Westerbeke 3.5 SBCG Operator's Manual

.

OPERATORS.

MANUAL

3.5

SBCG

Single

60Hz

Phase

GASOLINE

and

50Hz

· ·

ERATOR

CALIFORNIA

PROPOSITION

65

WARNING

Marine

exhaust

are

known

to

cause

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

and

include:

and

Sleepiness • Inability

THE

attention.

inspected

diesel

and

some

to

the

cancer,

other

reproductive

A

Carbon

Monoxide

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

gasoline

of

its

State

birth

engine

constituents

of

California

defects,

harm.

wARNING:

Monoxide,

Is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

IMMEDIATELY. down

repaired.

ANY

the

an

of

Carbon

in

Twitching

to

Think

OF

If

unit

and

odorless

and

Temples

THESE

symptoms

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

persist,

restart

This

WARNING WESTERBEKE bulkhead

WESTERBEKE CARBON living/Sleeping

They

are

obtainable

DECAL

and

near

your

also

MONOXIDE

quarters

Inexpensive

at

your

is

provided

should

be

nxed

engine

recommends

local

or

generator.

DETECTORS

of

your

and

easily

marine

by to

a

Installing

In

the

vessel.

store.

Gasoline

with

an ETHANOL

content

h

11

h

19

er

th

an

and

10°'

may

(E10)

10

void

11

as

not

""

a~iOY~'et~

warranty.

f!l!l\1

t

Engines

&

Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety manual

caused

by

failure

precautions.

take the

personnel,

The following safety the

American

PREVENT

A

while

power.

•

Do

enclosures and covers in place.

• Shut off electrical power before accessing electrical equipment.

•

Use equipment.

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

• Remove wristwatch and all jewelry when working electrical equipment.

PREVENT

A

exhaust

Know

necessary

and

your

Boat and

ELECTRIC

WARNING:

engine

is

Letbal

voltage

not operate this machinery without electrical

insulated

BURNS-

WARNING:

system

bot!

• Monitor engine antifreeze coolant level at the plastic coolant recovery tank and periodically at the filler cap location on the water jacketed exhaust manifold, but only when the engine is COLD.

I A

WARIIIIG:

• In case

of

an engine overheat,

before touching the engine or checking the coolant.

carefuUy.

to

foUow

fundamental

when

tfongerous

precautions

machinery.

instructions

Yacht

Most

accidents

rules

conditions exist and

to

protect yourself, your

are

in

compliance

Council

(ABYC)

SHOCK

Do

not

touch

AC

electrical

running,

mats

CDIII/IDnents. A running

01

when

connected

is

present

whenever working on electrical

HOT

Do

not

touch

S!Baar...,.....,

at

these

dry,

ENGINE

hot

engine

i#jaryor-!

allow

the engine to cool

connections!

engine

are

and

with

standards.

Cllllllet:fions

to

shore

not damp

parts

01

gets

on

very

PREVENT

A

• Prevent sparks to occur near the carburetor, pump, or other potential sources of spilled fuel vapors. Use a suitable container to catch all fuel when

removing the

•

Do

Backfire can cause severe injury or death.

• Do not smoke or permit the fuel system. engine/generator clean and free of debris to minimize the

• Be

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's

• All fuel

•

Do

• Shut off the

• Do not alter or modify the fuel

• Be sure all

• Be certain fuel line fittings

• Make sure a

BURNS-

WARNING:

flash

not operate with the air cleaner/silencer removed.

chances

of

aware-

fire.

BURNS

WARNING:

01

death!

hatches closed when fueling. Open and ventilate cabin

after

fueling. Check below for fumes/vapor before running the before starting your engine.

when ventilated area and out

not fill the fuel

the fuel system. spill. sources servicing. the fuel system.

free

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

blower.

vapors

handling and storing fuels. Store fuel

of

the reach

fuel

DO

NOf

of

fire

Ensure proper ventilation exists when servicing

fuel

of

leaks.

FIRE

Fire

can

cause

injury

01

death!

fires.

Do

not smoke or permit flames or

fuel

line, filter, fuel

fuel

line, carburetor, or

flames

Keep

the compartment and the

Wipe

up all spilled

diesel fuel will burn.

fuel

or sparks

fuel

filters.

to

occur near

and engine oil.

-EXPLOSION

Explosions

are

highly

away

tank{s)

service

Take

allow

near

the

supplies have a positive shutoff

fire

extinguisher is installed nearby and is

from

fuel

vapors

can

Run the blower

explosive.

from spark-producing equipment

of

children.

while the engine is runnitig.

valve

care

in

any smoking, open flames, or other

fuel

system

are

for

four minutes

Use

extreme

in

at

the engine when servicing

catching

any

fuel that might

or engine when

system.

adequately tightened and

NFPA

are appropriate

in

this

environment.

or

fuel

cause

care

a well-

valve.

use.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

STARTING

Accidental

starting

can

cause

injury

Dtt/ealh!

11

Thm

OFF

the DC breaker

unit's

battery

selector

engine.

•

Make

certain

all

personnel are clear

starting.

• Make certain re-installed before starting the engine.

BATIERY

A

WARNING:

or

death!

• Do not smoke or

being serviced. highly explosive gas, which arcing or by lit tobacco products. Shut equipment in during servicing.

• Never connect positive ( +) connection

Do not test the battery condition by shorting the tennmals

together. Ventilate any compartment containing batteries to prevent accumulation disturb the battery charger connections while the battery is being charged.

•

Avoid burns

wristwatch, rings, and the battery.

• Always the battery connections. Remove the negative lead first and reconnect it last when servicing the

BATTERY

A

WARNING:

severe

Injury

11

When servicing the battery or checking the electrolyte

level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid which destructive. it off at once with into the eyes inadvertently when removing electrolyte caps.

all

covers,

EXPLOSION

Battery

Lead

the

Sparks could ignite

of

explosive gases.

contacting the terminals with tools, etc., to prevent

or

sparks that could cause ~ explosion. Remo':e

tum

the battery charger off before disconnecting

ACID

SUlfuric

111

death!

If

it comes in contact with your skin, wash

on

the

control panel or

switch

to

OFF

before servicing

of

the engine before

guards,

explosion

allow

an

acid batteries emit hydrogen, a

vicinity

negative{-) battery cable to the

terminal

any

water.

and hatches are

can

cause

Injury

open flame near the battery

can

be

ignited by

o~

all

el~trical

to

prevent electrical

of

the starter solenoi?.

b~

gases

To

avoid sparks,

other Jewelry before handling

acid

In

batteries

Acid may splash

arcmg

o~

fuel vapors.

battery.

can

on

elec~cal

cause

the skin or

tum

do

is

the

the.

not

TOXIC

• Ensure that the exhaust system is adequate to expel gases

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

• Do not run the generator set or engine unless the boat

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifold/

water-injected

Run

blowers when running the

equipped with a functioning marine carbon monoxide

detector that complies with

boat

builder or dealer for installation

detectors.

• For additional information, refer to ABYC Tii-22

(educational infonnation on Carbon Monoxide).

A

WARNING:

odorless nausea

• Do not use copper tubing in diesel exhaust systems.

•

• Although diesel engine exhaust gases are not

AVOID

A

or

• Do not service the engine while

gas.

or

Diesel fumes systems. Exhaust sulfur causes rapid deterioration copper tubing resulting in exhaust/water leakage.

Do

not install exhaust outlet where exhaust

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

of

exhaust fumes from gasoline engines, carbon monoxide

gas

is

present in diesel exhaust symptoms or signs poisoning are:

Vomiting

Dizziness

Headache

Nausea

MOVING

WARNING:

death!

situation arises in which it make operating adjustments, use extreme care to touching moving parts components.

carbon

elbow

Inhalation

death!

can

exhaust

GASES

monoxide

is securely attached.

carbon

lllflllllxide prodllces

rapidly

discharge outlet

Avoid

overloading the craft.

of

carbon monoxide inhalation or

Inability to Throbbing in temples

(CO}

ge11erator

ABYC

A-24. Consult your

of

(CD}

flu-like

destroy

copper tubing in exhaust

3.tld

fumes.

think

Muscular twitching Weakness

and sleepiness

PARTS

Rotating

parts

can

cause

it

is running.

is

absolutely necessary to

and

hot exhaust system

is a

deadly

set

or

engine.

approved

is

an

lnrlslb/e

symptoms,

can

be

If

the engine

close or restrict the

as

toxic

Some of the

coherently

injury

If

gas!

is

of

drawn

as

a

avoid

j..,.,IWESTERBEICE

l Engines & Generators

ii

•

Do

not

wear

loose equipment; jackets,

could

•

Make

Keep

places

•

Do

not

~e

engine

•

Do

the

exhaust

generator

death

HAZARDOUS

A

WARNING:

,,.,

•

Never

•

Do flame

•

Do

open

A

WARNING:

llflllltally

shirtst

be

caught

sure

protective

at

all

check

not

allow

is

can

occur.

operate

not

run

arrester

not

run

(when

Dr

physically

tie

back

sleeves,

in

all

attaching

shields

times.

fluid

is

operating.

any

discharge

operating.

NOISE

High

an

the

engine

removed.

engines

installed).

BD

clothing

moving

levels

swimming

engine

nDt

or jewelry when servicing

long

hair

rings,

parts.

hardware and

guards

or

the

opening

Carbon

nDise

levels

without

with

the

for

long

periods

WDik

Dn

Incapacitated

SAFETY

and

avoid

wearlng

necklaces

or

for

Monoxide

air intake (silencer) or

or bracelets that

is

properly

in

drive

belt's

activity

the

can

its muffier installed.

with their

machinery

by

tightened.

their respective

tension

around or near

generator while the

poisoning or

cause

hearing

enclosures

when

fatigue!

INSTRUCTIONS

lOose

while

you

ABYC,

INSTAI!LING

Read

for tions

ABYC "Standards

Craft" . ·

Order

NFPA

''Frre Protection Standard for Motor

Order from:

USCG

"USCG

are

NFPA

AND

ENGINES

the

following

safety

codes

and

when

installing your engine.

(American Boat and

and Technical Ipformation

from:

ABYC 613

Third Street, Suite

Annapolis, MD 21403

www.abycinc.org

(National Frre Protection

NFPA

11

Tracy Drive

Avon

Industrial Park

Avon,

MA 02322

(United

Order

from:

U.S.

Government Printing Office

Washington,

States

33CFR183"

D.C.

USCG

AND

ABYC,

standards.

10

~t

20404·

PUBLICATIONS

FOR

GENERATORS

NFPA

and

USCG

publications

Follow

Yacht

Quard)

their recommenda-

Council)

Reports

Association)

Craft"

for

Small

OPERATORS

Many

of

in

your

notes

to

carefully,

procedures.

GASOUNE

Preparations begin

with a thorough

Yacht

Council's

a

combination

Sections

H-2

Ventiiatio~

H-24

Gasoline

P-1

Installation for

P-4

;Marine

BllAC

All

installations

Regulations

MANUAL

the

preceding

Operators

highlight

maintain

ENGINE

to

il)stall a

(ABYC)

of

the

ABYC

for

Fuel'

of

Propulsion

Inboard

and

DC

Electrical

must

(FCR).

safety

Manual

critical

your

AND

examination

sources

standards

Boats

Systems

Exhaust

and

Auxiliary

Engines

comply

information.

equipment,

gasoline

standards. l:ncJuding

tips

and

warnings are repeated

along

with

other cautions and

Read your

and

follow

GENERATOR

engine

or generator

of

the

American Boat

These standards

the

USCG

of

particular interest

using

Gasoline

Systems

Engines

and

Transmissions

Systems

with

on

Boats

the

Federal Code of

manual

all

safety

INSTALLATIONS

should

and

are

from

and

the

NFPA.

are:

Engines & Generators

iii

CARBON

MONOXIDE

"CO"/

LOW-CO

GENERATORS

DESCRIPTION

Carbon monoxide is

a colorless, tasteless,

gas

that

can

one

of

the

major

threat that must not Westerbeke

normal

levels of

99%.

Several standards parts

per million

Regulator

EPA

ACGffi.

EPA

NIOSH

OSHA

ACGffi

NIOSH

(IDLH)

1200

ppm

IMMEDIATELY

A city

in

California characterizes

concentration this

Parts

per

25

100

200

Even though the Westerbeke Low-CO normal levels 99%.,

an exhaust extremely dangerous. For this important be sure it is always

detector sounds, signal.

You

Leave

the detector

evacuate the boat

professional help.

As

soon

as

to

dilution

exhaust outlet, the higher

"CO"

kill

you

without

safety

be

underestimated.

Low-CO

CO

in

for

"ppm"

generators

CO

is

the

so-called

DANGEROUS

way:

Million

generator

of

CO

in

leak

to

install a

can not taste,

CO

in

leaves

the

CO

turned

do

not

on,

leaving

open

is

a component of engine

odorless, risks

the

have

and

ppm

9

25 35 35

50 125 200

1200

generators

the

of untreated

detector

tum it

tum off

the

air.

IMPORTANT

lighter than air poisonous

any

warning.

associated

are

engine exhaust

been

hours

IDLH

concentration·

TO

LIFE

the

Responses

Permissible exposure apparent

No

poisoning for long period.

Allowable Should not

this

level time. A headache

normally

are

engine exhaust

reason

on

and

off,

smell,

or

all

ports

and

exhaust

The closer a

the

concentration

CO

poisoning

with

boating. It

designed

published, expressed

of

exposure:

Exposure

to

by

approximately

Hours

8 8

1

8

0.5

0.0

AND

HEALTH.

effect

of

CO

toxic

symptoms.

for several hours.

be

exposed above

for any period of

possible

produces

designed

exhaust

near functioning

assuming

otherwise

engines

hatches

outlet,

in

two

it

is

extremely

the

person

mild frontal

to three hours.

very low

to

by

approximately

would

generator

it

detect

and

open,

level

of

eXhaust.

is

reduce

level,

reduce

be

and

properly.

is

a false

CO.

generators,

and

seek

is

subject

is

to

the

CO.

INFORMATION

In

It

is

a

in

no

levels

to

If

this

a closed or underneath a stem potentially rise exhaust system gas. eXhaust

Westerbeke

99% engine's air/fuel ration coupled special catalyst. model because system components are models others, models.

The fuel system which

air/fuel ratio control components: sensors, electronics and of

CO these output.

CO

always, load.

INSPECTION

The catalyst is critical to

intrusion into compromise Westerbeke's exhaust system installation instructions

dated June

NOTE:

covered product mandated andCARB.

Maintenance of the engine or important. Fuel

MUST Inspection of

critically loosening surface of flush, intrusion. The addressed. gasket must casting

needed. gasket, while CO

space,

to

Therefore,

reduction of typical

thus

reduction,

components

concentration also

honeycomb

analyzer.

one

to

provide a margin of

Low-CO

each

being adequate

producing different

purchased

the

worst

the

2016 Revision 4 must be adhered to.

Water

intrusion

under

warranty

by

various

the

be

properly

the

important.

the

metal

the

If

there

be

must

be

Upon

and

exhaust

the

engine

such

as

the

engine

swim

platform,

the

undiluted level

due

to a lack of

should never

generators

CO

emissions engine is

for

accomplishes

is comprised of

any

variability

can and will

varies

case

CO

engine's exhaust

proper

warranty,

nor

the

regulating

any

components

flow

of

filters,

maintained.

catalyst

The clamp

catalyst.

appearance

cause

of

is

irregularity,

replaced. The

inspected

careful reassembly of

elbow,

is

running.

fresh

rely

safety.

achieve

CO

by

precise

with

are

not

different.

commonized

some

and

CO

sub-assemblies, others.

Because of

in

cause

with

load.

concentration

optimizing

operation

is

not a

neither

fuel

air

exhaust

Any

the

of

product

Westerbeke

emissions

authorities

affecting

to

the

filters,

flame

at

the

prescribed intervals is

elbow

to

provide a

visual

is

most

irregularity

the

water

also

for

check

This

must

compartment, concentrations emanating

air

on

after treatment

the

Also,

aeross

extra-adequate for

levels

the

many

the

functioning of

variability of

CO

system

the

from

to

dilute

dilution of

an

approximate

control

control of

same

for

certain

several

for

different

required

different

machined

the

extreme

Usually,

occurs

levels.

Any

will

likely

catalyst.

defect

and

the

but not

at

s normal

specific

engine

irregularity

injected

corrosion

for

the

arrester

is

removed

view

likely

must

catalyst

the

catalyst,

the

presence

be

performed

warranty

such

flow

is

critically

screens

of the

of a result of be identified

and exhaust and

the

boat,

will

the

exhaust

the

in

a

every

fuel

engine

precise

castings,

level

any

the

CO

maximum

water

quickly

is

not

as

EPA

of air

by output

the

nonnal

water

sealing

elbow

replaced

new

sealing

of

CO with

the

into

and

as

a

IV

EMISSIONS

This genset meets the requirements Emissions Standards

California users unauthorized modifications or replacement air intake, or speed control system components that affect engine emissions are prohibited. Unauthorized modification, removal or replacement

Federal Emissions Compliance Period: The Federal

Emissions Compliance Period referred indicates the number has been shown

Catagory C=

Emissions

Engine Fuel Requirements

Engine Valve Adjustment See MAINTENANCE SCHEDULE.

Engine Ignition Timing See MAINTENANCE SCHEDULE. Engine Engine

Engine Emission Contol System

Catalyst See Oxygen Sensor See MAINTENANCE SCHEDULE. Back

Lubricating

Adjustments

Pressure

as

stated

of

this genset should

of

the engine label

of

operating hours for which the engine

to

meet Federal Emissions requirements.

250 hrs, B=500 hrs, A

Warranty

Information

Oil Requirements See ENGINE OIL RECOMMENDATIONS.

of

California's Exhaust

on

the nameplate.

be

to

=lOOO.hrs.

aware that

of

fuel, exhaust,

is

prohibited.

on the nameplate

EMISSIONS

111e

California emissions control warranty statement is located packet, factory.

The engine

RECOMMENDATIONS.

ECU. The engine emission control system consists

manufacture.

MAINTENANCE SCHEDULE.

See MAINTENANCE SCHEDULE.

CONTROL

if

INFORMATION

information

is

certified to operate on unleaded gasoline. See FUEL

You

should carefully review operator (Owner) Installation and other manuals and information you receive with your genset.

maintenance or service should seek assistance from an approved dealer.

California genset users may use the table below

locating information related to the Califomia Air Resources

Board requirements for emissions control.

as

this manual when the genset is shipped from the

If

you are unsure that the installation, use,

of

your genset is authorized, you

WESTERBEKE

TABLE

of

engine design and precision

as

in

the same

an

aid

in

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

Dry,

but hot, exhaust gas can be sampled at the 118NPf 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 dry stack exhaust 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 ingested. repaired

The

catalyst

of

engine operation.

of

satisfactory

or

each

CO

analyzer.

of

Only analyzers with probes should be used at this

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

500

hours

(which

of

the water injected exhaust

the analyzer, safety concerns over

be

sure no water is being

CO

concentrations

be

replaced

levels

of

the water flow and just

every 2,000

must

be

done

ever

occurs

exhaust gas with an

be

sampled.

of

high levels

first).

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, TIF, Testo, TSI, Bacharach, Fluke, Monoxor, Fyrite, Zellwgwer Analytics, Industrial Scientific Corp, GFG, Teledyne and others. Westerbeke recommends analyzers with a probe connected to the analyzer by a length 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.

of

the analyzer,

of

CO

levels from the

CO analyzers:

of

transparent

but

they allow you

the boat's exhaust outlet.

of

TPI,

CO

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

Contents.

the

CO

the

Engines & Generators

vi

When

installing WES1ERBEKE

be

attention

paid to

the

following

INSTALLATION

engines

information:

and

generators it is important that strict

CODES

Strict federal regulations, when

SIPHON·

For installations where or will be below break

minim~

the exhaust manifold injection port raw water damage

H

to

siphon-break.

NOTE:

operation. engine

EXHAUST

The exhaust system's hose Exhaust Hose is and and system under

AND

REGULATIONS

ABYC

installing engines

and

BREAK

the

exhaust manifold/water injected exhaust elbow

the

vessel's waterline, provisions must be

in

the

raw water

of 20" above the vessel's

you

have

any

the vessel's waterline under

A siphon-break

Failure

damag~.

supply

to

the engine and possible flooding

doubt

about

requires

to

properly maintain a siphon-break

Consult

the

SYSTEM

MUST

recommended.

turns

without

turns

.In

MUST be designed

any

the

need

this

regard,

sea conditions

of additiinal

a single length of corrugated exhaust hose can be

to

and

guidelines,

generators

hose

the

position of

the

vessel's

periodic inspection and cleaning

siphon-break manufacturer for proper maintenance.

The

prevent

at

any

and

safety codes must

in a marine

to

the

exhaust

waterline.

is

at or below the load waterline will result in

various

be

certified for marine

use

of

this

fitting

the

entry

angle

of vessels heal.

environment.

made

elbow.

This hose must be looped a

Failure

the

and

to

use a siphon-break when

of

the

water -injected exhaust elbow relative

operating conditions, install a

can

use.

type

of hose allows for extreme bends

clamps

of water into the exhaust system

to

be

complied

to install a

boat.

to

ensure

result

in

catastrophic

Corrugated Marine

accomplish these bends

with

is

close

to

siphon~

proper

used.

The

AVAILABLE YOUR DEALER

fROM

WESTERBEKE

A

detailed engines to

and

download

Marine

Installation generators, from

our

Manual

is

supplied

website

at

Engines & Generators .

covering

with

www.westerbeke.com.

VJii

each

gasoline

unit. A pdf

and

diesel,

is

available

TABLE

Parts

Identification

Introduction

lnstanation

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

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

Raw Raw

Measuring

Changing

Fuel,

Engine

Control

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

Preparations

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

Initial

Safety

Maintenance Engine

Changing the Engine Oil.. ........................... 14

Fuel

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

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

Fuel Pump ....................................................

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

Cooling

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

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

' ' Hear Exchanger ....................................

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

Water Intake Strainer ................................... 18

DC

Circuit/Battery

Shore

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

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

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

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

Back

Catalyst

Oil

Panels • Starting/Stopping

for

Priming

ShutdOWD

Schedule

Lubricating

System

Power

Traasfer

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

Pressure

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

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

and

Engine

Coolaat

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

Procedure

Initial

the

SWitches

Fuel

Start·Up

System

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

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

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

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

System

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

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

............... ~ .............................

Switch

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

OF

...

1 o

11·

12

14

15 15 15 15

l6

16 17

,.~

.....

11

:.:

..... 18

19

l9

CONTENTS

2

3

5

6

7

8

9

Engine

Bleeding Raw

Engine Wiring

Generator· BCG SBCG Lay·Up,and Generator

Suggested

Components

Spark Plugs .... : ............................................. 22

Catn Sensor .................................................. 23

Air

Screen ........................................... ; ........ 20

ECU .............................................................

Adjustments

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

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

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

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

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

Replacing the Tuning Belt. ..........................

the

Water

Troubleshooting

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

Diagrams

DC

Control Panel ........................................

ECU

Components ........................................

Engine Block

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

Fuel Systein .................................................. 39

Throttle Body ............................................... 39

Auxiliary Hamess .....

Troubleshooting

Internal

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

Fuel

System ................................. 25

Pump

(Exploded

View)

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

~.omponents

~

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

lnfoi'IQ8tion

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

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

Wiring

Dlagram

Recommissioning

SpecHicaUons

Spare

Parts .......................................

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

20

21 21

21

23

24

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

.......................... 38

~

..................... 39

26

28

36

37

39

40

.41

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

42.

.43

44

45

I..,.,~WESTII!ERSilKE

Engines & Generators

1

PARTS

IDENTIFICATION

3.5

SBCG

GENERATOR

REAR

STEPPER

MOTOR

IGNITION

MODl!LE

under

this

cover

l(l

~K2-K3-RELAYSJTifi8ER

EXTERNAL

FILTER'

CONNECTION

MODULE

TERMINAL

LEFT

SIDE

STRIP'

~-'J'~:HCHiiU.t£rER

FAULT

LED'S

START/STOP

,

CIRCUIT

IGNITION

SWITCH

BREAKER

MODULE

FRONT

VOLTAGE

REGULATOR

~

EXIHAUI!rr

ELBOW

Engines & Generators

2

RIGHT

SIDE

INTRODUCTION

These high performance marine engines are products WESTERBEKE's long years

technology. We take great pride in the superior durability and dependable performance

Thank you for selecting WESTERBEKE.

In order to get the full use and benefit from your generator, it

is

important that you operate and maintain it correctly. This manual is designed to help you do this. Please read this manual carefully and observe

throughout. your nearest WESTERBEKE dealer for assistance.

This is your operators manual. A parts catalog provided and a technical manual WESTERBEKE dealer. equipment, contact your WESTERBEKE dealer for WESTERBEKE'

WARRANTY

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

Customer

Should your engine require servicing, contact

S installation manual.

PROCEDURES

If, after 60 days

Identification

of

experience and advanced

of

our engines and generators.

all

the safety precautions

is

available from your

If

you are planning to install this

of

submitting the Warranty Registry

Card

is

of

also

IWIWESTERBEKE

I

Customer Identification MR. WESTERBEKE MAIN STREET

HOMETOWN, USA Model Expires

OWNER

Ser.#

SERIAL

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 on

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

NUMBER

ENGINE. SERIAL NUMBER

generator's serial

a decal on the the generator control panel. Take the time

SPECIACATION

MODEL

,

. .

.

~~

'::,.,

~

___

~----

......::..-

LOCATION

·I

LOCATED

~~

.

Q_

..

number

on

~'-._

.::::;

and model number is located

the blank decal below. This will

when

seeking technical informa-

50 HZ.

THE

INTAKE

~t

BEHIND

MANIFOLD

of

HZ.

FtP~-----------

KW

___________

KVA

-----------

_

VOLTS---------

PRODUCT

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

WESTERBEKE CANNOT BE RESPONSIBLE CONTENT OF SUCH

RANTIES

THERETO, COMPLETENESS THEREOF AND

BE UABLE

INCURRED IN OF

THE

WESTERBEKE customers should keep in mind the time

span between printings and the unavoidable existence product software. The product software provided with WESTERBEKE products, whether from WESTERBEKE or other suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product.

SOFTWARE

SOFTWARE,

OR

REPRESENTATIONS WITH RESPECT

INCLUDING

FOR

ANY TYPE OF DAMAGE

CONNECTION WITH

FURNISHING

ACCURACY,

OR

USE

of

WESTERBEKE product software

MAKES

TIMEUNESS

WIU

OR

OF SUCH

of

earlier WESTERBEKE

FOR

THE

NO

WAR-

OR

IN

NO

EVENT

OR

INJURY

ARISING OUT

SOFTWARE.

AMPS---------

ENG.

HP

ENG.

SER.

GEN.

SER.

PF/PHASE WIRES

RATING

INSUL

TEMP.

BAITERY

C.I.O.

Fill

in

the

information

3

-------

NO. NO.

----

________

_______

ClASS

RISE

__

----

------

----------

_ _

for

your

own

reference.

I

lbJ

INTRODUCTION

ORDERING

Whenever replacement parts generator and engine model include a complete part description part needed Also insist

will fit

specifications

NOTES,

As

this manual takes maintenance schedules, generator, critical information NOTES, follows:

NOTE:

A

observed, the

A

followed,

NOTE:

by WESTERBEKE. Affix this decal engine

SPARES

Certain spare parts your WESTERBEKE generator

SUGGESTED SPARE PARTS).

as

proper

the

way. spares on-board inventory of the proper WESTERBEKE

PARTS

are

needed,

and

serial numbers.

(see

the

separately furnished Parts

upon

WESTERBEKE packaged parts

or

generic

CAUTIONS

CAUTIONS,

An

CAUTION:

engine

WARNING:

A carbon monoxide warning decal has been provided

room.

WESTERBEKE will provide

and

parts

are

frequently

as

original equipment.

AND

WARNINGS

you

through

and

troubleshooting

will

and

WARNINGS.

operating procedure essential to note.

Procedures,

can

result

or

generator.

in

the

damage

which

Procedures,

can

result

in

personal

AND

ACCESSORIES

will

be

needed

or

Often

fuel

and

oil filters

accessories brochure

can

be

to

always provide

and

part number

Catalog).

not

made

to

the

operating procedures,

of

your

be

highlighted by

An

explanation

if

not

strictly

or

destruction

which

if

not

properly

injury

or

loss

in

a visible location

to

support and maintain

engine

when

even simple

difficult

assist

you

to

obtain

with

in preparing

the

In

addition,

for

each

because

the

same

of

life.

in

the

cruising (see

items

such

along

a suggested

an

parts.

PROTECTING

Care

at

the

have resulted in a WESTERBEKE generator capable of

many

thousands of hours

manufacturer cannot control installed in the vessel or the manner in which operated buyer/owner -operator.

NOTE:

Seven important steps

•

Proper An

ej]icient

•

an

anti-siphon break

YOUR

factory during assembly

and

serviced in the

INVESTMENT

and

thorough testing

of

dependable service. However

how

or

where

the generator

field.

This

is

up

to

ensure long generator

engine and generator installation.

well-designed exhaust system that includes

to

prevent

water

from entering

the

unit

is

life:

t.'te

engine.

• Changing the engine oil and oil filters ing

hours.

•

Proper

maintenance

nents according

of

all engine and generator

to

the maintenance schedule

every

100

in

operat·

compo-

this

manual.

•

1/se

clean,:,

unleaded

•

Winterize

your engine according

Recommissioning" section

UNDERSTANDING

The gasoline engine driving ways

similar

to

are

in-line, and camshaft which pressure block.

To a large preventive maintenance that is required of a gasoline automobile engine. The most impottant generator's longevity are proper ventilation, maintenance of the

fuel

CARBON

WESTERBEKE recommends mounting a carbon detector even in small amounts,

The presence of carbon monoxide indicated

from

the elbow/exhaust hose, or the fumes entering

If

carbon monoxide is present, ventilate

air

and

the

type

lubrication system, and a water-cooled engine

degree, the generator's engine

system, ignition system, and cooling

MONOXIDE

in

the

vessels living quarters. Carbon monoxide,

engine or generator or

your

boat.

cotTect

fuel

#89

octane.

No

higher

than

to

the "loy-up and

in

this manual.

THE

GASOLINE

an

a gasoline automobile engine.

engine's cylinder

is

belt-driven. The engine incorporates a

GENERATOR

AC

generator

head

has

requires

factors

is

in

The

an

overhead

to

system.

DETECTOR

is

deadly.

an

exhaust

from

the

exhaust

from a nearby

the

the problem immediately!

area

vessel

with

EJO

many

cylinders

the

same

the

monoxide

leak

are

clean

the

ethanol

blend.

Engines & Generators

4

RIGGING

The engine/generator wire rope or chain

AND

LIFTING

is

fitted

slings

capable of supporting engine/generators weight to the erator

by

means

of tackle attached

eyes

have

been designed

slings

are

not

NOTE:

Rigging work

and competent

necessary.

in

is

best

handling

to

carry

done

machinery.

with

eyes

lifting

and

to

these

the

full

by

someone

eyes.

lift

the

slings.

weight:

experienced

INSTALLATION

Attach

the

engine/gen-

The

lifting

auxiliary

"':

SIDE

VIEW

LOCATION

AND

MOUNTING

A solid, level mounting platform proper operation of

allow adequate space ing.

Locate the generator away

away

from

bilge splash and

Refer

to

WESTERBEKE'S

information

your

generator. Select a location that will

on

all sides for ventilation

vapors.

installation

on

installing a Marine

is

very

from

living quarters,

manual

Generator

USE

THE LOCATING HOLES

important

and

for

in a boat.

PAN

AS A TEMPLATE

THE

PROPER

TO

THE

PLYWOOD

for

the

servicand

detailed

MOUNTING

BASE

FOR

RAW

J.D.

WATER

HOSE

INLET0.5in

(2.7mm)

TDPVIEW.

WATER HOSES

·FOUR

OUTLET

0.51n

(2.7mm)

1/2"

BOlTS

AND

DISCHARGE

I.D.

3/4"

PLYWOOD-BOLTED/FIBERGLASSED

IN

PLACE

BATTERY TO

REFER DIAGRAM

NOTE:

remote prevent unwanted stress

·

Ensure

that

mowued starter solenoid

ATTACHMENTS

STARTER

TO

the

MOTOR

THE

WIRING

IN

THIS

B+

battery

on

the

MANUAL

solenoid.

{-)NEGATIVE

LEAD

cable

is

.

connected

properly supported

to

the

to

(+)

POSITIVE

LEAD

DIMENSIONAL

For dimensional drawings. Westerbeke

cun-ent

drawings with

5

DIMENSION

(INCHES

AND

MM)

DRAWINGS

View

the

drawings

website www.westerbeke.com

dimensions.

for

on

the

the most

INSTALLATION/EXHAUST

SYSTEM

RAW

WATER

DISCHARGE

The fresh water that flows thru the engine is cooled by a

of

continuous flow the raw water

raw water (via the heat exchanger). As

is

discharged overboard, it is used to cool

the exhaust system.

RAW

WATER

SUPPLY

HOSE

(INSTALLING)

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

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

must

be

looped a minimum

of

the

of

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

installations where the water injected exhaust is close to

or

below the vessels loaded water line, provisions must be

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

of

The function

the syphon break

flow after the engine is shutdown. This flow,

will

fill the exhaust system and possibly the engine as well.

is

to stop the raw water

if

not stopped,

The raw water supply hose must be looped well above the

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

of

vessel operation to prevent syphoning

when the generator is not operating.

When the generators location is above the loaded water line

of

the vessel during all attitudes

advisable to loop

theraw

of

vessel operation, it

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 or

wire reinforced hose so it

looped

and

also provide proper mechanical support

will maintain its shape when

hose.

SIPHON

WHEN A SIPHON

IS

NOT

/

1/

I

/1'

/ /

/ / :

l '

Il

! :

HEAT

EXCHANGER

REQUIRED

,--

..........

---,, 1\

''

: : I I

~·(

RAWWATER

SUPPLYHOSE

BREAK

I

....

,

////

!/

:

II

: . I I

I I

BREAK

AVAILABLE

YOUR

WESTERBEKE

DEALER

.

,.--'\

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

~,

\

\ I

----

I I

FROM

~

~(((;r.

,,,,

(II··~

CO

for

TEST

is

still

the

PORT

EXHAUST

BACK

PRESSURE

Measure back pressure after the engine has reached its normal operating temperature and with rated an1perage output applied to the generator

(30 amps @60Hz and

15

amps @ 50Hz). Westerbekes Installation Manual Pub. #43400 has detailed information on back pressure.

~---:::----

//'

t

I

OR

USING

I

MEASURING

EXHAUST

PRESSURE

BACK

PRESSURE

NOT

EXCEED

IN

THE

WATER EXCEED A

PSI

GAUGE.

1.5

SHOULD

41"

(102.5cm)

COLUMN

PSI

WHEN

WATER COLUMN

BACK

'

\

'

"

Engine$ & Generators

6

POSITION

THE

TWO

AND

TIGHTEN

THE

CLAMP

FLANGES

SECURELY

OVER

(AND

GASKET)

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

Use

only unleaded gasoline with

higher. Higher octane octane gasoline Ethanol blends

When

fueling,

hatches

vessel.

the the

generator or main engines.

Use

only

keep

it careless handling or improper storage facilities. the

fuel

and

pure, Purchase a well-known brand of Install.and regularly service a

metal bowl type filter/water separator between and

the

smaller.

ENGINE

Use a heavy duty engine oil as called for in the

Specifications Section of engine

oil and filter after the initial 50 hours break-in operation. Then follow the oil and filter change SCHEDULE in

follow

and

companionways to prevent

Ventilate

clean fresh

clean.

The best

going

into the tank for your engine's daily

the

following practice

engine.

OIL

intervals

is

recommended.

will adversly affect engine performance.

must not exceed

U.S.

properly after fueling

fuel!

It

fuel

This filter rating must be

this manual. Change the

as

specified in MAINTENANCE

this

manual.

an

octane rating

The use of lower

E-10.

Coats Guard Regulations. Close all

fumes

from

and

before starting

is

important

can be rendered unsatisfactory

is

fuel.

good,

to

buy clean

advisable:

Coast Guard approved

the

10

microns

of

To

of

89

entering

fuel,

assure use

is

fuel

tank

or

and

by

that

clean

ENGINE

Engine

water. temperature by transferring heat from

coolant.

from distilled water will protect

PURCHASING

Rather

recommends adding coolant; the mixture will always be

There (green) and Propylene Glycol (red/purple). Either can but flush

COOLANT

coolant a 50/50 mixture of antifreeze and distilled

This coolant allows the engine

It

also

lubricates and protects

rust

and

corrosion. A 50/50 mixture of antifreeze

the

engine

to

run

at

its

the

engine

the

cooling system

to

-34"F (l.l2°C).

ANTIFREEZE

than

are

do

the

preparing the mixture,

buying the premixed antifreeze

two

not mix

engine

common

the

types

two

and

thoroughly.

WESTERBEKE

so

correct.

of antifreeze, Ethylene

if

changing

from

one

that

proper

to

the

and

when

Glycol

be

another,

used

Westerbeke Corporation does not approve disapprove the use oils

are

used,

using conventional be

as

listed in the MAINTENANCE SCHEDULE

section

of

this manual and.not extended

are

oils

used. NOTE: The information above supersedes all previous statements regarding synthetic oil.

OVER·

FILLING

CAUTION: unintenUonally

After shutdown, the oil in the engines internal pasages linger and take a number sump.

Allow at least a few hours

into the

(Re-starting the engine

internal passages

Over-filling the engine's and/or a smokey no

sump

start.

of

synthetic oils.

engine break-in must

oil. Oil change.intervals must

The oil sump

be

over-filled!

before

are

oil laden exhaust, hard starting

on

this

generator's

of

hours

to

f()r

checking

well lubricated).

the

dipstick reading.

is not a problem

sump

will result in erratic operation,

or

If

synthetic

be

performed

if

synthetic

engine

drain back into the

the oil to settle back

as

the engine's

and

can

possible

COOLANT

A,f.Oolant The purpose of

cool~

without the loss of coolant the

cooling system.

NOTE:

hose, pressure/jill

RECOVERY

recovery tank kit is supplied

this

recovery tank

expansion

This

is

best located

coolant

cap.

and

contraction during engine

recovery

at

or

TANK

with

is

to

allow for engine

and

without introducing air

tank,

with

its short length

above

the

cooling systems

each

generator.

()peration,

into

of

. Engines & Generators

-·r.

CONTROL

PANEL • START/STOP

PANEL

DESCRIPTION

To

Start: Press

release.

(The engine will crank on

the

switch

NOTE:

There

the

start button

Apply

a light load

to

warm

loads. To

Stop:

ECU

will receive

green

LED

NOTE:

This

is

not

running.

normal.

the

rocker

switch

and

will

indicate

is

a brief delay while

responds.

to

up

to

operating temperature before applying

Press

the

rocker switch

the

will

go

off indicating

green

LED

This

switch

to

the

start position

will

revert

to

its

center position).

start electronically. A green LED

the

engine

is

running.

the

ECU self-tests

the

generator

signal

may

is

part

~~~~----LED

and

allow

the

to

stop

and

release.

to

shut

the

engine

the

unit

has

shut-down.

illuminate

of

the

dimly

when

self diagnostic circuit and

HOURMETER

DISPLAYS/FAULT

START/STOP ROCKER

.GREEN

engine

down.

SWITCH

LED

before

The

the

and The

heavy

The

engine

is

LED'S

FAILURE

The

to

start after 8 seconds of cranking. Three start

be

performed before prevents prolonged cranking which exhaust filling with water

To problem, the

TO

START

start cycle

try repeat start

close

will

the

starting problem

automatically terminate if

an

underspeed

attempts

and

while solving

fault

can result in the

backing into the engine.

thru-hull (water intake

is

corrected

do

not

thru-hull.

~t~<r------3.34"

(84.84mm)

occurs.

and

valve).

forget

--,)o.l

the

engine

attempts

This

repairing

When

to

open

fails

can

the

(101.6mm)

SHUTDOWN

A shutdown stops

the

which

could cause an

create

AMPERAGE

There

is a very

the

unit's starting battery

the

generator

the

starting

the

starting battery

for

a period of

(Refer

is

when

generator because it

unsafe operating condition.

DRAIN

small amount of amperage being drawn

is

not

battery,

time.

lv;t---~1----

to

SAFETY

the

SHUIDOWN

EC:

U (Electronic Control has

damage

switch

to

the

by

the

electronics

in

use.

To

prevent

turn OFF either

when

the unit

detected

engine,

this

the

panel

20A

CIRCUIT

BREAKER SA

FUSE

PN

033769

MAIN

CIRCUIT

BREAKER

SWITCHES)

an

operating

the

generator,

on

the

and

draw

DC

will

not

Unit)

fault or

from

unit

when

down

of

breaker or

be operated

REMOTE PANEL (withFaultLEDs)

An optional remote panel and plug-in extension

harness are available that allows for remote operation of

the generator. The Start/Stop sequence

Once installed, the engine can

be

operated by either

panel.

0

L 2.60"

REMOTE

PANEL

NOTE:

For wiring these

refer

to

in

thus

manual.

((66.04mm)

(STOP/START

the

Wiring

Diagram section

0.

__J

SWITCH

remote

3.190"

ONLY)

panels,

is

identical.

(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 sure no other generator or utility power load lines.

• Be sure that 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 or open neutral can supply the wrong line-toneutral voltage on unbalanced loads.

• Visually examine the unit. Look for loose or missing parts, disconnect wires, unattached hoses, and check threaded connections. Make sure there

A

recommended be

switched and caused will

INSPECTION

the

engine oil level. Add oil to maintain the level at

the

fuel supply and examine the fuel filter/separator

the

DC

electrical system. Inspect wire connections

in

power systems with a neutral line that the

CAUTION:

starts

by

prevent a cold

When

that

OFF

until

to

warm

unanticipated

starting

a/J.AC

the

up.

This

operation

engine

is

the

loads,

especially

engine

has

precaution

from

stalling.

no leakage.

generator,

large

come

up

will

prevent

of

the

AC

is

connected to

it

is

motors,

to

speed

damage

machinery

and

TO

COOLANT

RECOVERY

'TANK

Coolant

•

Check

the

coolant level in both the plastic coolant

recovery tank and at the filler neck opening on the unit.

NOTE:

After the initial running

the engines 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 air bleed pet cock on the engines heat exchanger to allow any air left in that area it.

Open the pressure cap on the system filler neck and

ensure the system

fill the plastic coolant recovery tank

and

LOW

OIL

FILL

CAP

(YELLOW)

O·RING_]

After

is

completely full. Replace the cap and

r; I

I

I/

OIL

FILL

of

the generator, the air

shutdown and as the engine

air.

Once cooled,

to

be expelled. Then close

ha{f way between MAX

in

OIL

SUMP

..-

Y

9

COOLING

WATER

BY·PASS

INSPECT

PERIODICALLY

COOLING

WATER

OF

THE

FUEL·'

SYSTEM

FUEL

FILTER

.

NOTE:

The generators fuel system must be primed with fuel

before its initial start.

.

INSTRUCTIOIIS

t:

Conn~t·

fuel

:stores)

:injectors.~

.container and open

2.

Temporarily Primer Bulb

3. Operate

· system. Monitor into through

4.

Remove cap

5.

Remove

connection careful

6.

Start Check

7.

Re-bleed once

schrader.

a Snap-On #EEFI-500 or

bleed/pressure gauge set (available at

to

the

scbrader valve on the fuel

Direct the

the

primer

the

container.

the

purge

the

on the schrader

the

and

to

prevent

the

unit and

for

any

purge

line from

the

valve to

attach !l seperate fuel supply

to

the

fuel

inlet connection

bulb

mo'1.ng

the

fueVair

Once

clear

line,

stop priming.

fuel bleed/pressure gauge set

valve.

seperate

connect

any

allow

fuel

system

running,

fuel

supply hose

the

fuel

the

low

eq~ivalent

rail

this

the

purge

fuel

into

flow

through the purge line

fuel

free of air is

from

ships internal

spillage. ·

unit

to

warm

leaks.

first

then high pressure

tool

on

auto

at

into a

line.

hose

the

engines

and

the

supply.

up

and

supply

the

with

engine.

fuel

moving

replace the

inlet

Be

load

test.

~·

.

DErACHiUEL

AND

NOTE:

Tft~

fu~l

bleed/pressure gauge set the schrader valve running with the purge line directed into a container and be used to bleed any perfonning step #5. Care should be 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

dispose

any

the

free

fuel

on

the fuel module while the engine is

air

that

Fuel

and

smoking,

system.

of

leaks.

of

soiled

L/~,

FITTING

.·

·~

FROM

SHIPS

:

FIJ.EL

·~SCHRADER

:~VALVE

may

have entered the system while

taken when opening the

fuel

vapors

open

flames

or

be

certain

Wipe

rags.

up

any

that

spilled

INTERNAL

SUPPLY

CAP

c~

be connected to

are

explosive!

other

source

fuel

lines

fuel

..

·

Do

of

are

and

I~IWESTERBEKE

I Engines & Generators

10

SAFETY

SHUTDOWN

SENSORS

AND

SWITCHES

SAFETY

The engine Should a shutdown occur,

finding and correcting the

Engine starts, runs and then shuts down in the ENGINE TROUBLESHOOTING section

The following

circuits:

High

An injected exhaust elbow. Normally closed contacts, this switch will open and the temperature issue and de-energize the K2 and stopping the generator.

Main

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

SHUTDOWN

is

protected by four automatic shutdown circuits.

SWITCH/SENSORS

do

not attempt

cause.

is

a description

Exhaust

exhaust temperature switch

liiGH

TEMPERATURE

SWITCH

AC

Temperature

ECU will interpret this

EXHAUST______,

Circuit

Breaker

.

AC

to

restart without

Refer

to

the heading

of

this manual.

of

these automatic shutdown

Switch

is

located on the water

as

a high exhaust

K3

relays,

.

EXHAUST

power if there is an

ELBOW

'20A

CIRCUIT

iBREAKER

Fuses

A FL-15A fuse located on the control panel protects the

If

electrical wiring. will blow and shut down the engine.

20A

ATM

A fuse fails, the engine will continue

not

be

cha<ging.

Oil

Pressure

An oil pressure sensor Oil pressure on the sensor affects the sensor to the ECU. Should the voltage reach a preset the ECU will interpret this as a low oil pressure issue 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. If the oil pressure falls below 5 fuel pump and the engine will shut down. Thw switch will reset itself when the oil pressure

an amperage overload occurs, the

fuse protects the battery charging circuit.

to

run but the battery

~

ATM

20A.FUSE

Sensor

is

located off the engines oil

DC

voltage through

Switch

PSI, the switch will shut off

is

restored.

fuse

If

gallery.

value,

and

this will

the

·MAIN

AC

CIRCUIT

BREAKER

Engine

The generator's engine DC circuit type DC

also serves as an Emergency Stop Switch. Excessive DC

current draw or DC electrical overload anywhere in the instrument panel wiring or engine wiring will cause the breaker power No of restart the generator. The DC breaker must be cycled then ON fault situation has been repaired.

DC

Circuit

20 amp breaker mounted on the control box.

to

trip

to

the ECU will be interrupted, stopping the generator.

panel LED will illuminate. Check and repair the source

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

to

clear any ECU shutdown from the ECU after the

Breaker

is

protected by a rocker

This

the OFF position. In this event, the DC

OFF

Water

A water temperature sensor is located housing. This resistance of converts it to the corresponding engine coolant temperature. When the the CHECK ENGINE LED on the panel illuminates. If coolant temperature exceeds the shut-down threshold, the ECU will·open the K2 and K3 relays shutting down generator and the coolant temperature LED on the panel illuminate.

High/Low

Up) that is mounted under the flywheel. When the engine

speed falls or rises to a pre-set rpm level, the

down the engine and the fault LED for speed will illuminate.

Temperature

temperature. The ECU measures this resistance and

coolant temperature reaches the warning threshold,

RPM

The ECU monitors engine rpm via the MPU )Magnetic

Sensor

of

the sensor changes

Shutdown

at

the thermostat _

as

ECU will shut

11

a function

tlie

the

will

Pick-

MAINTENANCE·

SCHEDULE

WARNING:

gloves,

control

SCHEDULED

I

DAllY

Coolant

Engine

Fuel/Water

Fuel Visual

I

INITIAL

Valve

Generator

Engine

Exhaust

Zinc

Fuel Fuel

Spark

Flame

Water

Never and panel,

MAINTENANCE

CHECK

level

Oil

Level

St~parator

SUpply

Inspection

50

HOURS

Clearance

Drive

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

Oil

and

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

System

Anode

Filler

Inlet

Filter

Plugs

Arrester Pump

attempt

use

the

or

disconnsct

BEFORE

(owner

of

Engine

OF

Belt

Flltor

Screen

to

perform

corrBct

tools

the

START-UP

installed)

OPERATION

any

for

11ach

battery

StJrvlce

job.

When

tennina/s.

whl/11

th8

eogi'rllls

ssrviclng/replacing

EXPLANATION

Check

at

Oil

level

should

Check

for

manufacturer's

Fresh

unleaded

Check

for

wiring

and

should

be

Initial

Adjustment.

Measure Initial

engine

Initial

cheCk· anti-siphon buildup

on.,inside

Inspect/clean Initial

change. Initial

change. Check

gap

Initial

cleaning

Adjust

belt

tunnlng.

DC

OF

SCHEDULED

recovery

tank,

indicate.

water

and

dirt

recommendation.

gasoline

fuel,

oil

and

electrical

clean.

tension,

oil

and

at

50

valve

(0.035

of

tension

connections.

filter

hours,

operation.

passages;

in/0.8..().9

screen.

(3/8 -1/2

l~ept

spring

Wear

the

proper

components,

MAINTENANCE

if

empty,

check.at

between

MAX.

in

fuel.

Drain

with

an

octane

water

and

exhaust

Ensure

inspect

belt

change

at

50

then

every

250

Check

the

clean

and

mm)

deflection).

safsty

turn

off

manifold.

and

LOW

filter if

rating

leaks. that

condition.

hours,

hours.

exhaust

replace

equ/pmsnt

ths

20

amp

Add

on

dipstick.

necessary.

of

89

or

higher.

Check

for

bolts & rluts

Adjust

tension

then

change

Carefully

elbow

for

as

necessary.

DC

coolant

Do

Replace

rust

or

tight

as

both

inspect carbon

sut:h

as

circuit

if

needed.

not

overfill!

filter

per

corrosion.

Surface

of

needed.

every

100

for

leaks.

and/or

corrosion

goggJas

lmlaker

Inspect

the

engine

hours.

Check

and

on

the

I

EVERY

50

OPI!tR!\TING

Drive

Belts

'(Water

Starting

Batteries

Fuel

Pump

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

Zinc

Anode

I

EVERY

100

OPERATIN(l

Engine

011

a11d

Filler

Flame

Arrester

Screen

Timing

Belt

Generator Spark

I

EVERY

Valve

Generator

Impeller(.~

Drive

Plugs

250

OPERATING

Clearance

I

Belt

Pump)

(and

House

HOURS

Batteries)

HOURS

OR

WEEKLY

OR

YEARLY

~R

YEARLY

Inspect

for

tor

slipping,

Check

electrolyte

off

corrosion

Inspect

for

NOTE:

Wor*

a

difference.

Change

engine

Clean

screen,

Check

for

Measure

spring

Reference

·Check

plug

Adjust

valves.

'Wipe

generator

connections

unobstructed.

Inspect

impellar(s)

proper

tension

cracking

levels

if

needed.

leaks,

ensure

out

your

Inspect

oil

and

inspect

wear.

cracks

length,

Service

Bulletin

gap.

Ad]usVreplace

clean

and

overheated

for

and

of

condition.

(3/8'

wear.

Make Apply

fuel

awn

schedule,

monthly

filter.

rubber

sealing

and

stretching.

inspect

#276.

dust

and

wires

to

1/2"

Adjust

sure

cables

petroleum

and

electrical

to

determine

ring

belt

condition.

as

needed.

engine

or

windings.

Replace

deflection)

tension

jelly

boats

exhaust

as

and

or

replace

and

connections

to

terminals

coDnections

location,

schedule.

and

replace

Adjust

Remove

make

certain

neaded.

adjust

as

are

for

are

use

of

if

necessary.

as

needed.

vent

vents

if

needed.

in

good

corrosion

clean

and

shore

cover

and

are

power

clear

-----------------------------

Check

belt

order.

Glean

protection.

tight.

can

make

inspect

for

and

loose

Engines & Generators

12

SCHEDULED

EVERY

•Exhaust *Exhaust

Exhaust

*Exhaust

Fuel Fuel Generator

Hoses

Spark VIbration Zinc

I

EVERY

MAINTENANCE

250

OPERATING

CO

Level

Elbow

System

Filter

and

Filler

Inlet

Plugs

Isolators/Engine

Anode

500

OPERATING

Back

Pressure

0-Rings

HOURS

Mounts

HOURS

OR

YEARLY

OR

YEARLY

MAINTENANCE

EXPLANATION

SCHEDULE

OF

SCHEDULED

(cont.)

Sample

exhaust

with

CO

analyzer.

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

and and

that

AC

GENERATOR

hoses

spark

vibration

and

gasket

structural

gasket.

NOTE:

for

leaks.

corrosion

pressure

test

above

as replace replace

connections

should

Check

plugs.

replace

1.5

needed.

fuel

filter

inlet

fuel

INFORMATION.

be

firm

and

tighten

isolators,

brackets

zinc

and

anode.

0-rings

Check

build

to

psi

are

and

if

MAINTENANCE

integrity.

Replace

A

leaking

exhaust

anti-siphon

-up

ensure

or

41

and

all

filter.

clean

tight.

all

hose

and

Open

needed.

on

Inside

system

inches

sealing

and

secure.

Replace

clamps.

mounting

heat

valve

passages.

has

of

water

0-rings.

if

exchanger

if

elbow

or

operation.

Clean

not

developed

column

Ensure

wires

hoses

become

hardware.

end

is

corroded

gasket

Check

and

at

have

cap(s)

or

deteriorated.

can

cause

the

exhaust

replace

restrictions full

operating

no

chafing.

spongy,

brittle

and

clean

carbon

elbow

as

necessary.

that

will

amperage

or

out

debris.

Raw

Water

I

EVERY

Coolant

Engine

Valve

Starter

Dlverter

I

EYERY

*Engine

Heat

Exchanger

I

EVERY

*Oxygen

•catalyst

Pump

500

OPERATING

System

Compression,

Clearances

Motor

Valve

1000

OPERATING

Timing

Belt

2000

OPERATING

Sensor

Head

HOURS

Bolt

Torque

HOURS

OR

and

OR

EVERY

TWO

EVERY

YEARS

FOUR

YEARS

Remove

the

Inspect

check

Drain,

the

Incorrect bolt within

Check motor

Replace.

Remove

recommended

to

Remove

Remove Remove

dual

and

for

leaks

flush

and

thermostat

valve

torque

and

published solenoid

pinion

and

the

engine.

the

heat

and and

replace

drive.

replace

replace replace

pumps.

Follow

any

worn

and

for

proper

re-fill

the

and clearance

adjust

and

interval

cooling

coolant

will

the

valve

specifications.

motor

for

the

timing

could

exchanger

exhaust exhaust

the parts. pumping

system

pressure

result

in

clearances.

corrosion.

belt.

result

In

for

professional

oxygen catalyst.

instructions

Lubricate,

action.

with

poor

engine

Check

Remove

Failure

timing

sensor.

(assy.

appropriate

belt

cleaning

Inspect

#049103)

cap.

NOTE:

in

this

manual

reassemble

antifreeze

performance.

that

the

compression

and

lubricate.

to

replace

failure

resulting

and

pressure

every

and

1

,000

the

and

disassemble

insfull.

With

mix.

Check

the

Clean

and

timing In

major

testing.

hours.

engine

Replace

head

pressure

lubricate

belt

at

the

damage

both

pumps.

running,

is

the

starter

*WESTERBEKE

be

performed

recommends

by

an

this

authorized

service

mechanic.

NOTE:

The operation

be m.onitored

at

of

the unit's

least once

"WW

CO"

system must

an

operating season. This is to

ensure that the system is operating properly. Free system

for

diagnostic software is available

use with a laptop by

contacting your area Westerbeke Distributor.

ENGINE

LUBRICATING

OIL.

DESCRIPTION

Use a heavy SL;

or

SM.

hours

ofbr~~inoperation.

intervaLas in

this

inanual. . .

An

oil viscosity

engine

_in

Westerbe~

the use

·of

break-in change

interv!U~

SCHEDULE section of

synthetic oils

NOTE:··

The

statements-

CHANGING

.The

engine oil should be

from its attachment bracket

allow

the oil

hose

and

is properly secured in its holder after all of

drained

been .

..

duty

engine oil

Change the engine oil

specified in the MAINTENANCE SCHEDULE

of

S~lSW-40 ~ recolllll)en~ed

8)1

co~di~ons.

CorpOration

synthetic.

mu&t

Oils.

be peiforined usmg conventional

..

ID,ust

~-Used?:'·-:::

info~n

regarding

THE

ENGINE

to

drain, or attach a pump

pump

the old oil

with

an

API classification of

and

filter

Then

follow-the

.. . ...

and

aU

does

not

If

synthetic

~·~.listed

this

manual

· _ . . . ·

above

sup~rsedes

synthetic

oil.

. · . . .

seasons.

approve or disapprove

oils are

ill

tile

M.AJNTENANCE

and

OIL

warm.

Remove

and

lower it into a container

to

out.

Make

sure the oil drain hose

. . .

after

an

initial 50

oil

change

for this

used,

engine

oil,

Oil

nofbe

ex:teii,dedif

all

the

oil

drain

hose

the

end of

the

qld

Qil

has

,..,

..

:.·.'·

,.~"·":

.

';:.

SJ,

and

drain

·

liHAlfliiiWli

Wh~nremoving

·'puifCll

to

drain

to

lessen helpful and a plastic any

oil that's in

removed

· off

with

sealed

~talling

sealing

thin

coat of clean engine

the

oil

and

tighten

THE

a hole in the upper

the

oil

into

spillage. An automotive

in

removing

bag

to

make

the old

against

the oil

the

new

surface on

filter.

Screw the filter

the filter finnly

~IL

FILTER

the used oil

a container before

the

around

the·

filter.

sure

Oil

filter.

oil

the

filter,

and

old

oil

the

filter

Inspect

that

the rubber sealing gasket

If

this

filter

adapter,

filter

element,

oil

filter

oil

to

onto

by

you

may

find

lower portion of the

removing

filter

wrench

filter.

Place when the

old oil

rubber sealing

gently

wipe the

adapter free of

the

rubber sealing gasket

the threaded oil

hand.

~ould

some

paper

unscrewing

filter

gasket

remove

filter

Oil

,

SPIN-ON

:

OILFILTER

PN#048078.

it

helpful old

filter

it.

This

helps

be

towels

it

to

catch

as

it

is

comes

remains

it.

When

gasket's

and

apply

on

filter

stub,

to

.

a .

A

WARNING:

contaminants.

a~d

nails

thproughly discard used

Always emulsion

this prevent serious damage. is of a a siphoning through the water cooling circuit exhaust,

clothing

oil

properly.

observe the old oil

indicates the

condition

present

in

fault

in the exhaust system attached

filling

is

the

Avoid

or

rare, oil.

it

up into

Used

engine prolonged using

rags

containing

as

presence

it

does

Call

Water

present in the oil

the

oil

contains

skin

contact.

soap

and

water.

used

it is removed. A yellow/gray

of water in

require prompt attention

a competent

engine.

the

mechanic

to

harmful

Clean

Launder

oil.

Discard

oil.

Althqugh

can

be the

the

engine and/or

into

the

-~

skin

or

to

if

water

te.$tilt

· ·

NOTE:

Use

genuine

.

are

not

recommended.

REFIWNG

Add

fresh

run

the

pressure.

oil

. oil

filter

..

oil

engine

or

from

THE

through

for a few

Make

the

OIL

OVER-FILLING

CAUTION:

unintentionally

Mter linger

sump. the

sump

will provide (Re-starting

internal Over-filling

and/or a smokey possible

The

oil sump

be

shutdown,

and

Allow

passages

no

the oil

take a number of

at

least a

before checking the

an

even

the

engine is

are

the engine's

white

start.

WESTERBEKE

• •

SUMP

the

valve

moments

sure

there

oil

drain

on

over-filled!

in

the engines internal

few

hours

more

accurate dipstick

not

well

lubricated).

sump

oil

laden exhaust,

oil

filters.

· ·

cover.

After

while

checking

is

no

leakage

system.

this generator's engine can

hours

to

drain back

for the oil

dipstick.

a problem

will

An overnight

result in erratic

around

as

the

hard

Generic

refilling

the

passages

into

to

settle back

reading.

engine's

starting

filters

the

oil,

engine's

the

new

can

the

oil

{>eriod

operation,

and

into

Engines & Generators

14.

FUEL

SYSTEM

GASOLINE

Use only unleaded gasoline with an octane rating higher. Higher octane is recommended. The use oflower

octane gasoline will affect engine performance adversely

Ethanol blend must not exceed EIO.

NOTE:

The

generator compartment should have a gasoline

fume detector/alarm properly installed and

GASOLINE/WATER

A primary fuel filter of the water separating ,

type must be installed between the

and the engine to remove water and otqer contaminant's from be carried to the

Most installers include a

separator with the installation package they are aware of the problems that contaminant's in the

These gasoline filters must have

(not

"s~-through")

requirements. The valves to use impurities. This ffiter rating must

smaller.

.\¥hen

SEPARATOR

the

fuel before they can

fuel

system on the engine.

type

of

fuel

can cause.

to

meet U.S. Coats Guard

metal

~owls

have

~~ecki~g

f~r

AND

fuel

tank·

filtei/water. ·

as

metal bowls ·

drain

water and · ·

be

fo

·microns

of

89

or

working.

FUEL

.-~~=C~ER

or

..

ENGINE

Periodically check the leakage. then

Changing

1.

2. Ensure system

3. Unscrew the

4.

5.

FUEL

FILTER

fuel

connections

Replace

follow

ShtJ.t_the

system pressure using a Schrader valve located injector throttle as

high

· and catch or subdue any

filter element down and that may be present.

Replace and thread

Open the fuel supply to the generator and start the Ensur.e

-WJlRIIIN_I

t~tt~.··~xff,eme

the

filter

element after

the

MAINTENANCE

Filter

Element

fuel

sun_p_ly

to

the generator

fuel

pressure is at

body.

Use extreme care

as

45 PSI or

the

sealing

on

that there

·

more.

Use towels

fuel

bowl from the housing and pull the

off.

"0"

ring. Install the

the fuel bowl then tighten by

are

no leaks .. _

t':~-1:,,_,

.ispre$f#lit

•.

. to

pre~n,.spifl.age

.

,".

; -

..

'

and

the

first

SCHEDULE.

~ff.

zero.

Bleed off the

to

spray.

Use care

~.

to

inlhe

h~ntiaildlines~

. .

as

bowl

for

50

hours

on

pressure

wrap

the valve

catch any

new·

filter element

hand.

the

maybe

fuel

unit.

FUEL

PUMP

Periodically and

~-sure

are

tight and

maintenance

IN~T

To

ensure clean fuel into the fuel in-line fuel filter connected should be replaced every

1.

Shut fuel supply'lint}to from be present.

2.

Thread on the replacement inlet filter fuel supply line. tightening inlet

3. Tum

generator. Ensure that there

c~l).the

tll.at

'no

~lire.

The

free.

FUEL

FILTER

.off

the

fue~

supely

the·

pump inlet.

Use

the

fuel

filter.

on

the

fuel

supply

fuel

conrieetions

leakage

is

engfue

to

the fuel module. This filter

250 hours of operation.

to

the

the'inle.t

supply line

..

Take

care

when

to

the generator and start

to

and

out

present

mounted

filter and unscrew

are

and

that

fuel

lift

pump, there

generator.

to

catch

any

and

connecting and

so

as

not to distort the

no

leaks.

pump

Disconnect

connect the

of the

the

fittings

is

FUEL

MODULE

is

a small

-the

filter

fuel that

the

pump

the may

·.ENGINE

FUEL FILTER

AWARNING:

servicing

that

may

spill.

or

other

sources

servicing.

servicing

Shut

the

fuel

DO

of

Ensut~~

the

fuel

system.

NOT

allow

fire

near

proper

ventilation

system.

Take

any

the

valve

care

in

catching

smoking,

tu_el

system

exists

at

the

tank

open

when

any

fuel

flames

·

Engines & Generators

15

.

COOLING

SYSTEM

FRESH

Fresh water (antifreeze) belt

Some circulation exchanger. thermostat reacts coolant opening operating temperature

flow

ENGINE

WESTERBEKE recommends a

and

chemicals that can corrode internal engine surfaces.

The antifreeze performs a double run the ing

antifreeze that contains Supplemental Cooling Additives (SCAs) to

NOTE:

antifreeze

WATER

driven

of

the

to

will

through

COOLING

circulating

coolant by-passes

in

the

engine

The engine operating temperature

to

this

flow

through

change

as

it.

COOLANT

50%

distilled

at

proper temperatures engine circuit

that

long term protection.

Look

to

the

from

keep

for

that

water.

coolant

rust

and

the

antifreeze chemically balanced, crucial

the

new

is

now

CIRCUIT

is

moved

through

pump,

absorbing heat

the

thermostat

and

is

drawn

and

starts

to

the

heat

exchanger.

it

gains

control of

by

allowing

Distilled water

and

corrosion,.

environmentally

available.

more

mixture

duty.

by

transferring heat

lubricates and protects

Look for a good quality

the engine

through

open

allowing

The thermostat

the

or

less coolant

of

50%

is

free

It

allows

friendly

from

to

maintain

the

rises

engine

from

away

by

the heat

and

more

antifreeze

the

engine

from

the

long

a

engine.

the

cook

lasting

NOTE:

Periodically check

Ensure

that

the

upper and lower condition tightly.

CHANGING

The engine's coolant must be changed

MAINTENANCE

become contaminated, it can lead

to

A

and check that

Carry a spare

cap.

COOLANT

SCHEDULE.

CAUTION:

Proper

critical; a substantial

traced

back

to

cooling

Drain the engine coolant

heat exchanger bleed petcock

and

opehing pressure

on

the

top of

the

condition

rubber

the

vacuum

If

cooling

number

system

by

loosening

the

heat exchanger

of

the

seals

valve

opens

according

the

coolant

to

overheating

system

of

maintenance

engine

failures

corrosion.

the

drain

cap.

Also

pressure

are

in

good

and

to

the

is

allowed

problems.

can

plug

loosen

cap.

closes

to

is

be

on

the

air

The recommended

the

against will the

A proper engine coolant

The coolant recovery tank

traction of out introducing air provided

NOTE:

located

most extreme temperature. The antifreeze

also

retard rust within

circulating pump impeller

50/50 mixture

the

and

This

at

or

50/50

as

to

temperatures

engines coolant

into

the

must be installed

tank,

with

its

above

the

level

mixture

sltort

will

protect the engine

the

engine

and add

and

seals.

recommended will protect

of-

40"F.

allows

for

the

during

engine operation

system.

of

oefore

run

the

This recovery

oJ

plastcc

engine's

to

expansion

operating the

hose,

manifold.

the

tank

is

miX:ture

life of

the

and

con-

with-

is

engine.

best

A

CAUTION:

down

before

attempting

the

surface

can

be

Refilling

After

closing the engine block coolant the

manifold,

the

air

housing. Monitor

the

manifold

from

the

install Remove

coolannnix the

cap.

flow

into

stat

housing

After

checking

cool.

Coolant

the

engine

needed.

of

at

190°

the

into

the

start the engine

bleed

petcocks

the coolant

to

petcock

the

pressure

the

cap to

Run

the

recovery

is

cools

Clean

the

Coolant

manifold

the

on

halfway

engine

free

for

should

up

The

engine

F.

on

the

in

the manifold

filler

neck

is

free of air

cap.

th~

coolant

between

and

tank.

of air

leaks, stop

draw back

down.

Add

any

spilled coolant.

must

these

hot

drain,

and

when

and

manifold

and bubbles,

recovery

observe

When

bubbles,

the'

coolimt

be

allowed

procedures.

but

coolant

the

nm

and

when

LOW

the close that

generator

into

temperatures

pour

clean,

coolant

it at

slow

and

the

add the

coolant

clo~e

tank

and

MAX

the

coolant

petcock

and

the

cooling

to

the

recovery

as

the

petcock.

to

cool

Not

only

premixed

is

visible

idle.

Open

thermostat

needed.

flowing

petcock

and

fill

with

and

replace

expansion

on

the

thermo-

allow

system

tank

is

it

in

Fill

and

to

as

if

Engines & Generators

16

THERMOSTAT

A thermostat, located (illustrated below), controls allowing exchanger.

thermostat prevents coolant from heat hose coolant circulation in rise. of the engine operating temperature coolant and housing gasket.

more

When

exchanger.

on

the

sump plate

As

the

coolant

flow

can

be

replaced

to

in

the

or

less

coolant

the

engine

Some coolant

to

the

engine

warms

the

exchanger.

easily.

coolant the

coolant's

through

is

first

flowing

is

by-passed

the

exchanger.

and

up,

the The thermostat

Carry

filler

cap

housing ·

temperature

it

to

the

engine's heat

started,

the

closed

through

This

for coolant

thermostat

by

allowing

a spare thermostat

it

via a by-pass

provides

temperature

gains

more

is

accessible

COOLING

by

to the

for

control

or

less

and

SYSTEM

TO

WATER

EXHAUST

~A.~---____,

b~::J.1'-'E:-----RAW

COOLANT

WATER

DRAIN

COOLED

Replacing

Remove

housing

gasket, gasket before pressing it

Run

the

~

the

as

shown.

apply

engine

the

Thermostat

cap

screws

When

a thin

coat

and

check

oround

and

disassemble

installing of sealant into

for

!he thennostat

the

on

place.

normal

the

new

both

temperatures

housing/gosket.

~y~

THERMOSTAT

#048157

.

GASKET

ADD

SEALANT

AT

ASSEMBLY

#048150

THERMOSTAT ASSEMBLY

HEAT

EXCHANGER

Cool raw water exchanger. the

heat of which is then pumped discharged. through

The engine coolant

other; harmful deposits

Heat

After approximately and automotive radiator heat exchanger.)

NOTE:

that a heat exchanger cleaning

every 1000

the

this

Exchanger

pressure test

Operating

flows

through

As

the

engine

coolant passes

the

internal engine

into The engine coolant engine

and

the

and

raw

keeps

the

engine's water passages

found

in

raw

Service

1000

hours

the

engine's heat exchanger.

shop

should

in

silty and/or tropical waters

hours.

the inner

is

the

exhaust system

(now

circuit repeats itself.

water are independent of

water.

be

tubes

around

conducted

cooled)

of operation, be

able

to

performed more

thermostat

sides

of

and

of

the

these

to

the

raw

and

flows

clean

remove,

(A

local

clean

and

may

-.yo

and

the·

that

heat

tubes,

water

back

each

from

the

clean

test

the

require

often

than

WESTERBEKE

Engines & Generators

ZINC

ANODE

A

zinc

anode,

or pencil, circuit within anode in

the

raw of electrolysis condition the

anode

should

NOTE:

vessel

and

ZINC

ANODES

PN

011885

If

the which loosening hex

boss removing poor

condition, there are probably

exchanger.

the

inside of

exchanger

damaged (refer number),

NOTE:

not

require insulate housing

the

heat exchanger. The purpose of

is

to

sacrifice itself

water cooling circuit, thereby reducing

on

other components of

of

the

zinc anode should be

cleaned or replaced

be

carried

on

Electrolysis is the result

location; not that

.

I

NEW

zinc

pencil needs replacement,

the

zinc pencil is threaded the

anode

from possibly tearing off

the

zinc,

note

Remove the end of

all

zinc debris.

end

gasket in case

when

removing

to

your engine model's heat exchanger

o-ring, cover, and install a

The

threads

the preventing electrolysis action on.the

of

sealant.

zinc from the metal

Sealant should not

is

located

to

electrolysis action

as

required.

board.

of

the

l

.

REPLACE

with another

the

condition of

the

Always

the

end

the zinc anodes

of

in

the

raw

water

taking

the

system.

check!!d

each

particular installation

engine.

monthly

Spare

.

'

I

CLEAN & REUSE

hold

the

hex

with a wrench

wrench.

present

cover.

This

prevents

the

exchanger

it.

If

the

zinc

flakes

within

heat exchanger

have a spare

one

becomes

Replace

end

new

zinc

anode.

are

pipe

threads

be

used as it

the

heat exchanger

zinc.

cooling

the

zinc

the

effects

The

anodes

boss

while

shell. zinc

the

and

heat the

gasket

may

place

and

into

the

After

is

in

clean

part

and

do

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

be

always

(an impeller kit). Water pump impeller failures occur when

lubricant (water)

failures are not warrantable, and operators are cautioned to make sure water flow is present at start-up. Water pumps should blades.

NOTE:

(seals

a new pump and rebuild the original pump as a spare.

a spare impeller and impeller cover gasket aboard

is

not present during engine operation. Such

be

inspected periodically for broken or tom impeller

See MAINTENANCE SCHEDULE.

Should a failure occur with the pumps internal parts and

bearings) it may be more cost efficient to purchase

PUMP

COVER

INSPECT SURFACE

IMPELLER

FIT INTO

·WHEN THE WITH

THE

INSIDE

FOR

WEAR.

THE

HUB

SCREW

THE

SHAFT

ASSEMBLING,

IMPELLER

GLYCERIN

AND

SLOT

COAT

0-R/NG

to

run

dry. There should

CHANGING

Remove the cover screws and the cover will separate 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 install the replacement impeller with blades working the same direction.

2.

Using pliers, grab the impeller hub and withdraw the impeller from the pump. Inspect the inside of the pump, the cam, the inner wear plate, and the inside surface of the

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 of the

removed impeller.

5. Apply glycerin to the 0-ring, impeller, gasket, the wear

plate and assemble into the pump housing. Reassemble the upper pump are tight. Re-install any hoses that were removed.

6. Run the engine

properly. The engine should run at proper temperature. raw water should discharge from the exhaust and there should not be any leaks around the pumps.

THE

WATER

(raw

to

PUMP

of

water) making certain the fasteners

make certain both pumps are operating

IMPELLERS

the pump

dry.

of

the shaft lip seal.

of

the pump

as

Apply a

the

to

film

in

of

WIPE

THIS BEFORE COVER

SURFACE

INSTALLING

CLEAN THE

DRAIN

TUBE

A THIS LEAK UNIT. OF

PUMP

DRAIN

TUBE

TO

DRAIN

KEEP

THIS

OBSTRUCTIONS.

A

sure after and

To

increase the service life

mem

longer than 3 months.

dry location. Replace the cover plate on the pumps securely and ensure the thru hull seacock

WATER

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

SHAFT

SEAL

ALLOW

FROM

CLEAR

LEAK,

THE

WILL

AWAY

TUBE

WARNING:

that

the

pumps

engine

start.

correct

in the pump

THE

the

problem.

if

INTAKE

STRAINER

INCOMING RAW

WATER

SEACOCK

When

the

engine

is

started,

are

pumping

If

not,

"stop"

of

the engine will be in storage for

Store the impellers in a dark, cool, and

TYPICAL

within

the

engine

the impeller, do not install

is

closed.

is

a required component

RAW

WATER

(OWNER

INSTALLED)

make

30

seconds

at

once

STRAINER

INSPECT CLEAN

EVERY

100

HOURS

AND

18

DC

CIRCUIT/BATTERY

DESCRIPTION

The

DC

Circuit generator's engine. reviewing

The engine's circuits: start,

The engine

shown

on

when

troubleshooting

on

system

A

CAUTION:

circuit,

the

engine however, engine's

Specifications

The

minimum

used

in

the engine's

Battery

The engine supplies a continuous 6

voltage regulator thru

an 8 amp

functions

The

the

DC

Wiring

DC

wiring

run,

and

has a 12

the

Wiring

the

engine.

To

never

shut

is

running.

to

avoid

electrical

recommended

Charging

to

fuse

to

start, operate and

circuit

Diagram

is

designed

stop.

volt

DC

Diagrams.

or

when

avoid

damage

off

the Shut

electrical

circuit.

12

volt

Circuit

the

engine's

(and

the

is

electrical control circuit that

servicing

engine

off

shorts

capacity

DC

ships

stop

best understood

and

Wiring

with

three

Refer

to

these diagrams

the

DC

to

the

battery

the

control circuit

battery.

battery

engine

when

of

the

amp

charge This

switch

battery

working

dedicated battery

switch).

the

by Schematic. simple

basic

electrical

charging

while

switch, on

is

600-900

from the

charge

passes

is

the

CCA.

Testing

If

circuit, fuse it indicated, check the terminal connections

Battery

Review establish a systematic maintenance schedule engine's starting batteries

• Check

•

• 'Make certain that battery cable connections

•

NOTE:

remote prevent unwanted

the

Circuit

the

battery

is

not charging, check

remove

holder connection

should

the

indicate 13.0-

Maintenance

the

manufacturer's recommendations

the

electrolyte level and specific gravity

hydrometer.

Use

only

distilled water

level.

tight

to

the

battery posts (and

Keep

your

batteries clean

Ensure

that

mounted starter solenoid

fuse

the

stress

the

fuse.

and

test

with

a voltmeter between

and

ground.

13.1

and

to

B+

battery cable connected

on

With

the

volts.

If

only battery voltage

house batteries.

bring electrolytes

to

your

and

free

of

corrosion.

is

properly supported

the

solenoid.

at

the

engine).

To

test

engine

battery.

and

for

your

to

are

the running,

then

with

a

a proper

clean

to

the

to

the

is

and

SHORE

If

the

installer connects shore power

circuit,

this

must be Transfer diagrams simultaneous connection of shore power

Shore

Switch. Set

to

the

~

Shore

Power Transfer Switches are available from your

WESTERBEKE

done

by

means

the

transfer switch shown

OFF position. This switch prevents

SINGLE

]!

l

.

Power

dealer.

LINE

_,--

.....

,

I :

1

--"

~c:arountl:;r.N;::-)

----tit•

to

of

120

VOLT

~L1}

·(WH1')

POWER

the

vessel's

the

Shore Power

in

to

generator

SYSTEM

N ·sh;p'sload

Note:

N0240.Volt

equipment.

the

AC

output.

TRANSFER

A

utility

at

the covered responsibility

SWITCH

CAUTION:

shore

same

under

Damage power time.

the

to

make

This

to

and

generator

type

warranty;

sure

the

generator

output

of

generator

it

is

the

all

AC

can

result

are

connected

damage

installer's

connections

is

are

if

not

.

co"ect.

I

L1

Shore

N

I

Power

enerato:lt

Ground

....,;:~~.::;::-.:..:;~:;;,;;;;;;~~

Engine$ & Generator•

N J

230

L1

Shore

-

Ground

VOLT/50

HERTZ

lWO

Shlp·To·Shore

Ship's

LOAD

Shlp"s

Ground

WIRE

CONFIGURATION

Switch

SYSTEr

19

ENGINE

COMPONENT:s

SPARK

The first thereafter

PLUGS

spark:. 50 hour break-in

A

WARNING:

the

engine

IIIIIIOVing

$.PARI(

~LIIQ

8PA.RJ(

P~U~

t~Qll:

4Jct!te

the

spo;r~

oftbe

:

IBSPECu,IG

THE

plr,tg~,.wiU

Spark

INSPECT-FOR

WEAR&.

SPARK

PLUGS

plugs

should be

period,

and

replaced

is

hot.

Do

not

Allow

as

them.

QM:

~·-~

.,.

q.tpfiin.JJJ,;B

TQfl~q~;

11-l61b.,ft·(1~

Arm~Se~

plugs

app#¢

~tard

e~ie~

GAP~'-

CARBON

cleaned

then

inspected

needed.

remove

the

engine

"

~

2!i

to

carrosir:m.

t .

,

andre-gapped after the

every

250

hours

.

spark

plugs

while

to

cool

before

~-~.~.in),

N~q).

(he

thre04¢

making

prmia~

fit.~

of

~r.r~pval

. - .

-CAM

SENSOR

LOCATED FLYWHEEL

ON

HOUSING

TOP

OF

THE

AIR

SCREEN CLEANED HOURS

100 WITH A WA1FR

SUCH

AFTER

OF

OPERATING~

HOURS

FROM

AS

GUNK.

AIR

SCREEN

SHOULD

THE

FIRST

AND

THEN

ON.

SOLUBLE

CLEANER

BE

50

EACH

CLEAN

Warranty Void

If

label

is

damaged or

cover

is

removed.

No Serviceable Parts

Inside.

ECU

·

(ELECTRONIC (INSIDE

CONTROL

BOX)

UNIT)

To Adjust: Remove the

through the opening for a

.the

back

opening.

it

out ~ -

·-,"'·

Thread

--

-~

Y2

tum

sensor-

and

raised

the sensor

and

in

lock it in position.

rotate

the engine observing

round disc. Position this under

until

it

touches the disc, then

CONTROL

PANEL

.FAULT

LEOS

.START/STOP

ROCKER

SWITCH

,,2DA

CIRCUIT

'BREAKER

-...

Engines & Generators .

20

MAIN

CIRCUIT

BREAKER

ENGINE

GENERATOR

Generator models built prior and

older).

engine. remove the cover as shown. Follow the recommended inspection/adjustment periods found in the Schedule checked by -carefully measuring the spring length.

DRIVE

The generator's drive belt is located under the

To

access the belt for inspection and/or adjustment,

of

this manual. The proper belt tension can

BELT

(ADJUSTING)

to

April 2015 ( OC

1-1/Sin

!'"'

Q

Maintenance

{28.57mm}

).1

~~~

date

ADJUSTMENTS

BELT

code

be

ASSEMBLY

(vtewed from underneath)

IT

IS

NORMAL DUST ENGINE

COVER

GENERATOR

Generator

and

newer). the engine and is accessed by removing the cover as shown in the illustration above. Drive belt tension is adjusted at the factory with a spring length

It

is important that the spring length be re-adjusted at the

hour break-in period to 1 this re-adjustment at the 50 hour break-in is very important with regards to drive belt service life. Failure to perform the re-adjustment can result in premature drive belt failure .and

possible warranty denial on belt replacement. Reference Service Bulletin #276 dated May 6, recommended inspection/adjustment periods found in the Maintenance

DRIVE

models built after

The

Schedule

BELT

generator's drive

1/8"-

of

this manual.

(ADJUSTING)

April2015

1 1132"

on

belt

is located

(1.125"-

2015. Follow the

FOR

TO

ACCUMULATE

PAN,

{OD date code

of

1 inch (1.00").

SOME

SIMPLY

under

1.063").

IN

WIPE

50

BELT

THE

CLEAN

The Idler Arm/Spring should not

118-3/16 Excessive Idler bounce can belt tension. tension and Idler bounce can result in premature drive belt

wear and resulting failure. This applies to both older and

current models.

BELT

of

an inch during normal, steady state operation.

Operating with an insufficient drive belt

INITIAL

INSTALLATION

BOUNCE

be

caused·

by

"'ADD

1.1251NCH

SPACER

to

1.063

r ,.,.rf;,

more than

insufficient drive

~N.56105

INCH

=!'

Engines & Generators

21

MAINTAIN

THIS

SPRING

I

TENSION

ENGINE

ADJUSTMENTS

ENGINE

To engine, then shut it down.

1.

2. Install a compression adapter and gauge in a spark

3. Close the thru hull valve (seacock).

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

5. Test the compression pressure on the other cylinder.

6.

COMPRESSION

check the engine's compression pressure, warm up the

Remove both spark plug caps and both spark plugs.

plug hole.

pointer reaches it's maximum.

STANDARD

71

If either cylinder small amount and repeat the test. (a)

(b)

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

COMPRESSION

PSI

(5± 1

Kg/em')

of

If

additional oil causes an increase the piston ring and/or cylinder may or damaged. If

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

wear.

TEST

PRESSURE

(0.4±

is

below the standard try adding a

engine oil through the spark plug hole

0.1

MPa)

AT

500

RPM:

of

pressure,

be

worn

WATER

To remove, replace or adjust the belt, loosen the pivot bolt and release the adjusting bolt.

to slacken the belt for removal. When replacing or adjusting the belt, tighten so to have a widest span.

PUMP

BELT

Slide the water purilp bracket

3/8" -

112"

deflection at its

OIL

PRESSURE

The lubricating system 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 pressure, the oil 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:

A newly starter (cold) engine pressure up pressure as low as

on the load placed on the generator.

to 40 psi. A warmed engine can have an oil

is

a pressure feeding system using an

may

have

an

oil

30 psi. Oil pressure will vary depending

TESTING

To

mechanical oil pressure necessary to connect the two switch wires together engine to run. After warming up the engine, with the engine speed

OIL

PRESSURE

test

the.

oil pressure, remove the oil switch and install a

gauge,

in

it's place, it will

at

2200 rpm, read the oil pressure gauge.

PRESSURE:

between

30

and

40

psi

at

2200

rpm

b.e

for

the

22

VALVE

It the must must Perform

1.

CLEARANCE

is

routine

first

fifty

be

performed

be

the

Remove cylinder

the

way.

behind

2.

Remove

maintenance

hours

of

when

top

dead center of

following_

the

fuel

head

cover.

This

should

the

covet.

the

cylinder

NOTE:

WESTERBEKE adjustments information

to

adjust the valve clearance after

operation.

adjustment

pump

Unbolt

give

head

Valve

the

engine is cool

the

compression stroke.

steps:

and

filter assembly

the

good access

cover ..

clearance adjustment

coil and

to

ENGINE

ADJUSTMENTS

recommends

be

performed by a competent

below

and

from

move

is provided

the

piston

the

it out of

to

the valves

that

the

following engine

engine

assist

the

mechanic.

EXHAUST

mechanic.

the

VALVES

CYL.

#1~~~~:=::=;'1ib

SIDE

ADJUSTING

7.

Adjust the intake and exhaust valve clearance #2 using

NOTE:

the vent it

the

same sequence.

When

'loosening

adjusting screw

from

moving.

FEELER

with

SCREW

GAUGE

and tightening

a valve clearance driver

the

lock

for

nut,

cylinder

hold

to

pre

INTAKE

SIDE

3.

Remove driven

FLYWHEEL

. .

5.

Adjust cylinder

Loosen

a. b.

Insert adjusting

c.

Set

VALVE

INTAKE:

E

EXHAUST:

d,

Tighten

c.

Again,

6.

Tum

·driven

the.flywheei·coverto access the flywheei·and

pulley.

the

mtake

0

~

and

exhaust valve clearance for

· ·

VMAA~-

#I.

the

lock

nut.

a feeler

gauge

between

the valve

end

screw.

the

valve

clearance

CLEARANCE:

0.13 • 0.17mm

0.18 • 0.22mm

the

lock

check

the

driven

gear

pulley

with

by

the

(0.005 • 0.007in)

(0.007 • 0.009in)

nut.

valve

clearance.

and

align

the

"

'\7"

mark

adjusting

the

"2

on

and

the

screw.

0"

mark

cyliiJder

and

head.

the

on

the

VALVE

CLEARANCE

DRIVER

8.

Install the cylinder head rim

of the cover as indicated by

cover.

Apply sealant

the

TIGHTEN

PER

4.4·5.8

shaded

LOCKNUT

FT-LB_

to

area

drawing.

BOLT

TORQUE:

8-10

Nm

(0.8

-1.0kg-m)

5.8

--7.21b"ft

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

SEAL

THIS

WITH BLACK

AREA

LOCTITE

SILICONE

TORQUE

(0.6-0.8

the

inside

of

the

removed.

KG·M)

Engines & Generators

23

ENGINE

ADJUSTMENTS

INSPECTION/REPLACING

If

cracks,

replace the

LIMIT PUSHING

Replacement

1.

2.

3. Remove

4.

NOTE:

"0"

block. Please on the driven pulley cylinder

wear,

lengthening

timing

belt.

OF

ELONGATION:

WITH

Remove a.

·Spark

b. Recoil starter

Magneto

c. d. Alternator e. Alternator bracket Tum the crankshaft

and

pulley

Install the

After installing the timing

mark on

head.

MORE

YOUR

FINGER

of

the

parts

plugs

flywheel

assembly

the

"0"

the

timing

belt

the

drive pulley with

confirm

are

OF

or other

THAN

Timing

in

the

following

cup

and

align

mark

belt

from

that

th"e

aligned with

THE

1Dmm

Belt

"0"

on

the the

the

belt,

"1

&

damage

(0.41N}

drive

"0"

0"

TIMING

is·

DEFLECTION

order:

mark

on

cylinder

driven

pulley

when

the

on

the

or "2 &

the

"\1" mark

BELT

found,

the

head.

side.

aligning

cylinder

0"

BY

drive

side.

mark

on

the

NOTE:

Always

grease.

keep

the

timing belt away from any oil and

TIMING

BELT

ALTERNATOR

BRACKET

24

FUEL

SYSTEM

BLEEDING

THE

FUEL

SYSTEM

UNPLUG

. . .

THE

ELECTRICAL

FUEL-· MODULE

HARNESS

-

·

;fUEL

NOTE:

The

ever

the

fuel system

once

least entered the

following procedure must

is

serviced

a season

fuel

to

system

ensure that

is

dispeUed.

(filter

any

be

peiformed

changes,

air

that

etc)

may

INSTRUCTIONS

1. Connect a Snap-On #EEFI-500 or equivalent

fuel

bleed/pressure gauge set

fuel

rail

at the injectors

container.

2.

Unplug Shut

3. Disconnect the coil

not

4.

Close Put monitor.the purge line

•atrated

tainer,

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

the electrical harness

the

thru-hull that

wire

attempt

the

crank without starting for approximately 8 seconds then stop. the

ECU

ECU to remove amp DC breaker on the control panel.

to

start.

the

raw water thru-hull that

generator through

-fuel

is

seen tlowing through

stop initiating crank cycles.

You

will

be able to initiate

will

terminate a start cycle and trigger

the

fault by opening and closing the 20

and

direct

supplies

from

two

going

to

the

schrader

its

attached

sea

water

the

coil

supplies

to

th,ree

into

the.

this

NOTE:

three

valve

purge

line

to

the

fuel

to

the

so

the

engine

the

generator.

crank cycles

container.

hose

into

The

unit will

start cycles before

when

and at

have

on

into

a

modulel.

unit.

will

and

When

the

an

LED

the

con-

5.

Open

the

Reconnect

6.

Close

switch should switch. the

unit. approximately Connect a module. running. on

the

is

running.

7.

Stop

the through schrader

8.

Start

the

A

CAUTION:

not

allow

fire

near

tight

and

properly

raw

the

valve

and

hold

reach

Open

Start

gauge

Purge

Then

fuel

rail

engine.

the

purge

valve. engine

any

the

free

dispose

water

thru-hull

engine

to

the

it. Monitor pressure at the fuel rail.

approximately

the

thru-hull that supplies sea water

the

engine.

39-40

set

to

air

from

connect

and

purge

Carefully release pressure at

line

Replace

and

check

Fuel

and

smoking,

fuel

system.

of

leaks.

of

soiled

that supplies

harness

purge

psi

to

the

fi.I¢1

module

line and depress

40

psi. Release the

Pressure should remain at

while the engine is running.

the

schrader valve on

the

module while the engine

the

gauge set to the schrader

any

air from it while

and

remove

the

for

fuel

open

be

Wipe

cap

on

any

vapors

names

certain

up

any

the

tool

the

valve.

fuel leaks.

are

explosive!

or

other

that

fuel

spilled

rags.

the

generator.

the

from

source

lines

fuel

harness.

STOP

It

STOP

to

fuel

valve

engine

fuel

the

are

and

is

rail

Do

of

Engines & Generators

25

RAW

WATER

DESCRIPTION

Coolant (freshwater) cooled generators have dual water pumps while the raw water cooled models use a single water pump.

The

pumps are essentially the same. The upper pump mounts to the top shaft that fits into the shaft are driven simultaneously by the engines drive belt.

The following instructions apply to either pump:

PUMP

OVERHAUL

of

the lower pump and has a tang

of

the lower pump. Both pumps

on

the

Disassembly

The pump when removed from the engine will have the hose attachment nipple threaded into the inlet and outlet ports the pump along with a drive pulley attached to

the pump. remove these attachments noting their positions

before starting the

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

Dual

Pumps

pump disassembly.

the

Remove the cover screws and the cover will separate the

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

pump as shown

Remove the wear plate direction the impeller blades are working in the replacement impeller with blades working

in

the illustration.

to

expose the impeller. Notice the

so

in

direction.

2.

Remove the impeller using a pair hub and pulling it out

3. Remove the screw and sealing washer that hold the cam in

place. remove the cam and inner wear plate behind it.

the

4. Remove

5. Support press tlie shaft and bearing assembly out of

the pump.

6. Remove the

7. Support the outer bearing and push the shaft out bearing.

8. Remove the spacer and circlip .

dust plate and circlip.

the

pump body on an arbor press and with a drift,

0-ring

of

the pump with a twisting motion,

from the shaft.

of

pliers, grasping the

of

the pulley end

of

shaft

of

as to install

the same

of

the

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

0-RING

IMPELLER.

SIGNS

TEARING

AT

THE

BENDING

REPLACE

OF

WEAR

DUST

PLATE.

BASE

OF

VIGOROUSLY.

IF

THERE

CIRCLIP

IMPELLER FITS

SHAFT

A

INTO

SHAFT

O·RING

INNER

BEARING

SPACER

OUTER BEARING

Inspection

Inspect all parts and replace those showing wear and corrosion.

PULLEY

26

RAW

WATER

Reassembly

Wipe the inside surface of glycerin supplied in the impeller kit surfaces and

1. Install the circlip shaft. Support the outer bearing and

push the shaft into the bearing until the bearing contacts the circlip.

2.

Install the spacer against bearing and push the shaft into the bearing until it contacts the spacer.

3. Apply some glycerin onto the 0-ring and install it

shaft approximately

4. Warming the pump body should aid in installing the shaft and bearing assembly. Support the pump body on an arbor press. With a twisting motion, install the shaft and bearing assembly into the pump until the inner bearing seats the outer bearing should just clear the boss for circlip Rotate the shaft.

5. Install circlip B and push the shaft assembly until the

outer bearing just contacts circlip B and install the dust plate. Rotate the shaft. It should tum freely.

6.

Put some glycerin seat and slide it over the shaft white and seat it in the body of the on the inner area and with a

the shaft white ceramic face.

7. Install the brass plate and circlip

8. Install the wear plate, locking it in position on the dowel

pin.

to the exposed area

tmtil

the cerrunic

Dual Pumps

The

wear plate

9. Install the cam and place some gasket cement on threads

is

assembled above

of

the screw that secures it in place.

the

pump

dry.

Apply a fihn of

to

t4e inside pump

of

the shaft lip seal.

the

circlip. Support the inner

1/8" away from the inner beating.

It

should tum

on

the outer surface of the cerrunic seal

freely.

cerrunic facing out

pumw;

Place some glycerin

twistillg motion slide it over

ofthe

spring seal touches the

A.

the

impelle1:

on

the

and

B.

PUMP

UPPER PUMP

SET

SCREW

SHAFT

SCREWS

FASTENS

UPPERP/JMP

BODY

LOWER

THE

TO

THE

PUMP

0-RING

ONLY

NEEDS REPLACES SIGNS

OF

AGING.

DUAL

PUMPS

ASSEMBLY

GASKET

TO

BE

IF

IT

SHOWS

lO.Place some glycerin on the

inner surface of the and with a twisting motion install the impeller on the shaft

of the pump. Install the covers

secure the cover

NOTE:

Install

the

blades

are

working

removed

impeller.

cover and the cover sealing 0-ring

with the four cover screws.

new

impellers with a

in

the

same

inner

surface of the pump, the

0-ring and cover and

rotating

direction

of

motion

those

of

the

Dual Pumps

the

upper

pump

to

the

Assemble ntaking

sure

the

mounting screws

lower pump as illustrated

are

tight.

so

the

PULLEY

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

Engine

cranks,

Check

engine

LED

to

starting

stops.

LED

firing.

temp

is

illuminated.

pressure

battery.

comes

on.

LED

is

illuminated.

is

illuminated.

Note:

When servicing the engine/generator, the main circuit breaker (control panel) disconnects all switched

Possible

1.

DC

2.DC

3.K2

relay

4.Starter

5.DC

6.

Faulty

7.

Water

1.Fuel

2.Air

in

3.Fouled

4.Faulty

1.Fuel

2.Air 3

..

Faulty

4.

Faulty

1.Air

2.Faulty

3.Low

4.Faulty

1.Low

2.Dirty

3.High

4.

Flywheel

5.

Exhaust

6.Worn/fouled

7

.Faulty

1.

Raw

2.Coolant

3.

Faulty

4.Pump

5.0bstructed

6.Stuck

1.Loss

2.Faulty

1.0illevellow.

2.Faulty

3.Faulty

4.011

1.Circuit

2.Faulty

3.Faulty

1.Data

2.0xygen

3.Low

Cause

panel

breaker

battery

OFF.

faulty.

solenoid

battery

low/dead. starter filled

cylinder.

starvation.

fuel

system.

spark

ignition

starvation.

in

fuel

system.

shutdown

fuel

pump.

in

fuel

system.

fuel

pump.

octane

fuel

MAG

pick-up.

octane

fuel

air

intake

tension

loose.

restriction.

ignition

water

coolant

level impeller. belt

loose/broken.

by-pass

thermostat.

of

coolant exhaust

oil

pressure

oil

pressure

viscosity

fuse

faulty/blown.

circuit

regulator.

Log

needed

Sensor.

charge

off

and

OFF.

faulty.

solenoid.

plugs.

coil.

switch/sensor.

(lower

screen

ignition

wires.

spark

plug.

module.

flow

low.

hose.

flow/faulty

temperature

sendor. switch.

incorrect.

connection.

to

determine

in

starting

reset manually.

than

89).

than

89).

screen.

obstruction.

pump.

switch.

cause.

battery.

AC

power and can

be

ENGINE

TROUBLESHOOTING

Problem

Starter

stays

energized

Poor

performance

Black

exhaust

Blue

exhaust

Check

engine

Speed

LED's

Pair

of

Speed

Exterior

alarm

Engine runs for down. The the engine shuts down.

All fault LEDs

Engine LED on remote

running.

at

generator

smoke.

LED's

are

illuminated-no

LED

LED's

LED

is

illuminated.

15

+/-seconds, then shuts

SPEED LED illuminates

on

generator panel ON. Check

after

start.

speed.

illuminated.

flashing.

are

illuminated-flashing.

AFTER

ON. Engine is not

I

Possible

1.

2.Faulty

1.

2.Contaminated

1.Dirty

2.Generator

1.Lube

2.Crankcase

3.High

1.Diagnostic

1.

2.

1.AC

2.Fuel

1.

2.Faulty

Cause

Faulty

K1

relay.

starter

solenoid.

Low

octane

fuel.

fuel

air

screen.

is

overfilled.

oil

is

diluted.

breather

lube

oil

level.

software

Throttle

shaft

sticking.

Intake

manifold

vacuum

generator

Loose

L Oil Pressure Switch

2.

Time-Relay (053555)

I.

DEAD Battery.

overload.

starvation.

connection.

fire

suppression

pump.

tube

is

required.

leak.

shutdown

(#037323)

clogged.

devise.

Engine starts, runs for 20-30 seconds then Overspeeds.

LEDsON.

Shuts down with Overspeed

I

Air in Fuel System.

ENGINE

TROUBLESHOOTING/SOFTWARE

PCINTERFACESOFnNARE

The software be purchased from a local Westerbeke Distributor or

Dealer.

The

ECIO

used

with the 3.5SBCG model.

The software kit contains a needed communications

to connect between the generator's ECU and

cable ones laptop.

This Diagnostic Software is designed to aide the

technician operation and the functions.

Once downloaded, provides Idle and

Run

is

available in a kit pn#055410 and can

diagnostics found in the software kit is

in monitoring the Low

ECU (Electronic Control Unit)

this new improved software

Mode

diagnostics, Failure Record

Time Data Logging to EXCEL.

CO

generator's

LED

The

Diagnostic Software

and

Wmdows

128

megabytes of RAM communications cable USB communication port that known

The

Westerbeke communication

Diagnostic Software

to

the substituted. The Diagnostic multiple screens, tabs

in

the

The

Diagnostic Software

only When running diagnostics. Start a Data Log 20-25 seconds before starting the generator.

DISPLAY

PANEL

DIAGNOSTICS

7 laptop.

port.

When using

in

order to configure the

and

ECU

will occur

diagnostic process.

so

none

of the

values

will

run

These

must

(Random

plugs

into a

serial

to

the

adapter

must

if

any

communications

Software

and

pull

is

for

can

on

Windows

have a minimum

Access

serial

connection

USB

adapters,

is

using

Diagnostic

cable

is

unique

be

used

or

is

designed

down

menues

monitoring

be

changed.

98,

Memory).

the

MUST

Software.

to

otherwise

cable

with

to

aide

ONLY.

XP,

Vista

of

The

or a be

this

damage is

the user

It is read

Engines & Generators

30

SOFTWARE

DIAGNOST~CS

Engine

Engine IDLE state is:In

the IDLE state only Ambient

after the generator is started, shutdowns

1 Engine Coolant Temp Shorted

Engine Coolant Temp Open

2

Engine Coolant Temp Low

3

Engine

4

External Alarm Open circuit

5

Exhaust Temperature High

6

Battery Voltage Low Less than

7

Battery Voltage High

8

Ambient Air Temp Shorted

9

Ambient Air Temp

10

Ambient Air Temp

11

Ambient Air Temp High

12

13

14

IDLE

State

DC

Warnings:

circuit breaker on, generator not running

Air,

the

in

the

IDLE

state, only warnings. Shutdowns can occur

Coolant

Oil Pressure Sender Shorted

MAP

Sensor Possible Fault

T~mp

High

Open

Lqw

Temperature

CRANK

state

Short circuit (o ohms)

Short circuit

MAP reading out

(

Open

Reading less

-25°C (-13°F) o faulty temperature sensor

Reading more

95°C (203°F) o engine

Open circuit

More than

Open circuit

Reading less

-25°C (-13°F)

Reading more

63°C (145°F)

<10

Low

and

IU>a

and

.MAP

RUN

state warnings

circuit

than

11

volts

15

volts

than

(o

ohms)

of

or

>115

range

kPa)

Sensor

Possible

and

in

both

o faulty temperature sensor

o pinched

o faulty ECT sensor

o loose connection

o excessiyely cold weather

o faulty temperature

o external alarm fault (i.e. Fireboy)

o loose connection

o faulty exhaust temperature switch

o loose connection

. o weak

o blown fuse

o faulty regulator

0

loose connection

o faulty regulator

o faulty o pinched

•

faulty~

o loose connection

o excessively cold weather

o faulty

o excessively o bilge venting system faulty

• engine

o faulty temperature

o faulty oil pressure

o faulty

o pinched

o loose connection

Fault are logged.

shutdowns will apply. There

the

CRANK

or

heat

or

dead

air

or

air

heat

or

MAP

or

an.d

RUN states.·

bare

wire

in

harness

or

corroded wiring

sensor

soak after normal shutdown

or

corroded, wiring

or

corroded wiring

in

charging circuit

or

charging circuit

or

corroded wiring

or

charging circuit

temperature sensor

bare wire

~emperature

in

sensor

or

corroded wiring

temperature sensor

hot

weather

soak after normal shutdown

sensor

sender

bare wire

in

sensor

bare

wire in harness

or

corroaed wiring

If

the fault persists

harness

or

inadequate

harness

are

NO

15

Check

Engine

LED

Emission

Issue

Engines & Generators

31

*

Diagnostic

*

Low

DC

*

Map

Sensor

Software

battery

out

needed.

voltage

of

range.

(below

11

volts).

ENGINE

TROUBLESHOOTING/SOFTWARE

Engine CRANK State Shutdowns:

DIAGNOSTICS

"Engine

CRANK

state

is -

DC

circuit breaker on, generator start switch has been running speed yet. This state only lasts for a the

RUN state.

In

the

CRANK

state, warnings are

not

indicated on

logged.

Shutdown

Cam Sensor failure

1

Over-Crank Timeout

2

External Alarm

3

Battery Voltage Low

4

Speed Signal

5

Description

Not

Detected

No

signal detected by

Exceeds 8 second crank

No

few

seconds

the

on

a typical engine before

LED

display, and they are

Parameters

CAM

speed sensor

ECU

duration

Open circuit

Less than 8 volts

speed signal detected

byECU

pushed

o cam sensor adjusted improperly

o loose connection

o sensor tip contaminated with o faulty battery

o loose connection o fuel supply insufficient

o external alarm fault (i.e. Fireboy)

o loose connection

o faulty battery o faulty charging circuit

o blown fuse

o loose connection

o speed conditioning module faulty

o sensor tip contaminated with metal filings

o

Out

of

fuel

or

not

bled

properly

but

the

engine starts

not

logged.

Possible

or

or or

fuel

system

engine

is

not

and

All

shutdowns are

up to

transitions

cause

corroded wiring

metal

corroded wiring

-

filings

to

i

1----

6

MAP

Sensor

Fault

MAP

(

<10

reading

kPa

or

out

>115

of range

kPa)

o faulty

o pinched or

o loose connection

MAP

sensor

bare

wire

in

harness

or

corroded wiring

32

SOFTWARE

DIAGNOSTICS

Engine

In

the

when the warning condition is

Oil

Pressure warnings illuminate Engine EXhaust

RUN

state is -

RUN

state

Coolant

Temperature

Temperature warnings illuminate the ENGINE TEMP light.

State Warnings:

DC

circuit breaker on, generator successfully started and running

all

warnings are logged and a light

no

longer present. Warnings will be indicated

the

OIL PRESSURE light.

High illuminates the EXHAUST

will

be illuminated

TEMP

on

light.

External Alarm warning illuminates the EXT. ALARM light.

OverSpeed and UnderSpeed warnings illuminate the pair of SPEED lights.

All

other warnings illuminate the pair of CHECK ENGINE lights.

1 Engine

Engine

2

UnderSpeed

3

OverSpeed

4

OverLoad

5

Ctank Sensor Possible Fault Internal

6

Oil

7

Oil

8

Oil

9

Coolant

Temp

Lo_w

Temp High

Pressure Sender Shorted

Pressure Sender Open

Pressure

Low

Reading less than

-25oc (

-13°F)

Reading more than

95°C

(203°F)

1760

Under

rpm for 8+

seconds

Over

2375

rpm for 8+

seconds

Throttle

RPM

Short

Open

-Re-ading

wide

open and

<2200

ECU.

for

parameter

circuit (o ohms)

circuit

(oo

less than

sec

for 5

8+

sec

ohms)

12

o

excessively

o faulty temperature sensor

• faulty temperature sensor

0

engine heat soak after normal shutdown

o

excessive

o

fuel

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

o

excessive

o loose connection or corroded wiring

" sensor tip contaminated with metal filings

o speed conditioning module faulty

o faulty

o faulty oil pressure sender o loose connection or corroded wiring

psi

• check

o insure proper

.•

check lubrication system for

• blown fuse

10

Battery

Voltage

Low

Less

than

11

volts

o dead battery

o faulty regulator or charging circuit

• loose connection or corroded wiring

11

12

13

14

15

Battery Ambient

Ambient

Voltage

Air

Temp

Air

Temp

Air

Temp

Air

Temp

High

Shorted

More than

circuit

Short

Open Open circuit

Low

High

Reading less than

-25°C

Reading more than

9~tC

~

WESTERBEKE

Engines & Generators

15

volts

(o

ohms)

(-13°F)

(203°F)

o faulty regulator or charging circuit o faulty air temperature sensor

o pinched or bare

• faulty air temperature sensor

o loose connection or corroded o excessively cold weather

o excessively hot weather

bilge venting system faulty or inadequate

•

.•.faulty sensor

the control panel. The light(s) will go out

as

follows:

cold weather

load on generator

supply insufficient

load on generator

oil

pressure sender

or bare wire in harness

oil

level

oil

viscosity

leaks

wire

in harness

wiring

air temperature sensor

33

SOFTWARE

Engine RUN State Shutdowns:

DIAGNOSTICS

Engine RUN state is In

the RUN state all shutdowns are logged

shut

down

and

Oil

Pressure

Engine

shutdowns illuminate

Coolant

DC

circuit breaker on, generator successfully started and running

and

a light

the light(s) will stay illuminated until the

the

OIL

PRESSURE

Temperature shutdowns illuminate the Exhaust Temperature High shutdown illuminates the External Alarm shutdown illuminates OverSpeed and

All other shutdowns illuminate

E1:1gine

1

Engine Coolant Temp

2

Engine Coolant Temp High

3

UnderSpeed

4

OverSpeed

5

UnderSpeed

shutdowns illuminate the pair

the

Coolant J'emp Shorted

Open

the

EXT. ALARM light.

pair

of

CHECK

Short circuit (o ohms)

Open

Reading more

100°C (212°F)

Under

Over Over Over Over

2340 2160 2070

19aP

1620

rpm rpm rpm rpm

ENGINE

will

be

illuminated

12VDC

light.

ENGINE

EXHAUST

of

circuit

than

rpm

for

4

for

0.5

seconds

for

1.0

seconds

for

2.0

seconds

fQ!4:0

seconds

on

the control panel. The

power to

SPEED

TEMP

lights.

the

generator is cycled.

light.

lights.

o faulty temperature sensor o pinched

o faulty ECT sensor o loose connection

o faulty temperature sensor o engine

o excessive load on generator

sees

o fuel supply insufficient

o vacuum leak in intake manifold

o throttle shaft sticking

or

bare wire

heat

soak after normal shutdown

generator

in

harness

or

corroded wiring

or

will be

hoses

Crank Sensor Fault

6

Signal Loss

Crank

7

Throttle Loss

8

Oil Pressure Sender Shorted

9

Oil Pressure Sender Open

10

Oil Pressure

11

of

Low

Home

ECU

Internal

parameter,

speed signal intermittent

No

speed signal

to

ECU

3+ seconds

Internal

Short circuit

Open

Reading less

ECU

circuit

than

parameter

(o

ohms)

(oo

ohms)

8 psi for

ssec

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

for

o crank speed sensor faulty

. o speed conditioning module faulty

o throttle shaft sticking o battery weak

o faulty oil pressure sender o pinched

o faulty oil pressure sender

o loose connection o check oil level

a insure o check lubrication system for leaks

or

proper

or

bare

wire

or

oil viscosity

corroded wiring

in

harness

corroded wiring

34

SOFTWARE

DIAGNOSTICS

·

Engine RUN State Shutdowns: (€ontinued

Warning

Battery Voltage

12

Exhaust Temperature High

13

External

14

Wideband

15

Reading

Wideband

16

Failure Wideband

17

Heater failure

Description

Low

Alarm

02

Sensor (WB02)

Out of

Table

02

Sensor (WB02)

to

Cross

Stoich

02 Sensor (WB02)

Parameters

Less

than

10

volts

Open circuit

·

ECU

measures

A

<.70

or A> 2.oo, which

is out of the table range

A reading not crossing

above

and below

A=l.OO

least once per minute

Heater current out of

normal range

fr~m

previous page)

Possible

• dead battery

o

blown

fuse

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

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

• external alarm fault

o loose connection or corroded

o

excessiyely

flow

blocked

(i.e.

rich or lean combustion

• loose connection or corroded wiring

o

oxygen

o

excessively

o dirty or

at

o insufficient fuel supply or pressure

.,

loose connection or corroded wiring

•

oxygen

sensor faulty

rich or lean combustion

clogged

fuel

injector(s)

sensor faulty

cause

Wiring

.

Fireboy)

Wiring

35

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L/1

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~

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SUPPRESSION

SYSTEM

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DIAGRAM

DC

CONTROL

CONNECTIOti IS

TO

RUN.

AN

OPEN

CIRCUIT

FOR

-cB=o

I I O O

$TAll

SWITCH

ltD

ECU

r-..!l!!.E!,.!LA!,!Y.JLO!IOA~O~POW£!:!!!-WR'!!JDP:!:P!,LY!_-----1f++-lf+f-++~-~-::!ioi._E--"+-_,II•

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#54609

PANEL

NOT A POWER

ECU.JI·Z

OP.SE~DEt•SUS.GND

LED-

OUT ~ LOW

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SOURCE.

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STOP

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1

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WN118LK/8LU·20GA

ECU.J2•JO

WHT

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tCU.JZ·U

WNTI8UIGtf·20GA

ECU.JI·Il

WHTI8Ll/GtN•IOG•

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TEMP

LEG

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LEP

SPEED

INPUT

IF

tOll

HROM

LED

.,~.,

LEa

SWIT(MI

SWITCH!

BLI·IIG.

INPUT

SUPPLY

STUD

Engines & Generators

36

WIRING

DIAGRAM

ECU

ECU_J2

#54609

COMPONENTS

BLU·IBGA

WHT/BLK/GRN·ISGA

TAN·l6GA

ORG·I8GA

BLK·16GA GRY · 16GA

WHT/BLK/ORG·20GA WHT/BLK/REO·IBGA

WHT/BRN·20GA

WHT/ORG·20GA

WHT/VIO·I8GA

WHT/GRY·I8GA

FIRE.ALARM-2

PNK·IBGA

STEPPER·!

INJECTOR-I

WB02·4

RELAY

Kl-85

BATT

.GNO

K3·86

WB02·6

MAP-3

OP.SENDER-1

MAP-4

CAM·2

DC.P1·7

,..12

~

.....

~ ~

.....

0

-o

0 0 0 0 0 0 0

,....23

~

0

~ ~

0

0,....

0 ()

0 0

~

0

130

"'r

,...35

~

.....

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~

0

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24

ECU_JI

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0

0 0

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150

0

0 0

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23

16

INJECTOR.2

DC.PI-6

K3.85

WB02·2 WB02·1 ECT-

WHT/BLK/RED·I8G

GRN·I8GA

WHTIBLK/V10·20G GRN/YEL-20GA WHT/GRN-20GA

I

AIR.TEMP-1

MODULE-I

SPEED CAM-I

RED/V10·18GA

WHT/BLK/BRN·

WHT/BLU-20GA

WHT/YEL·

STEPPER-

16GA

STEPPER-4 STEPPER-3

A

K2·85 DC.PI-12

DC.PI·II DC.PI-10 DC.PI-9

A

WB02-5

2

BRN-18GA WHT·I8GA

VEL·

18GA WHT/RED-18GA WHT/BLK/BLU-20GA WHT/BLK/ORG-20GA WHTIBLKIGRY-20GA WHT/BLK/YEL-20GA

BLK/WHT-18GA

OP.SENDER-SENS.GND

20GA

DC.PI-8

EX.

TEMP

WHT/BLK/GRN-18GA

.I

WHT

/GRY-

WHT/BLK-18GA

18GA

Engines & Generators

37

WIRING

DIAGRAM

#54609

NOTE:

Relay(#041150) have a surge protection diode. Replacements

most have the

same.

ENGINE

QIL

PRESSURE

SENDER

!OP.SENDER>

Kf

RELAY

!CRANK>

~...;.:~86~~:l=-""'OC-PI•5

•

:

i

7

n!i'I---I--4---ECU.J2·8

KZ

RELAY

CFUEL

PUMP>

BLOCK

GRY•IGGA

COMPONENTS

OIIG•l8GA

STARTER

SOl

01010

~:.·~

18ATT+I . ·

BLl·8GA

~E~t~':._--

FUSE

BATTUY

IBY

0

OPTIONAL

SIITCH

CU$TDMEtl

r:::::l I

1:!:..!:t"

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I I I

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CD I MODULE

WI

RE

SIDE V I

<COil

RESISTANCE

COl

IGNITION MAGNETIC BATIERY IGNITION START HIGH CAM

NOTE:

CHARGE

COIL

SOLENOID

TENSION

SENSOR

TESTER

TOLERANCE±

GRII•IIGA

CONNECTOR

EW

VALUES

WINDING

PICK-UP

WINDING

(PRIMARY)

LEADS

USED-FLUKE

20%.

K3

( IWN/IGN I

H----<n5"1

IN

OHMS

12.5 148 -222

0.27-

0.26-

4.7

6.800

3.6 -3.8

MULTIMETER

RELAY

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0.41

0.35

-10.000

liON

l

BLK-·16611

Engines & Generators

38

12.5-

18.80,

WIRING

DIAGRAM

#54609

GRN/YEL-20GA

WHT/BLK/V10·20GA

RED/VIO-l6GA

TAN-IGGA

BLK/WHT-

WHT/BLK/ORG·20GA

18GA

WHT/8LK-18GA

EXHAUST

Jl-14

ECU

Jl-15

ECU

SYSTEM

K2·(87l

J2-

ECU ECU

ECU

I 0

J

I-

2 2

Jl-8

WHT

/GRY-

18GA

OP.SENDER.SENS.GND

ECU.J

COMPONENTS

I·

16

t>----f-----i t>------1r-i

WIDE OXYGEN

EXHAUST

TEMP

SWITCH

(EX.

TEMP l

(

WB02>

BAND

SENSOR

CONNECTOR

REMOTE

POWER

1

'

LED

O~T

-

'

START

'

STOP

'

LED

1

LED LED

'

0

LED

REMOTE

CONNECTOR

1

11

-:::_...

~~~;:

lo-::::~

:r-::o;;>,

:r-:::~

1r-:::~.,

:.-:::~.

L--1

POWER

RUN

'

START

'

STOP

•

START

RUN

SWITCH

OUT • OVERSPEED

O~T

•

EXH OUT -COOLANT OUT -LOW

INDICATOR

SWITCH

/STOP

INDICATOR

OUTPUT

TEMP

FAIL

TE~P

OIL

PRESS

OUTPUT

55345

SWITCH

PNK·I8GA

WHTIBLK/GRN·IBGA

WHT/BLK/YEL·20GA

WHT/BLK/GRY·20GA WHT/BLK/0RG•20GA WHT/BLK/BLU·20GA

AVAILABLE 15FT.

30

PN.054931

FT.

PN.054932

EXTENSION

ONLY.

0

r;~J

["-

T6

T5.

T_4

13

r--J

HARNESSES

• 8

- 8

RED-18GA WHT

/BLK/RED-

PNK-18GA

WHT/BLK/GRN·I8GA

18GA

-

co

Cl

>

I

54928

REMOTE

PANELS

Engines & Generators

39

WIRING

DIAGRAM

#54609

V

IJWHT·

/~

16GAl-------------;::::::::;;..:::t-4JITf

V

10/WHT

·loG

A

K2·67

SA

TIME~RELAY

TT

.GND

FUEL

SYSTEM

WHT/BLKIGRN·I&GA

ECU.J2·11

~~~~========~------------------~

FUEL

INJECTOR 4 I

UPPER

!

IN

L I l

V10·16GA

BLK

·18GA

CONNECTION FOR

ONLY

RUNS

(AUXI

INTAKE

THROTILE

AUX

BLOWER,

POWERED

OR

PRIMES.

FOR

WHEN

RELAY,

ETC.

ENGINE

BODY

FUEL

LOWER

INJECTOR

(

1NL21

12

8LU·I6GA

BRN·I8GA

YEL·IBGA

WHT·I8GA

WHT

/ORG

IIHT/BLK/RED·ISGA

ECU

J2·12

ECU

J2·35

ECU

J2·33

ECU

J2·34

• 20G4

ECU

J I • 5

t>---f-!!...<~:;:::,...J.j.!l.b!L-,

ECU

Jl·7

~>--+'-<8E=---.!~l!!...--j

AUXILIARY

RELAY

THROTTLE

STEPPER

MOTOR

(STEPPER I

TEMP

(AIR.

HARNESS

#055489

This harness plugs into an AUX connection located below the Fuel Cell.

or

It

provides

DC

power only when the engine is running

is being primed. MAXIMUM DC power is 400 milliamps,

sufficient to open or close a relay.

MAP

SENSOR

(MAP

INTAKE

I

AIR

SENSOR

TEMPI

#16

BLK

B-----=-~

#I

6 R [ D

Engines & Generators

39a

GENERATOR

USE

OF

ELECTRIC

The power required more

than

is

required to keep it running after it Some motors require others. Split-phase (AC) motors require more current under similar circumstances, than other types. They are monly used on easy-starting loads, such machines, or where loads are applied after the motor

started, such 7 times avoided, whenever possible, driven induction motors require from 2 to

start

varies with the load connected to

nected

current

fu

general,

to

medium

MOTOR

as

much current

by

a small generator. Capacitor and repulsion-

as

to

run. The current required to start

to

an

air compressor,

than

a motor

the

starting

SIZE

(HP)

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

1

MOTORS

to

start

an

electric motor

much

more current to start them than

small power tools. Because they require 5

to

start

as

to run, their

if

the electric motor

to

4 times

it

An

for

example, will require more

to

which

no

load is connected.

current

required

loads

to

start

will

be

approximately

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2

13

115-

'

is

considerably is

started.

as

washing

use

should be

is

to

as

much current any

motor

electric motor con-

Volt

motors

connected

as

follows:

AMPS

FOR

STARTING

(AMPERES)

6.4

to

22.4*

9.2

to

32.2*

10.4

to

72.8*

14.4

to

29.2*

20.4

to

40.8*

26

to

52

is

to

com-

be

INFORMATION

start,

to

Required

Run the generator first with

generator's capacity, indicted on the generators data plate. The output voltage should be checked periodically the generating plant and the appliances it supplies. To monitor voltage and load, check it with a portable meter amp probe.

Generator

Maintaining reasonable cleanliness

of

terminal boards and rectifiers may become corroded, insulation surfaces may start conducting if salts, dust, engine exhaust, carbon, etc. are allowed ventilation openings reduced life

In addition to periodic cleaning, the generator should

inspected overheated terminals andloose or damaged

Operating

Maintenance

of

windings.

for

tightness

Speed

no

load applied, then

and

finally loaded to

to

ensure proper operation of

to

may

cause excessive heating and

of

all connections, evidence of

its

is

important. Connections

build up. Clogged

full

wires.

at

half

capacity

be

the

as

and

*NOTE:

In

the

above

table

the

maximum Amps for Starting

more

for some small motors

for

this

is

that

the

hardest starting types (split-phase)

made

in

larger

sizes.

Because the heavy surge of current needed for starting

motors

is

required for only

be

damaged if it seconds. off on

If

all

other electrical loads

the electric

can

difficulty

motor.

than

for larger

an

instant, the generator will not

bring the motor

is

experienced

and,

if possible, reduce the load

ones.

T11e

up

to speed in a

in

starting motors, tum

reason

are

not

few

is

40

SBCG

DESCRIPTION

and

TROUBLESHOOTING

REFER

BRUSHLESS GENERATOR

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

60Hz

120

50Hz

230

CAPACITOR

RPM

at 2200

Volts

30.Ampsjor

Volts

15

Amps for

ALSO

TO

SBCG SBCG

THE

SPECIFICATION

TROUBLESHOOTING

Refer

to

the following page for

Schematic

CAUSE

No

AC

Residual Line • Neutral No

Load

Low Voltage

AC

Voltage

Inductive

NOTE:

belt under the generator base frame.

Output

AC

Output 60

and

Voltage

at

(6·8

VAC)

-100

Drop

Load

It

would

the

Volts

with

be

PAGE

BCG

Winding

FAULT

1.

Shorted

2.

Open

3.

Shorted

4.

5.

Shorted

6.

1.

2.

3.

1.

2.

3.

1.

2.

3.

important

the

BCG Internal

Resistances.

Stator.

Rotor

Shorted

Rotor Rotor

Open

Rotor

Faulty

Capacitor.

Open

Exciter

Shorted

Exciter

Faulty

Rotor

Faulty

Rotor

Faulty

Exciter

Faulty

Rotor

Faulty

Exciter

Amperage

to

inspect

CHART

Diode. Thermister.

Capacitor.

Diode.

Winding.

Diode. Winding.

Capacitor.

Diode.

Capacitor.

Overload.

the

pulley and drive

Wiring

AC

OUTPUT

CONNECTIONS

GREEN

1'0

STARTEIIllROUNIJ

AC

~___:c:.;.;;.;,;;;__--,

...O,...J---::8::-:LA:-:::CK::o;-

22DV·SOHZ

23DV/50Hz

120V/60Hz

DIAGRAM

..

.......,

AC

·CIRCUIT

BREAKER

41

S·BCG

BCGBACKEND COMPONENTS

(TOP

VIEW)

WINDING

RESISTANCESnNTERNAL

WIRING

DIAGRAM

WINDING

60

Hertz

Rotor Excitor Winding - 2.0 Ohm Capacitor

RESISTANCE

Models :

Winding - 4.0

Rating

Stator

-'

35 uF

ROTOR

(Measured

Wmding

Ohm

at

0.93 Ohm/winding..

SBCG

INTERNAL

20°C/68°F)

SO

Hertz

Rotor

Wmding-

Excitor Wmding - 2.5

Capacitor

WIRING

STATOR

, Bm,

· .

DIAGRAM

YelorGrn

WHITE

TERMINAL

Models :

Rating-

Stator

4.0

Ohm

31.5

BOARD

Winding 1.35 Ohm/winding

Ohm

uF

EXCITOR

I

•.

• •

42

BLACK

lll

li

RED

.

RED

l

~~~

) .

LAY-UP & RECOMMISSIONING

GENERAL

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

The procedures which follow will allow you to perform your

own lay-up and recommissioning, or you may use them as a

check list These procedures should afford your engine protection

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

If

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

if

CYLINDER/SPARK

Spray fogging oil into the open air intake, with the flame arrester removed, while the engine is running. The fogging

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 and firmly attach the high tension

LUBRICATION

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

oil sump. Remove and replace the oil filter and fill the sump with new oil.

ENGINE LUBRICATING OIL pages in this manual for the

oil changing procedure. Run the engine make sure there are no leaks.

A

CAUTION:

oil

in

the

and

combustion

chemicals internal

parts.

on

their boatyards to prepare their craft,

of

inactivity. Others prefer

others do the procedures.

of

your engine.

PLUGS

remove

them.

Rotate

the

engine by hand

the

spark plugs and tighten securely

Zeds.

SYSTEM

Use the correct grade

Do

not

leave

the

sump

over

the

lay-up

period.

deposits

which

can

combine

reduce

the

be

more than willing to

the

spark plugs

two

of

oil. Refer to the

engine's

old

engine

Lubricating

to

produce

life

of

your

harmful

engine's

and

complete

oil

INTAKE

Clean the filter screen in the flame arrester, and place a clean cloth lightly soaked in lube oil around the flame arrester to block any opening. Also place an oil-soaked cloth in the through-hull exhaust port, Make a note to remove cloths prior to start-up!

FUEL

Top off your fuel tanks with unleaded gasoline

or higher. A fuel conditioner such as stabil gasoline stabilizer 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 is accessible when the flywheel cover is removed. Make sure the battery connections are shut off before attempting to remove the starter. Take care in properly replacing any electrical connections removed from the starter.

SPARE

Lay-up time provides a good opportunity to inspect your Westerbeke engine to see or kit and order items not during the lay-up, such as filters and zinc anodes. Refer to the

MANIFOLD

SYSTEM

of

89 octane

no

leaks. Clean up any spilled oil.

MOTOR

of

the starter drive pinion is

PARTS

if

external items such as drive belts

coolant hoses need replacement. Check your basic spares

on

hand, or replace those items used

SPARE

PARTS

section

of

this manual.

BATTERIES

If

batteries are to make sure that they are fully charged, and will remain that way, to prevent them from freezing. the batteries will not remain fully charged, or that they will be subjected to severe environmental conditions, remove the batteries and store them in a warmer, more compatible environment.

be

left on board during the lay-up period,

If

there is any doubt that

Recommissioning

The recommissioning

seasonal lay-up generally follows the same procedures as those described in the section regarding preparation for starting and normal starts. However, some counteracted before starting the engine.

1.

Remove any rags that were placed in the exhaust, intake

manifold,

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 to proper tightness.

3.

Make certian the cooling system intake hose is attached and the thru-hull valve is open. .

or

to

make sure that the batteries are fully charged,

of

your Westerbeke engine after a

PREPARATIONS FOR STARTING

of

the lay-up procedures will need

flame arrester.

to

~

be

4.

Check the conditton replace as needed.

5. Make certain all electrical connections and switches are in the correct position and there are no-loads generator at start-up (see

6. Inspect the fresh water pump impeller, replace necessary.

7. Start the engine in accordance with the procedures

described in the section

of

WESTERBEKE

Engines & Generators

43

of

PREPARATIONS

this manual.

the heat exchanger zinc, clean or

on

the

GENERATOR).

if

FOR

STARTING

3.5

KW

SBCG

GENERATOR

SPECIFICATIONS

Engine

Type Bore & Stroke Total

Displacement Bearings Valve

System Compression Firing

Order

Aspiration

Direction

of Inclination Dry

Weight

Governor

,

Fuel

Pump Fuel Fuel

System Ignition

Timing

Ignition

Coil

Flame

Arrester

Fuel

Consumption

(Fun

Load)

Start

Motor

Starting

Battery

Capacity

Battery

Charging

DC

Amperage

ENGINE

Ratio

Rotation

Draw

SPECIFICATIONS

Two

cylinder,

four

2.40 x 2.36

21.4 Two Overhead

9.2:1 1-2 Naturally Counterclockwise 25°

188

Electronic

FUEL

Mechanical Unleaded Multi-port 12-Volt 12Volt. Metal

0.5

ELECTRICAL

12-Volt, 12-Volt,

600-900 11 70

inches

Cubic

Inches

main

bearings.

cam-cross

aspirated.

maximum

lbs

(8.55

Kg)

ECU

SYSTEM

fuel

89

octane

EFI

flywheel

screen

type.

GPH @ 2200

SYSTEM

0.6

Kw.

(-)negative

Cold

Amp

Amps

DC

cranking

angle

pump.

magneto.

Cranking

stroke

gasoline

(61 x 60

(.351iter)

flow.

viewed

from

of

operation

or

higher

RPM.

ground

Amps

engine.

mm)

the

back

·

gasoline.

(CCA)

end.

Type Oil

Filter

Oil

Capacity

Oil

Grade

General

Raw

Water

Pump

Raw

Water

Flow

AC

GENERATOR

Type Speed

3.5Kw

TUNE-UP

Spark

Plug

Gap

Spark

Plug

Torque

Bolt

Torque

Engine

Combustion Generator Engine

Ambient Recommendations

Cooling

Compartment

Temperature

LUBRICATION

Wet

sump

Full

flow,

1.5

qts.

API

specifications

SAE

10W-30,

COOLING

Fresh Thermostatically

Positive

belt

driven.

2.5-3.0

SYSTEM

system

paper

element,

(1.4

L)

10W-40,

SYSTEM

water

cooled

displacement

GPM

(9.5

(SINGLE

Brushless 3600

3000

3.5 2

RPM RPM/50Hz

KW -60

wire,

29

KW -50

wire,

15

Capacitor

/60Hz.

Hz

single

amp.

Hz

single

amp.

SPECIFICATIONS

0.032 -0.035in 11

-151b-ft

See

TORQUING

AIR

REQUIREMENTS

13

CFM

200

CFM

122" F (50°

(15-

(0.287

(5.66

C)

(0.8-

cmm)

maximum

trochoid

spin-on

SJ,

SL,SM

15W-40

via

raw

controlled

type,

-11.3

LPM)

PHASE)

phase,

0.9mm)

20

Nm)

THE

CYLINDER

type

pump.

or

better.

water

heat

exchanger.

rubber

120

230

HEAD.

disposals.

pump.

impeller,

volts

Engines & Generators

44

SUGGESTED

SPARE

PARTS·

SPARK

PLUGS

CONTACT

YOUR

WESTERBEKE

DEALER

ENGINE

MARINE

BELT

GASOLINE

FOR

SUGGESTIONS

WATER

FUEL

FILTER

CARTRIDGE

AND

O·Rl~~~

PUMP

BELT.

GENERATORS

AND

ADDITIONAL

.

..--.

INFORMATION

GASOLINE FUEL/WATER FILTERS

~

ATNl20A.FUSE.

ZINC ANODE

. '

IMPELLERS; AND

WESTERBEKE HAVING FOR

AT

WES1ERBEKE 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

·o-RINGS

GLYCERIN

ENOUGH

LEAST

TUBE

ALSO"

RECOMMENDS

OIL

ON-BOARD

ONE

OIL

CHANGE

also offers two Spare Parts Kits;

A

KIT

FILTER

DRIVE

BELT

ANODE

PLUGS

FUSE

PUMP

BELT FILTER EXCHANGER

KIT

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

0-RING

BELT

SET

KIT

SWITCH

ZINC

45

jr~

'WESTERBEKE

member

;f%,"'fdf

---

j

WESTERBEKE

J

MILES

WEBSITE:

CORPORATION • 150

STANDISH

WWW

INDUSTRIAL

WESTERBEKE.COM

PARK • TAUNTON

INDUSTRIAL

ROAD

MA

02780

10/2016/1233

Westerbeke 3.5 SBCG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual