Westerbeke 4.5 BCGB, 3.8 BCGB, 7.0 BCGB, 5.0 BCGB Operator's Manual

..,

·o

11

to""'

OPERATORS

4.5

3.8

FOR

BCGB -60HZ

BCGB -50Hz

THE

q

MANUAL

AND

7.0

5.0

BCGB-

60HZ

BCGB -50Hz

..

.

GASOLINE

GENERATORS

SINGLE

PUBLICATION

OCTOBER

2nd

WESTERBEKE

MYLES

STANDISH

WEBSITE:

WWW.WESTERBEKECOM

.

~

PHASE

N0.044200

REVISION

CORPORA

T/ON • 150

INDUSTRIAL

. . .

2015

JOHN

PARK • TAUNTON

HANCOCK

MA

..

ROAD

02780

A

WARNING:

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF GET

1leek

until

gasses

gas. can

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

contain

Carbon

and

include:

and

Sleepiness

THE

attention.

inspected

Carbon

Monoxide

death~

SymptomS

•

•Inability

ELSE

EXPERIENCE

FRESH

AIR

IMMEDIATELY.

Shut

down

and

A

WARNING

WESTERBEKE

bulkhead

WESTERBEKE CARBON living/sleeping

They obtainable

Monoxide,

is-poisonous

Throbbing

Muscular

Vomiting

repaired.

are

an

tlf

Carbon

in

Twitching

to

ANY

OF

the

unit

DECAL

and

near

your

also

MONOXIDE

quarters

inexpensive

at

your

odorless

and

Temples

Think

THESE

If

symptoms

and

is

should

engine

recommends

DETECTORS

local

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

restart

provided

be

or

of

your

and

easily

marine

persist,

by

fixed

to

a

generator.

installing in

the

vessel. store.

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

and

of

State

65

WARNING

gasoline

its

constituents

of

California

birth

defects,

harm.

engine

Gasoline

with

an ETHANOL conte·nt

higher

than

and

10°/o

may

(E10)

is

not

allowed

void warranty.

TM

Engines & Generators

Blank

page

I"MfUVESTERBBKE

l EnglneJ &

a..nerators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

tlzis

safety

manual

caused

by

failure

to

follow precautions. take

the

personne~

The

foUowing

American

PREVENT

A

while

these

• Do

enclosures

•

Shut equipment

•

Use equipment.

•

Make (particularly

•,

Remove electrical

PREVENT

A

exhaust

veryhotl

•

Monitor coolant location when

A

•

In

before

Know

when

necessary

Boat

WARNING:

engine

precautions

and your

ELECTRIC

machinery.

safety instructions are in complitmce with the

and

Yacllt Council (ABYC)

SHOCK

Do

not

Is

nmnlng.

connet:tlonsl

not

operate

off electrical power before accessing electrical

insulated

sure

WARNING:

system

recovery

the

WARNING:

case

of

touching

this

machinery,

and

covers

mats

whenever working on electrical

your clothing and skin are

shoes)

when

wristwatch

equipment.

BURNS-

Do

and

HOT

not

components. A running

engine

antifreeze

tank

on

the

water jacketed exhaust manifold, but only

engine

is

COLD.

Steam

an

engine overheat, allow the engine

the engine or checking the coolant.

cqrefuUy.

fundamental ntles and •

dangerous conditions

Most

accUlents

uist

to

protect yortrself, your

are

and

standtzrds.

touch

AC

electrical

Lethal

voltage

without electrical

in

place.

handling electrical equipment.

all jewelry when w9rking on

connections

is

present

dry,

not damp

at

·

ENGINE

touch

hot

engine

parts

Dr

engine

gets

coolant level at the plastic

and periodicaly at the filler cap

can

cause

Injury

or

death!

to

cool

'PREVENT

A

• Prevent flash fires. Do not smoke or permit sparks to occur neat the carburetor, pump, or other potential sources vapors. Use a suitable container to removing the fuel line; fuel filters. or other fuel

Do not operate

• arrester screen removed. Backfire can cause

or death.

IIi

Do not smoke or pennit the fuel

engine/generator clean and chances

PREVENT

A

Injury

•

Follow

.

hatches after the starting,

• All

when

well~ventilated

equipment and out

•

Do

• Shut off the fuel service valve at the engine

tho

spill. sources servicing. the fuel system.

• Do not alter or

•

Be

• Be certain fuel line fittings are adequately tightened free of leaks.

:

·•

Make sure a properly maintained Be familiar with its Extinguishers rated ABC by the for all applications encountered in this environment.

BURNS -FIRE

WARNING:

system components. -

system. Keep the compartment and the

of

BURNS -EXPLOSION

WARNING:

or

death!

re-fueling safety instructions.

closed when fueling. Open and

fueling.·

blower.

follow

fuel

vapors

handling and storing fuels.

not fill the fuel tank(s) while the engine

fuel system.

DO Nar allow any smoking,

of

sure all fuel supplies have a positive shutoff

Fire

can

cause

injury

or

death!·

fuel

line,

of

spilled

c..atch

all

with

the air cleaner/silencer or

flames·

or sparks

free

of

fire.

Wipe up all spilled

Explosions

Check'

Run the engine compartment blower

the

recommendation of

are

highly explosive. Use

from

fuel

below for fumes/vapor before

Store

area away from

Thke

fire

near

Ensure

proper

modify

fire

extinguisher

of

the reach

care in catching any fuel

the

fuel

the fuel system.

spark~producing

of

system

ot

veniil.ation exists when servicing

is

installed nearby

NFPA

to

debris

to

fuel

and engine

vapors

Keep

ihe

ventilate

the

vessel

extreme

fuel

ohildren.

opeTI;flames,

engtrte

proper

are appropriate

fuel

in

when

flames

filter,

or

fuel

flame

severe

occur

minimize the

can

vessel's

cabin prior

a

is

running.

that

valve.

or fuel

fuel

when

injury

near

oil.

ca.

running

to

builder.

care

servicing

might

or other

and

is

use.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

•

Thrn

unit's battery selector switch to engine.

•

Make starting.

•

Make re-installed before starting the engine.

BATTERY

A

WARNING:

or

death!

•

Do

not smoke being serviced. Lead acid batteries highly explosive gas, which

arcing equipment in the vicinity to prevent electncal arcmg during servicing.

• Never connect the positive ( +) connection terminal Do

not test the battery condition together. Sparks could ignite Ventilate any compartment contammg battenes to prevent accumulation disturb the battery charger connections while the battery is being charged.

• Avoid contacting the terminals with tools, etc., to prevent bums wristwatch, rings, and any other jewelry before handling the battery.

• Always the battery connections. Remove the negative lead first and

BATTERY

A

WARNING:

severe

•

When

level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain destructive. it

off into the eyes inadvertently when removing electrolyte caps.

STARTING

Accidental

OFF the

DC

breaker

certain all personnel are clear

certain all covers, guards,

starting

on

the control

OFF

can

cause

pan~l

before

of

the engine before

and

hatches are

servicing the

EXPLOSION

Battery

or

by

lit tobacco products. Shut

of

or

sparks that could cause

tum

the battery charger

reconnect it last when servicing the battery.

explosion

allow

an

negative(-)

explosive gases. To avoid sparks, do not

can

cause

injury

open flame near the battery

~mi~

hydrogen,

can

be

1gmted

by

o~

all

ele~tncal

battery cable to the

of

the starter

by

shorting the termmals

batt~I?'

gases

an

explosion. Remove

off

before .disconnecting

solenoi~.

o~

fuel vapors.

ACID

Sulfuric

injury

or

death!

servicing the battery

If

it comes in contact

at once with water.

acid

in

batteries

or

checking the electrolyte

sulfuri~

Acid

acid

w1th

your skin, wash

may splash

can

whic?

on

the skin

injury

or

tum

the

~

elec~cal

cause

is

or

TOXIC

• Ensure that the exhaust system is adequate to expel gases

•

• Although diesel engine exhaust gases are not as toxic as

·AVOID

EXHAUST

A

WARNING:

discharged from the engine. regularly for leaks

water-injected elbow is securely attached.

Be

sure the unit

Run

blowers when running the generator set

Do

not

run equipped with a functioning marine carbon monoxide detector that complies with boat

builder

detectors. For

additional information, refer to

(educational information

A

WARNING:

odorless nausea

gas.

or

Do

not use copper tubing Diesel fumes systems. Exhaust sulfur causes rapid deterioration copper tubing resulting

Do

not install exhaust outlet where exhaust can through portholes, vents, exhaust discharge outlet is enter the exhaust discharge outlet and close

of

flow

exhaust fumes from gasoline engines, carbon monoxide gas is present

poisoning are:

exhaust. Avoid overloading the craft.

symptoms

Vomiting Dizziness Headache Nausea Weakness and sleepiness

MOVING

A

WARNING:

or

death!

•

Do

not service the engine while it is running. situation arises in which it is absolutely necessary to make

operating adjustments, use extreme care to avoid touching moving parts and components.

GASES

Carbon

and

its surroundings are well ventilated.

the generator set

or

dealer for installation

Carbon

Inhalation

death!

can

rapidly destroy copper tubing in exhaust

in

diesel exhaust fumes.

or

signs

of

PARTS

Rotating

monoxide

make

on

monoxide

produces

in

or

carbon monoxide inhalation or

Inability Throbbing in temples Muscular twitching

parts

(CO)

is a deadly

Check

the exhaust system

sure the exhaust manifold/

or

engine unless the boat is

ABYC

A-24. Consult your

of

approved

ABYC

TH-22

Carbon Monoxide).

(CO)

is

an

invisible

flu-like

diesel exhaust systems.

exhaust/water leakage.

air conditioners.

near

the waterline, water could

can

hot

exhaust system

symptoms,

If

or

restrict the

Some

of

to

think coherently

cause

injury

If

gas!

engine.

of

be

drawn

the engine

the

a

Engines & Generators

ii

•

Do

not

wear

loose

equipment;

jackets,

could

•

Make Keep places

•

Do

not

the

engine

•

Do

not

the

exhaust generator death

HAZARDOUS

A

WARNING:

tie

shirts,

be

caught

sure

all

attaching hardware

protective

at

all

times.

check

fluid

is

operating.

allow-any

discharge

is

operating.

can

occur.

NOISE

back

sleeves,

High

loss/

•

Never

•

Do

not flame

arrester

•

Do

not open

(when

A

WARNING:

1111ntally

operate

run

the

removed.

run

engines

installed).

or

physically

an

engine with

Do

SAFETY

clothing or jewelry

long

hair and avoid wearing loose

rings, necklaces or bracelets that

in

moving

shields

levels or

swimming or activity around or near

parts.

and

guards

the

opening for the generator while

Carbon Monoxide poisoning or

.

nolss/evels

engine without

the

for long periods with their enclosures

not

work

on

Incapacitated

when

servicing

is

properly tightened.

in

their respective

drive belt's tension while

can

causs

hearing

its

muffler installed.

air intake (silencer) or

machinery

by

fatigue!

when

you

INSTRUCTIONS

ABYC, INSTALLING

Read for safety codes and standards. Follow their tions

ABYC (American Boat and "Standards and Technical Information Reports for

Craft"

Order

the

Order

are

NFPA

AND

ENGINES

the

following ABYC,

when

installing your engine.

from:

ABYC 613-Third Street, Suite Aprtapolis,

\vww.abycinc.org

NFPA -

"Pleasure and Commercial Motor Craft"

from:

National Fire Protection Association Battery March Quincy,

USCG.(United States

''regulatedions are

Code of Regulations"

from:

U.S. Washingt9n, D.C. 20404

MD

21403

No.3oi

Park

MA

02269

Government Printing Office

USCG

PUBLICATIONS

AND

GENERATORS

NPPA

and USCG publications .

Y4cht

Council)

10

(National Fire Protection Association)

Coast Guard)

under titles

CFR33

FOR

recommenda-

and

CFR46

Small

of

the

OPERATORS

Many

of

in

your

notes

to carefully, procedures.

GASOLINE

Preparations begin

with a thorough

Yacht

Council's

a

combination

Sections H-2

Ventilation

·

H-24

Gasoline

P-1

Installation for

P-4

Marine

B-llAC All

installations

Regulations www.abycinc.org

MANUAL

the

preceding

Operators

highlight

maintain

ENGINE

to

in~

(ABYC)

of

the

ABYC

for

Fuer Systems

of Exhaust Systems

Propulsion

Inboard

and

DC

Electrical

must

(PCR).

sources

safety

tips

and warnings are repeated

Manual

critical information. Read your manual

along with other cautions

your

equipment, and follow all safety

AND

GENERATOR

a gasoline engine or generator should

examination

standards. These standards are

lnc~uding

standards of particular interest

Boats

using

and

Auxiliary Engines

Engines

Systems on Boats

comply

of

Gasoline

and

Transmissions

with

the

INSTALLATIONS

the

American Boat

the

USCG and

Federal Code of

the

and

NFPA.

~:

and

from

Engines & Generators

iii

INSTALLATION

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

CODES

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

AND

REGULATIONS

SIPHON-BREAK

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

will

be

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

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

minimum

the exhaust manifold raw

If

you have any doubt about the position

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

siphon-break.

NOTE:

operation. engine

EXHAUST

The exhaust system's hose MUST be certified for marine use. Corrugated Marine Exhaust Hose is recommended. The use and turns without the and turns. system under any sea conditions and at any angle

of

20" above the vessel's waterline.

water

damage

A siphon-break

Failure

damage.

injection

to

the

requires

to

properly maintain a siphon-break

Consult

port

is

at

engine

and

possible

periodic inspection and cleaning

the

siphon-break manufacturer for proper maintenance.

SYSTEM

need

of

additional fitting and clamps to accomplish these bends

In this regard, a single length

MUST be designed to prevent the entry

Failure

or

below

flooding

of

the water-injected exhaust elbow relative

the

to

use

a siphon-break

load

waterline

of

the

boat.

will

when

result

install a

to

ensure

proper

can

result

in

catastrophic

of

this type

of

corrugated exhaust hose can be used. The

of

hose allows for extreme bends

of

water into the exhaust system

vessels heel.

in

AVAILABLE YOUR

··DEALER

SIPHON~ifiiEAJ(WiTH

LOOP'

FROM

WESTERBEKE

STAINLESS

A

detailed engines to

and

download

Marine

Installation generators, from

our

Manual

is

supplied

website

at

Engines & Generators

covering

with

www.westerbeke.com.

iv

each

gasoline

unit. A pdf

and

diesel,

is

available

TABLE

OF

CONTENTS

Parts

Identification

Introduction

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

Fuel,

Engine

Control

..

Oil

Panels Preparations Operating

Remote Panel ................................................. 9

Break-In

Safety

Instructions

Procedure/Dally

Shutdown Maintenance Cooling

Fuel

Carburetor Engine Oil Remote BCGB BCGB Remote

System

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

Thermostat ...................................................... 16

Heat Exchanger .............................................. 16

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

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

System

Carburetor .................................................... :

Fuel Lift Pump ................................................ 18

Gasdenser ........................................................ 18

Gasoline/Water Separator ............................... 18

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

Adjustments

Lub~icating

Pressure

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

Oil

Filter Wiring Wiring

Panel

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

-~·················

and

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

Engine

Coolant

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

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

for

Initial

Start-Up

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

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

SWitches

Schedule

Operation

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

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

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

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

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

011

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

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

Diagram Schematic

Wiring

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

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

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

..

2 3

.3

5 6

7

8

1 o

ll

12 14

15

17 17

18

19

20 21 22

23

24 25

Engine

Component Engine Generator BC

AC Battery Testing

Testing Battery

Shore Lay-up Generator Standard BCGB Metric Suggested

Adjustments

Speed Hertz Adjustment .................................

Torquing the Cylinder Head Bolts ................

Spark Plugs ............. ; .......................................

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

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

Choke Solenoid

Timing Belt ..................................................... 29

Engine Compression .... : ................................. 32

Testing

Troubleshooting

lnformatlon

Generator

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

Internal Wiring Schematic ..............................

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

Dual Exciter Model ........................................ 39

Terminal

Single

Board Circuit/Resistance the

Exciter

Field Testing Capacitor ..................................

Component Charging

Testing the Battery Charger ............................

Testing the Battery Charging Circuit ............. 44

Testing the Bridge Rectifier ..........................

Power

Transfer

and

Recommissioning

Specifications

Hardware

Conversions

Spare

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

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

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

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

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

Phase

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

Connections

Windings

Resistance

Circuit

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

SWitch

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

Values

(Charts)

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

Values

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

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

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

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

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

Torques

Parts

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

Chart

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

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

.....

26 26 26

27 27 28 28

33

34 36

37

.37

37 38

.40

40

.41 .41

42 43

43

.45

46

..47

49 50

51

52

53

j..,-#WESIEHBEICE

I

Eng,..

•

0enemors

1

WI'TER

INJECTED

EXKI'UST

COOli'NT

ENGINE

ElBOW

DRIUN

BCGB

. -

Oil

fill

·

PARTS

\DEHllflCAllOH

I'IR

INTAKE

REMOTE

PI'NEl

CONNECTION

-·

CIRCUIT

BREI'KER

GENERATOR

BI'CKEND

8

A.MP

fUSE

20

AMP

CIRCUIT'

BREAKER

KOURMETER

LEfT

CI'RBURETOR

S\DE

R\GHl

S\DE

flEXIBlE

REAR

MOUNT

.

RI'W

WATER

INJECTION

(SYPHON

BREAK

COK~ECTIOK)

KEI'T

EXCKI'NGER

C....q,_,_EIClL

Engines & Generators

2

fUEl

FRONl

UfT

PUMP

INTRODUCTION

This

WESTERBEKE Generator WESTERBEKE' technology. dependable performance of our engines and generators. Thank

you

In

order

to

it

is

important that you operate and maintain it manual manual throughout. your nearest WESTERBEKE dealer for assistance.

This provided and a Technical Manual WESTERBEKE this for

is

carefully and observe all the safety precautions

is

your Operators Manual. A Parts Catalog

equipment yourself, contact your WESTERBEKE dealer

WESTERBEKE'S Installation Manual.

WARRANTY

Your

WESTERBEKE

folder.

If

you card registering your warranty warranty writing number

with

and

S long years of experience

We

take

great pride

for

selecting WESTERBEKE.

get the

full

use and benefit

designed

to

help

Should your engine require servicing, contact

dealer.

Also, if

PROCEDURES

Warranty

have

not

received a customer identification

registration

model information, including the unit's serial

commission date.

form,

,.....,rWESTERBEKE

I Engines & Generators

Customer Identification

WESTERBEKE OWNER MAIN HOMETOWN, USA

Model BCGB Expires 9/20/02

STREET

Ser.

is

a product of

in

the superior durability

from

you

do

this. Please read this

is

available

you

are planning

is

included

60

days

after submitting

please contact the

#XXXXX-091 0

and

advanced

your generator,

correctly.

is

also

from

your

to

install

in

a separate

factory

in

This

the

and

WESTERBEKE OF

SUCH

SENTATIONS

RACY,

IN

NO

EVENT INJURY THE

FURNISHING

WESTERBEKE span between printings ofWESTERBEKE product software

and

the unavoidable existence of earlier WESTERBEKE manuals. WESTERBEKE products, whether from WESTERBEKE

other suppliers, must not and cannot

sively

as

not

only representatives of WESTERBEKE be

consulted

product software being consulted

SERIAL

· Fill

in

below

~~A-

?~

I

~I'

I J

.~.

The

engine number and serial number on

a decal

engine

The

generator serial number on

the

generator

CANNOT

SOFTWARE,

WITH

TIMEUNESS

BE

INCURRED

In

summation, product software provided

the

definitive authority

makes good sense but

to

NUMBER

the information f()r

referenc~,

BE

RESPONSIBLE

MAKES

RESPECT

OR

UABLE

IN

CONNECTION

OR

USE

customers should

determine the accuracy

NO

WARRANTIES

THERETO,

COMPLETENESS

FOR

ANY

TYPE

WITH

OF

SUCH

SOFTWARE.

also

be

on

the respective

is

imperative that appropriate

or

bv.

the

LOCATION/"\

~A'/:/),<

~/

~f>V

"

FOR

THE

INCLUDING

THEREOF

OF

DAMAGE

OR

ARISING

keep

in

relied

upon

the supplier

and

currentness of

customer.

·The

~

fJUfnber

))\

~~

znto

~l

.::JijiPiliiiiijiiiiiilliiijjiiiiiiiiijiiiiiijiiiiiii'\

II'

model

are

printed

on

the

manifold.

is

stamped

top

of

the

uu~'·"""'·

CONTENT

OR

REPREACCU-

AND

OR

OUT

mind

the

with exclu-

product.

in

question

engine

is

the

engme

WIU

OF

time

or

It

the

serial

st~mped

block.

CUSTOMER

The WESTERBEKE serial number number that can assist in determining the date of manufacture of your WESTERBEKE engine/generator. first character indicates the

second character represents

the

fourth and fifth number represents the manufacture. The 1999

and

PRODUCT

Product software (tech data, parts lists, manuals, brochures and

catalogs) provided from sources other WESTERBEKE CONTROL..

IDENTIFICATION

the

decade

BCGB

2002.

Models

SOFTWARE

are

not

within WESTERBEKE'S

CARD

is

(D=1990s,

the

year in

were

an

(Typical)

alphanumeric

E=2000s),

the

decade,

month

produced between

than

and

of

The

An additional decal

is

located

of

the

generator .

housing.

Engines & Generators

3

on

the

top

INTRODUCTION

ORDERING

Whenever replacement parts are needed, always provide the generator and engine model and serial numbers. In addition, include a complete part description and part needed (see the separately furnished insist upon WESTERBEKE packaged parts because or generic parts are frequently not made to the same specifications as original equipment.

NOTES,

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

NOTE:

A

observed, the

A

followed,

NOTE:

by WESTERBEKE. Affix this decal in a visable location in the engine room.

SPARES

Certain spare parts will be needed to support and maintain your WESTERBEKE generator or engine when cruising (see

SUGGESTED SPARE PARTS). Often even simple items such

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

PARTS

part number for each

Parts Catalog). Also

will fit

CAUTIONS

An

operating procedure essential to note.

CAUTION:

can

engine

or

WARNING:

can

A carbon monoxide warning decal has been provided

AND

WARNINGS

An explanation follows:

Procedures,

result

in

the

damage

which

or

if

generator.

Procedures,

result

In

personal

which

injury

If

ACCESSORIES

of

the proper WESTERBEKE parts.

of

your genera-

not

strictly

destruction

not

or

loss

of

properly

of

life.

PROTECTING

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

NOTE:

Six important steps to ensure long generator life:

• Proper engine

•

An

efficient well-designed exhaust system that includes

an

anti-siphon break to prevent water

engine.

• Changing the engine ing

hours.

• Proper maintenance

nents according to the maintenance schedule in this manual.

• Use clean, filtered unleaded fueL

• Winterize

Recommissioning" section in this manuaL

UNDERSTANDING

The gasoline engine driving an ways similar to a gasoline automobile engine. The cylinders are verticle in-line, and the engine's cylinder head has an overhead camshaft which is chain-driven. The engine utilizes a solid-state distributor which is horizontally mounted and camshaft-driven. The engine incorporates a pressure type lubrication system, and a fresh water-cooled engine block which is thermostatically-controlled. To a large degree, the generator's engine requires the same preventive maintenance that is required important factors to the generator's longevity are proper ventilation, maintenance cooling system and the generator backend.

YOUR

INVESTMENT

of

hours

of

dependable service. However the

or

where the generator is

or

the manner in which the unit is

and

generator installation

oil

and

oil filters every I 00 operat-

of

all engine

your

engine according to the "Lay-up

THE

GASOLINE

AC

generator is in many

of

a gasoline automobile engine. The most

of

the fuel system, ignition system,

and

from

and

generator compo-

GENERATOR

of

alignment.

entering the

and

Engines & Generators

4

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

A

CAUTION:

higher.

Ethanol Gasoline acceptable warranty.

Only use unleaded gasoline with higher. The use engine power and performance. Ethanol blended gasoline must not exceed EHf(lO%). Use use

in these models.

NOTE:

The

generator compartment should have a gasoline fume

deu:ctor/alarm

A

WARNING:

when

servicing

any

fuel

that

open

flames

tem

when

servicing

Care

Of

The

Use only clean properly filtered fuel! some components in the unit's fuel system are very critical;

dirt particles which might pass through the filter can damage

these finely finished pari$. and keep it clean. unsatisfactory facilities. To assure that the fuel going into the tank for your engine's daily advisable:

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

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

lls8

unleaded

gasoline

with

higher

percentages

for

use

in

these

of

a lower Octane gasoline will result in a loss

properly installed

Shut

off

the

fuel

may

spill.

or

other

sources

servicing.

Fuel

by

use is clean

Ensure

the

fuel

Supply

The

best fuel

careless handling

89

Octane

gasoline

must

not

exceed

of

models

an

Octane rating

of

higher blend is not acceptable for

and

working.

the

fuel

system.

DO

NOT

of

Take

allow

fire

proper

E10

Ethanol

and

may

valve

at care any

near

the

ventilation

smoking,

system.

The

fit

and

It

is important to

can

be

or

and

pure,

of

fuel.

buy

rendered

improper storage

ilil

following practice is

(11JD!o).

are

not

void

of

the

tank

in

catching fuel Sys·

exists

tolerance

clean fuel,

·

or

the

8910r,

of

tank

of

ENGINE

Use Specifications and Then the

Westerbeke Corporation does not approve the use break-in change intervals must SCHEDULE

synthetic oils are used.

NOTE:

statements regarding synthetic

ENGINE

WESTERBEKE and chemicals that can corrode internal engine surfaces.

The to run at proper temperatures the engine to the coolant. cooling circuit from rust and corrosion. Look for a good quality antifreeze that contains Supplemental Cooling Additives (SCAs') that keep the antifreeze chemically balanced, crucial to long term protection.

The before being poured into the cooling circuit.

NOTE:

antifreeze that

A proper 50/50 mixture as recommended will protect the engine coolant to temperatures

COOLANT

A coolant recovery tank kit is supplied with each generator. The coolant expansion and contraction during engine operation, without the loss the cooling system.

OIL

a heavy duty engine oil as called for in the

Section

filter after the initial

follow the oil and filter change intervals as specified in

MAINTENANCE

of

synthetic oil.

must

be performed using conventional oil. Oil

section

The

information above supersedes

of

the manual. Change the engine oil

50

hours

of

break-in operation.

SCHEDULE

If

synthetic oil is used, engine

be

as listed in te MAINTENANCE

of

the manual and not extended

oil.

in this manual.

or

disapprove

all

COOLANT

recommends a mixture

50%

distilled water. Distilled water is free from the

antifreeze performs double duty. It allows the engine

by

transferring heat away from

It

also lubricates and protects the

distilled water and antifreeze should

Use

the new environmentally-friendly,

is

now available.

of

RECOVERY

purpose

of

this recovery tank is to allow for engine

of

TANK

coolant and without introducing

-4Qop.

of

50% antifreeze

be

pre-mixed

long

lasting,

air

into

NOTE:

located at or above manifold.

Engines & Generators

5

This

tank,

with

the

its

shon

level

of

run

the

of

plastic

engine's

hose,

exhaust

is

best

CONTROL

PANELS

GENERATOR

The

ON components switches

Generator

The

ON contacts function fuel

pump. The

START/STOP momentary contacts contact function center (normal) position allows the generator started, and start/stop and

once released, reverts

~·position

in

an

emergency situation,

panel

stop

and

injector, should a malfunction is

being

be

should able

the remote control panel(s), preventing attempts

the

generator from their locations.

to

disconnect the battery during

to

perform

CONTROL

and

START/STOP

to

operate the generator

are

used

to

under OPERATING INSTRUCTIONS.

switch

is

a two-position switch

in

the

up

(on) position

in

the center position.

in

the center

also

enables the remote panel(s)

functions.

stops

the

switch) controls power

and

ignition relay coils,

performed

placed

in

the

maintenance.

PANEL

switches

start the generator -

switch

is

a three-position switch

in

the

up

The

up

(start) position

to

the

engine

as

o~cur.

During times

on

the generator, the

the

stationary (off) position.

are

at

and

a stationary contact

This

switch energizes

(start) position

and

down

center position. The

in

normal

it directly (unlike

to

the

thus

However,

this

time if it

the

see

with

(stop) positions.

operation

starter,

stopping

when

START/OFF

engine.

starts

only

functional

Both

Starting the

momentary

the

with

and

a stationary

to

be

run,

to

control

the

generator

down

as

well

the

remote

fuel

pump

the

maintenance

switch

This

will to

it

is

always best

is

not

required

The

once

the

as

engine

dis-

start

REMOTE

There for

1.

ON

1.

START/STOP

2.

Green

The contacts function fuel

The momentary contact functions

(stop) positions, and a stationary contact function

center position position (up) the ON to

the position, reverts

The condition. position, dims when START

PANEL

are

three functional components

generator operation:

switch

LED

indicator light

ON

switch

is

a two-position switch with

in

the

up

(on) position

in

the

center position. This switch energizes

pump. START/STOP

and

position,

switch

center position, run

this

to

the

Green

LED

It

the

engine starts, notifying

switch.

switch

The

center position

is

normally

this

switch starts

in

the

up

switch stops the generator,

center position,

indicator light indicates

lights

when

the engine

on

and

a stationary contact

is

a three-position switch

in

the

up

(start)

is a dual

in

the

off

mode.

When

the

generator (together

position)

mode.

the

off

ON

and

When

mode,

switch

is

cranking,

the

operator

once released,

in

the

is

the

remote

momentary

and

OFF/RUN

the stop (down)

and

once

engine

moved

and

to

panel

the

with

down

in

the

in

the

start

with

reverts

released,

running

to

the brightens realease

mode

start

the

GENERATOR

REMOTE

PANEL

CONTROL

PANEL

REMOTE

PANEL

Engines & Generators

6

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

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

• Check the engine oil level: add oil to maintain the level at the full mark on the dipstick.

• Check the fuel supply and examine the fuel filter/separator bowls for contaminants.

• Check the and battery cable connections.

• Check the coolant level in both the plastic recovery· tank and at the manifold.

NOTE:

the recovery the after tank will replace

Before manifold should tank

• Visually examine the unit. Look for loose or missing parts, disconnected wires, unattached hoses, and check threaded connections. Search for any gasoline leaks.

INSPECTION

DC

electrical system. Inspect wire connections

After

the

initial running

engine

:SO

cooling system will

tank.

Open

cooling system

the

engine has

be

the

subsequent operation

may

need

drawn

purged

be

to

is

into

air.

topped

be

of

the

be

purged

the

air bleed petcock

purged

cooled,

filled

of

air.

the

coolant

the

engines cooling system

of

the

off,

and

to

the

MAX

generator,

After shutdown and

from

generator, the

coolant recovery

level.

to

the

coolant

ensure

the

recovery

the

engines

air

that

to

in

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

• Examine the air inlet and outlet for air flow obstructions.

• Be sure no other generator the load lines.

• Be sure that in power systems with a neutral line that the neutral is properly grounded (or ungrounded) as the system

requires, and that generator neutral is properly connected

to the load neutral. In single phase systems an incomplete

or open neutral can supply the wrong line-to-neutral

voltage on unbalanced loads.

A

CAUTION:

recommended motors,

to precaution pated

cold

be

speed

operation

engine

and,

When

that

all

switched

in

cold

will

prevent

of

the

from

stalling.

or

starting

AC

loads,

OFF

until

climates,

damage

AC

machinery

utility power is connected to

the

generator,

IISpecially

the

engine

starts

to

caused

and

large

has

come

warm

by

unanticl·

will

prevent

It

Is

up.

up

This

a

Engines & Generators

7

OPERATING

INSTRUCTIONS

GENERATOR

Starting

To

start the generator, hold the momentary

up

(on)

switch in the together). After approximately one second, the starter will engage and the engine will crank . running, the starter will disengage, and the switch may then be released to return to its center position. Continue holding the sufficient oil pressure, then release

NOTE:

Should wait 20 than

20

START/STOP

Starting

Make certain the lubricating oil conforms with the ratings for the prevailing temperature. Check the table under

LUBRICATING

minimize voltage drop.

Stopping

To stop the generator, move the momentary START/STOP

switch to the down (oft) position then release it to the center (normal) position.

EMERGENCY

H the generator does not stop using the START/STOP switch,

remove the 8 amp fuse or disconnect the battery.

CONTROL

the

Generator

position , then hold the momentary START/STOP

up

(start) position (both switches are held up

the

engine fail

seconds,

seconds at a

~"'

and

/

....

~;-:>START

,"'

under

Cold

OIL.

the

Generator

PANEL

ON

switch in the

Once the engine is

START/STOP

(run

ON

switch until the engine has

it

to its center position.

to

start,

release

try

again.

Never

time.

SWITCH

Conditions

The battery should be fully charged to

run

both

the

starter

ON

SWITCH

switches,

ENGINE

mode)

more

STOPPING

GENERATOR

Abnormal

An abnormal stop is one in which the generator ceases

and comes to a stop as a result may cause damage to the engine, the generator, or create an unsafe operating condition. The fault stop conditions are:

1. Overspeed condition.

2. High engine temperature.

3. Low oil pressure.

CONTROL

St~p

PANEL

of

an operating fault which

to

run

A

CAUTION:

the

engine exhaust because raw

water

exhaust

this through-hull correcting

Engine

warrantable in

water

can

from

mind.

system

the

manifold

happening

damage

starting

with

pump cooling enter

the

shutoff,

the

cause

resulting

Issue;

Prolonged

can

result

raw

water.

Is

pumping

system

during

engine's

once

the

exhaust

by

closing draining of

the

from

the

owner/operator

cranking

in

filling

This

raw

water

cranking.

cylinders

system

the

raw

the

exhaust

excessive

raw

water

Intervals

the

engine

may

happen

through

This

by

way

fills.

water

muffler,

engine

entry

should

without

the

raw

of

the

Prevent

supply

and

cranking.

Is

not

a

keep

this.

Engines & Generators

4. High exhaust temperature. Should a fault condition occur, the engine will shutdown.

On

the remote panel the green ing an engine shutdown. located and corrected (see

LED

light will tum off indicat-

Once detected, the fault should be

ENGINE

TROUBLESHOOTING).

8

OPERATING

INSTRUCTIONS

REMOTE

Starting

To start the generator, hold the momentary

up (on) position (the green light will come on), then hold the

momentary

(both switches are held up together). After approximately one second, the starter will engage and the engine will crank (the green light will dim).

light will brighten)), the starter will disengage, and the START/STOP switch may then be released to return to its center (run mode) position. Continue holding the

until the engine has sufficient oil pressure, then -release it to its center position.

NOTE:

wait than 20 seconds

PANEL

the

Generator

ON

switch in the

START/STOP switch in the up (start) position

Once the engine is running (the green

ON

switch

Should the engine fail to start, release both switches,

20

seconds,

~...

START/STOP

and

try again. Never run the starter more

at

a time.

OFF/RUN·

__

'·,,

--<:~

STOP'.

SWITCif

OFF

ON

SWITCH

REMOTE

PANEL

Stopping

To

switch to the down (stop) position then release it to the center

(off/run mode) position. This will de-energize the K2 run

relay in the generator's control panel and stop the generator.

the

Generator

stop the generator, move the momentary START/STOP

Engines & Generators

9

BREAK-IN

After the generator has been started, check for proper opera-

tion and then encourage a fast warm-up. Run the generator

between

A

tor

by

PROCEDURE

20% to 60%

CAUTION:

running

Do

without a load.

of

full load for the first 10 hours.

not

attempt

to

break-In

PROCEDURE/DAILY

your

genera-

OPERATION

NOTE:

Some

unstable running may occur

This

condition should abate as normal operating temperature

is

reached and

A

CAUTION:

periods

of

loads

Do

not

time

without a load

are

applied.

operate

the

being

generator.

in

a cold

generator

placed

on

for

the

engine.

long

After the fust 10 hours

can be increased to the full-load rated output; then periodi-

cally vary the load.

Avoid overload at all times. An overload is signaled by a

smoky exhaust with reduced output voltage and frequency.

Monitor the current being drawn from the generator and keep

it within the generators' rating.

at 1800 rpm to produce 60 hertz, or at 1500 to produce

hertz, control by the current drawn from the generator.

To

protect against unintentional overloading

the generator's output leads should be routed through a cir-

cuit breaker that is rated at the rated output

NOTE:

current

amperage drawn

age.

See

CHECK

Follow this checklist each day before starting your generator.

• Record the hourmeter reading in your log (engine hours relate to the maintenance schedule).

• Visually inspect the engine for fuel, oil, or water leaks.

of

Be

aware

drawn

required for starting

GENERATOR INFORMATION

LIST

of

the generators' operation, the load

Since the generator operates

50

the generator's engine break-in is governed

of

the generator,

of

the generator.

of

motor starting

can

be 3 to

loads

and

the

high

motors.

5 times normal running amper-

in

This

this

starting

manual.

STOPPING

Remove the major AC loads from the generator one at a time. Allow the generator to run for a few minutes to stabilize the operating temperature and press the

CONTROL

NOTE:

the

maintenance schedule for

GENERATOR

Once the generator has been placed in operation, there may be governor adjustments required for engine speed (hertz) during the engine's break-in period this period (see under ENGINE ADJUSTMENTS. A no-load voltage adjustment may also be required in conjunction with the engine's speed adjustment (see

After

THE

GENERATOR

STOP switch down, (see

PANELS).

the

first 50 hours

of

generator operation check

the

50 hour service

check.

ADJUSTMENTS

(first

50

hours) or after

ENGINE SPEED (HER1Z) ADJUSTMENT

GENERATIOR

INFORMATION).

• Check the oil level (dipstick).

• Check the coolant level in the coolant recovery tank.

• Check your fuel supply.

• Check the starting batteries (weekly).

• Check the drive belt for wear and proper tension (weekly).

• Check for abnormal noise such as knocking, vibration and blow-back sounds.

• Confirm exhaust smoke:

is

When the engine When the engine is warm - almost Smokeless. When the engine

cold - White Smoke.

is

overloaded-

some Black Smoke.

Engines & Generators

10

SAFETY

SHUTDOWN

..

SAFETY

The engine is protected by a variety

Should a shutdown occur,

finding and co"ecting

Engine TROUBLESHOOTING

The following is a description switches:

High

An exhaust temperature switch is elbow. Normally closed, this switch will open and interrupt the DC voltage to the should the switch's sensor indicate an excessive exhaust temperature (an inadequate supply exhaust temperatures). This switch opens at

1320C).

SHUmOWN

starts,

runs

Exhaust

Temperature

This switch resets at approximately 225°F (107°C).

SWITCHES

of

do

no.t

attempt

the

cause. Refer to the heading

and

then

shuts down in the ENGINE

section

K2"run relay (shutting

of

this manual.

of

these automatic shutdown

Switch

locat~

of

raw water causes high

shutdown switches.

to

restart

without;

on the exhaust

off

the engine)

260-270°F (127-

..

Low

Oil

Pressure

Dual low oil pressure switches are located off the engine's oil

gallery manifold.

a static state. This switch functions in the automatic shutdown circuit when the unit is operating (5 psi rating). oil pressure switch is installed

ators. This switch is normally closed and functions in their

low oil pressure alarm system

Should the oil pressure drop to 10 psi while the generator is

operating, the

their low oil pressure alarm.

ther to

5 psi, the automatic shutdown circuit switch will open

interupting

off the generator.

sWitch

One

is normally open when the engine is in

only on

(10 psi rating).

SEA

RAY spec. switch will close activating

Should the oil pressure drop fur-

DC

voltage to the K2 run relay thereby shutting

SEA

RAY spec. gener-

The

second

TEMPERATURE SWITCH

High

Water

Temperature

A high water temperature switch is located at the thermostat housin,g.

· cooiant's operating temperature reach approximately 210op (99°C),_will relay thereby

1_95op

Normally closed, this switch, should' the fresh water

open and interrupt the

s1mttin_g_

(107°C).

TEMPERATURE SENDOR

Switch

DC

voltage to the K2

otf

the 'engine. This swftcli resets at ·

...

.

~un

Engines & Generators

OVERSPEED

BOARD

High

RPM

Shutdown

An

Overspeed

pulses.

to

Engine

The manual reset circuit breaker draw wiring event the generator will shut down because the opened breaker interrupts the should occur, check and repair the source After repairing the fault, reset the breaker and restart the generator.

Should the engine

a relay

on

this

the K2

run

automatically close once the engine stops.

Circuit

generator's engine is protected

or

electrical overload anywhere in the instrument panel

or

engine wiring will cause the breaker to trip. In this

Switch

PC

Board

in the

DC

circuit monitors coil

rpm

reach 2175 (approximately),

board

will

open

and

break

the

relay, Shutting the unit down.

Breaker

by

an engine mourited

(20 amps DC). Excessive current

DC

circuit

to

the 1<2-run relay.

of

·

DC

circuit

The

relay will

If

the problem.

·

this

11

MAINTENANCE

SCHEDULE

WARNING:

gloves,

and

panel,

or

tum

SCHEDULED

I

DAILY

Coolant Engine

Fuel/Water

Fuel

Visual

I

INITIAL

*Spark

Engine

*Exhaust

Air

*Valve

Inlet Fuel Mechanical

MAINTENANCE

CHECK

Level

Oil

Level

Separator

Supply

Inspection

50

HOURS

Plugs

011

and

System

Screen/Flame

Adjustment

Fuel

Filler

Filter

Governor

Never

attempt

use

the

off

the

BEFORE

of

Engine

OF

Filter

Arrester

to

perform

correct

tools

battery

switch.

START-UP

(owner

installed)

OPERATION

for

any

each

service

job.

When

while

the

engine

servicing/replacing

EXPLANATION

Check

at

Oil

level

Check

for

hours

or

Fresh

unleaded

performance. Check

for securing connections.

Clean/re-gap.

Initial

engine

Initial

check

Check

that Check

the

Remove,

necessary, Check

adjustment

Initial

change,

Initial

change,

Initial

oil

is

running.

recovery

should

water

once a year.

10%

fuel,

v-clamp

Look

oil

at

the

integrity/mounting

clean

then

change,

Wear

DC

components,

OF

SCHEDULED

tank,

if

indicate

between

and

dirt

gasoline

ethanol

oil

and

water

is

tight.

for

loose

and

filter

50

hours,

exhaust

hoses

and

re-install

once a year.

of

valve.

then

every

then

every

then

every

the

proper

MAINTENANCE

empty,

check MAX

in

fuel.

Drain

with

an

octane

maximum.

and

exhaust

No

exhaust

bolts/hardware

change

at

then

every

are

properly

security

screen

Check

again

250

hours

250

hours

250

hours

safety

tum

off

at

manifold.

and

LOW

filter

if

rating

leaks.

leaks

around

and

50

hours,

250

hours

attached

of

the

pack.

Inspect

at

500

or

once a year.

or

once a year.

or

once a year.

equipment

the

DC

Add

on

dipstick.

necessary.

of

89

or

higher.

Check

that

the

correct

then

change

or

once a year.

and

water

injected

rubber

hours.

circuit

coolant

Do

Replace

the

elbow.

as

needed.

both

that

the

exhaust

sealing

such

breaker

if

needed.

not

overfill!

filter

every

Lower

octane

water

injected

Inspect

wiring

every

Carefully

securing

elbow.

ring

and

•

as

goggles

on

100

hours.

inspect

clamps

replace

the

control

250

operating

will

affect

exhaust

and

electrical

for

are

if

and

engine

elbow

leaks.

tight.

I

EVERY

50

OPERATING

Drive

Belt

(water

Starting

Batteries

Electric

Fuel

Pump

Zinc

Anode

I

EVERY

100

OPERATING

Engine

Oil

and

Air

Intake

and

*WESTERBEKE

HOURS

pump)

Filter

recommends

OR

HOURS

this

MONTHLY

OR

YEARLY

service

be

performed

Inspect for

Check off

Inspect Inspect

your

Change Remove,

necessary.

by

an

knowledgeable

for

proper

slipping,

electrolyte

corrosion

for

leaks,

and

clean

own

inspection

engine

clean

tension

cracking

levels

if

needed.

ensure

zinc

oil

and

re-install

mechanic.

(3/8'

and

wear.

Make

sure

Apply

petroleum

fuel

and

anode.

Replace

schedule.

filter.

screen

to

112"

Adjust

cables

electrical

pack.

deflection) tension

or

and

connections

jelly

to

connections

if

necessary.

Inspect

and

adjust

replace

terminals

are

Note

rubber

if

as

needed.

are

for

corrosion

clean

the

condition,

sealing

needed.

Replace

in

good

and

ring

Check

cover.

order.

Clean

protection.

tight.

then

determine

and

replace

belt

if

1-.v-IWESI'ERBEKE

) Engines & Generators

.12'

MAINTENANCE

NOTE:

Use the engine hounneter gauge to log your engine hours

SCHEDULE

or

record

your

engune hours running time.

SCHEDULED

I

EVERY

*Exhaust

Fuel Inlet

*Generator

Hoses

*Ignition *Spark

Vibration Heat Mechanical

I

EVERY

Raw

*Exhaust

MAINTENANCE

250

OPERATING

Elbow/Exhaust

Filler

and

Fuel

Filler

Timing

Plugs

Isolators/Engine

Exchanger

Governor

500

OPERATING

Water

Pump

System

0-Rings

Catalyst

HOURS

System

Mounts

liOURS

OR

YEARLY

OR

YEARLY

EXPLANATION

Check

of

the

exhaust

chaffing.

NOTE:

Remove Remove Check

See

GENERATOR

Engine delaminated.

Check

Inspect, Check Open

heat

Change

Remove

plates.

Inspect.

the

structural

No

exhaust

An

exhaust

and

replace

and

replace

that

AC

hoses

should

Check

timing

and

clean,

vibration

exchanger

governor

the

purnp

Replace

OF

system

leak

connections

INFORMATION.

adjust

re-gap

isolators,

oil.

the

at

SCHEDULED

integrity

attached

leaks.

will

fuel inlet

be

firm

and

tighten

or

end

cover

impeller 2000

MAINTENANCE

of

the

to

the

Hoses

and

cause

exposure

filter

and

all

fuel

filter.

are

clean

and

tight.

all

hose

as

needed.

replace.

brackets

and

cap(s)

and

inspect

and

gasket.

operating

water

elbow.

muffler

sealing

and

Replace

clamps

mounting

clean

the

Lubricate

hours.

injected

All

hose

are

to

diesel

0-rings.

secure.

if as

out debris.

pump

assembly

exhaust

elbow

connections

in

good

serviceable

exhaust!

Ensure

wires

hoses

become

needed.

hardware.

Replace

for

the

impeller

casting.

should

have

spongy,

Replace

gasket

wear,

especially

when

Check

the

be

secure.

condition.

no

chafing.

brittle

or

as

needed.

and

0-rings

if

cam

and

re-assembling.

integrity

No

needed.

wear

EVERY

500

OPERATING

Ignition

Wires

•coolant

System

*Valve

Clearances

*Starter

Motor

EVERY

1000

OPERATING

*Engine

Timing

Belt

Heat

Exchanger

I

EVERY

2000

OPERATING

*Exhaust

System

*WESTERBEKE

recommends

Catalyst

HOURS

this

OR

EVERY

OR

service

TWO

EVERY

be

performed

YEARS

FIVE

YEARS

by

Inspect

for

Drain,

flush

thermostat

Adjust

valves.

Check

solenoid

motor

pinion

Remove

and

recommended to

the

engine.

Remove

the

Remove

and

an

knowledgeable

deterioration.

and

re-fill

the

and

coolant

pressure

(Incorrect

and

motor

drive.

replace

the·timing

interval

could

heat

exchanger

replace

exhaust

mechanic.

Test

cooling

valve

for

result

for

catalyst.

resistance.

system

cap.

clearance

corrosion.

belt.

NOTE:

in

timing

professional

with

appropriate

will

result

Remove

Failure

belt

cleaning

in

poor

and

to

replace

failure

and

antifreeze

engine

lubricate.

the

resulting

pressure

mix.

Replace

performance)

Clean

and

lubricate

timing

belt

in

major

damage

testing.

at

the

starter

13

COOLING

SYSTEM

DESCRIPTION

Westerbeke marine engines are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction circulates throughout the engine. This circulating fresh water coolant cools the engine block, its internal moving parts, and the engine oil. The heat fresh water coolant to raw water by means exchanger, similar water flows through the tubes fresh water coolant flows around the tubes; engine heat transferred to the fresh water coolant tube walls to the raw water which is then pumped into the exh11y_st

~

system where finally it is discharged overboard.

g

is

transferred to fresh water coolant which

is

transferred externally from the

of

a heat

in

function to

~.

COOLANT

an

automotive radiator. Raw

of

the heat exchanger whiie

is

conducted through the

RECOVERY

TANK

~!~~~~

In other words, the engine is cooled this coolant the transferred heat overboard through the exhaust system. The fresh water coolant and raw water circuits are independent engine allows the cooling water passages to stay clean and free from harmful deposits.

RAW

is

cooled by raw water, and the raw water carries

of

each other. Using only fresh water coolant within the

WATER/COOLANT

COOLANT

DIAGRAM

~

by

fresh water coolant,

RAWWAT~R-+

TO

SIPHEN

[IF

_,_-...,·

BREAK

REQUIRED]~

,__

\ \

I

- \

.,

\.1\

I

. I

~I

I

1_

COOLANT DRAIN

/I

//

/

RAW

WATER

D;SCHARGE/

Engines & Generators

NOTE:

WESTERBEKE recommends this raw water

discharge hose be looped above and down to the

. exhaust elbow as illustrated.

)

14

COOLING

SYSTEM

FRESH

NOTE:

recommended

fresh

Fresh water coolant is pumped through the engine by a circulating pump, absorbing heat from the engine. The coolant then passes through the thermostat into the manifold, to the heat exchanger where it is cooled, and returned to the engine block via the suction side engine is started cold, external coolant flow is prevented by the closed thermostat (although some eoolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the 'thermostat gradually opens, allowing full flow coolant to flow unrestricted to the external portion cooling system.

Coolant

A coolant recovery tank allows for engine coolant expansion

and contraction during engine operation, without any signifi-

cant loss

ing system. This tank should engine manifold level and should be easily accessible.

NOTE:

sure good closes

WATER

Refer

water

of

Periodically

cap.

Ensure

condition

tightly.

COOLING

to

the

ENGINE COOLANT section for

antifreeze

coolant.

Recovery

coolant and without introducing air into the cool-

check

that

and check that

Carry a spare

CIRCUIT

and water mixture

of

the circulating pump.When the

Tank

be

located at or.above the

the

condition

the

upper and lower rubber seals

the

vacuum

cap.

to

of

the engine's

of

the

valve

the

be

used

of

manifold

opens and

as

the

pres-

are

CHANGING

The engine's coolant must

MAINTENANCE SCHEDULE.

become contaminated,

A

COOLANT

CAUTION:

critical; a substantial traced

back

to

Drain 1he engine coolant by removing the drain plug on the engine block and opening the manifold pressure cap. Flush the system with fresh water, then reinstall the drain and start

the refill process.

NOTE:

The

drain petcock

be

used

to

help drain engine

A

WARNING:

Wear

protective

Refilling

After replacing the engine block drain plug, close the heat exchanger's coolant petcock. Then run the engine and

slowly pour clean, premixed coolant into the manifold.

Monitor the coolant in the manifold and add

the manifold to the filler neck and install the manifold pressure cap.

Remove the cap on the coolant recovery tank and fill with

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

After checking for leaks, stop the engine and allow it Coolant should draw back into the cooling system as the

in

engine cools down.

needed and check the coolant in the manifold. Clean

spilled coolant.

the

it

can lead to overheating problems.

Proper

cooling

number

cooling

system

on

Beware

gloves.

Coolant

Add

coolant to the recovery tank

be

changed according to the

If

the coolant is allowed to

system

of

maintenance

engine

failures

corrosion.

the

heat exchanger should

coolant.

of

the

hot

engine

coolant.

as

LOW

and

MAX

Is

can

be

also

needed. Fill

and replace

to

cool.

if

up

any

TOCOOLANT

RECOVERY

·

CHECKING

THE

PRESSURE

,

TANK:

CAP

COOLANT.EXPANSION

Engines & Generators

·

15

FROM

COOLANT

RECOVERY

TANK

··

COOLANT

IV!ANIF9LD

RETRACTION

COOLING

THERMOSTAT

A thennostat controls the coolant temperature as the coolant continuously flows through the closed cooling circuit. When the engine is coolant from flowing (some coolant is by-passed around the thennostat to prevent the exhaust manifold from over-heating). As the engine warms up, the thennostat gradually opens. The thennostat is accessible and can be checked, cleaned, or replaced easily.

Replacing

Remove the cap screws and disassemble the thennostat housing as shown. When installing the new thennostat and gasket, apply a thin coat ket before pressing it into place. screws. Run the engine and check for nonnal temperatures and that there are no leaks at the thennostat housing.

first started the closed thennostat prevents

Carry a spare thennostat and gasket.

the

Thermostat

of

sealant

on

both sides

Do

not over-tighten the cap

of

the gas-

SYSTEM

If

the zinc anodes need replacement, hold the hex boss into which the zinc anode is threaded with a wrench while loosening the anode with another wrench. This prevents the hex boss from possibly tearing off the exchanger shell. After removing the zinc, note the condition poor condition, there are probably alot the exchanger. Remove the end

clean the inside exchanger end gasket in case the present one becomes da:maged when removing the end cover. Replace the gasket (refer to your engine model's heat exchanger end gasket part number),

NOTE:

The

not

require insulate housinf!

TO

of

all zinc debris. Always have a spare heat

0-ring

and cover, and install a new zinc anode.

threads

the

sealant.

zinc from

of

the

zinc anodes

Sealant should not be used

the

metal

oreventing electrolysis action

ENGINE

BLOCK

f.·:;·

of

it.

If

the zinc is in

of

zinc flakes within

of

the heat exchanger and

are

pipe

threads

as

it

of

the

heat exchanger

on

the

zinc.

HEAT

EXCHANGER

may

and

do

THERMOSTAT ASSEMBLY

,APPLY

SE/j.LANT

TO

BOTH

SIDES

ZINC

ANODE.

A zinc anode (or pencil) is located in the raw water cooling

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

electrolysis on other components

of

dition

anode cleaned be carried onboard.

NOTE:

tion

the zinc anode should

or

replaced, as required. Spare anodes should

Electrolysis

and vessel

is

location,

the

result not that

The

be

checked monthly and the

of

each

of

NEW

purpose

of

the system. The con-

particular installa-

the

engine.

of

the zinc

REPLACE

ZINC~::

ANIDE.

HEAT

.

· The engine coolant (now cooled) flows back though the

EXCHANGER

Cool raw water flows through the inner tubes exchanger. As the engine coolant passes around these tubes the heat which is then pumped into the exhaust system and discharged.

engine and the circuit repeats itself. The engine coolant and raw water are independent other; this keeps the engine's water passages clean from the harmful deposits found in raw water.

Heat

After approximately 1000 hours and pressure test the engine's heat exchanger. (A local automotive radiator shop should be able to clean and test the heat exchanger).

NOTE:

of

Exchanger

Operating

that a heat exchanger cleaning

every 1000

~.'

. . . COOLANT.·

.

DRAIN.

of

the internal engine is conducted to the raw water

Service

of

operation, remove, clean

in

silty and/or tropical

be

hours.

waters

performed

more

the heat

of

may

require

often

each

then

Engines & Generators

16

RAW

WATER

NOTE:

Always install

the

strainer will always be self-priming.

A

clean engine's cooling strainer in

the

glass

Perform operation:

1.

Close

2.

Remove

3.

Clean

4.

Replace

5.

Reassemble

6.

Open

7.

Run

NOTE:

Also follow

aground.

If

the

engine temperature gauge ever normal may raw

reading,

have

water through

INTAKE

raw

water intake strainer

system.

when

making your periodic engine

should

the

following maintenance after

the

raw

and

clean

the

glass.

the

washer if

and

the

seacock.

the

engine

the

been

caught

STRAINER

the

strainer at or below

Include a

be

clear.

water seacock.

the

strainer

necessary.

install

the

and

check

the

above procedure after having

cause

may

up

in

the

cooling system

for

is

a vital component of

visual

inspection of

check.

every

filter.

strainer.

leaks.

shows

a higher

be

that

silt,

leaves

strainer, slowing

COOLING

the

waterline

The water

100

or

the

this

hours

run

than

grass

flow

so

the

of

hard

of

SYSTEM

RAW

WATER

The

raw non-ferrous housing has

flexible

within

the

On

no

account should

always

be

(an

impeller

when

lubricant operation. Such failures are are

cautioned

up.

The

broken

or

SCHEDULE.

NOTE:

Should a failure occur with

(seals

and

chase

a new pump and rebuild

Changing

Close

the

and,

with impeller out of Move

the

push

the

bling,

apply a thin

gasket.

Open

PUMP

water

pump

and

blades

which

impeller housing, producing a spare impeller

kit).

Raw

(raw

water)

to

make

raw

water

pump

torn

impeller blades.

bearings),

the

Raw

raw

water intake

the

aid

of

two

the

pump.

blades

to

conform

impeller

into

coating of lubricant

the

raw

is

a self-priming, rotary

a Neoprene

wipe

this

pump

and

water

pump

is

not

sure

raw

should

it may

be

Water

valve.

small screwdrivers,

Install

to

the

pump's

water intake

impeller.

against a

be

run

impeller cover gasket

impeller

not

present warrantable, water

flow

be

inspected periodically

See

MAINTENANCE

the

pumps internal parts

more

cost efficient

the

original

Pump

Remove

the

new

the

curved

housing.

valve.

pump

The

curved

the

pumping

dry.

There

failures

during

and

is

present

pump

Impeller

the

pump

carefully

impeller

cam

plate

When

to

the

impeller

with

a

impeller

cam

plate

action.

should

aboard

occur

engine

operators

at

start-

for

·

to

pur-

as a

spare.

cover

pry

the

and

gasket.

and

asseiti~

and

RAW

WATER

OWNER/BUILDER

INTAKE

INSTALLED

STRAINER

Engines &

17

A

CAUTION:

Impeller, the

cooling

exchanger.

Generators

they

circuit.

If

must

any

be

They

of

the

vanes

·located onen

TO

EXCHANGER

have

to

prevent

can

be

t

HEAT

broken

blockage

found

In

ALiGN SLOT

off

the

FITTING

SCREW

WITH

IN

THE

the

in

heat

THE

SHAFT

FUEL

GASOLINE

Only use unleaded gasoline with an Octane rating

higher. The use

engine power anq performance. Ethanol blerided gasoline must not exceed ElO (10% use in these models.

- -

NOTE:

The

detector/alarm properly installed

A

WARNING:

when

servicing

any

fuel

open

flames

tem

when

servicing

of

a lower Octane gasoline will result in a loss

).

Use

of

higher blend is not acceptable for

generator compartment should have a gasoline fume

and

working.

Shut

off

the

fuel

valve

the

fuel

that

may

or

other

servicing.

the

spill.

sources

Ensure

fuel

system.

DO

system.

NOT

of fire

proper

Take

care

allow

any

near

ventilation

at

the

in

catching

smoking,

the

fuel

of

891

tank

sys-

exists

or

SYSTEM

A

WARNING:

of

connections Make

sure

Ing

fuel

Is a fire

proper

system

components.

GASDENSER

Fuel

leakage

hazard

ventilation

at

and

exists

the

fuel

should

whenever

pump

be

co«ected.

or

its

servic-

\FUEL

LIFT

CARBURETOR

The

carburetor is a single barrel downdraft type with a solenoid

activated electric choke and electric fuel shutoff solenoid. Refer to CARBUREI'OR ADJUSTMENTS for more information.

IDLE

FUEL

SHUT-OFF

SOLENOID

~

.

~_A

CHOKE

'

GASDENSER

The gasdenser cools the fuel to prevent vapor lock, there maintenance required except making certain the fuel fittings are tight and secure.

GASOLINE/WATER

A primary fuel filter installed between the fuel tank and the engine to remove water and other contaminants from the fuel before they can be carried to the fuel system on the engine.

Most installers include a type the generator installation package as they are well aware the problems that contaminants in the fuel cim cause.

These gasoline filters must have through") to meet U.S. Coast Guard requirements. The metal

~?owls

have drain valves to use when checking for water and

impurities.

SEPARATOR

of

the water separating type must be

AND

FILTER

of

filter/water separator with

metal bowls (not "see-

is

no

of

FUEL

Lin

PUMP

Periodically check the fuel connections to and out and make sure that no leakeage is present and that the fittings are tight and secure. pump's mounting bolts should the mounting bolt to ensure proper

The engine mounted fuel lift located at the front

The

DC

ground connection at one

be

clean and well secured by

pump

is maintenance free.

of

the engine under the gasdenser.

operation.

of

the pump

of

the

It

is

Engines & Generators

18

GASOLINE

WATER

OWNER/BUILDER

SEPERATOR

AND

FILTER.

INSTALLED

CARBURETOR

ADJUSTMENTS

CARBURETOR

The carburetor cleanable metal

The choke is operated

solenoid stays activated.

solenoid circuit

switch. Once oil temperature reaches and the choke solenoid deactivates, opening the choke. This . helps prevent stalling

Air

Semen/Flame

The air screen/flame arrester

releasing the

of

operation,

screen in kerosene.

is

activated

hold-down every

is

a single barrel, down-draft type with a

screen

air intake filter/spark

by a 12

·when

the.

After

the engine starts

is

kept activated

on

a cold start.

VDC

ON

by

switch

the

arrester.

solenoid.

is

depressed and

(cold

start) the choke

oil

temperature

120op

the switch

This

Arrester

can

easily

be

removed by

clamp. Clean after the first 50

100

hours

from

then

on.

Clean the air

choke

opens

hours

carburetor

aean

then clean and inspect every the screen

Tighten the plug

Idle

Adjustment the jet slowly in until it seats,

turns.

Note:

induce

shut-down.

Filter

Screen

this filter element after the first 50 hours

250 operating hours. Replace

if

necessary.

and

make certain

Mixture

Jet

is

performed

An idle

mixture

a sooty exhaust

with

the

then

jet adjusted

discharge

of

operation,

th~re

are

no

leaks.

generator operating. Screw

back it out 1-1/2 to 2

too

far

off

at

engine

its seat

start-up

can

and

CARBURETOR

j....,.iWESIERBEICE

Engines & Generators

19

CARBURETOR FILTER

HEXHD

PLUG

SCREEN

ENGINE

DESCRIPTION

Use

a heavy duty engine oil Specifications Section and

filter after the initial 50 hours Then follow the oil and filter change intervals the

MAINTENANCE SCHEDULE in this manual.

Westerbeke Corporation does not approve or disapprove the

use

of

synthetic oil.

break-in must be performed using conventional oil.

change intervals must be

SCHEDULE section synthetic oils are used.

NOTE:

The

information

statements

CHANGING

The from allow hose is

properly

been Always

emulsion this

prevent

is

present in the oil. Raw water present in the oil can

be

the

engine and/or a siphoning through the raw water cooling

circuit

regarding

THE

ENGINE

engine

oil

should be warm. Remove the oil drain hose

its

attachment bracket and lower it into a container and

the

oil

to

drain, or attach a pump to the end

and

pump the old oil out. Make sure the oil drain hose

secured in its holder after all

drained.

observe the old oil

indicates the presence

condition

is

rare, it does require prompt attention to

s~rious

damage. Call a competent mechanic

result of a fault in the exhaust system attached

into

the

exhaust, filling into the engine.

as

called for in the

of

the manual. Change the engine oil

of

break-in operation.

as

specified in

If

synthetic oil is used, engine

as

listed in te MAINTENANCE

of

the manual and not extended

above

supersedes all p;evious

synthetic

oil.

OIL

of

the old oil has

as

it is removed. A yellow/gray

of

water in the oil. Although

Oil

if

the drain

if

water

to

LUBRICATING

A

contaminants. and

nails discard used

Replacing

When removing the used oil filter, you may find it helpful punch a hole in the upper and lower portion to drain the oil into a container before removing to lessen spillage. helpful in removing the old oil and a plastic bag around the filter when unscrewing it any oil that's in the filter. Inspect the old oil filter removed to make sure that the rubber sealing gasket comes

off with the old oil filter. sealed against the oil filter adapter, gently remove it. When installing the new oil filter element, wipe the filter gasket's sealing surface on the oil thin coat the oil filter. Screw the filter onto the threaded oil filter stub, and tighten the

NOTE:

are

not

the

REFILLING

Add fresh oil through the valve cover. After refilling run

the engine for a few moments while checking oil pressure. Make sure there is no leakage around the oil filter or from the oil drain system, and then stop the

· engine. Then check the quantity dipstick. Fill to, but not over, the FULL mark.

OIL

WARNING:

thoroughly

clothing

oil

properly.

of

Use

genuine WESTERBEKE oil filters.

recommended.

Used

Avoid

or

the

Oil

An automotive filter wrench should

clean engine oil to the rubber sealing gasket

filter firmly by hand.

THE

OIL

engine

oil

prolonged

using

soap

rags

containing

contains

skin

and

hannful

contact.

water.

used

oil.

Launder

Filter

of

the old filter

filter.

Place some paper towels

If

this rubber sealing gasket remains

filter adapter free

of

oil and

Generic

SUMP

of

oil with the lube oil

Clean

skin

or

Discard

it.

This helps

be

to

catch

as

it

is

apply

filters

the

engine's

new

to

a

on

oil,

Engines & Generators

20

FILTER

TO

OIL

GALLERY

OIL

PRESSURE

NOTE:

WESTERBEKE recommends that the following engine

adjustments be performed by a competent engine mechanic.

to

The information below is provided

assist the mechanic.

DESCRIPTION

The lubricating system is a pressure feeding system using an oil pump. The engine oil is drawn from the oil sump by oil pump, which drives the oil, under pressure, through the oil filter, oil cooler and various lubricating points 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 its specified range.

TESTING

To test the oil pressure, remove the hex head plug from the

oil manifold and install a mechanical oil pressure gauge in its place. After warming up the engine, set the engine speed at

1800 rpm and read the oil pressure gauge.

Oil

Pressure

Note:

sure up pressure as low as on the load placed on the generator.

OIL

PRESSURE

Between

30

and

40

psi

at

1800

rpm.

A newly started (cold) engine may have an oil pres-

to

70

or

80

psi. A warmed engine can have an oil

30

psi. Oil pressure will vary depending

·

the

LOW

OIL

PRESSURE

The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3

+ 0.1 kg/cm

worn bearings. For additional information on low oil pressure readings, see the

OIL

The generator is fitted with an oil pressure safety shutdown switch (normally open). Should the engine's oil pressure drop below the safe minimum, the switch contacts will open, interrupting the

down the engine.

2

).

A gradual loss

ENGINE TROUBLESHOOTING chart.

PRESSURE

SWITCH

DC

voltage to the K2 run relay, shutting

of

oil pressure usually indicates

NORMALLY

OPEN 5 PSI

RATED

+

PRESSURE

•

~

..=.

!BATTERY

~·

MECHANICAL OIL

PRESSURE

GAUGE

.

FROM

OIL

FILTER

Engines & Generators

21

INSTALLATION

This

popular accessory

ter

from

the engine

engine

room

NOTE:

Refer

instructions

bulkhead.

to

ENGINE

on

removing

is

to

a more convenient location

INSTALLING TIGHTEN CONTACTS

REMOTE

used

to

relocate the engine's oil

OIL

CHANGE

the

oiljilter.

A

THIN

AN

COAT

THIS

ADDITIONAL

THE

OF

KIT.

BASE.

in

CLEAN

THREAD

3/4

OIL

FILTER

such

this

manual for

OIL

TO

THE

KIT

TURN

AFTER

D-RING

ON,

THE

as

THEN

D-RING

(OPTIONAL)

To

install,

simply

WES1ERBEKE's remote filan

WHEN

HAND

install this kit

Contact your WES1ERBEKE dealer for more information.

NOTE:

Westerbeke

incorrect installation

PN#040078

remove the engine

oil

filter kit

with

the

oil

filter facing

is

not

responsible

of

the

Remote

oil

filter

as

shown.

down

for

engine

Oil

Filter.

FASTEN

(SCREWS

and

thread

Always

as

illustrated.

failure

SECURELY

TO A BULKHEAD

ARE

OWNER

on

due

to

SUPPLIED)

NOTE

THE ON REMOVED WILL

"IN"

THE

ADAPTER

FOR

BE

RECONNECTED

AND

"OUT"

MARKINGS

WHEN

THE

INSTALLATION

CORRECTLY.

A

CAUTION:

co«ectly. by-pass

from failure.

If

valve

reaching

If

there

immediately

HOSES

SO

THEY

It

the

oil

in

the

is

and·

ARE

'

is

vital

Rows

filter engine, no

oil

check

to

install

in

the

reverse

asembly

causing

pressure

the

hose

the

oil

lines

direction,

will

prevent

an

internal

reading,

shutdown

connections.

the

oil

engine

APPLY A THIN TER

GASKET

FILTER

CONTACTS

ADDmONAL

COAT

WHEN

THE

3/4

TURN.

OF

CLEAN

BASE,

OIL

AFTER

TIGHTEN

INSTALLING.

TO

THE

IT

FIL·

AN

·.

22

4.5KW

/7

.OKW

BCGB

GENERATOR

WIRING

DIAGRAM

#43864

.------+,

-4-

I

rJIATlBIY

12

we

Refer

to

OVERSPEED

-

-!-

Tl

'2

13

1

]

(

11

TERMINAL

0~

R7

page

~~~~

1

Ft

~:

H

.

BOARD

~~*4---4-~~~~-~~--~-+.

6f--t-----'

"'

E

"'

..

.

Ill

REDIVIO

......

111111

11ETER

NOTE:

To

by-pass the

when troubleshooting, move the connection connect with

Do

not operate the generator with the Overspeed Shutdown

by-passed. This is

T5.

o~erspeed

for

troubleshooting only.

Shutdown

. .

for

T3

test purposes

over to and

__

..,

...,

.....

_,.E.~n•giii!iniiiiie•s•&~G~e-neliir,iiila~toiiiirs;;..

23

4.5KW

/7

.OKW

BCGB

GENERATOR

1

l

rl

BATTERY

1

SWITCH

L I

1

20

I CIRCUIT

I

BREAKER

fl

I

r I CKTI(NCl

I I

12

VDC

AMP

AIIP

STOP

SW

I

'------,

WIRING

K I

KZ

I

SCHEMATIC

STARTER

SOLE

HOI

r--,

f2

IIAIIP

D

STARTER

#43864

FUEL

HOUR

PUMP

SOL.

METER

CHOKE

SOL.

STI>RT

~lj!C!!

NOTE:

ON

!.W!JCJ:I

To

by-pass the Overspeed Shutdown when troubleshooting, move the connection connect with

T5.

EXHAUST

TEMP

SWITCH

OIL

PIUS.

SWITCH

WATER

TEMP

SWITCH

'

_.....J2]

!altE

for

test purposes

T3

over to and

OVEISPEED SHUT

Tl

__

@__[i]_@l

!jQ!IEJlll

DOIII

11$412

DIODE

n

T4

II

12

Tl

TS

KI-START

AUX.

PlUS.

I

ru

OIL

$WITCH

Do not operate the generator with the Overspeed Shutdown

This is

for

by-passed.

troubleshooting only.

Engines & Generators

24

REMOTE

PANEL

WIRING

REMOTE

PANEL

SCHEMATIC

#043912

.--------------------------------.

I

#14

#14 #14

BLK

WHT

RED

YELIRED

WHT

RED/VIO

LED

<..>

>

0....

BLK

RED

....

I-

-

::t:

ill=

START/STOP

CKT

I

sw

ON

SW

RED

WHITE

L--------------~-------------1

PIGTAIL

This is a connecting into the 6 wires panels with 3 switches.

AVAILBLE HARNESS

WIRING EXTENSIONS

ADAPTER

15

pin male plug with 12" wires to use when

f1sFT

EXTENSION

I

L3DFT

EXTENSION

KIT

N0.0451

of

earlier model remote start/stop

HARNESS HARNESS

PN#043914 PN#D43860

09

VIEWED

MATING

FROM END

Engines & Generators

25

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjustments mechanic. The information below is provided to assist the mechanic.

ADJUSTMENTS

be

performed

by

a competent engine

ENGINE

SPEED

(HERTZ)

ADJUSTMENT

Governor

The

belt-driven,

the

engine's

determines

Governor

Operate perature

NOTE:

adjust the linkage before proceeding with the adjustment.

There tion).

1.

2.

3.

the

before

If

are

Increase/Decrease

sets

the between adjusted not

running.)

that

the graphite and

apply

Hunting/Regulation Adjustment.

engine

adjust hub.

The

adjusted

If

the

move

adjustment).

Bumper

no-load

a into

the

mechanically operated governor maintains

rpm

under

various load conditions. Engine speed

the

hertz

and

voltage output of

Adjusbnents

generator

thf!

governor

three

no-load

the

to

ball

lube

graphite

speed

this

eye

increase/decrease speed bolt

as

governor

the

spring

Screw

surge

governor

to

bring

the

unit

adjusting the governor

is

severely out

at no-load to obtain a safe

adjusting points

on

the

Speed Adjustment. This adjusting bolt

speed of the engine. (The linkage

governor

hold

Make

joint connectors

for

between

well.

wm

the

throttle sure

this

purpose.

lube

to

no-load

bolt

to

draw

surges

under load, adjust

away

from the.leverhub (check speed

Adjustment.

ONLY.

NEVER tum the bumper screw

so

far

that it increases

and

throttle lever should

full

open

linkage

are

properly lubricated.

Discqnnect

the

inside of

and

the

spring closer

This

the

generator.

up

to

operating

..

of

adjustment, manually

outpu~

governor (see illustra-

when

the

moves

the

joint.

If

the

variation

full-load

may

need

this

screw

is

used

the

no-load speed.

·

engine

freely

ball

is

too

to

the

to

eye bolt

to

tem-

voltage

arm

be

and

joint

in

great,

lever

be

remove

is

Use

to

Governor

1.

2. 'Governor Oil Capacity- 3 ounces

3. Change

4.

FRONTO~

ENGINE

Maintenance

Periodically lubricate the linkage the

governor arm and throttle

lubricant or equivalent.

NOTE:

Free movement

proper governor/throttle operation.

Synthetic oil

NOTE:

every 250 hours. To

change the oil, remove the drain plug

plug.

Once drained, replace the plug

the

oil

plug opening. Replace both plugs.

NOTE:

(Synthetic oil is recommended).

Periodically adjust the governor belt tension

BELTS ADJUSTMENT). Since belts stretch

stretching will,

action.

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

is

recommended.

Do

not

overfill the governor.

the

oil

at

50 hours then at least once a

fill

plug opening until it starts

Use IOW-30 engine oil.

to

some degree, affect

6

lever.

of

this linkage arm is important

4 2

arm

attaching

Use a graphite

lOW-30

and

to

the

exit

engine

and add

slightly,

govenor's

oil new

the

(see

points

year

level

oil

DRNE

oil.

or

oil

level

at

for

thru

this

7

liNKAGE

HUNTING REGULATION ADJUSTMENT

(UNDER)

FILL

TORQUING

Mter cylinder head bolts should be re-torqued.

Tighten shown. loosen between head bolt securely.

THE

CYLINDER

the

initial break-in period (approximately 50

the

cylinder head bolts according

Make sure the engine is cold

one

head bolt one-half tum and

43-

51lb-ft (60-70

in

the sequence. Tighten the

26

HEAD

Nm).

Then proceed

BOLTS

to

the

when

this

then

tighten it

RS

(rocker cover

hours),

sequence

is

done,

to

the

5

the

and

ENGINE

ADJUSTMENTS

SPARK

The spark plugs should be cleaned and regapped after the first 50 hour break-in period, then inspected every

therea~ter

Spark Spark

NOTE:

the of

PLUGS

and replaced as needed.

A

WARNING:

the

engine

removing

spark

the

plug

gap:

plug

torque:

Loctite

spark

them.

piugs

Do

not

remove

Is

hot.

Allow

the

0.031

+1~

0.002

ln.

10

-151b·fl (1.5-

Anti-Seize applied

will

retard

corrosion,

plugs

easier.

the

engine

(0.8-

0.05

2.31

kg·m).

to

the

250

spark

plugs

while

to

cool

before

mm).

threaded portion

making future

hours

removal

GAP

.

INSPECT

FOR

WEAR & CARBON

INSPECT DAMAGE

FOR

INSPECTING

·mE

SPARK

PLUGS

USEA

13/16"DEEPSOCKETWHEN

AND

INSTALLING

THE

SPARK

REMOVING

PLUG.

CHECK

FOR

DETERIORATION

AND

DAMAGE

of

DRIVE

The drive belt must belt tension can cause rapid wear service life the presence resulting in high operating temperatures.

The BCGB generator has two drive belts, one drives the governor and alternator and the other drives the raw water pump. The tension adjustment procedure for both belts follows:

1.

2.

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

4.

5. The drive belts are properly adjusted

BELT

ADJUSTMENT

be

properly tensioned. Excessive drive

of

the belt and reduce the

of

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

of

oil on the belt can cause belt slipping,

is

Remove the belt guard. To adjust the governor drive belt, loosen the two governor

. mounting bolts.

To adjust the raw water pump/fresh water pump drive belt, loosen the two raw water pump mounting bolts.

edges, and replace To loosen

governor in bolts.

To loosen pump drive belt, slide the raw water pump required, then retighten its mounting

no less than 3/8 inch (lOmm) and no more than 1/2 inch (12mm) as the belt is depressed with the thumb at the

midpoint between the two pulleys on the longest span

the belt.

NOTE:

or

Maintain a

for proper belt

carried on

A

WARNING:

drive

belt's

board.

tension

if

necessary.

tighten the governor drive belt, slide the

or

out as required, then retighten its mounting

tighten the raw water pump/fresh water

in

or out as

boln>.

if

it can be deflected

22

lb

pressure

oper:ation.

Never

attempt

while

the

Spare

engine

to

the

belt's outer face

belts should

to

check

or

Is

In

always

adjust

operation.

be

a

as

of

6.

Operate the generator for about 5 minutes, then shut down the generator and recheck the belt(s) tension.

7. Replace the belt guard.

27

ENGINE

NOTE:

WESTERBEKE adjustments The

information below

be

performed

ADJUSTMENTS

recommends

by

is

provided

that

the

following

a competent engine

to

assist

the

engine

mechanic.

VALVE

1.

Remove

2.

Rotate placing stroke closed. cylinder, intake

3.

Rotate rotation. its

exhaust cylinder chart).

CRANK

When

No. 1 piston

compression When

No. 1 piston

at

top

of

exhaust

CLEARANCE

the

rocker cover

the

crankshaft in the normal direction of rotation,

the

No.

with

the

Adjust

the

valve

for

the crankshaft

Locate

stroke.

and

ADJUSTMENT

and

gasket.

1 piston at the top of

exhaust and intake valves completely

the

intake

and

exhaust valves

exhaust valve

No.

the piston

Adjust the intake valve for

the

exhaust

for

3 cylinder (see chart).

1800

in

its

in

No.

valve

its

compression

for

No.

2 cylinder,

normal direction of

1 cylinder at the

for

No.

3 cylinder

CYLINDER#

ANGLE

1 2 3

is

set

at

top

of

stroke

is

positioned

IN

EX

IN

EX

•

and

No.

No. 1

the

top

2

(see

•

of

IGNITION

1.

Attach a timing light

front timing pointer

mark

chalk or a crayon.

2.

Start the engine

. temperature. Make sure the generator

a load on

3.

Using crankshaft pulley ing distributor

Timing

(no

TIMING

to

the

#1

to

indicate

on

the crankshaft pulley

and

warm it

it.

the timing light, align the timing

so

it is just slightly before

pointer.

load

Do

this

body.

Use

Specifications:

on

generator)

by

the

15" ± .5°

and

up

loosening

following timing

BTDC

spark plug

15°.

mark it

to

its

and

at

1800

Locate

normal

is

operating

mark

slowly

rpm

IGNITION

and

mark

the

timing

with

white

operating

without

in

the

front

the

first

tim-

rotating

specifications:

the

TIMING

4

..

Replace

gasket..

Rocker

VALVE

CLEARANCE

INTAKE

VAlVES

EXHAUST

VALVES

the

rocker cover along

cover

torque:

2.9-5.1

0.20mm

0.30inm

VALVE

CLEARANCE'

lb·lt (4- 7

(.008in)

(.012in)'.

with a new

Nm)

rocker cover

CHOKE

The choke solenoid

tions to close the choke plate m the carburetor when the

switch The choke solenoid de-energises once the engine starts

the ON switch is released. Some unstable running present when the engine starts cold, but should smooth out the engine reaches normal operating temperature.

Keep this solenoid plunger and choke shaft with graphite lube

SOLENOID

is a 12

volt DC operated unit that

is

depressed during engine start-up.

dry and periodically lubricate the linkage,

CHOKE SOLENOID.

..

may

func-

ON

and

be

as

28

ENGINE

NOTE:

WESTERBEKE adjustments The

information below

ADJUSTMENTS

recommends

be

peiformed by a competent engine mechanic.

is

provided

that

to

the

assist

following the

mechanic.

engine

TIMING

Timing

A

reduces

belt

IIIJSiy

these and

1.

2. Remove the plug on the left surface

BELT

INSPECTION

Belt

R~moval

CAUTION:

the

spmcket

These

parts

contaminated

parts,

camshaft

Thm the crankshaft clockwise to align· the timing mark on

the camshaft sprocket and timing belt rear cover.

NOTE:

always tum

TIMING

MARK.

and insert a rod with a diameter the counterbalance shaft.

NOTE:

Be

Bmm

(0.31

Water

service

and

should

check

oil

sure

to

in.).

life

tensioner

never

with

the

seals

the

use

AND

REPLACEMENT

01

oil

on

the

timing

of

the

belt.

Keep

tree

of

oil

and

be

c/1111ned.

dill

01

front

case,

for a psssible

crankshaft clockwise.

an inserting

Replace

oil. N oil

o/1

pump

oil

of

the cylinder block

of

8mrn (0.3iin.) to lock

rod

with a diameter

belt

the

timing

grease.

is

evident

oil

leak.

severely

if

serf·

seals,

on

of

5. Remove the timing belt.

NOTE:

If

the

timing belt

the

belt back

wise).

Camshaft

1. Remove the bolt without turning the camshaft.

to

indicate

Sprocket

is

to

the

Removal

be

reused,

direction

draw

of

rotation

an

arrow

(clock-

on

2.6

IN

(65MM)

---++--""N'""~·

ROD

CYLINDER

·BLOCK

3. Loosen the timing belt tensioner nut.

4. Move the timing belt tensioner toward the water pump, and temporarily tighten the nut to hold the tensioner in that position.

TIMING

BELT.TENSIONER

WATER

PUMP

Oil

Pump

Sprocket

1. Remove the nut.

Flange

Nut

Removal.

29

Crankshaft

Bolt

Removal

ENGINE

NOTE:

WESTERBEKE recommends that the following engine

adjustments be peiformed by a competent engine mechanic.

The information below is provided to assist the mechanic.

ADJUSTMENTS

Flange

Installation

1.

Lock the crankshaft in position.

NOTE:

Do not

tum

the crankshaft.

2. Remove the crankshaft bolt.

Timing

Belt

Inspection

Replace the belt

1.

Hardening resilience, and leaves no indent when pressed with gemail.

2. Cracks on rubber back.

3. Cracks

4. Cracks on tooth bottom.

5.

Cracks on belt.

6. Abnormal wear

they are sharp as

7.

Abnormal wear on teeth.

8.

Tooth missing and canvas fiber exposed.

if

any

of

the following conditions exist:

of

back rubber-back side is glossy, without

or

peeling

of

canvas.

of

belt sides.

if

cut by a knife.

The

sides are normal

firt-

if

1. Mount the flange so that its side shown by the heavy arrow in the illustration faces toward the sprocket.

FLANGE

d)NASHER

-~-®Q

Crankshaft

1.

Lock the crankshaft.

NOTE:

2. Tighten the crankshaft bolt to the specified torque.

Oil

Pump

1.

Insert a round the cylinder block to keep the counterbalance shaft from turning.

2. Install the oil

3.

Tighten the nut to the specified torque.

36 -41

Bolt

Installation

Do not

tum

Sprocket

pump

fl-lb

(50 -57

the crankshaft.

Flange

Nut

Installation

bar

into the plug hole in the left side

sprocket.

Nm)

~

of

CRACKS

OR

PEELING

·

RUBBER

EXPOSED

,__-~!Do.........,

Tensioner

1. Replace the tensioner

Inspection

when turned.

ABNORMAL (FLUFFY

5.

7.

if

the pulley binds, rattles

6.

TOOTH

AND

CANVAS

ER

8.

or

WEAR

STRAND)

Camshaft

1.

MISSING

EXPOSED

is noisy

Engines & Generators

Tighten the bolt to the specified torque.

Bolt

NUT

Torque:

Sprocket

58-72ft-

Bolt

Installation

lbs

(80

-100

Nm)

'OIL

PUMP

.

SPROCKET

BOLT

,30

Tensloner

1.

2.

Spring/Timing

Install

the

Hook

the tensioner bracket block.

3.

Move

the

water

pump;

Timing

Belt

1.

Align with

a marking

2.

Align the

marking

3.

Align with

the

mm

(2.56 round cylinder

MARKING TIMING

REAR

ON

BELT

COVER\

Tensioner

tensioner spring

and

onto

the stopper

timing belt tensioner

temporarily tighten

Installation

the

t:rlangular

the

notch

marking

on

the timing belt rear

in

the crankshaft sprocket

on

the

front

case.

the triangular marking

marking

bar into

in.)

or

the

on

the

front case,

longer, 8 mm

plug

hole

block.

ENGINE

NOTE:

WESTERBEKE

adjustments

The

information below

Installation

timing belt

the bend of

on

the

as

close

as

possible

the

tensioner

TIMING

BELT

TENSIONER

on

.the

camshaft sprocket

cover.

on

the

oil

pump

and

(0.31

in.)

in

the

left side of

be

performed

tensioner.

the

timing belt

cylinder

nut.

flange

sprocket

then

insert a

diameter

the

ADJUSTMENTS

recommends

by

is

provided

to

the

with

65

that

a competent

to

assist

At the

Standard

4.

If

the a. Pull out

side

b. the

c.

sprocket

5.

Set then in

NOTE:

not

belt the

6.

Apply to sure that

the

following

engine

mechanic.

the

mechanic.

this

time,

oil

pump

value: 4 to 5 teeth

FORWARD

the

movable

specified

of the cylinder

Thrn

the

round bar

Check that

is

the

timing belt over

over

that

order.

Ensure

slack.

has

been

round

counterclockwise

make

the

all

engine

check that

sprocket

1

to 2 teeth

\

REVERSE·

range

range,

the

round bar

oil

pump sprocket

can

the

in

the

specified

the

oil

pump sprocket

that

Keep

the

placed.

bar.

belt taut timing

the

moveable

is

according

In

forward reverse

oil

as

follows:

from

direction.

pump

the

In

of

the

correct

block.

one

again

be

inserted.

movable range of

value.

the

crankshaft sprocket

and

the

tension

side

round

bar inserted until

After

this

step,

force

to

the

on

the

tension

marks

are

lined

range

of

teeth

to

specifications.

sprocket

plug

turn

the

exceeds

hole

in

at a time

oil

pump

the

and

camshaft

of

the

be

timing

sure

sprocket,

belt

the

timing

to

remove

camshaft sprocket

side,

and

make

up.

on

OIL

PUMP

.

SPROCKET

left

until

is

TRIANGULAR·.

·

MARKiNG CAMSHAFT SPROCKET.

ON

WL.-C:...__.;.o!~LTRIANGULAR

.

MARKING ON

FRONT

CASE

CAMSHAFT SPROCKET

7.

Loosen

the making

PUMP

MARKING

SPROCKET

ON.OIL

~-.v'~~WESTERBEKE

Engines & Generators

water

the

temperorarily tightened tensioner

pump

use

of spring

31

side 1

or

2 turns,

force.

TENSION

and

tension

SIDE

nut

the

on belt

ENGINE

NOTE:

WESTERBEKE

adjustments

The

infonnation below

be

perfonned

ADJUSTMENTS

recommends

by

is

provided

that

the

following engine

a competent engine mechanic.

to

assist

the

mechanic.

8. Turn the crankshaft clockwise by nine camshaft sprocket

teeth

(81") to align the timing mark on the camshaft

sprocket with the tensioner set mark on the timing belt rear cover.

A

CAUTION:

proper

tension crankshaft check

the

9. Make sure that the timing belt teeth are engaged with the camshaft sprocket teeth along the portion sprocket shown below. Then tighten the tensioner nut.

16-22 H

10.

Pull the timing· belt in the center

toward the illustrated. back value.

Standard

This

operation

to

the

timing

counterclockwise

is

performed

belt,

so

and

push

do

not

the

to

turn

belt

give

tension.

'I

TENSIONER

~.hw,--1s~

by

the curved arrow in the illustration

·lb

(22-

30

Nm)

of

the tension side

seal~ng

Make

of

the belt arid the sealing line is the standard

Value:

gasket line for the belt cover, as

sure that the clearance between the

12mm

(0.47in.)

the

to

of

a

MARK

the

SEALING

LINE

2MM

(0.47

11. Pull out a rod from the plug hole the cylinder block and apply the specified sealant. Then tighten the plug to the specified torque.

Specified Tightening

Sealant

Torque:

Value:

15-22

3M

Nm

ATO

(11-16

Part

on

the left surface

No.

8660

H.lbs.)

or

IN)

of

equivalent.

Engines & Generators

32

COMPONENT

NOTE:

WESTERBEKE recommends that the following engine

testing adjustments be performed by a competent technician.

TESTING

GENERAL

All DC voltage measurements are made negative ground point unless specified otherwise. test measurements, make sure that a good ground for the meter is established, preferably the point where the negative battery is connected to the engine. Battery positive voltage indicated

AC voltage measurements should be made with a true RMS AC meter to insure measurement accuracy.

ENGINE.GROUNO

GROUND

as

B+ and should measure

AND

B(+)

CONNECTIONS

to

the engine battery

no

less than

In

11.5

making

volts.

RELAYS

The relays used in the control system have coils which are polarized by the fact that they have internal free wheeling suppression diodes across them. Relay coil terminal 86 must be maintained ( + ), terminal DC, and the coil resistance terminal 86, direct grounding for testing purposes.

85(-

).

The relay coil

is

typically 85 ohms. With B+ on

of

terminal

85

is

rated 12V

is

permissible

TAP

THE

·

GROUND

.........,-..,"""-:··

is

TO

B(+)

TESTING

THE

RELAY

.

..

·.

GROUND

CONNECTION

THE

TERMINAL.

RELAY

"CLICK"

TO

SHOULD

ON.

TERMINALS

TESTING

COIL

RESISTANCE

RELAYS

REMOVE RELAY

THIS

CONNECTOR

·33

The

following

engine

troubleshooting tables

problem

indicators and

problems. When

troubleshooting indicates

the

ELECTRICAL

may

reveal

other possible causes of the problem which are

not

listed

here.

SYSTEM

ENGINE

are

based upon certain

the

most likely causes of

an

electrical problem, see

WIRING

DIAGRAM,

TROUBLESHOOTING

NOTE:

The engines control system (electrical system) is

protected located

by a 20

on

Ampere manual reset circuit breaker

the control panel.

as

the

these

PROBLEM

Engine crank.

Engine fails

to

does

not

cranks start.

but

1.

2.

3.

4.

5.

6.

7.

'8.

9.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

PROBABLE

Voltage

drop

terminal.··

Engine

20A

tripped.

Battery

is

Loose

battery

Faulty

wire

Faulty

start

Faulty

start

Faulty

starter

Raw

water

Out

of

fuel.

Engine

is

a.

Carburetor

or

damaged.

needle

b.

Float

in

Repair

c.

Float

chamber securing gasket

Fuel

pump

Worn

or

High

tension

(wet

system).

Faulty

ignition

Faulty

distributor.

Faulty

run

Faulty

wire

No

engine

CAUSE

at

starter

circuit

breaker.

low

or

dead.

connections.

connection.

switch. relay

(K1

solenoid.

filled

cylinders.

flooded.

float

needle

Clean

valve

carburetor

or

replace

float.

gasket

screws

are

and/or

tighten

inoperative.

faulty

spark

wires

grounding

coil.

relay

(K2).

connection.

compression.

solenoid

).

valve

or

replace

is

leaking.

damaged

loose.

screws.

plugs.

has

Replace

open

the

or

PROBLEM

Engine and

then

down.

Engine but

does

up

to

speed.

Engine

starts,

shuts

starts,

not

hunts.

runs

come

1.

Faulty

(oil

temperature

2.

High temperature.

3.

Dirty

4.

Mechanical supply

5.

Low Faulty

6.

1.

Fuel

2.

Mechanical

fuel

3.

Throttle

4.

Faulty

5.

AC

6.

H_igh

1.

Low

2.

Generator

3.

Cracked

4.

Faulty

5.

Faulty High

~·

7.

Valves

8.

Governor

Dirty

9.

10.

Throttle

PROBABLE

shutdown

pressure,

engine

fuel/water

faulty.

oil

level

fuel

line

restriction.

supply

plate

fuel

generator

exhausl_Qressure.

battery

distributor

high

fuel

exhaust

are

fuel

linkage

CAUSE

switch,

water,

exhaust

or

overspeed).

water

or

exhaust

separator

check

valve

(If

installed)

in

sump.

pump.

check

valve

is

faulty. binding.

pumJ1.

overload.

voltage.

is

overloaded.

cap.

tension

wires.

pump.

back-pressure.

out

of

adjustment

is

out

of

adjustment

filters.

is

binding.

filters.

at

the

at

the

fuel

NOTE:

When troubleshooting the overspeed board, By-pass the board by lifting the T3 connector ( overspeed terminal board)

and

connecting it to the vacant T5 spade connector. Start the engine

is released, the overspeed switch is at fault. Refer to the

and

if

the engine continues to run when the

OVERSPEED WIRING DIAGRAM.

Engines & Generators

34

ON

switch

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

Engine

Low

oil

High

oil

misfires.

backfires.

overheats.

pressure.

Poor

1.

2.

Incorrect

3.

Dirty

4.

Cracked

5.

Faulty

6.

Spark

7.

Valve

1.

Spark wrong.

Incorrect

2.

Engine

3.

flooded tails

4.

Dirty

5.

Cracked

6.

Lean

1.

Coolant cooling

Faulty

2.

Belts

3.

4.

Raw

5.

Faulty

1.

Low

2.

Wrong

3.

Wrong

4.

Relief

5.

Faulty

6.

Faulty Dirty

1.

engine.

2.

Relief

PROBABLE

quality

fuel.

timing.

flame

arrester.

distributor

ignition

wires.

plugs

are

worn.

clearances

plu9·wires

timing.

is

flooded.

under

Engine

to

start

flame

arrester.

distributor

mixture.

loss.

Pressure

system.

raw

water

are

loose

or

water

pump

thermostat.

oil

level.

SAE

type

oil

filter.

valve

is

stuck.

oil

pump.

oil

filter.

oil

or

wrong

valve

is

stuck.

CAUSE

cap.

are

incorrect.

are

connected

See

Engine

cranks

cap.

test

pump

broken.

worn.

oil

in

the

SAE

type

is

but

impeller.

engine.

oil

in

the

PROBLEM

No

DC

charge

starting

battery.

Blue

exhaust discharge engine.

Black

exhaust discharge engine.

Poor

performance

at

generator

smoke

from

speed.

to

the

smoke

the

1.

Faulty battery

2.

Faulty

3.

Faulty

4.

Faulty windings.

5.

Blown

1.

Lube

2.

High

3.

Crankcase

4.

Valves incorrectly.

Dirty

1.

2.

Faulty

3.

Idle

4.

Valves adjusted.

5.

Lube

6.

Crankcase

1.

Main

2.

Carburetor Remove

3.

Fuel

Remove

4.

Air

Remove

5.

Governor

PROBABLE

connections

voltage

regulator.

battery

charging

bridge

rectifier.

generator

fuse.

oil

is

diluted.

lube

oil

level.

breather

are

worn

flame

arrester.

carburetor.

mixture

jet

are

worn

oil

is

diluted. breather

jet

clogge~.

inlet

and

clean.

pump

clogged.

and

clean.

intake

filter

screen

and

clean.

needs

CAUSE

to

control.

charger

hose

is

or

adjusted

too

rich.

or

incorrectly

hose

is

Remove

and

filter

clogged.

· dirty.

adjustment.

clogged.

cloaaed.

clean.

l"'IV'IW§IJBIBED

l

Engines

&

Genet'IJtOI's

35

GENERATOR

USE

OF

ELECTRIC

The power required to start an electric motor is considerably more than is required to keep Some motors require others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types. They are commonly used machines, or where loads are applied after the motor is started, such as small power tools. Because they require 7 times as much current to start as to run, their use should be avoided, whenever possible, ven by a small generator. Capacitor and repulsion-induction motors require from 2 to 4 times as much current to start as to run. The current required to start any motor varies with the load connected to it. compressor, for example, will require more current than a motor to which no load is connected.

In general, the current required to start 115-Volt motors con-

nected to medium starting loads will be approximately as follows:

MOTOR

SIZE

(HP)

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

1

*NOTE:

more

for

made

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

Required

Run the generator first with no load applied, then at half the generator's capacity, and finally loaded to its full capacity as indicted

the generating plant and the appliances voltmeter load, check

NOTE:

panel. generator.

In

the

for

some

this

is

that

in

larger

if

If

difficulty is experienced in starting motors, tum

Operating

on

the generator's data plate. The output voltage

should be checked periodically to ensure proper operation

or

ampmeter is not installed to monitor voltage and

it

When

the contains that vide

AC equipment

the

generator's AC terminal block

one

120 volt AC hot

This

will

MOTORS

it

running after it is started.

much

more current to start them than

on

easy-starting loads, such as washing

if

the electric motor is to be dri-

An electric motor connected to an air

AMPS

FOR

RUNNIN~)

(AMPERES

3.2

4.6

5.2

7.2

10.2 13

above table

small motors

the

hardest starting types (split-phase)

the

maximum Amps for Starting

than

for larger

AMPS

FOR

(~TARTING

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

ones.

The

reason

are

sizes.

of

current needed for starting

it can bring the motor up to speed in a few

if

possible, reduce the load

Speed

it

supplies.

with a portable meter and ampprobe.

vessel

in

which

the

generator

of

120 volts

leg

ensure

good motor starting

only,

be

for

the

vessel's distribution

it

configured

If

an AC

is

installed

is

recommended

to

response

from

5 to

not

of

pro-

the

INFORMATION

is

Generator

Frequency is a direct result indicated by the following:

• When the generator is run at 1800 rpm, the AC voltage output frequency is

• When the generator is run at 1500 rpm, the AC voltage output frequency is

Therefore, to change the generator's frequency, the generator's drive engine's speed must be changed. Along with a reconfiguring a regulator board voltage output adjustment must also be made.

Generator

• Maintaining reasonable cleanliness is important. Connections corroded, and insulation surfaces may start conducting

salts, dust, engine exhaust, carbon, etc. are allowed to

build up. Clogged ventilation openings may cause exces-

sive heating and reduced life

• For petroleum-base coatings, should

over all surfaces to reduce rusting and corrosion.

• In addition to periodic cleaning, the generator should be

inspected for tightness overheated terminals and loose

• The drive discs on single bearing generators should be

checked periodically and for any evidence should not be allowed to become rusty because rust may accelerate cracking. The bolts which fasten the drive disc to the generator shaft must be hardened steel

8,

ners

• The rear armature bearing is lubricated and sealed; no maintenance is required. However, noisy

• Examine bearing at periodic intervals. of motion is detectable, bearings are wearing shaft Repair must be made quickly or major components will rub and cause major damage to generator.

Carbon

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

monoxide, even

The presence leak from the engine

elbow/exhaust hose, are entering your boat.

If

air and correct the problem immediately!

Frequency

of

the AC output connections at the generator,

See ELECTRONIC GOVERNOR in this manual.

Maintenance

of

terminal boards and rectifiers may become

unu_sually

identified by 6 radial marks, one at each

of

or

shaft should be detected when force is applied.

of

carbon monoxide is present ventilate the area with clean

severe conditions, thin rust-inhibiting

the head.

rough-sounding, have it replaced.

bearing socket outside bearing has occurred.

Monoxide

Detector

in

of

carbon monoxide indicates an exhaust

Adjustment

of

engine/generator speed, as

60

Hertz.

50 Hertz.

of

windings.

be

sprayed or brushed

of

all connections, evidence

or

damaged wires.

if

possible for tightness

of

incipient cracking failure. Discs

if

the bearing becomes

small amounts is deadly.

or

generator, from the exhaust

or

that fumes from a nearby vessel

of

SAE grade

of

the 6 cor-

No

side movement

or

wear on

of

screws

if

side

Carbon

if

36

BC

GENERATOR

NOTE:

WESTERBEKE recommends that the following generator tests

and adjustments be performed by a qualified technician.

SINGLE

PHASE

DESCRIPTION

The BC generator requires only the driving force AC output. The stator houses two sets stator windings and the exciter windings. When the generator

is

started, residual magnetism in the four rotating poles induces a current in the stator which then generates an even larger current in the exciter windings. This mutual build up of

current in the four rotating poles and in the exciter windings quickly reaches the saturation point capacitor(s) and a regulated energy field is then maintained in the stator. At the same time, this regulated field produces a steady voltage in the stator windings which can then drawn off the generator's AC terminals to operate AC equipment. for

120 volts two-wire at 60 hertz two-wire at of

this manual for generator ratings. The generator's data plate gives the voltage, current and frequency rating generator. An AC wiring decal is affixed to the inside louvered cover at AC voltage connections is provided on the decal. An Integral

. Controller (I C)

a continuous DC charge to the generators starting battery when the generator is running. For more information see the INTEGRAL CONTROLLER DC CHARGER section in this manual.

is

a brushless, self-excited generator which

of

the

ef!.gine

to produce an

of

windings; the main

of

the

be

The

generator is a single-phase, re-connectable

or

115

volts

or

230 volts

50 hertz. Refer to the SPECIFICATIONS section

of

the

of

the

the.

generator end. A diagram

is

mounted inside the generator and supplies

of

the various

Circuit

A circuit breaker WESTERBEKE generators. This circuit breaker will automatically disconnect generator power overload. The circuit breaker can be manually shut off when servicing the generator to ensure that no power into the boat.

NOTE:

Culd-on

WESTERBEKE dealer.

Breaker

is

installed on all single phase

in

case

of

an

is

This circuit breaker is available as a WESTERBEKE

kit

for

earlier model generators; contact your

Circuit

7.0Kw

5.8Kw

4.5Kw

3.8Kw

Breaker

#042714 #042713 #042232 #042712

Part

Numbers

GENERATOR

SCHEMATIC

.

INTERNAL

WITH

CHARGING

WIRING

DC

BATTERY

CIRCUIT

·

electrical

coming

Engines & Generators

37

BC

GENERATOR

NOTE:

WESTERBEKE recommends that the following generator tests

rHl.''"··'"'·""'ru·"

be performed by a qualified technician.

SINGLE

PHASE

NOTE:

THE

#7

WIRE

SHOWN

CONNECTED

A

DEMONSTRATION

HOW

THESE

T/ONSCAN BE

MADE.

SINGLE

1.

Remove the louvered metal plate, at the back generator, covering the AC terminal connections and the capacitor(s).

2.

Start the generator and allow it to run for approximately five minutes so the engine can warm up. generator current from the generator (that is, shut off all electrical appliances). Make sure the engine's speed (Hertz) is cotTect. correct engine speed before proceeding.

3.

Refer the

correct configuration then check the generator's no-load voltage by measuring the voltage across the tral lead and the hot lead with a vplt meter record this reading. The generator's no-load voltage is 115- 124 volts at is

higher or lower than specified, proceed.

4.

Shut

(60 Hettz #6, or 50 Hertz #5) is plugged into the capacitor(s).

A

WARNING:

handling

tially

lethal

power

NOTE:

Simply cross the capacitor's two terminals with an insulated (plastic handle) screwdriver. This will discharge any excess electricity.

IS

AS

.

OF

CONNEC·

EXCITER

Adjust the governor as needed to obtain the

to

the AC LOAD CONNECTIONS DIAGRAM for

off

the generator. Make sure the correct Hertz lead

as

NO-LOAD

is

operating without any equipment drawing

60.5-61.5

Capacitors

they

store

charge

even

VOLTAGE

Hertz.

must

electricity

when

disconnected

ADJUSTMENT

Make

..

Make sure you

If

the voltage output

be

discharged

and

can

pack a poten-

from

of

sure the

the

before

source.

their

AC

neu-

SINGLE

60Hz

12il

l1

A

WARNING:··

voltage The

Touching shock. age

cause

6.

adjustment

capacitor

any

In

adjustment

your

5. There are three plugs grouped for the· capacitor terminal, #7, #8, and #9. is low, then disconnect the lower numbered plug and connect the plug with the next higher number. tor's no-load voltage is high, then disconnect the

numbered plug and connect the plug with the next lower number. Note that the plug presently connected

terminal may be any one

If

the generator's no-load voltage cannot be adjusted because the voltage needs to be increased and the highest numbered plug is already connected to the right terminal, or the voltage needs to be lowered and the lowest bered plug is connected, refer to the WESTERBEKE BC Generator Troubleshooting Guide).

Do

not

attempt

while

the

can

produce a 400-500

wiring

can

produce a severe

addltion1 attempting

while

the

generator

fingers

to

be

caught

If

of

EXCITER

VOLT

CONFIGURATiON

to

make a no-load

generator

is

operating.

volt

charge.

CIRCUIT

ILLUSTRATION

TERMINAL

electrical

to

make a no-load

is

operating

in

the

generator's

the generator's no-load voltage

the three plugs available.

volt-

could

If

the genera-

hig,her

to

BOARD

rotor.

this

num-

38

BC

GENERATOR

NOTE:

WESTERBEKE recommends that the following generator tests

and

adjustments be peiformed

SINGLE

by

a qualified technician.

PHASE

·so

Hz

120

DUAL

EXCITER

VOLT

CONF.IGURATION

CIRCUIT

ILLUSTRATION

DUAL

EXCITER

These

generators

ment

connectors

available

selection,

and

When proceed

1.

2.

A

for

60

#9,

are

making

as

Shut

the

Select

the

capacitor

RPM.

The

#8,

and produced group

can

will

increase between achieve

above.

WARNING:

the

unused

with

each

CIRCUIT

have

at

each capacitor. There are

each

capacitor.

Hertz

or

for

no-load

Hertz change or no-load voltage adjustments

follows:

generator

appropriate Hertz connection

#60,

60

Hertz,

three

other connectors at each capacitor,

#9,

will

have

by

the

generator.

be

plugged into each capacitor. No-load voltage

or

decrease approximately 8-10

connectors used

the

prescribed no-load·

Make

leads

are

other

or

In

MODEL

dual Hertz and no-load voltage adjust-

five

connectors

Two

connectors are for Hertz

50

Hertz,

and

three connectors,

voltage adjustment.

down.

to

plug into each

1800

RPM or

an

effect

on

One connector

in

any

certain

In

contac~

place

the

and

with

#50

Hertz,

the no-load voltage

from

volts

pair combination

voltag~

· illustrationed

· ·

Insulating

are

NOT

In

the

generator's

covers contact

#7, #8,

1500

each

to

#7,

on

NOTE:

Simply cross the capacitor's two terminals with an

insulated )plastic handle) screwdriver. This will.discharge

any excess electricity.

·NOTE:

When changing Hertz produced by the generator; an

at

and

electricity

charge

the governor

Hertz to be produced The Hertz

must

even

when

engine speed adjustment

AC

output connections on the terminal blocks

for

selected plug connection Hertz (#5)

moved when changing from 115 volts, 50

Hertz.

A

handling potentially their

the voltage

at

the capacitor must be changed for

or

60 Hertz (#6). The frame ground wire

WARNING:

as

power

Capacitors

they

store

lethal

source.

must

be made. The

must

50

Hertz to 230 volts,

be

discharged

and

can

pack

disconnected

be

50

must

before

a

from

be

39

AC

TERMINAL

ACTERMINAL

CIRCUIT

BREAKER

BOARD

®

BLACK'

CONNECTIONS

120V/60Hz

,BATTERY

CIRCUITS I RESISTANCE

230V/50Hz

115V/50Hz.

VALUES

GENERATOR'

SCHEMATIC

A

ROTATIN.G WITH

B

MAIN

' C

EXCITER

D

DC BRIDGE CONTROLLER.

INTERNAL

WITH

CHARGING

FIELD/AUXILIARY

DIODES.

STATOR

WINDINGS.

WINDINGS

BAffiRY

CHARGING

RECTIFIER

WIRING

DC

BATTERY

CIRCUIT

WINDiims

AND

CAPACITOR(S).

CIRCUIT

AND

WITH

INTEGRAL

CAPACITOR

4.5

7.0

WHEN CAPACITOR, THE

CAPACITOR

THE

7.0BC

BC BC

CHECKING

CHECK

SAME

RATING.

ROTOR CHARGER STATOR

,EXCITER

RATINGS

.

25MF

31.5MF

OR

REPLACING

THE

AND

REP

WINDING RESISTANCE VALUES

4.0

0.1

0.4

'2.2

RATING

!.ACE

WITH

{OHMS)

A

ON

4.5BC

ROTOR CHARGE

.

STATOR EXCITER

Engines & Generators

40.

BC

GENERATOR

SINGLE

PHASE

TESTING

An AC voltage is induced in these windings

field. can determine the condition ing.

RESIDUAL

Single Dual

AC voltage can be measured across the capadtor(s) while the generator is operating. This voltage may be as high as 500 volts AC. This voltage buildup is accomplished as the exciter windings charge the capacitor(s) and the capacitor(s) discharge back into the exciter windings. This AC voltage reading is taken between the connection plugged into the capacitor(s) while the generator is operating at its rated Hertz rating AC in the exciter windings produces a phase-imbalance type beneficial result that produces good motor starting characteristics for this type

To locate the #9 and the

NOTE:

and

Unplug any other connections from the capacitor(s) noting their position on the capacitor.

ter on plug connection #9 and the other lead on plug connection windings . Check to make sure there is no continuity to the ground/generator case from either check that no continuity exists between either the plug or the #9 plug and any on the exists between these two winding groups.

THE

EXCITER

Single

Capacitor

1.9

Ohms

Checking the residual voltage output from this winding

VOLTAGE:

Capacitor

Exciter

measure the resistance value

#9;

#50 Hertz. Measure the resistance value

Model:

of

field that effects the auxiliary windings: a

of

Three

numbered capacitor connections

and

two

Hertz connections, #50 and

AC

terminal block.

WINDINGS

Dual

Capacitor

1.3

Ohms

by

the rotating

of

the winding when troubleshoot-

10

-14

Volts

AC

from

each

7 - 9

Volts

AC

from

#60

Hertz connector and the #

(61.5-

62.0). This flow

generator.

of

the exciter windings,

#50 Hertz capacitor connections.

Place one lead

of

the two leads. Also

of

the main stator windings leads

If

continuity is found here, a fault

each

winding

exist:

#60.

of

the ohmme-

of

the exciter

#50 Hertz

400 to

of

#7,

satu-

#8,

·

3. With an ohmmeter set on the high R scale, place its plus (+)lead lead on the other capacitor connection. A resistance should be read and should rise slowly as the meter attempts to charge the capacitor. This indicates a presumably good capacitor.

4. Indications

a. Zero resistance or no rise in resistance value (shorted

b. Infinite resistance (open capacitor).

c. No continuity should be found between the capacitor's

S.

Capacitor Ratings _(Capacitor meter)

a.

b. Dual Capacitor Units: 31.5 microfarads (uF) 5°

NOTE:

on one capacitor connection and the negative(-)

of

a defective capacitor:

capacitor).

connections and the capacitor's case or base.

Single Capacitor Units: 25.0 microfarads (uF) 5°

The

capacitor

rating

is

marked

on

the

housing

of

the

capacitor:

25.0 Microfarad capacitor PN 035985

31.5 Microfarad capacitor PN

6. 12 volt

7. During 12 volt excitation, output voltage ranges are as

a. A slight rise in. the output voltage with the loading

b.

c. Normal output voltage as specified above, check

DC

excitation (low or no generator may be excited using 12 volts DC taken from the engine's starting battery. across the ings with any other numbered leads unplugged from the capacitors(s). The generator's reaction during flashing will help determine its fault.

follows:

the engine and/or a growling noise from the generator end will indicate a fault in the main stator windings.

No rise or very slight rise in the output voltage will

#50 and #9 leads

Single

Capacitor

22-

26VAC

indicate a fault in the exciter windings.

exciter circuit capacitor(s).

035978.

AC

output voltage) the

This

voltage is applied

of

the exciter circuit wind-

Dual

Exciter

12-

14 VAC

of

FIELD-

TESTING

With a capacitor meter, test the capacitor following the instructions included with the meter, and compare the results with the value shown on the capacitor. When a capacitor meter is not available, perform the following simple test:

1.

Marking them so they may be reattached correctly,

unplug the connections from the capacitor.

2. With a jumper, short across the two connections exposed in the previous step. charged

THE

CAPACITOR

This

ensures the capacitor is dis-

as

it would be at shutdown.

Engines & Generators

41

(+)12

VDC

(-)12

VDC

BC

GENERATOR

Testing

Component

SINGLE

Resistance

PHASE

Values

Rotating

Two voltage turns at rated rpm. The AC voltage passes through each the rotor carrier bearing. The AC sine wave and this DC voltage rotating field windings producing a DC field around these windings. This field affects the AC winding stator groups inducing an AC voltage in these windings that is

available at the AC terminal block connections.

1.

Field/Auxiliary

sets

of

windings are found in the rotor assembly. An

is

produced in two groups

two

diodes mounted on the isolated fixture just before the

is

Rotating Field/ Auxiliary Windings Single Capacitor 3.8

To

check the resistance values, rotate the engine's crank-

to

shaft

12

presume the diode ter's leads on the connection at the top of the diode and the other lead at the connection at the base Compare readings with the value above. ference lead on the top its isolated heat sink using a thin walled, deep well 7/16 in

NOTE:

can the

With the diode removed, both leads for the first group of rotating field/auxiliary windings will be isolated with interference from a possibly faulty diode. Check the resistance value of the rotating windings placing the ohmmeter's leads across the two exposed leads. Also, verify that ings and the rotor shaft attached touching the shaft: ity Repeat this same check on the second group of windings. Rotate the engine's.crankshaft

No continuity should be found between these two groups

position the diode(s)

o'clock.

(11

diode.

is

ond diode and connections at of windings.

To

make a quick check of these windings,

is

noted in the ohm value, carefully unsolder the

of

mm) socket.

The

aluminum heat sink that

be

bent carefully outboard

no

to

the winding lead and the other ohmmeter lead

found, a short exists

Windings

passed through the two groups

Ohm-

on

is

OK and place one

the diode and remove the diode from

continuity exists between these wind-

by

leaving one ohmmeter lead

no

continuity should exist. If continu-

..

and

Diodes

of

windings

Du~

the generator's shaft at

to

make easier access

180°

12

o'clock.

as

the rotor

is

changed

Excitor~

of

the

diode

to position the sec-

to

of.

the two main

DE

4.0 Ohm

the ohmme-

of

the diode.

If

a distinct dif-

threads

of

a DC of

by

AC

into

to

no

2. Diodes To

check the diode, unsolder the connection from the top

of

the diode. Place one ohmmeter lead on the connection

of

at the top diode's base. Then reverse the position leads.

A low resistance should be found with the leads in one direction, and infinite resistance (blocking) in the other direction. Different meters will read different resistance values through the diode.

NOTE:

values,

Diode Rating: 1600 volts 26 Amps The diode's rating is far in excess requirements. Most likely a diode failure will result from an overspeed or load surge.

Main

Stator

Capacitor

0.6 Ohms

Residual voltage measured between #1-#3 and #4-#6 will 2-3

volts block. This would are

okay.

generator.

r-6------------,-

: 2

I 3

\64

I 5

I

I 6

.__

---

__________

Group

#1

lead

#1

and terminal with lead #3. (Check that there

continuity Group

#2

lead #4 and terminal with lead #6. (Check that there continuity

Check for a possible short between the two groups windings by placing one lead of the ohmmeter on the terminal with the stator lead #3 and the other ohmmeter lead the terminal with stator lead #6. There should be ity between the two groups

the diode and the other ohmmeter lead

of

the ohmmeter

Different meter models may show different

but should

read

the

same

for

both

of

the circuit's

diodes.

Windings

Dual Single

Excitor

0.5 Ohms

AC

between each pair

l;>e

an indication that the stator windings

Check exciter windings and artificially excite the

...

J

-Measure of

-Measure

of

resistance value

Group

#1

windings to the case ground.)

resistance value between terminal with

Group #2 windings

of

NOTE:

THE TERMINAL ORDER.

THEY

to

of

stator windings.

leads at the terminal

NUMBERED

BLOCK

ARE

1 4 3

0 0 0

5 2 6

0 0 0

t:ERMINAL:.JIL[U;J(

betw..een

the case ground.)

ARE

AS

LEADS

NOT

SHOWN

terminal with

ON

IN

ANY BELOW

is

of

no

continu-

ohm

to

THE NUMERICAL

no

stator

on

the

be

Engines & Generators

42

BATTERY

CHARGING

CIRCUIT

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

The engine has a 12 volt shown on the Wiring Diagrams. Refer to these diagrams when troubleshooting system or the ertgine.

DC

Wtring Diagram and Wiring Schematic.

DC

electrical control circuit that is

or

when servicing the

DC

electrical

by

BAnERIES

A

CAUTION:

Ing

clrcut,

while

the

switch,

lng

Specifications

The minimum recommended capacity

the engine's 12-volt

Battery

Review the manufacturer's recommendations and then estab-

lish a systematic maintenance schedule for your engine's

starting batteries and house batteries.

however,

on

the

Maintenance

To

never

engine

engine's

avoid

shut

off

Is

running.

to

avoid

damage

the

to

engine

Shut

off

electrical

the

battery

the

shorts

electrical circuit.

of

DC

control circuit is 300 CCA.

battery

charg-

switch

engine

battery

when

work·

the battery used in

BAnERY

The generator supplies a continuous 17 amp charge from its battery charger to the starting battery.

NOTE:

generator windings are protected

TESTING

CHARGING

Should the battery charger

THE

BATTERY

CHARGER

RED

TO

CIRCUIT

.

BREAKER

or

bridge rectifier fail, the

by

a

30

amp fuse.

• Monitor your voltmeter for proper charging during engine operation.

• Check the electrolyte level and specific gravity with a

hydrometer.

• Use only distilled water to bring electrolytes to a proper level.

•

Make certain that battery cable connections are clean and tight to the battery posts (and to your engine).

• Keep your batteries clean and free

A

WARNING:

cause

severe

protective

bums

gear.

Sulfuric.

on

skin

acid

In

and

of

corrosion.

lead

batteries

damage

clothing.

·

can

Wear

TO

CIRCUIT

BREAKER

TO

GROUND

The generator supplies a continuous 17 amp charge from its

battery charger to the starting battery. To test the battery

put

charger negative

14V with the engine running. in'dicated, check that the battery charger terminal connections are tight. With the unit running, test between the ( terminals for 13.5V the charger.

a multimeter between the positive ( +) and

(-)leads

to the battery.

If

to

14V.

If

It

should indicate 13.5V to

only the battery voltage is

no charge is indicated, replace

+) and (-)

43

THE

BATTERY

CHARGING

CIRCUIT

INTEGRAL

The Integral Controller (I.C.) is an encapsulated, solid-state unit that supplies a DC charging voltage to the generator's

starting battery while the generator is opening.

Charging Voltage: Charging Amperage: 0 -

A separate bridge rectifier which converts the

I.

C.

unit. The I. C. unit senses the needs

and supplies a DC charge when one is needed. that the low), check the charging circuit and it's components as described in the following steps. Check all connections for cleanliness and tightness including the ground before replacing the I.C. unit.

NOTE:

produce a low

the

generator

The Integral Controller is, mounted inside the generator hous-

ing

in

on

the controller that will allow a

ment

NOTE:

circuit

internally.

the

newer

CONTROLLER

gr<ilup

of

stator windings supplies

I.

C.

unit

is

faulty (that is,

When

the

generator

charging

is

operated.

the 12:00 position. There

of±

2 volts.

New

four

wire

since

the

ballast resistor's function

(I.

C.)

13.0 - 14.0 volts

17.0.

is

first started,

rate.

This

is

DC

amps

AC

current to supply the

of

if

the' battery's charge is

charging

a

~oltage

DC

voltage output adjust-

controllers eliminate

DC

the starting battery

th~

the

is

Whenever replacing an early controller with

four

wire

model,

remove

the

ballast resistor and

AC

voltage to a

If

you suspect

I.

C.

unit will

rate

will

rise

as

output adjustment

ballast resistor

now handled

its

wiring.

Testing

1.

the

Battery

Bridge Rectifier

Normal

·engine is operating at 1800 rpm) is measured across the two illustrated).

AC voltage running to the bridge rectifier (approximate):

Normal DC) is measured across the two bridge

DC (approximate):

No-load off the

Full-load

Lift the two AC wire leads measure the resistance between these measure these two leads and the ground

RESISTANCE

AC

voltage running to the rectifier (while the

AC

connections on the bridge rectifier. (As

No-load Full-load off

voltage running from the bridge rectifier

off

DC

voltage running out

rectif}.er;

off

0.14 ohm.

BETWEEN

Charging

the

generator

the

generator

that is + and

generator

the

generator

No

AC

of

DC

-.

J7.0

18.5 volts

off

the

continuity

or

LEADS

Circuit

16.0 volts AC

17.5 volts

the rectifier (in volts

connections

volts DC

bridge

should

the

0.14

AC

DC

rectifier and

two

leads.

exist

main

stator windings.

OHMS

of

between

the

It

should

NO

ADJUSTMENT I FACTORY

BLACK

0

~

NOTE:

AC

output

·

circuits

m

"'

Bt

The

output,

battery

DfthE

but not

GROUND

GENERATOR

charging

generator.

NOTE:

Earlier model controllers

and white/black ground connections that

TO

CASE

circuit

is

totally separate from

The

generator output affects

the

reverse.

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

~

----------

~

.....

-------

SET

had

white/green(-) negative

are

the

·

DC

----------l

interchangeable.

. I

I

NOTE:

SOME

CONFIGURED

STYLE

BRIDGE

DIFFERENTLY,

~

''•

..........

..:,~"-"'•

MEASURING

VOLTAGE THEACLEADS

RECTIFIERS

IDENTIFY

THE(+)

:.

··,

··.

·.

.

·"'~·~

AC '-...._..___.,

B£TW££N

MAY

BE

and(-)

....

·,..

'·""{-

.:

........

......

,\.

/

TERMINALS.

II

I

''/

,,

•,,

1:

44

BATTERY

CHARGING

CIRCUIT

TESTING

(meter used A. Set the meter

B.

C.

D.

·

E.

H the rectifier fails

the rectifier as it

NOTE:

produce opposite' test

THE

.BRIDGE

FLUKE

on Connect the positive ( +) lead from the meter to point Taking the negative (-) lead, momentarily touch points #3, and #5. There should meter. Remove the positive ( +) lead from point negative (-) lead to it. Momentarily touch

Ohm

#3. the each point it touches. Leaving the negative (-) lead on point the positive ( +) lead. The meter should register no value. Place the positive(+) lead on point lead on point #3. 'Value. register

Different types and/or brands

meter should register an arbitrary

Reverse these connections and the meter should

no

Ohm

any

is defective.

RECTIFIER

multimeter)

Ohms scale.

be

no

Ohm

value registered on the

#1

The

meter again should register no Ohm

value.

of

the previous tests B through E, replace

of

test meters may

results.

#4.

#1,

#4

and connect the

point§

#1,

#2

and

Ohm

value at

#4,

touch point #5 with

Ohm

and the negative(-)

#2,

BRIDGE RECTIFIER·

,

(Number

sequence

when

viewed

#3

from

BRIDGE·

the

top)

#2

..

RECTIFIER

120

Generator

~

VOLT/60

HERTZ

NOTE: Diagram shows wire.120-Yolt with

TWO

WIRE

system

three-wire,120-Yolt

SHORE

POWER

CONFIGURATION

connections from

for a two-

the generator.

boat

system.

TRANSFER

230

VOLT/50

L1

SWITCH

HERTZ

~

0

5

4 3

0

2

TWO

8

N

WIRE

CONFIGURATION

~

"

•

z

~

....

ID

L-~1-1--...,L(ID

/....--,,

I

~r;

~~H-==-•N

·..-/

\

t___~.,_L1

Neutral

(WHT)

j Ground

z (GRNI

~

Shore

PoWer

If

the

installer connects shore power

circuit,

this Transfer Switch diagrams

to

must

the

..

be

done

by

..

Set

the

transfer switch

OFF position.

means

This

simultaneous connection of shore power

A

CAUTION:

utility

shore

at

the

same covered bility

to

power time.

under

make

Damage

and

This

the

warranty;

sure

all

to

the

generator-can

generator

type

of

generator

it

AC

connections

is

Ship-to-

Shore

PN

32008

(40Amps/Pole)

l2]

Ships Load

~~~~'o-Yolt

(I•

Equipment _

to

the

vessel's

of

the

Shore Power

shown

r8't,i~~~~

PN

· (125 PN32133

(200Amps/Pole)

32010

Amps/

Pole)

AC

in

the

switch prevents

to

output

the

"installer's

are

generator

are

damage

co"ect.

output.

result

If

connected

Is

not

responsi·

Switch

Pole)

(3

Pole)

,

Switching

A

before

vice-versa with cause

generator.

-

GENERATOR

GROUND

z

w w

a:

Cl

lL1 NJ

SHORE POWER

230Y

Shore

CAUTION:

switching

because

heavy

AC

damage

PN

32009

PN

32010

PN

..

N

-::-

32133

SHIP'S

LOAD

SHIP'S

GROUND

ll!

g GENERATOR/SHORE

::::i

SWITCH

ID

L----~1-(/;

(NEUTRAL)! l

.....------'-\-1

-::-

-~:'H-·--

7 6 I

' /

... _..-

SHORE

GROUND

'

50HZ

Power

Heavy

shore

loads

to

the

to

motor

power

voltage

on

the

exciter

Generator

leads

should

to

generator

surges

induced

vessel

being

circuit

components

Power

be

shut

power

by

switching

operated

ln.

off

or

may

~he

Engines &_Generators

46

LAY-UP & RECOMMISSIONING

General

Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the offseason or for long periods accomplish lay-up preparation themselves.

The procedures which follow will allow you to perform your

own lay-up and recommissioning,

if

others do the procedures.

These procedures should provide protection for your engine/generator during a lay-up and also help familiarize you with its maintenance needs.

If

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

Propeller

The transmission and propeller half couplings should always be opened up and the bolts removed when the boat is hauled out

of storage in the cradle. The flexibility severe strain on the propeller shaft the boat is taken out shaft has actually been bent by these strains. This does not apply to small boats that are hauled out

not in use, unless they have been dry for a considerable

period

Fresh

A

50-50

mended for use in the fresh water cooling system at all times. This solution may require a higher concentration depending on the area's winter climate. Check the solution to make sure the antifreeze protection is adequate.

Should more antifreeze be needed, from the engine block and add a more concentrated mixture.

Operate the engine to ensure a complete circulation and mixture

system. Then recheck the antifreeze solution's strength.

Lubrication

With the engine warm, drain all the engine oil from the oil sump. Remove and replace the oil filter

new oil.

LUBRICATING

change".

Run the engine and check for proper oil pressure and make sure there are no leaks.

Shaft

the water or moved from land to water, and during

of

time.

Water

of

the antifreeze concentration throughout the cooling

solution

Cooling

of

System

Use the correct grade

OIL

of

inactivity. Others prefer to

or

will serve as a checklist

He

will be more than willing to

Coupling

or

[Propulsion

of

or

put in the water. In some cases, the

Engine]

the boat oftens puts a

coupling or both, while

of

the water when

Circuit

antifreeze and distilled water is recom-

of

antifreeze,

drain

an appropriate amount

and

fill the sump with

of

oil. Refer to the ENGINE

pages in this manual for "engine oil

Fuel

System

Top off your fuel tanks with unleaded gasoline or higher. A fuel conditioner such as stabilizer should be added. Change the element in your gasoline/water separator and clean the metal bowl. Re-install and make certain there are no leaks. Clean up any spilled fuel.

Fuel

System

Top off your fuel tanks with No.2 diesel fuel. Fuel additives such as control algae and condition the fuel. Care should be taken that the additives used are compatible with the primary fuel filter/water seperator used in the system. Change the element in has one, and clean the seperator sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, as needed. Start the engine and allow it to run for system. Check for any leaks that may have been created in the fuel system during this servicing, correcting them as needed. Operating the engine for allow movement equipment on the engine.

Raw

Close the through-hull fitting. Remove the raw water intake hose from the fitting. gallon bucket check the zinc anode found in the primary heat exchanger on the engine and clean any zinc debis from inside the heat exchanger where the zinc anode is located. Clean the raw water strainer.

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

Start the engine and allow all through the raw water system. the engine. This antifreeze mixture should protect the raw water circuit from freezing during the winter lay-up, as well as providing corrosion protection.

Remove the impeller from your raw water pump (some antifreeze mixture will accompany it, so catch it in a bucket). Examine the impeller. Get a replacement, cover gasket. until recommissioning, but replace the cover and gasket.

BIOBOR and

ypur primary fuel filter/water seperator,

5 - 10 minutes to make sure no air is left in the fuel

Water

[Gasoline]

of

89

MARINESTABIL

[Diese~

STABIL

of

the treated fuel through the injection

Cooling

Place the end

of

clean fresh water. Before starting the engine,

or

Do

not replace the impeller (into the pump)

should be added at this time to

if

the fuel system

5 - 10 minutes will help

Circuit

of

this hose into a five

replace it as required and also clean

of

this mixture to be drawn

Once the bucket is empty, stop

if

needed, and a

octane

A

CAUTION:

oil

in

the

sump combustion chemicals internal

parts.

Do

over

deposits

which

can

not

leave

the

lay-up

combine

reduce

the

engine's

period.

to

produce

the

life

Engine

harmful

of

your

old

engine

oil

and

engine's

Intake

Place a clean cloth, lightly soaked in lubricating oil,

opening shove the cloth out

recommissioning, and an attempt is made to start the engine,

you may need assistance note to remove the cloth prior to start-up. The thru-hull exhaust port can be blocked in the same manner.

Manifold

of

the intake manifold to block the opening. Do not

and

Thru-Hull

of

sight.

of

Exhaust

(If

it is not visable at

the servicing dealer). Make a

47

in

the

LAY-UP

&

RECOMMISSIONING

Starter

Lubrication if access battery connections are shut off before attempting the connections removed from the starter.

Cylinder

If WESTERBEKE recommends removing access cylinders cylinder walls.

Make sure line sealing washers.

Intake

Clean cloth lightly soaked in lube oil around block through-hull start-up!

Cylinder

Spray fogging oil into arrestor removed, while the generator eil will stall out spark plugs for winter protection.

NOTE:

and

Motor

and

cleaning of

to

the starter permits

starter.

Take

care

Lubrication

you

anticipate a long lay-up period

to

the

cylinders. Squirt light lubricating

to

prevent the piston rings from sticking

you

have replacements for

Manifold

the

filter screen

any

opening. Also place

exhaust

Lubrication

the

The

spark plugs will need

regapping

at spring commissioning.

the

in

properly replacing

[Diese~

[Gasoline]

in

the flame arrester,

port.

Make a note

[Gasoline]

the

open air intake, with

engine and coat the valves, cylinders

starter

drive

pinion

its

removal. Make sure

any

(12

months or more)

the

fuel

the

injector

and

the

flame arrester

an

oil-soaked cloth

to

remove

is

running. The fogging

to

be

removed for cleaning

electrical

oil

place a clean

the

Batteries

If

batteries are make sure that they are way,

to

the

batteries will not remain

be

subjected batteries environment.

to

be left on board during

prevent them

to

severe environmental conditions, remove

and

store them

the

fully

charged, and

from

freezing.

fully

in

a warmer, more compatible

If

there

charged, or that they will

lay-up period,

will

remain that

is

any

is

advisable,

the

to

remove

injectors

into the

to

the

and

in

the

cloths

flame

doubt that

return

to

prior

and

the

for

to

Spare

Lay-up time provides a WESTERBEKE engine belts spares kit used during to

Parts

good

opportunity

to

see if external items

or

coolant hoses need replacement. Check your

and

SPARE

order items not

the

lay-up, such

PARTS

section of this manual.

as

on

filters

hand,

or replace those

and

to

inspect

zinc

your

such

anodes.

as

drive

basic

items

Refer

Jlecommissioning

The recommissioning of your WESTERBEKE engine after a seasonal lay-up generally follows those

presented section regarding preparation for starting and normal starts. However, counteracted before starting

1.

Remove the oil-soaked cloths from the intake manifold

2.

Remove the old gasket. Install the raw water removed during lay-up (or a replacement, if required). Install the

3.

Reinstall the batteries that up,

and terminals are clean Check

A

CAUTION:

and

eye batteries can

be cigarette, open electrical electrical

4. Remove

proper tightness

in

the

PREPARATIONS

some of the lay-up procedures will need

the

raw

water pump cover

raw

water pump cover

reconnect

to

make sure that the batteries are

protection

emit

ignited

cigar,

flame·near

equipment arcing

the

battery cables, making

and

that the connections

Wear

rubber

when

hydrogen, a highly

by

electrical

or

pipe.

the

battery

In

during

spark plugs,

[gasoline].

the

same procedures

FOR

the

engine.

and

with a new

were

removed during

gloves, a rubber

servicing

batteries.

explosive

arcing

or a lighted

Do

not

smoke

being

serviced.

the

vicinity

servicing.

wipe

clean, re-gap,

STARTING

gasket.

pump

fully

or

to

prevent

to

and

impeller

cover

the

sure

are

tight.

charged.

apron,

Lead

gas,

allow

an

Shut

and

as

be

discard

gasket.

lay-

the

acid

which

off

all

install

to

A

WARNING:

highly-explosive arcing

or a lighted

smoke

or

allow

serviced.

vicinity

Shut

to

Transmission

Check or change the fluid in the transmission Wipe

off grime and grease and touch Protect corrosion coating. Check that the transmission vent

the

coupling

Lead

gas,

cigarette,

an

open

off

all

electrical

prevent

electrical

[Propulsion

and

acid

batteries

which

can

be

Ignited

cigar,

or

flame

near

the

equipment

arcing

during

Engine]

up

the output flange with

emit

hydrogen,

by

pipe.

battery

In servicing.

as

any

unpainted

electrical

Do

not

being

the

required.

an

anti-

is

open.

5.

a

areas.

Engines & Generators

Check circuit it

is

not necessary solution engine short period of advisable, service, heat exchanger area.

6.

Start

the

in

the

this

manual.

48

the

condition of

and

clean or replace

from

the

is

put into operation, the system

time

as

either

to

inspect

engine

PREPARATIONS

the

zinc

the

to

flush the antifreeze/fresh water

raw

water coolant system.

with

no

adverse affects.

an

end of season or recommissioning

the

area where

and

clear

any

and

in

accordance with procedures described

FOR

INITIAL

anode

the all

in

the

raw

as

needed.

When

will

self-flush

It

zinc

is

located

zinc

debris

START-UP

water

Note

is

from

section

the

in

that

in

the

that

of

a

GENERATOR

SPECIFICATIONS

Engine

Type

Bore & Stroke

Total

Displacement Bearings Combustion Compression Firing Aspiration Direction Inclination

Governor Distributor Spark

Ignition Ignition

Fuel Fuel

Rame Carburetor

.Start

Starting Battery Battery

Generator Engine

Engine

NOTE:

compartment

Chamber

Order

of

Rotation

Plugs

Coil Timing

Pump

Arrester

Motor

Battery Capacity Charging

Cooling Combustion Cooling

Forced

ENGINE

3 w/counterbalance cooled

2.56 x 2.61

40.3 Four Semi-spherical

Ratio

9.8-1 1

Naturally Counterclockwise 25°

30•

Mechanical

Breakerless

14mm

12

15°

FUEL

Electric

Unleaded

Ethanol

Metal

Single-barrel

ELECTRICAL

12

300

AIR

REQUIREMENTS

ventilation

temperature

must

below

SPECIFICATIONS

cylinder, 4 cycle,

gasoline

cubic main

-3-2

continuous, temporary,

Volt

BTDC

shaft,

engine

inches

(.661iter)

bearings

aspirated

viewed

all

Distributor

at

1800

overhead

carburetored

(65.0 x 66.3

from

directions

rpm

camshaft

SYSTEM

fuel

pump

89

octane

or

E-10

maximum

downdraft

higher.

type

blend

screen

type

SYSTEM

volt

reduction

gear

with

solenoid

volt

negative

ground

Cold

Cranking

Amps(CCA)(min)

Integral

electric,

17

amps

225-

250

elm

(6.3-

70

cmm)

22.9

elm

(0.6

cmm)

100

elm

(2.8cmm)

be

provided

to

maintain

122°F

(50°C).

the

water

mm).

the

back

end

generator's

General

Fresh Raw

Water

Raw

Water Operating CooHng

.

Type Oil

Filter

Oil

Capacity

Oil

Grade

Operation

Type

Ratings

4.5KW

3.8KW

7.0KW

5.0KW

Spark Spark Cylinder Bolt

Torque

Valve Exhaust

Water

Pump

Row

Rate

Temperature

Water

Capacity

Oil

Pressure

AC

TUNE-UP

Plug

Gap

Plug

Torque

Head

Torque

Clearances

Valves

Fresh

water-cooled

cooled

heat Centrifugal Positive

displacement,

belt

driven.

5.0

gpm

(18.51pm) 150°-170° F 3

qts.

(2.8

LUBRICATING

Forced

lubrication

Fuel

flow,

paper

2.7

qts.

(2.61iters)

API

Specification

SAE 1 OW-40 30 -50

psi

GENERATOR

(SINGLE

Brushless, 1800

rpm/60Hz,

120

volts,

single

phase, 4 wire,

230

volts,

4

wire,

1.0

120

volts,

single

phase, 4 wire,

230

volts,

4

wire,

1.0

37.5

16.5

58.3

21.7

SPECIFICATIONS

0.031 ± .002

10.8 -15.2 60 -70

Nm

See

TORQUING

Intake

Valves:

0.30mm

(0.012in)

block

exchanger

type,

liters)

metal

(65°-

circuit impeller, rubber

at

1800

77°

SYSTEM

by

gear

element,

SJ,

SL

or

15W-40

(2.1 -3.5

kg/em')

four

pole

capacitor,

1500

rpm/50Hz

amps,

60Hz

1.0

amps,

factor

amps,

factor

inches

43-

51

THE

0.20mm

50

60

1.0 50

(0.8±0.05

ft-lbs

CYLINDER

power

lb-ft

through

raw

belt-driven

impeller,

rpm

C)

pump

spin-on

disposals

or

SM

Westerbeke 4.5 BCGB, 3.8 BCGB, 7.0 BCGB, 5.0 BCGB Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual