Westerbeke 20.0 BEDA, 25.0 BED, 16.0 BEDA, 25.0 BEDA, 20.0 BED Operator's Manual

OPERATORS

MANUAL

.MARINE

20.0

25.0

32.0

BEDA
BED

BEDA

DIESEL

·

Single

60

Hz

60Hz;

60

Hz

and

GENERATORS

16.0
20·

..

25.0

Three

BEDA

0·

BED

BEDA

Phase

50
50

50

·

Hz
Hz

Hz

PUBLICATION. N0.039685

REVISIONS

AUGUST 2017

WcSTERBEKECORPORATiON

MYLES

STAND{.S,f!

'WEBSITE; WWW.WESTERBEKE.COM '

,«"""'

.....

.....,'A(1f.A

Member

INDUSTRIAL

National

•1SOJ0HNHANCOCK

PARK • TAUNTON

Marine

Manufacturers

ROAD

MA

02780

Association

PROPOSITION

Diesel engine exhaust and some
of

its constituents are known to

the

State
cancer, birth defects, and other
reproductive harm.

Exhaust
colorless
unconsciousness
exposure

•Dizziness

•Nausea

•Headache

•

gasses

gas.

can

Weakness

contain

Carbon

include:

and

Sleepiness

CALIFORNIA

of

California

A

Carbon

Monoxide

and

death.

65

WARNING

to

cause

wARNING~

Monoxide,

is

poif¥Jnous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

•Inability

an

odorless

and

of

Carbon

in

Temples

Twitching

to

Think

and

can

cause

Monoxide

Coherently

IF

YOU
GET
seek
until

OR

ANYONE

OUT

INTO
medical
it

has

THE

attention.

been

inspected

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

ANY

OF

THESE
IMMEDIATELY.
down

the

repaired.

unit

If

_and

SYMPTOMS,

symptoms

do

not

restart

persist,

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this

caused
precautions.
take

personne~

The
the American Boat and

PREVENT

A

while
power.

11

11

II

II

11

PREVENT

A

exhaust
hot/

11

Monitor engine
coolant
location
when

A

Ill!

In

before touching

sqfety

manual

by

failure

the

necessary

following safety instructions

WARNING:

engine

Lethal

Do

not operate

enclosures
Shut

off electrical

equipment.

Use

insulated

equipment.·
Make

sure your clothing

(particularly
Remove

electrical

to

foUow

Know

when

precautions

and your

ELECTRIC

wristwatch

equipment.

Is

running.

voltage

this

and

covers

mats

shoes)

machinery.

Yacht

SHOCK

Do

not

Is

machinery without electrical

power

whenever

when

and

BURNS -HOT

WARNING:

system

recovery

the

WARNING:

case of an engine

Do

not

components. A running

antifreeze

tank

on

the

water

jacketed exhaust

engine

is

COLD.

Steam

overheat,

the

engine or checking the

carefully.

fundamental

dangerous

touch

or

present

in

all jewelry

Most

accidents

rules

conditions

to

protect

are

Council

AC

when

place.
before accessing electrical

working

and

skin

handling electrical

yourself,

in

compliance

(ABYC)

electrical
connected

at

these

connections/

on

electrical

are

dry,

when

working

connections

not

ENGINE

touch

hot

engine

parts

engine

coolant

and

periodically

can

cause

allow

level

manifold,

Injury

the

at

the

at

the

or

engine

death/

coolant.

are

and

exist

and

your

with

standards.

to

shore

damp

equipment.

on

or

gets

very

plastic

filler

cap

but

only

to

cool

PREVENT

A

.

11

Prevent

sparks
pump,
vapors.
removing the

m

Do
Backfire

II!!

Do

the
engine/generator
chances

l!il

Be

PREVENT

A

Injury

I!Rl

Follow
hatches
after
running
before starting your

II!!

All
when
ventilated area
and

!FJ

Do

~

Shut
the
spill.
sources
servicing.
the

l1ll

Do

m Be

rm

Be
free

~

Make

properly maintained. Be
Extinguishers rated
for

BURNS-

WARNING:

flash

fires.

to

occur near

or

other potential

Use

a suitable container

fuel

not

operate

can cause

not

smoke or pennit

fuel

system.

of

fire.

aware-

WARNING:

or

fueling.

fuel

out of

not

off

fuel

DO

fuel

not alter or

sure

certain

of leaks.

sure a

all

diesel

BURNS

death/

re-fueling safety instructions.

closed

Check

the

blower.

vapors

handling

the

reach of

fill

the

fuel

the

fuel

system.

Nar

of

fire

near

Ensure proper ventilation

system.

modify

all

fuel

fuel

fire

applications encountered

FIRE

Fire

can

Do

not

the

line,

carburetor,

with

the

severe

Keep

the

clean

and

Wipe

up

fuel

-EXPLOSION

Explosions

when

fueling.

below

Run

engine.

are

highly

and

storing

away

from

children.

tank(s)

service

valve

Take

care in

allow

any

the

fuel

the

supplies

line

extlDguisher

have a positive

fittings

familiar

ABC

cause

InJury

or

smoke

or

permit

carburetor,

sources

air cleaner/silencer

injury

flames

compartment

free of

all

spilled

will

from

for

the

blower

explosive:

fuels.

spark-pr9ducing

while the engine

smoking;·

system

fuel

are

is

by

the

fuel

of

spilled

to

catch

or

fuel

or

death.

or sparks

debris

fuel

burn.

fuel

vapors

Keep

Open

and

fumes/vapor

for

Use

Store

at

the

engine

catching

any

open

qr

engine

exists

system.

adequately

installed

with

its

Nf.PA

in

this

line,

and
and

ventilate

four

extreme

fuel

flames,

shutoff

nearby

proper

are

environmen~.

death!

flames

filter,

fuel

or

all

fuel

when

filters.

removed.

to

occur

the

to

minimize
engine

can

cause

the

vessel's

cabin

before

minutes

care
in a well­equipment

is

runnir!g.

when

servicing

fuel

that

or

when

when

servicing

valve.

tightened

and

use.

appropriate

or

fuel

fuel

near

the

oil.

might

other

and

is

·

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

111

1\Jrn

unit's

OFF

the

battery

STARTING

Accidental

DC

breaker

selector

on

switch

starting

to

can

cause

the control panel or

OFF

before servicing the

engine.

111

Make

certain

all

personnel

starting.

11

Make certain
re-installed before starting the

BATTERY

A

WARNING:

or

death!

11

Do not smoke or

serviced.

being
highly
arcing
equipment
during servicing.

all

covers, guards, and hatches

EXPLOSION

Battery

allow

Lead acid batteries emit hydrogen,

explosive

or

gas,

by

lit tobacco products. Shut

in

the

vicinity

a Never connect the negative(-) battery cable

positive (
Do
together.
Ventilate
accumulation of explosive
disturb
is

a

Avoid
bums or
wristwatch, rings,
the

111

Always
the

and reconnect it last

BATTERY

A

severe

111

When servicing the battery or checking the electrolyte

level,
protection. Batteries contain sulfuric
destructive.
it
into
caps.

+) connection terminal of

not

test

the

battery condition

Sparks could ignite battery

any

compartment containing batteries

the

battery charger connections while the battery

being

charged.

contacting the terminals with

sparks

that could cause

and

battery.

tum

the

battery charger off before disconnecting

battery connections.

ACID

WARNING:

Injury

wear rubber gloves, a rubber

off at once

the

or

death!

If

it comes

with

eyes

inadvertently

Sulfuric

water.

are

clear of

engine.

explosion

an

open

which can

to

prevent

gases.

any

other jewelry before handling

Remove

when

servicing

acid

in

in

contact

Acid

may

when

the

can

cause

flame

near the battery

be

ignited

o~

all

electrical

the

starter

by

shorting the temunals

gases

To

avoid

tools,

etc.,

an

explosion.

the

negative

the

battery.

batteries

with

removing electrolyte

apron,

acid

your

splash

can

and

which

on

engine before

are

Injury

by

ele~tncal

arcmg

to

solenoi~.

or

fuel

sparks,

lead

skin,

the

injury

turn

the

~

elec~cal

the

vapors.

to

prevent
do

not

to

prevent

Remove

first

cause

eye

is

wash

skin

or

TOXIC

IB

a Be sure

a

IB

a

11

1111

AVOID

111

EXHAUST

A

WARNING:

Ensure that
discharged from

regularly

water-injected

the

Run

blowers

Do

not

run
equipped with a functioning
detector that complies with
boat builder or dealer
detectors.

For additional information, refer

(educational information

A

WARNING:

odorless

nausea

gas.

or

death!

Do

not

use

Diesel

fumes
systems.
copper tubing resulting in exhaust/water leakage.

Do
through portholes,
exhaust discharge outlet
enter
flow

Although
exhaust
gas
symptoms
poisoning

Vomiting
Dizziness
Headache
Nausea

Exhaust sulfur causes rapid deterioration of

not

install exhaust outlet

the

exhaust

of

exhaust.

fumes

is

present

MOVING

A

WARNING:

or

death/

Do

not

service
situation arises
make

operating adjustments, use extreme care
touching moving parts
components.

GASES

Carbon

the

exhaust system

for

leaks

elbow

unit

when

the

generator set

Carbon

Inhalation

copper tubing

can

diesel engine exhaust

from

in

or

signs

are:

monoxide

the

engine. Check

and

make

is

securely

and

its surroundings

running

the

ABYC

for

installation of

on

Carbon Monoxide).

monoxide

produces

in

diesel

rapidly

destroy

vents,

or

air conditioners.

is

near the waterline,

discharge

Avoid

diesel exhaust

of

outlet

overloading

gasoline

carbon

Inability to think coherently
Throbbing in temples
Muscular twitching
Weakness

PARTS

Rotating

the
in

engine

which

parts

while

it

is

and

hot exhaust system

(CO)

Is a deadly

is

adequate

the

exhaust

sure

the

exhaust

attached.

are

generator

or

engine

unless

marine

carbon

A-24.

to

ABYC

(CO)

Is

flu-like

exhaust

copper

where

exhaust

and

close

the

craft.

gases

are

engines,
monoxide

absolutely necessary

fumes.

and

can

cause

it

is

carbon

Some of

sleepiness

running.

gas!

to

expel

system

manifold/

well

ventilated.

set

or

engine.

the

boat

monoxide

Consult

approved

an

your

lli-22

Invisible

symptoms,

systems.

tubing

in

exhaust

can

be

If

the

water

or

restrict

not

as

toxic

monoxide

the

inhalation

or

injury

If

a

to

to

avoid

gases

is

drawn
engine

could

the

as

Engines & Generators

ii

1111

Do

not

wear

loose

clothing

~quipment;

nngs,

.

moving

Ill

Make
Keep

places

II

Do

not

.

the

engine

1111

Stay
when
be

caught

HAZARDOUS

A

WARNING:

avoid

necklaces

parts.

sure

all

protective

at

all

times.

check

is

operating.

clear

of

the

the

engine

in

these

NOISE

wearing

or

bracelets

attl:!-ching

shields

~uid

levels

drive
is

running;

rotating

High

nolsel~vels

loss/

1111

Never

operate

an

engine

111

Do

not

run

an

engine

with

removed

A

WARNING:

mentally

I!IIPE~TORS

·Many
in

your
notes
carefully,
procedures.

or

of

the

Operators

to

highlight

m~ntain

Do

not

physically

MANUAL

preceding

Manual
critical

your

Incapacitated

safety

information.

equipment,

or jewelry

loose

that

hardware

and

guards

or

the

shaft

and

nair

parts.

without its

the

work

on

tips

along

with other

when

jackets,

could

be

is

properly

in

their

·

drive

belt's

the

transmission

and

clothing

can

caus11

·muffler

air

intake

machinery

by

fatigue!

and

warnings

cautions

Read

and

follow

SAFETY·INSTRUCTIONS

servicing

shirts,

sleeves,

caught

tightened.

respective

tension

can

hearing

installed.

(silencer)

when

are1"epeated

your

manual

all

safety

in

while

coupling

easily

you

are

and

AIBYC,

..

DNSTAB.I!.ING

Read
for

tions

ABYC

"Safety
Order

the

safety

when

(American

Standari:ls

From:

NFIP'A

ANIDl

MARINE

following

codes

and

installing

USCG

!ENGINES

ABYC,

Boat

for

NFPA

standards.

your

UNlVBRSAL

and

Small Craft" ·

IP'UBH.HCATIONS

Yacht

ABYC

613

Third

Dtreet,

Suite

10

Annapolis,
(

41

0)

·

www.abycinc.~rg

NFPA (National Fire Protection

"Fire Protection Standard for Motor Craft"
Order

NFPA

1

Battecymarch
P.O.
Quincy,

USCG (United

"CPR

Code
Order

U.S. Government Printing Office

Washington,

MD

990-4460

From:

Box

9101

MA

33

AND CFR46"

of Federal

From:

21403

Park

02269-9101

States

Coast

Regulations

D.C.

20404

Guard)

AND

and

USCG

Follow

their

Council)

Association)

!FOR

GIENERA'II'ORS

publications

recommenda-

engine

ENGINE

Preparations
ough
(ABYC)

sources

Sections

All
Regulations

AND

examination

stanclar.ds.

including

of

·

H-32
H-33
P-1

Installatiion

and

P-4

Marine
E-ll
TA

Batteries

installations

GENERATOR

to

install

an

engine

of

the

American

These

the

USCG

the

ABYC

standards

Ventilation
Diesel

Auxilliary

AC & DC

(FCR).

Fuel

Inboard

and

must

for

Systems

of Exhaust

Engines

Electrical

Battery

comply

BNSTALII.ATDONS

should

begin

with a thor-

Boat

and

Yacht

standards

boats

Engines

are a combination

and

the

NFPA.

of particular interest

using

diesel

Systems

and

Systems

Chargers

with

the

for

Transmissions

on

Federal

fuel

Propulsion

Boats

Code

Council's

of

are:

of

Engines & Generators

•••

HD

INSTALLATION

When installing WESTERBEKE engines and generators

attention be paid

CODES

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

AND

to

the following information:

REGULATIONS

it

is important that strict

SIPHON·BREAK

For installations where the exhaust manifold/water injected exhaust elbow is close to
or will

be

below the vessel's waterline, provisions must

break

in

the raw water supply hose to the exhaust elbow. This hose must be looped a

minimum

the
raw

If

you have any doubt about the position

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

of

20" above the vessel's waterline.

exhaust manifold injection porl

water

damage

to

the

engine

and

Failure

is

at

or

below

possible

flooding

of

the water-injected exhaust elbow relative '

siphon-break.

NOTE:

A siphon-break

operation.

engine

EXHAUST

The exhaust system's hose
Exhaust Hose is recommended. The use
and turns without the
and turns. In this regard, a single length
system
under any sea conditions and at any angle

Failure

damage.

SYSTEM

MUST

requires

to

properly maintain a siphon-break can

Consult

need

be designed to prevent the entry

periodic inspection and cleaning

the

siphon-break manufacturer for proper maintenance.

MUST

be

certified for marine use. Corrugated Marine

of

this type

of

additional fitting and clamps to accomplish these bends

of

corrugated exhaust hose can be used. The

of

vessels heel.

of

be

made to install a siphon-

to

use

a siphon-break

the

load

waterline

of

the

boat.

to

ensure

result

in

catastrophic

of

hose allows for extreme bends

water into the exhaust system

wiU

when

result

proper

in

.

AVAILABLE
YOUR

·'DEALER

\"sJPHON~MEAKWlTHSTAINLESS

LOOP'

FROM

WESTERBEKE

A

detailed

engines

to

download

Marine

and

generators,

from

Installation

our

website

Manual

is

supplied

at

Engines & Generators

covering

with

www.westerbeke.com.

each

gasoline

unit. A pdf

iv

and

diesel,

is

available

TABLE

OF

CONTENTS

Introduction

Warranty

Customer Identification Card ....................................... 2

Product Software .......................................................... 2

Notes, Cautions and Warnings ..................................... 2

Serial Number Location ..............................................

Understanding the Diesel Engine ................................

Ordering Parts ............................................................. .3

Spares and Accessories ................................................ 3

Control

Main

Remote Panel ............................................................... 4 Installation .................................................................. 20

Diesel

Diesel Fuel ................................................................... 5

Care

Engine Oil ...................................................................

Oil Pressure ....................................................... , .......... 5

Engine Coolant ............................................................. 5

Coolant Recovery Tank ................................................ 5

Preparations

Prestart Inspection ........................................................ 6

Generator Voltage ......................................................... 6

Starting/Stopping

The Starting System ..................................................... 7

Remote Starting

Starting Under Cold Conditions ................................... 8

Stopping
Remote
Safety

Generator

Description ................................................................... 9

After Start-up ............................................................... 9

Check List .................................................................... 9

Generator Adjustments ................................................. 9

The

Daily

Check List .................................................................. 10

Start

Maintenance
Engine

Description ................................................................. 13

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

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

Thermostat .................................................................. 14

Raw Water Cooling Circuit ........................................ 14

Heat Exchanger .......................................................... 14

Fuel

System

Diesel Fuel ................................................................. 16

Fuel Water Separator .................................................. 16

Fuel Lift

Fuel Injection

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

Procedures .................................................... 2

Panels

Fuel,

High Exhaust Temperature Switch ....................... 8

High Water Temperature Switch ........................... 8

Low

Engine Circuit Breaker ......................................... 8

Cooling

Coolant Recovery Tank ....................................... 14

To Refill the Coolant... ........................................ 14

To Replace The Thermostat ................................ 14

Raw Water

Changing the Raw Water Pump Impeller ........... 14

Zinc Anode .......................................................... 14

Heat Exchanger Service ...................................... 14

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

Panel .................................................................. .4

Engine

Of

The Fuel Supply ............................................. 5

Procedure ...................................................... 8

Stopping Procedure ......................................... 8

Shut down Switches .......................................... 8

Oil Pressure Switch ...................................... 8

Break-In

Routine

the Generator .....................................................

Oil

and

Engine

for

Initial

Start-Up

Procedure

Procedure .......................................... 7

Procedure

Coolant

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

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

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

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

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

Schedule

Circuit.

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

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

Pump

................................................ 14

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

Pumps .......................................................... 16

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

. 2

.3
.3

.4

5

.5

6

7

9

10

10

ll

13

16

Fuel Filters ................................................................. 17

Changing the Fuel Filters .................................... 17

Feed

Pump Strainer (32 KW) .................................... 17

Bleeding the Fuel System .......................................... 18

Fuel Pressure Gauge ................................................... 18

Fuel Additives ............................................................ 18

Spares .........................................................................

Engine

Remote
DC

DC

DC
DC
Remote
Electronic
Troubleshooting
Engine

Engine
Generator
The
Generator

Voltage
Shore

Lay-Up
Specifications
Specifications
Specifications 32
Photo
Photo

Photo
Torque
Standard

Metric
Suggested

Oil

Change

Engine Oil Change ..................................................... 19

Oil Pressure ................................................................ 19

Oil

Filter

Electrical

Engine 12 Volt

Battery Specification ..................................................

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

Glow

Plugs .................................................................

Electrical

Troubleshooting .......................................................... 22

Testing the Alternator ................................................. 22

Electrical
Electrical

Start/Stop

Governor

Adjustments

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

Drive Belt Adjustment ............................................... 28

Torquing Cylinder Head Bolts ................................... 29

Engine Compression .................................................. 29

Testing the Fuel Injectors ........................................... 29

Inspecting the

Troubleshooting

Troubleshooting Water Temp. and Oil Gauges ......... .32

Information

Use

of

Electric Motors ............................................... 33

BE

Generator

Internal Wiring Schematics ........................................ 35

AC

BE Three Phase (Six Wire) ........................................ 37

BE Three

Regulator

BE

Troubleshooting .................................................. .39

Power

and

Identification
Identification

Identification

Specifications

Hardware

Conversions

Spare

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

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

System

System/Aiternator

System
System

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

DC

Control Circuit... .........................

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

Wiring
Wiring

Panel

Diagram
Schematic

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

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

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

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

the

Electronic

Governor

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

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

Spray Pattern ..................................... .30

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

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

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

Voltage

Phase (Twelve Wire) ................................. .37

Transfer

Recommissioning

20
25

Connections

Adjustments

Switch

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

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

KW

BEDA

Generator

KW

BED

Generator

KW

BEDA

Generator

20

KW

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

25

KW

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

32

KW

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

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

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

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

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

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

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

Torques

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

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

Parts

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

l8
19

2o

21

21
21
21
21

22

24
25

25

26
27
28

. .31

.33

.34

.36

38

.40
.41

43
.45
.47
.49

.so

.51

52

53

54

55

Engines & Generators

1

INTRODUCTION

This WESTERBEKE Diesel Generator is a product
WESTERBEKE's long years
technology. We take great pride in the superior durability and
dependable performance
Thank you for selecting WESTERBEKE.

In

order to get the full use and benefit from your generator it
is important that you operate and maintain it correctly. This
manual is designed to help you do this.

manual carefully and observe all the safety precautions
throughout. Should your generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.

This is your operators manual. A parts catalog is also

provided and a technical manual is available from your

WESTERBEKE dealer.

equipment contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual.

WARRANTY

Your WESTERBEKE Warranty is included in a separate
folder.

If,

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

number and commission date.

Customer

/-.rAT/

PROCEDURES

after 60 days

Identification

WESTERBEKE

of

experience and advanced

of

our engines and generators.

Please read this

If

you are planning to install this

of

submitting the Warranty Registry

Card

of

I

Customer Identification
MR. GENERATOR
MAIN STREET
HOMETOWN, USA
Model

32

BEDA Ser.

Expires 4/4/98

OWNER

#UOOOO-D702

PRODUCT

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

WESTERBEKE
CONTENT
RANTIES
THERETO, INCLUDING ACCURACY, TIMELINESS
COMPLETENESS
BE

LIABLE
INCURRED
OF

THE FURNISHING

WESTERBEKE customers should also keep in mind the
time span between printings
software and the unavoidable existence
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE or other suppliers, must not and cannot
be relied upon exclusively as the definitive authority on
the respective product. It not only makes good sense
but is imperative that appropriate representatives

WESTERBEKE or the supplier in question be consulted
to determine the accuracy and currentness
product software being consulted by the customer.

NOTES,

As this manual takes you through the operating procedures,

maintenance schedules, and troubleshooting
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:

NOTE:

A

observed,

your

SOFTWARE

CANNOT

OF

SUCH

OR

REPRESENTATIONS

FOR

ANY

IN

CONNECTION WITH

CAUTIONS

An

operating procedure essential to note.

CAUTION:

engine.

Procedures,

can

result

BE

SOFTWARE,

THEREOF

TYPE

OR

USE

of

AND

WARNINGS

In

the

RESPONSIBLE

MAKES

WITH

AND

WILL

OF

DAMAGE

OF

SUCH

WESTERBEKE product

which

It

damage

or

FOR

NO

WAR-

RESPECT

IN

NO

OR

INJURY

OR

ARISING

SOFTWARE.

of

earlier

of

of

the

of

your marine

not

strictly

destruction

THE

OR

EVENT

OUT

of

The WESTERBEKE serial number is

number that can assist in determining the date

of

your WESTERBEKE engine or generator. The manu-

ture

is

facturer's date code

number and consists
numbers. The character indicates the decade.
B = 1970s, C = 1980s, D = 1990s, the first number represents

the year in the decade and the second and third numbers the

of

month

manufacture.

placed at the end

of

a character followed by three

an

alphanumeric

of

of

the engine serial

(A=

manufac-

1960s,

A

WARNING:

lowed,

can

Engines & Generators

2

Procedures,

result

In

which

persona/Injury

or

If

not
loss

properly

of

lite.

to/·

INTRODUCTION

SERIAL

The
are located on a decal on the generator housing. Take the
time to enter the information on the blank decal provided
below as this will provide a quick reference when seeking
technical information and/or ordering repair parts.

The engine serial number can also be found stamped into the
engine block just above the injection pump. The generator
serial number is stamped into the generator housing on the
flat surface on the left side

An

the engine model and serial number.

NUMBER

engine and generator serial numbers and model numbers

SPECIFICATION

MODEL
RPM

__________

KW

___________

KVA

-----------

LOCATION

_______

_
_

_

50 HZ.

60HZ.

VOLTS--------­AMPS

ENG.

ENG.

GEN.

PF/PHASE

WIRES

RATING
INSUL

TEMP.

---------

HP

-------

SER.

NO.

SEA.

NO.

----

________

_______

ClASS

RISE

----

I

_
_

__

BATTERY------

C.t.D.

----------

of

the generator.

identification plate on the engine manifold also displays

NOTE:

A carbon monoxide warning decal has been provided

by

WESTERBEKE.

engine

room.

UNDERSTANDING

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

Therefore, to a great extent, a diesel engine requires the

same preventive maintenance as a gasoline engine. The

most important factors are proper ventilation and proper

maintenance
Replacement
time periods specified
contamination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of

the same brand

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

however,
carburetor and ignition systems are done away with and in
their place is a single component - the fuel injection pump ­which performs the function

in

ORDERING

Whenever replacement parts are needed, always provide the
generator model number, engine serial number, and generator
serial number as they appear on the silver and black name
plate located on the generator end.
this information so we may properly identify your generator
set. In addition, include a complete part description and part
number for each part needed (see the separately furnished
Parts List). Also insist upon WESTERBEKE packaged parts
because
the same specifications as original equipment.

SPARES

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

will fit

AND

SPARE

Affix this decal

THE

DIESEL

of

the fuel, lubricating and cooling systems.

of

fuel and lubricating filter elements at the

is

a must, and frequent checking for

of

high detergent diesel lubrication oil

its method

of

handling and firing

in

a visible position

ENGINE

of

a gasoline engine; and the

of

valves, camshaft, pistons,

of

fuel. The

of

both.

PARTS

You

must provide us with

or

generic parts are frequently not made to

ACCESSORIES

be

needed to support and maintain your

of

spare parts.

B4RTS page in this manual. For Engine and

ACCESSORIES brochure.

in

the

of

GENERATOR

ID

DECAL

Engines & Generators

3

CONTROL

MAIN

PANEL

This manually-controlled WESTERBEKE diesel generator is
equipped with toggle switches
and, optionally, at a remote panel. All three switches are
momentary contact type and serve the following functions:

1.

PREHEAT:

single-throw switch.
heating the engine for easy starting and defeating
ing the engine's protective oil pressure switch. The defeat
function activates the fuel solenoid, instrument power,
nator excitation, electronic governor and provides power to
the START switch.

2.

START:

throw switch.
starter solenoid for starting the engine.

The

PREHEAT toggle switch is a double-pole,

The

The

START toggle switch is a double-pole, single-

The

switch, when activated, energizes the

operate electrically unless the PREHEAT switch
and held at the same

3.

STOP:

The
throw, normally closed switch. This switch provides power
the fuel solenoid, and the instrument cluster, after the oil
pressure
this switch opens the power circuit to the fuel solenoid,
thereby stopping the fuel flow
stopping the engine.

switqh has closed upon engine starting. Opening

time.

STOP toggle switch is a single-pole, single-

on

the engine's control panel

switch serves two purposes: pre-

or

bypass-

alter-

This

switch will not

is

depressed

to

the injection pump and

to

of

PANELS

NOTE:

When

the engine
gauge and the oil pressure
last temperature and oil pressure readings

will return

4.

EMERGENCY

rear

will open the
engine down.
when performing maintenance.

REMOTE

For remote operation

switches are used.
connected in parallel with the gauge panel's switches and

serve the same functions as in the gauge panel. The

switch is in series with the gauge panel's STOP switch and

serves the same function.

to

zero once electrical power is

STOP:

of

the control

DC

As the switch is not toggled it can be used

START/STOP

0

is

shiP

down,

the

water temperature

gauge will continue

to

register

displayed.

They

restored.

The EMERGENCY stop switch at the

box

is normally closed. When depressed, it

circuit to the control panel and shut the

PANEL

of

the generator system, the same three

The

PREHEAT and START switches are

STOP

STOP

@

RELEASE

STARTER

~

START

the

WATER

TEMPERATURE

COOLANT.

1W.T0·1-95°F

TEMPERATURE.

(80°

TO

1

2

GAUGE:

ENGINE

SHOULD

91°C).

INDICATE

CONTROL

PANEL

MUST~

PRESS.

FIRST

t'W'JMi'

0

.......

REMOTE

A

~2ND

PANEL

(OPTIONAL)

mL

PRESSURE:

PRESSURE­DEPENDING
50

TO

GENERAToR

57

PSI

PRESS

o·

ENGINE

THE

ON

LOAD,

(3.5

LUBRICATION

NEEDLE

WILL

BUT

SHOULD

TO

4.5

KG/CM).

OIL

FLUCTUATE

INDICATE

DC

VOLTMETER:

BATIERY
13VTO

IS

14V.

INDICATES

BEING

CHARGED.

THE

AMOUNT

SHOULD

THE.

SHOW

Engines & Generators

4

0

.

HOURMETER:

SHOULD
MAINTENANCE

REGISTERS

BE

USED

SCHEDULE.

ELAPSED

AS A GUIDE

FOR

TIME,
THE

AND

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use a diesel
SAE J 313
diesel

Care

Use

in
dirt
ondary
important
can

improper storage

the

following
Purchase a

to

recommended

Diesel

into

used.
Install and

filter/water separator

The

such

ENGINE

Use a heavy
CG-4,
initial 50
filter

SCHEDULE

not approve or
synthetic
using
in
manual

NOTE:

statements

SAE

For

FUEL

fuel

that

meets

and

has a Cetane

fuel

Of

The

only

clean

your

engines

pruticles

filters

be

rendered

tank

for

practice

combat

Kleen

the

diesel

Raycor

filters. A 10

according

which

to

buy

your

well-known

BACTERIAL

regulru·Iy

500

to

Fuel

Supply

diesel

fuel!

fuel

injection

might

can

damage

clean

fuel,

unsatisfactory

facilities.
engine's daily

is

advisable:

such

as

Bio-Bor

+ ·

Cetane

fuel

when

service a good,

between

MA

or 230

micron

ASTM

The clearance of

pass

these

To

brand

gro\Yth

Boost.

an

filter

OIL

duty

diesel

oil

CH-4

or

Cl-4.

Change

itours

of break-in operation. Then

change

the

all

intervals

oils

are

conventional

MAINTENANCE

and

not

The

information

regarding

OIL

VISCOSITY

temperature ranges: SAE lSW-40 or

as

in

this

manual.

disapprove

used,

oil.

be

extended

synthetic

specified

the
engine break-in must
Oil

change intervals

SCHEDULE

above

the

requirements

rating

of

D975

pump

is

through

finely

and

keep

by

careless

ensure

that

use

is

of

fuel.
in

the

and

an

to

help

Ultra

Low

visual-type

the

fuel

RMAM

with

if synthetic oils

are

element

an

API

the

engine

in

the

Westerbeke

use of synthetic oils. If

supersedes

of

#45

or

higher

the

very

critical;

the

primary

machined

it

clean.

The

handling

the

fuel

clean

and

The

use

of

fuel

tank

additive such

restore lubricity

Sulfur

diesel

tank

and

good

examples

is

recommended.

classification

oil

and

follow

MAINTENANCE

Corporation

be

must

section of

are

all

previous

oil.

SAE

No.

2-D
grade

components

invisible

and

sec-

pm1s.

It

is

best

fuel

or

going

into

pure,

the

additives

is

as

back

is

being

fuel

the

engine.

of

of

CF,

filter

after

the

oil

and

does

performed

be

as

listed

this

used.

lOW-40.

of

an

ENGINE

WESTERBEKE
and
chemicals

The
run
the
cooling
quality
Additives
balanced,

The
being

NOTE:

antifreeze

.

PURCHASING

.

Select
Antifreeze
additive
cylinder
brands
engines.
mixture
needed.
MAINTENANCE

COOLANT

recommends a mixture

50%

distilled

antifreeze

at

proper

engine

circuit

antifreeze

crucial

distilled water

poured

Look

water.

that

can
performs

temperatures

to

the

coolant,

from

that

(SCAs)

to

into

the

for

the

that

is

now

corrode

rust

contains

that

keep

long

and

cooling

new

available.

ANTIFREEZE

a brand of antifreeze specified for diesel

specified

to

protect against cavitation erosion of

walls.

that

offer

Select

will

Change

for diesel engines contains a special

Prestone andZerex

antifreeze specifically for

the

pre-mixed variety so that

always

be added to the cooling system

the

antifreeze mixture according

SCHEJ?ULE

MAINTENANCE

Change

number
protect

COOLANT

The

contraction

without
provided
water
operating

the

engine coolant

of operating

and

lubricate

hours

the

RECOVERY

coolant

recovery

of

introducing air

with

coolant conversion kit

the

engine.

the

fresh

tank

engines

water

r

of 50% antifreeze

Distilled

double

and

and

term

antifreeze

water

is

internal

by

engine

duty.

It

allows
transferring
lubricates

corrosion.

Supplemental

the

antifreeze chemically

protection.

circuit.

should

and

Look

be

free

from

surfaces.

the

heat

protects the

for

Cooling

premixed

environmentally-friendly

are

two

nationally

use

the

in

this

manual.

every

five

years

regardless of

as

the

engine

chemical

have a limited

additives

TANK

allows

for

the

expansion

coolant

during

engine

into

the

system.

cooled

and

models

must

This

and

be

recovery

with

installed

the

engine

away

from

a good

long

engines.
the

engine's

in diesel

correct

when

to

the

that

iife.

and

operation

the
before

to

before

lasting

known

the

tank

is

fresh

NOTE:

771is

located
can

be

at

located

particular

Engines & Generators

5

tank,

•vith

or

above

below

installation

its

the

the

short

level

level

makes

of

this

run

the

of

of

plastic

engines

the

engines

necessary.

hose,

is

manifold,

manifold

best

but

if

it

the

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

This section
ration, initial starting, break-in, starting (warm
stopping procedures. Follow the procedures as presented for
the conditions indicated and your WESTERBEKE generator
set will give reliable performance and long service life.

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

0 Check the engine oil level. Add oil

at the high mark

INSPECTION

of

the manual provides the operator with prepa-

or

cold) and

or

to

maintain the level

on

the dipstick.

after a

0 Check the fuel supply and examine the fuel filter/separa-

tor bowls for contaminants.

0 Check the

and battery cable connections. Make certain the ( +) bat­tery cable is connected to the starter solenoid and the
negative(-)
(this location is tagged).

DC

electrical system. Inspect wire connections

cable is connected to the engine ground stud

0 Check the coolant level in both the plastic recovery tank

and at the manifold.

0 Visually

parts, disconnected wires, unattached hoses, and check
threaded connections.

e_~ine

the unit. Look for loose

or

missing

0 Check load leads for correct connection as specified in

the wiring diagrams.

0 Examine air inlet and outlet for air flow obstructions.

0

Be

sure no other generator

to load lines.

0

Be

sure that in power systems with a neutral line that

the neutral is properly grounded (or ungrounded)

system requires, and that the generator neutral is properly
connected to the load neutral. In single phase and some
3-phase systems an incomplete
ply the wrong line-to-neutral voltage

loads.

or

utility power is connected

or

open neutral can sup-

on

unbalanced

as

the

0 Make sure the mounting installation is secure.
0 Make sure that the generator is properly grounded.

A

CAUTION:

recommended
be

switched

and,

in

cold

will

prevent

of

the

AC

When

that

all

OFF

until
climates,
damage

machinery

starting

AC

loads,

the

engine

starts

caused

and

will

the

generator,

especially

has

come

to

warm

up.

by

unanticipated

prevent a cold

it

large

up

to

This

precaution
operation

engine

is

motors,

speed

from

stalling.

GENERATOR

The speed
however, it is advisable to verify.

To

supply 60 hertz, the speed should be 1800 rpm at no-

load, and should not fall below 1800 rpm
percent
To supply
load. Generator voltage should build to its rated value within

5 seconds after rated speed is attained. Record or observe the

voltage
voltages are easily adjusted to optimum values no-load and
full-load (refer to
If

possible, apply actual service load

power

factor

ca011ot

be

dent, contact your authorized WESTERBEKE service dealer.

VOLTAGE

of

the generator engine is adjusted at the factory,

by

more than .005

.3

Hz

at full-load.

50

hertz, the speed should

of

the generator at no-load and at full-load (hot).

VOLTAGE

as

the load to be used in service.

adjusted to suitable values and a fault seems evi-

ADJUSTMENT in this manual).

be

1500 rpm at full-

or

test load

If

DIPSTICK

2DKW

of

the same

the voltage

The

MANIFOLD

PRESSURE

ENGINE

OIL

CAP

FILL

j...,.,IWESTERBEKE

) Engines & Generators

6

•DIPSTICK

32KW

DIPSTICK

25KW

STARTING/STOPPING

PROCEDURE

THE

STARTING

Westerbeke
glow

plugs
illustration
der.

The

glow

that

its

tip

glow

plug
glows

red

is

a rapid start

This

system
circuitry
depressed
while
button

NOTE:

HEAT
activates
HEAT intermittently

An
32
same.

PREHEAT:

panel lights,
HEAT
following

is

keeping

is

depressed

The

switch

the

•

GLOW

air

intake

KW

generator.

switch should be depressed

SYSTEM

diesel

generators

for

both nonnal

below

shows

plug

is

is

in

the

injector nozzle's spray

is

energized

at

the

tip

and

with

less

is

common

designed

for

START switch will not

Depress the

gauges

chart:

the

time

the

PREHEAT

is

depressed.

glow

plugs

heater

:

so

to

to

The

and

Temperature/Preheat

Atmospheric

+41

+41"F(

+23.F(-5"Cf

Limit

START:

While still depressing the

the

START

Upon

engine starting, release the

release the

15

psi.

Then

oil

pressure protective circuits

remain energized

Temperature

•f(

+5"C).

or

+5.C)

to

23~f

or

of

continuous

switch.

PREHEAT

as

long

higher

lower

This

and

use

electric starters assisted

and

cold weather starting. The

a cross-sectional

located

in

the combustion chamber

by

the

PREHEAT
assists in igniting the
wear

on

the

to

WES1ERBEKE diesels. The start

that the

specified in the preheat

crank the engine.

PREHEAT

button engaged, the

energize

Depressing

in

the

cylinder head

avoid overheating

is

used

in

place

preheat

PREHEAT

meters

(

-s·c)

use

will

switch until the oil pressure reaches

as

the high water temperature

continue

sequence described is

will

PREHEAT

engage the starter solenoid.

START

do

not

to

run.

view

of one cylin-

path.

When

button,

the

plug

fuel.

The result

starter.

button must

chart.

Then,

START

unless

the

PRE-

the

PREHEAT switch

so

use

the

the

glow

plugs.

of

glow pings

switch. The voltmeter and

be activated. The

in

accordance with the

Preheating

Approx.

Approx.
Approx.

30

seconds

activate,

Tillie

10

seconds

15

seconds

20

seconds

before

cranking

switch, depress

switch.

Do

and

the engine

not

the

be

PRE-

on

PRE-

low

by

so

the

the

will

Should the engine
depressed
wait 30 seconds; repeat
longer.

A

engine
filling

pump

Ing
engine's
the
closing
f/ralnlng

of

Ing

for

Never run the starter for more than 30 seconds.

CAUTION:

starting

with

Is

pumping

system

cylinders

exhaust

the

the

the

excessive

from

raw

owner/operator

Remote

The remote start
start panel except that
gauges.
lights
rpm.
since

A. When

B.

Once the engine starts, check the engine's instruments
proper
light load
temperature
applying

NOTE:

Starting

When

when

This indicates

the

starting of the generator

the
start/stop panel the LED light
START
engine this LED light will
the LED light will brighten signaling
START
depressed for a
up which closes

the series path for
green

LED

engine
After

the
released, the generator's starter
PREHEAT switch is operated
supplies voltage

oil

pressure

to

heavy

Some
Depressing
will help stabilize
temperature

the

engine.

not

start

when

the

START

10

to

20 seconds, release both switches

the

Prolonged

can

raw

water.

during

system

raw

water

exhaust

engine

water

should

result

This

raw

water

cranking.

by

way

fills.

Prevent

supply

muffler,

cranking.

entry

Is

keep

procedure

cranking

In

may

of

not a warrantable

above

Intervals

the

engine

happen

through

This

the

the

raw

water

exhaust

this

from
through-hull
and

correcting

Engine

this

In

mind.

Procedure

panel

is

the same

it

has

starting

the

PREHEAT

switch

switch.

is

running.
generator

the

to

unstable

the

reaches

at

a remote location, the green

generator

will

generator

come

loads.

is

when

the

switch

is

depressed

Continue

few

seconds to

the

oil

12V

remain brightly illuminated

is

started and

to

the

START

and

battery charging

and

up

to

running

PREHEAT switch for 10-15 second

the

engine

140-

150° F

~s

the

a green

running

pressure safety switch that

B+

140-150°

START

may

is

depressed at

will

and

dim.

When

to

hold the

allow

to

the

will

first

switch.

allow

LED

at

approximately

switch

not

illuminate.

the

starter cranks the

PREHEAT

fuel

the

START

not

because

voltage.

the

engine's operating

(60-66°

may occur

rpm

until

the

and

a

load

switch

and

preheat

without

exhaust

because

raw

water

can

system

the

enter

manifold

happening

shut-off,

the

cause

damage

Issue;

engine-mounted

light

and

no

can

be released

be

audible.

the

When

the engine

to

release

the

oil pressure

run

solenoid. The

while

switch

crank

unless

this

switch

Apply

C)

before

in

a cold

engine.

operating

is

applied

is

and

the

cool-

the

once

by

result-

the

LED

600

remote

the

starts

to

build

is

in

the

is

the

for

a

intervals

to

NOTE:

A voltage

when

is

depressed.

When

starting:

drop

will occur

the

preheat switch

STARTING

Make sure

the

prevailing temperature. Check

OIL section

Engines & Generators

7

UNDER

the

in

COLD

CONDITIONS

lubricating oil confonns with

the

this manual.

table

the

in

ratings

the

ENGINE

for

STARTING/STOPPING

PROCEDURE

STARTING

Make sure the lubricating oil conforms with the ratings for
the prevailing temperature. Check the table in the

OIL

section in this manual.

The

battery should be fully charged to minimize voltage

drop.
Use a sufficient amount

Temperature/Preheat

STOPPING

1. Remove the
allow the generator to run for three to five minutes to sta­bilize its operating temperatures.

2. Depress the
is completely stopped.

3. Now release the

Remote

To stop the generator, depress the STOP switch
which opens the normally closed
voltage to the engine's run circuit. The
switch must be held open until the generator
comes to a complete stop.

NOTE:

solenoid mounted on

de-energized shutting off
and 25

shutdown by

attached

UNDER

COLD

chart on the previous page.

PROCEDURE

AC

electrical load from the generator and

STOP switch and hold it until the generator

STOP switch.

Stopping

The

generator is stopped

/Gl1).

The

to

a lever

Procedure

the

32 KW Generator is

an

electric fuel solenoid that

on

CONDITIONS

ENGINE

of

preheat to aid in starting. See the

~+

path for

STOP

when

the electric

injection pump is

the

flow

of

fuel (Models 20 KW

is

the

fuel injection pump.

High

Water

A high
housing. Normally closed, this switch, should the fresh water
coolant's operating temperature reach approximately
(99°C),
solenoid
engine. This switch resets at

Low

Oil

A low oil pressure shutdown switch is located

engine's oil gallery. Normally open in a static state, this
switch's sensor monitors the engine's oil pressure.
engine's oil pressure fall to
interrupting the
tion pump, thereby shutting off the engine.

Temperature

water

temperature switch is located

will open and interrupt the

on

the-injection pump, thereby shutting off the

HIGH

WATER

TEMPERATURE

Pressure

Switch

DC

voltage to the fuel solenoid on the injec-

Switch

on

DC

voltage to the fuel

195°F (107°C).

SWITCH

5-10 psi;: this switch will open

the thermostat

210°F

off

the

Should the

SAFETY

The
down switches.

attempt

the

in the TROUBLESHOOTING section

manual. The following is a description

automatic shutdown switches:

High

An exhaust temperature switch is located on the exhaust

elbow. Normally closed, this switch
the
(shutting
an excessive exhaust temperature (an inadequate supply
raw water causes high exhaust temperatures). This switch
opens at
approximately

SHUTDOWN

engine is protected by three automatic shut-

Should shutdown occur, do not

to

restarl without finding and

cause.

Refer

Exhaust

DC

voltage to the fuel solenoid

HIGH
TEMPERATURE
SWITCH

Temperature

OFF

the engine) should the switch's sensor indicate

260-270°F (127-132°C). This switch resets at

225°F (107°C).

EXHAUST

SWITCHES

correcting

to

the heading "Engine Stops"

of

this

of

these

Switch

will open and interrupt _

on

the injection pump ·

of

OIL

PRESSURE

'SWITCH

-·

--s;;::og.

.

OIL
SENDER

LOW

OIL

PRESSURE

[20

KW

Engine

The generator's engine is proiected by an engine mounted

manual reset circuit breaker
draw

wiring

event most generators will shut down because
breaker disconnects the fuel supply.
check and repair the source
the fault, reset the breaker and restart the generator.

Circuit

or

electrical overload anywhere in the instrument panel

or

engine wiring will cause the breaker to trip. In this

SWITCH

SHOWN]

Breaker

(20 amps DC). Excessive current

the opened

If

this should occur,

of

the problem. After repairing

PRESSURE

Engines &

8

Generators

GENERATOR

BREAK-IN

PROCEDURE

DESCRIPTION

Although your engine has experienced a minimum
hour

of

test operations at the factory to make sure accurate
assembly procedures were followed and that the engine
ated properly, a break-in time
your engine is dependent upon how the engine is operated
and serviced during its initial hours

Breaking-in a new engine basically involves seating the
ton rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
scored, which is caused by overloading the generator during

the break-in period.
Your new engine requires approximately

conditioning operation to break in each moving part in order

to maximize the performance and service life

Perform this conditioning carefully, keeping in mind the

following:
Start the engine according to the STARTING

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

AFTER

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

START·UP

20% and 60%

A

CAUTION:

generator

by

running

Do

not

is

required. The service life

of

use.

50 hours

of

full-load for the first 10 hours.

attempt

to

break-in

without a load.

of

one

oper-

of

pis-

of

initial

of

the engine.

PROCEDURE

your

CHECK

THE

FOLLOWING

D Monitor the control panel gauges.

D Check for leaks

D Check for abnormal noise such as knocking, friction,

vibration and blow-back sounds.

of

fuel and engine oil.

D Confirm exhaust smoke:

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

To

protect against unintentional overloading
the generator's output leads should be routed through a
cuit breaker that is rated at the rated output

NOTE:

Be

aware

of

motor starting loads
draw required for starting motors. This starting amperage
draw can

GENERATOR INFORMATION

GENERATOR

Once the generator has been placed in operation, there may
be adjustments required for engine speed (hertz) during the
engine's break-in period (first
A no-load voltage adjustment may also be required in

junction with the engine's speed adjustment. See

GENERATOR INFORMATION in this manual.

be

3 to 5 times normal running amperage. See

in this manual.

ADJUSTMENTS

50

hours)

of

the generator,

of

the generator.

and

the high current

or

after this period.

cir-

con-

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

Avoid overload at all times.

smoky exhaust with reduced output voltage and frequency.

Monitor the current being drawn from the generator and keep
it within the generator's rating. Since the generator operates
at

1800

50

Hertz), control

the current drawn from the generator.

10

hours

of

the generator's operation, the load

An

overload is signaled by

rpm

to produce 60 hertz (or at 1500 rpm to produce

of

the generator's break-in is governed by

Engines & Generators

9

THE

DAILY

OPERATION

CHECK

Follow this check list each day before starting your generator.

LIST

0 Record the hourmeter reading in your log (engine hours

relate to the maintenance schedule.)

0 Visually inspect the generator for fuel, oil,

or

water leaks.

0 Check the oil level (dipstick).

0 Check the coolant level in the coolant recovery tank.

0 Check your diesel fuel supply.
0 Look for clean fuel in the fueVseparator transparent bowl.

0 Check for loose wires at the alternator.

0 Check the starting batteries (weekly).

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

START

(See STARTING PROCEDURES on previous pages).
Allow the engine to warm up for 5 to
operating temperature

applying AC loads. Apply loads systematically allowing the
generator to adjust to each load before applying the next.
Check the gauges for proper oil pressure, operating
ture, and

NOTE:

This condition should lessen as normal operating
ture is reached and loads are applied.

STOPPING

Remove the major AC loads from the generator one at a
time. Allow the generator to run for a few minutes to stabi­lize the operating temperature and depress the stop switch.
(See

THE

GENERATOR

10 minutes to reach

of

140° to 150°F ( 60°-66 °C) before

DC

voltage.

Some unstable running may occur in a cold engine.

A

CAUTION:

periods

of

SWPPING

Do

not

time

without a load

THE

GENERATOR

PROCEDURES

operate

being

the

generator

placed

on

previous pages.)

tempera-

for

on

the

tempera-

long

an

Engines & Generators

10

A

WARNING:

running.
use
servicing

NOTE:

the

Many

Wear

co«ect

any

of

difficult and may

MAINTENANCE

Never

attempt

the

proper

tools

for

of

the

engine's

the

following maintenance jobs

require

the

to

perform

safety

equipment

each

job.

Disconnect

DC

electrical

expert knowledge

SCHEDULE

any

equipment.

service

such

as

goggles

the

battery

are

simple but others

of

a service

while

the

and

terminals

mechanic.

engine

gloves,

when

are

more

is

and

SCHEDULED
MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Drive

Visual

Fuel
Starting

(and

Engine

Generator

Heat

Fuel/Water
Electronic

(if

applicable)

Exhaust

Engine

Separator

Oil

Level

Level

Belts

Inspection

Filter

BaHeries

House

BaHeries)

Oil

(and

Exchanger

Separator

Governor

System

Hoses

filter)

Zinc

of

Engine

Anode

Control

CHECK

EACH

DAY

D
D

D

D

D

weekly

D

D

weekly

HOURS

OF

OPERATION

50

100

250

500

750

1000

NOTE:

Please

keep

engine

surface

clean.

and

oil

will

inhibit

the

remain

cool.

engine's

D D D 0

ability

to

D

D D D D D D D

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0

0

0 0

0 0 D D

0

D

D

0

D

1250

Dirt

D

0

EXPLANATION

Diesel

No. 2 rating

Check

for

water

if

necessary).

Oil

level

should

dipstick.
Check

at

recovery

Add

coolant

Inspect

for

and

adjust

Check

for

fuel,

and

electrical

Check

for

loose

Initial

change

Every

50

operating

and

make

sure

excessive

Initial

change
Check

with

for

Inspect
exchanger

Change
Check

required
as

NOTE:

adjustment

Initial
for

the

buildup
necessary.

Hose
spongy.

corrosion.

engine

both

that

no

chafing.

additional

zinc

every

and

(hertz)

needed.

These

check

leaks.

Check

exhaust

on

should

Check

MAINTENANCE

of

45

and

dirt

indicate

tank;

if

needed.

proper

tension

if

needed.

Check

oil

and

connections.

belt

tension.

at

50

hrs,

hours

connections

oil & filter

every

100

AC

connections

See

GENERATOR

information.

anode,

replace

end

of

zinc

200

hours.

or

adjust

the

and

the

adjustment

during

or

after

at

50

hrs.,

anti-siphon

elbow

for

inside

passages;

Check

that

be

hard & tight.

and

tighten

OF

SCHEDULED

cetane

or

in

fuel

(drain/replace

between

if

water

then

change

hours.

anode

no-load
regulator

then

carbon

all

MAX.

empty,

check

(3/8"

to

belt

edges

leaks.

Keep

bolts & nuts

change

check

electrolyte

are

very

at

are

clean

if

needed,

debris.

speed

are

not a warrantable

the

unit's

every

valve

and/or

clean

connections

Replace

all

hose

higher.

and

at

manifold.

1/2"

deflection)

for

wear.

Inspect

wiring

every

250

levels

tight.

Clean

50

hrs.,

then

and

secure

SECTION

clear

in

the

board

adjustment

break-in.

250

hrs.

operation.

corrosion

and

replace

are

tight.

if

soft

clamps.

filter

LOW

on

tight.

hrs.

off

the

heat

panel,

Inspect

Check

as

or

Engines &

11

Generators

NOTE:

Use

engine hours

MAINTENANCE

the

engine hour meter gauge

by

running

time.

SCHEDULE

to

log your engine hours or

record

your

SCHEDULED

MAINTENANCE
Raw

Water

Pump

Coolant

System

Electric

Fuel

lift

Pump

Filter

(if

applicable)

DC

Alternator

Feed

Pump

Strainer

(if

applicable)

*Fuel

Injectors

*Starter

*Preheat

*Engine

*Torque

*Adjust

*Heat

Motor

Circuit

Cylinder

Compression

Cylinder

Hold-down

bolts

the

Valve

Exchanger

Head

Clearances

CHECK

EACH

DAY

HOURS

OF

OPERATION

50

100

250

500

750

1000

0 0 0

0

0 0 0

0

0

0 0 0

0

0

0

0

0 0

0

0 0

0 0

0 0 0

1250

0

0

0 0

0

0

0

EXPLANATION

MAINTENANCE

Remove

the

pump

gasket,

cam

and

cover

and

seals

(the

shaft

lubricate

Drain,
priate

Initial

filter

Check
bracket;

Clean

Check
spray

Check
and
pinion

Check
clean

Reinstall

Check

ENGINE

At

ENGINE

Adjust

ADJUSTMENTS).

Remove,

tested.

when

reassembling.

flush,

and

antifreeze

filter

change

every

250

hours.

DC

charge

tighten

electrical

every

250

and

adjust

condition

solenoid

lubricate.

drive.
operation

glow

compression

first

valve

(see

and

Clean

plugs;

with

anti-seize

ADJUSTMENTS).

50

hours,

ADJUSTMENTS).

Clearances

have

professionally

refill

mix.

from

operating

injection

of

check

then

OF

cover

and

for

wear.

can

turn,

cooling

at

50

hours,

alternator.

connections.

ENGINE

motor
and

lubricate

preheat

resistance

compound

pressure

every

(see

SCHEDULED

inspect

the

impeller,

Check

the

bearings

but

not

wobble).

system

with

appro-

then

change

Check

mounting

hours.

opening

for

pressure

ADJUSTMENTS).

corrosion.

solenoid.

and

timing

500

ENGINE

cleaned

the

starter

Remove

(4-6

on

hours

and

Remove

ohms).

threads.

(see

(see

pressure

and

motor

and

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

Engines & Generators

12

mechanic.

ENGINE

COOLING

CIRCUIT

DESCRIPTION

Westerbeke marine diesel generators are designed and
equipped for fresh water cooling. Heat produced in the

to

of

TANK

fresh

a heat

of

engine by combustion and friction is transferred
water coolant which circulates throughout the engine. This
circulating fresh water coolant cools the engine block and its

internal moving parts. The heat is transferred externally from

the fresh water coolant to raw water by means

exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes
fresh water coolant flows around the tubes; engine heat trans­ferred to the fresh water coolant
tube walls to the raw water which is then pumped into the
exhaust system where finally

w~rds,

other
coolant
transferred heat overboard through the exhaust system. The
fresh water coolant and raw water circuits are independent
each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.

Fresh

NOTE:

mended antifreeze and water mixture to be used as the fresh
water coolant.

Fresh water coolant
lating pump, absorbing heat from the engine. The coolant
then passes through the thermostat into the manifold, to the

heat exchanger where it

block via the suction side

the engine

IS cooled by raw water, and the raw water carries the

Water

Refer to ENGINE COOLANT section for the recom-

Circuit

is

of

the heat exchanger while

is

conducted through the

it

is discharged overboard. In

is

cooled by fresh water coolant, this

pumped through the engine by a circu-

is

cooled and returned to the engine

of

the circulating pump.

COOLANT

RECOVERY

When the engine is started cold, external coolant flow is pre­vented by the closed thermostat (although some coolant flow
is

bypassed around the thermostat to prevent the exhaust

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

thermostat gradually opens, allowing full flow

coolant to flow unrestricted to the external portion
cooling system.

Coolant

A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi­cant loss

' ing system. This tank should be located at

engine manifold level and should be easily accessible.

,CHANGING

The engine's coolant must be changed according to the

MAINTENANCE SCHEDULE. If the coolant is allowed to

become contaminated,

A

critical; a substantial

traced

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

NOTE:

to drain engine coolant.

A

Recovery

of

coolant and without introducing air into the cool-

COOLANT

CAUTION:

back

The drain

WARNING:

Wear

protective

Tank

it

can lead to overheating problems.

Proper

cooling

number

to

cooling

plug

system

on the heat exchanger can also

Beware

gloves.

of

of

the

system

engine

corrosion.

hot

engine

of

the engine's

of

the

or

above the

maintenance

failures

can

be

coolant.

is
be

used

TYPICAL
COOLING

ENGINE

CIRCUIT

Engines & Generators

13

THERMOSTAT

·HOUSIN.G

COOLANT

Q

..

ENGINE

COOLING

CIRCUIT

Refilling

After replacing the manifold drain plug, run the engine at
idle and slowly pour clean, premixed coolant into the mani­fold.

NOTE:

exchanger drain plug opening, close the drain
the system until the manifold remains full.

Monitor the coolant
the
sure cap.

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

After checking for leaks, stop the engine and allow it to cool.

Coolant should draw back into the cooling system as the
engine cools down. Add coolant to the

needed. Clean up any spilled coolant.

the

Coolant

When a steady flow

!llanifold to the filler neck and install the manifold pres-

COOLANT

of

coolant appears at the heat

plug

and fill

in

the manifold and add as needed. Fill

fill

LOW and MAX imd replace

·recovery tank if

RETRACTION

-----

MANIFOLD

PRESSURE

with

CAP

Replacing

Remove the·cap screws and disassemble the thermostat hous­ing as shown. When installing the new thermostat and gasket
apply a thin coat
pressing it into place. Do not over-tighten the cap screws.
Run the engine and check for normal temperatures and that
there are no leaks at the thermostat housing.

TO

MANIFOLD

the

Thermostat

of

sealant on both sides

of

the gasket before

/

AIR

BLEED

\~'----COOLANT

TEMPERATURE
SWITCH

PETCOCK

TO

COOLANT
RECOVERY
TANK

INSPECT

AND

THE

COOLANT
TANK
HOSE

NOTE:

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

CLEAN

RECOVERY

AND

ITS

CONNECTING

EVERY 3 MONTHS

Periodically check the condition

COOLANT

EXPANSION

of

the manifold pres-

THERMOSTAT

A thermostat, located near the manifold at the front

engine, controls the coolant temperature, as it continuously

flows through the closed cooling circuit. When the engine

is first started the closed thermostat prevents coolant from

flowing (some coolant is by-passed through a hole in the

thermostat to prevent the exhaust manifold from overheat­ing); as the engine warms up the thermostat gradually opens.

The thermostat is accessible and can be checked, cleaned, or

Carry

replaced easily.

a spare thermostat and gasket.

of

the

RAW

WATER

The raw water flow is created by a positive displacement
impeller pump. This pump draws water directly from the
ocean, lake, or river through a hose to the water strainer. The
raw water passes from the strainer through the heat
exchanger (through the heat exchanger tubes) where
the engine circulating fresh water
then discharged into the water injected exhaust elbow, mix­ing with and cooling the exhaust gasses. This mixture
exhaust gas and raw water is discharged overboard.

Raw

Water

The raw water pump is a self-priming, rotary pump with a

non-ferrous housing and a neoprene impeller.
has flexible vanes which wipe against a curved cam plate
within the impeller housing, producing the pumping action.
On no account should this pump be run dry, as water acts as
a lubricant for the impeller. There should always be a spare
impeller and impeller cover gasket aboard (an impeller kit).
Raw water pump impeller failures occur when lubricant (raw
water) is not present during engine operation. Such failures
are not warrantable, and operators are cautioned to make sure
raw water flow is present at start-up.

COOLING

Pump

CIRCUIT

cqolant. The raw water

The

it

cools

of

impeller

is

NOTE:

Should a failure occur with the pump's internalparts
(seals and bearings) it may be more cost efficient to purchase
a new

pump

Engines & Generators

14

and rebuild the original

pump

as a spare.

ENGINE

COOLING

CIRCUIT

Changing

Close the raw water intake valve. Remove the pump cover
and, with the aid
impeller out
Move the blades to conform to the curved cam plate and
push the impeller into the pump's housing. When assem­bling, apply a thin coating
gasket.

A

impeller,
cooling

the

Raw

Water

of

two small screwdrivers, carefully pry the

of

the pump. Install the new impeller and gasket.

Open the raw water intake valve.

.

RAW

CAUTION:

they

circuit.

H

must

They

any

be

Pump

Impeller

of

lubricant to the impeller and

WATER

PuMP.

of

the

vanes

found

to

prevent

can

often

be

found

h~ve

broken

blockage

In

the

off

in

heat

the

the

exchanger.

CLEAN

NEW

Zinc

Anode

' A zinc anode,

circuit within the heat exchanger.
anode is to sacrifice itself
in the· raw water cooling
of

elec::trolysis

dition

of
anode. cleaned
be carried

NOTE:

Electrolysis action is
installation and vessel location; not that

If the zinc pencil needs

which the zinc pencil is threaded

ening the anode with another wrench.

boss

from possibly tearing
removing
poor condition, there are probably a lot
the exchanger. Remove the end
clean the inside
exchanger end gasket in case the present one becomes dam­aged when removing the end cover. Replace the gasket (refer
to your engine model's heat exchanger end gasket part num­ber), o-ring, cover, and install a new zinc anode.

or

pencil, is located in the raw water cooling

on

other components

the zinc anode should be checked monthly and the

or

replaced as required. Spare anodes should

on

board.

the zinc, note the condition

of

all zinc debris. Always have a spare heat

AND

REUSE

to

electrolysis action taking place

dreuit, thereby reducing the effects

the

replacement~

off

REPLACE

The

purpose

of

the system.

result

of

eaciJ

of

hold the hex boss into

with a wrench while loos-

This

the exchanger shell. After

of

it.

of

of

the heat exchanger and

REPLACE

of

the zinc

The

particular

the

generator.

prevents the hex

If

the zinc is in

zinc flakes within

con-

HEAT

EXCHANGER

The heat exchanger is a copper cylinder which encloses a

number
the small copper tubes and the freshwater coolant from the
engine is circulated around the copper tubes. The raw water
removes heat from the freshwater coolant.

of

small copper tubes. Raw \Vater is pumped through

HEAT

EXCHANGER

[32

KW

SHOWN]

Engi(Jes & Generators

Heat

Exchanger

After approximately 1000 hours

and pressure test the engine's heat exchanger. (A local auto­motive radiator shop should
exchanger.)

NOTE:

Operating in silty and/or tropical waters may
that a heat exchanger cleaning
every 1000

hours.

Service

be

of

operation, remove, clean

able to clean and test the heat

require

be

performed

more

often

than

15

FUEL

SYSTEM

DIESEL

Use
not

FUEL

No. 2 diesel

use

kerosene or

fuel

with

a cetane rating of

home

heating

fuel.

FUELniATERSEPARATOR

A primary

installed between

water

be

carried

Mo~t!Jtstallers

lation
minants in

A typical
is

the
separator
tank
will
ment.
the
impurities. This
maintaining a

fuel

filter of

the

and

other contaminants

to

the

fuel

include a filter/water separator

.package

Raycor

and

affect

The owner/operator

fuel

as

they

the

fuel

fuel

filter/water separator is illustrated

Model

type

filter

engine-mounted

the

fuel

reaching

OWNER

FUEL
FILTER

the

process

proper

INSTALLED

WATER/SEPARATOR

the

water separating

fuel

tank

and

from

system

can

500

is

pump,

engine'iHnjection

filtration/separation

on

the

are

aware

of

cause.

MA.

Keep

not

installed between

fuel

system,

engine

filter,

is

responsible

is

accomplished

the

the

engine. .

the problems that conta-

in

45

type

engine

to

fuel

before

with

mind

that

the

any

water

and

injection

for

making

equipment

by

installing

system.

or

higher.

must

remove

they

the

below.

if a water

fuel

supply

in

the

equip-

certain

is

free

,and

be

can

instal-

This

fuel

of

Do

FUEL

INJECTION

The

fuel

injection

the diesel engine

in

handling. The

bench-tested
Speed

(hertz)

servicing dealer can perform

ENGINE ADJUSTMENT section in

of adjustments or repairs
injection service shop.

NOTE:

When
must be advised that
application.

,

NOTE:

The

injection pumps should only

authorized fuel injection service

PUMP

pump

is

the

most

and,

therefore, calls

fuel

injection pump

and

should not be tampered

and

timing are

servicing the injection

the

must

pump

the

only adjustments the

on

the

be

is

facility.

important component of

for

the

utmost

caution

has

been

thoroughly

with.

injection

this

performed

pump,

being used

pump.

manual.

by

the

service shop

in

be

serviced by

See

Other

a qualified

a generator

the

types

an

FUEL

LIFT

Periodically
and

make

sure

are

tight

.and
pump's
the

mounting

mounting

A

WARNING:

connections
Make

sure

fuel

system

PUMPS

check

the

fuel

that

no

leakage

~ure.

The

bolts

should

bolt

to

ensure

Fuel

is a

fire

hazard

proper

ventilation

components.

connectioil:,;

is

present

DC

ground

be clean

proper

leakage

at

and

exists

to

and

and

connection

and

pump

operation.

the

fuel

should

whenever

out

of

that

the

at

well

secured

pump

be

corrected.

servicing

the

fittings

one

or

pump

ofthe

by

Its

TYPICAL

FUEL

[25

INJECTION

KW

SHOWN]

TO

FUEL

FILTER

NOTE:

THE
ON
AN
OF
PUMP.

PUMP

FUEL

LIFT

THE

32

KW

INTEGRAL

THE

FUEL

PUMP
IS

PART

INJECTION

FUEL

LIFT

PUMPS

Engines & Generators

.16

FUEL

FUEL

FILTERS

The

fuel injection pump and the fuel injectors are precisely

manufactured and they must receive clean diesel fuel, free

of

from water and dirt. To ensure this flow
must pass through at least two fuel filters, a fuel water
rator and the engine's spin-on fuel filter. Visually inspect,
clean, and change these filters according to the maintenance
schedule in this manual.

··A-WARNING:

when

servicing

any

fuel

that

O/lflll

flames

tem

when

when

servicing

Shut

the

fuel

may

spill.

Df.

other

servicing.

the

fuel

off

the

system.

DO

NOT

sources

Ensure

proper

system.

fuel

allow

of

fire

clean fuel, the fuel

valve

at

Take

care

any

near

the

ventilatitlll

the

tank

in

catching

smoking,

fuel

sys·

exists

sepa-

SYSTEM

Changing

1.

Shut off·the fuel supply.
Open the bleed screw on top

2.
tainer under the fuel filter and open the drain on the bot­tom

3.

Close the drain and unscrew the bolt that secures the

bowl. The bowl and filter will drop down.

4.

aean

making certain that it lies squarely on the base recess.

5. Replace the upper sealing'ring and the
ter head. Install the new filter element and re-install the
retaining bolt.

6. Bleed the air from the filter assembly.

the

Fuel

Filter/32.0

of

the bowl and drain the fuel.

the base. Install a new sealing ring in the base

KW

of

the filter. Place a con-

"o"

ring in the fil-

'BLEED

SCREW

Changing

1. Shut the fuel supply off.

2. Loosen the fuel filter turning counterclockwise with a
filter wrench.

NOTE:

during
TEM after

3.

Wipe clean the sealing face on the housing bracket with a
rag, so the new filter

4. Lightly oil the sealing o-ring on the new filter. To
stall, tum the filter assembly clockwise carefully until the
o-ring contacts the sealing surface
Turn 2/3 further with the filter wrench.

5.

Tum on the fuel and start the engine. The normal preheat
function should quickly prime the system
should start.
follow the

PRESSURE

GAUGE

LOCATION----

BLEED

the

Fuel

The

cartridge contains

disassembly.

replaCing

If

the engine should fail to start immediately,

Priming instructions in this section.

Filter/20.0

fueL

Perform

the

the

spin-on

will seat properly.

KW

and

Take

care

PRIMING

filter.

of

the housing bracket.

25

not

THE

~d

KW

to

spill it

FUEL

the

rein-

engine

SYS-

SEALING

RING

FUEL

FILTER

[32

KW]

FUEL

FEED

PUMP

An additional fuel filter is located in the feed pump. This fil-

ter (strainer) is removed for cleaning
bolt at the bottom. This strainer should be cleaned every
operating hours. Use compressed air and/or clean with
kerosene.

STRAINER/32

KW

by

releasing the banjo

250

FUEL

FILTER

120·

AND

25-

KWJ

FUEL

FEED

[32

KW]

l"MriWESIERBEICE

l Engines & Generators

17

PUMP

FUEL

SYSTEM

BLEEDING

(PRIMING)

THE

FUEL

SYSTEM/20.0

AND25.0KW

There

is

one bleed point

for

the removal

screw

is
mounted on the engine. This screw should
two

turns

fuel

filter.

by

using the palm of your

the.pJimer pump on the

method

air

is

expelled, tighten the bleed screw. Depress

switch

10-20 seconds

fuel

filter
filter housing and the injection pump out of
back

to

the

NOTE:

When

filter assembly keep

plugs)

are

BLEEDING

To

bleed the
the bleed screw on
fuel

feed

Unscrew the knob

pop

will
knob

fully

pumping stroke.

screw,

bleed
Disconnect the

and

hose

fuel,

free

Reconnect the return line

strokes. Then push the cylinder in

Start the engine
Should unstable running occur open the

high pressure line
Loosen
wrench to catch the spurting
the nut

and

runs smoothly.

PRESSURE......__

GAUGE

LOCATION

of

located on the housing for the spin-on fuel filter

to

remove

Energizing

will

force air out through the bleed

housing

fuel

tank through the return.

using the preheat function

being

energized.

(PRIMING)

fuel

pump (see illustration).

up.

Slowly work this priming pump

upward

Pump until

then close

fuel

slowly pump

of

air,

is discharging from the line-stop pumping.

and

1!2

to

a full

proceed

FUEL

..........._

.......

..,.

_....,

in

the

on-engine

air.

On

the

20.0

KW

and

air

from

the upper

the

preheat switch

hand

to

top

of the filter

or

slowly pumping

to

force

any air

in

mind that the preheat elements (glow

Take

THE

FUEL

system

on

the 32.0

top

of the

fuel

on

the

fuel

feed pump

and

pushing it down

free

the

bleed

line return hose. Place towels under the

the

fuel

feed pump

and

work the pump a

check/correct

to

the injector

turn

place a cloth over

fu~l.

to

the

next

injector line until the engine

housing

for

slowly

housing

in

the

system

to

care not

SYSTEM/32.0

KW

filter

and

to

of air bubbles

screw.

and

secure

any

leaks.

to

expel air

When

fuel

system

to

25

KW

this bleed

be

opened one or

area

of

10-20

seconds or

depress

the

to

Generators open

and

nut

free

and

either

point.

Once all

the

preheat

primer

on

between

the

system and

bleed air

then

achieve a full

again.

the

from

overheat

the

by

it.

that secures the

in

of air retighten

them.

locate the

cylinder

pulling the

from

the open

When clear

few

more

the

line.

line and

release

KW

open

the

the

the

the

KW

FUEL

PRESSURE

The

20

KW:and

in-line gauge at the secondary

indicate the fuel inlet pressure. A positive fuel supply should

read 2.5
engine performance.
from

be purchased thru

FUEL

If

have
diesel
turers instructions).

to

3.5

the

fuel

ADDITIVES

fungus or bacteria

an

authorized dealer correct

fuel

biocide

GAUGE

25.0

KW

generators

psi.

Pressure below

Low

pressure indicates unclean

water separator·

your

local marine store.

is

causing

to

sterilize the

have

a connector for

fuel

filter .This gauge will

1.5

psi

will result

filter. A fuel

fuel

these

fuel

pressure gauge

problems

problems. Then use a

(follow the manufac-

you

in
fuel

should

an

poor

can

SPARES

While the likelihood of having
slim;.the possibility
that banjo washers, injector seat washers;
carried
your local WESTERBEKE dealer or distributor. If a leak
should develop
a simple tightening of
with a replacement

HIGH

1#11NJECTOR

on

board

PRESSURE

(32

BLEED

does

at

all

at

a banjo washer

found

LINE.-:..

KW)

•

SCREW

times.

the

to

servi~

.the

system

exist. Therefore, we recommend

and a

Purchase needed spares

that

cannot be corrected

fitting,

replace tM sealing washer

in

the

hardware

kit

fuel

for your

PRIMER

at

sea

filter

from

model.

be

by

(HAND)

is

PUMP

TO

FUEL

·

FUEL

FILTER

(20

KW ~ 25

KW)

j...,.,.IWESTERBEKE

l Engines & Generators

18

FILTER

FUEL

(32

FEED

KW]

PUMP

ENGINE

OIL

CHANGE

Engine

1. Draining the Oil Sump.

2.

Oil

Change

the

sump

drain

hose

(attached

while

the

engine

is

warm.
replace
securely.

NOTE:

.

the

hose

in

its bracket,

Thread

size for

isl/4NPT.

At~ays

yellow/gray emulsion indicates
the oil.
prompt
petent
water
exhaust
of
the
caused

siphon

RepJ~cement

oil

hole
drain

This

wrench

Although

attention

mechanic

present

system

raw

water

exhaust,

by
valve.

filter,

in

the

the

helps

observe

in

through

filling

the

poor

you

may

upper

oil

from

to

lessen

should

the

the

used

this

condition

to

prevent serious damage.

should water

the

oil

attached to

the

the

engine. This problem

location, of or

SUMP

DRAIN

of

the Oil Filter.

find

it

and

lower

it

into a container before removing
spillage. A

be

helpful

Discharge

Drain

lube

oil

can

be

the

raw

the

used

to

the

front of

the

used

oil

and

replace

pi/

drain

hose capped end

as

it

is

removed. A

the

presence of water

is

rare,

it

be

present

the

result of a

engine and/or a siphoning

water cooling circuit into

the

lack

HOSE

When

removing

helpful

and

cleaner

portion

of

the

small

automotive filter

in

removing

the

oil

through

the

engine)

completely,

the

end

does

require

Call

in

the

oil.

fault

is

often

of,

an

to

punch

old filter to

old oil

cap

in

a com-

Raw

in

the

anti-

the

used

filter.

it.

OIL

FILTER

(25

KW • 32

_.:...NOTE:

I

OIL

FILTER

(20

3.

Filling the Oil Sump.

cap

on

the

top

of

After

refilling,
checking
leakage
tem,

and

with

the

on

the
Immediately after
engine

a

there

are

NOTE:

rial

standards

_parts

_might

the

engine's

around

stop

lube

oil

dipstick,

to

make

no

oil

Generic

be

run

the

or diameters

the

engine

the

generator

oil

the

new

generator.

dipstick.

should

an

oil

sure

the

leaks

around

filters
entirely

Add

pressure.

oil

filter

Then

Fill

the

engine

filter

oil

are

not

different

new

oil

through

or

through

for a few

Make

or

from

check

to,

but

not

require

change

and

pressure

of

is

the

new

oil

recommended,

important items

from

genuine

the

the

side

moments

sure

the

oil

the

quantity

over

additional

oil

normal

filter.

there

the

as

DO

NOT

OILFILTBl

KW)

oil

filler

oil

fill.

while

is

drain

high

fill,

run

and

the

on

generic

parts.

no
sys-

of

mark

oil.

that

mate-

KW)

OVER

oil

the

TIGHTEN

NOTE:

Do not punch this hole without first loosening the

filter

to

make certain it

Place some
ter

when
(Oil or
cooling

the

old
rubber sealing gasket comes off
this rubber sealing gasket remains sealed against
engine

When
gasket's sealing surface on
and
gasket

threaded

by

hand.

paper

unscrewing

any

other

ability.

oil

filter

block,

gently

installing

apply a thin

on

the

new

oil

filter

Please keep

towels

fluid

as

it

the

coat

oil

nipple,

can

and

it

to

catch

on

the

is

removed

remove

new

oil

of

clean engine

filter.

and

be

removed!

a plastic bag around

any

engine reduces

your

engine clean.) Inspect
to
with

it.

filter

element, wipe

the

engine block free of

Screw

then

oil left

make

the

oil

the

filter

tighten

in

the

the

sure that

old

oil

to

the

rubber

onto

the

filter

the

fil-

filter.

engine's

the

filter.

If

the

the

filter

oil

the

firmly

EngitJes

A

contaminants.
and
discard
used

Oil

The engine's
oil

pressure

operation,

NOTE:

reading

pressure

depending

placed

& Generators

19

WARNING:

Avoid

nails

thoroughly

clothing

oil

properly.

Pressure

oil

pressure,

gauge

the

oil

pressure

A newly

upwards

reading

upon

on

the

started,

the

generator.

Used

engine
prolonged
using

StJBP

or

rags

containing

during

on

the

instrument

will

range

cold engine can have

of

60

psi.

A warmed engine

as

low

as

35

psi.

temperature

oil

contains

skin

contact.

and

water.

used

operatimt,

panel.

between

These

of

the

engine and

harmful

Launder

oil.

Discard

is

indicated

During

50

an

oil pressure

can

readings

Clean

normal

and

60

have

will

the

skin

or

by

psi.

an
vary
load

the

oil

INSTALLATION

This popular accessory

ter

from

the

engine

engine

room

bulkhead.

NOTE:

ual

Refer to

for

instructions

the

20

is

to a more

ENGINE

on

removing

KW

CONNECTION

REMOTE

used

to

relocate

convenient location

OIL

CHANGE

the

oil

filter.

SHOWN

the

page

OIL

engine's

such

in

this man-

FILTER

oil

fil-

as

an

(OPTIONAL)

To

install, simply remove the engine oil filter
WESTERBEKE's remote oil
install

this

kit

with

the

Contact

NOTE:

incorrect installation

your

WESTERBEKE dealer for

Westerbeke

is

not responsible for engine

of

filter

kit

oil filter facing

the Remote Oil

FASTEN

(SCREWS

and

as

shown.

down

as

illustrated.

more

information.

failure

Filter.

SECURELY

TO A BULKHEAD

ARE

OWNER

thread

Always

due

SUPPLIED)

on

to

APPLY A THIN
WHEN

INSTALLING
ADAPTER
ADDITIONAL
TACTS

ON,

THE

3/4

BASE.

COAT

THIS

THEN

TURN

OF

CLEAN

ADAPTER.

TIGHTEN

AfTER

OIL

(BY

THE

TO

THE

THREAD

HAND)

AN

O·RING

O·RING

THE

CON·

THE

FILTER
ONCE
THEN
TURN.

A

THIN

COAT

GASKET

THE

FILTER

TIGHTEN

IT

OF

CLEAN

WHEN

INSTALI.ING.

CONTACTS

AN

THE

ADDITIONAL

OIL

BASE,

TO

3/4

Engines & Generators

20

DC

ELECTRICAL

SYSTEM

ENGINE

The
shown
grams
trical

A

circuit,

the
howevtH,
engine's

Battery

The
the
Cranking

Battery

Review
lish a systematic maintenance schedule
starting

D Monitor your voltmeter

D Check the electrolyte level

12-VOLT

engine

has a 12

on

the

wiring

when

troubleshooting or when servicing

system

on

the

CAUTION:

never

eng/nels

electrical

Specification

minimum

engine's 12-volt

Amps

Care

the
batteries,

operation.

hydrometer.

lb

shut

running.

to

avoid

recommended capacity of

(CCA).

manufacturer's recommendations

and

DC

CONTROL

volt

DC

diagrams

engine.

avoid

damage

off

the

engine

Shut

electrical

CIRCUIT

electrical control circuit that

that

follow.

to
battery

off

the

shorts

circuit.

DC

control circuit is400-600Cold

house

batteries.

for

proper charging during engine

and

specific

Refer

the

battery

switch

engine

when

working

the

for

your

gravity

to

these dia-

the

DC

charging

while

battery

battery

and

then estab-

engine's

with a

is

elec-

switch,

on

the

used

in

GLOW

The
tion
become

The
When

should "click"
Glow

against a
The
test the power drain
to

·

Re-install the
plugs should get
25
short circuit.

PLUGS

glow

plug

chamber.

glow

plugs

tip

test resistance (1.1

A

WARNING:

'to

the

testing

seconds.

compound

A

CAUTION:

30

seconds.

They

red hot

plugs

PREHEAT

can

good

should

touch.

the

plugs.

plugs

If

When

on

the

is a small

when

are

on

be
ground
glow

Be

the

heater installed

run

off the engine starting

activated.

wired through

is

pressed

and

checked

red

(8

These

careful

in

very

plugs

reinstalling

threads.

Do

at

the

the

glow

by

unscrewing

(engine block)

hot.

You

to 9 amps

to

1.2

ohms).

glow

plugs

not

to

the

engine

hot

(at

the

don't heat

not

keep

glow

the

control

plug

should

can
per

burn

and

terminal

up

the

glow

plug

in

preheat

panel

and

turning

also

use

plug),

will

become

your

test

them

end)

quickly,

plugs,

on

each

pre-combus-

battery

solenoid.

this

begin

to

and

holding

them

an

ammeter

or

an

ohmmeter

very

fingers

again.

within

check

use

for

more

and

solenoid
get

hot.

them

on.

to

hot

when

The

20

to

for

a

anti-seize

than

D

Use

only

level.

D

Make

certain that

tight

to

D

Keep

your

A

WARNING:

cause

severe

protective

distilled water

battery

the

battery

posts

batteries clean

Sulfuric

bums

on

gear.

to

bring electrolytes

cable connections
(and to your engine).

and

free of

acid

In

lead

skin

and

damage

to

are

corrosion.

batteries

clothing.

a proper

clean

and

can

Wear

TERMINAL

AIR

INTAKE

Glow

plugs are
heat solenoid
intake that
bustion
occasional cleaning of
tors.

If

the

element

activated

HEATER

activates

quickly

chamber.

fails

and

the

not

used

heats

There

to

solenoid "clicks" on, replace

END

GLOW

PLUGS

on

the

32

KW

a heater element

the

air

as

it

is

no

maintenance

the

heat

element

up

and

when

generator.

in

is

drawn

its

the

preheat

the

engine's

into

required

electrical

sequence

the

The

pre-

air

the

com-

except

connec-

heater.

an

is

I

"fttiV'lWESTERBEICE

l Engines &

Generators

21

DC

ELECTRICAL

DESCRIPTION

The

charging system consists

regulator, an engine

cuit breaker, and a battery with connecting cables. Because
of

the use

of
regulator is very compact and is mounted internally
back

of

the alternator.

DC

integrated circuits (IC's) the electronic voltage

of

an alternator with a voltage

wiring harness, a mounted

DC

or

cir-

on the

SYSTEM/ALTERNATOR

1.

Start the Engine

2. After a few minutes
tery voltage at the battery terminals using a multi-meter

DC

set on
The voltage should

your alternator

volts.

of

running measure the starting bat-

be

increasing toward

is

working.

(14.0)

14

volts.

If

it is,

51

AMP

ALTERNATOR

DC

(GENERA'rblfCONNE-CTIONS).

TROUBLESHOOTING

A

WARNING:

hot.

Do

not

This troubleshooting section is to determine
exists with the charging circuit or with the alternator.
determined that the alternator or voltage regulator is bad, it is
best to have a qualified technician check it out.

The

alternator charging circuit charges the starting battery and
the service battery.
battery selector switch is usually mounted in the circuit to iso­late the batteries, so the starting battery is not discharged
along with the service battery.
starting battery but not the service battery, the problem is in
the service battery charging circuit and not with the alternator.

Testing

A

tain
from

the

WARNING:·

that

everyone

sheaves

A

failed

touch

until

An

isolator with a diode, a solenoid, or a

Alternator

Before

is

clear

and

belts

alternator

the

alternator

If

starting

of

during

can

become

has

cooled

if

the alternator is charging the

the

engine

moving

parts!

test

procedures.

a problems

make

Keep

very

down.

If

it is

cer·

away

MULTIMETER

TESTING

BATTERY-ALTERNATOR

4.

A.

B.

C.

D. Check the battery voltage.

THE

STARTING

(ENGINE

If
after the engine is started and run for a few minutes, a
problem exists with the alternator or the charging circuit.

A

·

RUNNING)

the starting battery voltage remains around 12 volts

Thm

off the engine. Inspect all wiring and connec-

tions. Insure that the battery terminals and the engine

ground connections are tight and clean.

CAUTION:

charging
switch

If

insure that it is on the correct setting.

Thm
engine.

condition the reading should

circuit,

when

a battery selector switch is in the charging circuit,

on the ignition switch, but do not start the

the

To

avoid

never

engine

0

COM

+

damage

shut

is

running!

If

(12.5)

0 I

to

the

off

the

engine

your battery is in good
be

12 to 13 volts.

MULTIMETER

battery

battery

NOTE:

Multimeters and

DC

andAC

cations. Always disconnect shore power cords, isolate
and A C converters and shutdown generators before perform-

DC

ing
knowledge

circuits are often mixed together in marine appli-

testing.

of

AC

DC

Circuits

NoAC

tests should

circuits. .

be

r,nade

without proper

DC

TESTING

BATTERY

(IGNITION

Engines & Generators

22

THE

·,VOLTAGE

-

ON • ENGINE

OFF)

COM

.

+

DC

ELECTRICAL

E.

Now check the voltage between the alternator output
terminal (B+) and ground. If the circuit is good, the
voltage at the alternator should
tery, or
age will
between the alternator and the

if

an isolator is

be

zero. If not, a problem exists in the circuit

nections - look for an opening

in

be

the same as the bat-

the circuit the alternator volt-

battery. Check all con­in

the charging circuit.

SYSTEM/ALTERNATOR

Alternator

4. Check the voltage
should have a voltage between 13 and 14 volts when the
engine is running. If not, there is a problem
battery charging circuit. Trouble-shoot the service battery
charging circuit by checking the wiring and connections,
the solenoid, isolator, battery switch and the battery itself.

is

Working

of

the service battery. This battery

in

the service

M

ULTIMETER

ITCH,

-

TESTING

BAnERY-ALTERNATOR

THE

(ENGINE

RUNNING)

STARTING

L

F.

Start

the

engine

again.

Check the voltage between the

alternator output and ground.

The

voltage reading for a properly operating alternator
should be between 13.5 and 14.5 volts.
tor is over­able service shop.

NOTE:

voltmeter
at the EXC terminal
tery

voltage at

If

12 volts is not present at the EXC terminal trace

wiring,

or

undercharging, have it repaired at a reli-

Bejore removing the alternator for

to

ensure

that 12 vofts DC excitation is present

if

the previous test showed only bat-

the

B output

look for breaks and poor connections.

terminaL

If

repair,

miD

0

COM

/

t'L

E

,ENGIN

~ROUND

your alterna-

use

your

the

.

MULTIMETER

A

CAUTION:

tor

charging

Megger}.

cln:ult

You

am

0

COM

When

can

damage

pfidorm/ng

do

not

use a high

the

-

SERVICE'

JIATT~IW.

TESTING
BAnERY

...

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tests

voltage

THE

(ENGINE

on

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SERVICE

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the

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on-off

switch
should be installed in this
circuit to disconnect the
starter from the battery in
an emergency
leaving the boat. Twelve
volt diesel engine starters
typically draw
amps when cranking. A
switch-with a continuous
rating

of

VDC will normally serve

his function, but a switch

must

never be used to

"make"

and

when

200

to300

175

amps at 12

the starter circuit.

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starter from the battery in

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volt diesel engine starters
typically

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amps when cranking. A
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of

rating

175 amps at
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START

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on-off switch

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test

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this

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0

REMOH

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.PINS

Engines & Generators

250

VOL

!METER

HOURMEIER

ELECTRONIC

GOVERNOR

ELECTRONIC

The system is composed

Controller-

1.

2. Sensor - Installed on the generator stator housing over the

flywheel ring gear.

3.

Actuator - Mounted at the front
attached with linkage to the throttle
pump.

Controller

1.

Speed. - This adjustment is used to raise
speed to the desired hertz.

2. Gain
actuator to the generator/engine load changes.

NOTE:

A high gain adjustment can induce an oscillating
the actuator producing a hunting mode. In such cases, lessen
the gain adjustment.

GOVERNING

Mounted inside the instrument panel box.

SYSTEM

of

three basic components:

of

the engine and

arm

Adjustments

-This

adjustment affects the reaction time

of

the injection

or

lower engine

of

the

of

Calibration

1. With no power to the governor (engine not running)

adjust the GAIN potentiometer to

2.

Start the engine and adjust the speed by turning the

SPEED potentiometer clockwise to desired speed.

NOTE:

Controllers are factory adjusted to minimum rpm.

However, for safety, one should be capable

engine

if

an overspeed should exist.

3. At

no

load, turn the GAIN potentiometer clockwise until
the engine begins to hunt.
physically upset the governor linkage.

4. Turn the gain potentiometer counterclockwise until the
engine runs stable.

9:00 o'clock.

of

disabling the

If

the engine does not hunt,

ELECTRONIC

GOVERNOR

TERMINAL

SPEED{.n

GAIN

j\J

LINEAR

ACTUATOR

KEEP

ACTUATOR

LINKAGE

WELL

LUBRICATED

FLYWHEEL

HOUSING

NOTE: A booklet

pdfform

SENSOR

TO

ELECTRONIC

CONTROLLER

"ELECTRONIC

off

our website: www.westerbeke.com under your specific model.

GOVERNORS" Analog Diesel Models. Is available in

Engines & Generators

26

LINEAR

ACTUATOR

(20

KW

SHOWN)

TROUBLESHOOTING

THE

ELECTRONIC

GOVERNOR

System

(Engine

Actuator
is

depressed

Actuator
engine

Problem

appears

runs

at

fully

extends

and

hunts

running.

dead

idle.)

when

stays

extended.

(oscillates)

PREHEAT

and

1.

Low

2.

Stuck

3.

No

signal
(Measure
engine

be

2.5

4.

Check
check
negative

a.

Purple

b.

Second

5.

Perform
terminals

DC

lead

(Preheat

a.

Low
actuator

b.

Battery
connections.

c.

Battery

but

1.

Check

actuator

Depress

a.

Actuator

b.

Actuator

connections.

NOTE:

Release

the

purple

1.

Linkage
binding.

2.

Improper
controller.

3.

Inadequate
controller,

Connect a DC
plus
controller

Lift

both

terminal
Connect

C

plus

DC

negative.

Momentarily

The

3a.

Sensor

away

erratic

Probable

battery

voltage

linkage.

or

weak

AC

voltage

is

running

volts

or

greater.

Actuator­for

battery

black

lead

lead

purple

the

following

at

the

at

the

controller

depressed).

voltage

connection.

voltage

voltage

not

the

controller.

leads

from

PREHEAT.

fully
does

PREHEAT

lead.

between

adjustment

DC

power

complete

voltmeter

and

negative

terminal

purple

block.
one

purple

terminal

depress

actuator

should

positioned

from

flywheel

signal

voltage

cause

at

controller.

signal

from

at

idle.

depress

voltage

at

terminal

to

black.

to

black.

check

actuator

(1.20·2.0

at

both

at

one

other.

Lift

one

the

terminal

extends.

not

fully

and

actuator

of

supply

the

leads

block.

leads

from

lead

and

the

PREHEAT.

fully

marginally

teeth

to

from

sensor.

sensor

Voltage

should

PREHEAT

between

block.

between

and

the

negative

terminal

VDC)

at

actuator

actuator

of

the

purple

block.

extend

reconnect

and

throttle

GAIN

on

to

following

across

the

at

the

the

to

the

other

to

the

extend.

too

giving

controller.

whlle

and

block.

either

lead

and

tests:

far

Check

1.

2.

3.

4.

1.

2.

3.

DC

NOTE:

3a.

wiring

Lubricate,
Check

housing.

Replace

leads.

a.

b.

c.

a.

b.

Lubricate/free-up.
Lessen

voltage

free

for

improperly

Replace

controller

Broken

actuator

Broken

actuator

Replace

Short

in

Replace

GAIN

If

actuator

If

the

voltage
connections,
due

to

remote

connections.

registering

12

VDC

System-

24

VDC

System

Reconnect

Check

the

VerificationJRemedy

for

cause.

Check

battery

up

linkage

between

controller

installed

or

or

adjust.

if

battery

lead.

lead.

the

actuator.

lead

to

actuator.

controller.

adjustment

does

not

fully

is

less

low

battery

panel

on

9.6

-19.2

actuator

position

of

than

installation

the

VDC

the

damaged

voltage

is

(Recalibrate

extend,

check

specified,

voltage,

voltage

and

meter

should

or

higher

VDC

or

higher

leads

properly

sensor.

the

check

small

state

of

sensor

not

present

Controller).

the

actuator

for

drop

wire

be:

after

making

charge.

and

throttle

at

loose

in

DC

sizes

in

flywheel

both

leads.
or

poor
circuit
making

this

arm.

test.

27

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjust­ments be performed by a competent engine mechanic. The information
below is provided to assist the mechanic.

ADJUSTMENTS

VALVE

NOTE:

engine's valves. See

BOLTS.

Pull off the air breather pipe from the rocker cover, and take
off the rocker cover bolts and the rocker cover to expose the
rocker shaft and valve assembly.

Position the No. 1 piston at Top Dead Center (TDC) on its
compression stroke and adjust the

illustrated.
Position the No. 4 piston at TDC

and adjust the
bered 1 to 8 from the front

Adjust each valve's clearance by inserting a
mm) feeler gauge between the rocker arm and the valve
stem. Make sure to adjust all valves to
while the engine is cold.

CLEARANCE

Retorque the cylinder head bolts before adjusting the

A

CAUTION:

engine

is

cold.

firing

order

of

to

the

specified

# 4, 5, 7 and 8 valves. The valves are num-

WHEN

NO. 4 CYLINDER

4 4

.4EXH~UST

I

41NTAKE

ADJUSTMENT

TORQUING THE CYLINDER HEAD

Adjust

the

valve

Valves

the

engine.

torque

3

EXHAUST

I

3

WHEN

NO.1

clearance

are

adjusted

Tighten

before

of

VALVE

IS

AT

TOP

~~

. I

2E~HAUST

31NTAKE

CYLINDER

by

the

adjusting

#

1,

2, 3 and 6 valves as

of

its compression stroke

the engine to the back.

0.012 inches (0.3 mm)

ADJUSTMENT

DEAD

CENTER

2

2

INTAKE

11

EXH~UST

2 1 1

IS

ATTOP

when

cylinder

cylinder

the

valves.

0.012 inch (0.3

SEQUENCE

1

INTAKE

I

DEAD

CENTER

the

in

the

head

bolts

DRIVE

For your safety, Westerbeke generator models come equipped
with belt guards that cover over the belt(s) on the front
engine.
installed for that purpose.) Operators are advised that proper
inspection, service, and maintenance is required.

Drive belts must be properly tensioned. Loose drive belts
will not provide proper alternator charging and will
ally damage the alternator. Drive belts that are too tight will
pull the alternator out

tor to wear out prematurely. Excessive drive belt tension can
also cause rapid wear
of
ence

high operating temperatures.
The drive belt

no less than 3/8 inch

(12mm) as the belt is depressed with the thumb at the

point between the two pulleys on the longest span

A spare belt or belts should always be carried on board.

Adjusting

2. Loosen the alternator adjusting strap bolt and the base

3. With the belt loose, inspect for wear, cracks, and frayed

BELT

ADJUSTMENT

of

("Out

of

sight - out

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

of

oil on the belt can cause belt slipping, resulting

is

properly adjusted if the belt can be deflected

A.

WARNING:

drive

belt's

1. Remove the belt guard.

mounting bolt.

edges.

4. Pivot the alternator on the base mounting bolt to the left

or right as required, to loosen or tighten.

5. Tighten the base mounting bolt and the adjusting strap
bolt.

6.

Operate the generator for about 5 minutes then shut down

and recheck the belt tension.

7.

Replace the guard.

Never

tension

Belt

Tension

of

mind." The belt guard is NOT

eventu-

of

alignment and/or cause the alterna-

of

the belt and reduce the service life

(10mm) and no more than 1/2 inch

mid-

of

the belt.

attempt

while

the

to

check

engine

or

adjust

is

in

operation.

the

in

the

Engines & Generators

28

ENGINE

TORQUING

Tighten the cylinder head bolts according
shown
when this is done, and loosen one head bolt one-half tum and
then tighten it between 85 to
the BED
require retorquing.

20

19

18

CYLINDER

in

the illustration below. Make sure the engine is cold

20KW and 25KW. The. 32 KW head bolts do NOT

13 9 5 4 8 12

HEAD

BOLTS

90 lb-ft. (11.8

CYLINDER

2 3

to

HEAD

the sequence

to

12.5 kg/m) for

BOLT

PATTERN

11

ADJUSTMENTS

16

NOTE:

In

case

of

severe vibrations and detonation noise, have

the injectors checked and overhauled

Poor

injection service center.
loss

of

positive fuel pressure to the injection

in injector faults.

TESTING

Remove the injectors and check injector spray
pressure and spray pattern. Correct as needed.

FUEL

INJECTORS

fuel quality, contaminates and

TESTER

by

an authorized fuel

pump

INJECTION
PRESSURE
TEST

will result

ENGINE

Check the compression pressure. To do this, warm the

engine, remove all

the fuel shut-off solenoid wire, and install a compression
adapter in the injector hole or glow plug hole. Connect a
compression tester on the adapter and crank the engine with
the starter motor until the pressure reaches a maximum value.
Repeat this process for each cylinder. Look for cylinders with
dramatically (at least
age of the others. Compression pressure should not differ by

more than 42.7 psi

If a -:veak
lem
ances for the weak cylinder, adjust as needed and test again.

If

cylinder to seal the rings and repeat the test.
comes up

Abnormally high readings on all cylinders indicate heavy

c~rbon

med by

COMPRESSION

fuel

injectors, or glow plugs, disconnect

20%) lower compression than the aver-

(3.0 kg/cm2) at 200 rpm.

COMPRESSION

cylinder

IS either valve-or piston related. Check the valve clear-

the cylinder

- the rings are faulty.

ac~umulations,

htgh pressures and noise.

TESTER

is

flanked by healthy cylinders, the prob-

is

still low apply a small amount

If

a condition that

might

of

oil into the

compression

be accompa-

1.

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

A

CAUTION:

such

velocity

of

fingers

bloodstream,

a.

!f

the diesel fuel

tt.

At the same time, clean or replace the fuel filter.

b. Set the nozzle tester in a clean place where there is

dust or dirt.

c.

Mount the nozzle and nozzle holder on the nozzle

tester.

d.

Operate the hand lever

bleed the

~~

_int~rvals

InJection startmg pressure. Refer to the models
Specification page for Injector Spray Pressure.

ADJUSTING

The

that

it

may

and

hands,

it

may

cause

air

in the nozzle line, then move the hand lever

of_

one stroke per second while reading the

of

nozzle and,

spray

injected

penetrate

destroying

of

the nozzle tester is stained,

tissue.

blood

poisoning.

of

nozzle tester several times

from

the

deeply

If it

if

into

it exceeds the

nozzle

enters

is

of

the

skin

the

repl~~e

no

to

!

ISHIM'THICKNESS

U.1mm
D.2mm
D.3mm
D.5mm

INJECTOR

Engines & Generators

29

ENGINE

ADJUSTMENTS

If the pressure
the

specified pressure

ness of
The shim

(0.0020
As

0.05

(71.1lb/in
When replacing

remove

is

different

the

adjusting shim.

has

10

different thicknesses for

in)

from

1.0

mm

(0.0020 in)

2

)

of injection pressure increases.

the

the

body

with

the specified torque.

INSPECTING

1.

Operate the

one
rectly
injects
strips.

THE

hand

stroke

per

in

its axial direction. A nozzle

fuel

in

an

Also, a spmy
defect. These defects
ging with
cleaned

dust

before

expose one's skin

skin

and

cause infection.)

from

the

by

increasing or decreasing

mm

(0.0393

is

shim,

in)

increased,

grip the retaining

a wrench. Tighten

SPRAY

lever of the

second

PAnERN

nozzle

to

check if the

oblique direction or

in

the

form

may

sometimes

and,

therefore,

reassembly.

to

this

all

(Care should

spray

standard value,

every

to

1.95

approx.

the

adjust

the

0.05 mm

mm

(0.0768

5.0

kg/cm

nut

in

a vise

retaining

thick-

nut

tester at intervals of

fuel

is

injected cor-

is

defective if

in

several separate

it

of particles indicates a

be

caused by

parts should

as

it

may

be

be

taken

penetrate

carefully

not

the

to

in).

2

and

to

clog-

to

2.

Apply

the

by

operating the

nozzle

tip.

on

the

bottom,
replaced. A
remain
indicate a defect.

pressure of

If

it

very

on

the

tip

CORRECT

115

kglcm2 (1635lb/in

hand

lever,

and

drips or has a

it

is

considered defective

small

amount

of

the

nozzle;

AFTER

DRIP

check

the

large

accumulation of

of

fuel

may

however,

WRONG

TEST

2

)

to

drips

and

should.

sometimes

this.

does

nozzle

from

not

the
fuel
be

NORMAL

FAULTY

ANGLE

CHATTERING

TEST

FAULTY

DIRECTION

Engines & Generators

30

ENGINE

TROUBLESHOOTING

The tables which follow indicate troubleshooting procedures
based upon certain problem indicators, the probable causes
the problems, and the recommendations to overcome these
problems.

Key

switch
depressed:
fuel

START
engagement.

START
indications

fuel
Generator

start,

Engine
Battery

Battery

Generator

on,
no

solenoid

SWITCH

switch

OK;

solenoid

engine

fuel

solenoid

can't

runs

not

engine

be
down.

charging

Problem

PREHEAT

panel

indications;

or

electrical

DEPRESSED,

is

depressed;

starter

solenoid

not

functioning.

cranks,

energized.

stopped.

stops.

switch
fuel

pump

no

panel

but

does

starter

OK

not

1.

Battery

2.

Emergency
20-Amp

2.

3.

1

0-Amp

preheat

4.

Loose

5.

Preheat

1.

Connection

2.

Faulty

3.

Faulty

4.

Loose

5.

Low

1.

Poor
Defective

2.

1.

Faulty

Preheat

2.

Faulty

1.

1.

Oil
High

2.

Low

3.

4.

Poor

DC

5.

1.

DC
Alternator

2.

Fuel

1.

2.

Switches
or

disconnected.

Fuel

3.

4.

20

Amp

Exhaust

5.

6.

Water

Probable

Switch

stop

circuit
breaker

solenoid.

battery

solenoid

to

switch.
solenoid.

battery

battery.

connections

fuel

fueling

system.

solenoid

DC

alternator.

Pressure

switch.

resistance

resistance

battery

connections.

alternator

charge

circuit

drive.

lift

pump

and/or

starvation.

circuit

system

in

fuel.

Cause

not

on.

switch

breaker

tripped

connections.

not

operating.

solenoid

connections.

to

fuel

solenoid.

faulty.

leak

to

leak.

not

charging

faulty.

failure.

wiring

breaker

is

restricted.

of

off.

tripped.

on

faulty.

solenoid.

ground.

..

loose

.

tripping.

Note:

The engine's electrical system is protected

by a 20

amp
manual reset circuit breaker located on a bracket at the rear
of

the engine. The preheat solenoid is close
emergency
bracket

STOP switch, which may be mounted on the same

or

on the back

of

the instrument panel, depending

by,

as

is the

upon the generator model.

Verification/Remedy

1.

Check

switch

and/or

battery

connections.

Check

2.

Reset

2.

circuit
Check

3.

Check(+)

4.

engine

Check

5.

Check

1.

2.

Check
Check

3.

Check

4.

Check

5.

Check

1.

Check

2.

fuel

1.

Check

1a.

Switch

1

b.

Replace

2c.

Check
Check

2.
1

..

Remove

1.

Observe
is

2.

Check
lines.

after

Check

3.

4.

Check
corrosion.

Check

5.

DC

1.

Perform

Testing

Check

2.

for
volts

Fuel

1.

pump
Inspect

2.

Inspect
Check

3.

Check

4.

Ensure
cause

5.

Check
exhaust

6.

Pump
bleed

emergency

breaker;

and

voltage

grouno
solenoid
connection.

switch
that
battery

battery

connections.
that

run

solenoid.

that

to

fuel

solenoid.

not

running.

wiring.

(Do

short

all
cable

connections,

ELECTRICAL

the

drive

loose

are

lift

pump

with

wiring

switches
fuel
for

breaker

tripping.

for
water

fuel

stop

switch

if

breaker

check

at

connection

stud.

with

12

volts
connections.

charge

12

volts

fuel

combine

batteries.

lift

pump.

Exc.

connection

if

gauges

Insert

not

start

is

located.

wires

connections

D.C.

voltage

Battery

belt

connections.

present

should

spare.

for

supply,

high

blockage,

elbow.

from

system.

trips

circuit

for

shorts

and

after

breaker

to

starter

Check

battery

"S"

terminal

ohmmeter.

are

present

state.

are

present

valves

are

open.

house

and

at

alternator,

and

panel

Test

the

oil

pressure

sensitive

engine.)

for

temperature

at

battery

check

belt

SYSTEM/ALTERNATOR.

check

Charging

tension.

Alternator

Check

at

the

Exc.

make a distinct

short

circuits

for

proper

fuel

valves,

DC

amperage

is

not

overly

collapsed

fuel

tank(s);

position.

again,

check

to

ground.

on

preheat

solenoid

cable

for

voltage.

at

the

at

the(+)

start

batteries.

lights

are

switch.

(0-

.25

Remove

connections

rise

to

for

tension,

of

generator

Circuit

in

should

output

with

terminal.

ticking

and

loose

operation.

fuel

lift

draw

during

sensitive

hose,

carbon

change

preheat

solenoid.

and(-)

connections.

solenoid

connection.

connection

repair

alternator.

activated

amp)

meter

locate

the

loose

connections,

test

alternator.

charging

this

manual.

turn

voltmeter.

sound.

connections.

pump.

operation.

to

heat

which

buildup

filters

and

solenoid

connection

on

the

when

engine

in

battery

and

replace

fault.

See

circuit.

freely.

Check

Ensure

Replace

would

at

to

See

12

,.,.,..,.,WES'TERBEKE

I

Engines & Generators

31

ENGINE

TROUBLESHOOTING

Generator

Generator
low

oil

pressure.

Generator
High

exhaust

Exhaust

smoking

Problem

engine

overheats/shuts

engine

shuts

engine

shuts

temperature.

problems

down,

down,

down.

Probable

1.

Raw

water

2.

Coolant

1.

loss

of

Oil

pressure

2.

1.

Exhaust

2.

High

temperature

too

low a temperature.

1.

Blue

smoke.

2.

White

smoke.

3.

Black

smoke.

not

not

circulating.

oil.

switch.

too

hot.

Cause

circulating.

switch

opens

at.

1.

Raw

2.

Obstruction

2a.

Thermostat-

Replace

2b.

loss

for

leaks.

2c.

Broken

2d.

Air

leak

bleed

1.

Check
oil

drain

Replace

2.

1.

Check

2.

Check
check

1.

Incorrect

1a.

Crankcase
through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel
insufficient
exhaust

3b.

Improperly

3c.

lack
ventilation.

3d.

Overload.

VerificationJRemedy

water

pump

failure.

at

raw

water

remove

thermostat.

of

coolant-

or

loose

in

system;

air.

Add

dipstick,

hose

oil

pressure

raw

water

for

satisfactory

with

ohmmeter,

grade

is

the

exhaust}.

is

running

injector

grade

burn

incomplete

air

system;

timed

of

air -check

and

check

belts-

run

engine

coolant

as

look

for

connection.

switch.

injection

operation

replace

of

engine

overfilled

with

cold.

or

incorrect

of

fuel.

due

for

proper

check

air

injectors

air

intake

oil

Check

impeller-

intake

or

raw

water

test

in

hot

water.

hoses,

hose

clamps,

tighten/replace.

and

open

at

look

with

if

faulty.

oil

filter

for

switch

oil

(oil

timing.

back

(Check

or

air

filter.

the

exhaust

pressure

poor

needed.

leaks

flow,

oil.

engine

injector

to

high

combustion

intake.}.

or

valves
and

replace.

filter.

drain

plug,

pressure

and

at

obstruction.

bypassed,

is

blowing

in

exhaust

for

restrictions

compression.

Check

for

etc.

cap

to

out

proper

or

in

TROUBLESHOOTING

If

the gauge reading is other

by

the

gauge

when

the instrument panel is energized,

is

to check for 12 volts

step
and

the

Negative (B-) terminals of the gauge.

Assuming

that there

is

than

what is nonnally indicated

DC

between the ignition (B+)

12 volts as required, leave the

WATER

TEMPERATURE

the

instrument panel energized( engine on( and perform the
following

1. Disconnect the sender wire at the gauge and see

steps:

gauge reads

zero,

which is the normal reading for this

if

the

situation.

2. Remove the electrical connection at the sender on the

to

engine and ground it
should register
this

situation.

full

the engine metal. The gauge

scale, which is the normal reading

Engines & Generators

first

for

AND

OIL

PRESSURE

If

both

of

the gauge
undoubtedly
conductor from

If

either

'.defective and should

Assuming the gauge is
sender

Check that the engine block is connected

OK

and

the

of

the gauge tests are negative, the gauge

to

the sender terminal at the ·gauge for continuity.

GAUGES

tests.

are positive, the gauge is

the problem lies either with the

sender

to

the gauge or with the

be replaced.

OK,

check the conductor from

to the ground.

Some starters have isolated ground terminals and
battery

is

connected to the starter (both plus and minus

terminals), the ground side will not necessarily

to

the block.

sender.

is

probably

if

the

be

connected

the

32

GENERATOR

INFORMATION

USE

OF

ELECTRIC

The power required to start
more than is required to keep it running after it is started.
Some motors require much more current to start them than
others. Split-phase
under similar circumstances, than other types. They are com­monly used on easy-starting loads, such as washing
machines,
started, such as small power tools. Because they require
7 times as much current to start as to run, their use should

avoided, whenever possible,
ven by a small generator. Capacitor and repulsion-induction
motors require from 2 to 4 times as much current to start as
to run. The current required to start any motor varies with the
load connected to it.
compressor, for example, will require more current than a

·motor to which no load is connected.

In

general, the current required to start

to medium starting loads

*NOTE:

more

for this is that the hardest starting types (split-phase) are

made

Because the heavy surge
motors is required for only an instant, the generator will not
be
seconds.
off
on

Required

Run the generator first with no load applied, then at half the
generator's capacity, and finally loaded to its full capacity as
indicted on the generator's data plate. The output voltage
should

the generating plant and the appliances it supplies.
voltmeter

load, check it with a portable meter and amp probe.

or

where loads are applied after the motor is

MOTOR

SIZE

(HP)

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

1

In the above table the maximum Amps for Starting is

for some small motors than for larger ones. The reason

in larger sizes.

damaged

all other electrical loads and,

the electric motor.

if

If

difficulty is experienced in starting motors, tum

Operating

be

checked periodically to ensure proper operation

or

ampmeter is not installed to monitor voltage and

MOTORS

an

electric motor is considerably

(Aq

motors require more current to start,

if

the electric motor is to be dri-

An

electric motor connected to an air

115-Volt

will

be

approximately as follows:

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2
13

of

current needed for starting

it can bring the motor up to speed in a few

if

possible, reduce the load

motors connected

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

Speed

If

an

5 to

be

not

of

AC

Generator

Frequency is a direct result
indicated by the following:

0 When the generator is run at 1800 RPM, the

output frequency is

0 When the generator is run at 1500 RPM, the

output frequency is 50 Hertz.

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

tor's drive engine's speed must be changed. Along with a
reconfiguring
a regulator board voltage output adjustment must also be
made.

Generator

Frequency

of

the

See ELECTRONIC GOVERNOR in this manual.

Adjustment

of

engine/generator speed, as

AC

60 Hertz.

AC

AC

output connections at the generator,

voltage

voltage

Maintenance

0 Maintaining reasonable cleanliness is important.

Connections
corroded, and insulation surfaces may start conducting
salts, dust, engine exhaust, carbon, etc. are allowed to
build up. Clogged ventilation openings may cause exces­sive heating and reduced life

of

terminal boards and rectifiers may become

of

windings.

if

0 For unusually severe conditions, thin rust-inhibiting petro-

leum-base coatings, should be sprayed

surfaces to reduce rusting and corrosion. Typical materials

suggested are Daubert Chemical Co.

and Ashland ''Tectyle 506" or equivalent.

or

brushed over all

"Non-RustAC-410"

0 In addition to periodic cleaning, the generator should be

inspected for (a) tightness

of

overheated terminals and (c) loose

of

all connections, (b) evidence

or

damaged wires.

0 The drive discs on single bearing generators should be

if

checked periodically

and for any evidence

should not be allowed to become rusty because rust may
accelerate cracking. The bolts which fasten the drive disc
to the generator shaft must

of

the head.

by

8, identified
ners

possible for tightness

of

incipient cracking failure. Discs

be

hardened steel SAE grade

6 radial marks, one at each

of

of

the 6 cor-

screws

0 The rear armature bearing is lubricated and sealed; no

maintenance is required. However,
noisy or rough-sounding, have it replaced.

if

the bearing becomes

0 Examine bearing at periodic intervals. No side movement

of

shaft should be detected when force is applied.
motion is detectable, bearings are wearing
shaft

of

bearing socket outside bearing has occurred.

be

Repair must

rub and cause major damage to generator.

made quickly

or

major components will

or

wear on

if

side

NOTE:

When the vessel in which the generator is installed

contains
that the generator
vide one

panel. This will ensure

generator.

AC

equipment

120

voltAC

of

120

volts only,

sAC

terminal block be configured to pro-

hot

leg for the

good

vessels

motor starting response from the

it

is

recommended

distribution

Engines & Generators

33

THE

SINGLE

BE

AND

GENERATOR

THREE

PHASE

DESCRIPTION

This generator is a
tor which requires only
duce

AC output. The copper
stator are responsible
erator.

The magnetic
be induced into
rotation. Diodes located
age

to

IX;

and
This creates
the

windings of the

which

is supplied
auxiliary windings
to

a voltage regulator. The regulator produces a DC voltage

to

further excite the exciter stator windings, enabling
erator to produce a
senses AC voltage output
exciter stator winding according

ator is furnishing.

INTERNAL

3

PHASE

four-IIDle,

for

field

the

related excitor rotor windings during

supply

an

electromagnetic

main

to

a load. An AC voltage

of

rated

To

maintain

TWELVE

brushless, self-exdted genera-

the

driving

the

produced causes

in

the

it

to

the

stator, inducing

the

main

AC output. The voltage regulator

and

WIRING

force

and

laminated

self-exciting feature of

exciter rotor rectify this volt-

windings of

field

which rotates through

stator

and

adjusts

DC

to

amperage

a constant voltage output.

SCHEMATIC

WIRE

RECONNECTABLE

of the engine

iron

in

the exciter

an

AC voltage

the

rotating

an

AC voltage

is

produced

is,

in

tum, supplied

excitation

load

the

r------....:.,··

I I

EXCITER

I A I I B I

J I I ROTOR I

1 I a 1

I

I I

I I
I I

.I

L.

.r- - - - + - - - - - - -,

3·:

L---+-----·--...r

this

the

to

to

'pro-

gen-

to

field.

in

the

gen-

the

gener-

CIRCUIT

A circuit breaker
tors. This circuit breaker will automatically disconnect gener-

ator power in case of
breaker can be manually shut off
tor

NOTE:

add-on

ERBEKE

BREAKER

is

installed on all WESTERBEKE genera-

an

electrical overload. The circuit

to

ensure that

This circuit breaker is available

kit for earlier model generators; contact your

dealer.

no

power

is

coming

,-.-----,

I C t

1

STATOR·

I_

...-+-!

--.r2__,.;.-;!r------:

:

4---3

L-4:~

..

ql~is

c:

~---7~--~---------

: rllli

...

I

"I

~~

190

:

...,.______

4

....

~:----~----=

§:§~§:

6 : :

8

•ri

I

'

'FUSE

6.3AMP

:

0

;

~!~MI

: Block

~

2

I

when

servicing the genera-

into the boat.

as a WESTERBEKE

CIRCUIT
PART

28

[16

25

[28

32

[25

BREAKER

NUMBERS

KW-

60Hz

KW-

50

KW..:.

60

KW-

58

KW-

60Hz

KW

-50

WEST-

NO.

Hz

NO.

Hz

NO.

Hz

NO.

NO.

Hz

NO.

42701
427181

42712

427111

42703

T D

81

REGULATOR

1-.v-IWESTERBEKE

l Engines & Generators

34

A.

EXCITOR

1.

Exciter Stator Windings

B.

ROTOR

1.

Auxiliary

2.Diodes

3.

Main

4.

Pozi

C.

MAIN

1.

Auxiliary

2.

- 7 Main Stator

3. Auxiliary
(AC

D.

AC

E.

REGULATOR

Windings

Rotor Windings

Resistor

STATOR

Windings
Windings

to Regulator)

TERMINAL

a.b.c.

Windings

BOARD

r--.,._----------,

EXCITER

STATOR

r-----~----------,

I I I
I I I

I

I I I

I

. I

I

I
I
I

I
I

L_

---------.l

I I

I I

I·
I

I I
I I

L-----~----------J

REGULATOR

EXCITER

ROTOR

INTERNAL

WIRING

SINGLE

I

I

1

. I

I

ROTOR

FIELD

I 1

PHASE

I

I

I

REO

BLUE

SCHEMATICS

RED

RED

t-----

I I

l

AUX

STATOR

RED

--1

. I

RED

RED

BLACK

GREEN

f"'-------

L-

---------.J

::r

0

...J
...J

LLI

>-

EXCITER

-·----,

THREE

6

WIRE

REGULATOR

YELLOW

PHASE

RECONNECTABLE

FUSE

6.3AMP

BLUE

.

vruow

/"'ffV'tWESTERBEICE

- ) Engines & Generators

35

GENERATOR

AC

VOLTAGE

CONNECTIONS

AC

VOLTAGE

NOTE:

erly positioned when changing the
of

the

AC

terminal block, use terminal ends for 1/4 inch studs that will

accept multi strand copper wire sized for the amperage rating
from the hot lead connection. The frame ground wire is white
or

white with a green strip. It connects between the neutral

stud and the generator frame.

120/240V - 60 Hz

CONNECTIONS

The frame ground wire (white/green) must

AC

output configuration

terminal block. For making connections to the

BE

SINGLE

0 0

L1

PHASE

120V-

60Hz

0 0

be

prop-

AC

,,

Generator

1.

2.

NOTE:

installations
ground
source

230'V

-50

Frequency

Frequency is a direct result

1800 rpm =

To

change generator frequency, follow the steps below:

Configure the AC terminal block for the desired voltage
frequency as shown. Ensure that the case ground
connected
stud.

The

circuit.

in the vessel.

Hz

0

60

hertz; 1500 rmp =

to

the correct terminal block neutral ground

white/green ground

where

the A C circuit has a separate neutral and

This will prevent

0 0

of

engine/generator speed:

50

hertz.

wire

may be removed in those

the

unit

from

being a ground

~

wire

is

20

KW

BED

SHOWN

CIRCUIT

BREAKER

~

JUN!P~J'IIS

REQUIRED

FOR

120V-

60

Hz

Engines & Generators

36

GENERATOR

AC

DESCRIPTION

.

The

regulator is equipped with seven numbered terminals (0
to 6) and their related brass jumpers. The illustrations show
connection points and jumpers for the 3 phase configuration
of

the generator. The sensing leads connect between pin #1

and pin

#0

NOTE:

the regulator board between terminal B and

#2 on the

on

the voltage regulator board.

Series Delta requires the installation

AC

terminal block and connection #2 and

of

q jumper on

0.

170 • 270V

180

·160V

VOLTAGE

CONNECTIONS

BLK

AVR

CASE GND

CASE

GN~

Ut

L1

L1

Vt

L2

Vt

L2

L3

L3

GRN

GRN

AVR

GND

3

PHASE

PARALLR

L-L-

208

L-N

-120

L·L-

190

L-N

-110

VOLTAGE

WYE

(STAR)

VAC

30

50

VAC

10

60

VAC

30

50

VAC

10

60

REGULATOR

Hz
Hz
Hz
Hz

BE

THREE

SERIES

L-L -450
L-N

-

265

L-L-

380

L-N

-2:30

PHASE

WYE

(STAR)

VAC

30

60

VAC

10

60

VAC

30

50

VAC

10

50

(TWELVE

BE

Hz
Hz
Hz
Hz

WIRE)

THREE

PHASE

L·L-

L2,

L3~N

L·L-

l2, L3-N-

A.

SERIES

repositioning

lead

ator

(SIX

SERIES

from

housing.

240

-

120

230
115

DELTA-

neutral

DELTA

WIRE)

VAC

3060Hz

VAC

10

VAC

3050Hz

VAC

1050Hz

Note

of

the

to

60

Hz

the

ground

gener-

1-.v-IWESTERBEKE

l Engines & Generators

37

J.

Jumperusing
Wire.

#10

AWG

VOLTAGE

REGULATOR

ADJUSTMENTS

Description

The

voltage regulator is an advanced design which ensures
optimum
complete protection circuitry to guard against operating
conditions that could

AC

alternator performance. It is equipped with

be detrimental to the

AC

alternator.

Volts

This potentiometer is used to adjust output voltage. At proper

engine operating speed the output voltage should
±1% from a no-load condition to
and from
ations up to -6%.

Prior to starting the engine,
mers (using a mini phillips screwdriver) fully in a counter
clockwise (Minimum) direction until you feel them hit their
stops.

Thm
(Maximum) in the same manner.

With the alternator running at no-load, at normal speed, and
with
age will oscillate.

The

lize. Increase the voltage to the desired
tion, only the green LED will stay lit.

power factor 1.0 - 0.8 with engine drive speed vari-

the

AMP

and HERTZ trimmers completely clockwise

VOLT adjust at minimum, it is possible that output volt-

Slowly rotate the VOLT adjust clockwise.

voltage output

of

the alternator will increase and stabi-

a.

full rated generator output

tum

the VOLT and STAB trim-

~alue.

be

held at

In this situa-

Stability

This potentiometer permits variation

. response to generator load changes so as to limit overcom-

pensation and obtain a minimum recovery time to the normal
voltage output.

In order to adjust the regulator stability the alternator must be

~

running
Tum

·starts to fluctuate.
terclockwise until the voltage is stable within 1
a volt.

e

-'

i

I

....

JlJl-load and the output must be monitored.

the STAB adjust slowly clockwise until the voltage

At

this point rotate the STAB adjust coun-

red

green

._

yellow..._

Hertz

Amp

Stab

Volt

of

the regulator's

or

2 tenths

of

Amp-Hertz

These two adjustments are used in conjunction with the two

protection circuits in the voltage regulator that are indicated

by the illumination

1.

Delayed overload protection (yellow LED).

2. Low speed protection (red LED).
Both systems have an intervention threshold which can

adjusted using the respective potentiometer. Each
circuits are able to cause
voltage to safeguard the excitor windings and prevent their
overheating.

The overload protection system has a delay which permits
temporary overloading
motor start-up
ulator also has a third LED (green), that
ator operation to indicate correct operation
with the generator.

Setting

In
must

1. Load the alternator to its rating, then decrease the speed

2. Rotate the

3. Slowly rotate the

4.

NOTE:·

remove

Setting

NOTE:

the

order to set the

be

loaded

the·el}gine by 10.10% (54 Hertz on
hertz

on

its stop. Wait about
put

of

the alternator should drop and the yellow LED light

should come on

output voltage increases to approximately 97%
voltage output at the start
the yellow LED light should come on.

Return to nominal speed, the yellow LED will tum off

and the alternator voltage will rise

Should this not happen, repeat the adjustment.

When changing

the 60 hertz jumper bar

the

If

the

jumper strap is

two

60 Hertz terminals.

setting,

the alternator should be running at

1.

To adjust the underspeed (low frequency) protection circuit,
lower the engine speed at
(54 hertz on

2. Rotate the Hertz adjustment counterclockwise slowly until
the alternator's
the same time the red

3. Increase the engine speed to its normal speed (frequency).
The red

put will return to normal.

With the above adjustments made, the regulator should func­tion normally .

of

a colored LED lights.

an

adequate reduction in excitor

of

the generator during times such as

or

other similar load surge demands. The reg-

glows during gener-

of

the regulator

Overload

AMP

to

50

hertz units).

AMP

Underspeed

unit

is

in

Protection

overload protection, the alternator

its full output rating.

60

hertz units, 45

adjustment counterclockwise until it hits

15-20 seconds after which the

..

AMP

adjustment clockwise until the

of

the adjustment.

to

its normal value.

from

60 hertz to 50 hertz operation,

from

the regulator board .

Protection

operating at 60 Hertz ensure that

place

on

the regulator board between the

In

order

to

adjust the underspeed

no-load.

90%

of

its normal running speed

60 hertz units, 45 hertz

AC

output voltage starts to decrease and at

"LED"

"LED"

light will go out and the

on

50

hertz units.

light comes on.

AC

be

of

the two

AC

of

the

At

this point

the

voltage out-

out-

of

VOLTAGE

REGULATOR

DIAGRAM

Engines & Generators

38

NOTE:

BE

PERFORMED

BE

TROUBLESHOOTING

AC

GENERATOR

WITH

TROUBLESHOOTING

ENGINE

OPERATING

AT

MUST

60

HERTZ

No

AC

voltage

Residual

15 • 20

Low

AC

60

-100VAC.

High

AC

150

VAC

·

Unstable

AC

voltage

60

·100

FAULT

voltage

volts

AC.

voltage

output

or

higher.

voltage

drop

volts

output

produced

output

voltage

output.

under

AC.

at

at

load

no

load.

at

no

no

load

load

1.

Short

or

main

stator

2.

Shorted

on

exciter

3.

Four

or

open

diodes

1.

Blown 6 AMP
auxiliary

2.

Faulty

voltage

1.

Open

or

exciter

2.

Open
rotor

1.

Faulty

1.

STB

1.

rotor 1 to 3 diodes.

or

winding.

voltage

pod

needs

adjustment.

Diode(s)
breaking
applied

PROBABLE

open

in

the

winding.

pozi-resistor

rotor.

more

shorted

on

exciter

buse

fuse

circuit

feed

to

regulator.
shorted
shorted

on

on
down

(inductive)

diodes
exciter

regulator.

regulator

exciter

rotor

when

1-3

or

rotor.

AVR.

in

load

is

diodes.

CAUSE

4.

Short

stator

5.

Short

field

3.

Shorted
stator

3.

Faulty

2.

Faulty

or

open

winding.

or

open

winding.

or

open

auxiliary

voltage

voltage

in

exciter

in

rotating

main

winding.

regulator.

regulator.

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

EXCITER
STATOR

r-----~----------,

I I I

I I I

I I

,---.....,I

.-----'

I

L-

I I

I I

I I

I I
I I

I I

I I

L-----~----------~

---------.J

RDTDR

I I

FIELD

'I

I

BLUE

RED

YELLOW

t-------1

I I
I

I

I

AUX

-----

RED

STATOR

RED

. I

_,

I

RED

I

I

FUSE

Rm

RED

®

W2

U1

GREER

BLACK

I'WV'IWEST&RBEICE

f Engines & .Generators

3,9

SHORE

POWER

TRANSFER

SWITCH

SHORE

Generator

~

If

cuit, this must

POWER

t t

I

L------,

I

f

L-----f-(j)

r-----t~

1 ,

I

I

I

CONNECTIONS

NOTE:

Diagram

shows
wire.
use

/,--

__

120•

dotted

...

,

~~

fZSi-

,./

Volt

system.

lines

for

connections

For a

the

other

three-

hot

(60

HERTZ)

for a two-

wire

system

leg.

Ship·

to•

Shore

PN

32008

(40AmpstPole)
PN

32009

(80Amps/

PN

32010

(125

Amps/

PN

32133

(200Amp&/Pole)

Switch

Pole)

Pole)

the installer connects shore power to the vessel's AC cir-

be

done by means

of

the Shore Power Transfer
Switch. Set the transfer switch shown in the diagrams to the
OFF

position. This switch prevents simultaneous connection

of

shore power to generator output.

A

CAUTION:

utility

shore

at

the

same
covered
bility

to

under

make

Damage
power
time.

the

sure

to

and

generator

This

type

wa"anty;

all

AC

connections

the

generator

output

of

generator

it

is

the

can

are

connected

damage

installer's

are

co"ect.

result

is

not

responsi-

if

120

VOLT/60HZ

Notice the repositioning

THREE

WIRE

of

the white wire ground load on the

CONFIGURATION

terminal block to the generator case.

Generator

~

J

;•

r.=.-t--4-w®lth

(3

Pole)

~

~

.

z

'----+--+--+-®

-~

Shore PoWer

Sw'tching

A

CAUTION:

before

switching
vice-versa
with

heavy

cause

damage

NOT-E!

Diagram

wire.

120·Volt

three-wire,120-Volt

/--

......

,

I

;;~-

j

z IGRN)

::8---l----"=c::;_

.,/

7round

-

Shore

because

AC

Power

Heavy

shore

loads

to

the

shows

connections

system

from

the

bo-at

1.2}

1 ·

motor

power

voltage

on

the

exciter

L1

... N .

It•

to

Generator

leads

to

generator
surges
vessel

being

circuit

for

a

two-

generator.

·system.

Ship-to-

Sttore

PN
(40Amps/Pole)

-----

Ships

Load

~~~~~-Volt

Equipment

Switch

32008

ia'1,~:~~Pole)

PN

32010

(125Amps/Pole)

PN

32133

(200Amps/Pole)

Power

should

be

shut

off

power

or

induced

by

switching

operated

components

may

in

the

(3

Pole)

generator.

Engines & Generators

40

LAY·UP

&

RECOMMISSIONING

GENERAL

Many owners rely
including engines
off-season or for
to

accomplish

The procedures

own

lay-up

check list
These procedures

during a lay-up and
maintenance needs

If

your
provide assistance. ·

you

have

local

if

servicing

Propeller

The transmission
be

opened

up and

out of

the

water or

storage

in

the cradle.
severe strain on the propeller shaft or coupling or both, while
the boat
shaft
apply
not
period of time.

Fresh

A
recommended for
This solution

antifreeze, depending
solution

Should
amount
mixture.

and
cooling

is

has

actually

to

small boats that

in

use,

Water

50-50

solution

to

more

from

Operate

mixture

system.

Lubrication

With

the

engine

sump.

Remove

with

new

oil.

ENGINE

oil
oil

LUBRICATING

changing
pressure and

A

CAUTION:

in

the

sump
combustion
chemicals
internal

on

their boatyards to prepare their craft,

and

generators, for lay-up during the

long

periods

lay-up preparation themselves.

which

and recommissioning, or you may use them

others

do

the

should

also

of

any

questions

dealer;

Shaft

Coupling

and

propeller half couplings should always

the

bolts removed when the boat is hauled

moved

The

taken out

unless

or

been
they

Cooling

of

antifreeze and distilled water is

use

may

require a higher concentration

make

sure

antifreeze
the

engine
the

engine

of

the

antifreeze

Now

recheck the antifreeze solution's strength.

of inactivity. Others prefer

follow

will allow you

procedures.

afford your engine protection

help

familiarize you with the

your engine.

regarding lay-up procedures, call

he

will

be

[Propulsion

from land to water, and during

flexibility

put in the water.

bent by these strains. This does not

are

have

been dry for a considerable

Circuit

in

the coolant system

on

the

the

antifreeze protection is adequate.

be needed, drain an appropriate

block and add a more concentrated

to ensure a complete circulation

of

hauled out

[Propulsion

area's winter climate. Check the

concentration throughout the

to

perform your

more than willing to

Engine]

the boat often puts a

In

some cases, the

of

the water when

Engine]

at

all times.

of

System

warm,

drain

all the engine oil from the oil

and

replace the oil filter and fill the sump

Use

the

correct

grade

of

oil. Refer to the

procedure.

over
deposits

which

parts.

OIL pages

Run the engine and check for proper

make

sure

there are

Do

n~

leave

the

lay-up

combine

can

reduce

in

no

the

engine's

period.

to

produce

the

life

this manual for the
leaks.

old

engine

Lubricating

oil

harmful

of

your

engine's

as

oil

and

Fuel

System

Top

off your fuel
or higher. A fuel conditioner such
stabilizer should be added. Change the element
gasoline/water separator and clean the metal bowl. Re-install
and make certain there are

a

fuel.

Fuel

System

Top

off your fuel

··additives should

' mix with the fuel being added and fuel still in

Additives. such
should

be·
condition the fuel. Care should be taken that the additives
used are compatible
separator used in the system. Change the element in your
primary fuel filter/water separator clean the separator
sediment bowl.

Change the fuel filter elements on the engine and bleed the
fuel system,
for 5 -

system. Check for
the fuel system during this servicing, correcting them as
needed. Operating the engine for 5 - 10 minutes will help
allow movement

equipment on the engine. ·

Raw

Water

Close the through-hull seacock. Remove
hose from the seacock. Place the end
gallon bucket
check the zinc anode found in the primary heat exchanger

the engine and clean or replace it as required, and
any zinc debris from inside the heat.exchanger where the
zinc anode is located. Clean the raw water strainer.

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

Start the engine and allow all of this mixture to be drawn
through the raw water system. Once the bucket is
the engine. This antifreeze mixture should protect the
water circuit from freezing during the winter lay-up,

as

providing corrosion protection.

Remove the impeller from your raw water pump (some

antifreeze mixture will accompany it, so catch it in a bucket).
Examine the impeller. Acquire a replacement, if needed, and
a cover gasket. Do not replace the impeller (into the pump)

until recommissioning, but replace the cover and gasket.

[Gasoline]

tanks

with unleaded gasoline

no

[Diesel]

tanks

with

No.

be

added prior

as

Bio-bor and Diesel Kleen + Cetane Boost

added at this time to control bacteria growth and

with

the primary fuel filter/water

as

needed. Start the engine and allow it to run

10

minutes

to

make sure

any

leaks that may have been created

of

the

treated fuel through the injection

Cooling

of

Circuit

clean fresh water. Before starting the engine,

area.

as

Sta-Bil gasoline

leaks. Clean

2D diesel fuel. Fuel

to

topping off

no

up

air

is

left

the

of

this hose into a

an

in

of

89

octane

in

your

any spilled

to

ensure

they

the

tank.

the fuel

in

raw water intake

five

on

also

clean

empty,

antifreeze

empty,

stop

raw

as

well

Engines & Generators

41

LAY·UP & RECOMMISSIONING

Starter

Lubrication and

if

battery connections
the
connections

Cylinder

If

WESTERBEKE

access
the
revolutions

If

to

the

Intake

Clean
cloth
block
through-hull

to

Cylinder

Remove
spray
coat

'Reinstall

NOTE:

and

tions.
attach

access

starter.

you

anticipate a

to

cylinder

your

en8ine

be

removed.

injectors

the

lightly

any

start-up!

fogging

the

At

gap

Re-install

the

Motor

cleaning

to

the

starter

Take

care

removed

Lubrication

recommends

the

cylinders.

walls.

and

re-install

does

Be

and

return

Manifold

filter

screen

soaked

opening.

exhaust port, Make a note to remove cloths prior

Lubrication

the

flame

oil

intake,

valves

the

flame

re-commissioning,

them.

Rotate

the

high

tension

Batteries

If

batteries
make
to

prevent
batteries
subjected
batteries·a:nd

environment.

A

are

to

sure

that

they

them

from

will

not

to

severe environmental conditions, remove the

store

WARNING:

highly-explosive
arcing

or a lighted

smoke

or

allow

serviced.

tit

Shut

prevent

electrical

Transmission

Check

or change

grime

and,

off
the

coupling and
coating.
additional

grease

Check

that

information,

of the starter drive pinion

permits its easy removal. Make

are

shut off before attempting

in

properly replacing any electrical

from the

starter.

is

to

[Diesel)

long

lay-up period
Squirt some Marvel Mystery Oill into

Rotate

the engine crankshaft by hand

the

glow

not

have

glow

sure

to

have replacement sealing

fuel line

(12

months or

removal

of

the glow

plugs.

plugs, the injectors will have

as

needed.

plugs

[Gasoline]

in the

flame

arrester, and place a clean

in

lube oil

Also

place

around

the flame arrester

an

oil-soaked cloth

in

[Gasoline]

arrester

into

be

remain

an

off

[Propulsion

the

the

and clean. Operate the engine and

the intake stalling the engine. This will

and cylinders with a

arrester.

remove

the

engine

by

spark plugs

Zeds.

left on board during the lay-up period,

are

fully charged, and will remain that

freezing.

them

Lead

gas,

cigarette,

open

all

an:lng

and

If

there is any doubt that the

fully charged, or that they will be

in a

warmer,·

acid

batteries

which

can

cigar,

«ame

near

electrical

equipment

during

pr6tec~

the

spark plugs and clean

hand

two complete

tighten securely

more compatible

emit

hydrogen,

be

ignited

or

the

by

pipe.

ballery

In

electrical

Do

not

being

the

Slii'JI!clng.

Engine]

fluid

in the transmission as

and touch up

output

flange

the

transmission vent

refer

to

the TRANSMISSION SECTION.

any

unpainted areas. Protect

with an anti-corrosion

is

open. For

required

advisable,

sure

the

remove

more)

for

two

washers

to

the

oil.

revolu-

and

firmly

a

vicinity

Wipe

Spare

Lay-up time provides a good opportunity to inspect your
Westerbeke engine to

Parts

see

if

external items such as drive belts
or coolant hoses need replacement. Check your basic
kit and order items not on hand, or replace those items
during the lay-up, such

SPARE

PAKI'S

section of this manual.

as

filters and zinc anodes. Refer

Recommissioning

The recommissioning of your Westerbeke engine after a

·-seasonal

• those descnbed in the
section regarding preparation for starting
However,.
counteracted before starting the engine.

for

1.

2. Remove the raw water pump cover and gasket and

3.

way,

lay-up generally follows the same procedures

PREPARATIONS

some

of

the lay-up procedures will need to

Remove the oil-soaked cloths from the intake

discard the old
removed during lay-up (or a replacement,
Install the raw water pump cover with a new cover

Reinstall the batteries
lay-up, and reconnect the battery cables, making
terminals

Check to make sure

A

CAUTION:

and

eye

protection

batteries

can

be

ignited

cigarette,

flame

near

electrical
arcing

during

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

proper tightness [gasoline].

5. Check the condition of the zinc anode in the

circuit and clean or replace the anode

that it

is

solution from the raw water coolant system.

engine is put into operation, the system will

short period
advisable,
service, to inspect the area where the zinc is located in the
heat exchanger and clear any and all zinc debris

g~et

Install

that

were removed during the

are

clean

and

that the connections

that

the batteries

Wear

rubber

gloves, a iubber

when

servicing

emil

hydrogen, a highly

by

electrical

cigar,

or

pipe.

the

battery

equipment

Do

being

In

the

arcing

not

serviced.

vicinity

servicing.

not necessary to flush the antifreeze/fresh

of

time with no adverse affects.

as

either

an

end of season or recommissioning

FOR

the

raw water pump

batteries.

explosive

01 a

smoke

to

area.

6. Start

.the

engine in accordance with procedures

in the

PREPARATIONS

manual.

FOR STARTING section of

STAKI7NG

and

normal

if

required).

are

are

fully

gas,

lighted

or

allow

Shut

Dff

prevent

as

needed.

spares

used

to

as

starts.

be

manifold.

impeller

gasket.

sure

tight.

charged.

apron,

Lead

acid

which

an

open

all

electrical

and

install

raw

water

Note

water

When

the

self-flush

It

is

from

described

this

the

the

in

that

to

a

Engines & Generators

42

SPECIFICATIONS

Engine

Type

Aspiration

Governor
Combustion
Bore & Stroke
Piston
Firing
otrectlon
Maximum

(at
Compression
Dimensions

Weight
Fuel

(approximate)
lnctination

Generator

Compression

(Limit

cylinders)

Valve

Valve

Valve
(engine

Engine

Injector
Engine

Chamber

Displacement

Order

of

Rotation

Torque

1800

rpm)

Ratio

Consumption

Power

Pressure

of

difference

Timing

Seat

Angle

Clearance

cold)

Speed

Pressure

Timing

WESTERBEKE

SPECIFICATIONS

Diesel,

four-cycle,
water-cooled
mechanism

Naturally

aspirated.
Electronic
Swirl

3.50 x 4.0
154
1-3-4-2
Clockwise,
1171b-ft

21:1

Height:

Width:

Length:

9431bs

2.0

Continuous

Temporary

Take

off

30

TUNE-UP

427

between

Intake

Exhaust

Governing

type

inches

cubic

inches

when

(16.18

28.50

22.00

45.79

(431.7

gph

(7.57

200

Horsepower

SPECIFICATIONS

psi

(30

(47.2

psi

(3.0

Intake

Opens
Closes

Exhaust

Opens

Closes

Intake

45"

Exhaust

30"

Intake

0.012

Exhaust

O.o12

1800

RPM

1500
1920 + 71·0
Static

0.205

60

RPM

50

timed -drop

:t

.005

four-cylinder,

Vertical,

(33

hp

at

(88.9 x 101.6

(2.51iters)

viewed

kg-m)

inches
inches
inches

kgs)

lph)

at

15"

(not

(maximum)

kg/em')

kg/em'})

17"

BTDC

47"

ABDC

51"

13"

inches

inches
Hertz

Hertz

psi

(135 + 5·0

inches

in-line
1800

from

full

to

exceed

at

200

BBDC

ATDC

(0.3

(0.3

valve

BTDC

fresh

overhead

rpm

maximum).

mm)

the

(723.9mm)
(546.1

(1163.3

rated

output

20

rpm

mm)

mm)

kg/em')

method

front

mm)
mm)

min.)

20

valve

KW

BEDA

General
Fuel

Fuel
Fuel
Nozzle
Fuel

(on
Air
Air

(engine

General

Operating

Fresh

Raw

Raw

at

System

(fresh

General

Oil

Sump
(not

Operating
(engine

Oil

GENERATOR

Injection

Pump

Injection

Timing

Riter

engine)

cleaner

Row

combustion)

Temperature

Water

Pump

Water

Pump

Water

Row,

1800

rpm
Capacity

water)

Riter

Capacity

including

Oil

hot)

Grade

FUEL

Open
No.

Diesel

ZEXEL

o•

TDC
Throttle
Spin-on

Metal

81.0

COOLING

Fresh
controlled

110
Centrifugal
Positive

beltdrivim.

14.0
before

11.5

LUBRICATION

Pressure
Full

filter)

Pressure

6.5
plus

50..60

API
or

SYSTEM

flow,

self

20

SAE

J313,

fuel

according

Model

VE

(Top

Dead
type
type,

full

screen

type

cfm

(2.29

SYSTEM

water-cooled

with

-190"

F (77-
type,

displacement,

gpm

(52.91pm)

discharging

qts

(10.881iters)

SYSTEM

fed

system

flow,

paper

U.S.

Qts

(6.151iters)

filter/cooler

psi

(3.5 -4.2

Specification

better.

SAE 1 OW-40

priming

cetane

to

Distributor

Center)

flow

cmm)

block,

heat

exchanger.

88.

C)

metal

impeller,
rubber

(measured

into

element,

assembly

kglcm

of

CF,

- 1

bleed

point

rating

of

45

ASTM

thermostatically·

exhaust

spin-on

2

)

CF-4,

or

15W·40

or

0975

belt-driven

impeller,

elbow).

type

CG-4,

CH-4,

higher.

Cl-4

l''fN'fWESIEIISEKE

Eng11N18

&

Generators

43

SPECIFICATIONS

Starting

Battery

Battery

capacity

DC

Charging

Alternator
Starter
Starting

Aid

DC

No-Load

Current

DC

Cranking

Current

AC

General -Single

Voltage -Single

Voltage

regulation:
Frequency
Rating

regulation:

(Volts

AC)

WESTERBEKE

ELECTRICAL

12-Vol~

(-)
400 -600
51

Amp

rated,

12-Volt,

Reduction

Glow

plugs,

±

2%

of

250 -300

GENERATOR

Phase

Phase

(SINGLE

Brushless,
lubricated
Reconnectable
with

solid

120

or

120/240

230

Volts -50

±

2%

no

0.30

Hertz

20

!WI-

60

120

Volts

120/240

Volts

161W/-

50

230

Volts

SYSTEM

negative

ground

Cold

Cranking

belt-driven

Gear,

sheathed

rated

Amps

Amps

(engine

four-pole,

single
state

load

no

166

72.7

single

voltage

Volts-

Hertz

to

load

Hertz

Amps
166/83

Hertz

Amps

revolving

bearing

full

load.

to

full

(1800

(1500

Amps

(CCA)

3

!WI

type

cold)

PHASE)

field

design.

phase

for

120/240

regulator.

60

Hertz

load.

rpm)

Amps

rpm)

20

Sealed

volts

KW

BEDA

General

20.0

16.0

Voltage
(60

Voltage

(50
Amperage

(60

Amperage
(50

Air
(60

Note:
Engine

Requirements
(60

GENERATOR

-3

Phase

!WI

-

60

!WI-

50

-3

Phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Requirements

Hertz

at

1800

Increase

Combustion

Hertz

at

1800

AC

GENERATOR

Hertz
Hertz

Phase

Phase

Brushless
Sealed
design.
WYE,
regulator

Low
High
DELTA

High
DELTA

Low
High
DELTA

High
DELTA

GENERATOR

Air

15%

425

for

81.0

air

RPM)
supply

RPM)

six

lubricated

12

Lead

high

voltage

with

voltage

WYE

voltage

WYE

voltage

WYE

voltage

WYE

voltage

WYE

voltage

WYE

COOLING

cfm

(12.74

50

Hertz

cfm

(2.29

(3

Phase)

pole,

revolving

single

bearing

reconnectable

Delta.

protection

operation

Solid
circuitry.

cmm)

1500

cmm)

field.

for

low

voltage

State

voltage

208

volts

480

volts

240

volts

380

volts

240

volts

70Amps
35Amps
60Amps

30.4Amps

52.5Amps

rpm

Engines & Generators

44

SPECIFICATIONS

WESTERBEKE

25

KW

BED

GENERATOR

Engine

Type

Aspiration

Governor
Combustion
Bore & Stroke

Piston
Firing
Direction
Maximum

(at
Compression

Dimensions

Weight
Fuel

(approximate)
Inclination

Generator

Chamber

Displacement

Order

of

Rotation

Torque

1800

rpm)

Ratio

Consumption

Power

SPECIFICATIONS

Diesel,

four-cycle,

water-cooled,

Take-off

mechanism
Naturally
Electronic

Swirl

3.74 x 4.13
182
1-3-4-2
Clockwise,
148

21:1
Height

Width:
Length:

971

2.9

Continuous

Temporary

40

(50

aspirated.

Governing

type

inches

cubic

inches

when

lb-ft

(20.46

28.56

23.30

49.90

lbs

(440

kgs)

gph

(1

0.9 I ph)

15°

20°

Horsepower

four-cylinder,

Vertical,

in-line

hp@

1800

(95 x 105

(2.981iters)

viewed

kg-m)

inches
inches
inches

at

full

(not

to

exceed

(maximum)

overhead

rpm

rnrn)

from

(726.4
(591.8

(1140.5

rated

fresh

maximum).

the

front

rnrn)
rnrn)

mm}

output

20

rnin.)

valve

General
Fuel

Fuel

Injection

Fuel

injection
Nozzle
Fuel

Filter

(on

engine)

Air

cleaner

Air

Flow

(engine

combustion)

General

Operating
Fresh

Water

Raw

Water

Raw

Water

at

1800

rpm

System

Capacity

(coolant)

Pump
Timing

Temperature

Pump

Pump

Row,

FUEL

SYSTEM

Open

flow,

self

No.

2-D

SAE

higher.

Diesel

ZEXEL

Model

o•

TDC

(Top

Throttle

type

Spin-on

type,

Metal

screen

94.6

cfm

(2.7

COOLING

Fresh

controlled

110- 19o· F (77-

Centrifugal
Positive

belt

15.0
before

11.5

SYSTEM

water-cooled

with

type,

displacement,

driven.

gpm

(56.71pm)

discharging

qts

(1

0.88

priming

-1

bleed

J313,

Cetane

according

Distributor

Center)

flow

blotk,

thermostatically-

exchanger.

as·

c)

metal

impeller,
rubber

(measured

into

exhaust

rating

lute
VE

Dead

full

type-cleanable

cmm)

heat

liters)

point
of

to

ASTM

belt-driven

impeller,

..,

elbow).

45

D975

or

Compression
(Limit

cylinders)

Valve

Valve

Valve
(engine

Injector
Engine

Engine

Pressure

of

difference

Timing

Seat

Angle

Clearance

warm)

Pressure

Timing

Speed

TUNE-UP

between

SPECIFICATIONS

427

psi

(47.2
Intake

Intake
Exhaust

Exhaust
Intake

Exhaust
Intake

Exhaust
1920 + 71-0
Static

0.205 ± .005
1800

1500

(30

kg/em')

psi

{3.0

kg/ern'})

Opens

17°

Closes

4r

Opens

51 o BBDC

Closes

13°

45•

30°

0.012

inches

0.012

inches

psi

timed -drop

inches

RPM -60
RPM -50

Hertz
Hertz

at

200

BTDC

ABDC

ATDC

(0.3

mrn)

(0.3

(135 + 5-0

valve

method

BTDC

rprn

mrn)

kg/em')

General
Oil

Filter

Sump

Capacity

(not

including

Operating
(engine

hot)

Oil

Grade

LUBRICATION

filter)

Oil

Pressure

Pressure
Full

flow,

6.5

U.S.

plus

filter/cooler

50 -60

psi

API

Specification

or

better.

SYSTEM

fed

system

paper

element,

qts

(6.15

liters)

assembly

(3.5 -4.2

of

SAE 1 OW-40

CF,

spin-on

kg/em')

CF-4,

or

15W-40

type

CG-4.

CH-4.

Cl-4

IW'IWESIE.RBEICE

l

EnglntiS & GeneratOI'S

45

SPECIFICATIONS

Starting

Battery

Battery

Capacity

DC

Charging

Alternator
Starter
Starting

Aid

DC

No-Load

Current

DC

Cranking

Current

AC

General -Single

Voltage -Single

Voltage

regulation:
Frequency
Rating

regulation:

(Volts

AC)

WESTERBEKE

ELECTRICAL

12-Volt,

(-)

400 -600

51

Amp

rated,

12-Volt,

Reduction

Glow

plugs,

±

2%

of

rated

250 -300

GENERATOR

Phase

Phase

(SINGLE

Brushless,
lubricated
Reconnectable
with

solid

120

or

1201240

220

Volts -50

±

2%

no

.3

Hertz

no

20

KW-

60

120

Volts

120/240

Volts

20

KW-

50

220

Volts

SYSTEM

negative

ground

Cold

Cranking

belt-driven

Gear

sheathed

type

Amps

Amps

(engine

four-pole,

single
state

load

208

87

single

voltage

Hertz

to

load

Hertz

Amps

208.109

Hertz

Amps

revolving

bearing

phase

Volts -60

full

load.

to

full

load.

(1800

(1500

Amps

(CCA)

cold)

PHASE)

field

for

Hertz

Sealed

120/240

design.

regulator.

rpm)

Amps

rpm)

25

volts

KW

BEDA

General

Voltage
(60

Voltage
(50

Amperage

(60

Amperage
(50

Air
(60

Note:
Engine

Requirements
(60

GENERATOR

-3

Phase

-3

Phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Requirements

Hertz

at

1800

Increase

Combustion

Hertz

at

1800

AC

GENERATOR

Brushless
Sealed
design.
WYE
tor

Low
High
DELTA

High
DELTA

Phase

Phase

Low
High
DELTA

High
DELTA

GENERATOR

Air

15%

1.0

for

94.6

air

RPM)
supply

RPM)

lubricated

12

and

with

protection

voltage

voltage

voltage

voltage

voltage

voltage

Power

50

Hertz

cfm

six

Lead

for

Factor

(2.7

(3

Phase)

pole,

revolving

single

bearing

reconnectable

Delta.

Solid

State

circuitry.

WYE

WYE

WYE

WYE

WYE

WYE

COOLING

425

cfm

(12.74

operation
cmm)

1500

field.

for

low

voltage

voltage

regula-

208

volts

480

volts

240

volts

380

volts

240

volts

86.7

Amps

37.6Amps

75.2

Amps

38.0Amps

65.6Amps

cmm)

rpm

Engines & Generators

46

SPECIFICATIONS

Engine

Type

Aspiration
Governor
Combustion

Bore & Stroke
Piston
Firing
Direction
Maximum

(at
Compression

Dimensions

Weight

Compression
(Limit

cylinders)

Valve

Engine

Injector

Valve

Valve
(engine

Engine

Chamber

Displacement

Order

of

Rotation

Torque

1800

rpm)

of

difference

liming

liming

Pressure

Seat

Angle

Clearance

cold)

Speed

SPECIFICATIONS

Ratio

TUNE-UP

Pressure

between

WESTERBEKE

Diesel,

four-cycle,
water-cooled,
mechanism

Naturally
Electronic
Swirl

type

3.94 x 4.33

210.8

cubic

1-3-4-2

Clockwise,

1661b-ft

18:1
Height:

Width:
Length:

10381bs

SPECIFICATIONS

427

psi

47.2

psi

Intake

Opens

Intake

Closes

Exhaust
Exhaust

Static

timed • drop

0.180 ± .005
2417 -2489
Intake

45•

Exhaust
Intake

0.012

Exhaust
1800

RPM

1500

RPM

Vertical,

(46

hp

aspirated.

Governing

inches

Inches

when

(23

kg-m)

30.0

inches

22.0

inches

44.6

inches

(471.8

kgs)

(30

kg/em')

(3.0

kg/em'})

19"
47"

Opens

52"

Closes

14•

inches

psi

(170 -175

30"

inches

0.014

inches

60

Hertz

50

Hertz

four-cylinder,

in-line

at

(100.1 x 110.0

viewed

BTDC
ABDC

overhead

1800

rpm

(3.51iters)

from

(762.0
(558.8mm)
(113.3

at

200

rpm

BBDC
ATOC

valve

method

BTDC

kg/em')

(0.3

mm)

(0.35

mm)

fresh

maximum).

mm)

the

front

mm)
mm)

32

valve

KW

BEDA

General
Fuel

Fuel
Fuel

Nozzle
Fuel

(on
Air
Air

(engine

General

Operating

Fresh

Raw

Raw
at

System
(fresh

General

Oil

Sump
(not

Operating
(engine

Oil

GENERATOR

Injection

Pump

Injection

liming

Filter

engine)
cleaner
Row

combustion)

Temperature

Water

Pump

Water

Pump

Water

Row,

1800

rpm

Capacity

water)

Riter

Capacity

including

Oil

hot)

Grade

FUEL

Open

No.

higher.

ZEXEL
12•
Orifice
Full

Metal
110

COOLING

Fresh
controlled

170
Centrifugal

Positive
belt

15.0
before

8.5

LUBRICATION

Pressure

Full

filter)

Pressure

6.3
plus

50-60

API
or

better.

SYSTEM

flow,

self

priming

20

SAE

J313,

Diesel

fuel

Model

PE

BTDC

type

Row

Replaceable

screen

type • cleanable

cfm

(3.1

cmm)

SYSTEM

water-cooled

with

heat

-190°

F

(77-

type,

displacement,

driven.

gpm

(56.71pm)

discharging

qts

(8.041iters)

SYSTEM

fed

system

flow,

paper

U.S.

qts

(6.0

filter/cooler

psi

(3.5 -4.2

Specification

SAE 1 OW-40

-1

cetane

according

(In-Line)

block,

exchanger.

88"

C)

metal

impeller,

rubeer

(measured

into

exhaust

'

element,

liters)

assembly

kg/em')

of

CF,

CF-4,

or

bleed

point

rating

of

45

or

to

ASTM

0975

thermostatically-

belt-driven

impeller,

elbow).

spin-on

type

CG-4,

CH-4,

15W-40

Cl-4

t'WV'IWESJERBEICS

I Engines &

Genet'lltol's

47

Starting

Battery

Battery

capacity

DC

Charging

Alternator
Starter
Starting

Aid

DC

No-Load

Current

DC

Cranking

Current

AC

General -Single

Voltage -Single

Voltage

regulation:
Frequency
Rating

regulation:

(Volts

AC)

WESTERBEKE

ELECTRICAL

12-Volt,

(-)
600 -900
51

Amp

rated,
12-Volt, 3 KW
Glow

plugs,

.1-.2

ohm

±

2%

of

250-

300

GENERATOR

Phase

Phase

(SINGLE

Brushless,
lubricated

Reconnectable

with

solid

120

or

120/240

220

Volts -50

±

2%

no

.3

Hertz

no

32

KW-

60

120

Volts

120/240

Volts

25

KW -50

220

Volts

SYSTEM

negative

ground

Cold

Cranking

belt-driven

sheathed

rated

Amps

Amps

(engine

four-pole,

single
state

load

266

108.7

single

voltage

Hertz

to

load

Hertz

Amps

266/133

Hertz

revolving

bearing

Volts-

full

load.

to

full

(1800

(1500

Amps

SPECIFICATIONS

Amps

(CCA)

type

cold)

PHASE)

field

design.

phase

for

120/240

regulator.

60

Hertz

load.

rpm)

Amps

rpm)

32

Sealed

volts

KW

BEDA

General-3 Phase

20.0

16.0

Voltage
(60

Voltage
(50

Amperage
(60
.8

Amperage
(50
.8

Air
(60

Note:
Engine

Requirements
(60

GENERATOR

KW -60

KW-

50

-3

Phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

power

factor

-3

Hertz)

power

factor

Requirements

Hertz

at

1800

Increase

Combustion

Hertz

at

1800

AC

GENERATOR

Hertz
Hertz

Phase

Phase

Brushless
Sealed

design.
WYE
tor

Low

High

DELTA

High

DELTA

Low

High

DELTA

High

DELTA

GENERATOR

Air

1.0

15%

110

air

RPM)
supply

RPM)

with

voltage

power

for

cfm

voltage

50

(3

six

pole,

lubricated

12

Lead

and

for

Delta.

protection

WYE

voltage

WYE

voltage

WYE

WYE

voltage

WYE

voltage

WYE

COOLING

factor

Hertz

operation

(3.1

cmm)

Phase)

revolving

Solid

cfm

field.

bearing

for

State

voltage

208
480
240volts

380
220

111.0Amps

48.1

96.2Amps

47.5Amps

82.0Amps

(15.0

1500

rpm

single

reconnectable

circuitry.

500

low

volts
volts

volts
volts

Amps

cmm)

voltage
regula-

j...,.,IWESTERBEKE

l

Engines & Generators

48

WESTERBEKE

BE

GENERATOR

20KW

MANUAL

PRIMER

PUMP

PARTS

IDENTIFICATION

EXHAUST

ELBOW

EXHAUST

o-----

TEMPERATURE

SWITCH

CONTROL

SENSOR

PANEL

AC

CONNECTIONS

UNIT

DATA

OUTLET

TAG

LED

HEAT

EMERGENCY

LIGHTS

STOP

LEFT

SIDE

L-----

UNIT

DC

CHARGING

RAW

I.

D.

PLATE

ALTERNATOR

WATER

PUMP

RIGHT

SIDE

Engines & Generators

49

STARTER

WITH

SOLENOID

WESTERBEKE

BE

GENERATOR

25KW

OIL

PRESSURE

SENDER

PARTS

IDENTIFICATION

EXHAUST

TEMPERATURE

SWITCH

AC

CONNECTIONS

IT

DATA

OUTLET

TAG

70•

EXHAUST

HEAT

EXCHANGER---

LED

ELB,OW·----

FRESH

LEFT

SIDE

WATER

FILL

CAP

LUBE

OIL

FILTER

LUBE

UNIT

DC

CHARGING

OIL

DRAIN

I.

D.

PLATE

ALTERNATOR

HOSE

DC

BATTERY

GROUND

CONNECTION

RIGHT

SIDE

Engines & Generators

50

STARTER

WITH

SOLENOID

32.0BEDA

PARTS

IDENTIFICATION

DRIVE

COVER

COOlANT

THERMOSTAT
HOUSING,

BElT

SIDE

Oil

FilL

FRONT

PRESSURE

CAP

Oil

Fill

CONNECTION

IPHON

TO

BREAK

INJECTORS

CONTROl
PANEl

CIRCUIT
BREAKER

REAR

LINEAR

ACTUATOR

GENERATOR
BACK-END

LED

INDICATOR

EMERGENCY

REAR

CONTROl
PANEl

LIGHT

STOP

OIL

PAN

WATER
EXHAUST

SWITCH

OIL

DRAIN

HOSE

AIR

INTAKE/SilENCER

INJECTED

ELBOW

ENGINE

OIL

FilL

LEFT

SIDE

COOLANT
PRESSURE

CAP

10

NAME

PLATE

FRONT

START

RAW

WATER

MOTOR

PUMP

HEAT
EXCHANGER

Engines & Generators

51

Oil

SUMP

TORQUE

SPECIFICATIONS

COMPONENT

Cylinder

head

Cylinder

head

Connecting

Main

bearing
Camshaft
Idler

Gear

Rocker

arm

Timing

gear

Rear

oil

seal

Oil

pan

bolts

Oil

pump

pipe

Fresh

water

Crankshaft

*

Injector

to

Injection

pipe

Intake

manifold

Exhaust

manifold

Back

plate
Flywheel
Damper

Timing

gear

Alternator

Thermostat
Thrust

plate

Oil

pressure

Oil

pressure

Engine

mounts
Alternator
Coolant

temperature

Coolant

temperature

Glow

plug
Camshaft
Injection

pump

bolts
cover

rod

cap

cap

thrust

plate

assembly

cover

cap

pump

pulley

head

flare

cover

bracket

housing

sender
switch

bracket

gear

gear

bolts

nut

nut

switch
sender

lb-ft

BEDA20.0

85-89

2-3
59-65
80-85
12-17
16-23
80-85
12-17

11.:...15
12-17

6-9

9-13

253-289 (35'-

43-51 (6.0-7.0)
18-22
12-17
20-24

24

-35

112-118

14-20
12-17

27-38

6-8

14-19

9-13

9-13
23-34
27-38
18-29
18-29

7-11

46-69

29-52

KW

(11.8

-12.5)
(0.3-0.45)
(8.2-

(11.0

-11.7)
(1.6­(2.2-3.2)

(11.0

-11.7)
(1.6­(1.5­(1.6­(0.8

-1.2)
(1.2

-1.8)

(2.5­(1.6­(2.7

-3.3)
(3.3

-4.8)

(15.5

-16.3)
(1.9-2.7)
(1.6­(3.8

-5.3)

(0.8

-1.1)

(1.9

~2.6)

(1.2

-1.8)

(1.2

-1.8)
(3.2­(3.8-5.3)
(2.5-4.0)
(2.5-4.0)
(1.0

-1.5)
(6.4

-9.5)
(4.0-9.0)

9.0)

2.4)

2.4)

2.0)

2.4)

40)

3.0)

2.4)

2.4)

4.7)

(m-Kg)

85-89

59-65
80-85
12-17
16-23
80-85
12-17·
11-15
12-17

253-289

12-17
18-22
12-17
20-24

24

112-118

14-20
12-17
27-38

14-19

23-34

27-38

18-29.

...

18~29

46-69

29-52

BED

2-3

6-9
9-13

-'35

6-8

9-13
9-13

7-11

25.0

KW

(11.8

-12.5)
(0.3­(8.2-

(11.0

-11.
(1.6­(2.2-

(11.0-11.7)

(1.6-2.4)
(1.5­(1.6­(0.8-1.2)
(1.2

-1.8)

(35-40)
(1.6­(2.5
(1.6­(2.7
(3.3

(15.5 -16.3)

(1.9-2.7)
(1.6­(3.8-5.3)
(0.8
(1.9­(1.2
(1.2
(3.2-4.7)
(3.8-5.3)
(2.5-4.0)
(2.5-4.0)
(1.0
(6.4-9.5)
(4.0-9.0)

0.45)

9.0)

2.4)

3.2)

2.0)

2.4)

2.4)

-3.0)

2.4)

-3.3)

-4.8)

2.4)

-1.1)

2.6)

-1.8)

-1.8)

-1.5)

7)

BEDA32.0

(Do

1.4-2.5

,.

59-65
72-77
14-19
14-19
14-19
14-19
14-19
14-19

5.8-8
9-13

253-289

12-17
18-22

14-19

17-20
28-38

KW

Not

Torque)

(0.2-0.~5)

(8.2

-9.'0)

(1

0.0-

,1
(1.9.-2.6)
(1.9-

2.6)

(1.9-2.6)

~

(1.9

-2.6)

(1.9-

2.6)

(1.9

-2.6)

(0.8

-1.1)

(1.2

-1.8)

(35-40)

(1.6-

2.4)

(2.5-

3.0)

(1.9

-2.6)

(2.3-2.7)

(3.8-5.3)

0.7)

130-145 (18-20)

16-24
14-19
27-38

5.8-8.0,
14-19

9-13

9-13
23-34
27-38

18-29
18-29

NA
NA

29-52

(2.2-M)
(1.9-2.6)
(3.8-5.3)
(0.8

-1.1)
(1.9-2.6)
(1.2

-1.8)
(1.2

-1.8)
(3.2

-4.7)
(3.8

-5.3)
(2.5-4.0)
(2.5

-4.0)

(4.0-9.0)

*

BEDA

20

I<JN

Generator

25

I<JN

bolt

tightened

and

BED

32

KW

evenly.

uses

an

injector

Generators

use

that

is

screwed

into

the

head

torque

injectors

that

are

bolted

to

the

head

I...,.,.IWESTERBEKE

)

Engines & Generators

52

43-

51

-torque

lb-ft
value

(6.0-

is

12

7.0).

to

17

lb-ft

(1.6 -2.4)

per

STANDARD

NOTE:

Unless stated othenvise for a specific assembly, use the following torque values when tightening standard hardware.

HARDWARE

TORQUES

Grade

6mm
8mm
1

Omm

1

Omm
12mm
12mm

12mm
13mm
14mm
14mm
16mm
16mm

Grade

6mm
8mm
1

Omm

1

Omm
12mm
12mm
12mm

4

6T

bolt
bolt

bolt
bolt
bolt
bolt
bolt
bolt
bolt
bolt
bolt
bolt

bolt
bolt

bolt
bolt
bolt
bolt
bolt

head/nul
head/nut

head/nut
head/nut
head/nut
head/nut
head/nut
head/nut
head/nut
head/nut
head/nut
head/nut

head/nut
head/nut

head/nut
head/nut
head/nut

head/nut
head/nut

Pitch

1.25

1.25

1.25

1.75

1.25

1

1.5
(ISO)

1.5

1.5

1.5
2

1.5
2

1

1.25

1.25

1.5

(ISO)

1.5

1.75

I

b-It

2.9-5.1

7.2-11.6

13.7-22.4

13.0-21.7

25.3-39.8

25.3-39.8

21.7-36.2

32.5-50.6

36.2-57.9

34.0-55.7

54.2-79.6

51.4-76.7

4.3-6.5

10.8-15.9

21.7-32.5

19.5-30.4

36.2-57.9

36.2-50.6

34.7-49.2

kg·m

0.4·0.7

1.0-1.6

1.9·3.1

1.8-q,O

3.5-5.5

3.5-5.5

3.0-5.0

4.5-7.0

5.0-8.0

4.7-7.7

7.5-11.0

7.1-10.6

0.6-0.9

1.5-2.2

3.0-4.5

2.7-4.2

5.0-8.0

5.0-7.0

4.8-6.8

Grade

7T,

8T

6mm

bolt

8mm

bolt

1

Omm

bolt

1

Omm

bolt

12mm

bolt

12mm

bolt

12mm

bolt

13mm

bot!

14mm

bolt

14mm

bolt

16mm

bolt

16mm

bolt

Grade 5 Cap

1/4

UNC

1/4

UNF

5/16

UNC

5/16

UNF

3/8

UNC

3/8

UNF

7/16

UNC

7/16

UNF

1/2

UNC

1/2

UNF

and

8.8
head/nut
head/nut

head/nut
head/nut
head/nut
head/nut
head/nut

head/nut

head/nut

head/nut
head/nut
head/nut

Screw

Pitch

1.25

1.25

1

1.25

1.5
(IS?)

1.5

1.75

1.5

1.5
2

1.5
2

I

b-It

5.8-8.7

14.5-21.7

28.9-39.8

26.8-37.6

54.2-75.9

50.6-65.1

43.4-61.5

57.9-86.8

72.3-108.5

68.7-101.3

108.5-166.4

101.3-159.1

9-11
11-13
18-20

21-23
28-33
30-35
44-49
50-55
68-73
73-80

kg-m

0.8-1.2

2.0-3.0

4.0-5.5

3.7-5.2

7.5-10.5

7.0-9.0

6.0-8.5

8.0-12.0

10.0-15.0

9.5-14.0

15.0-23.0

14.0-22.0

1.2-1.5

1.5-1.8

2.5-2.8

2.9-3.2

3.7-4.6

4.1-4.8

6.1-6.8

6.9-7.6

9.4-10.1

10.1-11.1

PARTS

Taper
Taper
Taper
Water
Oil
Side

Bearing

REQUIRING

screw
screw
screw

drain

pressure

SEALANT

1/2

"

1/4

"

1/8"

plug

switch

seal

cap

No.

1

BOLT

M6

M8
M10
M12
M14

Thread
Thread
Thread
Thread
Thread

Periphery
Contact

DIA.

GENERAL

SURFACES

(where

portion

(Gear

portion

(Cylinder

portion

(Cylinder

portion

(Cylinder

portion

(Cylinder

(Main

bearing

surface

with

SCREWS

BOLT

HEAD

MARK

4 7

0.3-0.5 0.8-1.0

10

1.0-1.3

1.0-1.3 1.5-2.2 2.5-3.5

1.8-2.5 3.0-4.2 5.0-7.0

3.0-4.2 5.5-7.5 9.5-12.0

5.0-7.0 8.0-11.0 16.0-19.0

SEALANTS

REQUIRING

to

mount

sealant

case)

block
head

rear
block
block

caps

No. 1 and

cylinder

block

Engines & Generators

right

right
right

SEALANT

coated

side,

pump

surface)

side,

rear

side

surface)

No.

parts)

cover)

middle

5)

portion)

SEALANT

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon
Permatex
Permatex

#68
#6B

53

METRIC

CONVERSIONS

INCHES TO MILLIMETERS MILLIMETERS

Inches

1 25.40
2 50.80
3
4
5

10

Inches

1
2
3
4
5
6

Yards

1 0.91440
2
3 2.74320
4 3.65760
5

101.60

127.00

254.00

10

MILLIMETERS = 1CENTIMETER,

Meters

0.0254

0.0508 8 0.2032 0.2 7.874 0.8 31.496

0.0762

0.1016 10 0.2540 0.4 15.748 1.0

0.1270

0.1524

TO

CONVERT

Meters Yards

1.82880 7 6.40080

4.57200

MOVE

TO

INCHES

Qtm

76.20

Inches mm

15
20
25

30

35

40

381.00 1

508.00

635.00 3

762.00

889.00

1016.00
100

CENTIMETERS= 1 METER = 39.37

mm

2

4
5

10

Inches

0.0394

0.0787

0.1181

0.1575

0.1969
03937

mm

15
20
25 0.9843
30
35
40 1.5748

INCHES

(3.3

INCHES TO METERS METERS TO INCHES

METERS

YARDS

DECIMAL

Inches

11
12 0.3048 0.6

TO

CENTIMETERS,

TO

METERS METERS TO YARDS

6

8
9

10 9.14400

POINT

FOR

Meters Meters

0.1778

7

9 0.2286 0.3

0.2794 0.5 19.685

MOVE

Meters

5.48640 1

7.31520

8.22960 4 4.37445

HIGHER

VALUES-

0.1 3.937 0.7 27.559

DECIMAL

Meters

2
3

5 5.46807

e.g.

Inches

11.811 0.9

Meters

1.1

23.622 1.2

POINT

TWO

PLACES

TO

THE

Yards

1.09361

2.18723 7 7.65529

3.28084

6,000

METERS=

Meters

6 6.56168

8
9 9.84252

10

6,561.68

YARDS

Inches

0.5906

0.7874

1.1811

1.3780

FEET)

Inches

35.433

39.370

43.307

47.244

RIGHT

Yards

8.74891

10.93614

lb kg lb kg kg lb kg

POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS

1

2

3
4 1.814 9
5 2.268

Gallons

1

2

3
4 15.14

5 18.93

Pints

1 0.47

2 0.95 7 3.31

3

4 1.89

5 2.37

0.454

0.907 7 3.175

1.361 8 3.629 3 6.614

GALLONS

Liters

3.79

7.57

11.36

PINTS

Liters

1.42

6 2.722 1 2.205 6 13.228

2 4.409

4.082 4 8.818 9 19.842

10 4.536 5

TO

LITERS

Gallons

10
20
30
40
50

TO

LITERS

Pints

6

8
9

10

Liters Liters

37.86

75.71 2 0.53

113.57 5 1.32 120 31.32

151.42

189.28

Liters

2.84 1

3.79

4.26 4 8.45

4.73

1

10
20

Liters

2
3

5

11,023

LITERS

Gallons

0.26 60

2.64

5.28

LITERS TO PINTS

Pints

2.11

4.23 7

6.34

10.57

TO GALLONS

TEMPERATURE

32

I

40

I

50

I

60

75

85

I I I I I I I I I

95

105

140

70

I I I I I I I I I I I I

0

10

5

15

20 25

30

35

40

60

lb

7
8

10 22.046

Liters

90

150 39.62
180 47.54

liters

6 12.68

8
9 19.02

10

175

80

212

100

15.432

17.637

Gallons

15.66

23.77

Pints

14.79

16.91

21.13

Of

oc

Engines & Generators

54

SUGGESTED

SPARE

PARTS

Carry

Thennostat
Gasket

Always
a

spare

and

carry

set.

Only

·

Fuel

Easy

'

case

Genuine

('

i

Uft

Pump

to

replace

of a failure.

in

Westerbeke

Fuel

Uft

Pump

Filter

Change

·

operating

every

hours.

250

Check
eaten
tropical
at
several

Heat

Clean

.at

Spare

Zinc

Anodes

often,

up

quickly

waters

marinas,

spares.

Exchanger

out

and

least

once a year.

Check
always

they

and

carry

inspect

Parts

·water

every

are

in

End

Gasket

gasket

Impeller

250

operating

have a spare

and

Gasket

set

on-board.

hours,

Oil

filters

Repiace
every
extras

Fuel

FueJ

line

fix a leak.

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

Kit
Kit

banjo

"A"

includes the basic spares.

"B"

is for more extensive off-shore cruising.

A

Kit

Impeller Kit
Heat Exchanger Gasket
Fuel Filter with Gasket

Oil Filter
Drive Belt
Zinc Anodes

Fuel Lift

with

every

100

operating

on-board.

Hardware

fittings,

Pump Filter

Kit

washers

oil

change

hours.

etc.

at

Keep

to

''orive

Belts

Inspect

SPARE

often,

cracking & fraying.

If

using a dual

alternator

matched

pair

PARTS

look

for

sheave

buy

belts.

KITS

Carry

several
Westerbeke
operating

filters.

hours.

Fuel

filters

on-board,

Water
Thermostat Kit

use

only

genuine

Change

B

Kit

Impeller Kit

Zinc Anodes
Complete Gasket Kit
Heat Exchanger Gasket
Injector
Fuel Filter with Gasket
Oil Filter
Drive Belt
Fuel Lift

every

250

Pump Repair Kit

Pump Filter

j...,.,IWESTERBEKE

l

Engines & Generators

55

1241-8/2017