Westerbeke 4.5 BCG, 4.5 BCGA, 3.5 BCG, 3.5 BCGA Operator's Manual

' !

~~lt·t.~5~~~,.,

·

OPERATORS

MANUAL

.f

4.5

3.5

MARINE

BCG(A)

BCG(A)·~

GASOLINE

SINGLE

PHASE

---·,,",'

" . -

-

60Hz

50Hz

GENE·RATOR

~

••

..

~

L

PUBLICATION NO.

NOVEMBER 2018

REVISION

WESTERBEKE

150

.. , TEL:

JOHN

[phone]

CORPORATION•

HANCOCK

037491

3

MYLES

ROAD,

•FAX: [phone] • WEBSITE:.wytw.WESTERBEKE.COM

TAUNTON,

STANDISH

MA

INDUSTRIAL

02780-7319

U.S.A.

PARK

£WARNING:

Exhaust
colorless
unconsciousness
exposure

•Dizziness

•Nausea

•Headache

•

IF

GET

·

$t1Bk

until

gasses

gas.
can

Weakness

YOU

DR

ANYONE

OUT

INTO

medical

It

ha$

been

contain

Carbon

and

Include:

and

Sleepiness

ELSE

THE

FRESH

attention.

inspected

Carbon

Monoxide,

Monoxide

death.

EXPERIENCE
Shut

is,paisonous

Sy,;,ptOIJIS~of

•

Throbbing

•Muscular

•Vomiting

•Inability

AIR

IMMEDIATELY. H symptoms
dawn

the

and

repaired.

A

WARNING

WESTERBEKE

bulkhead

WESTERBEKE

CARBON

•------llllL··.

/Iring/sleeping

They

are

obtainable

an

odorless

and

Carbon

in

Temples

Twitching

to

Think

ANY

OF

THESE

unit

and

do

DECAL

is

provided

and

should

near

your

engine

also

recommemlsinstalllng

MONOXIDE

inexpensive

at

DETECTORS

quarters

your

local

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

not

restart

by

be

fixed

or

generator.

in

of

your

easily

marine

vessel.

store.

and

to

the

a

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

and

of

State

65

gasoline

its

birth

WARNING

engine

constituents

of

California

defects,

harm.

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure
precautions.
take

the

persDnne~

As

the

safety

'this

sajetJ

necessary

and your

owntr

rules

and

..

infotlllatiOn

Kno.w

or

operator,

adviSories

B6Q!aiul·.YachtCotl1UJil(AJ'JYCJs'tantlards;.howeverso/ety

rl!Jks

are

.nOt

limited

pages;.

T~e.respom!/Jtlityjor

and

acflltd

risks

for

iriaintinance

exclzisivelj

activities;

to

the

PREVENTELECTRIC·SHOCK

•·WARNING:·

while

snglne

is

·

powsr.

Lethal

riiJ/tage.is

I Do not operate

enclosures

• Shut off electrical power before

equipment.

I Use insulated

equipment.

• Make sure your clothing

(particulatly

•

Remove.
electrical

PREVENT

and

shoes)

wristwatch

equipment.

BURNS -HOT

a\':tlARNlRG:

eibailst·Syst;,m·ooinpallents

veryhatl

, • Monitor engine antifreeze coolant level

coolant recovery
location
when the engine

on

the water jacketed exhaust

carefully.

to

follow

fundamental

when

dangerous

precautions

to

pr()tect

machinery.

always

observe

p1',ovU!edfor

is•

in

tzlignnient:With

to

the

infdrination

the

U!entifi,ctitioti•ofpotential

compliance

o:nd

with

Other

conditions

ownef/operator.

Do

not

tilllch

AC

running,

covers in place.

mats

or

when

present

this

rtl.a.Chinery

whenever working

when handling electrical

and

without electrical

and

skin

all

jewelry

ENGINE

Do

not.

tlJut:b

htft

•..

A

· · · ·

tank

is

COLD.

·'iilnitlng·englilegets

and

periodically

Most

accidents

rules

and

conditions

yourself,

the

following

yourconvenience.

·the

in

thefollowing

:all

safety•advisories,

belong

Blllt:trlcal

oannsctsd

at

accessing

caet:tions

these

connections!

electrical

on

electrical

are

dry,

not

When

working

to

;

lnlJ!lie

Pans

at

the plastic

at

the

manifold,

are

exist

and

your

American

shore

daIIip

equipment.

on

or

•·

;,..,;.

filler

cap

but only

PREVENT

A

• Prevent
sparks

..

eump,
vapors. Use a
reinoVing

•

·.

D()

·

Backfu,e

•

bo
the fuelsysteni.
engitie/generator clean and free
chances

• Be

PREVENT

A

injury

I Follow re-fueling safety instructions.

hatches

after fueling. Check below for fumes/vapor before

running the
before starting your engine.

•

All
when
well-ventilated area away
equipment

•

Do

• Shut off
servicing
that
flames,
engine
when

• Do

• Be sure

• Be certain
free

I Make sure a

properly maintained. Be familiar
Extinguishers rated
for

BURNS -FIRE

WARNING:

flash

to

or

not operate

not

smoke

aware -diesel

Firs

t:an

fires.

Do not smoke or permit

occur

near

the carburetor,

other potential

suit.able

the

fuel

with

ean

cause severe injury or

or permit

Keep

of

fire.

Wipe

sources

container to

line, carburetor, or

the air cleaner/silencer

flames

the compartment

up

all

fuel

will

cause

spilled

burn.

BURNS -EXPLOSION

WARNING:

or

death!

fuel

handling

not

fill

might

when

servicing

not

alter or

ofleaks.

all

applications encountered in this

closed

blower.

vapors

and

the

fuel

the

fuel

the

fuel

spill.

or other

servicing.

all

fuel

fuel

fire

Explosions

when

are

highly

and

out

of

tank(s)

service

system.
DO
sources

the

modify

supplies

line

extinguisher

tram

fueling. Open and ventilate

Run the blower

explosive.

storing fuels. Store

from

the reach

while

valve

Take

NOT

allow

of

fire

Ensure proper ventilation

fuel

system.

the

fuel

have

fittings

are adequately

ABC

by

injury

or

fuel

line,

of spilled

catch

fuel

death.

or

sparks

and

of

debris

fuel

and

fuel

vapors

Keep

for

four minutes

Use

extreme

fuel
spark-producing
of

children.

the engine

at

the

engine

care

in

catching

any

smoking,

near

the

fuel

system.

a positive shutoff

is

installed

with

its

the

NFPA

are

environment.

death!

flames

filter,

fuel

or

all

fuel

filters·

removed.

to occur

the

to

minimize
engine

can

the

vessel's

in a ·

is

runni?g.

when

open

system

vruve.

tightened

nearby

proper

appropriate

or
fuel

fuel

when'

near

oil.

cause

cabin

care

any

fuel

or

exists

and

and

is

use.

the

·

• ln case

of

an

engine overheat, allow the engine to

before touching

the

engine or checking

the

coolant.

cool

.

,Engtn~:'.&

Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect
generator. Remove the negative lead first and reconnect

it last.

• Make certain
starting.

• Make certain
installed before starting the engine.

BAnERY

A

WARNING:

or

death!

•

Do

not smoke
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
arcing or by lit tobacco products.
equipment in
ing servicing.

• Never connect the negative(-) battery cable.to the posi­tive (
not test the battery condition
together.
Ventilate
accumulation of explosive gases.
disturb the battery charger connections while the battery

is

being charged.

•

Avoid
burns or
wristwatch, rings, and
the battery.

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

STARTING

Accidental

the

battery cables before servicing the engine/

all

personnel

all

covers, guards, and hatches are re-

starting

are

clear

can

oaUStl

ln/UfY

of

the engine before

EXPLOSION

Battsry

or

the

+) connection terminal

Sparks could ignite battery gases or

any

compartment containing batteries to prevent

contacting the terminals with tools, etc., to prevent

sparks

t1xploslon

allow

an

gas, which can be ignited by electrical

vicinity

that could cause

to

any

oan

caUSB

Injury

open flame near the battery

Shut off

prevent electrical arcing dur-

of

the starter solenoid. Do

by

shorting the terminals

To

an

other jewelry before handling

all

electrical

.

..

fuel

vapors.

avoid sparks, do not

explosion. Remove

BAnERYACID

A

WARNING:

seveTB

Injury

• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec­tion.

Batteries contain sulfuric acid which is destructive.

If

it comes

water.

with
inadvertently

Sulfuric

or

death!

in

contact with your skin, wash it off at once

Acid may splash

when

acid

In

batteries

oan

·

on

the skin or into the eyes

removing electrolyte caps.

cause

TOXIC

• Ensure that the exhaust system is adequate to expel

• Be sure the unit and its surroundings are

• In addition to routine inspection of the exhaust system,

• For additional information refer toABYC

•

EXHAUST

A

WARNING:

discharged from
regularly
are

securely attached and no warping exists.
attention
exhaust pipe nipple.

install a carbon monoxide detector. Consult your boat
builder or dealer for installation of.approved detectors.

tional information

A

WARNING:

odor/BSS
nausea

Do

not use copper tubing in diesel exhaust systems.
fumes

can

tems.

Exhaust sulfur causes rapid deterioration

tubing resulting

• Do not install exhaust outlet where exhaust can

through portholes, vents, or air conditioners.
exhaust discharge outlet is near
enter

the

flow

of exhaust.

• Although diesel engine exhaust gases
exhaust
gas

is present
toms or signs of carbon monoxide inhalation or poisoning
are:

Vomiting
Dizziness
Throbbing
Muscular twitching

Intense headache

Weakness

AVOID

•

MOVING

A

WARNING:

or

d1111th!

Do

not service the engine while it

tion arises

operating adjustments, use extreme care to avoid

ing moving parts and hot exhaust system components.

GASES

carbon

monoxide

the

engine. Check the exhaust system

for

leaks and make

to

the manifold, water injection

on

Carbon Monoxide).

Carbon

gas.

lnllalatlon

or

dsath!

rapidly destroy copper tubing in exhaust

in

exhaust/water leakage.

exhaust discharge outlet

Avoid

overloading the craft.

fumes

from gasoline engines, carbon monoxide

in

diesel exhaust

in

temples

and sleepiness

(CO)

Is

sure

the exhaust manifolds

monoxidt1
prodllaes

(CO)

t/u-llkt1

the

waterline, water

and

close or restrict

are

fumes.

Some of the

a

deadly

elbow,

well

T-22

Is

not

PARTS

Rotating

in

which it is absolutely necessary to make

parts

can

oauss

is

running.

injury

Pay

close

and

ventilated.

(educa-

an

Invisible

symptoms,

of

be

If

the engine

as

toxic

If

a situa-

gas!

gases

Diesel

sys-

copper

drawn

could

the

symp-

touch-

··

as

l'W'IWESTERBEICE

f

Engines & Generators

ii

SAFETY

INSTRUCTIONS

II Do not wear loose clothing

equipment; avoid wearing loose jackets, shirts, sleeves,
rings, necklaces or bracelets that could be caught in
moving parts.

II Make sure all attaching hardware is properly tightened.

Keep protective shields and guards in their respective
places at all times.

II

Do

not check fluid levels

the engine is operating.

II

Do

not allow any swimming
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning
death can occur.

HAZARDOUS

A

WARNING:

NOISE

High

or

jewelry when servicing

or

the drive belt's tension while

or

activity around

noise

levels

can

cause

or

near

or

hearing

loss!

II Never operate an engine without its muffler installed.
II

Do

not run an engine with the air intake (silencer) or

flame arrested removed.

II

Do

not run engines for long periods with their enclosures

open (when installed).

A

WARNING:

are

mentally

Do

not

or

physically

work

on

machinery

incapacitated

when

by

fatigue!

you

ABYC,
INSTALLING

Read the following ABYC, NFPA and
for safety codes and standards. Follow
recommendations when installing your engine

ABYC

"Safety Standards for Small Craft"

Order

ABYC

613 Third Street, Suite 10
Annapolis,

www.abycinc.org

NFPA - (National Fire Protection Association)
"Pleasure and Commercial Motor Craft"

Order From:
National Fire Protection Association

Battery March

Quincy,

USCG

Regulations are under titles CFR33 and
of

NFPA

AND

USCG

ENGINES

(American Boat and Yacht Council)

From:

MD

21403

Park

MA

02269

(United States Coast Guard)

Regulations"

From:

Order

U.S.

Government Printing

Washington, D.C. 20404

AND

PUBLICATIONS

GENERATORS

USCG

their

CFR46

Office

FOR

publications

of

the

"Code

OPERATORS

Many

of

in

your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.

GASOLINE

Preparations to install a gasoline engine
begin with a thorough examination
Yacht Council's (ABYC) standards. These standards are a
combination

Sections

H-2 Ventilation for Boats using Gasoline
H-24 Gasoline Fuel Systems

P-1

Installation

for Propulsion and
P-4 Marine Inboard engines and Transmissions
E-11

AC

All installations must comply with the Federal Code
Regulations (FCR).
www.abycinc.org

MANUAL

the preceding safety tips and warnings are repeated

ENGINE

of

of

the ABYC standards

and

DC

AND

GENERATOR

of

sources including the

of

of

Exhaust systems

Auxiliary Engines

Electrical systems

INSTALLATIONS

or

generator should

the American Boat and

USCG

and the NFPA.

particular interest are:

On

Boats

of

Engines & Generators

iii

When

installing

attention be

WESTERBEKE

paid

to

the

INSTALLATION

following

engines
information:

and

generators

it

is

important

that

strict

CODES

Strict federal

when

AND

regulations,

installing

REGULATIONS

ABYC

guidelines,

engines

and

generators

in a marine

SIPHON·BREAK

For

installations

or

will

be

break

in

minimum

the exhaust manifokl injection port

raw

water damage to the engine and possible flooding

If

you

have

to

the

vessel's

siphon-break.

NOTE:

A
operation.
engine

damage.

EXHAUST

The exhaust system's hose
Exhaust
and

turns

and

turns

system

MUST

under

any

where

below

the

the

raw

water

of 20"

above

any

doubt

waterline

siphon-break

Failure

to

Consult

SYSTEM

Hose is

recommended.

without

.In this

the

regard,

be

designed

sea conditions

the

exhaust

vessel's

supply

the

about

under

requires

properly

the

need

a single

and

manifold/water

waterline,

hose

vessel's

the

the

periodic

maintain a siphon-break

siphon-break

MUST
of additiinal

to

prevent

at

provisions

to

the

waterline.

is

at or

position of

vessel's

inspection

be

certified

The

use

of

fitting

length

of

the

any

angle

exhaust

the

various

manufacturer

this

corrugated

entry

of

and

safety

codes

must

be

environment.

injected exhaust

must

be

made

elbow.

This

Failure

below

for
and

vessels

to

use a siphon-break when ·

the load waterline will result in

of

the

water-injected

operating

and

cleaning

can

for proper

marine

use.

type

of

hose

clamps

to

exhaust

of

water

into the

heal.

elbow

to install a

hose

must

boat.

exhaust

conditions,

to

ensure

result

in

maintenance.

Corrugated

allows

for

accomplish

hose

can

exhaust

catastrophic

complied

is

close

siphon-

be

looped

elbow

relative

install a

proper

Marine

extreme

these

be

used.

system

with

to

a

·

AVAILA9LE

YOUR

DEALER

SIPHON-BREAK
LOOP

bends

bends

The

FROM

WESTERBEKE

.

WITH

STAINLESS

A

detailed
engines
to

download

Marine

and

generators,
from

Installation

is

supplied

our

website

Engines & Generators

Manual
at

covering

with

each

gasoline

unit. A pdf

www.westerbeke.com.

iv

and

diesel,

is

available

TABLE

Parts

Identification
Introduction
Fuel,

Engine
Control
Preparations
Operating

Overspeed Shutdown ..................................... 9 Testing ......................................................... 25

Break·ln

Checklist.................................. . .................. 10

Safety

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

Low Oil Pressure Switch .............................

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

High RPM Shutdown Switch ......................

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

.

Maintenance

Catalytic Converter ......................................

Cooling

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

·Raw Water Pump .........................................

Changing Coolant ........................................ 16

Drive· Belt Adjustment ................................. 16

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

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

Fuel

System

Fuel Lift Pump .............................................

Carburetor Filter Screen ..............................

Gasoline/Water Filter ...................................

Gasdenser .....................................................

Carburetor .................................................... 19

Engine

Spm

......................................................... 3 Starter

Oil

Panels

for

Instructions

Procedure

Shutdown

Schedule

System

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

Oil

Change

on

Oil Filter .........................................

............................................. 2 Remote

and

Coolant

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

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

Initial

Start-Up

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

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

(Daily

Operation)

Switches

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

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

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

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

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

OF

CONTENTS

Oil

Filter

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

5

Motor

Testing ......................................................... 22

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

6 Disassembly .................................................

7

8 Integral Controller ....................................... 25

10

11
11
11
11
11
11

12 Torquing Cylinder Head Bolts .................... 30

13

14
15
15

17
17

18
18
18
18
18

20
20

Battery

Engine
Engine

Wiring
Wiring
Remote
Remote
Generator
BC

Lay-up
BCG
Torque
Suggested

Charging

Troubleshooting
Adjustments

Govemor ......................................................

Spark Plugs .................................................. 29

Choke Solenoid ........................................... 29

Ignition Wires .............................................. 29

Valve Clearance Adjustment ....................... 30

Ignition Timing ............................................ 30

Diagram

Schematic

Start
lnstrumentPanel

Information

Generator

Internal Wiring Diagram .............................

Circuit Breaker ............................................

BCA Wiring Diagram .................................

No-Load Voltage Adjustment ...................... 37

Resistance Figures ......................................

Shore Power Transfer Switch ..................... .39

and

Generator

Specifications

Spare

Circuit

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

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

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

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

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

Panel

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

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

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

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

Recommissioning

Specifications

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

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

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

Parts

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

21
22

23

24

26
28
28

31

.32

33
33
34
35
35
35

.36
.38
.40

42

44
45

Engines & Generators

1

PARTS

IDENTIFICATION

20AmpDC
Circuit

Breaker

LubeOI

Dipstick

Oil

Pressure

Switch

Heat

Exchanger/

Fresh Water Coolant

Medel

Data

·

TaQ

FBI

4JbeOU

Fill.

Exhaust Temperature

Distributor

45°

Exhaust

E>C

Battery

Connection

REAR

Switch

Elbow

Ground

Control.

SA

AC

Panel'-

&15AFUSES

Connections---

Outlet

Gasdenser

...........

Air

Intake

Flame

~ester

Carburetor with

--e--water

Choke

FRONT

Governor

Temperature

switch

Sea

Water

Pump

· Lube Oil Drain Hose

IW"IWESTERBEKB

(Engines & Generators

2

INTRODUCTION

This

WESTERBEKE
WESIBRBEKE'S long years of experience
technology.
and
Thank

In order

it

is
manual
manual
throughout.
your nearest

· ·

This
provided
WESIBRBEKE
equipment
for

WESIBRBEKE' S Installation Manual.

We

dependable

you

for

to

get

important that

is

designed

carefully

Should

WESIBRBEKE dealer for

is

your

Operators

and

a Technical

yourself,

WARRANTY

Your

WESIBRBEKE

folder.

If

you

have not received a customer identification
card registering
warranty registration

writing

with

model

number

and

commission

Generator

take

great pride

performance of our engines

selecting WESTERBEKE.
the

full

use

you

operate

to

help

and

observe all.the safety

your

Manual.

dealer.

If

contact

is

a product of

in

the superior

and

benefit from your

and

maintain it

you

do

this. Please read

generator require servicing, contact

A Parts Catalog

Manual

is

you

are

planning to install

your

WESTERBEKE

PROCEDURES

Warranty

your

warranty

form, , please contact the

infonnation, including

date

is

included in a separate

60

days

precautions

assistance.

available

after

the

and

advanced

durability

and

generators.

generator,

correctly.

this

is

also

from

your

dealer

submitting

factory

unit's

serial

this

in

This

the

WESTERBEKE

span

between

and

the

unavoidable existence of earlier WESTERBEKE
manuals.
WESTERBEKE
other
sively
not
representatives

be

product

SERIAL

The

·

sticRers

. engine's serial

engine

·

lube

illustration
quick

·

ordering

In

summation,

suppliers,

as

the

definitive authority

only

makes

consulted

to

software

NUMBER

engine's

affixed

block

oil

filter.

of

reference

service/repair parts.

SPECIFICATlON

MODEL

RPM

__________

KW

___________

customers

printings

products,

must
good

of WESIBRBEKE or the supplier in

determine

being

should

also

keep

in

of WESTERBEKE product

product software provided

whether from WESTERBEKE or

not

and cannot be relied upon

on

the respective

sense but

is

the

accuracy

consulted

imperative that

and

currentness of

by

the customer.

LOCATION

model

and

serial number can be found

to

either side of the generator housing.

number

can

also

be found stamped

on a flat

Take

_______

the

when

surface just

the

time

I.D.

sticker
seeking

_

_

_

above

and

to

enter this information

below,

as

this will provide a

50

tec.hnical

HZ.

information

60,

inboard of

HZ.

mind

the

software

with

exclu-

product.

appropriate

question

on

into

on

and/or

time

It

the

l.D.

The

the

the

the

Engines & .Generators

Customer Identification

WESTERBEKE
MAIN

STREET

HOMETOWN,

Model BCG -

. Expires

PRODUCT

Product software (tech
catalogs)
are

WESTERBEKE CANNOT
CONTENT OF SUCH SOFTWARE,
OR

. INCLUDING ACCURACY, TIMELINESS OR COMPLETE-

NESS, THEREOF

FOR'A'NYTYPE OF DAMAGE OR
CONNECTION
FURNISHING OR USE OF SUCH SOFTWARE.

____

SOFTWARE

provided from sources other than

not

within

WESTERBEKE'S CONTROL.

REPRESENTATIONS

AND

WITH

Ser.

data,

OR

USA

#

_

WILL

OWNER

----

parts lists, manuals,

BE

RESPONSIBLE FOR THE

WITH

RESPECT

IN

NO

ARISING

MAKES

EVENT

INJURY

OUT

OF THE

-

WESTERBEKE

NO WARRANTIES

THERETO,

BE

INCURRED

---

brochures

LIABLE

IN

and

·

KVA

-~---------

VOLTS

________

_

AMPS---------

ENG.

HP-------

ENG.

SER. NO.

GEN.

SER.

NO.

PF/PHASE

WIRES

RATING

INSUL

TEMP.

BATIERY

C.1.0.

Fill.

in

the

IE~!?i!•t

Engine

l.D.

___

________

_______

CLASS

RISE----

------

----------

information

Plate

_

_

_

__

for your

I

reference.

tl:JJ

=t=t~j

Engines & Generators

3

.

ORDERING

Whenever
generator
include
part
Also

will fit

specifications

NOTES,

As
maintenance
generator,,
CAUTIONS,

NOTE:

A

observed,

replacement

and

a complete part description and part

needed

(see

insist

upon

or

generic

CAUTIONS

this

manual

critical infonnation

An

operating

CAUTION:

can

engine.

A

WARNING:

fallowed,

NOTE:

by

WESTERBEKE.

the

engine

SPARES

Certain

WESTERBEKE

SUGGESTED

as

proper
way.
spares
on-board

NOTE:

manual).
the

drive

about

can

A

carbon

room.

AND

spares

fuel and oil

WESTERBEKE

and

accessories

inventory of

Also

available

These

engine.

these

ldts.

PARTS

parts

are

engine

model

and

the

separately furnished

WESTERBEKE

parts

are

frequently

as

original

takes

schedules,

and

result

equipment.

AND

WARNINGS

you

through

and

troubleshooting of

will

WARNINGS.

procedure

essential

Pracsdures,

in

the

damage

which

Procedures,

result

in

personal

monoxide

Affix

warning

this

decal

ACCESSORIES

will

be

needed

to

generator

SPARE

provide

Visit

PARTS).

filters

will

brochure

the

are

Spare

basic

our

website:

or

engine

can

provide

proper

Parts

service

Often

INTRODUCTION

needed,

serial

An

which

in a visable

support

be
to

www.westerbeke.com

always

provide

numbers.

packaged

not

the

operating

be

highlighted

explanation

to

if

not

or

If

injury

decal

has

when

even
difficult
you

with a suggested

assist

WESTERBEKE

Kits

(last

spares

In

number

Parts

Catalog).

parts

made

to

procedures,

your

follows:

note.

strictly

destruction

not

properly

or

loss

of

been

provided

location

and

maintain
cruising
simple

to

obtain

you

in

preparing

page

needed

in

addition,

because

the

by

life.

items

parts.

in

this

maintaining

the

for

each

same

NOTES,

of

your

in

your

(see

such

along

to

learn

an

the

PROTECTING

Care

at

the

have

resulted

many

thousands
manufacturer
installed in
operated
buyer/owner

NOTE:

Six

•

Proper

• An

efficient
anti-siphon
engine.

•

Changing
hours.

•

Proper
components
this

•

Use

•

Winterize
RECOMMISSIONING

UNDERSTANDING

The

gasoline

ways

similar

are

vertical
overhead
a solid-state distributor
camshaft-driven.
lubrication
which

is
generator's engine
maintenance
The

most important
proper ventilation,
system,

YOUR

INVESTMENT

factory

during

in a WESTERBEKE

of

hours

cannot

control

the

vessel

or

the

and

serviced in

operator.

important

engine and generator

maintenance

manual.

clean,

steps

well-designed

break

to

the

engine

according

filtered

unleaded

your

engine

prevent

of

THE

engine

driving

to a gasoline

in-line,

and

the

camshaft

system,

thennostatically

cooling

that

The

is

system

which

which

engine

and a fresh

requires

required

factors

maintenance

and

of

the

to

oll

assembly

manner

ensure

and ollfilters

all

to

according

section

GASOLINE

automobile

engine's cylinder

is

controlled.

the

to

and

thorough

generator

dependable

how

field.

exhaust

water

engine

the

fuel

service.

or

where

in

which

this

is

up

long

generator

installation.

system

from

entering

every

and

generator

maintenance

to

the

JAY-UP

in

this

manual.

ENGINE

an

AC

generator

engine.

chain-driven.

is

horizontally

incorporates a pressure

water-cooled
same

of a

gasoline

the

generator's

of

the

generator

The

To a large

preventative

automobile

the

fuel

back-end.

capable

However

the

generator

the

to

the

life:

that

includes

JOO

schedule

is

in

The

head

engine

mounted

engine

degree,

longevity

system,

testing

of

unit

is

the

operating

in

AND

many

cylinders

has

an

utilizes

and

type

block

the

engine.

are

ignition

the

is

an

CARBON

WESTERBEKE recommends mounting a carbon monoxide

detector in the vessels living quarters. Carbon monoxide,
even in small

The presence of carbon monoxide could indicate
leak
from
connected
exhaust.

If

carbon monoxide is present, ventilate the

air

MONOXIDE

amounts, is deadly.

from

the main engine or the generator's engine or

the exhaust elbow/exhaust hose system the engine is

to.

Even possibly from a neighboring vessel's

and

correct the problem immediately!

DETECTOR

area

an

exhaust

with clean

Engines & Generators

4

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

A

CAUTION:

·

hlgller.

,

acc,pta#Jls

Gaisoline

higher

Care

Use
components
particles
these
and
unsatisfactory
facilities.
engine's
advisable:

Purchase a well-known
Install and regularly service a

metal
and

Ethanol

Gfiiolln_e

warranty.

With

than

10% IE10l

and m.Y void

Of

The

only

clean properly

which

finely

finished

keep

it

clean.

To

daily

bowl

type

the

engine.

U,;,

unl1111d~d

gasoline

wi~h

hlgh_srpercentagBS

iar11Se

an

Fuel

in

the

by

assure that the

use is clean

!n·thesemodels

ETHANOL

content

is

not

wi11TJlnty.

Supply

filtered

unit's

fuel

might

pass

through

parts.

It

The

best

fuel

careless

filter/water separator between

handling

fuel

and

brand of

89

must

not

iillowed'

fuel!

system

is

important

can

going

pure, the

fuel.

good,

Octane

excesd

gasoline

E10

of·Bthanalare,

and

can

.

·

The clearance of

are

very critical; dirt

the filter

be

or improper

Coast

can

to

buy

clean

rendered

storage

into the tank

following

Guard

the

or

{100/a}.

not

void

the

some

damage

fuel,

for

your

practice

approved

fuel

tank

is

ENGINE

WESTERBEKE
and
chemicals

The antifreeze performs
run

the

cooling

quality

Additives
balanced,

The
being

NOTE:

antifreeze

A
engine

COOLANT

A
The
coolant expansion
without
the cooling

COOLANT

recommends a mixture

50%

distilled

that can corrode internal

at

proper

temperatures by transferring

engine

to

the coolant It

circuit

from

antifreCze

(SCAs)

crucial

to

distilled water and

poured

into

Look

for the

that

is

now

proper

50/50 mixture

coolant

temperature

RECOVERY

coolant

recovery tank kit is

pwpose of this

the

loss

of coolant

system.

water.

rust and

that contains

that keep

long term protection.

the

cooling circuit.

new

available.

recovery

and

~"""""-.;;"'-"'

of

50%

Distilled

double

·antifreeze

water

engine

duty.

also

lubricates

corrosion.

Supplemental

the

antifreeze

should

It

allows

Look

is

be

free

surfaces.

heat

and

for a good
Cooling

chemically

premixed

environmentally-friendly

as

recommended

to

temperatures

will

protect

of

TJ\NK

supplied

tank

contraction

and

is

to

during

without

with

each

allow

for

engine.

introducing

antifreeze

from

the

the

engine

away

from

prote.cts

long

-40°F.

generator.

engine

operation,

air

to

the

before

lasting

the

into

ENGINE

Use a good brand of engine
designations

this

Change
engine break-in operation.
change intervals

SCHEDULE in

Westerbeke Corporation

the
break-in MUST

change intervals

SCHEDULE

if

NOTE:

statements

OIL

as

manual.

the

engine

use

of synthetic

synthetic oils

The

information
regarding

listed in the

oil

and

as

specified in the MAINTENANCE

this

manual.

does

oils.

If

be

performed

must

be

as

section

in this manual and not

are

used.

above

synthetic oil

oil

with

an

API

and

SAE

SPECIF1CATION

filter

after

an

Then

follow

not

approve or

synthetic oils are

using

conventional

listed in the MAINTENANCE

supercedes all previous

usage.

initial 50

the oil

disapprove

used,

to

Section

hours

and

filter

engine
oil.

be

extended

of

Oil

of

NOTE:

This
located
manifold.

tank,

with

at

or above the level

its

short

run

of

of

the

engines exhaust

plastic

hose,

is

best

5

CONTROL

PANELS

DESCRIPTION

The generator
ON switch
switch (red).

The ON switch provides power to the start circuit.
switch by-passes
until the oil pressure reaches

START

The
cranks the engine.
switch is

The STOP switch

switch must
The panel also

•·A

Slow-blo

•An 8 Amp
any

optitmal

REMOTE

An optional
controlling

This panel
previously described. Also included

which glows
rpm' s. The purpose
release the START switch. It

engine/generator is running.

mounted

(black),

switch

depressed

be

depressed until the stop sequence is complete.

has

15Amp

Fuse

ref!iote.

START/STOP

remote

the

generator

has

the

once

control panelis equipped

a

START

the

pr;otective

energizes the start solenoid/starter which

1bis switch will not operate unless

and

will

two

Fuse

to

protect

_paf!elS.

start/stop panel

same ON, START,
the

of

switch(white) and a STOP

oil pressure shutdown switch

S -

10

psi.

held at

the

same time.

tum off the engine/generator.

fuses

!O

protect the DC circuit:

to

protect

f;tle

start:

c;ireuit.

the

engine

operating

PANEL

frOm

engine/generator has reached 600

the

LED is to alert

(OPTIONAL)

is

a remote location.

is

is

also an indication that

circuit

15AMPFUSE

RECORDING
FOR

8AMPFUSE

available

and

STOP functions

a green

()

the

LED

operator

HOURMETER

for

with

an

nus

the

on

nus

and

HOURS

MAINTENANCE

light

to

the

REMOTE

An

includes a water temperature gauge,

DC charging voltmeter, operating

switches.

REMOTE

The remote instrument panel has
installed
an

oil

locate<i
installed in the thermostat housing
is

adjacent to

on

the
each sender are tied off next
wiring harness).

The blue wire is for the oil pressure sender

is

for
between
removed.

DIAGRAM

NOTE:

installers responsibility

standards

INSTRUMENT

optional remote instrument

INSTRUMENT

on

the engine block, a water

pressure

threads

the water temperature sender.

When

gauge

on

the

engine.

the

oil

of

both senders. Electrical connections for

terminal board connections

Refer

to

the REMOTE

in this manual.

installing the optional

33

CFR

part

PANEL

PANEL

sender. Plugged ports

The

water temperature sender is

pressure

to

to

comply

183.

(OPTIONAL)

panel

is

available

oil

pressure gauge, ·

hounneter.!.

INSTAllATION

two

sending units to be

temperature

and

the

switch. Use sealing compound

the senders location ( in the

If

there

T-1

and

INSTRUMENT

remote

with

the

which

IU!.d

start/stop

sender and

for

each

are

oil

pressure sender

and

the tan wire

is

a jumper

T-2,

it should

WIRING

panels,

U.S.

it is

Coast

be

the

Guard

/

o~

,~~

~

~

Engines & Generators

6 .

PREPARATIONS

.COOLANT
:FILL

FOR

INITIAL

START

·UP

OIL

FILL

/

PRESTART

Before
longed

a Check

the

a Check

bowls

a Check

and

a Check

and at

NOTE:

the
recovery

the

after

tank will

replace

Before subsequent operation

manifold shoukl

tank

a

Visually

parts,

threaded

INSPECTION

starting
layoff,

full

battery

engine's coaling system will be purged ta
cooling

your

check

the

engine

mark

on

the

fuel

supply and examine

for

contaminants.

the

DC

electric.al

cable connections.

the

coolant

the

manifold.

After

the

tank.

Open

system is purged

the

engine
be

drawn

the

purged

may

need

to

exalnine

disconnected

connections.

generator for

the following
oil

level:

add

the dipstick.

system. Inspect

level

in both

initial running

the

air bleed petcock

has

cooled,
into
air.

be

tapped

be

filled

the

wires, unattached

the coolant

the

engine's

off,

to

unit. Look

Search for

of

of

the MAX

the

first

time

or

items:

oil

to

maintain

the

fuel

filter/separator

wire

the

plastic

recovery

of

the

generator.

to

air.

After shutdown and

from

the

generator;

and

for

any

cooling

the

loose

coolant

level.

or missing
hoses,
gasoline

system

and

after

a pro·

the

level

connections

tank

the

air

the

coolant

ensure

that

the

recovery

to

the

engine's

recovery

check

leaks.

in

at

a Check load leads for correct

thewiring diagrams.

a

Examine

a Be

the

a Be

neutral
requires,
to
or
age

A

recommended

motors,

to
precaution
pated

cold

the air inlet

sure

no

other generator or

load

lines.

sure

that

in power systems

is

properly grounded

and.that generator
theload neutral.
open

neutral

can

on

unbalanced

CAUTION:

thatal/AC loads,npecial/y/arge

be

switched

speed

and,

in

will

prevent

operation

engine

of

from

and

outlet for air

In

single phase

supply

the

loads.

Whenstart!ng

OFF

until

cold

climates,

damage

the

AC

machinery

stalling.

~onnections

utility

with

(or

ungrounded)

neutral

wrong

the

the

stat1s

caused

as

specified

flow

obstructions.

power

is

a neutral

is

systems

line

properly

an

line-to-neutral

generator,

engine

has

to

warm

by

unantici-

and

will

connected

as

the

connected

incomplete

it

come

up.

prevent

that

system

volt-

is

This

..(-MAX.

in

to

the

up

a

FULL

Enginll!s & Generators

7·

OPERATING

INSTRUCTIONS

STARTING

A

for a minimum

ventilating

fumes

1.

Depress

this

2.

Depress

· starts,
the

NOTE:

the

oil

pressure

maintain

3. Release

·A

when
caused
and

Once
atot and allow the engine to warm up to qperatingtemper-

ature
If

an

gauges

NOTE:

This

and

wlitn the geMratorloadsare

tHE

GENERATOR

WARNING:·.

from

the

primes

the

release the START switch: Continue to

ON

switch a few seconds longer. · · ·

Keeping

pressure

to

rise

the

the

CAUTION:

starting.

by

wlll prwent a

The engine

(130°-150°

optional instrument panel is installed, m6nitorthe

for

nonnalreadings. : <

Some

condition

Ventilate·fhe

of

nvs

minutes

blowers

thegeneratorcompartment

ignition.

unanticipated

unstable

remove

ON·

switch

carburetor. Contiµue

STAltT (white),

the

ON

switch depressed
shutdown
enough

ON

to

circuit

switch.

Al/AC

loads

Thlspr11caution

cold

engine

is

running apply

Fl 55°-56°C) before

running.

should smooth out anli.e.

generator

prior

any

sxploslve

and

hOid

it

down

to

when

<;ircuit

allowing the oil

close the switch and

must

be

will

prevent

operation

tmm

aJi~t

may

oq€ur:

of

Stalling.

appl)lin:g

applied

campanment

to

starting.

aad

depress

the gepyrator

/;>y-passes

switched

AC

foad

... · •. · .....

"~·if.

engine

Tbs

gasoline

bilges.

(5-15

seconds),

ON.

en.gage

off

damage

machinery

to the gener-

heavy

·.

·

,cof4<~~g~ne,.

wdtins

. . . . .

loads.

up

A

CAUTION:

the

engine
11Xhaust
pump
collllng

.

enter

m.anifold

ftom
throtlgb•htill
commtlng

Engine

warrantable

In

STOPPING

1.
generator
its operating temperature).

.

2.

~.

NOTE:

the

panel

With

Is

pu/llping

system

the

happening

damage:resultingfrom

mind.

Remoye

to

Depress·
When

the

In

an

stop

switch,

Prolonged

'starting

eiiglae's

once

thrl

THE.

the

run

the STOP (red) switch.

generator stops, release the STOP

emergency,

can

raw

water.
raw

during

cylinders

the.

exhaust

/Jyi:Josing

Shulog,

t:lluse

iS$11e:

the

GENERATOR

AC

loads

for

an

remove

t;ranklng

result

This

water

through

cranking.

by

system

thfJ

draining

11f

the

Bx't:e$S/ve

(Jwner/operator

front the generator

added 3 to 5 minutes

if

the

generator will not

the 8 amp

In

may

way

raw

the

raw

fuse

Intervals

fl/ling

the

bappen

tile

raw

This

law

of

t/NJ,exhaust

nils.

l'rwent

water

exhaust

engine

water

should

in

the

wlthoat

engine

because

water

water

can

this

supply

muffler,

cranking.

entry

is

keep

and

allow

(this

stabilizes

switch.

stop

control

the

and

not

a

this

the

using

·

··Engines

&

·Generators

8

OPERATING

ABNORMAL

An

abnormal

and

comes to a

may cause damage

unsafe operating condition. The fault stop conditions

1.

Overspeed condition!.

2.

High engine temperature.

3.

Low

4.

High exhaust temperature.

Should a fault condition

and

the

indicating that a fault has occurred. Once detected,

should

OVERSPEED

In

the

case

must

be

the

Stop

sequence.

If

the

overspeed switch itself

depressing

T-1

coil

end of
only

as

successful,

Do

not

switch.

STOP

stop

is

one

in

which

stop

as

a result of

to

the engine, the generator, or create

oilpressure.

occur,

green

LED

light on the remote panel will

be

located (see ENGINE

SHUTDOWN

of

an

overspeed

reset before re-starting

switch

mtarily

the

SIDP switch will not reset the

connection

the

T-1

wire

a

test

Re-start

replace

the

run

the generator

shutdown,

then proceed with

from

the

with

electrical

the

generator,

faulty

with

the

generator

an

operating fault

the engine will shut

TROUBLESHOOTING).

the

the

generator.

is

faulty

and re-setting it

overspeed

oversi:ieed

out

switch

tape.

By-pass

if

this by-pass

replacing

overspeed

Simply

the

normal

switch.

the

ceases

circuit,

and

this

ov~peed

go

tape

is

to

which

are:

down,

off

the

fault

circuit

depress

start

by

lift

the

circuit

.INSTRUCTIONS

NOTE:

Overspeed switches

nm

an

the

amperage (25 milliamps) at all times once the generator
connected
mately 18 ainp-hours
concerned with this slight amperage draw during normal
seasonal operation.
unused for many
amp ignition fuse
turn

A

shutdown
tampering
would
Injury

and.~use

REMOTE

The

operate the same
except that they have
remote location {where
be

audible). The
generatods running at
switch should
refer to

to

its starting

off

the

generator's

CAUTION:

always

with

cause

it,to

shQuld

the.gsnerator's

the

generator

PANELS

remote start-pqnel

as

green

be

released.

STARTING

draw

battery.

in

a

month.

However,
months,
from

the

it

the

starting

It

is

very

be

installed

ov,,,S,eed

control

Important

ma/function.

to

and

the

the

generator

green

LED

the

soun(i

LED

lights

about

For the remote start/stop

THE

GENERATOR

a small amount of

This

amounts to

It is not necessary

if the generator set

is

best

to

either

panel

on

the

battery

switch..

that

the

and

tunc,;oning.

shutdown

could

belt-driven

run

away.

remt>te

mounted

lights

of

indica,te

6QO

rpms.

madule.

be a

governor

inStrumentpanel

control

for

starting at

the

generator

when

Tuai

on

the

approxi-

is

remove

generator

overspeed

Any

cause

of

panel

may

the

is

when

sequence

previous

to

be

to

be

the

8

or

·

which

fail

a,

not

the

stm

pag~.

is

A

the

Refer

to

manual.

WARNING:

overspeed

the

sWitch

CONTROL

Do

not

by-p8S$ed.

PANEL

operate

WIRING

the

generator

DIAGRAM

with

·

in

this

l'W'IWESTERBEICE

) Engines & Generators

9

BREAK-IN

After

and

then encourage a

20%

A

tor

by

After
can

be

vary

the

Avoid
smoky
Monitor

it

within the:genetattifS'tatirig.

at

1800

hertz, control of

by

the current

To

protect against

the

generator's output

breaker that is

NOTE:

current drawn
amperage drawn
age.

See

PROCEDURE

the generator

to

60%

CAUTION:

running

the

first I 0

increased

foad;

qverl()~

eXhaust

the

rpm

Be

aware

GENERATOR

has

been

fast

of

full

load

·

Do.notattempt

without

~:all

withrc:do~

current beingdrawn·frc)tritb.e generator

to

produce

drawn.

rated

required

a

hours

of

to

the full'-load·rated output;then

· · · ·

tllJ1~,

60

the

generator's engine

from

unintentional

leads

at

the

of

motor staningloads

for starling

can

be $ to 5 tim¢s.normgl

INFOR°MA:Tl()_N

.

BREAK~IN

started,

check

warm-up.Run

for

the

first

10

'-"-

to

brsa/c-ln

/tfad~

the

generators'

An

9~6~

o~tput

vol~ge.and

PROCEDURE/DAILY

for

proper

operation

the

generator

hours.

YDllT

gsnera-

operation,

~s

signaledpy

the

periodically

rreqtiency.

and

Since

the

h~,

or

atJ500to

the generator.

overloading dfthe

should be

rated output

fnf)tors'.

generator

break~inis

routed

of

the

<»Z(j

in.

opetates

produce

governed

generator,
through
ge11erat0r.

the

This

riin,ning

this manual

a circuit

high

starting

amper-

between

load

_a·

keep

50

.

OPERATION

NOTE:

Some

unstable

This

condition

is

reached

A

periods
gsnerator.

STOPPING

Remove
Allow the:generatortb.run for a few minutes.to stabilize
operating

CONTROL

NOTE:

.

the

.

GENEllA.TOR·

Once
be governor
during
this

under
ment
speed

and

CAUTION:

of

time

THE

the

major

temperature

PANELS).

After the first 50 hours

»14interuzn,ce

the

generator

adjustments

the

engine's break-in period (first

period

(see

ENGINE ADJUSTMENTS. A

rnay

also

adjustment

running may occur

should abate as.normal operating

loads

are

applied.

Do

not

operate

without

a

load

the

being

in

a cold

gsnerator

placed

on

temperature

for

long

the

GENERATOR

AC

loads

from

the

and

press the STOP switch

schedule for

generator

of

generator operation check

the

50 hour service

one

down,

check.

ADJUsTIVJENTS

has been placed in

required for engine speed

ENGINE SPEED (HER1Z) ADJUSTMENT

be

required

(see

in

conjunction

GENERATIOR

operation,

SO

ne>-Ioad

INFORMATION).

hours) or

voltage

with

the

there

engine's

engine,

at a time.

the
(see

may

(hertz)

after

adjust-

CHECKLIST

Follow

this checklist each

a

R_ecord
relate

a

VISually

II

Check the

the hourmeter readifig in

to

the maintenance

inspect

the

engine

oil

level

{dipstick).

a Check the coolant level

a.

Check your

a

Check

a Check

a Check for

blow-by

a Confirm exhaust

When
When
When

fuel

supply.
the starting batteries·(weekly).
the

drive

belts

for wear and

abnormal

sounds.

the engine
the

engine

the

engine

noise such

smoke:

is

cold

is

wann - almost

is

overloaded -

day

before starting

yoi.Jr

log

schedule)~

for

fuel,

oil,

orwater

in

the coolant

- White

proper

as

knocking,

Smoke.

Smokeless.

some

recovery

Black

your

(engine

tank.

tension

vibration

Smoke.

generator.

hours

leaks.

(weekly).

and

EngiMs & .GenilratOts

10

.

SAFETY

The engine
Should a shutdown

finding and

Engine
TROUBLESHOOTING

The following is a description
switches:

SHUTDOWN

is

protected

SWITCHES

by

occur,

correcting tlie cause. Refer

starts,

nms and

then

section

SAFETY

a variety

do

of

shutdown switches.

not attempt

shuts

of

of

these automatic shutdown

to

to

down

in

this manual. .

SHUTDOWN

restart without

the heading ·
the

ENGINE

SWITCHES

low

Oil

Pressure

A low oil pressure shutdown switch
engine's
pressure.

the

ignition coil (which turns OFF

oil

gallery. The switch is·kept closed

Should the engine's oil pressure fall

switch

will open interrupting the

Switch

the

LOW

is

located off the

DC

vo!cage

engine).

Oil

PRESSURE

by

engine oil

to

10 -

to

the

SWITCH

15

psi,

EXHAUST

TEMPERATURE

SWITCH

Exhaust

An exhaust temperature switch

elbow. This switch will open and interrupt the
the ignition coil (which turns OFF the engine), should the
switch's sensor
inadequate supply·
temperatures). This

127°

(

Temperature

indicate an excessive exhaust temperature

of

raw water coolant causes high exhaust

switch opens at 260° - 270° F

- 132° C) and resets

Switch

is

located

at

approximately 225°F (107° C).

on

the exhaust

DC

voltage

to

(an

Oil

FILTER.

High

RPM

Shutdown

An

overspeed shutdown switch shuts OFF the generator set.

by

grounding out
speed reach approximately 2175 rpm. Reset
momentarily depressing the STOP switch. (Make sure
cause

of

the engine overspeed shutdown

Engine

Circuit

Breaker

The.

generator's engine
manual reset circuit breaker (20
draw

or electrical overload anywhere
wiring or engine wiring
event the generator will shut down because the opened

breaker interrupts the DC circuit
should occur, check and repair the source of the
After repairing the fault, reset the breaker and restart

generator.

SWitch

the

ignition system should

is

protected

will

by

amps

cause the breaker

to

the

the

engine's

the

switch

is

corrected).

an

engine

mounted

DC).

Excessive current

in

the instrument panel

to

trip.

K2-run

relay.

If

problem.

the

In

by

the

this

this

High

Water

A high water temperature switch
housing. This switch will open and intenupt the
to the ignition coil (which turns
fresh water coolant's operating temperature reach
approximately
This switch resets at

Temperature

205° F (96° C).

195°

F

(1

SWitch

is

located

OFF the engine), should

OT

C).

on

the thermostat

DC

voltage

the

. Engines"& Generators

Overspeed

Inside the Control Box on the generator is a solid state
Overspeed PC Board.
coil pulses.
Board grounds the ignition and shuts the generator down.
Press the STOP switch to re-set the
(For test purpose

will not re-set. Lift the

that
and attempt to start the generator).

11

PC

Board

It

monitors engine rpm via ignition

If

these pulses reach a preset point. The PC

PC

Board.

ONLY to determine a faulty PC Board

Tl

connection

off

the board

MAINTENANCE

SCHEDULE

WARNING:

gloves,
panel

SCHEDULED

Maintenance

I

DAILY

Coolant

Engine

Fuel/Water

Fuel

Visual

I

INITIAL

•spark
Engine

*Exhaust

"Valve

Air

carburetor
Mechanical

Never

and

use

or

tum

MAINTENANCE

procedures

CHECK

level

Oil

Level

Separator

Supply

Inspection

50

HOURS

Plugs

Oil

and

System

Adjustment

Screen/flame

Filler

Govemor

attempt

the

correct

off

the

battery

are

BEFORE

START-UP

(owner

ol

Engine

OF

OPERATION

Fitter

Arrester

Screen

to

perform

tools

SWltch.

all

detailed

installed)

tor

in

any

each

this

service

jab.

manual.

while

the

When

engln

servicing/replacing

EXPLARATION

Check
Oil
Check

hours
Fresh

ner1iom1anr~e

Check
securing

connections.

Clean/regap.
Initial

Initial
Check
Check

Check
Remove,

necessary,
Clean
Initial

fS

tunning.

at

recovery

level

should

for

water

or

once

a

unleaded

10"4

for

fuel,

v-clamp

Look

engine

oil

check

at

that

the

the

integrity/mounting

adjustment

clean

then

screen

at

oil

change,

Wear

DC

components,

OF

SCHEDULED

tank,

if

empty,

indicate

between

and

dirt

in

fuel.

gasottne

with

ethanol

maximum.

oil

and

water

is

tight

No

for

loose

and

filter

change

50

hours,

then

exhaust

hoses

of

valve.

Check

and

re-install

every

once a year.

50

hours

!hen

then

every

the

propet

safety

tum

oft

MAINTENANCE

check

at

manifold.

MAX

and

LOW

Drain

filter

if

necessary.

an

octane

rating

and

exhaust

leaks

at

50

hours.

250

properly

o1

again

pack.

250

hours

or

leaks.

around

and

hours

attached

the

water

at

500

Inspect

hours.

once a year.

exhaust

bolts/hardware

every

are

security

screen

every

250

equipment

the

DC

Add

on

dipstick.

of

89

or

Check

the

correct

then

change

or

once a year.

and

injected

hours.

rubber

circuit

coolant

Replace

higher.

that

the

elbow.

as

needed.

both

!hat

exhaust

Torque

sealing

Sllch

break8r

if

Do

not

filter

Lower

water

Inspect

every

carefully

the

securing

head

ring

as

goggles

on

needed.

overfill!

every

octane

injected

wiring

100

inspect

clams

elbow.

bolts

and

replace

the

250

wm

exhaust
and

hours.

tor

first.

and

control

operating

affect

engine

elbow

electrical

leaks.

are

tight

if

I

EVERY

Drive

Belt

Starting

Electric
Zinc

Anode

I

EVERY

Engine

Air

Screen/Flame

I

EVERY

*Exhaust

NOTE:

See

data

Carburetor

•Generator

50

OPERATING

(water

pump)

Batteries

Fuel

Pump

and

100

OPERATING

Oil

and

Filter

Arrester

250

OPERATING

Elbow/Exhaust

Some

models

below.

Filter

Screen

HOURS

Gasdenser

HOURS

HOURS

System

have

catalytic

OR

MONTHLY

OR

YEARLY

OR

YEARLY

converters

Inspect

for

for

slipping,

Check

electrolyte

off

corrosion

Inspect

for

Inspect

and

your

own

Change

engine

Remove.

clean

necessary.

Check

the

of

the

exhaust

chaffing.

No

NOTE:

An

Clean.

replace

Check

that

See

GENERATOR

proper

tension

cracking

levels.

if

needed.

leaks.

ensure

clean

zinc

inspection

oil

and

and

re-install

structural

system

exhaust

exhaust

teak

fuel

inlet

AC

connections

INFORMATION.

(318"

and

wear.

Make

Apply

fuel

and

anode.

sctiedule.

filter.

screen

integrity

of

attached

leaks.

Hoses

will

cause

screen.

are

to

112"

deflection)

Adjust

tension

sure

cables

petroleum

electrical

Replace

if

pack.

the

water

to

the

elbow.

and

muffler

exposure

clean

and

and

or

replace

and

connections

jelly

to

terminals

connections

necessary.

Inspect

rubber

injected

exhaust

All

hose

are

In

to

diesel

secure.

Ensure

adjust

if

as

needed.

are

for

are

clean

Note

the

condition.

sealing

elbow

connections

gOOd

serviceable

exhaust!

wires

needed.

Replace

in

good

corrosion

and

tight.

ring

and

casting.

should

have

no

Check

belt

cover.

order.

Clean

protection.

then

determine

replace

Check

be

secure.

condition.

chafing.

if

the

integrity

No

NOTE:

Use

the

engine hourmeter

MAINTENANCE

gauge

to

log

your engine hours or

SCHEDULE

record

your engine hours

running

time.

SCHEDULED

I

EVERY

Hoses

•1gnltlon

•spark

•Vibration
Heat
Mechanical

I

EVERY

Raw

•Exhaust

I

EVERY

Ignition

•Coolant

•valve
*starter

EVERY

MAINTENANCE

250

OPERATING

Timing

-------

Plugs

lsolalorsJEngine

Exchanger

Governor

500

OPERATING

Water

Pump

System

500

OPERATING

Wires

System

Clearances

Motor

1000

HOURS

Mounts

HOURS

catalyst

HOURS

·-------------~·

OPERATING

HOURS

OR

YEARLY

·~-----------

----------------------------~-~~-.

-~--------~·-

OR

YEARLY

OR

EVERY

TWO

OR

OR

EVERY

YEARS

FIVE

YEARS

EXPLANATION

Engine
delaminated.

Check

1

nspect,

Check

Open
Change

Remove
plates.

Inspect

Inspect
Drain,

thermostat

Adjust

Check
starter

hoses

should

Check

timing

and

clean,

vibration

heat

exchanger

governor

the

pump

Replace

and/or

for

deterioration.

flush

and

and

valves.

solenoid

motor

OF

SCHEDULED

and

adjust

re-gap

isolators,

oil.

cover

the

impeller

replace.

re-fill

coolant

(Incorrect

and

pinion

be

firm
tighten

as

or

replace.

and

See

the

pressure

varve

motor

drive.

MAINTENANCE

and

tight.

all

hose

needed.

brackets

and

cap(s)

and

clean

and

inspect

the

and

gasket.

Data

below.

Inspect

resistance.

cooling

system

cap.

clearance

for

corrosion.

Replace

if

clamps

as

mounting

out

debris.

pump

assembly

Lubricate

*

with

appropriate

wiH

result

Remove

hoses

become

needed.

hardware.

Replace

.

for

the

impener

antifreeze

in

poor

engine

and

lubricate.

spongy,

Replace

gasket

wear,

especially

at

re-assembly.

performance.

Clean

brittle

as

needed.

and

mix.

and

or

0-rings

cam

Replace

lubricate

if

needed.

and

wear

the

the

•Engine

Timing

Belt

Heat

Exchanger

Cylinder

Head

Bolts

NOTE:

Keep

the

engine

surface

clean.

Dirt

*WESTERBEKE

*CATALYIC

ADDED

A Catalvtic Converter

exhaust

the

current

California

~>o

not

operate the engine without the Catalyst assembly /

recommends

this

CONVERTER

TO

PRODUCTION

to

reduce exhaust emissions

U$.

Environmental Protection Agency

Air

Resources

MODELS

has

been installed on the engine's

Board

service

exhaust emission standards. ,

mstaJled.
Every 500 operating
converter should be

hours

a visual inspection

performed.

Remove

assembly from the exhaust manifold

part

for damage,

is

not

"tisible

The

complete assembly with housing

, internal

pai1

carbon

through

is

not

build-up,

the element, replace

available separately.

and

oil

will

inhibit

be

performed

.... ( Date

and

Code

to conform with

of

the

converter

and

inspect the internal

or

soot deposits.

the

converter.

must

be

replaced.

the

the

Inspect
damage.

Remove
Re-torque

engine's

by

an

knowledgeable

0608

)

and

the "

If

light

The

timing

belt.

Replace

as

needed.

the

heat

bolts

ability

exchanger

(engine

to

cold).

remain

for

professional

Adjust

cool.

valves

mechanic.

EXHl\U~r

MANIFOLO

;-"Ip"'

1~

~.

''-...

~

'§

- _

Failure

cleaning

after

to

replace

re-torque.

belt

and

can

result

pressure

in

testing.

severe

engine

(CONT.)

NOTE: Signs that the

arul a sooty

exhaust. Do not allow sea water to contact the internal part.

Cataly.~t

may

1ieed

replacing

are

high exhaust back pressure

lwlWESTERBEKE

(Engines & Generators

13

COOLING

SYSTEM

DESCRIPTION

Westerbeke marine engines
fresh water cooling. Heat produced in the engine by combus­tion and friction is transferred to fresh water coolant which
circulates throughout the engine. This circulating fresh water

the

coolant cools
the engine oil.
fresh water coolant to raw
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes
fresh water coolant flows around
ferred to
tube walls
exhaust system where finally

In other words, the engine is cooled by fresh water coolant,
this coolant is cooled
the transferred heat overboard through the exhaust system.

The

dent
engine allows the cooling water passages to stay clean and

free from harmful deposits. ,,..·--.._'-......_

the

fresh water coolant

of

each

engine block, its internal moving parts, and

The

heat is transferred externally from the

fresh water coolant is conducted through the

to

the

raw water

other. Using only fresh water coolant within the

are

designed and equipped for

water

by means

of

the heat exchanger while

th~

which

is then pumped into the

it

is

discharged overboard.

by

raw water, and the raw water carries

and

raw

water circuits are indepen-

of

a heat

tubes; engine heat trans-

ENGINE

WATER

INJECTED ELBOW

---.. ---

Coolant

A coolant recovery
and contraction during engine operation, without any signifi­cant loss
ing system. This tank should

engine manifold level and should

COOLING

----

Recovery

of

coolant and without introducing

COOLANT

EXPANSION

DIAGRAM

FIRESSURE

tank

KEEP

THESE

A

'FULL

FLOW

THE

COOLANT

CLEANER

(TYPICAL)

CAP

Tank

allows for engine coolant expansion

be

located at or above the

be

easily accessible.

jTO

COOLANT

TANK

PASSAGES

OF

RECOVERY

WORKS

CLEAR

COOLANT

TO

TANK

WELL)

TO

AND

(A

air

into the cool··

RECOVERY

ENSURE

FROM
PIPE

·

FRESH

WATER¢

RAWWATER

NOTE:

Periodically check

cap.

sure
good condition

....

Ensure that

and

closes tightly. Carry a

INCOMING

RAW

WATER

MANIFOLD

·PRESSURE
CAP

the

condition

the

upper and lower rubber seals

of

the

manifold pres-

are

check that the vacuum vplve.opens and

spare

cap.

in

RAW

WATER

DRAIN

14

RAW

WATER

NOTE:

Always

install

the strainer will

A

clean

raw

water

engine's cooling

strainer

in the

Perfonn

operation:

1. Close the

2;

3.

4. Replace

5.

6.

7.

NOTE:

aground.

If

normal
may
raw

when

glass

the

Remove

·

Clean

the

Reassemble

Open

the

Run

the

Also follow the

the

engine

reading,

have

been

water

through

making

should

following

raw

and

glass.

the

seacock.

engine

temperature

INTAKE

always

washer

and

1he

caught

the

intake

system.

your periodic

be

clear.

maintenance

water

clean

the

if

install

and

check

above

cause

up

tl;te

cooling

be

seacock.

STRAINER

strainer

strainer is a

Include a

necessary.

gauge

may

in

~

at

or

self-priming.

visual

engine

after

strainer

filter.

the

strainer.

for

leaks.

procedure

ever

be

that

the

strainer,

system

below

vital

inspection

every

after

shows

silt,

slowing

COOLING

the

waterline

component

check.

having

a higher

leaves or

100

the

of this

The

hours

nm

than

grass

flow

of

water

hard

the

of

of

SYSTEM

RAW

so

The

non-ferrous,~9usjng

has_

wiililit

On

always

(an impeller kit).
when

·

operation.

are

up.

broken

SCHEDULE.

NOTE:

(seals
chase

Changing

Close

and,

impeller out of the

Move

push
bling,
gasket.

WATER

raw

water

flexible

ihe@peller

no

a.ccount

be a

lubricant

Such
cautioned
The

raw

or

tom

Should

and

bearings),

a

new

the

raw

with

the

the

blades

the

impeller

apply

Open

PUMP

pump

is a

self-priming,

and

a

Neoprene

b,lade8

which

wipe

housing,

should

spare

impeller and

Raw

(raw

failures

to

make

water

pump

impeller

a

failure

pump

and

the

Raw

water

intake

aid

of

two·

pump.

to

conform

into the pump's

a thin

coating

the nt,W water intake

this

water

water)

are

sure

should be

blades.

occur

it

may be

rebuild

Water

small

producing

pump

p\Jmp

is not

not

raw

valve.

Install

to

of

rotary

impeller.

against a

the

ITe

run

impeµer

warrantable,

water

cover

impeller

present

flow

inspected

See

MAINTENANCE

with

the

purnP,

more

cost

the

original

Pump

Impeller

Remove

screwdrivers.

the

new

the

curved

housing.

lubricant

to the impeller

valve.

pump

with a

The

impeller

curved

cam

plate

pumping

dry.

failures

during

and

is

~

efficient to pur-

pump

the

carefully pry

impeller and gasket.

cam

When

action.

There

should

gasket

aboard

occur

engine

operators

present at
periodically

internal

pump

plate

start-

parts

as a spare.

cover

and

assem-

and

for

the

RAW

WATER

SEAUllGWAS~

IMPELLER

STRAINER

RAW

WATER

RAW

WATER

The

raw

impeller

water

source

water

strainer.
through
the

heat

ing

fresh

into

the

ing

the

exhaust

water

is

discharge

OWNER

COOLING

water

flow

is

pump.

This

pump

(ocean,

The

raw

the

raw

water

exchanger

water

water-injected
discharged

pressure.

tubes)

coolant.
gasses.

overboard

INSTALLED

CIRCUIT

created

by a positive

draws

lake,

or river)

water

passes

pump

to the

where

Th~.

raw

e:itfumst

This

elbow,

mixture of exhaust

by

INTAKE

STRAINER

(TYPICAL)

displacement

water

directly

through a hose

from

the

heat

exchanger

it

cools

the engine

water

is

then

mixing

the

engine's exhaust

from

the

to

the

strainer

(through

circulat-

discharged

with

and

gas

and

gas

raw

A

impeller,

the

exchanger.

cool-

raw

PUMP

CAUTION:

cooling

they

circuit.

ff

must

any

be

They

of the

located

often

vanes

to

prevent

can

have

be

found

APPLY

OR

AT

broken

LUBRICANT

LIQUID

SOAP

ASSEMBLY

off

the

biacicage

in

the

in

heat

lwlWESTERBEKS

)

Engines

& Generators

15·.

COOLING

SYSTEM

CHANGING

The

engine's

MAJNlENANCE

become

A

critical; a
traced

Drain.
engine

the

system

the

refill

NOTE:

be

used

A

Wear

Refilling

After

exchanger~s-c_oolant

slowly
Monitor

the

manifold

pressure
Remove

coolant
the

cap.

flow
After

Coolant
engine
needed
spilled

COOLANT

cooiant

SCHEDULE.

contaminated,

CAUTION:

bat:k

the

e11gine

block

process.

The

to

WARNJNG:

protective

replacing

pour

the

cap.

the

mix

Run

into

the

checking

should

cools

and

coolant.

Proper

substantial

to

coo/Ing

coolant

and

opening

with

fresh

drain

petcock

help

drain

.Bewate

gloves.

the

Coolant

the

engine

clean,

premixed

coolant

to

the

filler

cap

on

the

to

halfway

the

engine

recovery

for

leaks,

draw

down.

Add

check

the

petcock.

in

must

it

can

cooling

number

syst,em

by

water,

on

engine

the

neck

coolant
between

and

tank.

stop

back

coolant

coolant

be

changed

If

lead

of

corrosion.

removing

the

manifold

then

reinstall

the

heat

coolant.

of

the

block

drain

Then

coolant

manjfold

and

recovery

LOW

observe

the

into

the

to

in

the

the
to

overheating

syst9111

engine

exchanger

hot

run

into

and

install

the

engine

cooling

the

manifold.

according

coolant is

maintenance

failures

the

~

pressure

the

drain

engine

coolant.

plug, close

the engine

the

manifold.

add

as

the

manifold

tank

and

and

MAX

coolant

and

allow

system

recovery

Gean

to

the

allowed

problems.

can

plug

on

cap.

Flush

and

should

also

the

heat

at

idle

needed.

fill

with

and

replace

expansion

it

to

as

the

tank

if

up

to

is

be

the

start

·

and

Fill

cool.

any

DRIVE

For

your
with
engine.
installed
inspection,

Drive

will

not

ally

damage
pull

the

tor

to

also

cause

of

th~~

ence

high

The·

drive

no

less
(12mm)
point

. A

spare

A

dtlre

BELT

ADJUSTMENT

safety,

Weste:rbeke

belt

guards that cover over the

("Out

of

sight

-out

for

that

purpose.)

service,

beltS

must

provide

alternator out of

wear

ont

rapid wear

water pump's

of

oil

on·

operating

belt is

than 3/8 inch (lOmm)

as

the

between

belt

WARNING:

belt's

GOVERNOR

and

maintenance

be

properly

proper alternator charging and

the

alternator.

prematurely.

of

the belt

the

or

tension

can

temperatures.

properly

belt is

depressed

two

pulleys

belts

should

NeWll

attempt

while

generator models

belt(s)

of

mind."

The belt

Operators

tensioned.

Drive

alignment

Excessive

the

belt

bearing.

cause belt slipping, resulting

adjusted

always

the

are

is

belts

that are too tight

and/or

and reduce the

A

slack

if

the belt

and

no

more

with

the

on

the

longest span

be carried

to

t:heck

engine

come

on

the

advised

required.

Loose

drive

cause

drive belt

belt

can

than 1/2

thumb

on

or

ad/usttbe

Is

la

apBtBllan.

guard

that

will

the

tension

service

or

the

be

at

of

board.

equipped

front

of

is

NOT

proper

belts

eventu-

will

alterna-

can

life

pres-

in

deflected

inch

the

mid-

the

belt.

FRESHWATER

·

PUMP

the

PULLEY

Adjusting

L

Remove

2.

Loosen

the

mounting

3.

With

the belt loose,

edges.

4.

Pivot

the

or

right

as

5.

Tighten
bolt.

6.

Operate
and

Engines & Generaters

the

the

recheck

16

Ben

Tension

the

belt

alternator

bolt.

altematOr

required,

base

generator

the belt

guard.

adjusting

inspect

on

the

to

loosen

mounting

for

tension.

FRONT

strap bolt and

for

wear,

cracks,

base

mounting

or

tighten.

bolt

and

the adjusting strap

about 5 minutes

7.

Replace

CRANKSl-JAFT

the

base

and

ftayed

bolt

to

the

left

then·shut

the

down

guard.

PULLEY

COOLING

SYSTEM

Heat

After approximately 1000

and

tive
exchanger).

Exchanger

pressure

radiator

·~

test

shop

Service

hours

the

engine's

should be able

ZINC

ANODES

of operation,

heat

exchanger.

to

clean

remove,

(A

and test

local

the

clean

automo-

heat

HEAT

EXCHANGER

Cool

raw

water

flows
exchanger.
heat
is

then

engine

the

The
other;

harmful

NOTE:

that a heat exchanger

every

As the

en~e

of

the internal

pumped

coolant

circuit

repeats

engine coolant and

this

keeps

deposits

Operating

1000

hours.

engrne
into
(now

itself.

the engine's water

found

in

the

silty

through

cooled)

cleaning

the

inner tubes of

coolant

exhaust

raw

in

and/or.tropical waters

passes

around these tubes

is

conducted

system

flows

water are independent of

raw

water.

be

to the

and

discharged.

back

though

passages

peiformed

THERMOSTAT

A thermostat controls the coolant temperature

continuously
the

engine is first started
coolant
thermostat
heating).
opens.
cleaned,
gasket.

If

you

bring

flows

through

from

flowing

to

prevent

As

the engine

The

thermostat

or

replaced

suspect a

to a boil. A working

easily.

faulty

(some

the.exhaust

warms

is

thermostat,

the

closed

cooling circuit.

the

closed

thermostat

coolant

is by-passed

manifold

up,

the

thennostat

accessible

Carry a spare thennostat

thermostat should

and

can

place it

in

raw

clean

more

as

prevents

from

be

checked,

a pan

open

the

heat

water

the

engine

from

may

require

often

the

coolant

around

over-

gradually

and

of

about

which

The

each

the

then

When

.

the

water

1/2

!he

and

.~d

a

NEW

.

ZINC

ANODE

A

zinc

anode

·

circuit

within

anode

is

to

in

the

raw

of

electrolysis

dition

of the zinc

anode

cleaned

be

carried

NOTE:

Electrolysis

and

vessel

If

the

zinc

which

the
loosening
hex

boss

from
removing
poor

condition, there

the

exchanger.

clean

the

inside
exchanger end gasket in case
damaged

(refer

to

your engine model's

number),

NOTE:

The

not

require
insulate
housing

the
preventing

THROWOUT

(or

pencil)

the

heat

sacrifice itself

water

cooling

on

other

anode

or

replaced,

onboard.

is

location, not

anodes

need

zinc

anode

the:

anode

possibly

the zinc,

when
0-ring and

threads

note

Remove the end

of

all

removing

of

sealant.

zinc

Sealant

from

electrolysis

exchanger.

components

should

the

that

replacement,

is·

threaded

with

tearing

the

are

zinc

cover,

the

the

is located

to

electrolysis

circuit,

thereby

be

as

required.

r.esult

of

of

the

another

off

condition

probably

of

debris.

the present one

the

end
heat

and

install a

zinc

anodes

should not

metal

of

action

THROWOUT

in

the

raw

water

The

purpose of

action

reducing

of the

system.

checked

each

engine.

with a wrench

wrench.

the

alot of zinc
the heat

~ways

cover.

exchanger

the

monthly

Spare

particular

hold

the

This

exchanger

of it.

If

exchanger

have a

Replace the

new

are

pipe

be

used as

heat

exchanger

on

the

anodes

hex

the

becomes

end

zinc

zinc.

cooling

the

zinc

taking

the

effects

The

and

installation

boss

while

prevents

shell.

zinc

flakes

spare

gasket

gasket

anode.

threads.

it

may

CLEAN
REUSE.

place

con-

the

should

into

the

After

is

in

within

and

heat

part

and

AND

do

THERMOSTAT

ASSEMBLY

lwlWESTERBEKE

I Engines & Generators

17

GASOLINE

Use unleaded

follow
companionways
ventilate after

NOTE:

The

fume

detector/alarm

U.S.

generator

89

Coast

fueling.

AWARNING:

when

serrfalng

Ing

any

tliSI

that

ing,

open

flames or

fuel
tion

system

•xtsts

Wbea

Whea

octane

or

Gtiard

regtilations,

to

prevent fuines

compartment

properly

Shat

oN

the

fuel

may

spOI.

other

servicing.

servicing

higher gasoline.

close off

frOm

entering the

should

installed

the

system.

DD

SOIHces

the fuel

fuel

valve

Take

NOT

of

Ensure

and

allow

proper

$1SIBlll.

When

haVe

working.

at

care

aily$mtik-

fire

near

FUEL

fueling,

all

hatches

boat,

a

gasoline

the

tank

Jn

catch·

the

vent/la·

SYSTEM

and

and

coiled around the

12V

CONNECTION

FUEL

CONNECTION

GAS

DENSER

The

gasdenser consists

located between the

pump. The gasdenser cools the fuel

[OCK.

of

a portion

rnw

water intake line and insulated. It

raw

water intake and the

!,l' / / . ._,,,.

/Ii

FIJEl

TO

~RB

'

of

to

/

the

fuel

help

prevent vapor

line

raw

that

water

is

is

WATER

GASOLl~ATER

A primary

installed between the

water

be

carried to

Most installers

the

the problems that contaminants in the

These

through")
bowls

impurities. ·

fuel

and other

the

generator installation package

gf.ISoline

to

meet

have·

drain

SEPARATOR

filter

of

the water

fuel

conUilllinants

~lsys~.()n

in~1lli.te

filters

must

U.S.

'Valves

a

type

Coast·

to

separatfug

tank and the erigine

from

the~elbefore

the

engilii;:

of

filter/w;~f:·;s~P~for

as

have

metal

Guard

use

when cheeking for

GASOLINMtYAJER
SEPERATOR & FILTER

AND.>FILTER

·

type must

to

remove

they

be

cari

· •

with

they

~·

:W,~lfaw~

fuel

can

~se,:

...

bQWls

(not

"seek

r¢quirements. The

metlil

wa~r

...

··

··

·

of

and

MOUNTING

.

FUa

LIFT

PUMP

Periodically check the
and

make sure that

are

tight

and
pump's mounting bolts
the

mounting bolt to ensure proper pump

The

engine mounted

A

WARNING:

connections
Make.sure

faelsystim

no

secure. The

Fuel

Is

a fire

proper

comp;,nents.

BOLT

fuel

connections to

leakeage is present and thattlte

DC

ground

sboUld

fuel

lift pump is

leakage

hazard

ventilation

FUEL

LIFT

PUMP

imd

conn~tion

be

clean and

operation.

~aimenance

at

the

fuel

and

should

be

exists

wheneVlt

·

out

of the

at

<;ine

well

se9ilred

free.

pump

or

corrected.

sentii:ing

pU!JlP

fittings

of

the

by

. · .

·.

its

·

CARBURETOR

This generator has just
carburetor.

·

shown.

screen should be cleaned periodically.

To

Clean

the

. /w,wesJERIJEIC2

Ensflne.s.~

18·

:

..

Generators

FILTER

remove

filter

~.

SCREEN

one

filter screen that is located in the

the

filter

screen

screen, unscrew

or,

if

needed, replace

the

plug

it.

This

as

FUEL

SYSTEM

CARBURETOR

The carburetor
cleanable

On

early
heating element
the

engine

12-volt solenoid. It activates the

was

depressed.

a cold

start.

Air

Screen/Flame

The air
releasing the hold-down
of operation,

in a water

is

a single barrel, down-draft type a

metal

screen air intake filter/spark

models,

screen/flame

the

which

starts.

later

It

could

every 1 hours

soluble

cleaner

choke

was

opens

models

be

kept

Arrester

arrester can easily

clamp.

from

such

electric

the

choke

the

choke

choke

on

tn

Clean after

then

as

GUNK.

arrester.

using

a

automatically

was

operated

when

the

this

manner

be

removed

the

on.

Clean

12~volt

once

by

a

ON

switch

to

assist in

by

first

S?

hours

the

arr

screen

e

Carburetor

Clean
then
the
there

Idle

Adjustment

the

turns.

Note:

induce a

down.

I

this

clean

screen

are

no

Mixture

jet

slowly

An idle

sooty

Filter

filter

element

and

inspect

if

necessary.

leaks.

Jet

is

performed

in

until

mixture.jet

exhaust

Screen

after

every

Tighten

it

seats,

discharge

the

250

the

with

the

then

adjusted

first

50

hours

operating

plug

and

generator

back

it

too

far off its seat

at

engine

of

operation,

hours.

Replace

make

certain

oper~ting.

out

1/2

start-up

Screw

to 1 tum.

can

and

shut-

IDLE

MIXTURE

Engines & Generators

SCREW

19

ENGINE

OIL

CHANGE

Engine

1.

2. Replacement

NOTE:

to make certain it

Oil

Change

Draining the Oil Sump. Discharge the
the

sump

drain

hose

(attached
while the
replace the hose
securely.

WARM
THE

OILINTO

SUITABLE

Always observe

yellow/gray

the

Oil.

prompt attention
petenf mechanic should water
water present
exhaust system

raw water through the

of
the exhaust, filling
caused

siP,ho~

oil

filter,
hole in
drain

This helps

ter wrench should

Do

Place some paper
ter

when

·(oil or

cooling

old oil
sealing gasket
ber sealing gasket
block, gently

When
gasket's sealing
apply
on

the

filter

engine

is

warm.

Drain

in

its

bracket,

THE

ENGINE.

SHUTDOWN

A

CONTAINER

emulsion

Although this condition is rare,

in

by

the

poor

yalve ..

of

you

may

the

upper

the

oil

from

to

lessen

not punch this

can

unscrewing

any

other

ability.

filter

as

it

came

remove

installing

a thin coat of clean

new

oil

filter.

nipple, and

AND

DRAIN

the

used

oil

as

indicates

to

prevent serious damage. Call a

the

oil

can

be

attached

Please

to

the engine and/or a siphoning

raw

the

engine. This problem is often

location

the Oil Filter. When removing

find

and

it

be

be

towels

fluid

is

removed

remains

the

surface

then

of

it

helpful

lower

portion

into

a container before removing

spillage. A small style automotive fil-

helpful

in removing the old oil

hole

without first loosening the filter

removed!

and

it

to

catch

on

the

keep your engine clean.) Inspect

to

off

with

sealed

it.

new

oil

filter

on

the

engine

Screw

the

tighten

used

oil

through

to

the

front

of

the

engine)

the

used

oil

completely,

and

replace

the

end

cap

.

it

is

removed.

the

presence

be

present

the

result of a fault

water cooling circuit

or the lack of an

and cleaner to punch a

of

a plastic bag around

any

oil left

engine reduces the engine's

make

the

old oil

against

element, wipe the

engine block free

oil

to

filter onto

the

filter

A

of

water

in

it

does

require

com-

in

the oil.

Raw

in

the

into

anti-

the

~

the old filter

in

sure that the rubber

filter.

the

the

rubber gasket

the

firmly

to

the

the

filter.

If

this rub-

engine

of

threaded

~y

hand.

it.

filter.

fil-

filter

oil

oil

the

and

3. Filling the Oil Sump.

cap

on

the

top

After

refilling,

the

checking
leakage
tem,

and

with

the

mark

NOTE:

Generic
standards or diameters
might

be

after

an

sure the oil pressure is normal
around the

A

WARNING:

Cllllfaminants.

and

nails

discard

used

oH

Oil

Pressure

The engine's oil pressure,
the

oil

pressure gauge on
mal

operation,

psi.

NOTE:A

reading
pressure reading as low
depending
placed on

engine's

around

stop

the

lube

oil

on

the

dipstick,

fil.ters

entirely

oil

fi/.ter

change and oil

new

oil

Avoid

tboroaghly

clothing

/lfOlllllly.

the

newly

started,

upwards

upon the temperature

the

generator.

Add

of

the

engine or through the

run

the

generator

oil

the

new

oil

generator.

dipstick.

should

SEALING

APPLY

CLEAN

WHEN

ASSEMBLING

NEW

are not

of

important items on generic parts

different

filter.

Used

from

engine

prolonged
using

01

mgs

containing

during

the

oil

pressure

co~J

of

60

psi.

A warmed engine

as

35

new

oil

through

for a few moments while

pressure.

Fill

GASKET

FILTER

Make

filter

or from the oil drain

Then

check the quantity

to,

but

the

engine require additional

OIL

side

sure there is

not

over the

the

oil

SPIN·ON

TURN

HAND

recommended,

genuine parts. Immediately

fill,

run

and

that there are

oil

r:ontalns

skin

soap

and

operation, is indicated

instrument panel. During

will

range

engine can

psi.

These readings will vary

of

the

as the material

the engine to make ·

no

llannful

contact.

water.

used

have

engine

Clean

Launder

ail.

Discard

between 35

an

oil pressure

can

have

and

oil filler

fill.

no

sys-

of

high

OIL

FLTER

TIGHT

oil leaks

skin

01

by

nor-

and

an oil

the load

oil

oil.

ENGINE

BLOCK

55

lwlWESTEliBEICE

l Engines &

Generators

20

REMOTE

OIL

INSTALLATION

This popular accessory is used to relocate the engine's
ter from the engine
engine room bulkhead.

NOTE:

Refer

instructions

To

install, simply remove the engine

WESTERBEKE's remote oil filter kit
install

this

kit with the

Contact your WESTERBEKE dealer

to

to

ENGINE OIL

on

removing

APPLY A THIN
INSTALLING
TIGHTEN
CONTACTS

a more convenient location such as

oil

CHANGE

the

oil

filter

THIS

AN.

ADDITIONAL

THE

filter.

facing

COAT

OF

KIT.

BASE.

oil

as
down

for

CLEAN

THREAfJ

in

th{s

manual

filter and thread

shown.

Always

as

illustrated.

more information.

OIL

TO

THE

KIT

ON,

AFl'ER

THE

O·RING
THE

3/4

THE

TURN

FILTER

PN.

040078

oil

fil­an

for

on

WHEN

THEN

HAND

O·RING

IN

CONNECTION.

(OPTIOttAL)

NOTE:

Wes~rbeke

incorrect

FASTEN

(SCREWS

HOSE

installation

A

CAUTION:

rectly.

If

the

pass

valve

In

Ito/II

reaching

failure.

If

tilers

Immediately

SECURELY

TO

ABULl(HEAD

ARE

OWNER

S~PPUED)

oil

and

is

It

flowsln

the

tilter.

the

is

check

not

responsible

of

the

Remote

is

vital

the

assembly
engine
no

all

preS$11Te

the

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OIL

FILTER.

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AT

CONNECTION
REMOTE

THE

THE

HOSE

IN

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...

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APPLY

A

THIN

COAT

OF

CLEAN

OIL

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GASKET

WHEN

CQNTACTS

THE

INSTALLING.

BA~E.

TIGHTEN

AFTER

THE

IT

AN

THE

ALTER

ADDITIONAL·

FILTER

Engines & Generators

-21

STARTER

MOTOR

DESCRIPTION

The starter

• A

•

An

ture

•. A switch
ating
supplies

The
high-speed

arate

ion

shaft

exposed

smoothly

motor shaft is

lever

are

ADJUSTMENT

-

If

any

should

Pinion

1.

Connecta

and
and

A

seconds

.

2.

Lightly

· stroke (called

3.

If

2.0

of

number

can

be

roughly

divided

motor

section

which

generates a drive

ovexrunning

torque,

the

starter

is a new

intetrlal-rediiCtion

from

the

shaft. A l."Cduttion

atld

a pinion

outside·the

without

mechanism,

identical

abnormality

be

disassetn.bled

Gap

~e

starter

stop.

~AutioN:

clutch

section

preventing

section

ovemtnning

load

current

motor

becoming

supp(>rted

to

conventional

AND-JIEPAIR

lnsp~etlon

patteey

body,

Never

(solenoid)

clutch

to

type;

small,

shaft;

gear

shaft.

The

starter

at

switch

and

~

- ·

is

foun~

and

(12V)

·~d

apply

motor

aoatlnawsly.

push

the

pfuion

pillion

gap).

the

.pim.oti

gap

is

not

within

mni);

adjust

it

by

increasing

shims

on

the

solenoid.

of shims

increases.

into

the

which

transmits

overrun

which is operated

through a lever

the

motor.

Ught-weight

starter.

the

pinfon

is

installed

pinion

so

that the pinion

fouled with dust

both

ends on ball

overrunning

ones.

..

by

the

repaired.

after

The

pinion

slides

between

slidirig

following

.

between

the

bafflt;

back

The

the

starter

pinion·

driYe

voltage

at1d

measure

the standard range,(0:5

or decreasingtl:ie

gap

is

decreased

following

power.

starting.

when

atld

and

is

shaft

oiily

on

the

pint

is

not

may

slide

and

grease.

bearings.

clutch

inner

tests,

terminal

sht>nld

tor

over

the

return

sections:

an

arma-

actu-

which

called

is

the

motor

The

cixc:uit

the

starter

rotate

10

number

as

the

sep-

pin-

The

S

to

.

a

out

No-Load

1.

2.

-----------•

A

tlghtrm

type

that

statter

·in

Test

Connect

as

illustrated.

When

the

the

starter

the

current

semble

the

CAUTION:

lffll'Y

starter

of a

dtreat-drlvt

rotation

oontaat

the

11witch

must

or

starter

Whlt:b

with

SOl.ENOllJ·

Petfonn

satisfactory,

1. Inspect

the

( +)

and

M

and

between
between

the

body.

following

replace the solenoid

the

solenoid

{-)

and

the

body.

tenninals
terminais S and

~.

L_LJ

ammeter,

starter

Ilse

tBrmlnal

is

clo6ed,

run

smoothly

and

thla/c

voltmeter,

the pinion

speed

is out

repair

wlrlls

snare/y.

it.

(at

as

and

3000

of

much

This

makes a rotating.sound

fJll•

statfilr.

at

the

pln/OiJ

tip,

bl

the

pinion

gear

when

tests.

If

any

test result is

assembly.

for

continuity

between

There

S

and

terminals

should

be

M.

Continuity will be

the

body

battery to the starter

must

protrude

rpm

or

more).

specification,

BATTERY

as

possible

Is

a

solenoid

louder.than

When

detecting

t:atefUI

between

S and the

no

and

not

to

If

piOtrudes.

not

terminals

body

continuity

terminal Mand

found

found-

and

If

disas-

and

shift·

come

and

PINION

GAP

·

NOT~

2. Connect a battery

A

than

Engin~s

~.

22

& Generators

----

Disc<mnect

and M for

The

pinion

CAUTION:

10

seaotf~

...

-

@

MULTIMETER

the

wire

from

to

the

(-

).

Have a switch

drive

should

Da

not

apply

whBll

testin!I

terminal

solenoid

extend

•s

in the + lead and

fully out.

battery

the

solenald.

ourretit

M.

terminal S

for

for

( +)

close

mars

it.

.

ATIRACTION

3.

TEST

Holding

minal

S (

pinion

fully~

Yfhen

released

BATIERY

test.

With a battery

+)

and

to

The

from

the

pinion

holding

starter

must

connected

body,

manually

remain

with

your

STARTER

to

the

solenoid

pull out

at

that position

hand.

ter-

the

even

MOTOR

4.

Return

test:.

rninal

M (-)and

pinion

fully.

when

released

With

a battery connected to.the solenoid

to

the starter

The pinion must.return

from

holding

body,

manually·pull out the .

to

its

by

hand.

:ter-

original position

STARTER

1.

Disconne~t

2.

Loosen

the

3.

Remove
fastening the brush

4.

With
remove
the

·

5.

,.Remove

washer;

6.

Unscrew
same
adjustment will

DISASSEMBLY

the

solenoid

the

the brushes pulled away

the yoke

armature

the

the bolts

time, the

STARTER

.

MOTOR

·BATTfRY

the

wire

from

the solenoid

two

screws·

fastening

assembly.
tWo

long through bolts

holder.

Remove the rear bracket.

from

and

brush holder

out.

cover,

pry the snap ring out, and remove the

and

remove the center bracket. At the

washers

for the pinion shaft end play

come

off.

INSPECT

FOR

WEAR & CHIPPING

termin&l

the

solenoid. Remove

and

the armature,

assembly.

· ·

two

M (-

).

screws.

Then pull

7.

Pull
front

8.

On
pinion

9.

At

each

a

bearing

pi:ess-fitted

off,

out

the

reduction gear lever

bracket.

the

pinion

side,

and

pinion shaft. ·

end

of the

puller.

It

in

the front bracket.

replace

the front bracket

SOLENOID

'-.ADJUSTING

SHIMS

RETURN

pry

the

armature,

is

imJ?ossible

TEST

and

snap ring

remove

to replace

If

that bearing

assembly.

lever

spring

out,

and pull out the

the

ball bearing with

the

ball bearing
has

from.

wom

the

Engines & Generators

23

'

.,

'----··

NOTE:

lnspect,

if necessary

solenoid,

following

clean

brnsh,

armature,

pages.

.

and

replace

commuter,

etc.

See

the

The

DC

Circuit

on

the

BCG ·functions

st.op

the generator's engine. The circuit
reviewing
The engine's
circuits:

The
shown
when
system

.

BAnERIES

A

ing

while
switch,
ing

the

DC

Wrring

DC

wiring

start,

run

and

engine

has

a

12

on

the

Wrring

troubleshooting or

or

the

engine.

CAUTION:

circut,

the

however.

on

the

To

never

shut

engine

is

engine's

to

Diagram

is

designed

stop.

volt DC electrical control circuit that

Diagrams. Refer

when

servicing

avoid

damage

off

the

engine

running.

avoid

electrical

Shut

electrical

circuit.

Specifications

The

minimum

the engine's 12-volt DC control circuit

recommended capacity

BATTERY

to

start, operate

is

best

understood

and

Wrring

Schematic.

with

three simple

to

these

the

DC

to

the

battery

battery

off

the

engine

shorts

.of

the battery used

is

400

CCA.

when

basic

diagrams

electrical

charg-

switch

battery

work-

CHARGING

and

by

is

in

Battery

Review
lish a systematic
starting

•

•

•

•

•

CIRCUIT

Maintenance

the

manufacturer's recommendations

batteries

Monitor
operation.

Check
hydrometer

Use
level.

Make
tight

Keep

A

cause

protective

your

the

electrolyte

.

only

distilled

certain

to

the

battery

your batteries

WARNING:

severe

gear.

bums

maintenance
and

house

voltmeter

level

water

that

battery

posts

clean

Sulfuric

on

skin

and

schedule for your engine's

batteries.

for

proper charging

and

specific gravity

to

bring

electrolytes

cable

connections

(and

to

your engine).

and

free

of corrosion.

acid

in

lead

and

damage

during

to a proper

are

batteries

clothing.

then

with

clean

can

Wear

estab-

engine

a

and

BATTERY

The generator supplies a continuous 10
battery charger
charger put a multimeter between the positive ( +) and
negative(-)

14V
indicated, check that the battery charger terminal connections
are
tenninals
the

NOTE:

(INTEGRAL

CHARGER

with

the

tight.

With

fod3.5V

charger.

FOR

THE

CONTROLLER),

amp

charge

to

the starting battery.

leads to the battery. It should indicate

engine running.

the unit running, test between the ( +)

to

DESCRIPTION

14V.

AND

REFER

If

If

TO

To

only

the

no

charge

TESTING

THE

FOLLOWING

test the battery

battery voltage

is

i9dicated, replace

OF

THE

BATTERY

from

13.5V

and

PAGE.

its

.to

1s.

(-)

CHARGEH

Engines

&:

GeneratoI.s.

24

BATTERY

CHARGING

CIRCUIT

INTEGRAL

The Integral Controller (l.C.) is

unit that supplies a

starting battery

Charging Voltage:
Charging Amperage: 0 • 10.0 amps

A separate
bridge rectifier
I.C.

unit.
and supplies a DC charge
that the I.C. unit is
low),
described
cleanliness and tightness including the ground before

the

r.c.

NOTE:

produce a low
the

generator is

The Integral Controller
ing

in the 12:00

on

the

ment

NOTE:

circuit

·

internally.

the

~wer

wiring.

BRIDGE
RECTIFIER

GREEN!MlitE.
NEGATIVE({.

TERMINAL

oFRECTIFIER

CONTROLLER

DC

while

group

of stator

which

The

I.C.

unit senses the

faulty

check the

unit.

When

controller that will allow a DC voltage output

of± 2 volts.

New
since the ballast resistor's

in

the

the

charging

four

Whenever

four

wire

--*~

charging

following

generator is first

operated.

position.

wire

replacing

model,

BRIDGE
RECTIFIER

(l.C.)

an

encapsulated, solid-state

charging voltage to the generator's

the generator

~.o

windings

converts the

when

(that is,

circuit

steps. Check all connections for

rate.

is

mounted inside the generator

There

controllers eliminate the ballast resistor

remove

is

opening.

. 14.0 volts DC

DC

supplies AC

AC

current

needs

of

the starting battery

one is needed

if

the battery's

and

it's components

started,

'This

·

is

a voltage output

function

an

early stylr controller with

the l

charging

is

the ballast resistor

YELLOW/WHITE

~~W~l°6F

voltage

to

supply

..

If

you

.suspect

charge

as

replacing

C.

unit

rate will

now

rise

adjustment

adjust-

handled

INTEGRAL

.

CONTROLLER

RECTIFIER

to

the

is

will

hous-

and

as

a

its

Testing

1.

2. AC winding: 0.10.obm

3.

NOTE:

produce

the

Battery

Bridge Rectifier

Normal

engine is operating at
two
illustrated).

AC

Normal
DC)
bridge

DC
(approximate):

Lift the

measure,
ohmmeter.

should exist

the

Testing the Bridge Rectifier (meter
a. Set your ohmmeter's scale

b. Connect

c.

d.

e.

AC

voltage

AC

connections

voltage

No-load off the generator 16.0 volts AC
Full-load off the generator

voltage running

No-load off the generator 17.0 volts DC
Full-load off the generator . · 18.5 volts DC

main

needle

point
momentarily touch
meter should register
points

Remove
connect
points
deflect

Leaving

·

touch
should take place.

Place
(-) lead
register

resistance). Reverse

ter should
fails
fier because it

Different types and/or

running

DC voltage

is measured across

rectifier; that is + and

two

AC

the resistance

It

between

AC stator

to

z.ero.

the

#4.

Taking

touched.

the

the

#1,

#2,

when

the

point

the

positive ( +)

on

any

any of the previous

oppositf'.

Charging

running

1800

on

the

to

the

running

the

from

wire leads off

between

should

measure

these

windings.

(

+)

positive lead

the

ob:mmeter's

poirits

no

positive ( +) lead

negative(-)

and

#3.

each

point

negative ohmmeter (-) lead

#S

with

the positive

lead

point #3.

deflection

again

test

register

is

defective.

results.

The

these

Circuit

to

the

rectifier

zpm)

is

measured

bridge

rectifier. (As

bridge

rectifier

17.S

out of.the rectifier

two

DC

connections

-.

the

bridge

rectifier

the

bridge rectifier

these

0.10

ohm.

two

leads

and the

used

on

RXl (+DC)

from

negative (-)

#1,

#2,

#3,

deflection for

from

lead;

momentarily

The

ohmmeter's

is

touched.

lead.

on

point

ohmmeter

{no

deflection

connections

no

deflection.

tests

(A-E),

brands

of

test

volts AC

two

No

the

and

point #4

#1

again

indicated

replace

meters

(while

the

across

the

(approximate):

(in

volts

of

the

and

leads

with

continuity

ground

-

Simpson

and

set

ohmmeter

any

needle

on

No

and

and

If

the

to

lead,

#5. The

of the

and

touch

should

point

#4,

deflection

the

negative

should

not

infinite

the

ohmme-

rectifier

the

recti-

may

an

or

260)

the

ohm-

.

iNTEGRAL

CONTROLLER

Engines &·Generators

;

25

POINTl4

.

BRIDGE

RECTIFIER

POINTl3

POINTl5

MOUNTING

HOLE

The

following

certain engine

causes

of

the

When

trouble$hooting

the

GENEKA,TOR

reveal other
listed

possible

below.

ENGINE:.JROUBLESHOOTING

troubleshooting tables are

problem

indicators

problems.

iµdicat~AA.electrical

WIRINGDIAGRAMS; 8.$ these may

c::auses

of

the

.based

arid

the

mosdikely

problem which are not

upon

problem,

see

NOTE:

The

engine

protected by a

next.

located
terminal'.

of this

of

this

to

Refer

ma,n,ualfor

reset

circuit

:t

control system (electrical system) is

20

..

Atnpere manual

the

starter motor and

to

the model photographs at the beginning

a photograph showing the

breaker.

reset

circuit breaker

the

(-)

·

ground

exact

position

PROBLEM

Engine

does

crank.

Engine

cran.ks

fails

to

start.

not

but

PROBABLE

1.

Voltage

drop

at

terminal,

2.

Engine

20A

circuit

tripped.·

..

··

3;

Batter)'

is

tow

or

4.

Loose

battery

connections.

5.

Fauttywire

6.

Faulty

7.

Faulty

8.

Raw

1.

Out

2.

Filters
fuel.

3.

Voltage
switch.

4.

Carburetor

5.

Faulty

6.

Engine
a.

Carburetor

or

needle~valve

b.

Floatin
Repair

c

•.

Float

·

7.

Fuel

8.

Wom

9.

Hlgfi

10.

FaulfyJgnition

11.

F~ulty

12.

Faulty

13.

No

connectton.

start

switch.

starter

solenoid.

water

filled c finders.

offtiel.

are

clogged

drop

at(+)

filter

ballast

resistor.

is

flooded.

float

damaged.

securing
gasket

lift

orfauity

tension

engine

Clean

carburetor

orrepl~·flOat

chamber

screws

and/orttghten

p1,1mp

inQperative.

sparkpluys.

wires

con.

distributor.

wire

connection.

compre~ion.

CAUSE

starter

solenoid

breaker

dead.

by

contaminated

at

overspeed

screen

is

needle

or
is

leaking.

gas{{et

.are

loose,flepla

grounding.

has

.

clogged.

valve

open

replace

the

damagecl

screws;

or

·

PROBLEM

Engine

starts,

and

thenshllts

down.

runs

1.

2.

3.

4.

5.

B~

PROBABLE

Faulty

shutdown

(oil

pressure

..

temperature
1-!lghengine

temperature.

Dirty

Low

FauHy

faulty

or

water

fuel/water

oil

level

in

fuel

lift

enginetemperature

sensor.

7.

Faulty

stop

switch.

8.

C~cuit

breaker

9.

Check

the

valve

line,

lift

um

1.

Engine
but

does

up

to

speed.

Engine

starts,

not

hunts.

runs

come

2.

3.

4.

5.

6.

7.

1.

2.

3.

4.

5.

6.

7.

8.

9.

fuelllne
fuel

AC.

restriction.

Mechanical
Throttle

FauHy

faulty

Hi h exhaust
Governor
Generator
Cracked
Faulty
Faulty
High
Valves
Dirty
Throttle

check

supply

Is

plate

tuel

lift

wire

connection.

generator

is

out

Is

overloaded.

distributor

high

tension

fuel

pump.

exhaust

are

out

fuel

filters.

linkage

L-..-------L-----------..l

CAUSE

switch;

water.

exhaust

overspeed}.

or

exhaust

seperator

sump.

pump.

is

in

is

not

faulty.
binding.

pump.

overload.

ressure.

of

back-pressure.

of

is

filters.

tripping.

the

fuel

supply

drawin

fuel.

valve

at

the

adjustment

cap

wires.

adjustment.

binding.

(continued)

':M!t=:'!a!~>.

26

ENGINE

TROUBLESHOOTING

Engine

Engine

Engine

Low

I

PROBLEM

misfires.

bacRfires.

overheats.

oil

pressure.

1.

Poor
Incorrect

2.

3.

Dirty

4.

Cracked

5.

Faulty

Spark

6.

7.

High

8.

Valve
Spark

1.

wrong.

2.

Incorrect

3.

Engine

flooded

to

Dirty

4.

5.

Cracked
High

6.

7.

Choke

Coolant

1.

cooling
Faulty

2.

3,

Belts

4.

Raw

Faulty

5.

6.

Heat

7.

Collasped

1.

Low

Wrong

2.

Wrong

3.

Relief

4.

Faulty

5.

Faulty

6.

Faulty

7.

PROBABLE

quality

timing.

flame

arrester.

distributor

ignition

plugs

exhaust

clearances

plug

wires

timing.

is

flooded.

under

start·

flame

arrester.

distributor

exhaust

is

stuck

loss.

system.

raw

water

are

loose

water

pump

thermostat.

exchanger

hose.

oil

level.

SAE

type

valve

is

oil

pump,

engine

oil

filter.

CAUSE

fuel.

cap.

wires.

are

worn.

back-pressure.

are

incorrect.

are

connected

See

Engine

Engine

cranks

cap.

back-pressure.

closed.

Pressure

type
oil

bearings.

pump

or

broken.

worn.

is

clogged.

oil

filter.

stuck.

test

impeller.

in

the

engine,

is

but

fails

.

PROBLEM

High

oil

pressure.

No

DC

charge

starting

battery.

Blue

exhaust
discharge
engine.

Black

exhaust
discharge
engine.

smoke

from

from

to

the

the

smoke

the

1.

Dirty

engine.

2.

Relief

1.

Faulty

2.

Faulty

3.

Faulty
windings.

4.

Connections
loose

5.

Faulty

1.

Lube
High

2.

3.

Crankcase

4.

Valves
incorrectly.

5.

Piston
or

unseated.

1.

Dirty

2.

Faulty

3.

Idle

mixture

4.

Valves

·

adjusted.

5.

Lube
Piston

6.

Crankcase

7.

PROBABLE

oil

or

wrong

valve

is

stuck.

connections.

bridge

rectifier.

generator

or

controller.

oil

lube

are

rings

flame

carburetor.

are

oil

rings

to

faulty.

is

diluted.

oil

level.

breather

worn

are

arrester.

jet

worn

is

diluted.

are

breather

charger

the

or
worn

too

or

worn

CAUSE

SAE

type

controller

hose.is

clogged.

adjusted

rich.

incorrectly

or

unseated.

hose

is

oil

in

the

are

clogged.

I

Engines &

27

Generators

NOTE:

WESTERBEKE

adjustments

The

information

ENGINE

ADJUSTMENTS

recommends

be

peiformed by a competent

below

is provided

that

to

the

assist

following

engine

the

mechanic.

engine

mechanic.

ENGINE

SPEED

(HERTZ)

ADJUSTMENT

Governor

The

belt-driven, mechanically operated governor maintains

the engine's rpm under various load conditions. Engine speed

of

determines the hertz and voltage output

Governor

Operate the generator to bring the unit up to operating
temperature before adjusting the governor.

NOTE:

adjust
before proceeding

There are three adjusting points on the governor
(see illustration).

1.

Increase/Decrease

sets the no-load speed
between the governor arm and throttle lever should be
adjusted to hold the throttle full open when the engine is
not running.) Make sure this linkage moves freely and
that the ball joint connectors are properly lubricated.
graphite lube for this purpose. Disconnect the ball joint
and apply graphite lube to the inside

2.

Hunting/Regulation Adjustment.

engine speed between no-load and full-load is too great,
adjust this eye bolt to draw the spring closer to the lever
hub. The increase/decrease speed bolt may need to be
adjusted as well.

If

move the spring away from the lever hub (check speed
adjustment).

3.

Bumper

a no-load surge
into the governor so far that

Adjustments

If

the

governor

the

linkage

the governor surges under load, adjust this eye bolt to

Screw

is

severely out
at no-load
with

to

the

adjustment.

obtain a

Speed Adjustment. This adjusting bolt ·

of

the engine. (The linkage arm

Adjustment. This screw is used to remove

ONLY.

NEVER

it

increases the no-load speed.

the generator.

of

adjustment, manually

safe

output

voltage

Use

of

the joint.

If

the variation in

tum the bumper screw

Governor

· 1. Periodically lubricate the linkage

Maintenance

the governor arm and throttle lever.

or

Free

equivalent

movement

of

lubricant

NOTE:

proper governor/throttle operation.

2.

Governor

(Synthetic oil is recommended)

operating hours.

3. To change the oil, remove the oil
container under the governor and remove
drallt plug.

Allow the oil to completely drain. Replace
drain plug. Then remove the
located on the back
with three ounces
out
plug and the oil

KEEP

LINKAGE

WELL

LUBRICATED

THRO

TILE

LEVER

HUNTING
REGULATION
ADJUSTMENT

Oil Capacity: 3 ounces

NOTE:

of

the governor. Fill the governor

of

oil

of

the

oil

fill

level opening. Replace

fill

plug.

LINKAGE

ARM

.

INCREASE/DECREASE
SPEED

ADJUSTMENT

Do

or

arm

attaching points at

Use a graphite

this

linkage arm is imponant for

SAE

lOW/30 oil.

Change

not

oveifill the governor.

fill

alle~

more until oil ·starts

the oil every 250

plug. Place a small

the

governor

the

governor

head oil fill level plug

to

the

allen head

flow

4. Periodically adjust the governor belt tension (see DRIVE

BELT ADJUSTMENTS). Since belts stretch slightly, this

stretching will, to some degree, affect the governor's
action.

Engines & Generators

28

ENGINE

ADJUSTMENTS

SPARK

The spark plugs should be cleaned and regapped after the
first
thereafter and replaced

Spark
Spark

NOTE:

the spark plugs will· retard corrosion, making fature removal
of

PLUGS

50 hour break-in period, then inspected every 250 hours

as

needed.

A

WARNING:

the

engine

removing

plug

gap:

plug

torque:

wctite

the spark plugs easier.

Do

not

is

hot.

remove

Allow

the

the

engine

spark
to

cool

them.

0.031

- ±

0.0002

in.

(0.8

- 0.05

mm).

10

-15

lb-ft

(1.5 -2.31

Anti-Seize applied to the threaded

kg-m).

plugs

before

ponion

while

of

GAP

INSPECT

FOR

WEAR & CARBON

INSPECT
DAMAGE

FOR

INSPECTING
THE

SPARK

PLUGS

:--____CHECK

FOR

DETERIORATION

AND

DAMAGE

CHOKE

The choke solenoid is a
tions to close the choke plate in the carburetor when the ON
switch is depressed during engine start-up.

The choke solenoid de-energises once the engine starts and

the

present when the engine starts cold but should smooth out

the engine reaches operating temperature.
Keep this solenoid

between the solenoid and the choke lever.

SOLENOID

12

volt

DC

operated unit that func-

ON switch is released. Some unstable running may be

dry and periodically lubricate the linkage

CARBURETOR

as

HIGH

TENSION

Check the ignition
compartment heat can deteriorate the wires.

Check the resistance

because the wire connection inside the cap may become
seperated or the insulator may be damaged. When removing
the wires from the spark plugs, grasp and twist the moulded
cap, then pull the cap off the spark

The

resistance value

CORDS

wire~

(IGNITION

every 500 operating hours as engine

of

each wire. Do not pull

is

410

ohm

plug.

per

inch

WIRES}

of

on

the wire

wire.

CHECKING

RESISTANCE

Engines & Generators

29

NOTE:

WESTERBEKE

adjustments

The

z"nfoniiation

ENGINE

be

performed

ADJUSTMENTS

recommends

by

below

is provided

that the following engine

a competent engine

to

assist the

mechanic.

mechanic,.

VALVE

NOTE:

engine's

BOLTS).

1.

2.

3. Rotate the crankshaft

CLEARANCE

Retorque the cylinder head bolts before adjusting

valves

(see

Remove the rocker cover and gasket

Rotate the crankshaft in the normal direction

placing

stroke with the exhaust and intake valves completely

closed. Adjust the intake

cylinder,

intake valve

rotation. Locate
its exhaust stroke. Adjust the intake valve for
cylinder and the exhaust valve for

chart).

the

No.

the exhaust valve

ADJUSTMENT

TORQUING

1 piston at the top of its compression

for

No.

3 cylinder (see chart).

180"

the

piston

THE CYUNDER

and

exhaust valves for

for

No. 2 cylinder,

in its

normal

in

No. 1 cylinder at the

No.

3 cylinder (see

direction

CYLINDER#

CRANK

ANGLE

1 2 3

When

No. 1 piston

compression

When

No. 1 piston

at

top

of

exhaust

stfOke

stroke

is

set

at

is

positioned

top

of

IN

• •

EX

IN

•

•

•

EX

HEAD

of

rotation,

No.

and

of

No.

the

top

2

•

the

1

of

IGNmON

1.

Attach
front timing pointer to indicate

mark

chalk or crayon.

2. Start the engllie and

temperature.

a load on

3.

Using
crankshaft pulley so it
timing
the
specifications.

Timing

TIMING

a timing light

on

the crankshaft

Make sure

it.

the timing light,

pointer.

distributor

body.

SpecHicallons:

Do

to

warm

this

Use

111°

(no

the

#1

spark

plug

10".

Locate the timing

pulley

and

mark

it

up

to

its

the

generator is operating

align

the

timing

is

just slightly before

by

loosening and

the

following

:1:

5°

BTDC

on

generator)

at

load

and

mark

the

it

with

white

nonnal operating

without

mark

in

the

front

the

first

slowly

rotatiiig

timing

1800

rpm

4

••

Replace the rocker cover along with a new rocker cover
gasket..

ROCKER

COVER

TORQUE:

2.9 • 5.1

lb-ft

VALVE

CLEARANCE

HOT:

IN
EX

0.25mm

0.30mm

(0.4 • 0.7

(0.0098

(0.0118

kg·m)

In)

in)

TORQUING

After

cylinder head bolts should
Tighten

shown.
loosen

between 36.2 - 43.4 lb-ft

the

next

cover

FRONT

OF..,....,__,

ENGINE

......,._....

THE

the

initial break-in

the cylinder head bolts according to

Make sure the engine is cold when

one

head bolt one-half tum

head bolt in the

stud)

securely.

6 4 2

IGNITION

CYLINDER

HEAD

period

(approximately 50 hours),

be

re-torqued.

and

{5.0 -6.0

sequence.

Kg-m).
Tighten the

TIMING

BOLTS

the

sequence

this

is

then

tighten

Then

RS

done,

it

proceed

(rocker

the

and

to

,7

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Engines & Generators

.

·33.

USE

OF

ELECTRIC

The

power

required

than

is

required

to

require

much

more

(AC)

motors

require

circumstances,
easy-starting
applied
Because

run,

their
motor
repulsion-induction
current
varies

with

to

an

air

motor

In

general,

to

medium

MOTOR

*NOTE:

more

for

this

is

that

larger

Because
required
can

bring
experienced
and,

if

REQUIRED

Run

the

ator's

capacity,

on

the

checked

plant

and

meter

is

portable

NOTE:

tains

AC
generator's
volt

AC

good

motor

than

loads,

after

the

motor

they

require 5 to 7 times

use

should

is

to

be

driven

to

start

as

the

load

compressor,

to

which

no

the

current

starting

SIZE

(HP)

1/6

1/4

1/3
1/2
3/4

1

In

the

above

some

small

the

hardest

sizes.

the

heavy

for

only

the

motor

in

starting

possible,

reduce

OPERATING

generator

and

generator's

periodically

the

appliances

not

installed

meter

and

When

the

equipment

AC

terminal

hot

legfor

starting

to

an

data

vessel

MOTORS

to

start

keep

it

running

current

more

other

types.

such

as

is

started,

be

avoided,

by a small

motors

run.

The

connected

for

example,

load

is

required

loads

will

AMPS

RUNNING

{AMPERES)

table

motors

starting

surge

of

instant,

up

to

speed

motors,

the

first

with

finally

plate.

to

ensure

it

to

monitor

amprobe.

in

of

120

block

the

vessel's

response

an

electric

motor

after

to

start

them

current

to

start,

They

are

washing

require

connected.

3.2

4.6

5.2

7.2

10.2
13

the

current

load

machines,

such

as

as

much

whenever

generator.

from 2 to 4 times

current

required

to

it.

An

will

to

start

be

approximately

FOR

maximumAmpsfor

than

for

larger

types

(split-phase)

needed

the

generator

in a few

turn off

on

the

SPEED

no

load

applied,

loaded

to

its

The

output

proper

operation

supplies.

which

volts

If

voltage

the

generator

only,

it

be

configured

distribution

from

the

GENERATOR

is

considerably

it

is

started.

than

others.

under

similar

commonly

or

small

power
current
possible,

Capacitor

to

electric

motor

require

more

115-Volt

all
electric

full

an

generator.

motors

as

ones.

for

starting

will

not

seconds.

other

electrical

motor.

then

capacity

voltage

should

of

AC

voltmeter

and

load,

is

is

recommended

to

provide

panel.

where

to

start

follows:

AMPS

STARTING

(AMPERES)

6.4

9.2

10.4

14.4

20.4
26

Starting

The

are

be

If

at

the

check

installed

This

Some

motors

Split-phase

used

on

loads

tools.

start

as

if

the

electric

and

as

much

any

motor

connected

current

connected

FOR

to

22.4*

to

32.2*

to

72.8*

to

29.2*

to

40.8*

to

52

reason

not

made

motors

damaged

difficulty

loads

half

the

as

indicated

be

generating

or

amp-

it

with

con-

that

one

120

will

ensure

more

are

to

than

is

for

in

is

if
is

gener-

a

the

a

it

INFORMATION

GENERATOR

Frequency
by

the

following:

•

When
output

•

When
output

Therefore,
drive

engine's

of

the

AC

GENERATOR

•

Maintaining
Connections

ccmoded,
salts,
up.
heating

•

For
petroleum

all

surfaces

• In

addition
inspected
overheated

•

The
checked
for
not
cracking.
generator
identified
the

•

The
maintenance
noisy

•

Examine
of

the
motion
Repair
and

Carbon

WESTERBEKE
detector
even

The
from

exhaust
entering

If

carbon

air

and

FREQUENCY

is a direct

the

frequency

the

frequency

to

output

generator

generator

change

speed

must

connections

result,

is

is

the

MAINTENANCE

reasonable

of

terminal

and

insulation

dust,

engine

exhaust,

Clogged

unusually

drive

any

be

head.

cause

ventilation

and

reduce

severe

based

to

reduce

to

periodic

for

tightness

terminals

discs

on

periodically

evidence

allowed

to

The

bolts

shaft

must

by 6 radial

rear

f\ffilature

is

required.

or

rough-sounding,

the

bearing

shaft

should

is

detectable,

must

be

made

major

coatings

of

become

damage

Monoxide

recommends

in

the

vessel's

in

small

amounts,

presence

the

engine

hose,

your

monoxide

correct

of

carbon

or

or

that

boat.

the

generator

problem

of

engine/generator

is

run

at

60

Hertz.

is

run

at

50

Hertz.

generator's

be

changed

at

the

cleanliness

boards

surfaces

carbon,

openings

life

of

windings.

conditions,

should

rusting

cleaning,

of

all

and

loose

single

bearing

if

possible

incipient

rusty

which

fasten

be

hardened

marks,

one

bearing

is
However,
have

at

periodic

be

detected

inspect

quickly

to

the

Detector--------.

living

quarters.

is

deadly.

monoxide

or

fumes

from a nearby

is

present,

immediately!

ADJUSTMENT

speed,

as

1800

rpm,

the

AC

voltage

1500

rpm,

the

AC

voltage

frequency,

along

generator.

and

may

thin

be

and

corrosion.

the

connections,

or

for

cracking

because

the

at

lubricated

it

replaced.

intervals.

when

the

bearing

or

major

generator.

mounting a carbon

from

ventilate

the

generator's

with a reconfiguring

is

important.

rectifiers

etc.

may

sprayed

damaged
generator's

tightness

steel

each

if

indicates

the

may

start

conducting

are

allowed

cause

excessive

rust-inhibiting

or

brushed

generator

drive

the

force

Carbon

should

evidence

wires.

should

of

failure.

Discs

rust

may

disc

SAE

grade

of

the 6 comers

and

sealed;

bearing

No

side

is

applied.

and

shaft

components

monoxide,

an

exhaust

exhaust

vessel

the

area

become

screws

accelerate

to

the

becomes

monoxide

elbow/
are

with

mdicated

if

to

build

over

be

of

be

and

should

8,

of

no

movement

If

side

for

wear.

will

rub

leak

clean

Engines & Generators

34

BC·

·GENERATOR··SINGLE·•PHASE

NOTE:

WESTERBEKE

and

adjustl'Ttents

reccmunefUisJhat

be

peiformed

by

a

qualifi.e<J

th{followingge~eratortests

tech.nician.

DESCRIPTION

The BC generator

requires only
AC

output.

stator windings and

is

started, residual magnetism

induces

larger

of

windings
capacitor(s)
thestator.
steady
drawn·
equipment.
120
AC

section
data
the
the
various
Integral
supplies a continuous
battery.

see

section in

a currentin

current

cmrent

in

quicJ<ly

At

voltage
off the generator's

volt

AC

two-wire,

ofthis

plate gives the
generator.
louvered cover

AC

Conttoller(IC)is mounted inside

when

the1NTEGRAL

this

is

a brushless.

the

driving

The stator

in

the

and

the

in

The generator is a single-phase, reconnectable

two-wire or

at

manual

An

voltage connections

the

houses

the
the

the

exciter

four

rotating

reaches

a regulated

same time, this

the

stator windings which

50

hertz.

for

voltage,

AC

wiring

at

the

DC

generator

CONTROUER DC

rmmual

self~exdted

force

of

the

engine

two

sets

of

exciter

windings.

in

the

four rotating

stator

which

then

windings;

poles

the saturation point

energy

AC

terrnina1s

110

volt

Refer

generator ratings.

current

decal

generator

charge to

is

running.

'This

and

field

regulzited

AC

two-wire

to

the

SPECIFICATIONS

and

is

affixed

end. A diagram

is

provided

the

For

generator

to

produce

windings;

When

the

generates

mutual

in

the

exciter

of

the

is

!hen

maintained

field

produces a

can

then

to

operate

or

The

generator's

frequency

to

the

on

the

the

generator

generators

more.

information

CHARGER

which

an

the

main

generator

poles

an

even

b,uild

be

AC

220

volt

rating of

inside of

of

the

decal.

and

starting

up

An

in

Circuit

A circuit breaker is installed
WESTBRBEKE
automatically disconnect generator power in case of

electrical overload.
off

coming

NOTE:

add-on kit
WESTERBEKE dealer.

60 Hz · 4.5 Kw Circuit Breaker Part Number 42232
50 Hz -

Breaker

on

all

single phase

generators. This circuit

The

circuit breaker can

when

s~rvicing

into

This circuit breaker

for

3.

7 Kw Circuit Breaker Part Number 42712

the

generator to ensure that

the

boat.

is

available as a WESTERBEKE

earlier model generators, contact your

breaker

be

manually shut

no

will

power

an

is

A.

'ROTATING

WITH

B.

MAIN

C.

EXCITER

D.

DC
BRIDGE

CONTROLLER~

FIELD/AUXILIARY

DIODES.
STAToR

WINDINGS.

WINDINGS

BATTERY:,CHAl3.GJNQ

RECTIFlfR

. . . .

WINDINGS

AND

CAPACITOR(S).

CIRCUIT

ANO

INTEGRAL

WITH

35

6

~·A

s 2 6

0 0 0

DUAL

EXCITER

CIRCUIT

BCA

GENERATOR

(60

HERTZ

D

ONLY)

1 4

0 0

0

s 2

0 0 0

GENERATOR

WITH

INTERNALWIRING

DC

BATTERY

SCHEMATIC

CHARGING

CIRCUIT

ACTERMINAL

A.

ROTATING
WITH

B.

MAIN

C.

EXCITER

D.

DC
BRIDGE

CONTROLLER.

FIELD/AUXILIARY

DIODES.
STATOR

WINDINGS

BATTERY

RECTIFIER

BLOCK

WINDINGS.

AND

CAPACITDR(S).

CHARGING

CIRCUIT

AND

INTEGRAL

WINDINGS

WITH

lw/WESIERBEICE

f

Englrr_es

& Generators

36

SINGLE

i.

1.

3.

EXCITER

Remove

generator,
the

Start

five

generatOr
current
appliances).
correct
obtain

Referring

checkthegenetator'sno-Ioad
wltage
meter.
no-load

the

tl_le

capacitor(s).

the

generator

minutes

from

Adjust

the

across

Make

\IOltllge

voltage

louvered

covering

so

the

is

opetating

the

generator

Make

the

correct

to

the

AC

the

sure

is

output

HO-LOAD

the

an4

engine

srire

fuel

engine

loa4

neutral

you

115

is

higher

proceed.

® @

BC.GENERATOR

NOTE:

lvEsTERBEKE

and

adjus~

VOLTAGE

metal

plate,

AC

terminal

aU()W

it

«J

can

warm

without

record

any

(that

the

engine'~

tbrottle/speecMinkag~aS

speed

before

connections

\loltage

lead

and

this

-

124

volts

or

lower

ADJUSTMENT

at

the

back

conD.eetions

· ·

run

for

apprpximately

up.Make

equipment

is,

shut

off

speed

(Hertz)

prOOeeding.

diagram

by

measuring

the

hot

lead

reading.

at

60.5

than

The

-

specified,

~ommends

be

performed

of

the

and

sure

the

dra\\fing

an

electrical

below,

6LS

~

is

needed

the

with a volt

generator's

Hertz.

If

SINGLE

thatw

by

a

qtliJlt/ifid

__________

·

to

·

5.

6.

following

techriicirin..

A

WARfllNG:

age

ild/:uililentWblle

capao/tou:an

any

wiring

addition,

at

While

fingers

ta

There

are

minal,

#!7,

low,

then

nect

the

tor's

no-load
numbered
number.

terminal

·If

the

generator's

because

numbered
or

the

vpltage-needs

bered

p1ug

Oenetator

PHASE

generator

/lo

pnlituae

can

produn a severe

attempting

the/Jeneratar

be

caught

three

plugs

#8,

and#9.

disconnect

plug

with

voltage

plug

and

Note

that

may

be

any_

the

voltage

plug

is

is

cbnnected,

Troublesh_o?!iit~

tests

;.....__

not

attsmpt

the

genetatar

a

480-500

to

lllake a no-load

Is

O/llfStlng

In

the

generator's

grouped

If

the

generator's

the

lower

the

next

higher

is

high,

then

connect

the

no-load

needs

already

plug

one

to

be

the

presently

of"tbe

voltage

to

be

connected

lowered

refer

Guide).

____

to,maks a no-load

Is

operating.

volt

charge.

elecfl/cal

voltage

could

rotor.

for

the

right

no-load

numbered

plug

three

increased

to

the

plug

number.

disconnect

with

the

connected

plugs

cannot

be adjusted

and

to

the

and

the

WES1ERBEKE

The

Jquahlng

shack.

In

ad/ust·

cause

capacitor

voltage

and

If

the

genera-

the

higher

next

to

available.

the

highest

right

terminal,

lowest

num-

_

volt-

your

ter-

is

con-

lower

this

BC

23DV/50Hz

4.

Shut off

(60

·

capacitor(s).

Hertz

the

generator.

#6,

or

AWARNINQ:

handlllig

tlill/y

power

NOTE:

insulated
any·excess

asthBystare

lstha/·

charge

sourae~

Simply

cross

(plastic

electricity.

handle)

Make

50

Hertz

#S)

CapaoHor.t

m-'.1'tl dl#hliflllld

6/ectr/olty

even

when

the

capacitor's

screwdriver.

fr

GRoUNDED

INSIDEOl"THE

GENERATOR

sure

the

correct

is

pttlgged

alid

can

into

plak a

dlsconneated

two

tennint'.lls

This

will

Hertz

lead

the

before

paten·

tram

thtllr

with

an

discharge

TO

THE

CASE

A

WARNING:

ths

unasell

leads

With

nab

other

housing.

5

BCD

See

the

BNCHNE

ADJUSTING

Maire

certain

are

In

plaae

or

In

contact

GENEM. . il'OR

.

120V/60Hz

ADJUSTMENT

THE

ENGJNE

the

and

with

BACK

END

SPEED.

lnsalatlng.covers

are

NOT

In

contact

the

generator's

NOTE:

THE

#1

SHOWN
DEMONSTRATION
THESt

BE

MADE.

SHOWN

WIRE

CONNECTED

CONNECTIONS

...

t'ERWNAL

\

SINGLE

EXCITER

section

in

this

manual

an.

JS

AS

A

OF

HOW

CAN

·BLOCK

CIRCUIT

for

Engines & Generators

37

BC

GENERATOR

CAUTION:

TO

TOUCH

COULD

BURN

RESISTANCE

CHECK

4.5

CHECK

4.5

60

50

NOTE:

speed

THE

SINGLE

BCG & BCGA

THE

SINGLE

BCG & BCGA

CHECK

THE

Hz

60.5 · 61.5

Hz

50.5 -51.5

Adjust
adjustment

FIGURES

RESISTANCE

EXCITER

EXCITER

CIRCUIT

.......

CAPACITOR

CIRCUIT

.......

ENGINES

the

engines

CAPACITOR

~lY·

DO

NOT

ALLOW

THE

GENERATORS

THE

WINDINGS.

OF

1.9

OHM

31.5

uF ± 5°

SPEED

speed

to

obtain

the

ANY

THE

EXCITER

by

correct

11

OF

THESE

HOUSING

using

the

hertz.

PLUGS

OR

(CONNECTIONS).

OTHER

WIRES

WINDINGS

governors

AS

THAT

WESTERBEKE'S.
for

BC

Generators

website:

LOAD

NONE

-

1'1,tJJfJfJf,.YVest~dJ&.ke.

APPLIED

4-POLE

HALF

FULL

NOTE:

The

output

proper

operation
supplies.
monitor
and

If

an

AC

the

voltage

amp-probe.

"AC

Electrical

is

available

SPEED.

(RPM)

1830

..

(1530)

1800

(1500)

1755

(1455).

should

of

the

Voltmeter

and

Testing & Troubleshooting

in

pdf

form.

Download

com.

FREQUENCY

(HERTZ)

62

(52)

60

(50)

I

59.

(49)

I

I

be

checked

generator

or

Ampmeter

load,

check

GENERATOR.

1

I

I

I

periodically

and

the

it

with a portable

from

120V

(110)

122

(112)

120.

(110)

110

(100)

to

ensure

appliances

is

not

installed

Guide"

our

VOLTAGE

230V

235

230

225

it

to

meter

Engines & Generators

38

SHORE

120

POWER

VOLT/60

HERTZ

TWO

TRANSFER

WIRE

CONFIGURATION

SWITCH

Switching

If

the

installer

circuit,

this

must

Thansfer

diagrams.

Switch

to

simultaneous

A

CAUTION:

atUlty

share

at

the

same
conretl
bHity

to

undsr

make

g

-

ID

!i:

-

!

I

:

z:

Shore

Power

connects

be

done

..

Set

the

OFF

connection

Damage

power
time.

Tiiis

the

sum

.

NOTE1D19.-

wlq,

-

to

shore

power

by

means

the transfer

position.

and

warranty;

all

12Q•Yolt

tllNe-1re,

This

of

shore

ta

the

generator

type

al

It

AC

connections

s'-S

.,....,,

120-V01t - a,stem.

Generator

to

of

switch

switch

power

generator

output

g1111erator

Is

the

Power

the

vessel's AC

the

Shore

shown

prevents

to

generator

can

am
damage

Installer's

are

CIClllllectlaal

- -

tor•

...

-.

Power

in

the

output.

result

connectsd

Is

rssponsl·

corrsct.

-

H

not

. A

CAUTION:

befon1

switching

vics-veTSa

with

hsary

causs

damage

generator.

/ N

G1

G2

t

I
I

I.

'----+<D

r--:--J~

I ,

I

I

I

I

I

I

I

HeartT

motor

shors

panr

because

AC

...

voltage

loads

on

th11

to

the

excltlll'

NOTE:

-

,,,-,

__

Die9ftllll

dotted

!&..l..

~

....

11-

\ wire.1ZO.VoltSJStem.

leads.should

ts

gsneratar

surges

Induced

vessel

being

opllfllled

aln:ult

components

1111oW

COllMctioa

For•three-wiN

for the

other

bot

be

shut

off

power

by

switt:hlng

In

tor a

--

•-

lee·

or

may

tbs

Engine_s

39

&_Generators

LAY

..

UP & RECOMMISSIONING

General

Many

owners

rely

on

their boatyards
including engines and generators,
season

or

for

long periods of inactivity.

accomplish lay-up preparation themselves.
The procedures which follow

lay-up

own
if

others

These procedures should provide protection
engine/generator during a lay-up
you with

If

you
your local servicing
provide assistance.

Propeller

The transmission and propeller half couplings should always
be opened
out of the water or moved from land
storage

· severe strain
the boat
shaft
apply

not

period of

Fresh

A 50-50 solution

mended
This solution
depending on
make sure the antifreeze protection

Should
from
Operate

ture of

system. Then recheck the antifreeze solution's strength.

Lubrication

With
sump. Remove and replace the oil filter
new

LUBRICATING

change".
Run the engine and check for proper

sure there are

and recommissioning, or

do

the procedures.

its

maintenance needs.

have

any

questions regarding lay-up procedures,

dealer.

He will be more than willing

Shaft

Coupling

up

and

the bolts removed

in

the cradle. The flexibility of the boat oftens puts a

on

the propeller shaft or coupling or both, while

is

taken

out or put in the

has

actually been bent

to

small boats that are hauled out of the water

in

use,

unless they have been dry for a considerable

time.

Water

Cooling

of

for

use in the fresh water cooling

may

require a higher

the

area's winter climate. Check the solution to

more

antifreeze

the

engine block and add a more concentrated mixture.

the

engine

to

the

antifreeze concentration throughout the cooling

by

Circuit

antifreeze and distilled water is

be

needed,

ensure a complete circulation

System

the

engine wann, drain all the engine

oil.

Use

the

correct grade

OIL

pages in this manual

no

leaks.

to

prepare their craft,

for

lay-up during

Others

will

allow

you

will

serve

and

also

help

[Propulsion

when

the

to

water,

water.

In some cases,

these strains. This does not

system

concentration

is

adequate.

drain

an

appropriate

.and

of

oil.

Refer

for

oil

pressure and make

the

prefer

to

perform your

as

a checklist

for

your

familiarize

Engine]

boat

is

and during

when

recom-

at

all

of

antifreeze,

and

oil

from

the

fill

the

sump

to

the

ENGINE

"engine

off-

to

call

to

hauled

the

times.

amount

mix-

oil

oil

with

Fuel

System

Top

off

higher. A fuel

or
stabilizer
gasoline/water separator
Re-install
up

any

Fuel

System

Top off your fuel tanks with No. 2 diesel fuel. Fuel additives
such as
this time

be taken that the additives used are compatible with the

primary fuel filter/water separator used in the system. Change
the element in your primary fuel filter/water separator,
fuel system has one,

Change the fuel filter elements

fuel system, as needed.

10 minutes

for 5 -

system. Check for any leaks that may have been created in

the fuel system during this servicing, correcting them as

needed.

allow movement

equipment

Raw

Water

Close the through-hull fitting. Remove the
hose from

gallon
check the
the engine and clean or replace it
any

zinc

anode
Start the

fresh water through the system. When the bucket
stop

the
solution slightly stronger than
protection

Start

the
through
the

engine.
water circuit
as

providing corrosion protection.

Remove
antifreeze
Examine
cover
until recommissioning, but replace the cover

[Gasoline]

your

fuel

tanks

with

should

and

spilled

conditioner such

be

added.

and

make

certain there

fuel.

unleaded gasoline of

as

MARINE.STABIL

Change the element in your

clean the metal bowl.

are

no

leaks. Clean

89

octane

·

[Diesel]

BIOBOR

to

Operating the engine for 5-10 minutes will help

bucket of clean fresh

debis

is

located.

engine

engine

engine

the

the

gasket.

and

DIESEL

control algae

and

Start the engine and allow it

to

make

of

the treated fuel through the injection

on

the engine.

Cooling

the

fitting.

zinc

anode
from

in

your

raw

This antifreeze mixture should protect the raw

from

impeller

mixture

the

impeller.

Do

Circuit

Place

found

inside the heat exchanger

Clean the

and

allow

and

refill

area.

and

allow

water system. Once

freezing during the winter

from

will

accompany it, so catch it

Get a replacement, if

not replace

KLEEN

and

condition the fuel. Care should

clean the separator sediment bowl.

on

sure

no

the

end of

water.

in

the

raw

water

the

raw

the bucket with

needed

all

of this mixture

your raw water

the

should be added at

the engine and bleed the

air is left in the fuel

raw

water intake

this

hose

into

a five

Before starting the engine,

primary heat exchanger

as

required

water

the

impeller

and

also

where

strainer.

pump

to

draw the

is

empty,

an

antifreeze

for winter freeze

to

be

drawn

bucket

is

empty,

lay-up,

pump

(some

in

a bucket).

needed,

(into

the

pump)

and

gasket

the·

as

and a

if

to

run

clean

zinc

well

the

on

stop

A

CAUTION:

all

in

the
combustion
chemicals
Internal

parts.

sump

aver

deposits

which

Do

not

the

combine

can

reduce

leave

lay-up

the

the

period.

to

engine's

Engine
produce
life

of

your

harmful

old

engine

ail

and

engine's

Intake

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

recommissioning, and
you
note
exhaust port

Engines & Generators

Manifold

may

to

remove the cloth prior

40

the

intake manifold

cloth

out of

need

assistance of

can

be blocked

and

Thru-Hull

sight.

an

attempt

(If

the

in

to
it

to

the

Exhaust

block

is

not

is

made

servicing

start-up.

same

the

opening.

visable

to

dealer).

The

manner.

CONnNUED

oil,

at

start

the
Make a

thru-hull

in

the

Do

engine,

not

LAY·UP

Starter

Lubrication

if access
battery connections
the
connections removed

Cylinder

If

WES'IERBEKE recommends removing the
access
cylinders
cylinder walls.

Make sure you have replacements for

line sealing washers.

Intake

Clean the filter screen
cloth lightly soaked

block
through-hull
start-up!

Cylinder

Spray fogging
arrestor removed, while the generator

ail will stall out the engine and coat the valves, cylinders
spark plugs for winter protection.

NOTE:

and regapping at spring

Motor

and

cleaning

to

the starter

starter.

Take care

Lubrication

you anticipate a long

to

the cylinders. Squirt light lubricating oil into the

to

prevent

Manifold

any

opening. Also place an oil-soaked cloth

exhaust

Lubrication

oil

The

spark plugs will need

of

the

starter

drive

permits

its

removal.

are

shut off before attempting

in

properly replacing any electrical

from

the

starter.

(Diese4

. .

lay-up

period (12 months or more)

the

piston rings

from

the

(Gasoline]

in

the flame arrester,

in

lube oil around the flame arrester

port.

Make a note

to

remove

[Gasoline]

into the

open

air intake, with the flame

is

running. The fogging

to

be

removed for cleaning

commissioning.

pinion

Make sure the

sticking

injector

is

to

fuel

injectors for

to

and

and

place a clean

in

cloths

&

advisable,

remove

the

the

Batteries

If

batteries
make
way,
the
be subjected
batteries and store
environment

are

to

be left on board during the lay-up period,

sure that

to

batteries will not remain fully charged, or that they will

they

are

fully

charged, and will remain that

prevent

them

from

freezing.

to severe environmental conditions, remove the

them in a warmer, more compatible

If

there

is

any

doubt that

RECOMMISSIONING

Spare

Parts

Lay-up

time

provides a good opportunity

return

to

prior

and

WESTERBEKE engine
belts or coolant hoses
spares

kit and order items

used

during the lay-up,

to

SPARE

Recommissioning

The

reco~ssioning

seasonal lay-up generally follows the
those

presented
section regarding preparation for starting
However,
counteracted before starting the engine.

1.

Remove the oil-soaked cloths

2. Remove the

old

the

to

removed during lay-up (or a replacement,
Install the

3.

Reinstall the batteries that were
up,

and reconnect the battery cables,
terminals are clean
Check

A

CAUTION:

and

eye
batteries
can

be

cigarette,
open

flame·
electrical
electrical

4.

Remove the spark

proper tightness

PARTS

in

some of the lay-up procedures

raw

gasket Install

raw

to

make sure that the batteries

protection

emit

Ignited

cigar,

near
equipment
arcing

to

see

if

need

replacement Check your basic

not

on

such

as

filters

section of this

of your

the

PREPARATIONS

water pump cover

water pump cover

and

Wear

when

manual.

WESTERBEKE

the

raw water

that the

rubber

gloves, a rubber

servit:lng

hydrogen, a highly

by

electrical

or

pipe.

the

dudng

plugs,

[gasoline].

Do

battery

In

the

servicing.

wipe

arcing

not
being

vicinity

to

inspect your

external

hand,

from

items

or

replace those

and

zinc

same

procedures

FOR

STARTING

and

normal starts.

will

the intake manifold

and

gasket.

pump

impeller

if

with

a new cover

removed

connections

during the lay-

making

are

fully

batteries.

explosive

or a lighted

smoke

or

serviced.

to

prevent

clean,

re-gap,

such

as

drive

items

anodes. Refer

engine after a

as

need

to

be

and

discard

required).

gasket.

sure the

are tight.

charged.

apron,

Lead

acid

gas,

which

allow

an

Shut

off

and install

all

to

A

WARNING:

highly-explosive
arcing

or a lighted

smoke

or

allow
serviced.
vicinity

to

Transmission

Check

or change the fluid

Wipe

off grime and grease and touch up any unpainted areas.

Protect

the coupling

corrosion coating. Check that the transmission vent

Lead

gas,

cigarette,

an

open

Shut

off

all

prevent

electrical

[Propulsion

and

acid

batteries

which

can

cigar,

flame

near

electrical

arcing

Engine]

in

the transmission

the output flange with

emn

hydrogen,

be

lgnfted

by

or

pipe.

the

battery

equipment

during

In

servicing.

as

electrical

Do

not
being

the

required.

an

anti-

is open.

a

5.

Check

the condition

circuit and clean or replace the

· it

is

not

necessary to flush the antifreeze/fresh

· solution from the
engine

is

put into operation, the

short period of time

advisable,

service,

heat
area.

6.

Start the engine

in

the

this

as

to

inspect

exchanger and clear

PREPARATIONS

manual.

41

of

the

zinc

anode

in

the

anode

as

needed.

raw

water coolant

with

no

either

an

end of

the

area where

any and

in

accordance with procedures described

FOR

system

adverse

season

the
all

INITIAL

system.

will

affects.
or recommissioning

zinc

is

zinc

debris

START-UP

raw water

Note

water

When

the

self-flush

It

is

located

from

section

·

in

that

in

the

that

of

a

BCG

GENERATOR

SPECIFICATIONS

Engine

Type

Governor
Combustion Chamber

Bore

& Stroke

Piston

Displacement

Firing

Order

Direction

of

Rotation
Maximum
Compression
Compression

(Limit

Valve

Valve

Valve

(engine

Engine

Dimensions

Dry
Fuel
Inclination

INTAKE

IGNmON

Torque

(at

1800

rpm)
Ratio
Pressure

Qf

difference between

Timing Intake

Seat

Angle

Clearance

warm)

Speed

Weight

Consumption

SYSTEM

Carburetor

(STD

SYSTEM

type)

General

Gasoline,
Vertical,
(8

bhp at

Hoof, llyball

Multi-sphere

2.44 x 2.38

2.62 x 3.19" ( 66.6 x 81mm

33.4

cubic

51.6

cubic

1-2-3

·Clockwise,

13.5

lbf-ft

10.0:t
19&

cylinders

1

(21psi ( 1.5kglcmi'

Intake

Exhaust
Exhaust

lntake45"
Exhaust

Intake
F.xhaust

1800

·

1500

Length:

· Width:·
Height:

Approx.

0.8

U.S.

Continuous
Temporary

Manual

with

Battery

distributor

plugs.

four-cycle, three-cyl:nder,

In-line

overhead

valve

speed

.x.69,5

mechanism

regulation.

mm)

1800

type,

inches

rpm,

type.

maximum).

5%

(92.Q

>A-MODEL.

inches

(.547

viewed

2

)

kgf.pm

1

])

32"

BTDC

52"

ABDC

56"

BBDC

28°

ATDC

(0.25

inches

(0.30

hertz.
hertz.

inches

(673.1

inches

(465:8

Inches

(595.4mm)

lbs

(140. i kgs)

{3.02

lph)

(not

to

appr&Ved

12-volts

points,

. .

llter)

liter J

from the front

at

400

rpm(213.3psiI15,0

<2l

A-MODEL

(

62"

A-MODEL)

(

62°Ji-MODEL}.

(

28°

mm)

mm)

mm)

min)

at

full

rated

exceed

valve,

!lame

(negative

ignition

inches ( 0.846

when

9.5:1

(A·MODEL)

ps~{11.0

Opens
Closes

Opens
Closes

45"

0.010

inches

0.012

rpm

60

rpm

50

26.50

1s.:!4

23.44
309

gph

14°

20•

with

butterlly Shaped

U.S.C.G.

ignition,

with

fresh

water-cooled

A-MODEL

(A-MODEL)

)

M1/jODEL}

output (approximate).

20

min.)

single barrel

arrester.

ground),

coil

and

spark

kg(

cm;!)

FUEL

SYSTEM

General

Fuel

Fuel

Pump

Fuel

Screens

Air

cleaner

Air

Row

COOLING

LUBRICATION

ELEcTiuCAL

SYSTEM

General

Operating
Fresh

Water

Sea

Water

Sea

Water

(measured

into

exhaust

System

General

OD

Filter

Sump

Capacity

Operating

OU

Grade

Starting Battery

Battery

DC

Battery

(on

(engine

combustion)

Temperature

Pump

Pump

Row,

at

before

elbow)

Capacity

SYSTEM

(not including

OD

Pressure

SYSTEM

capacity

Charger

engine)

1800

rpm

discharging

(fresh

water)

(engine hot)

Conventional

Regular

of

89

12-volt
Reusable

Metal

18

cfm

Fresh
thermoslatlcally-controlled

with

130 -150"F
Centrifugal

Positive

fUter)

carburetor

or

unleaded

or higher.

DC;

lift capacity 5

screen type

scnien

type -

(0.509

cmm)

water-cooled

a

heat

exchanger.

(55

-

66"C

type,

belt-driven,

displacement,

3.75-4.0

U.S.

4.2

U.S.

qts

Fully-Force
crankshaft-drlVen.

FuU

llow,

papar

3.0

qts

(2.8

50 -70

psi

AP/

category

SAE

30W

or

12-volt,

24

(recommended)

400

to

600

Integral controller

Oocated

in the

gasoline

Oocated

cleanable.

at

1800

bloek,

)

gl)m (14.19-15.141pm)

(3.9

fed

liters)

(3.5 • 4.9

SJ,SN,

10W-30

A-H,

CCA

type

with

ft

(1.5

rpm.

rubber

liters)

type

element,

kg/cm2)

SL,

(-)

negative

(28

A-H

RATED

tS:.volt.

AC

alternator).

fuel

pump.

With

an octane

m)

at inlet

to

1.13:1.
impeller,

by Trochold

spin-on

SM,

or

grouiid

in cold

10

amp

rating

cartrurator).

belt-driven.

pump.

type.

better.

areas).

OistribiJtor
Spark

Plug

Spark

Plug

Thread

Type

Size

Conventional,

14x1.25

Westefbeke

(Pdways

when

contact-point type.

mm_pltch

part number

Identify the generator

ordering parts.

(0.55 x 0.05

See

33805

page

in.)

model

5.)

1-W:IWBSTSRBEKE

(Engines & Generators

42

Starter

DC

No-Load

DC

Cranking

Current

Current

12-volt,

ro

amp(max.)

100 -125

1.2

KW,

Magnlito engaging

at

amps

(engine

11.5

type.

volts.

cold).

BCG

AC

General-3

GENERATOR

GENERATOR

Phase

SPECIFICATIONS

Brushless,
exciting.

Pre-lubricated,
Reconnectable

single

four-pole,

Capacitor

single
120

phase

revolving

saturated

bearing

volts

or

120/240

field.Self

field

excitation.

design.

volts,

Voltage

Voltage

Regulation:

Frequency

Rating

60
50
AC

Generator
Air
(60

Note:

Engine

Requirements

(60

TUNE-UP

Spark
Contact
Timing

Dwell
Emissions

(Models

Regulation:

(Volts

Hertz

(1800

Hertz

(1500

Circuit

Breaker

Cooling

Requirements,

hertz)

at

1800

Increase

Combustion

Hertz

at

1800

SPECIFICATIONS

Plug

gap

Point

Clearance

Angle

Control

August

AC)

rpm)
rpm)

air

1996

rpm

supply

Air

RPM)

System

on)

120

or

220

Volts -50

±

5%

± 3

Hertz

120

Volts

230

Volts

To

be

amperage

225 -240

15%

for

50

18

cfm

0.028 -0.031

0.017 -0.018
11° ± 5°
58 -66°
Three

1201240

no

load

(5%)

37.5
16

rated

at

and

cfm

Hertz

(0.509

BTDC

way

catalyst

Volts -60

Hertz

to

full

load.

no

load

Amps

Amps

120%

of

voltage

output

(6.4 -6.6

operation

cmm)

inches

(0.70 -0.80

Inches

(0.4 -0.5

at

1800

Hertz

to

full

the

generator's

cmm)

1500

rpm

rpm

load

rated

mm)

mm)

lwlWESTERBEKE

l

Engines & Generators

43

TORQUE

SPECIFICATIONS

Cylinder

Crankshaft
Rocker

Spark
Timing
Timing
Timing

Valve

Oil

Flywheel·

Exhaust

plug

adjusting

pan

Intake

Head

cover to

belt cover #1

belt cover

belt

drain

bolts

manifOld

mariifOld

Bolts*

pulley

to

cylinder

to

cylinder

#2

tensioner

screws

plUg

and

(*See

crankshaft

block

head

oil

pan

the Torquing. Cylinder

36.2-43.4

Head

Bolts section)

36.2-43.4

2.9-5.1.

10.8-15.2

3.2-4.8

5.2-7.8

23.1-34.7

9.4-13.0

25.3-32.5

28.9-36.2

8.4-12.6

7.5~

5.0-6.0

5.0-6.0

0.4-0.7

1.5-2.1

0.44-0.66

0.72-1.0?

3.2-4.8

1.3

-1.8

3.5-4.5

4.0-5.0

1.16-1.74

10.8 1.04-1.56

Grade4T

6rnm

amm

10mm

1

Omm

12mm

12mm

12mrr(.bolt

13mm
14mm

14mm

16rnm

1

amm

Gm.Qe6T

6mm bolt

Srnm

1omm

10mm
12mm
12mm

12mm

bOlt

head/nut.

bolt

head/nut

bolt

head/nut

.bolt

head/nut

bolt

head/nut

bolt

head/nut
head/nut

bOlt

bOlt

bolt

bolt

bolt·

bolt

ijolt

bOlt

bolt

bolt

bolt

Unless

hardware.

head/nut
head/nut
heao/nut
head/nut

heidfnut

headfnut
head/nut
head/nut
headlnut
head/nut
headfnut
headfnut

stated

Pitch

1.25

..

1.25

1.5

. 1.25

1.5

1.75

1.5

1.5

2

1.5
2

,

1.25

1.25

1.5·

1.25

1.5

1.75

TABLE

otherwise

(ISO)

(ISO)

OF

STANDARD

tor a

specific

lb-ft

5.1

2.9-

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 4.7 • 7.7

54.2- 79.6

51.4- 76.7

4,3.

6.5

10.s~

·1s.9

21.7 -

:32;5

19.5- 30.4

36,2- 57.9

36.2-

.50.6

34.7- 49.2

HARDWARE

assembly,

kg-m

0.4-

0.7

1.0

- 1.6

1.9-

3.1

1.8-

3.0

3.5-

5.5

3.5·

5.5

3.0-

5.0

4.5- 7.0

5.0 - 8.0

7.5

·11.0

7.1

-10.6

0.6 - 0.9 1/4UNC

1.5.

2,2

3.0-

4.5

2.7 • 4.2

s.o-

a.o

5.0.

7.0

4.8-

6.8

TIGHTENING

use

the

following

Gm.d~

~mdi Q {<il~riW

torque

7T.

ST

6mm

bolt

Smm

bolt

1omm

bolt

1omm

bolt

12mm

bolt

12mm bolt head/nut

12mm

bolt

13mrn

bolt

14rnm

bolt

14mm

bolt

bolt

16rnm

16mm

bolt

1/4UNF

S/16UNC

5/161.JNF

3/8000

3/8UNF

7/16UNC

7/16UNF

1/2UNC

1/2

TORQUES

values

And

a.a

hea(l/lllJt

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

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

UNF

when

1

1..25

1.2$

1.5

1.25

1.5

1.75

1.5

1.5
2

1.5

2

tightening

(ISO)

standard

8.7

5.8-

14;5 - 21.7

28,9-

39,8

26.8- 37.6 . 3

54.z

••

15.9

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

13

11

-

20

18 -

21

•

23

33

28

-

35

30 -

49

44

-

55

-

50

73 9.4-10.1

68 -

80

73 -

0.8-

1.2

2.0-

3.0

4;0.

5.5

.. 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

10.1

·11.1

44

CONTACT

YOUR

SUGGESTED

WESTERBEKE

WESTERBEKE

DEALER

SPARE

MARINE

FOR

GASOLINE

SUGGESTIONS

PARTS

GENERATORS

AND

ADDITIONAL

INFORMATI9N

THERMOSTAT
GASKET

AND

SPARK

PLUGS

HARDWARE

MOLDED

RAW

GASKa

HOSE

WATER

AND

KIT

KIT

"

PUMP

IMPELLERS

DISTRIBUTER
AND

WIRES

CAP

\'. SSTERBEKE also offers two Spare Parts Kits,
each packaged
KIT

A includes the basic spares.

KIT B is

in

a rugged, rust free toolbox.

for more extensive off-shore cruising.

KIT

A

Impeller Kit
Heat Exchanger Gasket
Oil Filter
Drive Belt
Zinc Anodes
Spark Plugs

WESTERBEKE
ENGINE
AND A GALLON

SPARE

PARTS

Engines·& Generators

45

RECOMMENDS

OIL

(YOUR

OF

PREMIXED

KITS

BRAND)

CARRYING

FOR

AN

OIL

COOLANT

ENOUGH

CHANGE(5

SPARE

QTS.)

KITB

Impeller Kit

Pump Repair Kit

Water

Thermostat Kit
Zinc Anodes
Complete Gasket Kit

Heat Exchanger Gasket
Oil Filter
Drive Belt

Spark Plugs

Engines & Generators

1253-9/2018