Westerbeke 33KW EDE, 26KW EDE, 23.5KW EDE, 25.5KW EDE, 21.0KW EDE Operator's Manual

'OPERATORS

MANUAL

D·NET

33KW

26KW

- -

EDE • 60Hz EDE • 50Hz

DIESEL

.

21.0KW

25.5KW

GENERATORS

28.5KW

23.5KW EDE • 60Hz EDE··

50Hz

EDE • 60Hz

EDE • 50Hz

WESTERBEKE

MYLES

WEB

SITE:

CORPORATION

STANDISH

INDUSTRIAL

WWW.WESTERBEKECOM

-150

JOHN

PARK -TAUNTON

HANCOCK

MA

ROAD

02780

.F..I" Member Nallonal Marine Manufacturers Assocrotlon

·

CALIFORNIA

PROPOSITION

65

WARNING

Marine

exhaust

are

known

to

cause

and

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea

-Headache

-

gasses

gas.

can

Weakness

contain

Carbon

include:

and

Sleepiness

diesel

and

other

and

to

death.

some

cancer,

Monoxide

and

gasoline

of

its

constituents

the

State

of

birth

reproductive

A

WARNING

Carbon

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

GET

OUT

seek

medical

until

it

WARNING

Generators

Produce

CARBON

Regular

Maintenance

ri?i![~E!::!!!~~

MONOXIDE

Required

A

WARNING

should

be

fixed

generator.

WESTERBEKE MONOXIDE of

your

obtainable

DETECTORS

vessel.

at

OR

ANYONE

INTO

THE

attention.

has

been

DECAL

is

to a bulkhead

also

recommends

They

are

your

local

ELSE

FRESH

inspected

provided

in

the inexpensive marine

EXPERIENCE

AIR

IMMEDIATELY.

Shut

down

and

by

WESTERBEKE

near

your

installing

living/sleeping

store.

ANY

the

repaired.

engine

CARBON

and

easily

OF

THESE

If

symptoms

unit

and

or

quarters

SYMPTOMS,

persist,

do

not

restart

Engines & Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety manual carefully. Most accidents are caused by failure to

precautions.

take the necessary precautions to protect yourself,

personnel, and your machinery.

The following safety instructions are in compliance with

the American Boat

PREVENT

A

while

power.

•

Do

enclosures

•

Shut equipment.

•

Use equipment.

• Make (particularly shoes)

• Remove wristwatch electrical equipment.

•

Do circuits, except through a

transfer

result if

• Electrical shock results

capacitor. together.

PREVENT

A

exhaust very

• Always check

recovery

A

•

In before touching

ELECTRIC

WARNING:

engine

Lethal

not

operate this machinery without electrical

off electrical power before accessing electrical

insulated

sure

not

connect utility shore power

switch.

this

BURNS -HOT

WARNING:

system

hot!

tank.

WARNING:

case of

follow fumkzmental rules

Know

when

dangerous conditions exist and

and

Yacht Council (ABYC) standards.

SHOCK

Do

not

touch

is

running,

voltage

and

covers

mats

your clothing

Damage

procedure

Discharge capacitor

or

when

is

present

in

place.

whenever working

and

when

handling electrical equipment.

and

all

jewelry

ship-to-shon'O

to

vessels

is

not

from

ENGINE

Do

not

touch

components. A running

the

engine coolant level at

Steam

can

cause

an

engine overheat,

the

engine or checking

and

AC

electrical connected

at

these

skin

are

AC

followed. handling a charged

by

shorting tenninals

hot

engine

injury

allow

connections

to

connections!

on

electrical

dry,

not

when

working

to

vessels

double

generator

parts

engine

the

or

death!

the

engine

the

coolant.

damp

AC

gets

coolant

your

shore

on

throw

may

or

to

cool

PREVENT

A

• Prevent sparks pump, vapors. removing

•

Do arrester.

•

Do

Backfire

•

Do the engine/generator clean chances of

•

Be

PREVENT

A

injury

• Follow re-fueling safety instructions. hatches closed when fueling.

after fueling. Check below running before starting your engine.

•

All when well-ventilated area equipment

•

Do

• Shut off the spill. sources

servicing.

the

•

Do

• Be

• Be certain free

•

Make properly maintained. Be familiar Extinguishers rated

for

BURNS -FIRE

WARNING:

flash to occur near or other potential sources of spilled

Use

not operate without a Coast Guard Approved

Backfire

not operate with

not smoke or pennit fuel

system.

aware - diesel

Fire

can

fires.

Do

not smoke or permit

the

a suitable container

the

fuel

line, carburetor, or

can

cause severe injury or

the

can

cause

severe

Keep

the

and

fire.

Wipe

up

fuel

cause

injury

carburetor,

to

air cleaner/silencer

injury

or

flames

or

sparks

compartment

free

of debris

all spilled

will

bum.

BURNS -EXPLOSION

WARNING:

or

death!

fuel

handling

not

fill

fuel

DO

of

fuel not alter or modify

sure

of

leaks.

sure a fire

all

applications

the

blower.

vapors

and

the

fuel

system.

NOT

fire

Ensure

system.

all

fuel

Explosions

are

highly

and

storing

out of

fuel

tank(s) while

service

Take

allow

near

the

proper

supplies have a positive shutoff

line

extinguisher

encountered

from

Open

for

Run

the

blower

explosive.

fuels.

away

from

the

reach of children.

valve

care

in

catching

any

smoking, open

fuel

system

ventilation

the

fuel

fittings

are

ABC

by

the

fuel

fumes/vapor before

Store

spark-producing

the

at

the

or

system.

adequately tightened

is

installed

with

NFPA

in

this

or

death!

fuel

line,

fuel

catch all

fuel

filters.

death.

to

and

to

fuel

and

vapors

Keep

the

and

ventilate

for

four minutes

Use

extreme

fuel

in

engine

when

any

fuel

flames,

engine

when

exists

when

nearby

its

proper

are

appropriate

environment.

flames

or

filter,

fuel

or

fuel

when

flame

death.

removed.

occur

near the minimize engine

oil.

can

cause

vessels

cabin

care

a

is

running.

servicing

that might

or other

servicing

valve.

and use.

the

and

is

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect generator. it

last.

• Make certain

starting.

• Make certain

re-installed before starting

BATTERY

A

WARNING:

or

death!

•

Do

not smoke or being highly explosive arcing or by lit tobacco products. equipment during

• Never connect positive (+) connection tenninal of Do

not test together. Ventilate

accumulation of explosive

disturb the battery charger connections

is

being charged.

•

Avoid bums or sparks that could cause

wristwatch,

the

battery.

•

Always the

battery connections. Remove and

reconnect

BATTERY

A

WARNING:

severe

STARTING

Accidental

the

battery cables before servicing

Remove

all

personnel are clear of

all

covers, guards,

starting

the

negative lead

the

EXPLOSION

Battery

serviced. Lead acid batteries emit hydrogen, a

in

the vicinity

servicing.

the

battery condition

Sparks could ignite battery

any

comparttnent containing batteries

contacting

rings,

tum

the

it

explosion

allow

an

open

gas,

which

can

to

prevent electrical

negative (-) battery cable

gases.

the

tenninals with

and

any

other jewelry before handling

battery charger off before disconnecting last

when

disconnecting

ACID

injury

Sulfuric

or

death!

acid

in

can

cause

first

and

the

engine before

and

hatches

engine.

can

cause

flame

near

be

ignited

by

Shut off

by

To

an

the

batteries

all

the

starter solenoid.

shorting

gases

or

avoid

sparks,

while

tools,

etc., to prevent

explosion. Remove

negative lead

the

can

injury

the

reconnect

are

injury

the

battery

electrical electrical arcing

to

the

terminals

fuel

to

the

battery.

cause

engine/

vapors.

prevent

do

not

battery

first

TOXIC

• Ensure that

•

• For additional information refer

•

• Although diesel engine exhaust gases are not

AVOID

EXHAUST

A

WARNING:

discharged regularly manifolds/water-injected

Be

sure

the

Run

blowers when running

Do

not

run equipped detector that complies with ABYCA-24. Consult your boat

builder or dealer

detectors.

(educational information

A

WARNING:

odorless nausea

gas.

or

death!

Do

not

use fumes

can systems. copper tubing resulting

Do through portholes, exhaust discharge outlet enter

flow

exhaust gas symptoms or

poisoning

Vomiting

Dizziness

Headache

Nausea

Exhaust sulfur causes rapid deterioration of

not install exhaust outlet where exhaust

the

of exhaust.

fumes

is

present

MOVING

GASES

Carbon

the

from

for

leaks

unit

the

generator

with

a functioning marine carbon

Carbon

Inhalation

copper tubing

rapidly

exhaust discharge outlet

from

in

signs

are:

Inability Throbbing Muscular twitching Weakness

monoxide

exhaust system

the

engine. Check

and

make sure

elbow

and

its

surroundings are

the

set

or engine unless

for

installation of approved

on

Carbon Monoxide).

monoxide

produces

in

diesel

destroy

Avoid

diesel exhaust

copper

in

exhaust/water leakage.

vents,

or air conditioners. If

is

near

overloading

gasoline engines, carbon monoxide

of carbon monoxide inhalation or

to

think coherently

in

temples

and

sleepiness

PARTS

(CO)

is a deadly

is

adequate

the

is

securely

generator set or

to

ABYC

(CO)

flu·like

exhaust

tubing

the

waterline, water could

and

the

fumes.

to

exhaust system

exhaust

attached.

well

monoxide

T-22

is

an

invisible

symptoms,

systems.

in

exhaust

can

close

or restrict

craft.

Some of

gas!

expel

gases

ventilated.

engine.

the

boat

Diesel

be

drawn

the

engine

the

as

toxic

the

is

as

•

When

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

at

once

the

into

caps.

eyes

the

battery or checking

If

it

comes

with

water.

inadvertently

in

contact

Acid

may

splash

when

removing electrolyte

with

the

and

your

on

electrolyte

eye

is

skin,

wash

the

skin

or

-..y'

A

WARNING:

or

death!

it

• Do not service situation arises

make

operating

touching

components.

WESTERBEKE

Engines & Generators

i i

the

moving

Rotating

in

adjustments,

engine

which

parts

while

it

and

can

cause

injury

it

is

running. If a

is

absolutely necessary

use

extreme

hot exhaust system

care

to

avoid

SAFETY

INSTRUCTIONS

• Do not wear loose clothing or jewelry equipment; tie back

jackets, shirts, sleeves, could be caught

• Make

•

• Stay clear of

HAZARDOUS

A

sure

all

Keep

protective shields

all

the

times.

is

engine

places at Do

not check

the

engine

when be

caught in these rotating

NOISE

WARNING:

long

hair

and

rings,

necklaces or bracelets that

in

moving

attaching hardware

fluid

levels or

operating. the

drive shaft is

running; hair

High

and

noise

parts.

guards

the

and

parts.

levels

avoid wearing loose

is

properly tightened.

in

drive belts tension while

the

transmission coupling

and

can

loss!

• Never operate

• Do not run

removed.

• Do not

open.

A

WARNING:

mentally

an

engine with

run

engines

00

or

physically

engine without

for

long periods with their enclosures

not

work

incapaCitated

its

the

air

intake (silencer)

on

machinery

muffler

by

when

servicing

their respective

clothing

cause

can

hearing

installed.

when

you

fatigue!

easily

are

ABYC, INSTALLING

Read for recommendations when installing your

ABYC (American Boat "Safety Standards

Order

NFPA

"Fire Protection Standard Order

USCG (United States Coast

"USCG 33CFR183"

Order

NFPA

AND

USCG

PUBLICATIONS

DIESEL

the

following

safety codes

from:

ABYC 3069

Solomon's Island

Edgewater,

from:

NFPA

11

Tracy Drive

Avon

Avon,

from:

U.S. Washington,

MD

(National Fire Protection Association)

Industrial Park

MA 02322

Government Printing Office

D.C.

ENGINES

ABYC,

and

for

21037

NFPA

standards. Follow their

and

Yacht

Small Craft"

Rd.

for

Motor Craft"

Guard)

20404

and

Council)

USCG

engine.

FOR

publications

OPERATORS

Many

of

in

your Operators Manual along with other cautions

notes

to carefully, procedures.

GASOLINE

Preparations to install thorough examination of the American Boat Council's combination of sources including

Sections of the

H-2 P-l Exhaust Systems P-4 E-9

All

installations must comply with the Federal Code of

Regulations

MANUAL

the

preceding safety

highlight critical information.

maintain your equipment,

ENGINE

(ABYC)

Ventilation

Inboard Engines

DC

Electrical Systems

(FCR).

AND

an

standards. These standards are a

ABYC

tips

and

GENERATOR

engine should begin with a

the

standards of particular interest

warnings Read

your

and

follow

INSTALLATIONS

and

USCG

and

are

manual

all

safety

Yacht

the

repeated

and

NFPA.

are:

~

WESTERBEKE

Engines & Generators

iii

When

installing

attention

WESTERBEKE

be

paid

to

the

following

INSTALLATION

engines and generators it

information:

is

important that strict

CODES

Strict federal regulations,

when

AND

installing

REGULATIONS

engines

ABYC

and

guidelines,

generators

SIPHON-BREAK

For installations or

will

be

break

in

the

minimum of

the exhaust manifold injection port raw

water damage

If

you

have

to the vessel's waterline under

siphon-break.

NOTE:

A siphon-break operation. engine

damage.

EXHAUST

The exhaust hose must be certified prevent water of

the

vessels

where

below

the

raw

water supply

20" above

to

any

doubt

Failure

to

Consult

SYSTEM

from

entering

hull.

the

exhaust manifold/water injected exhaust elbow

vessel's

waterline,

hose

the

vessel's

the engine and

about

the

position of

the

vessel's

requires

properly

periodic

maintain a siphon-break

the

siphon-break

the

exhaust under

and

safety

in a marine

provisions must be

to

the

exhaust

waterline.

is

at or

possihl£

various

inspection

manufacturer for proper

for

marine

environment.

elbow.

Failure

below

the

flooding

the

water-injected exhaust

operating conditions, install a

and

use.

The system must be desigued

any

sea

codes must

made

This hose must be looped a

to

use a siphon-break when

wad

of

the

cleaning

can

conditions

be

complied

is

close

to install a

waterline will resull in

boat.

to

ensure

result

in

maintenance.

and

siphon-

elbow

relative

proper

catastrophic

at

any

angle

with

to

AVAILABLE YOUR DEALER

FROM

WESTERBEKE

A

detailed diesel, dealer.

40

page

engines

and

Marine

Installation

generators,

is

Engines & Generators

iv

Manual

available

covering

from

your

gasoline

and

WESTERBEKE

TABLE

Parts

Identification Introduction Fuel,

Engine Preparations Oigital Remote Generator Daily

Routine

Maintenance

Fuel

System

Cooling

Raw Water Intake Strainer. ................................

Draining the Raw water System ........................

Fresh Water Cooling Circuit .............................. 14

Changing the Coolant... ...................................... 14

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

Raw Water Cooling Circuit... ............................. 16

Heat Exchanger .................................................. 16

Raw Water

Engine

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

Remote Oil Filter

Starter Wiring Engine

Alternator

Battery Care ....................................................... 24

Glow

Plugs Wiring Engine Alternator

Battery Care ....................................................... 26

Glow

Plugs

Engine

Oil Pressure ........................................................ 28

Engine Compression .......................................... 28

Valve Adjustment ............................................... 28

Drive Belt Adjustment ....................................... 29

Fuel Injectors ...................................................... 29

Magnetic Generator Generator Twelve Generator Electronic Internal Exciter Shore

Power Lay·Up Metric Suggested Water

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

Oil

for

Control

Stop/Start

Break·ln

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

Schedule

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

System

Lubricating

Motor

(Troubleshooting)

Diagram

Troubleshooting

Testing

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

Diagrams

Troubleshooting

Testing

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

Adjustments

Plck·Up

Specifications

Information

Lead

Wiring

Voltage

Regulation

Wiring

Rotor/Rotating

Transfer

and

Recommissioning

Conversion

Spares

Heater

Connections

OF

CONTENTS

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

and

Engine

Initial

Panel

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

Panel

Procedure

Coolant

Start

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

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

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

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

(Chart)

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

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

Pump ............................................... 16

011

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

(Optional)

#52413

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

(Chart)

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

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

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

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

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

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

(Chart)

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

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

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

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

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

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

Connections

Adjustment

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

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

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

Diagram

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

Field

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

Switch

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

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

Data

(Chart)

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

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

(Optional)

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

8A

10

.

12

.

13

15 13

15

17 17

.18

19 21 22

24

27

20 22

24

27 28

.30

31

.33

34

.35 .36

37

.38

39

.40 .42

.4

3

.44

2

3

5

6

7

9 9

Engines &

1

Generators

PARTS

IDENTIFICATION

CONNECTION

FOR

SIPHON

BREAK

DIGITAL

CDNTROL

PANEL

Fl

8A

FUSE

REAR

FUEL

LIFT

AIR

INTAKE

.,LtN.'tH_"

AIR

BLEED

PETCOC:Ki.:~

DRIVE

COVER

.

DC

ALTEIINAnIR-----

FRDNT

FLEXIBLE

ISOLATED

MOUNTS

COOLANT

RIGHT

SIDE

CONTROL

LEFT SIDE

Engines & Generators

2

OIL

FILL

THERMOSTAT

f--~INJIECTION

PUMP

1lc::::LI.L---11AW

WATER

PUMP

[J..e---

DIL

DRAIN

HOSE

HEAT

BREAKER

HIGH

EXHAUST TEMPERATUR£ SWITCH

SYPHON

BREAK

CONNECTION

'"n."

••

MOTOR

INTRODUCTION

This WESlERBEKE Diesel Generator

WESlERBEKE's long

We

technology.

dependable performance of our engines

you

Thank

In order

is

importan~

it This manual manual carefully throughout. your nearest WES1ERBEKE dealer

This

is

your operators manual. A parts catalog provided WES1ERBEKE equipment, contact WES1ERBEKE'S installation manual.

WARRANTY

Your

WESTERBEKE Warranty

folder.

If,

fonn

you

registering writing

serial

with

number

Customer

take great pride

for selecting WES1ERBEKE.

to

get

the

that

is

designed

Should your engine require servicing, contact

and

a technical manual

PROCEDURES

after

60

have

not

your

warranty,

model

and

Identification

years

of experience

in

the superior durability

full

use

and

benefit

you

operate

and

observe

dealer.

your

days

of

received a customer

information, including

cOnun1ssion

and

to

help

you

all

the

is

available

If

you

are planning

WES1ERBEKE dealer for

is

included

SUbmitting please contact

date.

Card

maintain

do safety precautions

for

the

''''''''WESTERBEKE

I

Customer Identification MR.

GENERATOR MAINS1REET HOMETOWN, Model Expires

USA

OWNER

Ser.

#

is

a product of

and

advanced

and

generators.

from

your generator,

it

correctly.

this.

Please

assistance.

is

from

to

install

in

a separate

Warranty

identification

the

factory

the

unit's

read

also

your

this

Registry

card

in

and

this

PRODUCT

Product brochures WESTERBEKE

WESTERBEKE CONTENT

RANTIES

THERETO, COMPLETENESS THEREOF AND

BE LIABLE INCURRED IN CONNECTION

THE

OF

WES1ERBEKE customers span and

the product software. The product software provided WES1ERBEKE products, whether other suppliers, must not sively

only

not representatives ofWES1ERBEKE or

be

consulted

product software being consulted

PROTECTING

Care at the

have resulted

many thousands of hours manufacturer cannot control installed in operated and serviced buyer/owner-operator.

NOTE:

• Proper engine and generator installation and alignment.

•

An an anti-siphon break to prevent water from entering the

SOFTWARE

software,

and

OR

FURNISHING

between

unavoidable

as

the

makes

Six imponant steps

efficient weU·designed exhaust system that includes

(technical

catalogs), provided

are

not

CANNOT BE RESPONSIBLE

OF

SUCH

REPRESENTATIONS WITH RESPECT

INCLUDING

FOR

ANY TYPE OF DAMAGE

printings of WES1ERBEKE product

existence of earlier WES1ERBEKE

definitive authority

good

to

determine

YOUR

factory

during assembly and thorough testing

in

a WES1ERBEKE generator capable of

the

vessel

data,

parts

lists,

from

sources

within

WESTERBEKE's

SOFTWARE,

ACCURACY,

OR

USE

should

and

sense

but

the

MAKES

WILL

WITH

OF SUCH

keep

from

cannot

be

on

the

is

imperative that

the

accuracy

by

the

TIMELINESS

OR ARISING OUT

in

WES1ERBEKE

relied

respective prodtict.Jt

supplier

and

customer.

INVESTMENT

of

dependable service. However

how

or where

or the manner

in

the

field.

to

in

which

This is

up

ensure long generator

manuals,

FOR

NO

IN

NO

OR

SOFTWARE.

mind

upon

currentness

the

generator

the

to

other

than

control.

THE

WAR-

OR

EVENT

INJURY

the

time

software

with

exclu-

appropriate

in

question

of

unit

is

the

life:

or

the

is

engine.

NOTES,

As

maintenance

engine, critical information CAUTIONS,

NOTE:

A

ohsorved,

your

A

followed,

CAUTIONS

this

manual takes

schedules,

and

An operating procedure essential

CAUTION:

can

engine.

WARNING:

can

AND

you

through

and

WARNINGS.

Procedures

result

In

the

Procedures

result

In

pelSonal

WARNINGS

troubleshooting

will

be An

which,

damage

which,

the

highlighted

explanation

injury

operating procedures,

of

your

marine

by

NOTES,

follows:

to

note.

If

not

strictly

or

destruction

If

not

properly

or

loss

of

~

of

life.

WESTERBEKE

Engines & Generators

3

• Changing the engine oil and oil filters according

maintenance schedule.

• Proper maintenance

nents according to the maintenance

of

all engine

and

generator compo·

scheduk

to

in this

manual

•

Use

clean, filtered unleaded fueL

• Winterize your engine according to the "Lay-up and

Recommissioning"

section

in

this

manual.

the

INTRODUCTION

SERIAL

NUMBER

LOCATION

The engine's model number and serial number are located on a nameplate mounted on the side

of

the engine.

The engine's serial number can also

be

found stamped into

the engine block

on

the flat surface

of

the block just above

and inboard

of

the injection pump. Take the time

to

enter this

information

on

the illustration

of

the nameplate shown below,

as this will provide a quick reference when seeking technical

informatio~

and/or ordering repair parts. p

An identification plate on the top

of

the engine air intake also

displays the engine model and serial number.

CARBON

MONOXIDE

DETECTOR

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

Carbon

monoxide,

even

in

small

amounts,

is deadly.

The

presence

of

carbon

monoxide

indicates

an

exhaust

leak

from

the

engine

or

generator

or

from

the

exhaust

elbow/exhaust hose,

or

the fumes from a nearby vessel are

entering your boat.

If

carbon

monoxide

is

present,

ventilate

the

area

with

clean

air and correct the problem immediately!

NOTE:

A carbon monoxide warning decal has been provided

by

WESTERBEKE. Affix this decal in a visible position in the

engine

room.

UNDERSTANDING

THE

DIESEL

ENGINE

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 of

the same general type as that

of

a gasoline engine; and the

diesel engine

has

the

same

types

of valves,

camshaft,

pistons,

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

of

the fuel, lubricating and cooling systems.

Replacement

of

fuel and lubricating filter elements at the 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

of

high detergent diesel lubrication oil

designed specifically for diesel engines.

The diesel engine does differ from the gasoline engine, however, in its method

of

handling and firing

of

fuel. The carburetor and ignition systems are done away with and in their place is a single component - the fuel injection pump -

which performs the function

of

both.

ORDERING

PARTS

Whenever

replacement/service

parts

are

needed,

always

provide

the

generator

model

number,

engine

serial

number,

and

generator

serial

number

as

they

appear

on

the

silver

and

black narae plate located on the generator end. You must

provide

us

with

this

infonnation

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

Parts List). Also insist upon

WESTERBEKE packaged parts because will fit or generic

parts are frequently not made

to

the sarae specifications

as

original equipment.

SPARES

AND

ACCESSORIES

Certain spares will be needed

to

support and maintain your WESTERBEKE generator. Your local WESTERBEKE dealer will assist you in preparing an inventory

of

spare parts. See the SPARE PARTS page in this manual. For Engine and Generator Accessories, see the

ACCESSORIES brochure.

INSTALLATION

MANUAL

Publication #43400 provides detailed information for

installing

generators.

Engines & Generators

4

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

FUEL

Use

fuel

that

meets

the

requirements or specification of

Class

2-D

(ASTM),

and

has

a cetane rating of

#4S

or

better.

Care

Of

The

Fuel

Supply

Use

only

clean diesel

fuel!

The clearance of

the

components

in

your

fuel

injection

pump

is

very

critical; invisible dirt

particles

which

might

pass

through

the

filter

can

damage

these

finely

finished

parts.

It

is

important

to

buy

clean

fuel,

and

keep

it

clean. The best

fuel

can

be

rendered

unsatisfactory

by

careless handling or improper storage

facilities.

To

assure

that

the

fuel

going

into

the

tank

for

your

engine's daily

use

is

clean

and

pure,

the

following practice

is

advisable: Purchase a well-known brand of

fuel.

The

use

of additives

to

combat BACTERIAL growth

in

the

fuel

tank

is

recom-

mended

such

as

Bio-Bor

and

an

additive

such

as

Diesel

Kleen

+ Cetane Boost

to

restore lubricity back

into

the

fuel

when

an

Ultra

Low

Sulfur diesel

is

being

used.

Install

and

regularly service a good, visual-type

fuel

filter/water separator between

the

fuel

tank

and

the

engine.

The

Raycor

SOO

MA

or 230

RMAM

are

good examples of

such

filters.

ENGINE

DlL

Use

a heavy duty diesel oil with

an

API

classification

of

CF,

CG-4, CH-4 or CI-4. Change the engine

oil

and filter

after the initial

SO

hours

of

break-in operation. Then follow

the

oil

and filter change intervals

as

specified

in

the

MAINTENANCE

SCHEDULE

in

this manual.

The

use

of

synthetic oil

is

peonited ONLY after the initial

break-in period

of

SO

hours

of

engine operation has been

achieved.

A

CAUTION:

00

not

allow

two

or

more

brands

of

engine

011

to

mix.

Each

brand

contains

Its

own

additives;

additives

of

different

brands

could

react

in

the

mixture

to

produce

properties

harmful

to

your

engine.

SAE Oil Viscosity

Grades

For all temperature ranges:

SAE

lOW-30

or

SAE

ISW-40

ENGINE

COOLANT

WESTERBEKE recommends a mixture of

SO%

antifreeze

and

SO%

distilled

water.

Distilled water

is

free

from

the

chemicals that can corrode internal engine surfaces. The

antifreeze perfoons double

duty.

It

allows

the engine

to

run

at proper temperatures

by

transfemng

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

to

long teon protection.

The

distilled water

and

antifreeze should

be

premixed

before

being poured into

the

cooling circuit.

NOTE:

Look/or

the /lew environmelltallyjriendly long lasting

antifreeze that

is

now available.

PURCHASING

ANTIFREEZE

Rather

than

preparing

the

mixture, WESTERBEKE

recommends buying

the

premixed antifreeze

so

that

so

that

when

adding coolant

the

mixture

will

always

be

correct.

There are

two

common types of antifreeze, Ethylene

Glycol

(green)

and

Propylene Glycol (red/purple), either

can

be

used

but do

not

mix

the

two

and

if changing

from

one

to

another,

flush

the

engine thoroughly.

Premixed antifreeze for

DIESEL Engines:

Specification

#ASTM 053456.

MAINTENANCE

Change

the

engine coolant every

five

years

regardless of

the

number of operating hours

as

the

chemical additives

that

protect

and

lubricate

the

engine have a

limited

life.

COOLANT

RECOVERY

TANK

The

coolant recovery tank allows

for

the

expansion

and

contraction of

the

engines coolant

during

engine operation

without introducing

air

into

the

system. This recovery

tank

is

provided

with

fresh

water cooled

models

and

with

the

fresh

water coolant conversion kit

and

must

be

installed

before

operating

the

engine.

~

WESTERBEKE

Engines & Generators

5

Revised November 2009

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before starting your generator for the fIrst time prolonged layoff, check the following items:

• Make certain the cooling water thru-hull petcock

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

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

bowls

• Check the DC electrical system. Inspect wire connections 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 the load lines.

•

Be

neutral is properly grounded (or ungrounded) as the system

requires, and that generator neutral is properly connected

the

to

open

or age

• Visually examine the unit. Look for loose

parta, disconnected wires, unattached hoses, and check threaded connections. Search for any

INSPECTION

or

after a

is

open.

for

contaminants.

sure no other generator

sure that in power systems with a neutral line that the

load neutral.

neutral can supply the wrong line-to-neutral volt-

on

unbalanced loads.

In

or

utility power

single phase systems an incomplete

is

connected

or

missing

fuet leaks.

to

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 initial running the engine recovery tank.

the cooling system is purged

after the engine has cooled, the coolant Jrom the recovery tank will be drawn into the engine replace the purged

BeJore subsequent operation manifold should be topped off, tank may need to be filled to the

When

that

aI/

switched

and,

in

cold

will

prevent

operation

engine

starting

AC

OFF

of

from

the

loads,

espeCially

until

the

climates,

damage

the

AC

stalling,

oj

the generator, the

generator,

large

engine

machinery

starts

caused

has

to

warm

by

and

it

is

come

up.

will

air

s cooling system will be purged to the coolant

Open the air bleed petcock to ensure that

oj

air.

After

shutdown

and

s cooling system to

air.

oJthe

generator, the engines

and

the coolant recovery

MAX

level.

COOLANT

RECOVERY MAINTAIN

COOlANT

AT

1/2

TANK

LEVEL

FULL

in

OIL

FILTER~

V~~2(1"~::S~lg~OIL

Ii

Lv<,M",uABOVE

OIL

FILTER

__

~I

OIL

'i'

https://manualmachine.com/

FILL

II

& Generators

6

DIGITAL

CONTROL

PANEL

CONTROL

BOX

B

AMP

FUSE

PROTECTS

THE

PANEL

ELECTRONICS

FROM

A

HIGH

AMP

UVt,HLlIAU_-L

'" I

f'",/C~'"

INDICATOR

LIGHTS

---1----1-

20

AMP

DCCClllCUIT--r1l"1'

BREAKER

DESCRIPTION

WESTERBEKE'S' Digital Control Panel provides

the

operator

with

an

LCD

display that continuously monitors

all

the

operations of

the

generator in easy

to

understand

text messages.

NOTE:

Operating temperatures may cause the LCD display

to vary in color. This is nonnal

and

a change in color will

not affect the operation

of

the control panel.

START

SEQUENCE'

With

the

pre-start inspection completed, press

the

START

button

and

the

automatic sequence will begin. The

six

indicator lights

will

illuntinate

green

and

th~

panel will

display

the

following

text:

fW'IWESTERBEKE

I Engines &

Cienerators

Pre Heatil)g ......

7 Seconds

RUN

SEQUENCE

. Waiting

for

operator

Press start

to

engage generator

Cranking ......

As

the

display cycles thru

the

engine

functions,

the

speed

will

come

up

to

1800

rpm's-60Hz (1500rmp's-50Hz)

and

oil

pressure

and

engine coolant

will

rise

to

their

normal

read-

ings.

The functions

will

cycle

in

the

following

sequence:

o

Engine Speed

1800 RPM

.::oJ

2500

.SCROLL

. Coolant Temperature

172F

" !

o

30.

.

SCROLL

NOTE:

During operation the color

of

the LCD display may vary.

Caused by heat, this is

nomwi

and no cause

for

concern

__

"cARROW

_~8GtIULL

LOCK

IL

___

·DO\~NARROW

__

PRIIME

BUTTON

ENERGIZES

THE

FUEL

PUMP

-_

.•

TOne

BUTTON

~.T"DT

BUTTON

Battery Voltage

13.5

vqc

•

30

SCROLL.

Engine Hours

3.8 HOURS.

SCROLL

AC Phase Voltage

A.

119

V .

B.

121

V.

SCROLL

LOCK

Oil Pressure

40 PSI

o 100

SCROLL

AC

Frequency

59.4

SCROLL

AC

Line Voltage

240

V.

,.

LOCK

To

stop

the

continuing sequence, press

the

SCROLL

LOCK

button.

This enables

the

operator

to

monitor a single function

for

any

length of

time.

The

word

LOCK

will

appear

in

the

comer.

Use

the

up

and

down arrows

to

find

and

observe other

functions.

To

resume scrolling, press

the

SCROLL

LOCK

button

again.

Up

and

Down

Arrows

When

the

display

is

in

its

cycling

mode,

the

UP

and

Down

arrows

can be used to adjust

the

dark

and

light

contrast of

the

screen.

FUEL

PRIMING

Use

the

PRIME

button

on

the

digital control

panel

to

purge

air

and

bring

fuel

back into

the

fuel

lines

after perfornting

fuel

filter

maintenance.

LCD

DISPLAY

Periodically

clean

the

control

panel

and

its

LCD

screen

using

a soft

cloth

.

Engines & Generators

7

STOP

SEQUENCE

To

stop

the

generator, press the S1DP

will cycle thru

the

following text messages

DIGITAL

button.

The

d,isplay

and

shutdown.

CONTROL

PANEL

Examples:

Failure

Light

Coolant

Temperature

is

red.

Light

is

orange.

Waiting

Shutting

Down

THE

AND

Engine Shutdown

FAILURE

If

a problem occurs, the generator

FAILURE

LIGHT/SHUTDOWN

light will illuminate red. In addition,

WILL

engage generator

CONTROL

IN A FEW

GO

BLANK

will

indicator lights will change from green where

the trouble has occurred

message what

has

happened.

and

the

CAUTION: When servicing/changing

The DC power most

be turned off using

either the DC breaker or the battery switch.

for

operator

Press start to

PANEL

WILL

MOMENTS

shutdown

to

orange

display

DC

POWER-DOWN

THE

DISPLAY

and

one

of

to

reveal

will

text

components.

the

Reset

Failure

Oil

Pressure

Reset

When

a failure

wiring

diagram,

assist in solving

There are displayed but

can easily isolate

Before restarting breaker ON and cycling

many

they

must be

position

to

the generator

again.

High Engine Temp.

ECU

to ReStart

Light

is

red.

Light

is

orange.

Low

Oil Pressure

ECU

to Restart

occurs,

refer

to

the

troubleshooting

and

general operating text

the

trouble.

combinations

are

all self explanatory

and

correct the problem should

the

generator,

pushed

reset

the

is

restarted,

of

messages

the

to

the

OFF

ECD.

Once the problem

the

LCD

20

and

amp

position,

display

in

this

that

can

the operator

one

DC

circuit

and

back

is

will

chart,

manual

be

occur.

to corrected begin

to

the

CHANGING

(DC

breaker

When

changing

frequency on

positioned:

CONTROL INTERNAL

CAUTION

The electronic components in the Digital Diesels draw a amperage (milli-amps)from the generator's starting battery unit is in a static much ECU This can he time with concerned with seaso"al use. However, used best NMEA-2000 system generator's control

as

and

for a number

10

NOTE:

Keep in

the

DC

(WESTERLINK

very small amount

state. This maybe as

50

mtlli-amps

50

niil~!-ampsfor

as

mitch as 72 amp-hours in a months

no

generator use. It is not necessary to be

this slight amperage draw during normal

disconnect the

mind

power

supply

BOX

COMPONENTS

or

NMEA·2000):

when

for

the system

each display.

if

the generator set is not to be

of

months, such

DC

power

-or

shut

off

boxfor

a WESTERLINK system.

that the Westerbc:ke gener:ator maybe

for

the vessel's

(SO/60Hz)

the

ECU

of

the

as

winter storage, it is

to the generator with a

the .DC breaker

NMEA~2000

FREQUENCY

must

be

off)

the

generators

lor

switch

must

50Hz

60Hz

be

board

ON

OFF

.

OIl

the

network.

#f

I':;;

-

..

=J

...

~~~;

LCD

DISPLAY

NOTE:

DURING OPERATION THE

OF

THE LCD CAUSED AND

BY

NO CAUSE FOR CONCERN.

PANEL

DISPlAY

HEAT.

THIS IS NORMAL

MAY

COWR

VARY.

8

REMOTE

STOP/START

PANEL

DESCRIPTION

A remote stopped connecting harnesses come of these can be combined

NOTE:

WESTERBEKE

panel

is

available that

and

started

from

For additional information, contact your local

dealer.

3·1/4"

(82.!55MIII)

REMOTE

PANEI../PIG

PN052560

allows

any

location

in

three different lengths

for

a maximum

TA

II

~

AND

the generator

on

the

boat.

run

at

75'

EXTENSION

to

be

The

and

two

(22.17M).

HARNESSES

These

two

6"

(152.4MM)

dimensions

are

CONNECTING

15'

(4.75M)

30'

(9.1M)

60'

(18.2M)

the

measurement

EXTENSION

CABLES

of

the

PN PN PN

052959

052789

052960

cut-out

opening.

-'.~~

~

WESTERBEKE

Engines & Generators

B'A

GENERATOR

BREAK-IN

PROCEDURE

DESCRIPTION

Although your engine has experienced a minimum

of

hour assembly procedures were followed and that the engine operated properly, a break-in time is required. The service life operated and serviced during its initial hours

Breaking-in a new engine basically involves seating the

piston

and smoky operation indicate that the cylinder walls are glazed engine during the break-in period.

Your new engine requires approximately 50 hours conditioning operation to break in each moving part in order

to maximize the performance and service life

Perform this conditiOning carefully, keeping in mind the following:

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

AFTER

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

test operations at the factory

of

your engine is dependent upon how the engine is

rings

to

the

cylinder walls. Excessive oil

or

scored, which is caused

START·UP

of

full-load for the first

to

make sure accurate

by

overloading the

of

use.

consumption

of

initial

of

the engine.

10

hours.

one

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

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

current

NOTE:

draw requiredfor starting motors. This starting amperage 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 SPEED (HERTZ)

ENGINE

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

10

hours

of

the generator's operation, the load

all times. An overload is signaled by smoky

Since the generator operates at 1800

to

of

the generator's break-in is governed by the

drawn

from

the

generator.

Be aware

oImotor

be

3 to 5 times normal running amperage. See

starting loads and the high current

ADJUSTMENTS

50 hours) or after this

ADJUSTMENT) under

ADJUSTMENTS

..

A no-load voltage adjustment

produce 50

THE

CHECK

Follow this check list each day before starting your generator.

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

• Record the hourmeter reading in your log (engine hours

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

• Check the oil level (dipstick).

• Check the coolant level in the coolant recovery tank.

• Check your fuel supply.

• Check the starting batteries (weekly).

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

CHECK WITH THE ENGINE RUNNING.

•

LIST

off

in the

relate to the maintenance schedule.) Any deficiency

be

Check for abnormal noise such as knocking, vibrating and

blow-back sounds.

position before starting.

or

problems in the following items must

corrected before start up.

DAILY

ROUTINE

NOTE:

Some unstable running may occur in a cold engine.

This condition should abate

is reached and loads are applied.

A

CAUTION:

periods

of

00

time

without a load

generator.

STOPPING

Remove the the generator to run for 3-5 minutes to stabilize the operating temperature, then momentarily depress the stop button and release. The generator the

DC

safety precaution.

THE

GENERATOR

AC

loads from the generator one at a time.Allow

circuit breaker to prevent unintentional starts

as

normal operating temperature

not

operate

wiII

the

generator

being

placed

automatically shut down.

on

for

the

long

Tum

as

a

off

• Confirm exhaust smoke: When the engine is cold - White

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

Smoke.

-.,.y-

WESTERBEKE

Engines & Generators

9

A

running. use

the

servicing

NOTE:

Many

difficult

MAINTENANCE

WARNING:

Wear

co"ect

any

and

may

Never

the

proper

tools

of

the

of

the following maintenance jobs are simple but others are more

require the expert knowledge

attempt

safety

for

each

engine's

to

perform

equipment

job.

Disconnect

DC

electrical

SCHEDULE

any

service

such

as

the

equipment.

of

a service mechanic.

while

goggles

battery

the

engine

and

gloves,

terminals

is

and

when

SCHEDULEO MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

Visual

Fuel Inlet Starting

(and

Engine

Generator

Heat

FilterlWater Separator

Exhaust

Engine

Separator

Oil

Level

Belts

Inspection

Filter

Fuel

Filter

Batteries

House

BaUeries)

Oil

(and

Exchanger

System

Hoses

of

Engine

filter)

Zinc

Anode

CHECK

EACH

DAY

0 0

0

weekly

0

weekly

HOURS

OF

OPERATION

100

250

keep

the

0

500

engine

engine's

0 0

50

NOTE:

Please

and

oil

will

inhibit

remain

cool.

0 0

0 0 0

0 0 0 0

0

0 0 0

0

0 0 0

0

750

1000 1250

surface

clean.

ability

to

0

0 0 0

0

Dirt

0 0

0

0 0

0

Diesel

No.2

Check

for

if

necessary).

Oil

level

should

dipstick. Check

at

recovery

Add

coolant

Inspect

for

and

adjust

Check

for

and

electrical

Check

for

Initial

change Replace. Every

50

operating

and

make

excessive Initial

engine change

both

Check

that

with

no

chafing.

for

additional

Inspect

zinc

exchanger

Change

the

Initial

check for

leaks.

Check

the

exhaust

buildup

on

necessary.

Hose

should

spongy.

Check

EXPLANATION

rating

water

and

indicate

if

needed.

proper

if

needed.

fuel,

oil

connections.

loose

belt

at

50

sure

connections

corrosion.

oil & filter

every

AC

connections

See

information.

anode,

end

of

filter

and/or

at

50

anti-siphon

elbow

inside

Check

be

hard & tight.

and

OF

MAINTENANCE

of

45

cetane

dirt

in

between

tank;

if

empty,

tension

(3/8'

Check

and

water

tension.

hrs,

then

hours

check

change

250

hours.

GENERATOR

replace

zinc

anode

drain

hrs.,

then

for

carbon

passages;

that

all

connections

tighten

SCHEDULED

or

higher.

fuel

(drain/replace

MAX.

and

check

at

to

112'

depression)

belt

edges

for

leaks.

Inspect

Keep

bolts & nuts

change

every

electrolyte

are

very

tight.

at

50

hrs.,

are

clean

and

MAINTENANCE

if

needed,

clear

debris.

water

every

200

every

250

hrs.

valve

operation.

andlor

corrosion

clean

and

replace

are

Replace

if

all

hose

clamps.

filter

LOW

manifold.

wear.

wiring

tight.

250

levels

Clean

then

secure

the

hrs.

Inspect

Check

as

tight.

soft

or

on

hrs.

off

heat

CAUTION:

A

components, either

the

DC

When

the

DC

power

breaker

servicing/changing

must

be

Dr

the

battery

turned

switch.

DC

off

using

Engines & Generators

10

Revised November 2009

MAINTENANCE

NOTE:

Use the engine hour meter gauge to log

engine hours

by

rurming time.

SCHEDULE

your

engine hours

or

record

your

SCHEDULED MAINTENANCE

Raw

Water

Pump

At

8{}{)

operating hours,

disassemble and inspect

for overhaul.

Coolant

Electric

System

Fuellifl

Pump

'Fuellnjeclors

'Starler

'Preheat

'Engine

Molor

Circuit

Cylinder

Compression

'Adjust

the

Valve

Clearances

'Heat

Exchanger

'Water

tnjected

Exhaust

Elbow

CHECK

EACH

DAY

50

0

HOURS

100

OF

250

0

OPERATION

500

750

0

0 0

0 0 0

0

1000 1250

0

EXPLANATION

Remove and

when Drain,

the

gasket,

cam

seals

reassembling.

flush,

(the

appropriate Periodically

inspect

the

Check

and

adjust

spray

condition

Check

solenoid

and

lubricate.

pinion

drive.

Check

operation

clean

glow

Reinstall Check

(see Adjust

(see

Remove,

with

compression

Engine

Valve

ENGINE

have

tested.

Check

casting

operation.

Replace

OF

SCHEDULED

MAINTENANCE

pump

cover

and

cover

for

wear.

shaft

should

not

and

refill

cooling

antifreeze

check

fuel

plugs;

mix.

the

wiring

line

connections.

injection

(see

ENGINE

and

motor

Clean

and

of

preheat

check

anti-seize

pressure

connections

opening

ADJUSTMENTS).

for

lubricate

solenoid.

resistance

compound

and

Adjustments).

Clearances

ADJUSTMENTS).

professionally

integrity

a3

cleaned

every

500

needed.

inspect

impeller,

Check

wobble).

system

with

pressure

corrosion.

the

starter

Remove

(4-6

on

threads.

timing

and

hours

the

bearings

Lubricate

the

and

Remove

motor

and

ohms).

pressure

of

'WESTERBEKE

CAUTION

generator's starting battery when

This can be

normal seasonal use. However,

to the generator with a NMEA-2000 system

NOTE:

Keep

A

components. either

recommends

(WESTERLINK

as

much as

ill

mind that the Westerbeke generator maybe the

CAUTION:

the

DC

the

DC

breaker

this

service

or

NMEA-20DD):

72

amp-hours

When

serviCing/changing

power

or

The electronic componems

the unit is in a static state. This maybe as much as

in

if

the generator set is not to be used

must

the

battery

be

performed

a months time with no generator use. It is no/necessary

o(shl#

off

by

an

authorized

ill

the

for

DC

breaker on the generators control box

DC

power slIpplyfor the vessels NMEA-2000 network.

mechanic.

the Digital Diesels draw a very small amount

a number

of

50

milli-ampsfor the system

months,

.Hlcll

DC

be

turned

off

using

switch.

Engines & Generators

of

amperage (milli-amps)from the

ECU

and

50

fa

be concerned with this slight amperage draw during

as willter storage, it is best to disconnect the

for

a WESTERLlNK system.

milli-amps

for

each display.

DC

power

11

FUEL

SYSTEM

DIESEL

Use No.2 diesel fuel with a Celane rating

conjunction with Ultra Low Sulphur Diesel. such as

help restore fuel lubrication (product #3025).

FUEL

A primary installed between the water

be carried

A typical fuel filter/water separator diagram. This is the Raycor Model 500 that if a water separator type filter is

fuel supply tank

in tion equipment. The owner/operator certain the free

and

FUEL

The fuel injection pump is the most important component the diesel engine, requiring the utmost caution in handling. The fuel injection pump has been thoroughly bench-tested

and

it authorized fuel injection pump service facility. attempt shims with the injection pump, leave on engine.

FUEL

"Diesel Kleen" produced by Power Services

WATER

apd other contaminants

the

fuel

of

impurities. This process is accomplished

maintaining a proper

INJECTlDN

the

owner-operator

If

it requires servicing, remove it and take it

to disassemble and repair it.

SEPARATDR

fuel

filter of the water separating

fuel

tank

and

the engine

from

the

to

the

fuel

system

and

engine-mounted

will affect the fuel

reaching the engine's injection equipment is

TYPICAL

FILTERJWATER

SEPARATOR

on

the engine.

is

illustrated

not

fuel

pump, engine

is

responsible for making

filtration/separation

FUEL

PUMP

is

cautioned

not

Do

of

45

or

higher.

Use

an

additive

PS

type

must

be

to

remove

fuel

before

they

can

in

this

MA.

Keep

in

mind

installed between the

system,

10

element

to

attempt

not send the timing

filter,

by

system.

micron

to Do

any

water

and

injec-

installing

filter

recommended.

to

service

an

not

to

In

FUEL ASSEMBLY

of

ENGINE

Periodically check

leakage. Change

the

Changing

1. Shut off the fuel

2.

3. Wipe

4.

5.

6.

FUEL

FILTER

the

filter

MAINTENANCE

the

NDTE:

Slide a plastic bag up over the fuel filter cartridge

as it will be full

Unscrew the cartridge cartridge

with clean

To with diesel before installing. This reduce engines

Install Open the fuel

help

and

both

reduce

the

fuel

the

SCHEDULE.

Filter

supply.

of

its

gasket.

the housing and the

fuel.

fuel

priming time needed

system before starting.

new cartridge

supply.

FILTER

fuel

connections

element after the

Cartridge

fuel.

from

its housing

top

system priming,

and

spin

Run

the engine

LIGHTLY WITH WHEN THENEWFUEL

and

the

first

and

of the

fill

will

dramatically

to

purge air

on

real tight

to

WIPE

CLEAN

FUEL

INSTALLING

CARTRIDGE

filter

bowl for

50

houTS.

See

remove

new

the

fuel

from

inspect for leaks.

the

cartridge

filter

the

by

hand.

BLEED

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

fuel return system.

. Q

SCREW

to

be delivered

SPEED

to

the fuel tank through the

ADJUSTMENT

FACTORY

SET

in

the

FUEL

INJECTIDN

PUMP

EngInes & Generators

12

FUEL

FILTER

CARTRIDGE

INCOMING

FUEL

LIFT

PUMP

Periodically check the pump and fittings are tight and secure. The one secured

operations

INLET

To in-line filter should

make

of

the

pumps mounting bolts should be clean

by

the

mounting bolts

.

FUEL

FILTER

ensure clean

fuel

filter connected

be

fuel

connections

sure that

fuel

replaced every 250 hours of operation.

no

leakage

into the fuel lift pump, there

to

the

FUEL

to

and out of the

is

present

DC

ground connection at

to

ensure proper pump

fuel

lift pump

and

is

elbow.

that the

well

a small

This

COOLING

DESCRIPTION

Westerbeke marine diesel engines are designed and equipped

by

of a heat

coolant,

carries

com-

Raw

this

the

of

for fresh water cooling. Heat produced in the engine

and

bustion which circulates throughout the engine. This circulating fresh water coolanteools the engine block

parts,

from

the

exchanger,

water flows through the tubes

fresh

ferred

walls

tube

exhaust system where finally it is discharged overboard. In

other

coolant

transferred heat overboard through the exhaust system. The

fresh

each other. Using only fresh water coolant within the engine allows harmful deposits.

RAW

A major boatyardlbuilder installed intake strainer.

friction

and

the engine oil. The heat is transferred externally

fresh

similar

water

coolant flows around the tubes; engine heat trans-

to

the fresh water coolant

to

words,

is

cooled

water

coolant

the

cooling water passages to stay clean and free from

WATER

part

is

transferred to fresh water coolant

..

its internal moving

water

coolant

in

function

the raw water which

the

engine

by

raw

and

INTAKE

of

the raw water cooling system is a proper

to

raw

water

to

an

automotive

of

the heat exchanger while

is

conducted through the

is

then pumped into the

is

cooled

by

fresh

water,

and

the

raw

water

circuits

STRAINER

by

water

raw

are

means

radiator.

water

independent

SYSTEM

WASHER-:!~~Sl1

FILTER

TYPICAL

INCOMING

RAW

WATER

SEACOCK

--=CCCO::;>-

RAW

WATER

(Owner

".-

".;

INTAKE

Installed)

.

STRAINER

INSPECT CLEAN

EVERY

100

HOURS

AND

NOTE:

Always

the

strainer

A clean engine's cooling system. Include a visual inspection strainer

in the

glass

Perform operation:

1.

Close

Remove

2.

3. Clean the glass. Replace

4.

S.

Reassemble and install the strainer. Open

6.

7. Run

NOTE:

Also

aground.

If

the

engine normal reading, the cause may be that silt, leaves or grass may have been caught up in the strainer, slowing the flow of raw water through the cooling system.

install the strainer at

will always be self-priming.

raw

water intake strainer is a vital component

when

making your periodic engine check. The water

should

be

clear.

the

following maintenance after every 100 hours

the

raw

water

seacock.

and clean the strainer filter.

the washer

the

seacock.

the

engine and check for leaks.

follow the above procedure after having run hard

temperature gauge ever shows a higher than

if

necessary.

or

below the waterline so

of

this

the

of

DRAINING

When freezing temperatures are expected, it is best to

protect

from damage.

This procedure water intake hose from the vessels thru-hull fitting. Close intake end into a large container

Before starting the engine, remove the engine thermostat (replace the gasket and cover). This will ensure a full flow of

water thru the engine. Re-install

flushing Run the unit for

" cooling system.

Provide an external fresh water supply for the bucket to maintain the water level in the bucket while the unit is being operated during the flushing process.

The fresh water will flush out the engines water passages and

, exhaust lines.

probability

then prior to shutting the unit down substitute the fresh water

supply with a concentrated antifreeze mixture and run this

through the engine

for both the engine and exhaust system.

When

seacocks are open so the engine will quickly receive fresh

water.

water

THE

RAW

WATER

the

raw

water

cooling

is

best accomplished by disconnecting the

valve before disconnecting

is complete.

IO

minutes or longer to adequately flush the

If

the engine is being stored and there is a

of

freezing, flush the engine with fresh water and

to

provide freeze and corrosion protection

recommissioning,

if

the

engine

is

stowed

can

stay

in

the

engine.

circuit

of

fresh water.

make

certain

where

SYSTEM

and

engine

the

hose. Insert the hose

the

thermostat

the

valves

it

is

wann,

exhaust

once

and

the

fresh

the

-..:

WESTERBEKE

Engines & Generators

13

COOLING

SYSTEM

KEEP

mESE

A

FULL

FLOW

mE

COOLANT

CLEANER

WORKS

FRESH

NOTE:

ommended

fresh

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

When vented by the closed thermostat (although some coolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the thermostat gradually opens, allowing full flow coolant to flow unrestricted to the external portion

~olin~

RECOVERY

PASSAGES

OF

RECOVERY

WATER

Refer

water

via

the suction side

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

s¥stem.

TOCOOuwr

TANK

CLEAR

COOLANT

TO

TANK

WELL)

COOLING

to

the ENGINE

antifreeze and water mixture to be used as the

coolant

TO

ENSURE

ANO

mOM

( A

PIPE

CIRCUIT

COOLANT

of

the circulating pump.

KEEP

COOLANT

CLEAR

section

THE

PASSAGE

for

of

the rec-

the engine's

of

the

CHANGING

The

engine's coolant must be changed according to the

MAINTENANCE SCHEDULE.

become contaminated,

A

crItIcal; a 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 the refill process.

NOTE:

to

help.

COOLANT

If

the coolant is allowed to

it

can lead to overheating problems

CAUTION:

back

The drain on the heat exchonger should also be used

drain engine

ENGINE

COOLANT

(19mm

Proper

substantial

to

cooling

coolant.

BLOCK

DRAIN

HEX)

cooling

number

system

of

engIne

corroSion.

maintenance

failures

OIL

~~

--fl

Is

can

be

GALLERY

FROM

coouwr

RECOVERY

NOTE:

pressure cap. Ensure the upper good the closes tightly. CarlY a spare cap. coolant coolant able to expand

to

and

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 above the engine manifold level and should be easily accessible.

TANK

COOLANT

PeriodicaUy check the condition

condition. Check to ensure

vacuum valve opens

Check also to ensure the

passage is clear within

the,

and

from

the coolont recovClytank

Recovery

of

coolant and without introducing air into the cool-

and

so

system is

cOn1ract

Tank

RETRACTION

of

the manifold

and

lower rubber seals are in

SEAL

Refilling

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

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

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

A.fter Checking for leaks, stop the engine and allow it to cool.

Coolant.should draw back into the cooling system as

engine cools down. Add coolant to the recovery tank needed. Clean up any spilled coolant.

the

is

free

Coolant

of

air bubbles, close the petcock and

LOW

and

When

the petcock on the thenno-

of

air bubbles, close that petcock.

MAX

Open

and replace

the

if

NOTE:

This tank, with its short I'U1I

located

at

or

above the level

of

the engine s manifold.

plastic /wse, is best

Engines & Generators

14

A

WARNING:

Wear

protectIve

Beware

gloves.

of

the

hot

engine

coolant.

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.

is

When the engine

vents coolant from flowing (some coolant through a hole in the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the thermostat gradually opens. The thermostat is accessible and can be checked, cleaned, or replaced easily. Carry a spare thermostat and gasket.

FROM

COOLANT

RECOVERY

first started, the closed thermostat pre-

is

by-passed

LOOSEN

THIS

HOSE

_

~e-assemble

~.

-1

of

the

CLAMP

REPLACING

1.

Drain

and drain the coolant to the approximate level off the

thermostat housing. This can be done using the heat

exchanger drain plug.

2. Rotate the thermostat assembly: Loosen the hose clamp as shown and remove the three allen screws that hold down the thermostat housing cover, the assembly can now

be

twisted enough

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

THE

THERMOSTAT

ofT

some coolant: Release the coolant pressure cap

to

access the gasket and thermostat.

and

thermostat: When

of

sealant on

of

the gasket before pressing it into place.

HEAT EXCHANGER

COOLANT

~t:

ORAIN

PLUG

Tum the cover back into place and

( tighten the three screws. Do not over-tighten! Tighten the

hose clamp and tighten the drains. Top off the coolant and run the engine. Check for normal temperature and for any

~

leaks around the thermostat assembly.

THERMOSTAT

ASSEMBLY

GASKET

SEAL

WITH

HI-

TACK

THEllMOSTATHOUSING

A

down is

the

temperatures

rr-(,-----

CAUTION:

before

surface

AIR

BLEEO

PETCOCK

THERMOSTAT HOUSING

The

aUempting

of

can

COVER

the

be

engine

these

engine

at 190'

//Just

be

aI/owed

procedures.

hot but

coolant

F.

to

Not

cool

only

En.gifles & Gen.erators

15

COOLING

SYSTEM

RAW

WATER

COOLING

CIRCUIT

The

raw

water

flow is created by a positive displacement

impeller

pump. This

pump

draws

water

directly from the

ocean,

lake,

or

river through a

hose

to the water strainer.

The

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

of

exhaust

gas

and

raw water is pushed overboard.

Raw

Water

Pump

HEAT

EXCHANGER

BAD

The

raw

water

pump

is a self-priming, rotary

pump

with a

CLEAN

non-ferrous housing

and

a neoprene impeller.

The

impeller

DEBRIS.

BOTH

ENDS

has

flexible

vanes

which wipe against a curved

cam

plate

CLEAN AND REUSE

within

the

impeller housing, producing

the

pumping action.

On

no

account

should this

pump

be run

dryas

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 water flow

.is

J?resent

at

s~-up.

NOTE:

Should

afailure

occur with the

pumps

internal parts

(seals

and

bearings), it

may

be

more cost efficient to

purchase a

new

pump

and rebuild the original

pump

as

a spare.

InspictlnglChanging

the

Raw

Water

Pump

Impeller

Close

the

raw

water

intake valve.

Remove

the

pump

cover

and,

with

the

proper

size impeller tool, carefully pry the

impeller

out

of

the

pump

(the impeller

can

be

pried

out

using

a

pair

of

screwdrivers

if

an impeller puller is unavailable. Take

care

not

to

tear

the impeller). Install

the

new

impeller and

.gasket.

Move

the blades to confOnD to

the

curved

cam

plate

and

push

the

impeller into the

pumps

housing.

When

assembling, apply a thin coating

of

lubricant to the impeller

and

gasket.

Open

the

raw

water

intake

valve.

Run

the

engine

and

check

for

leaks

around

the pump. Also

check

for

water

discharge

at

the

stem

tube. Absence

of

W-ilter

flow indicates the

pump

has

not

primed

itself properly.

NOTE:

Never

allow the

pump

to run dry. Even a short

period

of

dry

running

may

destroy the impeller.

RAW

WATER

PUMP

PN

52650

INSPECTION:

CHECK

THE

BASE

OF

EACH

BLADE

BY

BENDING

VIGOROUSLY.

REPLACE

THE

IMPELLER

IF

THERE

ARE

ANY

CRACKS.

Heat

Exchanger

ZINC

ANODES

The

heat exchanger

is a copper

tube which

encloses

a num-

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

of

the zinc apode 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

the system.

The

con-

dition

of

the zinc anode should

be

checked monthly

and

the

anode cleaned

or

replaced as required.

Spare

anodes should

be carried

on

board.

NOTE:

Electrolysis action is the result

of

each particular

installation and

vessel location;

not

that

of

the generator.

If

the

zinc

pencil needs replacement, hold

the

hex boss into

which the zinc pencil is threaded with a

wrench

while loos-

ening

the

anode with another wrench. This prevents the hex

boss from possibly tearing

off

the exchanger shell.

After

removing

the zinc, note the condition

of

it.

If

the zinc is in

poor

condition, there are probably a lot

of

zinc

flakes within

the exchanger. Remove the

end

of

the heat exchanger

and

clean

the

inside

of

all zinc debris.

Always

have

a spare heat

exchanger

end gasket in case the present

one

becomes

dam-

aged

when

removing the end cover. Replace the gasket (refer

to

your

engine model's heat exchanger end

gasket

part num-

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

Heat

Exchanger

Service

After approximately

1000

hours

of

operation, remove, clean

and pressure test the engine's heat exchanger.

(A

local auto-

motive radiator shop should

be

able to clean

and

test the heat

exchanger.)

.

NOTE:

Operating in silty and/or tropical waters

may

require

RAI""VAT.ii'<

that a

heat

exchanger cleaning

be

performed more often than

every

1000

hours.

Engines·& Generators

16

ENGINE

LUBRICATING

OIL

ENGINE

OIL

CHANGE

1.

Draining the oil sump. Discharge the used oil through

the sump drain hose (attached to the front

of

the engine)

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

hose

capped

end

is

114

NFT.

g:@

SIDE

OIL

FILTER

A

SlOE

OIL

FILL

IS

LOCATED

THE

OIL

APPLY

CLEAN

ENGINE

OIL

INSTALLING

Bl!:""l~-8mlm

[11/161

SOCKET

FOR

EXTENSION

114"

NPT

WtPE

SURFACE

CLEAN

BEFORE

INSTALLING.

\\\I<tMUV'

USING

AN

8MM

(11176')

SOCKET

TO

DRAtN

THE

OtL

OR

PUMP

THE

WARMED

OtL

UP

THRU

THE

HOSE.

Always observe the used oil as

it

is

removed. A

yellow/gray emulsion indicates

the

presence

of

water

in

the

oil. Although this condition

is

rare, it does require

prompt

attention

to

prevent

serious

damage.

Call

a

qualified mechanic

should

water

be

present

in

the

oiL

Raw

water

present

in

the

oil

can

be

the

result

of a fault

in

the

exhaust

system attached

to

the engine andIor a

siphoning

of

raw

water

through

the

raw

water

cooling

circuit

into

the exhaust, filling the engine. This problem is

often caused

by

the

absence

of

an

anti-siphon

valve,

its

poor lOcation

or

lack

of

maintenance.

2.

Replacing

the oilfilter. When removing the used oil

filter, you may find it helpful and cleaner

to

punch a hole

in

the

upper and lower portion

of

the old filter to drain the

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.

NOTE:

Do

not

punch

this

hole

withoutfirst

loosening

the

filter

to

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.

If this rubber

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

of

oil

and

apply

a thin coat

of

clean engine oil

to

the rubber gasket

on

the

new oil filter. Screw the filter onto the threaded oil

filter nipple on the oil filter bracket, and tighten the filter

firmly

by hand.

NOTE:

The

engine

oil

is

cooled

by

engine

coolant

flowing

through

passages

in

the

oil

filter

bracket

hOl/sing

assembly

NOTE:

Generic filters are not recommended, as the

material standards

or

diameters

of

important items on

generic parts might be entirely different from genuine

parts. Immediately after an oil filter change and oil

fill,

run

the engine to make sure the oil pressure

is

nonnal

and that there are no oil leaks around the new oil filter.

3.

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

cap on the top

of

the engine. After refilling, run the engine for a few moments while checking the oil pressure. Make sure there is no leakage around the new oil filter

or

from the oil drain system, and stop the engme.

Then check the quantity

of

oil with the lube oil dipstick. Fill to, but not over the high mark on the dipstick, should the engine require additional oil.

A

WARNING:

Used

engine

oil

contains

harmful

contaminants.

Avoid

prolonged

skin

contact.

Clean

skin

and

nails

thoroughly

using

soap

and

water.

Launder

or

discard

clothing

or

rags

containing

used

oil.

Discard

used

oil

properly.

~

WESTERBEKE

Engines & Generators

17

INSTALLATION

Irhls

popular accessory

iN

from

the

engine to a more

engine

room

bulkhead.

tlOTE:

Refer

to

ENGINE

Instructions

trb

install,

on

removing

'simply WEsTERBEKE's remote lnstall

this

kit

with

your

Contact

WES'IERBEKE

is

remove

the

oil

used to

convenient

OIL

CHANGE

the

oil

the

engine

oil

filter kit

filter

REMOTE

relocate

filter.

facing

dealer

oil

as down

for

the

location

in

this

.

filter

and

shown.

as

more

engine's

information.

OIL

oil

such

as

.

manualfor

thread

on

Always

illustrated.

FILTER

(OPTIONAL)

NOTE:

filan

incorrect

A

rectly.

pass

from failure.

Immediately

Westerbeke

installation

CAUTION:

If valve reaching

If

the

in

there

oil

the

and

is

not

of

It

is

flows

filter

engine

is

no

check

responsible

the

Remote

vital

in

the

assembly

oil

pressure

the

for

engine

failure

Oil

Filter.

to

install

the

oil

lines

cor·

reverse

causing

~!!!A~?:.ctiOJ1S.

direction,

will

prevent

an

intemal

readIng,

the

oil

engine

shutdown

due

by·

to

THE

our

CONNECTION

MUST

ATTACH

OIL

FILTER.

TO

AT

CONNECTION REMOTE

APPLY A THIN INSTALLING TIGHTEN CONTACTS

unor""'~

THE

IN

THE

COAT

THIS

AN

ADDITIONAL

THE

BASE.

ll'JIJ1j

OF

CLEAN

KIT.

THREAD

>:;:::..

I,

3/4

....

OIL

TO

THE

TORN

___

THE

O·RING

KIT

ON.

AFTER

THE MUST

C"O,iN;;Nn,,,EC,,TIDN

WHEN

THEN

HAND

THE

O-RING

IN

CONNECTION

ATTACH

AT

OIL

FILTER.

TO

FASTEN

HOSE

THE

SECURELY

(SCREWS

ARE

our

TO A BULlrn""o

OWNER

.urrlltu,

..

.,

....

APPLY A THIN GASKET cqNTACTS

COAT

WHEN

THE

OF

CLEAN

iNSTALLING.

BASE,

AFTER

TIGHTEN

OIL

TO

THE

IT

AN

ADDITIONAL'

FILTER

Engines & Generators

18

STARTER

MOTOR

DESCRIPTION

The

starting

system

includes

and

starter

button.

When

the

starter

button

on

current

flows

and

energizes energized into to

serves flywheel.

To pinion

is

engine motor

Once ping contact flow magnetic plunger from

TERMINALS·--~

the

reach

to

prevent

gear

splined

may

itself

the

with

of

electricity

is

its

engllgement

coil

becomes

coil,

and

the

starter

push

that

.

damage

incorporates

to

the

starter annature

speed

started

button

activation

the

battery-to-start

fields

and

released,

an

closes a set

motor. starter

to

tile

an

the

rotation

is

of

the

is

interrupted

the

starter

its

movement

with

the

battery,

the

inslJument

the

starter's

electromagnet,

of

contacts

At

the

same

pinion

to

mesh

starter

motor

over-running

shaft.

of

the

released,

solenoid.

the

cables

to

ceases

also

engine

the

The

the

starter

panel

solenoid

which

time,

with

when

(one-way)

The

rotation

pinion

but

current

plunger

by a coil

starter.

its

rotation.

pulls

the

flywheel.

SOLENOID

the

!he

the

flow

This

starter

motor,

is

depressed, coil. pulls

allow

plunger

teeth

engine

clutch

of

not

the

ceases,

is

pulled

spring,

weakens

As

the

solenoid,

The

the

plunger

high

current

also

on

tile

starts,

which

the

running

starter

stop-

out

and

the

solenoid

drive

gear

of

the

SOLENOID

IGNITION TERMINAL

To

test

the

ignition

circuit,

of

the

small

temlinal Use a screwdriver, ignition

terrninal

the

solenoid.

If

the starter cranks, the fault

If

the solenoid

motor

is

probably

don't

to

the

clicks

faulty.

studs

positive

but nothing

~"'---(M)

\ I n

locate

tlle

and

touch

is

wired

the

blade,

battery

lies

else

ignition(s)

connection

with

temlinal

to

tlle

ignition

to

iwnp

the ignition circuit.

happens, the starter

circuit).

from

that

terminal

TERMINAL

(it

is

one

on

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 muitimeter, stud

If

you

more

on

read

the

on

the

wiring,

than

and

Repair

start

12

the

10

temlinals

solenoid

volts,

particular

engine

try

seconds

or

replace

test

the starter

attention

block.

cranking

at a time,

looking

any

the

voltage

and

the

ships

batteries

colmections

the

starter

then

for

wann

trouble

between

engine

is

faulty.

to

tile

spots

spots.

block

are

(temlinals)

growld

for a few

run

your

tilat

the

positive

(ground).

at

full

wire

seconds,

hand

indicate

temlinal

charge

are

along

SOLENOID

IGNITION TERMINAL

If

nothing at

.

Check

tile

connections.

A

WARNING:

fly

when space gasoline_

all

battery

It

jumping

is

free

c~rt~ifQ+-

happens the

isolation

is

also

possible

There terminals.

of

potentially

solenoid

switch

tilat

will

and

be

Be

explosive

__

H"'--(M)

~

isn't getting current.

inspect

the

wiring

tile

solenoid

arching

certain-the

is

defective.

and

sparks engine

fumes,

(+)

POSITIVE

TERMINAL

will

especially

~

WESTERBEKE

Engines & Generators

19

IGNITION

TERMINAL

Test

again

screwdl1ver screwdriver would

A

starting screwdriver.

~«i~V-""';:::---(M)

by

jumping blade blade

cause a short.

WARNING:

current

the firmly to

touch

There

should

two

large

between

the

solenoid

will be

flowing

~

the

be

____

----)TERMINAl

tenninal

studs.

0,

starter

arching

thru

studs.

Do

as

the

STARTER

(+)

POSITIVE

TERMINAL

Hold

the

not

allow

tlle

casing,

this

the

full

blade

of

the

MOTOR

SERVICE

Westerbeke serviced

If

replacing certified standards.

TO

1.

DiscOlmect

2.

If

starter

3.

Label wires

4,

Remove

5.

Remove will

uses a standard

or

rebuilt

at

the

starter

for

marine

If

in

doubt,

REMOVE

necessary,

FOR

the

negative

remove

motor.

and

disconnect

to

touch,

tape

tlle

starter

the

starter

have

to

be

turned

marine

any

starter

motor,

make

use.

Automotive

contact

your

SERVICE

battery

any

components

the

wiring

over

the mounting from

the

to a different

starter

motor

automotive

certain

the

starters

WESTERBEKE

cable.

to

gain

from

the

terminals).

bolts.

engine.

In

some

angle

which

new

do

not

full

starter.

cases

to

clear

can

be

service

center.

motor

is

meet

USCG

dealer.

access

to

(Do

not

the

starter

obstructions.

the

allow

If

the starter

If

the

If

no

arching occurred. There

NOTE:

the

pre-engaged engages screwdriver motor without provide magnetic field for the

solenoid

starter

Starter

the

power

spins, fails

motors

model, starter to

bypass

engaging

are

bad.

the

solenoid

to

spin, the motor

are

either

the

solenoid

motor

to

theflywheel

the

solenoid

the

flywheel.

to

the

solenoid.

arm

to

move

is

faulty.

is

no

juice reacbing

inertia

also

on

such

Turn

Hopefully

even

probably

type

or

moves

of

the

a starter

the

starter

it

though

faulty.

the

solenoid.

pre-engaged.

an

arm

that

engine.

will

the

Using

will

run

switch create contacts

In

a

the

on

enough

inside

to

Engine's & Generators

20

#52951

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,

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,,,",,~WESTERBEKE

, Eng/ires & Generators

21

ENGINE

TROUBLESHOOTING

The

following

troubleshooting table describes certain

problems

relating

to

engine service,

the

probable

causes

of

the

problems,

and

the recommendations to overcome these

problems.

Problem

Probable

Cause

START

BUTTON

depressed,

no

panel

1.

Battery

Switch

not

on.

indications.

2.

Circuit

breaker

tripped/off.

5.

Loose

battery

connections.

START

BUTTON

depressed,

no

starter

1.

Connection

to

solenoid

faulty.

engagement.

2.

Faulty

solenoid.

3.

Loose

battery

connections.

4.

Low

batte

ry.

5.

Kl

relay.

START

BUTTON

depressed;

panel

1.

Poor

connections

to

fuel

solenoid.

indications

OK;

starter

solenoid

OK

fuel

solenoid

not

functioning.

2.

Defective

fuel

solenoid.

Generator

engine

cranks,

but

does

not

1.

Faulty

fueling

system.

start,

fuel

solenoid

energized.

2.

Preheat

solenoid

faulty.

Battery

runs

down.

1.

High

resistance

leak

to

ground.

2.

Low

resistance

leak.

3.

Poor

battery

connections.

4.

DC

alternator

not

charging,

Battery

not

charging

1.

DC

charge

circuit

faulty.

2.

Alternator

drive.

Generator

engine

stops.

1.

Fuel

lift

pump

failure.

er

is

dirty.

2.

Switches

and/or

wiring

loose

or

disconnected,

3.

Fuel

starvation,

4.

20

Amp

circuit

breaker

tripping.

5,

Exhaust

system

is

restricted.

b.

Water

in-fuel.

7.

Air

intake

obstruction.

Engine

starts,

runs

and

shuts

down

1.

Oil

pressure

switch.

2.

Water

temperature

switch.

Engine

starts,

runs

at

idle

1.

Electronic

governor

system

faulty

Note:

The engine's electrical system is protected by a

20

amp

manual reset circuit breaker located

on

a bracket

at

the rear

of

the engine.

Verificalion/Remedy

1.

Check

switch

and/or

battery

connections.

2.

Reset

breaker;

if

breaker

trips

again,

check

preheat

solenoid

circuit

and

check

circuit

for

shorts

to

ground.

4.

Check

(+)

connection

to

starter

solenoid

and

(-)

connection

to

engine

ground

stud.

Check

battery

cable

connections.

1.

Check

connection.

2.

Check

that

12

volts

are

present

at

the

solenoid

connection.

3.

Check

battery

connections.

4.

Check

battery

charge

state.

5.

Check

Kl

relay.

1.

Check

connections.

2.

Check

that

12

volts

are

present

at

the

(+)

connection

on

the

fuel

run

solenoid.

1.

Check

that

fuel

valves

are

open.

1a.

Switch

to

combine

house

and

start

batteries.

lb.

Replace

battenes.

le.

Check

fuel

lift

pump.

ld.

Change

inlet

fuel

filter.

2.

Check

solenoid.

1.

Check

wiring.

Insert

sensitive

(0 -.25

amp)

meter

in

battery

lines.

Do

not

start

engine.

Remove

connections

and

replace

after

short

is

located.

2.

Check

all

wires

for

temperature

rise

to

locate

the

fault.

3.

Check

cable

connections

at

battery

for

loose

connections,

corrosion.

4.

Check

connections,

check

belt

tension.

test

alternator.

See

DC

ELECTRICAL

SYSTEM/ALTERNATOR.

1.

Perform

D.C.

voltage

check

of

generator

charging

circuit.

See

DC

ELECTRICAL

SYSTEM/ALTERNATOR

in

this

manual.

2.

Check

drive

belt

tension.

Alternator

should

tum

freely.

Check

for

loose

connections.

Check

output

voltmeter.

Ensure

12

volts

are

present

at

the

Exc.

terminal.

1.

Fuel

lift

pump

should

make

a

distinct

ticking

sound.

Replace.

2.

Inspect

wiring

for

short

circuits

and

loose

connections,

Inspect

switches

for

proper

operation,

3.

Check

fuel

supply,

fuel

valves,

Fuel

filters)

fuel

lift

pump

..

4.

Check

for

high

DC

amperage

draw

during

operation.

Ensure

breaker

is

not

overly

sensitive

to

heat

which

would

cause

tripping.

5,

Check

for

blockage

or

collapsed

muftler.

6.

Pump

water

from

fuel

tank(s);

change

filters

and

bleed

fuel

system.

7.

Check

air

intake_

1.

Check

oil

pressure

switch.

2.

Check

water

temperature

switch.

1.

Check

governor

system

components.

I~/WESTERBEKE

(continued)

. I Engines & Generators

22

ENGINE

TROUBLESHOOTING

Exhaust

smoking

LCD

DISPLAYS

No

LCD

Display

Oil

Pressure

Coolant

Temperature

Exhaust

Temperature/External

Battery

Voltage

Generator

LED

Edges

Waiting

Voltage

Frequency

Display

turn

for

pink

ECU

Problem

problems

Fault

Probable

1.

Blue

smoke.

2.

White

smoke.

3.

Black

smoke.

Check

1.

2.

1.

2.

3.

4.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

6.

1.

2.

3.

4.

1.

2.

3.

1.

2.

3.

1.

battery.

20

amp

breaker Oillevellow/oilleak. Lack

of

oil

Ground

connection.

Faulty

control

Check

system

Check

water

Faulty

Temperature

Ground

connection.

Faulty

control

Check

sea

Faulty

exhaust

Ground

connection.

Faulty

control

Sea

water

Fire

suppressor

Check

alternator

Check

charge

Check

battery

Faulty

control

Check

AC Improper Faulty Check Check Amperage Compartment

too

ECU

control

Engine

fuel

high.

or

voltage

display

Cause

off.

pressure.

module.

coolant

pump

module.

water

flow.

temperature

module.

pump.

system.

drive voltage. connections. module.

voltage

output.

sense module. speed.

supply.

load.

ambient

level.

drive

belt.

sensor.

belt.

connections.

temperature

switch.

Incorrect

1.

1a.

Crankcase

through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel

burn insufficient exhaust

3b.

Improperly

3c.

Lack

ventilation.

3d.

Overload.

Battery

1.

2.

Turn

breaker

Check

1.

2.

Test

oil

filter,

Check

3

Inspect

4.

Add

coolant.

1.

2.

Test

oil

3

Check

4.

Check

5.

1.

Inspect

2.

TesVreplace. Check

3

Check

4.

Inspect

5.

Check

6.

1.

Adjust Check

2.

3

Check

4.

Check

1.

Adjust Check

2.

Check

3

Adjust.

1.

2.

Inspect Check

3

Ventilate

1.

Note:

This

will

Check

1.

NEMA

Verllicatlon/Remedy

grade

of

engine

is

overfilled

the

exhaust).

is

running

injector

grade incomplete

air

system;

timed

of

air -check

on.

oil

level,

pressure.

inspect

oil

ground

all

plug

Check

pressure, sensor/replace. ground plug

connections/replace.

thru

hull

ground plug

connections.

impeller/replace. systemlby-pass. tenSion/replace

excitation,

+ and·

plug

connections/replace. voltageltroubleshoot connections. plug

connections/replace.

filters/replace

load

with

compartment.

Heat

will

nat

effect

compatibility

2000

or

with

cold.

or

incorrect

of

fuel.

due

for

proper

check

air

injectors

air

intake

add

oil

and

If

OK,

test

pump.

circuit.

connections/replace.

for

leaks.

replace

circuil.

fitting,

hose

circuit.

if

worn.

replace/repair

cables

from

filters.

amprobe.

often

change

the

operation

of

ECU/display

Westlink.

oil.

engine

oil

injector

timing.

to

high

back

combustion

intake.).

or

valves and

air

repair

leaks.

oil

pressure

belt.

and

strainer.

alternator.

battery

to

generator

Test

fuel

the

color

of

the

lor

(oil

is

pressure

(Check

or

poor

filter.

sendor,

Correct

engine.

for

cause.

pump

of

an

engine.

blowing

out

in

exhaust

for

restrictions

compression.

Check

for

proper

inspect

as

needed.

operation.

ICD

displar

or

in

oil

Engines & Generators

23

'10

ORANGE

TO

STARTER

ALTERNATORS

B

SOLENOID

60

AMP

ALTERNATOR

EXCITER TERMINAL

R

TESTING/TROUBLESHOOTING

VOLTAGE

The device Ibe

voltage

system The

thick-film adjusted encapsulated possible damage

REGULATOR

integral voltage regulator

which

senses

the

applied

voltage.

regulator design utilizes all-silicon semi conductors

assembly techniques. After

to

the

to

Ibe

proper regulating valve,

to

protect

due

to

is

an

electronic switching

system voltage

field

in

Ibe

circuit

handling or vibration.

level

order to maintain a proper

Ibe

voltage

Ibe

and

the

components

and

switches

has

entire circuit

and

been

is

from

#16

VIOLETR

TO

K-3

RELAY

.

'16

RED

ACTUATOR

TO

DESCRIPTION

The following iofonnation applies Ibat

are

supplied

Generators.

ELECTRICAL

The charging system consists of

regulator,

circuit breaker

of

Ibe

ose of integrated circuits (IC's), regulator back

It

voltage regulator) using the loads provide charging system electrical

is

of

the

is desirable to

that

the

ALTERNATOR

The stator rectifier package converts battery charging

Power

alternator

package contained These alternators produce a rated output

output an are of

the

to

the

is

achieved

ambient temperature of 75°P

designed

-40°

to

wilb

WES1ERBEKE'S Engines

CHARGING

an

engine DC wiring hamess, a mounted

and

a battery

very compact alternator.

test

are

a pennanent part of

technician

as

system.

and

Ibe

charging system (alternator and

with

well

as

the

OESCRIPTION

is

connected

AC

regulator

is

provided

to

operate

212°P

to

a three-phase, full-wave bridge

which

contains generated and

in

at

(-40°

in

accessories,

and

Ibe

by

the

alternator.

approximately 6000 alternator

in

an

to

!OO°C).

to

Ibe

CIRCUIT

an

alternator

wilb

connecting

is

mounted

wiring

hamess and electrical

Ibe

system

an

operational test of the major components of

six

diodes.

the

stator

field

of

field

diode (or diode

(23.8°<::).

ambient temperature range

REFER

TO DIAGRAM MANUAL WIRING

standard

Ibe

electronic voltage

internally or

to a DC

the

integral regulator

of

The

THE

IN

FOR

CONNECTIONS

alternato~

and

wilb a voltage

cables.

and

williben

The

bridge

output

trio)

60

amps.

alternators

WIRING

THIS

ALL

DC

Because

on

Ibe

for

Rated

rpm

at

the

ALTERNATOR

Use

this

exists

wilb deterntined that have

a qualified technician check

A

WARNING:

alternator alternator

LOW

BATTERY/FAULTY

If

Ibe

starter only of spinning faulty

connection in

problem.

PRELIMINARY

Before starting

testing

the

1. Make certain your alternator

2.

Check if

it

is

3.

Check that all tenninals, connectors and and

tight. resistance undercharging or damage corroded battery reaching a

4.

Check A

low

readings

NOTE:

An

selector switch is usually mounted

the batteries so the starting battery is not discharged along

with the house batteries.

starting battery but not the house battery, the alternator is

OK

and

the problem is in the battery charging circuit.

TROUBLESHOOTING

troubleshooting section

Ibe

charging circuit or

the

alternator or voltage regulator

A

working

can

become

until

if

has

cooled.

alternator

very

hot.

to

deterntine

with

it.

Do

not

the

runs

CIRCUIT

moans

or

makes

a clicking sound instead

Ibe

engine

to

life

it

is

Ibe

starting circuit

likely a

low

and

INSPECTION

the

actual

alternator

following checks are recommended.

Ibe

drive

belts

for proper tension.

worn

or

glazed.

Loose

or

corroded connections cause

and

this

could cause overcharging,

cables

could prevent the

fully

charged condition.

Ibe

condition of

or discharged battery

in

Ibe

tests.

isolator with a diode, a solenoid,

Ibe

If

the isolator is charging the

is

to

the

battery

may

securely

and

voltage

charging

and

cause false or

in

the circuit to isolate

if

a

alternator.

hot. A failed

touch

the

battery

not

an

regulator,

mounted.

Replace

plugs

system.

battery

charge if

or

a battery

problem

If

it

is

faulty,

or

a

alternator

Ibe

belt

are

clean

high

Badly

from

necessary.

misleading

is

Engines & Generators

24

ALTERNATORS

TESTING

A

certain

away

1.

2. After the engine

THE

ALTERNATOR

CAUTION:

that

from

Start

the Engine.

starting multimeter set on DC volts.

If

the voltage

a.

alternator is working.

b.If

the voltage remains around exists with either the alternator or the charging circuit; continue with

Before

starting

everyone

sheaves

battery voltage at the battery termin'lls using a

is

clear

and

belts

has

run for a few minutes, measure the

is

increasing toward 14 volts, the

Steps 3 through 6.

the

of

moving

during

12

engine

test

make

parts!

procedures.

volts, a problem

TESTING/TROUBLESHOOTING

MEASURING BATTERY

(IGNITION

ENGINE

Keep

VOLTAGE

ON

MEASURING BATTERY

(ENGINE

3.

111m

Ensure that the connections are tight and clean

If

a battery selector switch

4. that it

S.

111m

engine.

6. Check the condition the reading should

VOLTAGE

RUNNING)

otT

the

engine. Inspect all wiring and connections.

battery terminals and the engine ground

is

on the correct setting.

on

the

ignition switch,

battery

voltage.

is

in the charging circuit,ensure

but

do

not

start

the

If

your battery is in good

be

12

to

13

volts.

TESTING

1. Connect the positive probe to the output terminal

2. Wiggle the engine wiring harness while observing the

3.

4. Repeat the same measurement, the negative probe to

The voltage reading should

If

S.

inspect the wiring for breaks and poor connections. Jump 12 volts from a battery) and operate the alternator. is 13-14 volts,

THE

OUTPUT

connect the negative probe to ground.

voltmeter. The meter should indicate the approximate battery voltage, and should not vary.

or

if

obtained,

output

circuit

damaged wiring. Start

the

ground, the positive probe to B with the engine running.

If

volts. it repaired at a reliable service shop.

the previous test reads only battery voltage at terminal B, use the meter to measure the DC excitation terminal.

the reading varies, check the alternator

for

engine.

your alternator is over

If

12 volts is not present at exciter terminal

..

CIRCUIT

If

no reading is

loose

or

dirty connections

be

between 13.5 and 14.5

or

under-charging, have

12

volt source (such as the

If

the voltage output

then the alternator is OK.

Band

or

.TERNIINALR

R,

TESTING CIRCUIT

Engines & Generators

25

THE

OUTPUT

ENGINE

#10

ORANGE

TO

STARTER

RUNNING

B

~UU'NOIU-f~~~1!

#16

VIOLET

TO

R

K·3

RELAY

#16

REO

ACTUATOR

TO

ALTERNATORS

TESTING/TROUBLESHOOTING

TESTING

1.

Connect the positive (+) multimeter probe to the excitation terminal

H lead to ground.

2.

10m

the ignition switch to the on position and note

the multimeter reading. The reading should be

2.5 volts (see illustration).

TESTING

EXCITATION

CIRCUIT

(ENGINE' RUNNING)

THE

3.

If

the

reading is

rotor field circuit probably is shorted or grounded.

4.

If

the

reading is between 6.0 and 7.0 Yolts, the rotor

field circuit probably is open.

S.

If

no

reading is obtained, an open exists in the

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

lead and the negative multimeter probe

If

the multimeter now indicates an approximate battery

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

THE

EXCITATION

R on the alternator and the negative

between.

If

no voltage is indicated, check the

CIRCUIT

OUTPUT

75

and 1.1

TERMINAL

EXCITER TERMINAL

Yolts,

the

to

ground.

1.3

to

of

R.

CHECKING

Check the voltage have a voltage between running. charging circuit. Troubleshoot the service battery charging circuit isolator, battery switch, and the battery itself.

When the problem is back terminal studs. Also clean the connecting terminals from wiring harness.

ALTERNATOR

If

tests indicate a failed alternator, it

sembled and repaired. Any good alternator service shop can

do

the job.

NOTE:

instructions standard altemators.

BATTERY

The minimum recommended capacity the engine's Cranking Amps (CCA).

Review the manufacturer's reconunendations and establish a systematic maintenance schedule for your

engine's starting batteries

• Monitor your voltmeter for proper charging during

engine operation.

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

• Use only distilled water level.

• Make certain that battery cable connections tight

THE

SERVICE

of

the service battery. this battery should

If

not,

there

is

by

checking the wiring and connections,

has

in

operation, take the time

BATTERY

13

and

14

volts when the engine is

a problem in the service battery

the

been solved and before

to

tighten and clean the

the

alternator

REPAIR

will

need

to

be

WESTERBEKE'S Service Manual has detailed

for

the disassembly

and

repair

a/their

CARE

of

the battery used in

12

volt DC control circuit is 800-1000 Cold

then

and

house batteries.

to

the battery posts (and

bring electrolytes

to

your engine).

to

a proper

are

clean

solenoid,

the

disas-

and

TESTING

THE EXCITATION CIRCUIT

ENGINE RUNNING

"

OUTPUT

TERMINAL

EXCITER

TERMINAL

R

REMOVE

FROM

TERMINALR

Engines & Generators

26

GLOW

PLUGS

DESCRIPTION

The

glow

plugs

are

wired

When

PREHEAT

should "click"

through the preheat

is

pressed at the control panel

on

and

the

glow plug should begin

solenoid.

this

to

INSPECTION

To

inspect the tions, then unscrew or unclamp each plug head.

Thoroughly clean each plug's tip and soft brush and cleaning solution oil deposits. While cleaning, examine the tip for wear bum erosion; if

plug,

remove the eleclrical terminal

to

remove all

it

has eroded

too

much, replace

from

threads

the

connec-

the

carbon

the

cylinder with

plug.

TESTING

An accurate

Touch

other to the body plug used ao

multimeter to test

A

to

the

testing

way

to test glow plugs

one prod

will with

WARNING:

touch.

to

of

have a 1.0 -

the

plug

Be

careful

the

plugs.

the glow plug's wire connection,

in

These

is

the

glow plug,

1.5

ohm resistance.

or out of the engine.

the

power drain

glow

not

plugs

to

burn

as

(8

will

with

an

ohmmeter.

shown. A good

Ibis

method

You

can

also

- 9

amps

per

become

your

fingers

very

when

solenoid

get

hot.

a

and

the

glow

can

use

plug).

hot

be

Re-install

plugs should

seconds. circuit. compound

A

than

GLOW

the

If

When

WARNING:

30

seconds.

PLUG

TIGHTENING

plugs

in

the

engine

and

test

them

get

very

hot

(at

the terminal end)

the

plugs don't

reinstalling

on

the

threads.

00

1.0

-

1.5

M-KG

.6'===<===-=:~

heat

up

quickly,

the

glow

plugs, use

not

keep

a

glow

plug

TORQUE

(7

-11

FHB)

TESTING

AN

KEYI'PREI~EAT

WITH

OHMMETER

ON

check

on

again.

within 7 to

for

a short

anti-seize

for

more

TERMINAL

TIP

The

15

END

GLOW

REFER DIAGRAM MANUAL WIRING

PLUGS

TO

FOR

CONNECTIONS

THE

IN

WIRING

THIS

ALL

USING TEST

LIGHT

A

+

Engines & Generators

27

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjust-

ments

be

peiformed

below is provided to assist the mechanic.

by a competent engine mechanic. The information

ADJUSTMENTS

PLUG

. remove all fuel injectors, or glow plugs, disconnect the

"~Shut_Off

'''-.,. the injector hole or glow plug hole. Connect a compression

'Jif:ffI'~~

OIL

PRESSURE

TESTING

To

tesJ

the oil pressure,_l'effiove the oil pressure sender, then

GAUGE

OIL

PRESSURE

install a mechanical oil pressure gauge in it's place. After wanning the

OIL

LOW

The specific safe minimum oil pressure ualloss

up

.the

engine, set the engine speed at idle and read

oil pressure gauge.

PRESSURE

WILL

RANGE

BETWEEN

OIL

PRESSURE

of

oil pressure usually indicates worn bearings. For

50

AND

55PSI

is

5 -

AT

1800

10

psi. A grad-

RPM

additional information on low oil pressure readings, see

ENGINE

TROUBLESHOOTING

charlo

"-.,.

the

ENGINE

Check the compression pressure.

COMPRESSION

To

do

this wann the engine,

fuel

solenoid wire, and install a compression adapter

tester on the adapter and crank the engine with

the

in

starter

motor until the pressure reaches a maximum value. Repeat this process for each cylinder. Look for cylinders with

Idnumltic,ally

(at least 20%) lower compression than

the

,m'enlge of the others. Compression pressure should not differ

by

more than 35.5 psi (2.5 kg/cm') at 280 rpm.

If

a weak cylinder is flanked by healthy cylinder, the problem is either valve or piston related. Check the valve clearances for the weak cylinder, adjust cylinder cylinder comes

is

still

to

seal the rings

up -the

low,

apply a small amount

and

rings are

faulty.

needed and test again.

of

oil into the

repeat the test.

If

the

compression

as

Abnormally high readings on all cylinders indicates heavy carbon accumulations, a condition that might be accompanied by high pressures and noise.

NOTE:

In case

cause

may

INJECTORS. Poor

positive

injector faults.

of

severe vibrations

be

fuel

injector problems, see FUEL

fuel

quality, contaminates

fuel

pressure to the injection

and

detonation noise, the

and

pump

will result in

loss

of

When re-installing the glow plugs use anti-seize compound.

VALVE

ADJUSTMENT

Remoye the glow plugs from the cylinder so the engine can be easily

manu3Uy cover. Rotate valve operatidnfor cylinder #1 and bring the #1 piston Top

Dead

Center referencing the charl should put the valves for cylinder #1 in Adjust the remaining valves following

VALVE

CLEARANCE

When

No.1

piston

is

compressed

Top

Dead

Center

When

No.1

piston

is

overlap position

in

.'::~~~

it:

rotated. Remove the valve train rocker

the

engine crank manually and observe the

of

the compression stroke. Adjust

below.

Rotate

the

crankshaft 360'. This

the

overlap position.

the

ch;ut

(ENGINE

COLD)

1st

2nd 3rd 4th

1st

2nd 3rd 4th

IN

0 0

0

I

--'L

~

i!iIl

I·

0.23 -0.27mm

EX

0

VALVE

(ENGINE

0.23 -0.27mm (0.0091 -0.0106

(0.0091 • 0.0106

EX

IN

0 0 0

0

CLEARANCE

COLD)

in)

IN

0

the

below.

0

up

valves

in)

EX

0

to

COMPRESSION

ADAPTER", "

~

TESTER

",:>;

..

,+~;./:.

~~~INJECTOROR

~

TESTING COMPRESSION

ENGINE

GLOW

PLUG

HOLE

,.yo

WESTERBEKE

Engines & Generators

28

ENGINE

ADJUSTMENTS

DRIVE

For equipped front guard advised that proper inspection, service, and maintenance is required.

The belt tension service life the resulting

The and tension

L

2.

3.

4_

5.

6.

7.

FUEL

NOTE:

be

provided

REMOVING

rIllE: Injector

1.

2

BELT

ADJUSTMENT

your

safety,

WESTERBEKE

with

belt guards that cover over the belt(s) on the

of

the engine. ("Out

is

NOT

installed for that purpose.) Operators are

drive

belt

must

be

properly tensioned. Excessive drive

can

cause rapid wear

of

the fresh water pump's bearing. A slack belt

presence

generator

alternator

Remove Loosen

mounting

.

With

edges.

Pivot

or

right

The

no

(l2mm)

.

midpoint the

A

drive

Operate

the

Replace

of

oil on the belt can cause belt slipping,

in

high

operating temperatures.

have two drive belts,

and the other drives the raw water pump. The

adjustment

the

the belt loose, inspect· for wear, cracks and frayed

the

as

drive

less

than

as

belt.

WARNING:

ben's

the

generator

the

procedure for both belts is as follows:

the

belt guard.

alternator adjusting strap bolt and the base

bolt.

alternator on the base mounting bolt to the left

required, to loosen

belts are properly adjusted

3/8

inch (lOmm) and

the belt is depressed with the thumb at the

between the two pulleys on the longest

Never

tension

while

generator for about 5 minutes, then shut down

and recheck the belts) tension.

belt guard.

generator models

of

sight - out

of

or

attempt

the

engine

the belt and reduce the

one

tighten.

no

to

check

INJECTORS

WESTERBEKE

performed

by a competent

to

assist

THE

must

Disconnect

loosen

the

lines

and

move

them

bending

Using

its lose the fuel return line to each injector.

the

a 17mm long socket, remove the fuel return line in

entirety

the

from

two

the

mechanic.

recommends

engine

that

the

mechanic.

INJECTORS

be

serviced

the high pressure lines from the injectors and

at

their attachment to the injection pump

out

lines.

the

sealing washers and banjo bolt

in a "clean

of

the way

top

of

the injectors. Avoid

of

the injectors. Take care not to

come

of

mind."

The

belt

drives the governor

if

it can

be

deflected

more than

is

in

following

room"

l!2

span

or

adjust

operation.

engine

The

injonnation

e1Wironment.

that

attaches

inch

a

NOTE:

prior any

hole.

by

side

it and

3. The injector seats in the cylinder head on a copper sealing washer. This washer should

or

injector and replaced with a new washer tor is reinstalled.

INJECTION

1. Using the nozzle tester, check the spray pattern and injection starting pressure limit, adjust or replace the nozzle. tester, take the following precautions:

A

of skin entelS

of

Inspecting

1. Operate the hand lever

one stroke

rectly in its axial direction. A nozzle is defective injects fuel in an oblique direction strips. Also, a spray in the form defect. These defects may sometimes be caused by clogging with dust and, therefore, all parts should he carefully

adjustments

below

is

Engines & Genera,tors

cleaned

2. Apply the pressure by operating the hand lever,

nozzle tip.

on the bottom, it is considered defective and should be

replaced. A very small remain on the tip indicate a defect.

CHATTERING

Clean

the

area around

to

lifting

it out

of

the

rust

or debris from falling down

If

the

injector will not lift out easily and

carbon

build

up

or

the

with

the

aid

of

the 17mm deep socket wrench

then

lift it

out.

TESTING

of

CAUTION:

such

velocity

of

fingelS

the

Spray

before

DRIPTEST

TEST

The

spray

that

It

and

hands,

bloodstream,

INJECTION

Pattern

per

second to check

reassembly.

~

NORMAL

,.d

of

1635 lb/in' (115 kg/cm') to nozzle

If

it

drips

or

amount

of

the nozzle; however, this does not

kiI

the

base

of

the injector

cylinder head

like,

work

be

nozzle and,

Injected

may

penetrate

destroying

It

may

cause

PRESSURE

of

the nozzle tester at intervals

if

of

llilOO

and

check the drips from the

has a large accumulation

of

to

help prevent

into

the injector

is

the

injector side

removed with the

when

the injec-

if

it exceeds the

When

using

from

the

nozzle

deeply

Into

tissue.

If

blood

pOisoning.

TEST

INJECTION

140

·150

(1991·2133

the fuel is injected cor-

or

inseveral separate

particles indicates a

],

~

FAUlTY

V,

,if

fuel may sometimes

~

dI

omp

TEST

held

in to

to

free

nozzle

Is

the

It

PRESSURE

Kgl/cm'

PSI)

of

if

it

'"

FAULTY

..

','

~t

of

fuel

@

>.,

,.

29

ENGINE

ADJUSTMENTS

TESTING

Test

values.

If

the

pick

magnetic pick up from the generator housing and visually inspect the contact end.

the

NOTE:

provided with the new magnetic pick

SPEED VOLTAGE

1.5 -

RESISTANCE

THE

MAGNETIC

the

speed

sensor connector

values

are

correct,

up.

With

the

wires disconnected, unscrew

unit.

Carefully follow the installation instructions

SENSOR

2.5

(while

VAC

(at

TEST

VALUES

cranking)

rest)

~~,

PICK

UP

COIL

for

voltage

remove

If

950 -1000

"?'~(:::'

and

inspect

any damage

up

ohm

~

MPU-MAGNETtC

is

detected, replace

coil.

PIC~

and

resistance

the

magnetic

the

K-UP~

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 gear's teeth directly under the opening. Thread the into the opening until it gently contacts the tooth (Thread is 3/8" x 24). Back the MPU out of the opening one tum and then lock it in this position with

jam

the

approximately 0.030 inches away'from the

ring gear teeth. To

ensure the MPU is positioned correctly, slowly rotate the crankshaft by physical contact between the

If

contact is felt between the MPU and the flywheel teeth,

the

MPU may be damaged. Remove the MPU and inspect

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.

as

nut. This will position the end

if

necessary and repeat the above

When replacing the Magnetic Pick-Up (MPU) it

be replaced without cutting and splicing into the

[MPUjINSTALLATION

to position the flat

360'

by hand to assure there is no

of

one

MPU and the ring gear teeth.

of

flat

of

the MPU

flats

the ring

MPU

of

this'

of the

AC

~'

~0.030tn

--

Engines & Generators

30

SPECIFICATIONS

Engine

Type

Aspiration

Compression

Governor

Combustion

Bore & Stroke

Piston

Hp@1800rpm Hp@ Rong

Inclination

Weight

Compression

(allowable

Variation

cylinders

Injection Engine

Valve (engine

Injector

Valve

Ratio

Chamber

Displacement

1500rpm Order

(dry)

Pressure

limtt)

between

Timing

Speed

Clearance

cold)

Pressure

Timing

25.5/23.5KW, 28.5/23.5KW,

ENGINE

TUNE-UP

SPECIFICATIONS

Diesel,

four-cycle,

water-cooled,

fouf-cylinder,

vertical

in-line

mechanism.

Naturally

aspirated

21.8:1

Electronic

Swirl

type

98 x 110

mms

(3.86 x 4.93

3.31

Itters

(202.53

cubic

inches) 55 48 1-3-4-2

Continuous

Temporary

11351bs

20°

30°

(514.8

(not

kgs)

to

exceed

SPECIFICATIONS

626

psi

(44

kgf/cm')

at

472

psi

(30.5

10%

or

less

rBTDC 1800

rpm

1500

rpm

0.23

to

0.27

(0.00091

to

1991

to

2134

Intake

Opens W BTDC

Intake

Closes

Exhaust

Opens

Exhaust

Closes

60

Hertz

50

Hertz

mm

0.0106

36°

kgf/cm')

inches)

psi

(140

ABDC

45°

BBDC

1 r

ATDC

250

at

to

250

150

fresh

overhead

iinches)

10

min.)

rpm

kgf/cm')

valve

33.0.26.0KW

COOLING

General

Operating

Fresh

Raw

System

(fresh Raw

(at

General

Fuel Fuel Fuel

Injector

Fuel Air Air

General

Oil Sump

(includes

Operating

(engine

Oil

Temperature

Water

Capacity

water)

Water

1800

rpm)

Injection Injection

Nozzle

Filter Intake Flow

Combustion

Filter

Capacity

oil

Oil

hot)

Grade

Pump

Flow

Rate

Pump

Timing

LUBRICATION

filter)

Pressure

EDE

SYSTEM

Fresh

water-cooled

thermostatically-controlled 160

-180° F (71 -82°

Centrifugal

Positive

displacement,

gear-driven.

16

qts

(15.1Itters)

11.0

gpm

FUEL

SYSTEM

Open

flow,

(electromagnetic

No.2

diesel

Bosch

type

r

BTDC

(spill)

Bosch

throttle

Spin-on

type

Metal

screenlintake

105

ctm

(3.0

Pressure

fed

Full

flow,

14.0

U.S.

28 -57

psi

API

Specification

SAE

10W-30,

type,

metal

(41.6Ipm)

seH

bleeding,

fuel

(cetane

mini-pump

type

cmm)

SYSTEM

system

paper

element,

qts

(13.2Itters)

(2.0 -4.0

CF,

15W-40

engine

C)

impeller,

rubber

pump)

rating

silencer

with

spin-on

kg/em')

CG-4,

block,

with

heat

belt-doven

impeller,

self

priming

of

45

box

external

Cf-4

exchanger.

or

higher)

relief

type

or

CH-4

valve

ELECTRICAL

Starting

Battery

CapacITy

Battery DC

Charging

Aliemator Starter Starting

Aid

DC

Cran~ng

Current

12-Voli 800-1000 60

Amp

2.5Kw, Glow 400 -600

DC

CCA

rated,

12VDC

plugs,

(includes

(-)

SYSTEM

negative

belt-doven

direct

sheathed

ground

dove

type

glow

plugs)

~

WESTERBEKE

Engines & Generators

31

Air

Requirements

(generator

NOTE:

Generator

Ambient

cooling)

Increase

Compartment

Temperature

GENERATOR

0.8

Power

cooling

air

flow

15%

122° F (50°

COOLING

factor

untt.

for

slower

tuming

C)

maximum

500

CFM

50hz

(15.0

units.

CMM)

AC

GENERATOR

Single

Phase

Vottage

Regu~tion

Frequency Rating

60

12.5

50

9.3KW

Generator

Air

(Single

Generator

Ambient

Regulation

(Vans

Hz

requirements

AC)

(1800

rpm)

KW

(1500

rpm)

Cooling

& 3

phase)

Compartment

Temperature

Recommendations

SPECIFICATIONS

(Single

Brushless, Sealed Lead volts, With

120 230

± 2%

.3

120 1201240

230

400

NOTE:

operation

122'F

NOTE:

to

temperatures

six-

lubricated,

reconnectable

60hz.)

(Series

solid

state

or

1201240

Volts -50

no

load

Hertz (.5%)

volts

cfm

(11.3

Increase

(1500

(50'C)

Forced

maintain

generator

Phase)

pole,

revolving

single-bearing

(Double

Star

voltage

regulator.

votts -60

Hertz

to

full

load.

no

load

to

212.5

amps

212.5/106.3

91.3

amps

cmm)

air

supplY

rpm)

maximum

venlilation

compartment

below

104'F

field.

Delta

for

230

hertz

full

load.

amps

15%

should

(40'C).

design.

for

1201240

volts,

for

50

be

provided

12

50hz)

Heltz

25.5/21.0KW

Three

Phase

Voltage

-3

(60

Voltage' 3 Phase (50

Amperage· 3 phase (60

Amperage (50

Generator Air

(60

Generator Ambient Recommendations

phase

Hertz)

-3

Hertz)

requirements

Hz)

phase

Cooling

at

1800

Compartment

Temperature

EDE

AC

GENERATOR

rpm

(3

Brushless, lubricated,

reconnectable.

Low High DELTA

High DELTA

Low High DElTA

High DELTA

225 -250

NOTE:

operation

122'F

NOTE:

to

temperatures

six'pole, single-bearing

Vottage

Voltage

Vottage

Voltage

cfm

Increase

(1500

(50'C)

Forced

maintain

generator

Solid

WYE WYE

WYE

WYE WYE

WYE

(5.66 . 6.37

air

rpm)

maximum

venlilation

below

Phase)

revolving

field.

design.

state

voltage

240 480 277

400 230

76 38

66.5

37.9

65.9

cmm)

supply

15%

should

compartment

104'F

(40'C).

Sealed

12

Lead

regulator.

Volts Volts Volts

Volts Volts

Amps Amps

Amps

for

50

Hertz

be

provided

AC

GENERATOR

Single

Phase

Vottage

Regulation Frequency Rating

60

50

Generator

Air

(Single

Generator

Ambient

Recommendations

Regulation

(Vans

Hz

requirements

AC)

(1800

rpm)

(1500

rpm)

Cooling

& 3

phase)

Compartment

Temperature

SPECIFICATIONS

(Single

Brushless, Sealed Lead votts, With

120 230

± 2%

.3

120

120/240

230

400

NOTE:

operation

122'F

NOTE:

to

temperatures

six-

lubricated,

reconnectable

60hz.)

solid

state

or

1201240

Volts -50

no

load

Hertz (.5%)

votts

volts

cfm

(11.3

Increase

(1500

(50'C)

Forced

maintain

generator

Phase)

pole,

revol~ng

Single-bearing

(Double

(Series

Star

vottage volts·

60

Hertz

to

full

load.

no

load

to

237.5

237.5/f

102.2

cmm)

air

supPlY

rpm)

maximum

ventilation

compattment

below

104'F

field.

Delta

for

230

regulator.

hertz

full

load.

amps

18.8

amps

15%

lor50

should

(40'C).

design.

for

1201240

volts,

Heltz

be

provided

12

50hz)

28.5/23.5KW

Three

Phase

Voltage

-3

(60

Voltage' 3 Phase (50

Amperage (60

Amperage· 3 phase (50

Generator Air

(60

Generator

Ambient

Recommendations

phase

Hertz)

-3

Hertz)

requirements

Hz)

phase

Cooling

at

1800

Compartment

Temperature

EDE

AC

GENERATOR

rpm

(3

Brushless, lubricated, reconnectable.

Low High DElTA

High DELTA

Low High DELTA

High DElTA

225 -250

NOTE:

operation

122'F

NOTE:

to

temperatures

six'pole, single-bearing

Vottage

Voltage

Vottage

V~tage

Voltage

cfm

Increase

(1500

(50'C)

Forced

maintain

generator

Solid

WYE WYE

WYE

WYE WYE

,WYE

(5.66 -6.37

maximum

ventilation

below

Phase)

revolving

state

air

supplY

rpm)

should

compattment

104'F

field.

design.

vottage

240 480 277

400 230

85.8

42.9

74.3

42.4

73.8

cmm)

15%

lor

be

(40'C).

Sealed

12

Lead

regulalor.

Volts Volts Volts

Volts Volts

Amps Amps Amps

Amps Amps

50

Heltz

provided

~

WESTERBEKE

Engines & Generators

32

AC

GENERATOR

Single

Phase

Voltage

Regulation Frequency Rating

&0

50

Generator

Air

(Single

Generator

Ambient

Regulation

(Volts

11800

rpm)

115011

rpm)

Cooling

AC)

Hz

requirements

& 3

phase)

Compartment

Temperature

Recommendations

SPECIFICATIONS

(Single

Brushless,

Sealed Lead voHs, Wfih

120 230

±2%

.3

120

120/240

230

500

NOTE:

operation

122'F

NOTE:

to

temperatures

six-

lubricated,

reconnectable

60hz.)

(Series

solid

state

or

1201240

Volts -50

no

load

Hertz

(.5%)

volts

voHs

cfm

(14.1

Increase

(1500

(50'C)

Forced

maintain

generator

Phase)

pole,

revolving

single-bearing

(Double

Star

voltage

regulator.

volts -60

Hertz

to

tuilioad.

no

load

to

275

amps

275/137.5

113

amps

cmm)

air

supply

rpm)

maximum

ventilation

compartment

below

104'F

field.

Delta

tor

230

hertz

tuilioad.

amps

15%

should

(40'C).

design.

tor

volts,

for

50

be

provided

12

1201240

50hz)

Hertz

33.0/26.0KW

Three

Phase

Voltage

-3

(60

Voltage

(50

Amperage (60

Amperage (50

Generator

Air

(60

Generator

Ambient

Recommendations

phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

requirements

Hz)

phase

-3

phase

Cooling

at

1800

Compartment

Temperature

EDE

AC

GENERATOR

rpm

(3

Brushless, lubricated, reconnectable.

Low High DELTA

High DELTA

Low High DELTA

High DELTA

225 -250

NOTE:

operation

122'F

NOTE:

to

lemperatures

six-pole, single-bearing

Voltage

ctm

Increase

(1500

(50'C)

Forced

maintain

generator

Solid

WYE

(5.66 -6.37

maximum

ventilation

below

Phase)

revolving

state

air

supply

rpm)

compartment

104'F

freld.

design.

voltage

240 480 277

400 230

99.3

49.6

86.0

46.9

81.6

cmm)

15%

should

(40'C).

Sealed

12

Lead

regulator.

Volts Volts Volts

Volts Volts

Amps Amps Amps

Amps Amps

for

50

Hertz

be

provided

""'"

WESTERBEKE

Engines & Generators

32A

GENERATOR

USE

OF

ELECTRIC

The power required

more than

Some

others. Split-phase under similar circumstances, than other monly machines, or where loads are applied after started; 7

times avoided, whenever possible, ven motors require from 2

to

run.

load connected to

compressor,

motor

In

general,

10

medium

'NOTE:

more

for

made

Because the heavy surge motors be damaged

seconds. off all other electrical loads and, if possible, reduce the load

on

the

Required

Run generator's capacity, and finally loaded indicted should be checked periodically the voltmeter or ampmeter load,

is

required

motors

require

used

on

such

as

much current

by a small generator. Capacitor

The

current

for

to

which no load

the

current

s1ID1ing

MOTOR

SIZE

(HP)

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

1

In the above table the maximum

for

some small motors than fa r larger ones.

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

in

larger

is

required for only

if

it can bring the motor up to speed

If

difficulty

electric

motoT.

Operating

the generator first with no load applied, then at half the

on

the generator's data plate. The output voltage

generating plant and the appliances it supplies. If

check it

with

MOTORS

to

start

an

electric motor

to

keep it running after it

much

more

current

CAC)

motors require more current

easy-starting loads,

small power tools. Because

to

start

as

if

the electric motor is

to

4 times

required

it.

An electric motor connected

example, will

is

required

loads

will

AMPS

RUNNING

(AMPEREi»

sizes.

of

is

experienced

as

to

start

require

connected.

10

start

be

approximately

FOR

3.2

4.6

5.2

7.2

10.2 13

current needed for starting

an

instant, the generator will not

to

types.

such

as

to

run,

their

and

repulsion-induction

much

current

any

motor

more

115-

Volt

Amps

in

starting motors, tum

Speed

to

its

to

ensure proper operation of

is

not installed

a portable meter and amp probe.

to

monitor voltage

is

considerably is

started.

start

them

than

to

start,

They are

washing

the

motor

they

use

varies

current

molOrs as

follows:

AMPS

(7TARTIN~)

AMPERES

6.4

to

9.2

to

10.4

to

14.4

to

20.4

to

26

for Starting is

full

com-

is

require 5

should be

to

be dri-

to

start

with

to

an air

than

connected

FOR

22.4'

32.2'

72.S'

29.2'

40.S'

to

52

The

reason

in a few

capacity

an

AC

a

INFORMATION

to

as

the

as

and

Generator

Frequency

cated

o

When

output frequency

Therefore, drive engine's speed must be changed

uring

Generator

o Maintaining reasonable cleanliness

Connections corroded, salts, build sive heating and reduced life of windings.

o For unusually severe conditions,

petroleum-base coatings, should be sprayed or brushed

over

o

In inspected overheated tenninals

o The drive discs

checked periodically if possible for tightness for

not be allowed

accelerate cracking. The bolts which fasten the drive disc

to

the generator shaft must be hardened steel SAE grade identified by 6 the

o The rear armature bearing

m

noisy or rough-sounding, have it replaced.

o Examine bearing at periodic intervals. No side movement

of motion

wear.

will

WESTERBEKE recommends mounting a carbon monoxide detector Monoxide, even in small amounts, is deadly.

The presence of carbon monoxide indicates

from the engine or exhaust hose, or

entering your boat.

If carbon monoxide

air and correct the problem

Frequency

is

a direct result of engine/generator

by

the following:

the

generator

to

change the generator's frequency, the generator's

of

the

AC

output connections at

Maintenance

of

tenninal boards

and

insulation surfaces may start conducting if

dust,

engine exhaust, carbon, etc.

up.

Clogged ventilation openings may cause exces-

all

surfaces

addition

any

head.

...

intenance

shaft should be detected

to

periodic cleaning, the generator

for

tightness of

on

evidence

to

radial

is

required.

is

detectable, inspect

Repair must be

rub

and

cause

Carbon Monoxide Detector

of

tllat

Adjustment

speed,

is

run

at

1800

RPM,

the

AC

voltage

is

60

Hertz.

.a1ong

with

a reconfig-

the

generator.

is

important.

and

rectifiers

thin

rust-inhibiting

to

reduce

rusting

and

all

connections, evidence of

and

loose or damaged

single bearing generators should be

incipient cracking

become rusty because rust may

marl<s,

one

is

lubricated

However,

when

the

made

quickly or major components

major

damage

in

the vesssel's living quarters. Carbon

g~nerator

fumes

is

or

from

present, ventilate

ilIDllediately!

failure.

at

each

if

the

force

bearing

to

generator.

from

the exhaust elbow/

a nearby vessel are

may

are

allowed

con:osion.

should

wires.

of

screws

Discs

of the 6 comers

and

sealed;

bearing

is

applied.

and

tlle

shaft

an

exhaust

area

becomes

with

as

indi-

become

to

be

and

should

no

If

side

for

leak

clean

8,

of

~

WESTERBEKE

Engines & Generators

33

. (SERIES WYE)

SERIES STAR

TWELVE

L

1

2

3

LEAD

N

WINDING/TERMINAL

AND

(NOMINAL)

(pARALLEL WYE)

PARAllEL STAR

VOLTAGES

L

3

11

BOARD

N

CONNECTIONS

L

SERIES

DElTA

10-'11 2-3

o 0

L1

50 Hz L-L 400 volts

50 Hz L-N 230 volts 60 Hz L-L.480 volts 60 Hz L-N 277 volts

PARALLEL DELTA

L L

L1

5

L2

6-7

o

9

L3

L

6-8

9

11

L3

5

4-8-12

N

L

SINGLE PARALLEL

o

L

10-12

1-3

0

T

L1

50 50 Hz L-N 115 volts

60 60 Hz L-N 138 volts

PHASE

ZIG-ZAG

7

L N

10-12

0'

1 3 5 7

N

1.1

2-4

5-7

(

L2 L3

Hz

L-L 200 volts

Hz

L-L 240 volts

2-4

()

L2

6-8

0

9t

t

N

6-9

~

.:11

L

0

9

8

L

10-11 2

0 0

1~12

L1

50 Hz L-L 230 volts

50 Hz L-N 115 volts 60 Hz L-L 277 volts 60

Hz

(Refer to Note

L\.

THREE

PHASE

ZIG·ZAG

Q

10r3;:'5

L

.9

8-10

0 0 0

~

l1

7 6

ru

I

1

6-7

3

0

5-4

(

L2

L-N

9-8

1.3

138 volts

#

,~2

11

N

~.

2-12

L2

5

Q

I

,

4-6

0

L3

I)

5

4

L

o

_L

3-7-11

rD

N

50 Hz L-L 115 volts 60

Hz

L-L 138 volts

DOUBLE

DELTA

L

7

8-11

4

2-3

6-9

10

L

1

0 0

0

1

10

~2

50 50 60

60

12

5

N

Hz

L-L

230 volts

Hz

L-N

Hz

L-L 240 volts

Hz

L-N

115

120

7 4

L1

volts

50 Hz L-L 230 volts 50 Hz 60

Hz

60 Hz L-N (Refer to Note

Nole

#1

The nominal value.

Note

The rated 0,866,

Single

phase

cun-ent

#2

17l1"ee

pOlver

Engines & Generators

L-N

115 volts

L-L

277 volts

138

volts

#1)

phase

ampemge

must

not

phase

zig-zag connection.

must

be

multiplied

34

load,

exceed

the

by

50 Hz

50 Hz 60 Hz L-L 415 volts 60 Hz L-N 240 volts (Refer to

DOUBLE

DELTA

2-WIRE

7

L 4

8-11

0

(

1

10

N

L-L L-N

2-3

~

5 12

50

Hz

60

Hz

346 volts

Note

L-N L-N

200 volts

#2)

6-9

0

7 )4

L1

230

volts

240

volts

10

L

0

CHANGING

HERTZ

AND

VOLTAGE

A

CAUTION:

As a precaution

against

an

unintentional

start,

shut

off

the

20

Amp

DC

breaker

on

the

control

panel.

1.

Refer

to

the previous page that illustrates the various

AC

voltage output configurations for both

the

60 Hertz

and

50 Hertz applications. Select

the

configuration

for

the

HertziVoltage required.

2.

Reconfigure

the

12

AC

connections

on

the

tenninal board carefully following the illustration. Reference below

the

voltage sensing diagram

and

it;s

connections

to

the

AC

terminal block. There

are

three line connections when needed and a neutral. These connections

MUST correspond

to

and be connected

to

the

line

(L)

connections on the

AC

tenninal board

and

the

neutral connection

as

well

to

it's corresponding

connection. Failure

to

properly connect these voltage

sense connections can result in

an

AC

output voltage

fault shut down either

from

low or high

AC

voltage or

incorrect

AC

voltage displayed on the LCD

display.

NOTE:

When reconfiguring the

AC

output, ensure that the

A

VR

Neutral and line connections are properly connected

to

the

AC

temtinal block.

3.

111ere

are

Ull'ee

line

connections.

When

an

L3

is

not

present on the

AC

tenninal block, insulate and

tie

off

the

L3

connection

from

tl1e

Voltage

Sensing Board.

4.

Inside the control box, locate

the

ECU

and

position

the HertzlFrequency dip switch in the correct position for the HertzlFrequency desired.

S.

Verify

all

connections

are

correct

and

turn off

any

A C

panel breakers;

6.

Start

the

generator and monitor

the

AC

output voltage at

the generator's tenninal board. Line

to

line, line

to

neutral.

Adjust the voltage regulator board

as

needea

to

obtain the

correct voltage.

Check the generator hertzlfrequency with

your hertz

meter.

7.

Turn on the

AC

panel breakers

and

load unit and monitor

the

operation.

WHEN

CHANGING

THE

GE~'ERATOR,S""'~

FREQUENCY

(50(60

HZ)

SWITCH

#1

ON

THE

COIITROL

PANEL

ECU

BOARD

MUST

BE

SWITCHED:

ON

FOR

50

HZ

AIID

OFF

FOR

60

HZ.

DIP

SWITCH

ECU

SWITCHES

AC

OUTPUT

CONFIGURATIONS

VOLTAGE

SENSING

BOARD

CONNECTIONS

"SERIES WYE-

480VfGO

Hz

380V/SO

Hz

0

CJ

AVR

o

~

·PARALLEL

WYE-

208V/60

Hz

190V/50

Hz

116

WHT

0

60

HZ

JUMPER

t

REMovE

FOR

50

HZ)

[ill

0

''7

6'

9

[TIl

0

1+'0

8t1r

0 0

[EJ

-oouBLE

DEl. T A-

[3·WIRE

SPLIT SINGLE PHASEI

IZO·2>lOV/60

Hl

r

IO·220V/50

Hz

2'

3

0

6+7

0

[Ot

I [

0

• -SERrES DELTA2>lOV/60

Hz

220V/50

Hz

z

~

z

n

"

~

w

~

•

m

"

¥"'''O

f

"'1111

II

~

I

"b

',.

[EJ

o

-PARALLEL DELTA[ZOV/50

Hz

[IOV/50

Hz

[ill

0

''7

6'9

[EJ

O·

--1't

I 0 t 8t

[ I

0

~

2t

3tl2

-DOU8LE DELTA-

r2·WIRE

SINGLE PHASE]

240V/60

Hl

220V/50

flz

~

z

~

n

~

"

w

~

m

•

'V"""O

,.

U

:!

H

~

-

II

.

\, \,

i

o "

~I

~

"

•

ffil

[TI]

25.5·33.0

EDE I-PHASE / 3·PHASE

NOTE:

TIe

off

rhe

L3 sensillg

connection wizen

110t

ill lise .

....v-

WESTERBEKE

Engines & Generators

35

ADJUSTABLE OVERLOAD INTERVENTION

AOJUSTABLETHRESHOLD OFUNDERSPEEO PROTECTION

INTERVENTION

/Hert

ELECTRONIC

THRESH

Am

'"

Stab

volt

OLD

N

~~Oo

p~

z~

~i§

1·-;

~1E

------;

PROTECTIO

REGULATION

=

~~

I-

L

f=I:TI 0

DESCRIPTION

The

voltage

performance. circuitry protection to guard against operating conditions that could information details the voltage regulators adjustments connections. qualified technician.

TERMINAl

#1.

#2.

#3.

#3A.

#4.

#5.

#6. #7.

#58. #5C.

POSSIBLE

Exciter connected dark

blue

yellow) Supply:

1.

The

SR712

(in

connected be is

also

generator

the

2.

The generator supply.

of

the

regulator (AVR) ensures optimum

"This

advanced design AVR is equipped with

be

detrimental to the

These

AC

generator.

procedures should

CONNECTIONS

Excitation Exciter

between

Exciter

Supply Sensing Supply Jumper Not

Not Sensing

field

DC

negative.

field

jumper

5 and 3A is less than 160 VAC.

field

DC

voltage to regulator (AC).

voltage.

voltage to regulator (AC).

to SA for used. used.

voltage.

to 3

positive.

60

Hz

if

the regulator

operation.

CONNECTIONS

Field:

should

SUPply coincides with the sensing.

case

connected

regUlator.

SUPply

The

exciter field negative should

to

tenninall

Or

black), while the positive (normally red

be

There

are two possibilities.

supply

of

three-phase generators, terminal 5 is normally

with the star point). Terminals 3 and 4 should

sensing.

does not have auxiliary winding for supplying

and sensing separate.

equipped with auxiliary winding for regulator

Supply

regulator.

of

the electronic regulator (normally

connected to

should

to

each other in such a way that the supply

This connection

is always connected to tenninals 3 and 5

tenninal3.

be

connected to tenninals 3 and 5

in

AC

generator

The

following

be

performed by a

AC

supply

be

In

this case the

necessary when the

"This

is the case

of

and

or

a

SR7-2G

0

1

0

-

5c

fa

_DO

~D

I

0

In

both 270 should

160 VAC, while the same tenninals should

voltage is between

Sensing: and phase only alternator phase.

Operation and low frequency protection correctly regulated.

A

present.

against

FUNCTIONS

Volt: With this potentiometer,

voltage generated

the screw is turned clockwise, the voltage screw is turned counterclockwise

Stab: If

turned clockwise, the stability decreases time decreases but the voltage tends to turned counterclockwise, the response time voltage tends to

In

order

using the following method.

1.

The and (turned fully counterclockwise).

2. Slightly filament lamp oscillates, at this point,

potentiometer slowly counterclockwise

stabilizes.

-

Iy

-

~

-

5

...,

-

-.

1}

4

...-I

3A

4

-

2

-

1

~

-

I

of

these cases, the

VAC.

But

it should

be

bridged for supply with voltage

Sensing should

can

vary from

and

therefore is normally connected

at

60

6 should

be

connected to each other in

WARNING:

Take

all

electrical

OF

This

potentiometer optimizes alternator

be

to

adjust this potentiometer correctly,

generator must

the potentiometer must

tum

clockwise until the light

AVR

5

AMP

,.----i

--l

_J

be

160

and

80

to

350

Hz:

When

Be

aware

necessary

hazards.

THE

REGULATOR

by

the alternator in a very

more

be

FUSE

CONNECT REMOVE

EXCITER

SR712

noted that tenninals 2

be.

FOR

60Hz

FOR

50Hz

FIELD

supply can

270

VAC.

connected to VAC.

The

operating at

that

high

precautionms

between

be

terminals

sensing

60

order

voltages

POTENTIOMETERS

it

is possible

it

decreases.

stable.

working, starting

be

at

to

increases,

and

be

less

increases

from

maximum

generated

tum

until

vary

from 80 to

and

3

80 and

left

open if the

4 and 5

is

single

to

one

Hz,

tenninals

to

keep the

may

to

safe

guard

adjust

the

simple

way.

if

performance.

the

response

stable.

we

advise

zero load

stability

by

the

light

SA

be

If

the

If

and the

the

Engines & Generators

36

ELECTRONIC

Hertz:

recalibrate this protection, you must take the generator to a

clockwise until

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

EXCITER

r---:I.,." I - I

:

I

I - I I

I

L

-----------

WlIh

this potentiometer, which is normally

by

the

pre-calibrated then sealed

to adjust the low frequency protection intervention. To·

nonnal zero load condition, turn the potentiometer

the

limit position is reached, then decrease

by

10

the nominal speed counterclockwise and measure the voltage value until decreased

When the speed decreases value, generator overheating. Even if protection at possible

Amp: intervention level

system has an intervention overload, necessary when starting motors or similar

applications. To

by minimum (counterclockwise) and wait about twenty seconds. During this period condition and while turning the generator voltage value At voltage increases

Fuse: The electronic regulator protects the alternator malfunction. The fuse replaced easily.

by

5 volts.

the

voltage also decreases proportionally, blocking

10%

to

calibrate

With

this

potentiometer, it

modify this protection,

15%

of

the normal load, tum the potentiometer

this point, while the initial overload is being removed,

%.

of the nominal value, ii is obviously

the

threshold at other values.

of

the overload protection. This protection

of

time

to

the

nominal value.

from

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

INTERNAL

12

WIRE

WITH

I

r-~--I---

I I I

A

I I

liB

il

- i

11.1

'I

manufacturer, it

Then tum

by

more than

we~dvise

delay,

you

must overload

the

voltage value decreases. In this

the

at

10%

is

overheating in cases of regulator

the

10%

calibrating

is

possible

which permits a temporary

potentiometer clockwise,

less than the nominal

equipped with a

WIRING

DIAGRAM

RECONNECTABLE

SR7·2G

-------,

ROTOR

T

~+

I.

J!

!l

II

L,-

(6)

-1>I-.J:

DIODE

~

is

potentiometer

of the nominal

to

adjust the

the

generator

to

fuse,

AVR

I

:

I

I.

L---r-----------'

REGULATION

possible

REFER

it

this

has

WIRING

IN

THIS

SR7·2G

TO

AC

SENSE

CONNECTIONS

TO

THE

COMPLETE

DIAGRAM MANUAL,

#52951

AVR

0

AVR

I'

,

rER~IHAl

SHOWN

FOR

l~:

3 : i 4

I

" ,

"

I

·

I

0

1I.llU

OI"

TO

PANEL

FUSE

STATOR

• ,

a

,

i:i3t

:

•

"

N

-

'

I

..

::.:.

.

III

m.1

'"

I ~ 8 U

11&

,

r~

L:.

11

'9

r"'-"'l

- StU

t-

'':'::

I I

I

I~

I

L..",_,,_"

CJ

I

t

fix

one.

the

which

12·

:

10

================t::::::i'========:

6

j---

lOut.

1F--o

'"=-'~

,,~

PO

'--,

'-,----,

'e

:

! i

I I

!

DlOCX

CO~N[CT'OHS

AR[

CONfiGURED

LO-1!Y.(

1201208

Il..OCK

" "

"

0

VAC

.

0

Tl:RMNAl.

!~I

-

EXCITER

m -

---"

'l

I

I i

*

I

ROTOR

lmOo~

",",.

~!:.'-

,.,,".

II]

I!\lWlWiJJjIJI

0

./oI.::::::'...::::J

D

U =

] -

~

]

, <Tno

:;:J

=

~------------~A"..-~---+J

=~====~======~~=---~===f----~

,;

if

i=

1Il---,

YElLOW

on",

AtuE

'"

''¥t7,WESTERBEKE

,

Engines & Generators

37

INTERNAL

WIRING

SCHEMATIC

EXCITER

,-------

I

EXCITER WINDINGS

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

ROTOR

ROTOR/ROTATING

-----

(6)

""'----l

=--1

A

-I>f-

DlOOE

f---.O---~-,--

FIELD

TRANSIENT

---

+1

FIELO

i

I

,

•

I

EXCITER WINDINGS

ROTOR

B

c

+

,

ISOLATION

DIODE

PLATES

GREEN

+

Engines & Generators

38

If

the

installer connects shore

cui~

this

must

OFF/SHIPS grams ous

connection

A

utility at

the covered sibility

A

before vice-versa ing may

the

Shore

GENERATOR

'NG1G2.

GEN.

to

the

OFF position.

CAUTION:

shore

power

same

time.

under

to

make

CAUTION:

switching

because

with

heavy

cause

damage

generator.

Power

1

,

~

I

'-----t<S>

-----'<'3>

r

I

'-i---fe

SHORE

power

be

done

by

means of

Set the transfer

'This

switch

of

shore power to generator

Damage

the

sure

Heavy

AC

Connections

,,'-,

....

__

.--~

to

the

generator

and

!Jenerator

This

type

of

generator

warranty;

all

shore

voltage

loads

to

it

AC

connections

motor

leads

power

to

surges

on

the

exciter circuit

is

vessel

(60

Ship

10

Shore

(ilL

--I

....

~)

~.;.'-+...,

I I

I

POWER

to

the

vessel's

the

SHORE

switCh

shown

prevents simultane-

output.

can

output

are damage

the

installer's

are

correct.

should

be

shut

generator

Induced

Hertz)

power

by

being

operated

components

Swllch

(3

AC

cir-

POWER!

in

the

dia-

result

if

connected

is not

respon-

off

or

switch·

in

Pole)

TRANSFER

230

Notice the repositioning.of minal

-GENERATOR

SWITCH

Volt/5o

block

GROUND

to

ILl

. .

SHORE

L1230V

Hertz

POWER

the generator

t;l.

'"

:s:

N

(NEUTRAL)'

N I

.

50Hz

Two

Wire

Configuration

the

white

case.

.Ll

1:5

GENERATOR,(SHORE

:J

'"

1

SHORE

GROUND

SWITCH

~-,

,~

'",

-;!JJ

. 2,'

'-~

/",,-

.tT--

I

;;:

,~

, '

....

_/

ground

tr-'

...

f I

. Shiplo

,

I

.

lead

Shore

Ll

N

~

on

the

ter-

Swilch'

SHIP'S LOAD

SHIP'S

GROUND

L...--++---T/~--

I

<i!~1

e:

m

:z:

...

•

POWER

,-_

==-+-----/11·

GROUND

I

~

,S2S1N,

SHORE

NOTE:

Diagram slwws connections

for

a two-wire, 120 volt system. For

three-Wire system, use the dotted lines

for

the other Iwt leg.

NEUTRAL

l'):t--t"=="N

....

NOTE:

a·

L_!2j

Ll

,SHIP'S

SHIP

-..v

SHORE

AND

LOAD

TO

SHORE SWITCHES

SINGLE

WESTERBEKE

Engines & Generators

POWER

CONNECTION

PHASE

ARE

TRANSFER

SHOWN

ONLY

AVAILABLE

AT

SWITCH ARE

FOR

YOUR WESTERBEKE DEALER .

39

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

check list These procedures should afford your engine protection

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

maintenance

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

provide

Propeller

The transmission and propeller half couplings should always be opened up and the bolts removed when the boat is hauled out storage in the cradle. The flexibility severe strain on the propeller shaft

the

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

Fresh

A 50-50 solution recommended for use in the coolant system at all times. This solution may require a higher concentration antifreeze, depending on the area's winter climate. Check the solution to make sure the antifreeze protection

Should more antifreeze be needed, drain amount from the engine block and add a more concentrated

mixture.

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

Lubrication

With the engine warm, drain all the engine oil from the oil sump. Remove and replace the oil filter and with new oil. ENGINE LUBRICATING OIL pages in this manual for the oil changing procedure. Run the engine and check for proper

oil

A

in combustion chemicals internal

or

for long periods

lay-up

and

recommissioning,

if

others

do

the procedures.

needs

of

your

engine.

assistance.

Shaft

Coupling

of

the water or moved from land

boat

is

taken

out

or

put

in

of

time.

Water

Cooling

of

Operate

the

of

the antifreeze concentration throughout the

Circuit

antifreeze and distilled water is

engine

to

System

Use the correct grade

pressure

the

and

make

CAUTION:

sump

over

Do

the

deposits

which

can

parts.

sure

there

not

leave

lay-up

combine

reduce

of

inactivity. Others prefer

or

you

may

use

[Propulsion

to

of

or

coupling or both, while

the

water.

Engine]

water, and during

the boat often puts a

In

some cases,

[Propulsion

of

is

an

appropriate

ensure a complete

of

oil. Refer to the

are

no

leaks.

the

engine's

period.

to

produce

the

life

Lubricating

of

fill

the sump

old

harmful

your

engine's

circulation

engine

them

as

to

the

Engine]

adequate.

oil

and

a

Fuel

System

Top off your fuel tanks with unleaded gasoline

or higher. A fuel conditioner such stabilizer should be added. 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 such as BiaBar and Diesel Kleen or 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, for 5 -

10 system. 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. Place the end 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

Start the engine and allow the raw water pump fresh water through the system. When the bucket is empty, stop the engine and refill the bucket with solution slightly stronger than needed for winter freeze

protection

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

water

as

Remove the impeller from your raw water pump (some

antifreeze

Examine the impeller. Acquire a replacement, a cover gasket. Do not replace the impeller (into the pump)

until

Check for any leaks that may have been created in

Water

anode

circuit

providing

recommissioning,

Intake

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

recommissioning, you

may

note

to

remove the cloth prior to start-up. The thru-hull

exhaust

[Gasoline]

of

89

as

Sta-Bil gasoline

Change the element in your

[Diesel]

No.2

diesel fuel. Fuel additives

Cetane Boost should be

if

the

fuel

system

as

needed. Start the engine and allow it

minutes to make sure no air

of

the treated fuel through the injection

Cooling

of

clean fresh water. Before starting the engine,

is

located.

in

your

area.

from

freezing

corrosion

mixture

Manifold

of

need

port

will

and

the intake manifold to block the opening. Do not

of

and

assistance of

can

be

blocked

has

Circuit

Clean

the

of

during

protection.

accompany

but

replace

Thru-Hull

sight.

(If

an

attempt

the

in

one,

and

clean

the

separator

is

left in the fuel

10

minutes will help

of

this hose into a five

raw

water

strainer.

to

draw the

an

antifreeze

this mixture

Once the bucket is empty, stop

the

it,

the

winter

so

catch

cover

to

be drawn

lay·up,

it

in a bucket).

if

needed, and

and

gasket.

Exhaust

it is not visible at

is

made

to

start

the

servicing

the

same

dealer.

manner.

Make

octane

to

run

as

well

engine,

a

Engines & Generators

40

LAY-UP

&

RECOMMISSIONING

Starter

Lubrication and cleaning

if access

battery connections are shut off before attempting the starter. Take care in properly replacing any electrical

connections

Cylinder

If WESTERBEKE recommends removing the glow plugs for access to the cylinders. Squirt light oil into the cylinders to prevent the piston rings from sticking Thrn the engine two revolutions by hand and then re-install the glow plugs.

Intake

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

Cylinder

Spray fogging oil into the open air intake, with the flame arrester removed, while the engine is running. The fogging oil will stall out the engine and coat the valves, cylinders and spark plugs for winter protection.

NOTE:

and re-gapping at spring

Motor

of

the starter drive pinion

to

the

starter

pennits

removed

from

Lubrication

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

Manifold

start-up!

[Gasoline]

Lubrication

The spark plugs will

its

easy

removal.

the

starter.

[Diesel}

to

[Gasoline]

need

to

be

removed

commissioning.

the cylinder walls.

to

remove cloths prior

Make

to

for

is

advisable,

sure

remove

to

cleaning

the

to

BaHeries

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

batteries

environment.

A

highly-explosive arcing smoke

serviced.

to

Transmission

Check or change the fluid in the transmission as required Wipe off grime and grease and touch up any unpainted areas.

the coating.

additional information, refer to the TRANSMISSION SECTION.

to

severe

and

store

WARNING:

or a lighted

or

allow

Shut

prevent

coupling

electrical

and

Check

environmental

them

Lead

gas,

cigarette,

an

open

off

all

[Propulsion

the

output

that

the

If

there

conditions,

in a warmer,

acid

batteries

which

can

cigar,

name

near

electrical

arcing

during

Engine]

flange

with

transmission

is

any doubt that the

remove

more

compatible

emit

hydrogen,

be

ignited

or

pipe.

the

battery

equipment

in

servicing.

an

anti-colTosion

vent

is

open.

by

electrical

00

not

being

the

For

way,

the

a

vicinity

Protect

Spare

Lay-up time provides a good opportunity

Westerbeke engine to see if external items such as drive belts

or coolant

kit and order items not on hand,

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

SPARE PARTS section

Parts

to

inspect your

hoses need replacement. Check your basic spares

or

replace those items used

of

this manual.

to

the

Recommissioning

The

recommissioning of

seasonal lay-up generally follows the same procedures as those described in the PREPARATIONS FOR STARTING section regarding preparation for starting and normal starts. However, some of the lay-up procedures will need counteracted before starting the engine.

1.

Remove the oil-soaked cloths from the intake manifold.

2. Remove the raw water pump cover and gasket and discard the old gasket. Install the raw water pump impeller

removed during lay-up (or a replacement,

Install

the

raw

3. Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making sure the

tenninals are clean and that the connections are tight.

Check to make sure that the batteries are fully charged.

A

CAUTION:

and

eye

protection batteries can cigarette, flame electrical arcing

4. Remove the spark plugs, wipe clean, n;-gap, and install proper tightness {gasoline}.

5. Check the condition

circuit

that it

solution from the raw water coolant system. When the

engine

short period

advisable,

service,

heat exchanger and clear any and all zinc debris from that

area.

6.

Start the engine in accordance with procedures described

in the

manual.

emit

hydrogen,

be

ignited

by

cigar,

near

the

battery

equipment

during

servicing.

and

clean

is

not necessary to flush the antifreeze/fresh water

is

put into operation, the system will self-flush

of

as

either

to

inspect

PREPARATIONS FOR STARTING section

your

water

pump

Wear

rubber

when

electrical

or

pipe.

being

in

of

or

replace

time with

an

the

area

Westerbeke

cover

gloves, a rubber servicing a

highly

arcing

00

not

serviced.

the

vicinity

the zinc anode in the raw water

the

no

adverse affects.

end

of

season

where

engine

with a new

batteries.

explosive

or a lighted

smoke

or

Shut

to

prevent

anode

as

or

recommissioning

the

zinc

after

if

required).

cover

apron,

Lead

gas,

allow

off

electrical

needed.

It

is

located

a

to be

gasket.

acid

which

an

open

all

Note

is

of

in

this

in

the

to

a

Engines & Generators

41

STANDARD

AND

LENGTH-DISTANCE

Inches

Feet Miles

(ft)

x

(in)

x

.305

1.609

25.4

=

Millimeters

=

Meters

=

Kilometers

METRIC

(mm)

(m)

x

3.281

(km)

x

CONVERSION

x

.0394

=

Feet

.0621

=

Miles

DATA

Inches

DISTANCE

1

EQUIVALENTS

Degree

Minute

of

Latitude

of

Latitude

VOLUME

Cubic

Inches

(in')

Imperial

Imperial Imperial Fluid US

US US

Pints Quarts Gallons Quarts Gallons

Ounces

Pints

(US Quarts Gallons

x

(US

(IMP

(IMP (IMP

29.573

pt)

qt)

gal)

MASS-WEIGHT

Ounces Pounds

(oz)

(Ib)

x

28.35

x

.454

PRESSURE

Pounds Inches Inches Inches Inches Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

Sq

In

=

= 1

x

16.387

pt)

qt)

(IMP

qt)

(IMP

x

.473

x

.946

x

=

Kilograms

(psi)

(Hg)

(Hg) (H20) (H20)

(H20)

60

Nm

=

x

.568

x

1.137

gal)

x

1.201

gal)

x

=

Milliliters

=

Liters(L)

=

Liters

3.785

Grams

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

=

111.120

=

1.862

Cubic

Centimeters

=

Liters

=

Liters

4.546

=

US

1.201

=

x

(L)

=

Liters

(g)

x

.035

(kg)

=

Kilopascals

=

psi

=

Kilopascals

=

Inches

=

psi

=

Kilopascals

km

(L)

Liters

Quarts

US

Gallons

.034

2.113

x

1.057

(L)

x

=

x

2.205

x

2.036

of

x

27.684

x

1.

76

(L)

x.88 = IMP

(L)

x

(US

=

Ounces =

Pints

=

Quarts

.264

=

Ounces

=

Pounds

(kPa)

=

Hg

(kPa)

Mercury

=

(kPa)

x

.061

=

IMP

.22

=

IMP

qt)

x

(US

gal)

Gallons

x

.145

x

.2961

x

13.783

H20

x

4.026

=in'

pt

qt

.833

x

=

gal

.833

=

psi

=

H20

=

Hg =

IMP

=

H20

qt

IMP

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles Kilometers

Per Per

(Hp)

Hour

IMP

Per

Liter

Gallons

Per

Liter

TEMPERATURE

Degree Degree

Fahrenheit Celsius

(OC) = (OF

(in-Ib)

(ft-Ib)

x

1.609

x

.745

=

Kilowatts

(MPG)

(Km/L)

US

(MPG)

(Km/L)

(OF) = (OC

-

32) x .56

x

.113

=

Newton

1.356

=

Newton

=

Kilometers

(Kw)

x

.354

=

Kilometers

x

2.352

=

x

.425

=

Kilometers

x

2.352

=

US

X

1.8) + 32

Engines & Generators

x

IMP

Meters

Per

1.34

MPG

Hour

Per

=

MPH

Per

(Nm)

(KPH)

Liter

x

8.85

x

.738

x

.621

(Km/L)

=in-Ib

=

ft-Ib

=

MPH

42

SUGGESTED

SPARE

PARTS

CONTACT

FUEUWATER FILTERS

YOUR

HEAT

GASKET

WESTERBEKE

""

'

EXCHANGER

AND

FUEL

END

O-RING

SYSTEM

DEALER

MARINE

FOR

ZINC

ANODE

DIESEL

ADDITIONAL

GENERATORS

SUGGESTIONS

FUEL

INJECTOR

AND

INFORMATION

MATCHING DRIVE BELTS

HARDWARE~KlIT~~~,,~,

THERMOSTAT GASKET

WESTERBEKE

each

packaged

Kit

"A" includes

Kit

"B"

is

for

more

KIT

A

ZINC

ANODES DRIVE OIL

FILTER

FUEL

FILTER

HEAT

EXCHANGER IMPELLER FUEL

SYSTEM FUEL

PUMP

AND

also

offers

two

Spare

in

a rugged hinged toolbox,

the

basic spares,

extensive off-shore cruising,

BELTS

GASKET

KIT

HARDWARE

INLET

FILTER

KIT

Parts

"

tJoeJl

SPARE

Kits,

INLET FUEL

FILTE~

.#

.fr

PARTS

KITS

~

D

"

~~S~D~~T'

IN A CANVAS

CARRYING

BAG

KIT

B

ZINC

ANODES DRIVE OIL

FILTER

FUEL

FILTER

HEAT

EXCHANGER

IMPELLER INJECTOR

OVERHAUL GLOW

FUEL

SYSTEM

FUEL

PUMP

BELTS

KIT

GASKET

PLUG

INLET,FllTER

GASKET

KIT

HARDWARE

KIT

Engines & Generators

43

WATER

HEATER

WATER

These engines

of

The

either in a high or low position in relation that the connecting hoses

run in a reasonably direct line without any loops which might trap

Hoses should rise continuously heater to heater to the engine.

then an air bleed petcock must

on

HEATER

engine coolant

water

heater

INSTALLATIONS

are

equipped with connections for the plumbing

to

transfer heat

should

be

from

to

an

on-board water

mounted

in

a convenient

to

the engine, so

the heater to the engine can

air.

from

their low point

the

engine so that air will rise naturally from

If

trapped air

the heater for bleeding air while filling the system.

!HERMOSTAT

HOUSING

is

able

to

rise

to

be installed at the higher fitting

I

heater.

location

at

the

the heater,

NOTE:

If

any portion

engine~

renwte expansion tank (Kit #024177)

circuit

tank into the heater circuit, choosing the higher

connections for

single line up to the tanks location

engine~

convenient location so The

system fill point. The plastic coolant recovery

when the remote expansion

tank

recovery tank

The pressure cap on the engine's manifold should installed after the engine's cooling system coolant. Finish filling the cooling system from tank after the system is filled and is free good coolant circulation. During engine operation, checking the engine's coolant should be done at the remote tank and not heaterto the remote expansion tank should be routed and supported enabling any of the system.

own

to

become

return.

remote expansion

serves the same function. Remove

at the engine manifold cap. The hose connection

so

it rises continuously from the heater

air

of

the heating circuit rises above the

pressure

if

cap,

then

a pressurized

must

the

highest point.

the

return.

Tee

Install

the

remote expansion

the

coolant level

tank

will

it has been already installed.

in the system to rise

Tee

at

the

heater,

and

now serve as a check and

tank

kit

is installed, since this

up

(aluminum)

be

installed in the

the

remote expansion

of

the two

and

plumb

the other back

tank

in

a

can

easily

be

tank

is

and

store the plastic

be

is

filled with

the

remote

of

air

and

exhibits

to

the

to

the tank and out

a

to

the

checked.

not

used

from

tank,

the

WATER

HEATER

--

-OWNERS

CONNECTIONS

---

HOT

NOTE:

An

air bleed

heat exchanger. Open this petcock when filling the engine's

coolant system

Close tightly after all the air is removed.

WATER

HOSE

WATER

TANK.

pet~ock

to

allow air

is located on the engine's

in

the

exchanger

to

escape.

,...

WESTERBEKE

Engines & Generators

44

Engines & Generators

Westerbeke 33KW EDE, 26KW EDE, 23.5KW EDE, 25.5KW EDE, 21.0KW EDE Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual