Westerbeke 3.5KW SBCG Operator's Manual

OPERATORS

MANUAL

- .

3.5KW

SBCG

60Hz

Single

GASOLINE

and

Phase

RATOH

50Hz

/

.

ow

Ca,bon

Monoxide

Emissions

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

CALIFORNIA

PROPOSITION

65

WARNING

Marine

exhaust

are

known

to

and

Exhaust colorless unconsciousness exposure

-

-Nausea

-Headache

-

IF GET seek until

gasses

gas.

can

Dizziness

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

contain

Carbon

include:

and

Sleepiness

THE

attention.

inspected

diesel

and

cause

other

Monoxide

and

death.

ELSE

FRESH

to

cancer,

Carbon

and

gasoline

some

of

its

constituents

the

State

of

birth

defects,

reproductive

A

WARNING:

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

- Inability

EXPERIENCE

AIR

IMMEDIATELY.

Shut

down

and

ANY

the

repaired.

engine

California

harm.

an

odorless

and

of

Carbon

in

Temples

Twitching

to

Think

OF

THESE

If

symptoms

unit

and

do

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

not

restart

This

WARNING WESTERBEKE bulkhead

WESTERBEKE CARBON IIvlng/sleeplng

They

are

obtainable

DECAL

and

near

your

also

MONOXIDE

quarters

Inexpensive

at

your

is

provided

should

be

fixed

engine

recommends

local

or

generator.

DETECTORS

of

your

and

easily

marine

by to

a

Installing

in

the

vessel. store.

Engines & Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this safety caused by failure to follow fundamental rules tions. Know when dangerous conditions exist necessary precautions to protect yourself, and

your

The following safety instructions are in compliance with

the American Boat

PREVENT

A

WARNING:

while

engine

these

connections!

• Do not operate this machinery without electrical enclosures and covers in place.

• Shut off electrical power before accessing electrical equipment.

• Use insulated equipment.

• Make sure your clothing and skin are (particularly shoes) when handling electrical equipment.

• Remove wristwatch and electrical equipment.

•

Do

noit connect utility shore power circuits, except through a ship-to-shore double throw transfer switch. Damage result if this procedure

• Electrical shock results from handling a charged capacitor. Discharge capacitor by shorting terminals together.

PREVENT

A

WARNING:

exhaust

very

hot!

• Always check the engine coolant level

recovery

A

WARNING:

• In case of before touching the engine or checking the coolant.

manual

machinery.

ELECTRIC

is

BURNS -HOT

system

tank.

an

engine overheat, allow the engine to cool

carefully. Most accidents are

and

Yacht Council (ABYC) standards.

SHOCK

Do

not

touch

AC

electrical

running.

mats

Lethal

voltage

whenever working

all

jewelry when working

to

vessel's

is

not followed.

AC

dry,

ENGINE

Do

not

touch

hot

engine

components. A running

Steam

can

cause

injury

and

precau-

and

take the

your

personnel,

connections

is

present

on

electrical

not damp

vessel's

engine

at

AC

generator

parts

or

gets

the coolant

or

death!

at

on

may

PREVENT

A

• Prevent sparks pump, or other potential sources vapors. Use a suitable container removing the components

•

Do arrester removed. Backfire can cause severe injury or death.

•

Do Backfire can cause severe injury or death.

• Do not smoke or permit the engine/generator clean and free chances

• Be aware - Diesel and gasoline will burn.

PREVENT

A

injury

• Follow re-fueling hatches fueling. blower. your

•

All when well-ventilated area away from spark-producing equipment and out of the reach of children.

• Do not

• Shut off the

spill. sources servicing. the

•

Do

• Be sure

• Be certain

free

• Make sure a

properly maintained. Be familiar with its proper Extinguishers rated ABC by the for

BURNS -FIRE

WARNING:

to

not opeerate with a Coast Guard Approved

not operate with the air cleaner/silencer removed.

fuel

Fire

can

cause

injury

or

death!

flash

fires.

Do not smoke or permit

occur near the carburetor,

fuel

lines, fuel filters, or other

..

flames

system. Keep the compartment and the of

fire.

Wipe

up

all spilled fuel and engine

fuel

of

spilled

to

catch

or sparks

of

debris to minimize the

flames

line,

fuel

all

fuel fuel

to

occur near

BURNS -EXPLOSION

WARNING:

or

death!

engine.

fuel

handling and storing fuels. Store

fill

fuel

DO

fuel

not alter or modify the fuel system.

of leaks.

all

applications encountered in this environment.

Explosions

safety

closed

when

Check

below

Run

the

blower

vapors

are

highly

the

fuel

tank(s) while the engine

the

fuel

service

system.

of

system.

all

Take

NOT allow any smoking, open

fire

near

the

Ensure proper ventilation exists

fuel supplies have a positive shutoff

fuel

line fittings

fire

extinguisher is installed nearby

from

fuel

instructions.

fueling.

Open

for

fumes/vapor before

for

four

minutes

explosive.

valve

at

the engine

care

in

catching

fuel

system

are

adequately tightened and

NFPA

vapors

Keep

and

Use

or

engine

ventilate

any

the

running

before

extreme

fuel

in a

is

when

fuel

flames,

when

are appropriate

filter,

or

fuel

when

system

flame

can

cause

vessel's

cabin

starting

care

running.

servicing

that might

or other

servicing

valve.

and use.

or fuel

oil.

after

the

is

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

•

To

prevent accidental starting when servicing the

generator, remove the 8 amp fuse from the control panel.

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

• Make certain all personnel are clear starting.

• Make certain all covers, guards, and hatches are re-installed before starting the engine.

BATTERY

~

________________________________________

A

WARNING:

or

death!

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

• Never connect the negative positive Do not test the battery condition by shorting the terminals together. Sparks could ignite battery gases Ventilate any compartment containing batteries to prevent

accumulation disturb the battery charger connections while the battery is being charged.

• Avoid contacting the terminals with tools, etc., to prevent bums

wristwatch, rings, and any other jewelry before handling the battery.

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

BATIERY

A

WARNING:

severe

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid, which destructive. off at once with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps.

STARTING

Accidental

starting

can

cause

of

the engine before

EXPLOSION

Battery

(+) connection terminal

of

or

sparks that could cause an explosion. Remove

explosion

(-)

explosive gases.

can

cause

injury

battery cable to the

of

the starter solenoid.

or

fuel vapors.

To

avoid sparks, do not

ACID

injury

Sulfuric

or

death!

If

it comes in contact with your skin, wash it

acid

in

batteries

can

injury

-,

cause

is

A

WARNING:

• Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. Pay close attention to the manifold, water injection elbow, and exhaust pipe nipple.

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

• In addition to routine inspection install a builder or dealer for installation

• For additional information, refer to ABYC T-22 (educational information on Carbon Monoxide).

4

A

WARNING:

odorless nausea

• Do not use copper tubing in exhaust systems. Exhaust

• Do not install exhaust outlet where exhaust can be drawn

• Although diesel engine exhaust gases are not as toxic

AVOID

A

or

• Do not service the engine while it

gas.

or

sulfur causes rapid deterioration resulting in exhaust/water leakage.

through portholes, vents, or air conditioners. exhaust discharge outlet is near the waterline. water could enter the exhaust discharge outlet and close or restrict the flow

of

exhaust fumes from gasoline engines, carbon monoxide gas is present in diesel exhaust fumes. Some symptoms or signs poisoning are:

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

MOVING

WARNING:

death!

situation arises in which it is absolutely necessary to make operating adjustments, use extreme care to avoid touching moving parts and hot exhaust system components.

Carbon

carbon

Inhalation

monoxide

monoxide detector. Consult your boat

Carbon

monoxide

produces

(CO)

is a deadly

of

the exhaust system,

of

approved detectors.

(CO)

is

an

flu-like

symptoms,

death!

of

copper tubing

exhaust. Avoid overloading the craft.

of

carbon monoxide inhalation or

PARTS

Rotating

parts

can

cause

is

running.

injury

invisible

If

the engine

of

If

gas!

as

the

a

Engines

..

II

& Generators

•

Do

not

wear

loose

equipment; jackets, shirts, sleeves, could

• Make sure Keep places

•

Do

not

the

engine

• Stay clear of when

be

caught

HAZARDOUS

A

WARNING:

tie

be

caught

all

attaching hardware

protective shields and guards

at

all

times.

check

fluid

is

operating. the

the

engine

in

these rotating parts.

NOISE

loss!

• Never operate

•

Do

not

run

an

removed.

•

Do

not

run

engines for

open.

A

WARNING:

mentally

or

physically

SAFETY

clothing

back long hair and avoid wearing loose

in

moving

levels or

drive shaft and the transmission coupling

is

running; hair

High

an

engine without

engine with

Do

not

or

jewelry

rings,

necklaces

parts.

is

the

drive belt's tension

and

noise

levels

can

its

the

air intake (silencer)

long

periods with their enclosures

work

on

machinery

incapacitated

when

servicing

or

bracelets that

properly tightened.

in

their respective

while

clothing can easily

cause

hearing

muffler

by

installed.

when

fatigue!

you

INSTRUCTIONS

ABYC, INSTALLING

Read for safety codes and standards. Follow their recommendations

ABYC

"Safety Standards for Small Craft" Order

NFPA

"Fire Protection Standard for Motor Craft" Order

USCG

"USCG 33CFR183" Order

are

NFPA

AND

DIESEL

the

following

when

installing your engine.

(American Boat

from:

ABYC 3069

Solomon's Island

Edgewater,

(National Fire Protection Association)

from:

NFPA

11

Tracy

Avon

Industrial Park

Avon,

MA

(United States Coast Guard)

from:

U.S.

Government Printing

Washington,

MD

Drive

02322

D.C.

ABYC,

21037

USCG

PUBLICATIONS

ENGINES

NFPA

and

Yacht

Council)

Rd.

Office

20404

USCG

FOR

publications

OPERATORS

Many

of

in

your Operators Manual along with other cautions

notes

to carefully, procedures.

GASOLINE

Preparations begin with a thorough examination of the American Boat

Yacht

Council's

a combination of sources including Sections of H-2

Ventilation

H-24

Gasoline

P-I

Exhaust Systems Inboard Engines

P-4 E-9

DC

All

installations must comply

Regulations

MANUAL

the

preceding safety

highlight critical information. Read your

maintain your equipment,

ENGINE

to

the

Electrical Systems

(FCR).

AND

install a gasoline engine or generator should

(ABYC)

ABYC

Fuel

Systems

tips

and

warnings

and

follow

GENERATOR

standards. These standards

standards of particular interest

with

the

INSTALLATIONS

the

USCG

and

Federal Code of

are

manual

all

safety

the

repeated

and

are

NFPA.

are:

and

from

Engines & Generators

iii

CARBON

MONOXIDE

"CO"I

LOW-CO·

GENERATORS

DESCRIPTION

Carbon is a colorless, gas one of threat

Westerbeke Low-CO generators are designed reduce

Several parts

1200

IMMEDIATELY'

. A city

concentration

Even though Westerbeke to reduce normal levels of dramatically, an exhaust extremely dangerous. For to install a always turned

d~tector

You

::(lefector

boat leaving ports and hatches open,

h~lp.

monoxide

that

the

that

normal

standards

per

Regulator

EPA

ACGW

EPA NIOSH OSHA

ACGm

NIOSH NIOSH

(IDLH)

ppm

in

Parts

per

25

100

200

sounds,

can

on,

As

soon

to

dilution

exhaust

"CO"

tasteless,

can

kill

you major safety must

not be

levels

for

miliion "ppm"

CO

is a component

odorless,

without

any

risks

associated

underestimated.

of

CO

in

the engine

CO

have

been

and

hours

ppm

9

lighter

warning.

published,

of

exposure:

Exposure

of

than

with

25 35 35 50 125 200 1200

is

the

so-called

DANGEROUS

California

this

way:

Million

CO

detector near the

ON

and FUNCTIONING

do

not taste, smell, or otherwise detect

turn off all engines and generators, evacuate

as

CO

leaves

in

the

open

outlet,

the

higher

IDLH

concentration-

TO

LIFE

AND

HEALTH.

characterizes

the

effect

Responses

Permissible exposure level, apparent toxic symptoms.

No

poisoning for long period.

Allowable for several hours. Should not be exposed above

this level for any period

time. A possible mild frontal headache

Low-CO generators

CO

leak

of

this

reason

not turn

it

off, assuming

the

exhaust

air.

The

the

concentration of

in

the

engine

untreated exhaust would

it

is

generatoP--afld

and

outlet,

closer a

person

IMPORTANT

engine

exhaust.

air

poisonous

CO

poisoning

boating.

exhaust.

It

to

dramatically_

expressed

INFORMATION

It

is

a

in

Hours

8 8

1

8 8

0.5

0.0

of

CO

,

no

of

two

to

three hours.

are

designed

exhaust

be

extremely important

to

properly.

it

is

CO.

seek

professional

the

level

is

CO.

be sure

a false signal.

Leave

to

If

this

is

subject

the

it

the

is

In a closed

underneath

or potentially exhaust gas. exhaust

. Westerbeke

CO

by with-after treatment emissions engine are

.c.ommonized

ad~quate

producing different

The air/fuel ratio control components: sensors,

CO

of these output.

CO

always,

load.

space,

such

a stem swim platform,

rise

to

the

system

due

Therefore,

precise control

is

fuel

reduction,

components

concentration

one

should never

to

provide a margin

Low-CO

are

not

the

different. Also, certain

across several engine

for

some

and extra adequate for

CO

system

which

purc~ased

electronics

the

worst

'and

any

can

also

case

INSPECTION

The

catalyst intrusion compromise

Westerbeke's

May

NOTE:

covered

product

mandated andCARB.

Maintenance the

engine or important. MUST

Inspection critically loosening surface of flush, intrusion.

addressed. gasket casting needed. gasket, while CO

analyzer.

is

into

the

exhaust system installation

nd

2004

2

Edition must be adhered

Water

intrusion under warranty

by

various

of

the

Fuel

be

properly

of

the

important.

the

metal

the

honeycomb

The

If

there

must

be

must

be inspected

Upon

and

exhau~t

the

engine

critical

engine's exhaust system

proper operation of

warranty,

nor

any

flow

filters,

catalyst

catalyst.

appear~ce

cause

is

replaced.

careful reassembly of

is

as

the

engine

compartment,

concentrations

undiluted level

to

a lack of

of

generators achieve reduction of typical

of

the engine's air/fuel

of

the exhaust

sa~e

for every model because each

levels for different

accomplishes

is

comprised of

sub-assemblies,

others.

variability

and

will

varies

CO

concentration

to

optimizing

is not a

neither

the

emissions

regulating

components

of

fuel

air

filters,

maintained.

at

the

The exhaust

clamp

to

Any

visual irregularity of

of the irregularity must be

irregularity,

The water injected

also

elbow,

check

running.

This

emanating

fresh

air

to

dilute

rely

on

dilution

safety.

in

a special catalyst.

fuel

system components

models

others,

the

required

many

different

machined

Because

in

cause variability of

with

product

the

functioning

load.

Usually,

CO the

to.

defect

of

the

occurs

levels.

will

catalyst.

instructions

Westerbeke s normal

.specific

authorities

affecting

to

the

flame

prescribed

elbow

provide a

is

most likely a

the

for

corrosion

for

must be

engine

arrester

is

view

catalyst

the

catalyst,

the

is

intervals

removed

presence

performed

from

the

of

ratio

being

thus

models.

precise

castings,

extreme

of

the

but

at

maximum

Any

likely

and

is

warranty

such

as

flow

critically

screens

of

the

result

identified

and

sealing

exhaust

and

replaced

new

of

the

boat,

will

the

exhaust

the

coupled

CO

level

any

CO

not

water

quickly

-

dated

not

EPA

of air into

is by output

nonnal

of

water

elbow

sealing CO with

and

as

a

Engines & Generators

IV

EMISSIONS

This genset meets the requirements Emissions Standards as stated on the nameplate.

of

California users unauthorized modifications or replacement

'intake, or speed control system components that affect

air engine emissions are prohibited. Unauthorized modification,

removal or replacement

Federal Emissions

Emissions Compliance indicates the number has been shown to meet Federal Emissions requirements.

Catagory C=

Emissions

Engine Fuel

Engine Valve Engine Ignition Timing See MAINTENANCE SCHEDULE.

Engine Engine

Engine Emission Contol System The engine emission control system consists

Catalyst See Oxygen Back

Pressure

this genset should be aware that

of

the engine label is prohibited.

Compliance Period: The Federal

Period referred to on the nameplate

of

operating hours for which the engine

250 hrs, B=500 hrs, A =1000.hrs.

Warranty

Requirements

Adjustment

Lubricating Adjustments

Sensor

Information

Oil

of

California's Exhaust

of

Requirements

You

should carefully review operator (Owner) Installation

and other manuals and information you receive with your

If

genset.

fuel, exhaust,

EMISSIONS

CONTROL

The California emissions control walTanty statement is located in the same packet,

if

information as this manual when the genset is shipped from the

factory. The engine is certified to operate on unleaded gasoline. See FUEL

RECOMMENDATIONS.

See MAINTENANCE SCHEDULE.

See ENGINE OIL RECOMMENDATIONS. ECU.

manufacture.

MAINTENANCE SCHEDULE.

See MAINTENANCE SCHEDULE. See MAINTENANCE SCHEDULE.

maintenance or service

should seek assistance from an approved WESTERBEKE

dealer. California genset users may use the table below as

locating information related to the California Air Resources Board requirements for emissions control.

INFORMATION

you are unsure that the installation, use,

TABLE

of

your genset

of

engine design and precision

is

authorized, you

an

aid

in

Engines & Generators

v

CARBON

MONOXIDE

"CO"I

LOW-CO

GENERATORS

IMPORTANT

Catalyst performance will degrade over time. As the generator accumulates operating hours, will increase. hours

Verification seasonally Verification involves actual sampling

appropriate

There are two locations where exhaust gas can be sampled.

Dry, but hot, exhaust gas can be sampled at the 1I8NPT plugged opening on the top elbow's casting. Measurements at this location may not be practical in all instances due to the high exhaust temperature, temperature limits temperatures involved or the possibility The other location is the boat's exhaust outlet, which . contains entrained cooling water (except systems). location and it is critical that the probe not ingest water. Probe-type analyzers have an air pump drawing a gas sample through the probe. As a result, they tend to ingest water when it is present. opening pointed in the direction out

of the tubing leading to the probe running continuously downhill. Observe the usually translucent tubing between the probe and the analyzer and be sure no water is being ingested. repaired

The

catalyst

of

engine

operation.

of

satisfactory

or

each

500

CO

analyzer.

of

Only analyzers with probes should

Be

sure to aim the probe downwards with the

the flow. Position the analyzer as high as possible with

If

any water is ingested into the analyzer, it must be

or

replaced and recalibrated.

must

CO

hours

(which

of

the water injected exhaust

the analyzer, safety concerns over

CO

concentrations

be

replaced

levels

of

the water flow and just

every

must

be

done

ever

occurs

first).

exhaust gas with an

of

high levels

dry stack exhaust

be

used at this

2,000

of

CO.

INFORMATION

Whenever taking the time to verify proper exhaust with a use the analyzer to from exhaust leaks. Pay close attention to the connection the cylinder block to the sump plate, the sump plated to the water injected exhaust elbow casting and all subsequent downstream exhaust components and hoses and connection points. Remember, exhaust gas that has not yet passed through the catalyst is raw exhaust, untreated exhaust gas and is very high in

Analyzers usually require periodic calibration. Follow the instructions that come with the analyzer very carefully regarding calibration.

The following are manufacturers that offer Extech, TIP, Testo, TSI, Bacharach, Fluke, Monoxor, Fyrite, Zellwgwer Analytics, Industrial Scientific Corp, GFG, TPI, Teledyne and others. Westerbeke recommends analyzers with a probe connected to tubing. They are slightly more expensive than those with the sensor built into one end to sample the exhaust coming out

co analyzer, always take theopportunity to

"sniff'

around the engine looking for CO

co content.

the' analyzer

of

by

the analyzer, but they allow you

of

co levels from the

CO

analyzers:

a length

the boat's exhaust outlet.

of

transparent

of

CO

When measuring ambient upwind level at the exhaust will be influenced upwards ambient level.

For exhaust

CO

level by also measuring

of

the exhaust outlet, especially in marinas. the

changing

back

at the exhaust outlet be aware

the

exhaust

pressure,

catalyst

refer

to

the

CO

away from and

and

measuring

Table

of

the

by

the

Contents.

CO

Engines & Generators

vi

INSTALLATION

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

CODES

Strict federal regulations, ABYC guidelines, and safety codes must be complied with

when installing engines and generators in a marine environment.

AND

REGULATIONS

SIPHON-BREAK

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

will be below the vessel's waterline, provisions must be made to install a siphon-

break:

in the raw water supply hose to the exhaust elbow. This hose must

minimum

the exhaust manifold injection port raw

If

you have any doubt about the position

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

water

of

20" above the vessel's waterline.

is

damage

to

the engine and possible flooding

Failure

at or

below

of

the water-injected exhaust elbow relative

to

use

the load

of

a siphon-break

waterline

the

boat.

siphon-break.

NOTE:

A siphon-break operation. engine

EXHAUST

The exhaust system's hose MUST be certified for marine use. Corrugated Marine

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

Failure

damage.

SYSTEM

MUST

requires

to

properly maintain a siphon-break

Consult

be

designed to prevent the entry

periodic inspection and cleaning

the

siphon-break manufacturer for proper maintenance.

of

additiinal fitting and clamps to accomplish these bends

of

to

can

result

this type

corrugated exhaust hose can be used. The

of

hose allows for extreme bends

of

water into the exhaust system

vessels heal.

be

will

install a

ensure

proper

in

catastrophic

looped a

when

result

in

AVAILABLE YOUR DEALER

fF\OM

WESTERBEKE

A

detailed engines to

and

download

Marine

Installation

generators,

from

our

Manual

is

supplied

website

at

Engines & Generators

covering

with

www.westerbeke.com.

each

gasoline

unit. A pdf

and

diesel,

is

available

TABLE

Parts

Identification

Introduction

Installation

Rigging and Lifting ................................................. 5

Location and Mounting ........................................... 5

Raw Water Discharge .............................................. 6

Raw Water Supply Hose .......................................... 6

Measuring Changing Fuel,

Engine

Control

Remote Panel ........................................................... 8

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

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

Back

Catalyst

Oil,

Panels -Starting/Stopping

Preparations

Pre-Start Inspection ................................................. 9

Initial

Priming

Safety

Shutdown

Maintenance

Engine

Fuel

Cooling

DC

Lubricating

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

System

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

Fuel

Inlet Fuel Filter ......................................................

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

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

System

Changing Coolant ..................................................

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

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

Water Pumps ..........................................................

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

Circuit/Battery

...

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

Pressure

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

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

and

Engine

Coolant..

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

Procedure

for

Initial

the

Fuel

Switches

Schedule

0i1..

Start-Up

System ...............................

....

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

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

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

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

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

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

..........

OF

CONTENTS

2 3

5

Shore

Power

Engine

Spark Plugs ............................................................ 20

Cam Sensor ............................................................

Air Screen .............................................................. 20

ECU

Engine

6

7

8

9

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

Oil Pressure ...........................................................

Engine Compression Test ...................................... 22

Remote

Water

Valve Clearance .....................................................

Replacing the Timing Belt.. .................................. .24

Bleeding

.

10

11 12 14

14 15

15 15 15

16 16 17 17 18 18

19

Raw

Water

Engine

Software Diagnostics ............................................. 30

Wiring

Diagrams

DC Control Panel .................................................. 36

ECU Components .................................................. 37

Engine Block Components .................................... 38

Exhaust System Components ................................ 39

Generator BCG

Troubleshooting

SBCG

Internal Lay-Up Generator Metric Suggested

Transfer

Components

....................................................................... 20

Adjustments

Oil Filter ................................................... 22

Pump Belt ................................................... 22

the

Fuel

Pump

Troubleshooting

Information

Wiring

and

Recommissioning

Specifications

Conversions .................................................

Spare

Switch

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

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

System

(Exploded

....

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

View)

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

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

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

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

Diagram

....

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

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

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

Parts

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

.

19 20

20

21 21 21

23

25

26 28

.40

41

.42

43

.44

.45

.46

Engines & Generators

1

PARTS

IDENTIFICATION

3.5

SBCG

GENERATOR

DC

REAR

STEPPER

VOLTAGE

REGUL,A'~;l:::';;~~~

~'W'-f-.

,e:;~!J..o.I.stARTISTOP

HOURMETER FAULT

LED'S

SWITCH

MOTOR

under

this

cover

K1-K2-K3-RELAYSfTIMER EXTERNAL

VOLTAGE

CONNECTION

MODULE

REGULATOR

MODULE

TERMINAL

LEFT

SIDE

STRIP

FRONT

CIRCUIT

BREAKER

C

MAlNJlREAKER

IGNITION

MODUL,E

AC

CIRCUIT

BREAKEI~"

,ExtIAUl)T

rrII.~'--~"L

MOTOR

RIGHT

HEAT

OIL

PRESSURE

SIDE

TEMP.

DRAIN

SWITCH

HOSE

EXCHANGER

SWITCH

Engines & Generators

2

INTRODUCTION

These high performance marine engines are products WESTERBEKE's technology. We take great pride in the superior durability and dependable performance Thank you for selecting WESTERBEKE.

In order to get the full use and benefit from your generator, it is important that you operate and maintain it correctly. This manual is designed to help you manual carefully and observe throughout. your nearest

This is your operators manual. A parts catalog is also provided and a technical manual is available from your WESTERBEKE equipment, contact your WESTERBEKE'S

WARRANTY

Your

WESTERBEKE folder. If, form you have not received a customer identification card registering your warranty, please contact the factory in writing with model information, including the unit's serial number and commission date.

lifter

Customer

long years

Should your engine require servicing, contact

WESTERBEKE

dealer.

installation manual.

of

experience and advanced

of

our engines and generators.

do

this. Please read this

all

the safety precautions

dealer for assistance.

If

you are planning to install this

WESTERBEKE

dealer for

PROCEDURES

Warranty is included in a separate

60

days

of

submitting the Warranty Registry

Identification

Card

of

IWIWESTERBEKE

I

Customer Identification

WESTERBEKE

MR. MAIN

STREET HOMETOWN, Model Expires

OWNER

USA

Ser. #

SERIAL

The plate located engine's serial number is also stamped

NUMBER

engine s serial

on

top

ENGINE SERIAL NUMBER'

. . 0 "

,.~~::

LOCATION

and

model number are etched

of

the unit (flywheel cover).

on

LOCATED THE

on

a name-

The

the engine block.

BEHIND

INTAKE

MANIFOLD

. i

<_

...

a

<.

.~

Take the time to 'enter this information on the illustration the

nameplate as shown above, as this will provide a quick reference when seeking technical information and/or ordering parts.

The

generators serial number and model number is located

on

a decal

on

the the generator control panel. Take the time

to

enter the information provide a quick reference tion and/or ordering parts.

on

~.

MODEl

RPM

KW

KVA

VOLTS

AMPS

_______

__________

___________

__________

________

_

~'-

.::

the

blank decal below. This will

when

seeking technical informa-

60

of

HZ.

PRODUCT

Product software, (technical data, parts lists, manuals, brochures and catalogs), provided from sources other than WESTERBEKE

WESTERBEKE CANNOT

CONTENT RANTIES OR REPRESENTATIONS WITH RESPECT THERETO, INCLUDING ACCURACY, TIMELINESS COMPLETENESS THEREOF BE

LIABLE FOR INCURRED OF

THE FURNISHING OR USE

WESTERBEKE span between printings and the unavoidable existence product software. The product software provided with WESTERBEKE other suppliers, must not and cannot sively as the definitive authority on the respective product.

SOFTWARE

are not within

OF

SUCH

SOFTWARE, MAKES NO

ANY

TYPE

IN

CONNECTION WITH OR ARISING

customers should keep in mind the time

of

products, whether from WESTERBEKE or

WESTERBEKE's

BE

RESPONSIBLE FOR THE

AND

WIll

OF

DAMAGE OR INJURY

OF

SUCH

WESTERBEKE

of

earlier WESTERBEKE

be

relied upon exclu-

control.

WAR-

OR

IN

NO

EVENT

OUT

SOFTWARE.

product software

ENG.

HP

ENG.

SER.

GEN.

SER.

PF

IPHASE

WIRES

RATING INSUL

TEMP.

BATTERY

C.I.D.

_________

Fill

in

the

information

Engines & Generators

3

______

_

NO. NO.

___

_

________

_______

CLASS

RISE

__

___

_____

_

for

your

own

reference.

I

$:J]

INTRODUCTION

ORDERING

Whenever replacement parts are needed, always provide the generator and engine model and serial numbers. In addition,

include a complete part description and part number for each part needed (see the separately furnished

Also insist upon WESTERBEKE packaged parts because

will fit or generic parts are frequently not made to the same

specifications as original equipment.

NOTES,

As this manual takes you through the operating procedures, maintenance schedules, and troubleshooting generator, critical information will be highlighted by NOTES, CAUTIONS, and WARNINGS. An explanation follows:

NOTE:

A

observed.

the

A

followed.

NOTE:

by WESTERBEKE. Affix this decal engine room.

SPARES

Certain spare parts will be needed to support and maintain your WESTERBEKE generator or engine when cruising (see SUGGESTED SPARE PARTS). Often even simple items such as

proper fuel and oil filters can be difficult to obtain along the way. WESTERBEKE will provide you with a suggested spares and accessories brochure to assist you in preparing an on-board inventory

PARTS

Parts Catalog).

CAUTIONS

An

operating procedure essential to note.

CAUTION:

can

engine

or

WARNING:

can

A carbon monoxide warning decal has been provided

AND

WARNINGS

Procedures.

result

in

the

damage

which

if

or

generator.

Procedures.

result

in

personal

which

if

injury

in

a visible location

ACCESSORIES

of

the proper WESTERBEKE parts.

of

your

not

strictly

destruction

not

properly

or

loss

of

life.

of

in

the

PROTECTING

Care at the factory during assembly and thorough testing have resulted in a WESTERBEKE generator capable many thousands manufacturer cannot control how installed in the vessel or the manner in which the unit operated and serviced in the field. This buyer/owner-operator.

NOTE:

Seven important steps to ensure long generator life:

• Proper engine

•

An

efficient well-designed exhaust system that includes an anti-siphon break to prevent water engine.

• Changing the engine oil ing hours.

• Proper maintenance nents according to the maintenance schedule in this manual.

•

Use

clean"

• Winterize Recommissioning" section in this manual.

UNDERSTANDING

The gasoline engine driving an AC generator

ways similar to a gasoline automobile engine. The cylinders are in-line, and the engine's cylinder head has camshaft which is belt-driven. The engine incorporates a pressure type lubrication system, and a water-cooled engine block.

To a large degree, the generator's engine requires the same preventive maintenance that is required automobile engine. The most impOltant factors to the generator's longevity are proper ventilation, maintenance

the fuel system, ignition system, and cooling system.

CARBON

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

in

small

The presence from the engine or generator

elbow/exhaust hose, or the fumes from a nearby vessel are entering your boat.

If carbon monoxide is present, ventilate the area with clean air and

COlTect

YOUR

INVESTMENT

of

hours

of

dependable service. However the

and

generator installation.

and

of

all engine

unleadedfuel

your

engine according to the "Lay-up

MONOXIDE

amounts,

of

carbon monoxide indicated

the problem immediately!

#89

THE

GASOLINE

DETECTOR

is deadly.

or

of

or

where the generator

is

up to the

from

entering

oil filters every 100 operat-

and

generator compo-

octane.

No

higher than E10 ethanol blend.

and

GENERATOR

is

in many

an

overhead

of

a gasoline

Carbon

from the exhaust

monoxide,

an

exhaust leak

is

t.'ie

of

Engines & Generators

4

RIGGING

The engine/generator

AND

LIFTING

is

fitted with lifting

eyes.

Attach

wire rope or chain slings capable of supporting the

engine/generators weight

by

means

erator

of

eyes have been designed

are

slings

NOTE:

and competent

not necessary.

Rigging work

in

handling

to

the

eyes

and

lift the engine/gen-

tackle attached

to

is

best done by someone experienced

carry

to

these slings.

the

full

weight:

machinery.

INSTALLATION

The

lifting

auxiliary

SIDE

VIEW

LOCATION

A solid, level mounting platform proper operation allow adequate space

AND

MOUNTING

is

very important

of

your generator. Select a location that will

on

all sides

for

ventilation and servic-

for

ing. Locate the generator away from living quarters, and away from bilge splash and vapors.

Refer

to

WESTERBEKE'S

information

on

installing a Marine

installation

Generator

USE LOCATING HOLES

manual

THE

PAN

THE

TO

THE

for

detailed

in a boat.

AS A TEMPLATEFOR

PROPER PLYWOOD

the

MOUNTING

BASE

RAW

1.0.

WATER

HOSE

INLET

O.Sin

(2.7mm)

BOTTOM

TOP

VIEW

WATER

OUTLET

AND

HOSES

·FDUR

O.Sln

1/2"

(2.7mm)

BOLTS

DlSCHr.RGE.

1.0.

'

3/4"

PLYWOOD-BOLTED/FIBERGLASSED

IN

PLACE

BATTERY TO

REFER DIAGRAM

ATTACHMENTS,

STARTER

TO

MOTOR

THE

WIRING

IN

THIS

MANUAL

(-)

NEGATIVE

LEAD

(+)

POSITIVE

LEAD

DIMENSIONAL

For dimensional drawings. Westerbeke current drawings with

Engines & Generators

5

DIMENSION

(INCHES

AND

MM)

DRAWINGS

View

the

drawings

website www.westerbeke.com

dimensions.

for

on

the

the most

INSTALLATION/EXHAUST

SYSTEM

RAW

WATER

The fresh water that flows thru the engine is cooled by a continuous flow the raw water is discharged overboard, it is used to cool

the exhaust system.

RAW

WATER

The raw water supply hose from the discharge conne.::tion on

the engines cooling system to the inlet connection water injected exhaust elbow

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

installations where the water injected exhaust is close to

On or

below the vessels loaded water line, provisions must be

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

flow after the engine is shutdown. This flow, will fill the exhaust system and possibly the engine as well.

The raw water supply hose must be looped well above the loaded water line to allow the syphon break to function

during all attitudes when the generator is not operating.

DISCHARGE

of

raw water (via the heat exchanger). As

SUPPLY

of

the syphon break is to stop the raw water

HOSE

(INSTALLING)

must

be

looped a minimum

if

not stopped,

of

vessel operation to prevent syphoning

of

the

of

When the generators location is above the loaded water line of

the vessel during all attitudes advisable to loop the raw water discharge hose at least 6 inches or more above the generator and then down to the inlet connection on the water injected exhaust elbow.

NOTE:

Always use a quality hose with good wall integrity wire reinforced hose so it will maintain its shape when looped and also provide proper mechanical support hose.

I

(

I

of

vessel operation, it is still

for

EXHAUST

or

the

ELBOW

:I

•

EXHAUST

Measure back pressure after the engine has reached its normal operating temperature and with rated amperage output applied to the generator Westerbekes Installation Manual Pub. #43400 has detailed information on back pressure .

BACK

PRESSURE

(30 amps @60Hz and

15

amps @ 50Hz).

....

~

/"

I

BACK

PRESSURE

NOT

EXCEED

IN

THE EXCEED A

PSI

GAUGE.

41"

WATER

1.5

PSI

SHOULD

(102.5cm)

COLUMN

WHEN

USING

OR

I

WATER COLUMN

HEAT

EXCHANGER

MEASURING EXHAUST PRESSURE

BACK

Engines & ,Generators

6

POSITION

THE

TWO

FLANGES

AND

TIGHTEN

THE

CLAMP

SECURELY

DVER

(AND

GASKET)

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

Use only unleaded gasoline with higher. Higher octane is recommended. The use octane gasoline will adversly affect engine performance. Ethanol blends must not exceed E-lO.

When fueling, follow U.S. Coats Guard Regulations. Close all hatches and companionways to prevent fumes from entering the vessel. Ventilate properly after fueling and before starting the generator or main engines.

Use only clean fresh fuel! keep it clean. The best fuel can be rendered unsatisfactory by careless handling or improper storage facilities. the fuel going into the tank for your engine's daily use is clean and pure, the following practice

Purchase a well-known brand Install and regularly service a good, Coast Guard approved

metal bowl type filter/water separator between the fuel tank and the engine. This filter smaller.

ENGINE

Use a heavy duty engine oil with an API classification of SJ, SL, or SM. Change the engine oil and filter after

50 hours interval section of this manual and not be extended if synthetic oils are used. An engine in all conditions Westerbeke Corporation does not approve or disapprove the

use of synthetic oils. must intervals must be SCHEDULE synthetic oils are used.

NOTE:

statements regarding synthetic oil.

OIL

of

break-in operation. Thenfolrow the oil change

as

specified in the

oil viscosity

be

performed using conventional oil. Oil change

The infonnation above supersedes all previous

of

as

section

It

rating

MAINTENANCE

SAE

15W-40 is recommended for this and

If

synthetic oils are use, engine break-in

listed in the

of

this manual and not be extended

an

octane

is

important

is

of

fuel.

all seasons.

MAINTENANCE

to

advisable:

must

be

rating

of

89

or

of

lower

buy clean fuel, and

To

assure that

10 microns

SCHEDULE

an"

or

initial

if

OVER-FILLING

CAUTION: unintentionally

After shutdown, the oil in the engines internal pasages can linger and take a number sump. Allow at least a few hours for the oil to settle back into the sump before checking the dipstick reading.

(Re-starting the engine is not a problem internal passages are well lubricated).

Over-filling the engine's sump will result in erratic operation, andlor a smokey oil laden exhaust, hard starting and possible no start.

The

oil

sump

be

over-filled!

on

this

generator's

of

hours to drain back into the

as

engine

the engine's

can

ENGINE

Engine coolant a 50/50 mixture

water. This coolant allows the engine to run at its proper temperature by transferring heat from the engine to the coolant. It also lubricates and protects the cooling system from rust and corrosion. A distilled water will protect the engine

PURCHASING

Rather than preparing the mixture, WESTERBEKE recommends buying the premixed antifreeze so that when adding coolant, the mixture will always be correct.

COOLANT

A coolant recovery tank kit The purpose coolant expansion and contraction during engine operation, without the loss the cooling system.

NOTE:

hose, is best located at

pressurelfill cap.

COOLANT

of

antifreeze and distilled

50/50 mixture of antifreeze and

to

_34°P

(1.12°C).

ANTIFREEZE

RECOVERY

of

this recovery tank

of

This coolant recovery tank, with its short length

TANK

is

supplied with each generator.

is

to allow for engine

coolant and without introducing air into

or

above the cooling systems

of

Engines

7

& Generators

CONTROL

PANEL • START/STOP

PANEL

DESCRIPTION

To

Start:

Press the rocker switch to the start position and release. (The switch will revert to its center position). The engine will crank and start electronically. A on the switch will indicate the engine is running.

NOTE:

There

is

a brief delay while

the

start button

Apply a light load to the generator and allow the engine

wann

to loads.

To

Stop:

ECU will receive the signal to shut the engine down. The green LED will go

NOTE:

This

is

not

running.

normal.

responds.

up to operating temperature before applying heavy

Press the rocker switch to stop and release. The

off

indicating the unit has shut-down.

green

LED

may illuminate dimly

This

is

part

7iAI~J.---

~~-1\

the

of

the

self diagnostic circuit and

1.--1----

green

LED

ECU self-tests

when

the

HOURMETER

LED

DISPLAYS/FAULT

START/STOP ROCKER

SWITCH

GREEN

LED

before

engine

is

LED'S

FAILURE

The start cycle will automatically terminate

to start after 8 seconds be performed before an underspeed fault occurs.

prevents prolonged cranking exhaust filling

To try repeat start attempts while solving and repairing the problem, close the thru-hull (water intake valve). When the starting problem is corrected do not forget to open the thru-hull.

~:'

TO

START

if

the engine fails

of

cranking. Three start attempts can

This

which

can

result

in

with

water

and

backing

into

the

engine.

·~f~·

OIL..IIIIJWUIIR!

__

~

...

([ .

"II"1I1IP

.

II!XT.

ImIAIUI8T

£Un

TRIP

911)-

the

(l01.6mm)

o 0

~----3.34"

(84.84mm)

--~

\..---Joo--f---_

SHUTDOWN

A shutdown is when the stops the generator because it has detected an operating fault which could cause damage to the engine, the generator, or create an unsafe operating condition.

(Refer to SAFETY SHUTDOWN SWITCHES)

ECru

(Electronic Control Unit)

2DA

CIRCUIT

BREAKER 8AFUSE

PN

033769

MAIN

CIRCUIT

BREAKER

REMOTE

A remote panel is available that allows for remote operation of

the generator. The panel comes with either a 15' or 30' plug-in extension harness. The start/stop sequence is identical. Once installed, the engine can be operated by either panel.

PANEL

o

~

REMOTE

PANEL

NOTE:

For wiring these

refer

to

in

thus

manual.

(with

Fault

Display)

IT.

2.60" «66.04mm) --.J

(STOP/START

remote

the

Wiring

Diagram section

3.190"

o

SWITCH

ONLY)

panels,

(81.03

mm)

Engines & Generators

8

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

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

• Make certain the cooling water thru-hull petcock is open.

•

Check the full mark on the dipstick.

•

Check

bowls for contaminants.

•

Check and battery cable connections.

• Check load leads for correct connection as specified in the wiring diagrams.

• Examine air inlet and outlet for air flow obstructions.

•

Be load lines.

• Be sure that in power systems with a neutral line that the neutral is properly grounded (or ungrounded) as the system requires, and that the generator neutral is properly connected to the load neutral. In single phase systems an incomplete neutral voltage

• Visually examine the unit. Look for loose or missing parts, disconnect wires, unattached hoses, and check threaded connections. Make sure there·is no leakage.

A

recommended be

switched

and

caused will

INSPECTION

the

engine oil level. Add oil to maintain the level at

the

fuel

supply

the

DC

electrical system. Inspect wire connections

sure no other generator

or

open neutral can supply the wrong line-to-

on

unbalanced loads.

CAUTION:.

starts

by

prevent a cold

When

starting

that

alMC

OFF

until

the

to

warm

up.

This

unanticipated

engine

and examine the fuel filter/separator

or

utility power is connected to

the

loads,

especially

engine

has

precaution

operation

from

stalling.

generator,

come

of

the

will

AC

large up

prevent

it

is

motors,

to

speed

damage

machinery

and

Coolant

•

Check

the

coolant

recovery tank and at the filler neck opening

NOTE:

After

the initial running the engine's cooling system should be purged to the plastic coolant recovery tank. cools, coolant should be drawn back into the engine's cooling system to replace the displaced open the to allow any it. ensure the system is completely full. Replace the cap·

fill the plastic coolant recovery tank

and

air

bleed petcock on the engine's heat exchanger

air

Open the pressure cap on the system filler neck

LOW.

OIL

FILL

CAP

(YELLOW)

level in both the plastic coolant

of

the generator, the air in

After

shutdown

left in that area to

and

air.

be

expelled. Thtm close

half

on

the unit.

as the engine

Once cooled,

and

way between

and

MAX

CONNECTS

TO

WATER

PUMP

FULL

r-t----

Engines & Generators

OIL

FILTER

COOLING

WATER

BY·PASS

INSPECT

PERIODICALLY

9

MING

OF

THE

FUEL

SYSTEM

SCHRADER

VALVE

INLET

FUEL

FILTER

FUEL

.

MODULE DIS_CONNECT

TO

HARNESS

NOTE:

The

generators fuel system must be primed with fuel

before its initial start.

INSTRUCTIONS

1. Connect a Snap On MT337B, OTC 7211 or equivalent fuel bleed/pressure gauge set (available at auto supply stores) to the schrader valve on the fuel rail at the injectors. Direct the purge line from this tool into a container and open the valve to the purge line.

2.

Temporarily attach a seperate fuel supply hose with Primer Bulb to the fuel inlet connection on the engine.

3.

Operate the primer bulb moving fuel into the engines fuel system. Monitor the fuel/air flow through the purge line into the container. through the purge line, stop priming.

4. Remove the fuel bleed/pressure gauge set and replace the cap on the schrader valve.

5. Remove the seperate fuel supply hose from the inlet

connection and connect the ships internal supply. Be careful to prevent any fuel spillage.

6. Start the unit and allow the unit to warm up and load test. Check for any fuel system leaks.

7. Re-bleed once running, low first then high pressure schrader.

Once clear fuel free

of

air

is

moving

~

~,

DETACH

FUEL

LINE

ANDFITriNG

NOTE:

The

fuel bleed/pressure gauge set the schrader valve on the fuel module while the engine is running with the purge line directed into a container and be used to bleed any air that may have entered the system while

peiforming step #5. Care should be taken when

valve on the purge line. It need only be opened slightly to allow any air to escape.

A

CAUTION:

not

allow

fire

near

tight

and

properly

Fuel

any

smoking,

the

fuel

free

of

dispose

and

system.

leaks.

of

soiled

fuel

open

be

Wipe

rags.

.,

.~

FROM

SHIPS

FUEL

·~SCHRADER

~

VALVE

vapors

flames

or

certain

up

any

that

spilled

INTERNAL

SUPPLY

CAP

c~~

be connected

opening the

are

explosive!

other

source

fuel

lines

fuel

Do

of

are

and

to

I

""fIY'IWESTERBEKE

I

Engines

& Generators

10

SAFETY

SHUTDOWN

SENSORS

AND

SWITCHES

SAFETY

The engine is protected by four automatic shutdown circuits.

Should a shutdown occur,

finding and correcting the

Engine starts, runs TROUBLESHOOTING section

The following is a description

circuits:

High

An exhaust temperature switch is located on the water

injected exhaust elbow. Normally closed contacts, this switch

will open and the temperature issue and de-energize the K2 and K3 relays, stopping the generator.

Main

The main circuit breaker at the control panel will automatically disconnect the AC power overload. This circuit breaker must be manually switched off when servicing the engine/generator.

SHUTDOWN

and

Exhaust

AC

Temperature

ECU will interpret this as a high exhaust

Circuit

SWITCH/SENSORS

do

not attempt

cause.

then shuts down in the ENGINE

of

these automatic shutdown

to

restart without

Refer to the heading

this manual.

Switch

.

EXHAUST

ElBOW

Breaker

if

there is an

20ACIRCUIT

iBREAKER

Fuses

A FL-8A fuse located on the control panel protects the elec-

If

trical wiring. blow and shut the engine down.

A

20A

ATM

fuse fails, the engine will continue to run but the battery will

not be charging.

an amperage overload occurs, the fuse will

fuse protects the battery charging circuit.

~

If

this

~

ATM

20AFUSE

Oil

Pressure

An oil pressure sensor is located off the engines oil gallery.

Oil pressure on the sensor affects the sensor to the ECU. Should the voltage reach a preset value,

ECU will interpret this as a low oil pressure issue and

the

open the K2 run relay, stopping the generator. The oil

pressure LED on the panel will illuminate.

Oil

Pressure

The oil pressure switch sensors the engine's oil pressure. the oil pressure falls below 5 PSI, the switch will shut off the fuel pump and the engine will shut down. Thw switch will reset itself when the oil pressure is restored.

Sensor

Switch

DC

voltage through the

If

'--=-l~-

Engine

The generator's engine

type DC 20 amp breaker mounted on the control box. This

also serves as an Emergency

current draw or DC electrical overload anywhere in the instrument panel wiring breaker to trip to the power to the No panel LED will illuminate. Check and repair the source

of

restart the generator. The DC breaker must be cycled OFF

then fault situation has been repaired.

DC

Circuit

ECU will be interrupted, stopping the generator.

the problem. After repairing the fault, reset the breaker and

ON

to clear any ECU shutdown from the ECU after the

Breaker

DC

circuit is protected by a rocker

Stop Switch. Excessive DC

or

engine wiring will cause the

OFF

position. In this event, the DC

SA

FUSE

.

MAIN

AC

BREAKER

CIRCUIT

Engines & Generators

Water

A water temperature sensor is located at the thermostat

housing. This resistance of converts it to the corresponding engine coolant temperature. When the coolant temperature reaches the warning threshold, the CHECK ENGINE LED on the panel illuminates. coolant temperature exceeds the shut-down threshold, the ECU will open the K2 and

generator and the coolant temperature LED on the panel will

illuminate.

High/Low

The ECU monitors engine rpm via the MPU )Magnetic PickUp) that is mounted under the flywheel. When the engine speed falls down the engine and the fault LED for speed will illuminate.

Temperature

temperature. The ECU measures this resistance and

RPM

or

rises to a pre-set rpm level, the ECU will shut

Sensor

of

the sensor changes as a function

K3

relays shutting down the

Shutdown

If

the

11

SCHEDULED EVERY

250

*Exhaust

CO

Level

*Exhaust

Elbow

Exhaust

System

*Exhaust

System

Fuel

Filter

and

Fuel

Filter

Inlet

Generator

Hoses

Spark

Plugs

Vibration

Isolators/Engine

Zinc

Anode

I

EVERY

500

Raw

Water

Pump

MAINTENANCE

OPERATING

Back

O-Rings

.oPERATING

HOURS

Pressure

Mounts

HOURS

OR

YEARLY

OR

YEARLY

MAINTENANCE

EXPLANATION

SCHEDULE

OF

SCHEDULED

(cont.)

Sample

exhaust

with

CO

Test

exhaust

elbow

for

Always

use a new

monoxide

Carefully for

Perform

increase

load. Remove Remove Check

See Engine

delaminated. Replace

Check Remove

Replace

Remove check

exposure!

inspect

carbon

and/or

back pressure

Correct

anti' and

that

AC

GENERATOR

hoses

spark

vibration

and gasket

the

Inspect

and

for

leaks

structural

gasket.

for

leaks.

corrosion

pressure

test

above

as

needed.

replace

fuel

replace

inlet

connections

INFORMATION.

should

be

and

plugs.

isolators,

zinc

and

O-rings

pumps.

any

and

for

firm tighten

proper

Check

replace

dual replace

MAINTENANCE

analyzer.

integrity.

NOTE:

A

Check

anti-siphon

build

-up

to

ensure

1.5

psi

or

41

filter

and

all

fuel

filter.

are

clean

and

tight.

all

hose

brackets

and

anode.

Open

if

needed.

Follow

the

worn

parts. pumping

Replace

leaking

exhaust

valve

on

inside

system

has

inches

of

sealing

a-rings.

and

secure.

Replace

clamps.

mounting

heat

exchanger

instructions

Lubricate,

action.

if

elbow

is

elbow

or

operation.

passages.

Clean

not

developed

water

column

Ensure

wires

if

hoses

become

hardware.

end

cap(s)

in

this

manual

reassemble

and

corroded

gasket

can

Check

the

and

replace

restrictions

at

full

operating

have

no

spongy,

and

disassemble

install.

or

deteriorated.

cause

carbon

exhaust

as

that

amperage

chafing.

brittle

clean

out

With

engine

elbow

necessary.

will

or

debris.

both

pumps.

running,

I

EVERY

500

OPERATING

Coolant

System

Engine

Compression,

Valve

Clearances

Starter

Motor

Diverter

Valve

I

EVERY

1000

OPERATING

*Engine

Timing

Belt

Heat

Exchanger

I

EVERY

2000

OPERATING

*Oxygen

Sensor

*

Catalyst

*WESTERBEKE

be

performed

HOURS

Head

Bolt

HOURS

recommends

by

an

authorized

OR

Torgue

OR

this

EVERY

TWO

and

EVERY

FOUR

service

mechanic.

YEARS

Drain,

flush

and

re-fill

the

COOling

system

with

the

thermostat

Incorrect bolt

torque

within

Check motor

Replace.

Remove

recommended to

the

Remove

Remove Remove

and

valve

clearance

and

published solenoid

pinion

drive.

and

replace

interval

engine.

the

heat

and

replace

and

replace

coolant

adjust

specifications.

and

motor

exchanger

NOTE: The operation

pressure

will

the

valve

for

the

timing

could

for

exhaust exhaust

cap.

result

in

poor

clearances.

corrosion.

belt.

NOTE:

result

in

timing

professional

oxygen

sensor.

catalyst.

appropriate

engine

Check

Remove

Failure

.belt

cleaning

Inspect

of

the unit's "Low-CO" system must

antifreeze

performance.

that

the

compression

and

lubricate.

to

replace

resulting

and

pressure

every

the

1,000

failure

Check

Clean

timing

in

major

testing.

hours.

mix.

the

pressure

and

belt

" be monitored at least once an operating season. This

"-'

help ensure that the system is operating properly. Free system

is

diagnostic software

available for use with a laptop by

contacting your area Westerbeke Distributor.

Replace

head

is

lubricate

at

the

damage

is

the

to

starter

Engines & Generators

13

SCHEDULED

EVERY

250

'Exhaust

CO

Level

·Exhaust

Elbow

Exhaust

System

·Exhaust

System

Fuel

Filter

and

Fuel

Filter

Inlet

Generator

Hoses

Spark

Plugs Vibration Zinc

I

EVERY

Isolators/Engine

Anode

500

MAINTENANCE

OPERATING

Back

O-Rings

OPERATING

HOURS

Pressure

Mounts

HOURS

OR

YEARLY

OR

YEARLY

MAINTENANCE

EXPLANATION

SCHEDULE

OF

SCHEDULED

(cant.)

Sample

exhaust

with

CO

Test

exhaust

elbow

for

Always

use a new

monoxide

Carefully

for

Perform increase load.

Remove Remove

Check See

Engine delaminated.

Replace Check

Remove

Replace

exposure!

inspect

carbon

and/or

back pressure

Correct

antr and

that

AC

GENERATOR

hoses

spark

vibration

and

gasket

structural

gasket.

for

leaks.

corrosion

pressure

test

above

as

needed.

replace

fuel

replace

inlet

connections

INFORMATION.

should

be

Check

and

plugs.

isolators,

replace

zinc

and

O-rings

analyzer.

NOTE:

Check

build

to

ensure

1.5

psi

filter

and

fuel

filter.

are

clean

firm

and

tighten

all

brackets

anode.

if

needed.

MAINTENANCE

integrity.

Replace

A

leaking

exhaust

anti-siphon

-up

or

41

all

tight.

hose

and

Open

on

inside

system

inches

sealing

and

secure.

Replace

clamps.

mounting

heat

valve

passages.

has

of

water

O-rings.

Ensure

if

hardware.

exchanger

if

elbow

operation.

not

developed

column

wires

hoses

become

end

is

corroded

or

gasket

Check

Clean

at

have

cap(s)

or

deteriorated.

can

cause

the

exhaust

and

replace

restrictions full

operating

no

chafing.

spongy,

brittle

and

clean

carbon

elbow

as

necessary.

that

will

amperage

or

out

debris.

Raw

Water

EVERY

Coolant

Engine

Valve

Clearances

Starter

Diverter

I

EVERY

'Engine

Heat

Exchanger

I

EVERY

·Oxygen

·Catalyst

Pump

500

OPERATING

System

Compression,

Motor

Valve

1000

Timing

2000

Sensor

Head

OPERATING

Belt

OPERATING

HOURS

Bolt

Torgue

HOURS

OR

and

OR

EVERY

TWO

FOUR

YEARS

Remove

the

and

for

leaks

flush

and

thermostat

valve

torque

and

published solenoid

pinion

and

the

engine.

the

and and

dual

replace

drive.

replace

heat

replace replace

Inspect

check

Drain, the

Incorrect bolt within

Check motor

Replace.

Remove

recommended

to

Remove

pumps.

Follow

any

worn

and

for

proper

re-fill

the

and clearance

adjust

and

interval

cooling

coolant

pressure

will

the

valve

specifications.

motor

for

the

timing

could

exchanger

exhaust

the

instructions parts. pumping

system

cap.

result

in

clearances.

corrosion.

belt.

NOTE:

result

in

for

professional

oxygen catalyst.

Lubricate,

action.

with

poor

engine

Check

Remove

Failure

timing

belt

cleaning

sensor.

Inspect

in

this

manual

reassemble

appropriate

performance.

that

the

and

lubricate.

to

replace

failure

resulting

and

every

and

disassemble

and

install.

antifreeze

compression

pressure

the

1,000

mix.

Check

Clean

timing

in

major

testing.

hours.

With

Replace

the

head

pressure

and

lubricate

belt

damage

both

engine

is

at

the

pumps.

running,

the

starter

*WESTERBEKE

be

performed

recommends

by

an

authorized

this

service

mechanic.

NOTE:

The operation

of

the unit's "SAFE be monitored at least once an operating season. This ensure that the system is operating properly. Free system diagnostic software is available

for

use with a laptop by

contacting your area Westerbeke Distributor.

Em:zines

& Generators

13

CO"

system must

is

to

ENGINE

LUBRICATING

DESCRIPTION

Use a

heavy

duty engine oil with

SL,

or

SM.

Change the engine oil and filter after

hours of break-in operation. Then follow the oil change '

interval

in this manual.

An oil viscosity

engine

Westerbeke Corporation the use break-in must be performed using conventional change intervals must be SCHEDULE section of synthetic oils

NOTE:

statements

CHANGING

The engine oil should from its attachment bracket and lower it into a container

as

specified in the MAINTENANCE SCHEDULE

in

all conditions,

of

synthetic

The

information

regarding

allow the oil hose

and

pump the old

is

properly secured

dr'

been

d

rune.

of

SAE-15W-40 is recommended for this

and

does

oils.

If

as

ibis manual and not be extended if

are

used.

'

above

synthetic

THE

ENGINE

be

warm.

to

drain, or attach a pump

oil

in

its holder after all of

an

API classification of

an

initial 50

all seasons.

not approve or disapprove

synthetic oils are

listed in the MAINTENANCE

supersedes all previous

oil.

used,

engine

oil.

Oil

OIL

Remove

out.

Make sure the oil drain

the

oil drain

to

the

end

of

the

old

Qil

~""!""".,,-

~':''''::

,-

'i.

hose

has

SJ,

and

drain

OIL

I;;nll.111:11111:1

When removing the used oil

ipunch

to

drain

to

lessen spillage. An automotive

helpful in removing and a plastic bag any

oil that's in the

removed

. off with the old oil

sealed against the oil filter installing the sealing surface

thin coat of clean engine oil

the

oil

and

tighten the filter

THE

OIL

FILTER

a hole in

the

filter.

the

upper and lower portion of

oil into a container before removing

the

old

around

the

filter.

to

make sure that the rubber sealing gasket

filter.

If

new

oil filter element, wipe the

on

the oil filter adapter free of oil

Screw

the

filter onto the threaded

firmly

SPIN-ON

.

OIL

PN#048078

filter,

you

may

find

it helpful

the

old

filter

it.

This

filter

wrench

oil

filter.

Place

filter

when

Inspect

the

old

this rubber sealing gasket remains

adapter,

gently remove

to

the

rubber sealing gasket

by

hand.

~hould

some

paper

unscrewing

oil

filter

oil

be

it

to

as

it

is

comes

it.

When

gasket's

and

apply a

filter

towels

stub,

FILTER

to

helps

catch

on

A

WARNING:

contaminants. and

nails

thllroughly discard used

Always observe emulsion indicates this condition prevent serious is of a fault in

a siphoning through the water cooling circuit into exhaust,

oil

present

clothing

properly.

in

filling

Used

engine

Avoid

prolonged using

soap

or

rags

containing

the

old oil

as

it

the

presence of water

is

rare,

it

does

require prompt attention

damage.

the

oil.

the

exhaust system attached

it

Call a competent mechanic if water

Water

present

up

into

the

engine.

oil

contains

skin

and

is

removed. A yellow/gray

in

the oil can

contact. water.

used

oil.

in

the

to

the

harmful

Launder

oil.

engine and/or

Clean

skin

or

Discard

Although

to

be

the result

the

NOTE:

Use

genuine WESTERBEKE

are

not

recommended.

REFILLING

Add

fresh oil through

run

the oil pressure. Make sure there oil

filter

engine

or from

THE

for a few

the

OIL

SUMP

the

oil drain

'

valve

moments

oil

cover.

while

is

no

leakage around

system.

filters.

Genericfilters

After refilling

checking

the

engine's

the

new

oil,

OVER-FILLING

CAUTION:

unintentionally

After shutdown, the oil in the engines internal

.

linger and take a number of hours sump. the

sump before checking the dipstick. An overnight period

will provide (Re-starting the engine

internal passages Over-filling the engine's sump

and/or a smokey white possible

The

oil

be

over-filled!

Allow at least a

an

even more accurate dipstick

are

no

start.

sump

on

this generator's engine

to

drain back into

few

hours

for

the

oil

is

not a problem

well

lubricated).

will

oil

laden exhaust, hard starting

as

result in erratic operation,

passages

the

to

settle back into

reading.

the

engine's

can

oil

and

Engines & Generators

14

FUEL

SYSTEM

GASOLINE

Use only unleaded gasoline higher. Higher octane is recommended. octane gasoline will affect engine performance adversely. Ethanol

NOTE:

fume detector/alarm properly installed and working.

blend

must

not

The

generator compartment should have a gasoline

GASOLlNEJWATER

A primary fuel filter

must

type and the engine to remove water and contaminant's from the fuel before they can be

Most separator with the installation package as they are aware contaminant's in the fuel can cause.

These gasoline filters must have (not requirements. valves to use impurities.

smaller. .

be

carried to the fuel system

installers include a type

"Set;-through") to meet

This

of

installed between the fuel tank

of

the problems that

The

metal bowls have drain

when

ctJ,eckiI).g

fIlter

with

an

octane rating

exceed

SEPARATOR

the water separating

E 1

o.

on

the engine.

of

filter/water.

AND

oth,er

metal bowls

U.s.

Coats Guard

(or

water and

rating

must

be

The

use

TYPICAL FILTER/WATER

,

SEPARATOR

iOmicrons

of

89

lower

or

FUEL

ENGINE

Periodically check the fuel connections and the bowl for leakage. Replace the filter element after the first then follow the

Changing

1. Shut the fuel

2. Ensure system fuel pressure is at zero. Bleed

3.

4. Replace the sealing

5.

FUEL

FILTER

50

hours

MAINTENANCE SCHEDULE.

Filter

Element

sUDply

to the generator off.

off

the

system pressure using a Schrader valve located on the injector throttle body. as high as 45 and catch

Unscrew the fuel bowl from the housing and pull the filter element down and off. Use care to catch any fuel

may

that

and thread on the fuel bowl then tighten

Open the fuel supply to the generator and start the unit.

Ensure that there are no leaks.

A

WARNING:

Use

extreme

PSI or more. Use towels to wrap the valve

or

subdue any fuel spray.

be

present.

care

Use extreme care as pressure maybe

"0"

ring. Install the new filter element

by

hand.

Fuel

is

present

in

the

hosing

toprevent"spiUage

and

lines.

FUEL

PUMP

Periodically

make sure that

and

are tight and maintenance free.

INLET

To ensure clean fuel into the fuel lift pump, there is a small in-line fuel filter connected to the fuel module. This filter should

1. Shut

fuel supply line to from the pump inlet. Take care to catch any fuel that may be

2. Thread fuel supply line. Use care when connecting and tightening the fuel supply line so as not to distort the inlet filter.

3.

Tum generator. Ensure that there are no leaks.

ch~k

the fuel conriections to and out

'no

leakage is present and that the fittings

secUre.

The engine mounted fuel pump is

FUEL

LIFT

thdnlet

PUMP

of

operation.

filter and unscrew the filter

PN#045354

FUEL

FILTER

be replaced every 250 hours

off

the fuel supply to the generator. Disconnect the

present.

on

the replacement inlet filter and connect the

on

the fuel supply to the generator and start the

of

the pump

FUEL MODULE

ENGINE

FUEL FILTER·

PRE·FILL

WITH

FRESH

FUEL,

AWARNING:

servicing

that

Dr serviCing. servicing

may

other

the

fuel

spill.

DO

sources

Ensur"

the

fuel

Shut

otr

system.

NOT

of

fire

proper

system.

the'tuel

Take

allow

any

near

the

ventilation

LUBRICATE

CLEAN PRESS

.

ON

OVER

valve

care

in

catching

smoking,

fuel

system

exists

FUEL

THE

at

WITI;I

AND

FILTER

THE.

the

tank

open

when

a-RING

when

any

fuel

flames

Engines & Generators

15

COOLING

SYSTEM

FRESH

Fresh water (antifreeze) belt driven circulating Some of circulation exchanger. The engine operating temperature rises

thermostat reacts

coolant

opening operating flow

ENGINE

WESTERBEKE recommends a mixture of

and chemicals that can corrode internal engine surfaces.

The antifreeze performs a double run

the engine

ing circuit

. antifreeze that contains Supplemental Cooling Additives

(SCAs) to

NOTE:

antifreeze

WATER

the

coolant by-passes

in

the

engine

to

flow

through

will

change

tymperature

through

it.

COOLANT

50%

distilled

at

proper temperatures

to

the coolant and lubricates and protects

from

rust and

that keep

long

term

protection.

Look for

that

is

the

now

COOLING

to

this

as

water.

the

new environmentally friendly

CIRCUIT

is

moved through the engine

pump,

absorbing heat

the

thermostat

and

is

drawn through

and

starts

to

open allowing

the

heat exchanger.

it

gains

control of

by

allowing more or less coolant

Distilled water

duty.

by

transferring heat

corrosiol1.

antifreeze chemically balanced, crucial

available.

Look for a good quality

from

the

to

maintain

the

heat

The

thermostat

the

engine

50%

antifreeze

is

free

from the

It

allows the engine

away

long

by

engine.

and

more

from

the

a

the

to

cook

lasting

NOTE:

Periodically check

Ensure

that

rhe

upper and lower rubber seals condition tightly.

CHANGING

The engine's coolant must be changed according

MAINTENANCE

become contaminated, it can lead

A

and check that

Carry a spare

COOLANT

SCHEDULE.

CAUTION:

critical; a substantial traced

back

to

cooling

Drain the engine coolant by loosening

heat exchanger and bleed petcock on

the

conditiQn

the

vacuum

cap.

PrDper

cooling

number

system

opel1ing

the

pressure

top of the heat exchanger

valve

If

the coolant to

overheating

system

of

engine

corrosion.

cap.

of

the

pressure

are

opens

is

maintenance

failures

the

drain plug

Also

cap.

in

good

and

closes

to

the

allowed

to

problems.

is

can

be

on

the

loosen the air

The recommended 50/50 mixture

against the most extreme temperature. The antifreeze will

also

retard rust within the engine and

the

circulating pump impeller and

A proper 50/50 mixture

engine coolant

The coolant recovery tank allows for the expansion and

traction of out introducing air into the system. This recovery provided anomust be installed

NOTE:

171is

located

to

the

engines coolant during engine operation

tank,

at

or

above

as

temperatures of -

with

its

sltort

the

level

will

protect

the

engine

miXture

add

to

the life of

seals.

recommended will protect the

4O"F.

tank

oefore

of

run

the

operating the

oJ

plastIC

engine:r

hose,

manifold.

engine.

is

best

con-

with-

is

A

CAUTION:

down

before

the

surface

can

be

at

Refilling

After coolant the the housing.

Monitor the from install

Remove coolant mix

the flow stat housing

After checking for leaks, stop cool. the needed.

the

closing

into the manifold manifold, start air

bleed

the

manifold

the

petcock

the

pressure

the

cap.

Run

into

the

Coolant should

engine cools

Clean

The

engine

attempting

of

the

0

190

F.

these

engine

Coolant

the

engine block drain, pour clean, premixed

and

the

engine

petcocks

coolant

to

cap to

the recovery

is

on

the manifold

in

the manifold

the filler neck and

is

free

of

cap.

on

the

coolant recovery tank

halfway between

engine and observe the coolant expansion

tank.

free

of air bubbles, close that petcock.

draw

down.

Add

up

any

spilled coolant.

must

be

allowed

procedures.

hot

but

coolant

when

the

coolant

and

run

it

at

and

when

air

bubbles,

When the petcock

the'

back into the cooling system

coolant

LOW

generator

to

clo.se

and

the

to

cool

Not

only

temperatures

is

visible

slow

idle.

the

thermostat

add

as

needed.

the

coolant

the

petcock

and

fill

MAX

and

on

the

and

allow

recovery

Open

flowing

with

thermo-

tank if

is

in

Fill

and

replace

it to

as

Engines & Generators

16

COOLING

THERMOSTAT

A thennostat, located in the coolant filler cap housing (illustrated below), controls the coolant's temperature by allowing more or less coolant through it to the engine's heat exchanger. When the engine is first started, the closed thennostat prevents coolant from flowing through it to the heat exchanger. hose

on

the sump plate to the exchanger. This provides for coolant circulation in the engine and for coolant temperature rise. As the coolant

of

the engine operating temperature by allowing more

coolant flow to the exchanger. The thennostat is accessible

and can be replaced easily. Carry a spare thennostat and

housing gasket.

Some coolant is by-passed via a by-pass

wanns

up, the thennostat gains control

or

less

SYSTEM

TO EXHAUST

~::k-----'-

~t::J1'(------RAW

COOLANT

WATER

DRAIN

COOLED

Replacing

Remove the cap screws and disasseinble the thennostat housing as shown. When installing the new thennostat and gasket, apply a thin coat gasket before pressing

Run the engine and check for nonnal temperatures and that

there are no leaks around the thennostat housing/gasket.

~~".v.

~

/~

THERMOSTAT

#048157

,GASKET

ADD

AT

#048150

the

'~

SEALANT

ASSEMBLY

Thermostat

of

sealant

it

into place.

.-

on

both sides

of

the -

/TOCOOLANT

l'RECOVER

::.JANK

...

(":

THERMOSTAT ASSEMBLY

HEAT

EXCHANGER

Cool raw water flows through the inner tubes exchanger. As the engine coolant passes around these tubes, the heat which is then pumped into the exhaust system and discharged. The engine coolant (now cooled) flows back through the engine and the circuit repeats itself.

The other; this keeps the engine's water passages clean from the harmful deposits found in raw water.

Heat

After approximately 1000 hours and pressure test the engine's heat exchanger. (A local

automotive radiator shop should be able to clean and test the

heat exchanger.)

of

the internal engine is conducted to the raw water

engine coolant and raw water are independent

Exchanger

Service

of

operation, remove, clean

of

the heat

of

each

ZINC

ANO'DE

A zinc anode,

circuit within the heat exchanger. The purpose

anode is to sacrifice itself to electrolysis action taking place in the raw water cooling circuit, thereby reducing the effects of

electrolysis on other components condition the anode cleaned should be carried

NOTE:

and

vessel location; not that

If

the zinc pencil needs replacement, hold the hex boss into

which the zinc pencil is threaded with a wrench while loosening the anode with another wrench. This prevents the hex boss from possibly tearing off the exchanger shell. After removing the zinc, note the condition poor condition, there are probably zinc flakes within the exchanger. Remove the end the inside exchanger end gasket in case the present one becomes

damaged when removing the end cover. Replace the gasket (refer to your engine model's heat exchanger end gasket part number), o-ring, cover, and install a new zinc anode.

NOTE:

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

or

pencil, is located in the raw water cooling

of

the system. The

of

the zinc anode should be checlq!d monthly and

or

replaced as required. Spare anodes

on

board.

Electrolysis is the result

NEW

of

all zinc debris. Always have a spare heat

The threads

of

the zinc anodes are pipe threads

of

each particular installation

of

the engine.

REPLACE

of

the heat exchanger and clean

CLEAN & REUSE

of

it.

If

of

the heat exchanger

on

the zinc.

of

the zinc

the zinc is in

and

do

NOTE:

Operating in silty and/or tropical waters may require

that a heat exchanger cleaning be performedmore often than every

1000 hours.

~

WESTERBEKE

Engines & Generators

17

COOLING

SYSTEM I WATER

PUMPS

DESCRIPTION

The fresh water cooling system has the raw water pump mounted above the fresh water (coolant) pump as illustrated. These pumps are self-priming, rotary pumps, with non-ferrous housings and Neoprene impellers. The impellers have flexible blades that wipe against a curved cam plate within the impeller housing, producing the pumping action.

These

pumps

can

not

be

allowed

always be a spare impeller and impeller cover gasket aboard (an impeller kit). Water pump impeller failures occur when lubricant (water) is not present during engine operation. Such failures are not warrantable, and operators are cautioned to make sure water flow is present at start-up. Water pumps should be inspected blades. See

NOTE:

(seals

MAINTENANCE

Should a failure occur

and bearings) it

a new pump and rebuild

PUMP

INSPECT SURFACE

IMPELLER

FIT INTO

WHEN

THE WITH

periixlically for broken or tom impeller

may

the

COVER

THE

INSIDE

FOR

WEAR.

THE

HUB

SCREW

THE

SHAFT

SLOT

ASSEMBLlNG,COAT

IMPELLER

GLYCERIN

AND

to

run

SCHEDULE. with

the

be

more

cost efficient

original pump

O-RING

dry.

There should

pumps internal parts

to

purchase

as a spare.

CHANGING

Remove the cover screws and the cover will separate the

upper pump (raw water) from the fresh water (coolant) pump

as shown in the illustration. Close the raw water thru hull

seacock. This will prevent water syphoning out

while the impeller is being changed.

1. Remove the wear plate to expose the impeller. Notice the direction the impeller blades are working in so as to install the replacement impeller with blades working in the same direction.

.2.

Using pliers, grab the impeller hub and withdraw the impeller from the pump. Inspect the inside the cam, the inner wear plate, and the inside surface cover plate for wear. Replace any worn components.

3. Wipe the inside surface glycerin supplied in the impeller kit to the inside pump surfaces and to the exposed area

4. Install the new impellers with a rotating motion so the blades are working in the same direction as those removed impeller.

5. Apply glycerin to the O-ring, impeller, gasket, the wear plate and assemble into the pump housing. Reassemble the upper pump (raw water) making certain the fasteners

are tight. Re-install any hoses that were removed.

6. Run the engine to make certain both pumps are operating properly. The engine should run at proper temperature. raw water should discharge from the exhaust and there

should not

THE

WATER

be

any leaks around the pumps.

PUMP

of

the pump dry. Apply a film

IMPELLERS

of

the pump

of

the pump,

of

the shaft lip seal.

of

the

WIPE

THIS

BEFORE

INSTALi.JNG

COVER

,

SURFACE

CLEAN

THE

r..J~---THIS

DRAIN

TUBE

SHOULD A PUMP

DRAIN

LEAK

TO

DRAIN

UNII

KEEP

.

OF

OBSTRUCTIONS.

TUBE

THIS

A

WARNING:

sure

that

the

after

engine

and

couect

To increase the service life

them in the pump

. longer than 3 months. Store the impellers in a dark, cool, and

dry location. Replace the cover plate on the pumps securely

and ensure the

SHAFT

WILL

AWAY

TUBE

WATER

A water intake strainer (raw water) is a required component when the generator is installed. Refer to the previous page for details.

SEAL

ALLOW

FROM

CLEAR

INII'KE

LEAK,

THE

When

the

engine

pumps

are

pumping

start.

If

not,

"stop"

the

problem.

of

if

the engine will

thru hull seacock is closed.

within

the

the impeller, do not install

be

STRAINER

INCOMING RAW

WATER

SEACOCK

~

TYPICAL

RAW

(OWNER

INSTALLED)

is

started,

30

seconds

engine

in storage for

WATER

STRAINER

INSPECT CLEAN

100

make

at

once

EVERY

HOURS

AND

Engines & Generators

18

DC

CIRCUIT

/BATTERY

DESCRIPTION

The

DC

Circuit functions to start, operate and stop the generator's engine. The circuit is best understood by reviewing the DC Wiring Diagram and Wiring Schematic. The engine's DC wiring is designed with three simple basic circuits: start, run, and stop.

The engine has a 12 volt

shown on the Wiring Diagrams. Refer to these diagrams when troubleshooting or when servicing the DC electrical system on the engine.

A

CAUTION:

circuit,

the

however,

engine's

never

engine

to

electrical

shut

is

running.

avoid

To

avoid

off

the Shut

electrical

circuit.

DC

electrical control circuit that is

damage

engine

off

the

shorts

to

the

battery

engine

when

battery

switch

battery

working

charging

while

switch,

on

the

Specifications

The minimum recommended capacity used

in the engine's 12 volt

Battery

The engine supplies a continuous 6 amp charge from the voltage regulator to the engine's battery. This charge passes thru an 8 amp fuse (and the ships battery switch).

Charging

DC

Circuit

of

the dedicated battery

control circuit is 600-900 CCA.

Testing

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

Battery

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

• Check the electrolyte level and specific gravity with a

• Use only distilled water to bring electrolytes to a proper

• Make certain that battery cable connections are clean and

• Keep your batteries clean and free

the

Circuit

the battery is not charging, check the fuse.

If

only battery voltage is

Maintenance

hydrometer.

level.

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

of

corrosion.

To

test the

SHORE

If

the installer connects shore power to the vessel's AC circuit, this must be done Transfer diagrams to the simultaneous connection

Shore Power Transfer Switches are available from your WESTERBEKE dealer.

Switch. Set the transfer switch shown in the

OFF

Generator

~.

1-

'------

~

Shore

SINGLE

'iii

r;

~

z

.".'

Power

i

\CjJ

1

by

means

of

the Shore Power

position. This switch prevents

of

shore power to generator output.

LINE

120

VOLT

1'''--

.....

Gl

®\

®/

,--_

.....

/--

..... , -----..L1}

~

C+-:

-+~~eutraI\¥l'Hl)~·_N.Ship"Load

,-_.,/

Ground

(GRN)

I"

POWER

SYSTEM

~~~40.Volt

equipment.

TRANSFER

A

CAUTION:

utility

shore

at

the

same

Engines

covered responsibility correct.

& Generators

under

enerato1"

Ground

r----r------~:J

l

L1

Shore

SWITCH

Damage power time.

the

to

make

N

'-:-(NCO"e-u-tr-'al~)

,-------\-(77J

N J

r

Power

230

to

the

generator

and

generator

This

type

warranty;

sure

L1

1j

Generator/Shore

.!l

Switch

III

...

" ,

,

, ,

,

,_

+-,

/(o;)-~

, '

... _

_

Shore

-

Ground

VOLT/50

of

generator

it

is

the

all

AC

-,

~L1

2,

.-

...

0':

...

HERTZ

output

installer's

connections

lWO

can

result

are

connected

damage

is

are

Shlp-To-Shore

Shlp's

LOAD

N

Shlp's

Ground

WIRE

CONFIGURATION

if

not

.

Switch

SYSTEM

19

ENGINE

COMPONENTS:

SPARK

The spark

first

thereafter

SPARK SPARK

NOTE:

the spark plugs

of

PLUGS

plugs

50

hour break-in period,

and

replaced

A

WARNING:

the

engine

is

hot.

removing

the

them.

PLUG

GAP:

0.032 -0.035io.

PLUG

TORQUE:

Loctite Anti-Seize applied

will

spark plugs

INSPECT

FOR

WEAR & CARBON

INSPECTl.NG

THE

SPARK

PLUGS

should be cleaned

then

as

needed.

Do

not

remove

Allow

the

engine

(0.8 -0.9mm).

11

-15Ib-ft

(15 -26

to

retard

corrosion,

easier.

t

GAP

~i

I

_~~

and

re-gapped after

inspected

the

every

spark

to

cool

Nm).

threaded portion

making

./

__ / DAMAGE

'"----CHECK

the

250

hours

plugs

while

before

of

future

removal

INSPECT

DETERIORATION

AND

FOR

DAMAGE

CAM

LOCATED

FLYWHEEL

ON

HOUSING

SENSOR

TOP

OF

THE

\

'=-::::::1'1-""

THE

AIR

SCREEN CLEANED HOURS 100 WITH A WATER

SUCH

AFTER

OF

HOURS

AS

GUNK.

OPERATING.

FROM

AIR

SCREEN

SHOULD

THE

FIRST

AND

THEN

ON.

SOLUBLE

BE

50

EACH

CLEAN

CLEANER

ECU

(ELECTRONIC

CONTROL

UNIT)

Engines & Generators

20

CONTROL

PANEL

HOURMETER

FAULT

LEOS

START/STOP

ROCKER

20A

CIRCUIT

BREAKER

8A

FUSE

MAIN

CIRCUIT

BREAKER

SWITCH

ENGINE

ADJUSTMENTS

ADJUSTING

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

The belt tension can be checked by measuring the

spring length.

The Idler ArmISpring should not

118-3116 Excessive Idler bounce can be caused by insufficient drive

belt tension. Operating with an insufficient drive belt tension

and Idler bounce can result in premature drive belt wear and resulting failure.

THE

DRIVE

of

an inch during nirmal, steady state operation.

1/8"

BELT

1-1/8in

10(

Q

HOL

. l

be

tight).

.

..

(28.57mm)

·1

~c=~

BOUNCE

"I

more than

II

. .

:;

~~.

R

J

BELT

ASSEMBLY

(viewed from underneath)

IT

IS

NORMAL

DUST

ENGINE

COVER

OIL

PRESSURE

The lubricating system is a pressure feeding system using an oil pump. The engine oil is drawn from the oil sump by the oil pump, which drives the oil, under pressure, through the oil filter and various lubricating parts in the engine. The oil then returns to the oil sump to repeat the continuous cycle. When the oil pressure exceeds the specified pushes open the relief valve in the oil pump and returns to the oil sump, keeping the oil pressure within it's specified range.

NOTE:

pressure pressure

on

the

A newly starter

up

to

40

as

low

load placed

(cold)

psi.

A warmed engine

as

30

psi.

Oil

on

the

generator.

engine

may

pressure will

FOR

TO

ACCUMULATE

PAN,

SIMPLY

pressUre, the oil

have

an

can

have

vary

SOME

BELT

IN

THE

WIPE

CLEAN

oil

an

oil

depending

TESTING

To test mechanical oil pressure gauge, in it's place, it

necessary to engine to run. After warming up the engine, with speed at 2200 rpm, read the oil pressure gauge.

OIL

PRESSURE

the,

oil pressure, remove the oil switch and install a

cOl.1nect

PRESSURE:

between

the two switch wires together for the

30

and

40

psi

at

2200

rpm

MECHANICAL PRESSURE

OIL

GAUGE

win

b,e

the engine

Engines & Generators

21

ENGINE

ADJUSTMENTS

ENGINE

To

COMPRESSION

TEST

check the engine's compression pressure, warm up the

engine, then shut it down.

1. Remove both spark plug caps and both spark plugs.

2. Install a compression adapter and gauge in a spark plug hole.

3. Close the thru hull valve (seacock).

4. Crank the engine several times quickly so that the gauge

pointer reaches it's maximum.

STANDARD

71

COMPRESSION

PSI

(5± 1 Kg/cm')

PRESSURE

(D.4±

D.1

MPa)

AT

5DD

RPM:

5. Test the compression pressure on the other cylinder.

If

either cylinder is below the standard

of

small amount

engine oil through the spark plug hole

try

adding a

and repeat the test. (a)

If

additional oil causes an increase

of

pressure, the piston ring and/or cylinder may be worn or

damaged.

(b)

If

additional oil does not increase compression pressure suspect poor valve contact, valve seizure or

valve wear.

6. Reinstall the two plugs, connect the wires and open the thru hull valve (seacock).

WATER

To

PUMP

BELT

remove, replace or adjust the belt, loosen the pivot bolt

and release the adjusting bolt. Slide the water pump bracket

to slacken the belt for removal. When replacing and adjusting the belt, set the belt very tight and tighten the bolt

and nut.

WATER

PUMP

~_

BRACKET

___

_

ADJUSTING

,-=,

1':::-.---""

~<l"Ii(/LY

BOLT

PIVOT

- I

~

BOLT

I

'~

'

__

REMOTE

OIL

FILTER

INSTALLATION

This popular accessory is used to relocate the engine's oil filter from the engine to a more convenient location such

an engine room bulkhead.

NOTE:

Refer to ENGINE OIL CHANGE in this manual

instructions on removing the oil filter.

A

CAUTION:

rectly.

If

pass

valve

from

reaching failure. imnledJratelvand

If

the

oil

in

the

there'is

.It

is

vital

to

install

flows

in

the

reverse

filter

assembly

engine

causing

no

oil

pressure

check

the

hose

"'-~~--'APPI

Y A INSTALLING TIGHTEN CONTACTS

the

direction,

will

an

reading,

connections.

THIN

COAT

THIS

AN

ADDITIONAL

THE

oil

lines

prevent

internal

shutdown

OF

CLEAN

KIT.

THREAD

3/4

BASE.

cor-

the

by-

the

oil

engine

OIL

TO

THE

KIT

DN.

TURN

AFTER

for

as

O·RING

THEN

THE

O·RING

(OPTIONAL)

To

install, simply remove the engine oil filter and thread on

WESTERBEKE's remote oil filter kit as shown. Always

install this kit with the oil filter facing

Contact your WESTERBEKE dealer for more information

NOTE:

Westerbeke is not responsible

incorrect installation

WHEN

HAND

of

the Remote Oil Filter.

FASTEN

(SCREWS

down

for

engine failure due to

SECURELY

TO A BULKHEAD

ARE

OWNER

SUPPLIED)

as

illustrated.

NOTE

THE

"IN"

AND

ON

THE REMOVED WILL

BE

"OUT"

AOAPTER

WHEN

FOR

~ECONNECTED

THE

INSTALLATION

CORRECTLY

HOSES

SO

THEY

ARE

Engines & Generators

22

. -

APPLY A THIN GASKET

WHEN

CONTACTS

THE

3/4

TURN.

COAT

OF

CLEAN

INSTALLING.

BASE.

TIGHTEN

OIL

AFTER

IT

TO

THE

FILTER

THE

FILTER

AN

ADDITIONAL

ENGINE

NOTE:

WESTERBEKE

adjustments

be

peifonned by a competent engine mechanic.

infonnation below

VALVE

It

the first fifty hours must be performed when the engine is cool and the piston must be the top dead center Perform the following adjustment steps:

1.

2. Remove the cylinder head cover.

CLEARANCE

is routine maintenance to adjust the valve clearance after

of

operation. Valve clearance adjustment

of

the compression stroke.

Remove the fuel pump and filter assembly from the cylinder head cover. Unbolt the coil and move it out the way. This should give good access behind the covet.

to

the valves

recommends

is

provided

of

ADJUSTMENTS

that

the

following engine

to

assist

the

mechanic.

EXHAUST SIDE

ADJUSTING

FEELER

7. Adjust the intake and exhaust valve clearance for cylinder

#2 using the same sequence.

NOTE:

When

loosening and tightening

the

adjusting screw

vent it from

moving.

with a valve

The

VALVES CYL.

'1

~f;6'-j~:::J#=:::::::1

INTAKE

SIDE

SCREW

GAUGE

the

lock

nut,

hold

clearance driver

to

pre

3. Remove the flywheel 'cover to access the flywheel driven pulley.

4. Tum the driven gear and align the driven pulley with the

"v'"

"I

and

0"

mark on the

mark on the cylinder head.

~hO:02

FLYWHEEL

5. Adjust the intake and exhaust valve clearance for cylinder a. Loosen the lock nut. b.

Insert a feeler gauge between the valve end and the

adjusting screw.

the

c. Set

VALVE

CLEARANCE:

INTAKE:

0.13 -o.17mm

E

EXHAUST:

d; Tighten the lock nut. e. Again, check the valve clearance.

6.

Tum the driven gear and align the "2 and driven pulley with

~

#1.

valve clearance by the adjusting screw.

0.18 -0.22mm

~

(0.005 -0.007in)

(0.007 -0.009in)

the"

V" mark on the cylinder pead.

VMAAK

0"

and

-

mark on the

VALVE CLEARANCE DRIVER

8. Install the cylinder head cover. Apply sealant to the inside of

the cover as indicated

rim drawing.

BOLT

TORQUE:

8 -10

Nm

(0.8

-1.0

kg-m)

9. Install the flywheel cover and re-attach any wires removed.

SEAL

WITH

BLACK

5.8

-7.2Ib.-ft

THIS LOCTITE

by

the shaded area

AREA

SILICONE

TIGHTEN PER

LOCKNUT

4.4-5.8

FT-LB

TORQUE

(0.6-0.8

of

the

KG-M)

Engines & Generators

23

ENGINE

ADJUSTMENTS

INSPECTIONJREPLACING

If

cracks,

wear,

lengthening

replace

LIMIT PUSHING

Replacement

1.

2.

3. Remove

4. Install the timing belt

NOTE:

"0"

block. Please confirm that the "1 & on the driven pulley are aligned with the

the

timing

belt.

OF

ELONGATION:

WITH

Remove

a .. Spark

b. Recoil starter

c. Magneto

d. Alternator assembly

e.

Alternator bracket

Thrn

the

pulley

and

After installing the timing belt, when the aligning

mark on the drive pulley with

cylinder head.

MORE

YOUR

FINGER

of

the

parts

plugs

flywheel

crankshaft

the

"0"

the

timing belt

THAN

Timing

in

the

cup

and

mark

from

OF

THE

or

otht!r

damage

10mm

(0.4

Belt

following

align

on

from

order:

"0"

the

cylinder

the

driven pulley

the drive pulley

"0"

0"

TIMING

IN)

mark

BELT

is

found,

DEFLECTION

on

on the cylinder

or

"2 &

"\1" mark on the

the

head.

side.

0"

BY

drive

side.

mark

o

NOTE:

Always keep the timing belt away from any oil

grease.

DRIVEN

PULLEY

TIMING

BELT

and

ALTERNATOR

BRACKET

Engines & Generators

24

FUEL

SYSTEM

PURGE

LINE

TO

CONTAINER

BLEEDING

THE

FUEL

SYSTEM

UNPLUG

THE

ELECTRICAL

FUEL MODULE DISCONNECT

HARNESS

NOTE:

The following procedure ever the least once a season to ensure that any air that may have entered the

fuel

system is serviced (filter changes, etc)

fuel

system is dispelled.

must

be performed when

and

at

INSTRUCTIONS

1. Connect a Snap On MT337B, OTC 7211 or equivalent

fuel bleed/pressure gauge set to the schrader valve on the fuel rail at the injectors and direct its purge line into a container.

2. Unplug the electrical harness attached to the fuel modulel.

Shut the thru-hull that supplies sea water to the unit.

3. Disconnect the coil wire from the coil so the engine will

not attempt to start.

4. Close the raw water thru-hull that supplies the generator.

Put the generator through two to three crank cycles and monitor the purge line going into the container. When

.airaled fuel is seen tlowing through this hose into the con-

tainer, stop initiating crank cycles.

crank without starting

You

stop. the

fault light,. The underspeed LED will flash. Reset the

ECU amp

will be able to initiate three start cycles before

ECU

will terminate a start cycle and trigger an LED

to remove the fault by opening and closing the 20

DC

breaker on the control panel.

for

approximately 8 seconds then

NOTE:

The unit will

TO

INTAKE

MANIFOLD

5. Open the raw water thru-hull that supplies the generator. Reconnect the engine harness to the fuel module harness.

6. Close the valve to the purge line and depress the switch and hold it. Monitor pressure at the fuel rail. should reach approximately 40 psi. Release the STOP switch. Open the thru-hull that supplies sea water to the unit. Start the engine. Pressure should remain at approximately Connect a gauge set to the schrader valve on the fuel module. Purge air from the module while the engine running. Then connect the gauge set to the schrader valve on the fuel rail and purge any air from it while the engine is

running.

7. Stop the engine. Carefully release pressure at the fuel rail through the purge line and remove the tool from the schrader valve. Replace the cap on the valve.

8. Start the engine and check for any fuel leaks.

A

CAUTION:

not

allow

fire

near

tight

and

properly

39-40 psi while the engine is running.

Fuel

and

fuel

vapors

any

smoking,

the

fuel

free

of

dispose

open

system.

leaks.

Wipe

of

soiled

flames

be

certain

up

rags.

any

or

that

spilled

are

explosive!

other

fuel

STOP

It

source

lines

are

and

is

Do

of

Engines & Generators

25

RAW

WATER

DESCRIPTION

Coolant pumps while pump. mounts shaft that are

The following instructions apply

PUMP

(fresh.

water)

cooled generators have

the

raw

water

The pumps are essentially

to

the

top

of the lower

fits

into the shaft of

driven simultaneously

OVERHAUL

cooled

models

the

pump

the

lower

by

the

engines drive belt. to

either

same.

and

pump.

dual

use

a single water

The

upper

has a tang

Both pumps

pump:

water

on

pump

the

Disassembly

The pump

attachment nipple threaded into the inlet and outlet the the before starting

1.

Remove

sealing

Dual Remove the cover screws

upper pump. (raw water) from the fresh water (coolant) pump

Remove the wear plate to expose the impeller. Notice the direction the impeller blades are working in so as to install the replacement impeller with blades working in the same direction.

2.

Remove

hub

3. Remove place. remove the cam and inner wear

4.

Remove

Support

5. press of

6.

Remove the O-ring

7.

Support

bearing.

8.

Remove

when

pump

pump.

removed

along

with

remove

the

four cover plate

from

a drive pulley attached

these

attachments noting their positions

pump

disassembly.

O-ring.

Pumps

and

as shown in the illustration.

the

impeller

and

pulling it out of the pump with a twisting

the

screw

the

dust plate

the

pump

the

shaft and bearing assembly out of

the

pump.

using

and

sealing washer that hold

and

body

on

from

the

outer bearing

the

spacer and circlip .

the

engine

will

have

to

the

shaft of

screws,

the cover will separate the

cover plate,

a pair of pliers, grasping

the

plate

behind

circlip.

an

arbor

press

tlnd

with

the

pulley

the

shaft.

and

push

the

shaft out of

the

ports

and

the

motion.

cam

it.

a drift,

the

hose

of

in

end

PUMP

LIGHTLY

GREASE

CHAMBER

WITH

INSPECTION: EACH REPLACE ARE

ANY

INSPECT AND IF

ANY

OR

THE

PUMP

GLYCERIN

IMPELLER

CHECK

BLADE

BY

THE

IMPELLER

CRACKS,

THE

O-RING

IMPELLER.

SIGNS

TEARING

AT

BENDING

REPLACE

OF

WEAR

DUST PLATE

THE

BASE

OF

VIGOROUSLY.

IF

THERE

CIRCLIP

IMPELLER FITS

SHAFT

m,;;'~r,"":~

·,'"-""',=C"",,,,,

A

INTO

SHAFT

O-RING

INNER BEARING

SPACER

OUTER BEARING

CIRCLIP

C

Inspection

Inspect corrosion.

all

parts

and

replace those showing

wear

and

PULLEY

Engines & Generators

26

R4'assembly

Wipe

the

inside surface of glycerin supplied surfaces and to

1.

Install

the

push

the shaft into

the

circlip.

2.

Install

th.~.spacer

bearing

contacts

3.

Apply

in

the

crrclip shaft Support the outer

and

push

the

spacer.

some glycerin onto

shaft approximately

4.

Warming and press. assembly the Rotate

5.

Install circlip B

the

pump

bearing

assembly.

With

a twisting motion;·install

into the pump untilthe inner

outer bearing should just clear

the

shaft.

outer bearing just contacts circlip B plate.

Rotate

the

6.

Pu~

some glycerin

seat

and

sUde

it over the shaft

and

seat

it

in

the

on

the

inner area

the

shaft

until

the

white

7. Install S.

Install

ceramic

the the

face. brass plate wear

pin.

Dual Pumps

The

wear plate

is

assembled

the

pump

the

impeller kit

exposed area of

the

bearing until

against

the

shaft

into

the

1/S"

away

body

should aid in installing

Support the

It should turn

and

push

the shaft

shaft.

It should

on

the

outer surface of

body of

and

with

the

a twisting

ceramic of

and

circlip A.

plate,

locking it

above

dry;

Apply

to

the

insid~

the

shaft

lip

bearing

the

bearing

circlip. Support

the

bearing

O-ring

and

install

from

the

inner

pump

body

the

shaft

bearing

the

boss

freely.

assembly

and

install

turn

freely.

the

white

ceramic

pum,. Place

some

motion

the

spring

seal

in

position

the·

impeller.

RAW

WATER

a film of

pump

seal.

and

contacts

the

inner

until

it

on

bearing.

the

shaft

on

an

arbor

and

bearing

seats

and

for circlip

until

the

dust

ceramic

facing

out

glycerin

slide it over

touches

on

the

dowel

the

B.

seal

PUMP

UPPER PUMP

SHAFT

SC~EWS

FASTENS

THE

UPPERPIlMP

BODY

TO

LOWER

THE

PUMP

O-RING

ONLY

NEEDS REPLACES SIGNS

OF

AGING.

.

DUAL

PUMPS

ASSEMBLY

GASKET

TO

BE

IF

IT

SHOWS

9.

Install

the

threads of

lO.Place

some inner surface of and

with

of

the

pump.

secure

the

NOTE:

Install

blades

are

working

removed

impeller.

Dual Pumps Assemble

making

the

sure

cam

and place some gasket cement

the

screw that secures it in

glycerin

the

on

cover

the

inner surface of

and

the cover sealing

a twisting motion install

Install

the

covers O-ring

cover

With

the

four cover

the

new impellers

in

upper pump

the

mounting

the

with a rotating

same

direction

to

the

lower pump

screws

are

the

screws.

tight.

place.

the

impeller

and

cover

of

those

as

on

the

pump,

O-ring

on

the

and

motion

so

of

the

illustrated

the

shaft

the

PULLEY

Engines & Generators

27

ENGINE

TROUBLESHOOTING

The following troubleshooting chart describes certain problems and causes relating to engine service. Also note there is a Diagnostic Troubleshooting section that follows.

Problem

Engine

does

not

crank.

Engine

cranks,

does

not

start

(engine

will

crank 8 seconds)

Engine

starts,

runs

and

the

shuts

down.

Engine

hunts.

Engine

misfires/back

Engine

overheats/engine

Exhaust

temp

Low

oil

pressure/oil

No

DC

charge

LED

to

starting

firing.

temp

is

illuminated.

pressure

battery.

LED

is

illuminated.

is

illuminated.

Note:

When

servicing

the

engine/generator, breaker (control panel) disconnects all switched off and

Possible

1.

2.DC

3.K2

4.Starter

5.DC

6.Faulty

7.Water

1.Fuel

2.Air

3.Fouled

4.Faulty

1.Fuel

2.Air

3.Faulty

4.

1.Air

2.Faulty

3.Low

4.Faulty

1.Low

2.

3.Hign

4.

5.

6.

7.

1.

2.Coolant

3.Faulty

4.Pump

5.0bstructed

6.Stuck

1.

2.Faulty

1.0illevellow.

2.

3.

4.0il

1.Circuit

2.

3.Faulty

Cause

DC

panel

breaker

battery

OFF.

relay

faulty.

solenoid

battery

low/dead. starter filled

cylinder.

starvation.

in

fuel

system.

spark

ignition

starvation.

in

fuel

system.

shutdown

Faulty

fuel

pump.

in

fuel

system.

fuel

pump.

octane

MAG

octane

Dirty

air

intake

tension

Flywheel

loose.

Exhaust

restriction. Worn/fouled Faulty

ignition

Raw

water

coolant

level

impeller.

belt

loose/broken.

by-pass

thermostat.

Loss

of

coolant

exhaust

Faulty

oil

pressure

Faulty

oil

pressure

viscosity

fuse

faulty/blown.

Faulty

circuit

regulator.

fuel pick-up.

fuel

spark

incorrect.

plugs.

ignition

reset

OFF.

faulty.

solenoid.

coil.

switch/sensor.

(lower

than

(lower

than

screen

screen.

wires.

plug.

module.

obstruction.

low.

hose.

flow/faulty

temperature

sendor. switch.

connection.

manually.

89).

pump.

switch.

the

main circuit

AC power and

can

be

Engines & Generators

28

ENGINE

TROUBLESHOOTING

Starter

Poor

performance

Black

exhaust

Blue

exhaust

Check

engine

Speed

LED's

Pair

of

Exterior

stays

Speed

alarm

Problem

energized

at

generator

smoke.

LED's

are

illuminated-no

LED

LED's

LED

is

illuminated.

after

start.

speed.

illuminated.

flashing.

are

illuminated-flashing.

Possible

1.Faulty

2.Faulty

1.

2.Contaminated

1.

2.Generator

1.Lube

2.Crankcase

3.High

1.Diagnostic

1.Throttle

2.lntake

1.AC

2.Fuel

1.Loose

2.Faulty

Low

octane

Dirty

air

oil lube

generator

starvation.

Cause

K1

relay.

starter

solenoid.

fuel.

screen.

is

overfilled.

is

diluted. breather

oil

level.

software

shaft

sticking.

manifold

overload.

connection.

fire

suppression

fuel

pump.

vacuum

tube

is

clogged.

required.

leak.

shutdown

devise.

Engines & Generators

29

ENGINE

TROUBLESHOOTING/SOFTWARE

DIAGNOSTICS

PC

INTERFACE

The software generator. Contact your local WESTERBEKE distributor. The interface communication cable needed to connect. between the generator's purchased from the distributor cable pn#049998

ECU AND (cable pn#055351 USB to ECU).

to This Diagnostic Software

in monitoring the Low ECU (Electronic Control Unit) functions.

Once downloaded, this new improved software provides Idle Mode diagnostics, Failure Record and Run Time Data Logging to EXCEL.

SOFTWARE

is

available free

ECU and ones laptop must be

CO generator's operation and the

of

charge for the 3.5 SBCG

COM port

is

designed to aide the technician

LED

DISPLAY

D~agnostic

The and Wmdows 7 laptop. These must have a minimum

128 megabytes

communications cable plugs into a serial connection or a

USB port. When using serial to USB adapters, the commu?ication port that the adapter is using MUST be known m order to configure the Diagnostic Software.

The Westerbeke communication cable is unique to this

Diagnostic So.ftware to the ECU substituted. The Diagnostic Software is designed with multiple screens, tabs and pull down menues to aide the user in the diagnostic process.

The Diagnostic Software only so none

Software will run on Windows 98,

of

RAM (Random Access Memory). The

~d

must be used or otherwise damage

Will

occur

if

any communications cable

is

for monitoring

of

the values can be changed.

ONLY.

XP,

Vista

of

is

It is read

PANEL

Engines & Generators

30

SOFTWARE

DIAGNOST~CS

Engine

Engine In the

after the generator

shutdowns in the

IDLE

state is:-

state

only

is

IDLE

State

DC

Ambient

started, the

state, only warnings. Shutdowns can occur in both the CRANK

1 Engine Coolant Temp

Engine Coolant Temp

2

Engine Coolant Temp

3

Engine

4

External

5

Exhaust Temperature High

6

BatteryVoltage

7

Battery

8

~bient

9

Ambient

10

Ambient

11

Ambient

12

Oil

13

MAP Sensor Possible Fault

14

COoUmt

T~mp

Alarm

Low

Voltage

High

Air

Temp

Air

Temp

Air Temp

Air

Temp

Shorted

Open

Lqw

High

Pressure Sender Shorted

Warnings:

circuit breaker on, generator not running

Ail"·

CRANK

Shorted

Open

Low

High

Temperature

state and

Short

Short circuit (0 ohms)

Short circuit

MAP reading out of range

(

Low

an'dMAP

RUN

state warnings and shutdowns

Sensor

circuit (0 ohms)

Open

circuit

Reading less than

-2SoC

(-13°F)

Reading more than a faulty temperature sensor

9SoC

(203°F)

Open

circuit

Open

circuit

Less

than

11

volts

More than

Open

15

volts

circuit

Reading less than

-2SoC

(-13°F)

Reading more than

63°C

(145°F)

(0

ohms)

<10

kPa

or

>115

kPa)

Possible

a faulty temperature sensor o pinched or bare

a faulty a loose connection or corroded

a excessiyely cold weather a faulty temperature sensor

•

engine heat soak after normal shutdown

Fault are logged.

~d

wire

ECT

sensor

If

will

apply. There are

RUN

states.·

in harness

the fault persists

NO

wiring

• external alarm fault (i.e. Fireboy)

a loose connection or corroded,wirlng

• faulty exhaust temperature switch

a loose connection or corroded wiring a weak or dead

a blown fuse in charging circuit

• faulty regulator or charging circuit

• loose connection or corroded wiring

• faulty regulator or charging circuit

a faulty air temperature sensor

• pinched or bare wire in harness

• faulty

aiI;~emperature

sensor

• loose connection or corroded wiring

• excessively cold weather

• faulty air

a excessively hot weather a bilge venting system faulty or inadequate a engine heat soak after normal shutdown

t~mperature

sensor

• faulty temperature sensor

• faulty oil pressure sender or bare wire in harness

• faulty

a pinched or bare wire in harness o loose connection or corro'ded

MAP

sensor

wiring

Engines & Generators

31

ENGINE

TROUBLESHOOTING/SOFTWARE

DIAGNOSTICS

Engine

"Engine

CRANK State Shutdowns:

CRANK

state is -

DC

circuit breaker on, generator start switch has been pushed running speed yet. This state only lasts for a few seconds on a typical engine before the

RUN state.

In

the

CRANK

state, warnings are

not

indicated on

the

LED

display,

and

they are

logged.

Shutdo·wn

Cam Sensor failure

1

Description

Paralnelel's

No

CAM

speed sensor

signal detected by

ECU

o cam sensor adjusted improperly

-loose

connection

- sensor tip contaminated with

-faulty battery

o loose connection o fuel supply insufficient

- external alarm fault (i.e. Fireboy)

-loose

o faulty battery

connection

-faulty charging circuit

-blown

o loose connection o loose connection

o speed conditioning module faulty o sensor

. -

Out not

of

bled

fuse

tip

contaminated with

fuel

or

properly

Over-Crank Timeout

2

External Alarm

3

Battery Voltage

4

Speed Signal Not Detected

5

Low

Exceeds 8 second crank

duration

Open circuit

Less

than

8 volts

No speed signal detected

byECU

but

the

engine starts

not

logged.

Possible

or

fuel

system

engine is

All

not

up

and

transitions

shutdowns are

cause

corroded wiring

metal

corroded wiring

corroded wiring corroded wiring

metal

to

filings

6

MAP

Sensor Fault

MAP

«10

reading

kPa

or

out

>115

of

kPa)

range

-faulty

o pinched

o loose connection

MAP

or

sensor

bare

wire

in

harness

or

corrbded wiring

Engines & Generators

32

SOFTWARE

DIAGNOSTICS

Engine

Engine In the

RUN

state

all

State

is -DC

Warnings:

circuit breaker on, generator successfully started and running

warnings are logged and a light

will

be illuminated on the control panel. The light(s) will

when the warning condition is no longer present. Warnings will be indicated as

Oil

Pressure warnings illuminate

Engine Coolant Temperature warnings illuminate the ENGINE

Exhaust Temperature High illuminates the EXHAUST

the,

OIL

PRESSURE

light.

TEMP

light.

External Alarm warning .illuminates the EXT. ALARM light. OverSpeed and UnderSpeed warnings illuminate the pair of

All

other warnings illuminate the pair of

1

Engine Coolant Temp

~w

2 Engine Coolant Temp High

UnderSpeed

3

OverSpeed

4

OverLoad

5

Crank Sensor Possible Fault Internal

6

Oil

7

8

9

10

11

12

13

14

15

Pressure Sender Shorted

Oil

Pressure Sender Open

Oil

Pressure

BatteIyVoltage

Low

BatteIyVoltage High More than

Air

Temp

Ambient

Air

Ambient Air

Ambient

Air

Shorted

Temp

Open Open circuit

Temp

Low

Temp

High o bilge venting system faulty or inadequate

CHECK

ENGINE lights.

Reading less than o excessively cold weather

-25°C

(-13°F)

. Reading more than

95°C

(203°F) o engine heat soak after normal shutdown

Under

1760

seconds

Over

2375

rpm for 8+

seconds

Throttle wide open and

RPM

<2200

ECU.

Short circuit (0 ohms)

circuit

Open

,Re'ading

less than

for 5 sec

Less than 11 volts

Short circuit (0 ohms)

Reading less than

-25°C

(-13°F)

Reading more than

9::t~

(203°F)

-.v'

WESTERBEKE

Engines & Generators

SPEED

rpm for 8+

for

8+ sec

parameter

(00

ohms)

12

psi

15

volts

lights.

o faulty temperature sensor

o excessive load on generator

o

fuel

supply insufficient

o vacuum leak in intake manifold or hoses o throttle shaft sticking

o excessive load on generator

o loose connection or corroded wiring

.;

sensor tip contaminated with metal filings

o speed conditioning module faulty

o faulty oil pressure sender o pinched or bare wire in harness

o faulty oil pressure sender o loose connection or corroded wiring

o check oil level o insure proper oil viscosity

,0

check lubrication system for leaks

o blown fuse o dead batteIy

o faulty regulator or charging circuit o loose connection or corroded wiring

o faulty regulator or charging circuit

o faulty air temperature sensor

o pinched or bare wire in harness

o faulty air temperature sensor

o loose connection or corroded o excessively cold weather

o faulty air temperature sensor o excessively hot weather

o faulty temperature sensor

follows:

wiring

go

out

33

SOFTWARE

DIAGNOSTICS

Engine

Engine RUN state is In

the RUN state all shutdowns

shut

down

Oil

Pressure

Engine

RUN

State

DC

and

the light(s)

shutdowns illuminate

Coolant

Temperature shutdowns illuminate the ENGINE

Shutdowns:

circuit breaker on, generator successfully started and running

are

will

logged

stay

illuminated until the

the

and

a light

OIL

PRESSURE light.

Exhaust Temperature High shutdown illuminates External Alarm shutdown illuminates OverSpeed

All other shutdowns illuminate

1

2

3

4

5

6

7

8

9

10

11

and

UnderSpeed

shutdowns illuminate the pair

the

E~gine

Engine Coolant Temp

Coolant J'emp Shorted Short circuit (0 ohms)

Open

Engine Coolant Temp High

UnderSpeed

OverSpeed

Crank Sensor Fault

Signal Loss

Crank

Throttle Loss of Home

Oil Pressure Sender Shorted

Oil Pressure Sender Open

Oil Pressure

Low

the

EXT.

ALARM light.

pair

of

CHECK ENGINE lights.

.....

Open circuit

Reading more

lOO°C

Under

Over

1650 rpm for 8 sec

2680 rpm for 0.5 sec Over 2460 rpm for 1.0 sec Over 2530 rpm for 2;0 sec

Over

2420 rpm for 4.0 sec

Internal

speed signal intermittent

No speed signal

3+ seconds

Internal

Short

circuit (0 ohms)

circuit (00 ohms)

Open

Reading less than 8 psi for

will

the

EXHAUST

(212°F)

ECU

parameter,

ECU

parameter

5 sec

be

illuminated

12VDC

of

SPEED lights.

than

to

ECU for

on

the control panel. The

power to

TEMP

the

generator is cycled.

light.

TEMP

light.

o faulty temperature sensor o pinched

o faulty ECT sensor o loose connection

o faulty temperature sensor o engine heat soak after normal shutdown

o excessive load on generator

o fuel

or

bare wire in harness

or

corroded wiring

insufficient

• vacuum leak in intake manifold

generator

or

• throttle shaft sticking

o loose connection

o sensor tip contaminated with metal filings

o crank speed sensor faulty

o speed conditioning module faulty

o loose connection

o sensor tip contaminated with metal filings o crank speed sensor faulty

o speed conditioning module faulty

or

corroded wiring

or

corroded wiring

• throttle shaft sticking

• battery weak

o faulty oil pressure sender

• pinched

o faulty oil pressure sender o loose connection

o check oil level o insure o check lubrication system for leaks

or

bare

proper

wire

in

harness

or

corroded wiring

oil viscosity

will

hoses

be

Engines & Generators

34

SOFTWARE

DIAGNOSTICS·

Engine RUN State Shutdowns:

'Yarning

Battery Voltage

12

Exhaust Temperature High Open circuit

13

External Alarm Open circuit

14

Wideband

15

Reading

Wideband

16

Failure to Cross Stoich

Wideband

17

Heater failure

Description

Low

02

Sensor

Out of Table

02

Sensor

02

Sensor (WB02)

(WB02)

Parameters

Less

ECU

A <.70 or A > 2.00, which

is out of the table range

A reading not crossing

above

and below 1.=1.00 at

least once per minute

Heater current out of

normal range

C€ontinued

than 10 volts

measures

fro~

previous page)

Possible

o dead battery o blown o faulty regulator or charging circuit o loose connection or corroded wiring

o faulty exhaust temperature switch o loose connection or corroded wiring o seawater

o external alarm fault o loose connection or corroded wiring

o

o loose connection or corroded wiring

o

o dirty or

o insufficient fuel supply or pressure o loose connection or corroded wiring

o

fuse

flow

excessiyely

oxygen

sensor faulty

excessively

clogged

oxygen

sensor faulty

blocked

(i.e.

rich or lean combustion

rich

or

lean combustion

fuel

injectorCs)

cause

.

Fireboy)

Engines & Generators

35

REO

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Engines & Generators

36

WIRING

DIAGRAM

#54609

BLU-18GA

WHT/BLK/GRN-16GA

TAN-16GA

ORG-18GA

RElAY

BLK-16GA GRY -16GA

STEPPER-I

INJECTOR-I

WB02-4

KI-8S

BA

TT

.GND

K3-86

ECU

.....

12

~

.....

23

~

.....

~

0

'"

- -

'"

0

~ ~

'" '"

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-

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0 0

0

0 0

0

0 0

0

-0 0

0

-0,

13

I

COMPONENTS

,.,:~5

~

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~

'"

,..,

~

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0

24

INJECTOR.2

DC.PI-6

K3.85

WHT/BLK/RED-18G

GRN-18GA

WHT/BLK/BRN-

STEPPER-2

ISGA

STEPPER-4 STEPPER-3

A

K2-SS DC_PI-12 DC.PI-II DC.PI-IO DC.PI-9

BRN-18GA

WHT-18GA

YEL-ISGA WHT/RED-18GA WHT/BLK/BLU-20GA WHT/BLK/ORG-20GA WHT/BLK/GRY-20GA WHT/BLK/YEL-20GA

WHT/BLK/ORG-20GA WHT/BLK/RED-18GA

WHT/BRN-20GA

OP.SENDER-I

WHTlORG -20GA

WHT/VIO-18GA

WHT/GRY-18GA

FIRE.ALARM-2

PNK-18GA

WB02-6

MAP-3

MAP-4

CAM-2

DCPI-7

8

150

~

"

~

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~

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~

0

0 0

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16

WB02-2 WB02-1

ECT

- I

AIR.TEMP-I SPEED

MODULE-I

CAM-I

RED/V

WHT/BLK/VIO-20G GRN/YEL·20GA WHT/GRN-20GA

WHT/BLU-20GA

WHT

IYEL-

IO-18GA

A

WB02-S

BLK/WHT·18GA

OP_SENDER-SENS.GND

20GA

DC.

PI

-8

WHT/BLK/GRN-18GA

E X.

TEMP. I WHT

IGRY -18GA

WHT/BLK·18GA

Engines & Generators

37

WIRING

DIAGRAM

#54609

WHTIBLK-I8GA

WHT/BLK-ZOGA

WHT/BlK-ZOGA AIR_TEMP-Z WHTIBlK-ZOGA ECT-Z WHTtBlK-18GA WHTISlK-18GA WHTtelK

WMTIBlK-Z8GA

WHTlBRN-20GA

RED/IIHT-UGA

FI~E_ALARM-GND

EXH_TEMP-Z

-lOG" SPEED

0t.PI-3

ENGINE

MAP-I

ECU_JI-ZII>-"'::::;k::lSENS-GND

CAM-GND

MODUlE-2

ECU_JI-6

~---<:::I

OIL

PRESSURE

SENDER

(OP_SENDER)

KI

RELAY

(CRANK)

r-[~8.O;~3c::--OC-PI-5

..

...

<>

:

:'

O:D--II-~-ECU_J2-.

K2

RELAY

(fUEL

PUMP)

BLOCK

GRI-I6GA

COMPONENTS

OAG-ISGA

STARTER

SOL

END

I D IBY

~

-~I ~ ~E~

leATT.'

11!J-4-~

N

o

,.

FUSE

I~~

__

OPTIONAL

BATTUY

CU$TOMER'

r::l

~

.

SWITCH

--.

I

+'

PB_SlUD_EIT

ECU_J2·!

AUX

rUEL_MODUlE_l TillE_DELAY

r--,

'-

_GND

,

I I I I I I I

BlK-180A

eU-IaOA

BlK·

IeGA

BlK·IeGA

BlK-ISGA

K3

RELAY

(RUNIIGNITION)

O:"D:::::::jI=~_

BlK

-IiClA

30

c

z

"l

..

c

CD

feU_J2-1. GRN-ISGA

...-j---D[D

\

COl

MODULE

WIRE

SPEED

MODULE

CONNECTOR

SIDE

VIEW

(CD

I)

IED/WHT-leGA

~

'----I-

.......

~~

.

RESISTANCE

CDIIGNITIDN MAGNETIC BATTERY

CHARGE

IGNITION

COIL

START

SOLENOID

HIGH

TENSION

SPEED

MODULE

CAM

SENSOR

NOTE:

TESTER USED-FLUKE MULTIMETER

TOLERANCE ± 20%.

VALUES

WIRING

PICK-UP

__

____

WINDlNG_D.27 -0.41

(PRIMARYI_0.26 -

LEADS

__

_______

DP_SENDU·SENS_GND

ECU_JI·ID .Hl/YEL·20GA

IN

OHMS

12.5

-18.8

148 -222

4.7

6.800

3.5 -3.7

3.6 -3.8

0.35

-10.000

ECU_J2-1

O.26-0.35fl

.HTIBlK-lOG"

GRY-IeGA

.:.

.

•

~

DI.!!.:

IfliA

~R[;';HT-~6Qu..>

148

_ 222fl

REO/VIO·leGA

'NT/VIO·18G"

IIHT/BlK-20GA

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PlC'UP

UMDtR

rlYWHHl

ALTERNATOR

Eeu

JI-I~

tcu

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OP_SE"DER·SE"S_GND

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(UNDER

ASSEMBLY

fLYWHEEL>

E==:...Ji---~rlllilillfili1il'1l~

II!!""--'l---"

Engines & Generators

38

12.5

-18.8fl

CAM

(CAM)

SENSOR

WIRING

DIAGRAM

#54609

GRNI

YEL -20GA

WHT/BlK/VIO-20GA

R[O/VIO-16GA

TAN-16GA

BlK/WHT-18GA

WHT/BlK/ORG-20GA

WHT

IBlK -18GA

EXHAUST

[CU

J 1 -

14

JI-15

ECU

K2-(87l

J2-IO

ECU [CU

J 1

-22

ECU

JI-8

WHT/GRY-18GA

OP

SYSTEM

_SENOER_SENS_GNO

ECU_JI-16

COMPONENTS

C>----,r---j

t>--~,....-l

EXHAUST

TEMP

SWITCH

(EX-TEMP)

WIDE

BAND

OXYGEN

(WB02)

SENSOR

r-r

~z

~::!

!e

•

o,

REM

OTE

CTOR

CONNE

r--i

:-

,_':::

~,

II

.-

1--=':::-

" .-

If-:::

I

"_

I.~:;

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....

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::

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-:

I

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,.-:;:;.

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REMOTE

CONNECTOR

I

:~j~:

I'

"-~~~~~~~--------------~~~~~~~----------,

'r~~"~~~~~~~~~---------'

',._~~

:5-:::;>

'i"~~~.

:'I"~~~'

:i"~~~.

L.--l

POWER

,

;.

~

•

0:-

·

":-

•

~

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•

0:-

'"

lEO

..

lED

•

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..

~~.~S~T~AR~T~S~W~'T~C~H~O~U~TP~U~T

I

-

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POWER

RUN

STOP

RUN I NO

OUT

SWITCH

OUTPUT

SWITCH

OUTPUT

OUT -OYERSPEEO

OUT -EXH

OUT -COOLANT

OUT -lOW

INDICATOR WHT/BLK/RED-18GA

SW I TCH

Oil

OUTPUT

55345

START/STOP

__

L...-

f-JI

ICATOR

PNK-18GA

WHTl6lKtGRN-18GA Q Y

TEMP

FAil TEMP PRESS

______

SWITCH

ONLY.

5i

.

J

..

:;

WHT

tBlK

IYEl WHTl6lK/GRY WHY

16lK

IORG

WHT

t6lK/BlU -20GA

--,

0'""'

I I

J

l

16615;",146

-20GA 20GA

-

20GA

RED-18GA

PNK -18GA

WHT/BLK/GRN-18GA

13()

~

.....,

I

J

In-

I

STAiT/STOP

Rite_

54928

REMDTE

Engines & Generators

PANELS

39

WIRING

DIAGRAM

#54609

I

I-----·-----r=~~~

VIO:rT~

V 10lWHT - I iGA

TIME-RELAY

K2-87

SA

TT

FUEL

PRESSURE

III

(OP

SYSTEM

01

L

SWITCH

.SWI

TCH)

WHTIBlKIGRN-16GA ECU_J2-11

L:~~~~~==::::::::::::::::::~~------------------l

FUEL

I

NJECTO~

(INLII

t I

BATT

_GND

BlK -16GA

VIO·16G4

_GND

BlK

6A

TT

_GND

6lK

-

I6G4

~-r<~E-'-r.!l-,*===~

-18GA

~+"'-<:::::-

CONNECTION

FOR

AUX

ONLY

RUNS (AUX)

BLOWER, POWERED OR

PRIMES.

FOR

RELAY,

ETC.

WHEN

ENGINE

UPPER

'HTIBlK/RED-I8GA

.HT

IBlK

-20G'"

,,,

WilT

IBlK-

20GA

BLU-18G4 BRN-18GA Hl-18GA WHT-18GA

WflT/ORG'20GA

OP_SENOER

"co-""

OP

.SENDER

ECU

J2-12

ECU

J2-35

ECU

J2'33

ECU

J2-

3~

ECU

JI-5

~+~::::::;e::::.-¥~....,

ECU

JI-7

_+""-<::::::oe::::'-Lp/C!!J!.---l

-SENS.GND

"._"

-SENS.GND

INTAKE

_+-I-<::::::OIlE;'-'.I..j!i~....J

-"

~~."

~WIIl

THROTILE

THROTTLE

STEPPER

MOTOR

(STEPPER)

BODY

MAP

SENSOR

(MAP)

INTAKE

TEMP

SENSOR

(AIR.TEMP)

AIR

Engines & Generators

39a

GENERATOR

USE

OF

ELECTRIC

The power required to start an electric motor is considerably. more than is required to keep it running after it is started.

Some motors require much more current to start them than others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types. They are commonly used on easy-starting loads, such machines, or where loads are applied after the motor is started, such as small powertools. Because they require 5 to 7 times as much current to start as to run, their use should be avoided, whenever possible, driven by a small generator. Capacitor and repulsioninduction motors require from 2 to 4 times as much current to start as to run. The current required to start any motor

varies with the load connected to it. An electric motor connected to an air compressor, for example, will require more current than a motor to which no load is connected.

In general,

to

medium starting loads will

MOTOR

(HP)

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

1

the

SIZE

current

MOTORS

if

the electric motor is to be

required

to

start U5-Volt motors connected

be

approximately

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

as

washing

as

AMPS

STARTING

(AMPERES)

6.4

9.2

10.4

14.4

20.4

follows:

FOR

to

22.4

to

32.2*

to

72.8

to

29.2*

to

40.8

26

to

52

*

-~

*

INFORMATION

Required

Run the generator first with no load applied, then generator's capacity, and finally loaded to its full capacity as indicted on the generators data plate. The output voltage should be checked periodically to ensure proper operation the generating plant and the appliances it supplies. To monitor voltage and load, check it with a portable meter and amp probe.

Generator

Maintaining reasonable cleanliness is important. Connections

of

terminal boards and rectifiers may become corroded, and insulation surfaces may start conducting exhaust, carbon, etc. are allowed to build up. Clogged ventilation openings may cause excessive heating and reduced life

In addition to periodic cleaning, the generator should be

inspected for tightness overheated terminals andloose or damaged wires.

Operating

Speed

Maintenance

of

windings.

of

all connections, evidence

at

if

salts, dust, engine

half the

of

*NOTE:

In

the above table the maximum Amps

more for some small motors than

for

this is that the hardest starting types (split-phase) are not

made in larger sizes.

Because the heavy surge motors is required for only an instant, the generator will not be damaged seconds. off all other electrical loads and, on the electric motor.

if

it can bring the motor up to speed in a few

If

difficulty is experienced in starting motors, turn

of

for

larger ones.

current needed for starting

if

possible, reduce the load

for

Starting is

TIw

reason

Engines

& Generators

40

SBCG

DESCRIPTION

and

TROUBLESHOOTING

REFER

BRUSHLESS GENERATOR

Engine

generator turns at

3600 (60Hz) 3000

60Hz

120

50Hz

230

CAPACITOR

RPM

at 2200

Volts

30.

Volts

is Amps for

ALSO

(50Hz)

Ampsfor

SBCG SBCG

TO

THE

SPECIFICATION

TROUBLESHOOTING

Refer

to

the

following page for

Schematic and

CAUSE

No

AC

Output

Voltage

Residual Line -Neutral No

Low Voltage

AC Inductive

Voltage

Load

(s-a

AC

Output 60

-100

Voltage

Load

NOTE:

It would

belt under

120V/60Hz

at

VAC)

Drop

the

RED

PAGE

the

BCG

Winding

FAULT

1.

Shorted

2.

Open

Stator.

3.

Shorted

4.

Shorted

5.

Shorted

6.

Open

Rotor

1.

Faulty

2.

Open

Exciter

3.

Shorted

1.

Volts

with

be

generator base frame.

ISOLATION

Faulty

2.

Faulty

3.

Faulty

1.

Faulty

2.

Faulty

3.

Amperage

important

.

POST

WHITE

N

to

BLACK

CHART

BCG Internal

Resistances.

Stator. Rotor

Diode.

Rotor

Thermister.

Rotor

Capacitor.

Diode.

Capacitor.

Winding.

Exciter

Winding

Rotor

Diode.

Rotor

Winding.

Exciter

Capacitor.

Rotor

Diode.

Exciter

Capacitor.

Overload.

inspect

the

AC

·CIRCUIT BREAKER

Wiring

..

pulley and

drive

AC

OUTPUT

CONNECTIONS

DIAGRAM

230V/50Hz

Engines & Generators

RED

IS.Q!J\TION

POST

41

SBCG

BCG

BACKEND

COMPONENTS

.

(TOP

VIEW)

WINDING

RESISTANCES/INTERNAL

WIRING

DIAGRAM

WINDING

60 Hertz Models: Stator Winding 0.93 Ohm/winding. Rotor Winding - 4.0 Excitor Winding - 2.0 Ohm Capacitor Rating -

RESISTANCE

(Measured

Ohm

35

oF

SBCG

ROTOR

at

20°C/68°F)

INTERNAL

I

'NWHITE

I

50 Hertz Models: Stator Winding 1.35 Ohm/winding. Rotor Winding - 4.0 Excitor Winding - 2.5 Capacitor Rating - 35

WIRING

STATOR

DIAGRAM

BROWN

WHITE

TERMINAL

BOARD

Ohm

oF

EXCITOR

CAPACITOR

,

I

"

I

•

Engines & Generators

42

BLACK

BLUE

II

RED

II

·1

~~

]

C~ACITOR

:1

RED

LAY-UP & RECOMMISSIONING

GENERAL

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

The procedures which follow will allow you own lay-up and recommissioning, or you check list if others

These procedures should afford your engine protection during a lay-up and also help familiarize maintenance needs of your engine.

If you have your local servicing dealer; he provide assistance.

CYLINDER/SPARK

Spray fogging oil into the open air intake, with the arrester removed, while the engine

oil will stall the engine and coat the intake components,

valves, cylinders and spark plugs for winter protection.

NOTE:

At

re-commissioning,

clean and gap

revolutions. Re-install the spark plugs and tighten securely

and firmly attach the high tension

LUBRICATION

With the engine warm, drain

oil sump. Remove and replace the oil filter and with

new

oil.

ENGINE LUBRICATING OIL pages in this manual for the

oil

changing procedure.

no

leaks.

A

CAUTION:

oil

in

the

and

combustion chemicals internal

parts.

do

the procedures.

any

questions regarding lay-up procedures, call

will

be more than willing

PLUGS

is

them.

Rotate

remove

the

engine by hand

leds.

SYSTEM

all

the lubricating oil from the

Use the correct grade of

Run

the engine make sure there

00

not

leave

the

engine's

sump

over

the

lay-up

period.

deposits

which

can

combine

reduce

the

life

to

perform your

may

use them

you

with the

running. The fogging

spark plugs and

two

fill

oil.

Refer

old

Lubricating

to

produce of

your

engine's

flame

complete

the sump

to

the

engine

oil

harmful

as

to

are

INTAKE

Clean the filter screen

cloth lightly soaked in lube oil around the

block through-hull exhaust port, Make a note prior

a

FUEL

Top or should be added. Change the element in your gasoline/water separator and clean the metal bowl. Re-install and make certain there are

STARTER

Lubrication and cleaning advisable, the pinion removed. Make sure the battery connections before attempting replacing

SPARE

Lay-up time provides a good opportunity Westerbeke engine to see if external items such or coolant hoses need replacement. Check your basic spares kit and order items not during the lay-up, such

the SPARE

MANIFOLD

any

opening. Also place

to

start-up!

SYSTEM

off your

higher. A fuel

fuel

MOTOR

any

electrical connections removed

PARTS

in

the

flame

arrester, and place a clean

flame

an

oil-soaked cloth in the

to

remove cloths

tanks with unleaded gasoline of

conditioner such

no

leaks. Clean

of

is

accessible when the

to

remove the starter.

on

as

section

as

stabil gasoline stabilizer

up

any spilled

the starter drive pinion

flywheel

are

Take

care in properly

from

to

inspect your

hand, or replace those items used filters

and zinc anodes. Refer

of

this manual.

arrester

89

oil.

is

shut off

the

as

drive belts

to

octane

cover

starter.

to

is

BATTERIES

If

batteries make sure that they are fully charged, and will remain that way, the batteries will not remain fully charged, or that they be subjected to severe environmental conditions, remove the batteries and store them environment.

are

to

be left

on

board during the lay-up period,

to

prevent them from freezing. If there

in

a warmer, more compatible

is

any

doubt that

will

Recommissioning

The recommissioning of your Westerbeke engine after a seasonal lay-up generally follows the same procedures those described section regarding preparation for starting and normal starts. However, some of the lay-up procedures counteracted before starting the engine.

1. Remove manifold, or

2.

Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making sure the terminals are clean and that the connections are tight. Check remove the sparl plugs, wipe clean, re-gap, and install proper tightness.

3. Make certian the cooling system intake hose

and

the thru-hull valve

in

the PREPARATIONS FOR STARTING

any

rags that were placed in the exhaust, intake

flame

arrester.

to

make sure that the batteries are fully charged,

is

open. .

will

need

to

is

attached

-.¥'

4.

Check replace

5.

as

be

to

Make certain in generator at start-up (see GENERATOR).

6.

Inspect the fresh water pump impeller, replace necessary.

7.

Start the engine

described

section

WESTERBEKE

Engines & Generators

43

the

conditlon

as

needed.

the correct position and there

in

of

this manual.

of

the heat exchanger

all

electrical connections and switches

in

accordance with the procedures

the PREPARATIONS

are

no-loads on the

FOR

STARTING

zinc,

clean or

are

if

3.5KW

SBCG

GENERATOR

SPECIFICATIONS

Engine

Type

Bore & Stroke

Total

Displacement

Bearings

Valve

System

Compression

Firing

Order Aspiration Direction

of

Rotation Inclination Dry

Weight

Governor

Fuel

Pump Fuel Fuel

System Ignition

TIming

Ignition

Coil

Flame

Arrester

Fuel

Consumption (Full

Load)

Start

Motor

Starting

Battery

Capacity

Battery Battery

Charging

DC

Amperage

ENGINE

Two

Ratio

FUEL

ELECTRICAL

Draw

SPECIFICATIONS

cylinder,

four

stroke

gasoline

2.40 x 2.76

21.4

Overhead

9.2:1

Cubic

main

inches

(61 x 60

Inches

(.35

bearings.

cam-cross

liter)

flow.

1 -2

Naturally

aspirated. Counterclockwise 25°

maximum

188

Ibs

Electronic

(8.55

ECU

angle

Kg)

viewed

of

operation

from

SYSTEM

Mechanical Unleaded Multi-port 12-Volt 12 Metal

0.5

flywheel

volt.

screen

GPH

fuel

pump.

89

octane

or

EFI

magneto.

type.

@ 2200 rpm .

higher

SYSTEM

12-Volt,0.6KW 12-Volt,

(-)

negative

ground

600-900

Cold

Cranking

Amps

11

Amp

70

Amps

DC

cranking

engine.

rnm)

the

back

gasoline.

(CCA)

end.

Type Oil

Filter

Oil

Capacity

Oil

Grade

General

Raw

Water

Pump

Raw

Water

Flow

AC

GENERATOR

Type Speed

3.5

Kw

TUNE-UP

Spark

Plug

Gap

Spark

Plug

Torque

Bolt

Torque

Engine

Combustion Generator Engine

Ambient

Cooling

Compartment

temperature

Recommendations

LUBRICATION

Wet Fuel

1.5

qts.

API

SJ

COOLING

Fresh Thermostatically

Positive belt

2.5 -3.0

sump

system

flow,

paper

(91.4L)

10W-40,

SYSTEM

water

cooled

displacement

driven.

GPM

SYSTEM

element,

(9.5

(SINGLE

Brushless 3600

3000RPM/50Hz

3.5 2

RPM/60Hz

KW -60

wire,

30

KW -50

wire,

15

Capacitor.

Hz

single

amp

Hz

single

amp

SPECIFICATIONS

0.032 -0.035in 11

-15Ib-ft

See

TORQUING

AIR

REQUIREMENTS

13

CFM

200

CFM

122 F (50

(15 -20

(0.287

(5.66

C)

maximum.

(0.8 -0.9mm)

cmm)

trochoid

spin-on

15W-40

via

raw

controlled

type,

-11.3

LPM)

PHASE)

phase,

Nm)

THE

CYLINDER

type

pump.

water

heat

exchanger.

rubber

120

230

HEAD.

disposals.

pump.

impeller,

volts

Engines & Generators

44

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(ft) x .305 = Meters

Miles x 1.609 = Kilometers

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

CONVERSION

DATA

DISTANCE

1

EQUIVALENTS

1

Degree

of

Minute

of

Latitude = 60 Latitude

VOLUME

Cubic

Inches

(in3) x 16.387 = Cubic Imperial Imperial Imperial Imperial Imperial Fluid US US US

Pints

(IMP Quarts Gallons Quarts Gallons

Ounces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

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

Quarts

(US

qt) x .946 = Liters

Gallons

(US

MASS-WEIGHT

Ounces

(oz) x 28.35 = Grams

Pounds

(Ib) x .454 = Kilogri3,ms

PRESSURE

Pounds

Inches Inches Inches Inches Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

Sq

In

Nm = 111.120

= 1

Nm = 1.852

pt) x .568 = Liters

(IMP

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

(IMP

qt) x 1,201 = US

(IMP

gal) x 1.201=

gal) x 3.785 = Liters

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

(psi) x 6.895 = Kilopascals

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

(Hg) x 3.377 (H20) x .07355 = Inches (H20) x .03613 = psi x 27.684 = H20

(H20) x .248 = Kilopascals

l::

km

Centimeters x .061

(L) x 1.76 = IMP

(L)

x.88 = IMP

(L) x .22 = IMP

Quarts

(US

qt) x .833 = IMP

US

Gallons

(US

(L) x 1.057 = Quarts

(L) x .264 = Gallons

(kPa) x .145 = psi

Kilopascals

(kPa) x .2961 = Hg

of

Mercury x 13.783 = H20

(kPa) x 4.026=

3

=in

pt

qt

gal

qt

gal) x .833 = IMP

H20

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH) x 1.609 = Kilometers

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles Kilometers

(Hp) x .745 = Kilowatts

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

(0C)

LIQUID

WEIGHTS

Diesel

Oil

Fresh

Water Gasoline Salt

Water

= 1

US

= 1

US

(in-Ib) x .113 = Newton

(ft-Ib) x 1.356 = Newton

(Kw) x 1.34 = MPH

(MPG) x .354 = Kilometers

(Km/L) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(Km/L) x 2.352 = US

(OF) = (OC X 1.8) + 32

=

(OF -32) x .56

gallon = 7.13

US

gallon

gallon = 6.1

gallon';'

Ibs

=8.33

Ibs

8.56

Ibs

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = ft-Ib

Hour

(KPH) x .621 = MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=In-lb

Engines & Generators

45

SPARK

PLUGS

CONTACT

YOUR

SUGGESTED

WESTERBEKE

THERMOSTAT AND

GASKET

ENGINE

MARINE

DEALER

FOR

BELT

WATER

SPARE

GASOLINE

SUGGESTIONS

FUEL CARTRIDGE AND

PUMP

PARTS

GENERATORS

AND

FILTER

a-RINGS

BELT

ADDITIONAL

INFORMATION

GASOLINE FUEL/WATER FILTERS

~

ATM

20A·FUSE

ZINC ANODE

WATER IMPELLERS, AND

GLYCERIN

WESTERBEKE HAVING FOR

AT

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

Kit A includes the basic spares. Kit B is for more extensive off-shore cruising.

KIT

IMPELLER

OIL

GENERATOR ZINC SPARK 20A WATER

FUEL HEAT

a-RINGS

TUBE

ALSO-

ENOUGH

LEAST

OIL

ONE

OIL

A

KIT

FILTER

DRIVE

ANODE

PLUGS

FUSE

PUMP

BELT FILTER EXCHANGER

KIT

RECOMMENDS

ON-BOARD

CHANGE

BELT

ZINC

SPARE

PARTS

KITS

HEAl

EXCHANGER

GASKET

KIT

B

IMPELLER OIL

FILTER GENERATOR ZINC

ANODE SPARK 20A

FUSE WATER FUEL

FILTER

COMPLETE

THERMOSTAT

WATER OIL

PRESSURE

HEAT

AND

KIT

DRIVE

PLUGS

PUMP

BELT

KIT

GASKET

KIT

PUMP

REPAIR

EXCHANGER

END

a-RING

BELT

SET

KIT

SWITCH

ZINC

Engines & Generators

46

jr...v-

'WESTERBEKE

WESTERBEKE

MILES

STANDISH

WEBSITE:

WWWWESTERBEKECOM

CORPORATION·

INDUSTRIAL

PARK • TAUNTON

150

INDUSTRIAL

ROAD

MA

02780

1171-412012

Westerbeke 3.5KW SBCG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual