Westerbeke 29.0 EGED, 23.0 EGED Operator's Manual

-(f.RIJ

.·

..

·

OPERATORS

.·

MARINE

29.0

EGED

" .

.,

()

·

.li

.

L D

~

'II'

MANUAL

DIESEL

60Hz

GENERATORS

23.0

_,.

.

"'

q

EGED

50

Hz

Single

PUBLICATION NO. 056402

and

REVISIONO

MARCH 2017

Three

Phase

.

member'

~---

§.J!H

WESTERBEKE

150

JOHN

TEL:

(508)823·7677 •

CORPORATION

HANCOCK

ROAD,

FAX:

{508)884-9688 •

• MYLES STANDISH

TAUNTON,

MA

WEBSITE:

INDUSTRIAL

02780·7319

WWW.

PARK

U.S.A.

WESTERBEKE.COM

PROPOSITION

Diesel engine exhaust and some of

its constituents are known the State cancerJ reproductive harm.

Exhaust colorless unconsciousness exposure

•

•Nausea

•Headache

•

gasses

gas. can

Dizziness

Weakness

contain

Carbon

and

include:

and

Sleepiness

CALIFORNIA

65

WARNING

to

of

California

birth defectsJ and other

A

wARNING:

Carbon

Monoxide

death.

Monoxide,

Symptoms

•

•Inability

to

is

poisonous

of

Throbbing

Muscular

Vomiting

to

cause

an

odorless

and

can

Carbon

Twitching

in

Temples

Think

Monoxide

Coherently

and

cause

IF

YOU GET seek until

OR

ANYONE

OUT

INTO medical it

has

THE

attention.

been

inspected

ELSE

EXPERIENCE

FRESH

AIR

IMMEDIATELY.

Shut

down

and

This

WARNING

WESTERBEKE

bulkhead WESTERBEKE

CARBON living/sleeping They

are

obtainable

ANY

OF

the

unit

repaired.

DECAL

and

should

near

your

engine

also

recommends

MONOXIDE

quarters

inexpensive

at

your

local

THESE

SYMPTOMS,

If

symptoms

and

do

is

provided

be

DETECTORS

of

and

easily

marine

not

restart

fixed

or

generator.

installing

your

vessel. store.

persist,

by to

in

a

the

SAFETY

INSTRUCTIONS

IRTRODUCnON

Read

this

safety

11Ullluol

caused

precautions.

toke the

personne4

The

the

by

failure

to

follow

Know

when

necessary

foUowing

American

PREVENT

A

WARNING:

while

IIIJine/s

tllese

t:D111181:ti1111SI

•

Do

not

enclosures

• Shut

•

off

equipment · Use

insulated

equipment Make

sure

(particularly

Remove electrical

PREVENT

A

WARNING:

8Xhstlst""""

precautions

and

your

machinery.

sofety

instruciions

Boat

and

ELEcTRIC

oPerate

and

electrical

your

wristwatch

equipment

liD

IIIII

runlling.

tbis

co:vers

power

mats

clothing

shoes)

SHOCK

machinery

whenever

when

BURRS-

Do

11111

comptlllllllls. A

,.

•

Monitor

coolant

location

when

j

AwA1818:

•

In

before

EingiQe

recovery·tank

on

the

engine is

case

of

touching

-~

the

water jacketed

___

an

engine

the

COLD.

overheat,

engine

carefully.

fundamental

dangerous

Yacht

tout:h

Lethal

in

and

HOT

fDIIDb

and

Most

accidents

rules

and

conditions

to

protect

yourself, your

are

in

compliance

Council

place.

before

and

handling electrical'equipment.

all

jewelry when

AC

electrical

raltage

without

accessing

working

skin

are dty, not

(ABYC)

standards.

t:llllllet:tiDifS

is

ptt~Sent

electrical

on electrical

working

ENGINE

bill

tlllg/ne

IIIIJIIIng

cooiant

periodiCaly

exhau.<tt

'

ievei

at

manifold,

patls

engine

at

the

filler

,.,.,_

allow

the

engine

or

checking

the

coolant.

are

exist

and

with

at

damp

or

gets

plastic

atp

but

to

cool

on

only

PREVENT

I A

•

Prevent

sparlcs

pump,

vapors.

removing

•

Do

Backfire

•

Do

the

engine

chances

• Be

PREVENT

A

Injury

• .

•

· •

• Be certain

•

BURNS-

WARIIIIIG:

flash

to

or

Use a suitable

not

operate

can

not smoke

fuel

system.

'clean

of

aware-

BURNS-

WARNING:

D1

dlllf#'l

Follow

re--fueling

hatches

after

the

your

All when well-ventilated equipment

Do Shut

closed

fueling.

blower.

engine.

fuel

vapors

handling

not fill

off

the

fuel

system.

spill.

DO

sources

servicing.

the

Qo

~~

free Make

Extinguishers

fuel

not alter or

sure

of

sure

properly for

all

applications

of

system.

all

leaks.

FIRE

Flnl"""

fires.

occur

near

other potential sources of spilled

the fuel

with

cause severe

or

J(eep

imd

fire.

wq,e

diesel

......

illjmp

Do not smoke

the

fuel

container

lines

or

the air cleaner/silencer

permit

flames

~compartment

free

of

debris

up

all

fuel

will

injector,

fuel

filters.

injury

spilled

bum.

or

permit

to

catch

or

death.

or

sparks

to

minimize

fuel

...

fuel

and

EXPLOSION

Exp/llsiiiiiS

safety

when

Check

Run

the

are

highly

and

area

and

out of the

the

fuel tank(s) while

fuel

service

Take

NOT

allow

fire

near

the

Ensure

maintained. Be

fuel

a

fire

modify

line

rated

proper

supplies

extinguisher

frllm

fuel

instructions.

fueling. below blower

storing

away

fittings

Open

for

fumes/vapor

per

four

explosive.

fuels.

from

spark-producing

~h

of

Valve

at

the

care

in

catching

any

smoking,

fuel

system

ventilation exists

the

fuel

system.

have a positive

are

?dequately

is

familiar

ABC by the

encountered in

V11J1D1S

Keep

and

ventilate

minutes

Use

Store

fuel

children.

the

,engine

engine

any

open

or

engine

installed

with

its

NFPA

this

environment.

are

_,

flames

line,

filter,

fuel

or

all

fuel

removed.

to

occur

the

engine

can

the

vessel's

refore

before

extreme

in

a

while

when

fuel

flames,

when

shutoff

tightened

nearby proper

appropriate

or

fuel

when

near

oil.

t:aiiSI1

the

cabin

running

starting

care

it

is

servicing

that

might

or

other

servicing

valve.

and

is

use.

]

.

running.

.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect generator.

last.

it

•

Make starting.

•

Make installed

BAmRY

A

WARNING:

or

death!

•

Do

not being highly arcing equipment ing

servicing.

•

Never tive not

test the together. Ventilate accumulation disturb is

being

•

Avoid bums wristwatch, the

battery.

•

Always the

battery connections. Remove

and

STARTING

Accidental

the

battery

Remove

certain

all

personnel

certain

all

covers,

before

starting

EXPLOSION

Battery

smoke or

serviced.

explosive

or

by

connect

( +) connection terminal of

Sparks

any

the

charged.

contacting

or

sparks

tum

reconnect

allow

Lead

gas,

lit

tobacco

in

the

vicinity

the

battery

could

compartment containing batteries

of

explosive

battery

the

that

rings,

the

battery

it

last

BAnERYACID

A

WARNING:

severe

injury

•

When

servicing

level,

wear rubber

tion.

Batteries

If

it comes

with

water.

inadvertently

Sulfuric

or

death!

contain

in

contact

Acid

when

the

may

starting

cables

the

negative

are

guards,

the

engine.

explosion

an

open

acid

batteries emit hydrogen, a

which

products.

to

negative(-) battery

condition

ignite

gases.

charger connections

terminals with

could

cause

and any

other jewelry before

charger off before disconnecting _

when

disconnecting

acid

battery or checking the electrolyte

gloves,

a rubber

sulfuric acid

with

your

splash

removing electrolyte caps.

before

lead

clear of

and

flame

can

be

Shut off

prevent

the

by

shorting

battery

To

an

the

in

batteries

skin,

on

the

can

cause

injury

servicing first

hatches

cause

near

ignited

electrical

starter solenoid.

gases

avoid

tools,

explosion.

negative lead first

apron,

which

wash

skin

and

the

cable

the

while

the

can

or

the

reconnect

engine

are

re-

injury

the

battery

by

electrical

all

electrical arcing

to the terminals

or

fuel

to

sparks,

the

etc.,

to

Remove

handling

battery.

cause

and eye is

destructive. it off at into

the

engine/

before

dur-

posi-

Do

vapors.

prevent

do

not

battery

prevent

protec-

once

eyes

TOXIC

•

EXHAUST

A

WARNING:

Ensure

that

the discharged regularly are attention exhaust pipe

•

Be

sure

•

In

addition install builder

• For tional

A

odorless nausea

•

Do fumes tems. tubing

•

Do

through exhaust discharge outlet enter flow

•

Although exhaust gas toms

are: Vomiting Dizziness Throbbing Muscular twitching Intense Weakness

AVOID

A

WARNING:

or

death!

•

Do tion operating adjustments, ing

from

for

leaks

securely

additional

attached

to

the

nipple.

the unit

to

routine inspection of

a carbon

or

dealer for installation

information

WARNING:

gas.

or

death!

not

use

copper

can

rapidly

Exhaust sulfur

resulting

not

install exhaust outlet

portholes,

the

exhaust

of exhaust.

diesel engine exhaust

fumes

is

present

or

signs

in

headache

and

MOVING

not

service

arises

in

moving

parts

GASES

Carbon

monoxide

exhaust

manifold,

monoxide

information refer

the

and

engine.

and

its

on

system

make

and

surroundings

Carbon

Inhalation

tubing

destroy

causes

in

exhaust/water

vents,

is

discharge

Avoid

overloading

from

gasoline

in

diesel

exhaust

of carbon monoxide

temples

sleepiness

(CO}

is

Check

sure

no

warping

water injection

detector.

of to

Monoxide).

monoxide produces

in

diesel

copper

tubing

rapid

where

or

air

conditioners.

near

the

outlet

gases

engines,

fumes.

PARTS

Rotating

the

which

engine

it

is

use

and

hot exhaust

parts

can

while

absolutely

extreme

is a deadly

adequate the

approved ABYC

the

exhaust

exists.

elbow,

are

well

the

exhaust

Consult

(CO)

to

T-22

is

flu-like

exhaust

deterioration

leakage.

and

it

systems.

in

exhaust

exhaust waterline,

close

or

the

craft.

are

not

carbon

Some

inhalation

cause

injury

is

running.

necessary

care

to

system

components.

gas!

expel

gases

system

manifolds

Pay

close

and

ventilated.

system,

your

boat

detectors.

(educa-

an

invisible

symptoms,

Diesel

sys-

of copper

can

be

drawn

If

the

engine

water

could

restrict

the

as

toxic

as

monoxide

of the

symp-

or

poisoning

If

a

situa-

to

m'ake

avoid

touch-

Engines & Generators

ii

a

Do

not

wear

loose

equipment: rings,

.

maving

•

Make Keep places

a Do

not

. the

engine

IIi

Stay when

be

caught

HAZARDOUS

A

WARNING:

avoid

necklaces

parts.

sure

all

protective

at

all

times.

check

is

clear

of the

the

engine

in

these

NOISE

attaching

fluid

operating.

IIISSI

~

Never

operate

• Do not

removed.

A

WARNING:

.

mBIItally

OPERATORS

·Many

of

the

in

yOur

opemtors

notes

to

highlight

carefully,

procedures.

m•tain

an

nm

an

engine

D1

physlally

MANUAL

preceding

Manual

critical

.

clothing

wearing

or

bmcelets

hardware

shields

and

levels

drive

shaft

is

running;

rotating

High

llt1ise

engine

without its

with

Dollllf

Pllltk

/muipat;llatstJ

safety

along

inforination.

your

equipment.

or

jewehy

loose

jackets,

that

could

is

guards

or

the

drive

and

the

h3ir and

parts.

IBvetsl:atl

the

air intake

Dll

macblnety

tips

and

warnings

with

other

Read

and

SAFETY

when

servicing

shirts,

sleeves,

be

caught

in

properly

in

transmission

clothing

-muffler

their

· ·

belt's

t:BIISfl

(sUencer)

tightened.

respective

tension

coupling

can

while

easily

bearing

installed.

PJbell,.

by

fatl!lllel

ate-repeated

cautions

your

follow

and

manual

all

safety

INSTRUCTIONS

are

ABYC,

..

INSTALLING

Read for tions

ABYC

"Safety

Order

ABYC

613

Annapolis,

(410)

·

www.abycinc.O!J NFPA

"Fue

Order

NFPA

1 P.O. Quincy,

USCG

"CFR

Code.ofFedeml

Order

U.S.

Washington,

NFPA

AND

USCG

the

safety

when

(American

Standaras

MARINE

following

codes

and

insialUng

ABYC,

standards.

your

Boat

and

for

Small

ENGINES

NFPA

UNIVERSAL

From:

Third

Dtreet, Suite

MD

21403

990-4460

(National

Protection

From~

Ba.tterymarch

Box

MA

(United

33

From:

Government Printing Office

Park

9101

02269--9101

States

AND

CFR46'•

D.C.

10

Fire

Protection

Standard

Regulations

for

Coast Guard)

20404

PUBUCAnONS

AND

and

USCG

Follow

their

Yacht

Council)

Craft'' .

Association)

Motor

Craft"

FOR

GENERATORS

publications

recommenda-

engine

ENGINE

Preparations

ough (ABYQ

soun:es

Sections

All Regulations

AID

examiDation

standat:ds.

including

of

the

H-32

Ventilation

H-33

Diesel

P-1

Installatiion

and

P-4

Marine

E-ll

AC & DC

TA

Batteries

installations

GENERATOR

to

install

an

engine

of

the

American

These

standards

the

USCG

and

ABYC

standards

for

boats

Fuel

Systems

of

Exhaust

Auxiliary

must

(FCR.).

Jnbo$'d

Electrical

and

Battery

comply

Engines

INSTALLATIONS

should

begin

Boat

and

ate

a

combination

the

NPPA.

of particular interest

using

diesel

Systems

and

Transmissions

Systems

Chargers

with

on

the Federal Code of

with

Yacht

fuel

for

Propulsion

Boats

.

a

thor-

Council's

of

are:

I""''V"IWESTERSEKB

(Engines

& Generators

•••

Ill

When

installing

attention

WESTERBEKE

be

paid to

the

following

.INSTALLATION

engines

information:

and

generators

it

is important that strict

CODES

Strict

when

AND

federal

regulations,

installing

REGULATIONS

engines

SIPHON-BREAK

For

installations

or

will

be

break

in

minimum

the

exhaust

raw

water

If

you

have

to·

the

vessel's

siphon-break.

NOTE:

A

operation.

en~ne

damage.

EXHAUST

·

Tlie

exhauSt

Exhaust

and

turns

and

turns

system

MUST

under

any

where

below

the

vessel's

the

raw

water

supply

of

2ft'

above

manifold

damage

any

to

doubt

injection

Ow

abOut'

watedirte.under

si.Phon~break

Failure

requires

to

properly

CoMllt the

SYSTEM

system's

Hose

without

.In

this

sea

is

hose

recommen~~

the~

regard, a single

be

designed

conditions

ABYC

guidelines,

and

generators

the

exhaust

waterline,

hose

the

vessel's

engine

the

..

siphon-break

'Mli~t:~

of additiinal

to

prevent

and

at

in

a

manifold/water

provisions

to

the

waterline.

porl

Ia

at

and

po~Bible

positii;>.n

the

,.

..

periodic

maintain a siphon-break

The

vessel's

. . .....

inspection

certified

use

of this type of

of t}w.

fitting

length

of

the

any

angle

and

safety

marine

environment.

injected

must

exhaust

elbow.

Failure

or

below

the

Jlboding

water-injected

various

operating

·and

manufacturer

for

marine

and

clamps

coxrugated

entry

of water·into

of

vessels

codes

must be complied

exhaust

be

made

This

to

use a siphon-break'

loaJ1

waterline

of

the

to

hose

boat.

elbow

install

must

exhaust

cOnditions,

cleaning

can·

for

hose;

9xhaust

heal.

result

proper

use.

Corrugated

a,llows

to

accomplish

hose

the

to

ensure

in

maintenance.

for extreme

can

exhaust

with

is

close

a

siphon-

be

looped

when

will

result

elbow

relative

install

a

proper

catastrophic

Marine

bends

these

bends

be

used.

syste~

to

a

in

:

AVAILABLE

YOUR.

.

DEALER

SIPHON-BREAK

LOOP

PART

'The

·

FROM

WESTERBEKE

FOR

NO.

WfTH

1"

HOSE

044010

.

fifAINLES,

A

detailed

engines

Js

also

We~lte:

Marine

an~

generators

available

www.westerbeke.com

lnstaHation

In

pdf

is

supplied

format

Manual

covering

wHb ~ unit

on

our

website

gasoline

to

download

l"YYV'IWESTERBEKE

l

Eng/,_

& Generators

iv

sold.

and This

diesel

manual

TABLE

Parts

Identification Introduction Fuel,

Engine

Preparations

Control

Manual

Starting/Stopping

Remote Panels ............................................... 8

Benerator

Daily

Routine Maintenance Fuel

System

Cooling

Raw

Draining the Raw Water System .................

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

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

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

Raw Heat Raw

Engine

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

Engine Engine

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

Fuel Injectors ...............................................

Troubleshooting Instrument Gauges ...........

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

Checking Valve

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

Oil

for

Panel

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

Engine Shut-Off ............................... 7

Break-In

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

Schedule

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

System

Water Intake ........................................

Water

Exchanger ...........................................

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

Lubricating Troubleshooting

AdJustments

Valve

Adjustment. ........................................ 20

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

and

Engine

Initial

Procedure

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

Cooling Circuit .........................

Oil

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

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

Clearance ...........................

Coolant..

Start·Up

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

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

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

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

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

OF

CONTENTS

2 3 5

6 Testing and Troubleshooting .......................

7

8

9 Removing for Service ..................................

9

1 o 12

t3',,

13

13 14 14 15 16 16 16

17

18 19

19

20

Glow

Plugs

Inspection and Testing .................................

Alternators

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

Starter

. Testing with Electrical Jumper ....................

Testing with Screwdriver .............................

Raw

Water Water Remote Block Specifications Benerator Twelve Electronic Internal AC

Outlet Shore Lay·Up Suggested Wiring

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

Motor

Heater

Lead

Power

and

Diagrams

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

Pump

011

Filter

Information

Regulation

Wiring

Configuration

Recommissioning.'

Spares

(Exploded

Installation

(Optional)

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

Winding

Diagram

Transfer

Connections

Switch

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

and

Schematics

View)

(Optional)

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

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

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

(AVR)

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

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

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

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

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

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

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

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

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

21

22 22

24

25 25

26

27

28 29 30

.30

31 .33 .34

35

37

.38

39 .41 .42

r.viWE§I"ERBEKE

l Engines & Generators

1

PARTS

IDENTIFICATION

OIL

I

FILL

CONNECTION SIPHON

REAR

FOR

BREAK

FUEL

LIFT

COOLANT

FILL

RIGHT

PUMP

SIDE

MANIFOLD

COOLA~T

DRIVE

BELT

COVER

DC

ALTERNATO

PRESSURE

FILL

FRONT.

CAP

FLEXIBLE MOUNTS

ISOLATED

CONTROl

LEFT.

SIDE

DC

FIELD

SYPHON CONNECTION

BREAK

BREAKER

Engines & Generators

2

This

WESTERBEKE WESTERBEKE's technology. dependable Thank

In

order

is

important manual manual throughout your

This

is

an Manual

ordered

Dealer

We

performance

you

for

to

get

that

is

designed

carefully

Should

nearest

WESTERBEKE

is

your

operators

Installation

is

available

in

book

WARRANTY

Your

WESTERBEKE

product Registration

register registering.

documentation

Card

Corporation Customer your

date

Customer

or

your

products

Identification

If.you

product

available.

model

Identification

Diesel

Generator

long

years

of

take

great

pride

of

our

engines

selecting the

WESTERBEKE.

full

use

and

benefit

you

operate

to

and

observe

your

Manual

in

form

and

help

you

do

all

generator

dealer

manual.

pdf

from a WESTERBEKFJUNIVERSAL

and

form

Along

Parts

is a product

experience

in

the

superior

and

from

maintain

this.

Please,

the

safety

require

for

assistance.

wi~

Information. A Semce

on

our website or

PROCEDURES

go

Warranty

you

can

to

our

warranty

do

not,

number,

package.

card

Statement is

There

fill out

and

mail to

website:www.

on

line.

in

the

mail

please

contact

serial

number and in

is a

westerbeke.com

You

within

the

Card

I,.,IWESTERSEKE

I Engines & Generators

Customer

MR. MAIN

HOMETOWN, Model Expires

NOTES,

As maintenance engine, CAUTIONS,

NOTE:

A

observed,

your

Identification

GENERATOR

STREET

CAUTIONS

this

manual

schedules,

critical

information

and

An

operating

CAUTION:

can

engine.

OWNER

USA

AND

takes

you

through

and

WARNINGS.

procedure

Proceduress

result

In

the

Serihl

#

WARNINGS

the operating

troubleshooting of your

will

be

highlighted

An

explanation

essential to note.

which

if

not

damage

or

destruction

INTRODUCTION

of

and

advanced

durability

generators.

your

generator

it

correctly~

read

precautions

servicing,

~

manual,

can

included

Warranty

Westerbeke

should

60

days

factory

service

procedures,

by

NOTES,

follows:

strictly

and

This

this

contact

.there

be

in

the

and

receive

of

and

have

marine

of

.

it

· a

·

PRODUCT

Pioduct brochures WESTERBEKE

WESTERBEKE CONTENT

WARRANTIES THERETO, COMP'zErENESS

BE

UABLE

iNCURRED

..

OF

THE

WESTERBEKE

time

software WESTERBEKE provided WESTERBEKE

be

relied

the

respective

but

is

WES'IERBEKE

to

detennine the

product

PROTECTING

care

have

Ill8I).Y

manuflicturer

install~

operat6jl buyer/owner.:Operator.

NOTE:

•

Proper

•

An

an engine.

SOFTWARE

software,

and

FURNISHING

span

between

and

with

upon·

imperative

software

at~

n$tdted in a

tbousands of hours

in the

'and

SU:

efficient

mzti:.siphon

. . . .

(tech

dlUa.

pans,

catalogs),

are

CANNOT

OF

SUCH

OR

INCLUDING

FOR

IN CONNECI10N WITH

customers should

the

tinavoidable existence of earlier ·

WESTERBEKE

exclusively

product

accuracy

YOUR.

factory during assembly and tl)orough

provided

not within WESTERBEKE's

BE RESPONSIBLE

SOFTWARE,

REPRESENTATIONS

ACCURACY;

THEREOF AND W1U

ANY TYPE OF

OR

USE

printirigs manuals. or other suppliers,

that appropriate representatives of

or

the

being consulted

ofWESTERBEKE

In

summation,

as

the

It

not only makes good

supplier

and

INVESTMENT·

WESTERBEKE

of

dependable

cannot

control how or where the

vessel

or the manner

serviced

;•

imp~rtant

in the

·

steps

field.

to

ensure

engine and generotor

weU-designed

breafc

to prevent

• Changing the engine oil and oil

maintenance scltedule.

•

.Proper

ne1its

mimuii!

·•

•

niainte1tizliee

accortli;ng

Use

clei:bi;:(ilierf!d

Wznterize

of

all

to

the maintenance

. .

#2

diesel fUel.

your engine

ticcoriliitg

Reco;mmissioninlf' section in this

lists,

manuals,

from

sources

MAKEs

TIMELINESS

DAMAGE

OR

OF

SUCH

also

keep

products,

must

definitive

in

question

currentness

by

the

generat9r

in

which

This

long

insttlllaiion

exhtiust

engine

system

water

filters'

a7ii1

to

manuaL

other

FOR

NO

WITH

RESPECT

IN

NO

OR

INJURY

ARISING

SOF1WARE.

in

mind

product

product whether not

and

cannot

authority

sense

be

consnited

of the

customer.

capable

~ce~

·However

generator

the

is

up to

the

generaJor

and.alignment.

that

from

entering

accordiit.g

generfdor

schedule

the

""Lay-up

than

control.

THE

.

OR

EVENT

OUT

the

software from

on

testing

of

unit

is

life:

irtt;,.ludes

..

to

compo-

in

this

and

·

the

is

the

tlie

·

A

·WARNING:

followed,

can

Procedures,

result

in

personal

which

injury or

If

not

loss

properly

of life.

Engines

& Generators

3

INTRODUCTION

SERIAL

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

exhaust manifold. The engine's serial number is also found stamped the engine block on a flat surface just above the the side oil fill ation below on the illustrated nameplate.

NUMBER

LOCATION

of

the water jacketed

opening. Take time to enter this inform-

50

HZ.

lo,cate<i

60HZ.

I

on

in

NOTE:

A carbon monoxide warning decal has been provided

by

WESTERBEKE. Affix this decal in a visible position in the

room.

engine

UNDERSTANDING

The diesel engine closely resembles the gasoline engine, since the mechanism

are

arranged above a closed crankcase; the crankshaft the same general type diesel engine connecting rods and lubricating system.

Therefore, same preventive maintenance most important factors maintenance of the Replacement of time periods specified contaillination (that system of

the

designed specifically for diesel engines.

The diesel engine however, carburetor and ignition systems are done away with their place is a single component - the which performs the function of both.

ORDERING

Whenever replacement/service parts provide the generator model and generator serial number black name plate located provide your generator description and part number for each part needed separately furnished Parts List). Also insist WESTERBEKE packaged parts because will parts original equipment.

to

is

also

same brand of high detergent diesel lubrication oil

in its method of handling and

PARTS

us

with

are

frequently not

THE

DIESEL

is essentially the

as

that

has

the same types of valves, camshaft, pistons,

a great extent, a diesel engine requires the

are

proper ventilation

fuel,

lubricating and cooling

fuel

and lubricating filter elements at the

is a must, and frequent checking

is,

water,

essential. Another important factor is the

does

differ from the gasoline engine,

on

this

information so

set.

In addition, include a complete part

made

ENGINE

same.

The cylinders

of

a gasoline engine;

as

a gasoline

sediment, etc.) in the

number,

as

they appear

the generator

we

to

the same specifications

engine.

and

firing

of

fuel

injection pump -

are

needed, always

engine serial

on

end.

may properly identify

upon

fit

and

proper

systems.

fuel

fuel.

number,

the

silver

You

(see

or

The

and

must

generic

is

the

for

the

of

use

in

and

as

An

identification plate on the top

displays the engine model and serial

CARBON

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

even

The presence from the engine elbow/exhaust entering your

If

carbon monoxide is present, ventilate the area

air

and correct the problem immediately!

MONOXIDE

in

small

amounts,

of

carbon monoxide indicates

or

hose,

boat.

DETECTOR

is deadly.

generator or from the exhaust

or the fumes from a nearby vessel

of

the engine air intake

number.

Carbon

monoxide,

an

exhaust leak

with

also

are

clean

Engines & Generators

SPARES

Certain spares WESTERBEKE generator. dealer

See the Generator

INSTALLATION

The Westerbeke Installation Manual publication supplied with this unit.

AND

ACCESSORIES

will

be needed

will

assist you in preparing an inventory

SPARE

PARTS page in this

Acces8ories,

to

support

Your

local WESTERBEKE

manual.

see

the

ACCESSORIES brochure.

MANUAL

4

and

maintain your

of

For Engine

#043268

spare

parts.

and

is

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use SAE diesel

Care

Use in dirt particles ondary impm1ant can improper storage the f-ollowing

Pin-chase a well-known to recommended such

Diesel

into

used. Install and regularly service a

filter/water separator between the The Raycor 500 such

ENGINE

Use a heavy CG-4, initial

filter

SCHEDULE

not approve or synthetic oils using in manual

·

NOTE:

statements

SAE

For

FUEL

a diesel

only clean

your

be

tank

combat BAC1ERIAL growth

the

fuel

that

J

313

and

has a Cetane

fuel

according

Of

The

Fuel

diesel

engines

filters

rendered

Kleen + Cetane

diesel

filters.

which

to

buy

for

your

practice

A

fuel

can

clean

unsatisfactory

engine's daily use

fuel

MA

10

meets

to

ASTM

Supply

fuel!

injection

might

damage

fuel,

facilities.

is

advisable:

brand

as

Bio-Bor

Boost.

when

or 230

micron

the

requirements

rating

0975

The clearance of

pump

pass

through

these

finely

and keep it dean.

by

careless

To

ensure

of

fuel. in

and

to

help

an

Ultra

Low

good,

fuel

RMAM

filter element

OIL

duty

diesel

oil

with

an

CH-4

or

CI-4.

Change

50

hours

of break-in operation. Then

change

the

all

intervals

in

this

manual.

disapprove

are

used,

conventional

MAINTENANCE SCHEDULE section of

and

The

infonnation regarding

OIL

VISCOSITY

temperature ranges: SAE

not

oil.

be

extended

synthetic

the

engine

as

specified

Westerbeke

the

use of synthetic oils.

engine break-in

Oil

change intervals must

if synthetic oils are

above

supersedes

oil.

..

15W-40

of

No.

2-D

of

#45

or

higher

grade

the

components

is

very

critical;

the

primary

machined

handling

that

the

is

clean

and

The

use

the

fuel

tank

an

additive

restore

Sulfur

visual-type

tank

and

are

good

is

recommended.

API classification ofCF,

oil

follow

in

the

MAINTENANCE

Corporation

must

all

or

parts.

The

fuel

going

pure,

of

additives

is

such

lubricity

diesel

fuel

the

examples

and

filter

the

be

performed

be

used.

invisible and

sec-

It

best

fuel

or

into

the

as

back

is

being

engine.

after

oil

does

If

as

listed

this

lOW-40

is

of

and

of

an

...

·

ENGINE

WESTERBEKE and chemicals

The

run the cooling quality Additives balanced,

The distilled water being

NOTE:

antifreezethat'is

.

PURCHASING

Select a brand of antifreeze specified for diesel engines.

Antifreeze

additive cylinder brands engines. mixture needed.

MA1NTENANCE

MAINTEN.A8CE

Change number protect

COOLANT

The

contraction

without

provided

water

operating

COOLANT

50%

distilled

that can corrode

antifreeze

at

proper

temperatures

engine

to the coolant,

circuit

antifreeze

(SCAs)

crucial

poured

into

Look

for

specified

to

protect

walls.

that

offer

Select

will

always

Change

the

eniirte coolant

of operating

and

lubricate

RECOVERY

coolant

recovery

of the engines coolant during

iJ;ttroducing

with

coolant

the

recommends a mixture

water.

Distilled

internal

performs

from

the

double

duty.

by

transferring

and

lubricates

rust

and

corrosion.

that

to

and

the

new

now

long

contains

keep

cooling

available.

Supplemental

the

antifreeze chemically

term

protection.

antifreeze

circuit.

environmentally-friendly

water

engine

It

should

of

is

allows

and

Look

be

ANTIFREEZE

for diesel engines contains a special

against cavitation erosion

Prestone and Zerex

antifreeze specifically

the

pre-mixed variety so that

be

added

the

antifreeze mixture according

SCHEJ?ULE

are

two nationally

for

to the cooling

in

this manual.

.

every

five

years

hours

as

the

chemical

the

engine

have a limited

TANK

tank

allows

for

the

expansion

engine

air

into

the

fresh

water

conversion

engine.

. . f

. I

cooled

kit

and

system.

This recovery tank

models

must

and

be

50%

antifreeze

free

from

surfaces.

the

heat

away

protects the

for a good

Cooling

premixed before

long

of

the engine's

use

in diesel

the

correct

system

regardless

additives

ll.fe.

operation

with

installed

the

engine

from

lasting

known

when

to

the

~f

that

and

the fresh before

to

the

is

NOTE:

This located can particular

Engines & Generators

..

5

be

located

at

tank,

;vith

or

above

below

installation

its

the

maJ:es

short

level

of

this

run

the

of

plastic

engines

the

engines

necessary.

hose,

is

tnanifold,

manifold

best

but

if

it

the

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before starting your generator prolonged layoff, check

•

Make

• Check the engine the

• Check bowls

• Check the and

• Check load leads the

• Examine the air inlet (Soundguard).

. •

Be the

• Be sure that neutral requires, to

or age

•

Visually parts, threaded connections. Search for

INSPECTION

the

certain the cooling water thru-hull petcock

oil

level:

full

mark

on

the

dipstick.

the

fuel

supply

and

for contaminants.

DC

electrical system. Inspect

battery cable connections.

for

correct connections

wiring

diagrams.

and

sure

no

other generator or utility power

load

lines.

in

power

systems

is

properly grounded

and

that generator

the

load neutral. In single phase

open

neutral

can

supply

on

unbalanced

examine

disconnected

loads.

the

wires,

unit.

for

the

first

time

or

after a

following

add

examine

outlet for air

the

Look for loose or missing

unattached

oil

with

(or

ungrounded)

neutral

wrong

any

items:

to

maintain

the

flow

a neutral line that

is

properly connected

systems

line-to-neutral

hoses, fuel'

the

fuel

fiiter/separator

wire

connections

as

specified

obstructions

is

connected

as

an

incomplete

and

leaks.

is

level at

the

check

open.

in

to

the

system

volt-

A

CAUTION:

recommended motors, up

to

speed

This

precaution unanticipated prevent a cold

• Check and

at

NOTE:

After the initial

the

engine's cooling system will

recovery

the

cooling system

after the engine

tank

will

replace

Before

manifold should tank

may

that

be

switched

and,

will

operation

engine

the

coolant level

the

manifold.

tank.

Open

be

drawn into the engine

the

purged

subsequent operation

need

to

COOLANT

AT

When

starting

all

AC

loads,

OFF

until

in

cold

climates,

prevent

of

the

from

stalling.

in

both

running

the

air bleed petcock

is

purged

has

cooled,

air.

be

topped

off,

be

filled

to

RECOVERY MAINTAIN

COOLANT

1/2

TANK

LEVEL

FULL

the

generator,

especially

the

engine

starts

damage

AC

machinery

the

plastic

of

the

be

purged

of

air.

After

the

coolant from

's

cooling

of

the

generator,

and

the

MAX

large

has

to

warm

caused

by

recovery

generator,

to

the

to

shutdown

the

system

coolant

level.

it

is

come

up.

and

will

the

coolant

ensure

recovery .

the

engine's

recovery

tank

air

that

and

to

in

GENERATOR

INSTRUMENT

CONTROL

PANELS

DESCRIPTION

The

Generators

gauge

package,

engine

light,

hourmeter. The

8 pin connector that

is

used to connect an optional remote Start/Stop panel or

a second Control Panel. When

an

with

jumper should be

troubleshoolin$·

OR

alATION

STARTING/STOPPING

--·

-

START:

activates supplies

.allowing

*STOP:

··opens De-acti.vati.ng

The

the

Instrument Control contrQl

emergency

These

comJ>9nents

optional

The

the

DC

fuel

DC

Secure

START

starter

power

delivery

STOP

circuit

it

and

panel

r9Cker

switches,

stop

toggle switch

are descdbed

is

on the side

is

connected,

kept

for

future

it

to

the

lifting

INSTRUCTIONS

rocker

switch,

motor.

The

starter M

·to

the

pull coil of

to

the

injectors.

rocker switch

supplying

shutting

when

power to

down ,th•

contains a compact

circuit

and a recording

below.

of

the Control Box

the

8 pin

needs

when

eye.

when

depressed.

terminal

the

fuel

solenoid

pressed

the·K2

engine

drive.

AND

fuses,

check

connector

then

and

held,

Run

Relay.

OPERATING

INSTRUCTIONS

NOTE:

gauges,

and

·

THIS

PANEL

REMOTFLYUJCATED;

TO

THE

CANA~SO

FOLLOWING.PAGE

It is important to closely monitor the panel

Become

take

immediate

BE

REFER.

aware

of

action

.,

EMERGENCY

20A

DC

BREAKER

the

normal

if

these

--·---

STOP·

engine

readings

-

-----~-

start

readings

to

vary.

..

-.

Fuse/DC

automotive panel:

the unit's

20A

rocker switch on the front When Box can

Remote

90ntrol instrument panel

Coolalt

temperature should normally indicate: 175° to.195°F (80°

Breaker:

type fuse to protect the-run circuit and remote

:A

20 amp DC breaker is on the control box protecting

DC circuits and acts

DC

Breaker/Emergency

depressed, it will

and

shut

the

be used as a breaker to prevent an accidental start.

Panel

box will

Temperature:

to

90°C).

*:MANUAL

Should is

de~energised

is equiped with a manual shut-off lever. This

the

fixed

the

fuel injection pmnp/Move this

it there until

The control box

as

of

the panel is Nonnally

open

the

engine down. When servicing.

Plug-In:

allow

or

the remote panel start/stop.

ENGINE

the engine

throttle

A plug

for the

mount:in~

Engine coolant (water)

SHUT·OFF

fail:

when the STOP button

le.ver

the

engine

has

a

7.5

an

Emergency Stop Switch.

Stop

Switcb

DC

circuit

to

on

the side on the

of

the remote

to stop

when

on

the side

comes

of

to a stop.

amp

:

This

the Control

this

the fuel shut off solenoid

is

the engine block below

l~ver

to the left Then

Engine

depending

• 35 to

DC

Volts:

and

show

oH

switch

Hourmeter:

for when to perfonn scheduled maintenance.

Prebeat:

purposes:

1. It activates

2.

lt

activates the Instrument.pahel.and Hour MeterDC power pump. the Hold

on the DC alternator.·

depressed. The engine

is

located just below

and

hold

release.

Oil

Pressure:

on the generator load but should range between

55

psi. ·

Indicates

13V

to

14V.

Registers elapsed time and is

The.

PREHEAT

th~

preheat circuit.

the

..

K2

cOilm

Oil Pressure (psi) may

the

amount

the

battery

is being

used

rocker switch serves two

Run Relay. This supplies

the fuel sol6!loid

and

.·

the

fluctuate

charged

as a guide

DC

power

to

the fuel

R terminal

·

to

1-w"IWESTERB§KE

) EngineS & Generators

7

...

-

OPTIONAL

REMOTE

CONTROL

PANELS

DESCRIPTION

There

are

several options available

operation

1.

2.

3.

The remote the

of

your generator.

Mo'unt

a second (repeating) Instrument Control

remote location.

Simply remove

control box

NOTE:

The

installing a basic start/stop panel

Mount a remote start/stop control panel

location.

control

the

Instrument Control Panel from the

and

mount it

Instrument

)?anels

connect to

box using the extension harnesses listed

as

a remote

Control

EXTENSION

PN#056236

PN#056235

Panel

the

15

HARNESS

EG EG

OPERATING

when

selecting

panel.

can

in

the

plug

DIESEL DIESEL

control

ina

(8 (8

be

on

PIN) PIN)

replaced

remote

Panel

box.

the back of

below.

15FT 30FT

INSTRUCTIONS

in

a

by

INSTRUMENT CONTROL

PN56246

PANEL(AS

A

REMOTE

PANEL)

REMOTE

The switches

the LED this

the rocker switch, this the rocker depressed for about reach

For the REMOTE and

START/STOP

Remote

same.

panel

generator has started. When depressing LED

wiring harness, refer

Start/Stop Panel

as

the Instrument Control

This

panel

will

illuminate when the

is

remote mounted,

will brighten. This indicates

switch.

The PREHEAT rocker

10

psi,

then

release

PANEL·

has

a RELEASE

PREHEAT

this

LED

will

dim.

4-5

seconds

it.

START/STOP

to

the Table of

the

to

PANEL

DESCRIPTION

same

three

rocker

Panel.

Their function

STARTER

LED

will

When

to

switch

allow the

the

release the

Contents.

LED.

is

depressed. When

indicate when

the

START

generator starts,

is

held

oil

pressure

wiring

diagram

is

This

START

to

REMOTE

PN56320

START/STOP

PANEL

Engines & Generators

8

DESCRIPTION

Although hour assembly operated life operated

Breaking piston and glazed during

Your conditioning to

maximize Perform following:

Start section. water

AFTER

Once operation generator

tO

your

engine has experienced a minimum of

of

test

operations

procedures

properly,

of

your

and

in a new

rings

smoky

or

scored,

the

break-in

new

engine requires approximately

this

the

engine

Run

pump,

a break-in time

engine

is

serviced

engine basically involves seating

to

the

cylinder

operation indicate that the cylinder

which

period.

operation

the

perfonnance

conditioning carefully, keeping in mind the

according

the

engine

oil

pressure, battery charging)

START·UP

the

generator

and between

hours.

has been started, check

then

encourage a fast

20%

GENERATOR

at

the factory

were

followed and that the engine

dependent

during

walls.

is caused by overloading

to

break

to

the

while checking that

and

60%

to

make

is

required. The service

upon

how

its initial hours of

Excessive

50

in

each moving pari in order

and

service life

STARTING

for

warm-up.

of full-load for

one

sure

accurate

the engine

oil

hours

of

PROCEDURE

all

are

Run

is

use.

the

consumption

walls

are

the

engine

of initial

the

engine.

systems

functioning.

proper

the

first

BREAK-IN

PROCEDURE

After

the

first

can

be

increased

periodically vary Avoid

overload smoky exhaust with reduced output voltage Monitor the current being drawn from

it within the generator's rating. Since

at

1800

rpm

50

Hertz), control

the

current drawn

NOTE:

Be

aware

draw

required

draw

can

be 3 to 5 times

GENERATOR

GENERATOR'

Once

the generator has been placed the initial 50 hours ofbreak.-in operation AC

(raw

voltage output may need adjustment using

pod on

the

GENERATOR

AVR

10

hours of to

the

at

all

to

produce

of

from

of

for starting

INFORMATION

the

generator's

the full-load rated

load.

times.

An

60

hertz (or at

the generator's break-in

the

generator.

motor starting

motors.

normal

output,

overload

the

1500

loads

This

running

in

this

manual.

operation,

is

generator

and

starting

amperage.

ADJUSTMENTS

in

operation

or

found in the generators control box.

section of this

manual

for

the

then

signaled

and

rpm

the

after,

infonnation.

frequency.

to

is

governed

high

amperage

and

the

voltage

by and

operates

produce

current

See

during

no-load Review

load

keep

by

CHECK

Follow

•

CHECK

•

LIST

this

check list

Check

that

all

generator circuit breakers (power

in

the

off position before starting.

Record relate

Any deficiency be

Visually Check Check Check

Check Check

Check

blow-back

Confirm When When When

the

hounnete:r

to

the maintenance schedule).

or

corrected before start-up.

inspect

the

oil

level

the

coolantlevel in the coolant recovery

your

fuel

the

starting

drive

belts

WITH

ENGINE

for

abnormal

sounds.

exhaust

the

engine

the

engine

the

engine

each

day

before starting your

reading in your

problems

engine for

(dipstick).

supply.

batteries

for wear

noise

·

smoke:

is

cold

is

warm-

is

overloaded - some black

in

the

fuel,

(weekly).

and

proper tension

RUNNING

such

as

- white smoke. almost

following

oil, or water

knocking, vibration

smokeless.

log

THE

generator. panel)

(engine

hours

items

leaks.

tank.

(weekly).

smoke.

DAILY

ROUTINE

NOTE:

This is

are

reached

CAUTION:

periods

=generator.

must

STOPPING

Remove time. the and

STOP.

and

Some

unstable

condition

and

Do

of

time

THE

the

AC

Allow

the generator

operating temperatures. Then

·hold.

depressed until the generator

should

loads

not

running

abate

are

operate

may

as

applied.

the

without a load

GENERATOR

amperage loads from the generator

to

run

occur

normal

operating

generator being

placed

for

3-5

depress

comes

in a cold

for

long

on

minutes

the STOP

to a complete

engine.

temperature

the

one

at

to

stabilize

switch

a

Engines & Generators

9

MAINTENANCE

SCHEDULE

WARNING:

gloves,

and

Box

or

tum

off

SCHEDULED

Maintenance

I

DAllY

Coolant Engine Fuel/Water

Fuel

Visual

Keep

wiHlnhibit

Drive

'INITIAl

Engine

*Exhaust

•valve Inlet

Fuel Generator

MAINTENANCE

procedures

CHECK

Level

Oil

Level

Separator

Supply

Inspection

the

engine

the

engines

Belts

50

HOURS

Oil

and

System

Adjustment

Fuel

Filter

filler

Nevsr

attempt

use

the

correct

thti

battery

are

BEFORE

surface

of

Engine

ability

START-UP

(owner

clean,

to

OF':OPERATION

Filter

to

perform

tools

switch.

all

detailed

installed}

dirt

and

dfsapate

oil

heat

for

in

any

each

this

SBtvice

job.

manual.

while

the

engine

When

SBtViclng/replacing

EXPLANATION

Check Oil

level

Check hours

Use there

Check securing connections

Inspect

Initial

Check Ensure

Check Initial Initial Check

is

at

recovery

should

for

water

or

once a year.

properly

is

adequate

for

fuel,

v-clamp

..

for

frayed

engine

oil

security

there

are

adjustment change. change.

that

AC

running.

filtered

Look

Wear

DC

components,

OF

SCHEDULED

tank,

if

indicate

between

and

dirt

#2

diesel

fuel

for

oil

and

water

is

tight.

for

loose

edges.

and

filter

of

water

Injected

no

leaks.

of

valves

connections

the

proper

MAINTENANCE

empty,

check

MAX

in

fuel.

Drain

with a Cetane

the

vessel's

and

exhaust

No

exhaust

bolts/hardware

Belts

must

change

at

50

exhaust

at

50

hours,

are

secure

turn

at

and

filter

needs.

leaks.

leaks

be

properly

hours,

elbow

then

with

safety

off

the

manifold.

LOW

on

if

necessary.

rating

Check

around

and

correct

tensioned.

then

to

exhaust

every

no

chafing.

equipment

DC

circuit

Add

coolant

dipstick.

Do

Replace

of

#45

or

higher.

that

the

water

the

elbow.

Inspect

as

needed.

every

250

hours.

manifold.

·

500

hours.

such

as

breaker

if

needed.

not

overfill!

filter

every

Check

injected

wifing

goggles

on

the

Control

250

operating

that

exhaust

and

electrical

and

elbow

I

EVERY

50

OPERATING

Drive

Belt

Starting

Batteries

Electric

Fuel

Pump

Zinc

Anode

I

EVERY

100

OPERATING

Air

Intake

and

Filter

*WESTERBEKE

recommends

HOURS

{if

applicable)

OR

this

MONTHLY

OR

YEARLY

service

be

performed

Inspect for

Check off

Inspect Inspect

your

Keep

by

an

knowledgeable

for

proper

slipping,

electrolyte

corrosion

for

leaks,

and

clean

own

inspection

air

intake

tension

cracking

levels

if

needed.

ensure

zinc

clear

mechanic.

(3/8"

and

wear.

Make

sure

Apply

petroleum

fuel

and

anode.

Replace

schedule.

of

obstructions.

to

1/2"

Adjust

cables

electrical

Clean

deflection)

tension

or

and

connections

jelly

to

connections

if

necessary.

air

fflter

and

adjust

replace

terminals

are

Note

the

(if

applicable).

if

needed.

as

needed.

are

in

for

corrosion

clean

condition,

Replace

good

and

Check

cover.

order.

Clean

protection.

tight.

then

determine

belt

l"fN'f'IIESIERBEICIE

· Engines & Generators

10

MAINTENANCE

NOTE:

Use the engine hourrneter gauge to log your engine hours

SCHEDULE

or

record

your

engune hours running time.

SCHEDULED

I

EVERY

Exhaust

Fuel

Inlet

Generator

Hoses

Fuel DC

Engine Raw

EVERY

Raw

Coolant

*Valve

Cooling

MAINTENANCE

250

OPERATING

Elbow/Exhaust

Filler

and

O·Rings

Fuel

Filter

Water

Separator

Alternator

Oil

and

Filter

Water

Pump

500

OPERATING

Water

Pump

System

Clearances

System

Hoses

System

Filler

Impeller

HOURS

OR

YEARLY

OR

FIVE

YEARS

EXPLANATION

Check

the

of

the

exhaust

chaffing.

NOTE:

An

Remove Remove Check

that

See

GENERATOR

Engine

delaminated. Inspect Inspect

Check

mounting

Change Remove

Remove and

cover

at

re-assembly.

Drain,

flush

condition and

connecting

Adjust

valves.

Check

hose

structual

No

exhaust

and

replace

and

replace

AC

hoses

should

Check

bowl

for

wiring,

engine

and

inspect

and

disassemble

for

wear

and

of

the

condition

OF

SCHEDULED

integrity

system

leaks.

leak

fuel inlet

connections

INFORMATION.

be

and

dirt

or

connections

bracket

oil

and

impeller.

and

re-fill

sealing

hose.

(Incorrect

of

attached

Hoses

will

cause

filter

fuel

are

firm

and

tighten

water

should

and

alternator

filter

every

the

corrosion.

the

cooling

gaskets

valve

and

securing

MAINTENANCE

the

water

injected

to

the

elbow.

All

and

muffler

are

exposure

and

filter.

clean

tight.

all

in

fuel.

250

Replace

pump

system

of

clearance

all

sealing

and

secure.

Replace

hose

clamps

Drain

be

tight.

bolt. hours if

blades

and

inspect

Replace

with

the

pressure

will

clamps,

to

diesel

0-rings.

and

Alternator

All

or

the

impeller

appropriate

result

replace

exhaust

hose

in

good

exhaust!

Ensure

if

hoses

as

needed.

replace

should yearly. have

cracks

all

parts:

cap.

Clean

in

poor

as

elbow

{asting.

connections

serviceable

wires

have

become

spongy,

filter.

should

be

and

needed.

clean

tight.

or

missing.

drive

gear,

gasket.

antifreeze out

coolant

engine

Check

the

should

be

secure.

condition.

no

chafing.

brittle

or

and

free

pump

shaft,

Lubricate

performance.)

mix.

Inspect

recovery

the

tank

integrity

No

of

corrision.

wear

impeller

the

plate

EVERY

1000

OPERATING

Heat

Exchanger

Starter

Motor

Fuel

Injectors

Position

Crankcase

*WESTERBEKE

recommends

HOURS

Ventilation

Valve

this

OR OR

service

EVERY

be

performed

FIVE

YEARS

Remove Check

starter Pressure Disassemble

by

an

knowledgeable

the

heat

solenoid

motor

pinion

test

the

and

exchanger

and

motor

drive. injectors, clean.

Replace

mechanic.

for

professional

for

corrosion.

rebuild

as

Remove

at

1500

needed.

cleaning

hours.

and

pressure

lubricate.

testing.

Clean

and

lubricate

the

Engines & Generators

11

DIESEL

Use of

combustion

peiformance.

· Cetane Boost to

FUEL

A primary instailed water be carried

A typical diagram. that fuel in tion

· certain free of

·and maintaining a proper

FUEL

The

the The

and

it

authorizep attempt shims with

FUEL

No.2-D

#45

"if

supply tank

the

equipment.

fuel

diesel

fuel

the

If

it requires servicing, remove it

(SAE

J313)

or

higher.

A lower

deposits

WATER

fuel

between

apd

other contaminants

to

fuel

This

a water separator type

fuel.

will

the

fuel

impurities.

INJECTION

injection

engine,

injection

owner-operator is cautioned

fuel

to disassemble

the

with

Use

an

additive

help

restore lubricity

SEPARATOR·

:filter

of

the

fuel

system

:filter/water

is

the

Raycor

and

engine-mounted

affect

the

The

owner/operator

reaching

This

TYPICAl

FILTER/WATER SEPARATOR

PUMP

pump

requiring

pump

injection

diesel

fuel

with a Cetane

Cetane

the

.

the

fuel.

separator

fuel

the engine's

process

filtration/separation

FUEl

is the most important

has been

pump

and

pump,

rating

exhaust

such

water separating

tank

on

Model

:filter

pump,

the

repair it.

and

as

"Diesel Kleen+ with

and

the

from

the

engine. is

illustrated

500

is

not

fuel

engine

is

responsible

injection

is

accomplished

utmost caution in

thoroughly

not

and

service

facility.

Do

leave

on

will

result

poor

low

..

type

engine

fuel

before

MA.

installed

system,

:filter,

1 0 element

to

attempt

take

it

not

send

engine.

FUEL

rating

in

engine

sulfur

diesel.

must

be

to

remove

they

can

in

this

Keep

in

mind

between

any

water

and

injec-

for

making

equipment

by

installing

system.

micron

filter

recommended.

component

handling.

bench-tested

to

service

to

an

Do

not

the

timing

SYSTEM

the

is

of

ENGINE

Perioilically Ieakage. the

Changing

1. Shut

2.

3.

4.

5.

6.

FUEL

check

Change

MAINTENANCE

the

off

the

'

NOTE:

Slide

as

it

wiU

be

l!nscrew cartridge

Wipe with

To with reduce engines

Install Open

both

clean

help

diesel

reduce

the

fuel

the

the and

fuel

FILTER

the

fuel

the

filter

SCHEDULE.

Filter

fuel

supply.

a plastic

full

of

fuel.

cartridge

its

gasket.

the

housing

fuel.

fuel

before

installing.

priming

new

time

system

cartridge

supply.

connections

element

after

Cartridge

bag

up

over

from

its

housing

and

the

top

system

priming,

This

needed

before

starting.

and

spin

Run

the

engine

LIGHTLY

WITH

WHEN

THE

ALTER

and

the

first

.

the fuel filter

and

of

the

fill

the

will

dramatically

to

purge

air

on

real

tight

to

inspect

WIPE

CLEAN

FUEL

INSTALLING

NEW

FUEL

CARTRIDGE

filter

50

remove

new

fuel

from

bowl

hours.

See

cartridge

the

cartridge

filter

the

by

ha!!d.

for

leaks.

for

BLEED

The bleed

open engine's air

fuel return

SCREW

position.

fuel

in the

~re.w

on

the

injection

This

will

then

allow

system and during engine

system

to

be delivered to

system.

pump

for ease

the

should

in

operation

fuel

tank

be

left

in

the

priming

allow

through

the

for

the

FUEL

Periodically pump fittings

. one ofthe

secured operations.

INLET

To

ensure

in-line

fil~r

,..,..,.,WESJ!RBEKE

.Engines

It

Generators

12

LIFT

PUMP

check

the

and

make

sure

that

are

tight

and

secure.

pumps

J.l10Unting

by

the

mounting

FUEb,FILTER

clean

fuel

into

fuel

filter

connected

should

be

replaced

fuel

connections

no

The bolts

bolts

the

to

every

iNCOMING

leakage

fuel

is

DC

ground

should

to

ensure

lift

pump,

th~

fuel

250

hours

FUEL

to

and

present

be

proper

lift

pump

of

out

of

the

and

that

the

connection

clean

pump

there

operation.

at

and

well

is a small

ell~ow.

This

DESCRIPnDN

Westerbeke for

fresh bustion which water parts, from

exchanger,

water

fresh ferred tube exhaust system other coolant is cooled transferred fresh each allows harmful

RAW

A major part of the boatyard/builder installed intake

NOTE:

the

strainer

A

clean engine's cooling strainer

in

the

Perform operation:

1.

Close the raw water seacock.

2.

Remove

3.

Clean

4.

Replace

5. Reassemble

6.

Open the seacock.

7.

Run

NOTE:

agroun4.

If

the engine temperature gauge ever

·

normal may

·raw

water through

marine diesel engines are designed

water cooling. Heat produced in

and

friction

circulates throughout coolant and

the

fresq

similar in

flows

through

water

coolant

to

the

walls

to

words,

heat

water

coolant

other.

Using

the

cooling water passages

deposits.

WATER

Always

will

raw

water intake strainer is a vital

when

glass

should be

the

following maintenance after

the

the washer

the

engine

Also

follow

reading,

have

been caught up in

is

transferred

c.ools

the

engine block; its internal

engine

oil.

The

water

coolant to

function

the

tubes

flows

around

fresh

water coolant

the

raw

water which

where

finally

the

engine

is

cooled

by

raw

water,

overboard through the exhaust

and

raw

only

fresh

INTAKE

install

always

system.

making

and

clean

glass.

and

the cause

STRAINER

raw

water cooling system

the strainer at

be

self-priming.

Include a visual inspection of your periodic engine check clear.

the

strainer

if

necessary.

install

the

and

check for

the

above

may

the

cooling

the

engine

to

fresh

water coolant·

the

engine.

heat is transferred

raw

to

of the heat exchanger

it

is

and

water circuits

water coolant

strainer.

procedure

be

the

strainer,

system.

This circulating

water

an

automotive

the

tubes;

is

conducted

is

then

discharged

by

fresh

the

raw

to

stay

strainer.

or

below

filter.

leaks.

after

shows

that

silt,

by

means

engine

through

pumped

overboard.

water

are

independent

within

clean

is a proper

the

component

every

having

a higher

leaves

slowing

COOLING

and

equipped

by

com-

fresh

moving

externally

of a heat

radiator.

coolant,

system.

and

100

Raw

while

heat

trans-

the

into

the

In

carries

The

the

engine

free

from

waterline

of

the

this

The

water

hours

run

hard

than

or

grass

the

flow

this

the

of

SYSTEM

STRAINER

'FILTER

of

so

SEALING

GASKET

--rJM""'

SEA

COCK

DRAINING

When

freezing temperatures

protect

·

from

damage.

This

procedure

water

intake hose

intake

end

into

Provide maintain operated during

Run

the

raw

water

Once

the raw water

buckets

engine water

circuit.

discharged

This

antifreeze mixture should protect the

system Re-attach

intake

valve

When

recommissioning, seacocks water.

If

water

can

'

TYPICAL

the

valve before disconnecting the hose. Insert

a large container of

an

the water

unit

content

and

.the

are

the

RAW

WATER

INTAKE

(Owner

Installed)

~

THE

RAW

WATER

raw water cooling circuit

is

best accomplished

from

the

external

system.

allow

from

exhaust

stay

fresh

level

in

the

flushing

for

10

minutes

system

with a 50/50

this

mixture

Once

this

antifreeze

the exhaust

from

water intake

before starting

make

open

so

the

engine will

engine

is

stowed

in

the

engine.

SYSTEM

are

expected,

vessels

fresh

water

supply

the

bucket while

process.

or longer

has

been

antifreeze

to

be pumped through

opening,

freezing.

valve

and

the

engine.

certain the

where

STRAINER

it

and

engine exhaust

by

disconnecting the

thru-hull

water.

mixture

fitting.

for

the

to

adequately

flushed,

mixture.

is

shut

the

raw

remember

valves

quickly

it

is

warm,

is best

bucket

the

unit is

replace

Run

visible

engine

water cooling

to

and

receive

the

INSPECT CLEAN

AND

EVERY

100HOURS

to

Close the

the

hose

to

being

flush

the

raw

being

down.

open

the

fresh

Engines & Generatol"$

13

COOLING

SYSTEM

FRESH

NOTE:

ommended antifreeze

fresh water coolant.

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

When the engine is started cold, external coolant flow 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 cooling system.

RECOVERY

FROM

RECOVERY

WATER

Refer to the

TO

COOLANT

TANK

COOLANT-

TANK

COOLING

ENGINE

CIRCUIT

COOLANT

and

water mixture to be used as the

of

the circulating pump.

KEEP

COOLANT

CLEAR

COOLANT

section

THE

PASSAGE

EXPANSION

for

the rec-

is

pre-

of

the engine's

of

the

PRESSURE

/CAP

CHANGING

The

engine's coolant must

MAINTENANCE

become contaminated,

A

critical; a substantial traced

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

NOTE:

to help drain engine coolant.

COOLANT

be

changed according to the

SCHEDULE. If the coolant is allowed to

it can lead to overheating problems.

CAUTION:

back

The drain on the heat exchanger should also be us(td

Proper

to

cooling

number

system

of

maintenance

engine

corrosion.

th~

refill process.

failures

OIL

GALLERY

can

is be

COOLANT

NOTE:

Periodically check the condition pressure cap. Ensure the good

condition. Check to ensure . the vacuum valve opens closes tightly. cap.

Check also to ensure the coolant passage is coolant

able to expand to

and

from the coolant recove1y

Coolant

A coolant recovery tank allows for engine coolant expansion

and contraction during engine operation, without any significant loss ing system. This tank should engine manifold level and should be

NOTE:

11zis

located

Cany

within. the,system is

and

Recovery

of

coolant and without introducing air into the cool-

tank, with its short run

at

or

above

upper

and

a spare

clear

so

contract

Tank

tlze

level

RETRACTION

and

lower rubber seals are

tank..

9e

located at or

ea.Sily

of

the engine

of

the manifold

~hove

the

accessible.

plastic hose, is best

:S

manifold.

SEAL

in

Refilling

After closing the engine block drain, pour clean, premixed antifreeze coolant into the open filler neck. When coolant is visible in the filler neck, start the engine. petcocks when present exchanger.

Monitor the coolant in the filler neck and add keep coolant is flowing from them close each. Top off the filler neck with coolant and install the pressure cap.

Remove the cap coolant the cap. Run the engine and observe the coolant expansion flow into the recovery tank.

After checking for leaks, stop the engine and allow it to cool. Coolant should draw engine cools down. needed. Clean up any spilled coolant.

A

Wear

the

Coolant

Open the air bleed

on

the thermostat housing and heat

as

needed to

it

filled. Monitor the air bleed petcocks and when clear

on

the coolant recovery tank and fill with

mix

to halfway between

back

Add

WARNING:

protective

Beware

gloves.

coolant to the recovery tank

LOW

and

MAX

and replace

into the cooling system as the

if

of

the

hot

engine

coolant.

Engines & Generators

14

COOLING

SYSTEM

THERMOSTAT

A thennostat, located near the manifold at the front of the

as

engine, controls the coolant temperature

flows

continuously

When

the engine is first started, the closed thermostat pre-

vents

coolant through a bole in the thermostat manifold thermostat gradually opens. The thermostat is accessible and spare thermostat

from

can

be

checked, cleaned, or replaced easily. Carry a

through the closed cooling circuit.

from

flowing

overheating). As the engine

and

gasket.

(some coolant

to

prevent the exhaust

the coolant

is

by~passed

warms

up,

the

~~.

,

....

~

....:::::::-:-

r tighten the three

· run

l~

1 . .

REPLACING

1. Drain off some

and thermostat housing. This can be exchanger

2.

Rotate the thermostat

as

shown

down

be twisted

3.

Remove/replace

installing

both side of the gasket before pressing it

THE

drain

the coolant to

drain

and

remove the

the

thermostat housing

enough

the

new

THERMOSTAT

coolant:

plug.

the gasket and thermostat:

HEAT

EXCHANGER

Release the coolant pressure

the

approximate

done

assembly:

three

allen

cover,

to

access

the

gasket and

parts,

apply

a thin coat of sealant on

/

4.

R,-

bose

· leaks

clamp

the

around

and~

screws.

and

tighten

engine.

Check

the thennostat

Thm

Do not

the

for

lhe

over-ti.ghten!

drains.

normal

assembly:

cov«

level

using

the

Loosen

Top

temperature

screws

the

assembly

back

off

the

that

thermostat.

into

intO

the

cap

off

the

heat

hose clamp

hold

can

now

When

place.

place>md

Tighten

coolant and and

for

·

the any

THERMOSTAT ASSEMBtY

GASKET

SEAL

WfTHHI-TACK

#052946

COOLANT TEMPERATURE

~NS~R

11035109

~·

THERMOSTAT

HOUSING

Engines & Generators

A

CAUTION:

down

before

attempting

is

the

surface

temperatures

The

of

can

e1111ine

the

engine

be

at

lfiUSI

these

hot

190•

F.

be

allowed

procedures.

but

coolant

to

Not

cool

DIJ.IY

15

COOLING

RAW

WATER

The raw water impeller pump. ocean, lake, or river through a hose to the water strainer. The . raw water passes exchanger (through the the engine then discharged into ing with exhaust

Raw

The

non-ferrous housing and a neoprene impeller. The impeller

has within the impeller housing, On lubricant

·impeller and impeller cover gasket aboard Raw water) are raw water

NOTE:

(seals and

purchase a new pump and rebuild

aspare. ·

·Inspecting/Changing

Close the and, impeller out

1\

care

gasket.

.

and' push

assembling, and gasket. Open the

Run the engine check for water discharge at the stem tube. Absence of flow

NOTE:

of

gas

Water

raw

flexible vanes which wipe against a curved cam plate

no

account should this pump be

water pump impeller failures occur

is

not warrantable, and operators

·-"

Should a failure occur with the pumps

with the proper size impeller tool, carefully pry the

pair of screwdrivers

riot

·Move

indicates the pump has not primed itself

Never

dry

running

COOUNG

flow

This pump draws water directly

from

·circulating fresh water coolant. The

and

cooling

and

raw water is pushed overboard.

CIRCUIT·

is

created by a positive displacement

from

the strainer through

beat exchanger tubes) where

the

water injected exhaust

the

exhaust gasses. This mixture of

the

heat

raw

elbow,

the

it

cools

water is

mix-

Pump

water pump

for

the

not present during engine operation. Such failures

flow

'

bearings),

raw

of

to

tear the impeller). Install the

the

impeller into the pumps housing. When

apply

allow

RAW

is

a self-priming, rotary

producing the pumping action.

run

impe1ler.

is present

~·-

··-

water intake valve. Remove the pump cover

the pump (the impeller

the

blades

and

may

WATER

PN52650

There should always

are

at

start-up.

-·

it may

be

more

cost efficient to

the

original pump

the

Raw

Water

if

an

impeller puller

to

conform

a thin coating

raw

water intake valve.

check for leaks around the

the

pump

destroy

the

to

of

lubricant to the impeller

to

run

dry.

impeller.

PUMP

pump

with a

dry

as

water

acts

be

a spare

(an

when

cautioned

internal

impeller

lubricant (raw

to

kit).

make

parts

as

Pump

Impeller

can

be pried out using

is

unavailable.

new.

impeller and

the curved cam plate

pump.

Also

w.ater

properly.

Even

a short period

as

sure

Take

SYSTEM.

a

Heat

The heat exchanger encloses a number pumped through these small tubes and antifreeze coolant from removes heat from the antifreeze coolant.

Zinc

A zinc anode, circuit within anode is in

the

of

electrolysis

dition ofthe zinc anode should

anode cleaned or replaced

carried

be

NOTE:

installation and

If

the zinc pencil needs replacement, hold which ening the anode with another wrench. This prevents the boss removing the zinc, poor condition, there

. the exchanger. Remove

clean the inside of exchanger end gasket aged

to

your engine model's heat exchanger

ber);

.

NEW

.BAD

Exchanger

the

engine

PN. 052493

is

made up

of

small cupro-ilickel tubes. Raw water

is

circulated around the

of

a copper tube which

tubes.

Anode

or

pencil,

is

located

the

heat

exchanger. The putpose of the zinc

to

sacrifice itself

raw

water cooling circuit, thereby reducing

on

other components

on

board.

Electrolysis

vessel

the zinc pencil

from

possibly tearing off the exchanger shell. Mter

when

removing

a-ring,

cover,

to

as

action

is

location;

is

threaded with a wrench while loos-

note

the

are

probably a lot of zinc

the

all

zinc debris. Always have a spare

in

case

the

end

and install a

in

the raw water cooling

electrolysis action taking place

of

the system. The

be

checked monthly and

required. Spare anodes should

the

result

of

each

not that

condition of it. If

end of the

the cover.

new

of

the

heat

exchanger

present one becomes

Replace the gasket (refer

end

gasket part

zinc pencil.

v.~RAW

WATER

-~·······'-----····

. .

DRAIN

-~

CLEAN' AND

'

REUSE

ZINC

ANODES

is

The

raw

water

the

effects

con-

the

particular

generator.

hex

boss into

hex

the

zinc

is

in

flakes

within

and

heat

dam-

num-

INSPECTION:

EACH

BLADE

BY

REPLACE

·ANY

THE

CRACKS.

CHECK

THE

BENOING

IMPELLER

BASE

OF

VIGOROUSLY.

IF

THERE

ARE

Heat

After approximately 1000 hours and

presSure

motive radiator shop should be able

i exchanger.)

•:

'

·. · NOTE:

,.,A,rrt:J'...;'

Enf1ines & Generators

that a heat exchanger cleaning be performed every 1000

16

Exchanger

Operating

test

the engine's

in

Service

sz'lty

hours.

of

operation,

heat

exchanger. (A local auto-

to

clean

and

and/or tropical waters

more

remove,

test the

may

often

clean

heat

require

than

ENGINE

LUBRICATING

OIL

ENGINE

1.

NOTE:

{)IL

CHANGE

Draining

the

while pletely, cap securely.

the

Oil

Sump.

Discharge the used oil through

sump drain hose (attached to the front

tl1e

engine is still warm. Drain the used oil com"

replace the hose in its bracket, and replace the end

Thread size

for

the lube

oil

drain

hose

of

the engine)

capped

I/4NPT.

\IW<CIVIUVI:

2.

Replacemmt

oil

filter,

in

hole

drain the oil from it into a container before removing

This helps

filter wrench should be helpful in removing the old oil

filter.

NOTE:

Do

to make certain it can be removed!

of

the

Oil Filter. When removing the used

you may find it helpful and cleaner to punch a

tl1e

upper and lower portion

to

lessen spillage. A small style automotive

not

punch this hole without

of

the old filter to

flrst

loosening the filter

end

DRAIN

UP

THRU

is

USING

THE

it.

·

AN

OIL

3. Filling

Use a good brand specification as stated this manual.

Change the engine oil and oil filter after the ofengine operation thereafter.

BMM

(11/16"}

OR

PUMP

HOSE.

the

Oil

Sump.Add cap on the top After refilling, run the generator for a checking the oil pressure. around the stop the engine. lube oil dipstick. Fill to, but not over the high mark on the dipstick, should the engine require additional oil.

break~in

SOCKET

THE

WARMED

of

the engine

new

oil filter or from the oil drain system, and

Then

of

engine oil having an API and SAE

in the SPECIFICATIONS section

operation and then every 250 hours of

·

new

or

Make

check the quantity

oil through the oil filler

through the side oil

few.

moments while

sure there is no leakage

of

initial 50 hours

fill.

oil with the

OIL

COOLER

of

When installing the

gasket's sealing surface

apply a thin coat

the new oil filter. Screw the filter nipple, and then tighten the filter firmly by hand.

WIPE

BEFORE

NOTE:

Use genuine

are

not

recommended. ·

new

of

SURFACE

INSTALLING.

oil filter element, wipe the filter

on

the engine block free

clean engine oil to the rubber gasket on

onto the threaded oil filter

APPLY

CLEAN

ENGINE

OIL

WHEN

INSTALLING

CLEAN

WESTERBEKE

oil

filters. Generic filters

of

oil and

Engines & Generators

17

A

WARNING:

contaminants.

and

nails discard used

oil

Avoid

thoroughly

clothing

properly.

.

Used

engine prolonged using

or

rags

oil

contains

skin

soap

and

containing

contact. water.

used

oil.

harmful.

Clean

Launder

Recycle

skin

or

ENGINE

TROUBLESHOOTING·

PROBLEM

Preheat Preheat

Preheat

Preheat No activation.

Preheat Preheat activate.

Preheat

Preheat solenoid

pump Preheat

Nothing Start

No

Start Unit

start

Unit

preheat while

Generator slows

Stop (Manual

20 unit

DC

depressed solenoid

depressed

solenoid

panel

or

depressed. solenoid,

No

depressed.

solenoid,

activate.

activation.

depressed.

activates.

depressed.

starter

activation.

depressed.

starts,

released.

starts,

release,

preheat

drive

and

stops.

depressed.

shut

amp

breaker

stops.

alternator

does

activates.

fuel

solenoid

panel,

fuel

solenoid

panel, No

shuts

down

shuts

down

stays

depressed.

engine

Engine

off

must

turned

not

charging.

not

activate.

fuel

activation.

fuel

when when

running

will

be

used).

OFF

pump

.

not

PROBABLE

1.

Poor

ground.

2.

No

voltage

3.

Faulty

solenoid.

1.

Open

diode.

2.

Fau!Jty

K2

1.

Faulty

current

2.

Faulty

fuel

1.

Faulty

ground.

2.

No

voltage

3.

Faulty

pump.

1.

Battery

2.

20

3._

7.6

1.

Faulty

2.

No terminal

3.

Faulty

4.

Faulty

1.

Faulty

2.

Faulty

1.

Faulty

1.

Faulty

2.

Air

3.

Block

4.

Co_ntaminated

1.

Faulty

1.

Faulty

2.

Faulty

1.

Drive

2.

Regulator

3.

Faulty

off.

amp

DC

amp

fuse

K1

relay.

voltage

or

starter starter. current

fuel safety

fuel

in

fuel tank

DC

alternator.

K2

relay.

fuel

belt.

alternator.

CAUSE

at

"S"

terminal.

TB2-2

relay.

timer.

solenoid.

to

fuel

pump.

breaker

blown.

at

solenoid

low

voltage.

solenoid.

timer.

solenoid.

shutdown

pump.

system.

vent.

fuel

filter(s).

solenoid.

circuit.

to

TB2-6.

off.

activation

switch.

1.

Check

2.

Check circuit.

3.

Replace

1.

Check

.

2.

TesVreplace.

1.

Test/replace.

2.

TesVreplace.

.

1.

Check

2.

Check

3.

Test

pump.

1.

Check/turn

2.

Check/turn

3.

Check/replace.-

1.

TesVreplace.

2.

Check circuit/charge

3.

TesVreplace.

4.

TesVreplace.

1.

TesVreplace.

2.

Test/replace.

1.

Check

1.

Test/replace.

2.

Test

system/correct.

3.

Check/clear

4.

Check/replace.

1.

Un-plug Repair/replace

1.

TeSVreplace.

2.

Test/replace.

1.

Check

2.

Check Correct.

3.

Repair/replace.

VERIFJCAnON,IREMEDY

good

ground

for

voltage,

solenoid.

diode/replace.

ground voltage

Jump

on. on.

voltage

switches.

blockage.

"R"

terminal.

tension/replace.

excitation

thru

jump

-voltage

circuit. circuit.

voltage

9.6

volts

or

battery.

Replace

Depress

alternator.

DC

voltage

mounting

to

pump.

better.

Check

'

as

needed.

stop,

at

"R"

bracket.

"S".

Replace.

shut

terminal.

Check

down

l"ff'V"iWESTERBEKE

. .

Engines

--

&

Generators

18

..

ENGINE

ADJUSTMENTS

·

DRIVE

For equipped of NOT proper

The belt tension can cause rapid wear service the resulting

The The

1.

2.

3.

4.

5.

6.

7.

BELT

ADJUSTMENT

your

safety,

WESTERBEKE generator models come

with

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

the

engine. ("Out of Sight-Out

installed

drive

presence of

generator tension adjustment procedure for the belt

A

drive

Remove Loosen the alternator adjusting strap bolt and the base

mounting bolt. With

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

right The

.

less (12mm) midpoint between the the

belt.

Operate and

Replace

for

that purpose). Operators are advised that

inspection, service and maintenance is required.

belts must

life

of

in

high

WARNING:

belt's

the

belt loose, inspect for

as

required,

drive

belt is properly adjusted

than

3/8

as

the

recheck the belt tension.

the

be

properly tensioned. Excessive

the fresh water pump's bearing. A slack belt or

oil

on

the belt can cause belt slipping,

operating temperatures.

has

one drive belt that drives the DC alternator.

Never

tension

the belt

while

belt guard.

to

loosen or tighten.

inch (10mm) and

is

depressed with the thumb at the

two

generator for about 5 minutes then shut down

belt guard.

of

Mind". The belt guard

of

the belt and reduce the ·

is

as

attempt

to

check

or

adjust

the

engine

pulleys on the longest span

is

in

operation.

wear,

cracks, and frayed

if

it can be deflected

no

more than 1/2 inch

follows:

drive

the

of

no

is

FUEL

INJECTORS

Fuel injectors should be removed for service/rebuild and reinstalled by a competent mechanic. Information regarding fuel

injector removal/inspection/rebuild/testing is found in the

Service Manual for the models listed in thus manual. An

authorized Fuel Injection shop should be contacted when

fuel

injection is required. Injector servicing Injection shop generally not

Authorized Fuel Injection Repair Shops can be located through your area yellow pages.

NOTE:

Clean

prior

to

any

rust

hole.

If

by

carbon

side

with

it

and

then

TYPICALALTERNATOR

ASSEMBLY

is

performed

fo1;1nd

in your standard diesel service

the

area around

lifting

it out

of

or debris from falling

the

injector will not lift out easily and is held

build

up

or

the

aid

of

the

lift it

out.

in

the

cylinder head

the

like,

l7mm

deep

a "clean room" environment

base down work

socket wrench

of

into

the

at

a Fuel

the

injector

to

help prevent

the

injector

shop.

si9-e

to

in to

free

TROUBLESHOOTING

If

the

gauge reading is other than what is normally indicated

by

the

gauge when the instrument panel

step

is

to

check for

and

the

Negative

Assuming instrument panel energized( engine on( and perform the following

1.

2.

that there is

steps:

Disconnect the sender wire gauge reads zero, which is the normal reading for this situation.

Remove engine

and should register this

situation.

12

volts DC between the ignition (B+)

(B-)

terminals of the gauge.

12

volts

as

required, leave the

at

the gauge and see

the

electrical connection at the sender

ground it

to

full

scale, which

the engine metal. The gauge

is

the normal reading for

WATER

is

energized, the first

if

on

TEMPERATURE

the

AND

If both undoubtedly OK and the problem lies either with the conductor from the sender to the gauge or with the

If either defective and should be replaced.

Assuming the gauge is OK, check the conductor sender

Check that the engine block is connected Some starters have isolated ground terminals and if battery terminals), the ground side will not necessarily be connected

to the block.

OIL

PRESSURE

of

the gauge tests are positive, the gauge is

of

the gauge tests are negative, the gauge

to

the sender terminal

is

connected to the starter (both plus and minus

GAUGES

at

the gauge for continuity.

to

the ground.

sender.

is

from

the

probably

the

NOTE:

WESTERBEKE

be

ments below

is

ENGINE

performed

provided

recommends

by

a competent

to

assist

ADJUSTMENTS

that

the

following engine adjust-

engine

the

mechanic.

The

information

OIL

MANIFOLD

TESTING

To

test

OIL

PRESSURE

the

oil

pressure, remove the oil pressure sender, then install a mechanical oil pressure gauge in it's place. After warming up the engine, set the engine speed the

oil

pressure gauge.

OIL

PRESSURE

LOW

·The

specific

ual

loss

WILL

RANGE

OIL

PRESSURE

safe

minimum oil pressure

of

oil

pressure usually indicates wom bearings. For

BETWEEN

50

AND

55PSI

is

5 -

at

idle and read .

AT

1800

RPM

10

psi. A grad-

additional information on low oil pressure readings, see

ENGINE

TROUBLESHOOTING

chart.

the

VALVE

ADJUSTMENT

(

located

TIMING

on

the

engine

WINDOW

bell

.

housing

)

ADJUSTING SCREWS.1

CHECKING

NOTE:

the

1.

Remove

2.

Align thru

the

compression

3.

Loosen

screw

4.

Loosen

5.

Slightly and screw Jock

6.

Loosen

side)

arm

specific

7.

Adjust side)

VALVE

Valve

clearance

engine

is

the

ITC

the

timing

#1

piston

the

Jock

(1).

the

Jock

push

screw

in

touch

the

nut.

the

lock

and

insert

and

the

bridge

clearance, then tighten the lc::k nut.

the clearance between the rocker arm (exhaust

and

the

CLEARANCE

must

be

checked and adjusted

cold.

head

cover.

timing

mark

on

the

flywheel

window

comes

stroke.·

the

the thickness gauge between the rocker

exhaust valve

on the bell housing) so that

to

the top dead center

nut

(2)

and loosen the adjusting

nut

and

return

the adjusting screw.

rocker arm (intake side) by your

adjusting screw slowly until you feel the

top

of the valve stem, then tighten the

nut

(4)

of

adjusting screw

head.

Set the adjusting screw to the

to

the specific clearance

(as

viewed

of

its

(3)

(push rod

FACTORY

when

fingers·

..

SPEC.

ADJUSTING SCREwS

3

location of piston

When

No.1

top

dead center

When

No.1

position

Tightening torque

piston is compression

piston is overlap

Cylinder head cover

screw

_cylinc!er

Adjuslmt.nt

1st

2nd 3rd

4th 1st

2nd

3rd

4th

...

,Y

I.

alve arrangement ·

IN.

* *

6.9 to 11.3

0.7 to 1.15 kgf·m

5.1

to

8.32 ft-lbs

N·m

EX.

* *

·Enttines & Generators

20

GLOW

PLUGS

DESCRIPTION

The

glow

plugs

are

When

PREHEAT

should "click"

on

is

and

INSPECTION

To

inspect

tions,

head.

soft oil

deposits.

burn

the

then

unscrew

Thoroughly

bru~

and.cleaning

While

erosion;

plug,

if

it

clean

cleaning,

has

TESTING

An

accurate

Touch other plug

will used an

multimeter

A

to

the

testing

way

to

'one

prod

to

the

to

the

body

of

have a 1.0 -1.5

wtth

the

plug

in

to test

WARNING:

touch.

the

Be

careful

plugs.

These

wired

through the preheat

pressed at the control

the

glow

plug

should

remove

or

test

the

unclamp

each

solution to

eroded

glow

plug's

glow

ohm

or

out

of the

power

glow

not

the electrical

each

plug

plug's

tip

remove

examine

too

plugs plug,

to

the

much,

is

with

wire

as

shown. A good

resistance.

engine.

drain

(8

plugs

will

burn

your

solenoid.

panel

this

begin

terminal

from

the

and

threads

all the

tip

for

wear

replace

connection,

- 9

an

ohnuneter.

This

You

amps

the

method

can

per

become

fingers

solenoid

to

get

connec-

cylinder with

carbon

and

plug.

and

glow

can

also

plug).

very

when

hot.

a

and

the

use

hot

be

Re-install plugs

should seconds. circuit. compound

GUIW

If

When

PLUG

the

plugs

in

get

very

the

plugs

don't heat

reinstalling

on

!he

threads.

TIGHTENING

1.0-1.5

M-KG

the

engine

hot

(at

the

glow

TORQUE

(7

-11

FT-LB)

and

tetnrinal

up

quickly,

plugs,

test

them end)

check

use

again.

within

7 to

for

a short

anti-seize

The

15

GLOW

'

#053140

REFER

TO DIAGRAM MANUAL WIRING

CONNECTIONS

PLUGS

THE

WIRING

IN

THIS

FOR

ALL

USING

A

TEST

LIGHT

I...,..,.IWESTERIIEKE

. ) Engines

~

GJ!.nera.tC!J'S

21

1#10

ORANGE

TO

STARTER

_A~TERNATORS

8

SOLENOID

TESTING/TROUBLESHOOTING

ALTERNATOR

·

'5DAMP

GROUND

VOLTAGE

The device the

voltage applied

system The

thick-film adjusted

encapsulated

possible

REGULATOR

integral voltage regulator

which senses the system voltage level

to

the

voltage.

regulator design utilizes all-silicon semi conductors

assembly techniques. After the

to the proper regulating valve, the entire circuit

to

protect the circuit and the

damage

due

to

is

an electronic

field

in order

handling or vibration.

to

maintain a proper

voltage

components

switching

and

switches

has

and

been

is

from

REFER

DIAGRAM

MANUAL

WIRING

DESCRIPTION

'The

following inforination applies

that

are

supplied with WESTERBEKE'S Engines

Generators.

ELECTRICAL

The

charging regulator, circuit breaker of

the

use of integrated circuits

regulator is

of

back

It is desirable

voltage

loads that are a

provide charging electl;;ical

regulator) using the wiring harness

ALTERNATOR

,The

stator rectifiey converts the AC generated in battery

Power alternator is provided

p~kage

These alternators produce a rated output of 50 output ambient temperature of designed to operate 212°

package which contains six diodes,

charging

to

is achieved at approxiillately

F (

-40o

CHARGING

system consists

an

engine DC

and

very

compact

the

alternator.

to

test the chargfug system (alternator and

permanent

the

technician with an operational test of the

system

as

system.

wiring

a battery

and

part

well

as

the

· ·

DESCRIPTION

is

connected.to a three-phase,.full-wave bridge

and

accessories,

the regulator

contained

to

100°

and.

the

by the

in

the

alternator.

75° F (23.8°

in

an

ambient temperature

C).

to

the

staijdard

CIRCUIT

of

an alternator

batness, a mounted DC

with

connecting

(IC's},

the

electronic voltage

is

mounted

of

the system

major

the

stator

field

.diode (or diode trio)

internally or on the

and

components

The

to

a DC output for

of the integral regulator

6000

alternator

C). The alternators

TO

THE

WIRING

IN

THIS

FOR

ALL

CONNECTIONS

alternators

and

with

a voltage

cables.

Because

electrical

and

will then

of the

bridge ·

amps.

Rated

rpm

range

of

-40o

at an

are

ALTERNATOR

Use

this

exists

with determined have

a qualified technician check

A

WARNING:

altematot alternator

LOW

BATTERY/FAULTY

If

the starter only moans or makes a clicking

of spinning the engine faulty

connection in the starting circuit

problem.

PREUMINARY

Before starting the actual alternator

testing the following checks are recommended.

Make certain your alternator is securely

1.

TROUBLEsHOOTING

troubleshooting section

the charging circuit or with the

that the alternator or voltage regulator

A

can

beciJIIIB

until

working

if

has

altemator

very

bot.

cooled.

CIRCUIT

to

life it is likely a low battery or a

INSPECTION

2. Check the drive belts for pioper tension.

if

it is worn or glazed.

3. Check that all terminals, connectors

and

tight Loose or corroded connections

to

resistance and undercharging or damage corroded battery cables could prevent the battery from reaching a fully

4.

Check

the condition

A

low

or discharged battery

readings in the tests.

NOTE:

An

isolator

selector

the

with starting OK

switch

batteries

the

house

battery

and

the

this

could

c_ause

charged

condition.

of

the battery

with a diode, a solenoid,

is

usually

so

the

batteries.

but

problem·is

mounted

starting

If

not

the

i1i

the

battery the hOJlSe

to

isolator

batt~'ry

to

detennine

it

runs

Do

not

and

voltage

and

overcharging,

the charging

and

may

cause false or

in

the

circuit

is

not

discharged

is

charging

btlttery,

the

charging

if

a

problem

alternator.

is

faulty,

· '

bot.

A

failed

touch

the

sOund

instead

not

an

alternator

regulator,

mounted.

Replace

plugs

cause system.

charge

or a

the beh

are clean

high

Badly

if

necessary.

misleading

battery

to

isolate

along

the

altemator

circUit.

,,.,•

If

.

I

it is

is

·

I..,.,.,.IWESTERBEKE

l

Enflil)@§..#

Gt!P~rators

22

ALTERNATORS

TESTING

A

certain

away

1. Start the Engine.

2.

THE

ALTERNATOR

CAUTION:

that

from

Mter

the engine has run for a few minutes, measure the

starting battery voltage at the battery

multimeter set

a.

If

the voltage is increasing toward 14 volts, the

alternator is working.

b.

If

the voltage remains around exists with either the alternator continue with Steps 3 through

Before

everyone

sheaves

on

starting

is

clear

and

belts

DC volts.

the

engine

of

moving

during

test

12

volts, a problem

or

6i.

TESTING/TROUBLESHOOTING

make

parts!

Keep

procedures.

termimJls using a

the charging circuit;

MEASURING BATTERY

VOLTAGE

3. Turn off the engine. Inspect all wiring and connection.s. .

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

4.

If

a battery selector switch

that it is on

5.

Check the battery voltage. condition the reading should be 12 to

6. Load test

weak/faulty cell.

the ·correct battery.

the

battery

is

in the charging circuit,ensure

If

your battery is in good

13

volts.

if

there is a possible issue with

TESTING

1.

2. Wiggle the engine wiring harness while observing the

3. Start the engine.

4. Repeat the same measurement, the negative probe to

The voltage reading should volts.

it

5.

If terminal terminal. inspect the wiring for breaks and poor connections. Jump 12 volts from a 12 volt source (such battery) and operate the alternator. is 13-14 volts,

THE

OUTPUT

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

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

or

if

obtained, output circuit for loose damaged wiring.

ground,

If

repaired at a reliable service shop.

the previous test reads only battery voltage at

the reading varies, check the alternator

~he

positive probe to B with the engine running.

your alternator is over

B,

use the meter to measure the DC excitation

If

12 volts is not present at exciter terminal R,

..

CIRCUIT

If

no reading is

or

dirty connections or

be

between 13.5 and 14.5

or

under-charging, have

If

the voltage output

then the alternator is OK.

as

the

Engines

23

TESTING CIRCUIT

&.

Generators

THE

OUTPUT

ENGINE

RUNNING

ALTERNATORS

. .

TESTING/TROUBLESHOOTING

TESTING

1.

Connect the positive ( +) multimeter probe to the excitation

lead

to

TESTING

.

EXCITATION

CIRCUIT

(ENGINE. RUNNING)

THE

2.

Start the engine and note the multimeter reading. The

reading should

If

the reading regulat01; repaired.

3.

If

no reading alternator/excitation the fault and correct. Jumper a terminal. The alternator output voltage should

14

VDC range indicating the alternator

THE

EXCITAnON

terminal

ground.

is faulty or the alternator itself and should

R'onthe

be

approximately battery charging voltage.

is

battery voltage, then

is

obtained,

CIRCUIT

alternator and the negative(-)

an

open exists in the

lead.

Disconnect the lead

12

the

VDC

source

is

DC alternator's

OK

be

to

determine

to

the R

be

in the

CHECKING

. Check the voltage

have a voltage between running. charging circuit Troubleshoot the circuit by checking the wiring and isolator, battery switch, and the battery

Whyn

-is

hack in operation, take the time

temiinai

wiring hamess.

ALTERNATOR

If

tests

sembled and repaired.

do

the job.

NOTE:

instructions for the disassembly standard.

BATTERY

The

minimum recommended capacity

the engine's

. Cranking Amps (CCA).

Review the manufacturer's recommendations and estab:tish engine's starting batteries and house batteries.

• Monitor your voltmeter for proper charging during engine operation.

•

ch~ck

hydro~eter.

•

U.S~.

level.

• Make certain that battery cable connections are tight to

THE

SERVICE

of

the service battery.

If

not,

there

is

the problem

studs. Also clean the connecting terminals

has

BATTERY

this

batteiy should

13

and 14 volts

a problem in the service battery

been solved and before

when

service

battery charging

connections,

itself.

to

tighten and

the engine

the

clean

REPAIR

indicate a failed alternator,

A:n.y

WESTERBEKE'SService Manual has detailed

altenwtors.

it

will need to

good alternator service

and

repair

of

their

be

CARE

of

the battery

12

volt

DC

control circuit is 800-1000 Cold

a systematic

the electrolyte level and specific gravity with a

only distilled water to bring electrolytes

the battery posts

maintenanCe

·

schedule for your

(and

to your engine).

to

is

solenoid,

alternator

the

from

the

disas-

shop

can

used

then

a proper

clean

and

in

TESTING

THE EXCITATION CIRCUIT

ENGINE·

.RUNNING

'·'

,,

OUTPUT

TERMINAL

EXCITER

TERMINAL

R

24

STARTER

ELECTRICAL

START

MOTOR

TESTING

.

BATTERY

SWITCH

NEGATIVE

~---··REFER

TYPICAL DIAGRAM

TROUBLESHOOl:ING/INSPECTION

Prior

to

testing, make certain the ships batteries are at full

charge

and

that the starting

(tenninals) are clean and tight. Pay particular attention to

the

grmmd

wire connections

To

check

the

wiring, cycles, not more than three crank cycles at a time, then run your hand along the wires

spots

that indicate resistance. Repair

spots.

Using

a multimeter, test the voltage between the positive

terminal stud on the start solenoid

(ground).

If

you

rend

12

volts,

If

nothing happens current. Check the battery and inspect the wiring connections. It

is

also possible that the solenoid is defective.

syste1i1

on

the engine block.

try

cranking the starter

and

terminals looking for warm .

and

the srnrter

at

all,

the

solenoid is

is

wiring connections

for

a few

or

replace any trouble

the engine block

faulty.

not

getting

TESTING

Remove the lead

·battery att{lched terminal.

'If

the push button

· wiring needs to

·

NOTE:

standard

TO

REMOVE

.1. Turn

,

2.

If to the starter motor.

3. Label

allow wires

4.

Remove the starter mounting bolts.

:

5.

Remove the

starter will obstructions,

NOTE:

approved replace the WESTERBELE dealer/distributor.·

WITH

AN

ELECTRICAL

TO

THE

ILLUSTRATION

the

Tenninal S

from

the electrical jumper. Leave the +

and

The

push

and

wired

connections have been checked, the starter

be

removed

This electricaljumper can

push button

FOR

off

the

DC

necessary,

WESTERBEKE uses an ignition

remove

and

disconnect

to

touch, tape

starter

have

by

the

U.S.

starter, purchase a new starter from a

wire

from the ignition and attach

clip

the

jumper

button

fru1s

should crank the starter.

to

crank

for

service.

and

two connecting wires.

SERVICE.

battery switch.

any components

the

wiring from the starter. (Do not

over

from

the

to

be

turned to a different angle to clear

Coast Guard.

JUMPER

BELOW

aligater fitting to that

the

starter and the batteries

be

fabricated using a

to

gain

the terminals).

engine.ln

sbme cases the

proof

starter

If

it is necessary to

positive

full

access

REFER

TOTHE.WIRING DIAGRAM FOR

WIRE

IN

THIS

MANUAL

CONECTIONS

STARTER/SOLENOID

.

Engines

& Generator$

TESTING

25

DESCRIPTION

The

starting

system

includes

and

struter

button.

.

When

the

struter

button

current

flows

and

energizes energized into to serves

flywheel. To

pinion

is engine motor

Once

ping

contact

flow magnetic plunger fi:om

TERMINALS

the

reach

to

prevent

gear

splined

may

itself.

the

with

of

electricity

is

its

engagement

coil

becomes

coil,

and

closes a set

the

starter

motor.

push

that

starter

·

damage

to

incorporates

to

the

struter

speed

the

struied

button

activation

fields

released,

of

the

battery-to~start

is

intermpted

and

the

its

with

the

battery,

on

the

instrument

the

starter's

an

electromagnet,

of

contacts

At

the

same

pinion

to

mesh

the

starter

motor

an

over-mmling(one-way)

annature

rotation

is

the

starter

movement

of

released,

solenoid.

cables to

ceases

the

engine

shaft.

the

The

the

also

pinion

flywheel.

starter

panel

solenoid

which

time,

with

when

The

rotation

but

current

plunger

by a coil

starter.

its

rotation.

pulls

the

SOLENOID

the

flow

This

STARTER

PN.053295

motor,

solenoid,

is

depressed,

coil.

The

pulls

the

plunger

allow

high

current

plunger

not

is spring,

starter

teeth

engine

clutch

of

the

ceases,

pulled

weakens

As

the

drive

also

on

the

starts,

which

mmling

starter

stop-

out

of

and

the

solenoid

gear

the

MOTOR

SOLENOID

IGNITION

TERMINAL.r

To

test

the·ignition

of

the

small

tenninal Use a screwdriver, ignjtion the

If If

motor

tem:linal

solenoid.

the

starter

the

solenoid

is

to

cranks,

clicks

probably

circuit,

studs

don't

the

positive

the

but

faulty.

locate

and

touch

fault nothing

\

the

is

wired

the

blade,

battery

lies

I

(

ignition(s)

to

the

to

connection

with

the

else

happens,

n

terminal

ignjtion

jump

from

terminal

ignition

the

(it

circuit).

that

circuit.

starter

is

on

one

MOTOR

TYPICAL

STARTER

REFER DIAGRAM

TROUBLESHOOTING

Prior and clean cOimections

To never the resistru1ce.

Using a multimeter,

stud

If

you

TO

to

that

and

check

more

wires

on

the

read

MOTOR

THE

Wiff!NG

IN

THIS

testing,

the

starting

tight.

on

the

wiring,

than

and

tenninals

Repair

strut

12

MANUAL

make

system

Pay

particular

the

engine

try

1 0

seconds

or

replace

test

solenoid

volts,

tl1e

TESTING

certain

v.'iring

block.

crarlkiug

at a time,

looking

mw

the

voltage

and

starter

the

ships

;:tttention

the

for

tr·ouble

the

engine

is

WITH A SCREWDRIVER

batteries

cormections

to

starter

then

wa1111

between

faulty.

the

for a few

run

spots

spots.

block

are

at

(te1minals)

ground

your

that

the

positive

(ground).

full

charge

wire

seconds,

hand

along

indicate

tenninal

are

SOLENOID

IGNITION

TERMINAL

. If

nothing

.

Check

the

cmmections.

A

WARNING:

fly

when

space

is

gasoline.

at

all

happens

battery

isolation

It

is

also

jumping

free

of

the

solenoid

switch

possible

There

that

will

terminals.

potf#ntially

explosive

isn't

and

inspect

the

solenoid

be

arching

Be

certain··the

~

getting

the

wiring

is

defective.

and

sparks engine

fumes!

current.

will

especially

Engines & Generators

26

IGNITION

TERMINAL

Test

again screwdriver screwdriver would

cause a short.

A

WARNING:

starting screwdriver.

by

jumping

blade

current

the

finnly

to

touch

There

5/iould

two

large

between

the

solenoid

will

be

flowing

the

be

temrinal

studs.

o~

starter

arching

thru'the

studs.

Do

as

STARTER

,

PN.053295

Hold

the

not

allow

the

casing,

this

the

full

blade

of

the

MOTOR

SERVICE

Westerbeke serviced

If

replacing certified standards.

TO

1.

Thm

.

·· · 2.

If

to the starter motor.

3. Label and disconnect the wiring from the allow

4. Remove

5. Remove the

· starter will obstructions,

NQTE:

approved replace the starter, purchase a new starter from a WESTERBELE dealer/distributor.·

uses a standard

or

rebuilt

at

the

starter

for

marine

If in

doubt,

REMOVE

necessary, remove

off

the

wires

the

FOR

DC

to touch, tape

starter mounting

starter

have

WESTERBEKE uses an ignition proof starter

by the

U.S.

marine

any

starter

motor

motor,

make

use.

Automotive

contact

your

SERVICE

battery switch.

any

components

from the

to be turned

Coast Guard.

starter

motor

automotive

certain

the

starters

do

WESTERBEKE

to

over~

tenninals).

b~lts.

,

engine~

to

a di'ffetent

If

it

ln·sbme

is necessary

which

new

not

gain

starter.

can

service

motor

meet

dealer.

full

cases

angle

be

center. is

USCG

access

(Do

the

to

clear

to

not

If

the

starter

spins,

the

solenoid is faulty.

If

the_

starter

fails

to

spin,

If

no arching occurred, there-is

solenoid.

NOTE:

Starter motors

In

the

pre-engaged

that

engages

Using

will

run battery. Hopefully it will move

the starter motor

a screwdriver

the

IJWtor

switch

even

though

are

either inertia type

model,

to

bypass the solenoid on such a starter

without engaging the flywheel. Tum the

on

to

provide

create

enough magnetic field for the

the

contacts inside the solenoid

the

motor

is probably faulty.

no

voltage reaching

or

pre-engaged.

the solenoid also moves an arm

to

the flywheel

the

power

of

to

the solenoid.

the

engine.

arm

are

bad.

the

to

1-w'IWESTERBEKE

)engines

&.

Generators

27

RAW

WATER

PUMP

#052650

DISASSEMBLY

1.

With

the

pump

removed

#3,

the

gasket

#4

and

2.

Remove cam#8.

3.

Remove

4.

Remove

S.

Support opening

6.

Press

the

slinger

7.

Remove and

8.

Push the CGtreetibstallation

the

the the

the

up.

the

shaft

pump

#13

bearing

shaft

impeller

cam

inner internal

pump

assembly

housing

will

come

#16-2

#16-1.

water

seal

opening.

securing

wear

housing

through

of

ASSEMBLY

1.

Assemble circlip the

·

position

FRONT

bearing #16-2 onto

#17

and

position

circlip. Install bearing

ii

so

it

contacts

ASSEMBLY

from

the

withdraw

screw

plate

#6.

circlip

#18.

on

a press with

#15,

#16-1,

the drive

out with

from

#7 out

Note the

the

of

the

orientation

new

seal.

the

bearing #16-2

#16-1

the

circlip and bearipg

engine,

the impeller

#10 and

shaft, extemal circlip

shaft Install extemal

onto

#6

remove

#17 and#16-2 out of end.

Spacer #14

shaft:

assembly.

pump

housing

of

so

it

the

sh;rft

WEAR

302574

#5.

the

impeller

the

· · .

just

contacts

and

#16-2.

PlATE

cover

the

through

seal for

·

.

and

#17

. .

2.

Install

the

spacer #14 and slinger

the

housing shaft/bearing assembly into appropriate press, press the shaft bearing

the

ho'!lsing intemal_

3.

Install theintemal circlip #18.

4.

Press

contacts no

binding.

.

S.

Apply seal

#7 properly orientated. Using a

the

seal

in

into

the

6.

Insta,ll some

7.

Apply housing

8.

Apply

·

will

contact the cover #3. Install

#3

and

9.

Re-install

so

to provide

an

easier

the

so

that the bearing #16-2

circlip #18 retaining slot ·

-the

shaft bearing assembly

the

internal circlip

rome

glycerine io the sealing lip of

over the shaft until it t9ntacts the

the

housing.

recess.

the~

se8Iant

some glycerine

and

some

secure with

the

Then carefully press the

wear plate

on the

install the impeller glycerine

the 6 screws·

pump

#18.

#6

cams

securing screw

to

the surface of

to

the

on

the engine.

·.#10

CAM

.053372

vanes

#13

on

press

housing.

so

Rotate

and the cam

#5.

the

Using

just

the bearing

the

twisting

the

of

the

gasket #4

#2.

RETAINING

the

shaft.

fit

of

the

an

assembly

clears

the

#16-2

shaft

the

shaft

motion,

recess

for

seal

#8,

applying

#10.

impeller's

impeller

and

SC.REW

Warm

into

to

ensure

water

fully

that cover

..

just

slide

the

#2'ENO

COVER

M4x-tox8MM

034463

SCREWS

(6)

l"ffi!:JWESTERBEKE

~

'!nqi!Jes & (Jenerators

ROTE:

a

glycerine

WESTERBEKE'S

053366

#18

- \ .

;:iEE

REAR

The

parts

pi:zck

·~

shown

are

included

PUMP

,.

ASSEMBLY

along

with .

in

KlT#053375

BELOW

.

·#16-l-2 .

. . .

SHAFT

BALL

BEARING

;em

cuP

........

,.-.

~~~~~P

GROOvE

f:irs

INTO

IN

. . . . .

PUMP

(2)

·

BODY

WATER

HEATER:

{OWNERS

OPTION))

INSTALLATION

WATER

These of engine coolant The either

that

run in a reasonably direct line without trap

Hoses

heater

heater to the then on the heater for bleeding air while

HEATER

engines

water heater should be mounted in a convenient location

in a

high

the

connecting

air.

should rise continuously to

the engine

an

air bleed petcock must

THERMOSTAT

INSTALLATIONS

are

equipped with connections for

to

or

low

engine.

transfer heat

position in relation

hoses

from

so

that

If

trapped

HOUSING

to

an

the heater

from

air

will

rise

air

is

be

installed at the higher

filling

on-board

to

any

their

miturally

able

to

the

loops

low

rise

the

water

engine,

engine

which

point

from

to

system.

plumbing

heater.

so

can

might

at

the

heater,

fitting

INSTRUCTIONS

NOTE:

If

any

portion engine's remote circuit tank connections single engine's convenient

The

system

when

tank serves the same junction.

recovery

The pressure installed coolant. tank after good coolant circulation.

. the engine's coolant should be

not at heater

supported so it rises continuously

~nabling

of

own

expansion

to

become

into

the

heater

for

line

up

return.

location

remote

expansion

fill

point.

the remote expansion tank kit is

tank

after

Finish

the

engine manifold

to

the remote expansion tank should·berouted any

the

system.

of

the

heatine

pressure

to

if it

cap

the

system

air in

cap,

then a pressurized'(aluminum)

tank

(Kit

#024177)

the

highest

point.

circuit,

choosing

the

return.

Tee

the

tanks

location

Install

the

remote

so

the

coolant level

tank

will

The plastic coolant

has

been

already

on

the

engine's manifold should

engine's cooling system

filling

the

cooling

is

filled

and

During

cap.

tl:}e

s}'stem

circuit

rises

above

must

be

installed

Tee

the

remote

the

hisher

of

at

the

heater,

and

the

other

expansion

now

serve

recovery

Remove

installed.

system

is

free

engine

done

at the remote

The hose connection

from

to

rise

can

installed,

and

from of operation,

the

up

to

tank

easily

as

a check and

tank is not used

store

is

filled

the

air

and

heater the

tank

the

in

expansion

the

two

plumb

a

back

to

in

a

be

checked.

since this

the

plastic

be

with remote

exhibits

checking

tank

and

from

and

to

the

tank,

and

out

the

WATER

HEATER

---

,.;·..-- .

_.....,...-

OWNERS

_ ...

FROM

HOT

CONNECTIDNS

HOT

WATER

OWNERS HEATER

NOTE:

An

thennostat engine's

from

the

HOSE

TANK.

HOT

WATER

(TYPICAL)

air

bleed petcock

housing. co,oling cooling

Open

system.

system

this

This

as

coolant

is

located

petcock

will

help

is

on

the when to

allow

added.

engine

filling

air

:r

the to

vent

Engines & Generators

29

REMOTE

OIL

FILTER

(OPTIONAL)

PN:054372

APPLY A THIN INSTALLING

TIGHTEN

CONTACTS

THE MUST CONNECTION REMOTE

COAT

THIS

AN

AODITIONAl3/4

THE

"OUT"

CONNECTION

ATTACH

TO

AT

OIL

FILTER.

OF

CLEAN

KIT.

THREAD

BASE.

HOSE

THE

"IN"

THE

NOTE;

on

for

~conndCt&d

. .

the

INSTALLATION

This

popular

ter

from

engine

NOTE:

in.Structions

To

install,

WESTBRBEKE's

install. Contact

accessory

the

engine

to

room

bulkhead. · ·

Refer

to

ENGINE

on

removing

simply

remove the engine oil filter and thread

remote oil filter kit as shown. Always -

this

kit

with the

your

WESTERBEKE dealer for more information.

OIL

TO

THE

O·RING

THE

KIT

TURN

/nstallationJ

ON,

AFTER

The

"ln

nand

kit (if

the

correctly.

'is.

used

a more convenient location such

OIL

the

oil

filter facing down

WHEN

THEN

HAND

THE

0-RING

"out"

hoses

so

to

CHANGE

ma1*im1s~

are

n:muvo:••.:.•

they

can

be

relocate the engine's oil fil-

in

this manual for

filter.

as

illustrated.

as

on

an

A

CAUTION:

cori'Bctly.,Jf by-pass from failure.

valve

reaching

If

there

immediately

APPLY A THIN FILTER

GASKET

FILTER

CONTACTS

tighten

It firmly by

It

is vital

the

oil

flows

in

the

filter

the

engine,

is

no

and

check

COAT

WHEN

in

oil

pressure

the

OF

CLEAN

INSTAlLING.

THE

BASE.

hand

to

install

the

reverse

asembly

causing

hose

connections.

OIL

TO

THE

AFTER

·

the

oil

direction,

will

prevent

an

intemal

reading,

THE

lines

the

oil

engine

shutdown

DESCRIPTION

A

Block

Heater

can

the

Block

Drain

plug which

block

the

side

power

cord

and

contain

illustrated Contact

NOTE:

and rnnning.

instructions.

your

WESTERBEKE DEALER

The

Block Heater must always be immersed

the

Block Heater can

be

installed

oil

fill.

items needed

not

(REMOVE BLOCK

'(OPTIONAL)

PN:055667

in

the engine block in

is

located on the side of

The Block Heater kits

to

install the heater with

for

more information ..

be

operated with the engine

TO

INSERT

HEATER)

(120V)

place

the

engine

include

in

coolant

BLOCK

PN:055668

of

the

HEATER

(240V)

·

~

.~})).W

BLOCK

HEATER

PN:055668 INCLUDES POWER CORD WITH A

SCHUKA PLUG (CEE 7/7 230V)

KIT

A

6'(1.83M)

v

.

240V

BLOCK

PN:055669 WITH POWER CORD

.

·ADAPTER

PN:055666

HEATER

KIT

120V

fY.T{WESTERBEKE.

Enaines & Generators

30

SPECIFICATIONS

•

GENERATORS

Engine

Type

Aspiration Compression Governor Combustion

Bore & Stroke Piston Firing

Inclination

Weight

Compression

(allowable Variation

cylinders Injection Engine

Valve (engine

Injector Valve

Starting Battery

DC Starter Starting Cold

General Oil Sump

(not Operating

(engine Oil

Displacement

Order

(dry)

limit)

between

Timing

Speed

Clearance

cold)

Pressure

Timing

Battery

Capacity

Charging

Aid

Cranking

Filter

Capacity

including

Oil

hot)

Grade

Chamber

:

Alternator

GENERAL

Diesel. water-cooled, mechanism.(42

Naturally

Ratio

TUNE-UP

Pressure

22.6:1 Electronic Swirl 98 x 110

3.62

1 -3-4

Continuous Temporary

11351bs

SPECIFICATIONS

626 (472

10%

9·sroc

1800

1500

0.23-0.27 (0.00091-0.01

1991Intake

Intake Exhaust

Exhaust

ELECTRICAL

12

Volt

800-

50

Amp

2.5Kw. Glow

Current

filter)

Pressure

150-

lUBRICATION

Pressure Full

14.0

28-

API SAE

four-cycle.

vertical

hp

aspirated.

type.

mm

(3.86

liters

(220.9

-2

20°

30°

(not

(514.8

kgs)

psi ( 44

kg/em')

psi

(30.5

kg/em')

or

less

rpm

60

Hertz

rpm

50

Hertz

mm

06)

2134

psi

Opens

14°

Closes

36°

Opens

45°

Closes

17o

SYSTEM

DC H negative

1000

Cold

rated.

belt-driven

12

VDC

direct

plugs.

sheathed

200

amps

·SY.STEM

fed

system

flow,

paper

element.

U.S.

qts

(13.2

57

psi

(2.0-

Specification

10W·40

or

15W-40

four-cylinder.

in-line

at

1800

rpm

x4.93

inches)

cubic

inches)

to

exceed

at

250

rpm

(140

-150

kgf/cm').

BTDC ABDC

BBDC ATDC

ground

Cranking

Amps

drive

type

(includes

glow

with

external

spin·on

liters)

4.0

kg/em')

CF.

CG-4.

or

29.0/23.0

fresh

overhead

valve

maximum).

10

min.)

(CCA}

plugs)

relief

valve.

type.

Cl-4

EGED

General

Operating Fresh Raw

Raw at

System (Fresh

General

Fuel Fuel Fuel Injector Fuel Air Air

Air (generator

NOTE:

Generator Ambient Recommendations

Single

Single Voltage-3 Phase

Voltage Frequency

Temperature

Water

Pump

Water

Pump

Water

Flow

1800

rpm.

Capacity

Water)

Injection

Pump

Injection

Timing

Nozzle

Filter Intake Flow

Combustion

Requirements

cooling)

Increase

Compartment

Temperature

Phase

regulation:

cooling

COOLING

Fresh

Ulermostatically-controlled

160° -180° F (71 Centrifugal Positive

gear-driven.

i

16.0

FUEL

Open (electromagnetic

No. 2 diesel Bosch

water-cooled

displacement,

1.0

US

gpm

qts

(15.11iters)

SYSTEM

flow.

type

SYSTEM

type,

(41.6lpm).

self

bleeding -self

oil

(cetane

mini

gosmc

Bosch

throttle

type.

Spin-on

Type

Metal

screen/intake

115

cfm

(3.2

cmm)

GENERATOR

0.8

air

flow

122°F

NOTE:

to

maintain

temperature

AC

GENERATOR

Brushless. lubricated,

nectable,

Reconnectable

120 230

±

outlet.

Power

factor

15%

tor

(500C)

Forced

four-pole single

with

or i 20/240 Volts-

50

2%

no

load

.3

Hertz

(.5%)

COOLING

for

slower

maximum

ventilation

generator

below

solid-state

to

Volts -60

Hertz

to

engine

o -

82°

metal

impeller, rubber

fuel

pump)

rating

pump

silencer

at

1800

unit.

500

turning

should

compartment

122'F

revolving

bearing

Double

full

rated

no

load

block,

with

heat

C)

belt-driven.

impeller,

priming

of

45

!Jox

rpm

CFM

(15.0

50

be

(50°C)

field.

design.

voltage

Delta

Hertz

amperage

to

fu!l

rated

exchanger.

or

higher).

CMM)

Hertz

units.

provided

sealed

12

wire

recon-

regulator.

outlet.

amperage

Engines & Generators

31

AC

GENERATOR

Single

Phase

Voltage

Regulation Frequency Rating

60

50

Generator Air (Single

Generator Ambient Recommendations

Regulation

(Volts

Hz

AC)

(1800

rpm)

(1500.

rpm)

Cooling

requirements

& 3

phase)

Compartment

Temperature

(Single

Brushless, Seal 12 120/240 volts,

120 230

±2% 3 Hertz (.5%)

120 120/240

230

500

NOTE:

operation

122°F

NOTE:

to temperatures

six-pole,

lubricated,

lead

reconnectable,

volts,

50hz)

with

or

120/240

Volts -50

no

load

volts

volts volts cfm

(14.1

Increase

(1500

(50°C)

Forced

maintain

generator

SPECIFICATIONS

29.0/23.0

Phase)

revolving

single

bearing

(Double

60hz.)

(Series

solid

state

volts-

60

Hertz

to

full

load.

no

load

275

amps

275/137.5 113

amps

cmm)

air

supply

rpm)

maximum

ventilation

compattment

below

122°F

hertz

to

full

15%

should

(50°C).

field.

design.

Delta

Star

for

regulator.

load.

amps

tor

50

be

provided

for

230

Hertz

Three

Voltage (60

Hertz)

Voltage

(50

Hertz)

Amperage (60

Hertz)

Amperage (50

Hertz)

Generator

Air

requirements

(60hz

Generator Ambient Recommendations

Phase

-3

phase

-3

Phase

- 3

phase

- 3

phase

Cooling

at

1800

rpm)

Compartment

Temperature

EGEO

AC

GENERATOR

Brushless, lubricated, reconnectable.

Low

Voltage

High

Voltage

DELTA High

Voltage

DELTA Low

Voltage

High

Voltage

DELTA High

Voltage

DELTA 500

cfm

NOTE:

operation

122°F

(50°C}

NOTE:

to

maintain

temperatures

(3

six-pole, single-bearing

Solid

WYE

(14.1

cmm)

Increase

air

(1500

rpm)

maximum

Forced

ventilation

generator

below

Phase)

revolving

field.

design.

state

voltage

240 480 277

400 230

87.3Amps

43.6

75.6

41.5

72.2

supply

15%

should

compattment

122"F

(50•C).

Sealed

12

Lead

regulator.

Volts Volts Volts

Volts Volts

Amps Amps

for

50

Hertz

be

provided

Engines & Generators

32

GENERATOR

USE

OF

ELECTRIC

The power required to start an electric motor is considerably more than Some motors require much more current to start them than . others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types. They are commonly used on easy-starting loads, such as washing machines, or where loads are applied after the motor is

started, such as smail power tools. Because they require 5 to 7 times as much current to start as to run, their use should be avoided, whenever possible, ven by a small generator. Capacitor and repulsion-induction motors require from 2 to 4 times as much current to start as to

run. The current required to start any motor varies with the load connected to compressor, for example, will require more current than a motor to which

In

general,

to

medium starting loads

*NOTE:

more

for

made

Because the heavy surge motors be

damaged if it can bring the motor up to speed in a few

seconds. off

all

on

the electric motor.

Required

Run the generator first with generator's capacity, and finally loaded indicted on the generator's data plate. The output voltage should the generating plant and the appliances it supplies. voltmeter or ampere meter is not installed to monitor voltage and

NOTE:

contains that vide panel. generator.

is

required to keep

the

current required to start 115-

MOTOR

SIZE

(HP)

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

1

In

the

above

for

some

this

is

that

the

in

larger

is

required.for only an instant, the generator will not

If

difficulty

other electrical loads and,

Operating

be

checked periodically to ensure proper operation

load, check it with a portable meter and

When

the

AC equipment

the

generator's AC terminal block be configured

one

120

voltAC hot

This

will

MOTORS

it

running after it is started.

if

the electric motor is to be dri-

it.

An electric motor connected to an air

no

load is connected.

Volt

motors connected

will

be

approximately as follows:

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

table

the

maximum Amps for Starting

small motors than for larger

hardest starting types (split-phase)

sizes.

of

current needed for starting

is

experienced in starting motors, turn

if

possible, reduce the load

Speed

vessel

in

of

ensure

good motor starting response from the

.

no

load applied, then

which the generator

120 volts

leg

only,

for

the

vessel's distribution

(AMPERES)

6.4

9.2

1

14.4

20.4

ones.

to

its fuil.capacity as

amp

it

is

AMPS

FOR

STARTING

to

22.4*

to

32.2*

0.4

to

72.8*

to

29.2*

to

40.8

•

2.0

to

52

The

reason

are

at

half

the

If

an

AC

probe~

is

installed

recommended

to

pro-

is

not

of

INFORMATION

Generator

Frequency is a direct result indicated by the following:

• When the generator is run at 1800 RPM, the AC voltage output frequency is

• When the generator is run at 1500 RPM, the AC voltage

output frequency is

Therefore, to change the generator's frequency, the genera-

tor's drive engine's speed must

6f

the

,sary.

Generator

• Maintaining reasonable cleanliness is important. Connections become corroded, and insulation

ducting allowed to build cause excessive heating and reduced life

• For unusually severe conditions, thin rust-inhibiting petroleum-base coatings, should be sprayed or brushed over surfaces to reduce rusting and corrosion. Typical materials suggested are Daubert Chemical Co. 41

• In addition to periodic cleaning, the generator should be inspected of

• The drive discs checked periodically and for any evidence

. should not

accelerate cracking. The bolts which fasten the drive disc

to the generator shaft must 8,

identified by 6 radial marks, one at each

ners

• The rear armature bearing is lubricated and sealed; no maintenance is required. However, noisy

• Examine bearing at periodic intervals.

of motion is detectable, bearings are wearing shaft Repair rub and cause major damage to generator.

The and decal generator

These

Frequency

AC

output connections at the generator is also neces-

Adjustment

of

engine/generator speed, as

60 Hertz.

50

Hertz.

be

changed. A reconfiguration

Maintenance

of

terminal boards and rectifiers may

su:faces may start con-

if

salts, dust, engine exhaust, carbon, etc. are

up. Clogged ventilation openings may

of.

windings.

"Non-Rust AC-

0"

and Ashland "Tectyle 506" or equivalent.

for

(a) tightness

overheated terminals and (c) loose

on

be

allowed to become rusty because rust may

of

the head.

or

rough-sounding, have it replaced.

shaft should be detected when force is applied.

of

bearing socket outside bearing has occurred.

n;mst

be

made quickly

generator's frequency

is

on

voltage

rating

the

inside

end

that

diagrams

data

includes

of

ail connections, (b) evidence

or

damaged wires.

single bearing generators should be

if

possible for tightness

of

incipient cracking failure. Discs

be

hardened steel SAE grade

if

the bearing becomes

or

major components will

plate

gives

the

voltage,current,

of

the

generator.

of

the

louvered

the

are

also

AC

voltage

shown

cover

of

the 6 cor-

No

side movement

o:r

wear on

An

AC

wiring

at

the

connections.

on

these

screws ,

all

if

side

pages.

(SERIES

WYE)

SERIES STAR

10::11 2-3 6-7

0 0

1

TWELVE

L

2

3

5 9

N

0

LEAD

L

5

4-8-12

WINDING/TERMINAL

AND

(NOMINAL)

(PARALLEL

WYE)

PARALLEL STAR

VOLTAGES

113

BOARD

L

"

L

10-12

l

0

CONNECTIONS

L

SERIES

DELTA

9

L

10-11 ..

0

10

8 7

N

2-3

·o

5-4

v

~

6-7

0

L

0

L1

50

60 60

PARALLEL DELTA

L

.

10-1~

L1

50

Hz

60HzL-L

DOUBLE DELTA

a-WIRE. 7

L

,._4--:....:;j.~--,~

8-11

0 0

10 5

1

f t

·

L2

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

L3 N

Hz

L-L 400 volts

Hz

L-N 230 volts

Hz

L-L

480 volts

Hz

L-N 277 volts

L

6-8

~·

5 7

L-L 115 volts

9 11

L2

2-3 . 6-9

N

L-L 240 volts L-N 120 volts

138 volts

12

115

l3

L1

volts

10

SINGLE PARALLEl

L

0

l

o·

50

50 60 Hz L-L 60

PHASE

ZIG-ZAG

7

5

L N

10-12

,.-{'-'--~

1 3 5 7

N

1..1

50 50 60 60 (Refer to Note #1)

Note

#1

Single

phase

The nominal value.

Note

#2

1111-ee

The rated

0.866.

L,.2

Hz

L-L 200 volts

Hz

L-N

Hz

L-N

2-4

L2

Hz

L-L 230 volts

Hz

L-N

Hz

L-L 277 volts

Hz

L-N

phase

current

phase

pm11er

must

L3

115 volts

240

138 volts

N

volts

ij

9-11

115 volts

138 volts

amperage load.

must

not

exceed the

zig-zag connection,

be multiplied

0

by

l-1·

50

50 60Hz 60Hz (Refer

THREE

PHASE

ZIG-ZAG

.

l

8-10

0

b

l1

50 50

60Hz 60 (Refer to Note #2)

DOUBLE DEJ.TA

a-WIRE.·

L

8-11

0

1

N

L2

Hz

L-L 230 volts

Hz

t-N 115 volts

L-L L-N 138 volts

L3

277

volts

to Note #1)

L\!_

'i;

2

~L

10,

. 4 6 5

.s

2-12

L2

Hz Hz

Hz

10

50 Hz L-N 230 volts 60Hz

4-6

0 0

5

9

Q

I

L3 N

'

L-L

346

volts

L-N 200 volts

L-L

415 volts

L-N 240 volts

2-3

6-9

0

~

12

7 4

5

L1

L-N 240 volts

3-7-11

r

t

10

o·

34

ADJUSTABLE OF

UNDERSPEED

PROTECTION

THRESHOLD

J'NTERVfNTIO'N

ELECTRONIC

ADJUSTABLE OVERLOAD

I'NTERVE'NTIO'N

THRESH

PROTECTJO

..

-~

.

_;./'

:

HAmrfzp

stab

volt

· .

e

PN.

OLD

'N

I·'---'

z~

1--l

=

:QO

~~

G;)::e·

~~.

REGULATION-AVR

052944.

.

SAMP.FUSE

/

1

B

7

:~

~

(PN.O

o·

·

«iil

.

0

1

..

oo:

""""'

::::

54456)

CONNECT REMOVE

FOR

60Hz

50Hz

DESCRIPnON

The voltage regulator

·Performance.

circuitry protection

could information connections. qualified

TERMINAL

#1. Excitation

#2. Exciter

between 5 and

#3.

Exciter

#3A.

Supply

#4.

Sensing

#5. Supply voltage to regulator

#6.

Jumper

#7. Not

#5B.

#5C.

POSSIBLE

ExCite~

connected dark blue

yellow) should be Supply: There

1. The supply

· SR7/2 (in case of three-phase connected with be connected

is

also sensing.

. generator

the

2.

The generator equipped with auxiliary supply. of

This.advanced design

be

detrimental

details

These

technician.

CONNECTIONS

field

field voltage

to

used.

Not

used.

Sensing

CONNECTIONS

Field:

to terminall of the

Or

black}.

supply

does

regulator.

supply

Supply

the

regulatm:.

to

the

procedilres

field

jumper

3A

DC

voltage.

SA

for

voltage.

The

exciter

while

ponnected

are

two

coincides

should

the

to

each other in

This

not

and

sensing

is

always

(AVR)

ensures

guard

against operating

the

AC

voltage

DC

negative.

to

3

is

less

positive,

to

regulator

60

Hz

field

the

to

possibilities.

with

be

connected to

generators,

star

po,int).

connection

have

auxiliary

separate.

connected

'{jositi~~'trtbrmally

the

~!i!'

11-

r-

~~::0

..

optimum

AVR

generator. regulators should ~ performed

if

the regulator

than

160

(AC),

(AC).

operation.

negative

electr9~

tehninal3.

sensing.

terminal 5 is

Terminals 3 and 4 should

such a way

in

necessary

winding

This

winding

AC

is

equipped

conditions

The

following

adjustments

AC

supply

VAC.

should

be

regulator

red or

In

this

case

terminals 3 and

that

the

when

for

supplying

is

the

case

for

regulator

to

terminals 3 and

D

generator

with

that

and

by

a

(poJ1.llally

·.

. . .

the

5

normally

supply

the

of a

5

0

.

D

[

0

. .

.

In both of 270 should

160

voltage

· Sensing: · Sensing and phase alternator

Operation and low

A

present. against

FUNCTIONS

Volt: voltage the screw

Stab:

·.Ifti!irie(i

:.

time~~but.thif:;vofta

'

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

tumecf

voltage

In order

using

1.

· and

2.

0:::

~

,......$.:

.......

~

4-

"'-f4

J:::..l

EXCITER

I:

FIELD

I

these

cases,

the SR7/2

VAC.

But

it

&J:wuld

be

bridged

VAC,

is between

can

vary

only

phase.

6 should be frequency

WARNING:

electrical

With

generated.by

screw

is

turned

This

~loC~se,~the:·~ility

coiiiiterdlock:Wise,

tends

to

the

following

The

g~erator

the

(turned

Slightly filanient potentiometer stabilizes.

'fer;

supply with

while the

and

at

Take

this

turned

potentiometer optimizes'altemator

a~just

potentiometer must be at

fully

tum

lamp

Sa.riie

160.~d.

shouldbe~connected

from

80

to

3SOVAC.

therefore

60

Hz:

conne<;ted

J?!Otection

all

OF

potentiometer,

counterclockwise it

to

be

counterclockwise).

clockwise until

is

When

Be

aware

necessary

hazarils.

THE

REGULATOR

the

alternator in a

clockwise,

' . ge .

more

stable.

this

potentiometer

method.

must

be

oscillates, slowly

counterclockwise until

supply

noted

that

terminals 2 and

voltage

terminals

270

normally

to

correctly

should

VAC.

The

connected

operating

eaeh other in

that

precautlo"- .

at

regulated.

high

sensing

POTENTIOMETERS

it

is possible

very

the voltage

decreases.

~reases.and

··

teilds.t6-beless

the

working,

at

..

response

this

litfie

correctly;·w~a4~se·

starting

maximum

the

light generated

point. tum

can

vary

between

be

left

to

termimtls

is to

60Hz,

order

voltages

to

adjust

simple

increases,

performance.

the

stable.

. .

increases

from

stability

the

from

80

3

80

and

open

if

4 and 5

single

one

terminals

to

keep

may

be

sate

guard

the

way.

if

the

response

If

and

zero

load

by

the

light

to

·

the

·

SA

the

If

the

I""'IV.jfYESISRBEKE

{EngJ.nes ~ (i.enerators

ELECTRONIC

REGULATION-

AVR

Hertz:

With

this

potentiometer, which is normally pre-calibrated to

adjust recalibrate normal clockwise the

nominal counterclockwise decreased

When

the value, generator protection

possible Amp:

With

intervention system overload,

then

the

low

frequency protection intervention.

tlus

protection,

zero

load condition, tum

until

the

speed

by

and

by 5 volts. speed

decreases

the

voltage

also

overheating.

at

10%

of

to

calibrate

this

potentiometer, it

level of

has

an

intervention

necessary

sealed

by

the manufacturer,

you

must take the generator'to a

limit position

10

%.

Then

the

potentiometer

is

reached, then decrease

turn

the potentiometer

it

measure the voltage value until it

by

more

than

10%

of decreases proportionally, blocking Even ifwe.,advise calibrating

the

nominal value, it

the

threshold at other

is

the

overload protection. This protection

delay,

which permits a temporary

when

starting motors or similar

is values.

possible

obviously

to

adjust

applications.

To

modify

by minimum During condition

the At

this

voltage

tlus

15%

of

the

(counterclockwise)

this

period

and

while

generator

voltage value at

point,

while

increases

protection,

normal

load, tum

of time

turning

the

to

the

you

must overload

the

potentiometer to

and

wait about twenty seconds.

the

voltage value decreases. In this

the

potentiometer clockwise, fix

10%

less than the nominal one.

the

initial overload is being removed, the

nominal

value.

Fuse: The electronic regulator is equipped with a protects malfunction.

the

alternator from overheating in cases of regulator

The

fuse

(250V.:.5A,

quick acting, F type) can be l C

is.

possible To.

has

the

nominal

this.

· the

generator

fuse,

which

TERMINAL

BL()CK

SHOWN

ARE

CONFIGURED

~ARALLEL·WYE

REHR

TO

56481

CONfIGURATION

AVR

I I

'---0---'

~B~LU

~.

'

Circuit

Breaker DC Field

___________

CONNECTIONS

fOR

190/208

VAC

fOR

OTHER

omONS

MODEL

SR7

0

~

:::l!L_

J"""c;:3

ill]

[g)

!ill

tf,IH1'

~

=

....,..~-

CONTROL

REFER

WIRING IN

THIS

:

.

EXCIT£R

r-----,

+-;~-~=·=r+~~

I

BLU

'-----._...

PANEL

TO

THE

COMPLETE

DIAGRAM

MANUAl.

'----;.9.:...-t;!

1 •

s I I 6

-.rEt

_ __.

#52951

11

i

--.

STATOR

l

TERMINAL

BLOCK

l

Ll,

i

&..

0

f5'IDOii:1

i

':

r;;

-

10

.

=

12

8

replaced

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

I 1 I I I

I

I A l I I

l t I I

easily.

EXCITER

r_:_.

_

_j

___

-:-

___

__.;

__

1

1 I 1 ·

I . I I

1 I I

I I I

I I I t

I

-----------

~L.T~B~.L~UE~#~16~

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VOLTAGE

REGULATOR

..

-.

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

·

·'FUsE

:J

50Hz

YEllOW

2

:========~·tf:::~i======

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t-

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RED

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I

·wiRE

WITH

WIRING

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SR7·2G

DIAGRAM

ABLE

AVR

~

s

1

.

Ef!gin~

36

& Generators

INTERNAL

WIRING

SCHEMATIC

NOTE: A booklet "BE Testing & Troubleshooting available in pdf

www.

westerbeke.com

GENERATORS"

form

to

download

Guide.

Ele~tri~al

A basic

gut~e

off our webstte

ts

EXCITER

ROTOR/ROTATING

GREER

FIELD

TRANSIENT

----i

RED

I

+

AC.

OUJPUJ-

"$ERIE$·~

.

:480Y

40QYI/50Hz·

EXCITER

ROTOR

WINDINGS

CDNFIGQRAliO

- . .

"PARALLEL.

l60l'!z

·

zo8V/66Hi 200V150Hz

;

__

WYE"

N

S_·

ISOlATION DIODE

PlATES

0

6+9

0

8+11

"SEFjlE$

i40V/60Hz

230V/50Hz

DELTA"

"'PARAL.U!L

12oV/60Hi

115V/50Hz

DELTA"

*CONNECT

BY

LOCAL

REGlJLAT

AC

BOND

IONS

WIRE

IF

REQUIRED

'"DOUSU!

13·WIRI!!.

120·240V

11

DELTA"

SPIJT SlliiOLI'!

/60Hz

0·

230V

/~QHz

37

PHASE!

EOE

I-PHASE I 3·PHASE

""DOIJBI.E

(2·WIRE

Z40V/60HZ

230Vi50Hz

DEl. TA"

SINGLE

PI:!ASEI

SHORE

If

the

installer

cuit,

this

OFF/SHIPS

grams

to

ous

connection

A

utility at

the

covered

sibility

A

CAUTION:

before

vfce~versa

ing

with

may

cal/SI1

the

generator.

Shore

Power

GENERATOR

coimects

must

be

done

GEN.

Set the transfer

the

OFF

position.

of

shor~

CAUTION:

shore same

to

switching

power time.

under

make

because

heavy

damage

Damage

the

sure

Heavy

shore

AC

Connections

shore

by

means

This

power to

to

and

generator

This

type

wauanty;

all

AC

motor.foads

power

voltage

loads

on

to

the

exc11er

Ship

POWER

power

to

the

of

the

SHORE

sWitch

shown

switch

prevents

generator

the

generator

output

of

generator

it

is

the

installer's

connections

to

!{enerator

surges

the

vessel

(60

to

Shore

are

should

induced

being

circuit

Hertz)

SWitch

TRANSFER

vessel's

output.

can are damage

components

POWER/

in

simultane-

resuit connected

respon-

correct.

be

shut

power

by

switch-

operated

(3

Pole)

AC

the

is

oU

or

cir-

dia-

if

not

In

SWITCH

230

Volt/50

Notice

minal

block

-GENERATOR GROUND

CONNECTION.S

Hertz

the

repositioning-of.

to

the

N

r-----3----+{3)

Two

Wire

Configur.ation

the

white

ground

generator

case.

.u

~

GENERATORiSHORE

::J

=

'-----+{'1

(NEUTML)•

,.....:-----t.~.

. .

SWITCH

,-,

" '

~f-l>'-___...1l1

I I

' 2 I

..

_

....

' ,

....

-

..

_...".

~'....,____.,___,.

I.

. '. ,

7 ' ,

,_,.

·~

.

Ship

lead

to

• N

on

Shore

the

ter-

Switch·

SHIP'S LDAO

·

t

~.

SHORE

NOTE:

Diagram

for

a

two-wire,

three-wire

for

the

other hot

~

.....

_

_/

---,

I

I I

I

l

SHORE

AND

SINGtE

ll1

SHORE

L1230V

POWER

,CONNECTION

PHASE

N J .

T

POWER

50Hz

TRANSFER

SHOWN

ONLY

SHORE

'='

GROUND

SWITCH

ARE

FOR

-=-

.GROUND

~ T oR-=o""'u~ND~..._---IIII•

NOTE:

SHIP

TO

PO.WER

shows connections'

120 volt system. For a

system. use the dotted lines

leg.

SHORE SWITCHES ARE AVAILABLE

AT

YOUR

WESTERBEKE

SHIP'S

DEALER.

(-w'lqBIERBEKE

)

Eng/!J~~·~·

Generators

38

LAY·UP

&

RECOMMISSIONING

GENERAL

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

The procedures which follow will allow you to perform your own lay-up and recommissioning, or you may use them as a

if

check list These procedures should afford your engine protection

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

If

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

Propeller

The transmission and propeller half couplings should always be

opened up and the bolts removed when the boat

of

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

Fresh

A 50-50 solution

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

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

solution to make sure the antifreeze protection is adequate. Should more antifreeze be needed, drain an appropriate

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

Lubrication

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

ENGINE

oil changing procedure. oil pressure and make sure there are no leaks.

A

in

the combustion chemicals

internal

others do the procedures.

of

your engine.

Shaft

Coupling

the water or moved from land to water, and during

is

taken out

of

time.

Water

of

or

Cooling

of

antifreeze and distilled water

the antifreeze concentration throughout the

System

Use

the correct grade

LUBRICATING

CAUTION:

sump

parts.

Do

over

the

deposits

which

can

not

of

inactivity. Others prefer

[Propulsion

of

or

put in the water. In some cases, the

dry for a considerable

Engine]

is

hauled

the boat often puts a

coupling or both, while

of

the water when

Circuit

is

of

to

ensure a complete circulation

of

oil. Refer to the

OIL

pages in this manual for the

Run

the engine and check for proper

leave

the

lay-up

period.

combine

reduce

the

engine's

to

produce

life

old

engine

Lubricating

harmful

of

your

engine's

oil

and

Fuel

System

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

fuel.

Fuel

System

Top off your fuel tanks with No. 2 diesel fuel. Fuel additives

as

such added at this time to control algae and condition the fuel. Care should with the primary fuel filter/water separator used in the system. Change the element in your primary fuel filter/water separator, sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, as needed. for 5 system. Check for any leaks that may have been created in the fuel system during this servicing, correcting them needed. Operating the engine for 5 - 10 minutes will help allow movement equipment on the engine.

Raw

Close the through-hull seacock. Remove the raw water intake

hose from the seacock.

gallon bucket check the zinc anode found in the primary heat exchanger on the engine and clean or replace it as required, and also clean any zinc debris from inside the heat exchanger where the zinc anode

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

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

water circuit from freezing during the winter lay-up, as

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

BioBor and Diesel Kleen + Cetane Boost should be

10

Water

providing corrosion protection.

Intake

Place a clean cloth, lightly soaked in lubricating oil, in the opening shove the cloth out recommissioning, and you may need assistance note

to

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

exhaust port can be blocked in the same manner.

[Gasoline]

of

89 octane

Sta-Bil gasoline

[Diesel]

be

taken that the additives used are compatible

if

the fuel system has one, and clean the separator

Start the engine and allow it to run

minutes to make sure no air

of

the treated fuel through the injection

Cooling

of

is

located. Clean the raw water strainer.

Manifold

of

the intake manifold to block the opening. Do not

Circuit

Place the end

clean fresh water. Before starting the engine,

of

and

Thru-Hull

of

sight. (If it is not visible at

an

attempt is made to start the engine,

of

the servicing dealer. Make a

is

left in the fuel

of

this hose into a five

this mixture

Exhaust

is

empty,

to

be drawn is

empty, stop

if

needed, and

as

well

Engines & Generators

39

LAY·UP

&

RECOMMISSIONING

Starter

Lubrication

if

battery connections the

connections removed

Cylinder

If

WESTERBEKE recommends removal of access each the revolutions

If to

the injectors and return

Intake

Clean cloth lightly soaked block through-hull exhaust to

Cylinder

After small amount of fogging

crankshaft manually

spark

NOTE:

the tightening properly and onto

Motor

and

cleaning of the starter drive pinion

access

to

the starter pennits its

are

starter.

Take

care

in

from

Lubrication

you

anticipate a

to

the

cylinder to help prevent

cylinder

your

engine

be

removed.

Manifold

the filter screen in

any

opening.

start-up!

long

cylinders. Squirt some Marvel Mystery

walls.

Rotate

and

re-install

does

not

Be

sure

[Gasoline}

in

Also

port,

Lubrication

engine shutdown,

two

plugs loosely

At

spring commissioning,

crankshaft two full

each

spark plug.

for

easy

removal. shut off before attempting properly replacing

the

starter.

[Diesel]

lay-up period

the

engine crankshaft

the

glow

have

glow

to

have

fuel

line

the

flame

lube

oil

place

Make a note

(12

piston

plugs. plugs, the injectors

replacement

as

needed.

arrester,

around

the

an

oil-soaked cloth

to

[Gasoline]

remove

winter.

revolutions.

connecting

the

spark

oil

into

each

cylinder.

complete revolutions. Re-install

lay-up.

remove

Re-install

the

high tension leads fully

Batteries

If

batteries make to

prevent them from batteries subjected batteries environment.

A

highly·exp/oslve arcing smoke serviced.

to

are

to

sure that they

will

not remain

to

severe environmental conditions,

and

store

WARNING:

or a lighted

or

allow

Shut

prevent

electric.al

be left on

are

fully

freezing.

fully

them

in a

Lead

acid

gas,

which

cigarette,

an

open

off

all

electrical

arcing

board

during the lay-up period,

charged,

wanner,

batteries

flame

and

If

there

is

or

more

can

be

ignited

ciga~

or

near

the

emit

equipment

during

servicing.

any

electrical

months

the

glow

rings

from

sealing

and

flame

remove

plugs

Rotate

the

plugs and

the

will

remain

any

doubt that

that

they

remove

compatible

hydrsg811,

by

pipe.

Bo

battery

in

is

advisable,

Make sure

to

or

adhering

by

hand

place a clean

arrester to

in

cloths

and

spark plugs,

will be

remove

more)

plugs

for

Oil

into

two

will

washers

the

prior

spray

the

rotate

that

the

have

a

way,

a

electrical

not being

the

vicinity

Spare

Lay-up Westerbeke or coolant

kit

during

SPARE

and

Parts

time

hoses

order

the

lay-up, such

PARTS

Recommissioning

The

recommissioning of your seasonal those

to

tion

However,

counteracted before starting

1.

for

2.

3.

4.

5.

6.

lay-up generally

described

regarding preparation for starting and normal

some

Remove

Remove discard removed Install

Reinstall the batteries that lay-up, terminals Check

A

and batteries can

the

and

to

CAUTION:

eye

protection

emit

be

ignited

cigarette,

flame

near

electrical

arcing

during

Remove proper tightness [gasoline].

Check

the

and

circuit that

it

is solution engine

is

short

period of advisable, service,

heat exchanger

area.

Start

in manual.

to

the

PREPARATIONS

provides a

engine

items

section of

in

of the lay-up procedures

the

oil-soaked cloths

the

raw

old

during

raw

reconnect the battery

are clean

make

good

opportunity

to

see if external

need

replacement. Check

not

on

hand,

as

filters

this

manual.

Westerbeke

follows

the

PREPARATIONS

the

water

pump

gasket.

Install the

lay-up (or a replacement,

water

pump

were

and

that

sure that

Wear

rubber

when

the

servicing hydrogen, a highly by

electrical

cigar,

or

pipe.

Bo

the

battery

equipment

being

in

the

vicinity

servicing.

the

spark plugs,

condition of

clean or replace

not necessary to

from

the

raw

put into operation,

time

as

either

inspect

and

engine

in

wipe

the

flush

water coolant

with

no

an

end

the

area where

clear

any

accordance

FOR

to

inspect

items

such your

or

replace

and

the

engine.

from

cover

the

connections are tight.

batteries

those

zinc

anodes.

engine after a

same

procedures

FOR

will

the

intake

and

gasket

raw

water

with a new

removed

cables,

are

making

gloves, a rubber

batteries.

explosive

arcing

or a lighted

not

smoke

or

serviced.

zinc

the

adverse

of season or recommissioning

and

STARTING

Shut

to

prevent

clean,

re-gap,

anode

in

anode

as

needed.

the

antifreeze/fresh water

system.

system will

affects.

the

zinc

all

zinc

with

procedures described

your

as

drive

basic

items

Refer

STARTING

starts.

need

to

manifold.

and

pump

impeller

if

required).

cover

during

the

sure

fully

charged.

apron,

Lead

gas,

which

allow

an

off

all

electrical

and

install

the

raw

water

Note

When self-flush

It

is

located

debris

from

section

of

belts

spares

used

to

as

sec-

be

gasket.

the

acid

open

the

in

that

this

the

to

a

Transmission

Check or change the

off

grime the coupling and the output coating. additional information, refer

Check that the

and

grease

[Propulsion

fluid

in

and

t{JUch

transmission

Engine]

the

transmission

up

any

flange

with

vent

to

the

TRANSMISSION SECTION.

as

unpainted

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anti-corrosion

is

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required

areas.

Wipe

Protect

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Engin~s

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1236-212017

Westerbeke 29.0 EGED, 23.0 EGED Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual