Westerbeke 3.0 BPMG, 3.0 BCG Operator's Manual

OPERATORS

MANUAL

Single

·

GASOL:IN.E

3

OBP

•

·•·

Phase I 60Hz

G.ENERATORS

.

MG.

· · ·

Fresh·Waterand

..

Ra·w

Fresh·Water

Water

Cooled

and

Cooled

Model

50Hz

Models

J'~'WESTERBEKE

. PUBLICATION NO. 48009

REVISION 7 APRIL2018

•

WESTERB£KE

JI

150

JOHN

.

""!f:Td...,

.,4;,.,};J Member National

CORPORATION•

HANCOCK

ROAD,

MYLES

TAUNTON,

lltlarinc

·].

STANDISH

MA

INDUSTRIAL

02780-7310

Manufacturers

U.S.A.

Associati<m

PARK

··--·

CALIFORNIA

PROPOSITION

65

WARNING

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF

·,

GET seek until

gasses

gas. can

Weakness

YOU

OR

OUT

INTO

medical

It

has

Marine

exhaust

are

known

to

cause

and

other

contain

Carbon

and

Include:

and

Sleepiness

ANYONE

been

ELSE

THE

FRESH

attention.

inspected

diesel

and

some

of

to

the

State

cancer,

reproductive

AwARNING:

Carbon

Monoxide

death.

Symptoms

. •

·•Muscular

•Vomiting

•Inability

EXPERIENCE

AIR

IMMEDIATELY.

Shut

down

and

gBSC)line

its

birth

engine

constituents

of

California

defects,

harm.

Monoxide,

is

poisonous

of

Throbbing

to

ANY

the

unit

repaired.

an

odorless

and

can

Carbon

Twitching

OF

in

Temples

Think

THESE

If

symptoms

and

do

Monoxide

Coherently

and

cause

SYMPTOMS,

persist,

not

restart

This

WARNING

WES'fERBEKE

bulkhead

WE81ERBEKE·alsa

CARBON

/Milg/sleeplng

.

Tlley

are

·

obtainable

DECAL

and

should

neat

iour

MONOXIDE

quartets

lnexpenstve

at

your

Is

provided

be

fixed

engine

recommends

or

generator.

DETECTORS

of

your

and

easily

local

marine

by

to

a

installing

in

the

vessel

•

store.

Gasoline

with

an ETHANOL

content

higher

· and

than

may

10°/o (E10)

void

warranty.

is

not

allowed

TM

Engines & Generators

page

SAFETY

INSTRUCTIONS

'INTRODUCTION

Read this safety manual carefully.

caused

by

failure to follow fundamental rules

precautions.

take the necessary precautions

personnel,

As

the.dwner

and

advisories

is

in

·

stanilalUB;

in

the

potential

mfiitdemit1ce·ai:tivilies.

to

theQWf18ffoperatm:

,

PREVENT

A

while

power.

111

Do enclosures and

B Shut off electrical

equipment

• Use insulated mats equipment

• Make sure your clothing

(particularly

•

Remove electrical equipment

PREVENT

A

exhaust hot!

• Monitor engine antifreeze coolant coolant location

when

A

Ill In case of

before touching the engine or checking

Know

when dangerous conditions exist

and

your

machin"J_. . __

or

ope(&loF,

provided

alignment

followfng

however,

and

8(iual

witfl

tbe'lftTlerican

satef;y

pages.

risks

ELECTRIC

WARNING:

eagiae

Lethal

not operate this

Do

is

m11aiag,

voltage

covers

,power

shoes)

wristwatch

BURNS-

WARNING:

system

recovery

the

WARNING:

Do

components. A running

tank

on

the

water jacketed exhaust

engine

is

Steam

an

engine

to

protect yourself, your

always

for

The

and

00.selW

your

convenience.

Boat

riSl(s

are

not

responsibility

for

compliance

other

condilions

SHOCK

not.taudl

is

machinery

whenever

when

and

HOT

not·tout:h

COLD.

overheat,

Ai:

or

when

jJresellt

without

in

place.

before

working

and

skin are

handling electrical equipment

all jewelry

ENGINE

hot

and

periodically

can

cause

allow

Most

accidents

and

..

. _ _ _ _

the

following.Bafety

This

safety

and

Yacht

limited

electrical

connBctrid

at

accessing

Council

to

the

for

the

ldentiticatioo

with

all

safely

belong

th~

connections!

electrical

on electrical

dry,

when

working

engine

parts

exclushlely

canDet:tions

to

electrical

not

engine

level

at the plastic

at

the

manifold,

injury

or

death!

the

engine

the

coolant.

are

and

rules

lnfonnation

(

ABYC)

infomlation

of

~Hes,

sho,.,,

damp

on

or

gets

very

filler

cap

but

only

to

cool

PREVENT

I A

•

Prevent sparks pump, vapors. removing

•

Do Backfire

• Do not smoke or pennit

the engine/generator clean chances

II

Be

PREVENT

. A

injury

•

•Follow hatches

after fueling. Check

running the before

ii

All

when ventilated and

-

•

Do

•

Shut

the

spill.

sources servicing.

the

1111

Do

Ill

Be

II

Be certain

free

II

Make

properly maintained. Be familiar Extinguishers rated for

BURNS -FIRE

WAlllllNG:

:Bash

to

or

Use a

not operate with the air cleaner/silencer

fuel

aware

Flm

IBll

"""""*'

fires. Do not smoke or pennit

occur near the other potential sources of

suitable

the

fuel

can cause

system.

of

Keep

fire'.

Wipe

- diesel fuel

container

line,

severe

the

up

carburetor,

injury or

flames

compartment

and

all

will

BURNS -EXPLOSION

WARNING:

or

death!

re-fueling safety

starting your

fuel

handling and storing fuels. Store

out of the reach of

not

fill

..

'·

off

fu~

DO Nor

fuel

not alter or

sure

all

of

leaks.

sure a fire extinguisher is installed

all

applications encountered in

clOsed

blower.

vapors

area

the

fuel

system.

of

fire

Ensure

system.

fuel

Explosions

instructi.OllS.

when

fueling.

below

Run

the

engine.

are

highly

explosive.

away

from spark-producing

children.

fuel

tank(s)

while

service

Tuke care in

allow

near

modify

supplies

line

valve

any

smolmig,

the

fuel

proper ventilation

the

fuel

have a positive

fittings

ABC

by the

ar

tlmllll

flames

fuel

line,

filter,

spilled

fuel

or fuel

to

catch

all

fuel

or

fuel

filters.

removeid.

death.

or

sparks

to

occur

and

the

free

of

debris

to

miniurire

spilled

fuel and

burn.

from

fas/

Open and ventilate

for fumes/vapor before

blow~

for

· · Use

the

engine

at

the

engine

catc~

open

system or

exists

system.

are

adequately

with

NFPA

Uiis

engine

rapotS

t:an

Keep

the

four

minutes

extreme

fuel

in a

equipment·

is

running.

when

any

fuel

:flames,

engine

when

shutoff

tightened

nearby

its proper

are

appropriate

environment.

vessel's

that

valve.

or fuel

when

near

the

oil.

tJllllSB

cabin

care

well-

servicing

might

or other

servicing

and

and is

use.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

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

• Make certain all personnel are clear starting.

• Make certain all covers, guards, and hatches are reinstalled before starting the engine.

BATTERY

A

WARNING:

or

death!

• Do not smoke or allow an open flame near the battery being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or equipment in the vicinity to prevent electrical arcing during servicing.

• Never connect the negative(-) battery cable to the posi-

tive(+) connection terminal not test the battery condition by shorting the terminals together. Sparks could ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation disturb the battery charger connections while the battery is being charged.

• Avoid contacting the terminals with tools, etc., to prevent bums or sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling the battery.

• Always tum the battery charger off before disconnecting the battery connections. Remove the negative lead first and reconnect it last when disconnecting the battery.

BATTERY

STARTING

Accidental

starting

can

cause

of

the engine before

EXPLOSION

Battery

by

lit tobacco products. Shut off all electrical

of

explosion

explosive gases. To avoid sparks, do not

can

cause

of

the starter solenoid. Do

ACID

injury

TOXIC

• Ensure that the exhaust system is adequate to expel gases

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system

regularly for leaks and make sure the exhaust manifolds

are securely attached and no warping exists. attention to the manifold, water injection elbow, and exhaust pipe nipple.

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

• In addition to routine inspection install a carbon monoxide detector. Consult your boat builder

• For additional information refer to ABYC T-22 (educa-

A

odorless nausea

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

• Do not install exhaust outlet where exhaust can be drawn

• Although diesel engine exhaust gases are not

AVOID

or

tional information on Carbon Monoxide).

WARNING:

gas.

or

death!

fumes can rapidly destroy copper tubing in exhaust systems. Exhaust sulfur causes rapid deterioration

tubing resulting in exhaust/water leakage.

through portholes, vents, or air conditioners. exhaust discharge outlet enter the exhaust discharge outlet and close or restrict the flow

of

exhaust. Avoid overloading the craft.

exhaust fumes from gasoline engines, carbon monoxide gas is present in diesel exhaust fumes. Some

toms or signs

are:

Vomiting Muscular twitching Dizziness Intense headache Throbbing in temples Weakness and sleepiness

MOVING

GASES

Carbon

dealer for installation

Inhalation

of

monoxide

Carbon

monoxide

produces

is

carbon monoxide inhalation or poisoning

(CO}

is a deadly

of

the exhaust system,

of

approved detectors.

(CO}

is

an

flu-like

near the waterline, water could

symptoms,

PARTS

gas!

Pay close

invisible

of

copper

If

the engine

as

toxic as

of

the symp-

A

WARNING:

severe

injury

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

If

it comes in contact with your skin, wash it off at once with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps.

Sulfuric

or

death!

acid

in

batteries

can

cause

Engines & Generators

A

WARNING:

or

death!

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

Rotating

is

parts

can

cause

absolutely necessary to make

ii

injury

If

a situa-

SAFETY

•

Do

not wear loose clothing or jewelry

equipment; tie back long hair and avoid wearing loose

jackets, shirts, sleeves, rings, necklaces

be caught in moving parts.

could

• Make sure all attaching hardware Keep

protective shields and guards in their respective

all

check

is

NOISE

times.

fluid

levels or the drive belt's tension

operating. the

drive shaft and the transmission coupling is

running; hair

these

rotating parts.

High

noise

levels

places at

•

Do

not

the engine

• Stay clear of when the engine be caught in

HAZARDOUS

A

WAR~ING:

loss!

• Never operate

• Do not run removed.

• Do

not

open.

A

WARNING:

mentally

an

engine with

run engines

Do

or

physically

engine without

the

air intake (silencer)

for

long periods

not

work

on

incapacitated

when

servicing

or

bracelets that

is

properly tightened.

and

clothing

can

cause

its

muffler

machinery

by

installed.

with

their enclosures

when

fatigue!

hearing

can

INSTRUCTIONS

while

easily

you

ABYC, INSTALLING

Read the following for safety codes and standards. Follow their tions

ABYC (American Boat and "Safety Standards for Small Craft"

Order

NFPA "Fire Protection Standard for Motor Craft''

Order

USCG "USCG 33CFR183"

Order

are

NFPA

when

installing your engine.

from:

ABYC 3069

Solomon's Island

Edgewater,

(National Fire Protection Association)

from:

NFPA 11

Tracy

Avon

Industrial Park

Avon,

MA 02322

(United States Coast Guard)

from:

U.S.

Government Printing

Washington,

AND

DIESEL

ABYC,

MD

21037

Drive

D.C.

USCG

PUBLICATIONS

ENGINES

NFPA

and

Yacht

Council)

Rd.

Office

20404

USCG

recommenda-

FOR

publications

OPERATORS

Many

of the preceding safety tips and warnings

in

your Operators Manual along with other cautions

notes

to carefully, maintain procedures.

GASOLINE

Preparations begin with a thorough examination of the American Boat and Yacht

Council's

a combination of sources including the Sections of the H-2

Ventilation H-24 Gasoline Fuel Systems P-1

Exhaust Systems

P-4

Inboard Engines

E-9

DC

All

installations must comply with the Federal Code of

Regulations

MANUAL

are

repeated

and

highlight critical information. Read your manual

your

equipment, and

ENGINE

to

Electrical Systems

(FCR).

AND

GENERATOR

install a gasoline engine or generator should

(ABYC)

ABYC

standards. These standards

standards of particular interest

follow

all

safety

INSTALLATIONS

are

USCG

and

the

NFPA.

are:

from

Engines & Generators

iii

INSTALLATION

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

CODES

Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

AND

REGULATIONS

SIPHON-BREAK

For installations where the exhaust manifold/water injected.exhaust elbow or will be below the vessel's waterline, provisions must be made to install a siphon-

to

break in the raw water supply hose

minimum

of

20" above the vessel's waterline. Failure

the exhaust manifold/water injected exhaust

water

line

of

the

vessel

will

result

of

the

flooding

If

you have any doubt about the position

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

vessel.

the exhaust elbow. This hose must be looped a

to

use

a siphon-break when

elbow

is

in

near or

raw

water

damage

of

the water-injected exhaust elbow relative

below

to

the engine and possible

siphon-break.

NOTE:

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

EXHAUST

The exhaust system's hose MUST be ce1tified for marine use. Conugated Mmine Exhaust Hose and turns without the need of additiinal fitting and clamps to accomplish these bends and turns .In this regard, a single length system

under any sea conditions and at any angle

SYSTEM

is

MUST

reconunended. The use

be

designed to prevent the entry

of

corrugated exhaust hose can be used. The

of

and

cleaning to ensure proper

for

proper maintenance.

this type

of

hose allows for extreme bends

of

water into the exhaust system

vessels heal.

is

close to

the loaded

install a

AVAILABLE YOUR DEALER

SIPHON-BREAK LOOP PART

FROM

WESTERBEKE

FOR

NO.

WITH

1"

HOSE

044010

STAINLESS

A

detailed

engines

.is

also

Website:

Marine

and

generators

available

www.westerbeke.com

Installation

is

supplied

in

pdf

format

Manual

on

covering

with

every

our

website

Engines & Generators

iv

gasoline

unit

sold.

to

download

and This

diesel

manual

TABLE

Parts

Identification

Parts

Identification Introduction Installation

Rigging and Lifting ...................................................... 6

Location and Mounting ................................................ 6

Raw Raw Water

Fuel,

Fresh Water Cooled Models ......................................... 8

Control

Remote

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

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

Water Discharge ................................................... 7

Engine

Panels • Starting/Stopping

Panel ............................................................... 9

Preparations

Pre-start Inspection ..................................................... 10

Fresh Water Cooled Models ....................................... 10

Safety

Shutdown

Overspeed Switch .......................................................

Main Circuit Breaker ..................................................

Fuses ...........................................................................

Exhaust Temperature Switch ......................................

Low

Oil Switch ..........................................................

High

Exhaust Temperature Switch .............................

Maintenance Engine

Fuel

Cooling

Lubricating

Changing the Oil Filter .............................................. 14

System

Changing the Fuel Filter ............................................ 15

Fuel

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

Pump

System

Water

Pump

Water Intake Strainer .................................................. 16

Changing the Impeller ................................................ 16

BCG

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

BPMG

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

Supply Hose .............................................. 7

Oil

and

Engine

Coolant..

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

Procedure

for

Initial

Start-Up

Switches

Schedule

................................................................. 15

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

Oil

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

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

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

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

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

OF

2

.4

...........

10

11

11 11 11 11 11

12 14

15

16

CONTENTS

3

6

8

9

Cooling Raw

Cooling

Carburetor DC

Shore Electronic Engine

Troubleshooting Wiring Generator BCG/BPMG BCG lay-Up Flushing Generator Metric Suggested

*Models manufactured with heat exchangers for cooling with fresh

water/coolant

fresh cooling via WESTERBEKE'S FRESH WATER COOLING

System

Water

Re-Assembly .............................................................. 19

System

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

Heat Exchanger .........................................................

Circuit/Battery

Power

Adjustments

Adjusting the Drive

Oil Pressure ................................................................ 25

Engine Compression Test ........................................... 26

Water

Pump

Ignition Timing ........................................................... 26

Spark Plug .................................................................. 27

Thermostat [Raw Water Cooled Model] .................... 27

Valve Clearance .......................................................... 28

Replacing the Timing

Diagram

Information

Internal

and

The

Conversions

[Fresh

Water

Cooled

Modelst

Pumps

[Overhaul)

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

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

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

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

Transfer

Governor

Switch

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

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

Belt

............................................ 25

Belt ........................................................ 26

Belt

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

Guide

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

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

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

Troubleshooting

Wiring

Diagram

Recommissioning

Cooling

Specifications

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

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

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

System

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

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

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

Spare

Parts

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

or

raw water cooled models that have been converted to .

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

KIT.

.17 .18

20

21

.21

22

23 23

24 25

29

30

32 33

.34

35 36

37

.38

39

~40

Engines & Generators

1

3.0KW

BC1G

GENERATOR

. .

EXHAUST". HOSE

CONNECTION'

PARTS

10-ENTIFICATION

1_DA

FU$J

GROUNDk°fRAP

IGNITION

CONTROL

MODULE

...--ACTUATOR

LEFT

SIDE

AC CIRCUIT

BREAKER

ENGINE

SERIAL

·

_Nl,IJA~ER

.

RIGHT SIDE

COOLANT SWITCH

DRIP

TEMPERATURE

·

CO~LANT

SERVICE

PAN

PRESSURE

CAP

SIDE

Engines & Generators

2

3.0

KW

BPMG

GENERATOR

1IGNITION

CONTROL

,MODULE

GENERATOR TECHNICAL DATA

LABEL

ENGINE

MAGNETIC

PICK-UP

SERIAL

NUMBER

PARTS

IDENTIFICATION

IGNITION

COIL

IPHONBREAK

•CONNECTION

SERVICE

SIDE

WATER

INJECTED

EXHAUST

ELBOW

IGNITION

EXHAUST

FUEL

COi

PUMP

ENGINE

SERIAL\;:

NUMBER

FRESHWATER

(COOLANT)

10AFUSE

\

,.....,

......

,

HOUR··

METER'~

--t.._

MODEL

~

GENERATOR

ACTUATOR

LEFT

ARBURETOR

COOLANT PUMP

SIDE

SERVICE

RAW

WATER

SIDE.·

PUMP

ZINC

ANODE

DRIP·PAN

Engin~t;;

& Generators

3

These

high

performance marine engines are products of WESTERBEKE's long years technology. dependable performance of Thank

In

order

it

is

Th.is

manual carefully throughout.

your nearest WESTERBEKE dealer for assistance.

This

provided WESTERBEKE dealer. equipment, contact your WESTERBEKE dealer for WESTERBEKE'

WARRANTY

Your folder. form registering your warranty, please contact the factory writing with model information, including the unit's serial number

Customer

We

take great pride in

you

for selecting WESTERBEKE.

to

get the

full

important that

manual

is

your operators manual. A parts catalog

and

you

is

designed

and

observe all

Should your engine require servicing, contact

a technical

S installation manual.

PROCEDURES

WESTERBEKE Warranty is included in a separate

If, after 60 days of submitting the

you

have

not received a customer identification card

and

commission

Identification

of

experience and advanced

the

superior durability

our_

engines and generators.

use

and benefit from your generator,

operate and maintain

to

help you

manual_

If

you are planning

do

the

safety precautions

is

available

date.

it

correctly.

this. Please read

is

from

to

install

Warranty

Card

also

INTRODUCTION

your

this

and

this

SERIAL

The

plate located on top engine's serial number is also stamped on the engine block.

NUMBER

engine's

serial and model number are etched on a

ENGINE SERIAL

NUMBEK-ll--ftti~roi··

-~a-

~

..

..--~·-~

Registry

in

Take the time to enter this the nameplate reference when seeking technical information and/or ordering parts.

generator's

The on

a decal on the the generator control panel. Take the to enter the infonnation on the blank decal below. This will provide a quick reference when seeking technical information and/or ordering parts.

as

shown above,

serial number and model number is located

LOCATION

of

the unit (flywheel cover). The .

L

g~~

~ation

as

-

on the illustration of

this will provide a quick

name-

time.

lw/WESTERBEKE

Customer Identification MR.

WESTERBEKE OWNER

MAIN STREET

HOMETOWN, Model Expires

PRODUCT

Product brochures

WESTERBEKE are not within WESTERBEKE's control.

WESTERBEKE CANNOT

CONTENT RANTIES THERETO, INCLUDING ACCURACY, TIMEUNESS OR

COMPLETENESS THEREOF BE INCURRED

OF

WESTERBEKE customers should

span between printings of WESTERBEKE product software

and

product software. The product software provided

WESTERBEKE products, whether

other suppliers, must not and cannot be relied upon exclu-

sively

software, (technical data, parts lists, manuals,

UABLE

THE FURNISHING OR USE

the

unavoidable existence of earlier WESTERBEKE

as

the definitive authority

USA

Ser.#

SOFTWARE

and

catalogs), provided

OF

SUCH

SOFTWARE, MAKES

OR REPRESENTATIONS WITH RESPECT

FOR

ANY

TYPE

IN

CONNECTION WITH

from

sources other

BE

RESPONSIBLE FOR THE

NO

AND

WILL

IN

NO

OF

DAMAGE OR INJURY

OR

ARISING

OF

SUCH

SOFTWARE.

keep

in

mind

from

WESTERBEKE

on

the respective product.

WAR-

EVENT

the

time

with

than

OUT

or

SPECIFICATION

MODEL---~----

RPNI

__________

KW

___________

.:·_:,__,·

KVA

-----------

VOLTS

AMPS

ENG. ENG.

GEN.

PF/PHASE

WIRES

RATING INSUL

TEMP.

BATTERY;,;

C.1.0.

Fill

in

________

---~----

HP-------

SER.

NO.

SER.

NO.

----

________

_______

CLASS

RISE

----

____

----------

the

information

_

..

_

__

_

for

50 HZ.

your

own

reference.

60 HZ.

I

$:JJ

4.

INTRODUCTION

ORDERING

Whenever replacement parts

generator and engine model and serial numbers. In addition, include a complete part description and part number for each part needed (see Also

insist upon WESTERBEKE packaged parts because

will

fit

specifications

NOTES,

As

this maintenance schedules, and troubleshooting of your generator, NOTES, follows:

NOTE:

A

observed, the

A

followed,

NOTE:

WESTERBEKE.

by e1J.gine

SPARES

Certain

your WESTERBEKE generator or engine

SUGGESTED

as

proper fuel and oil

the

way. spares on-board inventory of

PARTS

are

needed,

the

separately furnished

or generic parts are frequently not

as

original equipment.

CAUTIONS

manual takes

critical information will be highlighted

CAUTIONS,

An operating

CAUTION:

can

engine

or·generatar.

WARNING:

can

A carbon monoxide warning decal has

room.

AND

spare parts will

WESTERBEKE will provide

and

accessories brochure to assist

AND

WARNINGS

you

through the operating procedures,

and

WARNINGS.

procedure

Procedures,

result

in

the

damage

essential

which

Procedures,

result

In

personal

Affix

this

decal

ACCESSORIES

be

needed

SPARE

PARTS).

filters

the

Often even simple items

can be difficult

proper WESTERBEKE parts.

or

which

injury

in

a visible

to

support

you

always

Parts

made

An explanation

to

if

not

destruction

if

or

you

provide

Catalog).

to

by

note.

strictly

not

properly

loss

of

been

location

and

maintafu

when

cruising (see

to

obtain

with

a suggested

in preparing

the

same

of

·,

life.

provided

in

alort.g

the

s:Uch

an

PROTECTING

Care at the factory during assembly have

resulted in a WESTERBEKE generator capable of

many

thousands of manufacturer cannot control installed operated buyer/owner-operator.

NOTE:

Seven

•

Proper

•

An

efficient

an

anti-siphon break

YOUR

INVESTMENT

hours

of dependable service. However

how

in

the vessel or the manner in

and

serviced in

important

the

steps

field.

to

engine and generator

well-designed

to

prevent

exhaust

and

thorough testing

or where the generator

which

the

unit

This

is

up

to

the

ensure

long

generator

installation.

system

that

water

from entering

engine.

•

Chang;.ng ing

•

Proper nents

the

hours.

maintenance

according

engine

oil and oil filters

of

all engine and generator

to

the maintenance

every

schedule

100

in this

manual.

•

Use

clean,

filtered unleaded fuel.

,.

•

Winterize

Recommissioning"

•

Raw system

manual.

UNDERSTANDING

TQe

gasoline engine driving ways are

in-line, and the engine's cylinder head

camshaft which

pressure block.

To

a large degree, preventive maintenance that is required of a gasoline automobile generator's longevity the

fuel system, ignition system, and cooling

your engine according

section

Water

Cooled

according

Model

to

THE

similar to a gasoline automobile

is belt-driven. The engine incorporates a

type

lubrication system, and a water-cooled

the

generator's engine requires

engine.

The

are

in this manual.

- Flush the engine

the procedures found in this

GASOLINE

an

AC generator

most important factors

proper ventilation, maintenance of

to

the "Lay-up and

cooling

GENERATOR

is

in

many

engine.

The cylinders

has

an

overhead

the

to

the

system.

the

is

life:

includes

the

operat-

compo-

engine

same

Engines &

5

CARBON

WESTERBEKE recommends mounting a carbon detector in even

The presence from elbow/exhaust entering your

If

carbon monoxide

air

Generate>.rs

MONOXIDE

the

vessels

living quarters. Carbon monoxide,

in

small amounts, is deadly.

of

carbon monoxide indicated

the

engine or generator or

hose,

or

boat.

is

present, ventilate

and

correct

the

problem immediately!

DETECTOR

from

the

fumes

from a nearby

an

exhaust

the

area

exhaust

monoxide

leak

vessel

are

with

clean

RIGGING

The

wire

AND

engine/generator

rope

or

chain engine/generators erator

by

means

eyes

have

been

designed

slings

are

not

necessary.

NOTE:

and

competent

Rigging

work in

LIFTING

is

fitted

slings

capable

weight

to

of

tackle

attached

to

carry

is

best

done

handling

mo.chin(!ry.

INSTALLATION

with~lifting

of

the

eyes

the

by

eyes~

supporting

and

lift

to

these

full

weight:

someone

Attach

the

engine/gen-

slings.

The

auxiliary

experienced

lifting

SIDE

VIEW

LOCATION

A

solid, proper allow ing.

Locate

away

Refer information

AND

level

mounting

operation

adequate

from

to

space

the

generator

bilge

WESTERBEKE'S

on

iflStalling a Marine

MOUNTING

platform

of

your

generator.

on

all

sides

away

from

splash

and

vapors.

installation

is

very

important

Select a location

for

ventilation living

quarters,

manual

for

Generator

USE

THE

PAN

TO

AS

THE THE

LOCATING HOLES

for

the

that

will

and

servicand

detailed

in a boat.

A

TEMPLATE-FOR PROPER PLYWOOD

MOUNTING

BASE

AC

CONNECTIOM

-RAW

WATER

INLET

0.51n

t,D,

HOSE

DIMENSIONAL

For dimensional Westerbeke

current

website

drawings

(2.7mml

DRAWINGS

drawings.

www.westerbeke.com

with

dimensions.

View

WATER

OllTI.ET

HOSES

D.5in

the drawings

for

(2.7mm)

on

the

ANo

DISCHARGE

l.D.

the

most

.

314n

PLYWOOD-BOLTED/FIBERGLASSED

.

IN

PLACE

BATTERY TO

REFER DIAGRAM

ATTACHMENTS

STARTER

TO

MOTOR

THE

WIRING

IN

THIS

MANUAL

..

(·)NEGATIVE

LEAD

(+)POSmVE

LEAD

Engines & Generators

6

INSTALLATION

RAW

WATER

DISCHARGE

The raw water cooled 3.0KW Generator is cooled

internally

by

a continuous flow

of

raw water.

The fresh water cooled model is cooled internally by fresh

water (coolant). This coolant is cooled of

raw water (via the heat exchanger).

by

a continuous flow

Both model generators use the engine cooling raw water to

cool the exhaust system as it is discharged overboard. A raw water supply hose delivers the raw water from the engine to the water injected exhaust elbow.

RAW

WATER

The raw the engines cooling system to the inlet connection water injected exhaust elbow must

SUPPLY

water

supply hose from the discharge connection on

HOSE

be

looped a minimum

of

the

of

12 inches (30cm) above the vessels loaded water line. On

installations where the water injected exhaust is close to

or

below the vessels loaded water line, provisions must be

made to install a syphon break in the raw water supply hose.

of

The function

flow after the engine is shutdown. This flow, will fill the exhaust system

The raw water supply hose must

the syphon break is to stop the raw water

if

not stopped,

a?d

possibly the engine

be

looped well above the

as

well.

loaded water line to allow the syphon break to function during all attitudes

of

vessel operation to prevent syphoning

when the generator is not operating.

When the generators location is above the loaded waterline of

the vessel during all attitudes

of

vessel operation, it is still advisable to loop the raw water discharge hose at least 6 inches or more above the generator and then down to the inlet connection on the water injected exhaust elbow.

NOTE:

Always use quality hose with

good

wall integrity wire reinforced hose so it will maintain its shape when looped

and

also provide proper mechanical support

hose.

#053499

SIPHON

BREAK

AVAILABLE

YOUR

D~R-

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WATER INJECTED EXHAUST

RAW

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for

BREAK

or

the

~<er>~--'RAW

HEAT

EXCHANGER

WATER

;DRAIN

OIL

DRAIN

EXHAUST

HOSE

SYSTEM

EXHAUST OVERBOARD

Engines & Generators

7

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

, : A

Care

Use only clean your fuel injection pump is very ctitical; invisible dirt particles which might pass through the filter can damage these and keep it clean. The best fuel unsatisfactory by careless handling or improper storage facilities. engine's daily use advisable:

_ Purchase a well-known brand of

Install and regularly service a

CAUTION:~-----------'-----.

Use unleaded must not exceed ages of Ethanol are not acceptable for use in these

,

_and

can

Of

finely

metal bowl type filter/water separator between the and the engine.

ENGINE

Use a good brand and SAE as stated in the manual.Change the engine oil and oil hours

Of

of operation thereafter. Westerbeke Corporation does not approve or disapprove

the use

of break-in must change intervals must SCHEDULE-'section

if

synthetic

NOTE:

The

statements regarding synthetic

89

Octane gasoline or

ElO

void

the

The

Fuel

fuel!

finished parts.

To

assure that the

is

(10%).

warrenty.

Supply

The clearance of

It

is important to buy clean

fuel

clean and pure,

good,

higher.

Ethanol gasoline

Gasoline with higher percent-

models

the

components in

can

be rendered

going into the

the

fuel.

Coast Guard approved

tank

for your

following practice

fuel

OIL

of

engine oil, with

SPECIFICATIONS section

engine break-in operation and then every 100 hours

synthetic oil;

be

oil

is

itiformation above supersedes all previous

If

synthetic oil

performed using

be

as listed in the

of

used.

this manual and not

· -

an

filter

Conventional

oil.

API classification

after

the

initial

is

used, engine .

oil. Oil

MAINTENANCE

to

be extended

fuel,

tank

of

this

of

is

50

ENGINE

WESTERBEKE and chemicals

The run engine circuit

antifreeze (SCAs)

to

The

being

NOTE:

antifreeze

50%

antifreeze

at

proper

to

from

that

long

term

distilled

poured

Look

distilled

COOLANT

that

temperatures

the

coolant,

rust

that

keep

protection.

water

into

for

that

.

recommends a mixture

water.

can

corrode

perfonns

and

corrosion.

contains

the

antifreeze

and

the

cooling circuit

the

new

is

110W

available.

MAINTENANCE

Change number ptotect

COOLANT

The

_

contraction

and

coolant

without provided water

coolant

operating

the

engine coolant

of

operating

lubricate

RECOVERY

recovery

of

the

engines coolant

introducing

with

the

air into

fresh

water

conversion

engine.

hours the

allows

of

50%

Distilled

double

Supplemental

antifreeze

environmentally-friendly

engine

water

internal

duty.

by

transferring

lubricates

Look chemically

should

every

five

as

the

chemical

have a limited

is

engine

It

allows

and

protects

for a good

Cooling

be

years

free

surfaces.

heat

balanced,

premixed

regardless

additives

TANK

for

the

expansion

during

engine

the

cooled

kit

and

system.

models

must

This

and

be

installed

recovery

with

antifreeze

from

the

engine

away

from

the

cooling

quality

Additives

crucial

before

long

lasting

of the

that

life.

and

operation

tank is

the

fresh

before

to

the

NOTE:

Be very careful not

of

t~ie

oil sump will result in erratic operation white-smokeyloil laden exhaust starting or no start andfouled spark plugs.

Reference Service Bulletin

to

overfill the oil

discharge,

#256.

sump.

Overfilling

of

the

engine,

possible hard

NOTE:

T11is

located

at

or

can

be

located

particular

Engines & Generators

installation

8

tank,

above

with

below

its

the

short

level

makes

of

this

run

the

of

plastic

hose,

engine's

the

necessary.

manifold,

engine's manifold

1.s

best

but

if

it

the

CONTROL

DESCRIPTION

The control panel provides stop/start rocker switch

The plug-in connections go:vemor of

The ignition control mounted on the

A

before

caused and

sensor

th~

control panel along

CAUTION:

starting.

by

unanticipated

will

prevent a cold

STARTING

The

engitw

has a 12

To

Start: Press the rocker

release. The engine the

switch

will

show a RED

running. Apply

a light load to

warm

up

to operating

loads.

NOTE:

Some

unstable condition. and

A

periods otherwise severe

This

the

generator loads

CAUTION:

of

time

carbon

'damage

and a hourmeter.

and

remote

module

top

of

the

All

AC

This

precaution

VDC

will

the

temperature

running

should

smooth

Never

without

build·up

to

the

for

loads

crank

generator

are

operate

engine.

the

operator with a

the

engine wiring

panel

with a 10

with

it's plug-in

panel.

must

operation

engine

from

electric

switch

and

light

to

may occur

out as

applied.

the

an

amperage

may

PANEL·

simple

harness,

are

located

amp

be

will

o~

starter: to

the

start electronically

indicate

and

before

engine

occur

fuse.

wiring

switched

prevent

AC

machinery

starting

·

start

the

allow

applying

in

a cold engine .

the

engine

for

load

being

which

on

the

damage

position

engine

the

engine

warms

Ion~

can

side

is

off

and and

is

heavy

applied, cause

START/STOP

to

A

up

start

will This cranking

This

starting

with

PROCEDURE

WARNING:

switch

disengage

will

occur

with

is

ta

prevent

which

water

has

no

and

Should

the

been

depressed, a crank

the

starter

and

after

approximately

start.

prplonged

can

result

in

backing

into

engine

fail

stop

the

15

cranking

the

exhaust

the

engine.

START/STOP SWITCH

!

MAIN

CIRCUIT

BREAKER

to

start

limit circuit

starting

seconds

without

the

system

once

cycle.

of

engine

filling

the

STOPPING

To

Stop: Press

engine

will

ENOiNE

Abnormal

. An abnonnal

and

comes

cause

damage

operating

the

rocker

switch

to

shutdown

STAR1:

STOP;

and

the

LED

GENERATOR

OPERATION

Depress switch position.

ite,

I

RUN

LEO

when

START

engine

will remain

engine is running.

Depress switch

posi I ion.

RUN

LEO

Engine

wi

II

light

wil

turn

~STERBEKE

Sn>PJST.ART

Stop

(refer

stop

is

one

to a stop

condition.

to

the

as

engine,

DECAi.

to

SAFETY SHUTDOWN

in

which

the

a result of

· · .

the

generator,

an

stop

to

wi

generator

operating

and

release.

will

tum

START

LEO

will

I crank.

on

STOP

11

stop,

orr.

fault

or

create

The

off.

SWITCHES)

ceases

to

run

which

an

unsafe

REMOTE

A

remote

panel

of

the

generator.

plug-in

extension harness. The start/stop identical. either

panel.

NOTE:

Holding

depressed circuit

engaged.

may

Engines & Generators

g

PANEL

is

available that allows for

The

Once

installed,

the

..

keep

start

the start

will

panel

comes

the

(V\Tl

0

button

l

remote

with

either a 15' or 30'

sequence

engine

can

be

operated by

WESTERBEKE"

I

START

?='

~

I

. '

-

-·

·-

STOP

operation

is

0

PREPARATIONS

FOR,

INITIAL

START-UP

PRESTART

Before starting prolonged

•

Make

•,

Check the

• Check bowls

• Check and

• Check

,

wiring

• Examine

• Be sure load

•

Be the system connected incomplete

neutral

•

Visually parts, threaded

• Check and

INSPECTION

your

layoff,

certain

the

engine

full

mark

the

fuel

for

contaminant's.

the

DC

battery

cable

load

leads

diagrams.

air

no

other

lines.

sure that

neutral

is

requires,

to

or

voltage

examine

disconnected

connections.

the

coolant

at

the

manifold.

generator

check

the

cooling

oil

on

the

supply

electrical

connections. for

inlet

anµ

generator

in

power

properly

and

the

load

open

on

unbalanced

the

following

level:

dipstick.

and

system.

correct

outlet

systems

grounded

that

neutral.

neutral

unit Look

wires,

Search

level

in

set

for

water

thru-hull

add

oil

exarriine

Inspect

connection

for

air

or

utility

with a neutral

(or

the

generator

In single

can

supply

loads.

for

unattached

for

bott1

the

first

time

items:

petcock

to

maintain

the

fuel

wire

as

flow

obstructions.

power

ungrounded)

neutral

phase

the

loose

hoses,

any

gasoline

plastic

or after a

is

open.

the

level

filter/separator

connections

specified

is

wrong

or

and

recovery

in

connected

line

that

as

the

is

properly

systems

line-to-

missing

check

leaks.

tank

the

ati

at

to

NOTE:

After

the

initial running

the

engine's cooling system will be purged recovery the

. after the engine has cooled, the coolant from

tank will be drawn into the engine's cooling system replace

Before subsequent operation engine's manifold should be topped recovery

A

recommended be and,

wfll of

tank.

Open

cooling system

the

pflrged

tank_m_ay

CAUTION:

that

switched

in

prevent

the

OFF

cold

climates,

damage

AC

machinery

the air bleed petcock

is

purged

air.

need

When

all

until

caused and

of

air.

of

to

be filled

starting AC

loads,

the

engine

starts

to

by

will

prevent a cold

the

generator,

to

After shutdown and

the

g~erator,

off.

and

to

the

MAX

the

genera.tor,

especially

has

come

warm

up.

This

u11anticipated

stalling.

·.

COOLANT

THERMOSTAT HOUSING

PRESSURE

~.

TO

COOLANT

t.·

RECOVERY TANK

the

air

the coolant

ensure

that

the

recovery

to

the

coolant

level.

it

is

large

motors,

up

to

speed

precaution

operation

engine

CAP

in

from

SPIN-ON

OILFILTER',

COOLING

BY-PASS

INSPECT

Engines & Generators

WATER

PERIODICALLY

10

COOLANT SWITCH

TEMPERATURE

SAFETY

SHUTDOWN

SWITCHES

SAFETY

This engine is protected by

two

restart

·

the

ENGINE

OVERSPEED PC

The the engine down "if the engine speed (RPM'S) exceeds the

,operating speed required to run the generator. The overspeed

PC

SHUmOWN

fuseS.

Should a shutdown

without_jUulin,g

heading

Engine

TR.OUBLESHOarING

SWITCHES

three

occur,

and

correcting

Siarts,

runs .and

shutdown switches

do

not

the

cause.

then

shuts

s;ection

of

this

BO~

overspee1:i"PC

board

will reset itself once the engine shuts down. ·

~ard

inside

th~

control panel will shut ·

10AfUSE

OVERSPEED PC BOARD

attempt

Refer

down

manual.

and

to

in the

EXHAUST

An exhaust

exhaust elbow sensors an excessive exhaust (an

inadequate supply

above system, water hoses, etc. exhaust

LOW

Located just

the

engine's oil pressure

5 psi.

angle

TEMPERATURE

temperature

of

240°

F will shut the engine

wat.er

pump,

pump

This

switch will reset itself

cools.

EXHAUST

8.BOW

Oil

SWITCH

to

the

right

This

switch

will

shut the engine

of

operation, dipstick oil level and oil

SWITCH

switch located at the

cooling

of

if

water). A temperature

down.

belt,

seacock,

the oil

:filt.er,

the oil pressure falls

this

down.

will reset itself.

base

temperature

Inspect

water

strainer,

when

switch

to

Check

filter.

of

the

cooling

the

~

below

the

The

switch

MAIN

AC

CIRCUIT BOARD

MAIN

CIRCUIT

The

mam

automatically electrical overload.

Tum

off

the

panel

fuse

precaution.

BREAKER

circuit

breaker

disc;:onnect

AC

breaker and remove the

when servicing the unit

AC

at the control panel

the

AC

power

as

if

there is an

10

a safety

will

amp

FU$ES

A

JOA

fuse

lOca.t.ed

the

DC

el~trical

fuse will blow An 20A in-line fuse protects the battery .charging circuit

this

fuse

fails,

will

.IJ.~t

be

charging.

on the side

wiring.

and

.the

engine will continue

If

an

shut the engine

of

the control panel protects

.electrical

overload occurs the

down.

to

run but the battery

If

LOW

OIL

PRESSURE

67

OJt

FIL1tH

{);

HIGH

WATER

(Fresh

A high water temperature switch is located at housing, coolant's operating

(99°C), resets itself at l95"F (107°C). ·

will open and shut the engine down.

TEMPERATURE

Water

:Cooled

Normally closed,

·

THERMQSTAT HOUSING

:Model)

temperature reach

--~==~

this

J

SWltcH

switch, should the

approximately

the

This

SWITCH

-·~

\.

\

thermostat

fresh

water

210"F

switch

10AFUSE

.2DAFUSE

BATTERY

CHARGING

11

MAINTENANCE

SCHEDULE

WARNING:

gloves,

and

control

panel,

SCHEDULED

Maintenance

I

DAILY

Coolant

Engine

Fuel/Water

Fuel Visual

I

INITIAL

Valve Generator

Engine

Exhaust

Zinc

Fuel

Inlet

Spark

Rame Water

procedures

CHECK

Level

Oil

Level

Supply

Inspection

50

Clearance

Drive

Oil

System

Anode

Fitter

Fuel

Fitter

Plugs

Arrester

Pump

Never

use

the

or

disconnect

attempt

to

correct.tools

MAINTENANCE

are

all

detailed

BEFO!lE

START-UP

Separator

HOURS

and

of

Engine

OF

BeH

Filter

Screen

(owner

installed)

OPERATION

pertonn

for

the

battery

in

this

any

service

each

job.

terminals.

manual.

while

the

engine

When

servicing/replacing

EXPLANATION

Check Oil

CAUTION:

}\fter hours into accurate passages and/or

Check hours

Fresh Check

and

kept

Initial

Measure Initial

Initial Check buildup

Inspect/clean. Initial

Initial Check

Initial

Adjust

is

mnning.

at

recovery

level

should

The

sht.it-down,

to

drain

the

sump

dipstick

are

smokey

for

water

or

once a year,

unleaded

for

fuel,

electrical

clean.

adjustment

spring

engine check

anti-siphon

on

inside

change. change.

gap

(0.035in

cleaning

belt

tension

Wear

the

DC

components,

OF

SCHEDULED

tank,

if

empty,

indicate

between

oil

sump

on

the

back

before

reading.

well

white

and

gasoline

oil

connections.

length.

oil

and

at

50

of

screen.

this

oil

in

the

oil

checking

(Re-starting

oil

laden

dirt

in

fuel.

with

water

Ensure

cold).

Inspect

filter

change

then

operation.

clean

-1/2

engines

an

and

deflection).

into

lubricated).Over-filling

and

(engine

hours,

valve

passages:

(0.8 -0.9mm).

(3/8

proper

safety

equipment

tum

off

the

20

MAINTENANCE

check

at

manifold.

MAX

and

LOW

on

generators

sump.

the

exhaust,

Drain

octane

exhaust

belt

at

every

and

internal

Allow

dipstick.

the

hard

filter

rating

leaks.

that

bolts

condition.

50

hours,

250

hours

Check

that

replace

engine

passag~s

at

least a few

An

overnight

engine

is engines starting

if

necessary.

of

89

Check

and

nuts

Adjust then

or

the

as

necessary.

amp

DC

Add

coolant

dipstick.

Do

can

unintentionally

can

hours

period

not a problem

sump

will

and

possibly

Repla~e

or

higher.

for

rust

are

tight.

spring

length

change

both

once a year.

exhaust

elbow

such

circuit

if

needed.

not

linger

and

for

will

as

result

no

filter

or

corrosion.

Surface

as

every

Carefully

for

as

goggles

breaker

overfill!

be

over-mledl

take a number

the

oil

to

settle

provide

an

the

engine's

in

erratic

start.

every

250

Inspect

of

engine

needed.

100

hours.

inspect

carbon

and/or

and

an

the

of

back

even

more

internal

operation,

operating

wiring

should

for

leaks.

corrosion

be

I

EVERY

50

Starting

Fuel

Pump

Zinc

Anode

I

EVERY

Engine Air

Intake Timing Spark

Plugs

lmpeller(s)

NOTE:

OPERATING

Batteries

100

OPERATING

Oil

and

Filter

and

Filter

Bell

Refer

HOURS

OR

MONTHLY

(and

House

Batteries)

HOURS

OR

to

Service Bulletin #276 dated 6

adjustment.

YEARLY

Check

electrolyte

off

corrosion

Inspect

for

NOTE:

Work

difference.

Change Remove,

Check

for Inspect Inspect

May

2015 when performing generator drive belt

Engines & Generators

levels

if

needed.

leaks,

ensure

out

your

Inspect

engine

oil

and

clean

and

wear,

cracks

plug

gap.

AdjusVreplace

impeller(s)

Make Apply

fuel

own

monthly

filter.

re-install

and

for

condition.

sure

cables

petroleum

and

electrical

schedule,

to

determine

screen

stretching.

as

.needed.

Rep~ce

boats

pack.

12

and

connections

jelly

to

terminals

connections

location,

schedule.

as

needed.

use

are

of

are

for

s/'tore

in

good

corrosion

clean

and

power

order.

Clean

protection.

tight.

can

make

a

MAINTENANCE

NOTE:

Use the engine hounneter gauge to log your engine hours

SCHEDULE

or

record

your

engune hours running time.

SCHEDULED

I

EVERY

Valve Generator

*Exhaust *Exhaust

Exhaust

*Exhaust

Fuel Inlet Generator

Hoses

·~---~~---~--~-~--------

Vibration

Zinc

Generator

MAINTENANCE

250

OPERATING

Clearance

CO

level

Elbow

System

Filter

and

Fuel

Filter

Isolators/Engine

Anode

Drive

EXPLANATION

HOURS

OR

YEARLY

Adjust

·-------------------·---~-

·-----------------------------------------~

Back

Pressure

O·Rings

Mounts

·~-----·~~~--~~

Bell

valves.

Wipe

generator

connections

unobstructed.

Sample Check

exhaust

Always

use a new

carbon

monoxide!

Carefully carbon

and/or

Perform pressure Correct

as Remove Remove Check

that

See

GENERATOR

Engine

hoses

delaminated. Check

vibration

Remove Replace

Measure

NOTE:

Refer

and

exhaust

elbow

inspect

corrosion

back

pressure

above

needed.

and

replace

and

replace

AC

connections

should

Check

and

replace

gasket

spring

to

OF

SCHEDULED

clean

of

dust

CO

analyzer.

for

structural

leaks.

build-up

test

psi

or

fuel inlet

be

firm

and

tighten

zinc

0-rings

inspect

Bulletin

and

wires

NOTE:

Check

to

41

inches

filter

fuel

are

and

brackets

anode.

if

overheated

with

gasket.

for

1.5

INFORMATION.

isolators,

and

length,

Service

MAINTENANCE

engine

exhaust.

or

windings.

integrity.

A

leaking

anti-siphon

on

inside

ensure

of

and

all

sealing

filter.

clean

and

tight.

all

hose

and

Open

needed.

belt

condition.

276

dated

has

Make

Replace

exhaust

valve

passages.

not

developed

water

column

0-rings.

secure.

Replace

if

clamps

as

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

mounting

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

heat

exchanger

Adjust

May

6,

Remove

certain

if

elbow

operation.

Clean

restrictions

at

full

Ensure

wires

hoses

become

needed.

brackets.

and

spring

2015.

vent

cover

and

vents

are

clear

is

corroded

or

gasket

can

cause

Check

the

exhaust

and

replace

as

that

opera~ing

have

cap(s)

length

amperage

no

chafing.

spongy,

and

clean

as

needed.

will

brittle

inspect

for

and

deteriorated.

exposure

elbow

necessary.

·----

increase

load.

or

out

debris.

"

loose

to

for

I

EVERY

500

OPERATING

R11w

Waler

Pump

I

EVERY

500

OPERATING

Coolant

System

Valve

Clearances

Starter

Dlverter

EVERY

Heat

I

EVERY

•oxygen

•catalyst

----

Motor

Valve

1000

Exchanger

2000

Sensor

·-----

*WESTERBEKE

be

performed

HOURS

OPERATING

HOURS

recommends

by

an

knowledgeable

OR

OR OR

this

YEARLY

EVERY

service

mechanic.

TWO

YEARS

FIVE

YEARS

Remove

the

dual

pumps.

Follow

the

Inspect

and

check

Drain,

thermostat

Incorrect Check

motor Replace.

Remove

Remove Remove

replace

for

leaks

flush

and

valve

solenoid pinion

drive.

the

heat

and

replace

and

replace

NOTE:

and

for

re-fill

coolant

clearance

and

exchanger

The operation

monitored at least once

any

worn

proper

the

pressure

will

motor

exhaust exhaust

parts.

pumping

cooling

result

for

corrosion.

for

professional

oxygen catalyst.

instructions

Lubricate,

system

cap.

in

poor

sensor.

of

the unit's "Low-CO" system must be

an

in

this

manual

reassemble

action.

with

appropriate

engine

pertormance

Remove

and

lubricate.

cleaning

and

Inspect

every

operating system.

and

install.

antifreeze

Adjust

Clean

pressure

1000

hours

11iis

disassemble

mix.

testing.

that the system is operating properly. Contact your Westerbeke dealer to have this service

pelfonned

on your generator.

With

engine

Replace

valves

engine

and

lubricate

is

to help ensure

both

pumps.

running,

the

cold.

the

starter

En_qlnes

13

& Generators

ENGINE

!ENGINE

Use a good brand designations

this

Change the engine oil

engine change

SCHEDULE

Westerbeke Corporation

use

in must be performed using conventional

intervals must be as

SCHEDULE section

synthetic oils are used.

NOTE:

statements

CHANGING

The engine oil should be warm. Remove the oil drain hose from its attachment bracket and lower it into a container and

allow the oil to hose and pump the old oil out. Make sure the oil drain hose is been drained.

OIL

of

engine oil with an API ~ SAE

as

listed in the SPECIFICATION Section

manual.

~filter

l>:reak-in

interval

of

synthetic oils.

The

properly secured in its holder after all

operation. Then follow the oil and filter

as

specified in the

in

this

manual.

If

synthetic oils

listed in the

of

information

reganii.ng

THE

ililirl,

above

synthetic

ENGINE

or attach a pump to the end of the drain

after an

MAJNTENANCE

does

not approve

are

MAINTENANCE

this·mailual and not be extended

supersedes

oiL

OIL

initia1•50

pr

disapprove the

used,

engine break-

oil

Oil change

all

the old oil has

1

~-~.':;r:

'''':·.:··-

LUBRICATING

of

hours

of

if

·

..

Oil

WIPE

THIS CLEAN INSTALLING

CHANGING

When removing the used oil filter, you may find it helpful punch a hole in the upper and lower portion to

drain the oil into a container before removing

to

lessen spillage. An automotive filter wrench should be

helpful in removing the old oil and

a plastic bag around the filter when unscrewing it

any

oil that's in the removed to make sure that the rubber sealing gasket comes off with the old oil sealed against tlie oil filter adapter, gently remove it. When installing the new oil filter element, wipe the filter gasket's sealing surface on the oil filter adapter free thin coat the oil and tighten the filter firmly by hand.

THE

of

clean engine oil to the rubber sealing gasket on

filter.

Screw the filter onto the threaded oil filter stub,

SURFACE

BEFORE

FILTER

Oil

FILTER

filter.

Inspect the old oil filter

If

this rubber sealing gasket remains

filter.

OIL

FILTER

.OIL

PRESSURE

of

Place some

of

oil and apply a

ASSEMBLY

SWITCH

OIL

FILTER

•WRENCH

the

old filter

it.

This helps

pll,per

towels

to

catch

as

it

is

to

I

A

WARNING:

contaminants. and

nails

thoroughly discard used

Always observe the old oil emulsion indicates the presence this condition prevent serious damage. Call a competent mechanic is

present in the oil. Water present in the oil can be the result of a fault in the exhaust system attached a siphoning through the water cooling circuit into exhaust, filling it up into the engine.

INLET

To

in-line fuel filter connected to the fuel module. This filter should be replaced every

clothing

oil

properly.

FUEL

ensure clean fuel into the

Used

engine

Avoid

prolonged

using

or

rags

is

rare, it does require prompt attention

oil

contains

skin

contact.

soap

and

water.

containing

as

it

used

is

removed. A yellow/gray

of

water in

to

harmful

Launder

oil.

the

FILTER

fuel

lift pump, there

250 hours

of

operation.

Clean

Discard

oil.

Although

t<;>

if

engine and/or

the

is

a small

skin

or

water

NOTE:

Use

genuine WESTERBEKE oil.filters. Generic.filters

are

not recommended.

REFILLING

Add fresh oil through the valve cover. After refilling the oil,

run

the,engip~

oil

presslire. Make.•sure there is no leakage around the new oil filter or from the oil drain system, and then stop the engine. Then check the quantity dipstick. Fill

THE

OIL

SiJMP

for a few moments while checking the engine's

of

oil with the lube oil

to

the

FUlL

mark on the dipstick.

OVER-FILLING

CAUTION:

unintentionally

After shutdown, the oil in the engines internal passages can linger and take a number sump. Allow at least a few hours for the oil the

sump before checking the dipstick.

will provide an even more accurate dipstick reading. (Re-starting the engine

internal passages are well lubricated). Over-filling the engine's sump will result in erratic operation,

and/or a smokey white oil laden exhaust, hard starting and possible

no

The

oil sump on this generator's engine can

be

over-filled!

of

hours

to

drain back into

to

settle back into

An

overnight

is

not a problem

start.

as

the engine's

the

oil

pe1iod

Engines & Generators

14

GASOLINE

A

CAUTION:

higher.

exceed Ethanol can

void

Ethanol

E1D(itJ%}.

are

not

the

Use

unleaded

gasoline

Gasoline

acceptable

warranty.

must

with

far

89

Octane

not

higher

use

gasoline

exceed

percenf!Jges

in.

these

must

models

FUEL

or

not

of·

and

SYSTEM

OWNER

FUEL

INSTALLED

WATER

SEPERATOR

(WESTERBEKE

. . -

GASOLINE/WATER

A

primary installed between water be

carried

These through") bowls impurities.

Care

Use

your

particles

th~e

1

A

when any open system

when

fuel

and

other contaminan(s

to

gasoline

to meet

have

drilin

Of

The

only

clean

fuel

injection pump

which

finely

finished

WARNING:

servic.ing

fuel

that

names

when

servicing

PART

#49602}

SEPARATOR

filter

of the water separating tjpe must

the

fuel

the

fuel

system on the engine.

filters

must

U.S

..

Coats

valves

to

Fuel

Supply

fuel!

The clearance of the

is

might pass

P.arts.

Shut

a"

the

fuel

may

spill.

DO

or'other

servicing.

the

sources

fuel

tank

and

the

engine

from

the

fuel

have

metal bowls (not "see-

Guard

requirements. The

use

when

checking

very

critical; invisible dirt '

through

It is important

system.

Ensur~

the

NOT

the

fuel

Take

allow

of

fire

proper

filter

valve

care any

near

system.

to

remove

before

they

for

water

components

can

damage

to

buy clean

at

the

tank

in

catching

smoking,

the

fuel

ventilation

be

can

metal

and

in

fuel,

exists

.

':,:"·

-: . INCOMING

ENGINE

Periodically leakage. the

Changing

1. Shut off the fuel

2.

3. Remove

4. Inspect

5.

A

.

Use

FUEL

FILTER~

check

Change

MAJ!fTENANCE

.

Unscrew

·

to

come

filter

Press

the

tile

away

element

and

both

on a new

the

Filter

filter bowl

0-rings.

WARNING:

extreme

care

the

fuel

connections ~-the

filter

element

SC.HEDUIE.

Element

supply.

from

the

and

clean

replace the

Replace,:

filter

and

Fuel

Is

to

prevent

. .

·

from

housing.Remove

the

filter

replace

present

FUEL

after

the

the housing

bowl.

element

the

In

the

spillage

first

and

filter

bowl.

hosing

filter

50

hours.

replace

clean

and

bowl

allow

the

lines.

for

s~

bowl

the

bowl

ENGINE FUEL FILTER

FUEL

PUMP

Periodically and

make

are

tight

maintenance

A

connections

Make

fuel

NOTE:

fume detector/alarm properly installed

che.Ck

the

fuel

connections

sure

that

nQ

leakage

and

secure.

The

free.

WARNING:

Fuel

Is a fire

sure

proper

ventilation

system

co_mponents.

The

generator compartment should have a gasoline

is

engine

leakage

hazard

present.and

mounted

at

the

and

should

exists

. -.·w-WESTERBEKE

to

and

out of

that

fuel

pump

fuel

pump

be

corrected.

whenever

and

working.

the

pump

the

fittings

is

or

its

Sf!rvicing.

.

REPLACE BOTH

Engines & Gene(ators

15

0-RINGS

LUBRICATE CL£4N

FUEL

PRESS

THE

.

ON

OVER

THE

WITH

AND

FILTER

0-RING

COOLING

SYSTEM

RAW

WATER

NOTE:

Always install

the

strainer will always be self-priming.

A clean engine's

strainer when making your periodic engine in the glass should

Perform the following maintenance after every operation:

1. Close

2. Remove and clean

3.

Clean the

4.

Replace the washer if

5. Re-assemble

6.

Open the seacock.

7.

Run

NOTE:

Also follow

aground.

If

an

overheat occurs, the cause

grass

may

flow

of water through the cooling system

INTAKE

raw

water intake strainer is a vital component of the

c.ooling

the engine

system. Include a visual inspection of

the

raw

glass.

and

have been caught up in the strainer, slowing

STRAINER

the

strainer at or below

always

be

clear.

water seacock.

the

strainer

necessary.

install

the

and

check

for

the

above

procedure after having

filter.

strainer.

leaks.

may

be that silt, leaves

check.

the

waterline

100

The

hours

run

so

this water

of

hard

or

the

CHANGING

1.

Close the raw water intake valve to prevent

syphoning from

2.

Remove the pump turned (when installing the

in

Using

3.

4.

Inspect the impeller by bending each blade looking

cracks at each base. Also inspect the inside of the cam plate, the 0-ring, and the inner wear plate. Replace

Wipe

5. glycerin

6;

Install the blades are "working" impeller

7 •.

Apply pump any

8.

Open check for leaks cooling water is discharging overboard.

THE

RAW

WATER

the

pump.

cover.

Note

new

the

same direction).

pliers, grasp

any

the

inside of

to

the pumps interior and sealing 0-ring.

new

blades·.

glycerin

making certain the cover screws

hoses

that

the water intake valve, start

the

hub

of the impeller

worn

components.

the

pump dry and then apply a

impeller with a rotating motion

in

the

same direction

to

the impeller, install, and reassemble

may

have

Been

around

the

pump.

PUMP

the direction the blades

impeller,

removed.

and

Also

bend

are

run

make

and

the

water

the

as

the

tight.

sure

from

the

blades

pull

it

for

cover,

film

so

the

old

Replace .

engine

raw

are

out.

of

the

and

~

Q

WASHER

STRAINER

WATER

The water pump. (ocean, lake, or river) through a hose The water passes to discharged into the water-injected exhaust

with exhaust the

· thermostat controls maintenance

COOLING

flow

This pump draws water directly from the water source

the engine where it cools the engine. The water

and

cooling

gas

and cooling water

engine's

gas

CIRCUIT

is

created

from

the

discharge pressure. An internal engine

the

free.

>(j)

.

by

a positive displacement impeller

to

the

strainer through

exhaust gasses. This mixture of

is

discharged overboard by

water temperature. This thermostat is

FUEL

FILTER/

WATER

SEPARATOR·

[Owner

water

the

water pump

elbow,

Installed]

strainer.

is

then

mixing

A

WARNING:

sure

that engine and

co«ect

COVER

INSPECT OF WEAR. COAT ASSEMBLY.

ARE

THE

COVER

APPLY A THIN

OF

GLYCERIN

IF

ANY

IMPELLER

MISSING,

BE

FOUND BLOCKAGE COOLING

WIPE

CLEAN

INSTALLING COVER

TO

IN

CIRCUIT.

THIS

SURFACE

BEFORE

When

the

pump

start.

If

it

does

the

problem~

INSIDE

FOR

AT

BLADES

THEY

MUST PREVENT THE

THE

... :

.--..--.-~""

the

is

pumping

not,

engine

within

"stop"

FROM STRAINER

is

started,

30

the

engine

·

RAW

make

seconds

at

RAW

WATER

PUMP

CAM SCREW

WATER

after

once

Engines & Generators

'16

[FRESH

RAW

WATER

The

fresh mounted This

pump housing blades that impeller

account should

a spare impeller impeller

lubricant failures make

sure pump should be inspected periodically for broken impeller

NOTE:

Should a failure occur with the pumps internal parts .

(seals

and

a new pump and rebuild

PUMP

INSPECT SURFACE

IMPELLER

FIT

INTO

WHEN

.

THE WITH

PUMP

water cooled

above

the

fresh

is

a self-priming, rotary

and a Neoprene

wipe

against a curved

housing,

kit).

(water)

are not

blades.

THE

IMPELLER

producing

this.

pump

and

impeller cover gasket

Raw

water pump impeller failures occur

is

not present

warrantable,

water

flow

See

MAINTENANCE

bearings) it

DUAL

PUMPS

C"OVER

THE

INSIDE

FOR

WEAR.

HUB

SCREW

THE

SHAFT

SLOT

ASSEMBLING,

AND

GLYCERIN

(Fresh

Water

Pump)

model

has

the

raw

water (coolant) pump

pump

impeller.

is

present at

may

the

COAT

0-RING

The

cam

the

pumping

be

run

dry. There should

during

and

operators

start-up.

be

more

original

(FRESH

impeller

plate within

engine

SCHEDULE.

dJst efficient

pump

WATER

water

as

with

a non-ferrous

has

action.

aboard

operation.

are

cautioned

The

as a spare.

COOLED

COOLING

WATER

SYSTEM

COOLED

CHANGING

pump

illustrated.

flexible

the

Qn..nQ

al

ways

(an

when

raw

water

or tom

to

purchase

MODELS)

be

Such

to

Remove upper pump as seacock. while

1.

2.

3.

4.

5..

6.

MODELS]

THE

WATER

the

cover

screws

and

(raw

water)

from

shown

in

the

illustration. Close

This

will

prevent water

the

impeller

Remove

direction install

the

same

direction.

Using

pliers, impeller the

cam,

cover plate Wipe

the glycerin supplied surfaces

Install

the

blades

are

removed Apply

glycerin

plate

and

lipper

pump

tight:

Re-install

Ru~

the engine properly. raw.water should discharge

should

not

is

being changed.

the

wear plate to expose

the

impeller blades

replacement impeller

grab

the

impeller

from

the

pump.

the

inner

wear

for

wear.

Replace

inside surface of

in

the

and

to

the

exposed area of

new

impellers

working

impeller.

assemble

The engine should

be

to

(raw

any

the

water)

any

to

make

leaks

in

the

0-ring,

into

hoses

(Pump)

Inspect

plate,

impeller kit

with

the

making certain

certain

around

IMPELLERS

the

cover

the

fresh

water

the

raw

syphoning

the

are

working

with

hub

and

the

and

the

any

worn

the

pump

to

the

a rotating

same

direction

impeller,

pump

housing.

that

were

both

run

at proper

from

the

pumps.

will

separate

(coolant)

water

out of

impeller.

in

so

blades

working

withdraw

inside

of

inside

components.

dry.

Apply a film

the

inside

shaft

motion

as

those

gasket,

Reassemble

the

removed.

pumps

temperature.

exhaust

the

pump

thru

hull

the

pump

Notice

as

to

the

pump,

surface of

pump

lip

seal.

so

the

of

the

wear

fasteners

are

operating

and

there

in

the

of

the

are

0-RING

WIPE

BEFORE

'COVER

'

THIS

SURFACE

INSTALLING

CLEAN THE

DRAIN

TUBE

A

WARNING:

sure

that

the

engine

start.

and

correct

To

increase impeller longer

...

dry location. Replace

·''

and

WATER

A water intake strainer the

NOTE:

tube this

Engines & Generators

in

the

than 3 months.

ensure

the

INTAKE

generator

Shouid a pump shaft water seal leak

will allow

drain

tube

When

pump

If

it

does

the

problem.

the

service

pump

if

thru

hull

STRAINER

is

installed. Refer

the

leak

clear

of

the

is

pumping

not,

"stop"

life of

the

engine

Store

the

cover plate

seacock

(raw

water)

to

drain away

obstructions.

engine

within

the

impeller,

will

impeller

on

is

closed.

is

a required

to

the

is

started,

30

seconds

engine

do

be

in

storage

in a dark,

the

pump

from

the

make

after

at

once

not

install

for

cool,

securely

component

page

for

this

unit.

the

and

when

details.

drain

Keep

17

,

RAW

WATER

DESCRIPTION

Coolant (fresh water) cooled generators have dual water pumps while the raw water cooled models use a single water pump. The pumps are essentially the same. The upper pump mounts to the top shaft that are driven simultaneously by the engines drive belt.

The following instructions apply to either pump.

PUMP

fits

OVERHAUL

of

the lower pump and has a tang on the

into the shaft

of

the lower pump. Both pumps

Disassembly

The pump, when removed from the engine will have the hose

inlet

attachment nipple threaded into the

the pump along with a drive pulley attached to the shaft

the pump. Remove these attachments noting their positions

before starting the pump disassembly.

1.

Remove the four cover plate screws, cover plate, and sealing 0-ring.

Dual

Pumps

Remove

upper as

Remove direction the

the

cover

pump

shown

in

the

wear plate

the

replacement

screws

and

the

(raw

water)

from

the

illustration

to

expose

impeller blades

are

working

impeller with blades working

and outlet ports

cover will separate

fresh water (coolant) pump

the

impeller.

in

Notice

so

as

in

the

direction.

2.

Remove the impeller using a pair hub and pulling it out

3.

· Remove the screw and sealing washer that hold the cam

in place. Remove the cam and inner wear. plate behind

4. Remove the brass circlip A and brass plate found behind

the wear plate.

5.

·Remove the dust

6.

Support the pump body on an arbor press and with a drift, carefully press the shaft and bearing assembly out pump body out

7.

Remove fue slinger

8.

Support fue outer bearing and push the shaft out

bearing.

9. Remove the spacer and circlip

IO.Support the inner bearing and push the shaft out

bearing.

11.Remove the two piece ceramic shaft water seal.

pla,te

fue

pulley end.

0-ring

·

of

t11e

and circlip B.

of

pliers, grasping the

pump with a twisting motion.

from the shaft.

C.

to

of

the

install

same

of

fue

the

it.

PUMP

""

~°'

LIGHTLY

GREASE

CHAMBER

WITH

INSPECTION:

EACH REPLACE ARE

COVER

INSPECT ANO IF

OR

THE

PUMP

GLYCERIN

BLADE

THE

ANY

CRACKS.

THE

IMPELLER.

ANY

SIGNS

TEARING

IMPELLER

CHECK

AT

BY

BENDING

IMPELLER

0-RING

REPLACE

OF

WEAR

DUST PLATE

THE

BASE

OF

VIGOROUSLY.

IFTHERE

IMRELLER

FITS

°

~.·

t'~~'cjf

PULLEY

INTO

SHAFT

SLINGER 0-RING

l~NER

BEARING

SPACER

OUTER BEARING

CIRCLIP

c

SHAFT

Inspection

Inspect

all

parts and replace those showing wear and

corrosion.

Engines &

18

Gener~tors

RAW

Reassembly

Wipe

the

inside

surface glycerin surfaces

1.

2.

3.

4.

5.

supplied and

Install a glycerin

Install

the

push

the

circlip.

Install

the bearing contacts

Warming and

bearing

press.

With assembly the

outer bearing

Rotate

the

Install

circlip B

to

the

new

shaft

to

the

circlip

shaft

spacer against

and

push

the

spacer.

the

assembly.

a twisting

into

shaft.

outer bearing just contacts circlip B and install the dust plate.

Rotate

6.

Put

some

glycerin

seat

and

slide

and

seat

it

in

on

the

inner

area

the

shaft

until

white

ceramic

7.

Install

the

brass

8.

Install

the

wear

pin.

Dual Pumps

The

wear plate

is

of

the

pump dry. Apply a

in

the

impeller kit

exposed

lip

into

pump

the

It should turn

and

the

shaft.

it

over

the

area of the shaft

seal

in

the

pump

of

the

seal.

shaft.

Support the outer bearing

the

bearing until

the

circlip. Support the inner

the

shaft into

the

body should aid

Support

motion,

pump

should

the

install until the inner bearing seats and just clear the boss for circlip

freely.

push

the

shaft assembly until

It should turn

on

the outer surface of

the

shaft white ceramic facing out

body of the pump. Place

and

with

a twisting motion slide it over

ceramic of

the

face.

plate

and

circlip

plate,

locking it

assembled above

in

to

the inside pump

lip

body.

Apply some

the

bearing contacts

bearing until it

in

installing the shaft

pump body on

the

shaft and bearing

freely.

the

some

spring

seal

touches the

A.

position

the

on

impeller.

film

seal.

ceramic

the dowel

WATER

of ·

and

an

arbor

B.

the

seal

glycerin

PUMP

THE

TANG

OF

THE

UPPER

FITS

INTO

THE

LOWER

Off

THE

SHAFI

THE

END

SHAFT

SLOT

UPPER.

PUMP

SHAFT

IN

~

SCREWS

(}11

FASTENS

ilJ

UPPERPUMP BODYTOmE LOWER

THE

ONLY

REPLACES

SIGNS

DUAL ASSEMBLY

rHE

·

PUMP

O·RING!GASKET

NEtos

TO

BE

IF

IT

OF

SHOWS

AGING.

PUMPS

.

9.

Install

the

threads

10.Place and

of

NOTE:

blades removed

of

some

inner

surface of

with a twisting

the

pump.

secure

the

Install

are

impeller.

Dual Pumps

Assemble making

the

sure

cam

and

place some gasket cement on

the

screw

that secures it

glycerin

on the inner surface of

the

cover and

motion install

Install

the

cover

with

the four cover

the

new

impellers with a

working

in

the

upper

pump

the

mounting screws are

in

place.

the

pump,

the

cover sealing 0-ring

the

impeller

on

covers 0-ring and cover

screws.

rotating

same

direction

to

the lower pump as illustrated

tight.

of

motion

those

of

the

shaft

and

so

the

Engines & Generators

PULLEY

19

COOLING

SYSTEM

[FRESH

WATER

COOLED

MODELS]

FRESH

Fresh water coolant is pumped through the engine by a

circulating pump, absorbing heat from the engine. The coolant then passes through the thermostat into the manifold, to the heat exchanger where it engine block via the suction side When the engine is started cold, external coolant flow prevented by the closed thermostat (although some coolant flow circulation in the engine block). As the engine warms up, the thermostat gradually opens, allowing full flow

coolant to flow unrestricted to the external portion cooling system.

ENGINE

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

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

NOTE:

antifreeze that

The recommended

against the most extreme temperature. The antifreeze mixture will also retard rust within the engine and add to the life the circulating pump impeller and seals.

A proper engine coolant to temperatures

Coolant

The coolant recovery tank allows for the expansion and contraction

WATER

is

bypassed around the thermostat to provide coolant

COOLING

CIRCUIT

is

cooled and returned to the

of

the circulating pump.

of

the engine's

of

is

the

COOLANT

of

50% antifreeze

50% distilled water. Distilled water is free from the

It

allows the engine to

(SCA' S) that keep the antifreeze chemically

Look

for

the new environmentally friendly long lasting

is

now available.

50/50 mixture will protect the engine

of

50/50 mixture as recommended will protect the

of -40°F.

Recovery

of

the engines coolant during engine operation without introducing air into the system. This recovery tank provided with fresh water cooled models and with the fresh water coolant conversion kit and must be installed before operating the engine.

Tank

is

NOTE:

Periodically check the condition Ensure that the upper and lower rubber seals are condition and check that the vacuum valve opens and closes tightly. Carry a spare cap.

CHANGING

The engine's coolant must be changed according to the

MAINTENANCE

become contaminated, it can lead to overheating problems.

A

critical; a substantial traced

Drain the engine coolant by loosening the drain plug on the heat exchanger and opening pressure cap. Also loosen the air bleed petcock on the top

A

Wear

Refilling

Tighten the heat exchanger drain plug and slowly pour clean, premixed coolant in thru the coolant exchanger air bleed petcock loose to allow trapped air to escape. As the filling continues, start and run the engine. Close the air bleed petcock and fill until coolant tops off at the coolant

Remove the cap on the coolant recovery tank and coolant mix to halfway between LOW and MAX and replace 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 back into the cooling system as the

engine cools down. Add coolant to the recovery tank

needed and make certain the coolant is topped off at the pressure cap. Clean up any spilled coolant.

COOLANT

SCHEDULE.

CAUTION:

back

WARNING:

protective

Proper

to

cooling

Beware

gloves.

the

Coolant

fill.

Install the pressure cap.

cooling

number

system

of

the heat exchanger

of

the

of

the pressure cap.

in

If

the coolant is allowed to

system

of

maintenance

engine

failures

can

corrosion.

hot

engine

fill.

coolant.

Leave the heat

fill

good

is be

with

if

NOTE:

This tank, with its short run

located at

or

above the level

of

the engine's manifold.

plastic hose,

lw/WESTERBEKE

is

best

/ Engines & Generators

20

COOLING

THERMOSTAT·

Fresh water cooled

controls flows first

flowing

coolant circulation

up,

accessible Carry a spare

the

through

started~

(some

the

thermostat

and

coolant

the

closed

the

closed

coolant

in

gradually

can

be

thermostat

3;0KW

temperature

generators

cooling thermostat is

around

the

engine block).

opens.

checked,

and

gasket

SYSTEM

have a

thermostat

as

the

coolant

circuit.

When

prevents

the

cleaned,

coolant

thermostat

AB

The

thermostat

or

replaced

the

[FRESH

that,

continuously

the

engine

is

from

to

provide

engine

warms

is

easily.

WATER

COOLED

MODELS]

TO

WATER

EXHAUST

COOLED

Replacing

Remove the cap housing

gasket, gasket before pressing it

GASKET

ADD AT

HEAT

Cool exchanger.

.the

heat of the internal engine which discharged. The engine coolant through

The engine coolant other; hannful deposits

Heat

After approximately

and

pressure test the engine's heat exchanger. (A local

automotive radiator

heat

NOTE:

that a heat exchanger cleaning be perfonned more often than every

the

Thermostat

screws

and

as

shown.

apply a thin

SEALANT.

ASSEMBLY

THERMOSTAT HOUSING

When

coat

disassemble

installing of sealant into

place.

the

on

the

thermostat

new

thermostat and.

both

sides

of

the

EXCHANGER

raw

water

flows

through

As

the

engine

is

then

pumped

the

engine

this

keeps the engine's water passages clean

Exchanger

exchanger.)

Operating in silty and/pr tropical waters may require

1000 hours.

into

and

found

Service

1000

shop

the

inner

tubes

coolant passes

is

conducted

the

exhaust system

(now

the

circuit

raw

water are independent of

in

raw

water.

hours

should

around

cooled)

repe:'l.ts

itself.

of operation,

be

able

to

of

to

the

and

flows

remove;

clean

the

these

raw

back

from

and

heat

tubes,

water

each

test

the

dean

the

~

\J;r""

~a..1-----~

H?<------RAW

~

.

ZINC

ANODE

A

zinc

anode, circuit within anode

is

to

the

'raw

in

of electrolysis condition of the

anode

should

be carried

NOTE:

Electrolysis is the result

and vessel location; not that

If

the

zinc

which

the loosening hex

boss

removing

poor condition, there exchanger. the

inside of exchanger end gasket in case damaged when removing the

(refer to your engine model's heat exchanger

number),

NOTE:

The not require sealant. Sealant should not be used as insulate the zinc from the metal housing preventing electrolysis action on the

CLEAN

OUT

O·RING

AND

or pencil,

the

heat

sacrifice itself to electrolysis action

water cooling circuit, thereby reducing the

on

other components of

the

zinc anode should

cleaned or replaced

on

NEW

pencil needs replacement, hold

zinc

pencil

the

anode with another wrench.

from

possibly tearing off

the

zinc,

Remove

all

zinc

o-ring,

cover,

threads

DEBRIS

GASKET

is

located in the

exchanger.

board.

is

threaded with a

note.

the

are

probably zinc

the

end of

debris.

and

of

the zinc anodes are pipe threads and

The purpose of the

be

as

required.

of

each particular installation

of

the engine.

REPLACE

the

condition of it.

the

heat exchanger

Always

install a

have

the

present

end

cover.

new

of

the heat exchanger

COOLANT

WATER

raw

water cooling

the

system.

checked

Spare

CLEAN & REUSE

the

hex

wrench

This

exchanger

If

the

flakes

within

a spare heat

one

becomes

Replace

end

zinc

anode.

zinc.

DRAIN

zinc

taking

effects

The

monthly

anodes

boss

while

prevents

shell. zinc

the

and

the

gasket

gasket part

it

may

place

and

into

the

After

is

in

clean

do

21

DC

REGULATOR.

CARBURETOR

WITH

CARBURETOR

The carburetor cleanable metal screen air intake filter/spark arrester.

The de-richening valve

to close off a fuel port reducing the fuel mixture going into the engine after a cold start. The valve will be hot to touch during engine operation.

The air screen can easily be removed. Clean after the first hours

of

the air screen in a water soluble cleaner such as GUNK.

Fuel

Overflow

Excess fuel drains into the fuel overflow chamber but is

drawn out again at start-up. This chamber should be kept free of

contaminates. Cleaning every 250 operating hours should

be sufficient unless there

Idle

Mixture

The idler mixture jet

is

a single barrel, side draft type with a

is

operated by 12VDC. Its purpose

50

operation and every 100 hours from then on. Clean

Chamber

is

a fuel problem.

Jet

is

factory adjusted and plugged.

is

SPEED

ACTUATOR

De-Richening

The de-richening valve closes off a fuel port that is supplying additional fuel on a cold stmt after start-up. This is a thennal electric device that slowly moves a needle outward when AC is

applied to the device after start-up to close this fuel port.

To

check this device, with the engine running, measure the AC voltage across the two connections. voltage in the 25VAC the touch being sent to the device.

WINDING

OHM

Carburetor

A bowl drain slotted plug of

the carburetor bowl. This is located just inboard

actuators ball joint/clevis.

NOTE:

Ball joint linkage between actuator and throttle. Lube

periodically (use graphite lubricant) to maintain smooth

operation.

Valve

rm1ge.

The device will get warm/hot to

as

the engine operates as voltage

VALVE:

20

OHM

(APPROXIMATELY)

Bowl

Drain

is

located on the lower right corner

It

will be a low AC

is.

continually

of

the

Engines & Generators

22

DC

CIRCUIT

/BATTERY

DESCRIPTION

The

DC

Circuit functions to start, operate and stop the generator's engine. The circuit is best understood by reviewing the The engine's circuits: start, run, and stop.

The engine has a 12 volt shown on the Wiring Diagrams. Refer to these diagrams

when troubleshooting or when servicing the DC electrical

system on the engine.

A

CAUTION:

circuit, the

engine however, engine's

DC

wiring is designed with three simple basic

never

shut

is

running.

to

avoid

electrical

Wiring Diagram and Wiring Schematic.

DC

electrical control circuit that is

To

avoid

damage

off

the Shut

electrical

engine

off

the

shorts

to

the

battery

engine

when

charging

switch

while

battery

working

switch,

on

the

circuit.

Specifications

The minimum recommended capacity

the engine's 12-volt DC control circuit is

Battery

The engine has a flywheel mounted magneto and ari external DC volts approximately. The system is protected by a 20 amp buss type fuse.

Charging

voltage regulator. The system provides 9.5 amps at 13.5

Circuit

of

the battery used in

600-900 (CCA).

Testing

If

circuit, remove the fuse and test with a voltmeter between the fuse holder connection and ground. With the engine running, it should indicate 13-14 volts. indicated, check the terminal connections at the battery.

Battery

Review the manufacturer's recommendations and then establish a systematic maintenance schedule for your engine's starting batteries and house batteries.

• Check the electrolyte level and specific gravity with a

• Use only distilled water to bring electrolytes to a proper

• Make certain that battery cable connections are clean and

• Keep your batteries clean and free

the

Circuit

the battery

is

not charging, check the fuse.

If

only battery voltage is

Maintenance

hydrometer.

level.

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

of

corrosion.

To

test the

SHORE

POWER

DESCRIPTION

If

the installer connects shore power to the vessel's AC

circuit, this must be done by means

Transfer Switch. Set the transfer switch shown in the

diagrams to the simultaneous connection

Generator

~

1 =

OFF

position. This switch prevents

of

shore power to generator output.

SINGLE

LINE

120

of

the Shore Power

VOLT

SYSTEM

TRANSFER

A

utility at

the covered sibility

enerat&

Ground

SWITCH

CAUTION:

shore

power

same

time.

under

the

to

make

N

'-----'"i"$;J-~>

___

l

L1

NI

f

Shore

Power

230

Damage

sure

<Neutral> I I

VOLT/50

to

and

generator

This

type

warranty;

all

AC

L1

ti

Generator/Shore

,Jg

Switch

Ill

__...,:,

' ,

...

_

Shore

-

Ground

HERTZ

the

of

it

connections

. ,

_

...

generator

output

generator

is

the

installer's

are

~."'~

.~~

. N

Ground

TWO

WIRE

can

result

if

are

connected

damage

is

not

respon-

correct.

''<.I

~w.

~

\~~

~

. :

Ship-To-Shore

Ship's

LOAD

Ship's

CONFIGURATION

'1

'

Switch

SYSTEM

Engines & Generators

23

ELECTRONIC

DESCRIPTION

The

system

is

composed

1.

Controller. The PC board that governs the system is

Jocate,d

in

the

control panel. ·

2.

Sensor.

sures

3.

Actuator. Electronically controls the carburetor throttle.

Tue

the

Mounted on the flywheel cover, the sensor

the

speed of the engine (via the ring gear).

sensor

and

actuator

controller

(PC

board).

if

three basic components.

are

wired thru the wiring harness

.SENSOR

;

~~Wt/lb.

.@~li30in

mea-

to·

(0;762mm}

GOVERNOR

.CONTROL

PANEL

(INTERIOR VIEW)

CONTROLLER

GOVERNOR

PG

BOARD

GAIN

(P3}

'-STABILITY

SPEED

(P1)

ACTUATOR

FEEDBACK

(P2}

(P4)

'/Magnetic Pick-up

(MPU) po

950-1000

048057

Ohm

FLYW

RING

ADJUSTMENT

Speed.

This

engine's

2200RPM.

Gain. engine

Stability.

changes. AlternatQr.Feedback.

signal

NOTE:

require

ADJUSTING

Following

(Pl).

pots

The stops.

left

speed.

Adjusts

seems

Adjusts

to

the

Tliese adjustments are extremely delicate

proper meters

stability

..

adjt1sting

Tum

(counter-clockwise)

EEL

GEAR

~-

. . .

INSTALLING

THREAD

THE BACK AND

'i\-ctuATlifi

'·

'KEEP

THE

.

WELL

LUBRICATED

Fl.AT TIGHTEN

LEVER

LINKAGE

THE

OUT

SENSOR

ON

THE

RING

SENSOR

THE

JAM

,SPEED

PROCEDURE

adjustment is used to raise or lower the

This generator engine is set to run at

the overall set

sluggish, to high causes the engine to hunt.

the engine's response to generator load

. ·

throttle actuator.

THE·CONTROLLER

are

the

basic procedures for adjusting the speed

(P2),

gain

pots (except speed) have physical internal

tp

the right (clockwise) to increase, tum

of

the engine.

Adjusts the stability

for

measuring voltage

If

too low, the

of

the speed

and

PODS

(P3), and actuator feedback (P4)

to

decrease.

SENSOR

IN

TO

CONTACT

GEAR

TOOTH.

ONE

TURN

NUT

TO

ACTUATOR

and

RPM'

to

the

SECURE.

S.

Before

Ill

Ill Decrease the speed

IB

Start.

of that the

Decreasing the gain engine running at the throttle lever to cause hunting.

starting

Remove all loads to insure that loads

variations while these adjustment are

the

engine

and

tum

will

not be subjected

pot

to

off the

prevent

AC

circuit

to

made.

overspeed

Tum the other adjustment pots to the middle

th~

engix,>.e,

the unit by adjusting

AC

monitor speed

the.

and

SPEEO

adjust to

(Pl)

as

the

needed.

voltage output is in the correct range.

(P3)

damp~

no

load and proper speed,

no

load hunting.

If

necessary,

manually

voltage

at start

position.

decrease

gain in small increments to eliminate hunting .

. After the engine's no load

the

AC

circuit breaker can

applied.

· the stability

In

the

(P2)

event

pot

also changes how the engine

changes. · ·

If

the range

of

adjustment

pots do ,iot correct engine hunting, the actuator

(P4)

pot can

be

increased. This adjustment nals to the throttle ·control actuator. Increasing will deci:ease the amount Because

of

this, it is recommended the aojustment

speed

and gain are set

be

turned on

of

speed variations with

may

need

a,djustment.

respom;ls

of

eithe:t:

ga:i:Q

of

throttle 'control

and

the

ships

loads

This

to generator

(P3)

or

feedback

dampens

this.

resolution.

in very small increments. The gain and itability pots now

need

to

be

readjusted.

Most hunting problems

lems with the linkage between the tor.

Insure that the linkage

·and that it moves freely.

be lubricated with a graphite lubricant.

because

NOTE:

such throughout this

it

tends to collect dirt and dust.

Adjustments to

as

speed. /i"inp.y be necessary to readjust some pots

process.

oceur because

of

actl.lator

is

free

of

any debris or

It

is

recoIIllJilended

Do

one

parameter may affect

mechanical

and

the

that

not

use

breaker

up.

hek

rating

Verify

With

bump

correctly,

load

applied,

adjustment

load

stability

the

sig-

adjustment

be

made

may

prob-

carbure-

corrosion

!:}le

linkage

oil

others,

the

(P2)

24

ENGINE

ADJUSTING

The engine's drive belt is located under the engine. To access the belt, for inspection and/or adjustment, remove the cover as shown. Inspect the belt for wear along the edges

and for proper belt tension (belt should The belt tension can be checked spling length. 11/4ln

To

set the spring tension at 1-1/4", release the use a rod such shown) to tighten or loosen the spring tension, which in tum adjusts the tension

THE

DRIVE.

as

an allen wrench to

on

the belt.

BELT

by

r-~

be

tight).

meassming the

(31.79mm)

-r->=:::::::µ..

jam

tum

the adjusting: nut (as

ADJUSTMENTS

nut and

SHEAVE

VIEW

FROM

ARRANGEMENT

UNDER

BASE

FRAME

COVER

BElT

ASSEMBi:.Y VIEWED

*

IMPORTANT:

BULLETIN ADDITION

(LAST OF A SPACER

REFER

PAGE

TO

IN

ON

.

IT DUST ENGINE

FROM

THE

THIS

THE

IS

NORMAL

WESTERBEKE

MANUAL)

3.0BCG

FOR

TO

ACCUMULATE

PAN,

SIMPLY

BELOW

FOR

MODEL.

SOME

BELT

IN

THE

WIPE

CLEAN

SERVICE

THE

The Iub1icating system is a pressure feeding system using an oil pump. oil pump, which drives the oil, under pressure, through the oil filter and various lubricating then returns to the oil When the oil pressure exceeds the specified

pushes open the relief valve in the oil pump and returns the oil sump, keeping the oil pressure within it's specified range.

TESTING

To mechanical oil pressure gauge in it's place, it will be necessary to engine to run. After warming up the engine, with speed at

Oil

NOTE:

pressure

on

OIL

The generator is fitted with an oil pressure shutdown switch. Should the engine's oil pressure drop below the safe

minimum, the switch will shut the engine down to prevent damage by interrupting the

NOTE:

loss

additional information

ENGINE TROUBLESHOOTING

The

engine oil is drawn from the oil sump by the

paits in the engine. The oil

sump

to repeat the continuous cycle.

OIL

PRESSURE

test

the.

oil pressure, remove the oil switch and install a

·connect the two switch wires -together for the

2200 rpm, read the oil pressure gauge.

PRESSURE:

the

PRESSURE

of

between

30

and

40

psi

at

A newly starter (cold) engine

up

to

40

psi. A wanned engine can

as low

as

30

psi.

Oil pressure will

load placed on

the

generator.

SWITCH/SENSOR

DC

voltage to the ignition coil.

77w

specified minimum oil pressure

oil pressure usually indicates

on

low oil pressure

2200

may

worn

rpm

chart.

prei;sure, the oil

to

tlie engine

have

an

oil

have

an

oil

Val)I

depending

is 5 psi. A gradual bearings.

reading.1~

For

see

the

lw,WESTERBEKE

Enaines & Generators

'25.

ENGINE

ADJUSTMENTS

ENGINE

To engine,

1.

2.

3.

4.

COMPRESSION

check

the

engine's compression pressure, warm

then

shut it down.

Remove

both spark plug caps and both spark plugs.

TEST

Install a compression adapter and gauge in a spark plug

hole.

Close

the

tlu·u

hull valve (seacock).

Crank the engine several times quickly so

pointer reaches it's maximum.

STANDARD 71

psi, (5

186

psi, (13.8 kgf/cm ),

5.

Test

the

If

either cylinder is below the standard

small

and

repeat

(a)

If

the

or damaged.

(b)

If additional oil does not increase compression

COMPRESSION

.1

kgf/CM ) ,(0.50

(l.35

PRESSURE AT 500

MPa)

with decompressor

MPa)

without

compression pressure on the other cylinder.

tTy

amount of engine oil tlu·ough the spark plug hole

the

test.

additional oil causes an increase

piston ring and/or cylinder

nmy

of

be

pressure suspect poor valve contact, valve seizure or

valve

wear.

6.

Reinstall

thru

the

two

hull

valve (seacock).

plugs, connect the

wires

up

the

~hat

the gauge

RPM:

decompressor

adding a

pressl.Jre,

worn

and open the·

WATER

To

PUMP

BELT

remove, replace

or

aojust the belt, loosen and release the adjusting bolt. Slide the water to slacken the belt for removal. When replacing adjusting the belt, set and

nut

The dual water pumps on the

.

MODELS

use the saine drive belt and the adjustment is the

tl1e

belt very tight and tighten

FRESH

WATER

Bame.

WATER

'... '·,

PUMP

BRACKET

'V'"

''II-,,.:;....

'/;'~;

==-=M--<

I~

@:

-·-·--=~

the

pivot bolt

pump

bracket

and

the

COOLED

bolt

I

.1

IGNITION

The

that speed. with

There

10°,

Check

marking

TIMING

magneto employs the electric ignition advance system advances ignition timing with an increase

While mnning the engine, check the ignition tinting

a timing light.

are

nine

(9)

markings

15°,

20°,

25°,

30i

the

timing while observing the position

on

the

starter case.

(fDC,

0

35) on the flywheel cup.

,

ATDC

of

5° and BTDC 5°,

of

FLYWHEEL

engine

the carved

NOTE:

The

COOLED

BTDC

IGNITION IN

TIMING

DEGREES

a.djus~~ient

MODEL

is

the

same

for

the

FRESH

dual

pumps.

30

·25-1----+~.::;;....

20

10

5

0

""--"'---1+-,f-_..___..___.____,

0 3 4 5 6 x 103

___

Engine speed rpm

WATER

,

Engines & Generators

26

ENGINE

ADJUSTMENTS

SPARK

The spark

first

thereafter

SPARK SPARK

NOTE:

the

of

PLUGS

plugs

should be cleaned

50 hour break-in period, then inspected

and

A

WARNING:

the

engine

removing

PLUG

GAP:

PLUG

TORQUE:

Loctite

spark

plugs

the

spark

replaced

is

hot.

them.

D.032 -0.035in.

Anti-Seize applied

will

plugs

as

Do

not

Allow

11

-15

retard

easier.

needed.

remove

the

lb-ft

corrosion,

t

INSPECT

FOR

WEAR & CARBON

.

INSPECTl.NG THE

SPARK

PLUGS

USE A 518" FLEX-SOCKET

TO REMOVE & INSTALL SPARK PLUGS

and

re-gapped after the

the

spark

engine

to

(0.8 -0.9mm).

(15 -26

Nm).

to

the

threaded

making

every

250

hours

plugs

while

cool

before

portion

future

removal

~CHECK

FDR DETERIORATION AND

DAMAGE

of

·

THERMOSTAT

A thermostat continuously the engine is water

from thermostat As

the

engine

thermostat

you

suspect a

bring to a

and

easily.

replaced

If

and heated

[Raw

controls fiows

through

first

started,

fiowing

to is

close

(some

provide coolant circulation

warms

accessible

Carry

faulty

boil. A working

when

Water

the

coolant

the

closed

water

up,

the thermostat

and

can

a

spare

thermostat

thermostat,

thermostat

cold.

Cooled

temperature

closed

cooling

thermostat

is

by-passed

be

checked,

place

Models]

as

the

circuit.

prevents

around

in

the

engine

gradually

and

it

in a pan

should

opens.

cleaned,

gasket.

of

open

GASKET

APPLY

SEALANT

WHEN

INSTALLING

·THERMOSTAT ASSEMBLY

raw

water

When

the

block).

The

or

water

when

(PN.048150)

.

· ·

ZINC

ANODE

The

zinc

and

next to sacrifice itself water

cooling electrolysis condition of

[Raw

Water

anode

is located just below the thennostat cover

the

oil filter.The purpose

to

electrolysis action taking place in the

circuit,

th~reby

on

other components of the

the

zinc anode should be checked

the anode cleaned or replaceq

should be carried

NOTE:

Refer

pages

jot

and

Zinc

Anode

on

board.

to

the

Cooling

Fresh

Water Cooled Thennostat assemblies.

Cooled

Models]

of

the zinc anode

reducing the effects

system.

as

required. Spare

Syste1it

of

The

monthly

anodes

is

raw

and

to

ZINC

ANODE

THE

GASKET

THE

CASTING DAMAGED, POSITION. THE

REASSEMBLING

CAN

ADD

GASKET

IS

SEALED

AND,

UNLESS

BE

LEH

SEALANT

SURFACE

THE

WHEN

COVER.

TD

IN

TD

ZINC

ANODE

AND

GASKET

(PN.048017)

Engines & Generators

27

VALVE

It

the must

must

CLEARANCE

is routine

first

mainterni.nce

fifty hours of operation.

be

performed

be the

top

dead

to

when

center of

adjust

the

engine is

the

Perform the following adjustment

ENGINE

NOTE:

WESTERBEKE

ments be performed

the

valve clearance after

Valve

clearance adjustment cool

and

the

compression

steps:

stroke.

ADJUSTMENTS

~-a

piston

recommends

competent engine mechanic.

that

the

following engine adjust-

EXHAUST

SIDE

INTAKE.

SIDE

1.'

Remove head removing

the

cover.

This

the

fuel

hoses.

pump

assembly

2. Remove the cylinder

and

fuel

can be set

Disconnect

head

cover.

filter

the

from aside

two

ignition

FLYWHEEL BOLTS

the

COVER

cylinder

without

wires.

FEELER

GAUGE

5.

Adjust

the

intake

and

exhaust valve clearance

rYlitider

a. Loosen

#

i.

the

lock

nut.

b. Insert a·feeler gauge between

adjusting

c.

Set

~ALVE

INTAKE:

E

EXHAUST:

d. Tighten e.

Again,

6.

Tum

driven pulley with

7.

Adjust #2

using

NOTE:

the

adjusting

vent it from

screw.

the

valve

clearance by the adjusting

CLEARANCE:

0.13 -0.17mm

0.18 -0.22mm

the

lock

check

the

the driven gear

the

intake

and

the

same

sequence.

When

loosening and tightening

screw

moving:_

(0.005 • 0.007in)

(0.007 -0.0091n)

nut.

valve clearance.

and

the

" V" mark on

exhaust valve clearance fot cylinder

·with

for

the

valve

end

and

screw.

align the "2

and

the

O"

mark

cylinder

lock

ri.'ut,

a valve clearance driver

'

the

ori

head.

hold

to

pre

the

FLYWHEEL

NOTE:

The

governor sensor (mag pick-up)

disconnected at

4.

Tum

the driven gear

driven pulley

the

with

side

of

and

align the "I

the " V"

the

control

mark on

panel.

and

the

wires

O"

mark on the

cylinder

can

be

head.

Engines & Generators

28

VALVE

CLEARANCE DRIVER

8.

Install

the

rim

of

the

drawing.

9. Install

the

BOLTTORQUE: 8 -

10

Nm

cylinder head

cover

as

flywheel

(0.8

. . . .

-1.0

kg-m)

BACKSIDE

SEAL

WITH

BLACK

cover'.

Apply

sealant to

indicated

cover

THIS

LOCTltE

by

the

shaded

· · · · · ·

and

re-attach

5.8

-7

.2

lb-ft

AREA

SIL/CONE':""..~-&+-41---11-1.))

the

OJJl=ii===l~::;;::!!;::ttlc

area

sensor

..

the of

Wires

. . •

inside

the

ENGINE

ADJUSTMENTS

INSPECTION/REPLACING

If

cracks,

wear,

lengthening

replace

the

timing

belt

LIMIT

OF

PUSHING

ELONGATION:

WITH

Replacement

1.

Remove the parts in the following order:

a.

b. Voltage Regulator

c.

d.

e. Flywheel Housing

f.

g.

2.

Turn

the

pulley

and the

3. Remove the timing belt from the driven pulley side.

Install the timing belt froni the drive pulley side.

4.

MORE

YOUR

FINGER

of

the

Spark Plugs

Unplug MPU

Unplug Cam Sensor

Flywheel assembly

Altemafor Bracket

crru:ikshaft

"O"

OF

THE

TIMING

or

other damage is found,

THAN

1Dmm

(0.4

IN)

Timing

aild

:inark

Belt

align "O" mark

on the'cylinder bead.

BELT

DEFLECTION

·

on:

the drive

BY

0.4"

FLYWHEEL

·ASSEMBLY

··o

DEFLECTION W/FINGER

·NOTE:

After installing the timing

"O"

ino.rk

on

the

drive pulley with "O"

block. Please on the driven pulley cylinder

NOTE:

grea.se.

confirm that the

are aligned with the

head.

Always keep the timing belt away from

TIMING

BELT

belt,

when the aligning

"1

&

O"

on

the

cylinder

or

''2 &

''\!"mark

any

0"

mark

on the

oil and

ALTERNATOR

\

BRACKET

29

TROUBLESHOOTING

GUIDE

3.0

KW

When toubleshooting indicates an electrical problem, see the ELECTRICAL SYSTEM WIRING DIAGRAM, as this may reveal other possible causes below.

PROBLEM

Engine

does

not

crank.

Engine

starts,

runs

and

then

shuts

down. (Runs

for

10·15

seconds)

Engine

starts,

runs

but

does

not

up

to

Engine fails

(Engine for

15

Engine

come

speed.

cranks

to

stmt

will

crank

seconds)

hunts.

hut

of

the problem which are not listed

PROBABLE

1.

Voltage terminal.

2.

Main

3.

Battery

4.

Loose

5.

Faulty

6.

Faulty

7.

Faulty

8.

Faulty

9.

Water

1.

Faulty or

2.

Faulty

3.

Dirty

4.

Clogged

5.

Low

6.

Faulty

7.

No

8.

Clogged

1.

Faulty

2.

Electronic

3.

Fuel

4.

Fuel

5.

Actuator

6.

Actuator faulty.

7.

Air

8.

Exhaust

1.

Out

2.

Engine

3.

Faulty

4.

Faulty

5.

Faulty

6.

Bad

1.

Controller

2.

Faulty

3.

Fau!ty

4.

Improper

5.

Low

6.

High

7.

Dirty

8.

Generator

9.

Valves

CAUSE

drop

10

amp

is

low

battery wire start pc

board starter filled shutdown

exhaust

overspeed

fuel/water

fuel

oil

level

fuel

mag-pickup

pump. supply

linkage or

intake

restricted.

of

fuel. is

flooded. carburetor. choke ignition

spark

fuel PC

board. drive

DC

battery exhaust fuel

filter

need

at

starter

solenoid

fuse

blown.

or

dead.

connections.

connection.

switch.

solenoid

cylinders.

switcll,(oil

temperature).

PC

board.

separator

line.

in

sump.

pump.

filter

sensor.

governor

plugs

gain

pump.

overload.

controller

to

engine

restricted.

bimJing.

electrical

adjustment.

connections

(See

solenoid

coil.

adjustment

belt

tension.

voltage.

back

pressure.

pressure,

filter.

faulty,

Carburetor

needed.

page)

The following troubleshooting tables are based upon certain

engine problem indicators and the most likely causes problems

PROBLEM

Engine

misfires.

Engine

backfires.

Engine

overheats.

Low

oil

pressure.

High

oil

pressure.

No

DC

charge

starting

battery.

to

the

PROBABLE

1.

Poor

2.

Faulty

3.

Dirty

4.

Faulty

5.

Spark

6.

Binding

7.

High

8.

Valve

9.

Valve

1.

Faulty

2.

Incorrect

3.

Engine

flooded tails

4.

Dirty

5.

Faulty

6.

High

1.

Blockage the pump seperated

2.

Belts

3.

Obstructed

4.

Obstruction

1.

Low

2.

Wrong

3.

Oil

4.

Relief

5.

Faulty

6.

Faulty

7.

Boat

8.

Faulty

1.

Dirty engine.

2.

Relief

1.

Faulty

2.

20

3.

Faulty

4.

Faulty

CAUSE

quality

ignition

flame

ignition

plugs

actuator

exhaust

clearances' clearances

ignition

timing.

is

flooded.

uncler

to

start.

flame

ignition

exhaust

in

raw

water

impellers,

may

oil

level.

SAE

diluted

valve

oil

pump.

engine

heeled

oil

filter.

oil

or

valve

connections

amp

fuse voltage magneto.

fuel.

control

arrester.

wires.

are

worn.

linkage.

back-pressure.

are

incorrect.

are

incorrect.

control

See

Engine

arrester.

coil.

back-pressure.

cooling

water

intake,

intake

and

look

hoses.

be

loose

or

by-pass

hose.

in

engine

type

oil

in

with

fuel.

is

stuck.

bearings.

over

too

much.

wrong

SAE

is

stuck.

to

blown/faulty.

regulator.

cranks

broken.

cooling

magneto.

module.

Engine

but

flow:

strainer,

for

broken

system.

the

engine.

type

oil

of

the

is

inspect

in

the

or

--

Engines & Generators

30

TROUBLESHOOTING

GUIDE

PROBLEM

Blue

EXhaust

from

the

Engine

Black

exhaust

from

the

Engine

Poor

performance

at

generator

Starter after

Unit at

idle

Engine seconds shuts

stays

start

starts

speed

starts,

then

down

speed

and

Smoke

Discharge

smoke

Discharge

energized

runs

for a few

overspeeds

and

PROBABLE

1.

Lube

2.

High

3.

Crankcase

4.

Valves

5.

Piston

1.

Dirty

2.

Faulty

3.

Idle

4.

Accelerator

5.

Valves

6.

Piston

1.

Contaminates

2.

Faulty

3.

Electronic

adjustment.

1.

Faulty

2.

Faulty

1.

Check

2.

Faulty

1.

Faulty

2.

oil

lube

are rings

flame

carburetor.

mixture

are rings

fuel

MPU starter

MPU overspeed

MPU.

Faulty

CAUSE

is

diluted. oil breather

worn

arrester.

diaphragm

worn

pump/contaminated.

governor

Control

level.

hose

or

adjusted

are

worn

or

jet

too

rich.

or

incorrectly

are

worn

or

in

carburetor.

controller

suspected.

solenoid.

signal.

1.5 -2.0

board.

PC

Board

is

clogged.

incorrectly.

unseated.

leaking.

adjusted.

unseated.

needs

Check

MPU.

VAC

!

cranking.

Engine Will

stay

is

kept

NOTE:

MPU

Cranking: Running: (2200rpm)

4.0 -5.0

starts,

but

shuts

down.

running

depressed

voltages

1.5 -2.0

to

VAC

if

start

PC

board:

switch

BY-PASSING

A faulty Overspeed PC Board can unwanted shutdown. It can also engine is started and runs for shuts down.

1.

Control

THE

OVERSPEED

PC

Board.

be

the cause

be

the cause when the

10 -

15

seconds and then

1. Refer to the Wiring Diagram in this manual.

2.

Unplug the brown #6 wire that connects between pin #12 module. between the two components.

3. Without unplugging any connections on the coil relay, place a

of

the

15

pin plug connector and the ignition

The

wire plug connection is in the harness

jumper

between connection #30 and #87.

4. Manually controlling #30 and #87, start the engine

physically controlling the actuator/throttle keeping the

at

engine speed continues to run more than overspeed board exists.

NOTE:

17ie

above should only be generator with a by-passed overspeed board should not be nm

under

nonnal

a low comfortable range.

15

seconds, a faulty

pe1f

ormed as a test.

use.

17iis

can present a hazard.

If

BOARD

of

an

the engine

17ie

31

GENERATOR

RESISTANCE

VALUES

WIRING

IN

OHMS

DIAGRAM

IN

BLACK

ITALIC

MAG.PICK-UP

950-10000

SH\E:LO(D

n

T4

0.27

• 0.41{)

ALT.

COIL

RESISTANCE

MAGNETO

COIL..

EXCITER

COIL

PULSER

COIL

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

ALTERNATOR

IGNITION

COIL..

(Primary)

MAGNETIC

PICK-UP

START

SOLENOID

HIGH

TENSION

DE·RICH

VALVE _ _.

ACTUATOR

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

NOlE:

TESTER

TOLERANCE

OVERSPEED

CONTROL

......

~·'~·~s~L·~'~···~·-----~f!!AG.CO_t_l--1,....,-=>-··~"'~·~a~LK~I~··~·------------.

~~~~-------~-----+-----+--~

CARBURETOR

SOLENOIO

~

VOLTAGE

REGULATOR

VALUES

IN

OHMS

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

....................... 12.5·18.8

COIL

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

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

•.•..••.•••••••

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

LEADS

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

USED·

:l:

20%

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

FLUKE

PC

BOARD

PC

BOARD

1.4 • 2.1

148 • 22·2

0.27 • 0.41

0.26 -0.35

950-1000.

4.7

6.800·10.DOO

20

3.0

·3.1

MULTIMETER

(PN

(PN # 045369)

1.4 • 2.

tfl

---~f~-----c:J

UNIT

RESTART

UNIT

NOT

#0453'17)

BATTERY

I Z

CAN

RESORT

1t1s

au

ft,.

R(D/

ltl6

AEO

VDC

R£MOT£

I:

2:

3:

4:

JUMPER<

TERMlllA.LS "FlRESOY"

.TERMINALS

"EMERGENCY

1'18 -222

PULSER

HT

~---+--~

ll8

Blk

SHUTDOWN POSITIVE AUX.

SHUTDOWN

ENERGEHCY

GROUND

C·l

SI

MUST

1 I\ 2

CONNECTION

3 & 4

STOP

~-~EXCITER

i 16

YH/REQ

tl6

BLK

r

fl

COIL

~~

12.5

EXCITER

STARTER

SOLENOID

FUSE'.

IOA

TERMINAL

!+I

STOP

.

6(

REMOVED

ARE

FOR

ARE

FOR

SWITCH"

12.5 • 18.511

- 18.Sfl

COIL

4.7fl

START

SOLENOfO

COIL

IGNlllON

MODULE

ti

S

GRN/REO

RELAY

PANEL/REMOTE

CONTROL

COIL

CONNECTOR

PC

BOARD

116

t

# # 16

t

16

ENGINE

CONTROL

REO/\'IHT

BLK

ORG

YEL

R£

GRN

JIG

CONNECTOR

PC

BOARD

REDfVIO

IGNITION

COIL

+

l

SPARK PLUGS

OIL

PRESS

SWITCH

It

WA~T~

EXHAUST

TEMPERA11JRE

SWITCH

HOUR

METER

~

..

START/STOP

SWITCH

PART

NUMBERS:

AC

OUTPUT

REMOTE

RED

ISOLATION

CONNECTIONS

STOP/START

POST

120V

PANEL

60Hz

#048056

PANEL

EXTENSION

Engines & Generators

32

HARNESS

GREEN

15FT

TO

220V·50HZ

CONNECTIONS

FOR

230V50Hz

#048200,

STARTER

30

GROUND

FT

#048201

0

L

LOAD

RED

ISOLATION

0

Q

N

POST

WHITE

GREEN

GENERATOR

USE

OF

ELECTRIC

The power required

more than is required Some motors require much more current others. Split-phase under similar circumstances, than other monly used machines, or where started, 7 times

avoided, whenever possible, if driven induction motors require to

start varies nected current

In

general,

to

medium

-

*NOTE:

more for some small motors than for larger

for this

made

Because the heavy

motors

be damaged if it can bring

seconds. off all other electrical loads on the electric

.such as

much

by a small

as

to

with

to

an

than

the

MOTOR

(HP)

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

1

In

is

that

in

larger

is

required

If

on

as

run.

the

air compressor, for example, will require a motor

starting

SIZE

the

difficulty

MOTORS

to

start

an

electric motor

to

keep it running after it is started.

(AC)

motors require more

types.

easy-starting loads,

loads

are applied after

small power tools. Because they require 5

current

to

start

generator.

from 2 to 4 times

The current required

load connected

to

which

current

required

loads

will

AMPS

RUNNING

(AMPERES)

above table the maximum Amps for Starting

the

hardest starting types (split-phase)

sizes.

surge

of current needed

for

only

is

experienced

motor.

such

as

to

run,

the

electric motor

Capacitor

to-it.

An

no

load

to

start

115-Volt

be

approximately

FOR

3.2

'

4.6

5.2

7.2

10.2 13

an

instant,

the

motor

up

in

and,

if possible, reduce

as

and to

electric motor

is

the

starting motors, turn

is

considerably

to

strut them

cmTent

They are

washing

the

motor is

their

use

is

repulsion-

as

much current

start

any

connected.

motors as

follows:

AMPS

STARTING

(AMPERES)

6.4

to

9.2

to

10.4

to

14.4

to

20.4

to

26

to

ones.

for

starting

generator

to

speed

in a few

than

to

start,

com-

should be

to

be

motor

conmore

connected

FOR

22.4~

32.2*

72.8

*

29.2*

40.8* 52

The

reason

are

will

not

the

load

INFORMATION

to

'

not

is

Required

Run generator's capacity, indicted should be checked periodically the

generating plant

monitor voltage

amp

Generator

Maintaining reasonable cleanliness of terminal boards insulation surfaces exhaust, carbon, ventilation openings reduced life of windings.

In addition

inspected for tightness of overheated terminals andloose or damaged

Generator

BPMGModel

Should a failure occur

Model

adjustments free.

NOTE:

drive belt under the generator base frame.

BC Model

Refer

Operating

the

generator

on

first

the

generators data plate. The output voltage

and

probe.

Maintenance

and

may

etc.

to

periodic cleaning,

Failure

(no

AC

output).

to

the

generator. The generator

Contact

you

WESTERBEKE dealer or

It

would

be

important first

to

BCG Troubleshooting

load, check it

Speed

with

no

load

applied,

and

finally loaded

to

ensure proper operation of

the appliances it

with

is

rectifiers may become corroded,

start conducting if

are allowed

may

in

do

to

build

cause excessive heating

the

generator should be

all

connections, evidence of

a permanent magnet -BPMG

not attempt

to

in

the

then at

to

its

full

supplies.

a portable meter

important.

salts,

up.

Clogged

wires.

to

make

repairs or

is

maintenance

distributor.

inspect

the

pulley and

following

capacity

Connections dust,

pages.

half

To

and

the

as

and

engine

Engines & Generators

33

BCG/BPMG

- . • I ' . • . '

REFER

DESCRIPTION

ALSO

TO

and

.TROUBLESHOOTING

THE

SPECIFICATION

PAGE

BRUSHLESS GENERATOR

Engine generator turns 3600 (60Hz) 3000 (50Hz)

60Hz 50Hz

NOTE:

Refer to the following page

Wiring Schematic and BCG Winding Resistances.

RED

DIAGRAMS FOR

BOTH

ARE

MODELS

ISOLATIOU

for

POST

WHlTE

N

120V/60Hz

BCG/BPMG CONNECTIONS

GREEN

TO

STARTERllROIJND

AC

OUTPUT

DIAGRAM

Atf>-----~

-"'<:rf-----,-~

220V·50HZ

230V/50Hz

WHITE

BLACK

AC

o

CIRCUIT BREAKER

PERMANENT

GENERATOR

Engine

generator

3600 (60Hz)

120

60Hz 50Hz

230

RPM

120 230 Volts/13

the BCG Internal

BLACK

0

MAGNET

(BPMG)

RPM

at

2200

turns

at

3000 (50Hz) Volts/25 Volts/13

CAPACITOR

(BCG)

at

2200 at

Volts/25

Amps Amps

AC

CIRCUIT BREAKER

l1

IR

Amps Amps

TROUBLESHOOTING

CAUSE

No

AC

Output

Voltage

Residual

Line -Neutral No

Low

Voltage

AC Inductive

Refer to the following page Schematic

Voltage

Load

AC

Output

60 -100

Voltage

at

Drop

Load

and

the BCG Winding Resistances.

TROUBLESHOOTING

CAUSE

No

AC

Output

Voltage

Low

AC

Output

Voltage

60 -100

Vortage

Drop

Under

load

WINDING

PM

(Permanent Magnet) stator winding resistance 0.4 ohm he1tz model resistance is measured between line and neutral. 50 hertz models is 0.8 ohm.

NOTE:

The permanent magnet style generator can not assembled. must be replaced.

NOTE:

It would be important to inspect the pulley and drive belt under the generator base frame.

Volts

RESISTANCE

If

an electrical fault should occur, the generator

Volts

with

CHART

(BCG)

FAULT

1.

Shorted

2.

Open

Stator.

3.

Shorted

4.

Shorted

5.

Shorted

6.

Open

1.

Faulty

2.

Open

3.

Shorted

1.

Faulty

2.

Faulty

3.

Faulty

1.

Faulty

2.

Faulty

3.

Amperage

for

the

CHART

(BPMG)

FAULT

Shorted

1.

Open

Stator

1.

Faulty

1.

Generator

(Measured

Stator. Rotor

Diode.

Rotor

Thermister.

Rotor

Capacitor.

Rotor

Diode.

Capacitor.

Exciter

Winding.

Exciter

Winding.

Rotor

Diode.

Rotor

Winding.

Ex~iter

Capacitor.

Rotor

Diode.

Exciter

Capacitor.

Overload.

BCG

Internal Wiring

Stator

Winding.

Rotor.

Overload.

at

20°C/68°F)

be

dis-

Engines & Generators

34

BCGBACKEND

COMPONENTS

(TOP

VIEW)

60

Hertz Models : Rotor Winding Excitor Winding - 2.0 Capacitor Rating - 34

Stator

-

4~0

.CAPACITOR

IBESE

COMPONENTS

ARE

LOCATED

.

ROTOR

.

AC

TERMINAL

.

GROOND~

-$;i

Winding 0.93 Ohm/winding. 50 Hertz Models : Stator Winding 1.35 Ohm/winding.

Ohm

Qhm

uF

· .

WllllJINtl

. .

RESISTAflCE

(Measured

at

200C/68'F)

Rotor Winding - 4.0 Excitor Winding Capacitor Rating -31.55

..

2.5

BLOCK

Ohm

uF

ON

.

THE

THERMISTER

An

unwanted

then

and board.

1.

Refer

Unplug

2. of

the

wire

components.

3.

Without

·

place

shutdown

shuts

to

the

15

plug

connection

unplugging

a jumper

BCG

INTERNAL.WIRING

ROTOR

I

•N.WHITE

I - .

'12ov·

1·

.

I

luiA

' .

I

,

-.

K.

I

BY-PASSING

or

if

the

engine

runs

10-15 seconds

down

can

be caused

Wtting

Diagram in this manual.

brown

#6 wire that connects between pin #12

plug

connector and the ignition module. The

is in

any

between

connection #30 and #87.

by

a faulty over-speed

the

harness between the

connections on the coil

•

relay,

THE

two

DIAGRAM

·GREEN

WHITE

BLACK

' .

·YELLOW OR

BROWN

BLUE

''

!i

:1

:I

;1

·.

.

EXCITOR

ri

RED

61~

CAPACITOR

BOARD

4.

Manually controlling #30 and

physically controlling the actuator/throttle keeping engine speed at a low comfortable continues to

board exists.

NOTE:

The above should only be perfonned as a generator with a by-passed overspeed board should not run under nonnal

run

more than 15

use.

This can present a hazard.

#87,

start

range. H the

seconds,

the

a faulty

STATOR

,I!

OVERSPEED

engine

overspeed

test.

the

The

be

Engines & Generators

-

35'

LAY-UP

AND

RECOMMISSIONING

GENERAL

Many owners including engines and generators, for lay-up during the off-season or for long periods of inactivity. accomplish lay-up preparation themselves.

The procedures which follow will allow you own lay-up and recommissioning, or to use others do the procedures.

These procedures should afford your engine protection

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

maintenance needs

If

you your local servicing dealer; provide assistance.

ENGINE

If

the engine will be out more, the engine's cooling passages should be fresh

water.

and the impellers stowed in a cool, dark area.

for flushing the cooling system are shown on the next

page.

LUBRICATION

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

sump.

with new

ENGINE

oil changing procedure. Run

are

no

A

lubricating Lubricatlng·oil produce

·

your

rely

on their boatyards to prepare their craft,

Others prefer to

to

perform your

as

a check list

of

your engine.

have any questions regarding lay-up procedures, call

he

will

be

more than willing

COOLING

Also the water pump(s) should be disassembled

(Raw

Water

of

commission for 3 months or

Cooled

Models)

flushed

Instructions

with

SYSTEM

Remove and replace the oil filter and fill the sump

oil.

Use the correct grade

LUBRICATING

leaks.

CAUTION:

hannful

engine's

Do

oil

in

and

intemal

not

the

combustion,deposits

chemicals

OIL

leave

sump

parts.

of

oil.

refer to the

pages in this manual for the

the engine and make

the

engine's

ovet

the

lay"'up

whicb

can

reduce

sure

old

period

•.

combine

the

to

life

if

to

Qie

there

of

INTAKE

Clean the filter screen in the cloth lightly soaked in lube oil around the block any opening. Also place thru-hull exhaust port. Make note

start-up!

FUEL

Top or

should be separator and clean the metal certain there are

STARTER

Lubrication and cleaning of the starter drive pinion is advisable, the pinion removed. Make sure the battery connections before attempting to remove the starter. replacing

MANIFOLD

SYSTEM

off your fuel

higher. A fuel

added.

MOTOR

any

electrical connections removed from the

flame

arrester, and place a clean

flame

arrester

an

oil-soaked cloth in

to

remove cloths prior to

tanks

with unleaded

conditioner such

Change the element in your gasoline/water

bowl. Re-install and

no

leaks. Clean up any spilled

is

accessible when the

~oline

as

mann~

of.~9

sta~il

fuel.

flywheel

are

Take

care m properly

to

the

oc~e

gasohne

make

cover

shut off

starter.

SPARES

Lay-up time

WESTERBEKE

belts

spares kit and order items not on hand, or replace those items used during the lay-up, such to

the

provid~

or coolant hoses need replacement. Check your basic

SPARE

PARTS

a good opportunity

engine to see

as

section

of

to

inspect your

if

external items such

filters and zinc

this manual.

as

anodes.

drive

Refer

BATIERIES

If

batteries make sure they are to

prevent them from freezing. the batteries be subjected the environment.

are

to be

left;

on

board during the lay-up period,

fully charged, and will

will not remain fully charged, or that they will

to

severe environmental conditions, remove

batteries and store them in a

~~

that

If

there exists any doubt that

warmer;

more compatible

way,

is

Engines & Generators

. -

36

.

·

FLUSHING

THE

ENGINES

COOLING

SYSTE~

Engine flushing should t.W,ice

per

operating season, more often in those areas

the unit may not.be

locations where the unit is used year round, once every 4 months is recommended. This procedure water intake hose the hose end into a large container

Close

the

hose. Before starting the engine, remove the engine thermostat (replace the gasket of

water thru the engine.

flushing is

NOTE: Prior to flushing the engine, inspect the coolant by-

pass hose and its attachment fittings to insure that there are no obstructions occurring in the fittings or the hose.

Provide maintain the water level operated during the flushing process.

is best accomplished by disconnecting the

thru-hull

complete. A

an

external fresh water supply for the container to

be

performed a minimum

s1,1bjectto

from the vessel's thru-hull fitting. Insert

intake

and cover). This will ensure a full flow

winter storage.

of

fresh water.

valve

before

disconnecting

Re·install

in

the container while the unit is being

the

thermostat

of

at least

\Vhere

Int?ose

flushing the unit

once

Run the unit for

.

cooling system. The

fresh

exhaust lines: ability

of prior to shutting the supply with a concentrated antifreeze mixture and through the engine to provide freeze and corrosion protection for both the engine and exhaust system. When recommissioning, make certain the thru-hull intake valve is open water.

CAUTION:

supply

cause

i"ll:::r--,da~_ma

___

ige.

10

minutes or longer to adequately flush the

water will flush out the engine's water passages and

If

the engine

freezing, flush the engine with fresh water and then

so

the engine will quickly receive cooling

Do

directly

naading

to

of

v

'----------------

is

being stored

unit dowp. Substitute the fresh water

not

the

engine's

the

engine

connect

an

coaling

resulting

and

external

system. in

internal

there is a prob-

run this

fresh

water

This

can

.RAW

WATER

PUMP

. .

RAW

WATER

{\

FRESHWATER

ALTER

EXTERNAL

WATER

FRESH

SUPPLY

Engines & Generators

37

3.0

KW

GENERATOR

SPECIFICATIONS

Engine

Type Bore & Stroke Total

Displacement Beatings· Valve Compression Firing Aspiration Direction

Governor

·

System

Order

of Inclination Dry

Weight

Fuel

Pump Fuel Ignition

Timing

Ignition

Coil

Flame

Arrester Carburetor Fuel

Consumption

(Full

Load)

Ignition

Timing

Start

Motor

Starting

Battery

Capacity

Battery

Charging

DC

Amperage

Type

Oil

Filter

Oil

Capacity

Oil

Grade

Ratio

Rotation

ENGINE

SPECIFICATIONS

Two

cylinder.

2.32 x 2.36

20.01 Two

main Overhead 9:1

1

-2

Naturally Counterclockwise 25°

maximum

165

lbs

Electronic

FUEL

Mechanical Unleaded BTDC 12

volt. Metal Single

0.4

GPH @ 2200

12-Volt

ELECTRICAL

12-Volt 12-Volt,

600-900 11

Amp

Draw

70

Amps

LUBRICATION

Wet

sump

Fuel

flow,

1.5

qts.

API

Service

four

str()ke

inches

(59 x 60

Cubic

Inches beatings. cam-cross

aspirated.

viewed

angle

(75

Kg)

SYSTEM

fuel

pump.

89

octane

25°

(not

adjustable).

screen

type.

barrel

side

draft.

RPM/25

flywheel

magneto.

SYSTEM

reduction

gear

(-)negative

Cold

Cranking

DC

SYSTEM

system

trochoid

paper

element.

(91.4

L)

Categor}'

SAE

10W-30or15W-40

gasoline

(.33

liter)

flow.

from

of

operation

or

higher

with

ground

Amps

SJ,

mm)

the

gasoline.

Amps

solenoid.

(CCA)

type

pump.

spin-on

SL,

SM,

engine.

back

end.

disposals.

SN

or

better

General Raw

Water

Raw

Water

(into

water

exhaust

elbow)

Operating

Type

Speed

3.0Kw

Spark

Plug

Spark

Plug

Bolt

Torque

Engine

Combustion

Generator

Cooling

System

Fresh

Water

Pump Raw

Water

Raw

Water

(into

water

exhaust

elbow)

Operating

COOLING

Pump

Flow

injected

Temperature

AC

GENERATOR

TUNE-UP

Gap Torque

AIR

Cooling

FRESH

(coolant)

Pump

Row injected

Temperature

WATER

SYSTEM

Water

cooled

via

raw

water

pump.

Positive

displacement

belt

driven.

1.75

GPM'(before

2.0

GPM

(thermostat

140°F

(60°C)

(SINGLE

Permanent Brushless/capacitor

3600 3000

3.0 2

RPM / 60Hz. RPM I 50

KW -60

wire,

25

KW -50

wire,

13

magnet

amp.

Hz

Hz. single

single

type,

rubber

thermostat

open)

PHASE)

generator

(two

pole)

phase,

SPECIFICATIONS

0.032 -0.035in 11

-15

See

TORQUING

lb-ft

(15-

(0.8 -0.9mm)

20

Nm)

THE

CYLINDER

REQUIREMENTS

13

CFM

(0.287

cmm)

200

CFM

(5.66

cmm)

·

COOLED

Fresh

water

controlled

Positive driven

Positive

driven

2.5-3.0GPM

9.5 -11.3

180°F

thru a heat

displacement.

displacement,

LPM

(82°C)

cooled

MODELS

block,

thermostatically

exchanger.

rubber

impeller,

opens)

(two

pole)

120

volts

230

volts

HEAD.

impeller

belt

Engines & Generators

38

DECIMAL

TO

METRIC

EQUIVALENT

CHART

Fractions

an inch

·13/32 0.40625

of

Decimal (in.)

1/64 1/32 3/64 1/16 5/64 3/32

7164

1/8 9/64 5/32

11/64

3/16

13/64

7/32

15/64

1/4 0.250

17/64

9/32

19/64

5/16

21/64 11/32 23/64

3/8

25/64 0.390625

27/64

7/16

29/64

15/32 31/64

,1/2

.

'

Metric (mm)

0.015625

0.03125 0.79375 17/32 0.53125

0.046875

0.0625

0.078125 1.98437 37/64

0.09375 2.38125 19/32

0.109375 2.77812 39/64

0.125

0.140625 3.57187 41/64

0.15625 3.96875 21/32

0.171875

0.1875 4.76250 11/16

0.203125 5.15937

0.21875 5.55625 23/32

0.234375

0.265625

0.28125 7.14375 25/32

0.296875 7.54062 51/64

0.3125

0.328125

0.34375 8.73125 27/32

.0.359375 9.12812 55/64

0.375

0.421875

0.4375

0.453125

0.46875

0.484375

0.500

0.39688

1.19062

1.58750

3.175

4.36562

5.95312

'

6.35000

6.74687 49/64

7.93750

8.33437 53/64

9.52500

9.92187

10.31875

10.71562

11.11250

11.50937

11.90625

12.30312

12.70000

Fractions

an

Inch

33/64

35/64

9/16

5/8

43/64

45164

47164

3/4

13/16

7/8

57164

29/32 59/64

15/16 61/64 31/32 63/64

1

of

Decimal (in.)

0.515625

0.546875 13.89062

0.5625 14.28750

0.578125 14.68437

0.59375

0.609375

0.625

0.640625 16.27187

'

0.65625

0.671875

0.6875

0.703125

0.71875

0.734375

0.750

0.765625

0.78125

0.796875

0.8125

0.828125

.

0.84375

0.859375

0.875 22.22500

0.890625

0.90625

0.921875 23.41562

0.9375 23.81250

0.953125 24.20937

0.96875

0.984375 25.00312

1.00

Metric (mm)

13.09687

13.49375

15.08125

15.47812

15.87500

16.66875

17.06562

17.46250

17.85937

18.25625

18~65312

19.05000.

·19.44687

19.84375

20.24062

20.63750

21.03437

21.43125

21.82812

22.62187

23.01875

24.60625

25.40000

Engines & Generators

39

CONTACT

YOUR

SUGGESTED

WESTERBEKE

MARINE

DEALER

SPARE

GASOLINE

FOR

SUGGESTIONS

PARTS

GENERATORS

AND

ADDITIONAL

INFORMATION

SPARK

PLUGS

WATER

PUMP IMPEllERS, AND

GLYCERIN

O·RINGS

·

TUBE.

THERMOSTAT

·AND

GASKET

10AfuSE

(ONSIDEOF CONTROL

PANELF

~

ENGINE

BELT

'WATER

PUMP

.BELT

.,GASOLINE

FUELJWATER.

I

:

FILTERS

'ZINC

.

ANODE.

WESTERBEKE HAVING FOR

ENOUGH

AT

LEAST

___

WESTERBEKE each packaged Kit A includes Kit B

is

for

KIT

IMPELLER OIL GENERATOR ZINC SPARK 20A WATER

FUEL 10A

HEAT

ALSO

RECOMMENDS

OIL

ON-BOARD

ONE

OIL

CHANGE

___;_

____

also

offers

two

Spare

Parts·Kits,

in a rugged

the

basic

more extensive off-shore cruising.

hinged

spares.

toolbox.

A

KIT

FILTER

DRIVE

BELT

ANODES

FUSE

FILTER

FUSE

EXCHANGER

WITH

PLUGS

PUMP

KIT

GASKET

BELT

ZINC

SPARE

PARTS

Engines & Generators

KITS-----'--------

KIT

B ·

IMPELLER

OIL

FILTER GENERATOR ZINC

ANODES SPARK 20A WATER

FUEL 10A COMPLETE THERMOSTAT

WATER

OIL

HEAT

PLUGS

FUSE

PUMP

FILTER

FUSE

PUMP

PRESSURE

EXCHANGER

HEA

EXCHANGER

GASK~T

KIT

DRIVE

BELT

WITH

GASKET

BELT

KIT

GASKET

SET

KIT

REPAIR

SWITCH

ZINC

A.ND

o-mNG

KIT

END

·

40

Engines & Generators

DATE:

SUB.JECT:

SERVICE

__

24-Apr-1_5

Generator Drive Belt Performance

__

BULLETIN

BULLETIN NUMBER:

276

----

MODELS

AFFECTED: 3.5 SBCG and 3.0 BCG Gasoline Generators

DETAIL: Generator drive belt life performance improvements include a belt tension adjustment

change, produced Changes covered

Manufacturing dimension

if necessary, it is adjusted again to 1" prior to releasing

Important Note: Maximum due

the addition

on

or after manufacturing date code OD (April

made

under

of

1"

to

incorrect tension requires the belt be to adjusted

of

a spring spacer, and a new idler pulley. 3.5

are

enhancements, modification

warranty.

of

new

products includes. for optimum belt

in

our

assembly process as illustrated below.

performance

to

of

the drive belt

2015)

existing

the

and

to

will

products

break

in, adjusting

After

unit

for

prevention

1"

at

the

SBCG

have

generators

these changes.

in the field is not

the

first

hour

shipment.

of

potential failure

recommended

maintenance service.

the

belt

of

run time

50 hour

to

a

Generator drive belts for regular maintenance replacement

wlll

be

sold as a

pulley is

not

running the

to

1". After

adjustment to

My!J?~,

St0riDi~,h

k.it

with

required. Initial

unit

for

1 hour. varying AC loads in the process,

50

hours run time,

instructions that

adjustment

or

during the

includes

of

the belt with

scheduled service, inspection and

1" is required to ensure proper belt tension.

lndu"'.iri~_·d

P,;1r'<.

JSn

!o

WEST~RB[!(E

1

1n

H;:w1cocf<

www.westerbeke.com

COR!"OR

Ro;id, T;:iunton,

~T>ON

f\11/\

02780-73:19

required spring spacer. Replacing the

the

Add 1 !8"

1)

Tel:

(part

numbers

spacer

the

belt

Spacer

508.823.7677

remain the same)

installed is 1

must

be

adjusted again

Here

1t

F;.)'('.

::io8.88<'l.9(\~p,

".

After

Engines & Generators

125015-2018

Westerbeke 3.0 BPMG, 3.0 BCG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual