cover

tor

wear.

shaft

should

not

wobble).

and

refill

cooling

system

mix.

the

wiring

connections

line

connections.

injection

(see

and

Glean

of

check

~i-selze

opening

EN61NE

motor

for

and

lubricate

preheat

solenoid.

resistance

compound

ADJUSTMENTS).

corrosion.

ADJUSTMENtS).

professionally

'

integrity

as

cleaned

every

500

needed.

impeller,

Check

With

pressure

the

starter

Remove

(4.:S

on

threads.

and

hours

the

bearings

Lubricate

the

and·

and.

Remove

motor

and

ohms).

pressure

of

"'WESTERBEKE

CADnON

generator!!
This

can be as much

·

·. · ··

neriiiiilseiUiiiltllliiiiiHtiwiiliet;

to the generator

MOTE:

Keep

A

components;
either

recommends

(WEStEiiUNK

starting battery when

in

CAUTION:

the

DC

or

as

72

With

a

NMEA~2000

m~

that

When

the

DC

breaker

this

service

be

NMEA•2000):

amp-hours

the

Westerbeke

The

the

iftliiigenenuorflet

eler;tronic

unit

is

m a static

in

a months

system arshl/.t

generator

servicing/changing

power

must

be

or

the

battery

,.

..

·'

performe.d

components
state.

time

with

ts

iWtto·

off

the

maybe

DC

fumed

off

switch.

by

an

authorized

in

This

maybe

no

generator

be

usedfora·iiuiiiber•ofmonths;··SIIC~·as

DC

breaker

the

DC

power supply for

using;

mechanic.

the

Digital Diesels

as

much

use.

It is not necessary

on

the.

generator's

draw

a·

as

50

the

vessel's

NOTE;

previous maintenance schedules published for these

models.

very small amount

milli-amps for

control

This MAINTENANCE SCHEDULE supersedes all

the

system

to

be concerned with this

wiiiter

box far a

NMEA-2000

of

amperage

ECU

and

storage,·

tr·

WESTERLINK

network.

ia·best

(milU-ai71pS)

SO

milii-amps for

'itight

tiHiiscoiiiitid

system.

amperage

from the

each

draw

the

DCpoWtt

diSplay;

during

Engines & Generators

13

FUEL

SYSTEM

DIESEL

Use No.2 diesel fuel with a Cetane rating of
conjunction with Ultra
such

help restore

FUEL

A primary
installed between
water
be carried

A typical
diagram. This

that if a water separator type filter

fuel
in

tion
certain
free of impurities. This

·and

FUEL

The fuel injection pump
the diesel engine, requiring
The
and the owner-operator is cautioned not

it.

authorized
attempt
shims with

FUEL

Low

Sulphur

as

"Diesel Kleen" produced

fuel

lubrication (product

WATER

and

supply

the

fuel

equipment. The owner/operator

the

maintaining a proper

INJECTION

fuel

If

it requires servicing, remove it

tO

SEPARATOR

fuel

filter

of

the

water

the

fuel

tank
other contaminants
to

the

fuel

system

on

fuel

filter/water separator
is

the

tank

and

will

affect the

fuel

reaching

TYPICAL
FILTER/WATER
SEPARATOR

Raycor

Model

engine-mounted

fuel

pump,

the

engine's

process

filtration/separation

FUEL

PUMP

is

the

the

injection pump has been thoroughly

fuel

injection pump service

disassemble and repair it.

the

injection

pump,

Diesel.

by

Power

#3025).

separatin~

and

the

engme

from

the

fuel

the

engine.

is

illustrated

500

MA.

is

not

installed

fuel

engine

is

responsible

injection

is

accomplished

most important component of

utmost caution

to

and

take

facility.

Do

not

leave

on

engine.

45

or

higher.

In

Use.

an

additive

Services

type

before

system,

filter,

I 0

element

attempt

~end

PS

to

must

be

to

remove

they

can

in

this

Keep

in

mind

between

any

and

for

equipment

by

installing

system.

micron

recommended.

in

handling.

bench-test~

to

it

to

an

Do

not

the

the

water
injec­making

is

filter

service

timing

ENGINE

Periodically
leakage.

the

Changing

1.

2.

3.

4.

5.

6.

FUEL

check

Change

MAINTENANCE

the

Shut off

NOTE:

as

Unscrew
cartridge

Wipe
with

To
with
reduce the priming
engines

Install
Open

it

will

clean

help

diesel

the

Slide

both

reduce

fuel

the

the

be

the
and

fuel

FILTER

the

fuel

connections

the

filter

element

SCHEDULE.

Filter

Cartridge

fuel

supply.

a plastic

full

cartridge

its

the
fuel.

before installing.

system

new

of

fuel.

gasket.

housing

fuel

system

time

before

cartridge

supply.

bag

from

and

needed

and

Run

after

up

over

its

housing

the

top

priming,

This

starting.

spin

the

engine

LIGHTLY

WITH
WHEN
THE

FILTER

and

the

filter

the

first

50

the

fuel filter cartridge

and

remove

of

the

new

fill

the

fuel

will

dramatically

to

purge

air

from

on

real

tight

to

inspect for

WIPE

CLEAN

FUEL

INSTALLING

NEW

FUEL

CARTRIDGE

FUEL

'~53

bowl

hours.

See

the

cartridge

filter

the

by

hand.

leaks.

LIFT

for

PUMP

BLEED

The bleed
open position.
engine's
air
fuel return

SCREW

fuel

in

the system

screw

on the injection

This

system

to

system.

will

then

allow

and

during engine

be delivered

pump

for ease

to

the

should

fuel

be

in

priming

operation

tank

left

in

allow

through

the

the

for

the

14.

FUEL

LIFT

Periodically

pump

and

fittings

are

one of

the
secured
operations.

INLET

To
in-line

filter

by

FUELFILTER

ensure

fuel

should

PUMP

check

make

sure

tight

and

pumps

mounting

the

mounting

clean

fuel

filter

connected

be replaced

the

fuel

that

secure.

into

iNCOMING

connections

no

leakage
The
bolts

bolts

to

the

fuel

to

the

every

250

DC

ground

should

ensure

lift

fuel

hours

FUEL

to

is

present

be

proper

pump,

lift

of

and

out

of

and

that

connection

clean

and

pump

there

is a small

pump

ell~ow.

operation.

the

the

at

well

This

COOLING

DESCRIPTION

Westerbeke
for

fresh

bustion

which
water

parts,

from

exchanger, similar

water
fresh
ferred
tube
exhaust system
other
coolant
transferred heat overboard through
fresh

·

each
allows
harmful

RAW

A major part of the raw water cooling system
boatyard/builder installed intake

NOTE:

the

strainer will always be self-priming.

A clean raw water intake strainer
engine's cooling system. Include a visual inspection of
strainer
in

the glass should be

Perform
operation:

1.

Close the raw water seacock.

2.

Remove

3. Clean

4.

Replace the washer if

5. Reassemble and install the strainer.

6.

Open the seacock.

7.

Run

NOTE:

aground.

If

the
normal reading, the cause may be that silt, leaves or grass
may
raw

marine diesel engines

water cooling. Heat produced

and

friction

circulates throughout the
coolant cools the engine
and

the

the

fresh

flows

through

water

coolant

to

the

walls

to

words,

is

cooled

water

coolant

other.

Using

the

cooling water passages

deposits.

WATER

Always install

when

the

the

the

Also follow

engine temperature gauge ever shows a higher

have been caught

water through

is

transferred

engine

oil.

The heat

water coolant

in

function

the

tubes

flows

around

fresh

water coolant

the

raw

water which

where

finally

the

engine

is

cooled

by

raw

water,

and

raw

only

fresh water coolant within the engine

INTAKE

making your periodic engine

following maintenance after every

and

clean the strainer

glass.

engine and check for

STRAINER

the

strainer at or below

clear.

necessary.

the

above procedure after having

up

in the strainer, slowing

the

cooling

are

designed

in

the

to

fresh water coolant

engine.

block,.

to

raw
to
of

it

is

and

water circuits

system.

This

its internal moving

is

transferred externally

water

by

an

automotive

the

heat exchanger

the

tubes; engine heat

is

conducted through the

is

then

pumped into
discharged
by

fresh water coolant, this

the

raw

the

exhaust

are

to

stay clean

strainer.

is

a vital component of the

filter.

leaks.

and

engine

circulating

means

radiator.

overboard.

water

system.

independent of

and

is

the

check.

100

equipped

of a heat
while

carries

free

a proper

waterline

The

hours

run

the

by

the

than

flow

com-

fresh

Raw

trans-

In

the

The

from

this

water

of

hard

of

SYSTEM

WMHm~·

STRAINER
FILTER

so

.

··~

~...,...,=

INSPECT

.

CLEAN

100HDURS

TYPICAL

INCOMING
RAW

WATER

SEA

COCK

DRAINING

When

freezing temperatures are expected, it
protect the
from

datnage~

This procedure
water intake hose from the vessels thru-hull
intake valve before disconnecting the hose. Insert
end into a large container of fresh

Before starting the engine, remove the engine thermostat
(replace the gasket and cover). This
of water tbru the engine. Re-install the thermostat once
flushing

Run

cooli~g

Provide
maintain the water level in the bucket while the unit
operated during the

The

· exhaust lines.
probability of freezing,
then
supply with a concentrated antifreeze mixture and
through the engine
for both

When recommissioning, make
seacocks
water.
water

is

the unit

system.

an

fresh

water

prior

to

the

are

if the engine

can

stay in the engine.

RAW

WATER

INTAKE

(Owner

~

THE

RAW

raw

water cooling circuit and engine exhaust

is

best accomplished

complete. _

for

10

minutes or longer

external fresh water supply for

flushing

will

flush

If

the engine

shutting the unit down substitute the

to

engine and exhaust system.

open

so

is

Installed)

WATER

process.

out the engines water passages

is

being stored and there

flush

the engine

provide freeze and corrosion protection

certain

the

engine

stowed where it

STRAINER

SYSTEM

is

by

disconnecting

fitting.

water.

will

ensure a

to

adequately

the

with

fresh water and

the

valves

will

quickly receive fresh

is

warm,

best

full

bucket

fresh

run

and

the

to

Close the

the

flush

is

is

fresh

AND

EVERY

the

hose

flow

the

tb

being

and

a

water

this

Engines & Generators

15

COOLING

SYSTEM

FRESH

NOTE:

ommended antifreeze and water

fresh water

Fresh water coolant is pumped through the engine by a circu­lating pump, absorbing heat from the engine. The coolant
then passes through the thermostat into the manifold, to the
heat exchanger where it is cooled, and returned to the engine
block via the suction side

When the engine is started cold, external coolant flow is pre-

vented by the closed thermostat (although some coolant flow
is

manifold from overheating). As the engine warms up, the

thermostat gradually opens, allowing full flow
coolant to flow unrestricted to the external portion
cooling s¥stem.

RECOVERY

WATER

Refer

bypassed around the thermostat to prevent the exhaust

TO

COOLANT

TANK

fROM

COOLANT·

RECOVERY

COOLING

to

the

coolant.

TANK

CIRCUIT

ENGINE COOLANT section for

mixture

of

the circulating pump.

KEEP

COOLANT

CLEAR

THE

to

be

used

of

the engine's

PASSAGE

PRESSURE

/CAP

the

as

of

rec-

the

the

CHANGING

The engine's coolant must be changed according to the

MAINTENANCE

become contaminated, it can lead to overheating problems.

A

critical; a substantial

traced

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

NOTE:

to

help

.

~

COOLANT

SCHEDULE.

CAUTION:

back

The

drain

ENGINE

f

DOLANT

1

to

drain

engine

BLOCK

DRAIN

Proper

cooling

on

the

If

the coolant is allowed to

cooling

number

system

heat exchanger should

coolant.

system

of

engine

corrosion.

th~

maintenance

failures

refill process.

OIL

_jjft··~

-)fi

Is

can

be

also

be

us~d

GALLERY

COOLANT

NOTE:

Periodically check

cap.

pressure

good

condition.
the vacuum valve opens and
closes
cap.

Check also
coolOJtt
cool011.t

to

able
to

and from

Coolant

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

NOTE:

located

Ensure the upper and lower rubber seals

Check

tightly.

Carry

to
passage
within

expand and contract

is

the.

the

coolant recovery

Recovery

of

coolant and without introducing air into the cool-

T7ti.s

tOJtk,

with its short run

at or above the level

the

to

ensure

a spare

ensure

the

clear

so

system is

Tank

RETRACTION

condition

tank.

eruiily

of

plastic lwse,

of

the

engine's manifold.

of

the

~bove

accessible.

manifold

the

is

best

are

in

Refilling

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

Monitor the coolant in the manifold and add as needed. Fill
the manifold to the filler neck and when the coolant flowing
from the petcock
install the pressure cap.

Remove the cap on the coolant recovery tank and fill with
coolant mix to halfway between
the cap. Run the engine and observe the coolant expansion
flow into the recovery tank. When the petcock on the thermo­stat housing

~fter

Coolant should draw back into the cooling system as the .
eilgirie cools down. Add coolant to the recovery tank
needed. Clean up any spilled coolant.

A

Wear

the

Coolant

is

free

is

free

of

c~cking

WARNING:

protective

for leaks, stop the engine and allow it

Beware

gloves.

is

visible in

of

air bubbles, close the petcock and

LOW and

air bubbles, close that petcock.

of

the

hot

MAX

engine

and replace

coolant.

Open

to

cool.

if

Engines & Generators

16

COOLING

SYSTEM

THERMOSTAT

A thermostat, located near the manifold at the front
engine, controls the coolant temperature as the coolant
continuously flows through the closed cooling circuit.
When the engine is first started, the closed thermostat pre­vents coolant from flowing (some coolant is by-passed
through a hole in the thermostat to prevent the exhaust
manifold from overheating). As the engine warms up, the

The

thermostat gradually opens.
and can be checked, cleaned,
spare thermostat and gasket.

thermostat is accessible

or

replaced easily.

of

Carry

the '

a

REPLACING

1.

Drain off some coolant: Release the coolant pressure cap

and drain the coolant to the approximate
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
down the thermostat housing cover, the assembly can now
be twisted enough to access the gasket and thermostat.

3. Remove/replace the gasket and thermostat: When

installing the new parts, apply a thin coat
both side

THE

THERMOSTAT

level off the

three

allen screws that hold

of

of

the gasket before pressing it into place.

HEAT

EXCHANGER

sealant on

THERMOSTAT
ASSEMBLY

GASKET

SEAL

WITH

HI-TACK

.

#052946'

A

CAUTION:

down

before

is

the

surface

temperatures

""''l~llfrl,.._--AIR

THERMOSTAT

#053282

BLEED

PETCOCK

THERMOSTAT

HOUSING

The

attempting

of

can

COVER

the

be

engine

these

engine

at

190•

lfiUsf

be

allowed

procedures.

hot

but

coolant

F.

to

Not

cool

only

Engines & Generators

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,
raw water passes from the strainer through the heat
exchanger (through the heat exchanger tubes) where it cools
the engine circulating fresh water coolant. The raw water is
then discharged into the water injected exhaust elbow, mix­ing with and cooling the exhaust gasses. This mixture
exhaust gas and raw water is pushed overboard.

Raw

Water

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

no account should this pump be run dry as water acts as a

lubricant for the impeller. There should 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

w~ter

NOTE:

Should a failure occur with

(seals

and
purchase a new pump and rebuild
a

spare.

Inspecting/Changing

Close the raw water intake valve. Remove the pump cover
and, with the proper size impeller tool, carefully pry the
impeller out

a,

pair

of

care not to tear the impeller). Install the

gasket.

and push the impeller into the pumps housing. When

assembling, apply a thin coating
and gasket.

Run the engine and check for leaks around the pump. Also
check for water discharge at the stem tube. Absence
flow indicates the pump has not primed itself properly.

NOTE:

Never allow

of

dry

running

COOLING

or

river through a hose to the water strainer. The

CIRCUIT

of

Pump

flow is present at

bearings),

of

the pump (the impeller can be pried out using

screwdrivers

Move the blades to conform to the curved cam plate

Open

the

the

may

destroy

RAW

WATER

PN52650

s~rt-up.

the

pumps internal parts

it

may

be

more

cost efficient

the

original pump

the

Raw

Water

if

an impeller puller is unavailable. Take

new

of

lubricant to the impeller

raw

water

intake

valve.

pump

to

run

dry.

Even

the

impeller.

to

Pump

Impeller

impeller and

·'

a short period

as

of

PUMP

w~ter

1

SYSTEM,

NEW

.BAD

Heat

Exchanger

The heat exchanger
ber

of

small copper tubes. Raw water is pumped through 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. .

Zinc

Anode

A zinc anode, or pencil, is located in the raw water cooling
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

of

dition
anode cleaned
be carried on board.

NOTE:

installation and vessel location; not that

If

which the zinc pencil is threaded with a wrench while loos­ening the anode with another wrench. This prevents the hex
boss
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.

the zinc anode should be checked monthly and the

Electrolysis action is the result

the zinc pencil needs replacement, hold the hex boss into

from possibly tearing

PN. 052493

is

a copper tube which encloses a num-

..

of

the system. The con-

or

replaced as required. Spare anodes should

of

each particular

of

the

off

the exchanger shell. After

of

it.

If

of

zinc flakes within

of

the heat exchanger and

of

all zinc debris. Always have a spare heat

CLEAN'
AND
REUSE

ZINC

ANODES

of

the zinc

generator.

the zinc is in

·

INSPECTION:

EACH
REPLACE
ANY

CHECK

BLADE

BY

THE

CRACKS.

THE

BENDING

IMPELLER

BASE

OF

VIGOROUSLY.

IF

THERE

ARE

.

18

Heat

Exchanger

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

..

·:

exchanger.)

NOTE:

Operating
that a heat exchanger cleaning be performed
every 1000

hours.

Service

of

operation, remove, clean

in

silty and/or tropical waters may

more

require

often

than

ENGINE

LUBRICATING

OIL

ENGINE

1.

Always observe the used oil as it is removed. A
yellow/gray emulsion indicates the presence
the

prompt attention to prevent serious damage. Call a

qualified mechanic should water be present in the
Raw water present in the oil can be the result
the exhaust system attached to
siphoning
circuit into the exhaust, filling the engine. This problem is
often caused by the absence

poor location or lack

2.

NOTE:

OIL

CHANGE

Draining the oil sump. Discharge the used oil through

the sump drain hose (attached to the front
while the engine is warm. Drain the used oil completely,
replace the hose in its bracket and replace the end cap
securely.

NOTE:

Thread

size

for

the

lube

oil

drain

is

114

NFT.

oiL

Although this condition is rare, it does require

the·engine and/or a

of

raw water through the raw water cooling

of

an anti-siphon valve, its

of

maintenance.

Replacing the oilfilier. When removing the used oil

filter, you may find it helpful and cleaner to punch a hole

of

in the upper and lower portion

oil from it into a container before removing it. This helps
to lessen spillage. A small automotive filter wrench
should be helpful in removing the old oil filter.

Do

not

punch

this

hole

without

make

certain

it

can

be

removed.

Place some paper towels and a plastic bag around the
filter when unscrewing it to catch any oil left in the filter.
(Oil or any other fluid on the engine reduces the engine's
cooling ability. Keep your engine clean.) Inspect the old
oil filter as it is removed to make sure that the rubber
sealing gasket comes off with the old filter.

sealing gasket remains sealed against the filter bracket,
gently remove it.

When installing the new oil filter element, wipe the filter
gasket's sealing surface on the bracket free

apply a thin coat
on the new oil filter.
filter nipple on the oil filter bracket, and tighten the filter
firmly by hand.

NOTE:

The

through

passages

engine

of

clean engine oil to the rubber gasket

Screw the filter onto the threaded oil

oil

is

cooled

in

the

oil

filter

the old filter to drain the

first

by

engine

bracket

of

hose

capped

of

water in

of

loosening

If

of

coolant

housing

the engine)

end

TO
OIL

oiL

a fault in

the

filter

this rubber

oil and

jlowi>;g

assemb~y.

DRAIN

UP

THRU

to

~

SIDE

OIL

A

SIDE

IS

LOCATED

THE

OIL

~\

FILTER

OIL

FILL

FILTER'

:

APPLY
ENGINE

WHEN

I .

USING

AN

BMM

(11116")

THE

OIL

OR

PUMP

THE

HOSE.

NOTE:

material standards or diameters
generic parts might be entirely different from
parts. Immediately after

run

and that

3. Filling the Oil Sump. Add new oil through the oil filler

cap

engine for a few moments while checking the oil
pressure.
oil filter
Then check the quantity
Fill to, but not over the high mark
the engine require additional oil.

A

WARNING:

contaminants.
and

nails
discard
used

SOCKET

THE

WARMED

Generic filters

the

engine

there

on

the top

Make

or

from the oil drain system, and stop the engine.

thoroughly

clothing

oil

properly.

OIL

FILL

are

not

an

to

make

sure

are

no oil leaks around

of

the engine. After refilling, run the

sure there is no leakage around the new

of

Used

engine

Avoid

prolonged
using

or

rags

containing

,-1)

'

.,__.

-__,./

recommended,

of

important items

oil filter

the

oil with the lube oil dipstick.

soap

oil pressure

on

oil

contains

skin

contact.

and

water.

used

change

the

new

the dipstick, should

harmful

oil.

CLEAN

OIL

INSTALLING

as

the

on

genuine

and

oil

fill,

is

norinal
oil

filter.

Clean

skin

Launder

Discard

or

Engines

19

&_Generators

INSTALLATION

!This

popular accessory

ter

from

the

engine

engine

room

bulkhead. ·

NOTE:

Refer

to

ENGINE

tnstructions

tr"o

install, 'simply remove the engine

on

renwving

WES'IERBEKE's remote oil filter kit

lnstall

this

kit with the oil filter

Contact

your

WES'IERBEKE dealer

to

a more

is

used

OIL

the

to

relocate

convenient

CHANGE

oil

filter.

facing

REMOTE

OIL

PN.

the

location such

in

this

oil

fllter

as

shown.

down

as

for

more

engine's oil

manual

and

thread

Always

illustrated.

infonnation.

as

for

fil-

an

on

FILTER

(OPTIONAL)

054372

NOTE:

Westerbeke

incorrect

installation

A

CAUTION:

is

It

not

of

Is

responsible

the

Remote

vital

to

Install

for

Oil

engine

Filter.

the

of/lines

failure

·

cor-

due

to

THE

OUT

CONNECTION

MUST

ATIACH
CONNECTION
REMOTE

OIL

ATTHE

FILTER.

TO

THE

HOSE

IN

APPLY A THIN
INSTALLING
TIGHTEN
CONTACTS

THIS

AN

THE

·

COAT

OF

CLEAN

KIT.

THREAD

ADDITIONAL3/4

BASE.

TURN

OIL

THE

TO

THE

KIT

ON,

AFTER

0-RING

THEN

THE

0-RING

WHEN

HAND

APPLY A THIN
GASKETW}JEN
CONTACTS

COAT

INSTALLING.

THE

BASE,

OF

CLEAN

TIGHTEN

Oil

TO

AFTER

IT

AN

THE

FILTER

THE

FILTER

ADDITIONAl·

20

DESCRIPTION

The

starting

system

includes

and

stmter

button.

When

the

staiter

button

current

flows

and

energizes
energized
into
to
serves

flywheel.
To

pinion

is
engine
motor

Once

ping

contact

flow
magnetic
plunger
from

the

reach

to

prevent

gear

splined

may

itsel£

the

the

with

of

electricity

is

its

coil

becomes

coil,

and

closes a set

the

stmter

motor.

push

that

·

damage

incorporates

to

the

stmter

speed

the

stmted

button

activation

fields

released,

engagement

of

the

battery-to-stait

is

and

stmter

to

interrupted

the

its

on

the

the

an

electromagnet,

At

pinion

the

staiter

an

over-running

armature

rotation

is

released,

the

solenoid.

staiter

movement

with

the

the

battery,

instrument

stmter's

of

contacts

the

same
to

mesh

motor
shaft.

of

the

the

The

cables

to

the

ceases

also

engine

staiter

panel

solenoid

which

which

time,

with

when

(one-way)

The

rotation

pinion

but

current

plunger

by a coil

staiter.

its

rotation.

pulls

the

flywheel.

SOLENOID

the

t:he

the

flow

This

STARTER

PN.053295

motor,

solenoid,

is

depressed,

coil.

The

pulls

the

plunger

allow

high

current

plunger

also

teeth

on

the

engine

staits,

the

clutch

which

of

the

running

not

the

staiter

ceases,

stop-

is

pulled

out

of

spring,

and

the

weakens

As

starter

the

drive

the

solenoid

gear

MOTOR

SOLENOID

IGNITION

TERMINAL

To

test

the

ignition

of

the

small

temlinal
Use a screwdriver,
ignition

temllnal

the

solenoid.

If

the

starter cranks,

If

the

motor

solenoid

is

clicks

probably

circuit,

studs

don't

to

the

the

but nothing

faulty.

locate

and

touch

positive

fault

\

the

is

wired

the

blade,

battery

lies

ignition(s)

to

the

to

connection

with

the

else

happens,

temlinal

ignition

jump

ignition

circuit).

from

that

temlinal

circuit

the

starter

(it

is

on

one

MOTOR

TYPICAL

STARTER

REFER
DIAGRAM

MOTOR

TO

THE
IN

WIRING

THIS

MANUAL

TROUBLESHOOTING

Prior

to

testing,

make

certain

the

and

that

the

starting

system

wiring

clean

and

tight.

Pay

connections
To

check

never

the

wires

resistance.
Using a multimeter,

stud

If

you

more

on

read

the
and

the

on

the

wiring,

than

terminals

Repair

stait

12

volts,

10

or

solenoid

particular

engine

try

seconds

replace

test

the starter

attention

block.

cranking

at a time,

looking

any

the

voltage

and

the

ships

batteries

connections

to

the

stmter

then

for

wann

trouble

between

engine

is

faulty.

the

for a few

run

spots

spots.

the

block

are

at

(terminals)

ground

your

hand

that

indicate

positive

(ground).

full

charge

are

wire

seconds,

along

temlinal

SOLENOID

IGNITION

TERMINAL

If

nothing at

.

Check

the

connections.

A

WARNING:

fly

when

space

is

gasoline.

all

happens

battery

isolation

It

is

also

jumping

free

of

the

solenoid

switch

possible

There

that

will

terminals.

potentially

isn't

and

inspect

the

solenoid

be

arching

Be

certain·the

explosive

fumes,

getting

the

wiring

is

and

sparks
engine

current.

defective.

will

especially

21

IGNITION
TERMINAl

Test

again
screwchiver
screwchiver
would

A

starting
screwdriver.

by

jumping
blade
blade

cause a short.

WARNING:

current

the
fimliy
to

touch

There

should

two

large

between

the

solenoid

will
be

flowing

temlinal

the

be

studs.

Do

o~

starter

arching

thru

STARTER

(+)POSITIVE

_;TERMINAl

studs.

Hold

not

allow

casing,

as

the

full

the

blade

the

the

this

of

the

MOTOR

SERVICE

Westerbeke

serviced

If

replacing
ce1iified
standards.

TO

1.

Disconnect

2.

If
starter

3.

Label
wires

4.

Remove

5.

Remove
will

uses a standard

or

rebuilt

the

starter

for

marine

If

in

doubt,

REMOVE

the

necessary,

have

motor.

and

disconnect

to

touch,

the
the

to

remove

starter
starter

be

at

m1y

motor,

use.

Automotive

contact

FOR

SERVICE

negative

m1y

the

tape

over
mounting
from

tumed

mmine

starter

starter

motor

make

certain

your

WESTERBEKE

battery

cable.

components

wiring

from

the

temlirials).

bolts.

the

engine.

to a different

motor

automotive

the

starters

do

to

gain

the

In

some

angle

to

which

new

not

full

starter.

cases

clear

cm1

be

service

center.

motor

is

meet

USCG

dealer.

access

to

(Do

not

the

starter

obstructions.

the

allow

If

the

starter

If

the

starter

If

no

arching

NOTE:

Starter

the

pre-engaged
engages
screwdriver
motor
provide
magnetic
the

the

without

the

field for

solenoid

spins,
fails

occurred.

motors

model,
starter
to

bypass

engaging

power

are

bad.

the

to

motor

to

the

the

solenoid

spin,

There

are

the

to

the

solenoid

the

solenoid.

arm

the

motor

is

either

solenoid

the

flywheel

jly.vheel.

to

move

is

faulty.

is

no

juice

inertia

type

also

on

such a starter

Turn

Hopefully

even

though

probably

reaching

or

pre-engaged.

moves

an

of

the

engine.

the

starter

it

will

the

faulty.

the

solenoid.

arm

that

Using

will

run

switch

create

contacts

In

a

the

on

enough

inside

to

Engines & Generators

22

N

c.,.)

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#52951

(12

VOLT)

WITH

CONNECTIONS

FOR FIRE SUPPRESSION

.

SYSTE;M

AND REMOTEST ART/STOP PANEL

I - -

BATTERY

l

(''

I 2

VDC

SWITCH

1

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SUPR[SSIOH

SYST(M

CONNECTION

IS

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A

PO'IER

SOURCE.

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CIRCUIT

MUST

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CLOS(O

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SPECIFICATIONS

Engine

Type

Aspiration
Compression
Governor
Combustion
Bore & Stroke
Piston

Hp@

Hp@1500
Firing
Inclination

Weight

Compression

(allowable
Variation

Cylinders

Injection

Engine

Valve

(engine

Injector
Valve

Starting

Battery

DC

Starter

Starting

DC

Chamber

Displacement

1800

rpm

rpm

Order

(dry)

limit)

between

Timing

Speed

Clearance

cold)
Pressure

Timing

Battery

Capacity

Charging

Alternator

Aid

Cranking

Current

25.5/21.0KW,

GENERAL

Diesel,

four-cycle,

cooled,

vertical

mechanism.
Nata

rally

aspirated.

Ratio

TUNE-UP

Pressure

22.6:1
Electric
Swirl

type

·

98 x 110

mm

3.31

liters

(202.53

33.0/26.0

50

40
1-3-4-2
Continuous

Temporary
11351bs

20•

30•

(514.8

SPECIFICATIONS

626

psi ( 44
psi

(30.5

or

Jess

rpm
rpm

to

0.27

to

Opens
Closes

kgf/cm')

(60Hz)
(50Hz)

2134

Opens
Closes

472

10%

11.5• -12.5•
1800

1500

0.23

(0.00091 -0.0106

1991

Intake
Intake

Exhaust
Exhaust

ELECTRICAL

12

Volt,

(-)

negative

800

-1000

60A rated - belt driven .

2.5Kw,

12VDC

Glow

plugs,

400 -600

(includes

28.5/23.5KW,

four-cylinder,

in-line

(3.86 x 4.93

cubic

25.5/21.0 28.5/23.5

39
32

(not

to

kgs)

at

kgf/cm')

BTDC

mm

inches)

psi

(140

14•

BTDC

36•

ABDC

45•

BBDC

1 r

ATDC

SYSTEM

ground

Cold

Cranking

direct

drive

sheathed

glow

overhead

inches)

inches)

43
36

exceed

10

250

rpm

at

250

rp

to

150

kgf/cm').

Amps

type

plugs)

fresh

valve

water-

minutes)

(CCA)

33.0/26.0KW

COOLING

General

Operating
Fresh

Water

Raw

Water

System

Capacity

(fresh

water)

Raw

Water

(at

1800

rpm)

General

Fuel
Fuel

injection

Fuel

Injection

Injector

Nozzle

Fuel

Filter

Air

Intake

Air

Flow

Combustion

General
Oil

Filter

Sump

Capacity

(not

including

Operating
(engine

hot)

Oil

Grade

Generator
Air

requirements

NOTE:

Increase

Generator
Ambient

Temperature

Temperature

Pump

Pump

Flow

Pump
Timing

filter)

Oil

Pressure

Cooling

coolint

Compartment

Fresh
controlled

160 -180• F (71 -82•
Centrifugal
Positive

gear
16

11.0 gpm (41.6lpm)

FUEL

Open

(electromagnetic
No. 2 diesel
Bosch

11.SO -12.5•
Bosch
Spin-on
Metal
105

LUBRICATION

Pressure
Full

14.0

28-

API

SAE 1 OW-30

GENERATOR

0.8

air

flow

15%

122

EDE/EDEA

SYSTEM

water-cooled

displacement,

driven

US

qts

SYSTEM

flow,

type

tThrottle

type

screen/intake

cfm

(3.0

flow,

U.S.

57

psi

Specification

Power

tor tor

•F

(50°C)

block,

with

heat

exchanger.

type,

metal

(15.1

liters)

self

bleeding,

fuel

pump)

oil ( cetane

mini-pump

BTDC

type

silencer

cmm)

SYSTEM

fed

system

with

paper

element,

qts

(13.2

liters)

(2.0-

4.0

CF,

CG-4,

or

15W-40

COOLING

factor

unit.

500

slower

turning

maximum

thermostatically-

C)

impeller,

belt-driven.

rubber

impeller,

self

priming

rating

of

box

external

spin-on

kg/em')

Cl-4

cfm

(15.0

50

45

relief

type.

Hz

or

higher)

cmm)

units.

valve

Engines & Generators

26

AC

GENERATOR

Single

Phase

Voltage

Voltage

regulation:
Frequency
Rating

60

33.0KW
50

26.0KW

Generator
Air

(Single

Generator
Ambient

Recommendations

regulation:

(Volts

Hertz

Hertz

AC)

(1800

rpm)

(1500

rpm)

Cooling

Requirements

and 3 Phase)

Compartment

Temperature

SPECIFICATIONS

(Single

Brushless,
lubricated,
reconnectable
60hz)
solid

120
230

±2%

.3

120
120/240

230

225-250

NOTE:

operation

122•F

six-pole,
single-bearing

(series

state

voltage

or

120/240

Volts -50

no

load

Hertz (.5%)

Volts

Volts

Volts

cfm

Increase

(1500

(5o•c)

Phase)

revolving

(Double

Star

for

230

regulator.

Volts -60

Hertz.

to

full

load.

no

load

275Amps
275/137.5

113

Amps

(5.66-6.37

air

supply

rpm).

maximum

design.

Delta

volts.

Hertz

to

full

cmm)

15%

field.

for

120/240
50hz)

load

Amps

for

Sealed

12

Lead

50

volts,

With

Hertz

33.0/26.0KW

EDE/EDEA

AC

Three

Phase

33.0

KW • 60
KW • 50

-3

phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Cooling

Hertz)

at 1 BOO

Compartment

Temperature

HERTZ
HERTZ

phase

phase

26.0

Voltage

(60

Voltage

(50

Amperage

(60

Amperage
(50

Generator
Air

Requirements

(60

Generator
Ambient
Recommendations

GENERATOR

Brushless,

lubricated,

reconnectable.
Low

Voltage

High

Voltage

DELTA
High

Voltage

DELTA
Low

Voltage

High

Voltage

DELTA
High

Voltage

DELTA
225 -250

NOTE:

rpm

Increase

operation

122•F

(5o·c)

(3

Phase)

six-pole,

revolving

single-bearing

Solid

state

WYE

WYE

WYE

WYE

WYE

WYE

cfm

(5.66 -6.37

air

supply

(1500

rpm).

maximum

field.

design.

voltage

240
480
277

400
230

99.3

49.6Amps
B6.0Amps

46.9Amps

81.6

cmm)

15%

for

Sealed

12

Lead

regulator.

Volts
Volts
Volts

Volts
Volts

Amps

Amps

50

Hertz

27

AC

GENERATOR

Single

Phase

Voltage

Regulation

Voltage
Frequency
Rating

60

25.5KW
50

21.0KW

Generator
Air
(Single

Generator
Ambient
Recommendations

Regulation

(Volts

Hz

Hz

AC)

(1800

rpm)

(1500

rpm)

Cooling

requirements

& 3

phase)

Compartment

Temperature

(Single

Brushless,
Seal

lubricated,

12

lead

reconnectable,

120/240

volts,

volts,

50hz)

120

or

120/240

230

Volts -50

± 2%

no

load

.3

Hertz (.5%)

120

volts

120/240

volts

230

volts

225-250

elm

NOTE:

Increase

operation

122°F

(1500

(50°C)

SPECIFICATIONS

25.5/21.0

Phase)

six-pole,

revolving

bearing

(Double

(Series

state

hertz

load.

to

full

amps

amps

cmm)

field.

design.

Delta

Star

for

regulator.

load.

amps

15%

for

50

for

230

Hertz

Ambient

single

60hz.)

with

solid

volts -60

Hertz

to

full

no

load

212.5

212.5/106.3

91.3

(5.66-6.37

air

supply

rpm)

maximum

KW

AC

Three

Phase

reconnectable.
Voltage

(60

Hertz)

Voltage
(50

Hertz)

Amperage
(60

Hertz)

Amperage
(50

Hertz)

Generator
Air

requirements

(Single

Generator
Recommendations

Solid

-3

phase

-3

Phase

-3

phase

-3

phase

Cooling

& 3

phase)

Compartment

Temperature

EDE

GENERATOR

state

Brushless,

lubricated,

voltage

Low
High
DELTA

High
DELTA

Low
High
DELTA

High
DELTA

225-250

NOTE:

operation

122°F

six-pole,
single-bearing

regulator.
Voltage

WYE

Voltage

Voltage

Voltage

WYE

Voltage

Voltage

elm

Increase

(1500

(50°C)

(3

Phase)

revolving

WYE

WYE

WYE

WYE

(5.66-6.37

air

supply

rpm)

maximum

design.

240
480
277

400
230

76Amps
38Amps

66.5

37.9

65.9

cmm)

15%

field.

for

Sealed

12

Lead

Volts
Volts
Volts

Volts
Volts

Amps
Amps

Amps

50

Hertz

AC

GENERATOR

Single

Phase

Voltage

Voltage

Regulation
Frequency
Rating

60

28.5KW
50

23.5KW

Generator
Air

(Single

Generator
Ambient
Recommendations

Regulation

(Volts

Hz

Hz

AC)

(1800

rpm)

(1500

rpm)

Cooling

requirements

& 3

phase)

Compartment

Temperature

(Single

Brushless,
Seal

lubricated,

12

lead

reconnectable,

120/240

volts,

volts,

50hz)

120

or

120/240

230

Volts -50

± 2%

no

load

.3

Hertz (.5%)

120

volts

120/240

volts

230

volts

225-250

elm

NOTE:

Increase

operation

(1500

122°F

(50°C)

SPECIFICATIONS

28.5/23.5

Phase)

six-pole,

revolving

bearing

(Double

(Series

state

hertz

load.

to

full

amps

amps

cmni)

field.

design.

Delta

Star

for

regulator.

load.

amps

15%

for

50

for

230

Hertz

single

60hz.)

with

solid

volts -60

Hertz

to

full

no

load

237.5

237.5/118.78

102.2

(5.66-6.37

air

supply

rpm)

maximum

KW

AC

Three

Phase

Voltage

-3

(60

Voltage

(50

Amperage

(60

Amperage

(50
Generator

Air

(Single

Generator

Ambient

Recommendations

phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

Hertz)

requirements

phase

-3

phase

Cooling

& 3

phase)

Compartment

Temperature

EDE

GENERATOR

Brushless,
lubricated,
reconnectable.

Low
High
DELTA

High
DELTA

Low
High
DELTA

High
DELTA

225-250

NOTE:

operation

122°F

six-pole,
single-bearing

Voltage

WYE

Voltage

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

elm

Increase

(1500

(50°C)

(3

Solid

WYE

(5.66-6.37

air

rpm)

maximum

Phase)

revolving

design.

state

voltage

240
480
277

400
230

85.8Amps

42.9Amps

74.3Amps

42.4

73.8Amps

cmm)

supply

15%

field.

12

regulator.

Volts
Volts
Volts

Volts
Volts

Amps

for

Sealed

Lead

50

Hertz

28

ENGINE

TROUBLESHOOTING

LCD

DISPLAY·

FAULTS

PROBLEM

LCD

DISPLAY

NOT

ILLUMINATE

LOW

OIL

PRESSURE

HIGH

COOLANT

HIGH

EXHAUST

BATTERY

GENERATOR

Overspeed
Underspeed

LED
TURN

WAITING

VOLTAGE

FREQUENCY

(steady

(flashing

DISPLAY

EDGES

PINK

FOR

DOES

TEMPERATURE

TEMPERATURE

LED)

LED)

ECU

PROBABLE

1.

Check

battery.

2.

20

amp

breaker

3.

Loose

display

4.

1

amp

fuse

1.

Oillevellow/oilleak.

2.

Lack

of

oil

pressure

3.

Ground

connection.

4.

Faulty

control

5.

Faulty

oil

pressure

1.

Check

system

2.

Seawater

3.

Check

4.

Faulty

5.

Ground

6.

Faulty

1.

Check

2.

Faulty

3.

Ground

4.

Faulty

5.

Sea

6.

Faulty

1.

Check

2.

Check

3.

Check

4.

Faulty

1.

Check

2.

Check

3.

Amperage

4.

Crank

(underspeed

1.

Compartment
too

1.

ECU

2.

Loose

3.

Panel

4.

Blown 8 amp

5.

Terminating

6.

Battery

pump.

water

temperature

connection.

control
sea

water

exhaust

Connection.

control

water

pump.

fire

suppression
alternator
charge

battery

control

engine
fuel

supply.

load.

cycle

high.

and

LCD

cable

DC

breaker

Voltage

CAUSE

off.

connection.

blown

(faulty)

module

(ECU).

sensor.

coolant

level.

pump

drive

sensor.

module

(ECU).

flow.

temperature

module

(ECU).

drive

belt.

voltage.

connections.
module

(ECU).

speed.

with

no

start.

fault)

ambient

temperature

display

not

connection.

OFF.

fuse.

Resistors.

to

ECU.

..

belt.

switch.

system.

compatible

VERIFICATION/REMEDY

1.

Battery

on.

2.

Turn

breaker

on.

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

3.

Adjust

4.

Check

5.

Check

6.

Check

1.

Inspect
as

needed.

2.

TesVreplace.

3.

Check

4.

Check

5.

Inspect

6.

By-pass

1.

Adjust

2.

Check

3.

Check + and -cables

4.

Check

1.

Check

2.

Inspect

3.

Check + and -cables

4.

Check

1.

Ventilate

Note:

display.

1.

Check

2.

Check

3.

Turn

4.

Check/replace

5.

Check

per

resister

6.

Check

unplugged
present,

Check

impeller/pump/replace.

belt

tension,
sensor/replace.
ground
plug

connections/replace.

thru

hull

ground
plug

connections.

impeller/replace.

system/check.

tension/replace

excitation.

plug

connections/replace.

speed

setting.

filters/replace

cause

for

compartment.

Heat

wtll

This

will

compatibility
all

cable

ON,

check

all

terminating

measured

between

from

ECU

connections.

Determine

add

oil
connection.
plug

circuit.

fitting,

circuit.

Replace/repair

no

often

not

connections.

DC

fuse.

pins

ECU.

is

faulty.

cause

oil

and

repair

If

OK,

test

for

leaks.

hose

if

worn.

from

filters.

from

start.

change
effect

with

Westerlink

Check

resistors

across

P2-24

Power

oil

belt.

and

battery

Test

battery

the

the

across

DC

pin

and

turned

pump.

connections/replace.

replace

voltage

leaks.

pressure

strainer.

alternator

to

engine.

fuel

pump

to

engine.

color

of

operation

or

NMEA.

breaker.

voltage

across

are

in

place.

#4

and

P2-25.

ON.

sendor.

Correct

operation.

an

LCD

of

the

120

#5.

P2

ECU

If

voltage

inspect

engine.

fuseholder

ohm

plug

is

29

#10

ORANGE

TO

STARTER

B

SOLENOID

\

ALTERNATORS

60

AMP

ALTERNATOR

CASE

TESTING/TROUBLESHOOTING

GROUND

VOLTAGE

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

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

REGULATOR

or

vibration.

#16

VIOLET

TO

R

K-3

RELAY

#16

RED

ACTUATOR

TO

REFER

TO
DIAGRAM
MANUAL

FOR

WIRING

CONNECTIONS

THE

IN

WIRING

THIS

ALL

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

of

back

It

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

ALTERNATOR

The stator is connected to a three-phase, full-wave bridge
rectifier package which contains six diodes. The bridge

converts the AC generated in the stator to a DC output for
battery charging and accessories,

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

These alternators produce a rated output
output is achieved at approximately
an ambient temperature

are designed to operate in an ambient temperature range
of

-40° to 212°F (-40° to 100°C).

CHARGING

DC

of

integrated circuits (IC's), the electronic voltage

the alternator.

CIRCUIT

of

wiring harness, a mounted DC

of

DESCRIPTION

of

75°F (23.8°C). The alternators

S Engines and

an alternator with a voltage

on

the

the system and will then

of

the

of

the

of

the integral regulator

of

60 amps. Rated

6000 alternator rpm at

ALTERNATOR

Use this troubleshooting section to determine
exists with the charging circuit
determined that the alternator
have a qualified technician check it.

A

WARNING:

alternator
alternator

LOW

BATIERY

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

it is worn

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

resistance and this could cause overcharging,
undercharging

corroded battery cables could prevent the
reaching a fully charged condition.

4. Check the condition

A low

readings in the tests.

NOTE:

An isolator
selector switch
the

batteries

with

the
starting battery but not the house
OK and

TROUBLESHOOTING

if

a problem

or

with the alternator.

or

voltage regulator is faulty,

·

A

can

become

until

if

/FAULTY

working

has

alternator

very

hot.

Do

runs

not

touch

hot. A failed

the

cooled.

CIRCUIT

or

makes a clicking sound instead

INSPECTION

or

glazed.

or

corroded connections cause high

or

damage to the charging system. Badly

batt.ery from

of

the battery and charge

or

discharged battery may cause false or misleading

with a diode, a solenoid,

is

usually mounted

so

the

starting battery

house batteries.

If

the

in

is

isolator

the

circuit

not discharged

is

battery,

the

problem

is

in

the

battery charging

if

or a battery

to

charging

the

alternator

circuit.

necessary.

isolate

the

If

it is

along

is

30

ALTERNATORS

TESTING

A

certain
away

1.

2.

THE

ALTERNATOR

CAUTION:

that

from

Start

the Engine.

Mter

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

a.

If

the voltage is increasing toward 14 volts, the

alternator is working.

If

the voltage remains around

b.

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

Before

everyone

sheaves

is

and

starting

clear

of

belts

during

the

engine

moving

parts!

test

procedures.

12

volts, a problem

61.

make

TESTING/TROUBLESHOOTING

MEASURING
BATTERY

(IGNITION
ENGINE

Keep

VOLTAGE

ON

OFF)

MEASURING
BATTERY

(ENGINE

3.

Thm

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

4.

If

a battery selector switch

that it is on the correct setting.

5.

Thm

engine.

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

VOLTAGE

RUNNING)

off

the

on the ignition switch,

1,;=!-'llE(lUL"~

engine. Inspect all wiring and connections.

is

in the charging circuit,ensure

but

do

not

If

your battery is in good

12

to

13

start

volts.

the

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.

. battery) and operate the alternator.

THE

OUTPUT

connect the negative probe to ground.

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

Start

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

rep~red

it
If

terminal B, use the meter to measure the
terminal.
inspect the wiring for breaks and
Jump 12 volts from a 12 volt source (such as the

is 13-14 volts,

or

if

the reading varies, check the alternator

the

engine.

If

your alternator is over

at a reliable service shop.

the previous test reads only battery voltage at

If

12 volts is not present at exciter terminal

..

CIRCUIT

If

no reading is

or

dirty connections

be

between 13.5 and 14.5

or

under-charging, have

poor

connections.

If

the voltage output

then the alternator is OK.

or

DC

excitation

R,

31

TESTING

CIRCUIT

THE

ENGINE

OUTPUT

RUNNING

1#16

"{0

VIOLETR

K-3

RELAY

1#16

RED

ACTUATOR

TO

ALTERNATORS

TESTING/TROUBLESHOOTING

TESTING

THE

EXCITATION

CIRCUIT

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

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

lead to ground.

Thrn

the

2.
the multimeter reading. The reading should

2.5 volts (see illustration).

TESTING

THE

ignition

switch

to

the

on

position and note

OUTPUT

EXCITATION
CIRCUIT

(ENGINE.
RUNNING)

3.

If

the

reading

rotor field circuit probably is shorted or grounded.

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

6.0

and

7.0 volts, the rotor

an open exists in the

or

in the excitation circuit

or

dirty connections

be

1.3 to

TERMINAL

volts, the

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.

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

THE

SERVICE

of

the service battery. this battery should

If

not, there is a problem in the service battery

BATTERY

13

and 14 volts when the engine is

REPAIR

WESTERBEKE'S Service Manual has detailed

the

disassembly and

repair

of

their

standard alternators.

BAnERYCARE

The minimum recommended capacity
the engine's 12 volt DC control circuit is 800-1000 Cold
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.

• Use only distilled water to bring electrolytes to a proper

level.

• Make certain that battery cable connections are clean and

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

of

the battery used in

TESTING

THE
EXCITATION
CIRCUIT

ENGINE
RUNNING

,,

OUTPUT

TERMINAL

EXCITER
TERMINAL

R

/-.y-IWESTERBEKE

) Engines & Generators

32

GLOW

PLUGS

DESCRIPTION

The glow plugs are wired through the preheat solenoid.

PREHEAT is pressed at the control panel this solenoid

When

"click" on and the glow plug should begin to get hot.

should

INSPECTION

To inspect the plug, remove the electrical terminal connec­tions, then unscrew or unclamp each plug from the cylinder
head. Thoroughly clean each plug's tip and threads with a
soft brush
oil deposits. While cleaning, examine the tip for wear and
bum

and

erosion;

cleaning solution to remove all the carbon and

if

it has eroded too much, replace the plug.

TESTING

An accurate way to test glow plugs is with an ohmmeter.
Touch one prod to the glow plug's wire connection, and the
other to the body
plug will have a
used with the plug in
an multimeter to test the power drain

A

WARNING:

to

the

touch.

testing

the

of

the glow plug, as shown. A good glow

1.0 - 1.5 ohm resistance. This method can
or

out

of

the engine. You can also use

(8

- 9 amps per plug).

These

glow

plugs

wi/1

become

Be

careful

not

to

burn

your

fingers

plugs.

very

when

hot

be

Re-install the plugs in the engine and test them again. The
plugs should get very hot (at the terminal end) within 7 to

seconds.
circuit. When reinstalling the glow plugs, use anti-seize
compound on the threads.

A

than

GLOW

If

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

WARNING:

30

seconds.

PLUG

TIGHTENING

1.0-

1.5

Do

not

TORQUE

M·KG

keep a glow

(7

·11

FT-LB)

plug

on

for

more

15

GLOW

#053140

REFER

TO
DIAGRAM
MANUAL

WIRING

CONNECTIONS

FOR

PLUGS

THE

WIRING

IN

THIS

ALL

USING

TEST

LIGHT

A

33

NOTE:

WESTERBEKE

ments

be

below

is

ENGINE

peifonned

provided

ADJUSTMENTS

recommends

by a competent

to

assist

the

that

engine

mechanic.

the

following

mechanic.

engine

The

information

adjust-

,

.

,

'~cover.

"-.

'-.....

lllNI~.

ilo..

TESTING

To

test

OIL

PRESSURE

the

oil pressure, remove the

·

oil

pressure

sender,

then

install a mechanical oil pressure gauge in it's place. Mter

warming
the

OIL

LOW

The
ual
additional information

ENGINE

up

the engine, set

oil pressure

PRESSURE

specific

WILL

OIL

PRESSURE

safe minimum oil pressure

gauge.

RANGE

the

engine speed

BETWEEN

50.

AND

loss of oil pressure usually indicates

on

low

oil

pressure readings,

TROUBLESHOOTING

chart.

55PSI

is

5-

worn

at

idle and read .

AT

1800

RPM

10

psi. A grad-

bearings.

see

For

the

VALVE

Remove
be

ADJUSTMENT

th~

glow

easily

manually

Rotate the engine crank

· valve operation
Top

Dead

Center of

. referencing

should put

Adjust

VALVE

When
piston
compressed
Top
Center

When
piston
overlap
position

the

the

the

remaining

CLEARANCE

No.1

is

Dead

No.1

is

in

plugs

from

rotated.

for

cylinder

the

compression

chart

be

lew.

valves

for

cylinder

valves

(ENGINE COLD}

IN

1st

0 0 0

2nd
3rd
4th

1st

2nd

0

3rd
4th

the

cylinder

Remove

manually

#1

and

Rotate

#1

following

0.23-

EX

0

so

the

engine

the

valve

train

rocker

and

observe

bring

the

#1

piston

stroke.

Adjust

the

crankshaft

in

the

the

0.27mm

(0.0091-

IN

EX

0 0 0
0 0

0 0

0 0

0 0

overlap

chart

360°.

below.

0.01061n)

IN

0 0

can

the

up

the

valves

This

position.

EX

to

Engines & Generators

34

ENGINE

ADJUSTMENTS

DRIVE

For your
equipped
front of the engine.

guard
advised that proper inspection, service, and maintenance
required.

The drive belt must be properly tensioned. Excessive drive

belt tension
service life of the fresh water pump's bearing. A slack belt or
the presence of oil
resulting in high operating temperatures.

The generator has one drive belt that drives the

2.

3.

4.

5. The drive belt ·

7.

provided

BELT

ADJUSTMENT

safety,

WESTERBEKE generator

with belt guards that cover over

("Out of sight - out

is

NOT installed for that purpose.) Operators

can

cause rapid wear of the belt

on

the belt can cause belt slipping,

DC alternator. The tension adjustment procedure for the
belt is

as

follows:

1.

Remove
Loosen

mounting
With

edges.
Pivot

or

no

(12mm)

. midpoint between the

the

A

drive

6.

Operate
the

Replace

FUEL

NOTE:

be

performed

REMOVING

NOTE:

1.

Disconnect
loosen
and
bending

2.

Using a

its
lose
the

the

belt

guard.

the

alternator adjusting strap bolt

bolt.

the

belt

loose,

inspecHorwear,

the

alternator

right

as

required,

less

than

as

the belt

belt.

WARNING:

b~lt's

tension

the

generator

the

on

to

is

properly adjusted

3/8 inch (lOmm)

is

Never

while

generator

and

recheck

belt

guard.

INJECTORS

WESTERBEKE

by a competent

to

assist

THE

Injector

must

the

lines

move

them

the

17mm

entirety

the

two

fuel

return

recommends

the

mechanic.

INJECTORS

be

serviced in a

the

high pressure

at their attachment

out of

lines.

long socket,

from

the

top

sealing washers

line

to

the base

loosen

depressed with the

two

attempt

for

the

each

or

and

pulleys

the

engine

about 5

the

belts) tension.

engine

lines

way

remove

of

the

and

injector.

mounting

to

that

mechanic.

"clean

of

injectors.

models

the

of

mind." The belt

cracks

tighten.

if

it

no

more

on

the

check

is

in

minutes,

the

following

room"

from

to

the injection

the

injectors.

the

fuel

banjo bolt that attaches

come

belt(s)

on

the

are

and

reduce

the

and

the

base

and

frayed

bolt

to

the

left

can

be

deflected

than

1/2

inch

thumb

at

the

longest span of

or

adjust

a

operation.

then

shut

down

engine

The

information

environment.

the injectors and

pump

Avoid

return

line

Take

care

not

is

adjustments

to

below

in

NOTE:

prior
any

hole.
by

carbon
side
it

and

3.

The

ing

washer.
injector
tor

is

INJECTION

1.

Using

'

tion
limit,
tester,

A

of
skin

enters

Inspecting

1.

Operate
one
rectly
injects
strips.
defect.
ging
cleaned.before

is

DRIP

2.

Apply
by
nozzle

on
replaced. A
remain

indicate a

Clean

the

.area

around

the

to

lifting

it out

of

the

cylinder head

rust

or

debris

from falling

If

the

injector will not lift out easily and

build

up or

the

like,

with

the

aid

of

the

17mm

deep

then

lift

it

out.

injector seats in

This

and

replaced with a

reinstalled.

the

cylinder head

washer should

J:.lew

TESTING

the

nozzle

tester,

check

starting pressure of nozzle

adjust

or

replace the

take

the

following precautions:

CAUTION:

such

velocity

of

nngers

the

the

stroke per second

in

its

fuel

Also, a spray

These

with

TEST

the

operating the

tip.

the

bottom,

on

The

that

and

bloodstream,

Spray

Patter~

hand

lever

axial

direction. A nozzle

in

an

oblique direction

defects

dust

and,

reassembly.

pressure of 1635lb/in2 (115

hand

If

it

drips
it

is

very

small

the tip of the nozzle;

defect.

nozzle.

spray

Injected

it

may

penetrate

hands,

destroying

It

may

of

the

to

check if

in

the

form

may

sometimes

therefore, all

lever,

and check the

or

has

a large accumulation of

considered defective

amount

base

of

the injector

to

down

into

the injector

work

the

injector

socket

on

be

removed with

washer when

the

spray pattern

and,

if it exceeds

When

using

from

deeply

tissue.

cause

blood

nozzle tester

the

fuel

is

defective

or

in

several

of particles

be

parts

should

ttl

l·

:~

FAULTY

f£

kglcm

of

fuel

may

however,

help prevent

is

held

side

wrench

a copper seal-

the

to

free

the

the

injec-

and

injec-

the

nozzle

nozzle

Into

the

If

It

poisoning.

INJECTION

140

(1991 -2133

is

caused

and

this

PRESSURE

-150

Kgl/cm'

PSI)

at

intervals

injected

if

it

separate

indicates

by

clog-

be

carefully

~

•;

!'t

'·

'•'

fa',

2

to

nozzle

)

drips

from

should

sometimes

does

not

in
to

Is

·

of

cor-

a .

FAULTY

the

fuel

be

Engines & Generators

35

DRIP

TEST

ENGINE

ADJUSTMENTS

TESTING

Test the speed sensor connector for voltage and resistance
values.

If

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

NOTE:

provided with the new magnetic pick up coil.

SPEED
VOLTAGE

1.5-2.5

RESISTANCE

THE

MAGNETIC

CarefUlly follow the installation instructions

SENSOR

(while

VAC

(at

TEST

VALUES

cranking)

rest)

PICK

UP

COIL

unscrew the

If

any damage is detected, replace

950

-1

000

ohm

MAGNETIC

The MPU is installed in the threaded opening on the side
of

the flywheel bellhousing. This positions the MPU over
the teeth
Viewing through this opening, manually rotate the engine

crankshaft so as to position the flat
gear's teeth directly under the opening. Thread the MPU
into the opening until
tooth (Thread is 3/8" x 24). Back the MPU out
opening one
the

jam

approximately 0.030 inches away' from the fiats

ring gear teeth.
To

en~.ure

the crankshaft
physical contact between the MPU and the ring gear teeth.

If

contact is felt between the

MPU may be damaged. Remove the MPU and inspect

the
it. Replace

installation procedure.

NOTE:

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

PICK-UP

of

the flywheel ring gear.

tum

nut. This will position the end

the MPU is positioned correctly, slowly rotate

by

if

necessary and repeat the above

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

[MPU]

it

and then lock it in this position with

360° by hand to assure there is no

INSTALLATION

of

one

of

the ring

gently contacts the flat

of

the MPU

MJ:>U

and the flywheel teeth,

of
of

of

this ·
the

the

AC

Engines & Generators

36

GENERATOR

USE

OF

ELECTRIC

The power required to start an electric motor

more than is required to keep it running after it is started.

Some motors require much more current
others. Split-phase (AC) motors require more current
under similar circumstances, than other types. They are com­monly

used

on easy-starting loads, such
machines, or where loads are applied after the motor
started; such
7 times
avoided, whenever possible,
ven

by
motors require
to

run. The current required to start
load connected
compressor, for example, will require more current than a
motor

In

general,
to

medium

MOTOR

*NOTE:

more

for this

made

Because the heavy surge
rr:otors
be damaged
seconds.
off all other electrical loads and,
on the electric motor.

Required

Run the generator first with no load applied, then at half the
generator's capacity, and finally loaded
indicted on the generator's data plate. The output voltage
should be checked periodically to ensure proper operation
the generating plant and the appliances it supplies.
voltmeter or ampmeter
load, check it with a portable meter

as

as

much current

a small generator. Capacitor and repulsion-induction

to

which no load

the

current

starting

SIZE

(HP)

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

3/4

1

In

the

above table the maximum Amps for Starting

for some small nwtors than for larger

is

that the hardest starting types (split-phase)

in

larger

is

required for only an instant, the generator will not

if

If

difficulty is experienced in starting motors, tum

Operating

MOTORS

is

considerably

to

start them than

to

as

washing

is

small power tools. Because they require 5

to

start

as

to

run, their use should be

if

the electric motor is

from 2

to

4 times

to

it.

An electric motor connected

is

required

loads

will

AMPS

(AMPERES)

as

connected.

to

start

be

approximately

FOR

RUNNING

3.2

4.6

5.2

7.2

10.2
13

much current to start
any

115-

motor varies with the

Volt

ones.

to

to

an air

motors

connected

as

follows:

AMPS

FOR

(7TARTING

AMPERES)

6.4

to

22.4*

9.2

to

32.2*

1

0.4

to

72.8

14.4

to

29.2*

20.4

to

40.8

26

to

52

The

are

sizes.

of

current needed for starting

it can bring the motor

up

to speed in a

if

possible, reduce the load

few

Speed

to

its full capacity

If

an

is

not installed

to

monitor voltage

and

amp probe.

start,

be dri-

as

•

•

reason

not

AC

and

INFORMATION

to

as

of

Generator

Frequency
cated

D When the generator

output frequency

Therefore,
drive engine's speed must
uring

Generator

D Maintaining reasonable cleanliness

Connections
corroded, and insulation surfaces may start conducting if
salts, dust, engine exhaust, carbon, etc. are allowed
build
sive heating and reduced life of windings.

D For unusually severe conditions, thin rust-inhibiting

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

D In addition

inspected for tightness of

overheated terminals and loose or damaged wires.

D The drive discs on single bearing generators should

checked periodically if possible for tightness of screws
for any evidence
not be allowed to become rusty because rust may
accelerate cracking. The bolts which fasten the drive disc

is

to
identified
the head.

D The rear armature bearing

mc.i.ntenance
noisy or rough-sounding, have it replaced.

D Examine bearing at periodic intervals. No side movement

of

motion is detectable, inspect the bearing
wear.
will rub and cause major damage

WESTERBEKE recommends mounting a carbon

monoxide detector in the vesssel's living quarters. Carbon

Monoxide, even in small amounts, is deadly. ·

The presence of carbon monoxide indicates
from the engine or generator or
exhaust hose, or that fumes from a nearby vessel are
entering your boat.

If

air and correct the problem i1mnediately!

Frequency

is

a direct result

by

the following:

is

to

change the generator's frequency, the generator's

of

the AC output connections at the generator.

Maintenance

of

terminal boards and rectifiers may become

up.

Clogged ventilation openings may cause exces-

to

periodic cleaning, the generator should be

of

the generator shaft must be hardened steel SAE grade

by

6 radial marks, one at each

is required. However,

shaft should be detected when force

Repair must be made quickly or major components

Carbon

carbon monoxide

Adjustment

of

engine/generator speed,

is

run

at

1800

RPM, the

60

Hertz.

be

changed .along

all

connections, evidence of

incipient cracking failure. Discs should

is

lubricated and sealed;

to

Monoxide Detector

from the exhaust elbow/

is

present, ventilate the area

with

is

important.

of

the 6 comers of

if

the bearing becomes

is

applied.

and

generator.

as

AC

voltage

a reconfig-

be

no

If

shaft for

an

exhaust leak

with

indi-

to

and

8,

side

clean

37

(SERIES WYE)

SERIES
STAR

10.:11 2-3

0

TWELVE

L

2

3

0

5

N

6-7

0

9

LEAD

L

5

4-8-12

WINDING/TERMINAL

AND

(NOMINAL)

(PARALLEL WYE)

PARALLEL
STAR

L

10-12

VOLTAGES

113

0

2-4

5-7

BOARD

L

N

6-8

9-11

L

0

CONNECTIONS

L

12

1

SERIES
DELTA

11

v

9

8 7

L

10-11 . 2-3

0

1-12

~

N

6-7

·o

5-4

9-8

0

L

0

DOUBLE
DELTA

3-wire

50
50
60

60

L.:2

Hz

Hz
Hz

Hz

L1

PARALLEL
DELTA

L

1 3 5 7

L1

50

Hz

L-L 115 volts

60Hz

L-L

L3

L-L

400

volts

L-N

230

volts
L-L480
L-N

2-4

~

L2

volts

277 volts

L

6-8

11

9

L3

138 volts

N

10

L L

SINGLE

PARALLEL

L

0

PHASE

ZIG-ZAG

L

N

L.2

50

Hz

L-L

50

Hz

L-N

60

Hz

L-L

60Hz

L-N

7

5

10-12

r-{

1 3

2-4

{

5 7

1..1

l2

50

Hz

L-L

SO

Hz

L-N

60Hz

L-L 277 volts

60Hz

L-N

(Refer to Note #1)

L3

200

volts

115 volts

240

volts

138

volts

10

N

S-9

~

9-11

230

volts

115

volts

138

volts

N

0

50
50
60Hz

60Hz

(Refer to Note #

THREE

PHASE

ZIG-ZAG

8-10

0

L1

Hz

L-L 230 volts

Hz

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

L~

~·~2

11

~l

10,

' 4 6 5

l

.s

2-12

0

5

9

I

L2

'

L3

N

4-6

0

9

L3

1)

3-7-11

r-D

8-11

2-3

6-9

0 0

0

5 12 7 4

115

t

l1

volts

N

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

L-L 240 volts

60Hz

L-N 120 volts

Note

#1

Single
The phase
nominal value.

Note

The rated

0.866.

cun-ent must not exceed the

#2

Three

power

Engines & Generators

phase

amperage load.

phase

zig-zag connection.

must·be multiplied by

38

7

L 4

8-11

0

1

10

N

50

60Hz

2-3

6-9

0

~

5 12

7 4

L1

Hz L-N 230 volts

L-N 240 volts

10

0

INTERNAL

WIRING

SCHEMATIC

EXCITER

EXCITER
WINDINGS

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

ROTOR

ROTOR/ROTATING

A

FIELD

TRANSIENT

+

EXCITER
WINDINGS

ROTOR

8

c

+

+

,

ISOLATION
DIODE

PLATES

GREEN

+

RED

+

GREEN

RED

+

Engines & Generators

39

A

CAUTION:

unintentional
on

the

control

1.

Refer

to

the

voltage

50

output

Hertz

applications.

Hertz/Voltage

2.

Reconfigure
board

carefully

below

the

to

the

AC
connections
connections
the

line

(L)

the

neutral

connection.

sense

connections

fault

shut

incorrect

NOTE:

A

VR

Neutral

'When

AC

reconfiguring

and

theAC tenitinal

As a precaution

start,

shut

panel.

previous

page

configurations

required.

the

12

AC

following
voltage
terminal

when
MUST

sensing

block.

needed

correspond

connections

connection

Failure

to

can

down

either

voltage

line

connections

displayed

block.

off

the

20

that

for

Select

the

connections

the

illustration.

diagram

There

and a neutral.

on

the

as

well

to

properly

result

in

from

low

the

AC

output,
are

CHANGING

against

illustrates

AC

connect
an

an

Amp

DC

breaker

the

various

both

the

60

Hertz

configuration

on

the

terminal

Reference

and

it;s

connections

are

three

line

These

to

and

be

connected

it's

or

on

AC

~e

terminal

high

board

corresponding

these

voltage

output

voltage

AC

voltage

LCD

display.

ensure

that

properly connected

AC

OUTPUT

for

and

the

and

the

HERTZ

AC

to

or

to

CONFIGURATIONS

ANil

VOLTAGE

3.

There
present

the

L3

4.

Inside
Hertz/Frequency
Hertz/Frequency

5.

Verify

panel

6.

Stmt
the

generator's
Adjust
correct

your

7.

Thrn

the

operation.

WHEN

CHANGING

FREQUENCY

ON

THE

CONmOL

BOARD

MUST

ON

FOR

50

are

three

on

the

connection

1he

control

all

connections

breakers;

the

generator

the

voltage

voltage.

hertz

meter.

on

the

AC

THE

(50160

HZ)

PANEL

BE

SWITCHED:

HiAND

OFF

line

connections.

AC

terminal
from

box,
dip
desired.

and

terminal

regulator

Check

panel

SWITCH

ECU

FOR

1he

locate

switch

are

correct

monitor

board.

the

breakers

11

60HZ.

When

block,

insulate

Voltage

the

ECU

in

the

correct

·
and

the

Line

board

as

generator

and

VOLTAGE

an

L3

is

and

tie

Sensing

and

Board.

position

position

tum

off

any

AC

output

voltage

to

line,

line

needea

to

obtain

hertz/frequency

load

unit

and

DIP

SWITCH

ECU

SWITCHES

SENSE

BOARD

not

.

off

the

for

the

AC

to

neutral.

with

monitor

at

the

#053762

"SERIES

480V/60
380V/50

NOTE:

ECU

REQUIRED

CHANGING

I.

2.

·

3.

ANY

CHANGING
DELTA

CONFIGURATION.
CHANGING
AND

3-WIRE
CHANGING
3-PHASE.

WYE"

Hz
Hz

0

AVR

0

TO

BE

RE-PROGRAMED

OF

THE

FOLLOWING

AC

WIRING

AC

WIRING

I-PH

BACKEND

BETWEEN

"PARALLEL

SETTINGS
BETWEEN
BETWEEN

WYE

2-WIRE

I-PHASE

VOLTAGE

WHEN

AND

AND

WYE"

Hz
Hz

I-PH

208V/60

190V/50

SENSING

BOARD

CONNECTIONS

2+3

0

6+7

0

I 0+ I I

0 0

"SERIES

"DOUBLE

(3-WIRE

SPUT SIIIOLE PHASE!
120-240V/60
II0-220V/50

25.5-33.0

0

6+9

0

8+1 I

DELTA"

.Hz

HZ

EDE

DELTA"

240V/60

ZZOV/50

1-PHASE

Hz
Hz

. I 3"PHASE

"PARALLEL DELTA"

120V/60
IIOV/50

[ill'-1--i!:) 0

4+7

[]]

{()())

2~2

'1XlUBL.E

(2-WIRE

SINGLE PHASE!
240V/60
220V/50

NOTE:

l"t~Y'tWESTERBEICE

) Engines & Generators

connection

Hz

Hz

6+9

0

8+ I I

DELTA"

Hz
Hz

PIN

Tie

53328

off

the

wizen

REV

B

L3 sensing

not

in

use.

40

ELECTRONIC

REGULATION-

PN.052944

ADJUSTABLE

OF

UNDERSPEED

PROTECTION

THRESHOLD
INTERVENTION'

ADJUSTABLE
OVERLOAD

INTERVENTION

THRESHO

PROTECT/0

/Hert

LD
N

,.___,

~Amp

z~

1----'!

Stab

-..:;

volt

r.:::::::J

~~oo

~

<£).~

-3E-O

IDi

. 7

®§

§)~.

-

i-

r-

,-r::o D

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 AC generator. The following
information details the voltage regulators adjustments and

connections. These procedures should be performed by a
qualified technician.

TERMINAL

#1. Excitation field

#2. Exciter field jumper to 3

#3. Exciter field DC positive.
#3A.

#4. Sensing voltage.

#5.

#6. Jumper to

#7. Not used.

#5B.
#5C.

POSSIBLE

Exciter
connected to terminal1
dark blue
yellow) should

Supply:

1. The supply coincides with the sensing.
SR7 /2 supply should
(in case
connected with the star point). Terminals 3 and 4 should
be connected to each other
is also sensing. This connection in necessary when the
generator does not have auxiliary winding for supplying
the regulator.

2.

The
generator equipped with auxiliary winding for regulator
supply.
of

CONNECTIONS

DC

negative.

if

the regulator AC supply

between 5 and

Supply voltage to regulator (AC).

Supply voltage to regulator (AC).

Not

used.

Sensing voltage.

5A

3A

is less than 160 VAC.

for

60

Hz

operation.

CONNECTIONS

Field: The exciter field negative should be

of

the electroni,e regulator (normally

or

black), while the -positive '{normally red

be

connected to terminal3.

There are two possibilities.

In

this case the

be

connected to terminals 3 and 5

of

three-phase generators, terminal 5 is normally

in

such a way that the supply

supply and sensing separate. This is the case

Supply is always connected to terminals 3 and 5

the regulator.

or

of

a

0.

ll

~~,

00

.

J

D:::

0

-=-rl

I

0

· Sensing: Sensing should

· time decrease$

!

In

both

of

270 VAC.

should

be

bridged
160 VAC, while the same terminals should be left open
voltage is between

and can vary from
phase only and therefore is normally connected to one
alternator phase.

Operation
and 6 should be conne<;ted to each other in order to keep the
low frequency protection correctly regulated .

A

WARNING:

present.
against

FUNCTIONS

Volt: With this potentiometer,
voltage generated
the screw is turned clockwise, the voltage increases,

screw is turned counterclockwise
Stab:

·

If

turned clockwise,. the stability

turned counterclock).vise, ihe response
voltage tends to be more stable.

In order to adjust this potentiometer correctly;
using the following method.

1. The generator must

2. Slightly turn clockwise until the light generated

electrical

This potentiometer optimizes alternator performance.

and the potentiometer must be at maximum stability
(turned fully counterclockwise).

filament lamp oscillates, at this point, turn the

potentiometer slowly counterclockwise until the light

stabilizes.

AVR

5

AMP

FUSE

k

-Sa

~

-

~

~

¥

~7

~

,......~

.......

~

~

*

~-~~

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

it sl,lould be noted that terminals 2 and 3

for

at

60

Hz:

Take

all

OF·THE

by

but

CONNECT

.:.__j

REMOVE

EXCITER

I

supply with voltage between 80 and

160 and 270 VAC.

be.

80 to 3SOVAC. The sensing is single

When operating at 60 Hz, terminals

.

Be

aware

necessary

hazards.

REGULATOR

the alternator in a very simple way.

the

~voftage

be

working, starting from zero load

FOR

60Hz

FOR

50Hz

FIELD

if

the

connected to terminals 4 and 5

that

high

voltages

precautionms

to

may

safe

be

guard

POTENTIOMETERS

it

is possible to adjust the

If

if

the

it

decreases.

dc:c_reases

ten~stcr

and the response

be

less stable.

time

increases and the

we ac)vise·

by

If

the

5A

Engines & Generators

41

ELECTRONIC

Hertz: With this potentiometer, which is normally

pre-calibrated then sealed by the manufacturer,
to adjust the low frequency protection intervention. To.

recalibrate this protection, you must take the generator to a
normal zero load condition, tum the potentiometer
clockwise until the limit position is reached, then decrease
the nominal speed
counterclockwise and measure the voltage value until it has

decreased by 5 volts.
When the speed decreases

value, the voltage also decreases proportionally, blocking
generator overheating. Even
protection at

possible to calibrate the threshold at other values.
Amp:

With this potentiometer,
intervention level
system has an intervention delay, which permits a temporary
overload, necessary when starting motors

applications.

To modify this protection, you must overload the generator
by 15%

minimum (counterclockwise) and wait about twenty seconds.
During this period
condition and while turning the potentiometer clockwise, fix
the generator voltage value at
At this point, while the initial overload is being removed, the
voltage increases to the nominal value.

Fuse: The electronic regulator is equipped with a fuse, which

protects the alternator from overheating in cases
malfunction.

replaced easily.

of

by

10 %. Then tum the potentiometer

by

more than 10%

if

we f!dvise calibrating this

10%

of

the nominal value, it is obviously

it

is possible to adjust the

of

the overload protection. This protection

the normal load, tum the potentiometer to

of

time the voltage value decreases.

10% less than the nominal one.

The

fuse (250V-5A, quick acting, F type) can be

or

similar

of

it

is possible

the nominal

In

of

regulator

this

REGULATION-

TO

AC

CONNECTIONS

REFER

TO

THE

WIRING

IN

DIAGRAM

THIS

MANUAL.

I I

I

t

f--.:,

~

II

..-----!:J

Circuit Breaker
DC

Field

#053633

AVR

SENSE

COMPLETE

#52951

AVR

0

'bf

fj-

~

D

~:J;mnr

-7;

~

~11681[

:

I

*"

0

II

LT.

OLU

BLU

TO

PANEL

FUSE

=t=.~,==f~§~~~~~=jT=='l\

t16 W T

=.:ua

li4B

'

~

....

TERMINAL

SHOWN,

fOR

LO·WY.E

TERMNAL

i -

EXCITER

r"-"1

~

SLU

r-

·.:__-~.

! [ [ . J I

! I ¥

ig=

. I

- .

L... I ';"'-=. I I

ROTOR

BLOCK

CONNECTIONS

ARE

CONF

IGUREO

120/208

!LOCK

..

--,

~112

=-IQ

-8

- 6

l'El

•

-;

II

-,.

VAC

Amp·

Hertz

stab.

volt-

:;

60Hz

YELLOW

RED

REO

nLUE

42

If

the installer connects shore

cuit,

this

must

be

done
OFF/SHIPS
grams

1

ous

connection

A

utility

at

the

covered

sibility

A

before

vice-versa
ing
may
the

Shore

GENERATOR

GEN.

to

the

OFF

CAUTION:

shore

power

same

time.

under

to

make

CAUTION:

switching

because

with

heavy

cause

damage

generator.

Power

Set

position. This

of shore power

Damage

the

sure

Heavy

shore

AC

loads

Connections

by

means

the

transfer

to

and

generator

This

type

warranty;

all

AC

motor

power

voltage

on

to

the

exciter circuit

Ship

SHORE

power

to

the

of

the

SHORE

switch

switch

prevents

to

generator

the

generator

output

of

generator

it

is

the

installer's

connections

leads

should

to

generator

surges

induced

the

vessel

being

(60

Hertz)

to

Shore

SWitch

POWER

vessel's

shown

'

are

AC

POWER/

in

the

simultane-

output.

can

result

If

are

connected

damage

be

components

Is

respon-

correct.

shut

off

power

or

by

switch-

operated

(3

Pole)

TRANSFER

cir­dia-

not

in

230

Notice
minal

-GENERATOR

SWITCH

Volt/50

block

GROUND

Hertz

Two

Wire

the

repositioning

to

the

N

W·

!::::

=

==

.----4-----o~

<>f

generator

.

L1

~

:S

ta

L----H1

the

white

case.

GENERATOR/SHORE

1

Configuration

ground

lead

·

Ship

SWITCH

.,-,

" '

~IL1

.-(3

•

®1

..

_

..

' "

to

on

Shore

the

ter-

Switch

.,

..

SHIP'S
LOAD

·

'

I

I

I
I

L---f<D

r

I

I

I

1

I

t

lS2S1

SHORE

NOTE:

Diagram

for a

two-wire,

three-wire

for

the

other hot

.:.

,.

....

--,

~l--'

,

__

-----'~

.....tr-;1

~-

~-

N I

•

POWER

system,

.,

I

'\

1

, _

_....,

~

G-RO_U_N_D___..,

shows

connections·

120

volt

system.

use

the

leg.

--..,

I

I

I

I

I

I

I

I

..

~~j

__

dotted lines

For

N

--llt•

NOTE:

a ·

'SHIP'S

SHIP

LOAD

TO

SHORE SWITCHES

l

L1

' T

SHORE

L1

230V

SHORE

AND

SINGLE

POWER

CONNECTION

PHASE

ARE

AVAILABLE

N J

POWER

50Hz

-=

.

TRANSFER

SHOWN

ONLY

AT

SHORE

GROUND

=

GROUND

SHIP'S

SWITCH
ARE

FOR

YOUR WESTERBEKE DEALER .

l"WV"IWESTERBEICE

l Engines & Generators

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
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 as a
check list

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

If

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

Propeller

The transmission and propeller half couplings should always
be opened up and the bolts removed when the boat is hauled
out
storage in the cradle. The flexibility
severe strain
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. Operate the engine to ensure a complete circulation

and mixture

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

Lubrication

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

sump. Remove and replace the oil filter and fill the sump
with new oil. Use the correct grade

ENGINE LUBRICATING OIL pages in this manual for the

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

A

in
combustion
chemicals
internal

or

for long periods

if

others do the procedures.

of

your engine.

Shaft

Coupling

of

the water or moved from land to water, and during

on

the propeller shaft or coupling or both, while

of

time.

Water

Cooling

of

antifreeze and distilled water is

of

the antifreeze concentration throughout the

of

inactivity. Others prefer

{Propulsion

of

the boat often puts a

of

dry for a considerable

Circuit

[Propulsion

Engine]

the water when

Engine]

of

System

of

oil. Refer to the

CAUTION:

the

sump

parts.

Do

over

the

deposits

which

can

not

leave

lay-up

combine

reduce

the

engine's

period.

to

produce

the

life

old

engine

Lubricating

harmful

of

your

engine's

oil

oil

and

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. 2 diesel fuel. Fuel additives

such as
added at this time to control algae and condition the fuel.

Care should be taken that the additives used are compatible

with the primary fuel filter/water separator used in the
system. Change the element in your primary fuel filter/water
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

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

Close the through-hull seacock. Remove the raw water intake
hose from the seacock.
gallon bucket
check the zinc anode found in the primary heat exchanger on
the engine and clean or replace it as required, and also clean
any zinc debris from inside the heat exchanger where the
zinc anode 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 an antifreeze
solution slightly stronger than needed for winter freeze
protection in your area.

Start the engine and allow all
through the raw water system.
the engine. This antifreeze mixture should protect the raw
water circuit from freezing during the winter lay-up, as well
as providing corrosion protection.

Remove the impeller from your raw water pump (some
antifreeze mixture will accompany it, so catch it in a bucket).
Examine the impeller. Acquire a replacement,
a cover gasket. Do not replace the impeller (into the pump)
until recommissioning, but replace the cover and gasket.

BioBor and Diesel Kleen + Cetane Boost should be

- l 0 minutes to make sure no air is left in the fuel

Water

Intake

Place a clean cloth, lightly soaked in lubricating oil, in the
opening
shove the cloth out
recommissioning, and an attempt is made to start the engine,
you may need assistance
note to remove the cloth prior to start-up. The thru-hull
exhaust port can be blocked in the same manner.

[Gasoline]

of

89 octane

Sta-Bil gasoline

[Diesel]

if

the fuel system has one, and clean the separator

- l 0 minutes will help

of

the treated fuel through the injection

Cooling

of

Manifold

of

the intake manifold to block the opening. Do not

Circuit

Place the end

clean fresh water. Before starting the engine,

and

Thru-Hull

of

sight.

(If

of

the servicing dealer. Make a

of

this hose into a five

of

this mixture to be drawn

Once the bucket is empty, stop

if

needed, and

Exhaust

it is not visible at

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
each cylinder to help prevent the piston rings from adhering to
the cylinder walls. Rotate the engine crankshaft by hand two
revolutions and re-install the glow plugs.

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

Intake

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

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

to start-up!

Cylinder

After engine shutdown, remove the spark plugs and spray a

small amount

crankshaft manually two complete revolutions. Re-install the

spark plugs loosely for winter lay-up.

NOTE:

the crankshaft two full revolutions. Re-install the spark plugs,
tightening properly
onto each spark plug.

Motor

of

the starter drive pinion

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

Lubrication

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

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

Manifold

Lubrication

of

fogging oil into each cylinder. Rotate the

At

spring commissioning, remove the plugs

[Diesel]

of

the glow plugs for

[Gasoline]

[Gasoline]

and

connecting the high tension leads fully

is

advisable,

Oil into

and

rotate

Batteries

If

batteries are to be left on board during the lay-up period,
make sure that they are fully charged, and will remain that
to prevent them from freezing.
batteries will not remain fully charged, or that they will be

subjected to severe environmental conditions, remove the
batteries and store them in a warmer, more compatible
environment.

A

WARNING:

highly-explosive
arcing

or a lighted

smoke

or
serviced.
to

prevent

Lead

gas,

allow

an

Shut

off

electrical

cigarette,

open

all

If

acid

batteries

which

can

flame

electrical

arcing

during

there

is

any doubt that the

emit

be

ignited

cigar,

or

pipe.

near

the

equipment

servicing.

hydrogen,

by

electrical

Do

battery

in

the

not

being

way,

a

vicinity

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

SPARE PARTS section

Parts

if

external items such

as

filters and zinc anodes. Refer to the

of

this manual.

as

drive belts

Recommissioning

The recommissioning
seasonal lay-up generally follows the same procedures
those described in the PREPARATIONS FOR STARTING 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, if required).

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,
flame
electrical
arcing

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

proper tightness

5. Check the condition
circuit and clean or replace the anode as needed. Note

6.

emit

be

ignited

cigar,

near

the

equipment

during

that it is not necessary to flush the antifreeze/fresh water
solution from the raw water coolant system. When the

is

engine
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.

Start the engine in accordance with procedures described
in the
manual.

put into operation, the system will self-flush in a

PREPARATIONS FOR STARTING section

of

your Westerbeke engine after a

of

the lay-up procedures will need to be

Wear

rubber

gloves, a rubber

when

servicing

hydrogen, a highly

by

electrical

or

pipe.

Do

battery

being

in

the

batteries.

explosive

arcing

or a lighted

not

smoke

serviced.

vicinity

or

Shut

to

prevent

Lead

gas,

allow

off

servicing.

[gasoline].

of

the zinc anode in the raw water

of

time with no adverse affects.

of

season

It

or

recommissioning

as

apron,

acid

which

an

open

all

electrical

is

of

this

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
coating. Check that the transmission vent
additional information, refer to the

[Propulsion

Engine]

TRANSMISSION SECTION.

an

anti-corrosion

is

open. For

~

WESTERBEKE

Engines & Generators

45

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(ft) x .305 = Meters

Miles x 1.609 = Kilometers

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

CONVERSION

DATA

DISTANCE

1
1

EQUIVALENTS

Degree

of

Latitude = 60

Minute

of

Latitude= 1 Nm = 1.862

VOLUME

Cubic

Inches
Imperial
Imperial
Imperial
Imperial
Imperial
Fluid

Ounces x 29.573 = Milliliters x .034 = Ounces

US

Pints

US

Quarts

US

Gallons

3

(in

Pints

(IMP

Quarts

(IMP
Gallons
Quarts

(IMP
Gallons

(US

pt) x .473 = Liters(L) x 2.113 = Pints

(US

qt) x .946 = Liters

(US

gal) x 3.785 = Liters

MASS-WEIGHT

Ounces
Pounds

(oz) x 28.35

(lb) x .454 = Kilograms

PRESSURE

Pounds
Inches
Inches
Inches
Inches
Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

Sq

In

Nm = 111.120

)

x

16.387

=Cubic

pt) x .568 = Liters

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

qt) x 1.201 = US

(IMP

gal) x 1.201 = US

=Grams

(psi) x 6.895 = Kilopascals

(Hg) x .4912

(Hg) x 3.377 = Kilopascals
(H20) x .07355
(H20) x .03613

(H20) x .248 = Kilopascals

(g) x .035

(kg) x 2.205 = Pounds

=psi x

=Inches
=psi x

km

km

Centimeters x .061

(L) x 1.76 = IMP

(L)

Quarts

Gallons

(L) x 1.057 = Quarts

(L) x .264

=Ounces

2.036 = Hg

of

27.684 = H20

3

=in

pt

x.88 = IMP

(L) x .22 = IMP

(US

(US

=Gallons

(kPa) x .145 = psi

(kPa) x .2961 = Hg

Mercury x 13.783 = H20

(kPa) x 4.026 = H20

qt

gal

qt) x .833 = IMP

gal) x .833 = IMP

qt

gal

TORQUE

Pounds-Force

Pounds-Force

VELOCITY

Miles

Per

POWER

Horsepower

FUEL

CONSUMPTION

Miles

Per
Kilometers
Miles

Per
Kilometers

TEMPERATURE

Degree
Degree

Fahrenheit
Celsius

Inches

(in-lb) x .113

Feet

(ft-lb) x 1.356 = Newton

Hour

(MPH) x 1.609 = Kilometers

(Hp) x .745

Hour

IMP

Per

Liter

Gallons

Per

Liter

(°C) = (°F -32) x .56

=Kilowatts

(MPG) x .354
(Km/L) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(Km/L) x 2.352

(°F) = (°C X 1.8) + 32

46

=Newton

(Kw) x 1.34

=Kilometers

=

U~

MPG

Meters

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = ft-lb

Hour

(KPH) x .621 = MPH

=MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=in-lb

WATER

HEATER

WATER

These engines are equipped with connections for the plumbing
of
The

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

Hoses should rise continuously from their low point at the
heater to the engine so that air will rise naturally from the
heater to the engine.
then an air bleed petcock must
on the heater for bleeding air while filling the system.

HEATER

engine coolant to transfer heat to an on-board water heater.

water heater should

in

a high

!HERMOSTAT

INSTALLATIONS

be

mounted

or

low position in relation to the engine, so

If

trapped air is able to rise to the heater,

HOUSING

in

a convenient location

be

installed at the higher fitting

NOTE:

If

any portion
engines own pressure
remote

expansion tank (Kit #024177) must

circuit

to

become
the

tank into
connections for
single line
engines
convenient location

The

remote

system fill point. The plastic coolant recovery tank

when the remote expansion tank kit

tank serves the same function. Remove and

recovery

The

pressure cap
installed after the engine's cooling system is filled with
coolant. Finish filling the cooling system from the remote
tank after the system is filled and is free
good coolant circulation. During engine operation, checking
the engine's coolant should

not at the engine manifold cap.

heater to the remote expansion tank

supported so
enabling any
of

the system.

heater

up

return.

expansion tank will now serve as a check and

tank if

it

of

the

heatinr circuit

cap,

then

a pressurized (aluminum)

the

highest point.

circuit,

choosing

the

return.

Tee

at

the

to

the

tanks location

Install

the

remote

expansion tank

so

the

coolant level

it

has been already

on

the engine's manifold should be

be

done at the remote tank and

The

rises continuously from the heater to the tank,

air

in the system to rise up to the tank and out

rises

above

the

be

installed

Tee

the

remote

the

higher

heater,

and plumb a

and

the

other back

can

easily

is installed, since this

store

installed.

of

air and exhibits

hose connection from the
should·be routed and

expansion

of

the

in

a

be

checked.

is

the

plastic

in
two
to

not used

the

the

WATER

HEATER

--

_.,........-...-OWNERS

FROM

~

CONNECTIONS

---

HOT

HOT

WATER

WATER

NOTE:

An air bleed pet;ock

heat

exchanger.
coolant system
Close

tightly after all

HOSE

TANK.

is

located

Qpen

this petcock when filling

to

allow air

the

air

in

the

is

on

exchanger

removed.

the

engines

the

engines

to

escape.

I

...

IWESTERBEKE

l

Engines & Generators

47

SUGGESTED

SPARE

PARTS

CONTACT

YOUR

WESTERBEKE

WESTERBEKE

FUEL

SYSTEM

HARDWARE

DEALER

KITkm~~~

MARINE

FOR

ZINC

ANODE

DIESEL

ADDITIONAL

GENERATORS

SUGGESTIONS

<

FUEL

INJECTOR

~

AND

MATCHING

'DRIVE

BELTS

INFORMATION

THERMOSTAT
GASKET

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

Kit

"A"

includes the basic spares.

Kit "B"

is

for more extensive off-shore cruising.

KIT

A

ZINC

ANODES
DRIVE
OIL

FILTER

FUEL

FILTER

HEAT

EXCHANGER
IMPELLER
FUEL

SYSTEM

FUEL

PUMP

BELTS

KIT

INLET

AND

GASKET

HARDWARE

FILTER

KIT

SPARE

PARTS

KITS

KIT

B

ZINC

ANODES

DRIVE

BELTS

OIL

FILTER

FUEL

FILTER

HEAT

EXCHANGER

IMPELLER
INJECTOR

OVERHAUL
GLOW

FUEL
FUEL

KIT

PLUG
SYSTEM
PUMP

GASKET

GASKET

INLET,FILTER

KIT

HARDWARE

KIT

48

Engines & Generators

1179-rev 5

/11

-2012