Westerbeke 3.0KW BPMG, 3.0KW BCG Operator's Manual

3 0

".,y

,-

..

- -

K

'w··"

"

B P M

_/

,

G'

'Fresh

,Raw

.

Water

Cooled

and

"

Models

"'3

•

.

~

. C GiFresh

,

REVISION

JUNE

NO.

5

2011

Water

48009

Cooled

WESTERBEKE

WEsTcRBCKE

160JOHN

--

Af.MMA

CORPORATION.

HANCOCK

....

ROAD,

--------

Member Notional Marine ManufacturersAssociation

MYLeS

TAUNTON,

STANDISH

MA

0278{J-7319

---------

INDUSTRIAL

U.S.A.

- -

~

PARK

---

Modell

."

-.

-----

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

CALIFORNIA

PROPOSITION

65

WARNING

Marine

exhaust

are

known

to

cause

and

Exhaust colorless unconsciousness exposure

o

o o

IF GET seek until

gasses

gas.

can Dizziness Nausea Headache

Weakness

YOU

OR

ANYONE

OUT

INTO

medical

it

has

been

contain

Carbon

and

Include:

and

Sleepilress

THE

attention.

Inspected

diesel

and

alid

some

to

the

cancer,

other

reproduCfive

A

Carbon

Monoxide

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

gasoline

of

its

State

birth

engine

constituents

of

California

defects,

harm.

WARNING:

Monoxide,

is

poisonous

Symptoms

;0

Throbbing

'0

Muscular

o

Vomiting

o

Inability

IMMEDIATELY. down

repaired.

ANY

the

an

of

Carbon

in

Twitching

to

Think

OF

If

unit

and

'

odorless

and

Temples

THESE

symptoms

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

restart

persist,

TlIls

WARNING

WES7'ERBEKE

bulkheadneaf

WE8TERBEKEalso CARBON Ilvilig/steeping

TlIeyare

dbtalnable

DECAL

and

should

your

eliglne

recommends

MONOXIDE

qualfers

In8xpenslve

at

yOUi"

local

is

provided

be

DETECTORS

of

and

easily

filarine

by

"xed

to

01

generator.

Installing

In

YOUI

vessel. store.

.

a

the

"""

WESTERBEKE

Englties & Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure

tions.

Know

necessary

and

The the

precautions

your

machinery.

following

American

PREVENT

A

WARNING:

while

engine

power.

Lethal

•

Do

not

enclosures

•

Shut

off

equipment.

•

Use

insulated

equipment.

•

Make

sure

(particularly

•

Remove

electrical

•

Do

not circuits, transfer result

if

• Electrical shock results tor.

Discharge

PREVENT

A

WARNING:

exhaust

very

hot!

•

Always recovery

A

WARNING:

• In

case

before

to

follow

when

dangerous

to

safety

instructions

Boat

and

ELECTRIC

is

SHOCK

Do

not

running,

voltage

operate

connect utility

this

machinery

and

covers

electrical

wristwatch

equipment.

except through a ship-to-shore switch. this

mats

your

clothing

shoes)

Damage

procedure

capacitor

power before

whenever

when

and

BURNS -HOT

Do

not

system

components. A running

check the engine coolant level

tank.

Steam

of

an

engine overheat,

touching

the engine

carefully.

Most

fundamental

conditions

protect

yourself,

are

Yacht

Council

touch

AC

electrical

or

when

connected

is

present

in

shore

is

from

at

without

place.

accessing

working

and

skin

handling electrical

all

jewelry

power

to

vessel's

not

followed. handling a

by

shorting

ENGINE

touch

hot

can

cause

allow

or

checking

accidents rules

exist and

your

in

compliance

(ABYC)

connections

these

connections!

electrical

on

electrical

are

dry,

not

when

working

to

vessel's

double

AC

generator

charged

terminals

engine

parts

engine

at

the

injury

or

the

engine

the

are

and

precautake

personnel,

with

standards.

to

shore

damp

equipment.

on

AC

throw

may

capaci-

together.

.

or

gets

coolant

death!

to

cool

coolant.

the

PREVENT

A

• Prevent sparks

pump,

vapors. removing

•

Do arrester

death.

•

Do Backfire

•

PREVENT

A

injury

• Follow

• All

•

• Shut off

•

• Be sure

•

• Make sure a fire extinguisher

BURNS -FIRE

WARNING:

to

or

not operate

Do

not smoke the fuel engine/generator clean chances of

Be

aware -

Fire

flash

fires.

Do

occur

near

other

potential

Use a suitable

the

fuel

line,

with

removed.

can

system.

cause

fire.

diesel

Backfire

with

or

pennit

Keep

Wipe

severe

fuel will

can

the

a Coast

the

BURNS -EXPLOSION

WARNING:

or

death!

hatches closed

after

fueling. ning the starting

fuel

when

handling tilated area out of the

Do

not

the fuel

spill. DO sources ing.

Ensure proper ventilation

fuel

system.

Do

not

Be

certain

free

of

properly Extinguishers rated for

all

Explosions

re-fueling

blower.

your vapors

fill

the

system.

of

alter

all

leaks.

maintained:

applications encountere4 in

safety

when

Check

below

Run

engine.

are

highly

and

storing

away

from

reach

of children.

the

fuel

tank(s)

fuel

service

Take

NOT

allow

fire

near

the

or

modify

fuel

supplies have a positive shutoff

fuel

line

fittings

ABC

cause

not

carburetor,

sources

container

carburetor,

air cleaner/silencer removed.

flames

the

compartment

and

up

all

instructions.

fueling.

the blower

explosive.

spark-producing

valve care in any

fuel

the

Be

familiar

injury

or

death!

smoke or pennit flames

fuel

line,

filter,

of spilled fuel or

to

catch

all

fuel

or

fuel

filters.

Guard

Approved

can

cause

severe injury

injury or

free

from

for

fuels.

while

smoking,

system

by

death.

or

sparks

of

debris

spilled

fuel

bum.

fuel

vapors

Keep

Open

and

fumes/vapor before

for

four

Use

Store

the

engine is

at

the

engine

catching

open

or

engine

exists

when

fuel

system.

are

adequately

is

installed

with

the

NFPA

this

flame

to occur near

and the

to minimize

and engine

can

the vessel's

ventilate

minutes before

extreme

fuel in a

equipment

running.

when

any

fuel that

flames,

when

servicing

tightened

nearby

its

proper

are

appropriate

environment.

or fuel

fuel

when

or

the

oil.

cause

cahin

run-

care

well-ven-

and

servicing

might

or

other

servic-

the

valve.

and

is

use.

EngInes & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the generator. it

last.

•

Make starting.

•

Make installed before

BATTERY

A

WARNING:

or

death!

•

Do

not smoke being highly

arcing equipment ing

servicing.

•

Never

tive not

test the

together.

Ventilate

accumulation of

disturb

is

being

•

Avoid

burns

wristwatch,

the

battery.

•

Always

the

battery

and

BATTERY

STARTING

Remove

certain

all

certain

all

EXPLOSION

or

serviced.

explosive or by lit

in

the

connect

(+) connection

battery

Sparks could

any

compartment

the

battery

charged.

contacting

or

sparks

rings,

turn

the

connections.

reconnect it

ACID

Accidental

battery

personnel

covers,

starting

Battery

allow

Lead

gas,

tobacco

vicinity

the

negative condition

explosive

charger

the

that

and

battery last

cables

the

negative

guards,

the

explosion

an

acid

batteries

which

products.

to

terminal

ignite

termioals

could

any

charger

Remove

when

starting

are

open

gases.

connections

cause

other

disconnecting

can

before

servicing

lead

first

clear

of the engine

and

hatches are

engine.

can

flame

emit hydrogen, a

can

be

ignited

Shut off

prevent

containing

electrical

(-)

battery

of

the

starter

by

shorting the

battery

gases

To

avoid

with

tools,

an

explosion.

jewelry before

off before

the negative lead

cause

and

reconnect

cause

injury

near the

by

all

electrical

arcing

cable

to

solenoid.

termioals

or

fuel

batteries

sparks,

while the

etc.,

disconnecting

the

battery.

injlllY

the

engine!

before

re-

battery

electrical

dur-

the

posi-

Do

vapors.

to

prevent

do

battery

to

prevent

Remove

handling

first

not

TOXIC

EXHAUST

A

WARNING:

•

Ensure

that the discharged regularly

are

securely attention exhaust

•

Be

•

In install builder or dealer

•

For tional information

A

odorless nausea

•

AVOID

pipe

sure

the unit

addition

a carbon

additional

WARNING:

gas.

or

Do

not

use

fumes

can

tems.

Exhaust sulfur

tubing

resulting

Do

not install through exhaust enter

the

flow

of exhaust.

Although

exhaust gas

is

present in

toms

or

are:

Vomiting Dizziness Throbbing

MOVING

GASES

Carbon

monoxide

exhaust

from

the

engine.

for leaks to

attached

the

manifold,

nipple.

and

to

routine

monoxide

for

information

and

make

and

its

inspection of

installation of

on

Carbon

Inhalation

produces

death!

copper

tubing

rapidly

destroy

causes

in

exhaust/water

exhaust portholes, discharge outlet

exhaust

diesel

fumes sigus of

in

temples

vents,

discharge

Avoid engine

from

gasoline diesel carbon

outlet

PARTS

(CO)

system

is

adequate

Check

the

sure

the

no

warping

water

injection

surroundings

the

detector.

approved

refer

to

ABYC

Monoxide).

monoxide

(CO)

Ou-like

in

diesel

exhaust

copper

tuhing

rapid deterioration

leakage.

where

or

air

conditioners.

is

near

the

outlet

and

overloading

exhaust

monoxide

gases

engines,

fumes.

Muscular Intense Weakness

headache

inhalation or poisoning

twitching

is a

deadly

exhaust system

exhaust manifolds

exists.

elbow, and

are

well ventilated.

exhaust system,

Consult

T-22 (educa-

is

an

gas!

to expel gases

Pay close

your boat

detectors.

invisible

symptoms,

systems. Diesel

in

exhaust

exhaust can be waterline,

close

or

the

craft.

are

not

carbon

Some

and

sleepiness

sys-

of

copper

If

the engine

water

restrict the

as

toxic

monoxide

of the

drawn

could

as

symp-

A

WARNING:

severe

injury

•

When

servicing

level,

wear rubber

tion.

Batteries

If

it

comes in contact

with

water.

. inadvertently

Sulfuric

or

death!

contain

Acid

when

the

battery

gloves,

may

removing

acid

a rubber

sulfuric

with

your

splash

in

batteries

or

checking the electrolyte

apron,

acid

which

skin,

wash it off

on

the skin or into the

electrolyte

can

cause

and

eye

is

destructive.

caps.

~

A

or

protec-

at

once eyes

WESTERBEKE

Engines & Generators

•

ii

WARNING:

Rotating

death!

Do

not

service

tion

arises operatingadjustrnents, ing

moving

in

parts

the

engine while it is

which

it

and

parts

can

is

absolutely

use

extreme

hot exhaust

cause

running.

necessary

care

to

system

injury

If

a situa-

to

make

avoid

touch-

components.

•

Do

not

wear

loose

equipment; jackets, shirts, could

•

Make

Keep places

•

Do

not check

the

engine

•

Stay

when be caught in

HAZARDOUS

A

WARNING:

tie

be

caught

sure

all

protective

at

all

times.

is

clear of

the

engine

NOISE

back sleeves,

attaching

fluid

operating. the

these

loss!

• Never operate

•

Do

not run

removed.

•

Do

not

open.

A

WARNING:

mentally

an

engine

run

engines

or

physically

clotlring

long

hair

rings,

in

moving

hardware

shields

and

levels

drive

shaft

is

running;

rotating

.

High

noise/eVl1ls

engine

without

with

for

long

Do

not

worlc

incapacitated

or

jewelry

and

necklaces

parts.

guards

or

the

and

hair

parts.

the

air

periods

on

machinery

SAFETY

when

avoid wearing

or

bracelets

is

properly

in their

drive

belt's

the

transmission

and

clotlring

can

cause

its

muffler

intake

(silencer)

with their

by

fatigue!

servicing

loose

tightened.

respective

tension

coupling

can

easily

hearing

installed.

enclosures

when

you

INSTRUCTIONS

that

while

are

ABYC, INSTALLING

Read for tions

ABYC

"Safety Order

NFPA

"Fire Order

NFPA

the

safety

when

(American Standards

from:

ABYC

3069

Edgewater,

(National

Protection

from:

NFPA

11

Tracy

Avon

Avon,

USCG

(United

''USCG Order

from:

U.S.

Goverurnent Printing

Washington,

AND

DIESEL

following

codes

and

installing

Solomon's

MD

Fire Protection

Standard

Drive

Industrial

MA

02322

States

33CFR183"

D.C.

USCG

ENGINES·

ABYC,

standards.

your

engine.

Boat

and

for

Small

Island

Rd.

21037

for Motor

Park

Coast

20404

PUBLICATIONS

NFPA

and

Follow

Yacht

Council)

Craft"

Association)

Craft"

Guard)

Office

USCG

pUblications

their

recommenda-

FOR

OPERATORS

Many

of

your

in notes

to carefully, procedures.

GASOLINE

Preparations begin with a

Yacht

Council's

a combination of Sections of the H-2

Ventilation

H-24

Gasoline

Exhaust

P-l P-4

Inboard

&9

DC

All

installations

Regulations

MANUAL

the

preceding safety

Operators

highlight critical

maintain your

ENGINE

to

install a gasoline

thorough

(ABYC)

sources

ABYC

Fuel

Systems

Engines

Electrical Systems

must

(FCR).

Manual

AND

exantination

standards

Systems

comply

tips

and

warnings

along

with

other cautions

information.

equipment,

Read your

and follow

GENERATOR

engine

of the American

standards.

including

These standards

the

USCG and

of particular interest

with

the Federal

are

repeated

and

manual

all

safety

INSTALLATIONS

or generator should

Boat

and

are

from

the

NFPA.

are:

Code

of

-."y:

WESTERBEKE

Engines &

iii

Generators

INSTALLATION

When installing WESlERBEKE engines

paid

to

attention be

CODES

Strict when

AND

federal installing

the following

REGULATIONS

regulations,

engines

ABYC

and generators in a

information:

guidelines,

SIPHON·BREAK

For

installations

or will

be break in minimum

the

the exhaust manifold raw

water

If

you

have

to the vessel's

siphon-break.

NOTE:

A

siphon-break operation. engine

damage.

EXHAUST

The exhaust prevent

of the

water

vessels

where

below

the

raw

water

of 20"

above

damage

Failure

any

doubt

waterline

to

Consult

SYSTEM

hose

must be certified for

from

entering

hull.

the exhaust manifold/water injected exhaust

vessel's waterline,

supply

hose

to

the exhaust

the vessel's

injection

the engine and

about

under

requires

properly

the

waterline.

port

is

at or

possible

the position of

the vessel's

periodic

maintain a siphon-break

siphon-break

marine

the exhaust

and

generators

and

safety

marine

provisions

Failure

below

flooding

the

water-injected

various

inspection

manufacturer

use.

under

any

it is

codes

environment.

must

be

made

elbow.

This

to

use a siphon-break

the

load

waterline

of

the

operating

and

The

sea

conditions, install a

cleaning

can

result

for

proper

system

conditions

important

must

be complied

elbow

to

install a

hose

must

boat.

exhaust

to

ensure

in

catastrophic

maintenance.

must

be

and at

that strict

is

close

siphon-

be

looped a

wiu

result in

elbow

proper

designed

any

with

to

when

relative

to

angle

AVAILABLE YOUR DEALER

FROM

WESTERBEKE

A detailed 40 page diesel, engines

Marine product. .

Marine

and

generators,

Installation Manual covering gasoline

is

snpplied with each Westerbeke

-.-v:

WESTERBEKE

Engines & Generators

iv

and

TABLE

OF

CONTENTS

Parts

Identification

Parts

Identification IntroducUon Installation

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

Lncation and Raw

Raw

Fuel,

Fresh

Control

Remote

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

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

Water Water Supply

Engine

Oil

Water

Panels -Starting/Stopping

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

Preparations

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

Fresh Water

Safety

Shutdown

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

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

Fuses

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

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

Lnw

Oil

Switch ..........................................................

High

Exhaust Temperature

Maintenance

Engine

Fuel

Cooling

Lubricating

Changing the

System

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

Fnel Pump .................................................................

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

System

Water

Pump ................................................................

Water

Intake Strainer ..................................................

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

BCG

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

BPMG

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

Mounting

Discharge ................................................... 7

and

Cooled

................................................ 6

Hose

.............................................. 7

Engine

Coolant..

Models ......................................... 8

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

Procedure

for

Initial

Start-Up

Cooled

Models .......................................

Switches

Scbedule

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

DiI

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

Oil

Filter ..............................................

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

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

Switch

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

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

2

3

.4

6

8

...........

9

10 l0 10

11

ll

11

l1

12 14 14

15 15

15

16

16 16 16

Cooling Raw

Cooling

System

Water

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

System

ThermostaL ........ , ........ , ................ ,

Heat Exchanger ........ ,

[Fresh

Water

Cooled

Models]·

Pumps

[Overhaul]

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

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

.... , .. , ..

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

.... , ..

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

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

,

... , ..

Carburetor , ............ , .................. , ... , ........... , .... , .... , .. " ........

·DC

ClrcuitlBattery

Shore

Power Electronic Engine

Adjusting the Drive Belt .................... , .................... ,

Governor

Adjustments

Oil

Pressure , .............................. , .................. ,

Engine Water

Ignition Timing, ............ , .......... , ........ , ...................... ,

Spark Thermostat Valve

Compression

Pump

Plug , .... , ........ , .... , ............................................

Clearance .......... , ...................... , .......... ,

Replacing the Timing

Troubleshooting Wiring Generator BCG/BPMG

BCG Lay-Up Flushing Genetator

Metric Suggested

*Models

Diagram

Information

Troubleshooting

Internal

and

The

Specifications

Conversions

Spare

manufactured

waterlcoolant or raw water

fresh

cooling

via WESTERBEKE'S FRESH

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

Transfer

Switch

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

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

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

Tes!""

....... ,

.. , ..

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

Belt

..

[Raw

Guide

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

Water

.................. , .... , .. , ............ " ........

Cooled

Belt

..

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

ModeIJ

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

......

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

....

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

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

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

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

Wiring

RecommiSSioning

Cooling

Diagram

System

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

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

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

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

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

Parts , .... , .. , ............ , ..... , ........ , .. , ...... , ..

with

heat

exchangers

cooled

models

for

cooling

that

have

WATER

with

been

COOUNG

..

, ..........

.. , .. " ..

, ..........

..

" ........

,

........

fresh

converted

KIT.

17 18

19

,20

,il

21

.22

23 23

24

25

..

25 25 26

26

..

26

,.27

27

.28

..

29

,.30

..32

33

.34

35

36 37

.38 .39

.42

to

-

.

..-v:

WESTERBEKE

Engines & Generators

1

3.0KW,

BC\G

GENERATOR

I

WATER

INJO,EC,gTC;WED,,,,'

'EXHAUST«

EXHAust, HOSE CONNECTION'

PARTS

BATTERY VOLTAGE,

"'f-~)f.

lD'ENTlfICATION"'

.,

'

CONTROL

MODULE

LEFT

sIDe

METER

START/STOP SWITCH

CONTROL

AC CIRCUIT

BREIIKER

RIGIIT

SIDE

,

COOLANT SWITCH

~CDOLAINT

DRIP

PAN

TEMPERATURE

PRES!IURE

EXHAUST'

TEMPERATURE SWITCH

.

DIPSTICK

SERVICE

SIDE

"IIV'

WESTERBEKE

Engines & Generators

2

\

i,

3.0

KW

PARTS

BPMG

GENERATOR

iDENTIFICATION

ENGINE

SERIAL

MAGNErtC

"

PICK·UP

~'.""'u"

COIL

'CONNECTION

.

SERVICE

SIDE

WATER

INJECTED

ELBOW

ENGINE

NUMBER

FRESHWATER (COOLANT)

MODEL

CONTROL

!

LEFT

~"'OlATI!RMDUNT

PUMP

SIDE

--ZING

SERVICE

WATER

SIDE

PUMP

HEAT

EXCHANGER

;~

ANOOE

\

FUEL

,-

Engin'I; & Generators

3

These

high

performance WES1ERBEKE's technology. dependable performance of our Thank

In

order

it

is This manual throughout.

your

This

provided WES1ERBEKE equipment, contact your WES1ERBEKE'S installation

We

take great

you

for

selecting

to

get

the full

important that

manual

is

designed

carefully and

Should

nearest

WES1ERBEKE dealer

is

your

operators

and

a technical

marine

long

years

WESTERBEKE.

use

you

operate

to

observe

your

engine

manual. A parts

manual

dealer.

If

WESTERBEKE

pride

and

help

you

engines

of experience

in engines

benefit

and

you

all

require

are manual.

are

the

superior durability

and

from

maintain

do

this.

the

safety

servicing,

for

assistance.

catalog

is

available'from your

planning

INTRODUCTION

products of

and

advanced

generators.

your generator,

it correctly.

Please read

precautions

contact

is

also

to

install

this

dealer for

and

this

SERIAL

The plate located engine's serial number

NUMBER

engine

~

ENGINE SERIAL

LOCATION

serial

and model number are etched on a name-

on

top

of the lmit

(flywheel

is

also stamped

cover). The .

on

the

engine block.

WARRANTY

Your

WESTERBEKE folder. form

you registering writing

serial

number

Customer

I

PROCEDURES

Warranty

If,

after

60

days

of submitting

have

not received a customer identification card

your

warranty,

with

model information, including

and

commission

Identification

is

included

the

Warranty

please contact the

date.

Card

in

a separate

factory

the

unit's

"fIV'IWESTERBEKE

Registry

in

I

Customer Identification MR.

WESTERBEKE

MAIN STREET

HOMETOWN, Model

Expires

PRODUCT

Product software, (technical data, parts lists, manuals, hrochures WESTERBEKE are not within WES1ERBEKE's control.

WESTERBEKE CANNOT

CONTENT

RANTIES

THERETO, INCLUDING ACCURACY, TIMELINESS OR COMPLETENESS

BE

LMBLE

INCURRED

OF

WESTERBEKE customers should

span and product software. The product software WESTERBEKE

other

sively

SOFTWARE

and

catalogs), provided

OF

OR

REPRESENTATIONS WITH RESPECT

FOR

IN

THE FURNISHING OR USE OF SUCH SOFTWARE.

between

the

suppliers,

printings of WES1ERBEKE product software

unavoidable existence of earlier WES1ERBEKE

as

the

definitive authority

OWNER

USA

from

sources other

BE

RESPONSIBLE FOR THE

SUCH

SOFTWARE, MAKES NO WAR-

THEREOF AND WILL

ANY

TYPE

OF

DAMAGE

CONNECTION WITH OR ARISING

products, whether

must

not

and

cannot

on

IN

NO

OR

INJURY

keep

in

mind

provided

from

WESTERBEKE or

be

relied

upon

the

respective product.

the

with

than

EVENT

OUT

time

exclu-

Take the time the nameplate reference when seeking technical information andlor ordering parts.

generator~

The on

a decal to enter the information on the blank decal provide a quick reference when seeking technical informa-

tion andlor ordering parts.

Fill

in

to

'enter on

as

serial number and model number is located

on

the

information

shown above,

the generator control

for

as

your

this

own

the

illustration

will provide a quick

pane\.

Take the time

below.

This will

reference.

~

of

EngInes &

4

Generators

INTRODUCTION

ORDERING

Whenever replacement generator include a part

needed

Also insist

will

fit

specifications

NDTES,

As

tltis maintenance generator, NOTES, follows:

NOTE:

A

observed,

the

A·

followed,

NOTE:

by

WESTERBEKE.

engine

SPARES

Certain spare parts your

SUGGESTED

as

proper

the

way. spares on-board inventory of

PARTS

and

engine

model

complete

upon

or

generic parts

part

(see

the

separately

WESTERBEKE

as

original

CAUTlDNS

manual

An

CAUTION:

engine

WARNING:

A

room.

WESTERBEKE

and

takes

you

schedules,

critical infonnation will be

CAUTIONS,

operating

procedure

Procedures,

can

result

or

generator.

Procedures,

can

result

carbon

monoxide

Affix

AND

ACCESSDRIES

will

SPARE

fuel and oil

WESTERBEKE

accessories

parts

are

needed,

and

serial

description

furnished

are

frequently

equipment.

AND

WARNINGS

through

and

troubleshooting of

and

WARNINGS.

essential

which

in

the

damage

in

personal

warning

this

decal

be

needed

generator

PARTS).

filters

brochure

the

can

will

provide

proper

or engine

Often even

be difficult

to

always

provide

numbers.

and part

packaged

not

the

operating highlighted

if

or

which

injury

decalluls

in a visible

to

support

you

assist

WESTERBEKE

In

number

Parts

Catalog).

parts

made

to

procedares,

your

An explanation

to

note.

not

strictly

destruction

if

not

properly

or

loss

of

been

location

and

when

cruising (see

simple

to

obtain

with

a suggested

you

in

preparing

addition,

for each

because

the

same

by

of

life.

provided

maintain

items

alol1g

parts.

the

in

the

;,

.s.uch

an

PRDTECTING

Care

at

the

have

resulted

many

thousands manufacturer installed operated buyer/owner-operator.

NOTE:

Seven

•

Proper

• An efficient an

anti-siphon

YOUR

factory

during

in a WESTERBEKE

of

hours

cannot

control

in

the

vessel

or

and

serviced

important

engine

in the

and generator

well-designed

break

INVESTMENT

of

the

steps

to

engine.

• Changing

the

engine oil

inghours.

•

Proper

nents

maintenance

according

to

of

the

manual.

•

Use

clean,

filtered

•

Winterize

Recommissioning"

• Raw

system

your engine

Water

according

Cooled

unlended fuel

section

Model -

to

the

manual

UNDERSTANDING

The

gasoline

ways

sintilar

are

in-lioe, camshaft pressure block.

To

a large

preventive

automobile generator's the

fuel

and

which

type

degree,

maintenance

engine. longevity

system,

THE

engine

driving

to

a gasoline

the

engine's

is

belt-driven.

lubrication

the

The most

are

ignition

generator's engine requires

that

system,

assembly

and

generator capable of

dependable

how

or

where

manner

in

which the mtit

field.

This

is

t~

ensure

long

installation.

exhaust

preveat

and

all

system

water

oil

filters

engine

and generator compo-

maintenance

according

procedures

GASOLINE

an

automobile

cylinder

system,

proper

to the "Lay-up

in

this

manual.

Flush

the engine

found in this

GENERATOR

AC

generator is in

engine. The cylinders

head has

The

engine incorporates a

and

a water-cooled engine

is

required

important

ventilation,

and

cooling

thorongh testing

service. However the

the generator is

is

up

to the

generator

lite:

that includes

from entering the

every

100

operat-

schedule in

this

and

cooling

many

an

overhead

the

same

of

a gasoline

factors

to

the

maintenance

system.

of

CARBON

WESTERBEKE

detector in even

The presence of carbon from elbow/exhaust entering

If

carbon

air

MONOXIDE

the

vessels

in

small amounts, is

the

engine

hose,

your

boat.

monoxide

and correct

the

recommends

or generator

5

DETECTOR

living

deadly.

monoxide

or the

fumes

is

present,

problem

immediately!

mounting a carbon

quarters.

or

Carbon monoxide,

indicated

from

the exhaust

from

a nearby

ventilate

the

area

an

exhaust

monoxide

leak

vessel

are

with

clean

RIGGING

The wire

AND

engine/generator

rope

or

chain engine/generators erator

by

means

eyes

have

been

slings

are

not

necessary.

NOTE:

Rigging

. and

competent

LIFTING

is

fitted

slings

capable

weight

to

of

tackle

attached

designed

work

in

to

is

best

handling

with·lifting

of

supporting

the

eyes

and

to

carry

the

full

done

by

someone

machinery.

lift

these

eyes:

Attach

the

slings.

weight:

experienced

INSTALLATION

engine/gen-

The

lifting

auxiliary

.

SIDE

VIEW

LOCATION

A

solid, proper allow ing.

Locate

away

Refer information

AND

level

mounting

operation

adequate

from

to

WESTERBEKE'S

of

space

the

generator

bilge

splash

on

installing a Marine

MOUNTING

platform is

your

generator.

on

all

and

away

installation

sides

for

from

vapors.

very Select a

living

Generator

i/SE LOCATING HOLES

important

location

ventilation

quarters,

manual

for

in a boat.

DRIP

THE

PAN

AS A TEMPLATE

THE

TO

THE

for

the

that

will

and

servicand

detailed

TRAY/P.AN

PROPER

MOUNTING

PLYWOOO

BASE

FOR

AC

CDNNECUON

RAW

WATER

INLET

O.Sln

1.0.

HOSE

.

.l.IflOERNEA.TH

(2.7mm)

VIEW

~~~~~

DIMENSIONAL

For

dimensional Westerbeke current

drawings

DRAWINGS

drawings.

website

www.westerbeke.comforthemost

with

dimensions,

View

the

drawings

WATER

OUTlETilND

HOSES

D.51n

(2.7mm)

FOUR

1/2"

on the

DISCHARGE

1.0.

BOLTS

3/4"

PLYWOOD-BOLTEDIFIBERGLASSED

.

IN

PLACE

BATTERY TO

REFER DIAGRAM

ATTACHMENTS.

STARTER

TO

MOTOR

THE

WIRING

IN

THIS

MANUAL

(01

NEGATIVE·

LEAD

Engines & Generators

6

RAW

WATER

The

raw water cooled 3.0KW Generator

internally

The

fresh water cooled model

water

(coolant).

of

raw

water

Both model generators cool

the

water

supply

the water injected

RAW

WATER

The

raw the engines cooling water injected

12 inches

On installations

or

below

made

to

The

function

flow

after

will

fill

The

raw

loaded

during when

the

DISCHARGE

by a continuous

This

(via

the

exhaust

hose

system

delivers

exhaust

SUPPLY

water

supply

exhaust

(30cm)

above

where

the

vessels

install a

the

water water all

syphon

of

the

engine

exhaust

supply

line

attitudes

generator

to

coolant heat

use

as

hose

system

elbow

the

loaded

break

syphon

is

shutdown.

system

hose

allow

of

vessel

is

not

flow

of

is

cooled by a

exchanger).

the engine cooling

it

is

discharged

the

raw

elbow.

HOSE

from

to

the

must be looped a

vessels

water

in

break

and

must

the

syphon break to

operation

operating.

is

cooled

raw

water.

is

cooled

internally

continuous

overboard. A raw

water

from

the

discharge

connection

inlet connection of

loaded

water

injected exhaust

line, provisions

the

raw

water

is

to stop

the

This

flow,

if

possibly

be

the

looped

engine

well

function

to

prevent

INSTALLATION

When

the

vessel

of

advisable

inches

by

fresh

flow

raw

water

engine

the

ntinimum

line. is

close

must

supply

hose.

raw

water

not

stopped,

as

well.

above

the

syphoning

be

to

on

SIPHON

AVAILABLE

of

:

YOUR

,

DEALER,

to

. /

:':I/'I'''-'''~'

-

or

inlet

connection

NOTE:

Always

wire

reinforced

looped

and also

hose.

BREAK

FROM

WESTERBEKE

-, -'-

""::

. ...-<.'" \ I I I I

"":")-\

<.,

.....

,/

\.-

)...........

. " ! I I I

i I I : ;

Y<>-

1_-

;;& I :

WATER

:

INJECTED EXHAUST

.

generators

during

to

loop

more

the

above

on

use

hose

location

all

raw

the

quality

so

provide

RAW

SU~PPLY

...

--

~'."'"',

,..,../

"I

. I I

:1,1

--

I

,

i

is

above

the

loaded waterline

attitudes of

water

the

generator

water injected

hose with

it

will maintain

vessel

discharge

and

exhaust

good

operation,

hose

at least 6

then

down

elbow.

wall

integrity or

its

slwpe when

proper mechanical support for

WHEN A SIPHON IS

NOT

REOYIREQ

WATER

HOSE

'\

\

'I

./'--',

/--7--,;:-\--

I

//

I I \ " \

I I I I

I t 1

r:

I r I

[I

\

'.

I I

I .

I 1

:1

\

it

to

is

still

the

BREAK

~'M:t4--IRAWWATER

HEAT

EXCHANGER

EXHAUST

DRAIN

HOSE

EXHAUST OVERBOARD

SYSTEM

Engines

7

&.

Generators

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

A

CAUTION:

rating

of

harm

to

your

Care

Of

The

Use

only

clean

your

fuel

injection pump

particles

these and unsatisfactory facilities. engine's

advisable: Purchase a well-known brand of

Install

metal and

ENGINE

Use a

SL, hours of break-in operation. interval in An oil viscosity engine Westerbeke

the break-in must be performed

change

SCHEDULE section of

synthetic

NOTE:

statements

which

finely

keep

it clean. The best

To

daily

and

bowl

the

engine.

OIL

heavy

or

SM.

as

this

manual.

in

all conditions and all seasons.

use

of synthetic oils.

intervals must be

oils

The

Only

ag

or

higher.

engine

Fuel

fuel!

The

might pass

finished

regnlarJy

type

Change the

specified in

Corporation

information

regarding

parts.

by

careless

assure that

use

is clean

service a

filter/water

duty engine

of

SAE-1SW-40

are

used.

use

unleaded

Leaded

and

violate

Supply

clearance

is

very

through

It

is

fuel

handling

the

fuel

and

good,

separator

oil

with

engine

Then

the

MAINTENANCE SCHEDULE

does

If

synthetic

using

as

listed

this

manual

above

synthetic

fuel

with

an

octane

fuel

will

cause

serious

your

wa"anty.

of the

components

critical;

important

can

going

pure,

oil

not

supersedes

oil.

invisible dirt

the

filter

can

damage

to

buy

clean

be rendered

or improper

into

the

fuel.

Coast

between

an

API

and

filter

follow the

is recommended for this

approve or

oils

conventional

in the MAINTENANCE

and

storage

the

tank

following

Guard

classification

are

not

all

practice

approved

the

fuel

after

an

oil

change

disapprove

used,

engine

oil.

be extended

in

fuel,

is

tank

of

SJ,

initial 50

Oil

if

ENGINE

WESTERBEKE and chemicals

The

to

the cooling

antifreeze (SCAs')

to

The poured

NOTE:

antifreeze

A engine

COOLANT

50%

distilled

that

can

antifreeze

run

at

engine

long

water

proper

perfonns double

proper

to

the

circuit

from

that

contains

that

keep

term

protection.

and

antifreeze

into

the

Use

the

new

that

is

50/50

coolant to temperatures of -40'F.

ANTIFREEZE

Antifreeze Freezing

COOLANT

A coolant The coolant without

the

concentration

Temperature

RECOVERY

recovery

purpose of

expansion

the

loss

cooling

system.

recommends a mixture

water.

Distilled

corrode

temperatures

coolant.

cooling

now

mixture

It

rust

and

supplemental

the

antifreeze

should be

circuit.

environmentally-friendly,

available.

as

water

internal

recommended

engine

duty.

by transfening heat away

also

lubricates

corrosion.

chemically

premixed

PROTECTION

23% 14'F

(-10'C)

30%

8'F

(-13'C)

TANK

tank

kit

is

supplied

this

recovery tank

and

contraction

of coolant and

is

during

without

of

50%

is

free

from

surfaces.

It

allows

the

and

protects

Use

a good

cooling

additives

balanced,

before

long

will protect

CHART

35%

-4'F

(-20'C)

with

each

to

allow

for engine

engine

introducing air

antifreeze

the

engine

from the

quality

crucial

being

lasting,

the

50%

-40'F

(-40'C)

generator.

operation,

into

NOTE:

Be

very

careful

not

to

overfill

the

oil

of

the

oil

sump

will

result

in

erratic

operation white-smokeyloilladen starting

Reference

or

no

start andfouled

Service

exhaust

Bulletin

spark

#256.

discharge,

plugs.

sump.

of

the

possible

Overfilling

engine,

hard

Englne",.&

(3ener~

8

CONTROL

PANEL·

DESCRIPTION

The control panel provides the operator with a simple

stoplstart

The plug-in connections for the engine goyemor sensor of

The ignition control module with it's plug-in wiring mounted on the

A

before caused and

rocker

the

control

panel

CAUTION:

starting.

by

unanticipated

will

prevent a cold

switch

and a hourmeter.

and

remote panel are located on

along

with a

10

amp

top

of the panel.

All

AC

loads

must

be

This

precaution

operation

engine

,-

will

of

from

wiring

hamess,

fuse.

switched

prevent

AC

machinery

starting

the

off

damage

STARTING

The engille has a

To

Start;"~""s

release.

'the switch will

runniog. . Apply a light load

warm loads.

NOTE:

condition. and

The

up

to operating temperature before applying heavy

Some

the

generator

12

VDCelectric starter:'"

the

rocker switch

engine

will crank

show a RED

to

the generator and

unstable

This

running

should smooth out as

loads

are

to

the start position

and

start electrortically

light

to

indicate

allow

may

occur in a cold engine,

the

engine

applied.

the

engine

warlizs

START/STOP

side

is

and and

is

to

up

A

WARNING:

start

switch

will

diseqgl/ge

This

will cranking, rhis,is

,

starting

with

water,and

PROCEDURE

Should

thllllngine

hasfleendepressed, a crank

the

startllr

and

stupthe

occur

after

approximately

with

nil

start.

til

preventprolllnged

which

can

result

backing

cranking

in

the

intll

the

fail

to

starting

15

secllnds

without

exhaust

engine.

start

IInce

limit

cirt;uit

cyclll.

IIf

the

system

the

engine

filling

A

CAUTION:

periods otherwise

severe

of

damage

Neller

timewithol/t

carbon

to

STOPPING

To

Stop:

Press

the

engine will shutdown

GENERATOR

STAR:T:

when

STOP:

r&gESTEBBEKE

:

ENOINESTOPJS7ARTDEcAL

Abnormal

,

Ao and

'cause

operating

Stop

abnonnal

comes

to a stop

damage

condition.

stop

to

the

(refer to

operate

bulld'up

the

engine.

rocker switclll<>stoP

and

the

engine

an

amperage

tnayoccur

the

'LED~¥ht

for

long

load

being

whi"hcan

,and

release.

will1.lJm

applied, calise

off.

OPERATION

Depre$$ pO$ition.

lite.

RUN

Depre$$ pO$ition. RUN

is one in which the generator ceases

as

$witch

to

START

STARTLED·.'II

engine will

LED

will

engine

$witch

Engine

LED

wi

II

SAFETY

a result of

engine, the generator, or create

-"

,.

, ,

crank.

remain

i$

turn

SHUTDOWN

an

on

running.

to

STOP

will

$t.,.

orr.

SWfTCm:Sj

operating fault which

,-

'-"

'

The

I"

an

to

run

may

unsafe

,.

'.' ,

REMOTE

IG-ilmote o{The

generator.

plug~in

extension identical. either panel.

NOTE:

Holding

depressed will circuit

engaged.

PANEL

panel' is:available that allows for remote operation

The

papel

comeS

with either a 15' or 30'

Once

installed,

h~ess.

The statlfstop seqllence is

the

engine

can

be operated by

/V\T/WESTERBEKE

•

START

o

the

keep

start

the

o

button

start

STOP

E1J9ine~

&

Generators

9

PREPARATIONS

FOfHNITIAL

START-UP

i

;

PRESTART

Before prolonged

•

Make

•

Check the

•

Check bowls

•

Check and battery

• Check wiring

•

Examine

• Be

load

•

Be the

system connected

incomplete

neutral

•

Visually parts, threaded

A

INSPECTION

starting

layoff,

certain

the

engine

full

mark

the

fuel

for

contaminant's.

the

DC

load diagrams.

air

sure

no

lines.

sure

that

neutral

is

reqnires,

to

voltage

examine

disconnected

connections.

CAUTION:

recommended be

switched and, will

prevent

of

the

in

cold

AC

machinery

OFF

climates,

damage

stalling.

your

generator

check

the

cooling

oil

on

the

supply

electrical~ystem.

cable

connections.

leads

for correct connection

inlet an" outlet

other

generator

in

power

properly

and that the generator

the

load

or

open

on

unbalanced

the

When

that

all

until

set for the

the

following

water

level:

add

dipstick.

and

examine

for

or

systems

grounded

neutral.

neutral

can

unit.

Look for loose

wires,

unattached

Search for any

starting AC

loads,

the

engine

starts

to caused and

by

will

prevent a cold

first

time

items:

thro-hull oil

Inspect

air

utility power

with a

(or

In

single

supply

loads.

the

especially

has

warm

petcock

to

maiotain

the

fuel

filter/separator

wire

as

specified

flow

obstructions.

is

neutral

ungrounded)

neutral

phase

the

wrong

or

hoses,

and

gasoline

generator,

large

come

up

up.

This

unanticipated

engine

or

after

a

is

open.

the

level

at

connections

in

the

connected

line

is

systems

missing

leaks.

it

is

that

as

the

properly

an

line-to-

check

to

motors,

to

speed precaution operation

from

FRESH

•

lIiATICa

Check recovery

NOTE:

the

engine's

plastic

the

engine

the

engines

Once

;

heat

'\

expelled. system

full.

tank

'.

FRESH

COOLED

the

coolant

tank

After

the

cooling

coolant

cools,

cooling

cooled,

exchanger

Then

filler

OIL

open

neck

the

WATER

MODELS.

level

and

at

initial

recovery

coolant

the

to

allow

close

and

cap

between

I

IW""==

»,.,...,..-""!

in both the

the filler neck

running

system should

syst~m

air

it.

ensure

and fill'thii'plastic coolant

MAX and

of

tank.

After

should

to

replace

bleed,

any air

Open thepressure

tbe,

plastic

opening

the

generator,

be

purged

shutdown

be

drawn

the

'petcock

left

in S)I§tem LOW.

coolant

on

back into

displaced

on

the

that

area

cap

is

completely

the

to

the

and

engines

to

on

the

recovery

COOLANT

unit.

air

and

air.

be

in

as

CONNECTS

\

TOWATER

PUMP

FULL

t+---

~

WESTERBEKE

Engines & Generators

10

OIL

FILTER

INCOMING

FUE~

SAFETY

SHUTDOWN

SWITCHES

SAFETY

This~ngin~js

two

restan

the

ENGINE

OVERSPEED

The the operating PC

SHUTDOWN

Protected

fuses:

Should a shutdown

without

finding and co"ecting the

heading

Engine

sttirts,

TROUBLESHOOTING

SWITCH

overspeed

engine

board

down speed will

reset itself

PC

board

if

the

required

SWITCHES

by

engine

three

shutdowu

occur,

do

not attempt

runs and then shuts

section of

inside

the control panel

speed (RPM'S)

to

run

the

generator.

once

the

engine

shuts

PC

BOARD

switches

callse.

down

this

manual.

will

exceeds

The

down.

FUSE

and

to

Refer

to

in the

shut .' .

the

overspeed

TEMPERATURE SWITCH

EXHAUST

An

exhaust exhaust (an

inadequate above system,

water exhaust

LOW

Located the

engine's

5

psi.

angle

will reset itself.

TEMPERATURE

temperature

elbow

sensors

supply

240°

F will shut the

water

pump,

hoses,

etc.

cools.

OIL

SWITCH

just

to

the right of

oil

pressure

This

switch

of operation, dipstick oil level and oil

switch

an

excessive exhaust temperature

of

cooling

engine

pump

belt,

This

switch will reset itself when the

EXHAUST ELBOW

the

if

the

will

shut

the

SWITCH

located at the base of

water).

seacock, water strainer,

oil

oil pressure

engine

down.

filter,

this

down.

A temperature

Inspect the

switch sensors

falls

to

below

Check the

filter.

the

cooling

The switch

.

CONTROL

'.

PANEL

MAIN

The

CIRCUIT

main

circuit breaker at

BREAKER

automatically disconnect the electrical

This when power is

overload.

circuit breaker should be

servicing the engine/generator

coming

into the

boat.

manually.

FUSES

A

IDA

fuse

located

the

DC

electrical wiring.

fuse

will blow and shut the

An

20Ain-1ine

this

fuse

fails,

.

will.~ot

be

charging.

on

the

fuse

protects the

the engine

If

will

rrII--rC--c---MIIIN

AC

the

control panel

AC

power

manually

to

ensure

The

breaker

side

of the control

an

electrical overload

engine

down.

battery

continue

to

BREAKER

will

if

there

is

an

switched off

that

is

reset

panel

charging

run

but

circuit.

the

CIRCUIT

no

protects

occurs

battery

the

If

.

LOW

HIGH

(Fresh

Water

A

high

water temperature switch

housing.

. coolant's operating temperature reach

(99·C),

will

,

resets

itself

Cooled

Normally closed,

open

and

shut the engine

at

195"1'

flr§"'==="""iiIT1r'h~<L.f/

Model)

is

this

switch, should

located

OIL

PRESSURE

at

the thermostat

the

fresh

approxiroately

down.

This

switch

.

(LGIJOLANT_

.. A PIPE

SWITCH

\

water,

210"1'

RECOVERYTANK\

KEEP

THIS

FREE

FROM

CLEANER

WORKS

NICELY

HOSE

DEBRIS.

.

~,

=4))

20A

10A

FUSE

-

-~-

~

...

-

FUSE

BAmRY

~

CHA.RGING

~

WESTERBEKE

Engln_e'!:&

11

-

~'-'

Generators

A

WARNING:

running. use

the

servicing

NOTE:

Many

difficult

and

Wear

correct

any

of

the

may

MAINTENANCE

Never

the

proper

tools

the

following

require

attempt

for

engine's

the

to

safety

equipment

each

Job.

DC

electrical

maintenance

expert

knowledge

perform

Disconnect

SCHEDULE

any

service

such

as

the

equipment.

jobs

are

simple

of

a service

while

goggles

battery

but

mechanic.

the

engine

and

gloves,

terminals

others

are

is and

when

more

SCHEDULED MAINTENANCE

Fuel

Supply

FueljWater

Engine Drive

GENERATOR

Visual

Spark Generator

Fuel

Starting (and

Engine

Separator

Oil

Level

Belt

Inspection

Plugs

Filler

Batteries

House

Batteries)

Oll/Filter

* 0

of

Engine

CHECK

EACH

DAY

0

weekly

HOURS

OF

OPERATION

50

100

250

500

750

CJ

NOTE:

Please

keep

engine

surface

and

oil

will

inhibit

the

engine's

ability

remain

cool.

0 0 0 0 0 0 0

0 0

0 0 0

0 0 0 0 0

0

0 0

0

0 0

1000

0

clean.

to

1250

Dirt

0

EXPLANATION

Unleaded higher

Check

if Maintain Inspect

spring every

Check and Check

Check Check

with for

Initial Every

and excessive

Initial change

gasoline

for

necessary).

at

and

tension.

1000

for

electrical

for

gap.

that

no

chafing·

additional

change

50

operating

make

engine

both

MAINTENANCE

with

water

and

dirt

the

full

level.

adjust

at

Inspect

hours.

fuel,

oil

and

connections.

loose

belt

tension.

Inspect

for

AC

connections

see

information. at

50

hrs, hours

sure

connections

corrosion.

oil & filter

every

100

OF

SCHEDULED

octane

rating

in

fuel

(drain/replace

first

25

hours.

Measure

edges

for

wear.

water

leaks.

Inspect

Keep

bolts & nuts

burning

and

corrosion.

are

clean

GENERATOR

then

check

change

hours.

INFORMATION

change

electrolyte

are

very

at

50

of

89

Replace

wiring

and

secure

every

tight.

hrs.,

or

filter

tight.

250

hrs.

levels

Clean

then

off

*

OVER-FILLING CAUTION:

unintentionally

After shut·down, linger

sump. into period

(Re-starting internal passages are

Over-filling and/or possibly

The

and

take a number of

Allow

at

the

sump

before checking

will provide

the

the engines

smokey

no

start.

oil

sump

on

be

over-filledl

the

oil in the

hours

least a

few

hours

an

even

more

engine

is

not a problem

well

lubricated).

sump

white oil laden

this

generators

engines

the

will

exhaust,

internal

to

drain back into

for the oil

dipstick. An overnight

accurate dipstick

as

result in erratic

hard starting

engine

passages

to

settle back

the

engine's

'WESTERBEKE mechanic.

can

the

oil

reading.

operation,

and

~

WESTERBEKE

EngJnes~_

12

recommends

Generators

this

service

be

performed

by

an

authorized

NOTE:

Use

engine

hours

MAINTENANCE

the

engine

hour

meter

gauge

by

running

time.

SCHEDULE

to

log

your

engine

hours

or

record

your

SCHEDULED MAINTENANCE

•

Adjust

the

Valve

Clearances

Carburetor (Flame

Exhaust

Engine

Engine Raw

At

800

disassemble

overhaul.

Fresh (if

Raw

See

Fresh

(If

Heat

'Starter

'Engine

Compression

'Exhaust

Air

Arrester)

System

Hoses

Zinc

Anode

Water

Pump

operatIng

hours,

and

inspect

Water

Pump

applicable)

Water

Cooling

note

below

Water

Cooling

applicable)

Exchanger

Motor

Cylinder

Elbow

Screen

'WESTERBEKE

CHECK

EACH

DAY

for

System

recommends

50

this

HOURS

100

D

D D D

D

0 D

D D

D

D D D D D D

D

service

be

OF

250

500

D D D

pertormed

OPERATION

750

D

0

D

0 D

0

D

D D

by

1000

D

0

D D

1250

D 0 D

D

D D

D

an

authorized

Initial

Clean

D

Initial

D

for

D

mechanic.

EXPLANATION

MAINTENANCE

adjustment

at

check

leaks. exhaust inside

passages;

Check

that

Hose

should

spongy. Inspect Remove

wear.

Replace

Lubricate Remove

pump.

Remove

and

inside

O-rings.

Flush

the

year

round,

Drain,

flush,

appropriate

Clean

or

cap

and

hours

for

Check

solenoid

lubricate.

drive. Incorrect

performance. and

adjust

Test

exhaust

casting

WARNING: A defective

carbon

at

50

ours,

then

at

50

hrs.,

Check

siphon

elbow

for

carbon

clean

all

connections

be

hard & tight.

Check

and

tighten

and replace

the

pump

cover

if

needed.

both

when

raw

water

pump

the

cover

for

system

twice

flush

every 4 months

and

refill

antifreeze

replace

anode.

clean

out

debris.

professional

and

Clean

and

valve

clearance

Check

valve

clearances,.

elbow

for

is

corroded

monoxide

leakagel

if

cover

wear.

motor lubricate

compression

or

OF

SCHEDULED

hours,

then

every

100

hours.

then

every

250

brake

operation.

and/or

corrosion

and

replace

as

are

tight.

Replace

all

hose

clamps.

necessary.

and

inspect

the

Also

inspect

reassembling.

to

access

the

and

inspect

Also

inspect

per

season.

If

or

every

cooling

system

mix.

Open

heat

exchanger

Remove

cleaning

will

CiiStingintegrily. deteriorated.

exhaust

and

for

corrosion.

the

starter

result

pressure

elbow

every

pressure

in

poor

500

hours

hrs.

Inspect

Check

the

buildup

necessary.

if

soft

or

impeller

the

O-rings.

fresh

water

the

impeller

the

sealing

the

unit

is

100

hours.

with

end

1000

testing.

Remove

motor

pinion

engine

and

timing

Replace

if

can

cause

.

on

for

used

and

NOTE:

Flushing

shawn

elsewhere

the

in

raw

this

water

cooled

manual.

models

is

~

WESTERBEKE

Engines & Generators

13

ENGINE

LUBRICATING

DESCRIPTION

Use a

heavy

duty

engine

oil with

SL,

or

SM.

Change hours of interval in

An

engine in WesterliekeCorporation the break-iii change SCHEDULE section of this manual

synthetico~a,reused,,-___~

NOTE:

statements

CHANGING

,-.

The from

allow hose is properly secured in been

break-in

as

specified

this

manual.

on

viscosity

all

use

"Of

synthetic

must

intervals

The

information regarding

,.

engine

oil

its

attachment bracket and lower it

the

oil

and

pump

drained.

the engine oil

operation.

in

the

of

SAE-15W-40

conditions

be performed using

must

oils.

be

and

does

If

as

above

synthetic

THE

ENGINE

should

be

warm.

to

drain,

or

attach a

the old

oil

its

holder

an

API

"classification

and

filter

after

Then

follow

the

oil

MAINTENANCE SCHEDULE

is

recommended for this

all

Seasons.

not

approve

synthetic

listed

in.

___

superseaes

conventional

or

disapprove

oils

are

used,

the MAlNTENANCE

and

not

beexteilded

•.

.

all

change

engine

oil.

"'"c.

of

initial

Oil

SJ,

50

if

.

oil.

OIL

Remove

pump

out. Make sure

after

into

to

all of

DlL

the

oil a container

the

end

the

oil

the

ORA!N

drain

of

drain

hose

the

has

and

drain

hose

"

CHANGING

..\Vhen removing the used

.

'p)ll\eh

to to helpful and a plastic

any

removed

off sealed installing sealing

thin

the

and

NOTE:

are

OIL

"WIPE

:CLEAN

"~,o.v,"~,!!m

OIL

THE

a hole in the upper

drain

the

oil

into a container before removing it. This

lessen

spillage. An

in

removing

bag

oil

that's in the

to

make

with

the old oil

against the

the new

surface on

coat

of clean

oil

filter.

Screw the

tighten

the

Use

genuine

not

recommended.

THIS

SURFACE.

BEFORE

FILTER

011.

FILTER

oil

and

automotive

the

old

around

the

filter.

Inspect the old

sure

that

filter.

If

oil

filter

oil

filter

the

oil

filter

engine

oil

filter

firmly

WESTERBEKE

OIL

FILTER

ASSEMBLY

PRESSURE

filter,

you

may

lower

portion of the old

filter

wrench

oil

filter.

Place

filter

when

unscrewing

oil

the rubber

this

adapter,

element, wipe the filter gasket's

to

onto

by

sealing

rubber sealing gasket

gently

adapter

the rubber sealing gasket

hand.

free

the threaded oil

oil

filters.

SWITCH

find

it

helpful

should be

some

paper

filter

as

gasket comes

remove

it.

of oil and

filter

Generic

filter

towels

it

to

it

is

remains

When

apply

stub,

filters

helps

catch

to

a

on

A

WARNING:

contaminants.

and

nails

thoroughly discard used

Always emulsion this prevent serious is

present in

of a fault in the exhaust system attached

a siphoning exhaust,

clothing

oil

properly.

observe

indicates

condition is rare, it

filling

Avoid

the

damage.

the

oil.

through

it

up

Used

engine prolonged using

or

rags

old oil

the

presence of

does

Call a competent

Water

the

water cooling circuit into

into

the engine. "

oil

contains

skin

soap

and

containing

as

it

is

removed. water

require

prompt

present in the

contact.

water.

used

in

harmful

Clean

Launder

oil.

Discard

A yellow/gray

the

oil.

attention

mechanic

oil

can

be the result

to

the

engine andlor

skin

or

Although

to

if

water

the

"

-.v

REFILLING

Addfresh oil through nirithe,engineJor a oil"

pressure.

oil

filter

engine.

dipstick.

or

from

Then

Fill

THE

Make

to

OVER-FILLING

CAUTION: The on sump on this generator's engine can unintentionally be over-filled! After

shutdown,

linger

and

take a

sump.

Allow

the

sump

before

will

provide

(Re-starting internal

Over-filling andlor possible

an

the

passages

the engine's

a smokey

no

start.

WESTERBEKE

Engines & Generators

14,

OIL

SUMP

the

valve

few

moments

'sure

there

is

the

oil

drain

system, and then stop the

check the quantity

the FULL mark

the

oil

in

the engines internal

number

at least a

checking

even

engine

are

white

of hours to drain back into

few

hours for the oil

the dipstick. An overnight peliod

more

accurate dipstick reading.

is

not a problem

welliublicated).

sump

oil

laden exhaust, hard starting

cover.

After refilling the

while

checking

no leakage

of

oil with the lube

on

the dipstick.

as

will result in erratic

the

around

passages

to

settle back

the engine's

oil,

engine's

the

new

oil

can

the

oil

operation,

and

into

FUEL

SYSTEM

GASOLINE

Use

unleaded recommended. Regnlations, close off

prevent

properly main

engines.

,A

when

any

open

system

when

GASOLINEJWATER

A

primary installed water

carried

be Most installers include a

installation package contaminant's in

These through") bowls impurities.

89

octane

When

gasoline

after

WARNING:

servicing

fuel

"ames

servicing

between

and

gasoline

have

fumes

fueling

Shut

the

that

may

spill.

or

other

when

servicing.

the

fuel

filter

of

the

other contaminant's

to

the

fuel

as

the

fuel

fiiters

to meet

drain

U.S.

valves

or

higher

fueling,

all

hatches

from

and

before

off

fuel

system.

00

sources

Ensure

fuel

system.

SEPARATOR

the

water

fuel

tank

system

filter/water

they

can

must

have

,Coats

to

use

gasoline.

follow

and

entering the

starting

the

fuel

Take

NOT

allow

of

fire

proper

separating

and the engine

from

on

the engine.

are

aware

cause.

metal bowls (not

Guard requirements.

when

Higher

U.S.

Coats

companionways

vessel.

the

generator

valve

at

care

any

smoking,

near

the

ventilation

AND

FILTER

type

the

fuel

before

separator with

of

the

problems

checking

octane is

Guard

Ventilate

the

tank

in

catching

fuel

must be

to

remove

they

the

"see-

The

for

water

to

or

exists

can

that

metal

and

ENGINE

Periodically leakage. the

1.

2.

3.

4.

5.

FUEL

check

Change

MAINTENANCE

Shut

off

the

Unscrew

to

come

away

,

filter

element andclefui ille

'Remove

Inspect

both

Press

on

FILTER

the

filter

fuel

the

filter

from

and

replace the

O-rings.

a new

filter

fuel

connections

element

SC,HEDULE.

supply.

bowl from the housing

the housing.Remove and replace the

filter

Replace

and replace the

and

after

the first

bowl.

element and

if

necessary.

the

filter

50

hours.

and

allow

cle,,!,

bowl.

bowl for

See

bowl

the bowl

FUEL

PUMP

Periodically'

and

make

are

tight

A

connections

Make

fuel

NOTE:

fume detectorlalarm

check

sure

that

and

secure.

WARNING:

is a fire

sure

proper

system

components.

The

generator compartment should

the

fuel

connections

no

leakage

The

engine

Fuel

leakage

hazard

ventilation

properly

to

and

is

present

mounted

and

installed and

at

the

should

exists

and

fuel

whenever

out

of

that

the

pump

be

corrected.

servicing

.

have

a gasoline

working.

the

pump

fittings

is

or

its

A

WARNING:

Use

'

ENGINE FUEL FILTER,

care

Fuel

is

present

to

prevent

.....,E=;;y.::;~LUBRICATE

in

the

spfllage

CLEAN PRESS ON

hosing

WITH

FUEL

THE

FILTER

OVER

THE

and

AND

a-RING

lines.

~

WESTERBEKE

Engines & Generators

15

COOLING

SYSTEM

RAW

WATER

NOTE:

Always

the

strainer

A clean

engine's strainer. when making your periodic engine in the

glaSs

Perform the followiug maintenance after every 100 hours opetation: .

1. Close the raw water

2. Remove and clean the strainer

3. Clean the

4. Replace the washer if

5. Re-assemble and iustall the strainer.

6. Open the seacock.

7. Run

NOTE:

Also

INTAKE

install

the

will

always

raw

water intake strainer

C.doling

the

system. Include a visual iuspection

should always be

glass.

engine and

follow

the

above

STRAINER

strainer

be

seacock.

necessary.

check

at

orbelow

self-priming.

is

a vital component

clear.

filter.

for

le!lks.

procedure

after

the

check.

having

waterline

of

this

The water

run

aground.

If

an overheat occurs, the

grass

may

have been caught

flo",

of

water through

cause.

may

up

iu the strainer, slowiug the

the

cooling system '

be

that silt, leaves or

so

the

of

hard

CHANGING

1. Close the

syphoning

2.

Remove turned (when iustalling the

iu

3.

Using

4. Inspect the impeller by bendiog each cracks at each base. Also iuspect the iuside the cam plate, the O-ring, and the iuner wear pldte. Replace

5.

Wipe

. glycerin

6. Install the blades

impeller blades.

7 •.

Apply pump

any

8,

Open the water iutake valve, start and run check for leaks around the cooling water

THE

RAW

WATER

raw

water iutake valve

from the

the

same

pliers, grasp the

any

the iuside

to

the pumps interior and sealiug O-ring.

ri'ew

ate

"working" in the same direction

glycerin

making certaiu the cover screws

hoses

that may

pump.

pump

cover.

Note the direction the blades are

new

direction).

hub

of

ihe impeller and pull it out.

worn

components.

of

the pump

impeller with a rotatidg motion so the

to

the impeller, iustall, and reassemble the

hlive:1ieen

is

discharging overboard.

drY

pump.

PUIVIP

to

prevent water from

impeller. bend the blades

blad~

and then apply

are

removed.

Also

make

.

looking for

of

the

cdver,

Ii

fthn

as

the old

tight. Replace

the

engine and

sure raw

of

FUEL

FILTER!

"WATER

IOwner

WATER

The water pump. This pump

(ocean, lake, or river) through a hose to the water strainer.

The water passes from the strainer through the water pump

to the engine where

discharged iuto the water-iujected exhaust with and cooling the exhaust gasses. This mixture exhaust gas and cooling water is discharged overboard by the engine's gas discharge pressure. An iutemal engine thermostat controls the water temperature. This thermostat maintenance

COOLING

flow

CIRCUIT'

is

created by a positive displacement impeller

draws

it

cools

free.

water directly from the water source

the engine. The water

SEPARATOR'

Installed]

is

elbow,

mixing

of

then'

A

sure engine

and

COVER

INSPECT OF

THE

COVER

WEAR.

APPLY A THIN

COAT

OF

ASSEMBLY.

IF

ANY

IMPELLER

ARE

MISSING,

BE

FOUND BLOCKAGE!N COOLING

WIPETHISSURFACE

CLEAM

BEFORE INSTALUNG COVER

f

is

WARNING:

that

the

pump

start.

If

it

does

correct

THE

GLYCERIN

CIRCUIT.

INSIDE

THEY

TO

THE

the

problem.

FOR

AT

BLADES

''=~~~~~~

.

When

Is

pumping

not,

the

engine

within

"stop"

.'F!lOM

STRAINER

is

started,

30

the

THE

·FITS THE

RAW

seconds

engine

'.

IMPELLER

INTO SHAFT

WATER

make

after

at

once

RAWWATER

PUMP

HUB

THEBLOT

SCREW

IN

-.,.y'

WESTERBEKE

. EngiT)e",& Generators

16

[FRESH

RAW

WATER

The

fresh mounted TItis

pump

housing and a

that

blades

impeller

account

a spare impeller

impeller lubricant

failures

sure

make

should

pump

impeller blades.

NOTE:

ShOUld a failure

(seals

and

a new

pump.

-

IPIJM"P"C"'O"'VE'"R'~

INSPECT

SURFACE

IMPELLER

FITTHE INTO

'WHEN

THE

WITH.GLYCERIN

PUMP

water

cooled

above

the

is

a self-priming,

Neoprene

wipe

against a

housing,

should

kit).

(water)

are

ci

IMPELLER

producing

this

and impeller

Raw

water

is

not warrantable,

water

flow

be inspected

See

bearings) it

and

rebuild

DUAL

PUMPS

THE

INSIDE

FOR

WEAR.

HUB

SCREW

THE

SHAFT

ASSEMBLUVG.

AND

(Fresh

Water

model

has

fresh

water

(coolant)

rotary

impeller.

pump

not present

is

present

MAINTENANCE

occur

may

the

'

SLOT

COAT

The impeller

curved

cam

the

pumping

be

run

dry. There

cover

impeller during

and

operators

at

periodically

with

bema,,,,:.,st

original

(FRESH

-~--

Pump)

the raw

start-up. The

the

water

pump

with a non-ferrous

plate

action.

gasket

aboard

failures

engine

are

for

broken

SCHEDULE.

pumps

efficient

pump

WATER

COOLING

WATER

pump

as

illustrated.

has

flexible

within

the

QzwQ

should

always

(an

occur

when

operation.

cautioned

raw

internal

as a spare.

COOLED

water

or

tom

parts.

to

purchase

MODELS)

Such

to

SYSTEM

COOLED

CHANGING

Remove upper

as

shown seacock. while

1.

be

Remove direction install same

2.

Using impeller the cover

3.

Wipe glycerin surfaces

4.

Install blades removed

5.

Apply

piale

'upper

tight:

6.

Run. properly. raw

should

MODELS]

THE

WATER

·the

cover

screws

pump

(raw

waler)

in the

illustration.

This

will

prevent

the

impeller

the

direction.

pliers.

cam,

plate

the inside

the

are

glycerin to

and

pump

Re-install

the

water

not be

is

being

the

wear plate

the impeller blades

replacement impeller

grab

the impeller

from

the

pump.

the

inner

wear plate, and

for

wear.

surface supplied and to

impeller.

assemble

engine

The

the

new

impellers

working

(raw

any

to

engine

should

any

in the impeller

the

water)

make certain

discharge

leaks

(Pump)

and the

from the

Close

water

changed.

to

expose

Inspect

Replace

of the

exposed

with a

in the

same

O-ring,

into

the

making

hoses that

should

around

IMPEllERS

cover

will

fresh

water

the

raw

syphoaing

the

impeller.

are

working

with

blades

hub

and withdraw

the

inside

the

inside surface of the

any

worn

pump

dry.

kit

to

area

of

the

rotating

direction

impeller,

pump

housing.

certain

were

removed.

both

pumps

run

at

proper

from

the

exhaust

the

pumps.

separate the

(coolant)

water

thru hull

out of the

Notice

in

so

as

working in the

of

the

components.

Apply

a fihn

the inside

shaft lip

gasket,

seal.

motion

so

as

those

the

Reassemble the

the

fasteners

are operating

temperature.

and

pump

to

the

pump,

pump

the

of

the

wear

there

the

of

are

.

'WIPE

,.!BtFORE

"COVER

SURFACE

INSTALLING

CLEAN

THE

DRAIN

TUBE

".

, . A

""""

WESTERBEKE

Engines & Generators

A

WARNING:

sure

that

the

pump

engine

start.

If

it

does

and

correct

To

increase

:

impeller longer

dry

location.

and

ensure

WATER

water

the

generator is installed. Refer

NOTE:

tube

will

this

drain

the

problem.

the

service

in the

pump

than 3

months.

Replace the cover

the

thru

hull seacock

INTAKE

intake strainer (raw

Should a

allow

tube

STRAINER

pump

the

leak

clear

When

the

Is

pumping

not,

life

of

if

the engine

Store the

sluift

water

to

drain

of

obstructions.

engine

within

"stop"

the

impeller,

impeller

plate

is

water)

to

away

Is

started,

30

the

engine

will

be in storage

in a

on

the

closed.

is

a required component

the

leak

from

make

seconds

at

do

not

install

dark,

cool,

pump

securely

page

occur,

this

the

unit.

after

once

the

for

and

for

details.

drain

Keep

when

'

17

, \

DESCRIPTION

Coolllllt pumps pump. mounts sh!lft are

The

PUMP

(~

water) cooled

while

th.e

The

pumps

to

the

top

that

fits

i)1t(l.

driv~\l

simultaneously

following

instructions

OVERHAUL

raw water

are

essentially

of the lower

th~

s).t!lft

Disassembly

The.

pump

w~n

removed attachment the

pump.

the.

pump.

before starting the puinp

1.

~emove

sealing

Dual

Remove

upper

pump

Remove direction the direction.

2.

Remove

hub

3.

Removll

place;

4.

Remove

5.

Support.the.pump body

press

qf

6.

Remove

7,

Support

bearing.

S.

Remove.the

nipple

along

remove

the four cover

O-ring.

Pumps

the

cover

pump

(raw

as

shown

th~

wear

the

impeller blades

replacement

the

and.

pulling

the

reIl\ove

the dust

the

sbaft and bearing

the

pump.

the

outer bearing·

threaded

with a drive

these

screws

water)

in

the

plate

impeller

it

out.

screw

and

the

cam

plate

O-ring

from

spacer and

generators

cooled

pump

of

the

by

the

apply

from

the

into.the

have

models

the lower

same. and

pump.

use

The

has a

engines drive to

either

pump:

engine

will.

inlet

anI!

pllileyattachel!

attachments

noting their positions

disassembly.

plate

and

from

screws,

the

cover

cover will separate fresh water

illustration.

to

expose

the

impeller.

are

working

with

blades

working

using a pair

of

the

of pliers,grasping

pump

with a

sealing washer.that.hold and

inner

wear plate

and

circlip.

on

an

arbor press

assembly

the

shaft.

and

circlip

out of

push the shaft out of

.

RAW

dual

water

a single

upper

IIlI\g

Both

belt.

have

outlet

to.

the

~

plate,

(coolant)

Notice

in

so

as

in·

the

twisting

the

behind

lind

with

the

pUlley

WATER

water

pump

on

the

pumps

the

hose

ports

o{

of

and

the

to

install

same

.the

motion.

cam

in

it.

a drift,

end

the

PUMP

INSPECTION: EACH

BLADE

REPLACE

..-:::=~:--<~

LIGHTLY

GREASE

CHAMBER

WITH

AMiE

AN

.

INSPECT

AND

IF

ANY

OR

TEARING

THE

PUMP

GLYCERIN

IMPELLER

CHECK BY

BENDING

THE

IMPELLER

CRACKS.

THE

O-RING

IMPELLER.

SIGNS

REPLACE

OF

AT

THE

VIGOROUSLY.

IF

WEAR

BASE

THERE

OF

O-RING

INNER

BEARING

.

SPACER

OUTER BEARING

SCREW

Inspection

IIispeet

all

parts

and replace

corrosion.

those

showing

wear

and

PULLEY

Eng~'!~~~Eerators

18

I

Reassembly

Wipe

the

inside

surface

of

the

pump glycerin surfaces

1.

2.

3.

4.

5.

6.

7. Install the

8.

supplied and

Install the push

the shaft

the

circlip.

Instiill

the spacer bearing contacts

Apply

some

to

circlip

and the

in

the

exposed

into

push

spacer.

glycerin

shaft approximately Warming

and press. assembly the outer Rotate

Install circlip B

the

bearing

With a

into

bearing

the

pump

assembly.

twisting

the

shaft.

It

and outer bearing just plate.

Rotate

the

shaft.

Put some seat and slide it and seat on the shaft white

Install the

the

inner

ceramic

glycerin

it

in

the

area

until

brass wear

over

body

and

the

face.

plate

plate.

the

impeller kit

area

of

shaft.

Support

the

bearing until the bearing contacts

against

the

circlip. Support

the

shaft into the bearing

onto

the

liS"

away

body

should

Support the pump body

motiolj;

pump

install the shaft

until the inner bearing seats

should just clear the

shonld

turn

push

the

shaft assembly

contacts

on

circlip B and install

It

should

the

outer

the shaft white ceramic facing out

of

the

pumW.

with a twisting motion

ceramic

of

the

and circlip

locking

it

pin.

DUO/Pumps

The wear plate is assembled above the

9. Install the threads

earn

of'the

and place

screw

that

some

secures

RAW

dIy.

Apply

a film of

to

the inside

the shaft

the outer

D-ring

and

from

the

aid in installing the shaft

boss

freely.

turn

freely.

surface of the ceramic

Place some glycerin

spring

A.

in position

impeller.

gasket cement

it in

place.

lip

bearing

until

install it

inner

for circlip

until

seal

touches

on

pump

sea:(.

and

the

inner

it

bearing.

on

an arbor

and

the

slide

it over

the

dowel

on

the

'

on

bearing

dust

WATER

PUMP

the

and

B.

seal

the

UPPER PUMP

SHAFT

,SC~EW~

"

~~:;::::~~

_

fASTENS

THE'

UPPER

PUMP,

BOOYTO'THE LOWER

PUMP

O"RING

, :

ONLY

NEEDS

.'

REPLACES SIGNS

DUAL

ASSEMBLY

•

IF

OF

AGING.

PUMPS

''.

••

GASKET

TO

BE

IT

SHOWS'

10.Place some irmer

with a twisting

and

of

the

secure the

NOTE:

Install

blades

are

removed

Dual Pumps Assemble the

making sure

glycerin

surface of

pump.

Install the

cover

the

working

impeller.

upper

the

mounting

on

the

inner surface of the

the

cover

and

the cover sealing D-ring

motion install the impeller

covers

D-ring

With

the four cover screws.

new

impellers with a

in

the

same

direction

pump

to

the

lower pump as illustrated

screws

are

rotaJing

tight.

and

of

those

pump.

on

the shaft

cover and

motion

of

the

~

the

so

the

WESTERBEKE

Engines &

<>enerators

-.c...:_"_-_-=--.~,~.

.

t9

PULLEY

COOLING

SYSTEM

[FRESH

WATER

COOLED

MODELS]

FRESH

Fresh circulating coolant to engine When prevented flow circulation thermostat coolant cooling

ENGINE

WESTERBEKE and chenticals that

The antifreeze run the cooling quality Additives balanced,

NOTE:

antifreeze that

The recommended

against the most will

the circulating

A engine coolant

COOLANT

WATER

water

pump,

then

the

heat exchanger

block

the

engine by

is

bypassed

in gradually

to

flow

system.

COOLANT

50%

distilled

at

proper

engine

to

circuit

antifreeze

(SC~S)

crucial

Look for

also

retard

proper

50150

RECOVERY

COOLING

coolant

absorbing

passes

via

the

is

the

closed around

the

engine

unrestricted

recommends

water.

can

performs a double temperatures the coolant

from

that

to

the

is

now

extreme

rust

pump

mixture

to

temperatures

TANK

Coolant

The coolant recovery traction out introducing air into provided

water

operating the

Recovery

of the engines coolant

with

fresh

coolaot conversion

engine.

CIRCUIT

is

pumped

through

where

suction

started

opens,

corrode

rust

contains

that

long

new

availilble.

50150

within

impeller

Tank

tank

water

through

heat

from

the

thermostat

it

is

cooled

side

of the circulating

cold,

external

thermostat

the block).

Distilled

internal

by

and

keep

term

environmentally friendly

ntixture temperature.

the

as

recommended

the

cooled

kit

(although

thermostat

As

the

allowing

to

the

external

a ntixture

water

engine

duty.

transferring

lubricates

corrosion.

Supplemental

the

antifreeze

protection.

will

engine

and

seals.

of

- 40'F.

allows

for the expaosion aod

during

system.

aod

This

models

must

the

engine

the

engine.

into

and

returned

coolant

some

to

provide

engine

full

flow

portion

of

50%

is

free

surfaces.

It

allows

heat

and

protects

Look

for a good

Cooling

chentically

protect The

antifreeze

and

add

will

engine

operation

recovery

aod

be installed

by

The

the

manifold,

pump.

flow

coolant

coolant warms of

the

of

antifreeze

from

the

away

long

the

engine

to

the

protect

tank

with

the before

a

to

the

is

up,

the engine's the

the

engine

from

the

lasting

ntixture

life of

the

con-

with-

is

fresh

to

NOTE:

Periodically

Ensure

that condition tightly.

and

Carry a

CHANGING

The

engine's coolaot

MAINTENANCE

become

contaminated, it

A

CAUTION:

check

the

upper and lower

check

that

spare

COOLANT

SCHEDULE.

Proper critical; a substantial traced

back

to

cooling

Drain

the

engine coolaot heatexchaoger aod bleed

petcock

A

WARNING:

Wear

protective

Refilling

Tighten

premixed exchaoger escape.

Close

the

Remove

coolaot

the

flow

After Coolant engine needed pressure

the

the heat exchaoger

coolaot

air bleed petcock loose

As

the

air bleed petcock aod

coolaot

cap.

fill.

the

mix

Run the engine aod

into

the recovery

checking for

should

cools

aod

cap.

opening

on

the

Beware

gloves.

Coolant

in

filling

Install the

cap

on

the

to

halfway between

leaks,

draw

down.

Add

make

certain the coolant

Clean

the

condition

rubber

the

vacuum

cap.

must

be

chaoged

If

can

lead

cooling

number'

of

system

by

loosening

pressure

top

of the

heat

of

the

drain

thru

the

coolant

continues, start

fill

pressure

coolaot

tank.

back into

up

aoy

recovery

LOW

observe

stop the

the

coolaot

spilled

of

the

pressure

seals

valve

opens and closes

according

the

coolaot

to

overheating

system

maintenance

engine

failures

corrosion.

the

drain plug

cap.

Also

exchaoger

hot

engine

plug

and

slowly pour

fill.

Leave the heat

to

allow

trapped air

and

run

until

coolaot

cap.

tank

and

MAX

the

coolaot

engine

and

cooling

to

coolant.

system

the

recovery tank if

is

topped

are

in

good

to the

is allowed

problems.

can

on

loosen

coolant.

the

engine.

tops

off

aod

fill

with

and

expaosion

allow

it

to

as

the

off

at

the

cap.

to

Is

be

the

air

clean,

to

at

replace

cool.

NOTE:

This

tank,

with

its

short

run

of

plastic

located at or

above

the

level

of

the

engine's

.'

hase,

is

manifold.

-..v:

best

WESTERBEKE

Engines & Generators

20

.

THERMOSTAT

Fresh

waier

cooled3.0KW

controls

.

flows first

flOwing

coolarit up, accessible Carry a spare

the

coolant

through the

started;

the thermostat

the'

closed

(some

coolant

circulation in the

and

can

thermostat

COOLING

temperature

closed

cooling thermostat is

around thethennostat

engine

gradually

be.

checked,

and

SYSTEM

generators

as

the

circuit.

prevents

block).

opens.

The thennostat

cleaned,

gasket

have

coolant

a thennostat

continuously

when the

.coolant

to

As

the.

engine

or replaced

[FRESH

that,

engine

is

from

provide

warms

is

easily.

WATER

COOLED

,

ZINC

MODELS]

r--."

-i

(TO

WATERC(}DLED

EXHAUST'

,

Replacing

Remove housing

gasket, gasket before pressing it into

Run

the

th~re

iGASKET

;AD,D,

AT

HEAT

Cool exchanger.

.the

heat of the internal engine is conducted which discharged, through

The

engine other; harmful

Heat

After and

pressure

automotive radiator

exchanger.)

heat

NOTE:

that a heat exchanger cleaning every

the

Thermostat

the

cap

screws

and disassemble the thennostat

as

shown.

apply

engine and

".re

no

§SS£EAnLAqBNi~T'i"1V<

M.

When

installing

a thin coat of sealant

place.

check

for

nonnal temperatures

around

the

thennostat housing/gasket.

THERMOSTAT HO,USING

EXCHANGER

raw

water

flows

through the inner

As

the engine coolant passes around these

is

then

pnmped into the exhaust system and

The engine coolant

the

engine

and

coolant and

this

keeps

the engine's water passages clean

deposits

foood

Exchanger

approximately

test the engine's heat

Operating

1000

in

hours,

the

in raw

Service

1000

shop

silty and/or tropical waters

(now

circuit

raw

water are independent of each

water.

hours

of operation,

should be able

be

the

new

on

both sides of

cooled)

repe!ils

itself.

exchanger,

to

performed

thennostat

the

and

of

the heat

to

the

raw

flows

back

from

remove, (A

local

clean

and

may

more

often

anel,

f'i'1.\l~~

that

ZINC

A

zinc

circuit

anode in

the

of

electrolysis condition the

anode

should

NOTE:

and

vessel

If

the

tubes,

water

the

clean

which loosening hex

boss removing poor

exchanger.

the'inside

excHanger damaged (refer

number),

NOTE:

test the

require

than

not

require

insulate

housing

.AI~..---",COIOLJI,NT

8Ji.IIC~----~R~'W

ANODE

anode,

or

pencil,

is

locate<!

within

the

heatexdllulger

is

to

sacrifice itself

raw water

be carried

Electrolysis

zinc pencil

the

condition,

to

The

prev~nting

cooling

on

other

of

the

zinc

cleaned

on

location;

NEW

needs

zinc

pencil

the

anode

from

possibly

the

zinc,

there

Remove

of

all

zinc

end gasket in case the present

when

removing

your engine model's heat exchanger end

a-ring,

cover,

threads

sealant.

the zinc

from

to

circuit,

components of

anode

or

replaced

board.

is

the

result

not

that

replacement, hold the hex boss

is

threaded with a wrench

with

another

tearing off the exchanger

note.

the condition

are

probably

the

end

debris.

and

of

the

zinc anodes

Sealant

the

electrolysis action

in

the

raw

..

The

purpose

electrolysis

should be checked monthly

as

of

the

REPLACE

of

the heat exchanger

Always

the end

install a new

should

metal

thereby

the

reqnired.

each

particular

engine.

wrench.

of

zinc

have

cover.

are

not

of

the

heat

on

acrion

reducing the

CLEAN & REUSE

it.

flakes

Replace

be

WATER

water

cooling

of the

taking system. The Spare

anodes

installation

while

This

prevents

shell.

If

the

zinc

within

and

a spare heat

one

becomes

the

gasket

zinc

anode.

pipe

threads

used

as

it

exchanger

the

zinc.

DRAIN

zinc

place

effects

and

into

the

After

is

in

the

clean

gasket

part

and

may

do

~WEsTERBEKE

';i

'Engines & Generators

21

,CARBURETOR

CARBUREtOR

Th~

carburetOr

cleanable

The

de-richening

to

close

the

engine

during

engine

The

air

hours

of

the

air

screen

Fuel

Overflow

Excess drawn

out

of

contaminates.

be

sufficient

De-Richening

The

de-richening

i

additional electric DC

power

To

check

apply

DC

devise

should

outward.

Idle

Mixture

The

idler mixture jet

is a

single

metal screen air intake

valve is operated

off a fuel port

after a col4

.operation.·.

screen

operatiori

in a water

reducing start.

~an

easily

and

every

Chamber

fuel

drains

into

the

again

at

start-up.

Cleaning

unless

there

Valve

valve

closes

fuel

on

a cold start after start

device

that

slowly

is

applied after start

this

valve.

remove

voltage

the

get hot

devise

across

and

will

Jet

is

factory

barrel;

side

draft

type

filter/spark

by

12VDC.

the

fuel

mixture

The

valve

will

be

removed.

100

soluble cleaner such

fuel

This

every

is a fuel

moves

from

its electrical

the needle

remain

hours

overflow

chamber 250

problem.

off a

fuel

a needle

up

to

the

hot

during

adjusted

Clean

from

chamber but

should

operating

port

up.

outward

close

carburetor connections.

will

slowly

and

with

arrester.

Its,purpose

going

hot

after

then

as

GUNK

hours

that

This

is a thermal

this

fuel

engine

plugged.

a

into

to

touch

the

first

on.

Clean

is

be

kept

should

is

supplying when

port.

(cold)

The'

move

operation

is.

50

free

an4'

.

CHAMBER

Carburetor

A'bowl of

the

carburetor

actuators

NOTE:

periodically

operation.

Bowl

drain

slotted plug

ball

jointiclevis.

Ball joint

(use

DE·RICHENING

Drain

is

located

bow},

This

linkage

graphite

between

lubricant)

iBDWL

'

on

the

lower right

is

located

just inboard

actuator and throttle.

to

maintain smooth

of

SCREEN

comer

the

Lube

DC

REGIJLATlJR.

~

WESTERBEKE

En!1lnes

';;;:II"

,,"TllliTn.

KEEP WELL

&

~i!n~;ators

Remove the

LEVER

mE

LINKAGE

LUBRICATED

SCREEN

the

screen

for

circlip

cleaning

to

access

22

IiC

CIRCUIT

/BATTERY

DESCRIPTION

The

DC

Circuit functions generator's engine. reviewing The engine's circuits:

The shown when troubleshooting or when

system

A

circuit, the however, engine's

the

DC

wiring

start,

run,

engine

has a

12

on

the Wiring Diagrams.

on

the

engine.

CAUTION:

never

shut

engine

is

running.

to

avoid

electrical

to

start,

The

circuit

Wuing Diagram

is

designed

and

stop.

volt

DC

To

avoid

damage

off

the

engine

Shut

electrical

circuit.

- .

Specifications

The.

minimwn

the engine's 12-volt

Battery

The

engine

ric

voltage

volts

approximately.

buss

type

recoll)ffiended

DC

Charging

has a

regnlator.

fuse.

Circuit

flywheel

The

control circuit

mounted

The system

system

operate

is

best

understood

and

Wiring

with

three

electrical

Refer

servicing

to

control to

these

the

battery

off

the

engine

shorts

when

capacity of the

is

600-900

magneto

provides

is

protected

and

stop

Schematic.

simple

circuit

diagrams

DC

electrical

battery

switch

battery

working

battery

and

9.5

amps

by a 20

the

by

basic

that

is

charging

while

switch, on.the

.

..

"-

used

in

(CCA).

ali

external.

at

13.5

amp

Testing

If

circuit, fuse it indicated,

Battery

Review establish engine's starting batteries

•

.

the

battery

remove the

holder

should

indicate

check the tenuinal

Maintenance

the

a systematic

Check

the electrolyte

hydrometer.

Use

only

level.

Make

certain that

tight

to

Keep

your batteries

Circuit

is not

charging,

fuse

and

connection

manufacturer's

distilled

the battery

and

13-14

volts.

maintenance

water

battery

posts

clean

check

the

test

with

a voltmeter between

ground.

recommendations

and

level

With

If

only

connections

schedule

house

and

specific

to

bring

electrolytes

cable

connections

(and

to

and

free

battery

batteries.

your

of

fuse.

To

test the

the engine runuing,

voltage is

at

the

battery.

and then

for

your

gravity

with a

to

a proper

are clean

engine)

.

corrosion.

the

and

DESCRIPTION

If

the installer

crrcuit,

this Transfer Switch. Set diagrams

simultaneous connection

. ' N

to

:"!~"'"

t

'----

.connects

must be

the

OFF

.

SINGLE

;'

done

shore power

by

m'ea:ns

the

transfer

position. This

of

shore

LINE

120

SHORE

POWER

.

to

the vessel's

of the

Shore

switch

shown in the

switch

prevents

power

to

generator

VOLT

SYSTEM

AC

Power

output.

-.,.y'"

TRANSFER

A

CAUTION:

utility

shore

at

the

sametinie. covered sibility

WESTERBEKE

Engines & Generators

under

to

make

enerat~

Ground

r---~------~~@3

1

L1

Shore

SWITCH

power

the

N

'-:(N::-.-U'""

N I

,

Power

230

Damage

sure

to

and

generator

This

type

warranty;

all

AC

L1

ii

Generator/Shore

.!!!

Switch

al

L-L';:'-"',

·~~L1

, ,

'-~

--,

...

-:I):-,"';@)5

,~-.,'

Shore

1

- Ground

.

VOLT/50

HERtz

the

generator

output

are

of

generator

iUs

the

connections

damage

installer's

are

'.~.~~

_.

®}

~

®J

.

TWO

N

. Shlp's

';;"

Ground

WIRE

can

resultlt

connected

is

not

respon-

correct.

~

ShTp~1b-Shore

Ship's

LOAD

CONFIGURATION

.

;I~~

<

~witch

SYSTEM

23

DESCRIPTION

The

system

is

composed if

1.

Controller.

locat~d

2.

Sensor.

sures

the

The

in

the

control

Mounted on

speed of the

PC

3. Actuator. Electronically controls The

sensor

and actuator

the

controller

ADJUSTMENT

board).

PROCEDURE

Speed. This adjustment engine's

2200 Gain. Adjusts

engine Stability.

speed.

RPM.

seems

This generator

the

sluggish,

Adjusts

overall set of the

the engine's

changes. Alternator Feedback.

signal

to

the throttle actuator.

NOTE:

These adjustments are extremely delicate

require proper meters

three

basic

board

that

panel.

the

flywheel

eng\fle

(via

are

wired thru

is

used

to

engine

to

high

causes

response

Adjusts

for

the

measuring voltage

governs

components.

cover,

the

ring

the

carbnretor

the

raise

or

is

engine.

the

stability

ELECTRONIC

the

system

is

the

sensor

mea-

GOVERffOR

gear).

throttle.

wiring

hamess

to

Following (P1). pots

The stops. left

Before starting the engine

•

• Start

of that

Decreasing engine the gain

0.0301"

(0.762mm)\

After the applied. the also changes.

SENSOR

If pots

lower the

set

to

run at

If

too

low,

the

engine

to

hunt.

to

generator load

of the speed

and

RPM·S.

o

i

~,<.u

.

CONTROL

(P2)

PANEL

.

(INTERIOR

VIEW)

,

are'the basic procedures for

stability

C\

(P2),

gain

(P3), and actuator feedback (P4)

.

________

adjusting

SPEED

(P1)

ACTUATOR FEEDBACK

_

the

(P4)

speed

..

adjusting

Thrn

(counter-clockwise)

Remove to

insure that

variations Decrease Turn

the

throttle

in

the

AC stability (P2)

changes

the

dopot correct engine hunting, the

(P4)

potcan be

nals

to.the

will

decrease the Because in

very

now

need

Most lems

with

tor.

lnsure that and

that

be

lubricated

because

NOTE:

such as speed. It may be necessary to readjust some pots throughout this process. '

pots

(except

to

the right (clockwise)

all

loads

while

the

speed

the

other

adjustment

engine,

unit

AC

running

small

by

adjusting

voltage

the

gain

at

lever

increments

engine's

monitor

no

to

no

circuit breaker can be turned

In

the

event

pot

how

the

range

of adjustment of either

increased.

throttle contml

amount

of

this,

it

small

increments.

to

be

readjusted.

hunting

problems

the

linkage between the actuator

the

it

moves

freely.

with a graphite

it

tends

to

Adjustments to one parameter may affect others.

speed)

have physical internal

to

decrease.

and

turn off the

will not be subjected

these

adjustment are

pot

to

prevent

pots

to

speed and adjust

the SPEED (P1)

output

is

in

the correct

(P3) dampens

no

load and proper

cause hunting.

to

If

eliminate

load speed and gain

of speed variations

may

need

adjustment.

engine responds

This adjustment actuator.

of throttle control

is

recommended

The

gain

occur because of

linkage

is

free of

It

is

reconuyended lubricant.

collect dirt and

to

increase,

AC

circuit

made.

overspeed

the

middle

to

as

load

speed,

necessary,

hunting.

are

on

and

with

to

generator

gain

(P3)

actuator

lncreasing

the

adjustment

and

stability

mechanical

any

debris

Do

dust.

turn

breaker

to

voltage

at start position.

the

hertz rating

needed.

range. hunting.

manually

decrease

set

correctly,

the

ships

loads

This

adjustment

or

stability

feedback

dampens

this

resolution.

pots

and

the

or

corrosion

that

the

not

use

to

Verify

With

applied, load

adjustment

be

carbure-

oil

the

up.

the

bump

the

load

(P2)

the

sig-

made

may

prob-

linkage

Engines'&, Generators

24 '

ADJUSTING

The engine's

access the cover and

for

The belt tension

spring

,...L;=;:J......jJAM

To

set the spring

and

use

nut

(as

in

turn adjusts

THE

drive

the belt,

as

shown.

proper belt

length.'

a rod such

shown)

for

to

th~

DRIVE

BELT

belt

is

located

inspection

Inspect

tension

can

be

NUT

tension

as

tigh~ti

tension

and/or adjustment, remove

the belt for

(belt should

checked

I

rod

at!

an.

allen

w.rench

or

looseri

Oil

the

ENGINE

under

the

engine.

wear

along the

be

tight).

by

meassuring

II.8'~,

release the jam

to

turn

the

spring

belt.

To

the

adjusting

tension,

ADJUSTMENTS

BELT

edges

nut

which

ASSEMBLY

VIEWED

FROM

BENEATH

COVER

.

IT

IS

NORMAL DUST ENGINE

FOR

TO

ACCUMULATE

PAN,

SOME

SIMPLY

BELT

IN

WIPE

\

ROO

THE

CLEAN

lUll

PRESSURE

'The

lubricating

oil

pump.

oil

pump,

oil

filter

and

theu

returns

When

the

pushes

open

the

oil

sump,

range.

TESTING

To

test

the

,

mechanical necessary

to

engine speed

at

2200

OIL

PRESSURE:

NOTE:

A

newly pressure pressure

on

OIL

The switch.

up as

the

load

PRESSURE

generator

Should the engine's

mifliminn,

damage

by

system

The

engine oil is

which

drives the

various

to the oil

oil

OIL

oil

to

connect

run.

to

low

placed

lubricating parts in the

pressure

the

relief

keeping

PRESSURE

pressure,

pressure

After wanning

Ipm,

read

between

started

40

psi. A warmed

as

14 on

SWITCH/SENSOR

is

fitted

the

switch

interrupting

is a pressure

drawn

oil,

sump

to exceeds valve

in

the

oil

pressure

remove

gauge

the

two

switch

the

oil

14

and

40

(cold)

engine,

psi.

Oil

the

generator.

with

an

oil

will

shut the engine

the

DC

feeding

from

under

pressure,

repeat the

the

specified

the oil

pump within

the oil

switch

in

it's

place,

wires

up

the

engine,

pressure

psi

AT

2200

may

engine

pressure

oil pressure

pressure voltage

system using

the oil

sump

through

engine.

continuous

pressure,

and returns to

it's specified

and

it

will

together

with

gauge.

rpm

have

an

can

have

will

vary

shutdown

drop

below

down

to

the

ignition

by

the

The

oil

cycle.

the oil

install a

be

for the

the engine

oil an

oil

depending

the

safe

to

prevent

coil.

an

NOTE:

loss additional

ENGINE

Engin~$

& Generators

25

The

specified

of

oil

pressure

infonnation

TROUBLESHOOTING

minimum

usually

on

low

oil

pressure

indicates

oil

pressure chart.

worn

is

5 psi A

bearings.

readings,

gradual

For

see

the

ENGINE

ADJUSTMENTS

ENGINE

To engine,

1.

2.

3.

4.

5.

6.

COMPRESSION

check

the engine's compression

then

shut it

down. Remove Install a compression adapter

plug Close Crank

pointer reaches it's

STANDARD

Test

If

small and

Ca)

(b)

Reinstall the

thru hull valve

both

spark

hole.

the thru

the

71

PSI

the compression pressure

either cylinder

amount of engine oil

repeat the

If

additional oil causes

the piston

or

damaged.

If

additional oil pressure or valve

hull

engine

several

COMPRESSION

(5'" 1

Kg/em')

is

test.

ring

andlor cylinder

suspect

wear.

two

plugs, connect the

(seacock).

TEST

plug

caps

valve

Cseacock).

times

maximum.

PRESSURE

(0.4'"

0.1

below the

through

an

does

not

poor valve

pressure,

and

both

and

gauge

quickly

AT

500

MPa)

on

the

standard

increase

may

increase

contact,

warm

spark

in a spark

so

that

RPM:

other

cylinder.

try

adding

tlle

spark

of

pressure,

be

wom

compression

valve

wires

and

.

up

the

plugs.

the

gauge

a

plug

seizure

open

hole

the

WATER

To and

to

adjusting

and The

MODELS

remove,

release

slacken

nut.

dual

PUMP

water use

replace

the

BELT

adjusting

belt for

belt, set

pumps

the

same

or

aajust the belt,

bolt.

removal.

the

belt very tight

on

the

FRESH

drive

belt and the adjustment

loosen

Slide the

When

WATER

the pivot bolt

water

pump bracket

replacing and

and

tighten the bolt

COOLED

is

the

same.

RAW

WATER

PUMP

.I\U;'UO'"NO

.

BOLT

IGNITION

The

that speed.

'with

There

10°,15°,20°,25°,30°,35) on the Check

marking

TIMING

magneto

advances

While

a timing

are

nine (9)

the timing

on the

employs

ignition

running

light.

markings

while

starter

the electric ignition

timing with

the engine, check the ignition

(IDC, AlDC

observing the position

case.

an

increase of

flywheel

n

~

-

..

advance

5°

FLYWHEEL

'system

engine

and B1DC

cup.

of

the

-----

timing

carved

5°,

- -

BTDC IGNITION IN

DEGREES

'-~

=-

~

"II

{(

;i

lIiC

;:::==-=-~CARVED·MARKINGS

t'fllV"IWESTERBEKE

I Engines & Generators

--

'_.2-_.

-

.-

TIMING

:30

25~.~--~~~------

20

10

o

L--<.--+f-,f-

........

--'----'-

o 1 3 4 5 6 X

Engine speed rpm

·r

.....

10'

26

ENGINE

ADJUSTMENTS

SPARK

The

first

thereafter

PLUGS

spark

plugs should

50

hour

and

A

WARNING:

the

engine

removing

SPARK

PLUG

GAP:

SPARK

PLUG

TORQUE:

NOTE:

Loctite

the

spark

plugs

of

the

spark

.

INSPECTloNG THE

SPARK

PLUGS

break-in

replaced

Do

is

hot.

Allow

them.

0.032 -0.035in. 11 -151b·fl

Anti-Seize

will

retard

plugs

easier.

GAP

be

cleaned and

period,

then inspected

as

needed.

not

remove

the

(15 -26

applied

corrosion,

..Jt'----_

~

the

engine

(0.8

·0.9mm).

to

the

re-gapped

spark

to

cool

Nm).

threaded

making

after

the

every

250

hours

plugs

while

before

portion

future

removal

INSPEGTFDR

DAMAGE

of

0

THERMOSTAT

A thermostat

continuously

the

engine

water

from thermostat As

the engine thermostat replaced

If

and heated

you

bring

easily.

suspect a

and

[Raw

controls flows

is

first

flowing

to

provide

is

accessible

to a boil. A working

close

the

tlrrough

started,

(some

coolant circulation

warms

up,

Carry a

faulty

when

Water

Cooled

coolant

the

closed

the

closed

water

the

thermostat

and

can

be

spare

thermostat

thermostat,

thermostat

cold.

Models]

temperature

cooling

thermostat

is

by-passed

in

gradually

checked,

and

place it

should

as

the

circuit.

prevents

around

the

engine

cleaned,

gasket.

in a pan

raw

the

opens.

or

of water

open

water

When

the

block).

The

when

0 0

i::=::::t'----,~'''''''(FDR

DETERIORATION

AND

DAMAGE

DE-RICHENING VALVE

The

de-richening valve

is

12

volt

DC

operated. through a port this valve closes as the engine This

valve

will be warm/hot

running.

is

ZINC

ANODE

The

zinc

and

next sacrifice itself water

cooling electrolysis condition

the

anode

should

be

NOTE:

Refer

pages for

anti

Zinc

[Raw

anode

is located just below the thermostat cover

to

the oil filter.The pwpose

to

circuit,

on other components

of the zinc

cleaned or replaceq carried on

to

the

Fresh

Anode

is

mounted on the carburetor and

On

a cold start extra

to

the touch while the engine

Water

electrolysis action taking place in the

th~reby

anode

board.

Cooling

Water

Cooled

reducing

of

the

should be checked

as

required.

Systel;1

Cooled

The17nostat

Models]

of

the zinc anode is to

the

system.

Spare

assemhlies.

fuel

warms

effects

monthly

is

of

The

anodes

supplied

up.

raw

and

ZINC

ANODE

THE

GASKET

THE

CASTING

DAMAGED,

POSITION.

THE

REASSEMBLING

ADD

GASKET

IS

SEALED

AND,

UNLESS

CAN

BE

LEFT

SEALANT

SUI1F/J,GE

'THE

COVER.

TO

IN

TO

WHEN

'.

GASKET

• : '

APPLY

WHEN

ASSEMBLY

ZINC

ANODE

AND

GASKET

(PN.048017)

!

(PN.048150)

SEALANT INSTALLING

0

THERMOSTAT

Engines

27

& Gener"tors

VALVE

CLEARANCE

It is

routine

maintenance

the

firstfifty hours of operation.

must

be

perfonned when the engine is

must

be

the top

dead

center

Perform

1.

2.

the

following

Remove

head

the

cover.

This

discouneqting Remove

the cylinder head

fuel

the

adjustment

pump assembly

hoses.

to

adjust

and

of

the

fuel

can

COver

the

valve

Valve

clearance

cool

compression

steps:

filter

from

be

set

aside

..

ENGINE

clearance

ADJUSTI'v'IENTS

after

adjustment

and the

piston

stroke.

the

cylinder

without

EXHAUST SIDE

7.

Adjust

#2

using

NOTE:

the

adjusting

vent

it

ADJUSTING

FEELER

the

intake

the

same

When

loosening

screw

from

I1Wving.

GAUGE

and

exhaust

sequence.

and

with a valve

__

valve

clearance

tightening

clearance

~

the

#2

for

lock

driver

INTAKE. SIDE

cylinder

nut, hold

to

pre

3.

Remove

driven

NOTE:

disconnected

FLYWHEEL

5.

Adjust

cylinder

a.

Loosen

b. Insert

adjusting

e.

Set

VALVE INTAKE: EXHAUST:

d.

TIghten

e.

Again,

6.

Tum driven

the

flywheel

pull~y.

The

governor

at

the

cover

sensor

sid

of

the

l?

access

(mag

control

the flywheel

pick-up)

paneL

wires

the intske and exhaust valve clearance for

#l.

the lock nut.

a.feeler gauge between the valve end and the

screw.

the valve clearance by the adjusting

CLEARANCE:

0.13 -0.17mm

0.18·

the lock

check

the

driven

pulley

(0.095 -0.007in)

0.22mm

(0.007 -O.OOgin)

nut

the valve clearance.

gear and align

with

the "

'\7"

mark

the

"2 and

on

screw.

0"

the cylinder

can

mark

and

be

on

head.

. .

the

VALVE CLEARANCE DRIVER

8.

Install

the

rim of

the

drawing.

BDLTTDRQUE:

8 -10

Nm

9. Install

the

cylinder cover

(0.8

-1.0

flywheel

TORQUE

~~~~i1i:::::::;(PRE-SETTING

\lead

cover.

Apply

sealant

as

indicated

kg-m)

cover

SEAL WITH BLACK

by

5.8

-7.2Ib-ft

and

THIS

AREA

LOCTITE

SILICONE

the shaded

re-attach the

area

sensor

to

the inside

of

the

wires.

WRENCH

TYPE}

EngInes ~ .Generators

28

.

ENGINE

ADJUSTMENTS

.INSPECTION/REPLACING

If

cracks,

wear,

lengthening

replace

UMIT PUSHING

Replacement

1.

OF

Remove

a.

.spark

Il.

Recoil c.Magneto d.

Alternator

e.

Alternator

Thm the

2. pulley

3.'

Remove

4.

Install

NOTE:

After installing

"0"

inark

block.

PlefUJe

the

on cylinder

NOTE:

Always

grefUJe.

the

timing

belt

ELONGATION:

WITH

and

the

driven

head.

MORE

YOUR

FINGER

of

the

parts

plugs

starter

flywheel

assembly

bracket

crankshaft

the

"0"

the

timing

on

the

drive

confirm

pulley

keep

the

are

or

THAN

Timing

in

the

following

cup

and

mark

belt

from

belt

from

the

timing

pulley

thea

the

aligned

timing

OF

other

10mm

allgn

on

the

with

"1

belt

THE

TIMING

damage

(0.4111)

Belt

order:

"0"

mark

the

cyllnder

the

driven

drive

belt,

when

"0"

&

0"

with

the

awtry

pulley

on

or

"'i/"

from

BELT

is

found,

OEFLECTION

pulley

the

"2

on

the

head.

side.

aligning

cylinder

&

0"

mark

any

BY

drive

side.

on

oil

mark

and

the

o~·.·

FLYWHEEL

~J~t

~

CUP

~D

DRIVEN

PULLEY

\7

MARK

,

TIMING

BELT

.DRIVE

PULLEY

Engines & Generators

29

TROUBLESHOOTING

GUIDE

3.0

KW

When toubleshooting ELECTRICAL reveal

other

SYSTEM

possible causes of

below.

PROBLEM

Engine

does

not

crank.

Engine

starts,

runs

and

then

shuts

down. (Runs

lor

10-15

seconds)

Engine

starts,

runs

but

does

not

speed.

cranks

10

starL

will

seconds)

hunts.

come

but

crank

up

to

Engine fails

(Engine lor

15

Engine

indicates

an

electrical

WIRING

the

PROBABLE

1.

Voltage terminal.

2.

Main

10

3.

Battery Loose

4.

5.

6.

7.

B.

9.

1.

2.

3.

4.

5.

6.

7.

B.

1.

2.

3.

4.

5.

6.

7.

B.

1.

2.

3.

4.

<-·,5~

6.

1.

2.

3.

4.

5.

6.

7.

B.

9.

battery

Faulty

wire

Faulty

start

Faulty

pc

Faulty

starter

Water

filled

Faulty

shutdown

or

exhaust

Faulty

overspeed

Dirty

fuel/water Clogged Low

oil

Faulty

fuel

No

fuel

Clogged

Faulty

mag-pickup

Electronic Fuel

pump.

Fuel

supply Actuator Actuator

faulty.

Air

intake

Exhaust

Out

of Engine Faulty

carburetor.

Faulty

choke

Faulty

ignilion

Bad

spark Controller Faulty

fuel

Faulty

PC Improper Low

DC

High

exhaust

Dirty

fuel Generator Valves

DIAGRAM,

problem

which

CAUSE

drop

at

starter

amp

fuse

is

low

or

dead.

connections. connection. switch.

board

solenoid

cylinders.

switCh,(oil

temperature).

PC

separator

fuel

line.

level

in

sump.

pump.

fuel

filter

governor

to

engine

linkage

binding.

Dr

electrical

restricted.

fuel.

is

flooded.

solenoid

coil.

plugs

gain

adjustment

pump.

board. drive

belt

battery

voltage.

back

filter

overload.

need

adjustment

problem,

as

this

are

solenoid

blown.

board.

filter.

sensor.

controller

restricted.

connections

(See

Carburetor

lension.

pressure.

see the

may

not listed.

pressure,

faulty,

page)

needed.

The following troubleshooting engine

problem

indicators

and

problems

PROBLEM

Engine

misfires.

Engine

backfires.

Engine

overheats.

Low

oil

pressure,

High

oil

pressure.

110

DC

charge

starting

battery.

to

PROBABLE

1.

2.

3.

4.

5.

6.

7.

8.

9.

1.

2.

3.

4.

5.

6.

1.

2.

3.

4.

1.

2.

3.

4.

5.

6.

7.

B.

1.

the

Poor Faulty Dirty Faulty

Spark Binding High Valve Valve

Faulty

Incorrect Engine

ffooded falls

Dirty Faulty High

Blockage the

pump seperated

Belts

Obstructed Obstruction

Low

Wrong Oil

Relief Faulty Faulty Boal Faulty

Dirty engine.

Relief

2. Faulty

1.

20

2.

Faulty

3.

Faulty

4.

tables

are

the

most

CAUSE

quality

fuel.

ignition

flame

arrester. ignition plugs

are

actuator

exhaust

back-pressure. clearances clearances

ignition

timing.

is

flooded.

under

to

start.

flame

arrester.

ignition

exhaust

in

cooling

raw

water

impellers,

hoses.

may

be

by-pass

in

oil

level.

SAE

type

diluted

with

valve

is

oil

pump.

engine

heeled

over

oil

filter.

oil

or

wrong

valve

is

connections

amp

fuse voltage magneto.

based upon certain

likely causes of

control

module.

wires.

worn.

linkage.

are

incorrect.

are

incorrect.

control

module.

See

Engine

is

Engine

cranks

but

coil.

back-pressure.

water

flow:

intake,

intake

strainer,

and

look

for

broken

loose

Dr

broken.

hose.

engine

cooling

system.

oil

in

the

engine.

fuel.

stuck.

bearings.

too

much.

SAE

type

oil

stuck.

to

magneto.

blown/faulty.

regulator.

the

inspect

or

in

Ihe

Engines & Generators

.30

.

TROUBLESHOOTING

GUIDE,

I'ilOBLEM

Biue

Exhaus(SmDke

from

the

Engine

Black

exhaust

from

the

Engine

Poor

pertormance

at

generator

Starter

stays

after

start

Unit

starts

at

idle

speed

Note:

MPU

Cranking: Running: (2200

4.0 -5.0

rpm)

smoke

speed

energized

and

runs

voltages

1.5 -2.0

Discharge'

Discharge

to

PC

VAC

..

board:

PROBABLE

i

Lubeoi!

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

CAUSE

"

is

diluted:

lube

Dillevel. breather

are

worn

rings

flame

carburetor.

mixture

are

worn

rings

fuel

pump/contaminated.

governor

MPU starter

MPU

overspeed

hose

or

adjusted

are

worn

arrester.

jet

tOO

rich.

diaphragm

or

incorrectly

are

worn

in

carburetor.

controiler

suspected.

solenoid.

signal.

1.5 -2.0

board.

is

clogged.

incorrectly.

or

unseated.

leaking.

or

unseated.

Check

VAC

adjusted.

needs

MPU.

cranking.

BY-PASSING

A faulty Overspeed unwanted engibe

shuts

1.

2.

shutdown.

is

started

down.

Refer

to

the

Unplug of

the

IS

the

wire plug connection

THE

PC

Board

It

can

and

runs

for

Wiring

Diagram in this

brown

#6

wire

plug connector

is

OVERSPEED

can

be

also

be

the canse

10 -IS

that connects

and

the

in

the

hamess between

components.

3.

Without

unplugging

any

connections

place a jumper between connection

4.

Manually controlling #30

and

#87, start physically controlling the actuator/throttle engine

speed

at a low comfortable

continues

board

NOTE:

generator run

under

The

to

run

more

than

IS

exists.

above

should

only

be

with

a by-passed overspeed board

normal

use.

This

can

present a

seconds, a

peiformed

the

cause of

seconds

manual.

ignition

on

,the

#30

and

range.

hazard.

BOARD

an

when

the

and

then

between

the

as a test.

module.

the

coilrelay,

#87.

engine

keeping

If

the

faulty

should

two

the

engine

overspeed

The'

not

#12

The

be

-.,.y:

WESTERBEKE'

fitties.

&

31

Gener~tors

_

•

MAG.PICK-UP

95()"100ro

SRIELDE

nu

COHTROL

PC

BOARD

O.21-0.41D

ALT.

COIL

RESISTANCE

MAGNETO

COIL..

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

EXCITER

CDlL

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

PULSER

CDlL..

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

ALTERNATOR

IGNITION

COIL.

COIL

....................... 0.26·

(Primary)

MAGNETIC START HIGH CARBERATOR

ACTUATOR

TOLERANCE ± 20%

NOTE:

SOLENOID

TENSION

TESTER

PICK·UP

LEADS

SOLENOID

•••••••••••••••••••••••••••

USED·

OVERSPEED

..

;;

",~I-

...

; ..

;;

i

VALUES

••••••••••••••••.

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

••

~.

;i;

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

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

..........

FLUKE

PC

RESISTANCE

~16

HlKIRED

118

1.4·2.1n~

MAG.

CARBURETOR

IN

MULTlMETER.

BOARD

VEl/REO

COIL'

SOLENOlD

OHMS

1.4 -2.1

12.5

-18.8

148 -222

O.21-

0.41

0.35

8nO

4.7

6.8nO·1D.OOO

20

3.0

-3.1

(PN

#045377)

r---+

NOT

GENERATOR

VALUES

1.4

-2.m

;MAG.

6

BlK

148-222D

PUL8fRCOIL

1116

REDI

KT

II

YH

II

tiL

FUSE

RED

BATTERY

SfjlTCU

If---''''-'''''''--

J'~NElIREWOTE

CONNECTOR

RtMOU:

SHUTDOWN

J:

POSITI'IE

2:

AUX.

3:

EIlERGENCY

4:

GROUND

JUIlPER{Sl

TERMINALS

.IFIREBOY"

:TERMINALS

"EMERGENCY

BATTERl

0

o

STARTER

UN

I T

CAN

RESTART

U!iITCAN

RESTART

t'&

12

VDC

o

WIRING

IN

COIL

tie

tl6

till

BlK/RED

YEL

!IlK

I'

~

116 liE

tl6

BLl!

~12.5-18.6n

EXCITER

taO

CARS

STARTER

SOLeNOID

rUSE

lOA

TERM I HAL

ItJ

SJlUTDOWN

STOP

(.J

.

MUST

BE

REMO'l£D

1 & 2

ARE

FOR

CONNECTION

3 & 4

ARE

FOR

STOP

SWITCH"

OHMS

12.5

-18.5a

.EXCf1ER

COIL

[ONITlON

MOOUL.E

COIL

.

./'

SOLENOID

..

4.lD

START

SOLENrJJO

DIAGRAM

IN

BLACK

;

liB G IRED

"

ITALIC

con.

RElAY

J

<i!0C1

-@@W

-

-<V®Gl

PANEL/REMOTE

CONTROL

CONNECTOR

PC

BOARD

;

."

I

116

tl6

tl60RG

tl6

#16

tl6

LK

(;

ORG

o

~

•

@.~

ENGINE

CONTROL

RED/WHT

BLK

YEL RED

GRN

118

RG

OJ)

,

COHNECTOR

PC

BOARD

IGNITION

COIL

IF B HT

"

ACTUATOR:

S.O·

01114

BlK

+

I

H-

I

,~

In

2:

'~'

11016

BLK

SPARK

PLUGS

OIl..

PResS

SWITCH

EXHAUST

.....,ERA11JI\E

SWITCH

a.1a

ACTUATOR

HOUR

METER

·

•

100

START/STOP

SWITCH

~

PART

NUMBERS:

REMOTE

STOPJSTART

PANEL

#048056

PANEL

EXTENSION

. Engines & Generatars

32

HARNESS

15FT

#048200,

30

FT

#048201

GENERATOR

INFORMATION

USE

OF

ELECTRIC

The

power

more

than

Some

motors

others.

Split-phase

under

similar

monly

used machines, started, 7 avoided, driven induction

to start

varies nected current

In

to

more

for

such

tiroes

as

whenever

by a small

as

with

to

an air

than a motor

general,

mediwn

MOTOR

(HP)

1/6

1/4 1/3 1/2

3/4

1

"NOTE:

made

Because motors be damaged seconds. off

for

this

in

all

other electrical

on

the electric

In

some

is

larger

the

is

If

required

is

on

or much current

motors

to

the load

the

starting

SIZE

the

to

required

require

(AC)

circumstances,

easy-starting

where

loads

as

small

possible,

generator.

require

run.

The

connected

compressor,

to

current

required

loads

above

table

small

that

the

hankst

sizes.

heavy

surge

required for

if

it

can

difficulty

motor.

MOTORS

start

an

electric

to

keep

it

runniog

much

more

current

motors

require

than

other

loads,

are

applied

power

tools.

to

start

as

if

the

electric

Capacitor

from 2 to 4 times

current

required

to

it.

for

example,

which

no

load

to

start

will be

approximately

AMPS

FOR

RUNNING

(AMPERE:st

3.2

4.6

-

5.2

7.2

10.2 13

the

maximum

motors

than

for larger

starting

of current needed

only

an

instant,

bring

the

motor

is

experienced

loads

and,

if

motor

after

to

more

types.

such

as

washing

after the Because to

run,

their

motor

and

repulsion-

as

to

start

An electric

will require

is

connected.

115,Volt

Amps for

types

(split-phase)

the generator

up

to

in starting

possible,

is

considerably

it

is

started.

start'

them

current

They

are

motor

they

require 5

use

should

is

to

much

current

any

motor

motors

connected

as

follows:

AMPS

FOR

STARTING

(AMPERES)

6.4

to

22.4'

9.2

to

32.2'

10.4

to

72.8'

14.4

to

29.2'

20.4

to

40.8'

26

to

52

Starting

ones.

The

for

starting

will

speed

in a

motors,

reduce

the

than

to

start,

com-

is

be

con-

more

reason

are

few

torn

load

to be

not

is

Required

Run generator's indicted should

the

generating monitor amp

Generator

Maintaining

teoninal boards

of insulation surfaces

exhaust, ventilation reduced

In

addition

inspected

overheated teoninals

Generator

BPMGModel

Should a failure Model adjustments free.

NOTE:

drive

BCModel Refer

the

generator

on

be

checked

voltage and

probe.

carbon,

life

for

(no

Contact

It

would

belt

to

BCG

under

Operating

first capacity, the

generators

plant

Maintenance

reasonable

etc.

openings

of

windings.

to

periodic

tightness

Failure

occur

AC

output).

to

the

you

be

the

Troubleshooting

Speed

with

no

load

applied,

and

finally

loaded

to

data

plate.

The output voltage

periodically

and

load,

and

rectifiers

may

are

may

cleaning,

of

andloose

in a permanent

generator.

WES1ERBEKE dealer

important

generator

to

the

appliances

check

it

cleanliness

may

start

conducting

allowed

cause

excessive

the

all

counections,

or

do

not

attempt

The

first

base

in the following

ensure

it supplies. To

with

a portable meter

is

important. Connections

become

to

build

generator

damaged

magnet

to

generator

to

inspect

frame.

then at half

its

full

proper operation of

corroded,

if

salts, dust,

up.

Clogged

heating and

should be

evidence of

wires.

- BPMG

make repairs or

is maintenance

or

distributor.

capacity

engine

the

as

and

the pulley and

pages.

~

WESTERBEKE

Engines & Generators

33

, .

NOTE:

Refer

Wiring

Schematic

DIAGRAMS FOR

BOTH

ARE

MODELS

BCGIBPMG'DESCRIPTION

to

the

following and BeG

RED

ISO"'"0N

REFER

i

.;

. 3600

i 50Hz 230

page

for

Winding

F'OST,

ALso

BRUSHLESS GENERATOR

Engine RPM at generoJot turns at

(60Hz)

60Hz 120

the

BeG

Resistances.

BLACK

TO

CAPACITOR

(BCG)

2200

3000 Volts/25 Volts/13

internal

o

AC

CIRCUIT BREAKER

THE

(50Hz)

Amps Amps

and

SPECIFICATION

TROUBLESHOOTING

PAGE

TROUBLESHOOTING

CAUSE

No

AC

Output

Voltage

Residual

Line-

No

Low Voltage

AC InduJ:\ive

Refer Schematic

Voltage

Neutral

Load

AC

Output 60 -100

Voltage

Load

to

the

at

Drop

following

and

the

Volts

with

BeG

CHART

FAULT

Shorted

1.

2,

Open

3.

Shorted Shorted

4.

Shorted

5 .

6,

Open Faulty

1.

2,

Open Shorted

3.

Faulty

1. Faulty

2.

3,

Faulty

1,

Faulty

.

Faulty

2.

3.

Amperage

page for

.Winding

(BCG)

Stator.

Rotor

Rotor Rotor

Rotor

Diode.

Capacitor.

Exciter

Winding.

Exciter

Rotor

Diode.

Rotor

Winding.

Exciter

Capacitor.

Rotor

Diode.

Exciter

Capacitor.

Overload.

the

BeG Internal

Resistances.

Diode. Thermister. Capacitor.

Winding.

Wiring

BCG/BPMG

CONNECTIONS

AC

OUTPUT

DIAGRAM

WHITE

~r.··"=~~l

I~}-

220V-5DHZ

BLACK"

230V/50Hz

\

REO

IS.P!ATION.

~T

"'.

AC

o

CIRCUIT BREAKER

!WHITE,.

PERMANENT GENERATOR

. Engine RPM at

generator

3600 60Hz 50Hz

p,ms

(60Hz)

120

Vtilts/25

230

Volts/13

'.

MAGNET

(BPMG)

2200

at

3000'

(50Hz)

Amps Amps

TROUBLESHOOTING

CAUSE

No

AC

Output

Voltage

Low

AC

Output

Voltage

60

·100

.

Voltage

Drop

Under

Load

WINDING

PM hertz

50

bertz

NOTE:

assembled. must

IR

,

NOTE:

belt

RESISTANCE

(pennanent

model resistancds measured between

models

The

permanent

If

an

be

replaced.

It would

under the

generator

Volls

Magnet)

is

0.8

magnet

electrical

be

important

CHART

FAULT

1.

Shorted Open

1.

Faulty

1.

Generator

(Measu

stator

winding

ohm.

style

fault should

to

base

frame.

(BPMG)

Stator

Winding.

Stator

Winding.

Rotor.

Overload

red

at

resistance

generator

occur,

inspect

the

.

20°C/68°F)

0.4

ohm

line

and

neutral.

can

not

be

the

generator

pulley

and

drive

dis-

Engines & Generators

34

BCG

WINDING

,

RESISTANCES/INTERNAL

.~~..

WIRING

..

. i ... . . --

DIAGRAM

..

.r.-'-.'AO'Tn"

~.~

.

BCG

BACKEND

COMPONENTS

(TOP

VIEW)

.~--

-

60

Rotor Excitor Capacitor

. - -

Hertz Models: Stator Winding 0.93 Ohm/winding.

Winding·

Rating·

_..

4.0 Ohm Rotor

2.0

Ohm Excitor

34

uF Capacitor

~

CAPACITOR

..-

REsllsrAiNcE

----

..

....

THESE

COMPONENTS

ARE

LOCATED

.

ROTOR

--'lIlC

-

(Measured

50

at

20°C/68°F)

Hertz Models: Stator Winding

Winding·

Rating·

.TEI~MIIIAL

--~

4.0

Ohm

2.5 35 uF

BLOCK:

.

Ohm

ON

1.35

Ohm/winding

THE

•.

'

BCGINTERNAL

ROTOR

I

'N

WHilE

I . .

i

120V

'-

I

I L

BLACK

I

I.

I

AC

CAPACITOR

TERMINAL

BY-PASSING

An unwanted shutdown or

and

then shuts down can be caused

board.

1.

Refer to the Wiring Diagram in

2.

Unplug the brown #6 wire that connects between of the

15

pin plug connector and wire plug connection components.

3.

Without unplugging place a jumper between connection #30 and

if

the engine runs

by

this

the

is

in

the harness between

any

connections

a faully over-speed

manual.

ignition

on

the coil

..

10-15

module.

#87.

•

,.

BOARO

seconds

the

two

relay,

WIRING

.

STATOR

.

'

..

THE

OVERSPEED

#12

The

BROWN

WHITE

BLACK

4.

Manually controlling #30 and

physically controlling the actuator/throttle keeping engine speed continues

board exists.

NOTE:

generator

run

under normal

DIAGRAM

I

r-

.

L...-

BLUE

BOARD

at

a low comfortable range:

to

run

more than

The

above

should

with a by-passed

use.

This

EXCITOR

rl'

ii

,REO

RED

i~

.1

15

only

be overspeed can

#87,

seconds, a faully

performed

present a

start

board

hazard.

..

the

engine

If

the

as a test.

should

the

engine

overspeed

The

not

be

~

WESTERBEKE

Engines & Generators

35

LAY-UP

AND

RECOMMISSIONING'

GENERAL

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

The procedures which follow own lay-up and recommissioning, others

do

the

procedures.

These procedures should afford your engine protection

during a lay-up and maintenance needs

If

you

have

any questions regarding lay-up procedures, call your local servicing dealer; he provide assistance.

ENGINE

If

more,

fresh and the impellers stowed in a for

page.

COOLING

the engine will be out

the

engine's cooling passages should be flushed with

water.

Also the water purnp(s) should be disassembled

flushing

LUBRICATION

With the engine

oil

sump.

Remove and replace

with

new

oil.

ENGINE

oil changing procedure. Run the engine and make sure there are

LUBRICATING

no

leaks.

A

CAUTION:

lubricating Lubricating produce

your

harmful

engine's

also

of

(Raw

the

cooling system are shown on the next

SYSTEM

warm,

Use the correct

00

011

in

the

011

and

chemicals

intemal

will

allow

you to perform your

or

to

use as a check list

help familiarize you with the

your

engine.

will

be more than willing

Water

Cooled

of

commission for 3 months or

cool,

dark area. Instructions

drain all

";"

liot

sump

combustion

the

grade

OIL

pages

leave

oVllr

which

the

lubricating oil from the

oil filter and

of oil. refer to the

in this manual for the

the

engine's

the

lay-up

deposits

can

reduce

parts.

the

Models)

fill

the

old period.

combine

the

to

sump

to

life

if

of

INTAKE

Clean cloth block thru-hull

start-up!

FUEL

Top

or should separator certain

STARTER

Lubrication

advisable, removed. before attempting to remove the replacing

MANIFOLD

the

filter screen

lightly

soaked

any

opening.

exhaust port. Make note

Also

SYSTEM

off your fuel

higher.

be

and

there

tanks

A fuel conditioner such

added.

Change the element

clean

are

no

MOTOR

and cleaning

the pirtion

Make sure any

electrical connections removed from the

in

the flame

in

lube oil around

place an oil-soaked cloth

with

the

metal bowl. Re-install

leaks.

Clean up

of

is

accessible

the

battery connections

arrester,

the

to

remove

unleaded

the starter drive pirtion is

g":,oline

as

stabil gasoline stabilizer

in

any

when

starter.

and

place

a clean

flame

arrester to

in

the

cloths prior to

~f

89

oc~e

your gasoline/water

and

make

spilled fuel.

the flywheel cover

are

shut off

Take

care

in

properly

starteI:

SPARES

Lay-up

time

provides a WESTERBEKE belts

or

coolant hoses

spares

kit and order

used

during

the lay-up, such as

to

the

SPARE

PARTS

engine

need

items

section

good

opportunity to inspect your

to

see

if

external items such as drive

replacement. Check your basic

not on hand,

of

filters

this

or

'7place those items

and

zmc

anodes. Refer

manual.

BATTERIES

Ifbatteries are to be left on board during the lay-up period,

make

sure

they are

to

prevent

them from freezing. the batteries will not remain fully charged, or that they will be

subjected

the batteries and store them in a

environment.

fully

charged, and

to severe enviromnental conditions, relllove

will

remain that

If

there exists any doubt that

warmer,

more compatible

is

way,

"y

WESTERBEKE

Engines &

36

Generators

.

RECOMMISSIONING

The

recommissioning seasonal those section regarding preparation However, counteracted before starting

1.

2.

3.

lay-up generally

presented

some of

Remove intake

Reinstall lay-up tenninals Check remove proper Make and

the

manifold,

the

and

are

to

make

the

tightness.

certain the

the thru-hull

of

in

the

PREPARATIONS

the

lay-up

any

rags or

flame

batteries

reconnect

clean

and

sure

spark

plugs,

cooling valve

your

WESTERBEKE

follows

for

starting

procedures

the

engine.

that

were

arrester.

that

were

the

battery

that

the

batteries

wipe

system

is

open.

I

FLUSHING

LAY-UP

engine

the

same procedures

FOR

STARTING

and

nonnal

will

need to be

placed

in

the exhaust,

removed

cables,

connections

are

clean,

fully

re-gap,

intake

during the

making

are

charged.

and

hose

is

THE

AND

RECOMMISSIONING

after

a

as

starts.

sure

the

tight.

install

to

attached

ENGINES

4.

Check

the condition of

clean

or replace the

5.

Check

the condition of the

replace

as

needed.

6.

Make

certain all electrical

the

correct position

generator

7.

Inspect necessary.

8.

Start the engine in

described

section

at

the fresh water

(Fresh

in the

of

this

COOLING

the

zinc

anode

as

heat

(Fresh

Water

connections

and

there

start

up.

(see

GENERATOR)

pump

Water

Cooled

accordance

PREPARATIONS

manual.

SYSTEM

anode

needed.

exchanger

Cooled

are

no-loads

impeller,

Models)

with

the

FOR

REMOVE

THERMOSTAT

DON'T

FORGET

REPLACE REPLACE

AND.

COVER

GASKET

in

the

circuit and

zinc,

Models)

and

switches

on

the

replace

if

procedures

STARTING

'--.

TO

clean or

are

in

RAW

WATER

The

cooling operating hours or when

This procedure water intake intake valve before disconnecting tbe bose. Insert the end

into

Before

(replace of

water

Hushing

NOTE:

pass

no obstructions occurring

Provide maintain the water level in operated during the

system should

is

best

hose

from

a large container of

starting the

the gasket and

thru the

is complete.

Prior

hose

and

an

exteroal fresh

to

flushing its

engine.

engine,

attachment

be

stored

accomplished

the

vessels

fresh

remove

cover)

..

Re-insta11

the

engine,

fittings

in

the

water

the

flushing

process.

flushed

out every

for

the winter

by

disconnecting

thru-hull

water.

the engine thennostat

This

will

the thermostat once

inspect the coolant

fittings

supply

bucket

fitting.

ensure a full

to

insure

or the

for

the

while

the unit

5QO

that

there

hose.

bucket

Close the

flow

is

the

hose

by-

are

to

being

EXTERNAL

•

A.

CAUTION:ob

supply

directly

cause

gooding

to

of

not the the

damage.

Run

the

unit for

cooling

the exhaust lines. probability then supply through for

When

system.

fresh water will

prior

with

the

both the engine and exhaust

recommissioning, se.cocks water.

if

water

can

10

If

the engine is

of

freezing,

to

shutting

a concentrated

engine

are

open

the engine

stay

in the engine.

minutes

flush

the

to

provide

so

the engine

is

stowed

WATER

SUPPLY

connect }i!gine's engine

or

out the

flush

unit

antifreeze

make

FRESH

an

cooling

resulting

longer to

engines

being

the

'engine

down

freeze

system.

certain

will

where

external

system. in

adequately

water

stnred

and

with

substitote

mixtore

and

corrosion

the

valves

quickly

it is

warm,

fresh

This

internal

passages

there

fresh

water

the

fresh water

and

run

protection

and

receive

the

water

can

flush

is

a

this

fresh

the

and

Engines & Generators

37

3.0

KW

BCG/BPMG

GENERATOR

SPECIFICATIONS

Engine

Type

Bore & Stroke

Total

Displaoement

Beanngs

Valve

System Compression Rnng Aspiration

Direction Inclination Dry

Governor

Fuel

Fuel Ignition Ignition Flame Carburetor Fuel

(Full Ignition

Ratio

Order

of

Rotation

Weight

Pump

Timing Coil

Arrester

Consumption

Load)

Timing

ENGINE

SPECIFICATIONS

Two

2.32 x 2.36

20.01

Two

Overhead 9:1 1 - 2 Naturally

Counterclockwise 25' 1651bs Electronic

FUEL

Mechanical Unleaded

BTDC 12

vall. Metal Single

0.4

12-Volt

cylinder,

four

inches

Cubic

Inches

main

bearings.

cam-cross

aspirated.

maximum

(75

angle

Kg)

SYSTEM

fuel

pump.

89

octane

25'

(not

adjustable).

screen

Iype.

barrel

side

GPH @ 2200

flywheel

stroke

gasoline

(59 x 60

(.33

liter)

flow.

viewed

from

of

operation

or

higher

draft.

RPMl25

Amps

magneto.

engine,

mm)

the

gasoline.

back

end.

General Raw

Water

Raw

Water

(into

water

exhaust

elbow)

Operating

Type

Temperature

Speed

3.0Kw

Spark

Plug

Spark

Plug

BoltTorque

Engine

Combustion

Generator

Cooling

COOLING

Pump

Flow

injected

AC

GENERATOR

TUNE-UP

Gap Torque

AIR

SYSTEM

Water

cooled

via

raw

water

pump.

Positive

displacement

belt

dnven.

1.75

GPM

(before

2.0

GPM

(thermostat

140'F

(60'C)

(SINGLE

Permanent

3600

3.0 2

RPM

KW -60

wire,

magnet

160Hz.

25

amp.

thermostat

Hz

single

Iype,

rubber

open)

PHASE)

generator

phase,

SPECIFICATIONS

0.032 -0.035in 11

-15Ib-ft

See

TORQUING

(0.8 -0.9mm)

(15 -20

Nm)

THE

CYLINDER

REQUIREMENTS

13

CFM

(0.287

cmm)

200

CFM

(5.66

cmm)

impeller,

opens)

120

volts

HEAD.

Start

Motor Starting Battery Battery DC

Amperage

Type Oil

Riter

Oil

Capacity

Oil

Grade

Battery Capacily Charging

Draw

ELECTRICAL

12-Volt

12-Vott, 600-900 11

Amp

70

Amps

LUBRICATION

Wet Fuel

1.5

API

SAB

reduction

(-)

Cold

sump flow,

qls.

(91.4

SJ,SL

IOW-30

SYSTEM

gear

negative

Cranking

DC

SYSTEM

system

paper

element,

L)

or

SM

or

with

ground

Amps

trochoid

15W-40

solenoid.

(CCA)

Iype

pump.

spin-on

disposals.

Cooling

System

Fresh

Water

Pump

Raw

Water

Raw

Water

(into

water

exhaust

elbow)

Operating

FRESH

(coolant)

Pump

Row injected

Temperature

WATER

COOLED

Fresh

water

controlled

Positive

driven

Posnive

driven

1.75

2.0 140' F (60'C)

cooled

thru a heat

displacement,

GPM

(before

GPM

(thermostat

MOOELS

block,

thermostatically

exchanger.

rubber

impeller

rubber

impeller

thermostat

opens)

open)

bett

belt

Engines & Generators

38

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(It) x .305 = Meters

Miles x 1.609 = Kilometers

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

CONVERSION

DATA

DISTANCE

EQUIVALENTS

1

Degree

of

Latitude = 60

1

Minute

of

Latitude

VOLUME

Cubic

Inches

(in') x 16.387 = Cubic Imperial Imperial Imperial Imperial

Fluid

Pints

(IMP

Quarts

(IMP Gallons Quarts

(IMP

Imperial

US US US

Gallons

Ounces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

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

Quarts

(US

qt) x .946 = Liters

Gallons

(US

gal) x 3.785 = Liters

MASS-WEIGHT

Ounces

(oz) x 28.35 = Grams

Pounds

(Ib) x .454 = Kilograms

PRESSURE

Pounds

Per

Sq

In

Inches

of

Mercury

Inches

of

Mercury

Inches

of

Water

Inches

of

Water

Inches

of

Water

Nm = 111.120

= 1

Nm = 1.852

pt) x .568 = Liters

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

qt) x 1.201 = US

(IMP

gal) x 1.201 = US

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

(psi) x 6.895 = Kilopascals

(Hg) x .4912 = psi x 2.036 = Hg

(Hg) x 3.377 = Kilopascals (HaD) X .07355 = Inches (HaD) X .03613 = psi x 27.684 = HaD

(HaD) X .248 = Kilopascals

km

Centimeters x .061

(L) x 1.76 = IMP

(L)

x.88 = IMP

(L) x .22 = IMP

Quarts

(US

qt) x .833 = IMP

Gallons

(US

(L) x 1.057 = Quarts

(L) x .264 = Gallons

(kPa) x .145 = psi

(kPa) x .2961 = Hg

of

Mercury x 13.783 = HaD

(kPa) x 4.026=

.'

=in'

pt

qt

gal

qt

gal) x .833 = IMP

HaD

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH) x 1.609 = Kilometers

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles

Kilometers

(Hp) x .745 = Kilowatts

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

(OC) = (OF -32) x .56

LIQUID

WEIGHTS

Diesel

Oil

Fresh

Water Gasoline Salt

Water

= 1

US

= 1

US

gallon = 6.1

US

(in-Ib) x .113 = Newton

(ft-Ib) x 1.356 = Newton

(Kw) x 1.34 = MPH

(MPG) x .354 = Kilometers

(Km/L) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(Km/L) x 2.352 = US

(OF) = ('C X 1.8) + 32

gallon = 7.131bs

gallon = 8.33

gallon = 8.56

Ibs

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = It-Ib

Hour

(KPH) x .621 = MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

~

WESTERBEKE

E!!9iI!!.S

39

&

Gent!~ators

DECIMAL

TO

METRIC

EQUIVALENT

CHART

Fractions

an inch

of

Decimal (in.)

1/64 1/32 0.03125 0.79375 17/32 3/64

1/16 5/64 0.078125 1.98437 37/64 3/32 7/64

1/8 9/64 5/32

11/64

3/16·

13/64

7/32 0.21875 5.55625 23/32

15/64 0.234375 5.95312 47/64

1/4

17/64 0.265625 6.74687 49/64

9/32

19/64

5/16

21/64

11/32

23/64

3/8 25/64 13/32 0.40625 10.31875 29/32 27/64

7/16

29/64 0.453125 11.50937

15/32 31/64 0.464375 12.30312 63/64

1/2

.

Metric (mm)

0.015625 0.39688 33/64

0.046875 1.19062

0.0625 1.58750

0.09375 2.38125 19/32 0.59375

0.109375

0.125

0.140625 3.57187 41/64 0.640625

0.15625 3.96875 21/32 0.65625

0.171875 4.36562 43/64

0.1875 4.76250 11/16 0.6875

0.203125

0.250

0.28125 7.14375 25/32 0.78125

0.296875 7.54062 51/64 0.796875

0.3125 7.93750 13/16

0.328125

0.34375

0.359375 9.12812

0.375 9.52500

0.390625 9.92187 57/64 0.890625

0.421875 10.71562

0.4375 11.11250 15/16

0.46875 11.90625

0.500 12.70000 1

2.77812 39/64

3.175

5.15937 45/64

6.35000

8.33437

8.73125 27/32

Fractions of

.

an inch

35/64

9/16

5/8 0.625

3/4

53/64

55/64

7/8

59/64

Decimal (in.) Metric (mm)

0.515625 13.09687

0.546875

. 0.828125

.61164>

·31/32

0.53125 13.49375

13.89062

0.5625

0.578125 14.68437

0.609375 15.47812

0.671875 17.06562

0.703125 17.85937

0.71875 18.25625

0.734375 18.65312

0.750 19.05000

0.765625 19.44687

0.8125 20.63750

0.84375 21.43125

0.859375 21.82812

0.875 22.22500

0.90625 23.01875

0.921875 23.41562

0.9375 23.81250

0.953125 24.20937

0.96875 24.60625

0.984375 25.00312

1.00 25.40000

·14.28750

15.08125

15.87500

16.27187

16.66875

17.46250

19.84375

20.24062

21.03437

22.62187

~

WESTERBEKE

Engln.es

40

& Generators

METRIC

CONVERSIONS

INCHES

Inches

1 25.40 2 3 4 5

10

mm

50.80

76.20

101.60

127.00

254.00

MILLIMETERS

INCHES

Inches Meters

1 2 3 4 5 0.1270 6 0.1524

0.0254

0.0508

0.0762 9

0.1016

TO

CONVERT

METERS

YARDS

Yards

1 0.91440 2 3 4 5

Meters

1.82880

2.74320

3.65760

4.57200

MOVE

DECIMAL

TO

MILLIMETERS MILLIMETERS TO INCHES

Inches

15 20

25 30 35

40

= 1

CENTIMETER,

TO

METERS METERS TO INCHES

Inches

7 0.1778 0.1 3.937 8 0.2032 0.2

10

11

12

TO

CENTIMETERS,

TO

METERS

Yards

6 5.48640 1 7 6.40080 2 2.18723 8 9 8.22960 4

10

POINT

FOR

mm

381.00 _

508.00 2 0.0787 20

635.00 3

762.00 4 0.1575 30

889.00 5 0.1969 35

1016.00 100

CENTIMETERS

Meters

0.2286

0.2540 0.4

0.2794 0.5

0.3048 0.6 23.622 MOVE

mm

1 0.0394 15

10

= 1

Meters

0.3

DECIMAL

Inches

0.1181 25

0.3937 40

METER = 39.37

Inches

7.874 0.8

11.811 0.9

15.748 1.0

19.685

POINT

TWO

PLACES

METERS TO YARDS

Meters

7.31520

9.14400

HIGHER

VALUES -e.g.

Meters

3

5

6,000

Yards

1.09361 6

3.28064 8

4.37445 9

5.46807

METERS = 6,561.68

INCHES

Meters

(3.3

FEET)

THE

RIGHT

YARDS

Inches

0.5906

0.7874

0.9843

1.1811

1.3780

1.5748

Inches

27.559

31.496

35.433

39.370

43.307

47.244

Yards

6.56168

8.74891

9.84252

mm

0.7

1.1

1.2 TO

7 7.65529

10 10.93614

POUNDS

Ib

1 2 3 4 5

kg

0.454

0.907 7 3.175 2

1.361

1.814

2.268

GALLONS

. Gallons

1 2 7.57 3 4 5

Liters'

3.79

11.36

15.14

la93

PINTS

Pints

1 2

3

4

5 2.37

32 40

Liters

0.47

0.95

1.42

1.89

50

I I I

I I I I I

o 5

10

TO

KILOGRAMS KILOGRAMS TO POUNDS

Ib

6 2.722 1

8 3.629 3 9

10

TO

LITERS LITERS TO GALLONS

Gallons

10 20 30 40 50

TO

LITERS LITERS TO PINTS

Pints

6 2.84 1 7 8 3.79 9

10

kg kg

4.082 4

4.536 5 11.023

Liters

37.86 1

75.71 2 0.53 90

113.57 5

151.42

189.28 20

Liters

3.31

4.26

4.73

Liters

10

Liters

2

3

4

5

Ib

2.205 6

4.409 7 15.432

6.614 8

8.818 9

Gallons

0.26 60 15.66

1.32

2.64 150

5.28 180 47.54

Pints

2.11

4.23 7 14.79

6.34 8

8.45 9

10.57

Liters

120 31.32

Liters

TEMPERATURE

60

I

15

70

75

I

I I

20 25

85

I I

30

95

105 140

I I I I

I I I I I

40

35

175 212

60

kg Ib

13.228

17.637

19.842

10

6 12.68

10

80

22.046

Gallons

23.77

39.62

Pints

16.91

19.02

21.13

100

OF

°C

~

WESTERBEICE

_E.tl!1'nes

.

&

41

~erBtors·

I

L

CONTACT

WESTERBEKE

YOUR

WESTERBEKE

SUGGESTED

MARINE·

DEALER

SPARE

GASOLINE

FOR

SUGGESTIONS

PARTS

GENERATORS

AND

ADDITIONAL

INFORMATION

.

'GASOLINE

IMI'I:LLtllli,

AND

GLYCERIN

.

WESTERBEKE HAVING FOR

ENOUGH

AT

LEAST

O-RINGS;

TUBE

'.

ALSO

RECOMMENDS

OIL

ON-BOARD

ONE

OIL

CHANGE

~

THERMOSTAT

iANDGASKET

.

-~

;

10A

FUSE

I,

(ON

SlOE

•

CONTROL

..

iiiL

,

OF

PANEL).

=F""'ILT'=ER""

FUEL

FILTER. CARTRIDGE AND

O-RINGS

-

'.

-T--.-1-.

. "'---

'ZINC

ANODE

------.-

--------

WESTERBEKE also

i each packaged in a rugged

, Kit A includes the

i Kit B

,

1

is

for

more extensive

KIT

A

IMPELLER OIL

FILTER

GENERATOR

ZINC

ANODES SPARK 20A

FUSE WATER FUEL

FILTER

10A

FUSE HEAT

EXCHANGER

offers

basic

KIT

DRIVE

WITH

PLUGS

PUMP

KIT

two

hinged

spares,

off-shore

BELT

ZINC

Spare

toolbox,

cruising,

BELT

GASKET',

Parts

SPARE

Kits;

"'"

PARTS

KITS---"------

WESTERBEKE

~nglnes

&

Gen_tlf1ltors_

.42

•

KIT

B'

IMPELLER OIL GENERATOR

ZINC

SPARK

20A WATER FUEL 10A COMPLETE THERMOSTAT

WATER OIL HEAT

KIT

FILTER

ANODES

PLUGS

FUSE

PUMP

FILTER

FUSE

GASKET

PUMP

PREIiSJjRE

EXCHANGER

DRIVE

WITH

BELT

KIT

REPAIR

SWITCH

ZINC

BELT

GASKET

SET

KIT

~

WESTERBEKE

Engines & Generators

1153612011

Westerbeke 3.0KW BPMG, 3.0KW BCG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual